Tad1642ge руководство по эксплуатации

Характеристики

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  Workshop and repair manual

  VVOOLLVVOO

  EENNGGIINNEE

  TTAADD11664400&&11664411&&11664422GGEE

  TTAADD11664411&&11664422VVEE

  7746012 7746022 — 774603209/2004

  33525071901_0_1

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  Workshop Manual

  Group 20 Technical Data

  TAD1640GE, TAD1641GE, TAD1642GE

  TAD1641VE, TAD1642VE

  I

  1(0)

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  Technical data

  Engine

  TAD1640GE, TAD1641GE, TAD1642GETAD1641VE, TAD1642VE

  Contents

  Safety
  information………………………………………… 2

  General information
  ……………………………………… 5

  Technical data

  General
  ………………………………………………………
  6

  Engine
  ……………………………………………………….
  6

  Valve mechanism ………………………………………..
  8

  Timing gear
  ………………………………………………… 11

  Reciprocating components …………………………….
  13

  Lubrication and oil systems……………………………
  16

  Fuel
  system………………………………………………..
  18

  Inlet and exhaust system ………………………………
  19Cooling system
  …………………………………………… 20

  Engine control system ………………………………….
  21

  Tightening torque
  ………………………………………… 22

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  Group 20General instructions

  Safety information

  This workshop manual contains technical data, des-criptions and
  repair instructions for the Volvo Penta

  products or product versions noted in the table of con-tents.
  Check that you have the correct Workshop Ma-nual for your
  engine.

  Check that the warning or information labels onthe product are
  always clearly visible. Replacelabels which have been damaged or
  paintedover.

  Never start the engine without the air cleaner fil-ter fitted.
  The rotating compressor turbine in theturbocharger can cause severe
  injury. Foreignobjects entering the intake ducts can also
  causemechanical damage.

  Never use start spray or similar products to aidstarting. They
  may cause an explosion in the in-let manifold. Danger of personal
  injury.

  Only start the engine in a well- ventilated area.When operated
  in a confined space, exhaust fu-mes and crankcase gases must be
  ventilatedfrom the engine bay or workshop area.

  Avoid opening the coolant filler cap when theengine is hot.
  Steam or hot coolant can sprayout and the system pressure will be
  lost. When

  needed, open the filler cap slowly and releasethe pressure in
  the system. Be extremely care-ful if a tap, plug or coolant hose
  has to be remo-ved from a hot engine. It is difficult to
  anticipatein which direction steam or hot coolant canspray out.

  Hot oil can cause burns. Avoid getting hot oil onthe skin.
  Ensure that the lubrication system isnot under pressure before
  carrying out any work

  on it. Never start or operate the engine with theoil filler cap
  removed, otherwise oil could beejected.

  Important

  In this book and on the product you will find the follo-wing
  special warning symbols.

  WARNING!Possible danger of personal injury,extensive damage to
  property or serious mecha-

  nical malfunction if the instructions are not follo-wed.

  IMPORTANT! Used to draw your attention to so-mething that can
  cause damage or malfunctionson a product or damage to property.

  NOTE: Is used to call attention to importantinformation, to
  facilitate work processes or operations.

  To give you a perspective of the risks which alwaysneed to be
  observed and precautions which alwayshave to be taken, we have
  noted them below.

  Immobilize the engine by turning off the powerwith the main
  switch(es) and locking it (them) inthe off position before starting
  service work. Fixa warning notice at the engine control point.

  All service work should normally be done on astationary engine.
  Some work however, such asadjustments, needs the engine running.
  Ap-

  proaching an engine which is operating is a sa-fety hazard.
  Remember that loose clothing orlong hair can fasten in rotating
  parts and causeserious personal injury.If work is done adjacent to
  a running engine, acareless movement or a dropped tool can lead,in
  the worst case, to personal injury. Take careto avoid contact with
  hot surfaces (exhaust pi-pes, Turbocharger (TC), air intake pipe,
  starterheater etc.) and hot liquids in lines and hoses onan engine
  which is running or which has justbeen stopped. Reinstall all
  protective parts

  removed during service operations before star-ting the
  engine.

  Read the available safety information, General in-formation and
  Repair instructions in the work-

  shop manual before you start to do any servicework.

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  General instructionsGroup 20

  Stop the engine before carrying out operationson the engine
  cooling system.

  Always use protective glasses or goggles whencarrying out work
  where there is a risk of splint-ers, grinding sparks, acid splashes
  or where oth-

  er chemicals are used. Your eyes are extremelysensitive, injury
  could cause blindness!

  Avoid getting oil on the skin! Repeated exposureto oil or
  exposure over a long period can resultin the skin becoming dry.
  Irritation, dryness, ec-zema and other skin problems can then
  occur.Used oil is more dangerous than fresh oil from ahealth
  aspect. Use protective gloves and avoidoil soaked clothes and shop
  rags. Wash regular-ly, especially before eating. There are
  special

  skin creams which counteract drying out of theskin and make it
  easier to clean off dirt afterwork is completed.

  Most chemicals intended for the product (e.g.engine and
  transmission oils, glycol, gasolineand diesel oil) or chemicals for
  workshop use(e.g. degreasers, paints and solvents) are hazar-dous.
  Read the instructions on the productpackage carefully! Always
  follow the safety pre-cautions for the product (for example use
  of

  breathing mask, eye protection, gloves etc.).Make sure that
  other personnel are not unkno-wingly exposed to hazardous
  chemicals, for ex-ample via the air. Ensure good ventilation in
  thework place. Follow the instructions providedwhen disposing of
  used or leftover chemicals.

  Exercise extreme care when leak detecting onthe fuel system and
  testing the fuel injectornozzles. Use eye protection. The jet from
  a fuelinjector is under very high pressure, and has

  considerable penetration ability; fuel can forceits way deep
  into body tissues and cause seri-ous damage. Danger of blood
  poisoning (septi-cemia).

  WARNING!The injector pipes must under nocircumstances be bent or
  reshaped. Damagedpipes must be replaced.

  All fuels, and many chemicals, are flammable.Do not allow naked
  flame or sparks in the vicini-ty. Certain thinner products and
  hydrogen frombatteries are easily ignitable and are explosivewhen
  mixed with air in the right proportions. NoSmoking! Ensure that the
  work area is well ven-tilated and take the necessary safety
  precau-

  tions before starting welding or grinding work. Al-ways ensure
  that there are fire extinguishers athand when work is being carried
  out.

  Make sure that oil and fuel soaked rags, andused fuel and oil
  filters are stored in a safe pla-ce. Rags soaked in oil can
  spontaneously igniteunder certain circumstances. Used fuel and
  oilfilters are polluting waste and must be handed toan approved
  waste management facility for de-struction, together with used
  lubrication oil, con-

  taminated fuel, paint residue, solvents, degreas-ers and wash
  residue.

  Never expose a battery to naked flameor electrical sparks. Never
  smoke close to thebatteries. The batteries give off hydrogen
  gasduring charging which when mixed with air canform an explosive
  gas — oxyhydrogen. This gasis easily ignited and highly explosive.
  A spark,which can be formed if the batteries are wronglyconnected,
  is enough to make a battery explode

  and cause damage. Do not shift the connectionswhen attempting to
  start the engine (spark risk)and do not lean over any of the
  batteries.

  Always ensure that the Plus (positive) and Mi-nus (negative)
  battery cables are correctly in-stalled on the corresponding
  terminal posts onthe batteries. Incorrect installation can result
  inserious damage to the electrical equipment. Re-fer to the wiring
  diagram.

  Always use protective goggles when chargingand handling the
  batteries. Battery electrolytecontains sulfuric acid which is
  highly corrosive.Should the battery electrolyte come into
  contactwith unprotected skin wash off immediatelyusing plenty of
  water and soap. If you get bat-tery acid in your eyes, flush at
  once with a ge-nerous amount of water, and get medical assis-tance
  at once.

  Stop the engine and turn off the power at themain switch(es)
  before carrying out work on theelectrical system.

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  Allmnna anvisningar

  4

  Grupp 20

  The clutch must be adjusted with the enginestationary.

  Use the lifting eyes fitted on the engine whenlifting the drive
  unit. Always check that thelifting equipment used is in good
  condition and

  has the load capacity to lift the engine (engineweight including
  gearbox, if fitted, and any extraequipment installed).Use an
  adjustable lifting beam, or lifting beamspecifically for the
  engine, to raise the engine toensure safe handling and to avoid
  damagingengine parts installed on the top of the engine.All chains
  and cables should run parallel to eachother and as perpendicular as
  possible in rela-tion to the top of the engine.If other equipment
  connected to the engine hasaltered its center of gravity, special
  lifting devi-

  ses may be needed to obtain the correct balan-ce and safe
  handling.Never carry out work on an engine suspendedon a hoist.

