Volvo Penta MD5A Diesel Marine Engine Workshop Manual (ebook).pdf

Publ. No. 3061

Dec. 1975

WORKSHOP MANUAL

MD5A

Marine diesel engine

ENGINE UNIT

FOREWORD

This workshop manual contains repair instructions for the MD5A marine diesel engine. The instructions

concerning overhauling describe the most suitable working method to be used with the special tools listed under

the heading “Special tools”.

Both the engine designation and its serial number must be clearly stated in all correspondence concerning the

engine and when ordering spare parts. We reserve the right to carry out design modifications and, for this

reason, the contents of this manual cannot he regarded as binding.

AB VOLVO PENTA

Technical Information Department

NEW UNITS OF MEASUREMENT

Technicians have long since tried to establish an internationally standardized system of

measurements. In 1960 a decision was made to use a system called SI (Systéme International

d’Unites). To a large extent, this system is based on earlier systems but the units have been

made uniform so that no conversions are necessary.

The SI-system is now being applied within industry in Europe, This manual contains the new SI-

units. The units used previously however, are also stated but in brackets.

The new units are:

Output is slated in kW (kilowatts)

earlier unit h.p. (horsepower)

Torque is stated in NM (Newton-metres)

earlier unit kpm (kilopond-metres)

Engine speed is stated in r/s (revolutions per second)

earlier unit r.p.m. (revolutions per minute)

Displacement and volumes are stated in dm 3 ( cubic decimetres)

earlier unit l (litres)

Pressure is stated in Pa (Pascal)

earlier unit kp/cm 2 (kiloponds per square centimetre).

Reproduction permitted if source quoted

CONTENTS

Presentation

Dismantling

Electrical system, thermostat housing cylinder head

Flywheel, fuel injector pump

Lubricating oil pump, camshaft, cylinder

Crankshaft, cylinder liner, camshaft bearing

Overhauling

Lubricating oil pump, sea-water pump

7 – 9

Feed pump

9 – 11

Fuel filter, crankshaft

Centrifugal governor, piston

12 – 13

Valve guides, nozzle sleeve

14 – 15

Valves, valve seats, rocker mechanism, injector

15 – 16

Hand start mechanism, camshaft

Assembling

Cylinder liner, crankshaft

Lubricating oil pump, transmission cover

Adjustment of control rod travel, assembling

flywheel cover

Oil sump, cylinder head, feed cover

20 – 21

Fuel filter, injector, thermostat

Flywheel, generator, valve adjustment

Checking injection angle

Bleeding the fuel system, electrical system

Fault-tracing system

Special tools

Technical data

30 – 33

Oil pump, transmission cover, governor

Cylinder, camshaft, governor

Wiring diagram

Presentation

1. Connection for hand start

2. Fuse box

3. Thermostat housing

4. Decompression lever

5. Injector

6. Oil filler Cap, engine

7. Water drain tap, gearbox

8. Oil drain plug, gearbox

9. Water drain tap, engine

10. Oil filler, gearbox

11. Sea-water pump

12. Dipstick, gearbox

13. Fuel filter

14. Bleed screw

15. Hand pump, fuel

16. Dipstick, engine

17. Oil filter

Repair instructions

Dismantling

1. Drain the cooling water and the oil from the engine. Clean

externally afterwards. Loosen the water hose between the

gearbox and the sea -water pump and remove the gearbox.

3. Remove the rocker cover and the fuel pipe between the

pump and the injector and unscrew the rocker gear. Note!

Pull the rocker gear straight up since it is centred with a

guide pin 1. The other hole 2 is an oil channel.

2. Remove the generator and its drive belt, starter motor,

fuel filter and fuel pump with the drain-off pipe (be careful of

fuel spillage), coolant water pump with hose and thermostat

housing, dipstick, temperature and oil pressure sensors.

Unscrew and discard the oil filter.

4. Remove the push-rods 1, remove the cylinder head and

the cylinder head gasket. Take care of the washers 2 under

the nuts.

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