How to Install a Volvo Engine Cover Guide

Volvo MD2010, MD2020, MD2030, MD2040 Engine cylinder head installation
 1. Clean the surface of the cylinder head and   cylinder
    block. Remove any rust or soot from the     screw hol es and threads for the cylinder     head screws.
2. Fit on the new cylinder head gasket.
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: I f the cylinder head is painted the    mating surfaces 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 hea

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

1st tightening
MD2O10. MD2020 10 Nm (7.40 ft.lbs)
MD2030 20 Nm (14.80 ft.lbs)
MD2040 30 Nm (22.10 ft.lbs
2nd tightening
MD2O10, MD2020 20 Nm (14.80 ft.lbs)
MD2030 35 Nm (25.80 ft.lbs)
MD2040 70 Nm (51.70 ft.lbs)
Final tightening
MD2O10, MD2020 35-40 Nm (26-30 ft.lbs)
MD2030 50-53 Nm (37-39 ft.lbs)
MD2040 90-95 Nm (66-70 ft.lbs

6. Fit the pull rods (2), valve caps (3,     MD2040 and
l ater versions of 2010, 2020,2030) and rocker
  mechanism (1).
7. Adjust the valve clearance as per   directions on
  page 34. Fit the valve cover.
  Fig. 33. Fitting of oil pressure pipe    (cylinder block -
  cylinder head / rocker mechanism)

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8. Fit the oil pressure pipe between the block    and
5. Tighten the cylinder head screws in three     stages as cylinder head (rocker mechanism on    MD2040).
  per the following. See tightening diagrams     Fig. 30-
  31.
 Tightening torque 10-13 Nm (7.4-9.6 ft.lbs).
 32
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    Technical
 data. Fit the conductor rail and connect the   electric
 cable.

11. Fit the copper gaskets, heat shields     (MD2030) and
  i nserts (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:
  60-70 Nm (44.3-51.7 ft.lbs)
  Tightening torque MD2030:
  80-85 Nm (59.0-62.7 ft.lbs).
  12. Put on new copper gasket and fit the     fuel leak pipe.
  Tighten the nuts and connect the return     pipe.
  13. Fit the delivery pipe complete.     Tightening torque
  20-25 Nm (14.8-18.4 ft.lbs).
14. MD2O10, MD2020, MD2030: Fit the induction    manifold.
  MD2040: Fit the inlet pipe complete with air   filter.
  Fig. 35. Fitting of thermostat (MD2O10,     MD2020,
  MD2030) and expansion tank.

15. MD2O10, MD2020: Fit the rubber seal,      thermostat
(3) and spring (2) in the heat exchanger      housing (1)
    Fig. 36. Fitting of thermostat (MD2040)

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

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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 relay, and to the refrigerant        temperature relay and
    sensor (where appropriate).
19. Fit the relay box.
20. MD2O10, MD2020: Fit the alternator and    clamp. Fit
   the drive belt.
   I
   Note: I t should be possible to press in    the belt approx. 10 mm (.40 in) between    the pulleys.
21. Connect the hose to the sea water pump and    tighten'the clip. Connect the exhaust    pipe.
   22. Fill with refrigerant. See    "Replenishment of refrigera t on page 64.
23. Connect the battery cables. Open the fuel    cocks
   and bottom valve. Start the engine and    check that 5.
   no leakage occurs

How to Update the Rocker Mechanism for Volvo MD2010, MD2020, MD2030, MD2040 Engines

 VOLVO MD2010, MD2020, MD2030, MD2040 Engine  Renovating the Rocker Mechanism

 

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1. MD2O10, MD2020, MD2030: Remove the screws
   . at the front and rear of the rocker    shaft.
   MD2040: Screw in a M8 screw in the threaded    hole
   i n the front edge of the rocker shaft. Fix    the screw
   head in a vice and pull out the rocker    shaft (alt. a
   withdrawing tool can be used

2. Dismantle the rocker mechanism. Remove the
rockers, springs and washers.
3. Clean the parts. Observe special care with the
rocker shaft's oil channels and oil holes in the rocker

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4. Check the wear on the rocker shaft with a micrometer (Fig. 26). Diameter min. 11.57 mm (.44555 in).

5. Check that the rocker bearing surfaces are not outof-round worn.
Calculate the clearance between the rocker and
shaft. The clearance must not exceed 0.2 mm
(.0078 in).
Check that the ball pin's spherical part is not deformed or worn. The threads should be undamaged
on the pin and lock nut. The locknut should be in
good condition.
The mating sphere of the rockers (against the valve) must not be unevenly worn or concave. Adjustment for minor wear can be made in a grinding
machine.
Note: MD2O10-2030. A new type of rocker (includi ng valve cap) has been introduced as from engine
number:
MD2010: 5101202984
MD2020: 5101308898
M D2030: 5101465653
Only the new type of rocker is available as a spare
part. If one or several of the older type of rocker
need to be replaced, all the rockers must be replaced at once, and valve caps installed on the
valve stems.

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6. Oil in the rocker mechanism and fit the different
parts.

VOLVO Engine Valve, Valve Seat Grinding Guide

  VOLVO MD2010, MD2020, MD2030, MD2040 Engine  Grinding of valves and valve seats

1. Use a valve spring tensioner and dismantle    the
   valve lock. Remove the valve spring    washers,
   springs and aloes. Place the parts in the    correct
   order in a valve rack. Remove the valve    stem seals.
2. Clean the part
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3. Check the wear on the valve spindle.    Measure the
   diameter with a micrometer at points I, II    and III as
   per Fig. 18.

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 4. Grind the valves in a valve grinding    machine
   Grind the sealing surface as little as    possible, just
  so that it is "clean". If the the valve disc   edge after
  grinding is less than 0.5 mm (.019 in) the   valve
  should be scrapped (see Fig. 19). The same   applies to valves with crooked valve   spindles

5. Check the wear on the valve guides (see "Checki ng of valve guides") before the valve seats are
treated.

6. Ream or grind the valve seats (Fig. 20). Grind of
j ust enough material so that the valve seat has the
right shape and a good mating surface.

Replace the valve seat when the distance "A" in Fig. 21,
measured with a new valve, exceeds 1.8 mm (.0708 in).
For replacement of the valve seat (inlet) see previous
page.
New seats are grind down so that the distance between the cylinder head plane and the valve disc
surface "A" is:
MD2O10, MD2020: 0.70-0.90 mm (.0275-.0354 in)
MD2030, MD2040 : 0.85-1.15 mm (.0334-.0452 in)

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7. Grind in the valves with grinding paste and check
the contact with marker dye

8. Fit the seals, valves, valve springs, spring washers,
valve lock and valve caps. See "Assembly of cylinder head" on page 31.