Volvo MD Engine Workshop Manual

Brand: Volvo

Model: MD

Category: Engine

Type: Engine Workshop Manual

Workshop Manual

Engine unit

MD11C, D, MD17C, D

2(0)

Safety precautions.............................................................................................................2

General Information ..........................................................................................................5

Repair instructions............................................................................................................6

Component guide..............................................................................................................8

DISMANTLING

Cylinder head.....................................................................................................................10

Cylinder liner ......................................................................................................................11

Pistons, con-rods ..............................................................................................................11

Timing gear ........................................................................................................................12

Flywheel.............................................................................................................................13

Crankshaft .........................................................................................................................14

Camshaft ...........................................................................................................................14

OVERHAULING

Dismantling cylinder head .................................................................................................15

Cleaning, inspection ..........................................................................................................15

Valve guides ......................................................................................................................15

Valve seats........................................................................................................................16

Valves................................................................................................................................16

Valve springs.....................................................................................................................16

Rocker mechanism ...........................................................................................................16

Valve tappets ....................................................................................................................16

Injector sleeve ...................................................................................................................17

Injector...............................................................................................................................17

Assembling cylinder head .................................................................................................18

Cleaning, checking crankcase ..........................................................................................18

Replacing main bearings ...................................................................................................18

Centrifugal governor ..........................................................................................................19

Pistons, liners....................................................................................................................19

Connecting rods.................................................................................................................20

Crankshaft .........................................................................................................................20

Camshaft ...........................................................................................................................20

Oil pump ............................................................................................................................20

Feed pump.........................................................................................................................21

Thermostat ........................................................................................................................21

Sea water pump.................................................................................................................21

Hand start ..........................................................................................................................23

ASSEMBLING

Crankshaft .........................................................................................................................24

Flywheel.............................................................................................................................25

Timing gear ........................................................................................................................25

Cylinders, cylinder liners ...................................................................................................27

Pistons and liners..............................................................................................................28

Cylinder head.....................................................................................................................29

Adjusting valve clearance .................................................................................................30

Injection pump ...................................................................................................................31

Checking control rod travel ...............................................................................................32

Venting the fuel system ....................................................................................................33

Checking injections angle .................................................................................................34

Adjusting engine speed .....................................................................................................34

Electrical system .............................................................................................................35

Wiring diagram ................................................................................................................35

Fault finding chart ...........................................................................................................36

Special tools ....................................................................................................................37

Technical data..................................................................................................................39

Cooling system, diagrammatic sketch .........................................................................43

Contents

Safety Precautions

Check that the warning or information decals on

the product are always clearly visible. Replace

decals that have been damaged or painted

over.

Never use start spray or similar to start the en-

gine. The starter element may cause an explo-

sion in the inlet manifold. Danger of personal in-

jury.

Avoid opening the filler cap for engine coolant

system (freshwater cooled engines) when the

engine is still hot. Steam or hot coolant can

spray out. Open the 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, en-

sure that exhaust gases and crankcase ventila-

tion emissions are ventilated out of the working

area.

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!

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.

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.

Immobilize 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.

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.

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 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 appar-

atus, protective goggles and gloves for ex-

ample). 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.

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 taken before carrying out

welding or grinding work. Always have a fire ex-

tinguisher 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 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, im-

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.

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 sufficient space to remove components with-

out danger of injury 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 following engines MD11C, D,

MD17C, D. The workshop manual displays the opera-

tions 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 dif-

ference is considerable the operations are described

separately. Engine designations and numbers are

given on the number plate (See page 9). The engine

designation and number should be given in all corre-

spondence 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 changes.

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 pro-

vided 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.

Repair instructions

The working methods described in the Service Man-

ual apply to work carried out in a workshop. The en-

gine has been removed from the boat and is installed

in an engine fixture. Unless otherwise stated recondi-

tioning 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 information

)

WARNING!

IMPORTANT!

NOTE!

are not in any way comprehensive since it is imposs-

ible to predict every circumstance under which serv-

ice work or repairs may be carried out. For this rea-

son 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

using these. Special tools are developed to rational-

ize working methods and make procedures as safe

as possible. It is therefore the responsibility of any

person 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 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

tightened 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

Tightening torques-protractor (angle)

tightening

Tightening using both a torque setting

and a protractor angle requires that

first the recommended torque is ap-

plied using a torque wrench and then

the recommended angle is added ac-

cording to the protractor scale. Ex-

ample: a 90° protractor tightening

means that the joint is tightened a

further 1/4 turn in one operation after

the stated tightening torque has been

applied.

