Volvo Md2010 Instruction manual

Workshop Manual

Engine

MD2010, MD2020, MD2030, MD2040

2(0)

Workshop Manual

Marine engines

MD201OA/B/C

•

MD202OA/B/C

•

MD203OA/B/C

•

MD204OA/B/C

Note!

The data given in this Workshop Manual refers in general to

engines in both A, B and C versions unless otherwise stated.

Contents

Technical data

Repair instructions



njection pump



njection pump



Wear tolerances



Adjustment of injection angle



Tightening torque



Adjustment of speed



Feed pump



Special tools



Fuel filter



Bleeding of fuel system



njector



Presentation

Checking of injector



Description of engine



Engine body

Cooling system

Description



Description



Repair instructions

Repair instructions:

Refrigerants



Cylinder head



Checking of refrigerant level



Valves. valve mechanism

.........................................



Cleaning



Cylinder block, pistons.

connecting rods



Circulation pump



Timing gears



Sea water pump



Camshaft



Replacing the thermostat



Crank mechanism



Checking the thermostat



Lubricating system

Description



Electrical system



Description



Repair instructions

mportant info



Oil pump



Starting with auxiliary battery



Replacing the oil filter



Troubleshooting, glow plug, charging

system



Cleaning the oil channels

.........................................



Alternator



Starter motor



Electrical components



Fuel system

Wiring diagram



Description



Extra equipment



ntroduction

This Workshop Manual contains technical specifica-

tions, descriptions and instructions for the repair of the

Volvo Penta products or product types described in the

Table of Contents. Check that you have the correct

Workshop Manual for your engine.

Before starting work on the engine read the "Safety Pre-

cautions", "Genera! Information" and "Repair Instruc-

tion" sections of this Workshop Manual carefully.

mportant

n this book and on the product you will find the follow-

ng special warning symbols.

WARNING!

Possible danger of personal injury,

extensive damage to property or serious me-

chanical malfunction if the instructions are not

followed.

MPORTANT

Used to draw your attention to

something that can cause damage or malfunc-

tions on a product or damage to property.

Note!

Used to draw your attention to important informa-

tion that will facilitate the work or operation in

progress.

Below is a summary of the risks involved and safety

precautions you should always observe or carry out

when operating or servicing the engine.

mmobilize the engine by turning off the power

supply to the engine at the main switch (switch-

es) and lock it (them) in the OFF position before

starting work. Set up a warning notice at the en-

gine control point or helm.

As a general rule all service operations must be

carried out with the engine stopped. However,

some work, for example certain adjustments re-

quire that the engine is running when they are

carried out. Approaching an engine which is op-

erating is a safety risk. Loose clothing or long

hair can fasten in rotating parts and cause seri-

ous personal injury. If working in proximity of an

engine which is operating, careless movements

or a dropped tool can result in personal injury.

Take care to avoid contact with hot surfaces (ex-

haust pipes, Turbocharger (

air intake pipe,

start element

etc

and hot liquids in lines and

hoses on an engine which is running or which

has just been stopped. Reinstall all protective

parts removed during service operations before

starting the engine.

Safety Precautions

Check that the warning or information labels on

the product are always clearly visible. Replace

abels which have been damaged or painted

over.

Engines with turbocharger (

Never start the

engine without installing the air cleaner (

ACL

)

filter.

The rotating compressor in the Turbo can

cause serious personal injury. Foreign objects

entering the intake ducts can also cause me-

chanical damage.

Never use start spray products or similar when

starting the engine. They may cause an explo-

sion in the inlet manifold. Danger of personal in-

jury.

Avoid opening the filler cap for engine coolant

system (freshwater cooled engines) when the

engine is still hot. Steam or hot coolant can

spray out. Open the filler cap slowly and release

the pressure in the system. Take great care if a

cock, plug or engine coolant line must be re-

moved from a hot engine. Steam or hot coolant

can spray out in any direction.

Hot oil can cause burns. Avoid getting hot oil on

the skin. Ensure that the lubrication system is

not under pressure before carrying out any work.

Never start or operate the engine with the oil fill-

er cap removed, otherwise oil could be ejected.

Stop the engine and close the sea cock before

carrying out operations on the engine cooling

system.

Only start the engine in a well-ventilated area. If

operating the engine in an enclosed area en-

sure that there is exhaust ventilation leading out

of the engine compartment or workshop area to

remove exhaust gases and crankcase ventila-

tion emissions.

Always use protective glasses or goggles when

carrying out work where there is a risk of splin-

ters, grinding sparks, acid splashes or where

other chemicals are used. The eyes are ex-

tremely sensitive, an injury could result in blind-

ness!

Avoid getting oil on the skin! Repeated expo-

sure to oil or exposure over a long period can

result in the skin becoming dry. Irritation, dry-

ness and eczema and other skin problems can

then occur. Used oil is more dangerous than

fresh oil from a health aspect. Use protective

gloves and avoid oil soaked clothes and shop

rags.

Wash regularly, especially before eating.

There are special skin creams which counteract

drying out of the skin and make it easier to clean

off dirt after work is completed.

Many chemicals used on the product (for ex-

ample engine and transmission oils, glycol,

gasoline and diesel oil), or chemicals used in

the workshop (for example degreasing agents,

paint and solvents) are dangerous to health.

Read the instructions on the product packaging

carefully! Always follow the safety precautions

for the product (for example use of protective

mask, glasses, gloves

etc

.).

Make sure that other

personnel are not exposed to hazardous chemi-

cals, for example in the air. Ensure good ventila-

tion in the work place. Follow the instructions

provided when disposing of used or leftover

chemicals.

Excercise

extreme care when leak detecting on

the fuel system and testing the fuel injector jets.

Use eye protection. The jet from a fuel injector

nozzle is under extremely high pressure and

has great penetrative energy, so the fuel can

penetrate deep into the body tissue and cause

serious personal injury. Danger of blood poison-

ng.

All fuels and many chemical substances are

flammable. Do not allow naked flame or sparks

n the vicinity. Fuel, certain thinner products and

hydrogen from batteries can be extremely flam-

mable and explosive when mixed with air.

Smoking is not to be permitted in the vicinity!

