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 ex changer
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 al ternator/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. https://www.heavydutydiag.com/product/volvo-impact-9116-parts-catalog-service-manual/ 9. Remove the expansion tank complete with heat ex changer.   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.

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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. Re move the conductor rail and unscrew the glow plug

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15. MD2010 , MD2020, MD2030 : Remove the circula tion pump.
      MD2030 : Note. The pump must be released/re moved 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 in l et pipe on MD2010 , MD2020 and MD2030 ).

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18. Release the nuts from the rockers' bearing brack ets. 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 sta ges.
     Note: Begin in the middle of the cylinder head and
    release the screws in a circle outwards.
    Lift off the cylinder head