  Never work alone when heavy components areto be dismantled, even
  when safe lifting devisessuch as lockable blocks & tackle are
  used.When using a lifting device two people are usu-ally required
  to do the work, one to take care ofthe lifting device and another
  to ensure thatcomponents are lifted clear and not damagedduring the
  lifting operations.

  Always make sure that there is enough spacefor disassembly where
  you are working, with norisk for personal or material damage.

  WARNING!The components in the electricalsystem and in the fuel
  system on Volvo Pentaproducts are designed and manufactured to
  mi-nimize the risk of fire and explosion. The enginemust not be run
  in areas where there are explo-sive materials.

  Always use fuels recommended by Volvo Pen-ta. Refer to the
  Instruction Book. Use of fuelsthat are of a lower quality can
  damage the engi-ne. On a diesel engine poor quality fuel can cau-se
  the control rod to seize and the engine tooverrev with resulting
  risk of damage to the eng-ine and personal injury. Poor fuel
  quality canalso lead to higher maintenance costs.

  Remember the following when washing with ahigh pressure washer:
  Never aim the water jet atseals, rubber hoses or electrical
  components.Never use a high pressure washer for enginecleaning.

  The injectors can leak fuel when the engine isstationary, if the
  tank is higher than the engineand the fuel pressure is
  positive.

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  Group 20

  General information

  Certified engines

  The manufacturer certifies that both new engines andthose in
  use, which are certified for national or regio-nal legislation,
  comply with the environmental require-ments. The following
  requirements for service andspare parts must be complied with, for
  Volvo Penta asa manufacturer to be responsible for ensuring
  thatengines in use comply with the stipulated environmen-tal
  requirements:

  Maintenance and service intervals recommendedby Volvo Penta must
  be complied with.

  Only Volvo Penta Original Spare Parts intendedfor the certified
  engine version may be used.

  Service related to injection pumps, pump settingsand injectors
  must always be done by an authori-zed Volvo Penta workshop.

  The engine must not be converted or modified inany way, except
  for the accessories and servicekits which Volvo Penta has approved
  for the engi-ne.

  Installation changes to the exhaust pipe and theengine bay air
  inlet ducts (ventilation ducts) mustnot be done without further
  discussion, since this

  could affect exhaust emissions.

  No tamper-seals may be broken by unauthorizedpersonnel.

  The general advice in the instruction book about ope-ration,
  care and maintenance, applies.

  IMPORTANT!When spare parts are needed,use only Volvo Penta
  Original Spares.

  The use of non-original spare parts means thatAB Volvo Penta can
  no longer be responsiblefor guaranteeing that the engine complies
  with

  the certified version.Any damage, injury and/or costs which
  arise dueto the use of non-original Volvo Penta spares forthe
  product in question will not be compensatedby Volvo Penta.

  About this Workshop Manual

  This workshop manual contains engine descriptionsand repair
  instructions for the standard versions ofTAD1640GE, TAD1641GE,
  TAD1642GE, TAD1641VEand TAD1642VE engines.

  The workshop manual, Technical data section, con-tains
  specifications and tightening torques for thestandard versions of
  TAD1640GE, TAD1641GE,TAD1642GE, TAD1641VE and TAD1642VE
  engines.This document contains all the references from theWorkshop
  manual.

  The Engine Designation and Engine Numbers can befound on the
  product plate.Please always include both the engine designationand
  the engine number in all correspondence.

  The Workshop Manual is produced primarily for theuse of Volvo
  Penta workshops and qualified Volvoservice technicians. For this
  reason the manual pres-upposes a certain basic knowledge and that
  the usercan carry out the mechanical/electrical work describedto a
  general standard of engineering competence.

  Volvo Penta products are under a continual process ofdevelopment
  and we therefore reserve all rights regar-ding changes and
  modifications. All the information in

  this manual is based on product specifications availa-ble at the
  time the book was published. Any materialchanges introduced into
  the product or service met-hods after this date are notified by
  means of ServiceBulletins.

  Spare parts

  Spare parts for the electrical and fuel systems aresubject to
  various national safety requirements. VolvoPenta Original Spares
  comply with these require-ments. No damage whatever, occasioned by
  use ofnon-original Volvo Penta spares for the product, willbe
  compensated by the warranty offered by VolvoPenta.

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  Technical data

  7

  Group 20

  Cylinder head

  Type
  …………………………………………………………….
  6 cyl

  Length
  …………………………………………………………..
  1194 mm (47.2″)

  Width
  ……………………………………………………………
  438 mm (17.24″)

  Height
  …………………………………………………………..
  135 mm (5.31″)

  Max. out-of-flatness (base plane)*……………………..
  0.02 mm (0.000787″)

  *on 100 mm (3.937″) measured length

  Cylinder head bolts

  Number of bolts
  ……………………………………………..38

  Dimension, thread
  ………………………………………….. M18

  Length
  …………………………………………………………..
  188 mm (7.40″)

  Cylinder liner

  Type
  …………………………………………………………….
  Wet, replaceable

  Height, total.
  …………………………………………………. 288 mm
  (11.34″)

  Sealing surface height above block plane ………….. 0.15 —
  0.21 mm (0.00612 — 0.00862″)No. of seal rings per cylinder liner
  ……………………..3

  Piston

  Type
  …………………………………………………………….
  aluminum

  Height above engine block plane ……………………….
  0.15 — 0.65 mm (0.00612 — 0.0256″)

  Diameter, combustion chamber ………………………… 98
  mm (3.86″)

  Depth, piston bowl:

  TAD1640GE………………………………………………..
  19.35 mm (0.76″)

  TAD1641GE………………………………………………..
  21.15 mm (0.83″)

  TAD1642GE………………………………………………..
  21.15 mm (0.83″)TAD1641VE
  ……………………………………………….. 19.35 mm
  (0.76″)

  TAD1642VE
  ……………………………………………….. 19.35 mm
  (0.76″)

  No. of ring grooves
  …………………………………………. 3

  Front
  marking…………………………………………………
  Arrow towards front

  Gudgeon pin diameter
  …………………………………….. 63 mm (2.48″)

  Piston ringsCompression rings

  Specification

  Quantity
  ………………………………………………………..2Piston
  ring clearance in groove:

  upper compression ring …………………………………
  —

  lower compression ring …………………………………
  0.07 mm (0.00276″) Wear tolerance 0.1 mm (0.003937″)

  Piston ring gap, measured at ring opening:

  upper compression ring …………………………………
  0.62 mm (0.00244″) Wear tolerance 0.85 mm (0.003346″)

  lower compression ring …………………………………
  1.1 mm (0.0433″) Wear tolerance 1.35 mm (0.0531″)

  Oil scraper ring

  Quantity
  ………………………………………………………..
  1

  Width, incl. spring
  ………………………………………….. 4.55 mm
  (0.179″)Piston ring clearance in groove,
  ……………………….. 0.04 mm (0.00157″) Wear tolerance 0.1
  mm (0.00393″)

  Piston ring gap, measured at ring opening………….. 0.55 mm
  (0.0216″) Wear tolerance 0.9 mm (0.00354″)

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  8

  Group 20Technical data

  Valve mechanism

  Valves

  Valve head, diameter:

  Inlet
  …………………………………………………………..49
  mm (1.93″)

  Exhaust
  ……………………………………………………..46 mm
  (1.81″)

  Valve stem, diameter:

  Inlet
  …………………………………………………………..10
  mm (0.394″)Exhaust
  …………………………………………………….. 10
  mm (0.394″)

  Valve seat angle (A):

  Inlet
  …………………………………………………………..19,5Exhaust
  ……………………………………………………..44,5

  Seat angle in cylinder head (B):

  Inlet
  …………………………………………………………..20Exhaust
  ……………………………………………………..45

  Dimension between valve head and cylinder head plane:

  Inlet
  …………………………………………………………..0.9
  — 1.4 mm (0.0354 — 0.0551″) Wear tolerance,
  max………………………………….. 1.5 mm (0.059055″)

  Exhaust
  …………………………………………………….. 1.4
  — 1.9 mm (0.0551 — 0.0748″) Wear tolerance, max
  ………………………………….. 2.0 mm (0.07874″)

  Note! When the valve seats are changed, the valves must be
  changed at the same time.

