Workshop Manual B

Engine 2(0)

MD, TMD, TAMD, AD 31

TMD, TAMD, AD 41
 Workshop Manual
Engines
MD, TMD, TAMD, AD 31A, B
TMD, TAMD, D, AD 41A, B
Contents

Safety Precautions .............................................. 2 Turbo-compressor

General Information ............................................ 5 Checking the supercharging pressure .................... 23
Repair Instructions .............................................. 6 Measures to be carried out when the
supercharging pressure is too low ......................... 24
Component guide .................................................. 8 Cleaning ................................................................ 24
Disassembling ...................................................... 25
Dismantling Measuring, inspection ........................................... 26
Fuel pipe, electrical equipment .............................. 10 Assembling ........................................................... 27
Circulation pump ................................................... 10 Fitting the turbo-compressor ................................. 28
Auxiliary drive gears .............................................. 11
Camshaft .............................................................. 11 Assembling
Pistons, connecting rods ....................................... 11 Crankshaft ............................................................ 29
Flywheel ............................................................... 12 Pistons, liners ....................................................... 29
Crankshaft ............................................................ 12 Oil pump ............................................................... 31
Flywheel ............................................................... 31
Overhaul Auxiliary drive gears .............................................. 31
Disassembling the cylinder head ........................... 13 Circulation pump ................................................... 33
Cleaning, inspection .............................................. 13 Oil cooler .............................................................. 33
Valve guides ......................................................... 14 Adjustment of valve clearance .............................. 34
Valves .................................................................. 15 Adjustment of injection angle ................................ 35
Valve seats ........................................................... 15 Exterior details ...................................................... 36
Valve springs ........................................................ 15 Venting the fuel system ........................................ 37
Rocker arm mechanism ........................................ 15 Adjusting the speed .............................................. 37
Injectors ................................................................ 15
Assembling the cylinder head ............................... 16 Wiring Diagram ................................................... 39
Cleaning and inspecting the cylinder block ............ 17
Pistons, cylinder liners .......................................... 17 Fault Finding Table ............................................. 43
Connecting rods .................................................... 18
Crankshaft ............................................................ 18 Special Tools ...................................................... 43
Camshaft .............................................................. 18
Oil pump ............................................................... 18 Technical Data ..................................................... 47
Sea-water pump .................................................... 19
Circulation pump ................................................... 20
After cooler ........................................................... 21
Oil cooler .............................................................. 22

1
 Safety Precautions

Introduction
This Workshop Manual contains technical data, Check that the warning or information decals on
descriptions and repair instructions for Volvo Penta the product are always clearly visible. Replace
products or product versions contained in the con- decals that have been damaged or painted over.
tents list. Ensure that the correct workshop literature
is being used. Engine with turbocharger: Never start the engine
Read the safety information and the Workshop without installing the air cleaner (ACL). The ro-
Manual “General Information” and “Repair Instruc- tating compressor in the Turbo can cause seri-
tions” carefully before starting work. ous personal injury. Foreign objects entering the
intake ducts can also cause mechanical dam-
Important age.
In this book and on the engine you will find the follow-
ing special warning symbols. 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-
WARNING! If these instructions are not fol-
jury.
lowed there is a danger of personal injury,
extensive damage to the product or serious Avoid opening the filler cap for engine coolant
mechanical malfunction. system (freshwater cooled engines) when the
IMPORTANT! Used to draw your attention to engine is still hot. Steam or hot coolant can
something that can cause damage, product spray out. Open the coolant filler cap carefully
malfunction or damage to property. and slowly to release pressure before removing
the cap completely. Take great care if a cock,
NOTE! Used to draw your attention to important in- plug or engine coolant line must be removed
formation that will facilitate work or operations. from a hot engine. It is difficult to anticipate in
which direction steam or hot coolant can spray
Below is a summary of the risks and safety precau- out.
tions you should always observe or carry out when
operating or servicing the engine. Hot oil can cause burns. Avoid skin contact with
hot oil. Ensure that the lubrication system is not
Immobilize the engine by turning off the power under pressure before commencing work on it.
supply to the engine at the main switch (switch- Never start or operate the engine with the oil fill-
es) and lock it (them) in the OFF position before er cap removed, otherwise oil could be ejected.
starting work. Set up a warning notice at the en-
Stop the engine and close the sea cock before
gine control point or helm.
carrying out operations on the engine cooling
system.
Generally, all servicing should be carried out
with the engine switched off. Some work (carry-
Only start the engine in a well-ventilated area. If
ing out certain adjustments for example) re-
operating the engine in an enclosed space, en-
quires the engine to be running. Approaching a
sure that exhaust gases and crankcase ventila-
running engine is dangerous. Loose clothing or
tion emissions are ventilated out of the working
long hair can fasten in rotating parts and cause
area.
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.

2
Always use protective goggles where there is Store oil and fuel-soaked rags and fuel and oil
a danger of pieces of metal, sparks from grind- filters safely. In certain conditions oil-soaked
ing, acid or other chemicals being thrown into rags can spontaneously ignite. Used fuel and
your eyes. Your eyes are very sensitive, injury oil filters are environmentally dangerous waste
can lead to loss of sight! and must be deposited at an approved site for
destruction together with used lubricating oil,
Avoid skin contact with oil. Long-term or re- contaminated fuel, paint remnants, solvent, de-
peated contact with oil can remove the natural greasing agents and waste from washing
oils from your skin. The result can be irritation, parts.
dry skin, eczema and other skin problems.
Used oil is more dangerous to health than new Never allow a naked flame or electric sparks
oil. Use protective gloves and avoid using oil- near the batteries. Never smoke in proximity to
soaked clothes and rags. Wash regularly, es- the batteries. The batteries give off hydrogen
pecially before meals. Use the correct barrier gas during charging which when mixed with air
cream to prevent dry skin and to make clean- can form an explosive gas – oxyhydrogen.
ing your skin easier. This gas is easily ignited and highly volatile.
Incorrect connection of the battery can cause
Most chemicals used in products (engine and a spark which is sufficient to cause an explo-
transmission oils, glycol, petrol and diesel oil) sion with resulting damage. Do not disturb bat-
and workshop chemicals (solvents and paints) tery connections when starting the engine
are hazardous to health Read the instructions (spark risk) and do not lean over batteries.
on the product packaging carefully! Always fol-
low safety instructions (using breathing appa- Never mix up the positive and negative battery
ratus, protective goggles and gloves for ex- terminals when installing. Incorrect installation
ample). Ensure that other personnel are not can result in serious damage to electrical
unwittingly exposed to hazardous substances equipment. Refer to wiring diagrams.
(by breathing them in for example). Ensure
that ventilation is good. Handle used and Always use protective goggles when charging
excess chemicals according to instructions. and handling batteries. The battery electrolyte
contains extremely corrosive sulfuric acid. If
Be extremely careful when tracing leaks in the this comes into contact with the skin, wash im-
fuel system and testing fuel injection nozzles. mediately with soap and plenty of water. If bat-
Use protective goggles! The jet ejected from a tery acid comes into contact with the eyes, im-
fuel injection nozzle is under very high pres- mediately flush with copious amounts of water
sure, it can penetrate body tissue and cause and obtain medical assistance.
serious injury There is a danger of blood poi-
soning. Turn off the engine and turn off power at main
switch(es) before carrying out work on the
All fuels and many chemicals are inflammable. electrical system.
Ensure that a naked flame or sparks cannot ig-
nite fuel or chemicals. Combined with air in Clutch adjustments must be carried out with
certain ratios, petrol, some solvents and hy- the engine turned off.
drogen 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 work-
place.

3
 Use the lifting eyes mounted on the engine/re- Components in the electrical system, ignition
verse gear when lifting the drive unit. system (gasoline engines) and fuel system on
Always check that lifting equipment is in good Volvo Penta products are designed and con-
condition and has sufficient load capacity to lift structed to minimize the risk of fire and explo-
the engine (engine weight including reverse sion. The engine must not be run in areas
gear and any extra equipment installed). where there are explosive materials.
To ensure safe handling and to avoid damaging
Always use fuels recommended by Volvo Pen-
engine components on top of the engine, use a
ta. Refer to the Instruction Book. The use of
lifting beam to raise the engine. All chains and
lower quality fuels can damage the engine. On
cables should run parallel to each other and as
a diesel engine poor quality fuel can cause the
perpendicular as possible in relation to the top
control rod to seize and the engine to overrev
of the engine.
with the resulting risk of damage to the engine
If extra equipment is installed on the engine al- and personal injury. Poor fuel quality can also
tering its center of gravity, a special lifting de- lead to higher maintenance costs.
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 se-
cured blocks are being used. Even where lift-
ing 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.

4
 General information
About the workshop manual Replacement parts
This workshop manual contains technical specifica- Replacement parts for electrical and fuel systems are
tion, descriptions and instructions for repairing subject to statutory requirements (US Coast Guard
Marine Diesel Engines MD, TMD, TAMD, AD31A, B Safety Regulations for example). Volvo Penta Genuine
and CE engines and TMD, TAMD, D, AD41A, B and parts meet these requirements. Any type of damage
CE engines. The product designation and number which results from the use of non-original Volvo Penta
should be given in all correspondence about the replacement parts for the product will not be covered
product. under any warranty provided by Volvo Penta.
This Workshop Manual has been developed primarily
for Volvo Penta service workshops and qualified
personnel. 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 publi-
cation will be provided in the form of Service Bulle-
tins.

