Volvo TAD1630G/GE/P/V, TAD1631G/GE, TID162AP, TWD1620G/GH, TWD1630G/GE/P/V, TD164KAE Diesel Engines Service Repair Workshop Manu

Workshop manual TAD1630G/GE/P/V, TAD1631G/GE, TID162AP, TWD1620G/GH, TWD1630G/GE/P/V, TD164KAE

Cylinder liners and pistons, fitting ................................ 45 Sealant between the fuel injection pump bearing housing and the cylinder block: TAD1630/TID162/TWD1620/TWD1630/TD164KAE .... 48 TAD1631 ..................................................................... 49 Seal on output shaft from timing gear to injection pump, replacing: TAD1630/TID162/TWD1620/TWD1630/TD164KAE . 50 TAD1631 ................................................................. 51 Front sealing ring for coolant pump, replacing .............. 53 Sealant, timing gear cover, replacement ...................... 54 Timing gears, removing ............................................... 55 Intermediate gears, replacing bearing .......................... 56 Timing gears, fitting ..................................................... 57 Polygon hub, replacing ................................................ 58 Sealant, transmission gear casing, replacing ............... 59 Camshaft, checking for wear ....................................... 59 Camshaft, replacing .................................................... 62 Camshaft bearings, replacing ...................................... 64 Main bearings, replacing, all ........................................ 66 Crank bearings, checking for wear or replacing, all ..... 67 Crankshaft, replacing .................................................. 68 Crankshaft .................................................................. 69 Inspection ................................................................ 69 Reconditioning ......................................................... 71 Flywheel, checking for warp ........................................ 71 Flywheel, replacing ...................................................... 72 Ring gear, replacing .................................................... 73 Flywheel casing, checking for warp ............................. 73 Flywheel bearing, replacing ......................................... 74 Crankshaft seal, rear, replacing ................................... 75 Crankshaft seal, front, replacing .................................. 76 Sealant, flywheel casing, replacing .............................. 77 Lubrication system ....................................................... 79 Design and Function .................................................... 79 General ....................................................................... 79 Oil cooler ..................................................................... 81 Service procedures ...................................................... 82 Lubricating oil pressure, checking ............................... 82 Oil filters, replacing ...................................................... 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 ........................................................ 21 Exposing engine body ................................................. 21 TAD1630/TAD1631 ..................................................... 21 TID162/TWD1620/TWD1630/TD164 ........................... 21 TAD1630/TAD1631/TID162/TWD1630/TD164 ............ 22 Cylinder head, removing .............................................. 23 Cylinder head, disassembling ...................................... 24 Cylinder head, pressure testing ................................... 25 Cylinder head, inspection ............................................ 26 Cylinder head, face-grinding ........................................ 26 Valve guides, inspection .............................................. 27 Valve guides, replacing ............................................... 28 Valve seats, replacing ................................................. 28 Valve seats, grinding ................................................... 29 Valves, grinding ........................................................... 29 Cylinder head, assembling .......................................... 30 Cylinder head, installation ............................................ 30 Rocker arm mechanism, reconditioning ....................... 33 Valves, adjusting ......................................................... 34 Copper sleeve for injectors, replacing .......................... 36 Cylinder liners and pistons, removing .......................... 37 Cylinder liners, measurement and inspection ............... 40 Cylinder liners, honing ................................................. 40 Cylinder liner seats, reconditioning .............................. 41 Cylinder block, face-grinding ....................................... 42 Pistons, checking ........................................................ 43 Pistons, fitting .............................................................. 43 Piston rings, inspection ............................................... 43 Connecting rods, inspection ........................................ 43 Pistons, piston rings and connecting rods, assembling .................................................................. 44 Workshop manual TAD1630G/GE/P/V, TAD1631G/GE, TID162AP, TWD1620G/GH, TWD1630G/GE/P/V, TD164KAE Contents