Ensure that the work area is well ventilated and

take the necessary safety precautions before

starting welding or grinding work. Always en-

sure that there are fire extinguishers at hand

when work is being carried out.

Ensure that rags soaked in oil or fuel and used

fuel or oil filters are stored safely. Rags soaked

n oil can spontaneously ignite under certain cir-

cumstances. Used fuel and oil filters are envi-

ronmentally dangerous waste and must be de-

posited at an approved site for destruction

together with used lubricating oil, contaminated

fuel, paint remnants, solvent, degreasing agents

and waste from washing parts.

Never expose a battery to naked flame or elec-

trical sparks. Never smoke in proximity to the

batteries. The batteries give off hydrogen gas

during charging which when mixed with air can

form an explosive gas -

oxyhydrogen

This gas

s easily ignited and highly volatile. Incorrect

connection of the battery can cause a single

spark which is sufficient to cause an explosion

with resulting damage. Do not shift the connec-

tions when attempting to start the engine (spark

risk) and do not lean over any of the batteries.

Always ensure that the Plus (positive) and Mi-

nus (negative) battery leads are correctly in-

stalled on the corresponding terminal posts on

the batteries. Incorrect installation can result in

serious damage to the electrical equipment. Re-

fer to the wiring diagrams.

Always use protective goggles when charging

and handling the batteries. Battery electrolyte

contains sulfuric acid which is highly corrosive.

Should the battery electrolyte come into contact

with unprotected skin wash off immediately us-

ng plenty of water and soap. If battery acid

comes in contact with the eyes, immediately

flush with plenty of water and obtain medical as-

sistance at once.

Turn the engine off and turn off the power at the

main

switch(es

)

before carrying out work on the

electrical system.

Clutch adjustments must be carried out with the

engine stopped.

About this Workshop Manual

This Workshop Manual contains technical specifica-

tions, descriptions and instructions for the repair of the

following engines in standard format:MD2010

MD2020

MD2030

MD2040

This Workshop Manual

can show operations carried out on any of the engines

sted above. As a result the illustrations and pictures in

the manual that show certain parts on the engines, do

not in some cases apply to all the engines listed. How-

ever the repair and service operations described are in

all essential details the same. Where they are not the

same this is stated in the manual and where the differ-

ence is considerable the operations are described sep-

arately. The Engine Designations and Engine Number

can be found on the product plate. Please always in-

clude both the engine designation and the engine

number in all correspondance

The Workshop Manual is produced primarily for the use

of Volvo Penta workshops and service technicians. For

this reason the manual presupposes a certain basic

knowledge of marine propulsion systems and that the

user can carry out themechanical/electrical

work de-

scribed to a general standard of engineering compet-

ence.

Volvo Penta products are under a continual process of

development and we therefore reserve all rights regard-

ng changes and modifications. All the information in

this manual is based on product specifications avail-

able at the time the book was published. Any essential

changes or modifications introduced into production or

updated or revised service methods introduced after the

date of publication will be provided in the form of Ser-

vice Bulletins.

Replacement parts

Replacement parts for the electrical and fuel systems

are subject to various national safety requirements, for

example the United States Coast Guard Safety Regula-

tions. Volvo Penta Original Spare Parts meet these

specifications. Any type of damage which is the result of

using replacement parts that are not original Volvo Pen-

ta replacement parts for the product in question will not

be covered under any warranty or guarantee provided

by AB Volvo Penta.

Certified engines

For engines certified for national and regional environ-

mental legislation the manufacturer undertakes to en-

sure compliance with such environmental requirements

for both new engines and engines is use. The product

must comply with the approved example on certifica-

tion. For Volvo Penta as the manufacturer to be able ac-

cept responsibility for the compliance of engines in use

with the set environmental requirements, the following

requirements for service and spare parts must be ful-

filled:

General Information

•

The service intervals and maintenance proced-

ures recommended by Volvo Penta must be fol-

owed.

•



Only Volvo Penta Genuine Spare Parts intended

for the certified engine version must be used.

•

Service of injection pumps, pump settings, and

njectors, shall always be conducted by an aut-

horised Volvo Penta workshop.

•

The engine must not be rebuilt or modified in any

way, with the exception of the accessories and

service kits that Volvo Penta has developed for

the engine.

•



nstallation adjustments on exhaust pipes and

supply air channels for the engine compartment

(ventilation channels) must not, without due care,

be conducted since this can influence exhaust

emissions.

•



Seals must not be broken by unauthorised per-

sonnel.

MPORTANT!

Use only Volvo Penta Genuine

Spare Parts.

The use of non genuine parts

mplies that AB Volvo Penta will no longer

assume responsibility for compliance of the

engine with the certified versions.

All types

of damage or costs resulting from the use of

non genuine Volvo Penta spare parts for the

product in question will not be regulated by

Volvo Penta.

The working methods described in the Workshop Man-

ual apply to work carried out in a workshop. The engine

has been removed from the boat and is installed in an

engine fixture. Unless otherwise stated reconditioning

work which can be carried out with the engine in place

follows the same working method.

Warning symbols used in this Workshop Manual (for full

explanation of the symbols refer to the section; "Safety

Precautions")

Note!

are not in any way comprehensive since it is impossible

to predict every circumstance under which service work

or repairs may be carried out. Volvo Penta AB can only

ndicate the risks considered likely to occur as a result

of incorrect working methods in a well-equipped work-

shop using working methods and tools tested by Volvo

Penta AB.

All operations described in the Workshop Manual for

which there are Volvo Penta Special Tools available

assume that these tools are used by the service techni-

cian or person carrying out the repair. Volvo Penta Spe-

cial Tools have been specifically developed to ensure

as safe and rational working methods as possible. It is

therefore the responsibility of the person or persons us-

ng other than Volvo Penta Special Tools or approved

Volvo Penta working methods (as described in a Work-

shop Manual or Service Bulletin), to acquaint them-

selves of the risk of personal injury or actual mechan-

ical damage or malfunction that can result from failing to

use the prescribed tools or working method.

n some cases special safety precautions and user in-

structions may be required in order to use the tools and

chemicals mentioned in the Workshop Manual. Always

follow these precautions as there are no specific in-

structions given in the Workshop Manual.

