Volvo Penta MD2040 Specifications
| Engine Model: Volvo Penta MD2040 |
| Engine Type: 4-cycle inline 3-cylinder naturally aspirated freshwater-cooled diesel |
| Total Displacement: 91.5 cu.in (1.5 L) |
| Rated Engine Power: 40 Hp (29.1 kW) at 3600 rpm |
| Fuel System Type: Indirect injection |
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The Volvo Penta MD2040 is a three-cylinder,
naturally aspirated marine diesel engine and the most powerful member of
the 2000-series range. Designed for larger sailing yachts and
displacement motor cruisers, the MD2040 is recognized for its smooth
running characteristics and high torque at low engine speeds. The engine
features a cast iron cylinder block and cylinder head, indirect
injection with an in-line injection pump, freshwater cooling with a heat
exchanger, and a freshwater-cooled exhaust manifold.
The MD2040 was offered with both MS2 reverse gear mechanical
transmission and 120S saildrive options, making it adaptable to various
vessel configurations. Production spanned multiple variants, including
MD2040-A, B, C, and D, with later versions incorporating improved
cooling systems and higher-output alternators.
Engine Type: Inline 3-cylinder, 4-cycle, water-cooled, naturally
aspirated marine diesel.
Displacement: 1.50 liters (91.5 cu.in).
Bore: 84.0 mm (3.31 in).
Stroke: 90.0 mm (3.54 in).
Compression Ratio: 22.0:1.
Firing Order: 1-2-3.
Crankshaft Power: 29.1 kW (40 hp) @ 3,600 rpm.
Propeller Shaft Power: 27.3 kW (37 hp) @ 3,600 rpm.
Valvetrain Configuration: Overhead Valve (OHV) with pushrod actuation,
operating 6 valves (2 valves per cylinder). The camshaft is located
within the cylinder block and driven by gears from the crankshaft. Valve
clearances are adjusted manually using threaded adjusters on rocker arms
with locking nuts.
The cylinder block is manufactured from cast iron with an open-deck
design. Bore diameter measures 84.0 mm (3.31 in). The block incorporates
pressed-in cast iron cylinder liners that are replaceable during major
overhauls. The crankshaft is forged steel with eight counterweights,
supported by four main bearings.
The block features a deep-skirt design extending below the crankshaft
centerline to provide rigidity for marine operation. A freshwater-cooled
exhaust manifold is integrated with the cylinder head cooling circuit to
reduce engine compartment temperatures and extend component life.
The cylinder head is manufactured from cast iron, matching the block
material to ensure uniform thermal expansion.
Valves: 6 total; 3 intake, 3 exhaust.
Intake Valve Diameter: 38.0 mm (1.50 in).
Exhaust Valve Diameter: 32.0 mm (1.26 in).
Valve Stem Diameter: 8.0 mm (0.31 in) for both intake and exhaust.
Valve Seat Inserts: Press-fit inserts; exhaust valve seats are
manufactured from heat-resistant alloy.
Valve Guides: Cast iron guides pressed into the cylinder head.
Valve Adjustment: Mechanical adjusters with threaded rocker arms and
lock nuts. Valve clearance is set with the engine cold. Intake
clearance: 0.20 mm (0.008 in); Exhaust clearance: 0.20 mm (0.008 in).
Camshaft: Chilled cast iron camshaft with induction-hardened lobes,
located within the cylinder block and driven by gears from the
crankshaft. Pushrods transfer motion to rocker arms.
Combustion Chamber: Indirect injection configuration utilizing a
pre-combustion chamber (swirl chamber) cast into the cylinder head. This
design provides smooth combustion and reduced mechanical noise.
The fuel system employs an in-line mechanical injection pump with
indirect injection through pre-combustion chambers. Injection Pump Type:
In-line mechanical injection pump with a mechanical governor. The
governor maintains stable idle speed and controls maximum engine speed.
Injectors: Mechanical pintle-type injectors with an opening pressure of
110-115 bar (1,595-1,668 psi). Injectors are connected to the injection
pump by individual high-pressure steel lines.
