Volvo Penta TAD1630G, Workshop Manual

Page 1: ...Workshop manual TAD1630G GE P V TAD1631G GE TID162AP TWD1620G GH TWD1630G GE P V TD164KAE ...

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Page 3: ... 82 Oil cooler replacing 83 Oil cooler leakage test 84 Oil pump replacing 85 Oil pump reconditioning 87 Contents General Information 3 Tools 11 Special tools 11 Other special equipment 15 Engine 16 Design and Function 16 Cylinder head 17 Cylinder block 17 Seals 17 Valve mechanism 18 Camshaft 18 Timing gears 18 Crankshaft pistons 19 Service procedures 20 Engine fixture attaching 20 Compression test...

Page 4: ... back pressure 113 Turbocharger checking bearing clearance 113 Schwitzer S4T and Holset H3B 113 Turbocharger reconditioning 115 Schwitzer S4T y TAD1630 1631 115 Holset TID162 TWD1620 TWD1630 120 Measures in case of turbo failure on TAD engines 123 Turbocharger replacing refitting on engine 123 Charge air cooler checking for leakage TAD engines 124 Cooling system 125 Design and Function 125 General...

Page 5: ... oil could be ejected Stop the engine before carrying out operations on the engine cooling system Only start the engine in a well ventilated area If oper ating the engine in an enclosed area en sure that there is exhaust ventilation leading out of the engine compartment or workshop area Introduction This Workshop manual contains descriptions and instruc tions for the repair of the Volvo Penta prod...

Page 6: ... the top of the engine All chains and cables should run parallel to each other and as perpendicular as possible in rela tion to the top of the engine Always use protective glasses or goggles when car rying out work where there is a risk of splinters grinding sparks acid splashes or where other chemicals are used The eyes are extremely sensi tive an injury could result in blindness Avoid getting oi...

Page 7: ...or damage to the engine or parts WARNING The components in the electrical system and in the fuel system on Volvo Penta products are de signed and manufactured to minimize the risk of fire and explosion The engine must not be run in areas where there are explosive materials Always use the fuels recommended by Volvo Penta Refer to the Instruction Book Use of fuels that are of a lower quality can dam...

Page 8: ...y warranty or guarantee provided by AB Volvo Penta Certified engines When performing service and repairs on an emissions certified engine that is used in an environment where ex haust emissions are governed by law it is important to be aware of the following Certification means that an engine type is controlled and ap proved by the appropriate authority The engine manufactur er warrants that all e...

Page 9: ...dirt or for eign objects entering the parts or systems since this can re sult in reduced service life or malfunctions Repair instructions Our common responsibility Every engine consists of many systems and components that work together If one component deviates from the tech nical specifications this can have dramatic consequences on the environmental impact of the engine even if it is otherwise i...

Page 10: ... the engines To ensure service work is correctly carried out it is important that the correct sealant and locking fluid type is used on the joint where the agents are required In this Volvo Penta Workshop manual the user will find that each section where these agents are applied in pro duction states which type was used on the engine During service operations use the same agent or an alterna tive ...

Page 11: ...th an oxy acetylene torch or be burned up afterwards in an uncontrolled manner Always use gloves made of chloroprene rubber gloves for handling chemicals and protective goggles Handle the removed seal in the same way as corrosive acid All residue including ash can be highly corrosive Never use compressed air to blow anything clean Put the remains in a plastic jar which is sealed and pro vided with...

Page 12: ...del 2 Spec no 3 Serial no 4 Rated net power without fan 5 Rated net power with fan 6 Max rpm 7 Prelift Inj timing T Turbo charged Key to engine model For example TAD1630GE T Turboalimentado A Air to air charge air cooler I Intercooler W Water to air charge air cooler D Diesel engine 16 Displacement liters 3 Generation 0 Version P Stationary engine Power Pac G Gen Set Engine H Raised engine output ...

Page 13: ...shings 999 6390 Gauge extension 999 6394 Spacer for liner extractor Tool Designation use 999 1083 Drift for valve guides 999 1801 Standard handle 18x200 999 1819 Puller 999 2000 Standard handle 25x200 999 2061 Drift for reconditioning coolant pump 999 2269 Drift for fitting flywheel 999 2412 Drift for reconditioning coolant pump 999 2457 Hollow drift for rocker arm bushings 999 2479 Holder for dia...

Page 14: ...for injection pump 999 6858 Drift for coolant pump Tool Designation use 999 6863 Hollow drift for thermostat seal 999 6960 Expander 999 6963 Puller plate 999 6966 Press tool 999 6942 Milling tool 999 6967 Drift for fitting sealing ring to cylinder liner 999 6969 Drift for camshaft bearings 999 6970 Guide tool for camshaft 999 6971 Handle camshaft bearings 999 6974 Drift for camshaft bearings 999 6...

Page 15: ...ssion test 999 8010 Puller for crankshaft seal 999 8011 Puller for seal Tool Designation use 999 8012 Hollow drift 999 8017 Press tool 999 8134 Thread cutting tool for copper sleeve 999 8140 Puller for copper sleeve 999 8238 Drift for seal 999 9179 Removal tool 999 9683 Dial indicator 999 9696 Magnetic stand 999 6962 Engine fixture 999 9179 999 8238 999 8140 999 8134 999 8017 999 8012 999 8011 999...

Page 16: ...Puller for polygon hub 884995 Drift for polygon hub 884997 Tool for crankshaft drive 885126 Piston ring compressor Tool Designation use 885184 Flange kit 885231 Connection tool for leakage check 885232 Sealing tool for leakage check 885341 Puller 885341 884969 884983 884994 884995 884997 885126 885184 885231 885232 ...

Page 17: ...on ring tool 998 6981 Oven 220V 998 6982 Oven 380V 998 7057 Measuring instrument 998 8183 Circlip pliers Tool Designation use 998 9876 Dial indicator 998 6485 Assembly stand 115 8959 Torque amplifier x6 981 2546 Pin brush copper sleeve 998 6173 Puller for rocker arm bushings 998 6175 Puller 998 8539 Compression gauge 998 5423 998 7057 115 8959 998 6485 998 6981 220V 998 6982 380V 998 8183 998 9876...

Page 18: ...Design and Function Group 21 16 Engine Design and Function ...

Page 19: ...on The main bearing caps are tied to the block sides by re inforcing plates Seals Cylinder block Cylinder liners Cylinder heads A direct contact sealing method is used The upper sealing face of the liner seals directly against the cylinder head with out a gasket The liner incorporates a flame retainer Be neath the liner collar is a sealing ring In addition there is an extra sealing ring between th...

Page 20: ... larger di mension than the other 6 The camshaft is driven via two idler gears Timing gears The timing gears are completely built in which means that the crankshaft hub and vibration damper are underneath the casing cover This gives a lower level of noise Genset en gines have an additional vibration damper in front of the pul ley The cooling fan is belt driven The coolant pump has a pulley to prov...

Page 21: ...ygon hub The rear and front crankshaft seal consists of a liptype seal ing ring The front sealing ring seals against a wear ring on the pulley The upper end of the connecting rods is trapezoidal in shape The bushing must be line bored after replacement The pistons are made of aluminum alloy have three piston rings and an inner oil drilling for cooling purposes ...

Page 22: ...e the oil cooler as shown in oil cooler replacing 2 Remove the spacer plate four screws 3 Remove the bypass filter and bracket four screws 4 Cover the holes with rags or equivalent to prevent dirt or for eign matter from entering the engine 5 Mount the engine fixture on the engine 6 Lift the engine in place and secure it with screws and nuts in the holes on the assembly stand four ...

