TAD 1343 VE (Repair Manual)
TAD 1343 VE (Repair Manual)
VOLVO
Engine
TAD1343GE
TAD1344GE
TAD1345GE
7748841
01/06/2010
33525078101_0_1
Workshop Manual
Group 00-08, 20-26, 32
I
5(0)
Content
General Information
00-0 General ................................................................................................ 2
00-9 Miscellaneous ..................................................................................... 6
Specifications
03-2 Specifications, Engine ....................................................................... 7
03-3 Specifications, Electrical ................................................................. 45
Special tools
08-2 Special Service Tools ....................................................................... 52
General
20-0 Engine Information, General ............................................................ 59
Engine
21-0 Engine Complete, General ............................................................. 116
21-1 Cylinder Head .................................................................................. 153
21-3 Cylinder Liner, Pistons ................................................................... 175
21-4 Valve Mechanism ............................................................................ 177
21-5 Timing Gears and Shaft ................................................................. 201
21-6 Crank Mechanism ........................................................................... 211
Fuel System
23-0 Fuel System, General ..................................................................... 245
23-3 Fuel Feed Pump and Filter ............................................................. 248
23-7 Injectors and Delivery Pipes .......................................................... 255
23-8 Control System, ECM, Data Sets ................................................... 266
Cooling System
26-0 Cooling System, General ............................................................... 278
26-2 Coolant Pump, Thermostat ............................................................ 284
26-3 Fan, Fan Shroud ............................................................................. 296
00-0 General
About this Workshop manual
General information
Certified engines
This Service Manual contains technical data, descriptions and maintenance and repair instructions for
standard model Volvo Penta products. A list of these
products may be found in the section Specifications.
When carrying out service and repair on emission-certified engines, it is important to be aware
of the following:
Spare Parts
Spare parts for the electrical and fuel systems are
subject to various national safety standards. Volvo
Penta Original Spare Parts meet these standards. No
damage of any kind caused by the use of spare parts
not approved by Volvo Penta will be compensated by
any warranty undertaking.
Maintenance and service intervals recommended by Volvo Penta must be complied with.
No warranty seals (where present on the product) may be broken by unauthorized persons.
7748841 06-2010
00-0 General
Repair instructions
Introduction
!
!
!
DANGER!
WARNING!
CAUTION!
IMPORTANT!, NOTICE!
are by no means comprehensive since not everything
can be foreseen as service work is carried out in the
most varied of circumstances. We call attention to
risks that may occur due to incorrect handling during
work in a well-equipped workshop using working
methods and tools tried and tested by us.
The service manual describes work operations carried out with the aid of Volvo Penta Special Tools,
where such have been developed. Volvo Penta Special Tools are designed to ensure the safest and most
rational working methods possible. It is therefore the
responsibility of anyone using tools or working methods other than those we recommend to ensure that
no risk of personal injury or mechanical damage is
present, or that malfunction can result.
In some cases, special safety regulations and user
instructions may be in force for the tools and chemicals mentioned in the Service Manual. These regulations must always be followed, and no special
instructions regarding this are to be found in the Service Manual.
Tightening torques
Tightening torques for vital fasteners that must be
applied using a torque wrench are indicated in the
Service Manual, chapter Tightening torques and in
the Manual's work descriptions. All torque indications
apply to clean threads, bolt heads and mating faces.
Indicated torque data apply to lightly-oiled or dry
threads. If lubricants, locking fluids or sealants are
required for fasteners, the correct type will be noted
in the job description.
7748841 06-2010
00-0 General
When torque/angle tightening, the fastener is tightened to a specified torque, and tightening then continues through a pre-determined angle.
In each service manual section concerned, the sealants used in product manufacture are indicated. The
same sealants, or sealants with equivalent properties, must be used for maintenance work.
Lock nuts
Removed locknuts may not be re-used; they must be
replaced by new ones, as locking properties are
impaired or lost with re-use.
In the case of lock nuts with plastic inserts the tightening torque indicated must be reduced if the nut has
the same nut height as a standard, all-metal hexagonal nut.
Reduce the torque by 25% for bolt sizes of 8 mm or
larger.
In the case of lock nuts with plastic inserts with a high
nut-height (where the all-metal thread is as high as a
standard hexagonal nut), the indicated torque
applies.
Strength classes
Nuts and bolts are subdivided into different strength
classes. The classification is shown by a marking on
the bolt head. Markings of a higher number indicate
stronger material. For example, a bolt marked 10-9 is
stronger than one marked 8-8.
For this reason, it is important that when bolts are
removed they are returned to their original locations
on re-assembly. When replacing bolts check the
applicable Spare parts catalogue to ensure the correct bolt is used.
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 regarding applicable
temperatures, hardening times and such.
Two basic types of compound are used:
RTV preparations (Room Temperature Vulcanizing).
Used most often together with gaskets, e.g. sealing
gasket joints, or are brushed on gaskets. RTV sealants are completely visible when the part has been
removed. Old RTV sealant must be removed before
the component is sealed again. Use denatured alcohol.
Anaerobic agents.
These agents cure (harden) in the absence of air.
These preparations are used when two solid components, e.g. two cast components, are fitted together
without a gasket. Common uses are also to lock and
seal plugs, stud threads, taps, oil pressure monitors
etc.
Hardened anaerobic preparations are glassy and for
this reason, the preparations are colored to make
them visible. Hardened anaerobic preparations are
highly resistant to solvents, and old compound cannot be removed. On re-assembly, it is important to
carefully degrease and wipe dry components first,
before applying new sealant in accordance with the
instructions.
7748841 06-2010
00-0 General
The following seals are most probably made from fluorocarbon rubber:
When fluorocarbon rubber is exposed to high temperatures (above 300C/572F), hydrofluoric acid
can form. This is highly corrosive. Contact with the
skin can result in severe chemical burns. Splashes in
your eyes can result in chemical wounds. If you
breathe in the fumes, your lungs can be permanently
damaged.
O-rings, regardless of where they are installed. Orings for cylinder liner sealing are almost always
made of fluorocarbon rubber.
Please note that seals which have not been
exposed to high temperature can be handled normally.
WARNING!
Seals must never be cut with a torch, or be burnt
afterwards in an uncontrolled manner. Risk for
poisonous gases.
WARNING!
Always use chloroprene rubber gloves (gloves for
chemicals handling) and goggles. Handle the
removed seal in the same way as corrosive acid. All
residue, including ash, can be highly corrosive. Never
use compressed air to blow clean.
Put the remains in a plastic container, seal it and
apply a warning label. Wash the gloves under running
water before removing them.
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00-9 Miscellaneous
00-9 Miscellaneous
Fan
IMPORTANT!
The engine is equipped with a so-called visco-fan.
When the fan is removed the viscous coupling must
always stand upright.
The coupling contains oil that will run out if it is laid on
its side, and because the oil cannot run back in the fan
will seize.
7748841 06-2010
10.9
May be re-installed
12.9
May be re-installed
IMPORTANT!
Check bolts which are to be re-installed. Damaged bolts,
e.g. with shear marks under heads must be scrapped.
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3
4
6
2
3
7
6
6
P0005219
60 5
60 5
120 5
20 3 Nm (14.75 2.21 lbf ft)
Stage 2
90 5
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Frame reinforcement
24 22 19 18 15 14 11 10
23 21 20 17 16 13 12
P0005220
60 5
16
27
24
22
21
23
20
19
18
17
15
1
5
6
P0005221
P0005222
29
28
2
10
4
3
7
8
9
11
12
13
14
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1
8
3
7
2
1
6
4
5
2
6
1
P0005223
110 5
90 5
10
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11
7
1
P0005224
P0005225
Flywheel housing
Tighten all bolts in sequence to the following torque:
M14 bolts
M10 bolts
M8 bolts
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11
P0005226
P0005290
P0005227
12
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Flywheel
10
12
14
13
11
3
9
P0005228
Flywheel
stage 1: Tighten the bolts in sequence, as illustrated
120 10
5
6
P0005229
P0005230
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13
8
5
6
7
4
P0005231
Vibration damper:
stage 1: Tighten the bolts in sequence, as illustrated
Cylinder Head
36 35 28 27 22 21 15 16 23 24 31 32
11
6
3
9
1
13
7
14
10
2
5
8
12
4
38 37 30 29 18 17 19 20 25 26 33 34
P0005232
14
120 5
90 5
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1
14/8
7
20
14/8
14/8
20
14/8
14/8
7
20
14/8
14/8
20
P0005233
20
14/8
14/8
20
20
20
20
14/8
20
10
90 5
120 5
120 5
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15
P0005234
60 5(1)
30 + 15 / 0(1)
45 5(1)
1) after contact
Spring plate
P0005235
Spring plate
16
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Valve Cover
13 12
11
10
15
16
17
18
19
14
9
20
p0005236
Valve Cover
Tighten the bolts in sequence, as illustrated
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17
4
P0005237
18
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Oil Cooler
1
P0005238
NOTICE! Tighten the bolts diagonally and finish off by tightening the first bolts again.
