Policy & Terms of use

Back to Library
Show Menu
Hide Menu

|

Boatinfo requires FlashPlayer 9 or newer to display this document!

Get Adobe Flash player



Publ. No. 2668 Dec. 1972 WORKSHOP MANUAL M 018·M 028· M 038 marine diesel engines . INT RODUCT ION This workshop manual contains desetiptions of repair works on the manne diesel engines MD 18, MD 28 and MO 3B. Since there arc differenr.es between the difhm!nl models, as far as extra equipment is concerned. it is imponant that you state engine type and serial munber when orderering Sl>arc p<.rts or in correspondence. The instructions in this manual describe the rnost suitable repair methods assuming the use of certain special Lools, li$ted uf'lder the headline ''$J)ecial Tools". We retain the right to carry ou1 dt!!:iiY'' mod ificatiQns and tor chis reason the contents of this book are not to be considered bmding. AB VOLVO PENTA Technical Information Dept. NEW MEASUREMENT UNITS The technicians have tOJlQ fought for an incernational standardized measuremenl system. In 1960 such a sys!em. called Sl (Systeme lnlcenational d'Unites... was established. This system is main1y built on previous system with the exception that the units (IH.. equal ized i.e. no con.,.ersl ons are needed. The european iudu:;try is now starting to use this Sl·systern. In this 1nnnual the new SI·UI'Iits are introduced. Units used earlier are given withul brackets. The new units are: Power is given in kW (kilowan) previous unit l-IP {Horsepower) Torque fs !J!Ven in Nm (Newron rnetcrl previous unit Kpm (kifl)pond meter) Engine rcvolut1ons are given in r/s (revolution per s..cond) previous umt rpm {revolution per minute) Volume is given in dm3 (cubic decimctcrl previous unit I (litre} REGISTER PRESENTATION . ENGINE BLOCK 0P.$Cr'iptinn 4 . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . • ........ ... . . .. . . Repair ins11uc-tions 5 . . , . . . . • . • . • . • • . • • • • • • • • • • • • • . . . . . . . . . . . . . . Compression Lest 5 . . . . . .•• ••••••••••• ••••••• _ • • • • • • • • • • • • • • • • Cytinder head and vatve system ...•••••••••.•.••••••• , . • • • . • . • . . . . . . 5 Cylinder block and piston . . . . . • • • • • • . • • • • • • • • • • • • • • • • • • . • . . . ... 9 . . Checki•'lg of compte:iSion ratio 12 .................... .. ................ Camshaft 12 . . . . . . . ...•...••.•.•••... , .•••. , ••••• .•••. ... .. .. .. Crankshaft 13 . . .. .. ....•.• ••.•.•... •.•• •. •.•••• .•. •.• .• .• .• .• . . Hand starter . . . . ......••••••.•••.••••••••••••.•.•• . . • . . . . . . . . 16 LUBRICATING SYSTEM Description 17 ..•• , • , ••••••••••.•.•.••••••••••••• , , •............ Rcp.ai•· instf'u<:tions , • , . • . . . . . . . . 17 ..... ..... .. . ..... . .. ....... .. .. Luboit-stl'ainer .....••.•••.•.•...•...••••••••••••.•.... ........ 17 Luboil·pump 18 ....•••....•...•.•...•.••••••••••.•.... . • . . . . . • . . Luboil·filtet ............................••.• _ .•••...•.•...... 18 FUEL SYSTEM Descriptio•' ................................• _ .•.... .......... 19 Repair instructions , ..... 19 ............................ _ .......... Ftlel injection pump ........................... _ ........... . . . . . 19 Adiustment of control rod travel ........• • . . . • . . 20 . . . . . . . ............ _ Checking of injection .111gle , , , , , , , , , , , •.. , .•.•. , • _ •............... 20 lrljectors 21 .. ... .. .. .... . ...... . . .... .. ... .... _ ........... . . . . . Fucl filu::r ... . .. ••.• ... ... .... . . . .. ... ...•.• _ ••••••.•.•...•.. 21 Air-venting of feel system 21 ................ ..•..•. _ .•.. .... ... . .. .. Checking of feed pump pressure .... . . . . . . . . . .....••................ 21 FcoU ..un1p . , , , , ••••.•........ . . ..... ..... •.. .•• •.•• , •••• , • , •22 Ccnuifugnl governor 23 ............. . . . . . .. . . ...... ••... ••. •••• .• .. COOLING SYSTEM Description 24 ................... ...............•.•............. Repa•r instructions ••.•...•. , ......................... , , , , , , , , .. 24 Sea water pump ......... . . . . . . ................ •.•....•. . . . . . . . 24 Thermostat ....... ..........................•......•.... , , , , 25 ELECTRICAL SYSTEM Description . . . . . . . . .... .....................................• 26 Wiri1)9 diagram ....................................••••••• , •• , •26 REVERSE GEAR Type RB .......................................... , ......••• 30 Type MS .•....................................... , .......... 32 SPECIAL TOOl·' PRESENTATION Fig. I MD 1B with rl:!\•crse getu' typo RB, ratio 1,87 ..1 1. Cormol le"Jer 15. 01'-.t'>ll'lfH..IOO le-fel 2. Connection shah tor handstan: 16. Valve cover G. Water·ccoled oxhaust manirold 20. Oil filt'Jr 7 The• motwt·hou-,.,,g 21. Oil drainaoe. engine Swrtu•· 22. Altt:rn;.r t\u'oo RR .,,:,.. 1 0...1 1n-..----•• ENGINE BLOCK DESCRIPTION Fig. 4. View ot MD 26 with reverse gear type MS, rat io 1,91:1 Cylinder block and crank case The cylinder blocks, be•ng ·d.emicaJ and •merdungable, are m.Jnufactured ot cast iron. The cylinders are surrounded Uy 3 cooling water jacket. Th! crankcase is manufactured of cast iron and provided with an inspectton cover. MD 38 has no tnspection cover but is instead provided wt th J remov· able oil sumn n•ectors are The r.ylmchtr hlock of lhf! engine is kept fn ploce by the cytindo. head which In turn Is bolted to the crank co.sc by mcons of long bolu. Cylinder head and valves The cyltnde• head. or1A ro1 each cylinder, is manufactut·ed ot a spec•al alloy Cd..l uon with high heat tesistanoe. The mounted '" th1nn copper sleaves, which are cooled dtrcctly by the cooling water. An eHectrve cool· 1ng of the InJectors IS hereby secured. The ..alves are mounted hanging in the cylinder held and are actuated by the camshaft vra valve lifters, lifting rods and ro cker arms The volve5 operate In replaceable valve guides. The ctear· ance between the vatve and lhe ro cker arm is set by n1cOt"'S oI adtUSHM(J scrttws Ill thft rocker arms. The rocker arms are lubricated bv an oil pipe which Is con necttul to the lubnt{ttmg oil pump, The mlet valve is provided with a sealing nng ;.qaif'lsl oil. Both inlet and outlet valves are provided with wear huts. Piston, piston rings and piston rod The p1ston rods are drop forged and tempered The main be.lnng shells have a wear surface of '-ad bronze. The pistons arem.anutac1ured of light aUoy and 1re provided with three rompression rings and one o il sttJpc ring The top comprttJStOn ring is chromium plattd tn order to dettea.. cylttiCfer wl!ar. The piston top he.s o circular hollowness whtch is combustion chamber. Gudgeon pin The gudgeon pin is maou factufed of sto31 and case hilt· de1led The case hardening qives the gudgeon pin a \'erv hard and \-"lear resistant st..rf.lce. At thr same time the core st1ll has &eh its tot4Jnessresoltmg in 1)1'111 ten$ilc strength Crank shaft and main bearings The crankshaft is m.acte oi drop fotgecJ l)teol i'lnd has surface hardened shaft journals. MD3B hHS rou• mc:un baonn9S. M02B has thret! and M018 h..