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 same 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. 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. 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

sizes 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 man-

ufacturer’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. Old sealant can be removed us-

ing methylated spirits in all cases.

Anaerobic agents. These agents cure in an absence

of air. They are used when two solid parts, for ex-

ample cast components, are installed face-to-face

without a gasket. They are also commonly used to

secure plugs, threads in stud bolts, cocks, oil pres-

sure 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.

Component guide

MD11D

MD11C and D

1. Stop device

2. Air bleed screw, injection pump

3. Injector

4. Delivery pipe nut

5. Temperature sender

6. Lock-screw, crankshaft centre bearing

7. Drain cocks, cooling water

8. Inspection cover

9. Oil drain plug, engine

10. Oil dipstick, reverse gear

11. Oil filler, reverse gear

12. Oil drain plug, reverse gear

13. Water drain plug, reverse gear

(MD11D, connection hose)

14. Decompression handle

(certain models)

15. Air filter

16. Oil filler, engine

17. Pressure equalizing valve (certain models)

18. Air bleed screw

19. Fine filter

20. Feed pump

21. Engine speed sender

22. Oil filter

23. Oil pressure sender

24. Oil strainer and oil dipstick (MD11C)

25. Oil pump

26. Oil dipstick, MD11D

MD11C

MD17C

MD17C and D

1. Fuse box

2. Decompression handle, certain mo-

dels

3. Air filter

4. Oil filler

5. Air bleed screw

6. Fine filter

7. Feed pump

8. Engine speed sender

9. Oil filter

10. Stop device

11. Adjustment screw - high idle speed

12. Adjustment screw - low idle speed

13. Leak-off pipe

14. Lifting eye

15. Delivery pipe

16. Injector

17. Thermostat housing

18. Oil dipstick

19. Drain cocks, cooling water

20. Engine type and number plate

21. Cooling water pump

MD17D

Dismantling

Drain off the engine cooling water, lubricating oil and

any fuel in the fuel filter and fuel injection pump.

Clean the outside of the engine.

1. A fixture for securing the engine in the engine

stand 9992520 may be used to advantage.

MD11: 884604. MD17: 884581.

2A. Take off the air cleaner, the leak-off oil pipe and

the delivery pipes. Fit protective caps.

The picture shows earlier type of injector up to

and including engine no. 50988 (MD11) and

16621 (MD17).

2B. The picture shows later type of injector from and

including engine no. 50989 (MD11) and 16622

(MD17).

3. Take off the coolant pipe between the sea water

pump and the exhaust manifold. Remove the

exhaust manifold (wrench width 13 mm).

4. Remove the valve covers. Undo the oil pipes on

the rocker arm shafts and dismantle the rocker

arm bearing brackets. Take out the push rods.

CYLINDER HEAD

5. Remove the eyebolt (or eyebolts) and nuts hold-

ing the cylinder heads (wrench width 19 mm).

Straighten out the oil pipes slightly and lift the

cylinder heads off.

6A. Disconnect the cables from the engine speed

sender, the oil pressure switch and the altern-

ator. MD11: Remove the alternator bracket to-

gether with the alternator. The picture shows the

earlier model MD11C up to and including engine

no. 52480 and MD11D from production start.

MD17: Remove the cover (earlier models) over

the V-belt and remove the alternator.

6B. MD11C: The picture shows the later models

from and including engine no. 52481.

CYLINDERS, CYLINDER LINERS

7. Lift the cylinders out. Remove the cylinder liners

by placing the cylinder with the bottom of the

liner on a flat support and strike the top face of

the cylinder with a rubber mallet.

PISTONS AND CONNECTING RODS

8. MD11: Remove the inspection covers on the

crankcase (6 mm socket head). MD17: Remove

the oil sump and strainer. NOTE! Remove the

sealing rings in the ends of the oil pump suction

pipe.

9. Remove the big-end bearing caps and take out

the connecting rods (and pistons). Mark the con-

necting rods (if this has not already been done).

Remove the valve tappets.

TIMING GEAR

10. Remove the crankcase breather/hand starter.

11. Remove the injection pump, sea water pump,

feed pump and the fuel filter.

