Workshop Manual I

Group 00-08, 20-26, 32-33 4(0)

TAD1640GE, TAD1641GE, TAD1642GE,

TWD1643GE, TAD1641VE, TAD1642VE,
TAD1643VE, TAD1650VE
Content

General Information
00-0 General ................................................................................................ 2

Specifications
03-0 General Specifications ....................................................................... 6
03-2 Specifications, Engine ....................................................................... 8
03-3 Specifications, Electrical ................................................................. 37

Safety and Other Instructions

05-1 Safety Instructions ........................................................................... 38

Special tools
08-1 Universal Tools ................................................................................. 42
08-2 Special Service Tools ....................................................................... 44

Service and Maintenance

17-3 Maintenance Service ........................................................................ 50

General
20-0 Engine Information, General ............................................................ 52

Engine
21-0 Engine Complete, General ............................................................... 98
21-4 Valve Mechanism ............................................................................ 203

Lubricating and Oil System

22-0 Lubricating and Oil System, General ............................................ 206
22-1 Oil pump and Line .......................................................................... 208
22-2 Oil filter ............................................................................................ 209
22-3 Oil cooler ......................................................................................... 215

Fuel System
23-0 Fuel System, General ..................................................................... 218
23-3 Fuel Feed Pump and Filter ............................................................. 223
23-7 Injectors and Delivery Pipes .......................................................... 226
23-8 Control System, ECM, Data Sets ................................................... 230

Inlet and Exhaust System

25-2 Exhaust Pipe, Silencer ................................................................... 232
25-5 Turbocharger .................................................................................. 234

Cooling System
26-0 Cooling System, General ............................................................... 247
26-1 Radiator, Heat Exchanger .............................................................. 255
26-2 Coolant Pump, Thermostat ............................................................ 259
26-5 Charge Air Cooler with Connections ............................................ 268

Alternator, Charge Regulator

32-1 Alternator ......................................................................................... 274

Starting System
33-1 Starter Motor ................................................................................... 278
Alphabetical index .................................................................................. 281
References to Service Bulletins ............................................................ 283
00-0 General
About this Workshop manual
General information Certified engines
This Service Manual contains technical data, descrip- When carrying out service and repair on emis-
tions and maintenance and repair instructions for sion-certified engines, it is important to be aware
standard model Volvo Penta products. A list of these of the following:
products may be found in the section Technical
Data. Certification means that an engine type has been
inspected and approved by the relevant authority.
The product designation and the serial number and The engine manufacturer guarantees that all engines
specification is indicated on the engine decal or type of the same type are manufactured to correspond to
plate. This information must be included in all corre- the certified engine.
spondence regarding the product. This places special demands on service and repair
work, namely:
The service manual is produced primarily for the use
of Volvo Penta workshops and their qualified person- • Maintenance and service intervals recom-
nel. It is assumed that any person using the Service mended by Volvo Penta must be complied with.
Manual has a fundamental knowledge of the product • Only spare parts approved by Volvo Penta may
and is able to carry out mechanical and electrical be used.
work to trade standard.
• Service on injection pumps, pump settings and
Volvo Penta continually develops its products; we injectors must always be carried out by an
therefore reserve the right to make changes. All infor- authorized Volvo Penta workshop.
mation in this manual is based on product data which
• The engine must not be converted or modified,
was available up to the date on which the manual was
except with accessories and service kits which
printed. New working methods and significant
Volvo Penta has approved for the engine.
changes introduced to the product after this date are
communicated in the form of Service bulletins. • No changes to the exhaust pipe and engine air
inlet duct installations may be made.
Spare Parts
• No warranty seals (where present on the prod-
Spare parts for the electrical and fuel systems are uct) may be broken by unauthorized persons.
subject to various national safety standards. Volvo
Penta Original Spare Parts meet these standards. No The general instructions in the Operator's Manual
damage of any kind caused by the use of spare parts concerning operation, service and maintenance
not approved by Volvo Penta will be compensated by apply.
any warranty undertaking.
IMPORTANT!
Neglected or poorly-performed care/service and the
use of spare parts not approved by Volvo Penta, will
mean that AB Volvo Penta no longer guarantees that
the engine conforms to the certified model.

Volvo Penta accepts no responsibility for damage or

costs arising as a result of failure to follow the above
mentioned standards.

2 7747722 01.2009
 00-0 General

Repair instructions
Introduction Our mutual responsibility
The working methods described in this manual are Each product comprises a large number of interacting
based on a workshop scenario where the product is systems and components. A deviation from the tech-
mounted in a holding fixture. Maintenance work is nical specification may dramatically increase the
often carried out in situ, in which case – if nothing else environmental impact of an otherwise reliable sys-
is indicated – using the same working methods as the tem. It is therefore critical that the stated wear toler-
workshop. ances be adhered to, that systems which can be
adjusted be correctly set up and that only Volvo Penta
Warning symbols that occur in the service manual. Original Parts are used. The intervals in the care and
For significance, refer to Safety Information . maintenance schedule must be followed.
! DANGER! Some systems, e.g. fuel systems, often require spe-
cial expertise and test equipment. A number of com-
! WARNING! ponents are factory-sealed, for among other things
environmental reasons. Warranty-sealed compo-
! CAUTION!
nents may not be worked on without authorization to
perform such work.
IMPORTANT!, NOTICE!
are by no means comprehensive since not everything Remember that most chemical products, incorrectly
can be foreseen as service work is carried out in the used, are harmful to the environment. Volvo Penta
most varied of circumstances. We call attention to recommends the use of biodegradable degreasers
risks that may occur due to incorrect handling during whenever components are cleaned, unless otherwise
work in a well-equipped workshop using working specified in the Service Manual. When working out-
methods and tools tried and tested by us. doors, take especial care to ensure that oils and wash
residues etc. are correctly properly for destruction.
The service manual describes work operations car-
ried out with the aid of Volvo Penta Special Tools,
where such have been developed. Volvo Penta Spe-
Tightening torques
cial Tools are designed to ensure the safest and most Tightening torques for vital fasteners that must be
rational working methods possible. It is therefore the applied using a torque wrench are indicated in the
responsibility of anyone using tools or working meth- Service Manual, chapter Tightening torques and in
ods other than those we recommend to ensure that the Manual's work descriptions. All torque indications
no risk of personal injury or mechanical damage is apply to clean threads, bolt heads and mating faces.
present, or that malfunction can result. Indicated torque data apply to lightly-oiled or dry
threads. If lubricants, locking fluids or sealants are
In some cases, special safety regulations and user required for fasteners, the correct type will be noted
instructions may be in force for the tools and chemi- in the job description.
cals mentioned in the Service Manual. These regu-
lations must always be followed, and no special
instructions regarding this are to be found in the Serv-
ice Manual.

By taking these basic precautions and using common

sense it will be possible to guard against most ele-
ments of risk. A clean workplace and a clean product
will eliminate many risks of personal injury and mal-
function.

Above all, when working on fuel systems, hydraulic

systems, lubrication systems, turbochargers, inlet
systems, bearings and seals, it is of the utmost impor-
tance that dirt and foreign objects are kept away, as
malfunctions or shortened service intervals may oth-
erwise result.

7747722 01.2009 3
00-0 General

Torque, angle tightening Sealing compounds etc.

When torque/angle tightening, the fastener is tight- To ensure service work is correctly carried out it is
ened to a specified torque, and tightening then con- important that the correct type of sealants and locking
tinues through a pre-determined angle. fluids are used on joints where such are required.

Example: For 90° angle tightening, the fastener is In each service manual section concerned, the seal-
turned a further 1/4 turn in one sequence, after the ants used in product manufacture are indicated. The
specified tightening torque has been achieved. same sealants, or sealants with equivalent proper-
ties, must be used for maintenance work.
Lock nuts
Make sure that mating surfaces are dry and free from
Removed locknuts may not be re-used; they must be oil, grease, paint and anti-corrosion agent before
replaced by new ones, as locking properties are applying sealant or locking fluid. Always follow the
impaired or lost with re-use. manufacturer's instructions regarding applicable
In the case of lock nuts with plastic inserts the tight- temperatures, hardening times and such.
ening torque indicated must be reduced if the nut has
the same nut height as a standard, all-metal hexag- Two basic types of compound are used:
onal nut.
RTV preparations (Room Temperature Vulcaniz-
Reduce the torque by 25% for bolt sizes of 8 mm or
ing).
larger.
Used most often together with gaskets, e.g. sealing
In the case of lock nuts with plastic inserts with a high
gasket joints, or are brushed on gaskets. RTV seal-
nut-height (where the all-metal thread is as high as a
ants are completely visible when the part has been
standard hexagonal nut), the indicated torque
removed. Old RTV sealant must be removed before
applies.
the component is sealed again. Use denatured alco-
hol.
Strength classes
Nuts and bolts are subdivided into different strength Anaerobic agents.
classes. The classification is shown by a marking on These agents cure (harden) in the absence of air.
the bolt head. Markings of a higher number indicate These preparations are used when two solid compo-
stronger material. For example, a bolt marked 10-9 is nents, e.g. two cast components, are fitted together
stronger than one marked 8-8. without a gasket. Common uses are also to lock and
seal plugs, stud threads, taps, oil pressure monitors
For this reason, it is important that when bolts are etc.
removed they are returned to their original locations
on re-assembly. When replacing bolts check the Hardened anaerobic preparations are glassy and for
applicable Spare parts catalogue to ensure the cor- this reason, the preparations are colored to make
rect bolt is used. them visible. Hardened anaerobic preparations are
highly resistant to solvents, and old compound can-
not 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.

4 7747722 01.2009
 00-0 General

Safety regulations for fluorocarbon The following seals are most probably made from flu-
rubber orocarbon rubber:

Fluorocarbon rubber is a common material in sealing Seal rings for the crankshaft, camshaft, idler shafts.
rings for shafts, and in O-rings, for example.
O-rings, regardless of where they are installed. O-
When fluorocarbon rubber is exposed to high tem- rings for cylinder liner sealing are almost always
peratures (above 300°C/572°F), hydrofluoric acid made of fluorocarbon rubber.
can form. This is highly corrosive. Contact with the
Please note that seals which have not been
skin can result in severe chemical burns. Splashes in
exposed to high temperature can be handled nor-
your eyes can result in chemical wounds. If you
mally.
breathe in the fumes, your lungs can be permanently
damaged.

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.

7747722 01.2009 5
03-0 General Specifications

03-0 General Specifications

Engine designation TAD1640GE TAD1641GE TAD1642GE TWD1643GE

Power, Prime/Stand-by Refer to the sales literature

Torque, Prime/Stand-by Refer to the sales literature
No. of cylindersl 6 6 6 6
Bore, mm (inch) 144 (5.67) 144 (5.67) 144 (5.67) 144 (5.67)
Stroke, mm (inch) 165 (6.50) 165 (6.50) 165 (6.50) 165 (6.50)
Cylinder volume, liter (inch3) 16,12 (983.9) 16,12 (983.9) 16,12 (983.9) 16,12 (983.9)
Weight dry, kg (ibs) 1440 (3175) 1440 (3175) 1480 (3263) 1700 (3748)
Weight wet, kg (ibs) 1510 (3329) 1510 (3329) 1550 (3417) 1770 (3902)
Firing order 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
Compression ratio 17,5:1 16,5:1 16,5:1 16,5:1
Low idle, rpm 900 900 900 900
High idle, rpm 1500/1800 1500/1800 1500/1800 1500/1800

Engine designation TAD1641VE TAD1642VE TAD1650VE

TAD1643VE
Power, Prime/Stand-by Refer to the sales literature
Torque, Prime/Stand-by Refer to the sales literature
No. of cylinders 6 6 6
Bore, mm (inch) 144 (5.67) 144 (5.67) 144 (5.67)
Stroke, mm (inch) 165 (6.50) 165 (6.50) 165 (6.50)
Cylinder volume, liter (inch3) 16,12 (983.9) 16,12 (983.9) 16,12 (983.9)
Weight dry, kg (ibs) 1480 (3263) 1480 (3263) 1425 (3142)
Weight wet, kg (ibs) 1550 (3417) 1550 (3417) 1495 (3296)
Firing order 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
Compression ratio 17,5:1 17,5:1 18,0:1
Low idle, rpm 600 600 700
High idle, rpm 1800 1800 1800–2000

6 7747722 01.2009
 03-0 General Specifications

7747722 01.2009 7
03-2 Specifications, Engine

03-2 Specifications, Engine

General Tightening Torques
General Tightening Torques
M6 standard bolt 8.8 10 ± 1.5 Nm (7.4 ± 1.1 lbf ft)
M8 standard bolt 8.8 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
M10 standard bolt 8.8 48 ± 8 Nm (35.4 ± 5.9 lbf ft)
M12 standard bolt 8.8 85 ± 15 Nm (62.7 ± 11.1 lbf ft)
M14 standard bolt 8.8 140 ± 25 Nm (103.3 ± 18.4 lbf ft)
M16 standard bolt 8.8 220 ± 35 Nm (162.3 ± 25.8 lbf ft)

NOTICE! Only torqued bolts may be re-installed.

Angle-tightened / stretch-limit bolts:

8.8 Must not be re-installed
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.

8 7747722 01.2009
 03-2 Specifications, Engine

Special Tightening Torques

Group 21: Engine

Front engine mounting, engine block 220 ± 35 Nm (162.3 ± 25.8 lbf ft)
Front engine mounting 220 ± 35 Nm (162.3 ± 25.8 lbf ft)
Rear engine mounting, flywheel housing 220 ± 35 Nm (162.3 ± 25.8 lbf ft)

Main bearing caps

stage 1 300 ± 20 Nm (221.3 ± 14.75 lbf ft)
stage 2 120° ±5° angle tightening

Big end bearing cap

stage 1 20 ± 3 Nm (14.75 ± 2.21 lbf ft)
stage 2 60 ± 5 Nm (44.25 ± 3.69 lbf ft)
stage 3 90° ± 5° angle tightening

Stiffening Frame

P0007087

NOTICE! Tighten the bolts in sequence, as illustrated.

stage 1 65 ± 5 Nm (47.9 ± 3.69 lbf ft)

stage 2 60° ± 5° angle tightening

7747722 01.2009 9
03-2 Specifications, Engine

Flywheel

P0007088

IMPORTANT!
Make sure the flange is clean and dry.
NOTICE! Tighten the bolts in sequence, as illustrated.

stage 1 60 ± 5 Nm (44.25 ± 3.69 lbf ft)

stage 2 120° ± 10° angle tightening

Flywheel Housing

P0006930

NOTICE! Apply 2 mm (0.08") silicone (part nos. 1161231 and 1161277) as illustrated.

stage 1: Torque all M14 bolts to 160 ± 20 Nm (118.0 ± 14.75 lbf ft)
Stage 2: Torque all M10 bolts to 48 ± 8 Nm (35.4 ± 5.9 lbf ft)
Stage 3: Torque all M8 bolts to 24 ± 4 Nm (17.7 ± 2.95 lbf ft)

10 7747722 01.2009
 03-2 Specifications, Engine

Vibration Damper, Crankshaft

P0007089
P0007090

NOTICE! Tighten the bolts in sequence, as illustrated. 90 ± 10 Nm (66.38 ± 7.38 lbf ft)

NOTICE! The 8.8 bolts on the oscillation damper may not

be re-used.

Cover, crankshaft seal

P0007091

NOTICE! Apply 2 mm (0.08") silicone (part nos. 1161231

and 1161277) as illustrated.

stage 1: Tighten all bolts by hand.

Stage 2: Torque bolts 2 and 7 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
Stage 3: Torque the remaining bolts to 24 ± 4 Nm (17.7 ± 2.95 lbf ft)

7747722 01.2009 11
03-2 Specifications, Engine

Valve Cover

P0007092

NOTICE! Tighten the bolts in sequence, as illustrated. 25 ± 3 Nm (18.44 ± 2.21 lbf ft)

Cylinder Head

P0007093

NOTICE! Tighten the bolts in sequence, as illustrated.

stage 1 60 + 10 / – 0 Nm (44.25 + 7.38 / – 0 lbf ft)

stage 2 90° ± 5° angle tightening
stage 3 90° ± 5° angle tightening

12 7747722 01.2009
 03-2 Specifications, Engine

Bearing Caps, Camshaft/Rocker Arm

Shaft, to engine nos. through 2016010024

P0007094

IMPORTANT!
Tighten the bolts in stages to ensure that the rocker arm
shaft lowers without being bent.

stage 1: Tighten bolts 1 through 7 15 ± 3 Nm (11.06 ± 2.21 lbf ft)

stage 2: Tighten bolts 1 through 7 90° ± 5° angle tightening
stage 3: Tighten bolts 8 through 14. Begin with bolt 11. 100 ± 10 Nm (73.76 ± 7.38 lbf ft)
stage 4: Tighten bolts 15 through 21 50 ± 5 Nm (36.88 ± 3.69 lbf ft)
stage 5: Tighten bolts 15 through 21 120° ±5° angle tightening
stage 6: Loosen bolts 8 through 14. –
stage 7: Tighten bolts 8 through 14 50 ± 5 Nm (36.88 ± 3.69 lbf ft)
stage 8: Tighten bolts 8 through 14 120° ±5° angle tightening

7747722 01.2009 13
03-2 Specifications, Engine

Bearing Caps, Camshaft/Rocker Arm

Shaft, from, and including, engine no.
2016010025.

1 1 2 3 4 5 6 7 6
15 ± 3 Nm 60 ± 5 Nm 20

2 7
100 ± 10 Nm 8 9 10 11 12 13 14 15 16 17 18 19
120º ± 5º

1 2 3 4 5 6 7
3 8
20
90º ± 5º 100º ± 5º

4 9
8 9 10 11 12 13 8 9 10 11 12 13
100 ± 10 Nm 50 ± 5 Nm

5 10
14 15 16 17 18 19 8 9 10 11 12 13
50 ± 5 Nm 120º ± 5º
P0008581

IMPORTANT! If the rocker arm shaft has been loosened or

removed, only the bolts that hold the shaft must
Tighten the bolts in stages to ensure that the rocker arm be tightened in accordance with the chart on re-
shaft bottoms against the bearing housing without bending. assembly.
Camshaft (camshaft and bearing caps in place).
Fit a drift to no. 7 bearing bracket (to protect the guide
sleeve).
stage 1: Tighten bolts 1 through 7 15 ± 3 Nm (11.06 ± 2.21 lbf ft)
stage 2: (with shorter extra bolts). Tighten bolts 8
through 13 100 ± 10 Nm (73.76 ± 7.38 lbf ft)
stage 3: Angle tighten screws 1 through 7 90° ± 5° angle tightening
Remove the extra bolts 8 through 13. Remove the drift from
no. 7 bearing bracket.

Rocker arm shaft (rocker arm shaft in place)

stage 4: Tighten bolts 8 through 13 in stages in the order
11, 10, 12, 9, 13, and 8 100 ± 10 Nm (73.76 ± 7.38 lbf ft)
stage 5: Tighten bolts 14 through 19 50 ± 5 Nm (36.88 ± 3.69 lbf ft)
stage 6: Tighten bolt 20 60 ± 5 Nm (44.25 ± 3.69 lbf ft)
stage 7: Angle tighten bolts 14 through 19 120° ±5° angle tightening
stage 8: Angle tighten bolt 20 100° ± 5° angle tightening
Loosen bolts 8 through 13.