\ two mau' LK!onngs. The main bearing shell s are e>echilngdblo and carr y J wear·SlH· ft.oc o1 lead bronze. REPAIR INSTRUCTIONS COMPRESSION TESTING To check the conditio'' oi the engine'" a simple way il is posstble to perform a comptession test. Fig. 5. Engines with electrical Stal'ting: 1. Run the engine warm. 2. Remove lhe inJectors and fit the compression gaugn by turns in each cylinder. whet(! the injectors ha11e been mount(.>d, 3. Move the speed control 10 lem position and rum the cng1ne by using the staner, until the highest value has been measuted on the compre$$iOil gauge. NS Take care that the battery is in oood condi rion. The pressure should be between 20-24 kp/cm2 (285-340 p.s.1.1. Most imponam 1s howe...er that the dJfference In ptes· sure between the cylinders ls not exceeding 10%. 4. Low pressure in all c:ylinders m1ght depend on b•g wear or piston rings and liners. Low pressure in one cylinder imJiCn the i11hH vah•es. Placu lhe valves in respecuvc guides NB Push invery carefufly the .nlet valves n ordel" not 10 damagethe sea1nnqs 3. Ftt valv..spnng:r. Hnd washers. The valve :tf)rings a1c fit· ted with the hghlly wound end again)t the cylinder tl:ead. F •t tl'le \VCilr hats. 4 Fnthe injectors bull do not 1 UhtUlin u complete picture of lhe eoOOiti< of the cyhru..l..trs, 111easuromcms must ther efore bu carri out at severa I different points. bolh la[erally and longitu1 CCl The degrco of woar decides lh.:;. .swps to be taken If thete ;u.. ..cratchcs Or scoflng or 'r the wear exceeds 0.25 mrn ( 0 10")th• pt5toru. Checking the pistons and fitting· in of piston rings 1. Check the ptstons for so•.nd'lcs Of othet tlam.ges. Remove the piStOn r inys With a pisrnn rin!J plici, 2. Clean the pistom. NB Be particularly careful wtth Lhe pbton rmg QI'OOves. 3. MC!casure the p•stons With a mtcromete.r ..ge. The 4 Check the deafence or the new p1s1on rings in the fJISton r1ng groo"'es hcc ftg no.18) 5. Chc..k 1he ptston ttrlfl g.:tp by pushing down a pisto'' nng in •he cylinder lJSli'IU a ptston 10 push With, (se.. ho nu. 19). The mfttburement shnll b.. to.ken below the IO\'.'CI IUiniiJg poant Ol the ptston. 6 Ftl the ptSIOO fllWJS USing JCUlton UllrJ plter. Ftt the Oth IMq fust. Thf> Oilflll9 C30 b.. 1Urned Blthtt W:Jy. The llipiCSSiOn Ii11<1.. ctl'.. lltted anti rhsto•w.m Rtotl ..V If t\ecessary, The conn-'!'..llrg rod Uu 1 \1'!.: alw..v.. rPplaccct wtHHl QVI.!r haul..ng IS dune. be-caLC• uf the ..t n.\tc'S Y-.orkmg 0'1th•..m Cheek lite conr t>•:ltn!] rod bustung"), ,_.,t!f..fcsl;ly us•n9 a.. !-}Ufjgeo. p,n a;Q.iJUQe There-nHJ)t be notu:eab!.! cit'.¥.Jn(C Replacing gudgeon pouand bushing 1. IV> 1r..the PI!.Wr> unrl r.<)tllb!C:IIng rod 2. R•·movc th+! lod 1HUI' 3 P es.s out 1'l•qwl!j.on p '' 111 n 1 a cl. 1fr 4 P ess OJt tl1 uI bl.l'l.hlnJ S n a nP\· hu..h''tiJ t.1o1._,e 1uu.. that the '*"cat ng hult! tre bush OIJ •nrJ,•.r:) w11h th.. hole '" tho CL:IIl•'L I ng ror 6 R..nm 01 tJia•nondU1 II lllP hushtnl) to .,n ,tecu•t..tt: II.Jfll linq fll WhPn clc.JJiJO[•• •:onecr the uudtl on r·ln .lwuld ..hde thrnhiJh tht• IJu.lunll 1nd e r iuown WPmht •Hhoutnnt•rea.:.lll• cl• u •• nn· I tt I 1 1he qudgeun p1 • ,,nd t,;ur!llP.t ..... •"''l rod bu..h•wJ, 8 F tone o.. t· r• cl•ns 9 \'1 m np the Jt h hnut 7f'PC I160"F I I oo togcthf=• ttl.. p•sl:lO lr"WI eonn.ct nq rod •JB It should ,)1· PQ1i bl.. to...!,;"" 1n Ihe gudl')t;'W1 r>'"• nr_-·.•er t'::Jmmer l tnlc pl.u.:e. 10. I it 1'11.: othe r cu d'l) II. Check that thu ctmn:ctlng n.nl runs ea1ily1r1ilw ..:onnecnng od bc..aruti:j, Fitt•ng the poslon ..nd cylondcr block Ched tt"\e comptesion loiiiiJ •!tt..rt"'c ttt.ng ..nd JJ)u..l if neet".s.:-rytSee "1\diUitlllq lhf': comprc..-..on •a t1o•·) Cle.ut lhP bcanng 1 (\nd tc.mksh-.ft bcJJ11)9JOtunAh ? 0 I Ill 111L' bed! illtl SUIt tt ·..Wrfl1 mOlUI oil 3 F1tp1s:on ..tnl u;nn t·lui•J rud 1 rc p..cttve :vhncJ• r hlock t1..ing a p•s•·_Hl rugrompreS.'jCf NrJ Be sure to t po bll> -:."e"ar edgc"J n 1·co cylinde b.o:;.t;. otr..an .xt J o-st ,);.., .. n'ln1 (008) JO 1 t; lnw?rCO'nnrctmq s rfa 1r• ylndt-t •• 'j 1 11 e ·yltnd hlr·t.. •nc.:ludu1the p st•_,, "" ng,nc. Nutf' Turn tht,; pt!ltt.Hl to lht> c..:orrec:t por.luuu lh>) fCCP...s m the P•..LOu ton JHust be d1tett1y undct thu lnJCCtOf ij ,,, ctnd ttqhH•n lh11 ·.·"'"l'l CJPS T ghtuung lO''IUP. u.. 7 MOl B. MD28; rlt PlC Hl'lf>PC11oncovers touotl•w vvtl ll..'I.·J qaskNs ami 'Tctmotox", 8. MD3B: Fitrh.. tJ!l strainer a nd the 011 ;ump Nl RepiJccthe \Cclh1nys Ill the ends ot thP otl I ne ofth o•lpump. Od chcm tn •n I pm th..1 o.t ttw Pnd ot th o•l I f"'IP fioe(> fig nu 3G b<'fu1.. t,....,.. oi l I ne htttl'\. Rep ace also tl•; ijilktt for ..he: oil sump Adjm:t1he-cornpn!uuo 1 a11o a.. r.e• ..tow Fitting the cylinder block (pls10n fitted) l 01l in the cylindf!t lwrt.' NB Postihlewear edge n•u!.t h remcOJ!Xl, 2 PId) 1. Ranlovc the i•'ljcctors. 2. Put down a lead wire. cllarneter app!'ox. 2 mm LOS"), 50-60 mm (2.0"-2,4") Into the cylonder (the poston must not be in T.D.C.I 3. Kl)cp the lead wire iJ'\ this posnion Jnd turn the engine ood let the piston poss T.O.C. Pull out carefully the lead wire. 4. Measure with a mictometer the part of rhc lead w1re flilttcd by the piston. The mcasuramcnt should be 0.8 0,9 mm (.031"-.035"). If this measurement IS 110t correct, the compression rat1o must be adjusted (Sec'' Adjustir.. tho cornpl'cssiontotio"). CAMSHAFT Removing the camshah 1. Remove the cylinder heads (see instructions on page 51. 2. Remove the luuir'lg 91!<:11 casmg hcc instructions on page 16). 3. Lift up lhe vHive lifters and place them In order in a stand. 