Volvo Penta KAMD42B Workshop Manual

Workshop Manual

A

Engine unit

2 (0)

MD6A, MD7A

AB Volvo Penta

Customer Support

Dept. 42200

SE-405 08 Gothenburg

Sweden

1

Workshop Manual

Marine diesel engines

MD6A, MD7A

Contents

Safety Precautions 2

General information 5

Repair methods 6

Presentation

MD6A 8

MD7A 9

Repair instructions 10

Electrical system 30

Special Tools 34

Technical Data 35

2

Safety Precautions

Introduction

This workshop manual contains technical data,

descriptions and repair instructions for Volvo Penta

products or product versions contained in the contents

list. Ensure that the correct workshop literature is being

used.

Read the safety information and the Workshop

Manual “General Information” and “Repair

Instructions” carefully before starting work.

Important

In this book and on the engine you will find the

following special warning symbols.

WARNING! If these instructions are not

followed there is a danger of personal injury,

extensive damage to the product or serious

mechanical 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

information that will facilitate work or operations.

Below is a summary of the risks and safety precautions

you should always observe or carry out when operating

or servicing the engine.

Immobilize the engine by turning off the power

supply to the engine at the main switch(es) and

lock it (them) in the OFF position before

starting work. Set up a warning notice at the

engine control point or helm.

Generally, all servicing should be carried out

with the engine switched off. Some work

(carrying out certain adjustments for example)

requires 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,

careless 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 engine is running or has been

turned off immediately prior to starting work on

it. Reinstall all protective parts removed during

service operations before starting the engine.

Check that the warning information decals on

the product are always clearly visible.

Replace decals that have been damaged or

painted over.

Engine with turbocharger: Never start the en-

gine without installing the air cleaner (ACL).

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 or similar to start the

engine. The starter element may cause an

explosion in the inlet manifold. Danger of

personal injury.

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.

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.

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

space, ensure that exhaust gases and

crankcase ventilation emissions are

ventilated out of the working area.

3

A

lways 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

repeated contact with oil can remove the

natural oils from your skin. The result can be

irritation, dry skin, eczema and 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 before 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

poisoning.

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

explosive. Smoking is prohibited! Ensure that

ventilation is good and that the necessary

safety precautions have been taken before

carrying out welding or grinding work. Always

have a fire extinguisher to hand in the

workplace.

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 destruction together with

used lubricating oil, contaminated fuel, paint

remnants, solvent, degreasing 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. Incorrect 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 equipment. 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 immediately with soap and

plenty of water. If battery acid comes into

contact with the eyes, immediately 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 electrical system.

Clutch adjustments must be carried out with

the engine turned off.

4

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 equipment 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 components are not trapped and damaged

when being lifted.

When working on-board ensure that there is

sufficient space to remove components

without danger of injury or damage.

Components in the electrical system, ignition

system (gasoline engines) and fuel system

on Volvo Penta products are designed and

constructed to minimize the risk of fire and

explosion. The engine must not be run in

areas where there are explosive materials.

Always use fuels recommended by Volvo

Penta. 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 over-rev with the resulting risk of

damage to the engine and personal injury.

Poor fuel quality can also lead to higher

maintenance costs.

5

General information

About the workshop manual

This workshop manual contains technical specifica-

tion, descriptions and instructions for repairing the

standard versions of the following engines

TAMD31M, TAMD31L, TAMD31P, AD31L, AD31P,

KAD32P, TAMD41H, TAMD41M, TAMD41P, AD41P,

TAMD42WJ, KAMD42A, KAMD42B, KAMD42P,

KAD42A, KAD42B, KAD42P, KAMD43P, KAD43P,

KAMD44P, KAD44P. 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 described separately. Engine

designations and numbers are given on the number

plate (See Workshop manual Group 21 Engine page

15). The engine designation and number should be

given in all correspondence about the engine.

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 provided 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

regulations, the following service and replacement

part requirements must be observed:

• The Service Intervals and maintenance operations

recommended by Volvo Penta must be observed.

• 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 carried

out be an authorized Volvo Penta workshop.

• The engine must not be modified in any way apart

from with accessories and service kits developed

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.

• 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.

6

Repair methods

The working methods described in the Service

Manual 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 occurring in the Workshop Manual

(for their meaning see Safety in formation)

WARNING!

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 fuel 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

significantly. It is therefore vital that wear tolerances

are maintained, that systems that can be adjusted

are adjusted properly and that Volvo Penta Genuine

Parts as used. The engine Maintenance Schedule

must be followed.

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 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 “Tightening Torques’ Where no tightening

torque is stated for a joint use the general tightening

torques according to the tables below. The tightening

torques stated are a guide and the joint does not

have to be tightened using a torque wrench.

Dimension Tightening Torques

Nm lbt.ft

M5 6 4,4

M6 10 7,4

M8 25 18,4

M10 50 36,9

M12 80 59,0

M14 140 103,3

7

Tightening torques-protractor (angle)

tightening

Tightening using both a torque

setting and a protractor angle

requires that first the

recommended torque is applied

using a torque wrench and then

the recommended angle is

added according to the

protractor scale. Example: a

9Q0 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

reduced if the Nylock® nut has the same head height

as a standard hexagonal nut without plastic insert.

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.

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

tolerance than one marked 8-8. It is therefore

important that bolts removed during the disassembly

of a bolted joint must be reinstalled in their original

position when assembling the joint, It 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 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.

Two 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,

Permatex®

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

reinstalling the part is carefully degreased and then

new sealant is applied.

The following anaerobic agents are mentioned in the

Service Manual: Loctite® 572 (white), Loctite® 241

(blue).

NOTE! Loctite® is the registered trademark of Loctite Corporation,

Permatex® is the registered trademark of the Permatex

Corporation.