Page 23: ...ons with all sensors and transducers on the sensor rack Disconnect the starter heater 3 Remove the filters and pipes for the turbo charger Remove stays and brackets 4 Remove the turbo charger from the exhaust pipe and charge air cooler 5 Remove the charge air cooler together with the inlet mani fold Fit adapter 999 8009 Attach the adapter by means of the in jector retainer and nut 2 Connect compre...

Page 24: ...to the pressure valve holders in the injection pump 8 Remove the pipe of the smoke limiter from the inlet pipe TAD1630P V only Remove the inlet manifold TAD1630 TAD1631 only 10 11 On the cylinder heads which are to be removed bend up the locking tabs on the exhaust manifold bolts 12 Remove the fuel return pipes together with the copper wash ers between the injectors 13 Remove the valve cover Remov...

Page 25: ...move the rocker arm bridge and both push rods Lift and turn the tappets 1 4 turn until they rest on the guide stud in the cylinder head or remove them Note Put all tappets and push rods in a stand or mark them to make sure that they are returned to their original positions when reinstalled Remove the injectors If an injector sticks in the copper sleeve fit tool 999 6400 and 999 8007 to the injecto...

Page 26: ... liner Cylinder head disassembling 1 Remove the valves and valve springs Use a valve spring clamp to compress the springs for removal of the valve col lets 2 Put the valves in a valve stand in the order they were fitted in the engine 3 Clean all parts Take particular care with the ducts for oil and coolant Carry out a leakage test ...

Page 27: ...ion valve Note The knob of the reduction valve can be locked with a circlip which is moved in an axial direction 2 Then close the bleed valve The pressure gauge dial pointer must not drop during minutes otherwise the gauge cannot be relied upon 3 Fit 999 6997 two to the cylinder head Note Tighten the wing nuts with care so as not do damage the rubber gaskets of the tool 4 Connect the hose between ...

Page 28: ...r head inspection Unevenness of the cylinder head face must not exceed 0 02 mm 0 0008 If the unevenness does exceed the maximum of 0 02 mm or if any blow by marks are observed the cylin der head must be face ground or replaced Make sure that the stud is secure IMPORTANT Replace all rubber seals Cylinder head face grinding Special tools 999 2479 998 9876 When face grinding check surface smoothness ...

Page 29: ...ides 2 Fit a new valve into a valve guide pushing the valve down until the stem rests against the flat surface underneath 3 Use a dial indicator with a magnetic stand placing the tip of the dial indicator against the edge of the valve 4 Move the valve sideways in the direction of the exhaust or inlet ducts Note the reading of the dial indicator Wear tolerances Inlet valve max play 0 30 mm 0 0118 E...

Page 30: ...e valve seat must be replaced when measurement A measured with a new valve exceeds 1 0 mm This measurement applies to both the inlet and exhaust valves Remove the old valve seat by cutting two diametrical notch es in the seat and cracking it with a chisel Note Be careful not to damage the cylinder head Thoroughly clean the seat location and check the cylinder head for cracks Measure the diameter o...

Page 31: ... 0 4 mm 0 0 0 0158 for both inlet and exhaust valves This angle is checked with a valve seat gauge after coating the seat contact surface with a light layer of marking paint Valves grinding Valve sealing angles Inlet 29 5 Exhaust 44 5 The sealing surface should be ground as little as possible just enough to remove all signs of damage If there is an edge of less than 1 40 mm 0 0552 on inlet valves ...

Page 32: ...ing surfaces are well cleaned Fit new gaskets Torque the plugs IMPORTANT The plugs must be tightened manually Plug diameter M30 60 Nm 44 3 ft lb 3 4 70 Nm 51 6 ft lb Cylinder head installation Special tools 999 2479 998 9876 115 8959 1 Use a brass wire brush to clean the sealing surfaces of the cylinder block IMPORTANT Take care not to scratch the contact surfaces which seal against the cylinder l...

Page 33: ...ld bolts 2 3 turns 7 Dip the cylinder head bolts completely into a rustproofing agent part No 282036 3 Then place the screws on a net to remove excess 8 Fit the bolts to the cylinder head 9 Tighten the head bolts in the specified order and in four stages 1st stage 50 Nm 36 9 ft lb 2nd stage 125 Nm 92 2 ft lb 3rd stage 200 Nm 147 5 ft lb Note Mark the socket and the cylinder head with a felt tipped...

Page 34: ... valve cover together with the gaskets 16 Fit the coolant distribution pipes and the thermostat housing 17 Torque the exhaust manifold bolts to 48 Nm 35 4 ft lb 18 Fit new O rings to the inlet pipes of all cylinders On TWD1630 the delivery pipes to the injectors have to be fitted before the inlet manifold 19 TAD1630P V only Connect the smoke limiter hose to the inlet pipe 20 Connect the cables to ...

Page 35: ...ker arm shaft and the ball screw The threads on the ball pin and lock nut must be in good con dition The surface of the rocker arms which is in contact with the valve must not be worn or pitted 4 Press out the rocker arm bushing using tools 999 1801 999 2457 and 999 6352 5 Fit the new bushing using tools 999 1801 and 999 6478 making sure that the oil holes align with the oil channels in the rocker...

Page 36: ...ve the plug in the flywheel casing and attach crank ing tool 998 3590 2 Remove the delivery pipe and the fuel return pipe 3 Remove all valve covers Note After removing the valve cover always check the torque on the studbolt to the rocker arm bridge Correct torque 48 Nm 35 4 ft lb 4 Crank the flywheel in the engine s direction of rotation until 1st piston is in the top dead center after the compres...

Page 37: ...ke and both valve pairs of 1st cylinder are rocking 12 Repeat stages 5 6 7 8 and 9 on valve pairs no 13 On completion of adjustment remove tool 998 3590 and fit the plug in the flywheel casing 14 Fit all valve covers Torque 20 Nm 14 8 ft lb 15 Fit the fuel delivery pipes and the fuel return pipes Note Fuel delivery pipes must never be bent or altered A damaged fuel delivery pipe should always be r...

Page 38: ...etainer and the injector fitting a protective plug to the injector and in the delivery valve holder in the injection pump 6 Remove the steel ring with puller 999 1819 7 Rotate the engine until the piston in the cylinder where the replacement of the copper sleeve is to be carried out is in its lower position 8 Grease the threaded tap on tool 999 8134 Note The grease ensures that swarf will not fall...

Page 39: ...aling ring of the copper sleeve from the cyl inder head 13 Clean the sealing surface between the cylinder head and the base of the copper sleeve Tool 9812546 can be used for this purpose 14 Fit a new sealing ring to the cylinder head 15 Remove the reamer from tool 999 6960 16 Fit a new copper sleeve to 999 6960 Fit the reamer 17 Smear the inside of the copper sleeve with engine oil 18 Fit the copp...

Page 40: ...tion of the copper sleeve 21 Screw down the nut until the reamer of the tool loosens from the copper sleeve 22 Remove tool 999 6960 23 Put the steel ring for the copper sleeve onto drift 999 25 Insert a new sealing ring into the steel ring 26 Fit the injector complete with retainer Torque the injector to 55 Nm 40 6 ft lb 27 Fit the valve cover 28 Remove the protective plugs from the injector Fit t...

Page 41: ...rankshaft so that the piston for the ac tual cylinder is at BDC 4 Remove the big end cap Tap up the connecting rod with for example the handle of a hammer so that the piston rings are released from the cylinder liner Lift off the piston and con necting rod Note Scrape off the soot edge on the upper part of the cylin der liner to simplify removal of the piston and connecting rod 5 Mark the piston a...

