Volvo Penta MD11 Instrucciones De Montaje página 5

or engines with lower engine numbers, refer to point 13.)
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1. Shut off the sea-water intake and remove the reverse gear suction line from the reverse gear. (S-drive:
Loosen the water pump suction line). Connect a hose with an inner diameter of 1/2" and place one end
in a bucket containing fresh-water. Ensure that the bucket is kept topped up and run the engine at idling
speed for a few minutes so that it is rinsed through by fresh-water. Then drain off all the water from the
engine and reverse gear and shut off all drain points.
2. Remove the cooling water tube and the hoses between the pressure side of the sea-water pump and
the thermostat housing. Also remove the hose fitting from the exhaust manifold. Then remove the hose
and the hose fitting between the thermostat housing and the water-cooled exhaust elbow.
3. Unscrew the existing screw (1). Loosen the delivery pipe clamp and rotate it 180°. Fit the cooling water
tube (2) with a rubber ring (3) at each end of the tube. Tighten the screw (1). Unscrew the second and
third uppermost screws from the front on the exhaust manifold. Fit the heat exchanger (4) with the
screws (35) and the flat washers (6).
4. Place the gasket (7) in the hose connection (8) and screw tight. Fit the connecting pipe (9) and a rub-
ber ring (3) to the heat exchanger and connect the hose (10) using two hose clamps (11).
5. Place the spacers (12) between the cylinder block and the bracket (13) and fit the bracket as high as
possible using the screws (14) and washers (15). Fit the expansion vessel (16) with the clamp (17),
screw (18) and washer (19). Screw the hose couplings (20) to the heat exchanger and water pump and
connect the hoses (21). In order to facilitate checking the coolant level the expansion vessel can be fit-
ted in a location outside the engine compartment. The lower edge of the vessel must, however, not be
fitted lower than the highest point of the engine.
6. Remove the existing thermostat housing and the thermostat. (Engines with lower engine numbers than
51594: Fit the by-pass pipe from kit 829962 as shown in fig.2. Use Araldite to attach the pipe.) Fit the
pipe (22) with a rubber ring (3) at each end. Then fit the thermostat housing (23), the new thermostat,
the new gasket with a screw (24) and washer (25).
7. Applies not to engines with serial numbers 52481-55700.
Dismantle the alternator, the alternator bracket and the V-belt. Remove the oil dipstick and the dipstick
cover. Fit the cover for the oil dipstick. Seal the threads and tighten the cover with approx. 9 Nm ( 7
kpm). Mount the pulley which is included in the kit on the alternator and fit the alternator and the pipe
for the dipstick.
8. Fit the nipple (36) in the exhaust manifold. Remove the starter motor.
Remove the existing screw from the front lower section of the exhaust manifold and fit the pipe (26)
with a rubber ring (3) at each end. Fit the coupling piece (27) with a spacer ring (28), gasket (29) and
Banjo screw (30). Screw the plug (31) into the connecting piece.
9. Fit the pipe (32), connect it to the expansion vessel with a hose (33) and hose clamps (11). The pipe is
attached to the block with a screw (34) and a washer (35).
10. Fit the pipes (37) and (38) with their one end in their respective positions. Fit the circulation pump (39)
and the starter motor with the two longer screws (40) and with two washers (41) between the brackets.
Fit the V-belt. Replace the temperature sender by the sender in the kit.
11. Open the sea-water intake and fill the system to maximum level with a 50 % mixture of glycol and
fresh-water. The engine has a capacity of approx. 3 litres. Start the engine and top up the system and
let it vent by unscrewing the temperature sender. Check that there are no leaks.
12. Where there is a risk of frost, drain sea water by removing the hose at the sea valve and the cover of
the sea-water pump.
13. On engines with a lower engine number than 51376, the flywheel must be machined as shown in fig. 3.
On engines with engine numbers lower than 51594, the exhaust manifold must be drilled as shown in
fig. 4.
NOTE! The assembly instructions do not apply to engines with dyna start.