Volvo Penta TAMD61A Engine Service & Repair Manual

Engine Workshop Manual 2(0) D TAMD61A, TAMD62A, TAMD63L-A, TAMD63P-A TAMD71A, TAMD71B, TAMD72A, TAMD72P-A, TAMD72WJ-A

Group 21 Engine body Marine engines TAMD61A • TAMD62A • TAMD63L-A • TAMD63P-A TAMD71A • TAMD71B • TAMD72A • TAMD72P-A TAMD72WJ-A Contents General instructions ............................................ 2 Special tools ........................................................ 9 Other special equipment ..................................... 12 Design and function Engine, generally ................................................. 13 Design differences, engine versions ................... 14 Identification signs .............................................. 15 Location of type approval plates ......................... 15 Component description ....................................... 24 Repair instructions General ............................................................... 30 Engine jig attachment ......................................... 31 Condition test, engine ......................................... 32 Compression test ................................................ 32 Cylinder head, renovation ................................... 32 Cylinder head, removal ....................................... 32 Cylinder head, stripping/assembly ....................... 34 Cylinder head, leakage test ................................. 35 Cylinder head, inspection .................................... 37 Valve guides, inspection ..................................... 38 Valve guides, replacement .................................. 38 Cylinder head, planing ......................................... 39 Cylinder head, milling the seal groove ................. 39 Valve seat, replacement ..................................... 42 Valve seat, grinding ............................................ 43 Valves, grinding .................................................. 44 Rocker mechanism, renovation ........................... 44 Checking the valve springs ................................. 46 Cylinder head, assembly ..................................... 46 Copper injector sleeve, replacement ................... 48 Cleaning seat for copper sleeve .......................... 49 Copper sleeve, assembly .................................... 50 Valves, adjustment ............................................. 52 Cylinder block, renovation .................................. 53 Piston and con rod, removal ............................... 53 Piston and con rod, inspection ............................ 54 Piston removal, gudgeon pin boss replacement ........................................................ 54 Piston, assembly ................................................ 55 Piston ring inspection and fit ............................... 56 Piston ring assembly .......................................... 56 Cylinder liner, inspection and measurement ........ 57 Cylinder liner, disassembly ................................. 57 Cylinder liner, honing ........................................... 58 Cylinder liner position, renovation ........................ 59 Cylinder liner, assembly ...................................... 60 Piston assembly ................................................. 61 Timing gears, disassembly ................................. 62 Timing gears, assembly ...................................... 65 Sealant application, timing gear lid ...................... 66 Seal ring, polygon hub, replacement ................... 66 Polygon hub, assembly ....................................... 67 Camshaft, wear check ........................................ 67 Camshaft, disassembly ...................................... 68 Inspection of valve lifters and camshaft .............. 69 Camshaft, measurement ..................................... 70 Camshaft bearing, replacement ........................... 70 Camshaft, assembly ........................................... 71 Crankcase, disassembly ..................................... 71 Inspection, crankshaft and bearings .................... 72 Crankshaft, renovation ........................................ 74 Cylinder block, inspection ................................... 75 Cylinder block, planing ........................................ 75 Crankshaft, assembly ......................................... 76 Big end bearings, replacement ............................ 77 Main bearings, replacement ................................ 78 Flywheel, replacement ........................................ 80 Gear ring, replacement ........................................ 81 Flywheel, indication ............................................. 82 Flywheel housing, indication ............................... 82 Crankshaft seal, rear, replacement ...................... 83 Flange seal, flywheel housing, replacement ........................................................ 83