8

Presentation

MD6A

1. Recess for starting crank

2. Oil filling, engine

3. Sealed crankcase ventilation

4. Intake silencer

5. Connection, fuel inlet

6. Feed pump

7. 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

9

MD7A

1. Oil dip-stick and oil filling, reverse gear

2. Cover, cooling water pump

3. Bleed-screw, fine filter

4. Fine filter

5. Decompression handle

6. Pressure pipe nut

7. Temperature sender

8. Injector

9. Thermostat housing

10. Oil filling, engine

11. Hand start

12. Cooling water drain, engine

13. Fuel injection pump

14. Oil dip-stick, engine

15. Cooling water drain, reverse gear

16. Air cleaner and intake silencer

17. Sender, rev, counter

18. Fuel pump (with hand pump)

19. Cooling water inlet, reduction gear

20. Oil drain, reverse gear, reduction gear

21. Warner, low oil pressure

22. Oil filter

10

Repair instructions

Drain the cooling water and oil from the engine. Then

clean the outside of the engine. Remove the reverse

gear, 4 bolts.

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.

3. Remove the thermostat housing (2 bolts) and the

hose clamp under the housing. Take the

thermostat out of the exhaust manifold. Note the

small O-ring which seals against the exhaust

manifold.

4. Remove the exhaust manifold (4 bolts).

11

5. Remove the rocker arm cover (2 nuts), the intake

manifold (4 bolts), the rocker arm (2 nuts) and

the cylinder head (9 bolts). Take care of the

washers.

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 care of

the control bracket. Discard the old gasket.

7. a. (BOSCH pump) Disconnect the pipe from the

fuel filter and remove the nuts for the fuel

injection pump.

7. b. (CAV pump) Disconnect the pipe from the fuel

filter and remove the nuts for the fuel injection

pump.

8. Remove the nut which drives the water pump.

Use the flywheel as a counterhold. Remove the

fuel injection pump and the gear wheel.

12

9. Remove the timing gear cover. NOTE! The small

round cover on which the fuel pump is mounted

has bolts with 3 different lengths. The bolts for

the 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.

10. Remove the flywheel. Remove the nut and use a

puller. The axle is tapered and provided with a

key. Use a counterhold when releasing the nut.

11. Knock out the hand starter pin in the camshaft.

Remove the protective cover (2 bolts). NOTE!

Scrap the sealing ring and fit a new one.

12. Remove the front cover behind the flywheel (11

bolts). Note the guide pins. Carefully tap all

round. Replace the gasket and the sealing ring.

13

13. Remove the sump as well as the nut and lock

washer for the camshaft. Use a counterhold on

the crankshaft.

14. Bend down the lock washer and release the bolt

securing the reverse gear flange to the

crankshaft. Use a counterhold. NOTE! Take care

of the key. Lever loose the rubber damper with a

screwdriver.

15. Remove the bolt for the intermediate gear. Dis-

card the sealing washer 1 under the bolt. Pull off

the intermediate gear.

16. Check that the shaft pin 1 for the intermediate

gear is secure.

14

17. Remove the gearwheel for the camshaft by tap-

ping the camshaft on the flywheel side with a

plastic mallet or similar tool. Lift out the shaft and

take care of the cover.

18. Remove the 4 bolts holding the timing gear ca-

sing. The casing also sits on guides. Carefully le-

ver all round and remove the casing.

19. Invert the engine and remove the oil strainer (2

bolts and 1 nut).

20. Unscrew the bolts and remove the caps. Then

carefully 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-

spective cylinders (see point 21). On earlier engi-

nes there is no marking on the pistons and con-

necting rods. During overhauling, these engines

must be marked in the same way as those

produced later on.

15

21. Mark the connecting rod and cap nearest the fly-

wheel with a peener. Peen as shown in Fig. 21.

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 condition. Lift

out the crankshaft.

23. Remove the centre nut and washer for the gear

wheel on the lubricating oil pump. The shaft is ta-

pered and the gear wheel sits on a key.

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.

16

25. 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.

26. 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 faced as desired.

Crankshaft

28. Check the drive gear on the crankshaft for wear

or damage. Remove the drive gear with a puller.

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.

17

Cylinder head

29. 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. 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

valves 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.

31. Replacing the valve guides.

With excessive clearance between the valve

stem and valve guide, the valve guide must be

replaced. (See under “Technical Data”.) Press

out the valve guides with tool 884538.

32. Fit new valve guides with tool 884549. Use a

press.

18

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 copper material. Fit the yoke on the stud

bolts holding the injector. Screw on the nut and

rotate until the sleeve is removed.

34. Replacing the 0-ring which seals between sleeve

and cylinder head.

Dip the 0-ring in soapy water before fitting it.

Wash and blow clean before filling the new

injector sleeve with tool 884539. knock in the

sleeve until it bottoms. Check to make sure that

the 0-ring is not damaged or has moved.

34. a. 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

applying marking blue to the bevel on the valve

disc and rotating it against the seat under light

pressure. If the blue is not distributed evenly on

the entire 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 filling them in their re-

spective guides. IMPORTANT! Make sure that

the valves and valve springs are re-filled in their

original positions. Place the cylinder head on its

edge and fit the valve 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

measuring 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.

19

Pressure-testing the injectors

37. Check the spray pattern at an opening pressure

of 180 kp/cm

2

(2560 Ibf/in

2

). Also check that the

fuel jets cease simultaneously at all four holes

and there is no dripping afterwards.

Adjusting the opening pressure

38. Adjust 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 washer.

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.

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:

40. Release the cover centre screw, lift out the strai-

ner 1 and clean it.

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Volvo Penta KAMD42B Workshop Manual

Volvo Penta KAMD42B Workshop Manual

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