14 7747722 01.2009
 03-2 Specifications, Engine

stage 9: Tighten bolts 8 through 13 50 ± 5 Nm (36.88 ± 3.69 lbf ft)

stage 10: Angle tighten bolts 8 through 13 120° ±5° angle tightening

Timing gear plate

P0007096

P0007097

NOTICE! Apply 2 mm (0.08") silicone (part nos. 1161231

and 1161277) to the back of the engine block as illustrated.
NOTICE! Tighten the bolts in sequence, as illustrated.

Bolts 1–27 28 ± 4 Nm (20.65 ± 2.95 lbf ft)

Bolt 28 60 ± 8 Nm (44.25 ± 5.90 lbf ft)

Timing gear cover, top

P0007098

NOTICE! Apply 2 mm (0.08") silicone (part nos. 1161231

and 1161277) as illustrated.
Tightening torques 24 ± 4 Nm (17.7 ± 2.95 lbf ft)

7747722 01.2009 15
03-2 Specifications, Engine

Transmission

5 1

3 7

4
8
1
2 6
3
5
6
4
2
3 1

5 6

2 4

P0007099

1 Drive gear, crankshaft

stage 1 60 ± 5 Nm (44.25 ± 3.69 lbf ft)
stage 2 120° ± 10° angle tightening

2 Intermediate gear, bull drive, outer

Tighten the bolts in sequence, as illustrated.
stage 1 45 ± 5 Nm (33.19 ± 3.69 lbf ft)
stage 2 90° ± 5° angle tightening

3 Intermediate gear, adjustable

Tighten the bolts in sequence, as illustrated.
stage 1 35 ± 4 Nm (25.81 ± 2.95 lbf ft)
stage 2 120° ±5° angle tightening

4 Drive gear, camshaft

Tighten the bolts in sequence, as illustrated.
stage 1 45 ± 5 Nm (33.19 ± 3.69 lbf ft)
stage 2 90° ± 5° angle tightening

5 Drive gear, steering servo and fuel feed pump 100 ± 10 Nm (73.76 ± 7.38 lbf ft)

6 Drive gear, air compressor 200 + 50 / – 0 Nm (147.51 + 36.88 / – 0 lbf ft)

16 7747722 01.2009
 03-2 Specifications, Engine

Group 22: Lubrication System

Oil Sump

P0007100

NOTICE! Tighten the bolts in sequence, as illustrated. 24 ± 4 Nm (17.7 ± 2.95 lbf ft)

Oil Pump
stage 1 35 ± 3 Nm (25.81 ± 2.21 lbf ft)
stage 2 (not 17 and 18) 90° ± 5° angle tightening

Oil cooler, retaining bolts

P0007101

NOTICE! Tighten the bolts in sequence, as illustrated. 24 ± 4 Nm (19.91 ± 2.95 lbf ft)

Oil pressure pipe

stage 1 tighten to zero play
stage 2
pipe diameter Ø 12 80 ± 10 Nm (59.00 ± 7.38 lbf ft)
pipe diameter Ø 18 110 ± 10 Nm (81.13 ± 7.38 lbf ft)
pipe diameter Ø 20 130 ± 10 Nm (95.88 ± 7.38 lbf ft)
pipe diameter Ø 22 170 ± 10 Nm (125.39 ± 7.38 lbf ft)
pipe diameter Ø 28 200 ± 10 Nm (147.51 ± 7.38 lbf ft)

7747722 01.2009 17
03-2 Specifications, Engine

Oil Valves
7
6

1 2

3 4

P0007023

1 Safety valve, lubricating oil pump 10 ± 2 Nm (7.39 ± 1.48 lbf ft)

2 Reducing valve 10 ± 2 Nm (7.39 ± 1.48 lbf ft)
3 Control valve, piston cooling 55 ± 5 Nm (40.57 ± 3.69 lbf ft)
4 Opening valve, piston cooling 55 ± 5 Nm (40.57 ± 3.69 lbf ft)
5 Overflow valve, oil cooler 10 ± 2 Nm (7.39 ± 1.48 lbf ft)
6 Overflow valve, bypass filter 12 ± 2 Nm (8.85 ± 1.48 lbf ft)
7 Overflow valve, full flow filter 55 ± 5 Nm (40.57 ± 3.69 lbf ft)

18 7747722 01.2009
 03-2 Specifications, Engine

Group 23: Fuel System

Feed pump – steering servo pump 25 ± 2 Nm (18.44 ± 1.48 lbf ft)

1 Copper sleeve, earlier model

2 Copper sleeve, earlier model (only ever
available as factory fit, not as spare part)
3 Copper sleeve, new model

Fixing yoke, unit injector (new or re-used copper sleeve type 3)

IMPORTANT!
Always use a new steel gasket beneath the unit injector.

First tightening
stage 1 20 ± 5 Nm (14.75 ± 3.69 lbf ft)
stage 2 180° ± 5° angle tightening

NOTICE! Loosen the fixing yoke bolt before doing the sec-
ond tightening.

Second tightening
stage 1 20 ± 5 Nm (14.75 ± 3.69 lbf ft)
stage 2 90° ± 5° angle tightening

Fixing yoke, unit injector (re-used copper sleeve, types 1 or 2)

NOTICE! The steel gasket must never be used under the unit injector.

stage 1 20 ± 5 Nm (14.75 ± 3.69 lbf ft)

stage 2 60° ± 5° angle tightening

Locknut for adjuster screw, unit injector

stage 1 tighten until it contacts
stage 2 45° ± 5° angle tightening

Lock nut, valve adjusting

stage 1 tighten until it contacts
stage 2 60° ± 5° angle tightening

7747722 01.2009 19
03-2 Specifications, Engine

Hollow bolt M16x1.5 50 ± 8 Nm (36.88 ± 5.90 lbf ft)

Hollow bolt M10x1 25 ± 4 Nm (18.44 ± 2.95 lbf ft)

20 7747722 01.2009
 03-2 Specifications, Engine

Group 25: Inlet and Exhaust System

Inlet manifold

P0007102

Inlet pipe 24 ± 4 Nm (17.7 ± 2.95 lbf ft)

NOTICE! Apply a 2 mm (approx 0.08") bead of sealing com-

pound 1161231-4, as illustrated.

Plug, M10 20 ± 3 Nm (14.75 ± 2.21 lbf ft)

Pressure/temperature sensor, charge air 12 ± 2 Nm (8.85 ± 1.48 lbf ft)

Exhaust header

P0007103

Stage 1: Tighten the bolts 1 until contact max. 10 Nm (7.38 lbf ft)
Step 2: Tighten the bolts 12 until contact max. 10 Nm (7.38 lbf ft)
Stage 3: Tighten the bolts 3 52 ± 4 Nm (38.35 ± 2.95 lbf ft)
Stage 4: Tighten the bolts 2 52 ± 4 Nm (38.35 ± 2.95 lbf ft)
Stage 5: Tighten the bolts 4 52 ± 4 Nm (38.35 ± 2.95 lbf ft)
Stage 6: Tighten the bolts 1 52 ± 4 Nm (38.35 ± 2.95 lbf ft)

7747722 01.2009 21
03-2 Specifications, Engine

Engine
Technical Data

Engine body
Cylinder block
Length 1156 mm (45.512")
Height, upper block plane - crankcase centerline 453 mm (17.835")
Height lower block plane - crankcase centerline 120 mm (4.724")
Crankcase pressure, normal value, irrespective of engine
speed max. 0.5 kPa

Cylinder Head
Type 6 cyl.
Length 1194 mm (47.008")
Width 438 mm (17.244")
Height 135 mm (5.315")
Max. out-of-planeness (bottom plane) (1) 0.02 mm (0.0008")
1) per 100 mm (3.937") measured length

Cylinder head bolts, Change

Number of bolts 38
Dimension, thread M18
Length 188 mm (7.402")

Cylinder Liner
Type Wet, replaceable
Height, total 288 mm (11.339")
Sealing surface height above block plane 0.15–0.21 mm (0.00591–0.00827")
No. of seal rings per cylinder liner 3
Bore 144.00–144.02 mm (5.669–5.670")

Piston
Type aluminum
Height above engine block plane 0.15–0.65 mm (0.00591–0.0256")
Diameter, combustion chamber 98 mm (3.858")
Depth, piston bowl:
TAD1640GE 19.35 mm (0.762")
TAD1641GE 21.15 mm (0.883")
TAD1642GE 21.15 mm (0.883")
TAD1643GE 21.15 mm (0.883")
TAD1641VE 19.35 mm (0.762")

22 7747722 01.2009
 03-2 Specifications, Engine

TAD1642VE 19.35 mm (0.762")

No. of ring grooves 3
Front marking Arrow towards front
Piston pin diameter 63 mm (2.480")

Piston rings
Compression Rings
Quantity 2
Piston ring clearance in groove:
upper compression ring –
0.07 mm (0.00276"),
lower compression ring wear tolerance 0.1 mm (0.00394")
Piston ring gap, measured at ring opening:
0.62 mm (0.0244"),
upper compression ring wear tolerance 0.85 mm (0.0335")
1.1 mm (0.0433"),
lower compression ring wear tolerance 1.35 mm (0.0531")
Oil ring
Quantity 1
Width, including spring 4.55 mm (0.179")
0.04 mm (0.00157"),
Piston ring clearance in groove wear tolerance 0.1 mm (0.00394")
0.55 mm (0.0217"),
Piston ring gap, measured at ring opening wear tolerance 0.9 mm (0.0354")

7747722 01.2009 23
03-2 Specifications, Engine

Valve mechanism
Valves
Valve head, diameter:
Inlet 49 mm (1.929")
Exhaust 46 mm (1.811")
Valve stem, diameter:
Inlet 10 mm (0.394")
Exhaust 10 mm (0.394")

P0007076

Valve seat angle (A):

Inlet 19,5°
Exhaust 44,5°
Seat angle in cylinder head (B):
Inlet 20°
Exhaust 45°
Dimension between valve head and cylinder head plane:
Inlet 0.9–1.4 mm (0.0354–0.0551")
Wear tolerance 1.5 mm (0.0591")
Exhaust 1.4–1.9 mm (0.0551–0.0748")
Wear tolerance 2.0 mm (0.0787")
NOTICE! If the valve seats are replaced, the valves must
also be replaced.
Valve clearance, cold engine, setting value:
Inlet 0.3 mm (0.0118")
Exhaust 0.6 mm (0.0236")
Valve clearance, cold engine, check value:
Inlet 0.25–0.35 mm (0.00984–0.0138")
Exhaust 0.55–0.65 mm (0.0217–0.0256")

24 7747722 01.2009
 03-2 Specifications, Engine

Valve seats

P0007077

Outer diameter (A)

Standard:
Inlet 52.1 mm (2.051")
Exhaust 49.1 mm (1.933")
Oversize dimension:
Inlet 52.2 mm (2.055")
Exhaust 49.2 mm (1.937")
Height (B):
Inlet 7.7 mm (0.303")
Exhaust 7.9 mm (0.311")

Valve seat position

P0007078

Diameter (C) standard:

Inlet 52.0 mm (2.047")
Exhaust 49.0 mm (1.929")
Diameter (C) oversize:
Inlet 52.2 mm (2.055")
Exhaust 49.2 mm (1.937")
Depth (D):
Inlet 11.7 mm (0.461")
Exhaust 11.7 mm (0.461")
Seat base radius (R):
Inlet max. 0.8 mm (0.0315")
Exhaust max. 0.8 mm (0.0315")

7747722 01.2009 25
03-2 Specifications, Engine

Valve guides
Length:
Inlet 83.5 mm (3.287")
Exhaust 83.5 mm (3.287")
Inner diameter:
Inlet 10 mm (0.394")
Exhaust 10 mm (0.394")
Height above cylinder head spring plane:
Inlet 24.4 ± 1.0 mm (0.961 ± 0.0394")
Exhaust 24.4 ± 1.0 mm (0.961 ± 0.0394")
Clearance, valve stem guide(1):
Inlet 0.025–0.054 mm (0.000984–0.00213")
Wear tolerance max. 0.4 mm (0.0157")
Exhaust 0.058–0.87 mm (0.00228–0.0343")
Wear tolerance max. 0.4 mm (0.0157")
1) The dimensions are calculated for the measurement method described in the workshop manual (Group 21).

Rocker arms
Bearing clearance max. 0.1 mm (0.00394")
Clearance rocker arm roller max. 0.1 mm (0.00394")

Valve spring
Inlet
Uncompressed length 67.5 mm (2.657")
With 522 N (117.35 lbf) load 57.0 mm (2.244")
With 1205 N (270.9 lbf) load 43.3 mm (1.705")
Coil bound length, max. 40.3 mm (1.587")
Exhaust
Outer valve springs:
Uncompressed length 69.3 mm (2.728")
With 930 N (209.1 lbf) load 54.0 mm (2.126")
With 1813 N (430.1 lbf) load 39.5 mm (1.555")
Coil bound length, max. 37.0 mm (1.457")
Inner valve spring:
Uncompressed length 67.0 mm (2.638")
With 465 N (104.5 lbf) load 51.0 mm (2.008")
With 887 N (199.4 lbf) load 36.5 mm (1.437")
Coil bound length, max. 34.0 mm (1.339")

26 7747722 01.2009
 03-2 Specifications, Engine

Engine Transmission
Timing gear wheels

P0006837

No. of teeth:
1 Drive gear, camshaft 84
2 Intermediate gear, adjustable 85
3 Intermediate gear, bull drive outer 84
Intermediate gear, bull drive, inner 56
4 Intermediate gear, servo pump 29
5 Drive gear, crankshaft 63
6 Drive gear, lubrication oil pump 37
7 Drive gear, steering servo and fuel feed pump 36

Gear lash 0.05–0.17 mm (0.00197–0.00669")

Shaft journal, intermediate gear, diameter Ø 99.97–99.99 mm (3.9358–3.9366")
Intermediate gear bush, diameter Ø 100.036–100.05 mm (3.9384–3.9390")
Radial clearance for intermediate gear max. 0.05 mm (0.00197")

Camshaft
Check camshaft setting, cold engine and valve clear-
ance =0.
At a flywheel position of 6° after TDC, the inlet valve must
be open 1.4 ± 0.3 mm (0.055 ± 0.012"). During this check,
the timing gear must be turned clockwise, seen from the
front, to take up all gear lash.
Drive gear wheel
No. of bearings 7
NOTICE! Only check values; not for machining.

7747722 01.2009 27
03-2 Specifications, Engine

Diameter, bearing journals, standard 69.97–70.00 mm (2.755–2.756")

Diameter, bearing journals, undersize dimension:
0.25 mm (0.00984") 69.72–69.78 mm (2.745–2.747")
0.50 mm (0.01968") 69.47–69.53 mm (2.735–2.737")
0.75 mm (0.02953") 69.22–69.28 mm (2.725–2.728")
Max. end float 0.35 mm (0.0138")
Max permissible ovality (with new bearings) 0.05 mm (0.00197")
Bearing, max. permissible wear on diameter 0.05 mm (0.00197")
Valve lift:
inlet 13.7 mm (0.539")
exhaust 14.5 mm (0.571")
Permitted wear between base circle and max lift max. 0.1 mm (0.00394")
Unit injector, stroke 18 mm (0.709")

Camshaft Bearings
Camshaft bearing thickness, standard 1.92 mm (0.0756")
Oversize dimension:
0.25 mm (0.00984") 2.05 mm (0.0807")
0.50 mm (0.01968") 2.17 mm (0.0854")
0.75 mm (0.02953") 2.30 mm (0.0906")

28 7747722 01.2009
 03-2 Specifications, Engine

Crank Mechanism
Crankshaft
Length 1,256 mm (49.449")
Crankshaft end float(1) 0.10–0.40 mm (0.0039–0.0157 in)
Ovality of main and big end bearings max. 0.01 mm (0.000394")
Taper on main and big end bearings max. 0.02 mm (0.000787")
Runout on center bearing 0.15 mm (0.00591")
1) Dimensions refer to oiled components.

Main bearing journal

C D
A
Ø

P0007079
R

NOTICE! Only check values; not for machining.

Diameter (Ø) standard 118 mm (4.646")
Undersize dimension:
0.25 mm (0.00984") 117.75 mm (4.636")
0.50 mm (0.0197”) 117.50 mm (4.626")
0.75 mm (0.030") 117.25 mm (4.616")
1.00 mm (0.0394") 117.00 mm (4.606")
1.25 mm (0.0492") 116.75 mm (4.596")
Surface finish, main bearing journal Ra 0.25 (9.84·10–6")
Surface finish, radius Ra 0.4 (1.575·10–5")
Width, thrust bearing journal (A) standard 49.0 mm (1.929")
Oversize dimension:
0.2 mm (0.00787"), thrust bearing 0.1 mm (0.00394") 49.2 mm (1.937")
0.4 mm (0.01575"), thrust bearing 0.2 mm (0.00787") 49.4 mm (1.945")
0.6 mm (0.02362"), thrust bearing 0.3 mm (0.0118") 49.6 mm (1.953")
Fillet radius (R) 4.5 mm (0.177")

7747722 01.2009 29
03-2 Specifications, Engine

Thrust washers (thrust bearings)

Width (B) standard 3.18 mm (0.1252")
Oversize dimension:
0.1 mm (0.00394") 3.28 mm (0.1291")
0.2 mm (0.00787") 3.38 mm (0.1331")
0.3 mm (0.0118") 3.48 mm (0.1370")
0.4 mm (0.016") 3.58 mm (0.1409")

Main bearing shells

Outer diameter (C) 123.12 mm (4.847")
Thickness (D) standard 2.51 mm (0.0988")
Oversize dimension:
0.25 mm (0.00984") 2.64 mm (0.104")
0.50 mm (0.0197”) 2.76 mm (0.109")
0.75 mm (0.0295") 2.89 mm (0.114 in)
1.00 mm (0.0394") 3.01 mm (0.119")
1.25 mm (0.0492") 3.14 mm (0.124")
Radial clearance, main bearings 0.07–0.14 mm (0.00276–0.00551")

Big end bearing journal

P0007080

NOTICE! Only check values; not for machining.

