Volvo Penta MD5A Marine Diesel Engine Workshop Manual

Publ. No. 3061 Dec. 1975 WORKSHOP MANUAL MD5A Marine diesel engine ENGINE UNIT FOREWORD This workshop manual contains repair instructions for the MD5A marine diesel engine. The instructions concerning overhauling describe the most suitable working method to be used with the special tools listed under the heading “Special tools “. Both the engine designation and its serial number must be clearly stated in all correspondence concerning the engine and when ordering spare parts. We reserve the right to carry out design modifications and, for this reason, the contents of this manual cannot he regarded as binding.

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AB VOLVO PENTA Technical Information Department NEW UNITS OF MEASUREMENT Technicians have long since tried to establish an internationally standardized system of measurements. In 1960 a decision was made to use a system called SI (Systéme International d’Unites). To a large extent, this system is based on earlier systems but the units have been made uniform so that no conversions are necessary. The SI-system is now being applied within industry in Europe, This manual contains the new SIunits. The units used previously however, are also stated but in brackets. The new units are: Output is slated in kW (kilowatts) earlier unit h.p. (horsepower) Torque is stated in NM (Newton-metres) earlier unit kpm (kilopond-metres) Engine speed is stated in r/s (revolutions per second) earlier unit r.p.m. (revolutions per minute) Displacement and volumes are stated in dm cubic decimetres) earlier unit l (litres) Pressure is stated in Pa (Pascal) 2 earlier unit kp/cm (kiloponds per square centimetre). 3( Reproduction permitted if source quoted CONTENTS Presentation Dismantling Electrical system, thermostat housing cylinder head Flywheel, fuel injector pump Oil pump, transmission cover, governor Lubricating oil pump, camshaft, cylinder Crankshaft, cylinder liner, camshaft bearing Overhauling Lubricating oil pump, sea-water pump Feed pump Fuel filter, crankshaft Centrifugal governor, piston Valve guides, nozzle sleeve Valves, valve seats, rocker mechanism, injector Hand start mechanism, camshaft Assembling Cylinder liner, crankshaft Cylinder, camshaft, governor Lubricating oil pump, transmission cover Adjustment of control rod travel, assembling flywheel cover Oil sump, cylinder head, feed cover Fuel filter, injector, thermostat Flywheel, generator, valve adjustment Checking injection angle Bleeding the fuel system, electrical system Wiring diagram Fault-tracing system Special tools Technical data 18 19 Presentation Connection for hand start Fuse box Thermostat housing Decompression lever Injector Oil filler Cap, engine Water drain tap, gearbox Oil drain plug, gearbox Water drain tap, engine 10. Oil filler, gearbox 11. Sea-water pump 12. Dipstick, gearbox 13. Fuel filter 14. Bleed screw 15. Hand pump, fuel 16. Dipstick, engine 17. Oil filter 2 Repair instructions Dismantling 1. Drain the cooling water and the oil from the engine. Clean externally afterwards. Loosen the water hose between the gearbox and the sea -water pump and remove the gearbox. 3. Remove the rocker cover and the fuel pipe between the pump and the injector and unscrew the rocker gear. Note! Pull the rocker gear straight up since it is centred with a guide pin 1. The other hole 2 is an oil channel. 2. Remove the generator and its drive belt, starter motor, fuel filter and fuel pump with the drain-off pipe (be careful of fuel spillage), coolant water pump with hose and thermostat housing, dipstick, temperature and oil pressure sensors. Unscrew and discard the oil filter. 4. Remove the push-rods 1, remove the cylinder head and the cylinder head gasket. Take care of the washers 2 under the nuts. 3 5. Remove the flywheel nuts. Spanner jaw width 55 mm (2 5/32 “). Use a wooden shaft or something similar as a counter force in the flywheel spokes. 7. Remove the cover for the injection pump. Note! The bracket for the cold start is fixed with one of the screws. Take care of the spring under the cover. 6. Fit tool 884078 to the flywheel. Afterwards screw in the centre screw on the tool until the flywheel loosens. 8. Prise the lower ball joint free from the pump with a screwdriver. 4 9. Remove the pump screws. Position the ball in the centre and remove the pump. 11. Remove the governor by loosening the hexagonal set screw (1), the governor and the gear wheel can then be withdrawn. 10. Remove the sump and then the transmission cover (13 screws). The lifting eye is fixed one of the screws. The cover is centralised by guide pins. 12. Remove the screw and the locking washer for the gearbox drive flange on the crankshaft and remove the flange with a puller. (Use counter force.) Remove the key afterwards. 5 13. Remove the lubricating oil pump. Discard the gasket.

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