By following these basic recommendations and using

common sense it is possible to avoid most of the risks

nvolved in the work. A clean work place and a clean

engine will eliminate many risks of personal injury and

engine malfunction.

Above all when working on the fuel system, engine lub-

rication system, air intake system, Turbocharger unit,

bearing seals and seals it is extremely important to ob-

serve the highest standards of cleanliness and avoid

dirt or foreign objects entering the parts or systems,

since this can result in reduced service life or malfunc-

tions.

WARNING!

MPORTANT!

Repair instructions and methods

Our joint responsibility

Every engine consists of many systems and compon-

ents that work together. If one component deviates from

the technical specifications this can have dramatic con-

sequences on the environmental impact of the engine

even if it is otherwise in good running order. It is there-

fore critical that the stated wear tolerances are ob-

served, that systems which can be adjusted are cor-

rectly set up and that only Volvo Penta Original Parts

are used on the engine. The stated service intervals in

the Maintenance Schedule must be followed.

Some systems, such as the components in the fuel sys-

tem, require special expertise and special testing equip-

ment for service and maintenance. Some components

are factory sealed for environmental and product spe-

cific reasons. Under no circumstances attempt to ser-

vice or repair a sealed component unless the service

technician carrying out the work is authorized to do so.

Bear in mind that most of the chemicals used around

boats are harmful to the environment if used incorrectly.

Volvo Penta recommends the use of bio-degradable

degreasing agents for all cleaning of engine compon-

ents unless otherwise stated in the Workshop Manual.

When working onboard a boat make a special point of

preventing oil, waste water from washing components

entering the

bilges

;

nstead remove all such waste for

safe disposal at an approved site for destruction.

Tightening

torques

The correct tighteningtorques for critical joints which

must be tightened using a torque wrench are listed un-

der "Technical Specifications - Tightening

Torques

and stated in the method descriptions in the Workshop

Manual. All tighteningtorques

apply to cleaned threads,

bolt heads and mating surfaces.Tigthening

torques

stated are for lightly oiled or dry threads. Where grease,

ocking or sealing agents are required for screwed

oints this is stated in both the operation description and

n "Tightening

Torques

Where no tightening torque is

stated for a joint use the general tighteningtorques

ac-

cording to the tables below. The tighteningtorques

stat-

ed are a guide and the joint does not have to be tight-

ened using a torque wrench.

Dimension Tightening torque

ft.Ibs

50 37

M12

80 59

M14

140 103

Tightening torque with Protractor tight-

ening (angle tightening)

Tightening using both a torque setting and a protractor

angle requires that first the recommended torque is ap-

plied using a torque wrench and then the recommended

angle is added according to the protractor scale. Ex-

ample: a 90° protractor tightening means that the joint is

tightened a further 1/4 turn in one operation after the

stated tightening torque has been applied.

Lock nuts

Do not re-use lock nuts that have been removed during

dissassembly

operations as these have reduced ser-

vice life when re-used - use new nuts when assem-

bling or reinstalling. For lock nuts with a plastic insert

such as

Nylock®

the tightening torque stated in the ta-

ble is reduced if the

Nylock®

nut has the same head

height as a standard hexagonal nut without plastic in-

sert. Reduce the tightening torque by 25% for bolt size

8 mm or larger. Where

Nylock®

nuts are higher, or of

the same height as a standard hexagonal nut, the

tightening

torques

given in the table apply.

Strength classes

Bolts and nuts are divided up into different classes of

strength; the class is indicated by the number on the

bolt head. A high number indicates stronger material,

for example a bolt marked 10-9 indicates a higher

strength than one marked 8-8. It is therefore important

that bolts removed during the disassembly of a bolted

oint must be reinstalled in their original position when

assembling the joint. If a bolt must be replaced check in

the replacement parts catalogue to make sure the cor-

rect bolt is used.

Sealant

A number of

sealants

and locking liquids are used on

the engines. The agents have varying properties and

are used for different types of jointing strengths, oper-

ating temperature ranges, resistance to oil and other

chemicals and for the different materials and gap sizes

n the engines.

To ensure service work is correctly carried out it is im-

portant that the correct sealant and locking fluid type is

used on the joint where the agents are required.

n this Volvo Penta Workshop Manual the user will find

that each section where these agents are applied in

production states which type was used on the engine.

During service operations use the same agent or an al-

ternative from a different manufacturer.

Make sure that mating surfaces are dry and free from

oil,

grease, paint and anti-corrosion agent before apply-

ng sealant or locking fluid. Always follow the manufac-

turer's instructions for use regarding temperature range,

curing time and any other instructions for the product.

Two different basic types of agent are used on the en-

gine and these are:

RTV

agent (Room temperature vulcanizing). Used for

gaskets, sealing gasket joints or coating gaskets.

RTV

s visible when a part has been disassembled; old

RTV

must be removed before resealing the joint.

The following

RTV

agents are mentioned in the Service

Manual:

Loctite®574, Volvo Penta P/N 840879-1,

Per-

matex® No. 3, Volvo Penta P/N 1161099-5,

Permatex®

77. Old sealant can be removed using

methylated

spirits in all cases.

Anaerobic agents. These agents cure in an absence of

air.

They are used when two solid parts, for example

cast components, are installed face-to-face without a

gasket. They are also commonly used to secure plugs,

threads in stud bolts, cocks, oil pressure switches and

so on. The cured material is glass-like and it is therefore

colored to make it visible. Cured anaerobic agents are

extremely resistant to solvents and the old agent cannot

be removed. When reinstalling the part is carefully de-

greased and then new sealant is applied.

The following anaerobic agents are mentioned in the

Workshop Manual:

Loctite®572 (white), Loctite®

241

(blue).

Note:

Loctite®

s the registered trademark of

Loctite

Corparation

Permatex® the registered trademark of the

Permatex

Corporation.

Safety rules for fluorocarbon rubber

Fluorocarbon rubber is a common material in seal

rings for shafts, and in O-rings, for example.

When fluorocarbon rubber is subjected to high tem-

peratures (above

300°C/572°F

hydrofluoric acid

can be formed, which is highly corrosive. Skin con-

tact can give severe chemical burns. Splashes in

your eyes can give severe chemical burns. If you

breathe in the fumes, your lungs can be permanently

damaged.

