Workshop Manual
Contents
1. ldli amp ig Speed iit t E SEL onl len e Oil pressure full speed hot engine cere Oil pressure idling hot engine pp Cylinders Material icons it ub Ud id Bore standard ai e tete ia 0 25 mm 0 010 oversize pp 0 50 mm 0 020 oversize pp Pistons ET Height total nee epe Height from gudgeon pin centre to piston crown Piston clearance in Cylinder pp Pistons standard diameter 0 25 mm 0 010 oversize 0 50 mm 0 020 oversize Gudgeon pins REI Gudgeon pin bushing diameter pp Clearance gudgeon pin bushing ppp Piston rings Compression rings NUMbET ii Oil Scraper ring number eseee The upper compression ring is chromium lined Piston rings are available for standard size 0 250 mm 0 010 and 0 500 mm 0 020 oversize Piston ring clearance in groove axially Upper compression ring pp Lower compression ring pp Oil seraper Firg cec eat Piston ring gap in cylinder Upper compression ring pp Lower compression ring pp Oil Scraper WING entretenu Crankshaft Material Crankshaft axial clearance eene Main bearing radial clearance pp Big end bearings radial clearance esses MD7A 10 kW 13 4 h p 2 76 mm 2 9921 82 mm 3 2283 0 744 dm 17 1 2 2 5 MPa 20 25 kp cm 284 355 Ibf in Clockwise 11 13 rev sec 650 780 rev min2. esee 216 KE A Reeder ie STARO e E A Capacity voi Compression ratio essen Compression pressure at starter motor speed Direction of rotation viewed towards flywheel img Be RE Oil pressure hot engine pp Oil pressure idling hot engine pp Cylinders Material 5 5 ec EE EE t Bote staridard s te dete men 0 500 mm 0 020 oversize ene Pistons Material nnee a a el Height from gudgeon pin centre to piston crown Piston clearance in Cylinder pp Pistons standard BE 0 500 mm 0 0207 oversize eee Gudgeon pins Diameter ica Ee EE Gudgeon pin bushing diameter pp Clearance gudgeon pin bushing pp Piston rings Compression rings number eee Oil Scraper ring NUMBET i Upper compression ring has chromium lining Piston rings are available for standard size and 0 500 mm 0 020 oversize Piston ring clearance in groove axially Upper compression ring pp Lower compression ring pp Oil Scraper ring rne eit tede conteret ceo Piston ring gap in cylinder Upper compression ring pp Lower compression ring eeeee eee eeeeeeeteeeeeeeeeeteneeeeaeees ac dii Crankshaft ET Crankshaft axial clearance pp Main bearing radial clearance pp Connecting rod radial clearance neee Measured with Moto Meter nipple 884535 and yoke 884543 MD6
3. 75 Adjusting the BOSCH injection pump a o 28 Turn over the engine until the valves in cylinder No 2 rock Continue to turn over the engine in the normal direction of rotation until marking 10 on flywheel coincides with the marking on the block Remove the pump inspection cover and check that the marking 1 coincides exactly with the pointer 2 Adjustments are made by slackening the pump securing nuts and turning the pump Tighten the nuts Check the setting by turning over the engine 1 4 turn in the opposite direction of rotation then back again to the 10 marking on the flywheel Check that the marking 1 and the pointer 2 still coincide Fit the inspection cover with the rubber gasket 75a Adjusting the CAV fuel injection pump a 76 Rotate the flywheel in a clockwise direction until both the valves on No 1 cylinder are closed compression stroke Assemble the pump so that the marking coinci des with that on the transmission housing see fig Fit on the gear wheel NOTE The figure 1 is to be turned towards the figure 1 of the intermedia te wheel Bleed the air from the pump with the bleed screws in the following order 1 2 3 Adjust the valves as follows Rotate the flywheel until both valves on a cylinder rock Turn the flywheel one further turn and ad just the valves for this cylinder Repeat the procedure for the other cylinder With a hot engine the clearance should be 0
4. Remove the key and clean the shaft Check for wear and grind the shaft if necessary See under Technical Data Clean the engine block and all other parts which must be re fitted Cylinder head 31 Replacing the valve guides 29 With excessive clearance between the valve stem and valve guide the valve guide must be repla ced See under Technical Data Press out the valve guides with tool 884538 Remove the valve tappets NOTE Carefully machine clean the valve tappets where they have been smoothed down 1 in order to serve as a counterhold for the torque wrench Do not force out the valve tappets as this could damage the block etc 30 32 Fit new valve guides with tool 884549 Use a press Remove the seals on the valve stems Remove the valve springs with the help of a valve spring remover Remove all the collets 1 Remove the valves IMPORTANT Place the valves in the or der in which they are removed Discard burnt val ves if the wear is excessive and grind valve seats if necessary See under Technical Data Seats and valves must be ground together so that the contact surfaces will be absolutely tight Removing the nozzle sleeves 33 Insert the expander screw on tool 884541 into the copper sleeve and screw anti clockwise until the screw has expanded and fastened in the sleeve Then pull hard so that the threads go into the cop per material Fit the yoke on the stud bolts holding the inject
5. Workshop Manual Engine unit 2 0 MD6A MD7A Workshop Manual Marine diesel engines MD6A MD7A Contents Safety PrecaltiONS eege AA A 2 General information pe 5 Repair methods EE ERREUR CREER 6 Presentation 8 9 Repair inistructions cit cid 10 Electrical eelef Augen tee aida ii 30 Special Tools narh hii di 34 TECHNICAL RI EE EREA EAA AA SA ie 35 Safety Precautions Introduction This Workshop Manual contains technical data de scriptions and repair instructions for Volvo Penta products or product versions contained in the con tents list Ensure that the correct workshop literature is being used Read the safety information and the Workshop Manual General Information and Repair In structions carefully before starting work Important In this book and on the engine you will find the follow ing special warning symbols AN WARNING If these instructions are not fol lowed there is a danger of personal injury ex tensive damage to the product or serious me chanical malfunction IMPORTANT Used to draw your attention to something that can cause damage product malfunction or damage to property NOTE Used to draw your attention to important infor mation that will facilitate work or operations Below is a summary of the risks and safety precau tions you should always observe or carry out when operating or servicing the engine AN Immobili
6. 0 35 0 40 MPa 3 5 4 0 kp cm 50 57 Ibf in 0 08 0 15 MPa 0 8 1 5 kp cm 11 21 Ibf in Cast iron 76 00 76 03 mm 2 9921 2 9933 76 25 76 28 mm 3 0020 3 0032 76 50 76 53 mm 3 0118 3 0130 Light alloy 76 4 mm 3 0079 51 4 mm 2 0236 0 073 0 118 mm 0 0029 0 0046 75 912 75 927 mm 2 9883 2 9893 76 162 76 177 mm 2 9985 2 9991 76 412 76 427 mm 3 0084 3 0090 28 000 28 004 mm 1 1024 1 1025 28 0125 28 0225 mm 1 1029 1 1032 0 0085 0 0230 mm 0 0003 0 0009 0 070 0 102 mm 0 0028 0 0040 0 050 0 082 mm 0 0020 0 0030 0 030 0 062 mm 0 0012 0 0024 0 30 0 50 mm 0 0120 0 020 0 30 0 50 mm 0 0120 0 020 0 25 0 50 mm 0 010 0 020 Nodular iron 0 080 0 313 mm 0 0032 0 0123 0 026 0 075 mm 0 0010 0 0030 0 026 0 075 mm 0 0010 0 0030 39 Main bearing journals Diameter standard 0 300 mm 0 0120 undersize pp 0 600 mm 0 0236 undersize pp Main bearing shells Thickness standard 0 300 mm 0 0120 oversize pp 0 600 mm 0 0236 oversize pp Big end journals Diameter standard 0 300 mm 0 0120 undersize pp 0 600 mm 0 0236 undersize pp Big end bearing Thickness standard 0 300 mm 0 0120 oversize pp 0 600 mm 0 0236 oversize pp Connecting rods End play at crankshaft iaa Camshaft End play Radial clearance in b Camshaft diameter Lift height of cams Bushing diameter