4. Remove the carricr·bolt on the •·ear em,J ur the cJmshaft. NB Thos bolt os lelt-hand thoeaded. 5. Pull off the r.am disc and the gaar at the same lime from the shall. 6. Loo..n ond remove the thrust flange which i.. Jotated behind the gear. 7. Then poll the camshaft str..ight out ro avo1d damagmg Ott 10 the bearing races and slide in the camshaft. S. ..feful not to detmetge the be.c.rmgs. NB If the oil .)UfllO ....futed, the camshaftmust be turned so..hat u en..s tn the oil ..ump cog dutch, 2. Fh lhe thr\lst flange and secure the bolts. NB There •s a cut un th11 instde of the thrust·plate whtch must be located facino the small oi I halo ifl tha cr..nkcosc. 3. Check the woodruH·key for damage• and 111 It on the shaft. (NB MD3B has two woodruff-koysl 4. Ftt the camshaft gear and cam disc. NB Th e punch 111111ks on the camshaft gear mu11 rcgistC!r with the punch mark on the crankshaft. stli! t19, no. 24. 5. Tighten the carrier bolt. f,ghtening torque MDIB. i'f\028. 80 Nm (8 kpm) (581b.fLI M038: 3:?0Nm (32 kpm) (231 lb.fL). 6. F1t the timing gear easing. Use a new gasket and sme•• it w•th ..Perm"tex" orsimilar oomPQUnd 2 Replacong camshaft bearings n,. btt.Hmgs art pres5ed into thP.ir recenei ancl artt llne·bored 01ttcr being pressed in, so that c:arushatt bearing repl..cemcnt can only be c.auied out wheu th& engine is completely disassembled. Whtn rJrt:t$$1n£1 tn the beanngs make sure that they are pressed '" in J way that the oil hole.. index wlth thu cor• ospun: )1\ h-caqnn U':i•nq w•.: lJHl! 1' ..r t.g. no 28. or :ool f\J 384489, 2 F1g 28. Tool (884489} fur toml)vul and fiwng at mam bearuu]s 1 -Dnlt (Flu ,11$0 lO stendnrd honrJio no.9991801 2 =Guide (used for MD3Bl 2 Pul COfJC[hcr the bconng halves us1ng il lohber·cO•t.l ilnd line £he beanng fo• n t::orrcct position (th.. fot.:kin.. tounges must (it tnto thu t:OI rcspondn11) reooss In the bl!oll"'9 $0Cilll l,;vth 1..1vcs rogcthN uSiniJa 1 11bbf!r cu1LI. Pres!. in the bn;;Hmq. us•no the tool no. 884t189, -:u rhJt the marks tit .. -• - Fittingthe crankshaft I Check the cleam.J of th.. crankshaft drillmg\ and tne contde" sort.aus tor tho ...mng s..lls. 011 1n the end ournah:. M028. MOJB: F •t thl' tnttormediate ..:mngJ on the "'""luhah. T'tenu>y IO•Soblc 10 t 1 them 7 Check the ax tal clc.at omc;e VS*ncJ a d1al test •ndlc.ato• If no axi•l cl\!llldrot Cht!fk It.· luu.t•on ot the axiul wa..herJ a_ r::t :fw c.vn..,,Jfl t1n'llru1 CJ(Odr :'ind thr camdis.c on the Cdtt•..h.Jlt MtJke sun• ltwy 1111 r.nrn•Clly located dl;(;t)JIJ 1nq to th.. n arklnf'l tSI\I't Ito. nn 2r1J. Tanhten tl'o lllh·hand 1h• "''d'..rf 1.u ttL' I loCh1W T!Uhll'lllng torque ....e "Tethmc.ll Outu" M01 B. M02B: Clmm 1he ft UtH htMI .ng hous1nq anrl r,t llttW l>..i nq ben fur. no. 30) Od trl the ll(l>!l.ulq rlriiJS to ovoid dtarntttiUIU lhem. I It thA lwurin(J hOt.l'iiii..J 9. r it the forward CfllllkShall SCQI.r..l rinq, flywhct:l, f;g, 30. Sealing crankcase-bearinghoUIIfljj, MDIB. M02B Replacing the crankshaft sealring MD3B: Remove the V-bolt guard I. Remove the generotor sttott:her and rnmovo the V beltS. 2. Unughten and remove the ''ul hnh.lmg rhe r1ywhcu1 3. Ptlll oH the flywheel using vulle no. 884078. 4, Remove the woodruff key. M01B, MD28: Untightcn and h.llltJvtt tht! sealing cover. 5 Tape over the key wuy in the crankshaft and put greAMt on the crankst-afl to avoid damaging tht! seh1109 rrng when fttted MOlB. MD2B: fit rhe new sealing ring in the se1Hng cover. Fit the cover togcthc• with u new gdsktH. MOJB: Fit anew seuhng nng for the crunkshah. 6. Remove the tape. f1t the woodruff·key arld then (,t the flywheel Toghtenong torque 700 Nm {70 kpml (506 fb.h.l. Use anew lock washer 1. Fn the V·belts andadjusl t.. V belt tens•on. M03B: Fit the V be'' guard. - Removing the timing gear casing 1. Loo..en and remove the t!Hllllltll st1:11'ler. Loosen and l'emovll: the inspection cover on the tuning gc..u casing. Press the sh<.ft out of the housing. Press as shown by 9. Remove the tock·screw {101 and pres,s out the bearings, the arrow, seefig. no. 32. spacet itnd che Willing rtng Loosen and remove cou..ing 01 geilrbox if mounted. 3. Remove the feed-pump and injection pump 4. loosen and remo.e tubes and hoses whidl have COI'Ulect un wrth the t1me gear casing. 5. Rcmo..,e the ttming gear castng. The fltttng is done in the reversed order. As regcnds fitting of the injectio n pump, soc "ruel Svstem". Us¢ o new gasket and $rTUwr tt with "Permatcx" or corresponding compound, HAND STARTER M01B •nd MD2B Fig. 32. Hand starter, MD1B. MD2B. II only the sealing ring (5J and the 0 ring (6) must be replocod, follow puints 4. 5, 6 and 8 Removal of the ball bttanng (7) is not necessary. Ref•t m che reversed otder Loosen and remove the hand'taner. 2. Removethe CO\'er (8, fig. roo.32) 3. Loosen the screws (9) and remove the !)Car. 4. Knock loose the sleeve ( 1) prcnud Oil 1he housing, 5 Drive out the pin (21, usc surmot t undet the shaft. 6 Onve out the spring pin (3• iatiU pull off the sleeve (4). fig. 33. Hand scarier, M03B (later execution} MD3B Removing 1. Unscrew the oil pipe for the cold starting device. 2. On engines with otlpre$$\lt@ gaU9Q: Remove the oilptpe andthe bracket for the o•lpt&sStue gouge, 3. Removt the hand Sl.Jrtcr. Disassembling 1. Loosen and remove thecover C1. fig. no. 33) together with the ll""' ond the sholl. 2. Remove the pin (2) and l)tCSS ot.lt the: shaft "' tho direction indicated by the ..utO'IoV. 3. If the bearings 111 and 14) are to be removed. loosen first rho lockring (3) NB The key 021 must be removed before thebeani'W) (14) •s taken out. 4 Remove thecover (41 5 Remove the screws (S)ond tho gear (6). 6. Romove the sleeve C7L 7. Remove the ptn (8) and pull out the sleeve (9). a. Ptcu out the shaft in tho direcuon indicated by tho Ol'row. 8. Remo.. the se4ling rong 15), the 0 rong (6) and the b•ll bearing 17). Ref,urng in revC($-C! a•der. Replace the sealtng ring. Before 1>reutn9 the shaft into the housing, ftll the space between the .tcaling ring and ball beanng and Ihe IMge space behind thft hall hel'tnng with heat rcsistOI''Il gtcusu. When the manual start has been ..eflltcd, check if there is: a piJy between the gear of the hand 5tarter and the gear of the cam shah If there is no clearance. increase the number Refu tn the revet'SP.d orcer Replace tht sullng rings. Grease the bearings and fill thespactS dose to the beanng.s w1th heat·reststant grease. 