5
 Repair instructions
The working methods described in the Service
Manual apply to work carried out in a workshop. The
Our joint responsibility
Each engine consists of many connected systems
engine has been removed from the boat and is
and components. If a component deviates from its
installed in an engine fixture. Unless otherwise
technical specification the environmental impact of an
stated reconditioning work which can be carried out
otherwise good engine may be increased significantly.
with the engine in place follows the same working
It is therefore vital that wear tolerances are main-
method.
tained, that systems that can be adjusted are adjusted
Warning symbols occurring in the Workshop Manual properly and that Volvo Penta Genuine Parts as used.
(for their meaning see Safety information) The engine Maintenance Schedule must be followed.
Some systems, such as the components in the fuel
WARNING! system, require special expertise and special testing
equipment for service and maintenance. Some com-
IMPORTANT! ponents are sealed at the factory for environmental
reasons. No work should be carried out on sealed
components except by authorized personnel.
NOTE! Bear in mind that most chemicals used on boats are
are not in any way comprehensive since it is imposs- harmful to the environment if used incorrectly. Volvo
ible to predict every circumstance under which service Penta recommends the use of biodegradable
work or repairs may be carried out. For this reason we degreasing agents for cleaning engine components,
can only highlight the risks that can arise when work unless otherwise stated in a workshop manual. Take
is carried out incorrectly in a well-equipped workshop special care when working on-board, that oil and
using working methods and tools developed by us. waste is taken for destruction and is not accidentally
pumped into the environment with bilge water.
All procedures for which there are Volvo Penta special
tools in this Workshop Manual are carried out using
these. Special tools are developed to rationalize
working methods and make procedures as safe as
Tightening torques
possible. It is therefore the responsibility of any Tightening torques for vital joints that must be tight-
person using tools or working methods other than the ened with a torque wrench are listed in workshop
ones recommended by us to ensure that there is no manual “Technical Data”: “Tightening Torques” and are
danger of injury, damage or malfunction resulting from contained in work descriptions in this Manual. All
these. torques apply for cleaned threads, screw heads and
mating surfaces. Torques apply for lightly oiled or dry
In some cases there may be special safety precau-
threads. If lubricants, locking fluid or sealing com-
tions and instructions for the use of tools and chem-
pound are required for a screwed joint this information
icals contained in this Workshop Manual. These
will be contained in the work description and in “Tight-
special instructions should always be followed if
ening Torques” Where no tightening torque is stated for
there are no separate instructions in the Workshop
a joint use the general tightening torques according to
Manual.
the tables below. The tightening torques stated are a
Certain elementary precautions and common sense guide and the joint does not have to be tightened using
can prevent most risks arising. A clean workplace a torque wrench.
and engine eliminates much of the danger of injury
and malfunction. Dimension Tightening Torques
It is of the greatest importance that no dirt or foreign Nm lbt.ft
particles get into the fuel system, lubrication sys- M5 6 4.4
tem, intake system, turbocharger, bearings and M6 10 7.4
seals when they are being worked on. The result can M8 25 18.4
be malfunction or a shorter operational life. M10 50 36.9
M12 80 59.0
M14 140 103.3

6
Tightening torques-protractor Sealants
(angle) tightening A number of sealants and locking liquids are used on
the engines. The agents have varying properties and
Tightening using both a torque setting are used for different types of jointing strengths,
and a protractor angle requires that operating temperature ranges, resistance to oil and
first the recommended torque is other chemicals and for the different materials and gap
applied using a torque wrench and sizes in the engines.
then the recommended angle is added
To ensure service work is correctly carried out it is
according to the protractor scale.
important that the correct sealant and locking fluid
Example: a 90° protractor tightening
type is used on the joint where the agents are re-
means that the joint is tightened a
quired.
further 1/4 turn in one operation after
the stated tightening torque has been In this Volvo Penta Service Manual the user will find
applied. 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.
Locknuts Make sure that mating surfaces are dry and free from
Do not re-use lock nuts that have been removed oil, grease, paint and anti-corrosion agent before
during dismantling as they have reduced service life applying sealant or locking fluid. Always follow the
when re-used – use new nuts when assembling or manufacturer’s instructions for use regarding; tempera-
reinstalling. For lock nuts with a plastic insert such ture range, curing time and any other instructions for the
as Nylock® the tightening torque stated in the table product.
is reduced if the Nylock® nut has the same head Two different basic types of agent are used on the
height as a standard hexagonal nut without plastic engine and these are:
insert. Reduce the tightening torque by 25% for bolt
RTV agent (Room temperature vulcanizing). Use for
size 8 mm or larger. Where Nylock® nuts are higher,
gaskets, sealing gasket joints or coating gaskets. RTV
or of the same height as a standard hexagonal nut,
agent is clearly visible when a component has been
the tightening torques given in the table apply.
dismantled; old RTV must be removed before the joint
is resealed.
The following RTV agents are mentioned in the Ser-
Tolerance classes vice Manual: Loctite® 574, Volvo Penta 840879-1,
Permatex® No. 3, Volvo Penta P/N 1161099-5,
Screws and nuts are divided into different strength
Permatex® No. 77. Old sealant can be removed using
classes, the class is indicated by the number on the
methylated spirits in all cases.
bolt head. A high number indicates stronger material,
for example a bolt marked 10-9 indicates a higher Anaerobic agents. These agents cure in an absence of
tolerance than one marked 8-8. It is therefore import- air. They are used when two solid parts, for example
ant that bolts removed during the disassembly of a cast components, are installed face-to-face without a
bolted joint must be reinstalled in their original gasket. They are also commonly used to secure
position when assembling the joint. If a bolt must be plugs, threads in stud bolts, cocks, oil pressure
replaced check in the replacement parts catalogue switches and so on. The cured material is glass-like
to make sure the correct bolt is used. 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 reinstall-
ing 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 Corpora-

tion, Permatex® is the registered trademark of the Permatex
Corporation.

7
 Engine Component Guide

D31

D41

Engine component guide

1. Sea water pump
2. Fresh water filler
3. Engine oil filler
4. Oil dipstick
5. Air filter
6. Engine serial number
7. Fuel filter
8. Feed pump
9. Pipe for oil bilge pump

8
 Dismantling
Drain off the cooling water of the engine, the lubric-
ating oil and fuel, if any, from the fuel filter and the
fuel injection pump. Clean the engine externally.

3. Remove the heat exchanger and its hose connections

as well as the ventilation-pipe to the turbo charger.

1. TAMD31 and 41: Remove the cooling water pipes

from the after-cooler. Remove the after-cooler.

4. Remove the pipes to and from the oil cooler. Remove

the oil filter and discard it. Remove the oil filter bracket
along with the oil cooler.

2. Remove the sea-water pump, all fuel pipes and fuel

hoses. Remove the fuel filter with its cover and the fuel
feed pump. Install protective caps on the fuel injectors.

5. Remove the oil pressure sensor and oil pressure

sender.

9
6. Remove the crankcase ventilation filter and the air fil- 9. Remove the electric distribution box on the exhaust
ter along with its bracket. Remove the oil dipstick pipe. manifold. Remove the turbo charger connecting pipes.
Remove the intake manifold. (Often there is no need Remove the exhaust manifold along with the turbo
to remove the intake manifold when overhauling the charger. Also remove the thermostat housing, the
engine.) fresh water circulation pump and the cable harness.
Disassemble the cylinder head.

7. Remove the alternator bracket and the alternator ten- 10. Remove the pulley, installed on the crankshaft poly-
sioning iron. Remove the alternator and the alternator gon hub. Remove the center bolt of the polygon hub.
V-belts. Remove the starter motor. Install the center bolt again, but less the washer, and
pull off the hub, using puller 884533.

8. Remove the valve cover. Disassemble the rocker arm 11. Remove the cover of the timing gear casing. Remove
assembly and remove the push rods. the 4 screws in the carrier of the fuel injection pump.
Remove the carrier of the sea-water pump and the
fuel injection pump drive.

10
12. Remove the 3 attachment screws of the fuel injection 15. Remove the oil pan, oil pipe and bracket. Also remove
pump and remove the pump. After having removed the reinforcement plate as well as pistons and piston
the 3 screws, also remove the intermediate gear. Then rods.
remove the center screw and pull off the camshaft NOTE! Be careful not to damage the piston cooling
gear, using puller 9992679. nozzles.

13. Use puller, 9992658, and pull off the crankshaft gear.

16. Use a liner puller and pull out the cylinder liners. Use
tool 884602, 884551 and 884231.

14. Remove the inspection covers and the valve lifters. Ar-
range the lifters in sequence! Remove the thrust
washer of the camshaft and lift out the camshaft.

11
The flywheel
17. Remove the flywheel damper, the flywheel and the fly-
wheel housing.

The crankshaft
18. Remove the main bearing caps and remove the
crankshaft.
NOTE! Lock nuts should not be reused but should al-
ways be replaced with new ones. The main bearing
caps are numbered and must be reinstalled in their
original positions. Remove the piston cooling nozzles.

12
 Overhaul

The cylinder head

1. Use a pair of pliers for valve springs and remove the

valve springs and the valves.
3. Cylinder head – hydrostatic testing
NOTE! Arrange the valves in sequence in a valve
stand. Remove and discard the rubber seals of the in- A. Use sealing washer, tool 9996531, to plug all coolant
let valves. Remove the injection nozzles. holes. Use screw, 955353 and nut, 955784, to tighten the
sealing washer.
B. Install the union washer, tool 9996532, on the end of
the cylinder head and connect the pressure testing de-
vice, tool 9996662. Use the gasket of the thermostat hous-
ing and the 4 screws, part number 955295, for the union
gasket.
2. Cleaning and checking C. Tighten the reduction valve until the pressure gauge
Clean all parts! Pay special attention to the lubricating indicates a pressure of 100 kPa (1 kp/cm2).
oil and coolant channels. Check the tightness by pres- D. Lower the cylinder head into water in order to find the
sure testing. Check the plane of the cylinder head with leakage, if any, and the location of the leakage.
a steel ruler. Should the irregularity of the plane ex- E. Use compressed air, after the pressure testing, to dry
ceed 0,10 mm over a length of 100 mm and 0,20 mm out the cylinder head.
over the whole length of the surface, the cylinder head
must be changed.