Oil Cooler, attachment bolts
4
D
p0005239
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19
1
2
p0005240
20
7748841 06-2010
p0005241
p0005242
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21
P0012337
P0012338
22
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C A
C
D
E
p0005243
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23
P0006696
Inlet Manifold
Torque the bolts
Exhaust Manifold
3
11
10
12
P0005246
Exhaust Manifold
Stage 1:
Tighten the bolts 1, 4 and 5, 8 and 9, 12 until they make
contact
Step 2:
Torque bolts 3 and 2
24
7748841 06-2010
Location of Sensors
2
8
4
7
5
6
9
14
10
13
11
12
P0004318
1 Auxiliary stop
2 Charge pressure sensor / Charge air temperature sensor
30 5 Nm
4 Crankcase sensor
30 5 Nm
30 5 Nm
clamp
insertable type
22 3 Nm
30 5 Nm
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25
Engine, General
NOTICE! Because the illustrations in the maintenance
literature are used for different engine variants, certain
details may vary compared to the actual model concerned. The essential information is always correct,
however.
No. of cylinders
Stroke
Cylinder volume
Injection sequence
Compression ratio
18,1:1
Compression
Low idle
900 rpm
High idle
1800 rpm
Total length
Total width
Total height
Type designation
26
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Engine
Technical Data
Engine body
Cylinder Head
Max unevenness (bottom surface)
38
Thread dimension
M16
Length
Cylinder block
Length
Cylinder Liner
Type
Wet, replaceable
1+3
Piston
Height above cylinder block plane, steel pistons
Front marking
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27
Piston rings
XXX
XXX
X
X
p0005201
Compression Rings
Quantity
Marking
(trapezoid profile)
Marking
28
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Valve mechanism
Valves
p0005201
42 mm (1.654 in)
40 mm (1.575 in)
8 mm (0.315 in)
24,5 0,2
Exhaust
Seat angle in cylinder head (B):
Inlet
Exhaust
39,5
25
40
p0005203
Specifications
Dimension (A) between valve head and cylinder head
plane:
Inlet
Exhaust
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Min. (A)
Wear value
1.0 mm
(0.0394 in)
1.35 mm
(0.0531 in)
Max 1.7 mm
(0.0669 in)
Max 2.1 mm
(0.0827 in)
29
Exhaust
Exhaust, EGR
P0004526
P0004953
30
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P0005197
Valve seats
A
B
p0005205
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Standard
45.1 mm
(1.7756 in)
43.1 mm
(1.6968 in)
Oversize dimension
45.3 mm (1.7835 in)
43.3 mm (1.7047 in)
7.55 mm
(0.2972 in)
7.5 mm
(0.2952 in)
31
p0005206
Diameter (C):
Standard
Inlet
45.0 mm (1.772 in)
Exhaust
43.0 mm (1.693 in)
Depth (D):
Inlet
Exhaust
Seat bottom radius (R):
Inlet / exhaust
Oversize dimension
45.2 (1.7795 in)
[0/+0.025 mm]
(0/+0.000984 in)
43.2 (1.7008 in)
[0/+0.025 mm]
(0/+0.000984 in)
Valve guides
999 9696
998 9876
p0005207
Length:
Inlet / exhaust
Inner diameter:
Inlet / exhaust
8 mm (0.315 in)
1) The dimension is calculated for the measurement method in the service literature; Refer toValve Guides, Inspection page 188.
32
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Rocker Arm
2
p0005208
Wear values
Bearing play (1)
Roller cam follower, clearance (2)
Valve springs
Inlet
Length uncompressed
Exhaust
Length uncompressed
7748841 06-2010
33
Engine Transmission
Timing gear wheels
1 Drive gear, crankshaft
2 Intermediate gear: outer gearwheel, inner gearwheel
3 Intermediate gear (adjustable)
4 Drive gear, camshaft
5 Intermediate gear
6 Drive gear, power steering pump and fuel feed
pump
7 Drive gear, lubrication oil pump
p0005209
34
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Camshaft
Camshaft drive
gearwheel
No. of bearings
69.4769.53 mm (2.7352.737")
18 mm (0.709 in)
Wear value
Max end float
Camshaft Bearings
Camshaft bearing thickness, standard
Oversize dimension:
0.25 mm (0.00984 in)
7748841 06-2010
35
Crank Mechanism
Crankshaft
Wear value
Crankshaft end float(1)
Machining value
Ovality of main bearing journals and connecting rod journal
P0005849
Diameter () standard
Undersize dimension:
0.25 mm (0.00984 in)
Oversize dimension:
0.2 mm (0.00787 in), thrust bearing 0.1 mm (0.00394 in)
36
7748841 06-2010
B
p0005210
Oversize dimension:
0.1 mm (0.00394 in)
Oversize dimension:
0.25 mm (0.00984 in)
7748841 06-2010
37
Big-end journals
G
E
D
B
p0005211
Diameter ()
Undersize dimension:
0.25 mm (0.00984 in)
Width (A)
Oversize dimension:
0.25 mm (0.00984 in)
38
7748841 06-2010
Connecting rod
201
201
201
201
Marking:
FRONT on the connecting rod faces forward.
The connecting rod and bearing caps are
marked in pairs with a three-digit serial number
(see illustration).
p0005212
Flywheel, installed
Runout, measured radius 150 mm (5.905 in)
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39
Lubrication System
Technical Data
Oil
Oil change volume
36 liter
9.51 US gals
11 liter
2.91 US gals
Oil Pressure
Operating speed (above 1100 rpm)
300550 kPa
43.579.8 psi
650 kPa
94.3 psi
200300 kPa
2943.5 psi
80120 kPa
11.617.4 psi
Oil temperature
Max oil temperature in oil sump
40
130 C
266 F
7748841 06-2010
Oil Filter
Number
Full flow filter
Bypass filter
Oil valves
3
105107 C
(221224.6 F)
Yellow
69 mm (2.717 in)
Compressed 1315 N
(2.93.4 lbf)
40 mm (1.575 in)
2
p0005213
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41
Fuel System
Technical Data
NOTICE! For the below-mentioned values, fuel is
required to fulfill the requirements specified in 03-0,
Fuel and Oils.
Feed pump
Feed pressure at:
600 rpm
100 kPa
14.5 PSI
1200 rpm
300 kPa
43.5 PSI
full load
300 kPa
43.5 PSI
Bypass valve
Opening pressure
300550 kPa
43.579.8 PSI
Unit injector
Pre-load
Tighten the adjuster screw to zero-clearance against
the camshaft. Then turn 4 flats; see illustration.
p0005214
42
7748841 06-2010
The pressure drop indicator control lamp lights up at a pressure drop relative to ambient air pressure of:
7748841 06-2010
50 5 kPa
43
Cooling System
Technical Data
Pressure cap
p0005215
Thermostat
Quantity
Opening temperature:
< 82 C (179.6 F)
Coolant
Type
Color
Green
Contains
Mix with
40/60
NOTICE! Do not use Volvo Coolant VCS (yellow in
color) in Volvo Penta engines.
NOTICE! Do not mix different kinds of coolant.
Refill quantity
Coolant quantity (engine, radiator and hoses):
TAD134053 GE/VE
44
7748841 06-2010
Temperature
(C) (F)
73796
52394
R Min
14945
4981
1900
-40 -20
p0005216
7748841 06-2010
R Nom
R Max
20
40
60
80 100
Impedance
Rmin
Impedance
Rnom
Impedance
Rmax
()
()
()
58
40
22
4
14
32
50
68
86
104
122
140
158
176
194
212
230
248
266
284
89496,5
45163,6
23871,0
13181,5
7555,7
4477,9
2747,3
1736,6
1127,3
750,0
510,4
354,5
251,6
181,4
133,1
99,2
75,0
57,6
44,7
34,8
105290,0
52394,0
27375,0
14945,0
8480,0
4981,0
3029,0
1900,0
1224,0
809,1
547,0
377,9
266,5
191,2
139,7
103,6
78,0
59,6
46,1
36,0
121083,5
59624,4
30879,0
16708,5
9404,3
5484,1
3310,7
2063,4
1320,7
868,2
583,6
401,3
281,4
201,0
146,3
108,0
81,0
61,6
47,5
37,2
150 302
27,4
28,5
29,6
50
40
30
20
10
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
45
45313
(C) (F)
26114
15462
R Min
R Nom
R Max
5896
2500
-40 -20
20
40
60
80 100
p0005217
40
30
20
10
0
10
20
25
30
40
50
60
70
80
90
100
110
120
130
140
40
22
4
14
32
50
68
77
86
104
122
140
158
176
194
212
230
248
266
284
Impedance
Rmin
Impedance
Rnom
Impedance
Rmax
()
()
()
40490
23580
14096
8642
5466
3542
2351
1941
1615
1118
798
573
421
313
237
182
140
109
86
68
45313
26114
15462
9377
5896
3792
2500
2057
1707
1175
834
596
435
323
243
186
144
113
89
71
50136
28647
16827
10152
6326
4043
2649
2173
1798
1231
870
618
451
332
250
191
148
116
93
74
Temperature
(C) (F)
p0005218
46
40
30
20
10
0
10
20
30
40
50
60
70
80
90
100
110
120
130
40
22
4
14
32
50
68
86
104
122
140
158
176
194
212
230
248
266
Impedance
Rmin
Impedance
Rnom
Impedance
Rmax
()
()
()
45301,0
25350,0
14785,0
8951,0
5605,0
3618,7
2401,9
1644,7
1152,4
819,1
590,3
431,0
318,68
238,43
180,42
137,63
106,09
82,58
48153,0
26854,0
15614,0
9426,0
5887,0
3791,1
2510,6
1715,4
1199,6
851,1
612,3
446,3
329,48
246,15
186,0
142,08
109,65
85,45
51006,0
28359,0
16443,0
9901,0
6168,0
3963,5
2619,3
1786,2
1246,7
883,0
634,2
461,6
340,27
253,86
191,58
146,52
113,21
88,32
7748841 06-2010
V = 0.48 Ubat 10 %
Inactive
V = 0.12 Ubat 10 %
Camshaft sensor
Distance to gearwheel
Crankcase sensor
Sensor alarm limit
7748841 06-2010
47
Read the safety information below and the service manual section About this Workshop manual and Repair
instructions carefully before repair and service work is begun.
