How to Strip and Inspect a Volvo Engine Cylinder

VOLVO MD2010, MD2020, MD2030, MD2040 Engine Cylinder head stripping and inspection

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1. Remove the valves and valve springs. Press    the
   springs together with a valve spring    tensioner and
   remove the valve lock. Place the valves in    order in
   a marked valve rack. Remove the valve stem    seals.
2. Clean all parts. Observe special care with    the
   channels for oil and refrigerant.
3. Remove residual soot and impurities from    the cylinder head's sealing surfaces.
   Note: Do not use use steel brush to clean    the cylinder head screw threads or under    the s

4.The flatness tolerance for the cylinder head is max. 0.12
mm (.00472"). Check in six positions ("A-F" as per Fig.
15 and 16). Use a feeler gauge and a ruler the sides of
which are precision rubbed as per DIN 874/Normal.

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5.I f the flatness is not within the permissible tolerance the
cylinder head should be replaced. If leakage or blow
marks are confirmed it is not necessary to check for flatness since the cylinder head must be replaced.
Check the valve seats and that the pin screws are tight.
For replacement of the valve seats (inlet) see next
page.


VOLVO PROSIS Offline Parts Catalog &Repair Manuals 11.2022

How to Remove Volvo Engine Block Cylinder Head

 VOLVO MD2010, MD2020, MD2030, MD2040 Engine body Dismantling of cylinder head

  

VOLVO PROSIS Offline Parts Catalog & Repair Manuals 11.2022 

1. Remove both battery leads. Close the fuel cocks.
2. Close the bottom valve and drain off the water in
   the sea and fresh water system.
3. Release the hose to the heat exchanger from the
   sea water pump. Release the exhaust pipe from
   the exhaust hook.
   Fig. 9. Dismantling of expansion tank with heat exchanger
4. Release the thick rubber hose under the heat ex- 1. Heat exchanger complete
   changer. (Note: the hose is filled with refrigerant). 2. MD2010, MD2020 : Spring
       Release the thin hose from the refrigerant pump. 3. MD2o10, MD2020: Thermostat

  5. 2010 , MD2020 : remove the drive belt for the alternator/refrigerant pump. Remove the alternator   and clamp

6.Release the relay box from the heat exchanger
  housing and hang it up.

7. Release the electric cables to the oil pressure relay
  and to the refrigerant temperature relay and sensor
  (where appropriate).
8. MD2040 : remove the cover at the front on the heat
  exchanger housing's right-hand side. Remove the
  spacer ring, thermostat and rubber seal.
VOLVO PROSIS Offline Parts Catalog & Repair Manuals 11.2022

9. Remove the expansion tank complete with heat exchanger.
  MD2010 , MD2020 : Remove the spring, thermostat
  and rubber seal from the heat exchanger housing.
10. MD2010, MD2020 , MD2030 :
  Remove the induction manifold.
  Release the relay box from the heat exchanger

  housing and hang it up.
   MD2040 :
   Remove the inlet pipe complete with air filter

11. Release the delivery pipe at the injection pump
   and injectors. Lift off the delivery pipes together.
   Protect the connections from impurities.

12. Remove the nut at the top of respective injectors
   and lift off the fuel leak pipe.

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13. Unscrew the injectors. Use a long socket, 80 mm.
  MD2010 , MD2020 , MD2030 = 22 mm
  MD2040 = 27 mm.
  Remove the copper gaskets under the injectors.
  MD2030 : Remove the heat shields (3, Fig. 10).
  MD2010 , MD2020 , MD2030 : Remove the inserts
  (4) and the lower copper washers.
               14. Release the electric cable to the glow plug. Remove the conductor rail and unscrew the glow plug

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15. MD2010 , MD2020, MD2030 : Remove the circulation pump.
      MD2030 : Note. The pump must be released/removed before the cylinder head   is  released. The
pump can otherwise be broken. Remove the spring
and thermostat.

                              Fig. 12. Dismantling of oil pressure pipe (cylinder
                                   block - cylinder head/rocker mechanism)

16. Remove the oil pressure pipe between the cylinder
  block and cylinder head (rocker mechanism on
  MD2040).

17. Remove the valve cover (built together with the inl et pipe on MD2010 , MD2020  and MD2030 ).

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18. Release the nuts from the rockers' bearing brackets. Remove the rocker  mechanism   (1, Fig. 13) and
 pull rods (2). Remove the valve caps (3, MD2040 )
 from the valve stem.

19. Release the cylinder head screws in several stages.
     Note: Begin in the middle of the cylinder head and
    release the screws in a circle outwards.
    Lift off the cylinder head