Diameter (Ø) 112 mm (4.409")
Undersize dimension:
0.25 mm (0.00984") 111.75 mm (4.400")
0.50 mm (0.0197”) 111.50 mm (4.390")
0.75 mm (0.0295") 111.25 mm (4.380")
1.00 mm (0.0394") 111.00 mm (4.370")
1.25 mm (0.0492") 110.75 mm (4.360")

30 7747722 01.2009
 03-2 Specifications, Engine

Surface finish, big end bearing journal Ra 0.25 (9.84·10–6")

Surface finish, radius Ra 0.4 (1.575·10–5")
Width (A) 60 mm (2.362")
Fillet radius (R) 4.5 mm (0.177")

Big end journal shells

Outer diameter (B) 116.8 mm (4.598")
Thickness (C) standard 2.35 mm (0.0925")
Oversize dimension:
0.25 mm (0.00984") 2.48 mm (0.0976")
0.50 mm (0.0197”) 2.60 mm (0.102")
0.75 mm (0.0295") 2.73 mm (0.107")
1.00 mm (0.0394") 2.85 mm (0.112")
1.25 mm (0.0492") 2.98 mm (0.117")
Diameter, bearing shell seat (D) 116.8 mm (4.598")

Connecting rod
Length, center - center (E) 280 mm (11.024")
Piston pin bush internal diameter (G) 63 mm (2.480")
End float, connecting rod - crankshaft(1) max. 0.35 mm (0.01378")
Big end bearing, radial clearance(1): max. 0.10 mm (0.00394")
Straightness, max. deviation on 100 mm (3.937") measured
length 0.06 mm (0.00236")
Twist, max. deviation on 100 mm (3.937") measured length 0.15 mm (0.00591")
1) Dimensions refer to oiled components.

P0007081

Marking:
“FRONT” on the connecting rod faces forwards.
The connecting rods and caps are marked in pairs, using a three digit serial number (see illustration).

7747722 01.2009 31
03-2 Specifications, Engine

Flywheel, Installed
Runout, measured radius 150 mm (5.905") max. 0.1 mm (0.00394")
No. of teeth on starter gear ring 153
Sensor grooves in flywheel 54

Flywheel Cover, Installed

Runout for mating face against clutch bellhousing. max. 0.1 mm (0.00394")
Runout for alignment against clutch bellhousing. max. 0.05 mm (0.00197")

Lubrication System
Technical Data
Oil
Oil change volume, incl. filter 48 liters (12.7 US gals)

Oil Pressure
Operating speed (above 1,100 rpm) 300–650 kPa (43.51–94.27 psi)
Low idle min. 160 kPa (min. 23.21 psi)

Oil temperature
Cold engine ambient temperature
Hot engine max. 125 °C (257 °F)

Lube Oil Pump

Type Gear driven
No. of teeth, drive wheel 37
Gear lash 0.05–0.40 mm (0.00197–0.0157")

Oil Filter
Full flow filter 2
Turbofilter (Bypass filter) 1

32 7747722 01.2009
 03-2 Specifications, Engine

Oil Valves

P0006839

A: Bypass valve, oil cooler

Spring, free length 69 mm (2.717")
Compressed 13–15 N (2.92–3.37 lbf) 40 mm (1.575")
B: Safety valve, lubricating oil pump
Marking Violet
C: Reduction valve, oil pressure
Marking Blue (not remote oil filter)
D: Control valve, piston cooling
Spring, free length 122 mm (4.803")
Compressed 60 N (13.49 lbf) 84 mm (3.307")
E: Opening valve, piston cooling
Spring, free length 122 mm (4.803")
Compressed 95 N (21.36 lbf) 63 mm (2.480")
F: Overflow valve, bypass filter
Spring, free length 69 mm (2.717")
Compressed 13–15 N (2.92–3.37 lbf) 40 mm (1.575")
G: Overflow valve, full flow filter
Spring, free length 69 mm (2.717")
Compressed 13–15 N (2.92–3.37 lbf) 40 mm (1.575")

7747722 01.2009 33
03-2 Specifications, Engine

Fuel System
Technical Data
Feed pump
Feed pressure at:
600 rpm min. 100 kPa (14.5 psi)
1,200 rpm min. 300 kPa (43.5 psi)
full load min. 300 kPa (43.5 psi)

Bypass valve
Opening pressure 400–550 kPa (58.0–79.8 psi)

Fuel amount

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

Unit injectors

P0007083

Pre-load 4 flats (0.85 mm (0.0335")); see illustration.

Tighten the adjuster screw to zero clearance against the
camshaft, then turn 4 flats.

34 7747722 01.2009
 03-2 Specifications, Engine

Inlet and Exhaust System

Technical Data
Turbo
TAD1640–1642GE/VE
Manufacturer/type I3K/K29
End float, turbine shaft max. 0.13 mm (0.00512")

TAD1650VE
Manufacturer/type Holset/HE551
End float, turbine shaft max. 0.127 mm (0.00500")

TWD1643GE
HP Turbo:
Manufacturer/type Holset/HE551
End float, turbine shaft max. 0.127 mm (0.00500")
LP Turbo:
Manufacturer/type Holset/HE82
End float, turbine shaft max. 0.152 mm (0.00598")

Inlet temperature indicator

Cold engine Ambient temperature
Hot engine, coolant temperature 75–95 °C (167–203 °F) max. 30 °C (86 °F) above ambient temperature

Pressure drop indicator

Pressure drop indicator alarms at an underpressure of 5 kPa (37.5 mm VP) (0.725 psi)

Charge pressure
1,500 rpm
TAD1640GE 232 kPa (33.65 psi)
TAD1641GE 240 kPa (34.81 psi)
TAD1642GE 268 kPa (38.87 psi)
TWD1643GE 358 kPa (51.92 psi)

1,800 rpm
TAD1640GE 231 kPa (33.50 psi)
TAD1641GE 252 kPa (36.55 psi)
TAD1642GE 262 kPa (38.00 psi)
TWD1643GE 356 kPa (51.63 psi)
TAD1641VE 193 kPa (27.99 psi)
TAD1642VE 225 kPa (32.63 psi)
TAD1650VE 200 kPa (29.01 psi)

7747722 01.2009 35
03-2 Specifications, Engine

Cooling System
Technical Data
General
Pressure cap opens at 75 kPa (10.88 psi)

Thermostat
Quantity 1
Opening temperature 82 °C (179.6 °F)
Fully open 92 °C (197.6 °F)

Coolant
Type Volvo Penta Coolant
Consists of Glycol and corrosion-inhibiting additives
Color Green
Mix with Water(according to ASTM D4985)
Mixing proportions (conc. coolant/water) 40/60

IMPORTANT!
Do not use Volvo VCS coolant (yellow in color) in Volvo
Penta engines.

Do not mix different kinds of coolant.

Refill quantity
Coolant quantity (engine, radiator and hoses):
TAD1640–42GE, TAD1641–43VE 60 liters (16 US gals)
TWD1643GE 95 liters (25 US gals)

36 7747722 01.2009
 03-3 Specifications, Electrical

03-3 Specifications, Electrical

Steering System
Sensor
Charge air pressure sensor
TAD1640–1642GE/VE, 1650VE, 1643VE
Check value 1.05–1.12 V at 100 kPa (14.50 PSI)
TWD1643GE
Check value 0.81–0.91 V at 100 kPa (14.50 PSI)

Camshaft sensor
Distance to camshaft 1.1 ± 0.4 mm (0.0433 ± 0.0157")

Flywheel sensor
Distance to flywheel 1.1 ± 0.4 mm (0.0433 ± 0.0157")

Pressure drop indicator

Active V = 0.48 x Ubat
Inactive V = 0.12 x Ubat

Charge air temperature sensor

P0007084

Coolant temperature sensor Engine oil temperature sensor

P0007085
P0007086

7747722 01.2009 37
05-1 Safety Instructions

05-1 Safety Instructions

Safety Information
This Service Manual contains repair instructions,
descriptions and technical data for products or product
designs from Volvo Penta. Ensure that you are using
the correct service manual.

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 dam-
age 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.

38 7747722 01.2009
 05-1 Safety Instructions

Immobilize the engine by turning off the power Avoid opening the coolant filling cap when the
! supply to the engine at the main switch ! engine is hot. Steam or hot coolant can spray
(switches) and lock it (them) in the off position out and system pressure will be lost. Open the
before starting work. Post a warning notice at filler cap slowly, and release the pressure in the
the main circuit breaker. cooling system if the filler cap or valve has to be
opened, or if a plug or coolant hose has to be
removed when the engine is hot.

As a rule, all service operations must be carried Hot oil can cause burns. Avoid skin contact with
! out with the engine stopped. However, some ! hot oil. Ensure that the lubrication system is not
work, such as adjustments, will require the under pressure before any work is begun.
engine to be running. Approaching an engine Never start or operate the engine with the oil
which is running is a safety risk. Bear in mind filler cap removed, because of the risk of oil
that loose clothing or long hair can fasten in ejection.
rotating parts and cause serious personal
injury.

Be aware of hot surfaces (exhaust pipes, tur- Never start the engine without installing the air
! bos, charge air pipes, starting heaters etc.) and ! filter. The rotating compressor turbine in the tur-
hot fluids in pipes and hoses on an engine that bocharger can cause severe injury. Foreign
is running or has just stopped. objects entering the intake ducts can also cause
If work is done adjacent to a running engine, a mechanical damage. Install all protective cov-
careless movement or a dropped tool may in the ers before the engine is started.
worst case lead to personal injury.

Ensure that the warning symbols or information Only start the engine in a well-ventilated space.
! decals on the product are always clearly visible. ! When running in a confined space, exhaust
Replace decals which have been damaged or fumes and crankcase gases must be led away
painted over. from the engine bay or workshop area.

Avoid getting oil on your skin! Protracted or The majority of chemicals e.g. engine and trans-
! repeated exposure to oil can cause skin to ! mission oils, glycol, gasoline, and diesel oil,
become dry. Irritation, dryness, eczema and together with chemicals for workshop use such
other skin problems may then result. From a as degreasing agents, paints and solvents, are
health standpoint, used oil is more dangerous injurious to health. Carefully read the instruc-
than new. Use protective gloves and avoid oil- tions on the product packaging! Always follow a
soaked clothes and rags. Wash regularly, espe- product's safety directions, e.g. use of protec-
cially before eating. Use suitable barrier creams tive mask, glasses, gloves etc. Ensure that
to counteract drying out of the skin and to aid other personnel are not exposed to substances
dirt removal. that are injurious to health. Ensure good venti-
lation. Handle used and leftover chemicals in
the prescribed manner.

Stop the engine and turn off the electrical supply Clutch adjustments must be carried out with the
! at the main switch(es) before carrying out work ! engine stopped.
on the electrical system.

7747722 01.2009 39
05-1 Safety Instructions

Always use protective glasses or goggles when Never start the engine with the valve cover
! carrying out work where a risk of splinters, ! removed. There is a risk of personal injury.
grinding sparks, splashes from acid or other
chemicals is present. Your eyes are extremely
sensitive; injury may cause blindness!

Never use start gas or similar products as a Stop the engine before working on the cooling
! starting aid. They may cause an explosion in the ! system.
inlet manifold. Danger of personal injury. Marine engines: Close the sea cock / cooling
water inlet valve before work on the cooling sys-
tem is begun.

All fuels, as well as many chemicals, are flam- Make sure that oil, fuel-soaked rags, and used
! mable. Do not allow open flames or sparks in ! fuel and oil filters are stored in a safe manner.
their vicinity. Gasoline, some thinners, and Rags soaked in oil can spontaneously ignite
hydrogen gas from batteries are extremely under certain circumstances. Used fuel and oil
flammable and explosive when mixed with air in filters are environmentally hazardous waste
the correct proportions. No Smoking! Ensure and must be handed to an approved waste
that the work area is well ventilated and take the management facility for destruction, as must
necessary safety precautions before welding or any used lubrication oil, contaminated fuel,
grinding work is begun. Always ensure that paint residue, solvents, degreasers and wash
there are fire extinguishers close at hand in the residue.
work area.

Batteries must never be exposed to open Never work alone when removing heavy com-
! flames or electric sparks. Never smoke in the ! ponents, even when using lifting devices such
vicinity of the batteries; they generate hydrogen as locking tackle lifts. When using a lifting
gas when charged, which is explosive when device, two people are usually required to do
mixed with air. This gas is easily ignited and the work - one to take care of the lifting device
highly explosive. A spark, which can be caused and the other to ensure that components are
by incorrect battery connection, is sufficient to lifted clear and not damaged during the lifting
cause a battery to explode and cause damage. operations.

Do not touch the connections during start

attempts. Sparking hazard! Do not lean over
batteries.

Never transpose the positive (+) and negative The existing lugs on the engine should be used
! (-) battery posts when installing batteries. Such ! for lifting. Always check that the lifting equip-
a transposition can result in serious damage to ment used is in good condition and has the load
electrical equipment. Refer to the wiring dia- capacity to lift the engine (engine weight includ-
gram. ing gearbox or extra equipment). For safe han-
Always use protective goggles when charging dling and to avoid damaging components fitted
and handling the batteries. Battery electrolyte to the top of the engine, the engine must be
contains sulfuric acid which is highly corrosive. lifted with a correctly adjusted lifting boom. All
Should the battery electrolyte come into contact chains or wires must run parallel to each other
with unprotected skin, wash it off immediately and as perpendicular to the engine as possible.
using soap and copious amounts of water. If you If other equipment attached to the engine has
get battery acid in your eyes, flush at once with altered its center of gravity, special lifting devi-
copious amounts of water and seek medical ces may be needed to obtain the correct bal-
assistance immediately. ance for safe handling. Never perform any work
on an engine that is only suspended from the
lifting equipment.

40 7747722 01.2009
 05-1 Safety Instructions

The components in the electrical and fuel sys- Exercise extreme caution when leak-detecting
! tems on Volvo Penta products are designed and ! on the fuel system and testing the fuel injector
manufactured to minimize the risk of fire and nozzles. Use eye protection. The jet from a fuel
explosion. The engine must not be run in areas nozzle has very high pressure and great pene-
where there are explosive materials. tration power. Fuel can force its way deep into
body tissue and cause severe injury. There is a
risk of blood poisoning (septicemia).

Only use fuels and lubricating oils recom- Never use a high-pressure washer for cleaning
! mended by Volvo Penta. Refer to the Operator's ! the engine.
Manual for the product in question. Use of fuels Pay attention to the following when using a high-
that are of a lower grade may damage the pressure washer on components other than the
engine, the injection pump and the injectors. On actual engine: Never direct the water jet at
a diesel engine, low grade fuel can cause the seals, rubber hoses or electrical components.
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 straight-

! ened under any circumstances. Cracks may
occur. Damaged pipes must be replaced.

7747722 01.2009 41
08-1 Universal Tools

08-1 Universal Tools

The following miscellaneous equipment is used when
working on the engine. The equipment can be ordered
from AB Volvo Penta by specifying the number indi-
cated.

P0002784

P0006821 P0002930

885531 Pressure testing kit 885633 Torque multiplier 885648 Counterhold

Cooling system
P0004342

P0006823 P0004344

885811 Protractor 885812 Timing tool 1159794 Torque wrench

3/8", 10–100 Nm
P0004315

P0006822

P0001875

9986485 Stand 9988539 Compression meter 9989876 Dial indicator

10
0

20
0
20

P0001881 P0004344
P0001879

9999683 Dial indicator (short 9999696 Magnetic stand 9999881 Torque wrench
probe)

42 7747722 01.2009
 08-1 Universal Tools

P0002793

88800083 Piston ring pliers

7747722 01.2009 43
08-2 Special Service Tools

08-2 Special Service Tools

The following special tools are used when working on
the engine. The tools can be ordered from AB Volvo
Penta by specifying the number indicated.

P0006764
P0006782

P0006792

885810 Fixture 9809726 Pneumatic hydraulic 9809729 Hydraulic cylinder

pump
For upper timing cover Used with 9809729 or Used with press tool 9990176
9992670. Replaces 9996222

P0006761 P0006763
P0006269

9986173 Puller 9986179 Puller 9990006 Puller

For flywheel bearings For flywheel bearings For unit injectors

p00006766
P0006765 P0006768

9990013 Slide hammer 9990107 Connection washer 9990114 Puller

Used for pressure testing Used for main bearing caps

P0006769 P0006770
P0004314

9990118 Cone 9990123 Pressure testing kit 9990124 Nipple

For installation of front crank-
shaft seal

44 7747722 01.2009
 08-2 Special Service Tools

P0006771

P0006772 P0006773

9990125 Nipple 9990143 Fixture 9990156 Adapter

For turbo pressure manometer Up to and including engine no. For sealing plug 9998251
2016010024

P0006776

P0006774 P0006775

9990157 Press tool 9990158 Piston ring com- 9990160 Fixture

pressor
For cylinder liner (7 pcs. For cylinder head
required)

P0006778
P0006777 P0006785

9990164 Fixture 9990165 Guide sleeve 9990166 Mounting tool

For pressure testing cylinder For valve spindle seal For rear crankshaft seal
head

P0006793
P0006795
P0006786

9990174 Drift 9990176 Press tool 9990185 Lifting tool

For removal/installation of valve For removal/installation of valve For rocker arm bridge
springs, outlet springs and valve guides

7747722 01.2009 45
08-2 Special Service Tools

P0006783
P0006779 P0006780

9990192 Puller 9990210 Valve spring com- 9991801 Standard handle

pressor
For rear crankshaft seal, used For e.g. changing flywheel
with 9996400 bearing
P0004328

P0006787
P0006791

9992000 Handle 9992269 Drift 9992479 Holder for dialindi-

cator
Standard handle For installation of flywheel bear-
ing

P0006794 P0006781 P0006784

9992670 Hand pump 9992873 Nipple 9993590 Rotation tool

Used with 9809729, alternative For pressure checking
to 9809726
P0004347

P0006788
p0006802

9996049 Draining hose 9996159 Adapter 9996239 Lifting tool

For hydraulic cylinder 9809729 For removal/installation of cyl-
inder head and flywheel hous-
ing, (2 pcs. required)

46 7747722 01.2009
 08-2 Special Service Tools

p0004330

P0002947

9996394 Support 9996395 Support 9996398 Manometer

P0004331

p0006800 P0004332

9996400 Slide hammer 9996441 Cover, with connect- 9996645 Puller

ing nipple
For cooling system leakage test
P0004333

P0006804 P0006807

9996662 Pressure testing kit 9996666 Nipple 9996845 Screw clamp

For pressure testing oil cooler
(2 pcs. required)

p0006798
p0006803
p0006801

9996963 Plate 9998246 Drift 9998248 Adapter

For removing/installing cylinder For removal/installation of valve For measuring cylinder com-
liners springs, inlet pression (6 pcs. required)

7747722 01.2009 47
08-2 Special Service Tools

P0006806

P0006808
P0006805

9998249 Protective sleeve 9998250 Sealing ring 9998251 Protection plug

For unit injectors (6 pcs. For fuel duct in cylinder head (2 For cylinder head (6 pcs.
required) pcs. required) required)

P0006810

P0006813 P0004349

9998252 Thread cutting tool 9998264 Lifting tool 9998339 Manometer

For removal of copper sleeve For camshaft

P0006816

P0006818 P0006820

9998487 Sleeve 9998494 Hose 9998502 Hose

For removal of oil filter For measuring fuel pressure For pressure testing cooling
(red), used with 9990123 and system (green), used with
9990124 9990123

P0006814
P0001859 P0006812

9998511 Lever 9998517 Adjustment tool 9998599 Cleaning kit

For checking/setting flywheel Complete kit for cleaning unit
and camshaft sensor injectors

48 7747722 01.2009
 08-2 Special Service Tools

P00068115 P0001878
P0006817

9998601 Fixture 9998629 Lifting tool 9999179 Extractor oil filter

For upper timing cover Thread M10, 2 pcs. required

p0006797
P0006789

P0006767

88800003 Fixture 88800021 Drift 88800064 Drift

Used with 9986485 (from and For removal of front crankshaft For changing valve guides
including engine no. seal (inlet), installation
2016010025)

p0006799 P0006790

P0006819

88800196 Drift 88800123 Plate 88800127 Drift

For removal of copper sleeve Used with 88800003 (from and For changing valve guides
including engine no. (exhaust), installation
2016010025)

P0006811
P0006809

p0006796

88800147 Drift 88800151 Drift 88800191 Extractor

For changing valve guides, For valve stem seal For copper sleeve
removal

7747722 01.2009 49
17-3 Maintenance Service

17-3 Maintenance Service

FSI = First Service Inspection C = Clean
S2 = First Time Service R = Replace
S = Lubrication service A = Adjustment
A – F = Type of service (regular service) L = Lubrication
I = Inspect (Clean, Adjust, Lubricate or Replace if nec-
essary)

FSI After the first 100-200 Hours

Primary fuel filter, draining condensed water I
Coolant Level I
Drive Belts I
Start and warm up engine
Coolant/oil/fuel, leakage I
Inspection with VODIA (Diagnostic Tool) I
Engine and transmission, abnormal noises I
Stop Engine
Engine Oil and Oil Filters / By-pass filter(1)(2) R
Restart engine
Oil pressure / oil leakage I

S2 After the First 1000 Hours

Valve clearance A

S Every 50–600 Hours / at Least Every 12 Months

Engine Oil and Oil Filters / By-pass filter(1)(2) R

1. Oil change intervals vary, depending on engine type, oil grade and
sulfur content of the fuel.
2. Change the filters during each oil change.