!
This symbol is used in the service manual and on the product, to call attention to the
fact that this is safety information. Always read such information very carefully.
Safety texts in the manual have the following order of priority:
DANGER!
Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING!
Indicates a hazardous situation which, if not avoided, could result in death or serious
personal injury.
CAUTION!
Indicates a hazardous situation which, if not avoided, could result in minor or moderate
personal injury.
IMPORTANT!
Is used to draw your attention to something that may cause minor damage or a minor
malfunction to the product or property.
NOTICE! Is used to draw your attention to important information that will facilitate the
work or operation in progress.
This symbol is used on our products in certain cases and refers to important information
in the instruction book. Make sure that warning and information symbols on the engine
are clearly visible and legible. Replace symbols which have been damaged or painted
over.
A compilation of safety precautions that must be taken and risks which must be paid attention to is
presented in the following pages.
48
7748841 06-2010
Be aware of hot surfaces (exhaust pipes, turbos, charge air pipes, starting heaters etc.) and
hot fluids in pipes and hoses on an engine that
is running or has just stopped.
If work is done adjacent to a running engine, a
careless movement or a dropped tool may in the
worst case lead to personal injury.
The majority of chemicals e.g. engine and transmission oils, glycol, gasoline, and diesel oil,
together with chemicals for workshop use such
as degreasing agents, paints and solvents, are
injurious to health. Carefully read the instructions on the product packaging! Always follow a
product's safety directions, e.g. use of protective mask, glasses, gloves etc. Ensure that
other personnel are not exposed to substances
that are injurious to health. Ensure good ventilation. Handle used and leftover chemicals in
the prescribed manner.
7748841 06-2010
49
All fuels, as well as many chemicals, are flammable. Do not allow open flames or sparks in
their vicinity. Gasoline, some thinners, and
hydrogen gas from batteries are extremely
flammable and explosive when mixed with air in
the correct proportions. No Smoking! Ensure
that the work area is well ventilated and take the
necessary safety precautions before welding or
grinding work is begun. Always ensure that
there are fire extinguishers close at hand in the
work area.
Never work alone when removing heavy 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 the other to ensure that components are
lifted clear and not damaged during the lifting
operations.
50
7748841 06-2010
The components in the electrical and fuel systems on Volvo Penta products are designed and
manufactured to minimize the risk of fire and
explosion. The engine must not be run in areas
where there are explosive materials.
Only use fuels and lubricating oils recommended by Volvo Penta. Refer to the Operator's
Manual for the product in question. Use of fuels
that are of a lower grade may damage the
engine, the injection pump and the injectors. On
a diesel engine, low grade fuel can cause the
control rod to bind and the engine to over-rev,
with the risk of engine damage and personal
injury as a result. Low fuel and oil grades may
result in high service, maintenance and repair
costs.
Fuel delivery pipes must not be bent or straightened under any circumstances. Cracks may
occur. Damaged pipes must be replaced.
7748841 06-2010
51
P0002947
9996398 Manometer
Adjusting e.g. lubricating oil
pressure.
P0004337
1678297 Spacer
For use with 9996398 Manometer.
P0001857
P0006822
P0006765
P0006269
9990006 Puller
P0006793
P0006779
9990192 Puller
Crankshaft seal.
52
P0004328
P0004314
9990124 Nipple
Banjo fitting, for use with
9996398 Manometer.
P0006785
P0006784
9992000 Handle
Replacement of e.g. crankshaft
seal.
7748841 06-2010
P0006763
P0004333
9986179 Puller
Flywheel bearing
9996666 Nipple
For use with, among other
things, 9996398 Manometer.
p0004329
9996394 Support
Support leg for 9996645 Puller.
P0004331
p0004330
9996395 Support
Support leg for 9996645 Puller.
P0004332
9996645 Puller
For use with cylinder liners.
P0004348
P0004347
p0006803
9998007 Adapter
For use with 9996400 Slide
hammer.
9998248 Adapter
Compression test (6 pcs.
required).
P0006805
P0004349
7748841 06-2010
9998339 Manometer
Checking charge air pressure.
53
P0001878
P0006814
P0006761
9986173 Puller
Flywheel bearing
9808570 Brush
9808616 Extender
9998580 Protective
sleeve.
P0006816
P0006767
9998487 Sleeve
Removal of filters.
88800021 Drift
Removal of crankshaft seal.
P0006806
P0006810
P0008420
P0002793
P0006811
88800191 Extractor
Removal of copper sleeve.
P0008418
P0010363
88800196 Drift
Installation of copper sleeve.
54
9809668 Extractor
Removal of copper sleeve.
7748841 06-2010
P0001872
P0004276
p0006800
88800151 Drift
P0010357
P0010358
88800117 Plate
For use with 88800003 Fixture.
9998674 Adapter
Removal of camshaft cap.
P0006804
P0010359
P0010361
P0010362
P0010364
9992955 Plate
Removal of cylinder liner.
7748841 06-2010
P0010360
P0010365
9998598 Sleeve
Removal of safety valve cover.
55
p0006797
p0006802
P0007585
88800003 Fixture
For use with 88800117 Plate.
P0006764
P00068115
P0006813
885810 Fixture
Installation of upper timing
cover.
9998601 Fixture
Installation of upper timing
cover.
P0006782
P0006792
P0006786
56
P0006788
9996159 Adapter
For 9809729 Hydraulic cylinder.
P0006789
88800064 Drift
Valve guides.
7748841 06-2010
P0006790
P0006794
p0006796
88800127 Drift
Valve guides.
P0006776
88800147 Drift
Valve guides.
P0006795
p0006801
9990160 Fixture
Cylinder head.
9990174 Drift
Valve springs.
P0006780
P0006778
9998246 Drift
Valve springs.
P0006791
P0006787
P0007596
9992269 Drift
Replacement of flywheel bearings.
9990263 Nipple
Measuring oil pressure.
P0004580
9998493 Hose
7748841 06-2010
57
Other Equipment
The following miscellaneous equipment is used when
working on the engine. The equipment can be ordered
from AB Volvo Penta by specifying the number indicated.
Orig
in
al
P0004344
P0002936
P0002930
P0002784
885648 Counterhold
For use with 885633 Torque
multiplier.
P0004343
P0004342
885510 Plugs
For use with e.g. fuel pressure
lines.
P0001859
P0001879
P0001875
20
20
10
9998511 Lever
P0001881
58
P0006823
7748841 06-2010
P0002050
1
A Chassis number
B Serial number
P0002051
2
A Engine designation
A
B
C
D
E
F
G
P0002052
P0002053
7748841 06-2010
C Serial number
59
P0006477
P0005998
60
7748841 06-2010
Cylinder Head
B
A
E
C
D
A
P0006000
The fuel channel to the unit injectors is drilled lengthwise through the cylinder head and has a machined,
ring-shaped space around each unit injector (C).
7748841 06-2010
61
P0006001
There are two guide pins on the right side of the cylinder head that ensure the valve cover is fitted in the
correct position.
62
7748841 06-2010
D
D
P0006002
7748841 06-2010
63
P0006003
P0006004
64
7748841 06-2010
Cylinder block
P0006005
7748841 06-2010
65
P0006006
66
7748841 06-2010
P0006007
7748841 06-2010
67
Sealing joints
68
7748841 06-2010
P0006009
7748841 06-2010
69
P0006010
70
7748841 06-2010
T
D
5
P0006011
The engine has an overhead camshaft and a fourvalve system. The camshaft is induction hardened
and supported by seven bearing brackets, where the
rear bearing also acts as a thrust bearing. Both the
bearing cups and bearing brackets are replaceable.