2 Fuel system ................................................................... 90 Design and Function .................................................... 90 General ....................................................................... 90 Fuel filters .................................................................... 90 Injection pump ............................................................. 91 TID162AP/TWD1620G/GH/TWD1630/GE ............... 91 TAD1630P/V/TWD1630P/V/TD164KAE .................. 91 TAD1630G/GE y TAD1631G/GE ............................ 92 Smoke limiter TAD1630P/V ......................................... 94 Feed pump .................................................................. 94 Manual pump ............................................................... 94 Instrucciones de reparación ........................................ 95 Service procedures ...................................................... 95 Injection pump, removal ............................................... 95 Fitting and adjusting the injection pump ........................ 95 Injection pump, setting with measuring tool 998 7057 ... 98 Pump coupling shaft, removing .................................. 101 Checking and replacing pump coupling laminates ...... 101 Injectors .................................................................... 101 Injectors, replacing .................................................... 102 Injectors, reconditioning ............................................. 103 Opening pressure, adjusting ...................................... 104 Fuel feed pressure, checking .................................... 104 Fuel filters, replacing .................................................. 105 Feed pump, replacing ................................................ 105 Feed pump, reconditioning ......................................... 106 Smoke limiter, TAD1630P/V ...................................... 107 Replacing the diaphragm ........................................ 107 Fuel system, bleeding ................................................ 108 Intake and exhaust systems ....................................... 109 Design and Function .................................................. 109 Charge air cooler ....................................................... 109 Turbocharger ............................................................. 109 Air filter ...................................................................... 110 Starter heater ............................................................ 110 Exhaust manifold ....................................................... 110 Service procedures .................................................... 111 Boost pressure, checking .......................................... 111 Rectifying low boost pressure ................................... 112 Checking exhaust 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 ..................................................................... 125 Service procedures .................................................... 128 Coolant pump, replacing ............................................ 128 Coolant pump, reconditioning ..................................... 130 Sleeve thermostats, replacing ................................... 140 Sleeve thermostats, checking ................................... 141 Coolant manifold seals, replacing .............................. 142 Coolant ...................................................................... 144 Anti-freeze ................................................................. 144 Volume ...................................................................... 144 Anti-corrosion additives ............................................. 144 Checking coolant level .............................................. 144 Draining the coolant ................................................... 144 Coolant, filling ............................................................ 145 Coolant temperature too high ..................................... 145 Coolant temperature too low ...................................... 145 Temperature gauge, checking ................................... 145 Level switch, checking .............................................. 145 Coolant leakage ........................................................ 146 Radiator and charge air cooler, checking ................... 146 Drive belts, adjusting ................................................. 146 Cooling system, cleaning ........................................... 146 Cooling system, pressure-testing ........................... 147 Checking pressure-testing device 999 6662 .......... 147 Pressure testing ..................................................... 147 Pressure valve, checking ...................................... 148 Electrical system ......................................................... 149 Important ................................................................... 149 Arc welding ............................................................... 149 Starting with auxiliary battery ..................................... 149 Electronic speed governor, wiring .............................. 150 Wiring diagrams ......................................................... 151 Troubleshooting ......................................................... 156

Safety Precautions 3 Safety Precautions If working in proximity of an engine which is operating, careless movements or a dropped tool can result in personal injury. Take care to avoid contact with hot surfaces (exhaust pipes, Turbocharger (TC), air intake pipe, starter heater etc.) and hot liquids in lines and hoses on an engine which is running or which has just been stopped. Reinstall all protective parts removed during service operations before starting the engine. Check that the warning or information labels on the product are always clearly visible. Replace labels which have been damaged or painted over. Never start the engine without installing the air cleaner (ACL) filter. The rotating compressor in the Turbo can cause serious personal injury. Foreign objects entering the intake ducts can also cause mechanical damage. Never use start spray products or similar when starting the engine. They may cause an explosion in the inlet manifold. Danger of personal injury. Avoid opening the coolant filler cap when the engine is hot. Steam or hot coolant can spray out and the system pressure will be lost. When needed, open the filler cap slowly and release the pressure in the system. Be very careful if a cock or plug or engine coolant line must be removed when the engine is hot. It is difficult to anticipate in which direction steam or hot coolant can spray out. Hot oil can cause burns. Avoid getting hot oil on the skin. Ensure that the lubrication system is not under pressure before carrying out any work. Never start or operate the engine with the oil filler cap removed, otherwise 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 operating the engine in an enclosed area ensure that there is exhaust ventilation leading out of the engine compartment or workshop area. Introduction This Workshop manual contains descriptions and instructions for the repair of the Volvo Penta products or product types. Check that you have the correct Workshop manual for your engine. Before starting work on the engine, read these safety precautions with care as well as ”General information” and ”Service procedures”. Important In this book and on the product you will find the following special warning symbols. WARNING! Possible danger of personal injury, exten- sive damage to property or serious mechanical malfunction if the instructions are not followed. IMPORTANT! Used to draw your attention to some- thing that can cause damage or malfunctions on a product or damage to property. Note: Used to draw your attention to important information that will facilitate the work or operation in progress. Below is a summary of the risks involved and safety precautions you should always observe or carry out when operating or servicing the engine. Immobilize the engine by turning off the power supply to the engine at the main switch (switches) and lock it (them) turned off before starting work. Set up a warning notice at the engine control point. As a general rule all service operations must be carried out with the engine stopped. However, some work, for example certain adjustments require that the engine is running when they are carried out. Ap- proaching an engine which is operating is a safety risk. Loose clothing or long hair can fasten in rotating parts and cause serious personal injury.