13
4. Valve guides
A. Check the wear of the valve guides by installing a new
valve in a valve guide. Lower the valve approximately 2
mm (0.078") and check wear. Measure the clearance with
a indicator gauge. If necessary, replace the valve guides.
Wear limits:
Inlet valve, max clearance ................... 0.15 mm (0.0059")
Outlet valve, max clearance ................ 0.17 mm (0.0067")
5. Valves
Grind the valves in a valve grinding machine. The angle
(D) should be 29.7° for the inlet valve and 44.7° for the
outlet valve. Should the thickness of the valve disc after
the grinding be less than 1.7 mm (0.0669"), the valve must
be discarded. Also discard a valve with a bent stem. Grind
the contact surface against the rocker arm if necessary.
A. (New valve) 0.05–0.65 mm (0.00197–0.0256")
B. Inlet: 1.5–3.0 mm (0.059–0.118"), Outlet: 1.4–2.9 mm
(0.055–0.114")
C. Inlet: 30°, Outlet: 45°
D. Inlet: 29.7°, Outlet: 44.7°

6. Valve seats
Mill or ream the valve seats. The angle (C) should be 30°
for inlet and 45° for outlet. (Check and if necessary re-
place the valve guides prior to working the valve
seats.) The width of the sealing surface should be 1.5–3.0
mm (0.059–0.118") for the inlet seat and 1.4–2.9 mm
(0.055–0.114") for the outlet seat. Replace the valve seat
when the measurement (A), measured with a new valve,
exceeds 0.65 mm (0.0256"). A new seat is ground to give
measurement (A) a value of 0.05 mm (0.00197").

B. Use mandrel 9992818 to press out the valve guides.

Coat the new valve guides externally with oil, and use
mandrel 9995028 to install them. The mandrel should be
depressed all the way down against the cylinder head.
Ream the valve guides if necessary.

14
Changing the valve seats
A. Remove the old valve seat by grinding two “nicks” as
shown in the picture. Split the seat with a screwdriver.
B. Ream the seat position to the correct dimension, see
8. Rocker arm mechanism
under ”Technical Data”. Cool the new seat in “dry ice” to
about –60°C and heat the cylinder head by flushing it in Disassemble the rocker arm mechanism and clean the
hot water. Use a mandrel to press down the seat. Work the components. Check the wear of the shaft and that of the
seat to adjust the height, the angle and the width to their rocker arm bushings. Should the bushings need to be re-
proper dimensions. placed, use mandrel 9991867 for removal and installation
(NOTE! Make sure that the oil hole in the bushing coin-
cides with that of the rocker arm). After the installation the
bushings must be reamed to a close running fit. 22.020–
22.041 mm (0.86732–0.86775").
Check the contact surface of the rocker arms against the
valve to make sure it is not hollowed. A minor adjustment
can be made in a valve grinding machine. Oil the shaft
and install the components.

7. Valve springs
Engine No.
31: –2203115306
41: –2204137475
Check the free length of the valve springs and the length
when loaded.
Length, unloaded ................................... 46 mm (1.811")
Length, loaded 267–312 N .................... 40 mm (1.5748")
767–852 N .................... 30 mm (1.1811")

Engine No.
31: 3303115307–
41: 2204137476–
Check the free length of the valve springs and the length
when loaded.
Length, unloaded ................................... 44.2 mm (1.755")
Length, loaded 136–158 N .................... 40.6 mm (1.598")
554–614 N .................... 29.7 mm (1.169")

15
 10. Fuel injector sleeve
Insert the expanding screw on the sleeve removal tool,
part number 884931, in the cooper sleeve and tighten
counter clockwise until the screw has caught in the
9. Removal and testing of nozzles sleeve. Tighten hard to allow the threads to eat into the
copper material. Then install the sleeve (1) on the screw
1. Remove the old oil leakage pipe and the pressure oil
and the nut (2). Turn until the sleeve has been removed.
pipe of the nozzle.
Replace the 2 sealing rings (3), sealing off between the
2. Remove the nut holding the nozzle yoke.
copper sleeve and the cylinder head. Oil the new sleeve
3. Install the nozzle puller screw on the nozzle. Make and install it along with the steel ring using tool 884945.
sure that the puller bottoms against the nozzle sleeve. Knock in the sleeve until it bottoms.
4. Install the nut on the nozzle screw until it is in contact
against the puller.
11. Assembling the cylinder head
5. Hold the nozzle screw and tighten the nut until the
Clean the cylinder head. Oil the valve stems and install
nozzle is coming off.
the valves. Do not forget the sealing rings on the inlet
Make sure that the nozzle yoke is free and not locking. valves.
Pull out the nozzle by hand.

Pressure testing the nozzle

Check the spray pattern. Opening pressure see Technical
Data. Also check that the fuel jets cease simultaneously at
all holes and that there is no dripping afterwards. Adjust
the opening pressure with adjusting washers (1), being
available in different thicknesses, from 1 mm (0.0394") to
1.95 mm (0.065") in steps of 0.05 mm (0.00197"). Disas-
semble the injectors and replace the adjustment washer
against a thinner or thicker respectively depending on
whether the pressure should be reduced or increased. As-
semble the injectors and check the opening pressure and
the spray pattern.

16
 Cylinder Block
B. Measure the diameter of the cylinder liner on several
points diametrically and on several points vertically, from
the top dead center to the bottom dead center (B and C).
Replace pistons and liners if the wear is 0.25–0.30 mm
(0.00984–0.0118"). Measure the piston diameter (A) at
right angles to the gudgeon pin hole and 15 mm (0.59")
from the lower edge. Calculate the maximum and mini-
mum clearance of the piston (the maximum and minimum
diameter of the liner respectively are reduced by the pis-
ton diameter).
Piston clearance (new parts):
Normal aspirated engine: 0.10–0.14 mm
(0.00394–0.00512")
Turbo charged engine: 0.08–0.12 mm
(0.00315–0.004724")

12. Cleaning and checking

Remove all plugs for the different channels and clean the
block carefully. Check to make sure that all channels are
free from deposits and that there are no cracks in the
block. Coat the plugs with sealant and install them again.

C. Measure the piston ring gap on new rings. If the cylin-

der liners are not new, the measurement should be taken
with the ring in the bottom dead center position.
The gap should be:
Compression rings: 0.40–0.65 mm (0.01574–0.02559")
Oil scraper rings: 0.25–0.40 mm (0.00984–0.01574")

13. Piston and liners D. Measure the clearance of the piston rings, in the piston
A. Piston and liners are matched and marked with a letter. ring grooves.
Thus, a piston marked “D” can only be used along with a NOTE! The upper ring should be in plane with the piston
liner marked with the same letter. Check the pistons and barrel surface at the point of the measuring, see the pic-
the liners for damages prior to the measuring. ture.
The clearance should be:
Upper compression ring: 0.08–0.13 mm
Class Cylinder diameter
(0.00315–0.005118")
C 92.00–92.01 (3.6220–3.6224") Lower compression ring: 0.07–0.10 mm
D 92.01–92.02 (3.6224–3.6228") (0.00276–0.003937")
E 92.02–92.03 (3.6228–3.6232") Oil scraper ring: 0.04–0.07 mm (0.00157–0.00276")

17
 16. Camshaft
14. Piston rods
Check the camshaft with regard to wear of cams and bear-
A. Check the piston rods for straightness and twist.
ing races. Also check the wear of the bearings. The bear-
ings are pressed into their positions and must be drilled
and milled after the installation. Maximum allowed wear
on bearing races and bearings respectively: 0.05 mm
(0.00197").

B. Check the piston rod bushing by using the gudgeon

pins as a gauge. There must be no noticeable clearance.
Should the bushing be in need of being replaced, use
mandrel 9996271 for removal and installation.
NOTE! Make sure that the oil hole of the bushing coin-
17. Oil pump
cides with that of the piston rod.
A. Remove the intermediate gear. Use puller 9996273 to
Ream the new bushings. When the tolerance is right, a
pull off the oil pump gear. Remove the key and the brass
well oiled gudgeon pin should slowly glide through the
washer.
bushing by its own weight.

15. Crankshaft
Measure the crankshaft bearings and main bearings. The
ovality must not exceed 0.04 mm (0.001575") and the ta-
per 0.05 mm (0.00197"). Should these values be exceed- B. Remove the attachment screws from the housing.
ed, the crankshaft must be ground to a suitable Press off the housing by installing the screws from the
under-dimension, see under “Technical Data”. front. Remove the pump gears.

18
 18. Sea-water pump
C. Check the housing for wear and scratches. Check the
sealing between the bracket and the pump housing. A. Remove the cover. Use two screwdrivers to bend out
When leaking, the surfaces are black. Replace the bush- the impeller (NOTE! Do not forget to protect the housing
ings if the radial clearance between the shaft and the from being damaged by the screwdrivers). Turn the pump
bushing is 0.15 mm (0.005906") or more. Ream the new and remove the locking ring. Again turn the pump and
bushings to a close running fit, whereby the housing press out the shaft, the bearings and the sealing rings.
should be screwed onto the bracket. Replace the interme-
diate gear if the radial clearance exceeds 0.20 mm
(0.00787"). Check the teeth surfaces, the outer diameter
and the end face of the pump gears. Also check the axial
clearance and the tooth surface clearance.

B. Grease the new bearings and install them. Make sure

they end up on the part of the shaft with the biggest dia-
meter.

C. Replace the old cam against a new one. Coat the seal-
D. Oil the various parts. Install the pump gears and the ings with grease and install them in the housing with the
housing. Install the brass washer and the key. sealing lips facing each other. Use mandrel tool 884347.
Press on the drive gear in a way that a 0.05 mm Install the O-ring and the washer between the two sealing
(0.00197") feeler gauge barely can be inserted between rings.
the gear and the brass washer. Install the intermediate Insert the shaft into the housing and make sure that the
gear with its from making facing forward. O-ring ends up on the shaft. Use mandrel tool 884347 to
install the shaft and bearings in the housing.

19
D. Install the locking ring. Install the impeller and its seal-
ing washers. Install the cover along with a new gasket.

19. Water circulation pump

A. Remove (press) the whole shaft along with the pump
wheel from the pump housing.
Remove the four screws and the carrier. Remove the lock-
ing ring and the pulley using the tool 9992265 together
with the counter hold 9996858.
Knock out the inner bearing and the shaft sealing using a
thin mandrel. Clean the housing and the pulley. Remove
the bearing from the pulley.