2 Safety information Introduction This Workshop Manual contains technical data, des- criptions and repair instructions for Volvo Penta pro- ducts or product versions contained in the contents list. Ensure that the correct workshop literature is be- ing used. Read the safety information and the Workshop Ma- nual “General Information” and “Repair Instruc- tions” carefully before starting work. Important In this book and on the engine you will find the follo- wing special warning symbols. WARNING! If these instructions are not followed there is a danger of personal injury, extensive damage to the product or serious mechanical malfunction. IMPORTANT! Used to draw your attention to so- mething that can cause damage, product mal- function or damage to property. NOTE! Used to draw your attention to important infor- mation that will facilitate work or operations. Below is a summary of the risks and safety precau- tions 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 (-swit- ches) and lock it (them) in the OFF position be- fore starting work. Set up a warning notice at the engine control point or helm. Generally, all servicing should be carried out with the engine switched off. Some work (carry- ing out certain adjustments for example) requi- res the engine to be running. Approaching a running engine is dangerous. Loose clothing or long hair can fasten in rotating parts and cause serious personal injury. If working in proximity to a running engine, care- less movements or a dropped tool can result in personal injury. Avoid burns. Take precautions to avoid hot surfaces (exhausts, turbochargers, charge air pipes and starter elements etc.) and liquids in supply lines and hoses when the engi- ne is running or has been turned off immediately prior to starting work on it. Reinstall all protecti- ve parts removed during service operations be- fore starting the engine. Check that the warning or information decals on the product are always clearly visible. Replace decals that have been damaged or painted over. Engine with turbocharger: Never start the engine without installing the air cleaner (ACL). The rota- ting compressor in the turbocharger can cause serious personal injury. Foreign objects entering the intake ducts can also cause mechanical da- mage. Never use start spray or similar to start the engi- ne. The starter element may cause an explosion in the inlet manifold. Danger of personal injury. Avoid opening the filler cap for engine coolant system (freshwater cooled engines) when the engine is still hot. Steam or hot coolant can spray out. Open the coolant filler cap carefully and slowly to release pressure before removing the cap completely. Take great care if a cock, plug or engine coolant line must be removed from a hot engine. It is difficult to anticipate in which direction steam or hot coolant can spray out. Hot oil can cause burns. Avoid skin contact with hot oil. Ensure that the lubrication system is not under pressure before commencing work on it. Never start or operate the engine with the oil fil- ler cap removed, otherwise oil could be ejected. Stop the engine and close the sea cock before carrying out operations on the engine cooling system. Start the engine only in a well-ventilated area. If operating the engine in an enclosed space, en- sure that exhaust gases and crankcase ventila- tion emissions are extracted from the working area. Always use protective goggles where there is a danger of pieces of metal, sparks from grinding, acid or other chemicals being thrown into your eyes. Your eyes are very sensitive, injury can lead to loss of sight!

3 Safety information Avoid skin contact with oil. Long-term or repea- ted contact with oil can remove the natural oils from your skin. The result can be irritation, dry skin, eczema and other skin problems. Used oil is more dangerous to health than new oil. Use protective gloves and avoid oil soaked clothes and rags. Wash regularly, especially before me- als. Use the correct barrier cream to prevent dry skin and to make cleaning your skin easier. Most chemicals used in products (engine and transmission oils, glycol, petrol and diesel oil) and workshop chemicals (solvents and paints) are hazardous to health Read the instructions on the product packaging carefully! Always follow safety instructions (using breathing apparatus, protective goggles and gloves for example). En- sure that other personnel are not unwittingly ex- posed to hazardous substances (by breathing them in for example). Ensure that ventilation is good. Handle used and excess chemicals ac- cording to instructions. Be extremely careful when tracing leaks in the fuel system and testing fuel injection nozzles. Use protective goggles! The jet ejected from a fuel injection nozzle is under very high pressure, it can penetrate body tissue and cause serious injury There is a danger of blood poisoning. All fuels and many chemicals are inflammable. Ensure that a naked flame or sparks cannot ig- nite fuel or chemicals. Combined with air in cer- tain ratios, petrol, some solvents and hydrogen from batteries are easily inflammable and explo- sive. Smoking is prohibited! Ensure that ventila- tion is good and that the necessary safety pre- cautions have been taken before carrying out welding or grinding work. Always have a fire ext- inguisher to hand in the workplace. Store oil and fuel-soaked rags and fuel and oil filters safely. In certain conditions oil-soaked rags can spontaneously ignite. Used fuel and oil filters are environmentally dangerous waste and must be deposited at an approved site for de- struction together with used lubricating oil, con- taminated fuel, paint remnants, solvent, degrea- sing agents and waste from washing parts. Never expose the batteries to a naked flame or electric 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 - oxyhydrogen. This gas is easily ignited and highly volatile. Incor- rect connection of the battery can cause a spark which is sufficient to cause an explosion with re- sulting damage. Do not disturb battery connections when starting the engine (spark risk) and do not lean over bat- teries. Never mix up the positive and negative battery terminals when installing. Incorrect installation can result in serious damage to electrical equip- ment. Refer to wiring diagrams. Always use protective goggles when charging and handling batteries. The battery electrolyte contains extremely corrosive sulfuric acid. If this comes into contact with the skin, wash im- mediately with soap and plenty of water. If bat- tery acid comes into contact with the eyes, im- mediately flush with copious amounts of water and obtain medical assistance. Turn off the engine and turn off power at main switch(es) before carrying out work on the elec- trical system. Clutch adjustments must be carried out with the engine turned off. Use the lifting eyes mounted on the engine/re- verse gear when lifting the drive unit. Always check that lifting equipment is in good condition and has sufficient load capacity to lift the engine (engine weight including reverse gear and any extra equipment installed). To ensure safe handling and to avoid damaging engine components on top of the engine, use a lifting beam to raise the engine. All chains and cables should run parallel to each other and as perpendicular as possible in relation to the top of the engine. If extra equipment is installed on the engine altering its center of gravity, a special lifting de- vice is required to achieve the correct balance for safe handling. Never carry out work on an engine suspended on a hoist.