7. Cylinder head Said ET Intake valves Disc diameter Stem diameter Valve seat angle Cylinder head seat angle pp Width of seat in cylin A EE Clearance hot engine ii Exhaust valves Disc diameter Stem diameter Valve seat angle Cylinder head seat angle ii Width of seat in cylin Clearance hot engine pp Valve guides Length intake valve Length exhaust valv i o Height above cylinde CRE orion eege ee ED QC r head spring face Clearance valve stem guide intake valve exhaust valve 40 49 984 50 000 mm 1 9679 1 9685 49 684 49 700 mm 1 9560 1 9567 49 384 49 400 mm 1 9442 1 9449 1 730 1 737 mm 0 0681 0 0684 1 880 1 887 mm 0 0740 0 0743 2 030 2 037 mm 0 0799 0 0802 49 984 50 000 mm 1 9679 1 9685 49 684 49 700 mm 1 9560 1 9567 49 384 49 400 mm 1 9442 1 9449 1 730 1 737 mm 0 0681 0 0684 1 880 1 887 mm 0 0740 0 0743 2 030 2 037 mm 0 0799 0 0802 0 25 0 50 mm 0 0100 0 0200 0 160 0 300 mm 0 0063 0 0118 0 018 0 083 mm 0 007 0 0033 43 992 44 008 mm 1 7320 1 7326 5 48 5 52 mm 0 2157 0 2173 44 026 44 075 mm 1 7333 1 7352 Special alloy cast iron 32 4 32 6 mm 1 2756 1 2835 7 955 7 970 mm 0 3132 0 3138 45 15 45 45 45 approx 1 mm 0 0
8. damaged the propeller must be replaced A pro peller blade can also be warped something which is very difficult to discover Place the propeller on a flat disc and measure the blades If a propeller blade is warped the propeller should be replaced Check the cooling system for leakage clogging etc Check to make sure the thermostat opens at the right temperature The thermostat can be removed after having taken down the thermostat housing at the front of the exhaust manifold See also Point 49 The pump body in the sea water pump is made of neoprene rubber which can be damaged with shortage of water e g in the event the sea water inlet is blocked Proceed according to Points 45 48 in the event the impeller and sealing rings have to be replaced NOTE If the boat is in the water the bottom cock must be closed before the sea water pump is removed But do not forget to open the cock again 33 Special Tools Part No Description 884537 Flaring tool for copper sleeve 884538 Drift for pressing out valve guides 884549 Drift for pressing in valve guides 884539 Drift for pressing in nozzle sleeves 884541 Tool for removing nozzle sleeves 884535 Nipple for compression gauge 884543 Yoke for installing nipple 34 Technical Data Technical Data MD6A General TYPO ds e EE Output DIN at 40 rev sec 2400 rev min Number of cylinders
9. no rev counter and temp gauge Cable marking Des Colour mm AWT A Beige 2 5 13 B BI Black 1 5 15 C Red 25 3 C Red 2 5 13 D Green 1 5 15 D Green 2 5 13 G Brown 1 5 15 H Blue 1 5 15 H Blue 25 3 30 ODOA mm Starter button Key switch Charging warning light Control light for oil pressure Switch Terminal board instrument panel resp engines Charging regulator Start generator Oil pressure indicator Battery 12 V max 60 Ah Main switch Fig 00 JO Om AS ON 11 12 13 14 15 16 17 18 19 83 Wiring diagram for late prod type MD6A Key switch Instrument panel switch Temperature gauge Warning light for low oil pressure Rev counter Warning light charging start generator Switch optional equipment Terminal board Warning light charging alternator optional equip ment Battery Main switch Start generator Alternator optional equipment Charging regulator Fuse Temperature sender Rev counter Oil pressure sender Other electrical equipment INSTRUMENT PANEL ENGINE Max BATTERI KAPACITET _SOAH 31 Wiring diagram MD7A CABLE MARKING Des A B B tO O0 ccc ET A Colour White Black Black Black Red Red Red Yellow Brown Blue Blue Green red Green
10. 1 9291 BOLO tie get etie ds 8 000 8 022 mm 0 3150 0 3158 Height above cylinder head spring face 10 7 11 0 mm 0 4212 0 4331 Clearance valve stemguide pp 0 040 0 084 mm 0 0016 0 0033 36 Valve springs Length e E e WEE Loaded with 150 N 15 kp 33 lbf pp Loaded with 230 N 23 kp 50 lbf pp Lubricating system Engine Oil capacity excl filter ps Oil capacity incl filter i Oil quality acc to API system pp Viscosity above 10 C 50 F Viscosity below 10 C 50 F Oil pressure hot engine idling speed Oil pressure hot engine full speed eeeeeeeee Reverse gear Oil quality Viscosity ii Oil capacity dm gts red 11 Oil capacity dm gts red 1 911 Combi reduction gear Reduction Qe Le Reversing mechanism and propeller hub Lubricating oil filter Designation cete ee eue Lubricating oil pump Relief valve spring Length off load eeeeeeee Loaded with 15 N 1 5 kp 3 3 ID Loaded with 46 N 4 6 kp 10 Ibf Axial clearance of gear wheels incl gasket Fuel system Fuel injection pump make Bosch Injectors make Bosch holders ssesssusss Nozzles Hole diameter aiite Eee adea tear Opening pre
11. 30 mm 0 012 for both the intake and exhaust valves 77 Oil the rocker arm and fit the rocker arm cover to gether with new gaskets Fit the intake manifold and gasket and install the air cleaner Fit the ven tilation hose between the rocker arm cover and air cleaner NOTE Fit the intake manifold with the flange dis placed towards the reverse gear side in order to provide space for the air cleaner 78 Fit the V belts and tension the alternator The belts are properly tensioned when they can be de pressed under normal thumb pressure about 3 4 mm 1 8 Depress between the start generator and flywheel 79 Fit the key in the crankshaft Heat the flange and fit it on the shaft Tighten it up with the bolt and the thick washer Tightening torque 80 Nm 8 kpm 57 Ibftf Bend down the thin washer over the bolt head Fit the rubber damper 80 Install the reverse gear and gasket and connect up the cooling water hose between the reverse gear and water pump Then fit the exhaust elbow 81 Fill the engine and reverse gear with oil Concer ning the oil quantity and quality see under Tech nical Data 29 Electrical system ELECTRICAL SYSTEM IMPORTANT 82 The following applies to engines fitted with alter nators 1 Never break the current between the alternator and battery while the engine is running If a main switch is fitted it must not be switched off until the engine has stopped Otherw
12. 7 When the engine has been stopped for a long time Bleeding is as follows Open the bleeder screw 1 on the fine fil ter See Point 68 Pump forward the fuel with the help of a hand primer until about 0 2 litre 0 2 qt fuel has run out Close the bleeder screw If you get poor pumping effect turn over the engine a bit So that the pump drive cam alters its position If the fuel injection pump has been removed or when starting an entirely new engine for the first time the fuel injection pump must be bled Pump with the hand primer for about 1 2 minute This automatically bleeds the fuel injection pump Slacken the delivery pipe nuts for the injectors and turn over the engine with the start generator until fuel comes from the delivery pipes Tighten up the delivery pipe nuts and start the engine Check the injectors with regard to their opening pressure tightness and spray pattern Max run ning time of 400 operating hours or once a season is recommended between these checks See also Points 37 and 38 In order to get the best possible operating econo my the engine speed selected should be mini mum 300 rev min below the max speed for the engine during lengthy periods of operation Note When the boat has been in the water for some time the max speed for the engine can drop due to growth on the outside of the hull Use anti fouling paint Check and clean the hull regu larly Check the propeller blades If a propeller blade is
13. Bosch Up to engine no 19999 Fuel injection pump CAV From engine no 20000 Injectors make Bosch holders pp Nozzles oct 3 eet ub Sa Liha oe ea AL alas Hole diameter Opening pressure pp ele Vue EE Advance angle Bosch pump pp Advance angle CAV PUMP pp Injection quantity Bosch pump pp Injection quantity CAV PUMP eee Feed pump 42 5 mm 1 6732 32 mm 1 2598 24 mm 0 9449 2 8 litres 2 5 Imp qts 2 9 US ats 3 0 litres 2 6 Imp qts 3 2 US qts CD DS SAE 20 W SAE 10 W 0 8 1 5 kp cm 11 4 21 3 Ibf in 3 5 4 0 kp cm 50 57 Ibf in Same as for engine 0 4 0 4 0 55 0 5 Same oil compartment as engine s Lubricating grease Shell Alvania EP2 or similar Gear wheel pump 45 mm 1 7717 40 mm 1 5748 29 mm 1 1417 0 048 0 084 mm 0 0020 0 0033 0 460 302 008 0 3222 F070 0 431 112 001 0 433 171 009 Four 0 23 mm 0 0091 185 193 kp cm 2631 2744 Ibf in 150 C 11 1 b t d c 14 0 1 b t d c 18 0 5 mg stroke at 43 rev sec 2580 rev min 17 5 0 5 mg stroke at 43 rev sec 2580 rev min Pierburg PE 15672 0 65 0 85 kp cm 9 2 12 0 Ibf in 41 Electrical system Battery VOI EE Battery capacity sess Starter Motor BOSCli ou Serge ale ria Starter motor output ii Alternator SEV Marchal pp Alterator OUtpUt nente e Battery electrolyte specific gravity Fully charged battery When charg