50 7747722 01.2009
 17-3 Maintenance Service

A Every 500 Hours / at Least Every 12th Month

Fuel Tank (sludge trap), Drain I
Inspection with VODIA (Diagnostic Tool) I
Primary fuel filter, draining condensed water I
Air Filter Inserts (Indicator), Engine I
Radiator I
Drive Belts I
Batteries, electrolyte level I

B Every 1000 Hours / at Least Every 12 Months

Primary fuel filter R
Air filter insert , motor R
Fuel Filter R
Coolant Filter R

C Every 2000 Hours

Valve clearance I

D Every 2000 Hours / at Least Every 24th Month

Turbocharger I
Turbocharger, Wastegate (TWD1643GE) I
Engine, with Respect to Leakage I
Engine, with Respect to Hose and Cable Clamping I
Engine, with Respect to Hose and Cable Clamping I
Air Filter, Tank Breather R
Air Filter, Compressor R

E Every 4000 hour / at Least Every 24 month

Belt Tensioner I
Drive Belts R

F Every 8000 Hours / at Least Every 48th Month

Coolant R

7747722 01.2009 51
20-0 Engine Information, General

20-0 Engine Information, General

Design and Function

Identification Numbers

1 2 3

P0002050

1
A Chassinummer
B Serienummer

P0002051

A A Motorbeteckning
B B Motoreffekt, netto (utan fläkt)
C C Max. varvtal
D
D Huvudprogramvara
E
F E Datasats 1
G F Datasats 2
P0002052
G Produktnummer

3
A Motorbeteckning
B Specifikationsnummer
P0002053
C Serienummer

52 7747722 01.2009
 20-0 Engine Information, General

Group 21: Engine

Cylinder Head

P0006830

The cylinder head is cast in one piece from a cast iron The oil pressure in the rocker arm mechanism is
alloy to provide a stable bearing for the overhead measured in a channel at plug (D).
camshaft.
For camshaft and rocker arm lubrication, a channel
The coolant thermostat housing is integrated into the has been drilled centrally in the left side of the cylinder
cylinder head (A). head (E).

The cylinder head has separate intake and outlet The valve guides are made of alloyed cast iron and all
channels with so-called crossflow for each cylinder valve guides have oil seals. The valve seats are
(B). replaceable and made from steel.

The fuel channel to the unit injectors has been drilled

lengthwise through the cylinder head and has a ring-
shaped space around each unit injector (C).

7747722 01.2009 53
20-0 Engine Information, General

Cylinder block

P0006832
P0006831

The cylinder block is made of cast iron and cast in one The cylinder block main bearing caps (A) are guided
piece. The sides of the cylinder block are arched (B) by sleeves pressed into the cylinder block (1). In order
around each cylinder, for high stiffness and good to avoid incorrect placement, the bearing caps are
sound damping. numbered 1 through 7 and are equipped with cast
bosses in both blocks (2) and caps (3). The underside
From and including engine no. 2016010025 there is of the bearing caps are also marked with arrows(C),
an outlet on the left side of the block for an oil sepa- which must be turned towards the engine inlet side.
rator.
The cylinder head gasket is made of steel in one
All lubricating oil channels are machined directly in the piece, for the whole engine. The gasket has vulcan-
block. There are two longitudinal channels, on the ized rubber seals for oil and coolant through flow. The
right side of the piston cooling channel and on the left gasket has also a number of convex dimples to pre-
side of the main lubricating channel. The channels are vent the cylinder head from sliding on the gasket
plugged front and back. The rear face also has a during installation, and damaging the rubber rings in
channel for oil supply to the timing gear. the gasket.
At the lower level of the block, a bracing frame of 6 The cylinder head is lowered onto the guide pins in
mm steel plate is installed to reduce vibrations and the cylinder head, with a small gap against the timing
thus also engine noise. gear plate. After this, the cylinder head is pulled hor-
izontally towards the timing gear plate. When it is in
The oil pan is made of plastic and suspended by 16
place, it is bolted to the engine block, and the dimples
spring-loaded bolts in the cylinder block foot. The seal
are flattened out.
between block and oil pan consists of a one-piece
rubber strip placed in a groove in the oil pan.

54 7747722 01.2009
 20-0 Engine Information, General

Piston, cylinder lining, connecting

rod
Cylinder Liner

P0006833

The cylinder block is equipped with wet, replaceable The lower part of cylinder liner is sealed by two rubber
cylinder liners that are centrifugally cast in cast iron rings. The upper ring, closest to the coolant, is black
alloy. and the lower one towards the oil side, purple.

The coolant space around the cylinder liners is sealed

against the cylinder block with three sealing rings. The
upper part is sealed by a ring below the liner collar.

7747722 01.2009 55
20-0 Engine Information, General

Piston and Connecting rod

P0006834

The pistons are made of aluminum and have three The connecting rods are forged and the lower big end
piston rings; the top ring is a “Keystone” compression is “fracture split” i.e. divided by a flat unmachined sur-
ring, the center ring is a compression ring with rec- face. The upper end has a pressed-in bushing that is
tangular cross section, and at the bottom ring is a lubricated via a drilled channel in the connecting rod.
spring loaded oil scraper ring.

56 7747722 01.2009
 20-0 Engine Information, General

Crankshaft, vibration damper,

flywheel

P0006835

The crankshaft is drop-forged in one piece and induc- The crankshaft timing gear is located at the rear of the
tion-hardened on the bearing surfaces for increased crankshaft. A guide pin in the crankshaft ensures that
strength and reduced risk of cracking. the gear wheel can not be wrongly installed. A silicone
rubber seal ring is located at the end of the crankshaft,
The crankshaft has 7 main bearings, each big end to seal between the crankshaft and the timing gear
bearing is between two main bearings. The thrust wheel.
bearings are integrated into the center main bearing.
Both the main and big end bearings have steel shells The combined timing gear cover/flywheel housing is
plated with lead/nickel and lined with lead bronze. located around the crankshaft timing gear wheel. A
Teflon seal seals between the flywheel housing and
The crankshaft may be re-ground to five undersize the crankshaft timing gear wheel, with an outer felt
dimensions. layer as a dust seal.
At the front and rear, the crankshaft is provided with The crankshaft timing gear wheel has a guide pin at
integrated hubs for attaching the timing gear wheels the rear that fits into the flywheel, so that it can not be
(rear) and oscillation damper/pulleys (front). wrongly installed. The flywheel bolts pass through the
flywheel and crankshaft timing gear and are fastened
A Teflon seal in the front cover seals the crankshaft
to the crankshaft.
front end; the seal has an outer felt coating that acts
as dust protection. The oscillation damper housing The flywheel peripheral surface has a number of mil-
contains a freely-rotating steel ring which serves as led groves for the injection system rpm sensor.
an inertial mass. The space between the steel ring
and the damper housing is filled with highly viscous Lubrication is via separate channels in the cylinder
silicone oil. Oscillations are dampened by the oil, block to each main bearing and from there a channel
which balances out the pulsating rotation of the crank- runs to the nearest big end bearing journal.
shaft and the even movement of the steel ring.

7747722 01.2009 57
20-0 Engine Information, General

Camshaft

P0006836

The overhead camshaft is induction-hardened. The From and including engine no. 2016010025 the mark-
bearing journals may be ground, and have replacea- ing is located at the front of the camshaft instead. TDC
ble bearing shells as spare parts. is used for basic camshaft setting, and must be
between the two marks on the bearing housing when
The camshaft is supported in seven bearing housings the flywheel is at the 0° mark. The numerical marks
that are line bored and numbered 1 through 7 seen are used for adjusting the valves and injectors.
from the front of the engine. The rear bearing is a
thrust bearing. Bolted to the camshaft bearing caps is the rocker arm
bridge, which serves as the bearing journal for the
The camshaft has three lobes per cylinder: one for the rocker arms with their pressed-in, surface-treated
inlet valves, one for the exhaust valves, and a lobe in steel bushings. A valve caliper transfers the rocker
between for the unit injector. arm movement to the valves. The rocker arm has a
roller in contact with the camshaft, and a ball socket
The camshaft gear is installed on the rear flange of
and adjuster screw in contact with the valve caliper.
the camshaft with a hydraulic oscillation damper on
the outside. Both the camshaft gear and the oscilla- The exhaust valves have double springs.
tion damper have holes for the camshaft guide pin, to
prevent incorrect assembly. There are teeth on the The valve guides are made of alloyed cast iron and
vibration damper that generate signals in the cam- the valve seats are made of steel. Both are replace-
shaft sensor. able as spare parts. All valve guides are fitted with oil
seals.
In front of the rearmost bearing housing there is a
flange with the camshaft mark, the numerical marks 1
through 6 and TDC (Top Dead Center).

58 7747722 01.2009
 20-0 Engine Information, General

Engine Transmission

1 Camshaft gear
2 Upper intermediate gear
3 Bull drive
4 Lower intermediate gear
5 Crankshaft gear
6 Drive gear, lubricating oil pump
7 7 fuel pump drive gear/servo pump

P0006837

The timing gears are located at the rear of the engine The camshaft gear (1) is bolted into the camshaft
on a 6 mm thick steel plate, bolted to the cylinder head flange and located by a guide pin. The oscillation
and engine block, and fixed with two guide sleeves damper with teeth for the camshaft sensor is installed
and a guide pin. All gear wheels have helical teeth and on the outside.
are nitride hardened.
The lower intermediate gear (4) is journaled by a dou-
The crankshaft gear (5) also acts as a spacer between ble-row ball bearing and drives the combined fuel
the crankshaft flange and the flywheel. It is fastened pump/servo pump. The gear is fastened with a bolt
with 12 pass-through bolts and fixed to the crankshaft that runs through the flywheel cover and is threaded
with two Allen bolts and a guide pin. into the cylinder block.

Above the crankshaft gear is a bull drive (3) consisting Drive gear (7) is installed on the servo pump pass-
of two gears bolted together. The gear wheels are pre- through shaft, which drives the fuel pump.
installed on a hub journaled on two conical roller
bearings. The inner gear wheel drives the upper The oil pump drive gear (6) is driven directly from the
(adjustable) intermediate gear (2) which in turn drives crankshaft gear.
the camshaft gear (1) and is journaled in a bush in the
hub.

Backlash must be adjusted between the upper inter-

mediate gear (2) and the camshaft gear (1) whenever
the timing gears have been serviced.

7747722 01.2009 59
20-0 Engine Information, General

Group 22: Lubrication System

Lubrication system, principle

Lubrication system for 16 liter industrial engines A low pressure turbo (LPT) is only fitted to TWD1643GE.

The engine is pressure lubricated by a gear pump The oil pump housing is made of aluminum. The pump
connected to the engine timing. Oil flow is controlled is driven directly by the crankshaft gear. The oil pump
by 7 valves. housing and the two pump gears are matched and
cannot be changed individually. The pump gear shafts
The lubricating oil pump is driven directly by the crank- are journaled directly in the oil pump housing. Suction
shaft gear and pumps oil to two full-flow filters and one and delivery pipes are made of steel and are sealed
turbo filter (bypass filter). The bypass filter has low against the pump cover and the oil distribution hous-
through-flow and a high degree of filtration. ing with rubber seals.
Two channels are drilled along the length of the cyl- The pump housing is bolted to the cylinder block foot
inder block, of which the left channel is for lubricating and acts as a bracket for the suction strainer, which
oil supply to all crank mechanism bearings. The lubri- is also fastened to the bracing frame. The oil pump
cating oil channel is plugged at both the front and rear. safety valve is located in the filter housing.
The other channel on the right side of the engine is The oil cooler is of flat type and located on the right
the piston cooling channel, which provides the pistons side of the engine, on the inside of the cooling jacket
with oil for lubrication and cooling. The piston cooling side door and totally immersed in coolant.
channel is plugged at both ends.

All bearings in the cylinder head are lubricated from

the hollow rocker arm bridge connected to the cylinder
block via a cast channel located centrally in the block.

60 7747722 01.2009
 20-0 Engine Information, General

Piston cooling system

1
2
P0006838

Piston cooling oil is filtered through full-flow filters, and The piston is cooled by oil by means of so-called cav-
is controlled by two spring loaded sleeve valves. ity cooling. The oil is sprayed vertically up in a channel
Valve (2) senses the pressure to and from the piston in the piston via the piston cooling nozzle in the cyl-
cooling valve and is in direct connection with the fil- inder block. The oil then continues up to a circular
tered oil channel. Valve (1) is a control valve and channel in the top of the piston and is drained back to
provides constant piston cooling pressure regardless the oil pan.
of engine rpm.

The opening valve (2) is a spring loaded sleeve valve

that opens and closes the oil flow. Opens at >2.5 bar,
closes at <2.5 bar.

The pressure regulating valve (1) for piston cooling is

a spring loaded sleeve valve. Oil enters through the
lower chamber and passes through the hole in the
intermediate wall to the upper chamber. The pressure
from the oil that is led upwards via the channel pushes
the sleeve down. The sleeve waist controls flow
through the intermediate wall and thus piston cooling
pressure, which is held constant.

7747722 01.2009 61
20-0 Engine Information, General

Valves, Overview

P0006839

A By-pass valve for oil cooler

B Safety valve
C Reduction valve
D Control valve for piston cooling
E Opening valve for piston cooling
F Overflow valve for bypass filter
G Overflow valve for full-flow filter

62 7747722 01.2009
 20-0 Engine Information, General

7747722 01.2009 63
20-0 Engine Information, General

Group 23: Fuel System

4 1

3 8
5
9
P0003106

E D

A B C

P0003108

The fuel system comprises(3) all earlier model VE and GE engines; however NOT TWD1643GE.

3. For engine designations refer to Identification Numbers page 52.

64 7747722 01.2009
 20-0 Engine Information, General

For each cylinder there is an electronically-controlled The overflow valve controls fuel pressure to the unit
unit injector which works at a very high pressure. The injectors. A check valve (7) ensures that fuel does not
pressure is generated mechanically by the overhead flow back when the engine is shut off.
camshaft, via the rocker arms. Actual injection is con-
trolled electronically by the control unit. The fuel then flows out at the front edge of the cylinder
head, whence it proceeds down to the filter housing
Fuel flows from the tank (1) to the control module where it is mixed with fuel from the suction side and
cooling coil (2), and from there through the fuel pre- fed back to the feed pump.
filter (3) and on to the fuel pump suction side. The fuel
pump (4) forces the fuel to the fuel filter housing, The feed pump has two valves: the safety valve (8)
through the main filter (5) and up to the longitudinal allows fuel to flow back to the suction side when the
cylinder head fuel channel. pressure rises too high (e.g. when the fuel filter is
clogged) and the check valve (9) opens when the
The fuel channel (6) supplies each unit injector with hand pump on the pre-filter is used.
fuel via a ring-shaped space around each injector.

A A unit injector is a combination of an injection D The control unit is bolted to the engine on four
pump and an injector that works at a much higher vibration-absorbing rubber mounts and is cooled
pressure than an ordinary injector. Opening by fuel through a cooling coil fastened to the out-
pressure is about 260 bar and working pressure side of the control unit, before the suction side of
can be up to 2,000 bar. the feed pump.
Injection timing and the amount of fuel for injec- The control unit receives continual information
tion is determined by the control unit, which sig- from a number of sensors on the engine, in order
nals electromagnetic fuel valves built into the to determine fuel volume and injection timing.
unit injector. Force is transferred to the unit injec- Control signals to the unit injector fuel valves are
tor via a rocker arm from a cam lobe on the transmitted via electric cables. The control unit
camshaft. stores any faults and deviations that occur in the
Unit injectors are manufactured and classified by system. Intermittent faults are also stored so that
tolerance. Each unit injector is marked with a they can be traced at a later date.
code on the top of the electrical connection.
When replacing, the new codes must be pro-
grammed.

B The fuel filter housing has a manual pump for E Excess fuel from the bypass valve is mixed with
venting the fuel system. Water drainage is car- fuel from the suction side in the filter housing,
ried out by hand at the water trap on the fuel pre- and fed back to the feed pump.
filter. A check valve built into the pump prevents
fuel from flowing back when the engine is shut-
down.

C The gear type feed pump is driven by the crank- Fuel system feed pressure is controlled by an
shaft via an intermediate gear. High pressure is overflow valve integrated into a hollow bolt,
needed in order to ensure that unit injectors are located in the return line from the cylinder head.
filled. The flow must be sufficient to even out any The opening pressure is 300–550 kPa; the high
temperature differences in the cylinder head fuel feed pressure is required to ensure the unit injec-
channel. tors are filled. The bypass valve also has an
integrated purging valve that automatically vents
the system, allowing a small volume of fuel back
to the tank.

7747722 01.2009 65
20-0 Engine Information, General

F G F

7 10

P0003107 9

F G F
A
D

E B C

P0003109

Fuel system with Stack Pipe (Raiser). Comprises(4) all late model engines except 1650VE.

4. For engine designations refer to Identification Numbers page 52.

66 7747722 01.2009
 20-0 Engine Information, General

For each cylinder there is an electronically-controlled The fuel channel (6) supplies each unit injector with
unit injector which works at a very high pressure. The fuel via a ring-shaped space around each injector.
pressure is generated mechanically by the overhead
camshaft, via the rocker arms. Actual injection is con- The fuel then flows out at the front edge of the cylinder
trolled electronically by the control unit. head, whence it proceeds to the overflow valve (7).