WARNING!

Be very careful when working on

engines which have been exposed to high tem-

peratures,

e.g

overheating during a seizure or

fire.

Seals must never be cut with an oxyacet-

ylene torch, or be burned up afterwards in an

uncontrolled manner.

•

Always use gloves made of

chloroprene

rubber

(gloves for handling chemicals) and protective

goggles.

•



Handle the removed seal in the same way as

corrosive acid. All residue, including ash, can be

highly corrosive. Never use compressed air to

blow anything clean.

•



Put the remains in a plastic box which is sealed

and provided with a warning label. Wash the

gloves under running water before removing

them.

The following seals are probably made from fluoro-

carbon rubber:

Seal rings for the crankshaft, camshaft, intermediate

shafts.

O-rings irrespective of where they are installed.

O-rings for cylinder liner sealing are almost always

made from fluorocarbon rubber.

Note that seals which have not been subjected to

high temperature can be handled normally.

Front marking*,

MD2010

MD2020

MD2030

MD2040



The pistons for certain engines also have an arrow in front

of the gudgeon pin hole which should point forwards.

Piston rings

Technical data

The arrow alt. "F" mark on piston top should be turned forwards

The "SHIBAURA" mark in the piston should be turned forwards

General

Engine designation



MD2010 MD2020 MD2030

M D2040

Number of cylinders



3 3

Cylinder diameter



67 mm

67 mm 75 mm

84 mm

(2.637 in) (2.637 in) (2.952 in)

(3.307 in)

Stroke length



64 mm 64 mm 72 mm

90 mm

(2.519 in) (2.519 in) (2.834 in) (3.543 in)

Swept volume, total



0.45 litres

(27.46

cu.in

)

0.68 litres

(41.49

cu.in

)

0.95 litres

(57.97

cu.in

)

1.50 litres

(91.53

cu.in

)

Power, see sales literature

dling speed



850 ±25 rpm 850 ±25 rpm 850 ±25 rpm 850 ±25 rpm

Deregulation speed/high idling



3900 ±25 rpm 3900 ±25 rpm 3900 ±25 rpm 3900 ±25 rpm

Compression ratio



23.5:1

23:1 22:1

Compression pressure with starter motor speed



>3000 kPa

>3000 kPa >3000 kPa

>3000 kPa

(>435 psi)

Firing order (cyl. No. 2 and 3 closest

to flywheel)



1-2

1-2-3 1-2-3

1-2-3

Direction of rotation see from front



Clockwise Clockwise

Clockwise

Max. permissible angle backwards during operation

20°

Max. side angle during operation



30° 30°

Valve clearance, idle cold engine:

nlet and outlet



0.20 mm

0.20 mm 0.20 mm

(.0078 in) (.0078 in) (.0078 in) (.0078 in)

Weight, engine without oil and water



98 kg 116 kg 129 kg 179 kg

(215.9lb) (255.5lb) (284.2lb)

(394.3 Ib)

Max. permissible counter pressure in exhaust pipe..

20 kPa

(2.9 psi)

20 kPa

(2.9 psi)

20 kPa

(2.9 psi)

20 kPa

(2.9 psi)

MD2010

M D2020

M D2030 M D2040

Compression rings:

Number



2 2 2

Top compression ring, height in mm



1.47-1.49 1.47-1.49 1.97-1.99

(0578-.0586 in)

(.0578-.0586 in) (.0775-.0783 in)

2nd compression ring, height in mm



1.47-1.49 1.97-1.99 1.47-1.49

(.0578-.0586 in)

(.0775-.0783 in) (.0578-.0586 in)

Oil ring:

Number



11 1

Height in mm



2.97-2.99

3.97-3.99

3.90-3.98

(.01169-1177 in)

(.01562-.1570 in) (.1535-.1566 in)

Pistons

MD2010

M D2030 M D2040

M D2020

Material



Height, total in mm



Aluminium alloy

59.045-59.095

Aluminium alloy

65.575-65.625

Aluminium alloy

87.66-87.74

(2.324-2.326 in) (2.581-2.583 in)

(3.451-3.454 in)

Height from gudgeon pin centre to piston top in mm

33.045-33.095 35.575-35.625

47.66-47.74

(1.300-1.302 in) (1.400-1.402 in)

(1.876-1.879 in)

Piston clearance in mm:



0.048-0.082

0.0425-0.0665

0.038-0.072

(.0018-.0032 in) (.0016-.0026 in)

(.0014-.0028 in)

ec nrcal data

Piston ring gap in cylinder measured in mm,

top compression ring



2nd compression ring



Oil ring



Piston ring clearance in groove measured in mm

top compression ring



2nd compression ring



oil ring

.........................................................................

Gudgeons pins

Clearance, gudgeon pin - gudgeon bushing in mm



Gudgeon pin - gudgeon pin hole in mm



Gudgeon pin diameter in mm



Gudgeon bushing's int. diameter in mm



Gudgeon pin hole's diameter in piston in mm



Cylinder head

Height in mm



Valve seats (inlet outlet)

nlet, diameter in mm



Outlet diameter in mm



Depth in mm



Crankshaft with bearing

(Replaceable bearing cups for main and

big end bearings)

Crankshaft, axial clearance in mm



Main bearing, radial

clearance in mm, No. 1



No. 2



No. 3



MD2010

0.1-0.3

(.0039-.0118 in)

0.035-0.072

(.0013-.0028 in)

0.055-0.092

(.0021-.0036 in)

MD2010

M D2020

0.13-0.25

(.0051-.0098 in)

0.10-0.22

(.0039-.0118 in)

0.10-0.30

(.0039-.0118 in)

0.06-0.10

(.0023-.0039 in)

0.05-0.09

(.0019-.0035 in)

0.02-0.06

(.0007-.0023 in)

MD2010

M D2020

0.013-0.030

(.0005-.0011 in)

-0.004- +0.008

(-.0001- +.0003 in)

18.996-19.002

(.7478-.7481 in)

19.015-19.026

(.7486-.7490 in)

18.998-19.004

(.7479-7481 in)

M D2010

M D2020

54.9-55.1

(2.161-2.169 in)

25.35-25.45

(.9980-1.001 in)

21.85-21.95

(.8602-.8641 in)