There are cams between each shaft journal: an inlet
cam, injection cam, exhaust cam and EGR
(TAD135053GE). The camshaft is driven by a gearwheel (1) from the engine timing. A hydraulic vibration
damper (2) is installed on the outside of the gearwheel.
Figure (A) shows a section through the valve mechanism for one pair of exhaust valves.
Each rocker arm acts on a so-called floating valve
yoke (3) that opens the valves. The rocker arm (4) is
supported by a bushing (6) on the rocker shaft (5).
Contact with the camshaft takes place via a roller (7)
and against the valve yoke by a ball seat (8).
The camshaft marking for static timing (TDC Top
Dead Center) and for valve and injector adjustments
is located on the camshaft front end (9) in front of the
front bearing bracket (10).
7748841 06-2010
71
Internal EGR
TAD1350GE, TAD1351GE, TAD1352GE,
TAD1353GE, TAD1354GE, TAD1355GE
General
P0006027
1
4
5
6
7
8
9
10
11
Camshaft
Exhaust rocker arm
Pump piston
Power piston
Check valve
Piston
Spring
Rocker arm, EGR
Exhaust lobe
72
7748841 06-2010
P0006028
1/: The control valve reduces oil pressure; the pressure is around 1 bar in the rocker arm shaft. The check
valve (7) is held open by the piston (8) being moved
forward by the spring (9). The oil channels are filled
with oil but the low pressure is not sufficient to raise
the pump piston (5) to its upper position.
EGR activation
P0006029
7748841 06-2010
When the pump piston (5) is forced to the upper position, the clearance between the EGR rocker arm (10)
and the exhaust rocker arm (4) is reduced.
73
P0006030
3/: The oil pressure lifts the pump piston (5) to the
upper position and occupies the space beneath the
piston. When oil has completely filled the system and
oil flow ceases, the check valve (7) closes. When the
EGR rocker arm (10) then rolls over the lobe,
P0006031
4/: After the exhaust valves have closed and the EGR
rocker arm no longer depresses the pump piston, the
oil that forced the power piston (6) down flows back
to the pump piston (5).
74
7748841 06-2010
P0006032
7748841 06-2010
75
2
3
2
P0006013
The crankshaft is drop forged and has induction hardened bearing journals and inserts. The crankshaft is
supported by seven main bearings with replaceable
bearing shells (1). There is also a thrust bearing in the
intermediate main bearing (B) comprising four halfmoon-shaped washers (2).
Front end (A) sealing is by means of a Teflon seal
(3) against the front crankshaft flange. There is also a
Teflon seal (4) at the rear (C) that seals against a
machined surface on the crankshaft gearwheel (5).
The gearwheel is fastened to the crankshaft with a
locating pin (6) and two bolts (7). There is a groove in
the rear crankshaft flange for an O-ring (8) that seals
between the flange and the flywheel.
76
7748841 06-2010
p0006014
7748841 06-2010
77
Engine Transmission
P0006015
78
7748841 06-2010
P0006016
7748841 06-2010
79
Covers
4
3
P0006017
80
7748841 06-2010
P0006018
7748841 06-2010
81
P0006019
B Safety valve
C Oil cooler thermostat valve
D Bypass valve for full-flow filter
E Opening valve for piston cooling
F Control valve for piston cooling
G Pressure take-off for piston cooling pressure
measurement
82
7748841 06-2010
11
5
9
D
13
A
12
P0006020
7748841 06-2010
83
P0006021
84
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2
1
3
P0006022
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85
P0006023
86
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Control valve
General
P0006033
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87
Neutral
The illustration below shows the control valve in the
neutral position, which means the engine is at rest. The
solenoid (9) is not activated and the valve slide (3)
rests against the retainer ring (1).
1 Retainer ring
2 Sleeve
3 Valve slide
4 Balance spring
5 Spring seat with ball holder
6 Valve ball
7 Cylinder
8 Bar
9 Solenoid
P0006034
10 Piston
11 Electrical connection
12 Pressure regulation orifice for control flow
13 Return orifice
14 Calibration orifice
15 Hole for oil flow to rocker arm
Normal operations
During normal engine operation the solenoid (9) is not
activated. The solenoid is in the control position and
forces oil through the orifice (15) to the rocker arm at
the same time as oil is able to flow through the calibration orifice (14) and on to the return orifice (13). This
reduces oil pressure to 1 bar (100 kPa) [14.5 PSI]
which is sufficient for lubricating the camshaft bearings
and valve mechanism.
P0006035
88
7748841 06-2010
Activation of EGR
When the engine is running and the EGR is activated,
the solenoid (9) is energized and the valve slide (3) is
forced to its end position fully open in that the
enclosed oil acts as a hydraulic lock. Full oil pressure
is now delivered to the rocker arm shaft and the EGR
function takes over.
P0006036
Deactivation of EGR
When the engine is running and the EGR function
released, the solenoid (9) is de-energized. The high
pressure that is present in the rocker arm shaft causes
the valve slide (3) to rapidly shut so that the oil return
connection (13) opens and oil drains out. When the oil
pressure falls to 1 bar (100 kPa) [14.5 PSI] the valve
slide is returned to the control position.
P0006663
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89
P0006024
7 Overflow valve
2 Feed pump
3 Fuel filter housing
4 Pre-filter with water separator
5 Venting valve
6 Fuel filter
8 Unit injector
10 Cooling loop for engine control unit
11 Level pipe
12 Venting nipple
13 Hand pump
90
7748841 06-2010
P0006025
1) Option.
7748841 06-2010
91
92
7748841 06-2010
Unit injectors
P0006026
7748841 06-2010
93
94
7748841 06-2010
P0003286
7748841 06-2010
95
96
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Crankcase venting
General
Because some of the products of combustion find their
way past pistons and piston rings (blow by) down to
the crankcase, the latter must be ventilated.
The engine can be delivered with one of two types of
crank case ventilation:
P0006037
7748841 06-2010
97
P0006038
98
7748841 06-2010
P0006039
7748841 06-2010
99
P0006040
100
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8
4
7
5
6
9
14
10
13
11
12
P0004318
1 Auxiliary stop
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101
Troubleshooting
A number of symptoms and possible causes of engine
malfunctions are described in the table below. Always
contact your Volvo Penta dealer if any problems occur
which you can not solve by yourself.
IMPORTANT!
Read through the safety advice for care and maintenance work in the chapter Safety precautions for boat
operation before you start work.
102
7748841 06-2010
Reason code
1 Discharged batteries
2 Poor contact/open circuit in electrical wiring
3 Main switch turned off
4 Main fuse faulty
5 Faulty ignition lock
6 Faulty main relay
7 Faulty starter motor/-solenoid
8 No fuel:
fuel cocks closed
fuel tank empty/wrong tank connected
9 Blocked fuel fine-filter/pre-filter (due to contaminations, or stratification in the fuel at low temperature)
10 Air in the fuel system
11 Water/contamination in fuel
12 Faulty unit injectors
13 In sufficient air supply to the engine:
blocked air filter
air leakage between the turbo and the engine's intake manifold
dirty compressor part in the turbocharger
faulty turbo compressor
poor engine room ventilation
14 Coolant temperature too high
15 Coolant temperature too low
16 Oil level too low
17 Coolant level too low
18 Air in the coolant system
19 Faulty circulation pump
20 Defective thermostat
21 Blocked charge air cooler
22 Oil level too high
23 Alternator drive belt slips
24 Water entry into engine
25 High back pressure in the exhaust system
26 Break in Pot+ cable to throttle
27 High temperature, charge air cooler
28 Blocked radiator
29 No pressure in cooling system
30 Check wastegate function
7748841 06-2010
103
External cleaning:
1 Remove guards as necessary, to access the
radiator.
IMPORTANT!
Take care that the radiator lamella are not damaged.
A high pressure washer may under no circumstances be used!
2 Clean with water and a mild detergent.
Use a soft brush.
3 Re-install removed parts.
Internal cleaning:
Further checks
Coolant circulation: Check that coolant circulates by letting the engine run at high speed.
Also check the expansion tank to see that coolant circulates. This can be an indication of a
fault in the cooling system.
Clogging
Is often caused by high coolant temperature, internal
or external blockage of the cooling system, or a combination of both. If the cooling system is blocked, it
must be cleaned.
104
7748841 06-2010
Removal
9998248
P0004964
P0004965
IMPORTANT!
Make sure that the area around the unit injectors
is clean before they are removed.
Remove the unit injectors, see Unit Injector,
Replace page 255 and mount the unit injector
protection (9998249). Clean the copper sleeves
as needed with cleaning kit 9998599.