Safety Precautions 4 Ensure that rags soaked in oil or fuel and used fuel or oil filters are stored safely. Rags soaked in oil can spontaneously ignite under certain circumstances. Used fuel and oil filters are environmentally dangerous waste and must be deposited at an approved site for destruction together with used lubricating oil, contaminated fuel, paint remnants, sol- vent, degreasing agents and waste from washing parts. Never expose a battery to naked flame or electrical sparks. Never smoke in proximity to the batteries. The batteries give off hydrogen gas during charging which when mixed with air can form an explosive gas - oxy- hydrogen. This gas is easily ignited and highly volatile. Incorrect connection of the battery can cause a single spark which is sufficient to cause an explosion with resulting damage. Do not shift the connections when attempting to start the engine (spark risk) and do not lean over any of the batteries. Always ensure that the Plus (positive) and Minus (negative) battery cables are correctly installed on the corresponding terminal posts on the batteries. Incor- rect installation can result in serious damage to the electrical equipment. Refer to the wiring diagrams. Always use protective goggles when charging and handling the batteries. Battery electrolyte contains sul- furic acid which is highly corrosive. Should the battery electrolyte come into contact with unprotected skin wash off immediately using plenty of water and soap. If battery acid comes in contact with the eyes, immediately flush with plenty of water and obtain medical as- sistance at once. Turn the engine off and turn off the power at the main switch(es) before carrying out work on the electrical system. Clutch adjustments must be carried out with the engine stopped. Use the lifting eyes fitted on the engine when lifting the drive unit. Always check that the lifting equipment used is in good condition and has the load capacity to lift the engine (engine weight including gearbox, if fitted, and any extra equipment installed). Use an ad- justable lifting beam or lifting beam specifically for the engine to raise the engine to ensure safe handling and to avoid damaging engine parts installed on 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 carrying 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 oil on the skin! Repeated exposure to oil or exposure over a long period can result in the skin becoming dry. Irritation, dryness and eczema and other skin problems can then occur. Used oil is more dangerous than fresh oil from a health aspect. Use protective gloves and avoid oil soaked clothes and shop rags. Wash regularly, especially before eating. There are special skin creams which counteract dry- ing out of the skin and make it easier to clean off dirt after work is completed. Many chemicals used on the product (for example engine and transmission oils, glycol, gasoline and diesel oil), or chemicals used in the workshop (for example degreasing agents, paint and solvents) are dangerous to health. Read the instructions on the product pack- aging with care! Always follow the safety precautions for the product (for example use of protective mask, glasses, gloves etc.). Make sure that other personnel are not exposed to hazardous chemicals, for example in the air. Ensure good ventilation in the work place. Follow the instructions provided when disposing of used or leftover chemicals. Exercise extreme care when leak detecting on the fuel system and testing the fuel injector nozzles. Use eye protection. The jet from a fuel injector nozzle is under extremely high pressure and has great penetrative en- ergy, so the fuel can penetrate deep into the body tis- sue and cause serious personal injury. Danger of blood poisoning. WARNING! The delivery pipes must under no circumstances be bent. Damaged pipes should be replaced. All fuels and many chemical substances are flammable. Do not allow naked flame or sparks in the vicinity. Fuel, certain thinner products and hydrogen from batteries can be extremely flammable and explosive when mixed with air. Smoking is not to be permitted in the vicinity! Ensure that the work area is well ventilated and take the necessary safety precautions before starting welding or grinding work. Always ensure that there are fire extinguishers at hand when work is being carried out.