2.05-2.15

(.0807-.0846 in)

M D2020

0.1

-0.3

(.0039-.0118 in)

0.035-0.072

(.0013-.0028 in)

0.035-0.072

(.0013-.0028 in)

0.055-0.092

(.0021-.0036 in)

M D2030 M D2040

0.15-0.27

0.20-0.35

(.0059-.0106 in)

(.0078-.0137 in)

0.12-0.24 0.20-0.40

(.0047-.0094 in) (.0078-.0157 in)

0.20-0.35 0.20-0.40

(.0078-.0137 in)

(.0078-.0157 in)

0.06-0.10

0.065-0.110

(.0023-.0039 in)

(.0025-.0043 in)

0.05-0.09

0.013-0.035

(.0019-.0035 in)

(.0005-.0013 in)

0.02-0.06

0.030-0.130

(.0007-.0023 in)

(.0011-.0051 in)

M D2030

MD2040

0.006-0.023

0.010-0.027

(.0002-.0009 in) (.0003-.0005 in)

-0.004- +0.006

-0.001- +0.011

(-.0001-+.0002 in)

(-.00003- +.0004 in)

20.998-21.002 27.994-28.000

(.8266-.8268 in) (1.1021-1.1023 in)

21.010-21.021 28.010-28.021

(.8271-.8275 in)

(1.1027-1.1031 in)

20.998-21.004 27.999-28.005

(.8266-.8269 in) (1.1023-1.1025 in)

MD2030 MD2040

64.6-65.4

69.7-70.3

(2.543-2.574 in)

(2.744-2.767 in)

30.35-30.45 36.35-36.45

(1.194-1.198 in) (1.431-1.435 in)

26.85-26.95

32.35-32.45

(1.0570-1.0610 in) (1.2736-1.2775 in)

2.25-2.35 2.05-2.15

(.0885-.0925 in)

(.0807-.0846 in)

M D2030 M D2040

0.05-0.30 0.1-0.4

(.0019-.0118 in)

(.0039-.0157 in)

0.039-0.106

0.044-0.116

(.0015-.0041 in)

(.0017-.0045 in)

0.039-0.106 0.044-0.116

(.0015-.0041 in)

(.0017-.0045 in)

0.039-0.092 0.044-0.102

(.0015-.0036 in)

(.0017-.0040 in)

Main bearing

Main bearing journals

Big-end bearing

Big-end bearing journals

Technical data

M D2030

MD2040

Diameter in mm, standard, bearing journal

No. 1



45.964-45.975

67.900-67.970

(1.8096-1.8100

(2.6732-2.6759

No.



45.964-45.975

67.900-67.970

(1.8096-1.8100

(2.6732-2.6759

No.



45.964-45.975

67.960-67.986

(1.8096-1.8100

(2.6755-2.6766

undersize, No. 1

0.25



45.854-45.934

67.650-67.720

(.0098

(1.8052-1.8084

(2.6633-2.6661

0.50



45.604-45.684

67.400-67.470

(.0196

(1.7954-1.7985

(2.6535-2.6562

undersize, No.

0.25



45.854-45.934

67.650-67.720

(.0098

(1.8052-1.8084

(2.6633-2.6661

0.50



45.604-45.684

67.400-67.470

(0196

(1.7954-1.7985

(2.6535-2.6562

undersize, No.

0.25



:....

45.714-45.725

67.710-67.736

(.0098

(1.7997-1.8001

(2.6657-2.6667

0.50



45.464-45.475

67.460-67.486

(.0196

(1.7899-1.7903

(2.6559-2.6569

MD2010 MD2020

Diameter in mm, standard, bearing journal

No. 1



42.964-42.975 42.964-42.975

(1.6915-1.6919

No.



45.964-45.975 42.964-42.975

(1.8096-1.8100

No.



45.964-45.975

(1.8096-1.8100

undersize, No. 1

0.25



42.760-42.786 42.760-42.786

(.0098



(1.6834-1.6844

0.50



42.510-42.536

(.0196



(1.6736-1.6746

undersize, No.

0.25



45.764-45.790

42.760-42.786

(.0098



(1.8017-1.8027

(1.6834-1.6844

0.50



45.514-45.540

42.510-42.536

(.0196



(1.7918-1.7929

(1.6736-1.6746

undersize, No.

0.25



45.764-45.790

(.0098



(1.8017-1.8027

0.50



45.514-45.540

(.0196



(1.7918-1.7929

MD2010

MD2020 MD2030

M D2040

Big-end bearing, radial clearance in mm



0.031-0.068

0.035-0.083

0.035-0.085

(.0012-.0026

(.0013-.0032

(.0013-.0033

Bearing journal length in mm



15.65-16.55

17.70-18.60 19.70-20.60

(.6161-.6515

(.6968-.7322

(.7755-.8110

Diameter in mm, standard



34.964-34.975

38.964-38.975

51.964-51.975

(1.3765-1.3769

(1.5340-1.5344

(2.0458-2.0463

undersize, 0.25



34.714-34.725

38.714-38.725

51.714-51.725

(0098

(1.3666-1.3671

(1.5240-1.5246

(2.0359-2.0364

0.50



34.464-34.475 38.464-38.475

51.464-51.475

(.0196

(1.3561-1.3572

(1.5143-1.5147

(2.0261-2.0266

Technical data

Big-end bearing shells

Connecting rods

Valve system

Valves

MD2010

MD2020

M D2030 M D2040

Inlet

Spindle diameter in mm



5.960-5.975

6.94-6.95

6.955-6.970

(.2346-.2352

(.2732-.2736

(.2738-.2744

Valve disc edge in mm



0.925-1.075

0.925-1.075 0.925-1.075

(.0364-.0423

Clearance in mm, valve spindle guide



0.045-0.072

0.050-0.075

0.03-0.06

(.0017-.0028)

(.0019-.0029

(.0011-.0023

Seat angle in cylinder head



45 0

Valve clearance in mm, cold engine



0.20 0.20 0.20

(.0078

Outlet

Spindle diameter in mm



5.940-5.955

6.94-6.95 6.94-6.95

(.2338-.2344

(.2732-.2736

Valve disc edge in mm



0.925-1.075 0.925-1.075

0.925-1.075

(.0364-.0423

Clearance in mm, valve spindle guide



0.045-0.072 0.050-0.075 0.050-0.075

(.0017-.0028

(.0019-.0029

Seat angle in cylinder head



45°

450

45°

Valve clearance in mm, cold engine



0.20 0.20 0.20

(.0078

(0078

(.0078

MD2010

MD2020

M D2030 M D2040

Fitted with replaceable bearing shells.