Page 42: ...to the risk of oil channels becoming clogged and the diffi culties to feed correctly 3 Remove the carbon edge at the top of the liner Also clean under the liner collar and the recess in the block 4 Use a low speed electric drill with a speed of 200 400 rpm and a Flex Hone tool type GBD Grade size 80 Lubricate the cylinder liner with light engine oil before and during honing Move the honing tool in...

Page 43: ... may be impos sible to turn the lining in the cylinder block Grinding with grinding paste under the liner collar can in such cases not be done Checking of the contact pattern with marking paint cannot be done 1 Fit the cylinder liner without sealing rings in the cylinder block and check the height of the sealing face Make a note of the dial indicator reading The correct height should be 0 06 0 10 ...

Page 44: ...e the milling tool and clean the liner shelf 7 Engines with liners that can be turned When 0 02 mm 0 0008 remains to the correct height stop the feeding motion and turn the milling tool several times Smear the bottom face of the liner collar with grinding paste Fit the liner and rotate it back and forth until the paste is worn out Remove the liner and carefully whip off the paste Re peat this unti...

Page 45: ...d Piston rings should also be replaced if there is noticeable wear or the cylinders are out of round since very often the rings do not take up the same position they had prior to removal Oil consumption is also a matter of significant importance concerning the time at which piston rings should be replaced Connecting rods inspection Check for cracks Check straightness and warping Warped or twisted ...

Page 46: ... pointing in the same direction Push the gudgeon pin in with drift 999 1801 and handle 999 1801 Note The gudgeon pin should enter easily it must not be knocked in 4 Fit the other circlip 5 Check that the connecting rod moves smoothly in the gudg eon pin journalling 6 Fit the piston rings to the piston using piston ring pliers Make sure that the markings on the piston ring face up wards and that th...

Page 47: ...the clamping tools and then the liner Cylinder liners and pistons fitting Special tools 999 2000 999 2479 998 3590 999 6236 999 6394 999 6395 999 6645 999 6963 999 6966 999 6967 998 9876 885126 1 Carefully clean the liner seat in the cylinder block Any rust or deposits on the sealing surfaces must be fully removed Use a cleaning fluid and a brass wire brush blowing dry with compressed air Note Scr...

Page 48: ...ring about 8 mm below the collar Note In the case of shims being used for the liner ap ply the bead of sealant to the liner shelf in the cylinder block Note Do not apply sealant between the shims and the liner collar After applying the sealant the liner must be installed within 20 minutes The liner must be clamped down with the clamping tool The clamping force must not be re moved before the cylin...

Page 49: ...ston and put it into the liner with the marking ar row pointing forward 15 Check that the bearing shells are a correct fit to the connect ing rod and caps Screw down the caps according to the markings using a torque of 250 Nm 184 5 ft lb 16 Fit the piston cooling nozzle Torque the nozzle nut to 25 Nm 18 45 ft lb 17 Check the piston height beneath the face of the cylinder block Turn the engine usin...

Page 50: ... tighten the screws within 20 minutes 2 Install the bearing housing on the engine block Tighten the screws until the bearing housing is tight against the engine block 3 Install the transmission gear casing Se Sealant timing gear casing replacing 4 Mount the screws through the timing gear casing Tighten the screws until the bearing housing is tight against trans mission gear casing Tighten the scre...

Page 51: ... 08 bead of sealing compound part No 1161277 around the cylinder block and timing cover See figure Note Bearing housing and thrust washer screws must be installed and tightened within 20 minutes 6 Install bearing housing with a new O ring against the tim ing cover Tighten screws in cylinder block Note Tighten screws alternately until the bearing housing is in contact with the cylinder block Then t...

Page 52: ...holding the pump coupling Note Do not remove the bolts which hold the flange discs to the flange since this would alter the setting of the injection pump Do not turn the injection pump or the engine 4 Remove the clamp screw holding the flange to the shaft 5 Remove the pump coupling and the flange Clean the shaft from paint before fitting puller 999 8011 to remove the seal 6 Remove the seal by scre...

Page 53: ...upling 14 Connect the batteries Seal on output shaft from timing gear to injection pump TAD1631 replacing Special tools 999 8011 999 8012 To replace the sealing ring in the bearing housing the fuel in jection pump and pump coupling must be removed See Re moving the injection pump 1 Screw puller 999 8011 into the sealing using a drift Press on the extractor at the same time so that its threads cut ...

Page 54: ...1 52 4 Locate seal ring on shaft and tap it in until the seal is level with the bearing housing Use drift 999 8012 5 Install flange pump coupling and injection pump Check the injection angle se Fitting and adjusting the injection pump ...

Page 55: ...ve belt and the belt pulley and the holder from the timing cover 2 Remove the sealing ring from the holder Press the new sealing ring into the holder using tools 999 2000 and 999 2929 4 Place a bead of sealant on the mating surface of the timing gear cover 5 Fit the holder on the timing cover 6 Fit the belt pulley and the drive belts ...

Page 56: ... the bolts holding the timing gear cover The through bolts too 8 Remove the timing gear cover Use a screwdriver as lever age and place it at relevant spots Tap carefully on the cover with a rubber mallet IMPORTANT Make sure not to damage the oil pan gasket Should the oil pan gasket be damaged the pan must be re moved and the gasket replaced Assembly 9 Remove the possible sealant residue from the t...

Page 57: ...nator drive belts The radiator along with hoses and connections Connect the electrical wires to the alternator 16 Fill up with coolant and set the electrical circuit breaker in on position Check to make sure that there are no leakag es Remove the plug in the flywheel Fit tool 999 3590 Re move the inspection cover for the camshaft on the rear of the engine Rotate the engine until the marked hole on...

Page 58: ...ives for the injection pump and the cam shaft last Intermediate gears replacing bearing 1 Disconnect the hub to the intermediate gears and thrust washers 2 1 Inner thrust washer 2 Hub 3 Intermediate gear 4 Outer thrust washer 5 Bearing bracket 6 Screws 4 ea Dry the mating surfaces so that they are clean Fit new thrusts washers lubricated with engine oil Then fit the hub and the intermediate gears ...

Page 59: ...intermediate gears 4pcs Check that the markings on the drives match See figure Torque the drives to 65 Nm 48 ft lb The intermediate gear for the oil pump shall be torqued to 48 Nm 35 4 ft lb 3 Fit the camshaft drive Check that the marking agrees with that on the intermediate drive Torque the drive to 60 Nm 44 3 ft lb 4 Fit the injection pump drive Note If the drive has not been previously marked t...

Page 60: ...cing with the timing gear cover removed Special tools 999 3590 884994 884995 Removal 1 Block the flywheel 2 Heat the polygon hub to a temperature of about 100 C 212 F Fit the hub using drift 884995 6 When the hub has cooled off torque the crankshaft s cen tral screw to 640 Nm 472 3 ft lb 7 Place the vibration damper on the polygon hub before fit ting the timing gear cover Remove the vibration damp...

Page 61: ...ll valve covers 3 Remove all rocker arm assemblies and push rods Note Mark the push rods or keep them in their proper order on a rack so that they can be put back in their original posi tions in the engine Apply a new string of sealant on the timing gear casing 2 mm 0 080 thick See figure Use sealant Part no 1161277 Install the casing within 20 minutes Note The gasket used on early engines is repl...

Page 62: ...ndicator to a magnetic stand 5 Put a steel ball in the bottom of no 1 tappet Put the magnetic stand on the front cylinder head Start check measuring at no 1 valve tappet Make sure that 999 6390 is on top of the steel ball Crank the engine until 999 6390 is at its bottom position Make sure that the tip of the dial indicator is pre loaded Set the dial indicator to zero 9 ...