20
B. Grease the bearings abundantly with a heat resistant
grease. Fill up the space inside the bearings with
grease. Install the bearing in the pulley. Use mandrel
9992268 to press the bearing into the pump housing
(turn the sealed side of the bearing facing the
water-side).

After-cooler
Remove the cover and washer underneath the
C. Put the deflector ring on the bearing and use mandrel after-cooler, and draw out the unit.
9998039 to install the shaft sealing. Wash the components, and clean them thoroughly. In the
NOTE! The carbon ring and the ceramic ring, being part of event of a possible leak, test the unit with compressed air
the sealing, must not come in contact with grease nor or paraffin. Test pressure should be 0.2 MPa (28.4 lbf/ in2).
touched by the fingers.
WARNING! Follow relevant safety regulations
when using test pressurization equipment.
Replace the components in the opposite order, and fit
new gasket rings.

D. Put the ceramic ring on the pump wheel and insert the
shaft through the sealing. Make sure the deflector ring is
properly located. Insert the shaft in a way that the pump
wheel ends up 0.8 mm (0.0315") inside the contact plane
of the housing.

21
 Pressure testing
Remove the oil cooler from the filter bracket. Make a plate
to cover the two holes in the housing. Provide the plate
with a connection for compressed air or similar. Bolt the
plate into the housing, using sealing rings. Make a pres-
sure test with approx. 0.7 MPa (7 kp/cm2) 100 lbf/in2.
NOTE! Follow valid safety regulations.

20. Oil cooler

Removing the end cover, replace the screws and screw in
approx 5 mm (0.2"). Dismantle the zinc electrode. Stand
the oil-cooler on the screws, ensure that it rests upon all
the screws. Tap with the help of the tool 884635 to loosen
the insert. Remove the insert and take off the two O-rings.
Wash the insert, use a brush which can be pushed into
the tubes. Also clean the housing. Check the zinc elec-
trode and if the length is less than 20 mm (0.7874 in) this
should be replaced. Fit new O-rings and push the insert
into the housing. Fit the end cover using a new gasket.

There are two positive pressure valves installed in the oil-

filter bracket. The rear for the piston cooling (opening
pressure 2.2–3.0 kp/cm2/31–42 psi.) and the forward for
the engine oil pressure 4.2–5.0 kp/cm2/60–71 psi.)

22
Turbo-compressor
In the event of excessive exhaust smoke or loss of engine
power, faulty action of the turbo-compressor is to be sus-
pected. The supercharging pressure should then be
checked. When speed slowly decreases the bottom of the
boat should also be examined and, if necessary, cleaned.

Supercharging pressure at different temperatures.

A. Supercharging pressure measured
B. Correction curves
C. Temperature of intake air

B. Measure the supercharging pressure under full load

and at full throttle whilst the engine speed passes rela-
tively slowly through a suitable speed, e.g. 3600 r/m for
LD-engines or 3000 r/m for MD-engines, see the Super-
charging Pressure Diagram under ”Technical Data”. The
21. Checking the supercharging supercharging pressure should not be less than the spe-
pressure cified minimum value. Check the engine speed with a
hand tachometer.
A. Connect a pressure gauge to the measuring connec-
tion on the intake manifold (see illustration). NOTE! It is important to maintain full loading long enough
to enable the pressure to stabilise if results are to be cor-
rect. Also note that the pressure varies with the tempera-
ture of the intake air, as shown in the diagram below. The
supercharging pressure is given at +20° (68°F), which im-
plies that the measured pressure must be corrected as
shown in the diagram if the intake air is not at this temper-
ature when the measurement is made.
Example: A measured pressure of 80 kPa (0.8 kp/cm2 =
11.3 lbf/in2) measured at –10°C (14°F) corresponds to 70
kPa (0.7 kp/cm2 = 9.9 lbf/in2) at +20°C (68°F), i.e. the pres-
sure decreases as the temperature rises, due to reduced
air density.

23
22. Measures to be carried out when the
supercharging pressure is too low

A. Air intake, air cleaner

Check that the air intake is not blocked. Check the air
cleaner and replace it if necessary.

B. Leakage
Check for leakage between the turbo housing and bear-
ing housing or between the compressor housing and the
bearing housing. Also check the joint between the turbo D. Cleaning
compressor and the inlet manifold. The compressor section can be cleaned with the unit still
on the engine, as follows:
Remove the compressor housing. Clean the compressor
housing, the compressor rotor and the bearing shield with
an agent such as white spirit. Fit the compressor housing
and remeasure the supercharging pressure.

If the supercharging pressure is still too low the follow-

ing checks should be made:

E. Throttle Control
Check that the throttle control can move the injection
pump throttle arm to the maximum position.

F. Injection Pump
C. Turbo-compressor
Check the injection angle and the high idle speed.
Remove the air cleaner. Check that the compressor rotor
If necessary, check the entire pump on a pump test bench.
is at rest and then see whether the rotor is stiff when
turned by hand. If the rotor is difficult to turn, the compres-
sor should be replaced or reconditioned. G. Feed Pressure
Measure the axial and radial clearances of the rotor unit. If necessary, replace the fuel fine filter and clean the
The radial clearance is measured on the turbine side (at pre-filter. There must be no fuel leakage.
the outer edge of the hub, see illustration).
Max. allowable axial clearance: 0.16 mm (0.00630 in).
Max. allowable radial clearance: 0.42 mm (0.01654 in). H. Injectors

If the wear limits are reached, the turbo-compressor Check the opening pressure and the spray pattern.
should be replaced or reconditioned.
If no faults are found: I. Condition of engine
Check whether the compressor section requires cleaning, Check the valve clearances and the compression pres-
see point D. Deposits of soot and oil can cause low super- sure. If the supercharging pressure is still unsatisfactory,
charging pressure. the compressor must be reconditioned or replaced.

24
Reconditioning
All moving parts of the turbo compressor are separately
balanced. This also applies to spare parts. A joint balanc-
ing after reconditioning may however be advantageous
from the viewpoint of life time length.

B. Remove the compressor rotor. Press the shaft out if the

rotor is stuck.

23.Disassembling
A. Make line-up marks between the turbine housing (1),
C. Remove the bearing end head (5) and press out the
the compressor housing (7) and the bearing housing (3).
piston ring retainer (9). Remove the piston rings, the oil
Remove the turbine housing and the compressor housing.
deflector plate (10), the thrust bearing (11) and the thrust
Clamp the turbine rotor and remove the compressor rotor
washer (12). Lift the bearing housing (1) and the heat
lock nut (8). The position of the wheel should be marked
shield (2) from the shaft. Remove the piston rings (14) and
in relation to the shaft.
the bushings (13).
Clean the coponents thoroughly, take care not to damage
them.

25
 D. Piston Rings, Piston Ring Retainers
Measure the width of the piston rings. This should be min:
1.2 mm (0.04724 in). Measure the width of the piston ring
grooves in the piston ring retainer. The width must not ex-
ceed 3.0 mm (0.11811).
24. Measuring, inspection
A. Turbine Rotor with Shaft Compressor Rotor
Check that the rotors and the shaft are free from mechan-
ical defects. The blades must not be worn or deformed.
Blades must never be straightened, and any damaged
parts must be replaced by new or reconditioned parts.
Place the shaft on two supports located under the bearing
positions, see illustration. Measure the out-of-truth of the
shaft at about 20 mm (0.7874 in) from the threaded por-
tion.
Max. allowable out-of-truth: 0.007 mm (0.00028 in). Check
the diameters at the shaft bearing positions.
Min. dia. 9.95 mm (0.39173 in). Check the width of the pis-
ton ring grooves in the shaft.
The width should be max. 3.0 mm (0.11811 in).

B. Bearing housing, Compressor housing,

Turbine housing
Check the housing for cracks and other damage. Measure B = Wearing Surfaces
the diameters of the bushing recesses in the bearing
housing. The diameter should be max. 16.064 mm
(0.63244 in). E. Thrust Washer, Thrust Bearing
Measure the thickness of the thrust washer.
This should be min. 1.47 mm (0.5787 in).
Check the wearing surfaces of the thrust bearing. The
angle, as shown in the illustration, should not exceed 30°.

C. Bushings
Check the bearing surfaces for damage. Measure the in-
ternal and external diameters.
Internal diameter, max: 10.00 mm (0.3937 in).
External diameter, min: 15.975 mm (0.62895 in).
Measure the lengths of the bushings. These should be
min: 11 mm (0.43307 in). Note that the bushings should
have a push fit in the bearing housing.

26
 C. Fit the bushing and the external lock ring on the com-
25. Assembling pressor side of the bearing housing.

Lubricate all moving parts involved in the assembly Fit the thrust washer (12), the thrust bearing (11) and the
process. oil deflector plate (10).

A. Fit the bushing and lock rings on the turbine side of the Fit the piston rings on the piston ring retainer (9).
bearing housing. Also fit the inner lock ring on the com- Arrange the piston ring gaps in the same way as on the
pressor side. Fit the heat shield (2) on the bearing hous- turbine side and fit the retainer in the bearing end head
ing. (5).
Clamp the hub of the turbine rotor (15) in a vice. Fit the
piston rings (14) and carefully fit the bearing housing over
the shaft.

D. Apply Curil T to the sealing surfaces of the bearing end

head and screw the head into the bearing housing.
NOTE! The self-locking bolts (4) should be replaced by
new ones. (If the old bolts are used, they should be se-
cured with Locktite).
1. Heat the compressor wheel to not more than 130°C,
and fit it against the stop on the shaft journal. Check
that the wheel and shaft are correctly lined up.
2. Wait until the components have cooled down to room
temperature.
3. Apply Loctite 640 to the thread of the shaft journal. Fit
the new nut as shown in the Figure, and tighten it. The
torque should be 10 Nm.
B. Fit the piston ring gaps 90° apart and at 45° with re-
spect to the oil inlet (see illustration). Compress the rings Then turn the nut through a further 60°.
so that they can be inserted in the bearing housing. After Use a T-handle and sleeve for the purpose, so that the
this, check that the heat shield turns easily. shaft is not biased.

