Volvo Piston,Piston Rings and Connecting Rod Assembly Guide

This article mainly introduces Piston,Piston Rings and Connecting Rod Assembly Guide

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 Note:Check that pistons of the correct oversize areused if the cylinders have been milled to oversize.
1.Fit one circlip in the piston.
2.Oil in the gudgeon pin and bushing.

3. Heat up the piston to approx.100℃(212F). Place the piston and connecting rod so that the markings correspond with Fig.49 or 50.
   MD2010, MD2020: With the marking on the con-
   necting rod's side upwards the arrow on the piston top should be turned in the same direction as per Fig.49.
   MD2030, MD2040: The marking on the connecting rod and the "SHIBAURA"mark in the piston should be turned in the same direction as per Fig.50.
   Push in the gudgeon pin.
   NOTE! The gudgeon pin should be able to be pressed in easily. It must not be knocked in.
4. Fit the other circlip.
5. Check that the connecting rod goes easily in the gudgeon pin bearing.
6. Check the big-end clearance. See "Inspection of crankshaft"and "Inspection of main and big-end bearings"on pages 46 and 47.
7. Check the piston ring gap in the cylinder bore(Fig.
   41 on page 35) and that the rings do not jam in the piston ring grooves.

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8. Fit the piston rings on the piston with a piston ring tong.
    Note: The rings should be turned as per Fig.51.
   MD2010, MD2020, MD2030: Fit the oil ring first
   (with the marking turned upwards). The opening in the expander spring should be placed 180° from the oil ring gap.

Volvo Industrial Enigne 280 Stern Drive Removal Steps

 
Volvo Industrial Enigne 280 Stern Drive Removal Steps

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This instruction gives you a guide on how to disassemble the stern drive of the Volvo Industrial Engine 208

1. Remove the propeller of the Singleprop stern drive according to the picture.

2. Remove the propeller of the Duoprop stern drive according to the picture. (Pictures show earlier models.)
Notice! Never mix propellers from different drives

3. Remove the hex socket head cap bolts that secure the zinc ring, and then remove it.


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4. Remove the oil drain plug and drain the oil. Remove the dipstick at the same time to facilitate the draining of the oil.


   Replace the drain plug and O-ring on the dipstick.

5  a. Sterndrive Models 280 and 285: Remove the cover (1) on the shifting mechanism and disconnect the shifting cable from the shifting plate, then remove the swivel. Then remove the shift cable locking plate (2).

   b. Sterndrive Model 290: Remove the cover on the shifting mechanism and disconnect the shift cable from the shift plate, then remove the swivel. Remove the screws securing the locking plate and push the locking plate down

6 a. Sterndrive Types 280 and 285:
    important! Double-check the rubber bellows for possible damage and check that the hose clamps are properly tightened.
   Notice! Universal joint bellows and their hose clamps should be replaced every two years. Please contact an authorised repair workshop and have them carry out
   Inspection and replacement of rubber bellows.

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  b. Sterndrive Types 290 and 290A:
   important! Double-check the rubber bellows for possible damage and check that the hose clamps are properly tightened.
   Notice! Universal joint bellows and their hose clamps should be replaced every two years.
   Please contact an authorized repair shop to have them perform rubber bellows

7 a inspection and replacement. Sterndrive Types 280 and 285: Remove the steering helmet and gimbal rubber bellows from the upper gearbox (1), remove the exhaust bellows from the intermediate housing (2), and remove the cooling water connection (3) water hose. Universal joint rubber bellows must be replaced every two years

  b. Sterndrive Type 290: Remove the steering helmet and gimbal rubber bellows from the upper gearbox (1), remove the exhaust bellows from the intermediate housing (2), and remove the cooling water connection (3) Cooling water hose. Universal joint rubber bellows must be

8 a is replaced once. Sterndrive Models 280 and 285: Remove the two locking screws that hold the journal in the beam guard. Using special tool 884874, support the stern drive from below and pull out the journal. Brass drifters are also available. bring up
    stern drive, then place it into a suitable
   in the base.
 
  b. Model 290 Sterndrive: Remove the two locking screws that hold the journal in the beam guard. Support the stern drive from below and tap the journal with a brass drifter or similar. Lift the stern drive and place it on
   in a suitable bracket.

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   Notice! Always replace the bushing (1).

Volvo_Penta_Md2040 Adjusting The Valves Gudie

    This article mainly introduces volvo_penta_md2040 Adjusting the valves

   Note! The clearance must never be checked when the engine is running.
   Valve clearance(cold engine): Inlet and outlet for all engines:0.20 mm(.0078 in).
1. Dismantle the valve cover.

2. Tum the engine in its normal direction of rotation until both valves for cylinder No.1  are closed(com-
   pression position). Continue turning the engine round until the marking of flywheel 

shows 00.

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3. MD2010: Check and adjust if necessary the valve clearance for cylinder No.1.
   Pull round the crankshaft 180°(1/2 turn) clockwise
   (see from front) and adjust the clearance for cylin-
  der No.2.