Safety Precautions 5 If extra equipment is installed on the engine which alters its center of gravity a special lifting device is required to obtain the correct balance for safe handling. Never carry out work on an engine suspended on a hoist. Never work alone when removing heavy engine components, even when using lifting devices such as locking tackle lifts. When using a lifting device two people are usually required to do the work, one to take care of the lifting device and another to ensure that components are lifted clear and not damaged during the lifting operations. Always check before starting work if there is enough room to carry out removal work without risk- ing personal injury 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 damage the engine. On a diesel engine poor quality fuel can cause the control rod to seize and the engine to overrev with resulting risk of damage to the engine and personal injury. Poor fuel quality can also lead to higher maintenance costs. Observe the following rules when cleaning with high- pressure water jets: Never direct the water jet at seals, rubber hoses, electrical components or the radiator. © 2001 AB VOLVO PENTA We reserve the right to make changes Printed on environmentally-friendly paper

General information Group 20 6 General information About this Workshop manual This Workshop manual contains descriptions and instructions for the repair of engines in standard format. The Engine Designation and Engine Numbers can be found on the product plate (see page 10). Please always include both the engine designation and the engine number in all cor- respondence. The Workshop manual is produced primarily for the use of Volvo Penta workshops and service technicians. For this reason the manual presupposes a certain basic knowl- edge and that the user can carry out the mechanical/electrical work described to a general standard of engineering competence. Volvo Penta products are under a continual process of de- velopment and we therefore reserve all rights regarding changes and modifications. All the information in this manual is based on product specifications available at the time the book was published. Any essential changes or modifications of the product or revised service methods introduced after the date of publication will be provided in the form of Service Bulletins. Spare parts Spare parts for the electrical and fuel systems are subject to various national safety requirements. Volvo Penta Original Spare Parts meet these specifications. Any type of damage which is the result of using spare parts that are not original Volvo Penta parts for the product in question will not be cov- ered under any 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 exhaust emissions are governed by law, it is important to be aware of the following: Certification means that an engine type is controlled and approved by the appropriate authority. The engine manufacturer warrants that all engines of the same type that are being made, are equivalent to the certified engine. The following special requirements regarding service and repairs apply: • Service and maintenance intervals recommended by Volvo Penta must be followed. • Only Volvo Penta Original Spare Parts may be used. • Service work on the injection pump, pump settings, and injectors must always be carried out by an authorized Volvo Penta workshop. • The engine must not be altered or modified in any way, except for accessories and service kits approved by Volvo Penta for that engine. • No modifications to the exhaust pipes and engine air intake pipes are allowed. • Any seals on the engine may not be broken by unau- thorized persons. For other matters, the general instructions in the Instruction Book apply. IMPORTANT! Neglected or substandard operation or service, as well as use of replacement parts other than AB Volvo Penta Original Parts will result in AB Volvo Penta being unable to assume any liability that the engine corresponds to the certificated engine vari- ant. AB Volvo Penta excludes any liability for all and any type of damage or costs caused by the use of replacement parts that are not Volvo Penta Original Parts for the product in question.

Group 20 Service procedures 7 The working methods described in the Workshop manual apply to work carried out in a workshop. The engine has been removed and is installed in an engine fixture. Unless otherwise stated reconditioning work which can be carried out with the engine in place follows the same working method. Warning symbols used in this Workshop manual (for full explanation of the symbols refer to the section ”Safety Pre- cautions”) WARNING! IMPORTANT! Note: are not in any way comprehensive since it is impossible to predict every circumstance under which service work or repairs may be carried out. AB Volvo Penta can only indicate the risks considered likely to occur as a result of incorrect working methods in a well equipped workshop using working methods and tools tested by AB Volvo Penta. All operations described in the Workshop manual for which there are Volvo Penta Special Tools available assume that these tools are used when carrying out the repair. Volvo Penta Special Tools have been specifically de- veloped to ensure as safe and rational working methods as possible. It is therefore the responsibility of anyone using other tools or other working methods than we recom- mend to determine that there is no risk of personal injury or mechanical damage or malfunction as a result. In some cases special safety precautions and user instructions may be required in order to use the tools and chemicals mentioned in the Workshop manual. Always follow these precautions. There are no specific instructions given in the Workshop manual. By following these basic recommendations and using common sense it is possible to avoid most of the risks involved in the work. A clean work place and a clean engine will elimi- nate many risks of personal injury and engine malfunction. Especially when working on the fuel system, engine lubrication system, air intake system, turbocharger unit, bearing seals and seals, it is extremely important to avoid dirt or foreign objects entering the parts or systems, since this can result 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 technical specifications this can have dramatic consequences on the environmental impact of the engine even if it is otherwise in good running order. It is therefore critical that the stated wear tolerances are observed, that systems which can be adjusted are correctly set up and that only Volvo Penta Orig- inal Parts are used on the engine. The stated service intervals in the Maintenance Schedule must be followed. Some systems, such as the components in the fuel system, require special expertise and special testing equipment for service and maintenance. Some components are factory sealed for environmental and product specific reasons. Un- der no circumstances attempt to service or repair a sealed component unless the service technician carrying out the work is authorized to do so. Bear in mind that most chemical products, incorrectly used, are hazardous to the environment. Volvo Penta recommends the use of bio-degradable degreasing agents for all cleaning of engine components unless otherwise stated in the Workshop manual. Pay special attention to make sure that oils and washing residue etc are handled correctly for destruction, and do not unintentionally end up in nature. Torque Correct torque for critical joints which must be tightened using a torque wrench are listed under ”Technical Data - torque” and stated in the method descriptions in the Work- shop manual. All torque data apply to cleaned threads, bolt heads and mating surfaces. Torque data stated apply to lightly oiled or dry threads. Where grease, locking or sealing agents are required for screwed joints this is stated in both the operation description and in ”torque”. Where no torque is stated for a joint use the general torque shown in the table below. The torques stated are a guide and the joint does not have to be tightened using a torque wrench. Dimension Torque Nm M5 ......................................... 6 M6 ....................................... 10 M8 ....................................... 25 M10 ..................................... 50 M12 ..................................... 80 M14 ................................... 140