14. Green Green Blue yellow White red Blue red Position List Charging warning light 2 3 4 5 6 7 9 0 1 1 1 32 Terminal board Starter motor 0 75 35 0 6 1 5 1 5 35 0 75 1 5 0 6 0 75 0 75 0 75 0 75 Warning light for high temp Warning light for low oil pressure AWG 15 19 18 19 15 15 11 18 15 18 18 18 18 18 Key switch 12 Alternator Siren 13 Fuse Alarm unit 14 Main switch Place for instrument extra equipment 15 Battery 16 Temperature sender 17 Oil pressure sender FAULT TRACING The fault tracing scheme below includes only those faults which arise most often during operation Fault tracing scheme to o S 38 2 L d o o s s9 8Eg Clo 55 FAULT Notes 9 gm oc jo c 9 889 58 92 e ejle2Pleg et e e9s e s 2 POOS PSBPS uu jus3uususg Main switch not on flat X battery broken electric cables see Point A Empty fuel tank closed xX X fuel cock blocked fuel filter see Point B Water air or impurities in x X Xx fuel see Point B x x X X Defective injectors see Point C Boatabnormally X loaded Growth on boat bottom see Point D X X Damaged propeller see Point E Clogging of cooling water X intake cooling jackets defective impeller or ther mostat see Point F A Check the state of charge of the battery with the help of a hydrometer which shows the specific grav
15. other skin problems Used oil is more dangerous to health than new oil Use protective gloves and avoid using oil soaked clothes and rags Wash regularly especially be fore meals Use the correct barrier cream to prevent dry skin and to make cleaning your skin easier Most chemicals used in products engine and transmission oils glycol petrol and diesel oil and workshop chemicals solvents and paints are hazardous to health Read the instructions on the product packaging carefully Always fol low safety instructions using breathing appara tus protective goggles and gloves for exam ple Ensure that other personnel are not unwittingly exposed to hazardous substances by breathing them in for example Ensure that ventilation is good Handle used and excess chemicals according to instructions Be extremely careful when tracing leaks in the fuel system and testing fuel injection nozzles Use protective goggles The jet ejected from a fuel injection nozzle is under very high pres sure it can penetrate body tissue and cause serious injury There is a danger of blood poison ing All fuels and many chemicals are inflammable Ensure that a naked flame or sparks cannot ig nite fuel or chemicals Combined with air in cer tain ratios petrol some solvents and hydrogen from batteries are easily inflammable and explo sive Smoking is prohibited Ensure that ventila tion is good and that the necessary safety pre cautions have been
16. taken before carrying out welding or grinding work Always have a fire ex tinguisher to hand in the workplace AN Store oil and fuel soaked rags and fuel and oil filters safely In certain conditions oil soaked rags can spontaneously ignite Used fuel and oil filters are environmentally dangerous waste and must be deposited at an approved site for de struction together with used lubricating oil con taminated fuel paint remnants solvent de greasing agents and waste from washing parts Never allow a naked flame or electric sparks near the batteries 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 is easily ignited and highly volatile Incor rect connection of the battery can cause a spark which is sufficient to cause an explosion with resulting damage Do not disturb battery connections when starting the engine spark risk and do not lean over batteries Never mix up the positive and negative battery terminals when installing Incorrect installation can result in serious damage to electrical equip ment Refer to wiring diagrams Always use protective goggles when charging and handling batteries The battery electrolyte contains extremely corrosive sulfuric acid If this comes into contact with the skin wash im mediately with soap and plenty of water If bat tery acid comes into contact with the eyes i
17. the opening pressure with adjuster washers 1 which are available in different thicknesses ranging from 1 mm 0 04 to 1 95 mm 0 08 at intervals of 0 05 mm 0 002 between each was her Screw apart the injector and replace the adjuster washer with a thinner or thicker one depending on whether the pressure has to be reduced or in creased Screw the injector together again and check the opening pressure and spray pattern Continue this procedure until results are satisfac tory 40 Release the cover centre screw lift out the strai ner 1 and clean it 41 Unscrew the six bolts holding the upper and lower sections of the pump body together Remove the pump lever spring 1 and unscrew the screw 2 which holds the pump lever shaft 43 Undo the screw 1 and pull out the manual pump lever 2 and replace the spring 3 if in poor condi tion NOTE Keep an eye on the rubber seal which is pressed into the body 42 Press down the diaphragm and shake forwards the pump lever shaft 1 until the pump lever loo sens Then pull the diaphragm out of the body Thoroughly clean the pump body and replace worn parts Re fit the manual pump lever Press the di aphragm in and fit the pump lever onto the di aphragm shaft Then insert the shaft and tighten it with the screw IMPORTANT Do not forget the washer on the screw Place the strainer on the upper body section and screw tight the cover and gasket Assemble the pump bo
18. 40 0 30 mm 0 012 27 4 27 6 mm 1 0787 1 0866 7 950 7 965 mm 0 3130 0 3136 45 15 45 45 45 approx 1 mm 0 040 0 30 mm 0 012 38 mm 1 4961 38 mm 1 4961 8 0 8 015 mm 0 3150 0 3156 8 85 9 15 mm 0 3484 0 3602 0 03 0 06 mm 0 0012 0 0024 0 035 0 065 mm 0 0014 0 0026 Valve springs Length offload inn lavare Loaded with 170 10 N 17 1 kp 37 522 Ibf Loaded with 300 20 N 30 2 kp 664 5 Ibf Lubricating system Engine Oil capacity excl filter ii Oil capacity incl filler ee a Oil quality ace to API system pp Viscosity above 10 C 50 F Viscosity below 10 C 50 F Oil pressure hot engine idling speed Oil pressure hot engine full speed Reverse gear Oil quality Viscosity i Oil capacity dm gts red 11 Oil capacity dm qts red 1 911 Combi reduction gear Reduction JO ar ovio ia ERA Eti eee Reversing mechanism and propeller hub Lubricating oil pump Relief valve spring Length off load eeeeeeee Loaded with 15 N 1 5 kp 3 3 Ibf nenene Loaded with 46 N 4 6 kp 10 Ibf Axial clearance of gear wheels incl gasket Fuel system Fuel injection pump make
19. A 7 4 kW 10 h p 2 70 mm 2 7560 82 mm 3 2283 0 63 dm 18 7 1 23 25 kp cm 327 355 Ibf in Clockwise 12 rev sec 700 rev min 4 kp cm 57 Ibf in 0 8 kp cm 11 Ibf in Cast iron 70 000 70 019 mm 2 7560 2 7566 70 500 70 519 mm 2 7755 2 7763 Light metal 81 mm 3 19 51 mm 2 00 0 086 0 130 mm 0 0034 0 0051 69 889 69 914 mm 2 7515 2 7525 70 389 70 414 mm 2 7712 2 7722 27 9975 28 0025 mm 1 1023 1 1025 28 0125 28 0225 mm 1 1029 1 1032 0 010 0 025 mm 0 0004 0 0010 0 062 0 113 mm 0 0024 0 0044 0 037 0 087 mm 0 0015 0 0034 0 037 0 089 mm 0 0015 0 0035 0 279 0 406 mm 0 0110 0 0160 0 203 0 330 mm 0 0080 0 0130 0 350 0 480 mm 0 0140 0 0189 Nodular iron 0 08 0 31 mm 0 0031 0 0122 0 026 0 075 mm 0 0010 0 0030 0 026 0 075 mm 0 0010 0 0030 35 Main bearing journals Diameter Standard iii eedem 49 984 50 000 mm 1 9679 1 9685 0 300 miri tinderslze eto etc te 49 684 49 700 mm 1 9560 1 9567 0 600 mm undersize eene 49 384 49 400 mm 1 9442 1 9449 Main bearing shells Thickness standard 1 730 1 737 mm 0 0681 0 0684 0 300 lu e ET 2 030 2 037 mm 0 0800 0 0802 0 600 imm EE 2 330 2 337 mm 0 0917 0 0920 Connecting rod journals Diameter standard 49 984 50 000 mm 1 9679 1 9685 0 300 mm underelze sse 49 684 49 700 mm 1 9560 1 9567 0 600 mm UNUB
