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