The D-engines have leak-off oil return pipes con-

nected to the inlet union (see also page 27).

12. Take off the timing gear cover.

13A. MD11C and MD17C. Remove the carrier on the

crankshaft (engines with RB-reverse gear have

a carrier drive, use a distance piece to protect

the shaft. Take care of the key.

13B. MD11D and MD17D. Remove the carrier on the

crankshaft. Use puller 884078 (for the flywheel),

use a distance piece to protect the shaft. Take

care of the key. Earlier types of puller 884078

can be modified by drilling three Ø 8.5 mm holes

(use the spline flange as a template).

14. Pull off the crankshaft gear with the aid of tool

884078. Remove the key, the spacing washer

and the thrust washer.

15. Unscrew the left handed carrier screw/nut on the

camshaft. Pull out the cam disc and the gear-

wheel together. (On MD11, the crankshaft can

be dismantled without taking off the camshaft

gearwheel).

16. MD11, certain models: Remove the belt pulley

that is mounted on the flywheel. MD17: Remove

the bearing shield.

FLYWHEEL

17. Bend out the lock washer and unscrew the cent-

ral nut. Pull off the flywheel using the puller

884078. Take care of the key. NOTE! The nut is

pulled using 500 Nm (50 kpm = 369 lbf.ft.)

18. Remove the starter motor and its bracket.

19. Remove the oil pump.

20. MD11: Remove the front engine brackets. Re-

move the bearing shield.

CRANKSHAFT

21. Remove the locating screw for the crankshaft

centre bearing (two in the case of MD17). Pull

the crankshaft out.

CAMSHAFT

22. Remove the thrust washer and lift the camshaft

out. MD17: Check that the oil hole is correctly

located when re-assembling.

23A. Remove the oil filter, the oil pressure switch and

the oil pipes for the rocker arm mechanism.

MD11: Remove the oil strainer. MD11C: Use tool

884714 (see 23B). MD11D: 30 mm hexagon (see

23C).

23B. MD11C.

Tool 884714.

23C. MD11D.

Hexagon, 30 mm.

24. Loosen the lock screw and remove the centrifu-

gal governor.

25. Unscrew the centre bearing (MD17, two bear-

ings). NOTE! Mark them so that they can be

re-fitted in the same positions.

Overhauling

Cylinder head

DISMANTLING

26. Remove the injectors and fit protective caps on

the tips of the nozzles.

27. Remove the wear caps from the valve stems.

Remove the valve springs with the aid of a

valve spring compressor. Place the valves in or-

der in a valve stand. Take off the sealing rings

that are fitted on the valve guides.

CLEANING, INSPECTION

28. Clean all parts. Pay particular attention to cool-

ant passages. In case of doubt, check for leak-

age by pressure testing. Water pressure 0.3

MPa (3 kg/cm

= 43 p.s.i.).

VALVE GUIDES

29. Check the valve guides for wear by inserting a

new valve. Measure the clearance with the aid of

a dial gauge. Replace the guides if necessary.

Wear limits:

Inlet valve,

max. clearance ..................0.15 mm (0.00591")

Exhaust valve,

max. clearance ..................0.17 mm (0.00669")

A = 18 mm (0.709")

30. Press out the valve guides using drift 9991459.

Oil the new guides externally and press them

into position with tool 884499. The tool should

be pressed right down against the cylinder head.

Ream the guides if necessary with broach

9994128.

VALVE SEATS AND VALVES

A = max 2.5 mm (0.10") C = 45°

B = 1±0.1 mm (0.040±0.004") D = 44,5°

31. Mill or ream the valve seats, the angle (C)

should be 45°. Check the valve guides and re-

place them if necessary before machining the

seats, see point 29. The width (B) of the sealing

surface should be 1±0.1 mm (0.040"±0.004").

Grind the valves in the valve grinding machine.

The angle (D) should be 44.5°. If the thickness

of the edge of the disc after grinding is less than

1.5 mm (0.059"), the valve should be rejected.

Discard also valves with bent stems or if the di-

mension (A) exceeds 2.5 mm (0.10"). If neces-

sary grind the surface on which the rocker arm

bears. Grind the valves in using grinding com-

pound and check the surface contact using

marking blue.

VALVE SPRINGS

32. Check the valve spring lengths both loaded and

unloaded.