Fuel flows from the tank (1) to the control module The overflow valve controls fuel pressure to the unit
cooling coil (2), and from there through the fuel pre- injectors. The fuel then flows to the filter housing, is
filter (3) and on to the fuel pump suction side. The fuel mixed with fuel from the suction side and is led back
pump (4) forces the fuel to the fuel filter housing, to the feed pump.
through the main filter (5) and up to the longitudinal
The feed pump has two valves: the safety valve (8)
cylinder head fuel channel.
allows fuel to flow back to the suction side when the
In order to ensure immediate start – even after long pressure rises too high (e.g. when the fuel filter is
periods of standstill – there are two volumes. Level clogged) and the check valve (9) opens when the
tubes, so-called raisers (F) are located in the cylinder hand pump on the pre-filter is used.
head inlet and outlet. The two raisers are connected
by the narrow hose (G). The check valve (10) pre-
vents fuel from running back to the tank when the
engine is stopped.

A A unit injector is a combination of an injection D The control unit is bolted to the engine on four
pump and an injector that works at a much higher vibration-absorbing rubber mounts and is cooled
pressure than an ordinary injector. Opening by fuel through a cooling coil fastened to the out-
pressure is about 260 bar and working pressure side of the control unit, before the suction side of
can be up to 2,000 bar. Injection timing and the the feed pump.
amount of fuel for injection is determined by the The control unit receives continual information
control unit, which signals electromagnetic fuel from a number of sensors on the engine, in order
valves built into the unit injector. Force is trans- to determine fuel volume and injection timing.
ferred to the unit injector via a rocker arm from a Control signals to the unit injector fuel valves are
cam lobe on the camshaft. Unit injectors are transmitted via electric cables. The control unit
manufactured and classified by tolerance. Each stores any faults and deviations that occur in the
unit injector is marked with a code on the top of system. Intermittent faults are also stored so that
the electrical connection. When replacing, the they can be traced at a later date.
new codes must be programmed.

B The fuel filter housing has a manual pump for E Excess fuel from the bypass valve is mixed with
venting the fuel system. Water drainage is car- fuel from the suction side in the filter housing,
ried out by hand at the water trap on the fuel pre- and fed back to the feed pump.
filter. A check valve built into the pump prevents
fuel from flowing back when the engine is shut-
down.

C The gear type feed pump is driven by the crank- Fuel system feed pressure is controlled by an
shaft via an intermediate gear. High pressure is overflow valve integrated into a hollow bolt,
needed in order to ensure that unit injectors are located in the return line from the cylinder head.
filled. The flow must be sufficient to even out any Opening pressure is 340–450 kPa; the high feed
temperature differences in the cylinder head fuel pressure is required to ensure the unit injectors
channel. are filled. A purging valve that automatically
vents the system, allowing a small volume of fuel
back to the tank, is fitted to the fuel filter housing.

F/G Level tubes, so-called raisers, are located in the

cylinder head inlet and outlet to ensure fuel is
available for immediate start. The dimensions of
the narrow hose and nipple must be kept and
may not be changed.

7747722 01.2009 67
20-0 Engine Information, General

Unit injectors
The working sequence of the unit injector can be div-
ided into four phases:
• Filling phase
• Leak-off phase
• Injection phase
• Pressure reduction phase

The pump piston always pumps the same volume of

The illustrations show the following positions:
fuel forwards and backwards through the injector; it is
1 Pump piston only when the fuel valve is closed that pressure is built
up and injection takes place. The duration and timing
2 Fuel duct
of the current impulse determines the volume of fuel
3 Injector needle injected and its timing.

Filling phase
During the filling phase, the pump piston travels
towards its upper position.

The highest point on the camshaft lobe is passed and

the rocker arm is on the way down towards the cam-
shaft base circle.

The fuel valve is open, since the solenoid valve is not

powered. This means that fuel can be drawn from the
fuel duct, past the fuel valve, and into the pump cylin-
der.

P0006840 Filling continues until the pump piston reaches its

upper position.

Leak-off phase
The leak-off phase starts when the camshaft has
turned to the position where the cam lobe operates the
rocker and starts to press the pump piston down. Fuel
flows back through the fuel valve and out into the fuel
duct.

The leak-off phase continues for as long as the fuel

valve is open.

P0006841

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The illustrations show the following positions:

1 Pump piston
2 Fuel duct
3 Injector needle

Injection phase
The injection phase starts when the solenoid valve is
activated by the control unit, and the fuel valve closes.

The camshaft lobe continues to press the pump piston

down, via the rocker arm. Since the passage through
the fuel valve is closed, pressure quickly builds up. The
pressure lifts the injector needle and injection takes
place.

The injection phase continues for as long as the fuel

valve is closed.

P0006842

Pressure reduction phase

The pressure reduction phase starts when the control
unit determines that the engine has received the
amount of fuel it needs, and so cuts the current impulse
to the solenoid valve. The fuel valve opens and fuel
flows back out into the fuel duct. Pressure falls rapidly
and the injector needle closes, so that injection ceases.

P0006843

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Group 25: Inlet and Exhaust System

TAD1640GE, TAD1641GE, TAD1641VE,
TAD1642GE, TAD1642VE, TAD1643VE,
TAD1650VE

Turbo

P0006844

The turbocharger is driven by the exhaust gas which As the compressor wheel rotates, air is drawn in from
passes through the exhaust turbine housing on its the air filter. Air is compressed and forced into the
way out to the exhaust system. engine cylinders after first having been cooled by
passing through the charge air cooler.
The exhaust flow causes the turbine wheel to rotate
and drive the compressor wheel, which is mounted on
the same shaft. The compressor wheel is located in a
housing between the air filter and the engine inlet
manifold.

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Twin Turbochargers
TWD1643GE

LPT

HPT

P0003111

Exhaust gasses first drive the high pressure turbo As the compressor wheels rotate, air is drawn in from
(HPT) for quick response to engine load, and then the the air filter. Air is compressed and forced into the
low pressure turbo (LPT). A wastegate is installed so engine cylinders after first having been cooled by
as not to overspeed the high pressure turbo. passing through the charge air coolers. Charge air is
cooled in two separate stages (after each turbo).
Exhaust gas flow causes the turbine wheels to rotate
and drive the compressor wheels.

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Closed crankcase venting

TAD1640GE, TAD1641GE, TAD1641VE,
TAD1642GE, TAD1642VE, TAD1643VE

Optional
Closed crankcase ventilation is available as Optional
Equipment (Optional) for TAD1640–42 VE, GE and
TWD1643GE.

In these examples, the engine is equipped with a sep-

arator and a centrifugal oil separator driven by engine
lubricating oil pressure. The separator separates oil
from the oil mist in the crankcase gases before the
gases are recirculated to the engine.

P0006845

1 Unfiltered crankcase gas from the engine

2 Filtered crankcase gas is returned to the engine
3 Lubricating oil under pressure to operate the oil separator
4 Lubricating oil returns to the sump

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Group 26: Cooling System

TAD1640GE, TAD1641GE, TAD1641VE,
TAD1642GE, TAD1642VE, TAD1643VE,
TAD1650VE

General

P0006846

Coolant is pumped directly into the engine by the When the coolant becomes hot it expands and the
coolant pump from the pump housing on the right- excess is forced up to the expansion tank. Any air in
hand side of the cylinder block. The majority of the the coolant will be removed here.
coolant passes between the oil cooler plates, while
some is forced into the cylinder liner lower cooling The thermostat is a so-called piston thermostat with
jackets. piston, sensor, seal and housing in one unit. It begins
to open at 86 °C (187 °F) and is fully open at 96 °C
After the oil cooler, the coolant is distributed to the (205 °F).
cylinder upper cooling jackets via calibrated holes,
and to the cylinder head. The cylinder head also The coolant pump is of impeller type and is driven by
receives returned coolant from the cylinder cooling a belt from the crankshaft. The impeller is made from
jackets. This part of the coolant enters the cylinder hard plastic. The pump shaft is journaled with a main-
head via nozzles that direct flow towards the outlet tenance-free, double ball bearing. The seal between
channels and the injector sleeves. the pump wheel and bearing is assured by a unit seal.
Between seal and bearing there is a space with a
The thermostat housing is located at the front end of drain channel that ends in a drain hole under the pump
the cylinder head. When the coolant is cold, the ther- shaft. Should the seal leak, this will show by coolant
mostat is closed and the coolant passes directly down leaking out through the drain hole, in which case
through the thermostat housing to the coolant pump replace the entire pump as a spare part.
and back into the engine.

When the coolant is hot, it is routed to the front outlet

on the thermostat housing and to the inlet at the bot-
tom of the radiator. Coolant is forced down through
the duct at the same time as it is cooled, and then it
is returned to the pump lower inlet. The coolant pump
then forces the coolant back into the engine again.

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General
TWD1643GE

P0006847

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TWD1643GE has a newly-designed cooling system A certain volume of cooling water (approx. 95 l/min)
that is more complicated than that of its predecessor [approx. 25.1 US gals./min.] is always fed from the
D16C. In order to achieve cooling performance suffi- thermostat housing, via a by-pass, directly back to the
cient for engine output, the engine is equipped with a pump. The priority valve is calibrated for the existing
TWD system, which means that the charge air coolers system and has a very important function ensuring
are water cooled. In addition, the system is designed that the flows in the system are correct.
as a double-circuit system with high and low temper-
ature circuits, in order to achieve a sufficiently low Coolant is fed from the high temperature circuit to the
cooling water temperature for the charge air coolers. low temperature circuit. The coolant is fed directly into
the low temperature radiator where it is cooled as far
The flow between the high and low temperature cir- as possible. The combination of low cooling air tem-
cuits is balanced by a priority valve. Because the perature and a relatively low coolant flow (approx. 90
system is balanced, changes cannot be made without l/min) [approx. 23.77 US gals./min.] through the low
affecting system flow. Incorrect flow can seriously temperature radiator provides very good cooling per-
effect the function and performance of the engine. formance. It is very important that the radiator assem-
bly is kept clean, otherwise there is a risk that the
The air-cooled radiators are located at the front of the coolant system temperature will quickly rise. The cool-
engine. The cooling assembly for the low temperature ant is fed from the radiator to the charge air coolers,
circuit is located closest to the fan in order to receive which are connected in parallel so that each receives
the coolest air. The engine is only supplied with a the same flow (approx. 45 l/min) [ca 11.9 US gals./
pressurizing fan. min.]. When the coolant has passed through the
charge air coolers it is mixed with water from the high
The cooling water circuit starts at the engine circula-
temperature circuit before returning to the coolant
tion pump, which has a capacity of 455 l/min (120.2
pump.
US gals./min. at 1,800 r.p.m. All flows indicated in the
illustration apply to 1,800 rpm. In order to prevent boiling in the charge air coolers at
different loads and coolant temperatures, the system
All cooling water coming from the thermostat enters
is fitted with a cold start valve that is controlled by the
the high temperature radiator. The high temperature
engine control unit. The cold start valve is used to
radiator is located after the low temperature radiator
safeguard coolant flow through the charge air coolers
in the air stream, which means that its cooling air will
when the thermostat is closed. Factors that must be
have a higher temperature than that of the low tem-
considered are: coolant temperature, charge air tem-
perature radiator. Cooling water flow is split after the
perature and engine torque. The cold start valve is
high temperature radiator and the greatest volume
primarily opened when the thermostat is closed (cold
(approx. 260 l/min) [approx. 68.7 US gals./min.] is fed
engine) which when closed completely blocks the flow
via the priority valve back to the coolant pump.
to the radiator assembly.

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Placement of Instrument Socket(s)

TAD1640GE, TAD1641GE, TAD1641VE,
TAD1642GE, TAD1642VE, TAD1643VE,
TAD1650VE

The figures below show where measuring points may

be located on the engines.

P0006848
1 4 5 2

P0006849

1 Crankcase pressure 4 Fuel feed pressure (before filter)

2 Lubricating oil pressure 5 Fuel feed pressure (after filter)
3 Charge air pressure / temp. after charge air 6 Piston cooling oil pressure
cooler.

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Placement of Instrument Socket(s)

TWD1643GE

The figures below show where measuring points may

be located on the engines.

4 5

P0006850

1 Crankcase pressure 4 Fuel feed pressure (before filter)

2 Lubricating oil pressure 5 Fuel feed pressure (after filter)
3 Charge air pressure / temp. after charge air 6 Piston cooling oil pressure
cooler.

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Location of Sensors
TAD1640GE, TAD1641GE, TAD1641VE,
TAD1642GE, TAD1642VE, TAD1643VE

P0006852

1 Coolant level sensor, in the expansion tank 8 Water-in-fuel sensor

2 Crankcase pressure sensor 9 Oil level sensor and oil temperature sensor
3 Underpressure sensor, air filter 10 Main circuit breaker 10 A
4 Auxiliary stop 11 Piston cooling oil pressure
5 (5)
charge air pressure and charge air tempera- 12 Camshaft position
ture sensor
6 Coolant temperature sensor 13 Oil pressure sensor
7 Fuel pressure sensor 14 Flywheel position and engine rpm

5. Combined

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Location of Sensors
TWD1643GE

P0006853

1 Coolant level sensor, in the expansion tank 9 Oil level sensor and oil temperature sensor
2 Crankcase pressure sensor 10 Main circuit breaker 10 A
3 Underpressure sensor, air filter 11 Piston cooling oil pressure
4 Auxiliary stop 12 Camshaft position
5 (6)
charge air pressure and charge air tempera- 13 Oil pressure sensor
ture sensor
6 Coolant temperature sensor 14 Flywheel position and engine rpm
7 Fuel pressure sensor 15 Exhaust temperature
8 Water-in-fuel sensor

6. Combined

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Location of Sensors
TAD1650VE

P0006851

1 Coolant level sensor, in the expansion tank 8 Oil level sensor and oil temperature sensor
2 Crankcase pressure sensor 9 Main circuit breaker 10 A
3 Auxiliary stop 10 Piston cooling oil pressure
4 (7) charge air pressure and charge air tempera- 11 Camshaft position
ture sensor
5 Coolant temperature sensor 12 Oil pressure sensor
6 Fuel pressure sensor 13 Flywheel position and engine rpm
7 Water-in-fuel sensor

7. Combined

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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 mainte-
nance work in the chapter Safety precautions for boat
operation before you start work.

Symptoms and possible causes

The diagnosis button lamp flashes
Please refer to Diagnostic Function
Engine can not be stopped
2, 5
Starter motor does not rotate
1, 2, 3, 4, 5, 6, 7, 24
Starter motor rotates slowly
1, 2
Starter motor rotates normally but engine does not start
8, 9, 10, 11,
Engine starts but stops again
8, 9, 10, 11, 13
Engine does not reach correct operating speed at full throttle
9, 10, 11, 12, 13, 21, 25, 26
Engine runs roughly
10, 11
High fuel consumption
12, 13, 15, 25
Black exhaust smoke
12, 13
Blue or white exhaust smoke
15, 22
Too low lubrication oil pressure
16
Excessive coolant temperature
17, 18, 19, 20, 28
Too low coolant temperature
20
No, or poor charge
2, 23
Too high exhaust temperature (only TWD1643GE)
13, 17, 18, 19, 21, 25, 27, 28, 29, 30

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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

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Common Interference Causes

Suitable actions
Functional Disturbances External cleaning:
For more detailed information and further fault tracing 1 Remove guards as necessary, to access the
help, See Operator's Manual, group 30, “MID 128, radiator.
PID 110, Engine coolant temperature”. If there is a IMPORTANT!
malfunction, first check the following items: Take care that the radiator lamella are not dam-
aged.
• Check that the coolant level is between the
A high pressure washer may under no circum-
markings on the expansion tank (at approx. 20°
stances be used!
C) [68 °F]. If the level in the expansion tank is
too low, top up and start the engine. If the cool- 2 Clean with water and a mild detergent.
ant disappears, there is internal or external Use a soft brush.
leakage.
3 Re-install removed parts.
• Check that the coolant is not contaminated. If
the coolant is contaminated, this signifies inter- Internal cleaning:
nal leakage (oil) or that the cooling system has
a blockage (deposits). Blockage in the cooling • Refer to Cooling System, Cleaning.
system is caused by one or more of the follow-
ing factors: Further checks
1 The coolant has not been changed at the • External and internal leakage in the cooling
specified intervals. system: Check if there is leakage in the system.

2 Incorrect mixture of coolant and water. • Coolant circulation: Check that coolant circu-
lates by letting the engine run at high speed.
3 Contaminated water has been used. Also check the expansion tank to see that cool-
ant circulates. This can be an indication of a
Clogging fault in the cooling system.
Is often caused by high coolant temperature, internal • Thermostat: Check thermostat function. Drain
or external blockage of the cooling system, or a com- enough coolant to allow the thermostat to be
bination of both. If the cooling system is blocked, it removed. Check the thermostat; refer to Ther-
must be cleaned. mostat, Function Check page 266.
• External dirt: Check that the cooler and/or the
charge air cooler are not clogged. If you cannot
see light through at least one third, the cooler
should be removed and cleaned.
Check if there is any internal or external leakage
in the cooling system.
• Internal contamination: Check that the cooler
and/or the charge air cooler are not clogged.

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Charge Pressure, Troubleshooting

Charge Air Pressure, Check

9998339 Manometer
9998493 Hose
9996666 Nipple
1 Connect the nipple with hose and pressure gauge
to the measuring point on the inlet manifold; refer
to Placement of Instrument Socket(s) page 76.
2 Compare this pressure with the pressure that can
be read with the VODIA tool; refer to “Workshop
manual, EMS 2”
If the two measurements show different values,
the pressure sensor is faulty and must be
changed.

Pressure drop indicator, check

NOTICE! For engine TWD1643GE the pressure drop
indicator is electrical and provides a signal to the
engine management system.

The points below do NOT apply to TWD1643GE.

1 Check that the air filter is clean and that there are
no obstructions to air entry.
2 Remove the pressure drop indicator from the air
filter housing
3 Check the pressure drop indicator by sucking out
air until the indicator shows red. Re-set by press-
ing the yellow button.
4 When for example the air filter is blocked and
pressure drop occurs, the pressure drop indicator
shows this by indicating red. Change the indicator
if it does not function according to the checks in
the previous steps (shows red).
5 Install the pressure drop indicator on the air filter
housing.

Exhaust system, inspection

1 Check that the exhaust system is a Volvo Penta
original component. (Does NOT apply to
TWD1643GE.)
2 Check whether the exhaust system has been
modified, has bends or damage that prevent
exhaust gas from flowing out.
If the exhaust system is not a Volvo Penta original
(NOT applicable to TWD1643GE), has been
modified, has bends or damage, exhaust back
pressure may be too high, which will entail
reduced engine power.

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Charge air cooler, checks (Does NOT

apply to TWD1643GE)
1 Check the charge air cooler for damage to the
cells and connections.
If there is any damage, change the charge air
cooler.
2 Check the charge air cooler and radiator for inter-
nal blockage.
If there is any blockage, clean in accordance with
Charge Air Cooler, External Cleaning page 85.