6tt(Qre fitttng check th'e cle..Htnlte bCtWI:('tl thC tWO 9CLlfS. Thtt covet (4) is no1 lO be tighlenad uruil the hand starter hos hco,, lil teCheck. through the opening if d on the e ngino. thu t C il a <:lcaraoc:c between th.. lowar gear of the hancl stJrte.. ond the camshJft geJr. If there is no clearance 1n· crease the number of gask..ts between the hand starter and LUBRICATING SYSTEM DESCRIPTION Fig. 34. lubricating system, M028 with reverse geor type RB 1. Oil filter 2. Oil pr..sure sending unh 3. Oil strainer <1. Oil osition. NB The cold starting device must not be engaged while taking the measurement. To get a COfrect measurement on M038 connect first com· pressed air ot 1 kp/cm2 (14 p.s.i.) to connection point E, see fig, no. 42. 3. The difference between the two measurements shall be 8,2:t0.1 mm 1.323"±.004").Adjust the control rod tra· vel if noccsso1ry by adjusting the screw (0 on fig. no. 42) inwardsandoutwards respectively. Checking theinjection angle Whenchecking the injection angle use a .,\-Vilbaer·tube... The test is done on the cylinder closest to the riming gear casing, 1. Fit the "Wilbacr tube" on the delivery pipe nipple. MD1B. MD28: Adjust the purnp for highest feeding. The cold starting device must no be engaged. M03B: Remove the inspection cower on the timing geM casing and adjust the control rod of tho pump so thllt Its reor end Is oven with the rear edge of the pun\p housino. 2. Turn 'he engine in the right direction of rotation until 3. Open up the level \l&lve on the tttllng ckt\lice sothat the level is 25-30 mmhtgh, counted from below. 4. Turn the engine in the duection of rolation until the comprassion stroke starts. 5. Continue tuming until the fuel starts rising in the glaM gauge. Then stop. MD1B, MD28: Placo tool no. 884057 on the shatt of the monu{ll stoner so thot the marked part is resting on the flywhoel. 6. Check where the marking of the flywheel stands. In order to make it easier to perform th1s on earliet executions of the MD3B, nothaving 1nspettion hole in the flyWheel guard, make a hole In the flywheel guard as per fig. no.44. 7. If the injection angle does not agree w1th prescribed value. increase or decrease the n•J..r of gaskets between the pump housing and the timing gear casing until correct value is received. 1. Glass 031.100 (fuel leveU 2. levvlvulvt control 3. Twing devlco housing 4. Connet110nnipple fig.43. Level controi iWilbaer tube I Fig. 44. Hole in the tlywheel guard on earlier executions ot MD3B. INJECTORS Air-venting the fuel system Check•ng and adJUSting rhe •nieeton must be done in a nozzle testing devtce '" eccordance wnh the recommendations of the manufacturer Regardong opening poossure, see "Technical Data". Removing 1. Clean the injector. delivery pipe and cylinder h!!ad round the injector. 2. Unscrew the delivery pipe and look off line from the injectors. Fit protective caps. 3. loosen both nuts retaining the injector to the cylinder head ond lifl up tho injector. Fitting 1. Turn the engine over a few revolutions to blow the copper sleeves cloon before fitting the injectors. Check that the contact surface for the injector in the bouom of the copper sleeve Is clean. 2. Shde down the injectors into position and then fit the washers :md nuts without tightening them. 3. Connect the leak-off line end delivery pipes Replace domagragm and gasket for leakage and movrng part$ for wear. Assembling 1 Wash the upperpart and the stramerU5tng gasolineand clean with compres5ed a..r. 2. Fil the inlet valveand •ts stop lever. Tighten the screw, but only sohard as to ensure good contact between the plate spnng and 1hepump ho1.1slng. 3. Push down ..he diaphragm, slide In the lever and check thot the lt-ver is correctly located relative to the diophragm r()d. Fit the shaft, stop scrowand the return spring. 4. Fit the upper part according tomarking and tighten it. 5. Fit the strainer. the gasket and the cover. Fitting I. Fit ontl tighten the feed pump. Oo not forget the 0 ring, sealing agarnst the bloc:k. 2. Connect the fuelfines. 3. Air vent the fuel S\f11em (see separate head line). Cleaning the strainer Loosen and remove the cover {1. fig. no. 46). Remove the - CENTRIFUGAL GOVERNOR I f Fig. 48. Removing 1. Loosen and remove the timing gear casing, see "Removing the timing gea1· casing". 2. Remove the stop screw, located on the right hand side of Lhc engine seen from the governor (see fig. no. 48). 3. Rel'nove the governor, usmg two screwdrivers. 4. Clean all parts. I I Fig. 49. Centrifugal governo• 1. Sliding pin 4. Ball bearing, 2. Gove-rnor V\>eight 5. Spacer 3. Gove-rn01 $prhlg Inspection 1. Check if the weights (2. fig. no. 491 are seizing or if cleal'ance between shaft and govemor weight is too I 2. Check if the pin (1) is sliding easily in tho shaft. 3. Check both ball bearings. Fitting is done in the reversed order to removing. Cll that all moving parts move easily and oil them in bcf fining. NB Make sure that the groove in the spacer is fac the stop screw. COOLING SYSTEM DESCRIPTION Fig. 50. Cooling System, M028 with reverse gear type MS 1. Reduction gear 2. Se.a-wute1 pvmp3. Thermostat 4.Thermostat h0u$1ng To provide effective cooling water circulation, the engine Is fitted with a sea·watcr pump. This pump is ritted on the liming gear casing and driven by the camshah 1hrough a carrier flange. The impeller in the sea..water pump is made of neoprene rubber and operate$ against a cam. The p.ump (2, fig. no. 50) sucks cooling water from outside the boat through the externally located sea..cock strainer and forces the water to lhe distribution housing (thermo· stat housing). The cooling water has the possibiltty of following two ways from the dislf'ibution housing. The thermostat t3) in the thermostat housing keeps the passage from the engine closed at the same time as it opens the passage from the distribution housing above the thermostat. The water in the t'ngine is thercrorc warmed up rapidly while the water supplied by the sea-water pump passes che engine through the bypass without cooling it. When the engine has obtained its norrYlttl operating temperature the thermostat opens the outlet hom the engine and the warm water is supplied out in the bypass line. The engine and 1he e-xhaust manifold is then filled with cold water and when this is reaching the thermostat this ctoces again the outlet from the cooling channels. In this way the thetmos-tat balances cooling water eitcula- REPAIR INSTRUCTIONS SEA·WATER PUMP ..?..