  Valve clearance, cold engine, setting value:

  Inlet
  …………………………………………………………..0.3
  mm (0.0118″)

  Exhaust
  …………………………………………………….. 0.6
  mm (0.0236″)

  Valve clearance, cold engine, check value:

  Inlet
  …………………………………………………………..
  0.25 -0.35 mm (0.00984 — 0.0138″)

  Exhaust
  …………………………………………………….. 0.55
  -0.65 mm (0.0216 — 0.0256″)

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  Technical data

  9

  Group 20

  Valve seats

  Outer diameter (A)

  Standard:

  Inlet
  …………………………………………………………..52
  mm (2.05″)

  Exhaust
  ……………………………………………………..49 mm
  (1.93″)

  Oversize:

  Inlet
  …………………………………………………………..52.2
  mm (2.06″)

  Exhaust
  …………………………………………………….. 49.2
  mm (1.94″)

  Height (B):

  Inlet
  …………………………………………………………..7.7
  mm (0.303″)

  Exhaust
  ……………………………………………………..7.9
  mm (0.311″)

  Valve seat bed

  Diameter (C) standard:

  Inlet
  …………………………………………………………..52.0
  mm (2.05″)

  Exhaust
  …………………………………………………….. 49.0
  mm (1.93″)

  Diameter (C) oversize:

  Inlet
  …………………………………………………………..
  52.2mm (2.06″)

  Exhaust
  …………………………………………………….. 49.2
  mm (1.94″)

  Depth (D):

  Inlet
  …………………………………………………………..11.7
  mm (0.46″)Exhaust
  …………………………………………………….. 11.7
  mm (0.46″)

  Seat base radius (R):

  Inlet
  …………………………………………………………..max
  0.8 mm (0.315″)Exhaust
  …………………………………………………….. max
  0.8 mm (0.315″)

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  Technical data

  10

  Group 20

  Valve guides

  Length:

  Inlet
  ……………………………………………………………83.5
  mm (3.29″)

  Exhaust
  ………………………………………………………
  83.5 mm (3.29″)

  Inner diameter:

  Inlet
  ……………………………………………………………10
  mm (0.39″)

  Exhaust
  ……………………………………………………… 10
  mm (0.39″)Height above cylinder head spring plane:

  Inlet
  ……………………………………………………………
  24.4 1.0 mm (1.00 0.157″)

  Exhaust
  ………………………………………………………
  24.4 1.0 mm (1.00 0.157″)

  Clearance, valve stem — guide*:

  Inlet
  ……………………………………………………………
  0.025 — 0.054 mm (0.00098 — 0.00213″)Wear tolerance max
  ………………………………………. 0.4 mm
  (0.01575″)

  Exhaust
  ………………………………………………………
  0.058 — 0.087 mm (0.00228 — 0.00342″)Wear tolerance max
  ………………………………………. 0.4 mm
  (0.01575″)

  * The dimensions have been calculated for the method of
  measurement described in the workshop manual (Group 21).

  Rocker arms

  Bearing clearance
  ………………………………………….. max 0.1 mm
  (0.00394″)

  Clearance rocker arm roller ………………………………
  max 0.1 mm (0.00394″)

  Valve springs

  Inlet

  Uncompressed length …………………………………..
  67.5 mm (2.66″)

  With 522 N (117.45 lbf) load …………………………..
  57.0 mm (2.24″)

  With 1205 N (271.13 lbf) load …………………………
  43.3 mm (1.70″)

  Coilbound length, max…………………………………..
  40.3 mm (1.59″)

  Exhaust

  Outer valve springs:

  Uncompressed length …………………………………..
  69.3 mm (2.73″)

  With 930 N (209 lbf) load ……………………………….
  54.0 mm (2.13inches)

  With 1813 N (408 lbf) load ……………………………..
  39.5 mm (1.56″)

  Coilbound length, max…………………………………..
  37.0 mm (1.46″)

  Inner valve spring:

  Uncompressed length …………………………………..
  67.0 mm (2.64″)

  With 465 N (105 lbf) load……………………………….
  51.0 mm (2.01″)

  With 887 N (200 lbf) load……………………………….
  36.5 mm (1.44″)

  Coilbound length, max…………………………………..
  34.0 mm (1.34″)

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  Technical data

  11

  Group 20

  Timing gear

  Timing gear wheels

  No. of teeth:

  1 Drive gear, camshaft
  …………………………………….84

  2 Idler wheel,
  adjustable…………………………………..85

  3 Idler wheel, bull gear outer
  …………………………….84

  Idler wheel, bull gear inner ……………………………..
  56

  4 Idler wheel, servo pump
  ………………………………..29

  5 Drive gear, crankshaft
  …………………………………..63

  6 Drive gear, lube-oil pump……………………………….
  37

  7 Drive gear, steering servo and fuel feed pump ….36

  Flank clearance
  …………………………………………….. 0.05-0.17 mm
  (0.00197 — 0.00669″)

  Shaft stub for idler wheel, diameter ……………………
  99.97-99.9999.97 mm (3.9358 -3.9366″)

  Bushing for idler wheel, diameter……………………….
  100.036-100.05 mm ( 3.9384-3.9567″)

  Radial clearance for idler wheel …………………………
  max 0.05 mm (0.00197″)

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  Technical data

  12

  Group 20

  Camshaft

  Check camshaft setting,cold engine andvalve clearance = 0.

  Inlet valve for cylinder 1, with flywheel position 6a.t.d.c.
  shouldbe open 1.4 0.3 mm (0.055 0.012″)

  When performing the check, thetiming gears must be rotated
  clockwise, when seen

  from the front, totake up all gear flank clearance.

  Drive
  …………………………………………………………….gear
  wheelNo of
  bearings………………………………………………..7

  NOTE:Only check values, not for machining.

  Diameter, bearing journals,standard …………………. 69.97
  — 70.00 mm (2.755 — 2.759″)

  Diameter,bearing journals, undersize:

  0,25
  …………………………………………………………..69.72
  — 69.78 mm (2.749 — 2.747″)

  0,50
  …………………………………………………………..69.47
  — 69.53 mm(2.735 — 2.737″)

  0,75
  …………………………………………………………..
  69.22 — 69.28 mm(2.725 — 2.727″)

  Max. end float
  ………………………………………………..0.35 mm
  (0.0138″)

  Max permissible ovality (with new bearings) ………..0.05mm
  (0.00197″)

  Bearing, max. permissible wear on diameter ……….0.05mm
  (0.00197″)Valvelift:

  inlet
  ……………………………………………………………13.7
  mm (0.54″)

  exhaust
  ………………………………………………………14.5
  mm (0.57″)

  Permitted wear between base circleand maxlift
  ………………………………………………..max 0.1 mm
  (0.00394″)

  Unit injector, stroke
  …………………………………………18 mm (0.71″)

  Camshaft bearings

  Camshaft bearing thickness, standard ……………….1.92
  mm(0.076″)

  Oversize:0,25
  …………………………………………………………..2.05
  mm (0.080″)

  0,50
  …………………………………………………………..2.17
  mm (0.085″)

  0,75
  …………………………………………………………..
  2.30 mm (0.090″)

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  Technical data

  13

  Group 20

  Reciprocating components

  Crankshaft

  Length
  …………………………………………………………..
  1256 mm (49.45″)

  Crankshaft, end float*
  …………………………………….. 0.15 mm (0.006″)

  Ovality of main and big end bearings ………………… max
  0.01 mm (0.000394″)

  Taper of main and big end bearings ………………….. max
  0.02 mm (0.000787″)

  Runout on center bearing …………………………………
  0.15 mm (0.006″)

  * Dimensions refer to oiled components.

  Main bearing journal

  NOTE! Only check values, not for machining.

  Diameter () standard
  …………………………………….. 118.0 mm (4.65″)

  Undersize:

  0.25 mm (0.01″)
  ………………………………………….. 117.75 mm
  (4.636″)

  0.50 mm (0.0197″) ……………………………………….
  117.50 mm (4.626″)

  0.75 mm (0.029″)
  ………………………………………… 117.25 mm
  (4.616″)

  1.00 mm (0.039″)
  ………………………………………… 117.00 mm
  (4.61″)

  1.25 mm (0.049″)
  ………………………………………… 116.75 mm
  (4.596″)

  Surface finish, main bearing journal ………………….. Ra
  0.25

  Surface finish, radius
  ………………………………………Ra 0.4

  Width thrust bearing journal (A) standard……………. 49.0
  mm (1.93″)

  Oversize:

  0.2 mm (0.007874″) (thrust bearing 0.003937″)….49.2 mm
  (1.937″)

  0.4 mm (0.01575″) (thrust bearing 0.007874″) ….. 49.4 mm
  (1.945″)

  0.6 mm (0.0236″) (thrust bearing 0.0118″) ……….. 49.6 mm
  (1.952″)

  Web flank radius (R)
  ……………………………………….. 4.5 mm (0.197″)

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  Technical data

  14

  Group 20

  Thrust washers (thrust bearing)

  Width (B) standard
  …………………………………………. 3.18 mm
  (0.125″)

  Oversize:

  0.1 mm (0.004″)
  ………………………………………….. 3.28 mm
  (0.129″)

  0.2 mm (0.008″)
  ………………………………………….. 3.38 mm
  (0.133″)

  0.3 mm (0.012″)
  ………………………………………….. 3.48 mm
  (0.137″)

  0.4 mm (0.016″)
  ………………………………………….. 3.58 mm
  (0.140″)

  Main bearing shells

  Outer diameter (C)
  …………………………………………. 123.12 mm
  (4.847″)

  Thickness (D) standard
  …………………………………… 2.51 mm (0.099″)

  Oversize:

  0.25 mm (0.0098″) ……………………………………….
  2.64 mm (0.104″)

  0.50 mm (0.0197″) ……………………………………….
  2.76 mm (0.109″)

  0.75 mm (0.0295″) ……………………………………….
  2.89 mm (0.114″)

  1.00 mm (0.039″)
  ………………………………………… 3.01 mm
  (0.118″)

  1.25 mm (0.049″)
  ………………………………………… 3.14 mm
  (0.124″)

  Radial clearance, main bearings………………………..
  0.07-0.14 mm (0.00275 — 0.00550″)

  Big end bearing journal

  Note! Only check values, not for machining.