7748841 06-2010
105
998 8539
P0004968
106
10
999 8248
11
Remove the middle piece and the oil pipe for the
rocker bridge.
12
7748841 06-2010
9998248
13
P0004964
Installation
14
15
16
17
18
19
20
Vent the fuel system, see Fuel system, bleeding page 245.
P0004965
7748841 06-2010
107
Install tool:
1 9998339 Manometer
2 9996666 Nipple
3 9990124 Nipple
P0005070
108
7748841 06-2010
P0010195
Alternative 2
WARNING!
Do not open the coolant filler cap when the engine is
warm. Steam or hot fluid could spray out, causing
severe burns.
Tools:
9996441 Cover, with connecting nipple
9996662 Pressure testing kit
1
P0010196
Alternative 3
WARNING!
Do not open the coolant filler cap when the engine is
warm. Steam or hot fluid could spray out, causing
severe burns.
Tools:
9996662 Pressure testing kit
9996049 Draining hose
1
7748841 06-2010
109
P0010197
110
7748841 06-2010
7748841 06-2010
111
Turbocharger, Inspection
112
Check that the turbocharger part number is correct for the engine variant. The wrong turbocharger for the engine variant might not provide
enough charge pressure, which would reduce
engine power.
Check that the turbocharger has the correct compressor housing. If the wrong compressor housing is installed on the turbocharger, the compressor wheel might have been damaged or have too
much clearance between wheel and housing. In
both cases, charge air pressure will be too low.
Check the turbocharger for damage to the compressor wheel and excessive end float on the turbine shaft.
Remove the exhaust pipe (muffler) from the turbocharger and check the turbine disc.
7748841 06-2010
Sensors, Adjustment
Sensor removed.
Tools:
88800031 Measuring tool
1
88800031
P0010198
P0010219
P0010218
7748841 06-2010
113
P0010220
114
7748841 06-2010
P0005072
Closed thermostat.
NOTICE! Always use a new seal, even if the thermostat is not replaced.
P0005073
Open thermostat.
7748841 06-2010
115
P0010532
116
7748841 06-2010
P0010531
P0010586
7748841 06-2010
P0010587
117
Exposing
1
P0006865
P0006866
118
7748841 06-2010
Remove the pipe between the air filter and turbocharger. Cover all openings.
Remove the air filter housing and mounting
bracket.
10
11
12
13
P0006867
P0006868
7748841 06-2010
119
P0009966
P0009967
120
7748841 06-2010
P0009968
P0009969
7748841 06-2010
121
P0009969
P0009967
122
7748841 06-2010
Vent the fuel system; refer to Fuel system, bleeding page 245.
P0009966
7748841 06-2010
123
Engine Disassembly
Timing Gear, Removal
Cylinder head removed; refer to Cylinder Head,
Removal page 153.
Tools:
9993590 Rotation tool
9998511 Lever
9998267 Guide sleeve
1
P0010123
P0010454
124
7748841 06-2010
P0010157
P0004300
P0010158
7748841 06-2010
125
P0010159
P0010160
P0010161
126
7748841 06-2010
10
11
P0010162
P0010163
P0010164
7748841 06-2010
127
13
Check that the crankshaft gear marking corresponds to the double gear.
P0010179
P0010180
128
7748841 06-2010
Check that the camshaft gear marking corresponds to the timing gear plate hole.
15
16
17
P0010181
P0010182
9998267
P0010184
7748841 06-2010
129
19
P0010185
P0010153
Pistons, Removal
Tools:
885822 Magnetic pen
1
9996966
P0010048
130
7748841 06-2010
P0010126
P0010127
1
P0010128
7748841 06-2010
131
P0010129
P0010130
P0010131
132
7748841 06-2010
10
P0010132
P0010133
7748841 06-2010
133
P0010134
9996645
9996394
9992955
P0010135
P0010136
134
7748841 06-2010
9996395
Lift out the liner with the tool and then remove the
tool from the liner.
Inspect the liners; refer to Cylinder Liner and Pistons, Inspection page 175.
P0010137
P0010138
Crankshaft, Removal
Tools:
9990114 Puller
9990013 Slide hammer
1
P0010156
7748841 06-2010
135
P0010165
P0010167
P0010168
136
7748841 06-2010
Lift the crankshaft and make sure that the connecting rods and main bearing cups do not come
out with the crankshaft.
P0010169
P0010170
7748841 06-2010
137
Engine Assembly
Crankshaft, Installation
Tools:
885811 Timing tool
885633 Torque multiplier
885648 Counterhold
9999696 Magnetic stand
9989876 Dial indicator
9998511 Lever
1
P0010167
P0010171
138
7748841 06-2010
P0010172
P0010173
P0010174
7748841 06-2010
139
11
P0005229
5
6
3
2
P0005230
P0010139
140
7748841 06-2010
Measure the height between the liner and the cylinder block plane. Measure the height of the liner
in two places, diagonal to each other.
Calculate the average of the two measurements.
For correct liner height above block plane, refer
to specifications. If the liner height is outside
specified tolerances, the liner seat must be
repaired (milled).
Always measure the highest point on the liner
sealing surface. Mark the liner's position with a
felt pen in order to re-install it in the exact same
position.
P0010134
P0006964
P0006965
7748841 06-2010
141
P0010140
P0006967
Pistons, Installation
Tools:
9996966 Press tool
9998531 Piston ring compressor
1
142
7748841 06-2010
Lift the piston into place with the piston ring clamp
and connecting rod (big end bearing lubricated).
Make sure the piston is facing the right direction
(so that the connecting rod is in the right position
on the crankshaft). Tap down the piston with a
hammer shaft.
Remove the piston ring clamp when the piston is
below it.
Re-install the press tools for the cylinder liner.
Press down the piston so that the connecting rod
touches the crankshaft.
Install the big end bearing caps and align it precisely with the crankshaft (big end bearing oiled).
Install the bolts.
Torque the bolts and check that the crankshaft
can be rotated.
P0010146
P0010126
P0010153
7748841 06-2010
143
P0005221
26
25
16
27
24
22
21
23
20
19
18
17
15
1
5
6
P0005222
144
29
28
7
8
9
2
10
4
3
11
12
13
14
7748841 06-2010
P0010186
P0010187
P0010186
7748841 06-2010
145
P0010189
P0010190
P0010191
146
7748841 06-2010
11
P0010192
P0010324
7748841 06-2010
147
13
P0010193
P0010325
148
7748841 06-2010
9999683
14
15
16
17
9999696
P0010544
P0010056
P0005224
7748841 06-2010
149
10
11
18
19
20
21
Install the covers with new seals. Install the crankshaft sensor with a new seal; refer to Sensors,
Adjustment page 113.
7
1
P0005225
P0010159
P0010158
150
7748841 06-2010
Install the fuel pump with drive unit and new seal.
Install new fuel line seals.
23
24
P0004300
P0010157
P0010147
7748841 06-2010
151
Install the oil filler with attachment and the oil dipstick.
26
27
P0010122
P0010123
152
7748841 06-2010
P0010027
P0010028
7748841 06-2010
153
P0010029
P0010030
154
7748841 06-2010
10
TAD135053GE:
Remove the springs from the EGR rocker arms.
P0010031
P0010032
P0010033
7748841 06-2010
155
12
13
P0010034
P0004965
6
5
4
3
P0010035
156
7748841 06-2010
15
1
2
P0010036
IMPORTANT!
make sure the vibration damper is protected from
impact and shocks.
Remove the camshaft gear.
P0010037
16
P0010038
7748841 06-2010
157
18
999 6400
999 8674
P0010039
CAUTION!
999 8264
20
P0010040
P0010040
9990013
9990006
P0001370
158
7748841 06-2010
22
23
24
999 8249
P0010041
999 8251
P0010042
P0010043
7748841 06-2010
159
26
27
P0010044
P0010045
P0010046
160
7748841 06-2010
999 6239
P0010047
29
9996966
P0010048
7748841 06-2010
161
P0010049
A
2
1
2
P0010050
162
7748841 06-2010
P0010051
36 35 28 27 22 21 15 16 23 24 31 32
11
6
3
9
1
13
7
14
10
2
5
8
12
4
38 37 30 29 18 17 19 20 25 26 33 34
P0005232
999 8264
CAUTION!
Cutting hazard! Protect your hands!
P0010040
P0010040
7748841 06-2010
163
10
11
P0010052
P0010053
P0010054
164
7748841 06-2010
9999683
12
13
14
9999696
P0010055
P0010056
P0010057
7748841 06-2010
165
16
17
P0005290
P0010058
999 8601
885 810
P0010059
166
7748841 06-2010
18
19
20
P0005227
9996400
9990156
P0010061
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167
22
23
24
P0010062
6
5
4
3
P0010063
P0004965
168
7748841 06-2010
TAD135055GE:
Install the EGR rocker arm springs. Make sure the
springs are positioned correctly on the rocker arm
ball tappet, but do not tighten the bolts (the bolts
are tightened after valve adjustment).