· 7 8 7 6 Fig. 51. Sea-water pump 1. l..Ot:kin!l :;(:t.:lw2. Cove' 3. G:.sket 4. Pump housing 5. O·ring Replacing impeller 6. Qmier 7. Stt.ling tinlJS 8. Q..ring 9. Shaft tO. Impeucr The impeller is made of neoprene rubber. The impeller can be damaged if lacking water i.e. when the water intake has been blocked. When ..eplacing impeller, do it as follows: L Remove the cover. Watch out for water pouring in through the pump. Pull ovl the shah with the impeller. using two scn:wdrivers, out of the housing just as much as needed for removing the screw (1, fig. nn. 51), holding the impeller. Put a piece of rubber or similar uncle.. the screw·drivers to prevent damaging the pump housing. 2. Pull the il)lpeller off the shaft. Clean tho pump housing internally an-d fit the new impello... Fit the cover with the original gasket. having the right thickness. Replacing the sealing rings 1. Remove the sea-\•,fater pump. Watch out for water pouring inlo the boat. Remove tho corrier (6,fig. no. Sl). 2. Loosen :.nd remove the cover. 3. P...1sh out the shaft togelher with the impeller. 4. Remove the sealing rings. 7. Knock ono of the sealing ring:S in place using the drift part no. 884499. One side of the sealing ring is provided with a spring -turn this side against the impeller. 8. Fit the impeller on the shaft. Grease the shaft and the shafl lodging in the cover with water resistant grease. 9. Push in the shaft with [he impeller into the pomp housir,g. NB Be careful not to damage the sealing ring. 10. Fit the O·ring and lhe second sealing ring carefully. (The spring loaded side or the sealing ring to be turned against the timing gear casing). 11. Fit the cover using a new, genuine gaske1. Check the carrier and Lhe big 0-ring. Replace them if necessary. 12. Put the carrier onto the shaft ar)d fit the pump. THERMOSTAT The thermostat is accessible when the thermostat hou! on 1hc exhaust manifold has been removed. Watch out wat<'r pouring i01o the boat. Test the thermostat U! water heating up. The thermostat shall open and cl occording to values given in "Technical Data". Fa.. thennostal must be rejected. Use new sealing rings wl fitting (MB38 has only one scaling l'ing}. Fig. 52. 1. Thermostat 2. The-r1Tl0$.at housing ELECTRICAL SYSTEM MD38 and M028 with MS r'evarse gEton (3.35 in.) clec,des the 1hickncss of the shims (2U. If the measurement. for cx(lmple, 1s 83 mm 13.27 in.), fit o washer with a thickness or 2 mm (.079''). I f wear ii so big that "X'' is less than 81 mm (3. 19 Jn.), the worn parts mus1 be replaced. Tho friction facing '" the gear and the cone are not replacahle. ASSE MBLING 1. Fit the bearing (36) and gear (37) and press the shart Into the housing (33). 2. Fot the gear (31) with the bearing (34) in the housing (33). 3. Put the cone (28) into the gear (31}. 4. Fit together the bearing Port !27). the bearing (29), the covar (24) and the gear {30) to one unit and tighten !he cover (24t. Fit the bearing so that the recess on one side or the bearing is facing the cogs on the geao (30). The bearing support (27) and tho wasl>er (24) Dlt! fitted in a way that the middle lhrough halo is turned upward!i. 5. Put in the unit mtha cone (28). 6. Fll the shaft (17) and tho sleeve (20) onto the cone (28). 7. Fie the reverse gear casing (32) over thP. assembled parts and tighten it to the housing (33). 8. Fit the bellows !18] and the coupling flonge (10). Check before fitting that the bolt 112) is well tightened and thai the key (15) is well located in its kew·way il''l the shart (17). 9. Fn the carrier t9L 1he shah 111. the cover 12). the blocking pin (8), the sleeve (4), the spring {5) and the interlock housing (6). Oil in the parts before fitting. The carrier (9) is fitted so 1hat the 0-marked sides are in the longitudinal axis of the engine. Fit the actuatlng le\•er and check the levef movement.. from neutral to ''ahead'' and "astetn". these movements should be equaL It movement one way considerably exceeds tha other, adjust be turning the carrier (9}. This is designed so that the cemre for the rectangula1· section is offset relative to 1he centre of the cylindrical s.ection (the guide). If the carriet is fitted so that the projcx:ting side is turned forward, the movement of the lever from "ahead" to neutral is fedueed. If the stud Is turned half a turn so thal the projeclioy parts is facing ostcrn, the movements or the lever from neutral to ''astern" Is reduced. Then check that lhe reverse geM engoge.. in both "ahead" and "astern" posilions. CHANGING THE POSITION OF THE ACTUAT· lNG SHAFT The clutch mechan•sm can be ploced in different posi1ions Fig. 58. Rear section of reverse gear RB (manoevering mechanism) 1, Interlock hQI)sing 5. Carrier 2 Interlock pm 6. Scaring housing :l Actuatinn shah 7. Rever. ge..r housing d. Co 8.Plug -011OI no. 884490. Pull o•. the c;,rr.er (1) vs•ng a pullet. 7 Loosen the low bolts (21 hc>dong the •nterrnod•ate housmg and I he front hous•ng lORe I.. 8 loO'-"n lhe bolt l }0) ond UT\WI!W •t tWO 10 lhtW turn<. 9 Tur-u the! r..vllrse gear and pot rt on thtt llimge or the fmnl kouslrtg. looae:, th. lockrinlJ 1411 ond tilt ofl the waem In plae four d11as.emhfi!C1 ma•n un11s; front hous..ng, lnhtrmed•.tle huuslnu, t..'ductlon gea.-;,nd rttllt hOUi•ng rM..IJ&(a,velv antl th-e thlh•no mechamsrn. By breok-down In lh& tevc.st uoar, Llis-assemb'e It 1111d tnspeet It ct.refullv Wttun rnlnor f-mdu appear iind WhP.I't th"'o con be loc.:otet.l 1u ohhel of ..he rttur main unit.... dlwssemlll.. uuly lhu unit conccrnod (..ceU!\der •e5peutive htH•t.l lln.. .. Front housmg I. R•mtllle th• bvlt r lOr. NB Do nut ((JI!Ifll "'" woshe11 (1? and 13) ,,,.j the •niro• (141. 2. Pllfl <1111 lhe s.>oft !30). NS Do not !..roo• •h• noddle boa• nlj).S 128 ond 30)und tho !Pioco• (29) 3 AormNt thttMIIno nny (4). 4, tn..PII mt1:t.t I.omlnr..flri, opcrzntons 5 1nr.l. 8 mu'\t bt.. c::unt>.l 5 RnmOYe lhe key (16) ond the foek ring (51. 6. Puw tl;c gear om of cho hont hoosmy_ Ust! lfrHt 884263- 7. Loosan rhe lock r'ing (7)ancl press out the bearing rhin9 t1cirt no. 884265. Intermediate housing I Remove the tape and orosr 001 rho •hall$ 151), ou !he plnnet geapOGt Ihe burlng !541 t11o "'olino "11!1 (6..) 