Inlet manifold, checks

1 Check that the inlet pipes are clean inside, and
undamaged. Crushed, damaged or dirty inlet
pipes can reduce the charge pressure.

Charge air pipes, checks

1 Inspect the charge air pipes for visible cracks and
external damage.
2 Check that there is no oil in the charge air pipes.
If the pipes are damaged or the union seal rings
leak, the charge pressure will be too low and
engine performance will be impaired.
If the pipes are contaminated with oil on the
inside, this indicates oil leakage in the turbo-
charger turbine shaft seal. In this case, the tur-
bocharger must be changed as a complete unit.

IMPORTANT!
If there is oil in charge air pipes and charge air
hoses, the charge air cooler and all pipes and
hoses in the charge air system must be very thor-
oughly cleaned inside, before the engine is started.

Charge Air Cooler, External

Cleaning
Remove guards as necessary, to access the cooler.
Clean with water and a mild detergent. Use a soft
brush. Be careful not to damage the radiator matrix.
Re-install the components.

IMPORTANT!
Do not use a high pressure power washer.

Test and Adjustments

Compression Test
The fuel system shall be emptied and the rocker bridge
removed, see Draining, Fuel Duct in Cylinder
Head page 219.

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20-0 Engine Information, General

9988539 Compression meter

9990185 Lifting tool
9998248 Adapter

Removal
1 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 226 and mount the unit injector
protection (9998249). Clean the copper sleeves
as needed with cleaning kit 9998599.
2 Fit all(8) adapters (6 pcs), tool 9998248 Adapter,
to the cylinder head and pull them on with the
injector retainers.
3 Oil valve caliper, cam shaft ridges and the rocker
bridge.

4 Fit the rocker bridge with 9990185 Lifting tool.

Torque the screws evenly along the rocker arm to
avoid that the rocker arm bends or warps.
Make sure that guide pins fit in the camshaft sup-
port bearing. Torque the rocker bridge as speci-
fied in 03-2, Technical Data. Use torque wrench.
5 Install the middle piece and the oil pipe to the
rocker bridge.
6 Check the valve clearance, see Valves and Unit
Injectors, Adjustment page 203, for all valves as
P0004965
specified in 03-2, Technical Data.

7 Remove both control wires from the starter motor

control connector (the two thin cables).
Connect one of the two free connectors on the
control connector to ground.

8. This in order to avoid repeating removal/refitting of rocker bridge

and unit injector and performing valve adjustment six times.

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 20-0 Engine Information, General

8 Connect the other connector to a switch, which in

turn is connected to the positive (plus) connection
on the starter motor.

9 Connect tool 9988539 Compression meter to

9998248 Adapter on the first cylinder.
10 NOTICE! Do not run the engine for more than 15
seconds at a time with intervals of 60 seconds.

Run the engine with the starter motor until the

compression meter needle has stopped (max
compression reading).
Read the value.
Move the compression meter to the next cylinder.
Repeat the test on all cylinders.
11 Remove the middle piece and the oil pipe for the
rocker bridge.
12 Remove the rocker bridge screws equally in
stages so that it is not bent.
Remove the bolts and carefully lift off the rocker
bridge using 9990185 Lifting tool.
13 Remove all adapters, tool 9998248 Adapter from
all cylinders.

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20-0 Engine Information, General

Installation
14 Mount the unit injectors and new o-rings, see the
Installation section in chapter Unit Injector,
Replace page 226.
15 Fit the rocker bridge with 9990185 Lifting tool.
Torque the screws evenly along the rocker arm to
avoid that the rocker arm bends or warps.
Make sure that guide pins fit in the camshaft sup-
port bearing. Torque the rocker bridge as speci-
fied in 03-2, Technical Data. Use torque wrench.
16 Install the middle piece and the oil pipe to the
rocker bridge.
17 Adjust valves and unit injectors, see Valves and
Unit Injectors, Adjustment page 203.
P0004965 18 Check and if needed change the valve cover
bearing. Install the valve cover.
19 Re-install the fuel lines. Use new sealings.
20 Vent the fuel system, see Fuel system, bleed-
ing page 218.

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Cooling System, Pressure Testing

9996441 Cover, with connecting nipple
9996662 Pressure testing kit

Check the pressure testing device 9996662 Pressure

testing kit before using it. See Cylinder Head, Pressure
Testing page 90.
1 Check that all hoses are free from defects.
2 Check that the cock on the pressure reduction
valve is fully opened.
3 Replace the coolant filler cap on the expansion
tank with cap 9996441 Cover, with connecting
nipple. Connect the pressure testing device to the
nipple on the lid.

P0006858

4 Connect the pressure-testing device to the com-

pressed air system and open the cock (B). Adjust
the pressure reduction valve (A) so that pressure
gauge shows a pressure of 70 kPa (10.2 PSI).
Close cock (B).
5 The pressure must not drop during two
minutes for the cooling system to be considered
free from leaks.

NOTICE! Repeat the pressure testing if you are

uncertain whether the cooling system leaks or
not.
6 Close the compressed air after the pressure test-
ing. Eliminate the excess pressure in the cooling
P0006858 system by unscrewing the pressure reduction
valve and opening the cock (B).
7 Remove the testing device.
8 Check coolant level in the expansion tank. Install
the regular coolant filler cap.
9 Start the engine and check for leaks.

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Cylinder Head, Pressure Testing

9990123 Pressure testing kit
9996239 Lifting tool
9986485 Stand
9990160 Fixture
9990107 Connection washer
9990164 Fixture

Checking the pressure test unit

Check pressure testing device 9990123 Pressure test-
ing kit before it is taken into service:
1 Connect the pressure testing device to the com-
pressed air mains.
2 Set the pressure gauge to 100 kPa (14.5 PSI)
using the reducing valve. The knob can be locked
with a retainer ring moved axially.

P0006858

3 Close the shut-off valve. The pressure on the

pressure gauge must not fall for 2 minutes, for the
device to be regarded as reliable.
4 Unscrew the knob on the reducing valve and
open the tap.

P0007006

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Pressure Testing
Cylinder head removed.

For all lifts of the cylinder head use 2 lifting chains, tool
9996239 Lifting tool; refer to 21-1, Cylinder Head,
Removal.
1 Wash the cylinder head in a washing bath.
2 Fit the cylinder head to an assembly stand, tool
9986485 Stand with the aid of 9990160 Fixture
and 4 bolts, M8 x 25.
3 Clean the mating surfaces on the cylinder head.
4 Fit seal plates, tool 9990164 Fixture to the cylin-
der head using the cylinder head bolts and M18
nuts (14 pcs. required).
5 Fit connection washer, tool 9990107 Connection
washer onto the thermostat housing seat. Secure
the washer with a G-clamp; see illustration.
P0007007 Leave the side cover in place.
6 Leave the temperature sensor in place.
Plug any coolant connections for the compressor.
7 Connect the pressure gauge hose to connection
washer, tool 9990107 Connection washer.
8 Remove the cylinder head including fixture from
the assembly stand.
Remove the fixture.
9 Put the cylinder head in a water bath, +70 °C
(+158 °F).
10 Connect air to the pressure testing unit.
Open the shut-off valve.
11 Adjust the reducing valve knob so that pressure
gauge shows a pressure of 50 kPa (7.25 psi).
Maintain the pressure for 1 minute.
12 Raise the pressure to 150 kPa (21.76 PSI). Lock
P0007008 the reducing valve knob with the retainer ring.
Close the shut-off valve.
13 After 1 to 2 minutes, check whether the pressure
has dropped, or if bubbles of air can be seen in
the water bath.
If bubbles are visible, check seal plates and
inspect the cylinder head for any cracks.
14 Unscrew the knob on the reducing valve to relieve
the pressure in the cylinder head, and open the
tap.
15 Take the cylinder head out of the water bath.
Attach the fixture.
Secure the cylinder head in the assembly stand.

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16 Blow the cylinder head dry. Be extra thorough

with the fuel channels.

IMPORTANT!
Make sure no dirt gets into the fuel channels, as
this may cause damage to the unit injectors.
17 Remove all the sealing washers and any plugs
installed for the pressure testing.
18 Remove the cylinder head including fixture from
the assembly stand.
Remove the fixture.

P0006858

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Turbocharger, Inspection
1 Check that the turbocharger part number is cor-
rect for the engine variant. The wrong turbo-
charger for the engine variant might not provide
enough charge pressure, which would reduce
engine power.
2 Check that the turbocharger has the correct com-
pressor housing. If the wrong compressor hous-
ing is installed on the turbocharger, the compres-
sor wheel might have been damaged or have too
much clearance between wheel and housing. In
both cases, charge air pressure will be too low.
3 Remove the inlet manifold from the turbocharger.
4 Check the turbocharger for damage to the com-
pressor wheel and excessive end float on the
turbine shaft.
5 If there is any damage on the compressor wheel
or excessive end float on the turbine shaft, the
turbocharger must be changed as a unit.
6 Remove the exhaust pipe (muffler) from the tur-
bocharger and check the turbine disc.
7 Check the turbine wheel for damage. If the turbine
wheel is damaged, the turbocharger must be
changed as a unit.

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Wastegate Valve, Adjustment

Localising
The wastegate valve link arm is on the side of the
wastegate housing.

9990123 Pressure testing kit

P0006860

1 Connect manometer, tool 9990123 Pressure test-

ing kit to the waste gate actuator and to com-
pressed air.
Adjust the tool to 4 bar (400 kPa) [58.02 PSI].

P0006861

94 7747722 01.2009
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2 Remove the lock pin from the link arm.

P0006862

3 Lift the link arm so that the wastegate flap closes

completely.

IMPORTANT!
Hold the adjusting rod with a pair of pliers when
adjusting, so that the membrane in the pressure
actuator is not damaged by turning.
4 Adjust the rod so that the holes coincide.

P0006863

7747722 01.2009 95
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5 Insert the lock pin and snap the lock into place on
the adjustment rod.
Tighten the lock nut.
6 Release the pressure from the tool and remove
it.
7 Reconnect the pressure hose to the wastegate
actuator.

P0006864

Flywheel Sensor Distance, Check

Camshaft Sensor Distance, Check

9993590 Rotation tool
9998517 Adjustment tool
1 Attach tool 9993590 Rotation tool and turn the
engine flywheel to 0°.
2 Remove the flywheel sensor.

P0006982

A 3 Slide the installation tool retainer ring so that it is

located around the middle of the tool.
4 Fit the tool in the sensor hole and carefully press
the tool in until it touches the flywheel.
5 Remove the tool and measure the distance
between the retainer ring and the end of the tool.
Note the measured value (A).
P0006983

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6 Put the sensor in the tool and measure the dis-

tance between the mating surface of the sensor
bracket and the end of the tool. Note the value
measured (B).
7 Calculate the existing sensor distance (D) as fol-
lows:
D = A – (B + 20) mm [+ 0.79 in].

Example
Distance A = 28.2 mm [1.11"]
P0006984 Distance B = 8 mm [0.315"]
D = 28.2 – (8 + 20) mm [1.11 – (0.315 + 0.79)"]
D = 0.2 mm [0.0079 in]
Compare the distance with the correct value;
refer to Steering System page 37. If necessary:
adjust using shims, thickness 0.6 mm (0.0236 in).

Clearance measured Number of

From To shims Part no.
0.2 mm 1.0 mm — —
(0.0079") (0.039")
–0.3 mm 0.3 mm 1 1677894
(–0.0118") (0.0118 in)
–0.6 mm –0.3 mm 2 1677894
(–0.0236") (–0.0118")

8 Install the sensor on the flywheel housing

together with any shims.
9 Remove the cranking tool and re-install the cover.

Drive Belt and Alternator Belt,

Inspection
Belts must be checked after operations while they are
still warm. The alternator belt and the drive belt must
be able to be depressed about 3–4 mm (0.12–0.16")
between the pulleys.
Both the alternator belt and the drive belt have auto-
matic belt tensioners and need not be adjusted.

7747722 01.2009 97
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21-0 Engine Complete, General

Replacement of Components

Group 21: Engine

Cylinder Liner and Pistons,

Inspection
Clean the cylinder liners carefully before inspec-
tion and measurement.

IMPORTANT!
Cylinder liners and pistons are classed together. This
means that cylinders and liners must not be mixed.

The piston and cylinder liner sets are only available as

a single, complete unit.

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 indi-

cator. 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 cyl-
inder liner as the base value.
2 Measure the cylinder liner at top and bottom dead
centers, and at several places vertically.
P0006962
At each measurement location, measurement
must be lengthwise and crosswise in relation to
the engine.
3 If wear is greater than 0.45–0.50 mm, a new com-
plete lining kit must be used (piston, liner, piston
rings, piston pin and seals).
Oil consumption also affects when cylinder liners
must be changed.
4 Remove the cylinder liner and do a crack check.
Be specially careful when checking the liner col-
lars.
The Magnaflux method may be used for this
check.

Pistons
5 Check for worn piston ring grooves, damaged
retainer ring grooves, cracks and other damage
to the pistons.
If the piston has deep scratches on its skirt, the
piston (liner kit) must be scrapped. The same
applies if the piston has one or more cracks in the

98 7747722 01.2009
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piston pin hole or in the bottom of the combustion

chamber.
Crack tests must be done using the chalk powder
method.

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Cylinder Liner and Pistons, Replace

(all)
9989876 Dial indicator
9990157 Press tool
9990158 Piston ring compressor
9992479 Holder for dialindicator
9993590 Rotation tool
9996394 Support
9996395 Support
9996645 Puller
9996963 Plate
9998511 Lever
88800083 Piston ring pliers

Removal
Cylinder head, oil pan, bracing frame and piston
cooling nozzles removed.

IMPORTANT!
It is important that the piston cooling nozzles be
removed before the pistons are removed. Damaged
nozzles may cause extensive engine damage.
1 Remove the protective cover in the flywheel
housing and install tool 9993590 Rotation tool.
Turn the crankshaft until access is gained to the
bolts on the connecting rod that is to be removed.

P0006884

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2 Remove the big end bearing caps and bearing

cups.
3 Remove the piston together with the connecting
rod.

IMPORTANT!
Replace the bearing cap on the connecting rod to avoid
damaging the split surface, as this is very sensitive.

P0006912

4 Pull the cylinder liner out of the block using tools

9996963 Plate, 9996645 Puller and
9996394 Support.
If necessary, extend using tool 9996395 Sup-
port.
5 Remove the cylinder liner sealing rings.

P0006913

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6 Remove the retainer rings from the piston and

press out the piston pin.
Remove the piston from the connecting rod.
7 Clean the sealing surfaces in the cylinder block
and the grooves for the sealing rings. Do not use
scrapers or other tools that can damage the seal-
ing surfaces.

P0006963

Installation
8 Check the cylinder block liner seat for damage. In
case of damage, the cylinder liner seat must be
reconditioned.
Fit the cylinder liner, without sealing rings.
Locate it using two tools9990157 Press tool.
9 Fit tool 9989876 Dial indicator into tool
9992479 Holder for dialindicator.
Place the holder with dial gauge across the cyl-
inder liner.
Zero the dial gauge with a couple of millimeters'
pre-load against the cylinder block plane.

P0006964

10 Measure the height between the cylinder 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, see
specifications. If the liner height above block
plane is outside the specified tolerance, the liner
collar in the cylinder block must be milled.

NOTICE! Always measure at the highest point of

the sealing surface. Mark the liner position in the
cylinder block with an felt-tip pen, so that it is
replaced in the same position during installation.
Repeat the procedure for the remaining cylinder
liners.
P0006965
11 Remove the two tools 9990157 Press tool. Pull
the cylinder liner out of the block.
Place the cylinder liners in the same sequence
that they were installed, together with any adjust-
ing spacers.

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12 Lubricate the sealing rings with the lubricant sup-

plied with the lining kit and install them on the
cylinder liners.

NOTICE! The purple seal ring must seat in the

lowest groove

P0006966

13 When the cylinder liner is fitted without shims, an

even, thick bead of about 0.8 mm (0.03”) of seal-
ing compound must be placed on the underside
of the cylinder liner collar.

NOTICE! Do not put sealing compound around

the entire liner. Leave a 2 mm (0.08”) gap.

P0006917

14 If the liner is installed with shims, the sealant bead

must be placed on the cylinder block liner seat.

IMPORTANT!
Sealant must not be used between the adjusting
spacers and the cylinder liner collar.
15 NOTICE! After sealing compound has been
applied, the liner must be installed within 5
minutes and fixed in the engine block using
two tools 9990157 Press tool.

P0006918

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16 Install one of the cylinder head bolts (A). Position

tool 9996963 Plate (D) above the cylinder liner
together with a suitable spacer (C) and press the
cylinder liner down using tool 9998511 Lever
(B).

P0006967

17 Lubricate the piston pin, the piston bearing seat

and the connecting rod bearing with engine oil.

FRO
NT

P0006920

18 Install the connecting rod in the piston with the

mark “FRONT” on the connecting rod and the
arrow on the piston facing the same direction.
Press in the piston pin.

NOTICE! It should be possible to press the piston

pin in without much force. If the resistance is too
great, the piston may need to be heated. The
connecting rod should turn freely on the piston
pin.

Install the retainer rings.

P0006921

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19 Install the piston rings. Use tool 88800083 Piston

ring pliers. The piston ring openings must be
evenly spaced in relation to each other.
The oil scraper ring opening must be diametrically
opposite the opening in the spring.

NOTICE! The two upper piston rings are marked

with letters or dots. The markings must face
upward. The oil scraper ring is symmetrical and
may face either way.

P0006968

20 Lubricate the piston and piston rings with engine

oil. Check that the piston ring openings are offset
120° in relation to each other.
21 Install the piston together with the connecting rod.

NOTICE! Connecting rods must be installed in

their original positions. The arrow on the piston
and the “FRONT” marking on the connecting rod
must face forwards. Use tool 9990158 Piston ring
compressor.

Temporarily remove the press tools when the pis-

ton is installed. Put the press tools back when the
piston is in place.
22 Lubricate the bearing journal and bearing shells
with engine oil. Install the bearing shells. Check
P0006923
that they are correctly aligned in the connecting
rods and bearing caps. Install the main bearing
cap according to the markings and torque as
specified; refer to Technical Data page 22.
23 Clean the piston cooling nozzle and check that it
is undamaged. Install the nozzle and torque
according to specifications; refer to Technical
Data page 22.

NOTICE! Make sure that the nozzle is directed

toward the cutout in the piston.

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Crankshaft, Inspection
The crankshaft is induction hardened.

Inspect the crankshaft very carefully to avoid unnec-

essary overhaul.
The following applies when the need for overhaul is
checked:
1 Clean the crankshaft carefully.
Measure the bearing journals' out-of-round, wear
and taper. Refer to Technical Data page 22 for
specifications.
2 Check whether there is any surface damage on
the bearing journals. If there is any damage on
the surface layer, the shaft must be re-ground.
3 Place the shaft pair of V-blocks, under 1st and 7th
main bearing journals. Alternatively, hold the
crankshaft between the two centers.
4 Measure crankshaft axial displacement (throw)
on the 4th main bearing.
For maximum permissible values, refer to Tech-
nical Data page 22.