26
27
28
P0010033
P0010034
7748841 06-2010
169
30
31
P0010031
P0010032
P0010064
170
7748841 06-2010
33
34
P0010065
P0010320
11
10
12
P0005246
7748841 06-2010
171
36
P0010029
P0010096
172
7748841 06-2010
38
39
P0010097
P0010098
P0010099
7748841 06-2010
173
13 12
11
10
15
16
17
40
41
42
43
44
18
19
14
9
20
p0005236
P0010028
P0010027
174
7748841 06-2010
Cylinder Liner
Measurement of cylinder liner wear can be done with
the liner installed in the cylinder block.
NOTICE! The cylinder liners must be taken out of the
engine block, to do a careful crack check.
1
Measure the cylinder liners with a cylinder indicator. In order to obtain the greatest possible
accuracy in the wear measurement, the cylinder
liner must first be set up with a gauge ring or
micrometer. Use the original diameter of the cylinder liner as the base value.
If wear is greater than 0.450.50 mm, a new complete lining kit must be used (piston, liner, piston
rings, piston pin and seals).
Oil consumption also affects when cylinder liners
must be changed.
P0006962
Pistons
5
7748841 06-2010
175
P0006994
176
Check the connecting rods for cracking, straightness and twist before any piston pin bush
replacement. Scrap the connecting rod if it is
cracked, bent or twisted.
When the piston pin bush is changed, the bush
must be machined (trapezoid piston pin end).
When the clearance is correct, an oiled piston pin
should slowly slide through the bush under its
own weight.
IMPORTANT!
Regarding max. allowed straightness and twist deviations, refer to Technical Data page 27.
P0006995
Use a new piston pin and measure the straightness of the connecting rod, using a fixture.
7748841 06-2010
P0004806
TDC
P0002568
7748841 06-2010
177
P0012060
P0012061
178
7748841 06-2010
240
P0012062
TDC
P0002568
7748841 06-2010
179
P0004806
P0004806
180
7748841 06-2010
P0002568
P0004951
7748841 06-2010
181
P0004952
P0004528
182
7748841 06-2010
P0004594
7748841 06-2010
183
P0004596
P0004596
184
7748841 06-2010
P0004594
10
11
P0004526
P0004953
7748841 06-2010
185
13
P0005197
TDC
P0002568
186
7748841 06-2010
15
16
P0004806
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187
2
IMPORTANT!
The cylinder head must not be put down so its
entire weight rests on the valve guides (see illustration).
Put the cylinder head on the bench with the valve
discs facing upwards.
999 9696
998 9876
p0005207
188
7748841 06-2010
CAUTION!
Risk of eye injury. Eye protection required.
Option 1
Tools:
9809726 Pneumatic hydraulic pump
9809729 Hydraulic cylinder
9990176 Press tool
9996159 Adapter
88800147 Drift
88800062 Drift
Optional tools
Tools:
9992670 Hand pump
Note: 9992670 is alternative to 9809726.
Removal
999 2670
980 9726
980 9729
999 0176
999 6159
888 00137
p0003637
7748841 06-2010
189
Installation
6
Heat the cylinder head with hot water while cooling the valve guides with e.g. carbon dioxide
snow.
Lubricate the cylinder head valve guides with
engine oil.
IMPORTANT!
Wear protective goggles when pressing.
999 2670
980 9726
980 9729
999 0176
999 6159
p0011273
888 00062
IMPORTANT!
After the valve guides have been changed, the cylinder
head must be cleaned carefully to prevent dirt particles
from getting into the fuel and oil ducts. Contamination
may cause failure or malfunction of the unit injectors.
Option 2
Tools:
9992000 Handle
88800147 Drift
88800062 Drift
NOTICE! If the valve seats must also be changed, this
must be done before the valve guides are removed.
CAUTION!
Risk of eye injury. Eye protection required.
190
7748841 06-2010
Removal
NOTICE! Take out the valve guides from beneath the
cylinder head.
1
Installation
3
Heat the cylinder head with hot water while cooling the valve guides with e.g. carbon dioxide
snow.
Lubricate the cylinder head valve guides with
engine oil.
CAUTION!
Risk of eye injury. Eye protection required.
4
Tap in the valve guide for the inlet valve using tool
88800062 Drift. Tap in the exhaust valve guide
using the same tool.
999 2000
IMPORTANT!
After the valve guides have been changed, the cylinder
head must be cleaned carefully to prevent dirt particles
from getting into the fuel and oil ducts. Contamination
may cause failure or malfunction of the unit injectors.
P0011274
7748841 06-2010
888 00062
191
Valves, Removal
Work is made easier if the cylinder head is fixed in an
equipment stand using tool 9990160 Fixture. Use 4
pcs. bolts M8 x 25.
NOTICE! It is important that the greatest possible
cleanliness is observed during work on the cylinder
head. Dirt particles in the fuel ducts can cause failure
or malfunction of the unit injectors.
Alternative 1
P0006996
Tools:
9809726 Pneumatic hydraulic pump
9809729 Hydraulic cylinder
9990160 Fixture
9990174 Drift
9992670 Hand pump
9996159 Adapter
9998246 Drift
Note: 9992670 Hand pump is alternative to
9809726 Pneumatic hydraulic pump .
Alternative 2
Tools:
9990210 Valve spring compressor
Alternative 1
1
192
7748841 06-2010
Alternative 2
Tools:
9990210 Valve spring compressor
1
P0006997
7748841 06-2010
193
Valves, Installation
Alternative 1
Tools:
9809726 Pneumatic hydraulic pump
9990165 Guide sleeve
9990174 Drift
9990176 Press tool
9990210 Valve spring compressor
9992670 Hand pump
9996159 Adapter
9998246 Drift
88800151 Drift
Note: 9992670 Hand pump is alternative to
9809726 Pneumatic hydraulic pump .
Alternative 2
Tools:
9990210 Valve spring compressor
1
P0006998
Alternative 1
3
194
7748841 06-2010
Alternative 2
Tools:
9990210 Valve spring compressor
1
Alternatively, tool 9990210 Valve spring compressor may be used instead of the hydraulic cylinder, in the same way as for Valves, Removal.
P0006997
7748841 06-2010
195
P0007076
25
24,5
P0010244
Inlet valve
40
39,5
P0010245
Exhaust valve
196
7748841 06-2010
Valves, grinding
1
P0007000
7748841 06-2010
197
P0007000
IMPORTANT!
Carefully cover the other surfaces on the cylinder head
to prevent any weld spatter from fastening.
P0007001
P0007002
198
7748841 06-2010
CAUTION!
Risk of eye injury. Eye protection required.
4
Clean the seat bed carefully and check the cylinder head for cracks.
P0007003
P0007004
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199
Removal
1
Installation
7
Transfer the valve spring compressor to no. 6 cylinder and repeat the tasks as above. Then crank
the engine so that no.3 and no.4 cylinder are at
TDC.
Repeat the procedure. Then continue with cylinders 2 and 5.
88800151
P0011236
200
10
11
12
Vent the fuel system; refer to Fuel system, bleeding page 245. Perform a function and leakage
check.
7748841 06-2010
Lighter scratches:
Hard wear:
IMPORTANT!
The camshaft and associated rocker arms must be
changed.
P0003896
P0003899
P0003898
P0003897
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201
P0007018
202
7748841 06-2010
Flywheel, Indication
Flywheel exposed; refer to Timing Gear,
Removal page 124.
Tools:
9993590 Rotation tool
9989876 Dial indicator
9999696 Magnetic stand
1
999 9696
998 9876
P0010194
7748841 06-2010
203
Put the heated gear ring onto the flywheel and tap
it into place with a soft mandrel and hammer.
Leave the gear ring to cool.
P0006979
P0006980
P0006981
204
7748841 06-2010
Sensors, Adjustment
Sensor removed.
Tools:
88800031 Measuring tool
1
88800031
P0010198
P0010219
P0010218
7748841 06-2010
205
P0010220
206
7748841 06-2010
Removal
1
P0006884
P0010124
7748841 06-2010
207
P0006970
NOTICE! If case of uncertainty, check in Technical Data page 27 which oversize dimensions are
available.
P0006971
Installation
7
P0006972
208
7748841 06-2010
10
11
P0006973
P0006974
7748841 06-2010
209
P0006975
210
13
14
15
16
Remove tool 9993590 Rotation tool from the flywheel housing and install the cover.
17
7748841 06-2010
Removal
1
Remove the right belt guard; refer to Belt Protector page 296.
P0004682
7748841 06-2010
211
P0004786
P0004785
212
7748841 06-2010
P0004787
11
P0004788
13
14
15
P0004789
7748841 06-2010
213
NOTICE! Incline the tool to ensure that the crankshaft is not damaged.
Assemble tool 9996400 Slide hammer and tool
9990192 Puller.
Remove the old seal by tapping in a puller inside
the seal and pulling it out with a slide hammer.