Diameter, gudgeon bushing's bearing position



21.000-21.021

23.000-23.021

30.500-30.516

(.8267-.8275

(.9055-.9063

(1.2007-1.2014

Bearing shell's bearing position



19.015-19.026 21.010-21.021

28.010-28.021

(.7486-.7490

(.0827-.8275

(1.1027-1.1031

Gudgeon bushing



19.015-19.026 21.010-21.021

28.010-28.021

(.7486-.7490

(.8271-.8275

(1.1027-1.1031

Axial clearance, connecting rod -crankshaft



0.031-0.079 0.035-0.083

0.035-0.083

(.0012-.0031

(.0013-.0032

MD2010

MD2020 MD2030

MD2040

Thickness in mm,

standard



1.484-1.497 1.482-1.495

(.0584-.0589

(.0583-.0588

oversize

0.25



1.609-1.622

1.607-1.620

(.0098

(.0633-.0638

(.0632-.0637

0.50

mm ............................

1.734-1.747

1.732-1.745

(.0196

(.0682-.0687

(.0681-.0687

Timing gears

Camshaft

M D2010 M D2020

MD2030 MD2040

Drive



Number of bearings



Gear wheel

Valve times:

nlet valves open B.T.D.C



13 013 0

16°

close A.B.D.C



430

40°

outlet valves open B.B.D.C



430

46°

close A.T.D.C



130

13 0

130

10 0

Technical data

Note: Temperatures with stable ambient temperature.

Fuelsystem

Valve springs

MD2010

MD2020 MD2030 MD2040

Length in mm (in) uncompressed



33(l.299) 33(l.299) 35(l.377) 35(l.377)

with 79.4 N (58.56 ft.lbf) compression



30.4 (1.196)

with 67.7 N (49.93 ft.lbf) compression



28.3 (1.114) 28.3 (1.114)

Push rods

Length in mm (in), total



146

157

195.8-196.2

(5.748) (5.748) (6.181)

(7.709-7.724)

Outer diameter in mm (in)



6.3 6.3 6.3

6.2-6.4

(.2480) (.2480)

(.2480)

(.2441-0.2520)

Rocker mechanism

Rocker shaft, diameter in mm



11.65-11.67 11.65-11.67

11.65-11.67

(.4586-.4594 in) (.4586-.4594 in) (.4586-.4594 in) (.4586-.4594 in)

Clearance in mm, rocker shaft - bushing



0.032-0.068 0.032-0.068 0.032-0.068

0.032-0.068

(.0012-.0026 in) (.0012-.0026 in) (.0012-.0026 in) (.0012-.0026 in)

Lubrication system

MD2010

MD2020

MD2030 MD2040

Oil pressure in kPa, hot engine at running speed

150-500 150-500

(21.7-73 lbf/in

(21.7-73 lbf/in z)

(21.7-73

lbf/int)

Oil pressure in kPa, idling



50-150 50-150 50-150 50-150

(7.25-22 lbf/in z)

(7.25-22lbf/in z)

Relief valve, opening pressure in kPa



294-490 294-490 294-490 245-345

(42.6-71 lbf/in')

(42.6-71 lbf/in

)

(42.6-71 lbf/in z)

(34.4-50 lbf/in z)

Oil pump:

Clearance, inner - outer impeller



0.01-0.15 mm 0.01-0.15 mm

0.01-0.15 mm

(.0004-.0059 in)

(.0004-.0059 in) (.0004-.0059 in) (.0004-.0059 in)

Axial clearance, impeller - cover



0.01-0.15 mm 0.01-0.15 mm

0.01-0.15 mm

(.0004-.0059 in)

(.0004-.0059 in) (.0004-.0059 in) (.0004-.0059 in)

Oil quality as per API system



Viscosity at -5 to +50°C* (+23 to +122°F)*



SAE 15W/40.

SAE 20W/50

Max. Oil volume incl. oil filter:

no engine tilt (version A/B)



no engine tilt (version C)



Min. Oil volume incl. oil filter:

no engine tilt (version A/B)



1.8 litres

(1.9 US quarts)

1.9-litres

(2.0 US quarts)

1.5 litres

3.4 litres

(3.6 US quarts)

2.8 litres

(3.0 US quarts)

3.0 litres

4.3 litres

(4.5 US quarts)

3.5 litres

(3.7 US quarts)

3.2 litres

6.4 litres

(6.7 US quarts)

5.7 litres

(6.0 US quarts)

5.5 litres

no engine tilt (version C)



(1.6 US quarts)

1.3 litres

(3.2 US quarts)

2.1 litres

(3.4 US quarts)

2.7 litres

(5.8 US quarts)

4.5 litres

(1.7 US quarts)

(2.2 US quarts)

(2.9 US quarts)

(4.8 US quarts)

MD2010 MD2020 MD2030 MD2040

njection sequence



1-2

1-2-3

Feed pump max. induction height in m (ft)



0.8 (2.62) 0.8 (2.62) 0.8 (2.62) 0.8 (2.62)

Feed pressure in kPa (lbf/inz)



15-25 (2.1-3.6) 15-25 (2.1-3.6) 15-25 (2.1-3.6) 15-25 (2.1-3.6)

njection pump

M D2010 M D2020

MD2030 MD2040

Start of injection, crankshaft position



25.5° ±1°

25.5° +1°

22.51±10

21.0°

±10

........................................................................

B.T.D.C

B.T.D.C'

27.7°

1 °

B.T.D. C 3

21.5°±1°

B.T.D.C

19.0°±1°

Pump element, diameter in mm (in)



4.5 (.1771)

B.T.D. C

4.5 (.1771)

B.T.D.C

5.5 (.2165)

B.T.D. C

6,7

5.5 (.2165)

stroke length in mm (in)



6(.2362) 6(.2362) 6(.2362) 7(.2755)

up to and including engine number 5101311299

from engine number 510101939 7

MD2040C

from engine number 5101311300

to and including engine number 510101938

MD2040A/B product number 868748

MD2040B product number 868778 13

Note:

refers to engine with timing gears and at approx. +20°C (+68°F).