20. Data Tightening Torques and are contained in work descriptions in this Manual All torques apply for cleaned threads screw heads and mating surfaces Torques apply for lightly oiled or dry threads If lubricants locking fluid or sealing com pound are required for a screwed joint this information will be contained in the work description and in Tight ening Torques Where no tightening torque is stated for a joint use the general tightening torques accord ing to the tables below The tightening torques stated are a guide and the joint does not have to be tight ened using a torque wrench Dimension Tightening Torques Nm Ibt ft M5 6 44 M6 10 74 M8 25 18 4 M10 50 36 9 M12 80 59 0 M14 140 103 3 Tightening torques protractor angle tightening Tightening using both a torque set ting and a protractor angle requires that first the recommended torque is applied using a torque wrench and then the recommended angle is add ed according to the protractor scale Example 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 Locknuts Do not re use lock nuts that have been removed dur ing dismantling as they have reduced service life when re used use new nuts when assembling or re installing For lock nuts with a plastic insert such as Nylock the tightening torque stated in the table is re duced if the Nylock nut has the sam
21. ards the figure on the intermediate gear Tigh ten up the gear wheel with the nut which also functions as a flange for the water pump Tightening torque 60 Nm 6 kpm 43 Ibftf Use a counterhold Tighten the camshaft nut Remove the counter hold Lau a 60 Fit the cylinder head gasket It can only be fitted in one way If the stud bolts in the cylinder head must be replaced fit the new ones to a torque of 20 Nm 2 kpm 14 Ibftf Fit the cylinder head All the nuts must have washers under them except the one on which the lift eyelet is fitted Tight ening torque 70 Nm 7 kpm 50 Ibftf NOTE Tightening is in three stages First stage 10 Nm 1 kpm 7 bim Second stage 40 Nm 4 kpm 29 Ibftf Third stage 70 Nm 7 kpm 50 Ibftf See tightening scheme below 58 Place the large flat washer on the intermediate gear with the bevel facing outwards and thereaf ter the steel rubber washer 1 Tighten with the bolt NOTE On earlier engines a plastic washer is used This must be scrapped and replaced by the steel rubber one 24 61 Place a new gasket on the inner timing gear cover 63 Place a new gasket on the water pump and fit it and fit the outer timing gear casing Two short with the two bolts Make sure that the groove in bolts are fitted at the bottom Trim off any part of the pump shaft engages in the flange nut the gasket which sticks out 62 Fit a new gasket and cover where the water pump 64 Fit
22. arried out with the engine in place follows the same working method Warning symbols occurring in the Workshop Manual for their meaning see Safety information AN WARNING AN IMPORTANT NOTE are not in any way comprehensive since it is impossi ble to predict every circumstance under which service work or repairs may be carried out For this reason we can only highlight the risks that can arise when work is carried out incorrectly in a well equipped workshop using working methods and tools developed by us All procedures for which there are Volvo Penta spe cial tools in this Workshop Manual are carried out us ing these Special tools are developed to rationalize working methods and make procedures as safe as possible It is therefore the responsibility of any per son using tools or working methods other than the ones recommended by us to ensure that there is no danger of injury damage or malfunction resulting from these In some cases there may be special safety precau tions and instructions for the use of tools and chemi cals contained in this Workshop Manual These spe cial instructions should always be followed if there are no separate instructions in the Workshop Manual Certain elementary precautions and common sense can prevent most risks arising A clean workplace and engine eliminates much of the danger of injury and malfunction It is of the greatest importance that no dirt or foreign particles get into the fue
23. care of the control bracket Discard the old gasket A B did Ten LE r f pm d a d 8 Remove the nut which drives the water pump gt B Use the flywheel as a counterhold Remove the fuel injection pump and the gear wheel ier 9 Remove the timing gear cover NOTE The small 11 Knock out the hand starter pin in the camshaft round cover on which the fuel pump is mounted Remove the protective cover 2 bolts NOTE has bolts with 3 different lengths The bolts for the Scrap the sealing ring and fit a new one large casing has two lengths The two bottom bolts are shorter than the others Carefully lever loose the timing gear casing from its guide pins Discard the gasket SESSEL geed A 10 Remove the flywheel Remove the nut and use a 12 Remove the front cover behind the flywheel 11 puller The axle is tapered and provided with a bolts Note the guide pins Carefully tap all round key Use a counterhold when releasing the nut Replace the gasket and the sealing ring 13 Remove the sump as well as the nut and lock 15 Remove the bolt for the intermediate gear Dis washer for the camshaft Use a counterhold on card the sealing washer 1 under the bolt Pull off the crankshaft the intermediate gear 14 Bend down the lock washer and release the bolt 16 Check that the shaft pin 1 for the intermediate securing the reverse gear flange to the gear is secure crankshaft Use a counterhold NOTE Take car
24. dy halves and fit the retaining washer 1 for the spring 2 on the mechanical pump lever 3 IMPORTANT The retaining washer can only be fitted in one way Fit the spring and then the O ring 4 which seals against the engine 20 Overhauling the sea water pump 45 Remove the cover 6 bolts Replace the impeller with the help of two screwdrivers or similar tools IMPORTANT Protect the edges on the pump body See Fig below Lever out the impeller with the screwdrivers so far that the bolt becomes vi sible zt p A A 46 Unscrew the bolt and pull the impeller off the shaft If the sealing rings also have to be repla ced the shaft can be pulled out entirely together with the impeller after which the bolt can be rele ased 47 Remove the sealing rings 2 and the O ring 1 ear lier engines and clean the pump body and shaft IMPORTANT The pump must be removed from the engine Check to make sure there is no burr on the shaft NOTE A new O ring must not be fi ted 48 Fit new sealing rings IMPORTANT Turn the se ling rings so that they are in their proper position and make sure that they do not block the drain t a hole in the pump body Grease the shaft and care fully fit it into the body Screw it through the sea ing rings but make sure the rings are not damaged when doing so Place the shaft so far into the housing that the bolt hole is outside Fit the impel ler and screw in the bol
25. e of the key Lever loose the rubber damper with a screwdriver EE reg a Qu mm 17 Remove the gearwheel for the camshaft by tap 19 Invert the engine and remove the oil strainer 2 ping the camshaft on the flywheel side with a bolts and 1 nut plastic mallet or similar tool Lift out the shaft and take care of the cover 20 Unscrew the bolts and remove the caps Then ca refully tap out the pistons and connecting rods Place connection rods and caps in the same pai ring as when removed to prevent them getting mixed up if they are not marked NOTE Also mark the piston and connecting rod for the re 18 Remove the 4 bolts holding the timing gear ca spective cylinders see point 21 On earlier engi sing The casing also sits on guides Carefully le nes there is no marking on the pistons and con ver all round and remove the casing necting rods During overhauling these engines must be marked in the same way as those produ ced later on 21 Mark the connecting rod and cap nearest the fly 23 Remove the centre nut and washer for the gear wheel with a peener Peen as shown in Fig 21 wheel on the lubricating oil pump The shaft is ta pered and the gear wheel sits on a key 22 Remove the main bearing caps and lubricating oil pump The main bearing caps are marked with a 2 or 3 The corresponding figures are punched into the block Replace the axial bearings 1 Check that the guide 2 for the caps is in good condit