4 Safety information Always use fuels recommended by Volvo Pen- ta. Refer to the Instruction Book. The use of lo- wer quality fuels can damage the engine. On a diesel engine poor quality fuel can cause the control rod to seize and the engine to overrev with the resulting risk of damage to the engine and personal injury. Poor fuel quality can also lead to higher maintenance costs. WARNING! The engine has pretensioned delive- ry lines. These pipes must under no circumstan- ces be bent. Damaged pipes should be repla- ced. Observe the following rules when cleaning with high-pressure water jets: Never direct the water jet at seals, rubber hoses or electrical compo- nents. Never use a high pressure jet when washing the engine. Never remove heavy components alone, even where secure lifting equipment such as secured blocks are being used. Even where lifting equip- ment is being used it is best to carry out the work with two people; one to operate the lifting equipment and the other to ensure that compo- nents are not trapped and damaged when being lifted. When working on-board ensure that there is suf- ficient space to remove components without danger of injury or damage. Components in the electrical system, ignition system (gasoline engines) and fuel system on Volvo Penta products are designed and cons- tructed to minimize the risk of fire and explosi- on. The engine must not be run in areas where there are explosive materials.

5 General information About the service manual This workshop manual contains technical data, de- scriptions and repair instructions for the standard versions of engine units TAMD61A, TAMD62A, TAMD63L-A, TAMD63P-A, TAMD71A, TAMD71B, TAMD72A, TAMD72P-A, TAMD72WJ-A. The workshop manual can show the tasks carried out on any of the engines noted above. This means that the illustrations and photographs may not coincide in some cases with other engines. The repair methods are essentially similar, however. If this is not the case, it will be noted. Important differences are noted separately. Engine designations and engine serial numbers are noted on the type approval sign (please refer to page 15). In all correspondence about an en- gine, the engine designation and serial number must always be given. The workshop manual has primarily been prepared for Volvo Penta’s service workshops and their qualified personnel. It is therefore assumed that people who make use of the book have basic knowledge of ma- rine propulsion systems and can carry out tasks of a mechanical/electrical nature which are associated with the trade. Volvo Penta continually improves its products, which means that we reserve the right to make changes. All information contained in this manual is based on prod- uct data which were available at the time the manual was sent to press. Any major changes made to the product or service methods after this time are notified in the form of service bulletins. Spare parts Spare parts for electrical systems and fuel systems are subject to various national safety requirements, e.g. US Coast Guard Safety Regulations. Volvo Penta spare parts meet these requirements. No com- pensation in respect of Volvo Penta guarantees will be given for any kind of damage or injury caused by the use of non-original Volvo Penta spare parts on the product in question. Certified engines On engines which are certified in accordance with na- tional and regional regulations (e.g. Bodensee), the manufacturer guarantees that the requirements are met by both new engines and engines in service. The product must be equivalent to the sample which was approved during certification. In order for Volvo Penta, as a manufacturer, to guarantee that engines in ser- vice meet the stated environmental requirements, the following requirements for service and spare parts must be met: The service intervals and service tasks recom- mended by Volvo Penta must be observed. Only Volvo Penta original parts, intended for the certified version of the engine, may be used. Service work related to the ignition system, igni- tion settings and fuel injection system (petrol (gasoline)) must always be carried out by an au- thorised Volvo Penta workshop. The engine must not be changed or modified in any way, with the exception of the accessories and service kits developed by Volvo Penta for the engine. Installation changes on exhaust pipes and air in- let pipes for the engine bay (ventilation ducts) must not be done without consultation, since this can affect exhaust emissions. No seals may be changed by unauthorised per- sonnel. IMPORTANT! When spare parts are required, use Volvo Penta original spares. The use of non-original spare parts means that Volvo Penta is no longer responsible for ensuring that the engine corresponds with the certified sample. No compensation in respect of Volvo Penta guarantees will be given for any kind of damage or injury caused by the use of non-original Volvo Penta spare parts on the product in question.