Page 63: ...0 3073 Min exhaust 7 35 mm 0 2896 11 Check the lifting height on all the other cams of the cam shaft in this same manner 12 Remove the magnetic stand the dial indicator and the steel ball 13 Fit the push rods in the order they were fitted previously 14 Fit the rocker arm assemblies 15 Adjust the valves fit the valve covers 16 Fit the delivery and fuel return pipes 17 Remove tool 999 3590 from the ...

Page 64: ...on cover 3 Crank the engine until 1st piston is at its T D C after the compression stroke 0 on the flywheel 4 Remove all rocker arm assemblies and push rods Re move the camshaft inspection covers Note Place the push rods in their proper order on a rack so that they can be put back in their original positions in the engine 5 Lift up all of the tappets Place them in order on a rack so they can be re...

Page 65: ...s and the axial bearing Pull out the cam shaft 11 Clean the new camshaft and lubricate the bearing pins and the camshaft tappets with engine oil 12 Push 999 6970 onto the camshaft 13 Fit the camshaft taking care not to damage the bearings 14 Fit and tighten the camshaft axial bearing Note The flat side of the axial bearing should be facing the cylinder block Torque 24 Nm 17 7 ft lb 15 Fit the cams...

Page 66: ... mark ings 19 Fit the rocker arm assemblies Adjust the valves 20 Remove tool 999 3590 from the flywheel casing Fit the plug and the inspection cover 21 Fit the valve covers 22 Fit the delivery and fuel return pipes Camshaft bearings replacing Camshaft removed Special tools 999 2000 999 6062 999 6071 999 6626 999 6969 999 6971 999 6974 Removal 1 Expose and remove the camshaft inspection covers 2 Kn...

Page 67: ...ool 999 6969and place it in bearing seat 5 Fit spindle 999 6062 and drift 999 6071 from the rear and press in the bearing 7 Press in bearing 6 in the same manner Use hollow drift 999 6626 to lengthen the spindle thread Turn the spindle and press in bearing 7 9 Carefully tap in bearings 4 3 and 2 in the stated order Use drift 999 6969 and handle 999 6971 10 Carefully tap in bearing 1 The lube chann...

Page 68: ...n the parts and check them for wear 10 Make sure that the correct size of bearing is being fitted 11 Oil the shaft journals and the new bearing shells 12 The upper bearing shells are slid into position by turning the crankshaft against the engine s direction of rotation 13 Fit the bearing caps together with the reinforcing plates 14 Remove the oil pump and the oil delivery pipe 4 Remove all bolts ...

Page 69: ...er 2 Remove the Plug from the flywheel casing Fit tool 999 3590 3 Crank the engine and remove the big end bearing caps 4 Clean all parts and check the bearing pins 5 Replace any damaged or worn bearing shells 6 Oil the bearing shells and fit them Fit the bearing caps ac cording to the markings and torque the bolts to 240 Nm 177 1 ft lb 7 Remove tool 999 3590 from the flywheel casing and fit the pl...

Page 70: ... Worn or damaged shells must be replaced 11 Put the bearing shells in their respective positions in the en gine block and caps Make sure that the bearing shells are correctly fitted and that the caps are undamaged 12 Smear the bearing pins with engine oil and carefully lift the crankshaft into position 13 Fit the thrust washers for the center main bearing axial bearing Due to the fixing recesses t...

Page 71: ...r out of roundness wear and taper See Workshop manual Technical Data B Assess the surface damage For nitro carburized shafts the following applies What on an induction hardened crankshaft may be re garded as scoring due to dirt can in the case of a nitro carburized shaft be the normal surface finish as on a new crankshaft The markings show up very clearly on a shaft that has been in use because of...

Page 72: ...ng applies 1 3 The shaft must be scrapped if there are longitudinal cracks on the journals and in the fillets 2 The shaft must be scrapped if there are crosswise cracks within the marked zone This applies to both crank pins and main bearing journals The shaft must be scrapped when cracks longer than 5 mm 0 2 are adjacent to the area around the oil holes Cracks shorter than 5 mm 0 2 can be removed ...

Page 73: ...netic powder test 10 The crankshaft must be carefully lapped and cleaned after nitro carburizing The crankshaft must always be thoroughly cleaned after reconditioning In order that all oil channels are cleaned efficiently late production crankshafts are fitted with threaded plugs in each piston rod These plugs should be re moved during the cleaning procedure Flywheel checking for warp Special tool...

Page 74: ...heel 3 Using the bolts lift off the flywheel 4 Clean the crankshaft flange contact surface 5 Check the guide pin replace it if damaged 6 Clean the flywheel contact surface which mates with the crankshaft flange Fit a new flywheel bearing Power Pack engines 7 Fit the flywheel and the bolts 8 Torque the flywheel to 260 Nm 191 8 ft lb ...

Page 75: ... to a shine at several places At the correct temperature these bright spots will become blue 180 200 C 356 392 F and heating should be stopped 4 Place the heated ring gear on the flywheel Tap it into posi tion using a soft drift and a hammer The ring gear should then be allowed to cool slowly in air 2 Fit cranking tool 999 3590 3 Fit a dial indicator to a magnetic stand Mount the magnetic stand on...

Page 76: ...t be concentric with the flywheel within 0 25 mm 0 0099 5 Should any of the readings in points 3 and 4 be exceeded check the contact of the flywheel casing against the cylin der block 6 Remove the rotating tool Flywheel bearing replacing Special tools 999 2269 1 Due to a hard fit the flywheel must be removed to allow the flywheel bearing to be removed using a suitable drift 2 Fit a new flywheel be...

Page 77: ...the crankshaft seal using tool 999 8010 4 Clean the seat of the sealing ring in the flywheel casing 5 Apply sealant to the outer edge of the sealing ring and oil the inner edge of the sealing ring before fitting it with tool 999 8238 and handle 999 2000 6 Lift the flywheel into position Refit the bolts 7 Block the flywheel using cranking tool 999 3590 8 Torque the flywheel bolts to 260 Nm 191 8 ft...

Page 78: ...tin 24 01 for more information Note Wear ring and seal ring should always be replaced at the same time 1 Remove the fan belt 2 Undo the bolts 6 ea to the outer vibration damper if fitted and remove the damper and the pulley 3 Remove the sealing ring in the timing gear cover and the wear ring on the pulley 4 Oil a new sealing ring Fit it with tool 884983 and 3 M10 x 80 mm bolts The seal is correctl...

Page 79: ...fan belts Sealant flywheel casing replacing Flywheel removed 1 Remove the flywheel casing from the cylinder block 2 Remove the old sealant from the cylinder block and on the flywheel casing 3 Apply an even 2 mm 0 080 thick bead of sealant part No 1161277 7 to the block 4 Fit the flywheel casing to the cylinder block Note The flywheel casing must be refitted within 20 min utes of applying the seala...

Page 80: ...Service procedures engine Group 21 78 Application of sealant to cylinder block ...

Page 81: ...ated by a gear wheel pump The system incorporates five valves 1 Safety valve 2 Bypass valve for oil cooler 3 By pass valve for oil filter 4 Reduction valve 5 Piston cooling valve The lubricating oil is cleaned by two full flow filters and one bypass filter The oil cooler is mounted on the side of the en gine ...

Page 82: ... points of the engine On the oil pump itself is a safety valve This opens when pressure in the system becomes too high allowing the oil to reach the suction side of the pump via a duct in the pump housing The reducer valve regulates the oil pressure A bypass valve opens when the counter pressure in the oil cooler becomes too high which occurs during cold starts and leads the oil past the oil coole...