Electrical system

M D2010

MD2020

MD2030

MD2040

System voltage



12V 12V

12V

Fuses



15A 15A

15A

Battery capacity (starter battery)



70 Ah 70 Ah 70 Ah 70 Ah

Glow plug:

rated voltage



10.5V 10.5V 10.5V

10.5V

current



6.9 A

6.9 A 6.9 A

Alternator

M D2010

MD2020

MD2030 MD2040

Output voltage at +20°C (+68°F)



14.2 ±0.15 V

14.2 ±0.15 V 14.2 ±0.15 V 14.2 ±0.15 V

Max. current



60 A

60 A 60 A 60 A

Power approx



840 W 840 W

840 W

Suppressor capacitor



2.2 µF 2.2 hF 2.2 hF

2.2 µF

Voltage regulator type



YV 77 YV 77

Starter motor

M D2010

MD2020

MD2030

MD2040

Starter motor, power approx



0.7 kW

1.2 kW

2.0 kW

Engine speed* with connected starter motor,

approx



340 rpm

300 rpm

285 rpm

265 rpm

Technical data

njector

MD2010 MD2020

MD2030

MD2040

Opening pressure (checking)



11.3-12.3 MPa 11.3-12.3 MPa

11.3-12.3 MPa

15.2-16.2 MPa

115-125 kp/cm

155-165 kp/cm

1639-1784 lbf/in

2205-2347 lbf/in

Opening pressure (adjustment)



11.8 MPa

15.7 MPa

120 kp/cm

160 kp/cm

Needle valve, diameter



1711 lbf/int

3.5 mm

1711 lbf/int

3.5 mm

1711 lbf/int

6mm

2276 lbf/int

4mm

(0.1378 in) (0.1378 in) (0.2362 in) (0.1575 in)

Journal diameter



(0.0394 in)

Jet angle



4° 4°

4°

Cooling system

MD2010

MD2020

MD2030 MD2040

Type



Overpressure, closed cooling system

Fresh water system volume, approx (vers. A/B).

2.1 litres

3.0 litres

4.0 litres

6.9 litres

Fresh water system volume, approx (vers. C) ....

2.2 US quarts

2.3 litres

3.2 US quarts

2.9 litres

4.2 US quarts

4.5 litres

7.3 US quarts

6.7 litres

Thermostat, number



Thermostat begins to open at



2.4 US quarts

±2°C

3.1 US quarts

1st

75° ±2°C

4.8 US quarts

1st

82° ±2°C

7.1 US quarts

82° ±2°C

(167° ±4°F)

(179° ±4°F)

fully open at



87°C (189°F) 87°C (189°F) 95°C (203°F)

95°C (203°F)

Thermostat valve's lifting height



6 mm

6mm

8 mm

(0.2362 in) (0.2362 in) (0.3150 in)

(0.3150 in)

Wear tolerances

Note:

Unless otherwise stated the given values refer to all engines.

General

Compression pressure at starter motor speed (min. 200 rpm) .... min. 25 kp/cm

(355.6 lbf/int)

Pistons

Piston clearance



Piston rings

Piston ring clearance in groove:

Compression rings



Oil ring



Piston ring gap in cylinder



Gudgeon pins

Gudgeon pin diameter:

MD2010

MD2020



MD2030



MD2040



Clearance, gudgeon pin - bushing



gudgeon pin - hole



Cylinder head

Distortion



Cylinder block

Distortion (top plane)



Cylinder diameter

MD2010

MD2020



0.2 mm (.00787 in) oversize



0.5 mm (.01969 in) oversize



MD2030



0.5 mm (.01969 in) oversize



1.0 mm (.03937 in) oversize



MD2040



0.5 mm (.01969 in) oversize



1.0 mm (.03937 in) oversize



max. 0.25 mm (.0098 in)

max. 0.15 mm (.0059 in)

max. 1.0 mm (.0393 in)

min. 18.98 mm (.7472 in)

min. 20.98 mm (.8259 in)

min. 27.98 mm (1.1015 in)

max. 0.08 mm (.0031 in)

max. 0.02 mm (.0007 in)

max. 0.12 mm (.0047 in)

max. 67.2 mm (2.6456 in)

max. 67.7 mm (2.6653 in)

max. 68.2 mm (2.6850 in)

max. 75.2 mm (2.9606 in)

max. 75.7 mm (2.9803 in)

max. 76.2 mm (3.0000 in)

max. 84.2 mm (3.3149 in)

max. 84.7 mm (3.3346 in)

max. 85.2 mm (3.3543 in)

Technical data

Crankshaft

Curvature



max. 0.06 mm (.00236 in)

Connecting rods

Linearity, deviation on 100 mm (3.937 in) measured length



max. 0.15 mm (.00590 in)

Distortion on 100 mm (3.937 in) measured length



max. 0.2 mm (.00787 in)

Axial clearance, crankshaft - connecting rod



max. 0.7 mm (.02755 in)

Valves

Max. valve clearance*, inlet and outlet (cold engine)



max. 0.5 mm (.01968 in)

Maximum permitted valve clearance before adjustment must be carried out

Starter motor

Commutator diameter:

MD2010

MD2020

MD2040



min. 31 mm (1.2204 in)

MD2030



min. 40 mm (1.5748 in)

Brush length



min. 11.5 mm (.4527 in)

Brush spring tension

MD2010

MD2020

MD2040



min. 8.8 N (2.0 lbf)

Brush spring tension

MD2030



min. 13.7 N (3.0 lbf)

Tightening torque inNm (ft.lbf)

The tightening torque given under respective engine is the final tightening torque.

The cylinder head should be tightened in three stages and in the correct sequence.

See tightening torque diagram on page 32.

Grease in the cylinder head screw threads with grease containing molybdenum disulphide.