  Diameter ()
  …………………………………………………. 112 mm
  (4.409″)

  Undersize:

  0.25 mm (0.0098″) ……………………………………….
  111.75 mm (4.40″)

  0.50 mm (0.0197″) ……………………………………….
  111.50 mm (4.3897″)

  0.75 mm (0.0295″) ……………………………………….
  111.25 mm (4.380″)

  1.00 mm (0.039″)
  ………………………………………… 111.00 mm
  (4.370″)

  1.25 mm (0.049″)
  ………………………………………… 110.75 mm
  (4.360″)

  Surface finish, big end bearing journal. ………………. Ra
  0.25

  Surface finish, radius
  ………………………………………Ra 0.4Width (A)
  ……………………………………………………….
  60mm (2.36″)

  Web flank radius
  (R)……………………………………….. 4.5 mm
  (0.177″)

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  Technical data

  15

  Group 20

  Big end journal shells

  Outer diameter (B)
  …………………………………………. 116,8 mm
  (4.598″)

  Thickness (C) standard
  …………………………………… 2.35 mm (0.092″)

  Oversize:

  0.25 mm (0.098″)
  ………………………………………… 2.48 mm
  (0.098″)

  0.50 mm (0.0197″) ……………………………………….
  2.60 mm (0.102″)

  0.75 mm (0.029″)
  ………………………………………… 2.73 mm
  (0.107″)1.00 mm (0.039″)
  ………………………………………… 2.85 mm
  (0.112″)

  1.25 mm (0.049″)
  ………………………………………… 2.98 mm
  (0.117″)

  Diameter, bearing shell seat (D) ………………………..
  116,8 mm (4.598″)

  Connecting rod

  Length, center — center (E)
  ………………………………. 280 mm (11.02″)

  Gudgeon pin bush internal diameter (G) …………….. 63 mm
  (2.48″)

  End float, connecting rod — crankshaft1: ………………max
  0.35 mm (0.014″)

  Big end bearing, radial clearance1: …………………….max
  0.10 mm (0.004″)

  Straightness, max. deviation on 100 mm (3.937″)measured length
  ……………………………………………. 0.06 mm
  (0.0024″)

  Twist, max. deviation on 100 mm (3.937″)measured length
  ……………………………………………. 0.15 mm
  (0.006″)1Dimensions refer to oiled components.

  Marking:

  FRONT on the connecting rod faces forwards.The connecting rods
  and caps are marked in pairs, using a three digit serial number
  (please refer to the illustra-tion).

  Flywheel, installed

  Runout, measured radius 150 mm (5.90″) ………….. max 0.1 mm
  (0.004″)

  No. of teeth on starter gear ring …………………………
  153

  Sensor grooves in flywheel
  ………………………………54

  Flywheel housing, installed

  Runout for mating face against bellhousing. ……….. max 0.1
  mm (0.004″)

  Radial runout for alignment against bellhousing. …..max 0.05
  mm (0.002″)

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  Technical data

  16

  Group 20

  Lubrication and oil systems

  Oil

  Oil change volume, incl filters …………………………..
  48 liter (50.7 US quart)

  Oil pressureOperating speed (above 1100
  rpm)……………………. 300 -650 kPa (43.5-94.25 psi)

  Low
  idle…………………………………………………………min
  160 kPa (23.2 psi)

  Oil temperature

  Cold engine
  ……………………………………………………
  ambient temperature

  Hot
  engine……………………………………………………..
  max 125C (257F)

  Lube oil pump

  Type
  …………………………………………………………….
  Gear driven

  No. of teeth, drive wheel
  ………………………………….37

  Flank clearance
  …………………………………………….. 0.05-0.40 mm
  (0.002 — 0.016″)

  Oil filter

  Full flow filter
  …………………………………………………. 2

  Turbofilter (Bypass filter)
  …………………………………. 1

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  18

  Group 20

  Fuel system

  Feed pump

  Feed pressure at:

  600
  rpm………………………………………………………
  min 100 kPa (14.5 psi)

  1200
  rpm…………………………………………………….min
  300 kPa (43.5 psi)

  full load
  ……………………………………………………… min
  300 kPa (43.5 psi)

  Bypass valve

  Opening pressure
  …………………………………………… 400 — 550 kPa
  (58 — 80 psi)

  Fuel quantity

  At low idle and with the engine unloaded, the fuel quantity
  should be inside area B.The engine should be run in at

  least 600 h.

  Unit injector

  Pre-load
  ………………………………………………………..
  3-4 spanner flats (0.75 0.1 mm (0.030 — 0.0040″) ), pleaserefer to
  the illustration.

  Tighten the adjustment screw to zero clearance against the
  camshaft, then turn 3-4 spanner flats.

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  Technical data

  19

  Group 20

  Inlet and exhaust system

  Turbocharger

  Manufacturer/type
  ………………………………………….. l3K/K29

  End float, turbine shaft
  ……………………………………. max 0.13 mm
  (0.005″)

  Inlet temperature indicator

  Cold engine
  ……………………………………………………
  Ambient temperature

  Hot engine, coolant temperature 75-95C(167-203F)
  …………………………………………………… max
  30C above ambient temperature

  Pressure drop indicator

  Pressure drop indicator warns

  at a pressure drop of
  ………………………………………. 5 kPa (37.5 mm VP) (
  0.725 psi)

  Boost pressure

  TAD1640GE…………………………………………………..231
  kPa (33.1
  psi)TAD1641GE…………………………………………………..265
  kPa (38.3
  psi)TAD1642GE…………………………………………………..273
  kPa (39,6 psi)

  TAD1641VE
  …………………………………………………..193 kPa
  (28.0 psi)TAD1642VE
  …………………………………………………..225 kPa
  (32.6 psi)

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  Technical data

  20

  Group 20

  Cooling system

  General

  Pressure cap opens at
  ……………………………………. 75 kPa (10.8 psi)

  ThermostatQuantity
  ………………………………………………………..1

  Opening
  temperature………………………………………. 86C
  (186.80F)

  Fully open
  …………………………………………………….. 96C
  (205F)

  Coolant

  Type
  …………………………………………………………….
  Volvo Original

  Consists of
  …………………………………………………… Glycol
  and corrosion-inhibiting additives

  Color
  …………………………………………………………….
  Green

  Mix with
  ………………………………………………………..
  Tap water

  Corrosion protection

  Only used when anti-freeze is not needed.

  Type
  …………………………………………………………….
  Volvo Original

  Mix with
  ………………………………………………………..
  Tap water

  NOTE: The corrosion inhibitor must not be mixed with other
  typesof coolants or corrosion inhibitors, since this can have
  adverse effects.

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  21

  Group 20

  Engine control system

  Engine control unit

  No. of pins
  ……………………………………………………. 2 x
  36

  SensorCharge pressure sensor

  Check value
  …………………………………………………..1.05 —
  1.30 V at 100 kPa (14.5 psi)

  Camshaft sensor

  Distance to camshaft
  ……………………………………… 1.1 0.4 mm (0.0433 —
  0.0157″)

  Flywheel sensor

  Distance to flywheel
  ……………………………………….. 1.1 0.4 mm (0.0433
  -0.0157″)

  Pressure drop indicator

  Active
  …………………………………………………………..V
  = 0.48 x Ubat

  Inactive
  …………………………………………………………
  V = 0.12 x Ubat

  Charge air temperature sensor

  Engine oil temperature sensorCoolant temperature sensor

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  Technical data

  22

  Group 20

  Tightening torque

  General tightening torques

  M6 standard screw 8.8
  ……………………………………. 10 1.5 Nm (7.4 1 lbf
  ft)

  M8 standard screw 8.8
  ……………………………………. 25 4 Nm (18.5 3 lbf
  ft)

  M10 standard screw 8.8 …………………………………..
  50 8 Nm (37 6 lbf ft)

  M12 standard screw 8.8 …………………………………..
  85 15 Nm (63 11 lbf ft)

  M14 standard screw 8.8 …………………………………..
  140 25 Nm (103 18 lbf ft)

  M16 standard screw 8.8 …………………………………..
  220 35 Nm (162 26 lbf ft)

  Only torqued screws can be re-installed.