Page 83: ...e gree of filtration The two full flow filters have a bypass valve which guaran tees lubrication of the engine should the filters become blocked Oil cooler The oil cooler maintains the temperature of the lubricating oil at a relatively low level which is advantageous from the point of view of wear and also maintains the oil s benefi cial qualities 2 Bypass valve for oil cooler 3 By pass valve for ...

Page 84: ...t and remove the 3 filters us ing tool 999 9179 2 Moisten the seals of the new filters with oil and screw the fil ters on by hand until the seals are in contact with the filter bracket Then tighten the filters by hand a further half turn Note Install only Volvo oil filters type Long Life The oil filters must not be damaged If the filter is dented it may crack resulting in engine breakdown 3 Fill t...

Page 85: ...block and spacer plate 4 Disconnect the oil cooler from the front coolant pipe 5 Fit new sealing rings to the engine block and to both coolant pipes 6 Push the new oil cooler onto the front coolant pipe 7 Bolt the oil cooler to the spacer plate and engine block 8 Replace the rear coolant pipe 9 Fill with coolant 10 Fill the engine with oil 11 Start the engine and check for leaks ...

Page 86: ...erature Drain off all water in the cooler 3 Fit leak detection tool 999 6845 and check that it seals cor rectly Lower the oil cooler into the bath which contains water that has the same temperature as the room The leakage test is to be carried out at 15 100 and 250 kPa 2 2 14 5 and 36 3 psi Begin at 15 kPa and then continue with 100 and 250 kPa The test period for test pressure each should last fo...

Page 87: ... 8012 Removal 1 Remove the delivery oil pipe 2 Remove the suction oil pipe 3 Remove the bolts for the bracket 4 Remove the pump together with the bracket 4 Remove the idler gear from the bracket 5 Remove the pump housing from the bracket Push the shaft out of the drive gear 6 Remove the pump from the bracket ...

Page 88: ...be 0 4 1 0 mm 0 0157 0 0394 10 Fit the idler gear to the bracket Torque 48 Nm 35 4 ft lb 11 Fit a new sealing ring to the suction pipe Fit the suction pipe to the pump Fit a new sealing ring to the delivery pipe Fit the delivery pipe Note When refitting the oil pump check the delivery pipe at its union with the block with regard to flattening of the pipe Push the delivery pipe in until it bottoms ...

Page 89: ... thrust washers hub and idler gear 2 Remove the pump housing from the bracket 3 Push the shaft out of the drive gear Safety valve removed Special tools 999 2677 999 6413 999 8012 4 Remove the gear wheel from the pump housing 5 Press the old bushings out of the pump housing and bracket using drift 999 2677 Press in the new bushings Note The bushings are ready machined as supplied and need not be re...

Page 90: ...118 The illustration numbers above refer to the relevant point in the text below 6 Check the housing for scoring and wear and also check for leakage between the bracket and pump housing In the case of leakage the surfaces will be black The bushings in the pump housing and bracket must be replaced The gear wheels of the pump must be checked concerning wear on the flanks of the teeth on the outer di...

Page 91: ...0 20 C 356 36 F Tap the drive gear on to the pump shaft The drive can also be pressed in using drift 999 6413 using 999 8012 as an anvil Note The clearance between the drive gear and the bracket should be 0 4 1 0 mm 0 0157 0 0394 12 Fit the thrust washers the hub the idler gear and the bearing end plate Fit the flange screws The illustration numbers above refer to the relevant point in the text be...

Page 92: ...ld side of the en gine right hand side of engine 1 Suction pipe 2 Injection pump 3 Feed pump 4 Manual pump 5 Bypass valve 6 Fuel filters 7 Fuel return pipe 8 Delivery pipes 9 Injectors 10 Fuel return pipe Fuel filters The fuel system is fitted with two parallel fuel filters and a common filter housing The fuel filters are of a disposable type and the filter cartridge is a specially wrapped paper f...

Page 93: ... carried out by specially trained mechanics with the required tools and testing devices at their disposal All warranties on the engine are void if the seals are broken by unqualified mechanics Ensure the greatest possible cleanliness when working with the fuel system TWD1620G GH TID162AG TWD1630G GE These engines have an RQ governor The RQ governor is mechanical and works by means of speed sensiti...

Page 94: ...d and the actual speed The difference value is converted into a signal to an electromagnet actuator which adjusts the injection pump s control rod to increase or de crease the injection quantity An overspeed protection must always be fitted beside the electronic governor to prevent bodily injury or material dam age if the engine should go out of control Seal screw removal When removing seal screw ...

Page 95: ...screw cannot be reused 5 New seal screws two different ones have a pre installed pre stressed nut on the conical thread During assembly you turn the nut until it releases the screw has left hand threads This provides correct torque Screws apply to en gines as follows Screw Engine 982138 TAD1630 982145 TAD1631 TD164 ...

Page 96: ...ever acts on the control rod to lower the maximum amount of fuel available In the case of a high boost pressure the lever permits the control rod to allow a higher maximum quantity of fuel Feed pump The feed pump is mounted on the injection pump and is driv en by the injection pump camshaft The feed pump pressure in the injection pump is determined by the bypass valve which is mounted on the injec...

Page 97: ...ate the engine with a ratchet handle to the compression stroke for No 1 s cylinder 0 marking on the flywheel The camshaft s marking hole should be pointing up 3 Turn back the flywheel in the opposite direction to the engine s direction of rotation about 90 from the starting point Then turn it forward in the direction of rotation until the correct number of degrees for the pump setting is imme diat...

Page 98: ...icator 998 9876 Adjust the measurement tip so that it rests on the lifter 9 Set the dial indicator to zero 10 Remove the overflow valve and hex socket plug from the pump so that No 1 s lifter is visible 7 Rotate the pump coupling until the lifter is at the base posi tion 8 Rotate the pump coupling in the engine s rotational di rection Check that the dial test indicator is still at zero when rotati...

Page 99: ... is necessary to start over from item 10 14 Torque the clamping screws to 85 Nm 62 7 ft lb 15 Check that the correct adjustment has been maintained by again rotate the engine backwards 90 and forwards to correct setting angle The dial test indicator should show the correct value for lift from basic circle See Workshop manual Technical Data 16 Remove the dial indicator and fixture 17 Fit the hex so...

Page 100: ...and test run the engine See Fuel system bleeding Remove the plug in the flywheel cover 16 mm hex socket key and fit rotating tool 999 3590 together with a ratchet Remove the inspection cover on the flywheel cover 3 Crank the flywheel in the direction of rotation until 1st cylinder is on compression 0 on the flywheel and the camshaft s marking hole pointing upwards 4 Crank the flywheel back against...

Page 101: ...upling about 1 4 turn in the pump direction of ro 7 Remove the plug in the governor housing and fit the measuring instrument sensor Ground the measuring in strument ground cable to a suitable place on the injection pump 8 Tighten down the pump coupling clamping bolt so much that the coupling with considerable resistance can be turned against the direction of rotation Note The pump coupling should ...

Page 102: ...ro cedure must be carried out again 10 Checking 11 Crank the flywheel back against the engine direction of rotation about 1 4 turn 12 Torque the pump coupling clamping bolt according to the specifications in the Workshop manual Technical Data Crank the flywheel in the direction of rotation until both the light emitting diodes on the instrument light up Read off the degree marking on the flywheel a...

Page 103: ...Gasket 4 Adjusting washer 5 Spring 6 Pressure pin 7 Guide pin 8 Guide 9 Guide pin 10 Diffuser 11 Diffuser nut Checking and replacing the laminates on the pump cou pling Check that the laminates on the pump coupling for the injec tion pump are not cracked or warped Start the engine and let it idle at about 500 rpm Check vis ually that the plates are not warped If the laminates have broken or are wa...