27
 26. Fitting the turbo-compressor
A. Change the engine oil and the lubricating oil filter.
Bearing damage in the turbo-compressor is almost always
caused by sludge deposits in the engine lubricating sys-
tem. The presence of sludge deposits can be checked by
lifting off the rocker arm casing. If deposits are found, the
complete lubrication system must be thoroughly cleaned
before a new or reconditioned turbo-compressor is fitted.
The correct grade of oil must be used (see “Technical
Data”), and oil changes must be carried out in accordance
with the instruction book in order to keep the engine
clean.
Also check the delivery and return lines to the turbo-com-
pressor.
B. Clean the intake line between the turbine and the air
E. Fit the O-ring on the bearing end head and fit the com-
cleaner. If the compressor rotor has been damaged, piec-
pressor housing (7).
es may still remain which can damage the new compres-
Torque 7 Nm (0.7 kpm) (5.0 ft/lbs). sor rotor.
Fit the turbine housing (1).
C. Fit the turbo-compressor on the engine. After this, inject
Tightening torque: 8 Nm (0.8 kpm) 5.8 ft/lbs).
lubricating oil into the compressor bearing system before
fitting the delivery oil line.
D. Turn the engine over, with the stop button pushed in,
until oil pressure is obtained. Then disconnect the upper
oil pipe on the turbo-compressor and check that oil is
coming out of it.

28
 Assembly
Use new gaskets, sealing rings, sealing washers and
locking washers. Coat the sealing rings with oil or grease
(the sealing rings of the cylinder liners are “painted” with
soap water) and oil all moving parts prior to assembly.

3. Install the cylinder liners using mandrel 9996598 and

standard shaft 9992000.

1. Put the cylinder liners in the block without sealing

rings. Use press tool 9996272. Measure the liner
height, measurement “A” in the picture. Measure four
points on each liner. Check that the support surface is
not damaged when resetting the dial indicator. The
check is made with dial indicator 9989876 and holder
9992479. The height should be 0.06–0.11 mm
(0.00236-0.00433"). However, the difference between
two adjacent liners must not exceed 0.02 mm
(0.000787"). Mark the liners to secure the same se-
quence during final assembly.

4. Install all piston cooling nozzles.

NOTE! New o-ring and locknuts must be used.

1 = violet
2 = Black
3 = Black

5. Install the main bearings and the crankshaft (lubricate

2. Lift out the liners and install the sealing rings as indi- the bearing surface with engine lubricating oil). Install
cated in the picture. “Paint” the sealing rings and the the two thrust washers in the engine block, one on
lower guides in the block with soap water. each side of the middle main bearing. Check the axial
clearance, which should be 0.10–0.31 mm (0.00394–
0.0122").

29
6. Install the main bearing caps in the proper sequence 8. Use a pair of piston ring pliers to install the piston
(the number 1 in the front). Tightening torque, see un- rings. The compression rings are marked “Top”. The
der “Technical Data”. Oil the threads! oil scraper ring can be turned as you like. Install the
crankshaft bearing shells.
Oil the pistons, the piston rings and the crankshaft
bearings. Turn the piston rings with the gaps turned
120° away from each other.
Install the pistons with the front marking facing for-
wards. Use the installation ring 9995031.
NOTE! Do not push down the pistons too far in order
not to damage the piston cooling nozzles.

7. Heat the pistons to a temperature of about 100°C. As-

semble the pistons and the piston rods in a way that
the front marking on the pistons and the numbering of
the piston rods end up as indicated in the picture.
9. Install the crankshaft bearing caps in a way that the
marking coincides with that of the piston rod. Oil the
threads. Tightening torque: 113 Nm (11.3 kpm).

30
 12. Oil the camshaft bearings. Install the camshaft, the
Oil pump spacer ring and the thrust washer. Install the screws.
10. Install the reinforcement plate. Dip the threads of the Check the axial clearance which must be 0.04–0.12
screws in an anti-rust agent maximum 24 hours prior mm (0.001575–0.00472").
to the assembly. At the time of the assembly the
screws must be drip-free. Clean the contact surfaces
carefully. Tightening torque 46±5 Nm (4.6±0.5 kpm).
Tighten the oil pump to the front main bearing. Install
new sealing rings as indicated in the picture.
NOTE! Install two yellow sealing rings on the pressure
pipe end being attached to the block. Tighten suction
pipe bracket to main bearing number 3 (on MD31)
and to main bearing number 5 (on MD41). Tighten the
oil pipes, and install the reduction valve (1) between
the pressure pipe and the pump.

Transmission
All gears in the transmission having anything to do with
the setting, are marked with a punch mark.

Flywheel
11. Replace the sealing ring in the flywheel housing.
Grease the new ring prior to installing the flywheel
housing. Install the flywheel housing and the inner
transmission cover.
Install the flywheel, tightening torque: 115 Nm (11.5 13. Check to make sure that the key of the crankshaft is
kpm). installed. Use tool 9992659 to press on the crankshaft
NOTE! There is a spacer sleeve in the flywheel which gear.
must fit the crankshaft. NOTE! Make sure that the gear engages the oil pump
gear.

31
14. Install the key on the camshaft. Heat the camshaft 16. Install the pump gear with the marking coinciding.
gear to a temperature of about 100°C and install it on NOTE! The gear is marked for 4 as well as 6 cylinder
the shaft. engines. Tighten the pump gear along with the carrier.
Install the intermediate gear on its pivot and make NOTE! The screw pattern is such that the carrier can
sure that the marking coincides. The pivot can be be installed in one way only.
turned as you like. Tightening torque: 24 Nm (2.4 Tightening torque: 23 Nm (2,3 kpm).
kpm). Tighten the camshaft gear. Tightening torque: Install the rubber carrier for the sea-water pump.
85 Nm (8.5 kpm).
Install the inlet manifold (use Silicone between the
cylinder head and the inlet manifold).

17. Replace the sealing ring in the transmission housing

cover. Soak the sealing ring in oil and then install the
cover along with a new gasket. Install the oil pan.

15. Set the marking of the carrier (see the picture) pointing
obliquely upwards towards the left (the marking then
points at the number 1 pressure pipe connection). In-
stall a new O-ring on the flange of the pump and in-
stall the fuel injection pump. Install the attachment
nuts of the injection pump but do not tighten them.

32
18. Coat the crankshaft pin with molybdenum disulphide.
Heat the polygon hub to a temperature of about 100°C 21. Install the oil pressure sensor and the oil pressure
and install it on the crankshaft. If necessary the hub sender.
can be pressed onto the crankshaft, using tool
9992659. Install the washer and the center bolt. Tight-
ening torque: 180 Nm (18 kpm). Install the pulley.
Tightening torque: 25 Nm (2.5 kpm).

19. Clean the valve lifters carefully and coat the contact
surface against the camshaft with molybdenum disul-
phide. Oil the valve guides in the block. Install the
valve lifters and the inspection covers.

Oil cooler
22. Install the oil filter bracket and the oil cooler. Install a
new oil filter, following the instruction on the filter.

Water circulation pump

20. Install the water circulation pump.

33
Cylinder head 24. Install the push rods and the rocker arm mechanism.
23. Put on the cylinder head gasket and the cylinder Tightening torque: 48 Nm (4.8 kpm).
head. Make sure the contact surface for the cylinder head
bolts are free from paint when assembling. Otherwise
there is a possibility of having a joint where the tightening
forces are badly distributed and subsequently a “leaking”
joint.
NOTE! The cylinder head bolts are phosphate treated,
therefore do no use a steel brush to clean them!
“Paint” the cylinder head bolts in an anti-rust agent, Volvo
Penta part number 282036 (or in mixture consisting of
75% “Tectyl 511” and 25 % White Spirit). When assem-
bling, the cylinder head bolts must be drip-free. Tighten
the cylinder head bolts alternatingly and in accordance
with the below tightening diagram:
1. 30 Nm (3.0 kpm)
2. 60 Nm (6.0 kpm)
3. 100 Nm (10.0 kpm)
4. Angle-tightening 90° in one sequence
5. Angle-tightening 90° in one sequence
A= Exhaust
B = Inlet

25. Adjusting the valves

A. NOTE! Do not adjust the valves while the engine is run-
ning!
Valve clearance (hot or cold engine): 0.40 mm (0.0157")
on all valves.
Adjust the valve clearance for number 1 cylinder with the
piston in position for firing.

The 4 cylinder engine

B. Turn the engine half a turn in the correct direction to ro-
tation and adjust the valve clearance for number 3 cylin-
der. Adjust the clearance for the other cylinders in order of
firing.
Order of firing: 1-3-4-2

The 6 cylinder engine

Turn the engine a third of a turn in the correct direction of
rotation and adjust the valve clearance for number 5 cylin-
der. Adjust the clearance for the other cylinders in the or-
der of firing.
Order of firing: 1-5-3-6-2-4

34
26. Setting the injection angle B. Install tool 884895 in the flywheel housing as indicated
(The valve covers and the pressure pipes must be re- in the picture. Then turn the engine in the correct direction
moved!) of rotation. When the engine reaches T.D.C. for cylinder
number 1, it stops because the dowel on the tool (884895)
A. Turn the engine in the correct direction of rotation until enters the corresponding hole in the flywheel.
number 1 cylinder is in top dead centre.
Then the reading on the indicator gauge should be ac-
The 4 cylinder engine cording to the adjustment data in workshop manual “Injec-
Turn the engine “backwards” (against the direction of rota- tion pump data”.
tion) to a position 45° B.T.D.C. Should the injection be late, ease off the attachment nuts
The 6 cylinder engine of the injection pump and turn the pump clockwise (seen
from the front). Should the injection be early, turn the
Turn the engine “backwards” (against the direction of rota-
pump anti-clockwise. Tighten the injection pump!
tion) to a position 30° B.T.D.C.
Remove the center screw at the rear end of the fuel injec-
tion pump. Install holder 885199 and the indicator gauge,
tool 884954. Set the indicator on Zero.

35
 30. Install the heat exchanger and its connection pipes.
External components Install the ventilation pipe on the turbo charger.
27. Install the exhaust manifold with new gaskets and the
thermostat housing. (Locate the cable harness be-
tween the thermostat housing and the water circula-
tion pump.) Install the oil dipstick.

