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

11.2021 Volvo Impact 9227 EPC+ Service Repair Offline Download & Installation Service

   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)

  Original Volvo Flash & Calibration Files for PTT Download
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.

Volvo Vodia Penta 2018 [5.2.5] Diagnostic Software

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

 

11.2021 Volvo Impact 9227 EPC+ Service Repair Offline Download

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

VOLVO PROSIS Offline Parts Catalog & Repair Manuals 11.2022

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.

Volvo Vodia Penta 2018 [5.2.5] Diagnostic Software

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
Volvo Vodia Penta 2018 [5.2.5] Diagnostic Software

3. Check the wear on the valve spindle.    Measure the
   diameter with a micrometer at points I, II    and III as
   per Fig. 18.

VOLVO PROSIS Offline Parts Catalog & Repair Manuals 11.2022

 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)

11.2021 Volvo Impact 9227 EPC+ Service Repair Offline Download

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.

How to Strip and Inspect a Volvo Engine Cylinder

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

Volvo Vodia Penta 2018[5.2.5] Diagnostic Software

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.

 11.2021 Volvo lmpact 9227 EPC+Service Repair Offline Download& Installation Service

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.

2022 Volvo Premium Tech Tool 2.8.150 with Developer Tool
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

VOLVO 88890300 Vocom Interface for VOLVO/Renault/UD/Mack Truck Diagnose

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 ).

Volvo Vodia Penta 2018 [5.2.5] Diagnostic Software

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

Volvo Piston,Piston Rings and Connecting Rod Assembly Guide

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

Volvo Tech Tool Diagnostic Software Training

 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.

07.2022 VOLVO Penta EPC Parts Catalog 6 Marine & Industrial Engines

Volvo Impact 9116 Parts Catalog & Service Manual 06.2021

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

2022 Volvo Premium Tech Tool 2.8.150 with Developer Tool

 

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.


VOLVO 88890300 Vocom Interface for VOLVO/Renault/UD/Mack Truck Diagnose
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.

Volvo Vodia Penta 2018 [5.2.5] Diagnostic Software

  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.

07.2022 VOLVO Penta EPC Parts Catalog 6 Marine & Industrial Engines

   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.

Original Volvo Flash & Calibration Files for PTT Download

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.

VOLVO PROSIS Offline Parts Catalog & Repair Manuals 01.2019

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).

07.2022 VOLVO Penta EPC Parts Catalog 6 Marine & Industrial Engines

  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.

07.2022 VOLVO Penta EPC Parts Catalog 6 Marine & Industrial Engines

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.

 

Volvo Impact 9116 Parts Catalog & Service Manual 07.06.2022

 

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)

2022 Volvo Premium Tech Tool 2.8.150 with Developer Tool

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.