Fuel Filtration: Dual-stage fuel filtration system. A primary filter
with water separator is mounted on the engine or bulkhead. A secondary
spin-on fine filter is mounted on the engine. Fuel Feed Pump: Mechanical
diaphragm pump operated by an eccentric lobe on the camshaft. A manual
primer lever is incorporated for system bleeding after filter
replacement.
Fuel Pressure: Injector opening pressure is 110-115 bar (1,595-1,668
psi). The fuel feed pump supplies fuel to the injection pump at low
pressure. Cold Start Device: A manual or automatic cold start advance
mechanism adjusts injection timing for cold engine operation.
The lubrication system is a full-flow, pressurized design utilizing a
gear-type oil pump driven by the crankshaft.
Oil Pump Type: Gear-type pump mounted to the front of the crankshaft
within the timing gear housing.
Oil Capacity: 6.4 liters (6.8 qt) including oil filter replacement.
Recommended Oil Viscosity: 15W-40 (single-grade in tropical climates).
Oil Quality Requirement: API CD, CE, CF, or later diesel-specific
classifications. Marine-grade oils with enhanced corrosion protection
are recommended for saltwater environments. Oil Pressure: At warm idle,
pressure ranges from 0.5-1.0 bar (7-14 psi). At rated speed (3,600 rpm),
pressure reaches 3.0-4.0 bar (44-58 psi).
Oil Cooler: Liquid-to-oil plate-type heat exchanger integrated into the
engine block, utilizing the freshwater cooling circuit for thermal
stabilization. Oil Filter: Full-flow spin-on canister type mounted to
the cylinder block. Crankcase Ventilation: Open or closed system
depending on variant. Marine installations often utilize an open system
with a breather hose routed to a collection bottle.
The cooling system is a freshwater (indirect) system with a heat
exchanger, separating the engine coolant circuit from the raw water
circuit. Water Pump Type: Centrifugal pumps for both freshwater and raw
water circuits. The freshwater pump circulates coolant through the
engine block and cylinder head. The raw water pump draws seawater
through the heat exchanger.
Thermostat: Wax-pellet type located in the coolant outlet housing.
Opening temperature is 70-75 °C (158-167 °F) for marine applications to
prevent overheating under load. Coolant Capacity (engine circuit):
4.0-5.0 liters (4.2-5.3 qt) inclusive of engine block, heat exchanger,
and expansion tank. Heat Exchanger: Tubular heat exchanger with a
corrosion-resistant tube stack. Raw water flows through the tubes;
engine coolant flows around the tubes.
Expansion Tank: Integrated expansion tank with a pressure cap rated at
0.5-0.7 bar (7-10 psi). Coolant Specification: Ethylene glycol-based
marine coolant with corrosion inhibitors suitable for cast iron and
aluminum heat exchanger components. Exhaust Manifold Cooling: The
exhaust manifold is freshwater-cooled, reducing surface temperatures and
lowering engine compartment heat load.
Timing System: Gear-driven timing system with precision-ground gears
transferring drive from the crankshaft to the camshaft and injection
pump. No belts or chains are utilized, providing extended service life
and reliability in marine environments.
Exhaust System: Water-cooled exhaust manifold with an elbow that injects
raw water into the exhaust stream, cooling exhaust gases before they
exit through the vessel’s exhaust system.
Intake System: Air intake with a flame arrestor and sound-reducing
intake silencer designed for marine engine compartments.
Electrical System: 12-volt system with a marine alternator. Early
variants (A/B) feature a 60A alternator. Later variants (C/D) feature an
upgraded 115A alternator with integrated charging regulation. Starter
Motor: 12V electric starter with a heavy-duty solenoid, designed for
marine operation with corrosion-resistant construction.
Overall Length: 850 mm (33.5 in) measured from accessory drive pulley
face to flywheel housing.
Overall Width: 560 mm (22.0 in) inclusive of exhaust manifold and
injection pump.
Overall Height: 650 mm (25.6 in) from oil pan bottom surface to valve
cover top surface.