  Torque and angle tightened / plastic limit tightened screws:

  8.8
  …………………………………………………………….
  should not be re-installed

  10.9
  …………………………………………………………..
  can be re-installed

  12.9
  …………………………………………………………..
  can be re-installed

  IMPORTANT! Check screws which are to be re-installed. Damaged
  screws, with marks of seizure etc. under theheads, must be
  scrapped.

  Tightening torque, group 21: Engine body

  Front engine mounting, engine block …………………. 220
  35 Nm (162 26 lbf ft)

  Front engine
  mounting…………………………………….. 220 35 Nm (162
  26 lbf ft)

  Rear engine mounting, flywheel housing…………….. 220 35
  Nm (162 26 lbf ft)

  Main bearing caps

  stage
  1……………………………………………………….
  300 20 Nm (220 15 lbf ft)

  stage
  2……………………………………………………….
  120 5 angle tightening

  Big end bearing cap

  stage
  1……………………………………………………….
  20 3 Nm (15 2 lbf ft)

  stage
  2……………………………………………………….
  60 5 Nm (44 4 lbf ft)

  stage
  3……………………………………………………….
  90 5 angle tightening

  Stiffening frame

  NOTE: Tighten in number order, as in the illustration.

  stage
  1……………………………………………………….
  65 5 Nm (48 4 lbf ft)

  stage
  2……………………………………………………….
  60 5 angle tightening

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  23

  Group 20

  Flywheel

  NOTE: Make sure that the flange is clean and dry.

  NOTE: Tighten the screws in number order, as in the
  illustration.

  stage 1
  ………………………………………………………. 60
  5 Nm (44 4 lbf ft)

  stage
  2……………………………………………………….
  120 10 angle tightening

  Flywheel housing

  NOTE: Apply 2 mm (approx 1/8 inch) silicone sealer as in the
  illustration.

  stage 1: Torque all M14 screws to …………………. 160 20
  Nm (118 15 lbf ft)

  stage 2: Torque all M10 screws to ………………….48 8 Nm
  (35 6 lbf ft)

  stage 3: Torque all M8 screws to ……………………24 4 Nm
  (18 3 lbf ft)

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  24

  Group 20

  Vibration damper ………………………………….. 90 10
  Nm (66 7 lbf ft)

  NOTE: Tighten the screws in number order, as in the
  illustration.The 8.8 screws on the vibration damper must not be
  re-used.

  Housing, crankcase seal

  NOTE: Apply 2 mm (approx 1/8 inch) silicone sealer as in the
  illustration.

  stage 1: Tighten all screws by hand.

  stage 2: Torque screws 2 and 7 to ……………… 24 4 Nm (18
  3 lbf ft)

  stage 3: Torque the remaining screws to …………. 24 4 Nm
  (18 3 lbf ft)

  1

  2

  3

  4 5

  6

  7

  8

  3

  1

  4

  2

  56

  7

  8

  10

  9

  12

  11

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  25

  Group 20

  Valve cover ……………………………………………
  25 3 Nm (18.5 2 lbf ft)

  NOTE: Tighten the screws in number order, as in the
  illustration.

  Cylinder head

  NOTE: Tighten the screws in number order, as in the
  illustration.

  stage 1
  ………………………………………………………. 60
  +10Nm

  stage 2
  ………………………………………………………. 90
  5 angle tighteningstage 3
  ………………………………………………………. 90
  5 angle tightening

  — 0

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  Group 20

  Bearing caps, camshaft/rocker arm shaftNote! Tighten the screws
  in stages, to ensure that the rocker arm shaft comes down without
  being bent.

  Stage 1: Tighten screws 1-7 ……………………………15
  3 Nm (11 2 lbf ft)

  Stage 2: Torque screws 1-7 to ………………………… 90
  5 angle tightening

  Stage 3: Tighten screws 8-14.Start with screw 11
  ……………………………100 10 Nm (74 7 lbf ft)

  Stage 4: Tighten screws 15-21 ………………………… 50
  5 Nm (37 4 lbf ft)

  Stage 5: Tighten screws 15-21 ………………………… 120
  5angle tightening

  Stage 6: Loosen screws 8-14 …………………………..

  Stage 7: Tighten screws 8-14………………………….. 50
  5 Nm (37 4 lbf ft)

  Stage 8: Tighten screws 8-14………………………….. 120
  5 angle tightening

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  Group 20

  Timing gear

  1 Driving gear, crankshaftstage
  1……………………………………………………….
  60 5 Nm (44 4 lbf ft)stage
  2……………………………………………………….
  120 10 angle tightening

  2 Idler gear, bull gear, outerTighten in order according to
  illustrationstage
  1……………………………………………………….
  45 5 Nm (33 4 lbf ft)stage
  2……………………………………………………….
  90 5 angle tightening

  3 Idler gear, adjustableTighten screws in order according to
  illustrationstage
  1……………………………………………………….
  35 4 Nm (26 3 lbf ft)stage
  2……………………………………………………….
  120 5 angle tightening

  4 Drive gear, camshaftTighten screws in order according to
  illustrationstage
  1……………………………………………………….
  45 5 Nm (33 4 lbf ft)stage
  2……………………………………………………….
  90 5angle tightening

  5 Drive gear, steering servo and fuel feed pump .100 10 Nm (74 7
  lbf ft)

  6 Drive wheel, air compressor……………………….. 200
  +50 Nm (147.5 +36.88 lbf ft)-0 -0

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  Group 20

  Tightening torque, group 22: Lubrication system

  Oil pan
  ………………………………………………….. 24 4 Nm
  (18 3 lbf ft)

  NOTE: Tighten the screws in number order, as in the
  illustration.

  Oil pump

  stage 1
  ………………………………………………………. 35
  3 Nm (26 2 lbf ft)

  stage
  2……………………………………………………….
  90 5 angle tightening

  Oil cooler, fixing screws ………………………………27
  4Nm (20 3 lbf ft)

  Oil pressure pipe

  stage 1
  ……………………………………………………….
  tighten to zero play

  stage 2pipe diameter 12
  ……………………………………….. 80 10 Nm (59 7 lbf
  ft)pipe diameter 18 ………………………………………..
  110 10 Nm (81 7 lbf ft)

  pipe diameter 20 ………………………………………..
  130 10 Nm (96 7 lbf ft)pipe diameter 22
  ……………………………………….. 170 10 Nm (125 7
  lbf ft)pipe diameter 28
  ……………………………………….. 200 10 Nm (148 7
  lbf ft)

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  Group 20

  Tightening torque, group 23: Fuel system

  Feed pump — steering servo pump…………………….. 25 2Nm
  (18.5 1.5 lbf ft)

  Fixing yoke, unit injector (new copper sleeve)

  First tightening

  Stage 1
  ……………………………………………………… 20
  5 Nm (15 4 lbf ft)Stage 2
  ……………………………………………………… 180
  5 angle tightening

  NOTE:Loosen the fastening yoke screw before performing the
  second tightening.

  Second tightening

  stage
  1……………………………………………………….
  20 5 Nm (15 3.7 lbf ft)

  stage
  2……………………………………………………….
  60 5angle tightening

  Fixing yoke, unit injector (re-used copper sleeve)

  stage
  1……………………………………………………….
  20 5 Nm (15 3.7 lbf ft)

  stage
  2……………………………………………………….
  60 5 angle tightening

  Lock nut for adjuster screw, unit injectorstage
  1……………………………………………………….
  tighten to contactstage
  2……………………………………………………….
  45 5 angle tightening

  Lock nut, valve adjustmentstage
  1……………………………………………………….
  tighten to contactstage
  2……………………………………………………….
  60 5 angle tightening

  Hollow screw M16x1.5 …………………………………….
  50 8 Nm (37 6 lbf ft)

  Hollow screw M10x1
  ………………………………………. 25 4 Nm (18.5 3 lbf
  ft)

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  Group 20

  Tightening torque, group 25: Inlet / exhaust system

  Inlet manifold
  ……………………………………………….24 4 Nm (18
  3 lbf ft)

  NOTE: Apply a 2 mm (approx 1/8″) bead of sealing compound
  1161231-4, as shown in illustration.