28. Install the air filter and the crankcase ventilation filter.
31. Install the after cooler and its connection pipes, (hoses
on later executions). Use “Silicone” between the after
cooler and the intake manifold.

29. Install the valve covers, the alternator, the starter

motor and the electric distribution box. Connect the
cables.

32. Install the sea-water pump, the fuel filter and its con-
nections. Install the sea-water filter.

36
 B. If the fuel injection pump has been removed, the pump
must also be vented. Work the hand pump for about half a
minute, the injection pump is then vented automatically.
Ease off the pressure pipe nuts at the injectors. Set the
control on “full throttle” and run the engine on the starter
motor until fuel free from air bubbles is coming out at the
33. Install the fuel feed pump. Tighten the injectors. Tight-
injectors. Tighten the pressure pipe nuts.
ening torque: 23 Nm (2.3 kpm).

34. Close all drain cocks. Fill up with lubricating oil and
coolant. Regarding lubricating oil quality and viscos-
ity, see under “Technical Data”. Vent the fuel system,
see under point 35! Test run the engine. Run through
all the check points under the heading “Delivery Ser-
vice” in the Warranty Certificate.

36. Adjusting the speed

NOTE! The lead seals may only be broken by specially
trained personnel.
Max unloaded speed
35. Venting the fuel system
Warm the engine up. Then run the engine light at the max-
NOTE! Watch out for fuel splashes. Use rags at the loca- imum speed. Check that the throttle arm (1) pressed up
tion of venting to prevent fuel from splashing. against the adjusting screw (3). Check with the pump
A. Open the venting screw on the fuel filter about 4 turns. speed given in technical data.
Use the hand pump to pump fuel until fuel without air Low Idle
bubbles is coming out. Should the pump action not be
Warm the engine up. Check the speed when the engine is
satisfactory, turn the engine somewhat to allow the driving
running light at the lowest speed. Check with the pump
cam of the pump to change its position. Close the venting
speed given in technical data. If necessary, adjust with ad-
screw.
justing screw (2).

37
37. Adjusting the solenoid for the exhaust brake
(Only engines in A-execution)
If the exhaust elbow and the solenoid for the exhaust
pressure regulator have been removed during repairs,
they must be refitted so that the solenoid does not burn.
When mounting the solenoid the exhaust elbow must be
adjusted as close as possible to its original position.
1. Fit the solenoid so that it coincides as far as possible
with its original position on the bracket. Check that the
lever for the butterfly valve in the exhaust elbow can
be turned easily.
2. Pull the solenoid by hand to its bottom position and
turn the exhaust elbow so that the clearance between
the pulling rod and the nut is 3–4 mm (0.035–0.080
ins) (see fig.). Tighten the exhaust elbow.
3. Check that the centre line for the pulling rod and the
solenoid coincide (seen from the side) when the sole-
noid is disengaged. Adjust if necessary.
4. Connect a check light between pin No. 3 and earth on
the solenoid (see fig.). Connect the solenoid. The
check light should now be on. If the light is not on, the
power must be turned off, otherwise the solenoid will
burn after appr. 1/2 minute. In that case adjust the so-
lenoid on the bracket until the light goes on. Check
that the clearance between the pulling rod and the nut
is 3–4 mm (0,12–0,15 ins) when the solenoid is tight-
ened.
5. Re-check that the centre line for the pulling rod and
the solenoid coincide (seen from the side) if the sole-
noid has been moved under point 4.

38
 Electrical Wiring Diagram (12V)

Instrument panel
1. Voltmeter 6. Switch for instrument lighting
2. Oil pressure gauge 7. Rev. counter
3. Coolant temperature gauge 8. Key switch
4. Printed circuit card 9. Alarm
5. Push button

39
 Electrical Wiring Diagram (12V)

Engine Wire colour

1. Coolant temperature check GR = Grey
2. Oil pressure check SB = Black
3. Oil pressure sender BN = Brown
4. Coolant temperature sender LBN = Light brown
5. Relay R = Red
6. Fuse PU = Purple
7. Preheating GN = Green
(Not engines in B-version) Y = Yellow
8. Exhaust pressure regulator W = White
(Not engines in B-versions) BL = Blue
LBL = Light blue

40
 Electrical Wiring Diagram (24V)

Instrument panel
1. Voltmeter 6. Switch for instrument lighting
2. Oil pressure gauge 7. Rev. counter
3. Coolant temperature gauge 8. Key switch
4. Printed circuit card 9. Alarm
5. Push button

41
 Electrical Wiring Diagram (24V)

Wire colour
Engine
GR = Grey
1. Coolant temperature check SB = Black
2. Oil pressure check BN = Brown
3. Oil pressure sender LBN = Light brown
4. Coolant temperature sender R = Red
5. Relay PU = Purple
6. Fuse GN = Green
7. Preheating Y = Yellow
(Not engines in B-version) W = White
8. Exhaust pressure regulator BL = Blue
(Not engines in B-version) LBL = Light blue

42
 Fault finding table
Engine does Engine stops Engine does Engine runs Engine CAUSE OF TROUBLE
not start not reach cor- irregularly or becomes
rect working vibrates abnormally hot
speed on full abnormally
throttle
Main switch not closed.
X Battery discharged. Break in
cable or main fuse block.

Fuel tank empty. Fuel cock

X X closed. Fuel filter blocked.

Water or impurities in fuel.

X X X Faulty injectors. Air in fuel
system.
Faulty rev. counter. Boat load-
X ed abnormally. Air cleaner
blocked. Fouling on boat bot-
tom or outboard mechanism.
X X Propeller damaged.

Coolant level too low, V-belts

broken or slipping.
Obstruction in sea-water filter,
X cooling water intake, oil cool-
er, cooling jackets or heat ex-
changer. Sea-water pump im-
peller fault. Thermostat faulty.

Special tools

9991867 Drift for removing and fitting housing bushing in

rocker arm

884533 Puller for Polygon hub on crankshaft

884635 Tool for removing oil cooler insert

43
 9992268 Drift for fitting bearing in circulation pump

9998039 Drift for fitting seal in circulation pump

9992479 Retainer for dial indicator when checking height of

liner flanges above cylinder block face

9992658 Puller for crankshaft gear

9992659 Press tool for fitting crankshaft gear and polygon

hub

9992679 Puller for camshaft gear

9992818 Drift for removing valve guides

9995028 Drift for fitting valve guides

9995031 Installing ring for piston

9996271 Drift for removing and fitting gudgeon pin bushings

44
 Press tools (two) for cylinder liners when measuring
9996272 height of cylinder liners

9996273 Puller for oil pump drive gear

Drift for fitting bearings and seal rings in seawater

884347
pump

884602+ Plate for cylinder liner puller. Should be supple-

884551+ mented with yoke from 884551 (MD5) and screw
884231 and nut from 884231 (MD21–32)

884954 Indicator gauge, cpl

9996662 Test pressure device for cylinder head

9996532 Connection washer for test pressure cylinder head

Sealing washers for test pressure cylinder head

9996531
(19 pcs)

884895 Setting tool for injection pump

45
 884931 Puller for injector sleeve

884945 Mandrel for installation of injector sleeve

885199 Holder for dial indicator

9992265 Puller for circulation pump pulley

9996858 Counterhold when removing cirkulation

pump pulley

46
 Technical data

General
Type designation ................................................................................ MD31, TMD31, TMD41, TAMD41,
......................................................................................................... TAMD31, AD31 AD41
Number of cylinders ........................................................................... 4 6
Cylinder diameter .............................................................................. 92.015 mm, 3.62264 in
Stroke .................................................................................................. 90 mm, 3.54331 in
Displacement, total ............................................................................ 2.39 dm3, 145 in3 3.59 dm3, 220 in3
Compression ratio (A-engines) ......................................................... 16:1 (MD31, 18:1) 16:1
Compression ratio (B- and CE-engines) ........................................... 17.5:1 17.5:1
Compression pressure at starter motor speed, 4 r/s (240 r/min) ..... 2.5 MPa (25 kp/cm 2) 355 lbs/in2
Order of firing (No. 6 (4) cylinder nearest flywheel) .......................... 1-3-4-2 1-5-3-6-2-4
Direction of rotation (viewed from front) ............................................ Clockwise
Output ................................................................................................. See applicable engine diagram
Torque ................................................................................................. See applicable engine diagram
Low idling ........................................................................................... 675–725 r/m 625–675 r/m
Pump settings
Power Governor Max
level overrun unloaded
speed r/m speed r/m
MD31A Light duty 3500 4000–4100
TMD31A Light duty 3800 4100–4200
TAMD31A Light duty 3800 4300–4400
TAMD31A Medium duty 3250 3700–3800
TMD41A Light duty 3800 4150–4250
TAMD41A Light duty 3800 4200–4300
TAMD41A Medium duty 3250 3850–3950
TAMD41A Medium duty 3600 4100–4200
TD31A 2600 2800–2900
TMD31B(CE) Pleasure duty 3900 4100–4200
AD31B(CE) Pleasure duty 3900 4300–4400
TAMD31B(CE)
TMD41B(CE) Pleasure duty 3900 4150–4250
AD41B(CE) Pleasure duty 3900 4200–4300
TAMD41B(CE)
TMD31B Pleasure duty 3900 4100–4200
AD31B Pleasure duty 3900 4300–4400
TAMD31B
TMD41B Pleasure duty 3900 4150–4250
AD41B Pleasure duty 3900 4200–4300
TAMD41B

Weight, engine without outboard drive or reversing gear about ..... MD31, 315 kg (693 lbs) TMD41, 410 kg
TMD31, 330 kg (902 lbs)
(726 lbs) TAMD41, 420 kg
TAMD31, 340 kg (924 lbs)
(748 lbs)

47
Supercharger Pressure Curve 1 = Lowest supercharging pressure at an output
in accordance with Medium duty curve of the
Supercharging pressure (measured in the inlet manifold)
engine diagram.
at 100 % load and full throttle and with an air temperature
of plus 20°C. Curve 2 = Lowest supercharging pressure at an output
in accordance with Light duty curve of the en-
If the measured is made at some other temperature, the
gine diagram.
measured pressure must be corrected in accordance with
the diagram on page 23. A considerably lower pressure is obtained at less than full
output.