Dry Weight: 179-200 kg (395-441 lb) depending on transmission
configuration (MS2 reverse gear or 120S saildrive).
Bore Pitch: 98.0 mm (3.86 in).
Intake Valve Clearance (cold): 0.20 mm (0.008 in).
Exhaust Valve Clearance (cold): 0.20 mm (0.008 in).
Valve Clearance Adjustment interval: 250 operating hours.
Timing Gear Inspection: Gear backlash inspection recommended every 1,000
hours.
Injector Opening Pressure: 110-115 bar (1,595-1,668 psi).
Injector Opening Pressure: Inspection interval is 500 operating hours.
Fuel Filter Replacement Interval: 250 hours or as indicated.
Engine Oil Change Interval: 250 hours or annually, whichever occurs
first.
Coolant Change Interval: 500 hours or 2 years.
Raw Water Pump Impeller Replacement: 250 hours or annually.
Glow Plug Inspection: Inspect every 500 hours; replace as required.
Idle Speed (warm, neutral): 800-850 rpm.
Compression Pressure: 2.5 MPa (363 psi) minimum specification per
cylinder.
Compression Pressure: 0.3 MPa (44 psi) maximum variation between
cylinders.
Cylinder Head Bolts, Step 1: 40 Nm (30 lb-ft).
Cylinder Head Bolts, Step 2: 80 Nm (59 lb-ft).
Cylinder Head Bolts, Step 3: 110-120 Nm (81-89 lb-ft).
Crankshaft Damper Pulley Bolt: 180-200 Nm (133-148 lb-ft).
Connecting Rod Cap Bolts: 50-55 Nm (37-41 lb-ft).
Main Bearing Cap Bolts: 80-90 Nm (59-66 lb-ft).
Camshaft Bearing Cap Bolts: 20-25 Nm (15-18 lb-ft).
Camshaft Drive Gear Bolts: 80-90 Nm (59-66 lb-ft).
Valve Cover Nuts: 8-10 Nm (6-7 lb-ft).
Rocker Arm Shaft Bolts: 20-25 Nm (15-18 lb-ft).
Intake Manifold Nuts: 20-25 Nm (15-18 lb-ft).
Exhaust Manifold Nuts: 25-30 Nm (18-22 lb-ft).
Oil Pan Bolts: 10-12 Nm (7-9 lb-ft).
Oil Pump Mounting Bolts: 20-25 Nm (15-18 lb-ft).
Water Pump Bolts (freshwater): 20-25 Nm (15-18 lb-ft).
Raw Water Pump Mounting Bolts: 10-12 Nm (7-9 lb-ft).
Heat Exchanger End Cover Bolts: 10-12 Nm (7-9 lb-ft).
Injection Pump Mounting Nuts: 20-25 Nm (15-18 lb-ft).
Injection Line Fittings: 20-25 Nm (15-18 lb-ft).
Injector Hold-Down Clamps: 30-35 Nm (22-26 lb-ft).
Flywheel / Drive Plate Bolts: 90-100 Nm (66-74 lb-ft).
Engine Mount Bracket Bolts: 45-55 Nm (33-41 lb-ft).
Glow Plugs: 20-25 Nm (15-18 lb-ft).
Sailboats (36-45 feet): The MD2040 is commonly installed in sailing
yachts from manufacturers including Bavaria, Beneteau, Jeanneau,
Hallberg-Rassy, and Malo. These vessels utilize the MD2040 with either
the 120S saildrive for reduced vibration and simplified installation or
the MS2 reverse gear with a shaft drive for traditional driveline
configurations.
Displacement Motor Cruisers: The MD2040 serves as a primary engine for
small displacement motor cruisers and trawlers up to 10 meters (33 feet)
in length, providing the low-speed torque required for displacement hull
operation.
Volvo Penta MD2040-A/B (early variants): Produced with 60A alternators
and first-generation cooling systems.
Volvo Penta MD2040-C/D (later variants): Produced with improved heat
exchanger designs, upgraded 115A alternators, and revised freshwater
circulation for enhanced cooling efficiency.
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