  Plug, M10
  ……………………………………………………..20 3
  Nm (15 2 lbf ft)

  Pressure/temperature sensor, charge air ……………. 12 2 Nm
  (9 1.5 lbf ft)

  Exhaust headerStage 1: Tighten screws 1 until they just touch
  (max 10 Nm (7.4 lbf-ft))

  Stage 2: Tighten screws 2 until they just touch (max 10 Nm (7.4
  lbf-ft))

  Stage 3: Tighten screws 3 ……………………………..52
  4 Nm (38 3 lbf ft)

  Stage 4: Tighten screws 2 ……………………………..52
  4 Nm (38 3 lbf ft)

  Stage 5: Tighten screws 4 ……………………………..52
  4 Nm (38 3 lbf ft)

  Stage 6: Tighten screws 1 ……………………………..52
  4 Nm (38 3 lbf ft)

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  Group 20

  ________________________________________________

  ________________________________________________

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  Notes

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  Report form

  Do you have any complaints or other comments about this
  manual.Please make a copy of this page, write your comments down
  and sendthem to us. The address is at the bottom. We would prefer
  you to write inEnglish or Swedish.

  From:
  …………………………………………………………….

  ……………………………………………………………………..

  ……………………………………………………………………..

  ……………………………………………………………………..

  Refers to publication:
  ………………………………………………………………………………………………………………..

  Publication No.: ……………………………. Date of
  issue:
  ……………………………………………………………………..

  Proposal/motivation:
  …………………………………………………………………………………………………………………

  ……………………………………………………………………………………………………………………………………………..

  ……………………………………………………………………………………………………………………………………………..

  ……………………………………………………………………………………………………………………………………………..

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  ……………………………………………………………………………………………………………………………………………..

  Date:
  ……………………………………………………………………….

  Signed:
  ……………………………………………………………………

  AB Volvo PentaTechnical Information

  Dept. 42200

  SE-405 08 Gteborg

  Sweden

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  Workshop Manual

  Group 21-26

  TAD1640GE, TAD1641GE, TAD1642GE

  TAD1641VE, TAD1642VE

  I

  4(0)

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  1

  Workshop Manual

  Group 21-26

  Contents

  Industrial engine

  TAD1640GE, TAD1641GE, TAD1642GETAD1641VE, TAD1642VE

  Safety information
  …………………………………………… 3Introduction
  ………………………………………………………
  3

  General information
  ………………………………………… 6

  About this Workshop Manual ………………………………
  6Flat Rates
  ………………………………………………………..
  6Spare parts
  ………………………………………………………
  6Certified engines
  ………………………………………………. 6

  Repair
  instructions………………………………………….. 7Our
  joint responsibility………………………………………..
  7Torque
  …………………………………………………………….
  7Torque-angle tightening
  ……………………………………… 8Lock nuts
  …………………………………………………………
  8Strength classes
  ………………………………………………. 8Sealant
  ……………………………………………………………
  8Safety rules for

  fluorocarbon rubber
  …………………………………………… 9Special tools
  …………………………………………………. 10Other
  special equipment …………………………………… 14

  Design and function
  ……………………………………….. 15Group 21: Engine
  body…………………………………… 15Cylinder head
  …………………………………………………..
  15Engine block
  ……………………………………………………
  16Cylinder liner
  ……………………………………………………
  17Pistons and connecting rods ………………………………
  18Crankshaft
  ………………………………………………………
  19Camshaft
  ………………………………………………………..
  20Transmission
  ………………………………………………….. 21

  Group 22 Lubrication system …………………………..
  22Piston cooling
  ………………………………………………….
  23Overview, valves
  …………………………………………….. 24Group 23
  Fuel system…………………………………….. 25Unit
  injector, work phases ………………………………….
  27Group 25 Intake and exhaust system ………………..
  29Turbocharger
  ……………………………………………………
  29Group 26 Cooling system ………………………………..
  30

  Troubleshooting / Tests and adjustments………… 31Symptoms
  and possible causes ………………………… 31Operational
  disturbances…………………………………… 32Clogging
  ………………………………………………………….
  32

  Placement of instrument socket ………………………….
  33Sensor overview
  ………………………………………………
  34Compression test
  …………………………………………….. 35Cooling
  system, pressure-testing ……………………….. 38

  Boost pressure, troubleshooting ………………………….
  39Turbocharger, checking
  …………………………………….. 41

  Exposing engine
  ……………………………………………. 42

  Fixture fitting
  …………………………………………………. 44

  Engine body, general overhaul ………………………..
  45Cylinder head,
  removal………………………………………
  45Transmission, removal
  ……………………………………… 56Pistons, removal
  ………………………………………………
  58Crankshaft, removal
  …………………………………………. 59Crankshaft,
  refitting…………………………………………..
  60Cylinder liner, fitting
  …………………………………………. 61Piston,
  pre-fitting………………………………………………
  62Pistons, fitting
  …………………………………………………. 64Piston
  cooling nozzle, fitting ………………………………
  64Transmission,
  fitting…………………………………………. 65

  Cylinder head, refitting
  ……………………………………… 71Camshaft, refitting
  …………………………………………… 74Gear
  backlash, adjusting……………………………………
  75Unit injector, refitting
  ………………………………………… 77Adjustment
  markings ……………………………………….. 79Valves
  and injectors, adjusting ………………………….. 79

  Reconditioning / replacing components ………….. 83Group 21:
  Engine body…………………………………… 83Cylinder
  liner and pistons, inspection ………………….. 83Cylinder
  liner and pistons, replacing (all) ……………… 84Crankshaft,
  inspection ……………………………………… 90Main
  bearings, replacing ……………………………………
  91

  Crank bearing, replacing (all)
  ……………………………… 94Flywheel bearing, replacing
  ……………………………….. 95Flywheel, replacing
  ………………………………………….. 96Ring gear,
  replacing ………………………………………….
  97Flywheel sensor distance, checking…………………….
  98Flywheel, checking for warp ……………………………….
  99Crankshaft seal, front,
  replacing…………………………100Crankshaft seal, rear,
  replacing …………………………. 102Connecting rod,
  checking…………………………………. 104Connecting rod
  bushing, check measurement ……… 104Valves, removal
  ………………………………………………105Valves,
  fitting ………………………………………………….
  107

  Valve seat, replacing
  ……………………………………….108Valve guides,
  inspection …………………………………..110Valve
  guides, replacing …………………………………….
  111Valve seat, grinding
  ………………………………………… 112

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  2

  Valves, grinding
  ………………………………………………113Valve stem
  seals, replacing ……………………………… 114Cylinder
  head, pressure testing …………………………. 116Copper
  sleeve for unit injector, replacing …………….. 119Camshaft,
  checking for wear …………………………….. 123Camshaft
  bearing housing, replacing ………………….. 124Camshaft
  sensor distance, checking ………………….125

  Transmission, replacing
  …………………………………… 126Group 22: Lubrication
  system ………………………… 132When working with
  chemicals, fuel and lubricating oil … 132Overview, control valves
  ………………………………….. 132Pressure reduction
  valve, replacing …………………… 133Bypass valve, oil
  filter, replacing………………………..133Oil pressure
  safety valve, replacing …………………… 134Piston cooling
  valves, replacing ………………………… 134Bypass valve
  oil filters, full flow, replacing ………….. 135Oil filters,
  checking ………………………………………….136Oil
  pressure sensor, checking ……………………………
  136Engine oil and oil filters, replacing
  ……………………… 137Pressure reduction valve, checking
  …………………… 138Safety valve,
  checking……………………………………..138Oil pump,
  replacing …………………………………………. 139Oil
  pump, checking ………………………………………….
  140Oil cooler
  ……………………………………………………….141Oil
  cooler, leakage test
  …………………………………….142Bypass valve oil
  cooler, replacing ……………………… 143Group 23: Fuel
  system…………………………………… 144Draining, fuel
  channel in cylinder head ……………….. 144Control module,
  replacing …………………………………. 145Fuel filters,
  replacing ………………………………………..
  147Primary fuel filter, change
  ………………………………… 148Fuel feed pump,
  replacing ………………………………… 149

  Unit injector,
  replacing……………………………………… 150Venting
  the fuel system ……………………………………153Group
  25: Inlet / exhaust systems …………………… 154Turbo,
  replacing
  ………………………………………………154Group 26:
  Cooling system……………………………… 156Cooling
  system, draining …………………………………..
  156Cooling system, cleaning
  …………………………………. 157Cooling system,
  pressure-testing ………………………. 158Cooling system,
  filling ……………………………………… 159Coolant
  pump, replacing ……………………………………
  160Thermostat, functional check …………………………….
  161Thermostat, replacing
  ……………………………………… 161

  Coolant filter,
  changing……………………………………..162Alternator
  belt/ Drive belt, checking …………………… 163Drive belt,
  changing …………………………………………
  163Alternator belts, changing
  ………………………………… 164

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  Safety information

  _

  3

  Safety information

  Introduction

  This Workshop Manual contains descriptions and ins-tructions for
  the repair of the Volvo Penta products orproduct versions. Check
  that you have the correctWorkshop Manual for your engine.