L Length unloaded ......................................50 mm (1.969")

Length when loaded with

300±20 N (30±2 kp = 66.6±4.41 lbf) ....... 39 mm (1.535")

Length when loaded with

560±30 N (56±3 kp = 123.5±6.6 lbf) ......... 32 mm (1.26")

ROCKER ARM MECHANISM

33. Dismantle the rocker arm mechanism and clean

the parts. Check the shaft and the bushes for

wear. If the bushes need to be replaced, the tool

884560 is used for pressing out and in. (Ensure

that the oil hole in the bush coincides with that

in the rocker arm). After having been pressed in,

the bushes should be reamed to give an accu-

rate running fit. Check whether the rocker arm

surface which bears on the valve is worn. Minor

adjustments can be made with the valve grind-

ing machine. Oil the shaft and fit the parts.

NOTE! Fit the wear caps on the valve stems.

VALVE TAPPETS

34. Check the valve tappets for wear. The cylindri-

cal surface should not be scored or porous. The

surface bearing on the camshaft should not be

rough or worn unevenly. Replace the tappets if

necessary.

INJECTOR SLEEVE

Drain the engine cooling water, if this has not already

been done.

35. Remove the sleeve using the tool 884081. Push

the expanding screw down into the sleeve and

screw anti-clockwise so that the screw expands

and grips the sleeve. Tighten until the threads

bite into the copper material. Fit the yoke onto

the stud bolts which hold the injector. Screw on

the nut and rotate until the sleeve is removed.

36. Remove the O-ring and carefully clean the hole

in which the sleeve is to fit. Grease and fit the

new O-ring. Oil the new sleeve and fit it using

tool 884077. Knock the sleeve in until it bot-

toms.

37. Oil-in the flaring tool 884085 and push it into the

sleeve (make sure that the pin is screwed back

39. Check the spray pattern at the correct opening

pressure. Up to and including engine no. 50988

(MD11), 16621 (MD17):

17.0 MPa (170 kp/cm

= 2418 p.s.i.)

From and including engine no. 50989 (MD11), 16622

(MD17):

24.5 MPa (245 kp/cm

= 3485 p.s.i.)

Also check that the fuel jets cease simultaneously at

all four holes and that there is no “dribble” afterwards.

+ 0.8

– 0

+ 0.8

– 0

+ 0.8

– 0

+ 0.8

– 0

correctly). Place nuts or washers on the stud

bolts so that the yoke can be clamped tightly

with the nuts. Screw the tool down as far as the

shoulder in the sleeve permits, thus flaring the

sleeve. Remove the tool.

38. Adjust the length of the sleeve outside the plane

of the cylinder head (dimension 0.9 mm,

0.035"). Also check that the sleeve is correctly

fitted (dimension 19.5 mm, 0.768").

INJECTORS

+ 114

– 0

+ 114

– 0

Up to and including engine no. 50988 (MD11), 16621

(MD17).

From and including engine no. 50989 (MD11), 16622

(MD17).

40. The opening pressure is adjusted by means of

screwing the injector apart and replacing the ad-

justed washer (1) with a washer of suitable

thickness.

ASSEMBLING THE CYLINDER HEAD

Crankcase

CLEANING AND INSPECTION

41A. Clean the cylinder head. Oil the new sealing

rings for the inlet valves. Place the pin of tool

No. 884497 in the valve guide. Push the seal

ring over the pin and knock the ring down care-

fully using the sleeve until the pin bottoms in the

sleeve.

B. Oil the valve stems and smear a little grease in

the inlet valve collet grooves. Place the valves

in their respective guides, screw the inlet valves

in carefully so as to avoid damaging the sealing

rings. Fit the valve springs with the aid of a

valve spring compressor.

42. Remove all core plugs and clean the crankcase

thoroughly. Check that all channels are free

from deposits and that there are no cracks in

the crankcase. Refit the plugs using a sealing

compound.

REPLACEMENT OF MAIN BEARINGS

43. Press the main bearings out using tool 884489

or a hydraulic press. NOTE! Check the positions

of the locking tongues so that the bearing is re-

moved in the right direction. Clean the oil chan-

nels before fitting new bearings.

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Volvo MD Engine Workshop Manual

Brand: Volvo

Model: MD

Category: Engine

Type: Engine Workshop Manual

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Volvo MD Engine Workshop Manual

Volvo MD Engine Workshop Manual

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