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.