Volvo Penta MD2010 MD2020 MD2030 MD2040 Workshop Owners Manual - English

Workshop Manual Engine 2(0) A MD2010, MD2020, MD2030, MD2040 Workshop Manual MD201OA/B/C · MD202OA/B/C Marine engines · MD203OA/B/C · MD204OA/B/C Contents Technical data I njection pump Wear tolerances Tightening torque Special tools Presentation 9 15 17 18 Repair instructions I njection pump Adjustment of injection angle Adjustment of speed Feed pump Fuel filter Bleeding of fuel system I njector Checking of injector Cooling system 54 55 57 58 59 59 60 61 Description of engine Engine body 19 Description Repair instructions: Cylinder head Valves.

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valve mechanism . Cylinder block, pistons. connecting rods Timing gears Camshaft Crank mechanism Lubricating system 24 25 28 34 40 44 46 Description Repair instructions Refrigerants Checking of refrigerant level Cleaning Circulation pump Sea water pump Replacing the thermostat Checking the thermostat Electrical system 62 63 64 65 66 66 67 67 Description Repair instructions Oil pump Replacing the oil filter Cleaning the oil channels . Fuel system Description 51 52 52 52 53 Description I mportant info Starting with auxiliary battery Troubleshooting, glow plug, charging system Alternator Starter motor Electrical components Wiring diagram Extra equipment 68 70 71 72 74 76 78 80 87 Note! The data given in this Workshop Manual refers in general to engines in both A, B and C versions unless otherwise stated. 1 This Workshop Manual contains technical specifications, 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. I ntroduction Safety Precautions 0 Before starting work on the engine read the “Safety Precautions “, “Genera! Information ” and “Repair Instruction ” sections of this Workshop Manual carefully. 0 Check that the warning or information labels on the product are always clearly visible. Replace l abels which have been damaged or painted over. Engines with turbocharger ( TC ): 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 mechanical damage. Never use start spray products or similar when starting the engine. They may cause an explosion in the inlet manifold. Danger of personal injury. I mportant I n this book and on the product you will find the followi ng special warning symbols. Q 4L Note! Used to draw your attention to important information that will facilitate the work or operation in progress. I MPORTANT! Used to draw your attention to something that can cause damage or malfunctions on a product or damage to property. WARNING! Possible danger of personal injury, extensive damage to property or serious mechanical malfunction if the instructions are not followed. IL 0 Below is a summary of the risks involved and safety precautions you should always observe or carry out when operating or servicing the engine. 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 removed 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 filler cap removed, otherwise oil could be ejected. I mmobilize the engine by turning off the power supply to the engine at the main switch (switches) and lock it (them) in the OFF position before starting work. Set up a warning notice at the engine 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 require that the engine is running when they are carried out. Approaching an engine which is operating is a safety risk. Loose clothing or long hair can fasten in rotating parts and cause serious 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 (exhaust pipes, Turbocharger (TC ), 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.

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