Page 104: ...rs and to the pressure valve on the injection pump 4 Remove return pipe and the brackets between the injectors and the injection pump 5 6 Remove the injector retainers Remove all injectors Note If it is difficult to remove the injectors tap gently on them using tools 999 6400 and 999 8007 7 Remove the sealing rings from the steel rings Note Clean the copper sleeve s seal using tool 981 2546 Use th...

Page 105: ...minated magnifying glass or injector microscope The dif fuser sleeve can also be examined under the microscope If the seat is dented the diffuser needle must be replaced to gether with the sleeve or in cases of less damage it may be lapped in a lapping or diffuser grinding machine 5 Check the other parts 6 Dip the diffuser parts in clean diesel or calibration oil 7 Reinstall adjust opening pressur...

Page 106: ...trokes per second the spray pat tern should be uniform and the fuel finely atomized On completion of the test plug the pipe connections and pro tect the diffuser tips with caps If this does not agree with the pressure stipulated by the Specifications the setting must be altered This is done by means of fitting adjusting washers Adjusting washer for opening pressure Fuel feed pressure checking Spec...

Page 107: ...ing Special tools 999 9179 1 Carefully clean around the filter bracket 2 Remove the filters with tool 999 9179 3 Moisten the seals of the new filters with oil and then screw on the filters by hand until the seals are in contact with the bracket Now tighten by hand a half turn further Check that the new filter has not been damaged If the filter is dent ed it may crack 4 Bleed the fuel system 5 Star...

Page 108: ...sing 9 Valve 2 Union 10 Spacer ring 3 Union 11 Pump plunger 4 O Ring 12 O Ring 5 Manual pump 13 Union 6 Gasket 14 O Ring 7 Cup spring 15 Push rod 8 Spring 6 Fit the spacer ring 10 into the pump plunger 11 7 Fit the valve 9 the cup spring 7 and the spring 8 to the pump plunger 11 Insert the pump plunger 11 into the pump housing 8 Fit the O ring 4 to the union 3 for the valve Remove the union 4 Remo...

Page 109: ...Rotate the diaphragm 90 and lift it out 4 Unscrew the nut 1 remove the diaphragm and screw in a new one 5 Fit the diaphragm in the smoke control device Note The groove 2 in the axle should be across the pump s length direction before rotation Check after fitting that the diaphragm s axle 3 is correctly secured in the yoke 6 Fit the cover and pipe Seal the screws 9 Fit the union 3 and the O ring 4 ...

Page 110: ...eed nipple 1 on the fuel filter Press the primer pump 2 until fuel free from bubbles of air starts to flow out Continue to pump 15 20 strokes Check that there is no fuel leakage Note In cases where the engine is equipped with fuel shut off valve it is often necessary to bleed on the injection pump as well This is done by opening the pressure equalizer 3 27 mm U key Pump manually until fuel free fr...

Page 111: ...s pressed from the turbo charger through the charge air cooler and into the inlet mani fold air to air cooling On the TWD1630 the charge air is cooled by the water cooled charge air cooler placed on top of and on the right hand side of the engine water to air cooling Turbocharger The turbo unit is of type TAD1630 TAD1631 Schwitzer S4T TWD1620 TID162 Holset HSB0870 B36 TWD1630 Holset H3B TD164KAE G...

Page 112: ... and post heating times are a factor of engine temperature The purpose of the starter heater is to warm up the air in the intake manifold when the engine is started The heated air makes for easier starting and also reduces the generation of exhaust smoke during cold starts Exhaust manifold The exhaust manifold is exposed to significant heat stresses and fluctuations and is therefore manufactured o...

Page 113: ...give a true picture of the situation it is essential that the full load condition is maintained a sufficient ly long period of time for the pressure to stabilize It should also be noted that boost pressure varies with the tempera ture of the intake air ambient air If boost pressure is measured at any other temperature than 25 C 77 F the boost pressure reading must be adjusted by means of the diagr...

Page 114: ...lace the filters when necessary 3 Accelerator linkage Check that the accelerator linkage provides full travel of the injection pump arm 4 Turbocharger Check if the rotor shaft is sluggish or if the turbine wheel and compressor wheel chafe against their housings Turn the wheel at first with a slight pressure and when with a slight axial pull If the wheel is sluggish the turbocharger must be immedia...

Page 115: ... it is required to ascer tain the degree of wear in the unit Measuring axial clearance Place a dial indicator with an 8 mm 5 16 shank in the hold er as shown Secure the dial indicator Place the holder on the compressor housing Make sure that the measuring point rests against the center of the shaft Press down the holder against the compressor intake and at the same time press the turbine rotor up ...

Page 116: ...ime as the rotor on the opposite end of the shaft is pushed upwards Set the indica tor to zero Pull the wheel upwards at the same time as the rotor at the opposite end of the shaft is pushed downwards Radial clearance Max compressor side 0 72 mm 0 028 For TD164KAE max 0 18 mm 0 007 For TWD1620 and TID162 max 0 15 mm 0 006 IMPORTANT Radial play shall be measured when the tur bine shaft is offset in...

Page 117: ...lips 16 Heat Shield 17 Piston ring 18 Turbine housing 19 Shaft and wheel complete 20 Snap ring 21 O Ring 22 Bearings 23 Oil deflector Disassembly 1 Mark the relative positions of the compressor cover 3 and turbine housing 19 to the bearing housing 13 2 Fix the turbine housing in the vise using soft jaws The turbo charger shaft should be vertical 3 Remove the V clamp 10 securing the compressor cove...

Page 118: ... circlips from both ends of the bearing housing remove the journal bear ings and inner circlips Cleaning of Parts 1 Aluminum parts Soak in a non caustic solvent until all deposits have been softened Clean surfaces with bristle brush and soft scraper Steam may be used providing bearing surfaces are protect ed 2 Cast iron parts Soak in non caustic solvent Alternatively blast Be careful with internal...

Page 119: ...s 4 Compressor cover 3 Visually inspect for evidence of contour damage Replace if damage is excessive 5 Turbine housing 18 Visually inspect for damage and excess temperature dam age such as cracking pitting warping erosion Reject and replace if damage is excessive 6 Turbine heat shield 16 Replace if cracked or warped 7 Piston ring holder 4 Check piston ring groove width max 1 58 mm 0 0623 and for ...

Page 120: ...ove in the bearing housing 12 Fit a new piston ring 6 into the piston ring holder 4 13 Assemble the piston ring holder assembly into the insert tak ing care not to damage the piston ring 14 Lubricate the O ring 21 and mount the insert into the bear ing housing and retain with the snap ring Ensure that the bevelled edge is turned upward 15 Fit the compressor wheel 1 and lock nut 2 On models that ha...

Page 121: ...Loctite 601 to the threads Note Use a T handle torque wrench together with a univer sal joint to avoid side loading the turbine wheel shaft 19 Fit the bearing assembly into the compressor cover 3 align with the marks fit the V clamp 10 and torque the locknut to 11 Nm 8 ft lb 20 Fit the bearing assembly into the turbine housing align with the marks fit the V clamp and torque the locknut to 11 Nm 8 ...

Page 122: ...ssor Wheel 8 Compressor Cover 11 Bearing bushing 12 Thrust bearing 13 Piston ring 16 Piston ring 28 V Band Clamp 31 Oil Slinger 32 O Ring 33 Oil Deflector 36 Thrust flange 37 Oil Control Ring 38 Heat Shield 43 Insert 51 Clamp 53 Washer 59 Screw 61 Compressor Wheel Locknut 62 Clamp Locknut 64 Snap ring 65 Snap ring 66 Snap ring 70 Gasket Oil Connection 71 Gasket Inlet ...