26. e head height as a standard hexagonal nut without plastic insert Re duce 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 tighten ing torques given in the table apply Tolerance classes Screws and nuts are divided into different strength classes 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 tol erance than one marked 8 8 lt is therefore important that bolts removed during the disassembly of a bolted joint 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 correct bolt is used Sealants 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 siz es in the engines To ensure service work is correctly carried out it is important that the correct sealant and locking fluid type is used on the joint where the agents are re quired In this Volvo Penta Service 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
27. ement may cause an explo sion in the inlet manifold Danger of personal in jury AN 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 coolant filler cap carefully and slowly to release pressure before removing the cap completely Take great care if a cock plug or engine coolant line must be removed from a hot engine It is difficult to anticipate in which direction steam or hot coolant can spray out AN Hot oil can cause burns Avoid skin contact with hot oil Ensure that the lubrication system is not under pressure before commencing work on it Never start or operate the engine with the oil filler cap removed otherwise oil could be ejected AN Stop the engine and close the sea cock before carrying out operations on the engine cooling System AN Only start the engine in a well ventilated area If operating the engine in an enclosed space en sure that exhaust gases and crankcase ventila tion emissions are ventilated out of the working area AN Always use protective goggles where there is a danger of pieces of metal sparks from grinding acid or other chemicals being thrown into your eyes Your eyes are very sensitive injury can lead to loss of sight Avoid skin contact with oil Long term or repeat ed contact with oil can remove the natural oils from your skin The result can be irritation dry skin eczema and
28. et reduction gear Oil drain reverse gear reduction gear Warner low oil pressure Oil filter 5 Er 8 9 10 d d Repair instructions Drain the cooling water and oil from the engine Then 3 Remove the thermostat housing 2 bolts and the clean the outside of the engine Remove the reverse hose clamp under the housing Take the thermo gear 4 bolts stat out of the exhaust manifold Note the small O ring which seals against the exhaust manifold Removal 1 Remove the air cleaner disconnect the alternator electric cables and the oil pressure cable remove the alternator and the drive belts Then remove the sea water pump the oil filter the fuel filter and the feed pump Look out for fuel and oil splash 2 Remove the injectors and pipes as well as the leak off oil pipe Discard the sealing washers on both sides of the leak off oil pipe 4 Remove the exhaust manifold 4 bolts 5 Remove the rocker arm cover 2 nuts the intake 7a BOSCH pump Disconnect the pipe from the fuel manifold 4 bolts the rocker arm 2 nuts and the filter and remove the nuts for the fuel injection cylinder head 9 bolts Take care of the washers pump 7b CAV pump Disconnect the pipe from the fuel fil ter and remove the nuts for the fuel injection pump 6 Remove the cover on which the water pump is mounted NOTE Two of the five bolts are shorter than the other three and are placed towards the centre of the engine Take
29. ing has to be carried out Cooling system Thermostat ZE AED potter dE e Starts e ln RE Fully PEN Ati aii WEAR TOLERANCES Cylinders Rebore for wear or if engine has abnormal fuel consumption Crankshaft Main bearing and connecting rod journals Permitted out ot roundness pp Permitted taper ps Max axial play on crankshaft A Camshaft Bearing journals permitted out of roundness Max clearance between camshaft and bushings Valves Max clearance between valve stem and guide Edge of valve disc should be min ppp Tightening torques Cylinder head nuts eee Cylinder head stud bolts pp Bolt for flange on crankshaft pp Flywheel n t EE Connecting rod bolts ail ia Water pump flange Bosch fuel injection pump Water pump flange CAV fuel injection pump Main e Tue CEET Nuts for fork for injectors ii Bolt for intermediate gear transmission Starter Motor Belt o Ad iot erect Bolt front engine mounting pp Bolt rear engine mounting pp Tightening scheme for cylinder head nuts 42 12V Max 120 Ah 0 001 311 115 1 1 kW 1 48 h p 70 229712 490W 35A 1 275 1 285 g cm 1 230 g cm Bellows thermostat 60 140 F 74 C 165 F 0 25 mm 0 010 0 06 mm 0 0024 0 05
30. ion Lift out the crankshaft 24 Remove the bolts 4 from the pump body cover and lift off the cover Clean the body and check that the gears are in good condition Replace da maged parts 25 26 Re fit the gears as shown in the Fig below Fit the cover together with a new gasket Tighten up the 4 bolts and rotate the shaft to make sure that it does not jam Fit the key in its groove and re fit the gear wheel Fit the spring washer and tighten up the gear with the nut Remove the bolt 1 for the relief valve and check that the spring 2 and piston are in good condition If there is anything suspicious about the opening pressure of the relief valve check the data for the spring See under Technical Data Lubricating oil pump Clean and re fit the piston and spring and tighten up the bolt 27 Check for wear on pistons piston rings and gud geon pins Replace if necessary The piston and connecting rod must be matchfitted as shown in fig A Make absolutely certain that the groove ring for the gudgeon pin is fitted in its groove The piston rings are fitted with a piston ring rod Begin with the oil ring 1 fig B in the lowest groove Continue with the compression ring 2 Finally fit the compression ring 3 NOTE The marking TOP must face upwards The other two rings can be fa ced as desired Crankshaft 28 Check the drive gear on the crankshaft for wear or damage Remove the drive gear with a puller
31. ioned in the Service Manual Loctite 572 white Loctite 241 blue NOTE Loctite is the registered trademark of Loctite Corpora tion Permatex is the registered trademark of the Permatex Corporation Presentation MD6A Recess for starting crank Oil filling engine Sealed crankcase ventilation Intake silencer Connection fuel inlet Feed pump Reduction reverse gear MS red 1 91 1 8 Control lever reverse gear 9 Oil filling reverse gear 10 Oil pressure contact 11 Lubricating oil filter 12 Start generator 13 Fuel filter 14 Water cooled exhaust manifold 15 Decompression handle 16 Injectors 17 Temperature sender 18 Cooling water outlet 19 Thermostat housing 20 Throttle lever 21 Stop lever 22 Fuel injection pump 23 Oil dipstick engine 24 Fuel return line connection 25 Sea water pump 26 Oil dipstick reverse gear NOOR WD ch MD7A 1 IO OTRE OO Oil dip stick and oil filling reverse gear Cover cooling water pump Bleed screw fine filter Fine filter Decompression handle Pressure pipe nut Temperature sender Injector Thermostat housing Oil filling engine 11 12 13 14 15 16 17 18 19 20 21 22 Hand start Cooling water drain engine Fuel injection pump Oil dip stick engine Cooling water drain reverse gear Air cleaner and intake silencer Sender rev counter Fuel pump with hand pump Cooling water inl