6 Repair instructions The work methods described in the Workshop Manual are applicable for a workshop environment. The engine is therefore removed from the boat and mounted in an engine block. Renovation work which does not require removal of the engine is conducted in situ with the same work methods, unless otherwise stated. The warning symbols used in the Workshop Manual (see Information on Safety for implication) WARNING! IMPORTANT! NOTE! These are in no way comprehensive, since we obviously cannot foresee everything, in that service work is conducted under the most various conditions. We can therefore only point out the risks which we consider can arise as a result of incorrect handling during work in a well-equipped workshop with work methods and tools which are proven by us. In the Workshop Manual all the work procedures for which there are special Volvo Penta tools are conducted with these. The special tools are specially produced to facilitate the most safe and rational work method possible. It is therefore the responsibility of persons using other tools or another work method than that which we recommend to ensure that no risk of personal injury, material damage or malfunction can occur. In some cases there may be special safety instructions and user instructions for the tools and chemicals named in the Workshop Manual. These instructions shall always be followed and there are no special instructions for this in the Workshop Manual. By means of taking certain elementary procedures and using a modicum of common sense, most risk factors can be prevented. A clean workplace and a clean engine eliminate many risks both of personal injury and malfunction. Especially during work on the fuel system, lubrication system, induction system, turbo, bearing unions and sealing unions, it is of the greatest importance that dirt or foreign particles do not get in, since this can result in malfunctioning or shorten the repair service- life. Our joint responsibility Each engine consists of a large number of interactive systems and components. The deviation of a component from the technical specification can dramatically increase the environmental impact from an otherwise first-rate engine. It is therefore of extreme importance to maintain the given wear tolerances, that systems capable of adjustment receive the correct setting, and that Volvo Penta Genuine Parts are used for the engine. The time intervals in the engine’s maintenance schedule must be followed. Certain systems, e.g. components in the fuel system, may require special competence and special test equipment. Certain components are sealed at the factory for environmental reasons. Work on sealed components must not be conducted unless authoris- ation for such work is held. Remember that most chemical products, incorrectly used, are hazardous to the environment. Volvo Penta recommends the use of biologically decomposing degreasing agents for all cleaning of engine components, unless otherwise stated in the Workshop Manual. When working on board a boat pay special attention to make sure that oils and washing residue are handled correctly for destruction, and do not unintentionally end up in the nature, e.g. in the bilge- water. Tightening torques Tightening torque for vital unions, which should be tightened with dynamometric wrenches, is listed in “Specifications: Tightening torque” and indicated in the manual’s work descriptions. All torque indications are applicable for cleaned threads, screw heads and mating surfaces. The torque indications refer to lightly oiled or dry threads. If lubricants, locking liquids or sealants are required for the screw union, the type is indicated in the work description and in “Tightening torques”. General tightening torque as per the table below is applicable for unions where special torque indications are not given. The torque indication is a standard value and the union does not require tightening with a dynamometric wrench. Size Tightening torques Nm lbf.ft M5 ................................................. 6 4.4 M6 ................................................. 10 7.4 M8 ................................................. 25 18.4 M10 ............................................... 50 36.9 M12 ............................................... 80 59.0 M14 ............................................... 140 103.3