IMPORTANT!
Crankshaft straightening is not permitted.
5 Check for cracks before and after any grinding.
Magnetic powder testing is used for this test, i.e.
fluorescent powder which is viewed under ultra-
violet light.

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Main bearing, Change

Oil pan removed

The method describes replacement of main bearings

with the crankshaft in place in the engine

9990013 Slide hammer

9990114 Puller
9993590 Rotation tool

Removal
1 Fit tool 9993590 Rotation tool.

P0006884

2 Remove the oil suction pipe and oil pump.

Remove the bracing frame.

P0006969

3 Remove one bearing cap.

P0006970

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4 Remove the upper main bearing shell by putting

a pin in the crankshaft oil hole and rolling the
bearing shell out by turning the crankshaft in the
direction of rotation with tool 9993590 Rotation
tool.
5 Clean and check the bearing seat, bearing cap,
shaft journal and bearing shell.
If the bearing has seized, the reason must be
determined before a new bearing is installed.
6 Check that the correct bearing dimension is used
when the bearing shells are changed.

NOTICE! If case of uncertainty, check in Techni-

cal Data page 22 which oversize dimensions are
P0006971
available.

Installation
7 Lubricate the shaft journal and the new bearing
shells with engine oil.
8 Install the upper bearing shell by turning the
crankshaft using tool 9993590 Rotation tool
against the direction of rotation with the pin in the
oil hole.

NOTICE! Check that the pressed-out bearing

shell heel is correctly aligned in the bearing seat
cutout.

Make sure that the upper bearing shells (those to

be located in the engine block) are equipped with
oil holes.

P0006972
NOTICE! Remove the pin when done.

9 Fit the main bearing cap together with the lower

bearing shell.

NOTICE! The main bearing caps are asymmetric

and can only be installed in one position. Note the
main bearing cap numbers showing their loca-
tions if several caps are removed simultaneously.

Torque the caps in two steps as specified; refer

to Technical Data page 22.
10 Change the other bearing shells, one a time, in
the same way as the first one. Each time a
changed is made, check that the crankshaft does
P0006973
not seize by turning it using tool 9993590 Rotation
tool.

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11 Check crankshaft end float and replace the thrust

washers if the clearance is too great or if the thrust
washers are damaged.

NOTICE! Measure the end float with a dial gauge.

Thrust bearings are available in a number of over-
size dimensions. Refer to Technical
Data page 22 for oversize dimensions and axial
play.

The crankshaft thrust bearing is located in the

center main bearing.
12 Use a narrow plastic or wood stick to remove the
thrust bearing washers from the cylinder block
bearing seat.

NOTICE! The thrust washers can only be placed

in one position.

P0006974

13 Check the axial play of the crankshaft when all

main bearing caps have been torqued; refer to
Technical Data page 22 for specification.
14 Install the bracing frame and torque according to
the tightening chart; refer to Technical
Data page 22.
15 Install the oil pump and oil suction pipe.
16 Remove tool 9993590 Rotation tool from the fly-
wheel housing and install the cover.
17 Install the oil pan.
P0006975 Add oil and change the oil filter.
Check the oil pressure.

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Big end bearing, Change (all)

Oil pan, oil suction pipe and bracing frame
removed.

9993590 Rotation tool

Removal
1 Fit tool 9993590 Rotation tool and turn the fly-
wheel until the bearing caps on connecting rods
1 and 6 are in a position that allows the bolts to
be removed.
2 Mark and remove the bearing caps on connecting
rods 1 and 6.

IMPORTANT!
Be careful not to damage the surfaces.
P0006884 3 Remove the bearing shells and clean the con-
necting rod and cap bearing seats.

NOTICE! Make sure the bearing caps are instal-

led on the same connecting rod.
4 Check the bearing journals and bearing caps.
5 Measure the shaft journals; if any value exceeds
the maximum allowed, the crankshaft must be
removed and remedied.

Installation
6 Fit the new the bearing shells and check that the
bearing size is correct. Make sure the bearing
shell guide pins is aligned with the connecting rod
recess.
7 Lubricate the bearing shells and the big end jour-
nals. Fit the bearing caps and torque the bolts as
specified; refer to Technical Data page 22.
8 Turn the flywheel so that connecting rods 5 and
2 are in position for bolt removal and repeat steps
2-7.
P0006976
9 Turn the flywheel so that connecting rods 3 and
4 are in position for bolt removal and repeat steps
2-7.
10 Check that no big end bearing binds.
11 Remove the turning tool from the flywheel hous-
ing and install the cover.
12 Install the bracing frame, oil suction pipe and oil
pan.
Add oil and change the oil filter.
Check the oil pressure.

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Flywheel Bearing, Change

9986173 Puller
9986179 Puller
9991801 Standard handle
9992269 Drift
1 Measure the bearing position on the flywheel.
2 Remove the old bearing using tool
9986173 Puller and 9986179 Puller.

P0006977

3 Tap the new bearing into the measured position,

using tool 9991801 Standard handle and
9992269 Drift.

P0006978

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Flywheel, Change
9993590 Rotation tool
9996239 Lifting tool
1 Remove the flywheel sensor.
2 Fit tool 9993590 Rotation tool.
3 Bolt tool 9996239 Lifting tool onto the flywheel
with two bolts.
Remove the flywheel retaining bolts. Use as the
turning tool as a counterhold.
Lift the flywheel away.
4 Clean the flywheel contact surface on the crank-
shaft.
5 Clean the flywheel. Check that the tracking sur-
faces for the flywheel sensor are clean.
6 Check that the flywheel guide pin is correctly
inserted into the crankshaft.
Check that there is no damage.
7 Lift the flywheel into position and install the retain-
ing bolts.
8 Torque the retaining bolts according to the tight-
ening chart; refer to Technical Data page 22. Use
tool 9993590 Rotation tool as a counterhold.
P0006931

9 Remove the cranking tool and re-install the cover.

10 Check the flywheel sensor clearance; refer to
Flywheel Sensor Distance, Check page 96.
Install the flywheel sensor.

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Gear Ring, Fywheel: Replace

Flywheel removed.
1 Drill 1–2 holes between teeth on the ring gear.
Split the gear ring at the drilled hole, using a cold
chisel. Lift the gear ring away from the flywheel.
2 Brush the flywheel contact surface clean with a
steel wire brush.

P0006979

3 Heat the new gear ring up to 180–200°C (356–

392 °F) with a welding torch or in an oven. The
gear ring must be evenly heated. Be careful not
to heat the gear ring up far with annealing as a
result.
Check the heat by polishing the ring bright at sev-
eral places. Stop heating when the polished sur-
faces become blued.

P0006980

4 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.

P0006981

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Flywheel, Indication
Pressure plate removed.

9989876 Dial indicator

9993590 Rotation tool
9999696 Magnetic stand
1 Install tool 9989876 Dial indicator and
9999696 Magnetic stand with the measuring tip
against the flywheel.
2 Remove the cover from the engine flywheel hous-
ing. Fit tool 9993590 Rotation tool.
3 Set the dial gauge to zero. Turn the flywheel and
observe the maximum value measured on the
dial gauge. This must not exceed 0.20 mm
(0.0079") on a measurement radius of 150 mm
(5.91").
If the runout is greater, remove the flywheel and
investigate whether there is any dirt or uneven-
ness between the flywheel and the crankshaft
flange.

P0006985 4 Remove tool 9993590 Rotation tool and install

the cover.

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Crankshaft seal, replace (front)

Option 1

9990118 Cone
9992000 Handle
88800021 Drift

Option 2

9990118 Cone
9990192 Puller
9992000 Handle
9996400 Slide hammer
88800021 Drift

Removal, alternative 1
1 Remove the crankshaft pulley and oscillation
damper (12 bolts).
2 Drill 2 holes Ø 3.5 mm (0.14") in the seal with the
aid of the guide holes in tool 88800021 Drift.
Brush grease on the drill to prevent dirt from get-
ting into the engine.
3 Screw two 5 mm self-tapping screws 5 mm (0.2")
into the seal.
4 Screw in two long thread M10 x 60 bolts into the
tool and pull the seal out. Remove the seal and
bolts from the tool.
5 Clean the seal area in the cover and the sealing
P0004789 surface on the crankshaft.

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21-0 Engine Complete, General

Removal, alternative 2

9990192 Puller
9996400 Slide hammer
1 Hammer out the seal with tool 9990192 Puller
together with 9996400 Slide hammer.

9990192 IMPORTANT!
Incline the tool to ensure that the crankshaft is not
damaged.

999 6400

P0006989

Installation

9992000 Handle
9993590 Rotation tool
88800021 Drift
1 Check that the plastic ring is correctly in place in
the new seal.

NOTICE! If the plastic ring is not in place in the

new seal, the seal ring may be damaged and
must not be used.
2 Clean the crankshaft sealing surface and cover.
Check that these are damage free.

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3 Install the new sealing ring and plastic ring onto

the crankshaft journal.

P0004791

4 Press home the seal toward the cover by hand.

P0004792

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21-0 Engine Complete, General

5 Remove the plastic ring.

P0004793

6 Carefully tap in the new seal until it bottoms

against the crankshaft journal. Remove the tool.
7 Ensure that the crankshaft, belt pulleys and hub
mating surfaces are clean and damage free.
8 Install the oscillation damper and pulley. Torque
according to specifications; refer to Special Tight-
ening Torques page 9.

P0004794

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Crankshaft Sealing, Change (rear)

9990166 Mounting tool
9990192 Puller
9992000 Handle
9996400 Slide hammer

Removal
1 Fit tool 9996400 Slide hammer and
9990192 Puller on the old seal by pressing it in or
tapping it in the with a slide hammer.

IMPORTANT!
Be careful not to damage the crankshaft. Incline
the tool inwards to ensure a good grip in the seal.
Hammer out the seal with the tool.
2 Clean the seal area in the flywheel housing (the
timing gear cover) and the sealing surface on the
crankshaft (sealing surfaces must be completely
clean and dry).
P0006990

Installation
3 Install the tool on the crankshaft and fasten it with
the bolts. Make sure that the plate on the tool is
touching the crankshaft before tightening it. The
washer must be placed on the center bolt as a
spacer. It determines how far the seal is pressed
into the cover.

P0006991

4 Install the plastic ring that the new seal is

mounted on and install the cover together with the
screw handle.

P0006992

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21-0 Engine Complete, General

5 Press in the seal using the tool; when the cover

bottoms against the tool, the seal will be in the
correct position.

IMPORTANT!
No lubricants may be used and surfaces must be
clean.
6 Remove the tool.

P0006993

Connecting Rod, Check

Important consideration when removing/installing
fracture-split connecting rods.

Installing a NEW connecting rod:

Carefully fix the connecting rod in a vise with soft jaw
pads.

Undo the connecting rod bolts a few turns and carefully

tap the bearing cap with a plastic faced hammer until
it loosens.

The split line can be difficult to find when the connect-

ing rod is assembled.

When the cap is separated from the connecting rod, it

may occur that a chip is missing or comes loose. This
does not affect the function of the connecting rod
adversely.

Handle the connecting rod and bearing cap carefully.

If any strike marks occur on the split line, this may
affect strength after torquing.

IMPORTANT!
If the connecting rod or bearing cap are damaged,
change the connecting rod.

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Connecting Rod Bushing, Check up

1 Check the connecting rods for cracking, straight-
ness 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.

3 IMPORTANT!
2 Regarding max. allowed straightness and twist devia-
tions, refer to Technical Data page 22.

P0006994 P0006995

2 Use a new piston pin and measure the straight-

ness of the connecting rod, using a fixture.
3 Measure connecting rod twist.

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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

9809726 Pneumatic hydraulic pump

9809729 Hydraulic cylinder
9990160 Fixture
P0006996 9990174 Drift
9992670 Hand pump
9996159 Adapter
9998246 Drift

Note: 9992670 Hand pump is alternative to

9809726 Pneumatic hydraulic pump .

Alternative 2

9990210 Valve spring compressor

Alternative 1
1 Fit tool 9809729 Hydraulic cylinder into tool
9990176 Press tool.
2 Install tool 9996159 Adapter and tool
9998246 Drift (inlet) or tool 9990174 Drift (outlet)
on the hydraulic cylinder. Place the tool in the
holes for the cylinder head retaining bolts.
Tighten the tool nuts.
3 Connect tool 9809726 Pneumatic hydraulic pump
(alternatively 9992670 Hand pump).
4 Press the valve spring washer down and remove
the collets.

NOTICE! Check that the tool does not damage

the unit injector electrical connector, if the injector
is left in place.

NOTICE! Put the valves and springs in a marked

stand, to facilitate putting components back in the
same places in the cylinder head.
5 Remove the remaining valves in the same way as
above, using the press tool.
6 Remove the oil seals from the valve guides.

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Alternative 2

9990210 Valve spring compressor

1 Lay the cylinder head on a flat, clean surface.
Make sure the cylinder head is not damaged
when the valves are to be removed.
2 Fit tool 9990210 Valve spring compressor in the
unit injector hole. Fix the tool in the bolt hole for
the unit injector yoke, M10 x 30.
3 Place the moving part of the tool over the valve
spring to be removed. Screw down the “wing nut”
on the tool until the valve washer has been
pressed down so far that the collets can be
removed.

NOTICE! Put the valves and springs in a marked

P0006997
stand, to facilitate putting components back in the
same places in the cylinder head.
4 Remove the remaining valves in the same way as
above.
5 Remove the oil seals from the valve guides.

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Valves, Installation
Alternative 1

9809726 Pneumatic hydraulic pump

9990165 Guide sleeve
9990174 Drift
9990176 Press tool
9990210 Valve spring compressor
9992670 Hand pump
9996159 Adapter
9998246 Drift

Note: 9992670 Hand pump is alternative to

9809726 Pneumatic hydraulic pump .

Alternative 2

9990210 Valve spring compressor

Alternative 1
1 Oil the valve stems and install the valves.
Oil the oil seals.
2 Install tool 9990165 Guide sleeve on the valve
stem and press the new oil seals down over the
valve guides.

NOTICE! Check that the oil seals are pressed

down properly.
3 Install the valve caliper guide pins.
Install the springs and valve spring washers.
Carefully press down the valve spring washer and
install the collets. Use tool 9990176 Press tool
together with 9809726 Pneumatic hydraulic
pump , 9996159 Adapter and 9998246 Drift (inlet)
P0006998 or 9990174 Drift (outlet), in the same way as for
Valves, Removal.

Alternative 2

9990210 Valve spring compressor

1 Alternatively, tool 9990210 Valve spring com-
pressor may be used instead of the hydraulic
cylinder, in the same way as for Valves, Removal.

P0006997

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Valve Seat, Change

Cylinder head and valves removed.

9989876 Dial indicator

9992479 Holder for dialindicator
1 The valve seats must be changed if a satisfactory
seal cannot be obtained or when the distance
(A) exceeds the value stated in the specification;
refer to Technical Data page 22.

P0007000

2 Grind the head off an old valve and weld it onto

the valve seat. Use a MAG welder, or a conven-
tional arc welder (with a stainless welding elec-
trode).

IMPORTANT!
Carefully cover the other surfaces on the cylinder head
to prevent any weld spatter from fastening.
P0007001

P0007002

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3 Place a suitable socket over the valve/valve guide

and carefully tap the valve seat out.

IMPORTANT!
Be careful not to damage the cylinder head.

CAUTION!
Risk of eye injury. Eye protection required.
4 Clean the seat bed carefully and check the cylin-
der head for cracks.
5 Measure the diameter of the valve seat bed in the
cylinder head. Determine whether a standard or
oversize dimension valve seat must be used.
P0007003 Carry out any necessary machining to the valve
seat bed; refer to Technical Data page 22.

6 Cool the seat in carbon dioxide snow between –

60 °C (–76 °F) and –70 °C (–94 °F) and heat the
cylinder head by flushing with hot water, or by
some other method.
Install the new valve seat using a drift.

NOTICE! Align the seat with the seat angle facing

the tool. Check sealing against the valve.

P0007004

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Valve Guides, Inspection

Refer to Valve Guides, Inspection page 204.

Valve Guides, Replacing

Cylinder head removed.

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.

Option 1

9809726 Pneumatic hydraulic pump

9809729 Hydraulic cylinder
9990176 Press tool
9996159 Adapter
88800064 Drift
88800127 Drift
88800147 Drift

Optional tools

9992670 Hand pump

Note: 9992670 is alternative to 9809726.

Removal
999 2670 980 9729 1 Install tool 9990176 Press toolinto the cylinder
980 9726 head retaining bolt holes.

NOTICE! Put washers between the nuts and the

cylinder head plane.
999 0176 2 Tighten the tool nuts.
999 6159 3 Install tool 9996159 Adapter in the hydraulic cyl-
888 00137 inder.
4 Fit tool 9809729 Hydraulic cylinder into tool
9990176 Press tool and press out the valve guide
using tool 88800147 Drift and9809726 Pneu-
matic hydraulic pump , alternatively
9992670 Hand pump.
5 Press the other valve guides out in the same way.

p0003637

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Installation
6 Heat the cylinder head with hot water while cool-
ing the valve guides with e.g. carbon dioxide
snow.
Lubricate the cylinder head valve guides with
engine oil.

IMPORTANT!
Wear protective goggles when pressing.
7 Press in the valve guide for the inlet valve using
tool 88800064 Drift. Press in the exhaust valve
guide using tool 88800127 Drift.
8 Press until the tool bottoms against the cylinder
head plane.
9 Remove the tool from the cylinder head.

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

9992000 Handle
88800064 Drift
88800127 Drift
88800147 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.

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Removal
NOTICE! Take out the valve guides from beneath the
cylinder head.

1 Tap out the valve guides with tool

88800147 Drift together with 9992000 Handle.
2 Tap the other valve guides out in the same way.

Installation
3 Heat the cylinder head with hot water while cool-
ing 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
tool88800064 Drift. Tap in the exhaust valve
guide using tool 88800127 Drift.
5 Tap until the tool bottoms against the cylinder
999 2000 head plane.
6 Repeat the procedure for the remaining valve
guides.

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.
888 00064
P0003640 888 00127

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Valve Seats and Valve, Grinding

For valve sealing angles, refer to Technical

Data page 22.

NOTICE! Spare part valve seats are already

machined, and do not need further grinding.

P0007076

P0008416

Inlet valve

P0008417

Exhaust valve

Valve seat, grinding

1 Before the valve seats are ground, the valve
guides must be checked and changed if wear tol-
erances have been exceeded.
2 When grinding valve seats, do not remove an
unnecessary amount of material; only remove
enough material to give the valve seat the correct
shape and a good mating surface.
3 Grind new seats down so far that the dimension
between the cylinder head plane and the valve

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disc surface, is in accordance with specifications;

refer also to Technical Data page 22.
4 Check the valve seat angle with a valve seat
gauge, once the seat mating surface has been
coated with a thin layer of marker dye.

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NOTICE! Spare part valves are already machined, and

do not need further grinding.

NOTICE! The sealing surface must be ground as little

as possible; however, enough to grind away all dam-
age.