32. is mar ked with Front and should point towards the fly wheel NOTE Fit the connecting rod which is marked with punch pops nearest the flywheel Ca refully tap the piston downwards through the in stallation tool with a wooden handle or similar Place the engine on its side and tighten up the caps Tightening torque 50 Nm 5 kpm 36 Ibftf Lock the bolts with the lock washers 53 Fit the protective cover for the starting crank 55 Fit a new gasket and install the timing gear casing Replace the sealing ring and gasket 4 bolts Tap carefully so as not to deform the guide pins 54 Fit the camshaft Observe due care so that the 56 Fit the key in the camshaft and then the gear sealing ring in the protective cover for the starting wheel Turn the gear wheel so that the figure crank is not damaged Knock the starting crank which is punched on the ring gear faces outwards pin into the camshaft Use a tube or similar as a Fit the star washer and the nut on the camshaft counterhold Tighten up later on see Point 59 When a new engine block is used a new shaft pin 1 for the intermediate gear must be fitted 23 57 Fit the intermediate gear Check that the 59 Install the fuel injection pump Use a new gasket punched in figures on the crankshaft drive and Fit the key on the pump shaft and install the gear camshaft gear wheel coincide with the marking on wheel IMPORTANT The figure must face the intermediate gear tow
33. ise no cable must be disconnected while the engine is running since this also can ruin the charging re gulator 2 Check regularly the battery battery cables and cable terminals The battery poles should be well cleaned and the cable terminals always well tightened and well greased to ensure continu ous function All cables in general must be well tightened there must be no loose connec tions Note On no account must the battery s po sitive and negative poles be mixed up when the battery is fitted Wiring diagrams ENGINE 2 3 4 s e When starting with the help of a helper battery first check that the helper battery has the same rated current as the standard one Connect the helper battery to the standard battery positive to positive and negative to negative Remove the helper battery when the engine has started Note The cables to the standard battery must not be broken With electrical welding on the engine or instal lation components the charging regulator ca bles must first be disconnected and insulated Both the battery cables must also be discon nected In the event of repairs to the alternator equipment both battery cables must first be disconnected The same applies if the battery has to be rapidly charged Never test any of the components with a screwdri ver etc against a terminal to see if it sparks INSTRUMENT PANEL Fig 82 Wiring diagram for the MD6A with start generator
34. ity of the battery acid This will vary with the state of charge see under Technical Data Also see under Electrical system on page 23 B Replace the fine filter by turning the hex head in the bottom of the container The fine filter and container are of the throw away type They must be discarded and a new one installed Check that the contact surface for the cover is absolutely cle an and that the filter gasket is in good condition Screw on the new filter tight by hand until the gas ket goes against the cover Then tighten the filter a further 1 2 turn The bottom of the filter contai ner has a drain plug for draining water and impuri ties that have accumulated in the fuel Bleed the fuel system after draining and replacing the filter also check for leakage Remove the feed pump cover and clean the pre filter in the fuel oil Then fit the filter with the pins facing upwards and place the gasket unda maged in position and tighten up the cover Bleed the fuel system Check and if necessary drain the extra fuel filter if such is fitted Look out for fuel splash Bleeding the fuel system To ensure that the engine starts the fuel system must be bled on the following occasions 1 When changing the fine filter 2 When draining through the drain plug 3 When cleaning the pre filter 4 When running the fuel tank empty 5 When instal ling the fuel injection pump 6 With leakage and when working on the fuel line
35. journals Permitted out ot roundness pp Permitted taper ps Max axial play on crankshaft pp Camshaft Bearing journals permitted out of roundness Max clearance between camshaft and bushings Valves Max clearance between valve stem and guide Edge of valve disc should be min pp TIGHTENING TORQUES Cylinder head nuts seen Cylinder head stud bolts eeseeeseeeeeeeeeeeneeeeneeeeneees Bolt for flange on crankshaft pp Flywheel nut EE Connecting rod lte eise ees Water pump flange i Main bearings EE Nuts for fork for injectors i Tightening scheme for cylinder head nuts 38 12V Max 60 Ah Bosch 0 010 350 004 135 W 90 W 0 74 kW 1 h p 1 275 1 285 g cm 1 230 g cm Bellows thermostat 60 140 F 74 C 165 F 0 25 mm 0 010 0 06 mm 0 0024 0 05 mm 0 0020 0 36 mm 0 0142 0 03 mm 0 0012 0 15 mm 0 0060 0 16 mm 0 0063 1 0 mm 0 0400 Nm Kpm Lbftf 70 7 20 2 70 7 180 18 50 5 60 6 50 5 8 0 8 Technical Data MD7A General Type designation ie Output at flywheel DIN at 43 rev sec 2600 rev min Number of cylinders AAA A O iain rtl Capacily ont dt ea ORE Oed Compression ratio pp Compression pressure at starter motor speed Direction of rotation viewed towards flywheel
36. l system lubrication system intake system turbocharger bearings and seals when they are being worked on The result can be malfunction or a shorter operational life Our joint responsibility Each engine consists of many connected systems and components If a component deviates from its technical specification the environmental impact of an otherwise good engine may be increased significant ly It is therefore vital that wear tolerances are main tained that systems that can be adjusted are adjust ed properly and that Volvo Penta Genuine Parts as used The engine Maintenance Schedule must be fol lowed Some systems such as the components in the fuel system require special expertise and special testing equipment for service and maintenance Some com ponents are sealed at the factory for environmental reasons No work should be carried out on sealed components except by authorized personnel Bear in mind that most chemicals used on boats are harmful to the environment if used incorrectly Volvo Penta recommends the use of biodegradable de greasing agents for cleaning engine components un less otherwise stated in a workshop manual Take special care when working on board that oil and waste is taken for destruction and is not accidentally pumped into the environment with bilge water Tightening torques Tightening torques for vital joints that must be tight ened with a torque wrench are listed in workshop manual Technical
37. m mediately flush with copious amounts of water and obtain medical assistance Turn off the engine and turn off power at main switch es before carrying out work on the elec trical system Clutch adjustments must be carried out with the engine turned off AN Use the lifting eyes mounted on the engine re verse gear when lifting the drive unit Always check that lifting equipment is in good condition and has sufficient load capacity to lift the engine engine weight including reverse gear and any extra equipment installed To ensure safe handling and to avoid damaging engine components on top of the engine use a lifting beam to raise the engine All chains and cables should run parallel to each other and as perpendicular as possible in relation to the top of the engine If extra equipment is installed on the engine al tering its center of gravity a special lifting de vice is required to achieve the correct balance for safe handling Never carry out work on an engine suspended on a hoist Never remove heavy components alone even where secure lifting equipment such as secured blocks are being used Even where lifting equip ment is being used it is best to carry out the work with two people one to operate the lifting equipment and the other to ensure that compo nents are not trapped and damaged when being lifted When working on board ensure that there is suf ficient space to remove components without danger of injur
38. mm 0 0020 0 40 mm 0 157 0 03 mm 0 0012 0 15 mm 0 0060 0 15 mm 0 0060 1 0 mm 0 0400 Nm Kpm Lbf ft 70 7 20 2 70 7 180 18 70 7 60 6 80 8 50 5 8 0 8 70 7 70 7 45 4 5 45 4 5 Ex HE VIP j bz N E UD TS ET a Es e p j i pu Ze Ss x Rat 4 t SET BE As P Mi t H 5 CS m SOS Eege d if E i SS M CANCERS TETTES R dE e l y N ERRADA EZIZIZZTA Cross section Longitudinal section 43 44 Notes Report form Do you have any complaints or other comments about this manual Please make a copy of this page write your comments down and post it to us The address is at the bottom of the page We would prefer you to write in English or Swedish AB Volvo Penta Customer Support Dept 42200 SE 405 08 Gothenburg Sweden 8661 90 usiBu3 G OEZO 44