Hexagonal screws

Rear cap (socket head screws)

Technical data

MD2010

M D 2020

M D 2030

M D2040

Cylinder head*



35-40 (25.8-29.5)

50-53 (36.9-39.1)

90-95 (66.4-70.1)

Main bearing:

top to bottom bearing cap (steel)



25-30 (18.4-22.1)

50-55 (36.9-40.5)

(aluminium)



;



20-25 (14.7-18.4)

Main bearing cap to cylinder block



25-30 (18.4-22.1)

25-30 (18.4-22.1) 50-55 (36.9-40.5) **

25-30 (18.4-22.1)***

Big-end bearing



21-26 (15.5-19.2)

30-35 (22.1-25.8)

50-55 (36.9-40.5)

End-plate/flywheel housing



13-17 (9.6-12.5) 47-55 (34.7-40.6) 13-17 (9.6-12.5)

Flywheel housing



24-29 (17.7-21.4)

Flywheel



70-80 (51.6-59.0)

60-70 (44.3-51.6)

Flexible coupling



9-12 (6.6-8.8) 9-12 (6.6-8.8)

9-12 (6.6-8.8)

Adapter plate for flywheel housing



24-29 (17.7-21.4)

24-29 (17.7-21.4) 24-29 (17.7-21.4)

Suction strainer, oil pump



9-13 (6.6-9.6) 9-13 (6.6-9.6)

9-13 (6.6-9.6)

Bottom plate



9-12 (6.6-8.6) 9-12 (6.6-8.6)

9-12 (6.6-8.6)

Sump



9-13 (6.6-9.6) 9-13 (6.6-9.6)

9-13 (6.6-9.6)

Drain plug, sump



30-40 (22.1-29.5)

Timing gear casing



9-12 (6.6-8.6) 9-12 (6.6-8.6)

9-12 (6.6-8.6)

Crankshaft pulley



90-100 (66-74)

120-130 (86-96)

280-340 (206-250)

njection pump



9-13 (6.6-9.6) 9-13 (6.6-9.6)

9-13 (6.6-9.6)

Bearing bracket, rocker shaft



20-25 (14.7-18.4)

Valve cover



10-12 (7.4-8.6) 10-12 (7.4-8.6)

8-12 (5.9-8.6

Pressure oil pipe (cylinder block-cylinder head).

10-13 (7.4-9.6) 10-13 (7.4-9.6)

0-13 (7.4-9.6)

njector



60-70 (44.3-51.6)

80-85 (59.0-62.7) 60-70 (44.3-51.6)

Delivery pipe



20-25 (14.7-18.4)

15-25 (11.0-18.4)

Pressure valve holder



35-39 (25.8-28.8) 40-45 (29.5-33.2)

40-45 (29.5-33.2)

Relief valve



60-70 (44.3-51.6)

60-70 (44.3-51.6) 60-70 (44.3-51.6)

Lock screw (max. fuel volume)



20-25 (14.7-18.4) 20-25 (14.7-18.4) 20-25 (14.7-18.4)

Lock screw (speed)



13-17 (9.6-12.5)

13-17(9.6-12.5)

Glow plug



15-20 (11.0-14.7)

2'76"(11. 0-14.7)

Oil pressure relay



15-20 (11.0-14.7)

Refrigerant temperature relay



25-30 (18.4-22.1) 25-30 (18.4-22.1) 25-30 (18.4-22,1)

Oil pressure sensor



15-20 (11.0-14.7)

Refrigerant temperature sensor



15-20 (11.0-14.7)

Special tools

Note. If necessary, the workshop should be equipped with 2 deep (minimum 80 mm) hexagonal sockets, 22 mm and

27mm, for removing the injectors. These sockets can be obtained from a well stocked tool supplier and are not

stocked by Volvo Penta.

885224-6



Engine fixture. The tool should be supplemented with 4 pcs pin

screws 479971-4, 4 pcs nuts 971095-5, 4 pcs screws 970964-3

(

M10x140), 4 pcs screws 955311-6 (M8x140), 4 pcs washers

960148-5 (M10), 4 pcs washers 960141-0 (M8) and the arms

from engine fixture 885050-5.

9992520-8



Overhaul stand

856927-9



Measuring plastic (disposable item)

9510060-8



Multimeter

OF)

9999179-6



Key for dismantling of fuel and oil filters.

885251-9



Adapter for measuring compression pressureMD2030

885252-7



Adapter for measuring compression pressure

MD2010

MD2020

and

MD2040

General

The engines are in-line, 4-stroke, marine diesel engines

fitted with top valves.

MD2010

has two cylinders, while

MD2020

MD2030

and

MD2040

have three cylinders.

The engines are of the pre-chamber type and equipped

with glow plugs which are activated before and during

starting.

The engines are fitted with thermostat regulated fresh

water cooling. The cooling system is divided into a

fresh water and a sea water system. The sea water

cools the fresh water system via a heat exchanger.

Lubricating takes place by means of an oil pressure

system where an oil pump presses oil to all the lubrica-

tion point. The oil system is provided with a replaceable

oil filter of the full-flow type.

The fuel system is protected from impurities by a re-

placeable fine filter.

Positioning of rating plates

Presentation

VOLVO



a,usan asseraBLY

PENTA

XXXX

(

XXXXXXXXXX(2)

XXX XXX (3)

XXXX (5)

XXXXXXXXXX(6)

XXX XXX (7)

Engine and transmission decal

Design differences, engine versions

This Workshop Manual applies to all engines

MD2010

2040 A, B, C

The most important differences are:

MD2010-40A

MD2010-40B

MD2010-40B has:

•



Unipolar electrical system

•



The fly wheel cover and the transmission (reverse

gear or S-drive) are electrically insulated from the

engine

MD2010-40B

MD2010-40C

MD2010-40C has:

•



Heat exchangers with improved cooling performan-

ce and extended expansion volume

•



Deeper and narrower oil sump

•



Reinforced generator mountings for 2010 and 2020

•



Common oil filter for 2010-40

vxUYeo

nCCOXnnxR' i0

•x



nvvxoR

TO;

XXXXXXX

XXX

(



VOLVO

XXXX

(1)



XXX

XXX (3)

PEP7TA

XXXXXXXXXX (2)

Engine plate

Product designation

Serial number

Product number

Certification number

Gear ratio

Presentation

2 3

MD201OA/B & MS2L

16 15



MD2010A/B & MS2L

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