Turbo-compressor
Make and type .................................................................................... KKK K26 2960 GA6.71 KKK K26 3262MAA10.71
Lubrication system ............................................................................. Pressure lubrication
Cooling system ................................................................................... Fresh-water cooling
Axial clearance, max .......................................................................... 0.16 mm (0.00630 in)
Radial clearance, max. (compressor side) ....................................... 0.42 mm (0.01654 in)

Cylinder Liners
Type .................................................................................................... Wet, replaceable
Cylinder diameter (no oversizes available) ...................................... 92.015 mm, 3.54390 in
Collar thickness .................................................................................. 9.00–9.03 mm, 0.3543–0.3555 in
Depth of liner recess from cylinder block face .................................. 8.920–8.940 mm, 0.35118–0.35197 in
Height of liner above cylinder block face see illustration ................. 0.06–0.11 mm, 0.00236–0.00433 in
Max. difference in height between adjacent liners ........................... 0.02 mm, 0.00079 in

48
Pistons
Aspirating engine Turbo engine
Overall height ..................................................................................... 101.60 mm 101.65 mm
4.0 in 4.001 in
Height from gudgeon pin centre to top of piston ............................... 66.55–66.60 mm 66.60–66.65 mm
2.620–2.622 in 2.622–2.624 in
Piston clearance ................................................................................ 0.10–0.14 mm 0.08–0.12 mm
0.00393–0.00551 in 0.00315–0.00472 in
Piston fitted in engine, height above cylinder block surface ............ 0.425–0.725 mm 0.475–0.775 mm
0.01673–0.02854 in 0.01870–0.03051 in
Front marking ...................................................................................... Arrow pointing towards front end
Material ............................................................................................... Light alloy with cast iron ring carriers

Piston rings
Compression rings, number .............................................................. 2
Upper compression ring, height ........................................................ 2,5 mm, 0.09843 in
Lower compression ring, height ........................................................ 2.478–2.490 mm, 0.94794–0.94844 in
Oil scraper ring, number .................................................................... 1
Height ................................................................................................. 3.978–3.990 mm, 0.15661–0.15708 in

Piston ring clearance in groove, axial:

Upper compression ring, see diagram .............................................. 0.08–0.13 mm, 0.00315–0.00512 in
Lower pressure ring ........................................................................... 0.07–0.10 mm, 0.00276–0.00394 in
Oil scraper ring ................................................................................... 0.04–0.07 mm, 0.00157–0.00276 in

Piston ring gap measured in cylinder liner:

Compression rings ............................................................................. 0.40–0.65 mm, 0.0157–0.0256 in
Oil ring ................................................................................................ 0.25–0.40 mm, 0.0098–0.0157 in

Gudgeon pins
Aspirating engine Turbo engine
Clearance, gudgeon pin–connecting rod bushing ........................... 0.014–0.022 mm, 0.014–0.022 mm,
........................................................................................................ 0.00055–0.00087 in 0.00055–0.00087 in
Clearance, gudgeon pin–gudgeon pin hole .................................... Max. 0.006 mm Max. 0.008 mm,
0.00024 in 0.00035 in
Grip fit, gudgeon pin–gudgeon pin hole ........................................... Max. 0.004 mm, Max. 0.002 mm,
0.00016 in 0.00008 in
Gudgeon pin diameter ....................................................................... 35.000–35.004 mm, 35.000–35.004 mm,
1.37795–1.37811 in 1.37795–1.37811 in
Connecting rod bushing, internal dia. ............................................... 35.018–35.022 mm, 35.018–35.022 mm,
1.37866–1.37882 in 1.37866–1.37882 in
Gudgeon pin hole dia. in piston ........................................................ 35.000–35.006 mm 35.002–35.008 mm,
1.3780–1.3782 in 1.37803–1.37826 in

49
 R = 3.9 mm

Crankshaft with bearings

Crankshaft end float ........................................................................... 0.10–0.31 mm, 0.00394–0.01220 in
Main bearings, radial clearance ........................................................ 0.04–0.09 mm, 0.00157–0.00354 in

Main Bearing Journals

Diameter, standard ............................................................................. 69.987–70.000 mm, 2.74788–1.75591 in
Undersize 0.25 mm, 0.01 in ............................................................... 69.737–69.750 mm, 2.74204–2.74607 in
0.50 mm, 0.02 in ............................................................... 69.487–69.500 mm, 2.73220–2.73623 in
0.75 mm, 0.03 in ............................................................... 69.237–69.250 mm, 2.72586–2.72639 in

With (A in figure) on crankshaft for pilot bearing with separate

thrust washers:
Standard ............................................................................................. 35.975–36.025 mm, 1.41634–1.418230 in
Oversize 0.2 mm 0.00787 in (thrust washers 0.1 mm 0.00394
in oversize) ......................................................................................... 36.175–36.225 mm, 1.42421–1.42617 in
Oversize 0.4 mm, 0.01575 in (thrust washers 0.2 mm 0.00787
in oversize) ......................................................................................... 36.375–36.425 mm, 1.43208–1.43403 in

Big-End Journals
Big-end bearings, radial clearance ................................................... 0.034–0.078 mm, 0.00134–0.00307 in
Length of bearing journals ................................................................. 38.95–39.05 mm, 1.53346–1.53740 in
Diameter, standard ............................................................................. 56.487–56.500 mm, 2.22390–2.22441 in
Undersize, 0.25 mm, 0.01 in .............................................................. 56.237–56.250 mm, 2.21012–2.21063 in
0.50 mm, 0.02 in .............................................................. 55.987–56.000 mm, 2.19685–2.20472 in
0.75 mm, 0.03 in .............................................................. 55.737–55.750 mm, 2.18307–2.19094 in

Main and Big-End Bearing Shells

Main bearing shells Big-End bearing shells
Thickness, standard ........................................................................... 2.970–2.979 mm, 1.724–1.733 mm,
0.11683–0.11728 in 0.06787–0.06819 in
Undersize, 0.25 mm, 0.01 in ............................................................. 3.095–3.104 mm, 1.849–1.858 mm,
0.12185–0.12221 in 0.07280–0.07315 in
0.50 mm, 0.02 in ............................................. 3.220–3.229 mm, 1.974–1.983 mm,
0.12677–0.12712 in 0.07771–0.07797 in
0.75 mm, 0.03 in ............................................. 3.345–3.354 mm, 2.099–2.108 mm,
0.13169–0.13205 in 0.086264–0.08299 in

Connecting rods
Marked 1 to 6 (1 to 4)
End float, connecting rod – crankshaft .............................................. 0.15–0.30 mm, 0.00591–0.01181 in
Dia. Big-end bearing shell recess ..................................................... 60.00–60.013 mm, 2.36220–2.36271 in
Dia. Connecting rod bearing bushing recess ................................... 39.000–39.039 mm, 1.53543–1.53697 in
Dia. Gudgeon pin bushing ................................................................. See “Gudgeon Pins”

50
Flywheel
Flywheel ring gear ............................................................................. 115 teeth

Camshaft
Drive ................................................................................................... Gear
Number of bearings ........................................................................... 7
Dia. of bearing journals ...................................................................... 52.981–53.000 mm, 2.08586–2.08661 in
End float ............................................................................................. 0.04–0.12 mm, 0.00157–0.00433 in
Radial clearance ................................................................................ 0.025–0.063 mm, 0.00098–0.000248 in

Camshaft bearings
Bearing diameter ................................................................................ 53.025–53.044 mm, 2.08759–2.08834 in

Auxiliary drive gears

Backlash ............................................................................................. 0.03–0.17 mm, 0.00118–0.00669 in
Radial clearance of idler gear ........................................................... 0.03–0.09 mm, 0.00118–0.00354 in
End float for idler gear ....................................................................... 0.03–0.15 mm, 0.00118–0.00591 in
Shaft for idler gear, dia. ...................................................................... 54.940–54.970 mm, 2.16299–2.16417 in
Bushing for idler gear, dia .................................................................. 55.000–55.030 mm, 2.16535–2.16653 in
Number of Teeth: Crankshaft Gear .................................................... 33
Idler Gear ............................................................................................ 41
Camshaft Gear ................................................................................... 66
Drive gear for injection/sea-water pump ........................................... 66

Valve Lay-Out and Cylinder Numbering

Valves, A = EXHAUST, B = INLET

Valve system
Valves Inlet Exhaust
Disc diameter ............................................................ 39.0 mm, 1.5354 in 37.0 mm, 1.4567 in
Stem diameter ........................................................... 7.955–7.970 mm, 7.925–7.940 mm,
0.31319–0.31378 in 0.31200–0.31259 in
Valve seat angle ........................................................ 29.7° 44.7°
Seat angle in cylinder head ...................................... 30° 45°
Clearance, (cold engine or at working temperature) 0.40 mm, 0.01575 in 0.40 mm, 0.01575 in

51
Valve seats

Valve seat Valve seat Recess

Inlet Exhaust
Diameter, standard (measurement A) ............................................... 40.564–40.580 mm 38.064–38.080 mm
1.5970–1.5976 in 1.4986–1.4992 in
Oversize ............................................................................................. 40.764–40.780 mm 38.264–38.280 mm
1.6049–1.6055 in 1.5064–1.5071 in
Height (measurement B) .................................................................... 7.0–7.05 mm 7.5–7.55 mm
0.2756–0.2775 in 0.29528–0.29725 in

Valve Seat Recess:

Dia. standard (measurement C) ........................................................ 40.500–40.525 mm 38.000–38.025 mm
1.5945–1.5955 in 1.4961–1.4970 in
Oversize ............................................................................................. 40.700–40.725 mm 38.200–38.225 mm
1.6024–1.6033 in 1.5040–1.5050 in
Depth (measurement D) .................................................................... 8.93–9.07 mm 9.43–9.57 mm
0.3516–0.3571 in 0.3713–0.3768 in
Bottom radius of recess (measurement R) ....................................... 0.4–0.5 mm 0.4–0.5 mm
0.01575–0.01969 in 0.01575–0.01969 in
The distance between the valve disc and the cylinder
head face should be .......................................................................... 0.05–0.45 mm 0.05–0.45 mm
0.0020–0.0177 in 0.0020–0.0177 in