39. ne This Workshop Manual has been developed primarily for Volvo Penta service workshops and qualified per sonnel Persons using this book are assumed to have a grounding in marine drive systems and be able to carry out related mechanical and electrical work Volvo Penta is continuously developing their prod ucts We therefore reserve the right to make chang es All the information contained in this book is based on product data available at the time of going to print Any essential changes or modifications introduced into production or updated or revised service methods introduced after the date of publication will be provid ed in the form of Service Bulletins Replacement parts Replacement parts for electrical and fuel systems are subject to statutory requirements US Coast Guard Safety Regulations for example Volvo Penta Genu ine parts meet these requirements Any type of dam age which results from the use of non original Volvo Penta replacement parts for the product will not be covered under any warranty provided by Volvo Penta Certified engines The manufacturer guarantees that certified new and currently operational engines meet national and re gional environmental regulations in Lake Constance for example The product must be the same as the example approved for certification purposes So that Volvo Penta as a manufacturer can guarantee that currently operational engines meet environmental reg ulations the followi
40. ng service and replacement part requirements must be observed e The Service Intervals and maintenance opera tions recommended by Volvo Penta must be ob served e Only Volvo Penta genuine replacement parts in tended for the certificated engine may be used The servicing of ignition timing and fuel injection systems gasoline or injector pumps pump set tings and injectors diesel must always be car ried out be an authorized Volvo Penta workshop e The engine must not be modified in any way apart from with accessories and service kits de veloped for it by Volvo Penta No modifications to the exhaust pipes and air supply ducts for the engine room ventilation ducts may be undertaken as this may effect ex haust emissions e Seals may only be broken by authorized person nel IMPORTANT Use only Volvo Penta Genuine Parts Use of non original AB Volvo Penta spare parts will result in AB Volvo Penta being un able to assume liability for the engine meet ing engine certification requirements Any type of damage resulting from the use of non original Volvo Penta replacement parts for the product will not be covered under any war ranty provided by AB Volvo Penta Repair methods The working methods described in the Service Manu al 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 c
41. on of the engine is completed bleed the fuel system through the bleeder screw 1 See more detailed instructions about this on page 25 Point B 69 Fit the key for the flywheel and push on the fly wheel Fit the thick washer and tighten up the fly wheel with the nut Tightening torque 180 Nm 18 kpm 130 Ibftf Use a counterhold through the flywheel 70 Oil the oil filter rubber gasket Fit the oil filter and the oil pressure contact Screw in the oil filter so far that the rubber gasket just touches the engine Then screw tight a further half turn IMPORTANT Screw by hand MD6A Install the stars generator with its bracket Screw tight the tensioning bar to the engine Ear lier engines have a washer placed between the engine and bracket MD7A Install the alternator with its bracket Screw tight the tensioning bar to the engine 72 Install the exhaust manifold Fit a new gasket Check to make sure that the rubber hose for the cooling water is in good condition Fit the cooling water hose from the cooling water pump and tigh ten up the hose clamp 27 73 Fit the injectors and the overflow pipe Tightening torque for injectors nuts 1 8 Nm 0 8 kpm 5 8 Ibftf NOTE Do not forget the new sealing wash ers 2 on both sides of the overflow pipe 74 Fit the fuel pipes between the injection pump and the injectors NOTE Check to make sure that the brake pipes are properly installed see Fig
42. or Screw on the nut and rotate until the sleeve is removed 34 Replacing the O ring which seals between sleeve and cylinder head Dip the O ring in soapy water before fitting it Wash and blow clean before fitting the new injec tor sleeve with tool 884539 Knock in the sleeve until it bottoms Check to make sure that the O ring is not damaged or has moved 34a Oil the spreader tool 884537 and push the tool into the sleeve en sure that the bolt is screwed back suffi ciently Place nuts or washers on the stud bolts so that the yoke can be securely attach ed with nuts Screw the tool down as far as the recess in the injector sleeve allows Thus pressing out the sleeve Remove the tool Installing the valves 35 Thoroughly clean the cylinder head valve guides and valve seats Use a small brush Check that the bevel on the seats is correctly ground by app lying marking blue to the bevel on the valve disc and rotating it against the seat under light pressu re If the blue is not distributed evenly on the enti re bevel surface of the seat this indicates a leaky valve grind the valve further and re check until results are successful The width of the seat should be approx 1 mm 0 04 Oil the valve stems before fitting them in their re spective guides IMPORTANT Make sure that the valves and valve springs are re fitted in their original positions Place the cylinder head on its edge and fit the valve
43. rSIZO earen a eaa ainei aE 49 384 49 400 mm 1 9442 1 9449 Connecting rod shells Thickness standard 1 730 1 737 mm 0 0681 0 0684 0 300 MM ovVefsilze EE 2 030 2 037 mm 0 0800 0 0802 0 600 mm oversize ennn n ennenen eenen 2 330 2 337 mm 0 0917 0 0920 Connecting rods End play at crankshaft ii 0 25 0 50 mm 0 0100 0 0200 Camshaft End play it id 0 160 0 300 mm 0 0063 0 0118 Radial clearance in bearing pp 0 017 0 083 mm 0 0007 0 0033 Camshaft diameter ne 43 992 44 008 mm 1 7320 1 7326 Bun ue 5 48 5 52 mm 0 2157 0 2173 Bushing diameter pp 44 025 44 075 mm 1 7333 1 7352 Cylinder head Matas Special alloy cast iron Intake valves Disc diameter ue 2 ed eee 28 8 29 0 mm 1 1338 1 1417 Stem diameter iii ei 7 938 7 960 mm 0 3125 0 3134 Valve Seat angle vis eve s 29 25 29 50 Cylinder head seat angle pp 30 Width of seat in cylinder head pp approx 1 mm 0 040 Clearance hot engine eese 0 30 mm 0 012 Exhaust valves Disc diameter eere eb mentes 26 3 26 5 mm 1 0354 1 0433 AE E te o es 7 938 7 960 mm 0 3125 0 3133 Valve seat angle Ne 29 25 29 50 Cylinder head seat angle pp 30 Width of seat in cylinder head pp approx 1 mm 0 040 Clearance hot engine pp 0 30 mm 0 012 Valve guides Length intake valve pp 43 mm 1 6930 Length exhaust valve pp 49 mm
44. same agent or an alternative from a different manufacturer Make sure that mating surfaces are dry and free from oil grease paint and anti corrosion agent before ap plying sealant or locking fluid Always follow the manufacturer s instructions for use regarding temperature range curing time and any other instructions for the product Tow different basic types of agent are used on the engine and these are RTV agent Room temperature vulcanizing Use for gaskets sealing gasket joints or coating gaskets RTV agent is clearly visible when a component has been dismantled old RTV must be removed before the joint is resealed The following RTV agents are mentioned in the Serv ice Manual Loctite 574 Volvo Penta 840879 1 Per matex No 3 Volvo Penta P N 1161099 5 Permatex No 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 exam ple cast components are installed face to face with out a gasket They are also commonly used to se cure 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 reinstall ing the part is carefully degreased and then new seal ant is applied The following anaerobic agents are ment