Page 123: ...ay be heated with a hot air pistol to max 130 C 266 F 5 Using circlip pliers remove the large circlip 66 WARNING Extreme caution is required during re moval 6 Slide out the insert 43 Remove the O ring 32 and the oil slinger 31 7 Carefully withdraw the shaft and remove the piston ring 16 Remove the oil deflector 33 8 Remove the thrust bearing 12 and the thrust flange 36 Using circlip pliers remove ...

Page 124: ...nch together with a univer sal joint to avoid side loading the turbine wheel shaft 18 Referring to the marks made previously fit the bearing hous ing using the V band clamp 28 19 Check the axial and radial clearance See section Checking bearing clearance 20 Referring to the marks made previously fit the compressor cover to the bearing housing using the screws and washers Finally check that the sha...

Page 125: ... cleaner and air cleaner are also changed as directed The initial measure is therefore to check the engine oil and the oil cleaner and if so required to replace the cleaner be fore the new turbo unit is fitted Preferably the engine should be run a few minutes before the new turbo unit is fitted Note As an extra precaution to prevent contaminated oil from reaching the turbocharger a strainer can be...

Page 126: ...d upon 3 Disconnect the charge air hoses from the charge air cooler 4 Fit connection tool 885231 and sealing tool 884232 together with new hoses if needed on the charge air cooler Un screw the pressure tester reduction valve Connect the pressure tester to the charge air cooler 5 Open the shut off valve knob and set the gauge to a pres sure of 70 kPa 10 2 psi with the reduction valve 6 Close the sh...

Page 127: ...sign and Function These illustrations are only examples of the design and function in the cooling systems for various engines 1 Radiator 2 Thermostats 3 Distributor pipe for coolant 4 Coolant pump 5 Coolant filter 6 Oil cooler 7 Charge air cooler ...

Page 128: ...he hottest part of the liner Through a small gap between the liner and the split shelf coolant is led upwards and returns through the cylinder head The coolant space of the cylinder heads is also divided into two horizontal planes This means that coolant entering the head from the block first circulates in the lower section around the valve seats and injector tips where cooling is vi tal The coola...

Page 129: ...r and containing a dosage of corrosion inhibiting additive When a new filter is fitted the anti corrosion additive is quickly leached out by the passing fluid Maximum through flow is 12 liter min Pictures show the TAD version The coolant pump is gearwheel driven and is journalled in a front two row ball bearing and a rear roller bearing A lip seal and a carbon ceramic seal are used to seal out oil...

Page 130: ... belt ten sion device and allow the generator to hang in the bracket 4 Remove the belt pulley Remove the holder for the coolant pump s sealing ring 5 Remove the central screw Remove the flange for the belt pulley with puller 999 6860 6 Disconnect the coolant connection at the thermostat hous ing 7 Disconnect the connection at the engine block 8 Remove the coolant pump s end cover Remove the coolan...

Page 131: ...he engine block and thermostat housing Use new sealing rings 3 Fit the flange for the belt pulley Use a torque wrench for the central screw Torque 60 Nm 44 3 ft lb 4 Replace the sealing ring in the sealing ring holder using tool 999 2000 and 999 2929 Scrape the mating surfaces clean Apply a bead of sealant and fit the holder for the sealing ring 5 Screw the belt pulley tight Fit the drive belt bel...

Page 132: ...eller Note Use a screwdriver to counter the coolant pump drive 3 Pull the impeller off of the pump shaft using a bolt size M10 x 70 Note Use a screwdriver to counter the coolant pump drive Turn the pump about face in the vise Remove the circlip holding the bearing and shaft in the pump housing 5 Remove the pump from the vise 6 Remove the set screws 3 holding the ball bearing in the pump housing 7 ...

Page 133: ...ss to bring the drive side facing up 10 Press out the seals 2 and the deflector ring with drift 999 1801 inserted through the roller bearing 11 Turn the pump over to put the drive side facing down Press the ball bearing out of the pump housing using tools 999 1801 and 999 2061 Remove the pump housing from the press 12 Press the gear wheel and the inner ring of the roller bear ing off the pump shaf...

Page 134: ... 999 2412 in the press Oil the pump shaft Press the pump shaft into the bearing Press un til the shaft edge bottoms against the bearing 15 Heat the stop ring to 160 C 320 F Press the ring onto the pump shaft until it stops against the inner race of the bearing 16 Heat the gear wheel to 160 C 320 F Press the gear wheel onto the pump shaft using tool 999 6998 Press until it bottoms Note 999 6998 is ...

Page 135: ...he outer race of the roller bearing Put the bearing with the text facing upwards into the pump housing Press the bearing into position using tool 999 6998 Press until its stops 20 Turn the coolant pump over to bring the drive side facing down in the press 21 Grease the edge of the seal Put the seal into the pump with the metal edge facing upwards 22 Press in the seal with tool 999 8000 Press until...

Page 136: ...ing 24 1 Pump shaft 2 Bearing race roller bearing 3 Gear wheel 4 Stop ring 5 Ball bearing Fit the pump shaft complete with ball bearing stop ring gear wheel and roller bearing race into the pump housing 25 Press in the pump shaft until the ball bearing is about 2 mm 0 080 from the circlip groove in the pump housing 26 Fit the circlip into the pump housing ...

Page 137: ...ecure the screws with locking fluid Part No 1161053 0 29 Turn the pump over in the hydraulic press to bring the drive side facing down Position the pump in the press so that the pump shaft is free and the walls of the pump shaft take up the pressing force 30 Mount the deflector ring onto the pump shaft with the edge facing down 31 Press on the deflector ring until tool 999 8000 bottoms against the...

Page 138: ...pump housing 33 Press in the seal with tool 999 6998 Mount dial indicator 998 9876 on tool 999 6999 Set the dial indicator so that it shows 20 0mm 0 8 against a flat surface 35 Position the pump in the press so that the pump stands on its shaft with the drive side facing down ...

Page 139: ...ump shaft 37 Place 999 6999 on the impeller so that the dial indicator probe is on the edge of the pump housing 38 Apply pressure to the impeller on the pump shaft until the dial indicator shows 15 2 mm 0 5988 39 Remove 999 6998 from the pump Check that the center of the impeller is 4 8 mm 0 1890 above the edge of the pump housing 40 Fit the screw in the center of the impeller ...

Page 140: ...n the coolant pump hous ing 2 Press on the new bearing 6 and the bearing shaft 5A with punch 999 2412 11 Install protective shield 7 spacer ring 8 and snap ring 9 Note Turn the spacer ring chamfer and lock ring shoulders towards the bearing Note All numbers in parenthesis refer to the illustration above the text 1 Note Mark the position of the gable 3 on the coolant pump housing 2 prior to removal...

Page 141: ...e between the shaft 5 and the press tool so the shaft is level with edges of the coolant pump housing Apply bearing grease and press the shaft 5 into the bearing shaft 5A 16 Screw 999 6315 into the bearing journal 5A where the belt pulley 4 is located until it bottoms Place a washer between the impeller and the press tool so the shaft 5 may protrude through the washer The washer should be 2 mm 0 0...

Page 142: ...sealing ring contact surfaces in the housing 7 Fit the new sealing ring to drift 999 6863 Note Fit the sealing ring with the wide metal edge facing up ward Drain the coolant 2 Remove the pipe between the thermostat housing and the upper radiator hose Push the pipe to one side 3 Remove the pipe between the coolant pump and the thermo stat housing 4 Remove the thermostat housing 5 Remove the thermos...