Valve Guides
Length ................................................................................................................. 59 mm 2.32283 in
Internal dia. (fitted) ............................................................................................. 8.000–8.015 mm, 0.31496–0.31555 in
Replacement type .............................................................................................. 8.000–8.022 mm, 0.31496–0.32362 in
Height above cyl. head spring plane ................................................................. 18 mm, 0.70866 in
Clearance, valve stem – valve guide:
Inlet valves ......................................................................................................... 0.030–0.060 mm, 0.00012–0.00024 in
Exhaust valves ................................................................................................... 0.060–0.090 mm, 0.00024–0.00035 in

Valve Springs
Length unloaded ................................................................................................ 46 mm, 1.81102 in
Length with loading of: 267–312 N (27.2–31.8 kp) 60–70 lbs .......................... 40 mm, 1.57480 in
Length with loading of: 767–852 N (78.2–86.2 kp) 170–190 lbs ...................... 30 mm, 1.18110 in

Rocker Arm Mechanism

Rocker arm bushing, dia. after pressing in and machining ............................... 22.020–22.041 mm, 0.86732–0.86775 in

52
Lubricating system
Oil pressure, hot engine, operating speed, lubricating oil ............... 0.42–0.5 MPa (4.2–5 kp/cm2)
59.7–71.1 lbf/in2
Oil pressure, hot engine, operating speed, piston cooling oil ......... 0.22–0.3 MPa (2.2–3 kp/cm2)
31.3–42.6 lbf/in2
Oil quality in accordance with API-system ........................................ CD
Viscosity ............................................................................................. SAE 15W/40

Oil capacity, including oil cleaner: ..................................................... 31-engine 41-engine

No engine inclination ......................................................................... 9 dm3 (litre) 10.5 dm3 (litre)
9.5 qts. 11 qts
15° engine inclination ........................................................................ 9.5 dm3 (litre) 11.5 dm3 (litre)
10.0 qts 12.0 qts.
Lubricating oil pump, type ................................................................. Gear
End float, pump gear .......................................................................... 0.07–0.15 mm
0.00276–0.00591 in
Backlash, pump gear ......................................................................... 0.15–0.35 mm
0.00591–0.01378 in
Dia., idler gear bearing sleeve .......................................................... 55.03–55.06 mm, 2.1665–2.1677 in
Bushing for idler gear ........................................................................ 54.07–55.00 mm, 2.12874–2.16535 in
Radial clearance for idler gear .......................................................... 0.03–0.09 mm, 0.00118–0.00354 in
Dia., oil pump bushings ..................................................................... 16.016–16.034 mm, 0.63055–0.63126 in
Clearance, thrust washer – oil pump drive gear ............................... 0.02–0.08 mm, 0.00079–0.00315 in
Number of teeth on oil pump drive gear ........................................... 39
Oil pump idler ..................................................................................... 36
Crankcase ventilation
Valve opens at .................................................................................... 0,8 kPa (0.008 kp/cm2), 0.114 lbf/in2

Fuel system
Direction of rotation of injection pump, seen from the front .............. Anti-clockwise
Order of injection ................................................................................ 1-3-4-2 1-5-3-6-2-4
Feed Pressure .................................................................................... 14.7–27.5 kPa (0.15–0.28 kp/cm2)
2.13–4.98 lbf/in2

Injection Pump
Make, type .......................................................................................... Bosch EP/VE 4/10 (MD31)
Bosch EP/VE 4/11 (TMD31, TAMD31)
Bosch EP/VE 6/11 (TMD41, TAMD41)
Feed Pump ......................................................................................... SOFABEX H 3403

Fuel Filter
Type designation ................................................................................ FJ/DBR 1 W5/144 FJ/DBR 1 W6/225

Injectors (A-engines)
Nozzle Holders, make and type ........................................................ Bosch KBAL 72 P19
Nozzles ............................................................................................... DLLA 144 P118 (MD31, DLLA 144 P138)
Type of Nozzle .................................................................................... Hole nozzles
Opening pressure .............................................................................. 25 MPa (250 kp/cm2) 3555.8 lbf/in2
Adjusting pressure (new spring) ....................................................... 25.5–26.3 MPa (255–263 kp/cm2)
3626.8–3740.6 lbf/in2

Injectors (B and CE engines)

Nozzle holders, make and type ......................................................... Bosch KBAL 72 P23
Nozzles ............................................................................................... DLLA 140 P196
Type of nozzle .................................................................................... Hole nozzles
Opening pressure .............................................................................. 26 MPa (260 kp/cm2) 3697 lbf/in2
Adjusting pressure (new spring) ....................................................... 26,5–27,5 MPa (265–275 kp/cm2)
3768–3910.6 lbf/in2

53
Cooling system
31-engine 41-engine
Type .................................................................................................... Overpressure
Capacity, including heat exchanger dm3 (lit.) ................................... 13 (MD31, 10) 19

Thermostats
Type .................................................................................................... Wax
Number ............................................................................................... 2
The thermostat should open at .......................................................... 74–78°C, 165.2–172.4°F
Fully open at ....................................................................................... 88–92°C, 190.4–197.6°F

Electrical system
System voltage ................................................................................... 12 V 24 V
Battery capacity .................................................................................. 140 Ah 70 Ah
Density of battery electrolyte:
Fully charged battery ......................................................................... 1.275–1.285
Battery to be recharged at ................................................................. 1.230
Alternator
Voltage/max. current .......................................................................... 14 V/50 A 28 V/55 A
Output ................................................................................................. 700 W 1540 W
Starter Motor
Output ................................................................................................. 2.5 kW (3.4 hp) 4 kW (5.4 hp)
Brush length ....................................................................................... min. 10 mm 0.3937 in
Brush spring force .............................................................................. 20–25 N (2–2.5 kp) 4.41–5.51 lb

Wear tolerances
Cylinders
Cylinder liners and pistons must be replaced when wear
amounts to 0.25–0.30 mm, 0.0098–0.0118 in.

Crankshaft
Permissible out-of-round on main and big-end
bearing journals, max. ....................................................................... 0.04 mm, 0.001575 in
Max. permissible taper on main and big-end journals ..................... 0.05 mm, 0.00197 in
Max. end float on crankshaft .............................................................. 0.40 mm, 0.01575 in

Valves
Valve stems, max. permissible wear .................................................. 0.02 mm, 0.00079 in
Max. permissible clearance between valve stem
and valve guide:
Inlet valves ......................................................................................... 0.15 mm, 0.00591 in
Exhaust valves ................................................................................... 0.17 mm, 0.00669 in
The valve edge should be, min. inlet ................................................. 1.7 mm, 0.06693 in
exhaust .................................................. 1.7 mm, 0.06693 in
The valve seat may be ground until the distance from the
valve disc (new valve) to the cylinder head surface is:
Inlet ..................................................................................................... 0.65 mm, 0.02559 in
Exhaust ............................................................................................... 0.65 mm, 0.02559 in

Camshaft
Max. permissible wear ....................................................................... 0.05 mm, 0.00197 in
Bearings, max. permissible wear ...................................................... 0.05 mm, 0.00197 in

54
Tightening torques

Tightening diagram, Cylinder Head Bolts.

1. 30 Nm (3.0 kpm)
2. 60 Nm (6.0 kpm)
3. 100 Nm (10.0 kpm)
4. Angle-tightening 90° in one sequence
5. Angle tightening 90° in one sequence

The bolt threads should be moistened with rust proofing medium (detail number 282036) before being fitted. The bolts
should be tightened in accordance with the diagram in five stages.
Note. The bolts must only be reused four times, then they have to be changed.

Nm (kpm)
Main bearings ................................................................................. 140 (14)
Big-end bearings ............................................................................. 113 (11.3)
Rocker arm shaft ............................................................................. 48 (4.8)
Thrust washer, camshaft bearings .................................................. 24 (2.4)
Camshaft gear ................................................................................. 85 (8.5)
Bearing journal for idler gear, auxiliary drive gears ...................... 24 (2.4)
Oil filter with oiled sealing ring ....................................................... 25 12.5)
Lubricating oil pump bracket .......................................................... 24 (2.4)
Rocker arm cover ............................................................................ 8 (0.8)
Auxiliary drive gear casing ............................................................. 20 (2)
Oil sump .......................................................................................... 15 (1.5)
Drain plug, oil sump ........................................................................ 60 (6)
Flywheel casing .............................................................................. 48 (4.8)
Flywheel .......................................................................................... 115 (11.5)
Vibration damper, attaching bolts ................................................... 24 (2.4)
Centre bolt for hub .......................................................................... 180 (18)
Gearwheel/driver ............................................................................. 24 (2.4)
Pressure valve retainers ................................................................. 40 (4)
Stop solenoid .................................................................................. 43 (4.3)
Injector, attaching nut ...................................................................... 24 (2.4)
Inlet manifold ................................................................................... 20 (2)
Exhaust manifold ............................................................................. 40 (4)

55
 Notes

56
 Report form

Do you have any complaints or other comments about this manual? Please make
a copy of this page, write your comments down and post it to us. The address is at
the bottom of the page. We would prefer you to write in English or Swedish.

From: ............................................................................

......................................................................................

......................................................................................
......................................................................................

Refers to publication: .............................................................................................................................................

Publication no.: ..................................................................... Issued: ....................................................................

Suggestion/reasons: ..............................................................................................................................................
..............................................................................................................................................................................

..............................................................................................................................................................................

..............................................................................................................................................................................
..............................................................................................................................................................................

..............................................................................................................................................................................

..............................................................................................................................................................................
..............................................................................................................................................................................

..............................................................................................................................................................................

Date: ...........................................................
Name: .........................................................

AB Volvo Penta
Customer Support
Dept. 42200
SE-405 08 Gothenburg
Sweden
7731268-4 English 02-2000