Group 20 Service procedures 8 Torquing with Protractor tightening (angle tightening) When torquing with protractor (angle tightening), the fastener is tightened to a predetermined torque and then turned a predetermined angle. Example: a 90° protractor tightening means that the joint is tightened a further 1/4 turn in one operation after the stated torque has been applied. Lock nuts Do not re-use lock nuts that have been removed during disassembly operations as these have reduced service life when re-used. For lock nuts with a plastic insert such as Ny- lock ® the torque stated in the table is reduced if the Nylock ® nut has the same head height as a standard hexagonal nut without plastic insert. Reduce the torque by 25% for bolt size 8 mm or larger. Where Nylock ® nuts are higher, where the metallic thread is of the same height as a standard hexagonal nut, the torques given in the table apply. Strength classes Bolts and nuts are divided up into different classes of strength; the class is indicated by the number on the bolt head. A higher number indicates stronger material. For example, a bolt marked 10-9 indicates a higher strength than one marked 8-8. It is therefore important that bolts removed during the disassembly of a bolted joint must be reinstalled in their original position when assembling the joint. If a bolt must be replaced check in the spare parts catalogue to make sure the correct bolt is used. Sealant A number of sealants and locking liquids are used on the engines. The agents have varying properties and are used for different types of jointing strengths, operating temperature ranges, resistance to oil and other chemicals and for the different materials and gap sizes in 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 from a different manufacturer. Make sure that mating surfaces are dry and free from oil, grease, paint and anti-corrosion agent before applying sealant or locking fluid. Always follow the manufacturer’s instructions for use regarding temperature range, curing time and any other instructions for the product. Two different basic types of agent are used on the engine and these are: 1. RTV agent (Room temperature vulcanizing). Used for gaskets, sealing gasket joints or coating gaskets. RTV is visible when a part has been disassembled; old RTV must be removed before resealing the joint. The following RTV agents are mentioned in the Workshop manual: Loctite ® 574, Permatex ® No. 3, Permatex ® No 77. Old sealant can be removed using denatured alcohol in all cases. 2. Anaerobic agents. These agents cure in an absence of air. They are used when two solid parts, for example cast components, are installed face-to-face without a gasket. They are also commonly used to secure plugs, threads in stud bolts, cocks, oil pressure switches etc. The cured material is glass-like and it is therefore colored to make it visible. Cured anaerobic agents are extremely resistant to solvents and the old agent cannot be removed. When reinstall- ing the part, degrease it carefully and then apply new sealant. The following anaerobic agents are mentioned in the Workshop manual: Loctite ® 572 (white), Loctite ® 241 (blue). Note: Loctite ® is a registered trademark of Loctite Corporation, Permatex ® is a registered trademark of the Permatex Corporation.

Volvo TAD1630G/GE/P/V, TAD1631G/GE, TID162AP, TWD1620G/GH, TWD1630G/GE/P/V, TD164KAE Diesel Engines Service Repair Workshop Manu

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