7 Safety information Angular tightening torque For angular tightening torque the screw union is tightened with a given torque, thereafter further tightening with a predetermined angle. Example: at 90° angular tightening the union is tightened and an additional 1/4 turn is made in a work procedure after the given tightening torque has been reached. Lock nuts Dismantled lock nuts shall not be reused but replaced with new items, since the locking properties diminish or are lost with repeated use. For lock nuts with plastic inserts, e.g. Nylock®, the tightening torque given in the table shall be reduced if the Nylock® nut has the same nut height as a standard full-metal hexagonal nut. The tightening torque is reduced by 25% for screw size 8 mm or larger. For Nylock® nuts with higher nut heights, where the full-metal thread is equally high as a standard hexagonal nut, the tightening torque as per the table are applicable. Strength classes Screws and nuts are divided into different strength classes; affiliation is indicated by the marking on the screw head. A higher number on the marking represents a stronger material, e.g. a screw marked 10-9 has a higher strength than a screw marked 8-8. It is therefore important when dismantling screw unions that the screws are refitted in their original places. For replacement of screws see the Parts Catalogue to ensure that the correct version is obtained. Sealants A number of different sealants and locking liquids are used on the engine. The properties of the mediums differ, and they are intended for different union strengths, temperature ranges, resistance to oils and other chemicals, and for the different materials and column sizes in the engine. In order to conduct satisfactory service work it is therefore important that the correct type of sealant and locking liquids are used for the unions where such are required. In the Workshop Manual we have indicated in respective chapters the agents which are used in our engine production. During service work the same agent, or agent with similar properties but of other manufacture, shall be used. When using sealants and locking liquids it is important that the surfaces are free from oil, grease, paint and anti-rust agent, and that they are dry. Always follow the instructions of the manufacturer concerning application temperature, hardening time and other instructions for the product. Two different basic types of agents are used on the engine, and these are characterised by: RTV-agent (Room temperature vulcanising). Most often used with gaskets, e.g. sealing of gasket joints or applied on gaskets. RTV-agent is fully visible when the part has been dismantled: old RTV-agent must be removed before the union is sealed again. The following RTV-agents are named in the Workshop Manual: Loctite® 574, Volvo Penta 840879-1, Permatex®. No. 3, Volvo Penta 1161099-5, Permatex® No. 77. Old sealant is removed in each case with denatured spirit. Anaerobic agents. These agents harden on the absence of air. The agent is used when two solid parts, e.g. cast components, are fitted together without gasket. A common application is also to secure and seal plugs, threads on pin bolts, taps, oil pressure relays, etc. Hardened anaerobic agents are transparent and therefore they are coloured to make them visible. Hardened anaerobic agents are very resistant to solvents and old agent cannot be removed. Careful degreasing is conducted prior to refitting, and new sealant is applied. The following anaerobic agents are named in the Workshop Manual: Loctite® 572 (white), Loctite® 241 (blue). NOTE! Loctite® is a registered trade-mark for Loctite Corporation, Permatex® is a registered trade-mark for Permatex Corporation.

8 Safety information Safety rules for fluorocarbon rubber Fluorocarbon rubber is a common material in seal rings for shafts, and in O-rings, for example. When fluorocarbon rubber is subjected to high temper- atures (above 300°C), hydrofluoric acid can be formed, which is highly corrosive. Skin contact can give severe chemical burns. Splashes in your eyes can give severe chemical burns. If you breathe in the fumes, your lungs can be permanently damaged. WARNING! Be very careful when working on en- gines which have been exposed to high temperatures, e.g. overheating during a seizure or fire. Seals must never be cut with an oxy- acetylene torch, or be burned up afterwards in an uncontrolled manner. Always use gloves made of chloroprene rubber (gloves for handling chemicals) and protective goggles. Handle the removed seal in the same way as cor- rosive acid. All residue, including ash, can be highly corrosive. Never use compressed air to blow anything clean. Put the remains in a plastic box which is sealed and provided with a warning label. Wash the gloves under running water before removing them. The following seals are probably made from fluorocar- bon rubber: Seal rings for the crankshaft, camshaft, intermediate shafts. O-rings irrespective of where they are installed. O- rings for cylinder liner sealing are almost always made from fluorocarbon rubber. Note that seals which have not been subjected to high temperature can be handled normally.