45. springs and collets 2 Use a valve spring tool Finally fit the rubber seal 1 MD6A on the intake valves Checking the cylinder head level finish 36 If there is any doubt as to the level finish of the cylinder head after carrying out repairs check as follows Completely disassemble the cylinder head and clean it thoroughly Measure with the help of a steel ruler check the ruler against a flat disc by placing it on the cylinder head face as shown by the arrows in the diagram below Then measure with a feeler gauge the gap between the ruler and the face of the cylinder head at the marked mea suring points A maximum gap of 0 00 0 10 mm 0 00 0 004 measured crisscross see diagram below and 0 00 0 10 mm 0 00 0 004 measured laterally see diagram below is approved If the measured gap is between 0 10 mm 0 004 and 0 20 mm 0 008 then the gap must be grinded If the gap exceeds 0 20 mm 0 008 replace the cylinder head with a new one Pressure testing the injectors 37 Check the spray pattern at an opening pressure of 180 kp cm 2560 Ibf in Also check that the fuel jets cease simultaneously at all four holes and there is no dripping afterwards Overhauling the feed pump 39 Exert force on the pump lever see Fig If the pump squeaks then it is in good condition If it does not the diaphragm must be replaced This is done as follows Adjusting the opening pressure 38 Adjust
46. ssure nennen Spray angle nenne di Advance angles 2 2 Ere tete meae Injection quantity cea cuo did items 47 mm 1 8504 30 mm 1 1811 21 mm 0 8268 2 8 litres 2 5 Imp qts 2 9 US ats 3 0 litres 2 6 Imp qts 3 2 US qts CD DS SAE 30 SAE 20W 0 8 1 5 kp cm 11 4 21 3 Ibf in 3 5 4 0 kp cm 50 57 Ibf in Same as for engine 0 4 0 4 0 55 0 5 same oil compartment as engine s Lubricating grease Shell Alvania EP2 or similar AC DELCO 1530838 type SA Gear wheel pump 45 mm 1 7717 40 mm 1 5748 29 mm 1 1417 0 048 0 084 mm 0 0020 0 0033 0 460 302 006 0 431 112 001 0 433 171 001 Four 0 22 mm 0 0087 180 kp cm 2560 Ibf in 150 12 20 mm stroke at 31 7 rev sec 1900 rev min 40 8 42 5 rev sec 2450 2550 rev min Bosch 0 450 133 001 Bosch 1 457 434 0611 Pierburg PE 15672 0 65 0 85 kp cm 9 2 12 0 Ibf in 37 Electrical system Battery voltage it Battery Capacity mito ii SEA Generator output max i Generator output CONTINUOUS pp Starter motor QU PUE i Battery electrolyte specific gravity Fully charged battery When charging has to be carried out Cooling system Thermostat iino RUE RUD pe eerta SES AAA 1 eue ud utei WEAR TOLERANCES Cylinders Drilled with wear or if engine has abnormal fuel consumption recedens Crankshaft Main bearing and connecting rod
47. t Then carefully push in the impeller until it bottoms Place a new gasket on the cover and tighten up with the 6 bolts 21 Checking the thermostat 49 Lower the thermostat into hot water and with a thermometer test to see whether the thermostat opens and closes at the right temperature It should start opening at 60 C 140 F and be fully open at 74 C 165 F If the thermostat is faulty it must be replaced Clean and fit a new rubber gas ket 1 on the thermostat Place a new O ring 2 for the water hole on the lower edge of the thermostat housing and fit the housing on the exhaust mani fold INSTALLING THE ENGINE 50 Before installing heat the crankshaft drive gear Place the key in the key slot on the crankshaft and press on the new drive gear Fit new bearing shells Oil the bearings Install the crankshaft Fit an axial bearing half 1 on each side of the intermediate main bearing with the oil grooves 2 facing outwards Oil and fit the bearing halves in the caps Place the caps according to the marking on the block Fit the remaining axial bearing halves on the inter mediate cap with the oil grooves facing outwards NOTE Fit a new O ring on the rear cap which is integrally built with the lubricating oil pump The tightening torque for the main bearings is 50 Nm b kpm 36 Ibftf Turn the engine 52 Turn the piston rings so that their respective gaps are apart from each other The piston top
48. the cover with new gasket over the camshaft is to be installed NOTE The control bracket is end NOTE The bolts have three different fitted with one of the bolts Two bolts are shorter lengths The Fig below shows where they are pla ced 25 65 Install the fuel pump Make sure that the O ring is in position Use a new O ring The pump is instal led with two inhex bolts and spring washers Check that the pump squeaks by pressing in the pump lever before installing the pump on the engi ne Connect up the fuel hoses 66 Release the lock wire securing the lubricating oil strainer Lift out the strainer wash it and blow it dry with compressed air Re fit it and lock it with the lock wire Turn the engine and fit the complete oil strainer 67 68 Fit the oil sump together with a new gasket The gasket can only be fitted in one way Begin with the four corner bolts for locating the sump into po sition Tighten all the bolts thoroughly Remove the sealing ring on the casing for the crankshaft flywheel side Fit a new sealing ring Trim off any part of the oil sump gasket that is sticking out Place a new gasket on the cover and fit it Carefully knock on the cover until it fits over the guide pins Tighten up the cover with the bolts Fit the rocker arm fuel filter and fuel lines NOTE Replace the fine filter insert see page 25 Point B by turning the hex head in the bottom of the container When the installati
49. y or damage Components in the electrical system ignition system gasoline engines and fuel system on Volvo Penta products are designed and con structed to minimize the risk of fire and explo sion The engine must not be run in areas where there are explosive materials Always use fuels recommended by Volvo Pen ta Refer to the Instruction Book The use of lower quality fuels can damage the engine On a diesel engine poor quality fuel can cause the control rod to seize and the engine to overrev with the resulting risk of damage to the engine and personal injury Poor fuel quality can also lead to higher maintenance costs General information About the workshop manual This workshop manual contains technical specifica tion descriptions and instructions for repairing the standard versions of the MD6A MD7A engines The workshop manual displays the operations carried out on any of the engines 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 above However the repair and service operations described are the same in all essential details Where they are not the same this is stated in the manual and where the difference is considerable the operations are de scribed separately Engine designations and numbers are given on the number plate The engine designation and number should be given in all correspondence about the engi
50. ze 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 AN Generally all servicing should be carried out with the engine switched off Some work carry ing out certain adjustments for example re quires the engine to be running Approaching a running engine is dangerous Loose clothing or long hair can fasten in rotating parts and cause serious personal injury If working in proximity to a running engine care less movements or a dropped tool can result in personal injury Avoid burns Take precautions to avoid hot surfaces exhausts turbochargers charge air pipes and starter elements etc and liquids in supply lines and hoses when the en gine is running or has been turned off immedi ately prior to starting work on it Reinstall all protective parts removed during service opera tions before starting the engine AN Check that the warning or information decals on the product are always clearly visible Replace decals that have been damaged or painted over AN Engine with turbocharger Never start the en gine without installing the air cleaner ACL The rotating compressor in the Turbo can cause se rious personal injury Foreign objects entering the intake ducts can also cause mechanical damage AN Never use start spray or similar to start the en gine The starter el
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