Page 143: ...fitting a new one Thermostats are removed according to the instructions shown under Sleeve thermostats replac ing 1 Check that the thermostat has closed fully This can be done by holding it up against the light There must be no visible gap If the thermostat does not close properly replace it 2 Heat water in a receptacle to TAD1630G TAD1631G TD164KAE 75 C 167 F Others 70 C 158 F Immerse the thermos...

Page 144: ...ipes as one unit 8 3 Disconnect the rear coolant pipe from the oil cooler 4 Remove screws 4 that hold the oil cooler to the center plate on the engine block 5 Disconnect the oil cooler from the front coolant pipe 6 Disconnect all pipe connections Disconnect electrical cables and engine temperature sen sor 9 Disconnect the coolant pipe from the thermostat housing 10 Remove the sealing rings 3 from ...

Page 145: ...the front coolant pipe 15 Bolt the oil cooler to the center plate and the cylinder block 16 Fit the rear coolant pipe to the oil cooler together with the new sealing rings 17 Fit the new seals to the coolant manifold 18 Fit the manifold as one unit 19 Restore the engine temperature sensor and the electrical connections 20 Fill with coolant 21 Replace the oil lost when the oil cooler was removed 22...

Page 146: ...ay to prevent corrosion is to use a suitable mixture of genuine Volvo Penta anti freeze glycol all year round at least 40 When there is never any danger of freezing and if a water glycol mixture is not used year round use water with Volvo Penta anti corrosion additives Part No 1141526 2 Anti corrosion additive is available in quantities of 1 2 liter Mixing ratio 1 30 Clean the cooling system thoro...

Page 147: ...gine has been started and has reached operating temperature Any remain ing air must be removed The engine must not be started un til the system has been vented and completely filled WARNING Do NOT open the pressure cap bleed cock when the engine is hot Steam or hot coolant can spray out and the system pressure will be lost The pressure loss means that circulation in the sys tem can be impaired lea...

Page 148: ...ial to remove all oxalic acid otherwise the remains can increase the risk of further corrosion 4 Dissolve 200 grams 7 oz of bicarbonate sodium hydro gen carbonate in 5 liters 5 3 qt of water an pour into the cooling system Top up with clean water Note Never use soda sodium carbonate Na2 CO3 as in correct handling can result in severe corrosion damage Checking radiator and charge air cooler Should ...

Page 149: ...k to make sure that there are no leaks Cooling system pressure testing Special tools 999 6662 998 9860 with compressed air and 999 6433 Or use standard pressure testing gear Checking pressure testing device 999 6662 Before using the pressure testing equipment it must be checked as follows A Check that the knob on the relief valve A is fully opened and connect the test device to the compressed air ...

Page 150: ...n among other things damage the coolant pump seal Note Always follow applicable safety regulations 7 Remove the testing device Pressure valve checking The pressure valve is located in the filler cap For this test the same pressure testing device is used as for testing for leakage in the cooling system See previous section 1 Drain part of the coolant and connect the pressure testing device with a n...

Page 151: ...ors the following is applicable IMPORTANT Never break the circuit between alter nator and battery when the engine is running The main switch must therefore not be switched off until the engine has stopped 1 Cables shall not be disconnected while the engine is running since this can also damage the voltage regulator 2 Batteries battery cables and cable terminals shall be checked regularly The batte...

Page 152: ...tch 6 Notice Later versions of stop solenoids have built in transient protection Therefore only a separate transient protection 7 for the Control Unit is required 1 Control Unit 5 Fuse fast 8A 9 Engine speed pickup for overspeed protection 2 Actuator 6 Main switch 10 Engine speed switch rpm switch 3 Pickup 7 Transient protection 11 Relay 4 Multi turn potentiometer 8 Stop solenoid Fuel shut off val...

Page 153: ...acle for auto matic stop shutdown in case of fault 13 Relay for starter heater 14 Starter heater 15 Starter motor 16 Battery 17 Alternator 18 Start relay 19 Coolant temp sensor 20 Coolant temp switch normally open 21 Oil pressure sensor 22 Oil pressure switch normally open 23 Coolant level switch option 24 Stop solenoid diagram 1 Fuel shut off valve diagram 2 energized during operation 25 Horn 26 ...

Page 154: ...code BL Blue OR Orange LBL Lightblue VO Violet BN Brown R Red LBN Lightbrown SB Black GN Green W White GR Grey Y Yellow Battery cable areas are related to battery positioning Distance starter motor batteries max 2 m 6 5 ft area 70 mm2 max 4 m 6 5 ft area 120 mm2 Relationshipmm2 AWG AmericanWiringGauge mm2 1 0 1 5 2 5 10 16 2 Instrument panel and engine except TWD1620 and ...

Page 155: ...ue VO Violet BN Brown R Red LBN Lightbrown SB Black GN Green W White GR Grey Y Yellow Battery cable areas are related to battery positioning Distance starter motor batteries max 2 m 6 5 ft area 70 mm2 max 4 m 6 5 ft area 120 mm2 Relationshipmm2 AWG AmericanWiringGauge mm2 1 0 1 5 2 5 10 16 AWG 16 17 15 16 13 7 5 2 Instrument panel and engine for TWD1620 and TID162 ...

Page 156: ...rrent relay operating current and instrument 4 Alarm separator 5 Connection 6 Terminal block extra receptacle fused for 16A Receptacle for automatic stop shutdown in case of fault 7 Warning lamp high coolant temp option 8 Warning lamp low coolant level option 9 Warning lamp low oil pressure option 10 Terminal block for engine cables 11 Coolant temp switch normally open 12 Oil pressure switch norma...

Page 157: ...Connection of time relay kit accessory for connection of starter heater 1 Time relay 2 Contact piece 8 pole 3 Ignition switch 4 Temperature switch option 5 Starter heater 6 Indicator lamp starter heater connected 7 Battery 8 High output relay for starter heater 9 Fuse 8A ...

Page 158: ...n the contacts Clean them and spray with damp in hibitor spray See Wiring diagrams Faulty ignition switch start button Replace ignition switch start button Faulty start relay Replace start relay Faulty starter motor solenoid Check starter motor solenoid Water in compression chamber Do not make any more attempts to start if you suspect water in compression chamber Check the engine Starter motor tur...

Page 159: ...e interlock button and the re lay for the starter heater Insufficient air flow to engine Blocked combustion air intake Check air intake for blockage 2 Engine starts but stops again or runs unevenly CAUSE REMEDY Air in fuel system Bleed the fuel system See Fuel system bleeding No fuel fuel cocks closed Open the fuel cocks fuel tank empty Fill with fuel fuel filters clogged due to contaminants keros...

Page 160: ... reach correct speed at wide open throttle CAUSE REMEDY Engine overloaded If possible reduce the load Insufficient fuel flow fuel filters clogged due to contaminants kerosene Fit new fuel filters pre filters and or fine filters precipitation in the fuel as a result of low outside temperature Bleed the system See Fuel system bleeding Water in fuel Clean fuel tank Drain water from pre filter if any ...

Page 161: ...ion Check that the stop lever is in full operating position 6 Engine runs on CAUSE REMEDY One of the semi automatic fuses in the junction box has Reset the fuse by pressing the button tripped position 5 in the engine wiring diagram Poor contact breaks in connections and electrical cables Rectify any open circuits loose connections Check for oxi dation on the contacts Clean them and spray with damp...

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Page 163: ... this page write your comments down and send them to us The address is at the bottom We would prefer you to write in English or Swedish From Refers to publication Publication No Date of issue Proposal Justification Date Signed AB Volvo Penta Teknisk Information Avd 42200 SE 405 08 Göteborg Sweden ...

Page 164: ...7742302 English 10 2002 ...