P0004790
Installation
9992000 Handle
9993590 Rotation tool
88800021 Drift.
17
18
19
Install the new seal ring and plastic ring onto the
crankshaft journal.
P0004791
214
7748841 06-2010
21
P0004792
P0004793
7748841 06-2010
215
23
24
25
26
27
P0004794
P0004786
216
7748841 06-2010
29
30
31
P0004787
P0004785
7748841 06-2010
217
33
34
35
36
Install the right belt guard: Refer to Belt Protector page 296.
37
38
39
Refill with coolant: Refer to Coolant Level, Checking and Topping Up page 280.
P0004682
218
7748841 06-2010
Removal
1
P0004796
7748841 06-2010
219
NOTICE! Be careful not to damage the crankshaft. Incline the tool inwards to ensure a good
grip in the seal.
P0004795
P0004954
220
7748841 06-2010
Installation
9990166 Mounting tool
7
P0004960
P0004957
7748841 06-2010
221
11
P0004959
P0004958
222
7748841 06-2010
Offer the flywheel into place and fit the key in the
keyway.
Install one bolt to render the lift safe.
14
15
P0004795
P0004796
7748841 06-2010
223
Crankshaft, Inspection
The crankshaft is induction hardened.
Inspect the crankshaft very carefully to avoid unnecessary overhaul.
The following applies when the need for overhaul is
checked:
1
224
7748841 06-2010
Removal
1
P0006884
P0010124
7748841 06-2010
225
P0006970
NOTICE! If case of uncertainty, check in Technical Data page 27 which oversize dimensions are
available.
P0006971
Installation
7
P0006972
226
7748841 06-2010
10
11
P0006973
P0006974
7748841 06-2010
227
P0006975
228
13
14
15
16
Remove tool (missing toolreference) from the flywheel housing and install the cover.
17
7748841 06-2010
Removal
1
P0010122
P0010454
7748841 06-2010
229
P0010535
CAUTION!
Cutting hazard! Protect your hands!
P0010536
P0010536
230
7748841 06-2010
Installation
7
CAUTION!
Cutting hazard! Protect your hands!
P0010536
P0010535
7748841 06-2010
231
11
P0010147
232
7748841 06-2010
P0010243
7748841 06-2010
233
P0010000
P0009999
234
7748841 06-2010
P0010001
Installation
6
Thoroughly clean the engine block contact surfaces for the bracket.
P0010002
IMPORTANT!
Sealant may absolutely not be used. The use of
sealant may result in engine breakdown.
P0010003
7748841 06-2010
235
10
Install the front and rear pipes to the oil cooler with
new seals. Install the hose to the turbocharger
with a new seal.
Install the pressure sensor connector. Clamp the
heat shield to the pressure sensor.
Install new oil filters.
Clamp the hose to the waste gate controller.
11
12
13
P0010004
P0010005
P0010006
236
7748841 06-2010
Remove the safety valve and make sure the Orings come with it.
Check that there is no dirt on the valve sealing
surface on the engine block.
P0010334
P0010335
P0010336
7748841 06-2010
237
P0010334
P00010341
P0010342
238
IMPORTANT!
No sealant may be used. The use of sealant may
result in engine breakdown.
7748841 06-2010
Removal
1
P0009970
P0009971
P0009972
7748841 06-2010
239
P0009973
P0009974
P0009975
P0009976
240
7748841 06-2010
P0009977
Installation
9
10
11
P0009975
P0009974
P0009973
7748841 06-2010
241
13
14
15
16
P0010538
P0009978
P0009979
242
7748841 06-2010
18
P0009971
P0010338
P0010339
7748841 06-2010
243
P0010340
244
7748841 06-2010
Open the nipple on the front fuel connection. Connect a drain hose.
P0004969
P0004970
7748841 06-2010
245
P0005062
P0005061
246
7748841 06-2010
P0005059
5
IMPORTANT!
Take great care to ensure that dirt does not enter
the fuel channel.
Use a suitable hose and blow the fuel through the
fuel channel in the cylinder head, so that it runs
out into the receptacle.
6
P0005060
7748841 06-2010
247
Install tool:
1 9998339 Manometer
2 9996666 Nipple
3 9990124 Nipple
P0005070
Removal
248
7748841 06-2010
P0009988
P0009989
P0009990
7748841 06-2010
249
P0009989
Installation
7
p0009992
P0009989
250
7748841 06-2010
10
11
P0009990
P0009989
P0009994
7748841 06-2010
251
Clean the fuel pump and fuel lines, and the fuel
pump drive device
P0004300
P0010541
P0010543
252
7748841 06-2010
Installation
6
Clean the sealing surfaces and install a new Oring on the drive unit.
P0010542
P0010541
P0010540
7748841 06-2010
253
10
11
Vent the fuel system; refer to Fuel system, bleeding page 245.
12
P0010539
P0004300
254
7748841 06-2010
Removal
1
P0010099
P0010033
7748841 06-2010
255
P0010034
P0004965
6
5
4
3
P0010035
256
7748841 06-2010
9990013
9990006
P0001370
10
11
999 8249
P0010041
999 8251
P0010042
7748841 06-2010
257
Installation
9990156 Adapter
9996400 Slide hammer
9990185 Lifting tool
3883671 Protective sleeve
3883672 Protective sleeve
12
13
9996400
9990156
P0010061
IMPORTANT!
The steel washer must be replaced every time an
injector is installed.
Install the injector and injector yoke. Turn the
injector so that the wiring connections are exactly
opposite the valve springs.
Install the retaining bolt and tighten according to
Special Tightening Torques page 8.
14
P0010062
258
7748841 06-2010
16
17
6
5
4
3
P0010035
P0004965
P0010033
7748841 06-2010
259
19
20
21
Install the valve cover. Replace gasket as necessary. Tighten according to Special Tightening
Torques page 8.
22
Vent the fuel system; refer to Fuel system, bleeding page 245.
P0010034
P0010099
13 12
11
10
15
16
17
18
19
14
9
20
p0005236
260
7748841 06-2010
999 8251
P0010042
P0006826
7748841 06-2010
261
P0007010
262
7748841 06-2010
11
12
13
P0007011
999 8580
980 8617
IMPORTANT!
This must be done so that tool no. 9998688 does
not damage the piston due to its length.
P0007012
14
P0010239
7748841 06-2010
263
88800196
P0003616
88800196
16
P0003617
264
7748841 06-2010
88800196
17
18
19
20
21
Install the rocker arm bridge and check the clearance of the valves and unit injectors.
22
23
P0003618
9998250
P0003619
7748841 06-2010
265
WARNING!
Disconnect power from the engine by disconnecting the negative battery terminal.
P0010470
266
7748841 06-2010
10
11
12
13
P0010470
7748841 06-2010
267
268
7748841 06-2010
P0009981
P0009983
7748841 06-2010
269
P0009984
P0009985
Installation
6
Inspect and clean the sealing surfaces on the cylinder head and inlet manifold.
P0009987
270
7748841 06-2010
10
P0010332
P0010241
P0010242
7748841 06-2010
271
12
13
P0010333
P0009984
P0009983
272
7748841 06-2010
15
16
17
P0009981
7748841 06-2010
273
25-5 Turbocharger
25-5 Turbocharger
Turbocharger, Inspection
274
Check that the turbocharger part number is correct for the engine variant. The wrong turbocharger for the engine variant might not provide
enough charge pressure, which would reduce
engine power.
Check that the turbocharger has the correct compressor housing. If the wrong compressor housing is installed on the turbocharger, the compressor wheel might have been damaged or have too
much clearance between wheel and housing. In
both cases, charge air pressure will be too low.
Check the turbocharger for damage to the compressor wheel and excessive end float on the turbine shaft.
Remove the exhaust pipe (muffler) from the turbocharger and check the turbine disc.
7748841 06-2010
25-5 Turbocharger
Turbo, Change
Removal
1
P0004694
P0004693
7748841 06-2010
275
25-5 Turbocharger
9
10
11
Remove the gasket and check the exhaust manifold sealing surface.
Blow through the manifold and check that there is
no contamination in the pipe.
Install a new gasket on the exhaust manifold
P0004784
P0004783
Installation
12
P0004784
276
7748841 06-2010
25-5 Turbocharger
P0004693
7748841 06-2010
13
14
15
16
Check that the turbocharger inlet pipe is thoroughly clean internally before it is installed
between the air filter and turbocharger.
Check that the pipe between the turbocharger
and charge air cooler is clean internally. if there
is contamination in the pipe, the charge air cooler
also requires internal cleaning.
Install the pipe between the turbocharger and the
charge air cooler.
Install the exhaust system.
Start the engine and check that no leakage is evident.
277
P0002095
P0006865
278
7748841 06-2010
7748841 06-2010
279
Refill with new, Volvo Penta-recommended cooling fluid. Refer to Technical Data page 44 and
Coolant Level, Checking and Topping
Up page 280.
