Volvo Penta Md5a Marine Diesel Engine Service Repair Workshop Manual Download
Electrical system, thermostat housing cylinder head 3
Flywheel, fuel injector pump 4
Oil pump, transmission cover, governor 5
Lubricating oil pump, camshaft, cylinder 6
Crankshaft, cylinder liner, camshaft bearing 7
Lubricating oil pump, sea-water pump 7 – 9
Feed pump 9 – 11
Fuel filter, crankshaft 11
Centrifugal governor, piston 12 – 13
Valve guides, nozzle sleeve 14 – 15
Valves, valve seats, rocker mechanism, injector 15 – 16
Hand start mechanism, camshaft 17
Cylinder liner, crankshaft 18
Cylinder, camshaft, governor 19
Lubricating oil pump, transmission cover 20
Adjustment of control rod travel, assembling
flywheel cover 20 – 21
Oil sump, cylinder head, feed cover 22
Fuel filter, injector, thermostat 22
Flywheel, generator, valve adjustment 24
Checking injection angle 25
Bleeding the fuel system, electrical system 26
Wiring diagram 27
Fault-tracing system 28
Special tools 29
Technical data 30 – 33
Check the charge state of the battery with the help of a
hydrometer which shows the specific gravity of the
battery acid. This varies according to the state of the
charge, (see the technical data). (See furthermore
“Electrical system” p. 26.)
B. Change the microfilter by unscrewing the hexagonal
head on the filter holder’s base. The microfilter and its
holder are of a discardable type which means that the old
filter is discarded and a new one fitted. Check that the
face of the cover is completely clean and that the filter
packing is undamaged. Screw the new filter by hand until
the packing contacts the cover. Then tighten the filter a
further half turn. There is a drain plug in the bottom of the
filter holder for draining water and impurities in the fuel.
Bleed the fuel system after draining and after a filter
change and then check for tightness.
Remove the cover on the feed pump and clean the prefilter
in diesel oil. Refit the filter with the notches upward
and fit an undamaged packing and tighten the cover.
Bleed the fuel system.
Check and drain when necessary the extra fuel filter if
one is fitted. Look out for spilled fuel.
C. Check the injector with reference to opening pressure,
tightness and jet shape. It is recommended that these
checks be carried out after a maximum operation time of
400 hours or once per season. See also paragraphs 55
D. To obtain the best operational economy, the engine
speed should be at least 300 r.p.m. less that the
maximum obtainable during extended running periods.
Note! If the boat has been in the water a considerable
time, the maximum obtainable engine speed can
decrease due to growth on the hull’s underside. Use
growth inhibiting bottom paint.
Check and clean the hull regularly.
E. Check that the propeller blades are whole. If any of the
propeller blades are damaged, the propeller should be
changed. A propeller blade can be out of line (twisted) —
this is very difficult to detect. Place the propeller on a flat
surface and measure the blades. If any blade is twisted
the propeller should be changed.
F. Check the coolant system from the point of view of
leakage, blockage etc.
Check that the thermostat opens at the correct temperature.
The thermostat can be taken out when the
thermostat housing has been dismantled. See also
The pump impeller in the sea water pump is made of
neoprene rubber and can be damaged when the water
supply is cut off, for instance if there is a blockage in the
sea water intake. Paragraphs 23—27 should be followed
when changing a pump impeller and sealing rings. Note)
If the boat is in the water the sea cock must be closed
before the sea water is dismantled. Do not forget to open
the cock again.
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