4.Turn round the crankshaft until the piston in ques-
  tion is in the lower tuming position.Dismantle the main bearing cap with lower bearing cup.

5.Place a pair of plastic hoses as protection over the connecting rod screws.Carefully tap up the con-
  necting rod with piston far enough so that the pis-
  ton rings are released from the cylinder bore.Lift off the piston together with the connecting rod.
  Note:Scrape off the soot strip in the top part of the cylinder bore to simplify dismantling.

6.Dismantle piston ring with a piston ring tongs.

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7.Remove the circlips for the gudgeon pin and dis-
  mantle the gudgeon pin carefully with a suitable mandrel.

  Inspection and matching of piston rings Check the wear surfaces and sides. Black patches on the surfaces imply poor contact and indicate that it is time to change the piston rings. The oil consumption is also a critical factor as to when a piston ring should be replaced.
  Check the piston ring gap(Fig.41). Push down the ring below the lower turning position by means of a pis-
  ton. Replace the piston ring if the gap exceeds 1.0 mm
  (.039 in).

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  Piston rings should also be replaced if there is noticea-
  ble wear or out-of-roundness in the cylinders since the rings seldom have the same position as they had before dis mantling.
  Check the piston ring gap also on new rings.
  See"Technical data"for size info.
  Check the clearance in the piston ring groove.Roll the ring in its groove in the piston and measure the clear-
  ance at a number of points with a feeler gauge.

Volvo_Penta_Md2040 Fitting of Cylinder Head Guide

  This article mainly introduces volvo_penta_md2040 Fitting of cylinder head

1. Clean the surface of the cylinder head and cylinder block. Remove any rust or soot from the screw ho-
   les and threads for the cylinder head screws.
2. Fit on the new cylinder head gasket.

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3. Apply grease containing molybdenum disulphide on the cylinder head screws.
   NOTE! The screws are surface treated and must not be cleaned with a steel brush.
   Note: If the cylinder head is painted the mating sur-
   faces for cylinder head screws must be free from paint, otherwise the clamping force in the screw union will be adversely affected.

4. Check that the tubular pins(guides) are fitted in the block. Place the two rear cylinder head screws in the cylinder head and fit the head

5. Tighten the cylinder head screws in three stages as per the following.See tightening diagrams Fig.30-
   31.

6. Fit the pull rods(2), valve caps(3, MD2040 and later versions of 2010,2020,2030) and rocker mechanism(1).

7. Adjust the valve clearance as per directions on page 34. Fit the valve cover.

 

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8. Fit the oil pressure pipe between the block and cylinder head(rocker mechanism on MD2040). Tightening torque 10-13 Nm(7.4-9.6ft. lbs).

9. MD2O10, MD2020: Fit the circulation pump.
MD2030: Fit the circulation pump and thermostat and spring(see Fig.35).
10. Fit the glow plug, Tightening torque: see Technicaldata. Fit the conductor rail and connect the electric cable.

11. Fit the copper gaskets, heat shields (MD2030) and inserts (MD2O10-MD2030) to the injectors as per Fig.34.
    Fit the injectors. Use socket L=80 mm (3.15 in), key width =22 mm(MD2O10-MD2030), and 27 mm
    (MD2040).
    Tightening torque MD2O10, MD2030, MD2040:
    60-70Nm(44.3-51.7ft. lbs)
    Tightening torque MD2030:
    80-85Nm(59.0-62.7 ft. lbs).

12. Put on new copper gasket and fit the fuel leak pipe.
    Tighten the nuts and connect the retum pipe.

13. Fit the delivery pipe complete. Tightening torque
    20-25Nm(14.8-18.4ft. lbs).

14. MD2010, MD2020, MD2030: Fit the induction mani-
    fold.
    MD2040: Fit the inlet pipe complete with air flter.

15. MD2O10, MD2020: Fit the rubber seal, thermostat
    (3) and spring(2) in the heat exchanger housing(1)

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16. Fit the expansion tank complete with heat exchan-
    ger. Connect the hoses to the heat exchanger housing and refrigerant pump. Tighten the hose clips.

 

 17. MD2040: Fit the rubber seal, thermostat and spacer ring in the heat exchanger housing. Fit the cover over the thermostat.

18. Connect the electric cables to the oil pressure re-
    lay, and to the refrigerant temperature relay and sensor(where appropriate).

19. Fit the relay box.

20. MD2O10, MD2020: Fit the altemator and clamp. Fit the drive belt Note: It should be possible to press in the belt ap-
prox.10 mm(40 in) between the pulleys.

21. Connect the hose to the sea water pump and tigh-
ten' the clip. Connect the exhaust pipe.

22. Fill with refrigerant. See"Replenishment of refrige-
ra t on page64.

23. Connect the battery cables. Open the fuel cocks and bottom valve. Start the engine and check that no leakage occurs.