  Before starting work on the engine, read these sa-fety
  precautions with care as well as General in-formation and Service
  procedures.

  Important

  In this book and on the product you will find the follow-

  ing special warning symbols.

  WARNING!Possible danger of personal injury,extensive damage to
  property or serious me-chanical malfunction if the instructions are
  notfollowed.

  IMPORTANT! Used to draw your attention tosomething that can
  cause damage or malfunc-tions on a product or damage to
  property.

  NOTE: Used to draw your attention to important infor-

  mation that will facilitate the work or operation
  inprogress.

  Below is a summary of the risks involved and safetyprecautions
  you should always observe or carry out

  when operating or servicing the engine.

  Immobilize the engine by turning off the powersupply to the
  engine at the main switch(switches) and lock it (them) turned off
  beforestarting work. Set up a warning notice at the en-gine control
  point.

  As a general rule all service operations must becarried out with
  the engine stopped. However,some work, for example certain
  adjustments re-quire that the engine is running when they
  arecarried out. Approaching an engine which is op-erating is a
  safety hazard. Remember that looseclothing or long hair can fasten
  in rotating partsand cause serious personal injury.

  If work is done adjacent to a running engine, acareless movement
  or a dropped tool can leadto personal injury in the worst case.

  Take care to avoid contact with hot surfaces(exhaust pipes,
  Turbocharger (TC), air intakepipe, starter heater etc.) and hot
  liquids in linesand hoses on an engine which is running orwhich has
  just been stopped. Reinstall all pro-tective parts removed during
  service operationsbefore starting the engine.

  Check that the warning or information labels onthe product are
  always clearly visible. Replacelabels which have been damaged or
  paintedover.

  Never start the engine without installing the aircleaner filter.
  The rotating compressor turbine inthe turbocharger can cause severe
  injury. Fo-reign objects entering the intake ducts can alsocause
  mechanical damage.

  Never use start spray or similar products as astarting aid. They
  may cause an explosion inthe inlet manifold. Danger of personal
  injury.

  Only start the engine in a well- ventilated area. If

  operating the engine in an enclosed area ensurethat there is
  exhaust ventilation leading out ofthe engine compartment or
  workshop area.

  Avoid opening the coolant filler cap when theengine is hot.
  Steam or hot coolant can sprayout and the system pressure will be
  lost. Whenneeded, open the filler cap slowly and releasethe
  pressure in the system. Be very careful if acock or plug or engine
  coolant line must beremoved when the engine is hot. It is difficult
  toanticipate in which direction steam or hot coo-

  lant can spray out.

  Hot oil can cause burns. Avoid getting hot oil onthe skin.
  Ensure that the lubrication system isnot under pressure before
  carrying out any work.Never start or operate the engine with the
  oil fil-ler cap removed, otherwise oil could be ejected.

  Stop the engine before carrying out operationson the engine
  cooling system.

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  4

  Always use protective glasses or goggles whencarrying out work
  where there is a risk of splint-ers, grinding sparks, acid splashes
  or where oth-er chemicals are used. The eyes are
  extremelysensitive. An injury could result in blindness!

  Avoid getting oil on the skin! Repeated exposureto oil or
  exposure over a long period can resultin the skin becoming dry.
  Irritation, dryness andeczema and other skin problems can then
  oc-cur. Used oil is more dangerous than fresh oilfrom a health
  aspect. Use protective gloves andavoid oil soaked clothes and shop
  rags. Washregularly, especially before eating. There arespecial
  skin creams which counteract drying outof the skin and make it
  easier to clean off dirtafter work is completed.

  Many chemicals used on the product (such asengine and
  transmission oils, glycol, gasolineand diesel oil), or chemicals
  used in the work-shop (such as degreasers, paint and solvents)are
  hazardous to health. Read the instructionson the product packaging
  with care! Always fol-low the safety precautions for the product
  (forexample use of protective mask, glasses, glo-ves etc.). Make
  sure that other personnel arenot unknowingly exposed to hazardous
  chemi-cals, for example in the air. Ensure good ventila-tion in the
  work place. Follow the instructions

  provided when disposing of used or leftover che-micals.

  Exercise extreme care when leak detecting onthe fuel system and
  testing the fuel injectornozzles. Use eye protection. The jet from
  a fuelinjector nozzle is under extremely high pressureand has great
  penetrative energy, so the fuelcan penetrate deep into the body
  tissue andcause serious personal injury. Danger of bloodpoisoning
  (septicemia).

  WARNING!The delivery pipes must under nocircumstances be bent.
  Damaged pipes shouldbe replaced.

  All fuels and many chemical substances areflammable. Do not
  allow naked flame or sparksin the vicinity. Certain thinner
  products and hy-drogen from batteries can be extremely flamma-ble
  and explosive when mixed with air in theright proportions. No
  Smoking! Ensure that the

  work area is well ventilated and take the neces-sary safety
  precautions before starting weldingor grinding work. Always ensure
  that there arefire extinguishers at hand when work is beingcarried
  out.

  Ensure that rags soaked in oil or fuel and usedfuel or oil
  filters are stored safely. Rags soakedin oil can spontaneously
  ignite under certain cir-cumstances. Used fuel and oil filters are
  envi-ronmentally dangerous waste and must be depo-sited at an
  approved site for destruction togetherwith used oil, contaminated
  fuel, left over paint,solvents, degreasers and waste from
  washingparts.

  Never expose a battery to naked flame or elec-trical sparks.
  Never smoke close to the batte-ries. The batteries give off
  hydrogen gas duringcharging which when mixed with air can form
  anexplosive gas — oxyhydrogen. This gas is easilyignited and highly
  explosive. A spark, which canbe caused by incorrect battery
  connection, cancause a single spark which is sufficient to cau-

  se an explosion with resulting damage. Do notshift the
  connections when attempting to startthe engine (spark risk) and do
  not lean over anyof the batteries.

  Always ensure that the Plus (positive) and Mi-nus (negative)
  battery cables are correctly in-stalled on the corresponding
  terminal posts onthe batteries. Incorrect installation can result
  inserious damage to the electrical equipment. Re-fer to the wiring
  diagram.

  Always use protective goggles when chargingand handling the
  batteries. Battery electrolytecontains sulfuric acid which is
  highly corrosive.Should the battery electrolyte come into
  contactwith unprotected skin wash off immediatelyusing plenty of
  water and soap. If battery acidcomes in contact with the eyes,
  immediatelyflush with plenty of water and obtain medical
  as-sistance at once.

  Turn the engine off and turn off the power at themain switch(es)
  before carrying out work on theelectrical system.

  Clutch adjustments must be carried out with theengine
  stopped.

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  5

  WARNING! The components in the electricalsystem and in the fuel
  system on Volvo Pentaproducts are designed and manufactured to
  mi-nimize the risk of fire and explosion. The enginemust not be run
  in areas where there are explo-sive materials.

  Always use fuels recommended by Volvo Pen-ta. Refer to the
  Instruction Book. Use of fuelsthat are of a lower quality can
  damage the engi-ne. On a diesel engine poor quality fuel can cau-se
  the control rod to seize and the engine tooverrev with resulting
  risk of damage to the eng-ine and personal injury. Poor fuel
  quality canalso lead to higher maintenance costs.

  Remember the following when washing with ahigh pressure washer:
  Never direct the water jet

  at seals, rubber hoses, electrical components orthe radiator.
  Never use the high pressure featurewhen cleaning an engine.

  Use the lifting eyes fitted on the engine whenlifting the drive
  unit. Always check that thelifting equipment used is in good
  condition andhas the load capacity to lift the engine (engineweight
  including gearbox, if fitted, and any extraequipment installed).
  Use an adjustable liftingbeam or lifting beam specifically for the
  engineto raise the engine to ensure safe handling andto avoid
  damaging engine parts installed on thetop of the engine. All chains
  and cables shouldrun parallel to each other and as perpendicularas
  possible in relation to the top of the engine. Ifextra equipment is
  installed on the engine whichalters its center of gravity a special
  lifting deviceis required to obtain the correct balance for
  safehandling.

  Never carry out work on an engine suspendedon a hoist.

  Never work alone when removing heavy enginecomponents, even when
  using lifting devicessuch as locking tackle lifts. When using a
  liftingdevice two people are usually required to do thework, one to
  take care of the lifting device andanother to ensure that
  components are lifted cle-ar and not damaged during the lifting
  operations.

  Always check before starting work if there isenough room to
  carry out removal work withoutrisking personal injury or damage to
  the engineor parts.

  2004 AB VOLVO PENTA

  We reserve the right to make modifications without prior
  notice.

  Printed on environmentally-friendly paper.