11 anv n' rhe111 must iwrepl• operuttons beln\'.' muon he r.drr•eU ouL 1. Loosen th•lnok rln9 153}. 3. Press the llange (57) out ol "'" rau• housing. ' slr.eve no. 884162. 4, Rem011e the 1ealmy unul56). Reduction gear (di..,ssemblingl Fig. 60. Redvct10n gear 1. Remove the plug (75) and the bolt (73). 2. Pull out the gear (70) using the puller no. 884078 (put a spacer between the cemre boh of the pullet aOO Lhe threaded stud). 3. Carefully knock out the gear (54) together with the bearings (61 and 631. Usc a brass drifl. 4. Remove the seali''9 ring (67). 5. Carefully clean the pans and inspect the bearings and gears. If any of them must be reptaced, see respective paragraphs below. NB the bearing (69) in the big gear (70) an0 bver the shal-t ends to rnevenl tllem from fo\111ng out, 4. Press In tho gear (32) I nto the bearing (34) using drift "884263. ·Ns Hofd against the inner rllca .of' tM bc.aring, Uliing drih 1"10. 88..8. Chetk 1 hHt tho ·cogs of Fig. 64. F•om. hot.stng I. Fil tho guiuing pins (50. tio no 63). In tho ft•o 1"16Us-rng .. fat that they project 3PProx. 2 mm (.08 .1\b(IIIO tho_ partition plane.. .2. Pr..-In tho b tho lro houQ, 138446£! ro ..old B!fBtnst tl mn..r rar.e of Uw be-uri,'l!J). 5. Lock the ge..t with tho loe1< ring 15). S. To protect the ·s.>aling ring (6) vvnon rlwng, put lit steeve f)(>, 884487 over tho .shaft end of the get Gl't:£ase the. _sealing l'ing and nt ll. Tum th.. spfi1 loaded .side or. the. sealing ring again it Lhe. beal'h!19, .. not press in the. '$eal;ng ri·ng fur:ther char" it ls ev.!!n wi 1he et.ge· of thP. housing. P.emovo .Lho steeve and tit tl .<•v 1161. Assembling 1he front housing with the interrr diate housing Ifig. no. G!l and 641 Fot the need!, beonng.. (28an.. JO) aruJ tho spac..r (< omo lhe sha.ft(38) 2 Tho oh..h i• befog flttod ]n the geao of the rrc housir11J. Fit olio bolt (1.0) with the steel wo•her (1: hras5 w .. ho1 (13/ and the shims (14). Do not sen dQwn ihe boll .'completely, two 01 tf'trllc turns s.hot l'tfma:in until h bottOms. 3. Tvm the gear an Jet it rest on the conc)(!CfJon flan.. Then pu 1 the coupting socket 1361omo the shaft 13 NB The drilling in the··eoup1in.g.-socket S:haH he turn .ngaimt the hont hQusi.ng, 4. PlaCl! the noddlp bearings (37 an.. :.\9) ond tho spat (38) on tb.c shaft (36). 5. Pt!t 'a new gasket {3) ·on 1hc sealing plane of 1 hf! ftc hqusifly. NB The hoiCs'l.n-the yaskel for th e _guidipin.•(501 mustbe located correctly. 6. Rer:novo the-tape, locaHntJ t.he s.haHsuf chc planet gc. in the intermediistu "ouslng, 7. Connect 1 he intermediate hou..iflg .w · tth frorit housl1 T1Jrn rhe ...hafts of the p1ane1 ncar!:, using a scr . drive•, >u that tho lockl..g pins. (501 will be i(>lla!al 9. Put the brass washer ..40) onto the shah. The grooves of the washer must be located cotrectly relative to the pin (42). 10. Lock the brass washer with the lock ring (41). NB Use o new lock ring. The operation is facilftated if the shafl is lifted upwards. 11. Turn around the reverse gear. Use tool no. 881\ 152, fixed in a screw vice. 12. Tighten the four bolts (2) an belonging washers. 13. Tighten the bolt (10). Tightening torque: 100 Nm (10 kpm) (72 lb.h.). Measure the axial clearance ir) the shaft unit (see fig. no. 65). The clearance should be 0.2-0,3 mm (.008"-.012"). I ncrease or decrease the number of shims until lhe COI'rect clcarClnce is re.ached. The shims are available in two thicknesses, 0,1 mm and 0,5 mm (.004" and .020"). 14. Fit the 0-ring (11) on the steeve (9).Grease the O·ring and push the sleeve into 1he gear. Be careful not to damage the 0-ring. 15. Lock the sleeve with the lock ring should be included when measuring. Fig. 66. 4c. Increase or decrease the number of shims until a clear· 3. Fit the key ( 16, fig. no. 64) on the gear (15f. Warm up the carrier (1 f to approx. 150° C (3000 F) and fit it. Reverse gear without reduction gear 4a. Turn the gear and let it rest on the flange of the front housing. Remove the tape holdi•)9 the shafts of the planet gears rn the intermediate housing. 4b. Turn the sllafts of the planat gears, using a screw driver, so that the locking pins (50) will be located in the grooves at the shaft end$. Reverse gear withreduction gear 4a. Measure on the intermediate housing the distance from the outer be.aring race to the rear plane of the housillC) (A,fig. no. &6). 4b. Measul'e the depth of the corresponding recess in the reduction gear (B. fig. no. 66). NB The old gasket Fig. 65. FINAL ASSEMBLY 1. Fit the manoevering mechamsm into the gear housing so that the bolt (23, fig. no. 61) in the otf-<:entre piston is moved towards starboard. 2. Remove the bolt (23) and all shims (24), Tighten the bolt and put the mechanism in neutral position. Try to turn the shaft (36). NB To be sure thot the coupling socket is torning with the shaft, the outgoing shaft end must be turned. Add one shim at the tirne until the shaft can be turned without resistance. After the ance of about 0,1-0,2 mn1 {.004"-.008") is reached. The shims are available in two thicknesses, 0,1 mm and 0,35 mm (.004" and .014"). 4d. Turn the shafts of the planet gears, using a screw driver, so that the locking pins (50) will be located in the g.-ooves at the shahends. Pur a new gasket on the tear plane of the intermediate housing and connect the teduction gear. All reverse gears 5. Fit the oil drain plug, (43, fig. no. 63). 6. Fill oil. Ch«k with the oil dip stick that correct "'"""'''"'' h..c: ·. ..., fill..orl SPECIAL TOOLS ENGINE 999J.:.S9 999412S Description Control device for injection angle Orift for fitting copper sleeve Puller for crankshaft andcrankshaft gear Puller for copper sleeve Spreader tool for copper sl1eeve !!8.!499 (J Tool for removing and fittiing or main bearing Tool for fi1ting of scaling ring for inlet valve Drift for fining of valve guide Drif-t for removing o·f valve guide Reamer for valve guide Drift for removing and fittingof rocker arm bushing REVERSE GEAR, TYPE MS 884488 884490 884500 8640.57 884078 88&001 sa«es ?99.tl!i.. 11 Pan. no. 884057 884085 884489 884497 884499 9991459 9994128 9994154 884487 Part. no. Description 884487 Sleeve for fitting of front sealing rir\g 884488 Dfif1 for fitting of gear 884490 Puller for sealing sleeve 884500 Drift forfitting or bearings TECHNICAL DATA ENGINE General TypedesignJtton Output COIN) at 42 r/sC2500 rpm), kWCHp) • Numberof cylinders ...