P0002095
280
7748841 06-2010
P0002095
P0010195
Alternative 2
WARNING!
Do not open the coolant filler cap when the engine is
warm. Steam or hot fluid could spray out, causing
severe burns.
Tools:
9996441 Cover, with connecting nipple
9996662 Pressure testing kit
7748841 06-2010
281
P0010196
Alternative 3
WARNING!
Do not open the coolant filler cap when the engine is
warm. Steam or hot fluid could spray out, causing
severe burns.
Tools:
9996662 Pressure testing kit
9996049 Draining hose
P0010197
282
7748841 06-2010
7748841 06-2010
283
Removal
1
Remove the right belt guard. Refer to Belt Protector page 296.
P0004682
284
7748841 06-2010
P0004683
Installation
6
P0004684
7748841 06-2010
285
10
Check the idler and tensioner pulleys on the automatic belt tensioner.
P0004683
P0004686
286
7748841 06-2010
12
13
Install the right belt guard. Refer to Belt Protector page 296.
P0004682
7748841 06-2010
287
Thermostat, Change
Tools:
9996049 Draining hose
Removal
1
Remove the upper belt guard; refer to Belt Protector page 296.
P0004690
P0004691
288
7748841 06-2010
Installation
5
Install the upper belt guard: Refer to Belt Protector page 296.
P0005071
P0004691
IMPORTANT!
Ensure that engine wiring is not pinched.
9
10
P0004690
7748841 06-2010
289
Drive Belts
Right belt guard removed; refer to Belt Protector page 296.
Removal
1
CAUTION!
Pinch hazard. Keep fingers clear.
Wind off the belt.
P0004685
290
7748841 06-2010
Installation
1
P0004686
CAUTION!
Pinch hazard. Keep fingers clear.
Wind on the belt.
P0004685
7748841 06-2010
291
Removal
1
P0004682
Installation
3
P0009982
292
7748841 06-2010
P0005072
Closed thermostat.
NOTICE! Always use a new seal, even if the thermostat is not replaced.
P0005073
Open thermostat.
7748841 06-2010
293
Removal
1
P0004963
Closed tap.
294
7748841 06-2010
Installation
3
P0004962
Open tap.
7748841 06-2010
295
P0004681
296
7748841 06-2010
P0004680
P0004689
7748841 06-2010
297
32-1 Alternator
32-1 Alternator
Alternator Belts, Change
Left belt guard removed; refer to Belt Protector page 296.
Coolant pump belt removed; refer to Drive
Belts page 290.
Removal
1
CAUTION!
Pinch hazard. Keep fingers clear.
Wind off the belt.
P0004688
Installation
1
P0004687
298
7748841 06-2010
32-1 Alternator
2
CAUTION!
Pinch hazard. Keep fingers clear.
Wind on the belt.
P0004688
Removal
1
P0009980
Installation
7748841 06-2010
299
Alphabetical index
About this Workshop manual................................ 2
Alternator............................................................... 298
Alternator Belts, Change....................................... 298
Belt Protector....................................................... 296
Belt Tensioner, Change................................. 292, 299
Bypass Valve, Oil Filter Bypass, Replace............. 238
Cable description................................................ 116
Camshaft and valve mechanism............................. 71
Camshaft Bearing Housing, Replace.................... 202
Camshaft, Wear Check......................................... 201
Charge Air Pipe, Leakage Check.................. 111, 268
Charge Pressure, Troubleshooting....................... 110
Common Interference Causes.............................. 104
Compression Test................................................. 105
Connecting Rod Bushing, Check up..................... 176
Connecting Rod, Check........................................ 176
Control System, ECM, Data Sets.......................... 266
Control Unit, Replace............................................ 266
Control valve........................................................... 87
Coolant Filter, Change.......................................... 294
Coolant Level, Checking and Topping Up............. 280
Coolant Pump, Change......................................... 284
Coolant Pump, Thermostat................................... 284
Cooling System.............................................. 44, 0
Cooling System, General...................................... 278
Cooling System, Pressure Testing................ 108, 281
Copper sleeve for unit injector, replace................. 261
Crank Mechanism........................................... 36, 211
Crankcase venting................................................... 97
Crankshaft seal, replace (front)............................. 211
Crankshaft Sealing, Change (rear)........................ 219
Crankshaft, Inspection........................................... 224
Crankshaft, Installation.......................................... 138
Crankshaft, Removal............................................. 135
Crankshaft, vibration damper, flywheel................... 76
Cylinder head, guides to cylinder block................... 69
Cylinder Head, Installation.................................... 162
Cylinder Head, Removal....................................... 153
Cylinder Liner and Pistons, Inspection.................. 175
Cylinder Liner, Installation..................................... 140
Cylinder Liner, Pistons.......................................... 175
Cylinder Liners, Removal...................................... 133
Design and Function............................................. 59
Draining the Cooling System................................. 278
Draining, Fuel Duct in Cylinder Head.................... 246
Drive Belts............................................................. 290
Engine........................................................... 27, 0
Engine Assembly................................................... 138
Engine body............................................................ 27
Engine Complete, General.................................... 116
Engine control system........................................... 101
Engine Disassembly.............................................. 124
Engine Fixture, Removal....................................... 122
Engine Information, General................................... 59
Engine Transmission......................................... 34, 78
Engine, General...................................................... 26
7748841 06-2010
Exposing................................................................ 118
Exposing the Engine............................................. 116
Fan............................................................................ 6
Fan, Fan Shroud................................................... 296
Fitting the Fixture................................................... 120
Flywheel, Indication............................................... 203
Fuel Feed Pressure, Check........................... 108, 248
Fuel Feed Pump and Filter.................................... 248
Fuel Feed Pump, Change..................................... 252
Fuel feed system, principle...................................... 91
Fuel Filter Bracket, Change................................... 248
Fuel System................................................... 42, 0
Fuel system, bleeding........................................... 245
Fuel System, General............................................ 245
Gear Ring, Fywheel: Replace............................. 204
General............................................................. 2, 0
General Tightening Torques...................................... 7
Group 21: Engine................................................ 8, 60
Group 22: Lubrication System........................... 18, 81
Group 23: Fuel System..................................... 21, 90
Group 25: Inlet and Exhaust System................. 24, 95
Group 26: Cooling System................................ 25, 99
Identification Numbers......................................... 59
Injectors and Delivery Pipes.................................. 255
Inlet and Exhaust Manifolds.................................. 269
Inlet and Exhaust System............................... 43, 0
Inlet and Exhaust System, General....................... 268
Inlet Manifold, Change.......................................... 269
Internal EGR............................................................ 72
Location of Sensors.............................................. 25
Lube Oil Pump, Installation................................... 143
Lube Oil Pump, Removal...................................... 130
Lubrication Oil Pump, Change.............................. 229
Lubrication System.................................................. 40
Lubrication system, principle................................... 83
Main bearing, Change................................. 207, 225
Miscellaneous............................................................ 6
Oil cooler.............................................................. 239
Oil Cooler, Replace............................................... 239
Oil filter.................................................................. 233
Oil Filter Bracket, Change..................................... 234
Oil Pressure Sensor, Check.................................. 233
Oil pump and Line................................................. 229
Oil pump and oil cooler............................................ 84
Other Equipment..................................................... 58
Piston cooling system.......................................... 86
Piston, cylinder lining, connecting rod..................... 70
Pistons, Installation............................................... 142
Pistons, Removal.................................................. 130
Repair instructions.................................................. 3
Safety Instructions................................................ 48
Safety Valve, Oil Pressure, Replace..................... 237
Sensors, Adjustment..................................... 113, 205
Special Service Tools.............................................. 52
Special Tightening Torques....................................... 8
301
Specifications, Electrical.......................................... 45
Specifications, Engine .............................................. 7
Steering System...................................................... 45
Technical Data............................... 27, 40, 42, 43, 44
Test and Adjustments............................................ 105
Thermostat Oil Cooler, Change............................. 243
Thermostat, Change.............................................. 288
Thermostat, Function Check......................... 115, 293
Timing Gear, Installation....................................... 144
Timing Gear, Removal.......................................... 124
Timing Gears and Shaft........................................ 201
Troubleshooting..................................................... 102
Turbo, Change...................................................... 275
Turbocharger......................................................... 274
Turbocharger, Inspection.............................. 112, 274
Unit Injector, Replace.......................................... 255
Unit injectors............................................................ 93
Valve Guides, Inspection.................................... 188
Valve Guides, Replacing....................................... 189
Valve Mechanism.................................................. 177
Valve mechanism.................................................... 29
Valve Seat, Change.............................................. 198
Valve Seats and Valve, Grinding........................... 196
Valve Stem Sealings, Replace.............................. 200
Valves and Unit Injectors, Adjustment........... 177, 180
Valves, Installation................................................ 194
Valves, Removal................................................... 192
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AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Gteborg
Sweden