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  General information

  6

  General information

  About this Workshop Manual

  The workshop manual contains a description of the

  engine and instructions for the repair of standard ver-sions of
  engine TAD1640GE, TAD1641GE,TAD1642GE, TAD1641VE and TAD1642VE.

  The workshop manual, Technical data, contains speci-fications
  and torque for standard versions of engineTAD1640GE, TAD1641GE,
  TAD1642GE, TAD1641VEand TAD1642VE. In this book you will find all
  referenc-es from the workshop manual.

  The Engine Designation and Engine Numbers can befound on the
  product plate.Please always include both the engine designation
  andthe engine number in all correspondence.

  The Workshop Manual is produced primarily for the useof Volvo
  Penta workshops and service technicians. Forthis reason the manual
  presupposes a certain basicknowledge and that the user can carry
  out the mecha-nical/electrical work described to a general standard
  ofengineering competence.

  AB Volvo Penta products are under a continual pro-cess of
  development and we therefore reserve all rightsregarding changes
  and modifications. All the informa-tion in this manual is based on
  product specificationsavailable at the time the book was published.
  Any es-sential changes or modifications of the product or revi-sed
  service methods introduced after the date of publi-cation will be
  provided in the form of Service Bulletins.

  Flat RatesOperation numbers that show in instruction
  headingsrefer to Volvo Penta Flat Rates.

  Spare parts

  Spare parts for the electrical and fuel systems are sub-ject to
  various national safety requirements. Volvo PentaOriginal Spare
  Parts meet these specifications. Any typeof damage which is the
  result of using spare parts thatare not original Volvo Penta parts
  for the product in ques-tion will not be covered under any warranty
  or guaranteeprovided by AB Volvo Penta.

  Certified engines

  Manufacturer warrants that both new and currently oper-

  ating engines that are certified to national and
  regionalenvironmental regulations meet environmental require-ments.
  The product must correspond to the engine thatwas approved during
  certification. In order that VolvoPenta, as manufacturer, will be
  able to warrant that en-gines in operation meet environmental
  requirements, thefollowing requirements for service and spare parts
  mustbe met:

  Service and maintenance intervals recommendedby Volvo Penta must
  be followed.

  Only Volvo Penta Original Spare Parts intended forthe certified
  engine version may be used.

  Service work that covers injection pumps, pumpsettings, and
  injectors must always be carried outby an authorized Volvo Penta
  workshop.

  The engine must not be altered or modified in anyway, except for
  accessories and service kitsdeveloped by Volvo Penta for that
  engine.

  No modifications to the exhaust pipes and engineroom air intake
  pipes are allowed.

  Any seals on the engine may not be broken byunauthorized
  persons.

  IMPORTANT!When spare parts are required,use only Volvo Penta
  original parts.

  Use of non-original parts will result in AB Volvo

  Penta being unable to warrant that the engine

  corresponds to the certificated engine version.

  Any type of damages or costs which are the re-sult of using
  spare parts that are not original Vol-vo Penta parts for the
  product in question will notbe paid for by AB Volvo Penta.

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  Repair instructions

  8

  Torque-angle tightening

  When torquing with protractor (angle tightening), thefastener is
  tightened to a predetermined torque andthen turned a predetermined
  angle. Example: a 90protractor tightening means that the joint is
  tightened afurther 1/4 turn in one operation after the stated
  torque

  has been applied.

  Sealant

  A number of sealants and locking liquids are used onthe engines.
  The properties of the preparations differ,and they are intended for
  different strengths of faste-ner, temperature, resistance to oil
  and other chemicals,and for the different materials and gap
  thicknesses

  found in the engine.To ensure service work is correctly carried
  out it is im-portant that the correct sealant and locking fluid
  type isused on the joint where the agents are required.

  In this Volvo Penta Workshop Manual the user will findthat each
  section where these agents are applied inproduction states which
  type was used on the engine.

  During service operations, use the same agent or analternative
  from a different manufacturer.

  Make sure that mating surfaces are dry and free fromoil, grease,
  paint and anti-corrosion agent before apply-

  ing sealant or locking fluid.Always follow the manufacturers
  instructions for useregarding temperature range, curing time and
  any otherinstructions for the product.

  Two different basic types of agent are used on the eng-ine.
  These are:

  RTV agent (Room temperature vulcanizing). Used forgaskets,
  sealing gasket joints or coating gaskets. RTVis visible when a part
  has been disassembled; old RTVmust be removed before resealing the
  joint.

  The following RTV agents are mentioned in the Work-

  shop Manual: Loctite574, PermatexNo. 3, Perma-texNo 77. Old
  sealant can be removed using denatu-red alcohol in all cases.

  Anaerobic agents. These agents cure in an absence ofair. They
  are used when two solid parts, for examplecast components, are
  installed face-to-face without agasket. They are also commonly used
  to secure plugs,threads in stud bolts, cocks, oil pressure switches
  etc.Hardened anaerobic preparations are glassy and forthis reason,
  the preparations are colored to make themvisible. Cured anaerobic
  agents are extremely resistantto solvents and the old agent cannot
  be removed.

  When reinstalling the part, degrease it carefully andthen apply
  new sealant.

  The following anaerobic agents are mentioned in theWorkshop
  Manual: Loctite572 (white), Loctite241(blue).

  NOTE: Loctite is a registered trademark of Loctite
  Corporation,Permatexis a registered trademark of the Permatex
  Corporation.

  Lock nuts

  Do not re-use lock nuts that have been removed duringdisassembly
  operations as these have reduced servicelife when re-used. For lock
  nuts with a plastic insertsuch as Nylockthe torque stated in the
  table is redu-ced if the Nylocknut has the same head height as
  astandard hexagonal nut without plastic insert. Reducethe torque by
  25% for screw size 8 mm or larger.

  Where Nylocknuts are higher, where the metallic th-read is of
  the same height as a standard hexagonalnut, the torques given in
  the as shown in table apply.

  Strength classes

  Screws and nuts are sub-divided into different strengthclasses.
  Classification is indicated by markings on the

  screw head. A higher number indicates a material withgreater
  strength. For example, a screw marked 10-9 isstronger than one
  marked 8-8. For this reason, it is im-portant when fasteners are
  dismantled, that the screwsare put back in the correct places when
  they are re-in-stalled. If a bolt must be replaced, check in the
  spareparts catalogue to make sure the correct bolt is used.

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  Repair instructions

  9

  Safety rules for

  fluorocarbon rubber

  Fluorocarbon rubber is a common material in seal ringsfor
  shafts, and in O-rings, for example.

  When fluorocarbon rubber is subjected to high tempe-

  ratures (above 300C/572F), hydrofluoric acidcan beformed, which
  is highly corrosive. Contact with the skincan result in severe
  chemical burns. Splashes in youreyes can result in severe chemical
  burns. If you brea-the in the fumes, your lungs can be permanently
  dama-ged.

  WARNING!Be very careful when working on eng-

  ines which have been exposed to high temperatu-res, e.g.
  overheating during a seizure or fire. Se-als must never be cut with
  a flame torch duringdisassembly, or burned in uncontrolled
  circums-tances afterwards.

  Always use gloves made of chloroprene rubber (glo-ves for
  handling chemicals) and protective goggles.

  Handle the removed seal in the same way as corro-sive acid. All
  residue, including ash, can be highlycorrosive. Never use
  compressed air to blow anyth-ing clean.

  Put the rest in a plastic jar which is sealed and pro-vided with
  a warning label. Wash the gloves underrunning water before removing
  them.

  The following seals are probably made from fluorocar-bon
  rubber:

  Seal rings for the crankshaft, camshaft, intermediate

  shafts.O-rings, regardless of where they are installed.
  O-ringsfor cylinder liner sealing are almost always made of
  flu-orocarbon rubber.

  Note that seals which have not been subjected tohigh temperature
  can be handled normally.

• 8/12/2019 TAD 1640, 1641, 1642 GE & TAD 1641 y 1642 VE
  Engine _ Workshop and Repair Manual _ 33525071901_0_1 _ Se

  50/276

  Special tools

  10

  885810 Fixture for upper transmission gear casing

  9986173 Puller, flywheel bearing

  9986179 Puller, flywheel bearing9990006 Puller, unit
  injector

  9990013 Slide hammer

  9990107 Connection washer for thermostat housingat cylinder head
  pressure testing

  9990112 Drift, removal of front crankshaft seal

  9990114 Puller for main bearing caps

  9990118 Cone, refitting front crankshaft seal

  9990123 Pressure testing device

  9990124 Nipple for checking of the f

On this page you can find and free download Volvo Penta workshop, service, repair and owner’s manuals in PDF. Also here are wiring diagrams.

Volvo Penta is a Swedish company, part of the Volvo Group, a manufacturer of marine and industrial engines.