•.••••• •...•••. Bore.mm (in.) ... .. . . . . . ......... . Stroke,mm Cin.) ........••••• , • •. • Displacement dm3 (cu.in.) . .... . . . . . . . . Comptesston ratio Compression pressutt while turning engine with starter motor, kp/cm2(p.s.l.) . . . . ... . Direction of rotation. seenfrom flywheel ... . High idlingspeed. r/s Cr.t>.m.) .......... . Lowidling speed, r/s(r.p.m.) . . •....... Cylinder block f\!1ateriol . . .. , .. , , . , ............. , , Bore.standard, mm On.) .••.••••..•.... 0.762 mm oversize, mm(in,) • • • . . . . . . . , , Piston Material Height, total.mrn (in.) ..••••••.•. • . . . • Height from gudgeon pin centre to piston top,mm(in.) •..••.................. Pistonclearanceincylinder,mm (il''l.), Pistonsavailableas: Standard.mm(ln.) ......••.•.•••••• 0.762 mm (.030") oversi>o,mm(in.) Gudgeon pin Oiametre • . . . . . . . .. . •. • . ..•••••. Gudgeonpin bushing diamerre, mm lin.) Clearan<>O gudgeon pin -buslung,mm (in)•.•• Piston rings Compres$ion rings .................. . Oil scraper ring .................... . Top compression ring is chromlum-pl\tted Pinon rings avaUable as: Standard, and 0.762 mm W.OOO") oversize Piston ring clearance in groove, axlolly: 1st compre-ssionring, mm (in.) . . ..... . 2nd eomprc$Sionring,mmUn.). . ..... . • • .•.•.. 3rdcompresston rmg, m m On.l ........ .. . Oil scraper ring, mm(inJ . , Piston ring gap in cylinder: ht comprenionring, mm(tn.) . ... . ... . 2nd compression ring,m1T1 (ln.) .•.•••••• MDlB 7.41101 I 056 134.21 . M028 M038 26.5 (36) 18.4 125) 2 3 88.9 (3.5) 90.0 (3.54) 1.12 (68.4) 1 1.68 (102.5) 20-24 1284-341) Clockwise 45 (2700) 9.2-10.8 1550-650) Castiron 88.90 (3.5001 89.6613.491) Light-alloy 103 l4.()55) 65 (2.55,9) 0.10-0.14 (0.004-0.0061 88.78 (3.495) 89.S4 (3.525) 28.000-28.004 (1.1024-1.1025) 28.014-28.025 (1.1029-1.1033) Close running fi1 0.060-0.092 l0.0024-0.00361 0.060-0.092 (0.0024-0.0036) 0.040-0.077 (0.0016-0.00301 0.030-0.062 (0.0012-0.0024) 0.40-0.55 (0.0157-0.02171 0.30-0.45l0.0118-0.0177) Cylinder head Malerial . .. . . ... . . . . . . . . , , , , , . . • . . Crankshaft Crankshaft axial clearance, mm (in,) ...... . Main bearing J'adial clearance, mm (in.I ..... . Big·end bearing radial clearance, mm (in.) Main bearing journals Oiame1re Standard, mm (in.) . , . , , . , ... . .. ... . 0.254 mm (.01 0") undersize, mm lin.) .. . 0.508 mm (.020") undersi..e. mm lin.) 0.762 mm (.030") undersizo, mm l in.) Main bearing shells Thickness Standard, mm (in.) . . . . . . .. .. . . , , , . . 0.254 mm (.010") oversize, mm (in.) 0.508 mm 1.020") oversize, mm (in,) 0.762 mm (.030") oversize. mrn (in.) Big-end bearing journals Diameter Standard, mm (in.I ........ ..... ... . 0.254 mm ).01()") und•rsi..e. mm (in.) 0.508 mm 1.020'') undersize. mm (in. I 0.762 mm {.030") undersize, rnrn (in.I Big-end bearing shells Thickness Standard, mm (in.) . . ... , . , . . . • • . . , . 0.254 mm (.010") oversize, mm Hn.) 0.508 mm (.020'') oversize. mm (in.) 0.762 mm (.030'') oversize, mm (in.) Piston rod Axial clearance at crankshaft, mm (il"l.) ..... . Camshaft Axial clearance, mm (in.) Radial clearance in bearings, mm {in. I The beatings are bored or reamed after being pntssed in Lifting height of cams, mm (in.) Valve system Inlet Disc diameter, mm (in,) . . . . . 4 • • • • 4 • • • • • Stem diameter, mm (in.) . . . . • • . . • . • . • . . Valve seat angle . . . . . . . . . . . 4 • • • • • • • • • Seat angle in cylinder head . . . • • • . • . . . . . . MD1B I MD2B Special-alloy cast-iron 0.08-0.35 (0.0031-0.0138) 0.038-0.100 (0.001 5-0.0039) 0.054-0.099 (0.0021 -0.0039) I MD3B 66.646-66.665 (2.6239-2.6246) 66.392-66.411 (2.6139-2.6146) 66.138-66.157 (2.6039-2.6046) 65.884-65.903 12.5939-·2.5946) 2.136-2.145 (0.0841-0.0844) 2.263-2.272 (0.0891-0.08941 2.390-2.399 (0.0941-0.09441 2.517-2.526 (0.0991-0.09941 53.966-53.985 (2.1246-2. 1254) 53.712-53.731 (2.1146-2.11541 53.458-53.477 (2.1046-2. 10541 53.204-53.223 (2.0946-2.09541 1 .384-1.391 10:0545-0.0548) 1.51 1-1.518 {0.0595-0.0598) 1 .638-1.645 10.0645-0.0648) 1 .765-1.772 {0.0695-0.0698) 0.05-0.25 10.0020-0.0098) 0.05-0.15 (0.0020-0.0059) 0.03-0.09 (0.0012-0.0035) 5. 75-5.85 (0.2264-0.2303) 38 (1.4961 7.955-7.970 (0.31 32-0.3 1 38) 44.5° 45.00 Exhaust valve: Disc diameter, mm (in.) , , , . , .... . . . . . . . Stem diameter. mm (in.) .............. . Valve seat angle .. , , , , , , , , , , , . . . . . . . . Seat angle in cylinder head , , , , , . . • • . . • . . Scot width in cylinder head. mrn (in.} ...... . Clearance, warm engine, mm (in.) Decompression device Max. depression of exhaust valve, mm (in.) Valve guide Length. mm lin.I Inner diameter after fitting and reaming, mm (in.) , , , , , , , , .. . . . . . . . . . . . . . . . . Height above cylinder head spring surface. mm On.) . . . . . . . . . . . . . . . . . . . . · · · · · · Clearance valve stem -guide: Inlet valve, mm Hn.l . . . . . . . . . . . . • . . . Exhaust valve. mm (in.t . . . . . . . . . . . .. . Valve spring Length. unloaded, mm {in. I ............ . loaded with 300±20 N {3012 kp) 166.14±4.41 lb). mm {in.) ........... . loaded with 560± 30 N {56±3 kp) {123.46t6.61 lb), mm lin.) . . • . . . . , . , , Lubricating system Oil capacitY, engine, dm3 \Imp. qts. =US qts.) incl RB·Qear, excl filter ....... , . . . , . , incl filter ..... ........ . excl MS-gear. exc1 filter . . . . . . . . . • . . . . incl filter . . . . . . . . . • . . . . Oil-grade. according to API-system , , , , .. . . . Viscosity above +20° C (68° F) .............. . below +20° C (68° F) . . . . . . . . . • • • . • • Oil-pressvre, warm engine. idling, kp/cm2 (p.s.i.) . . . . . . . . . . . . . .. . • . . , Oil-pressure. warm engine, max tis. kp/cm2 (p.s. i.) . . . . .. . . . . . . . . . . . • • . • • MS-gear Oil capacity with reduction gear, dm3 (Imp. qts. •US qts.) ........ . Oil-grade/viscosity Lubricating oil pomp Type .. . . . . . . . . . . . . . . . . • • • • • • • • • • Spring for reduction valve: Length. unloaded. mm (in.) .......... . loaded with 25±2 N (2.5±0,2 kp) (5.51±0.44 p.s.i.), mm (in.) . . . . . . . . . . . loaded with 35*2 N (3,5t0.2 kp) (7.72±0.44 p.s.i.), mm (in.) • • • • • • • • • • • M01B 1.7 (1.5=1.8) 1.95 (1.7=2.1) 1.7 (1.5a 1.8) 1.95 (1.7•2.1) I M02B JMD3B 34 (1.338) 7.925-7.940 \0.3120-0.3126} 44.5° 45.0° appro•. 1.5 \0.06} 0.35 (0.0 14) 0.5 (0.020) 59 (2.323) 8.0-8.015 (0.3150-0.3156) 18 (0.709) 0.03-0..06 (0.0012-0.0024) 0.06-0.09 (0.0024-0.0035) 50 [1.969} 39 (1.535) 32 (1.2601 3.0 \2.6•3.2) 3.25 (2.9=3.4) 3.0 \2.6=3.2) 3.25 (2.9=3.2) For serv·ice CD1 ) SAE 20 SAE 10 W 0.8-1.5· (1 1.4-21.3) 2.0-3.0• (28.4-42.7) 0.60 (0.53=0.63) Same as in engine Gear 40 (1.57) 34 (1.34) 31.5 (1.241 5.5 (4.8=5.81 5.75 (5.0=6.0) 5.5 (4.8=5.81 5. 75 (5.0=6.0) . . . 73-77 90 MD1B I MD2B I MD3B I Fuel system .... . . Injection pump, make Bosch PFR1 K75A380/1 1 PF R2 K75A381 /1 1 PF R3K75A382/1 I .....• Injectors, make Bosch, ... . ..... ....••••••. Nozzle holder KBL87S78/4 ............. . ...•••....• Noz-zle DLLA 150S720 Hole diameter, mm (in. t Four, 0.27 (0.01 1) , , , .........• Opening pressure kp/cm2 (p.s.i,} 170-178 (2417-2531 ) • , .....• Pre-injection angle 23-26° before T.D.C. Fuel filter Type 60$Ch F J/DW 2/3 .•.........• • • • • . • .••••••••• Filter insert Bosch F JSJ 32 U7 ........ , ....•. •.••••••• Feed pump . . . . . . . ........•• • •. Picrburg PE 15672 Feed pressure at 42 r/s (2500 rpm). kp/cm2 lp.s.i.) 0.65-0.85 (9.2-12.1) ......... . . . . .•.•••••• Electrical system Battery voltage. V ................... 12 Battery capacity MD2B and MD3B with starter (not dynastarterl. Ah Max. 150 .••......... ....... MD2B and MOl B with dynastartcr, Ah Max. 60 .•. Oynailarter Make Bosch LA/EJ90/1 2/2900 +1,0 R 2 .. .... .. . . .. .••••••••• Generator output, max .. , , 135 .. ........ . Generator output, continous. W......... 90 Starter motor 0.001.315.002 Make Bosch , . . . .... .. ..•••..•. . • , 1.344 (1.8) .............•.. , . • Output kW (Hp) Alternator .•.•..•......... Make SEV Motorola 827302 Output, W(A) .•...••...•......... 450 (38) Specific gravity of battery electrolyte: Fully charged battery, g/cm3 1.275-1.285 ........ , •• Start re-charging at g/cm3 .... , , , , 1.230 ... Cooling system Thermostat, type , , Bellows rhermostat ... . ...... Starts opening at ° C (0 F) (164-170} 60 (140) . •••. . . I. 1 57-60 (134-140 .. Fully open at o C (O F) ........... • (1941 74 (1641 72 (162) Reverse gear Type RB Ratio without additional gear ......... . 1.87:1 with additional gear , , , , 3.42:1 •.. .. . , .... . , .. , .... . Lubricating system ...... , , , , Common with engine TypeMS Ratio with reduction gear ... 0 0 ••• 1,91:1 .. , •• ................. . Lubricaling system , Separate {not common with engine) Oil capacity ioc:l reductiOI''I gear. dm3 WEAR TOLERANCES Cylinder block To be re-bored when wear attarnJ (01' 1f engine has abnormally high oil coosump-tionL mm (in.) . . ...... . . . . . . ....... . Crankshaft Main-and big-end bearing journals allo\rJedovalitv .mm (in,, . . . . . . . . . . . . . allowed taper, mm (in.) .... . . . • • . • • • • Max. aKial clearanoe on crankshatt. mm (on.) . . . . . . • • • • • . . . . , • , , , , • • • • • Valves Valve stem, allowed max \•o.ear, mm (in,) . , ... M..x clearance bttween stem -valvo guide i1)te1 valve, mm (in.) . . . ...... , , , , . . . exhaust valvn, mm (in.) .... ......... . Edge of valvedisc should bominimum, mm (in.) . . . . . . . • . . . . . . . . . . . . . . . . . . Distance from valve disc to contact surface of cylinder head, new valva. maximum, mm(in.) . . . . . . . . . . . • • • • • • • • , . . . . . . Camshaft Bearing journals, allowed oval ltV, mm (ln.) Bushings, allowed max wcJr, mm (ln.) TIGHTENING TORQUE Cylinder head nuts ................... Cylinder head bolts . , , , ... , ............ Intermediate bearings ......... ....... . Boltforcrankshaft gear . . • . • . • • • • ....•• Boltlor coupling hall (tngint with MS·rcvorsc gc:Jr) • • . . • . . • • .•.......... Flywheel-nut . • . . . . . • . . . . • . . . . . •.... Ptston rodbolts . • . • • • . • . • . • • . . . ,...• Injectors . . • . . . . . . . . . . . . . . . • . . . .••• Carrier forwater pump .......... ..... . M3in bearing cover .... • . . • • . • • • • , . , .• M01B I M02B 0.25 10,01 0) 0.06 (0.002) 0.05 (0.002) 0.40 (0.016) 0.02 (0.001) 0.15 (0.006) 0.17 (0.007) 1.0 (0.039) 2.5 (0.098) 0.03 (0.001) 0.05 (0.002) Nm (kpm) (lb.ft.) 110 (11) (80) 45 (4,5) 133) I MD3B I 80 18) (581 80 (8) 158) 140 (14) (101) 700 (70)(506) 65 (6,5) (471 20 (2,0) (14,5) 80 18) (58) 45 (4,5) (33) I 120 021 tB7l I 32o t32l !2311 VOLVO PENTA C:ORR£CTIONS AND ADDITIONS TO WORKSHOP MANUAl, PUBL NO 2668 On page. 12 of the above-mc.m.ionetl manual, the thickne» or the compressed cylif1dcr head gasket has been given as I. 2 mm (0. 047"). Please niter this mensurcment to 1. 4 mm You >re also r<:<1uened to alter the measurement "A"" in the example011 the same page, from 2. 9 mm (0. 114"") to 2. 7 rnm + Also, the control rod travel oo page 20 has been lndlcoted nt 8.2 -0.1 mm (0. 323 t 0. 004"'). 1"hls measure· ntcnt applies only to the MD38. Please Insert the following measurements for the MD20: 8. 6 • 0. 1 mm 339 t 0. 004"), and for the MDIB:9.1 t 0.l mm 358 ± 0. 004"). New valves The fuel lnjeetlon pumps have beert provided whh a nc"' type of delivery valve wltll effect from the following engine serial numbers:. MDlB: No 20471. M028: No 11507 and MD38: No 2276. The earlier type (pan No 243419) hasbeen replaced by the so-<:alled "cr=" valves with part No 833743. Only the newtype of valve will be >lOCked. Olffe:ent kinds of valves may not be fitted on the same pump. On engines with the newtype of delivery valves. the control rod navel is shortened by 1. .. mm (0. 06")xl. On these engines the control rod travel should be 7. G ! 0. I mm (0. 3 t 0. 004'") for the MDIB, 7. l ! 0.1 mm (0. 28! 0. 004'")fot the MD2Band 6. 7! 0. I mm (0. 26 ! 0. 004") for the MD3B. NOTE. If the control rod travel is alrerd, the high idle, 45 r/s (2700 r/m), should be checked and rr necessary ad)llStcd. x)This measurement conesponds 10 1. 6 turns on the adjuster screw for the MD IIJ and MD2U..nd t"-'O turns for the MD3B. in a number of caseswhen adjusting the pte·injeetion angle, there has been some difficultyin obtaining a sufficiently large angle (23 • U0B.T.D.C.) In spite of the fact that ooly .. seal hasbeen fitted between the fuel Injectionpump and the riming gear casing. Where such cases arise, l