Valves, grinding
1 Check dimension (A). If the dimension is greater
than the wear tolerance as specified in Technical
Data page 22, the valve must be changed.

NOTICE! Always change a valve with a bent

valve stem.
2 Check valve sealing with marker dye. If there is
any leakage, grind the valve seat again; refer to
Valve Seat, Grinding, then do a new check.
Once the results of grinding are acceptable, the
valve and seat may be lapped in with fine grinding
P0007000 paste.

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Valve Stem Sealings, Replace

9990165 Guide sleeve
9990210 Valve spring compressor
9993590 Rotation tool

Removal
1 Disconnect all current to the engine, by switching
off the main switch.
2 Remove the unit injectors; refer to the removal
section in Unit Injector, Replace page 226.
3 NOTICE! The piston must be at top dead center
when the valves are removed. This is to prevent
the valves from falling into the cylinder. Use tool
9993590 Rotation tool.
4 Compress the valve springs for no. 1 cylinder.
Use tool 9990210 Valve spring compressor.
5 Remove the valve washers, valve springs and
collets.
6 Remove the old valve stem seals.

Installation
7 Lubricate the valve stem with engine oil.
Fit tool 9990165 Guide sleeve to the valve stem.
Slide on the new seal and guide it over the man-
drel.
8 Install the valve springs, valve spring washers
and collets. To ensure the collets arrive in the
correct positions, carefully tap with a plastic faced
mallet.
9 Transfer the valve spring compressor to no. 6 cyl-
inder and repeat the above steps. Then crank the
engine so that no. 3 and no.4 cylinder are at top
dead center.
Repeat the procedure. Then continue with cylin-
ders 2 and 5.

NOTICE! The piston must be at top dead center

when the valves are removed. This is to prevent
the valves from falling into the cylinder. Use tool
9993590 Rotation tool.
10 Install the unit injectors; refer to the installation
section in Unit Injector, Replace page 226.
11 Adjust the valves and unit injectors; refer to
Valves and Unit Injectors, Adjust-
ment page 203.
12 Bleed the fuel system; refer to Fuel system,
bleeding page 218. Perform a function and leak-
age check.

Cylinder Head, Pressure Testing

Refer to Cylinder Head, Pressure Testing page 90.

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Copper sleeve for unit injector,

replace
Unit injector removed

1159794 Torque wrench

9809668 Extractor
9809667 Thread tap
9993590 Rotation tool
9996049 Draining hose
9998250 Sealing ring
9998251 Protection plug
9998252 Thread cutting tool
9998599 Cleaning kit
88800191 Extractor
88800196 Drift
1 Drain the coolant with the aid of a hose, tool
9996049 Draining hose. Refer to Draining the
Cooling System page 247.
2 If necessary, remove tool 9998251 Protection
plug.
3 Install 2 seal rings, tool 9998250 Sealing ring, to
prevent dirt from getting into the fuel ducts when
the copper sleeve is removed.

NOTICE! Make sure the piston is at bottom dead

center.

P0006890

4 Lubricate the tap, tool 9809667 Thread tap , with

grease in order to prevent swarf from falling into
the cylinder.
Screw the tap at least 20 mm (0.8") into the cop-
per sleeve, using tool 9998252 Thread cutting
tool.

NOTICE! Use tap 9809667.

5 Remove tool 9998252 Thread cutting tool and the
tap.

P0006826

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888 00191 6 Check that the tap, tool 9809668 Extractor is

installed on tool 88800191 Extractor.
Screw the tap into tool 88800191 Extractorat
least 15 mm (0.6") into the copper sleeve.
Remove the copper sleeve by turning the nut at
the same time as the tap is held fast.

P0007009

7 Use cleaning kit, tool 9998599 Cleaning kit and

an electric drill before fitting the new copper
sleeve.
Install tool 9998580 Protective sleeve in the injec-
tor well and fasten it with the holder (the “lugs”
must be cut off for the tool to fit).

NOTICE! Tool 9998580 Protective sleeve must

be used to prevent dirt from getting into the fuel
duct.
8 Clean the cylinder head walls for the copper
P0007010 sleeve with part no. 9808618.

9 Clean the copper sleeve seat using brush no.

9808614 together with the handle and holders.

P0007011

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10 Clean cylinder head holes with brush no.

999 8580 9808617.

980 8617 11 Remove tool 9998580 Protective sleeve.

12 Check that the piston is at bottom dead center.

NOTICE! This must be done so that tool no.

9998688, due to its length, does not damage the
piston.

P0007012

13 Always use the new version copper sleeve (3)

with two grooves at the upper edge, when chang-
ing.

NOTICE! When replacing an older version

cooper sleeve, all sleeves must be replaced with
the new version.

NOTICE! The steel gasket delivered with the new

copper sleeve must be used when installing the
unit injector.

Lubricate the O-ring on the copper sleeve with

soapy water.

NOTICE! Always use a new O-ring.

P0003615

1, 2. Older versions of the copper sleeve.

3. New version copper sleeve.

14 Put the copper sleeve on tool no. 88800196.

The steel gasket may not be used when installing
the copper sleeve. It may only be used when
installing the unit injector.
Oil the pin on the tool.

NOTICE! The tool only fits the new version cop-

per sleeve.
88800196

P0003616

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88800196 15 Place 88800196 together with the copper sleeve

in the cylinder head. Make sure the copper sleeve
bottoms in the cylinder head.
Install the unit injector yoke.
Use tool 1159794 Torque wrench to press in the
copper sleeve; torque 80 Nm (59 lbf ft).

P0003617

88800196 16 By holding the tap and turning the nut, the tap is
drawn onto tool 88800196 through the copper
sleeve tip.
Remove tool 88800196.

P0003618

17 Remove the protective rings, tools (2 pcs.)

9998250 Sealing ring.
18 Install the unit injectors. Also refer to the installa-
tion section in Unit Injector, Replace page 226.
19 Put the valve caliper back in accordance with the
marking.
20 Install the rocker arm bridge and check the clear-
ance of the valves and unit injectors.
21 Install the valve cover.
22 Fill up with coolant and check that no leakage
occurs. Refer also to Coolant Level, Checking
and Topping Up page 251.
9998250

P0003619

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Camshaft, Wear Check

Rocker bridge removed

Put a steel rule across the camshaft lobes, parallel with

the camshaft axis, to check whether the cam profiles
show signs of wear.

Measure the wear with a feeler gauge or wire gauge.

Alternatively, a digital caliper gauge may be used.

Compare the measured values with those specified in

Technical Data page 22.

P0007013

Guidlines for replacement

In normal conditions, unevenness may occur on the
surface of engine camshaft lobes. This does not mean
that the camshaft must be changed. These marks do
not have any negative influence on either engine per-
formance or the durability of the engine and its com-
ponents.

Examples of acceptable wear and unacceptable wear

are shown below.

Acceptable wear: Unacceptable wear:

The camshaft need not be changed. IMPORTANT!
The camshaft and associated rocker arms must be
changed.

P0003896 P0003899

P0003898 P0003897

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Camshaft Bearing Housing,

Replace
The factory-installed bearing housings are machined
together with the cylinder head, and may therefore not
be moved from one cylinder head to another.

Therefore, the first time one or more bearing housings

are replaced, all bearing housings must be replaced so
that the positions of the bearing housings can be
aligned. Bearing housings may then be replaced indi-
vidually.

P0007018

The holes for the guide sleeves are oval in the replace-
ment housings, which allows radial adjustment of the
center bearing housing and axial adjustment of the
front and rear bearing housings.

If a replacement housings are installed, mark them with

their numbers so they can be put back in the same
place as before, if they need to be removed.

P0007019

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Timing Gear, Replace

Valve cover, cable harness, upper timing gear
cover, camshaft sensor, oil pan, and oil pump
removed.

9996239 Lifting tool

9998601 Fixture
885810 Fixture

Removal
1 Remove the flywheel sensor.
2 Turn the engine to TDC on the camshaft and
check that the mark on the flywheel is at “0”.
3 Bolt lifting chain tool 9996239 Lifting toolonto the
flywheel. Remove the flywheel.

WARNING!
Pinch hazard.Keep fingers clear.

IMPORTANT!
The flywheel weighs about 40 kg (88.2 lbs).
4 Remove the starter motor, rear lifting eye and fuel
pump together with servo pump, the cover and
any rear engine mounts.

P0006931

5 Remove flywheel housing bolts. Remove the

housing using lifting eyes and lifting strap.
6 Remove the lower intermediate gear (4).
7 Remove the camshaft gear (1).
8 Remove the two bolts on the crankshaft gear (5)
and remove the gear using a suitable puller.

NOTICE! To protect the puller thread, place a

thick washer between the threaded shaft and the
crankshaft.

P0006908

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9 Remove the six Allen bolts in the bull drive hub

(3) and remove it complete.
10 Remove the upper intermediate gear (2).

NOTICE! Save the spacer plate behind the gear

and note how it is installed.
11 Remove the timing gear plate and clean both
sides.

P0006837

1 Camshaft gear
2 Upper intermediate gear
3 Bull drive
4 Lower intermediate gear
5 Crankshaft gear
6 Drive gear, lubricating oil pump
7 Drive gear for fuel feed pump/servo pump

Installation
NOTICE! Lubricate the inside of the gears before
installation.

12 Apply a 2 mm (0.08") thick bead of sealant on the

engine block and the cylinder head, as illustrated.

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13 Install the timing gear plate. Use new bolts that

are pre-treated with locking compound. Tighten
according to the specifications in Special Tight-
ening Torques page 9.

NOTICE! Torque within 20 minutes of sealant

being applied.

P0006926

14 Oil the spacer plate and install it together with the

upper intermediate gear (2). Tighten with low tor-
que, max. 10 Nm (2.25 lbf).

P0006837

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15 Install a new O-ring on the crankshaft.

16 Install the camshaft gear (5)and torque the Allen
bolts according to the specification in Special
Tightening Torques page 9.

P0006927

17 Install the bull drive kit (3) with the hole marking
between the two hole markings on the crankshaft
gear.

NOTICE! The bull drive inner and outer gears

have different gear pitch. For the camshaft to be
set correctly, the markings must correspond.

Tighten the bolts according to the specification in

Special Tightening Torques page 9.

P0006929

18 Install the lower intermediate gear (4) with a new

O-Ring.
19 Install the lubricating oil pump.
20 Screw two bolts in the crankshaft gear for crowbar
grip, to allow the crankshaft to be turned when
necessary.
21 Fit the camshaft gear (5) without the oscillation
damper; use nuts as spacers.

P0006928

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22 Place the gear so that the reference hole in the

timing gear plate is between the gear markings.
Temporarily tighten two bolts with low torque,
max. 10 Nm (2.25 lbf).
23 Remove the 2 lower bolts (1) in the adjustment
wheel. Check that the upper bolts are not tight-
ened.

P0006944

24 Place a 0.1 mm (0.004") feeler gauge on the

pressure side. Turn the camshaft gear against the
feeler gauge.
Torque the upper intermediate gear according to
step 1 in Special Tightening Torques page 9.
Remove the feeler gauge.

P0006947

25 Check the clearance as follows:

Fix the adjustment wheel.
Place a dial indicator on the camshaft gear, as
illustrated.
Turn the gear back and forth and compare the
result against the gear lash specification. Refer to
the Engine Transmission section in Technical
Data page 22.
26 If gear lash is correct; torque the intermediate
gear bolts (1) according to step 2 in Special Tight-
ening Torques page 9.

P0006948

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27 Remove the crankshaft seal and apply new seal-

ing compound to the flywheel housing, facing the
engine block.

P0006930

28 Install the flywheel housing. Check that the hous-

ing is aligned with the bottom edge of the engine
block.
29 Install a new crankshaft seal. See “Crankshaft
seal, front, replacing.” Replacement of Compo-
nents page 98.

IMPORTANT!
No lubrication. Must be installed completely dry.

P0007020

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30 Install the flywheel and tighten according to spec-

ifications in Special Tightening Torques page 9.
Refer to “Flywheel, indication” Replacement of
Components page 98.
Install the flywheel sensor and adjust it; refer to
Flywheel Sensor Distance, Check page 96.
31 Install the camshaft oscillation damper and
tighten according to specifications in Special
Tightening Torques page 9.
32 Apply a 2 mm (0.08") thick bead of sealant to the
upper timing gear casing contact surface, as illus-
trated.

P0006907

33 Fit the rubber seals and install the upper timing

gear casing.

P0006949

34 Only install the bolts (1) and tighten by hand. (The

holes are oblong so that the casing can be
pressed down against the rubber seal).

P0006950

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35 Press the casing down using tools 885810 Fix-

ture and 9998601 Fixture so that the cylinder
head and the upper timing gear casing sealing
surfaces are aligned.
Install the remaining bolts (2).
Tighten according to the specifications in Special
Tightening Torques page 9.

NOTICE! The timing gear casing must be instal-

led and torqued within 20 minutes of sealant
application.
36 Install the flywheel sensor and adjust it according
to Flywheel Sensor Distance, Check page 96.
37 Install the remaining removed components.
P0007021

999 8601
P0006952

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Exposing the Engine

Exposing
TAD1640GE, TAD1641GE, TAD1641VE,
TAD1642GE, TAD1642VE, TAD1643VE,
TAD1650VE
1 Drain the coolant; refer to Draining the Cooling
System page 247.
Drain the engine oil.

P0006865

2 Remove fuel connections to the fuel pump and

allow the fuel to run out into a suitable container.
Also loosen the upper connection on the cooling
coil and water drain.
3 Remove the hoses from the radiator and the
expansion tank.
4 Remove the heat shield above the turbo, if fitted.

P0006866

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5 Remove the air filter sensor.

6 Remove the pipe between the air filter and turbo-
charger. Cover all openings.
Remove the air filter housing and mounting
bracket.

P0006867

7 Remove muffler and attachments, if fitted.

Remove the turbo from the exhaust pipe, plus the
two the oil pipes.
Cover the turbo opening.
8 Remove the crankcase breather with its bracket
and oil separator.
9 Remove the pipe between the inlet manifold and
the charge air cooler. Cover all openings.
10 Remove the safety cover above the alternator, if
fitted.
11 Remove the radiator fan safety cover/grille and
remove the fan, the hub and its brackets to the
cylinder head.
12 Remove the coolant pipe from the thermostat.
P0006868 13 Remove the belt guard and drive belts.

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Exposing
TWD1643GE
1 Drain the coolant; refer to Draining the Cooling
System page 247.
Drain the engine oil.
2 Remove the radiator assembly.
Refer to removal for 26-1, Radiator Assembly
(Complete Unit), Change.

P0006865

3 Remove fuel connections to the fuel pump and

allow the fuel to run out into a suitable container.
Also loosen the upper connection on the cooling
coil and water drain.
4 Remove the heat shield above the turbo, if fitted.

P0006866

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5 Remove the air filter sensor.

6 Remove the pipe between the air filter and turbo-
charger. Cover all openings.
Remove the air filter housing and mounting
bracket.
7 Remove muffler and attachments, if fitted.
8 Remove the crankcase breather with its bracket
and oil separator.

P0006867

9 Remove both belt guards, right and left.

Leave the cover on the right guard.

P0006869

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10 Fit a 1/2” socket drive to the belt tensioner (1).

Lift the square wrench and unhook the drive belt.
11 Thread the drive belt round the fan and remove
it.
Remove the alternator belt.
12 Remove the cooling fan and fan hub.
13 Remove the upper radiator attachment and
bracket.

P0006870

14 Undo the connector and remove the control

panel.

P0006871

15 Remove both turbochargers, charge air cooler

and associated pipes and hoses.
Refer to removal for Turbo, Change page 234
and 26-5, Charge Air Cooler, Removal.

P0006872

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Heat Protection
TWD1643GE

The heat shield is an option and may be removed for

increased accessibility for certain types of repair work.
Re-install the heat shield carefully after completion of
work.

P0003624

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Fitting the Fixture

Engine Fixture, Installation
Applies to engine nos. through 2016010024

9990143 Fixture
1 Remove electrical distributor above the control
unit.
2 Remove cable harness and fuel lines to the con-
trol unit. Cover all openings.
Remove the control unit.
3 Remove fuel and electrical connections. Lift away
the fuel filter bracket together with the filter.
Cover all fuel connections.
4 Attach tool 9990143 Fixture using 7 bolts.

P0006873

Engine Disassembly
Cylinder Head, Removal
NOTICE! The illustrations in the manual conform in all
essential parts, but due to differences in models cannot
always be shown in greater detail.

Engine exposed and installed on stand, coolant

and fuel drained.

9990006 Puller
9990013 Slide hammer
9990157 Press tool
9990160 Fixture
9990185 Lifting tool
9990192 Puller
9993590 Rotation tool
9996239 Lifting tool
9996400 Slide hammer
9998249 Protective sleeve
9998251 Protection plug
9998264 Lifting tool
9998511 Lever
1 Remove the rear lifting eye/mounting bracket.
2 Remove the heat shields above the turbo, if this
was not done when the engine was exposed.

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3 Remove the oil pipes between the turbo and the

oil filter bracket and the engine block.
Cover all openings.

P0006875

4 Cover the turbo exhaust port and remove the

turbo.

P0006868

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5 Remove the exhaust manifold.

P0006876

6 Remove camshaft sensor (1), the flywheel sensor

(2) and the sensor on the oil filter bracket (3).
Remove the cable harness from sensors and
starter motor.

P0006877

7 Remove the fuel lines to the cylinder head (1) and

plug the connections.
8 Remove the valve cover and the crankcase
breather.

P0006878

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9 Clean around the unit injectors and remove the

unit injector contacts. Remove cable holders
together with cable harness.
Cut off cable ties and remove the cable harness
from the cable holder.

P0006879

10 Remove the bolt (1) from the cable bushing and

carefully extract the harness from the cylinder
head.

IMPORTANT!
Remove the bolt, do not split the cable bushing.
11 Remove the contact to the coolant sensor, the
hoses to the expansion tank and the rest of the
cable harness and lift it away.

P0006878 12 Remove the return fuel lines on the cylinder head

front edge and plug the connections.

13 Remove cables from any preheater on the intake

manifold.
14 The intake manifold must be removed if the cyl-
inder head fixture, tool 9990160 Fixture, is to be
used. Remove all bolts and remove the intake
manifold using tool 9998511 Lever against the
reinforcement bosses.

P0006880

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15 Remove the thermostat housing and thermostat,

and the front lifting eye.
16 Remove the bolts from the coolant pipe and the
hose clamp from the coolant hose.

P0006881

17 Remove the upper timing gear casing and

remove the rubber seals.

P0006882

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18 Remove the center piece for lubrication of the

rocker arm bridge, together with the delivery pipe.

P0006883

19 Remove the cover in the flywheel housing and

install tool 9993590 Rotation tool.

P0006884

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20 Turn the engine to TDC on the camshaft and

check that the mark on the flywheel is at “0”.
TDC

C
TD

P0003112

Early model.

P0006885

Late model.

21 Remove the camshaft gear together with the

oscillation damper.

NOTICE! The oscillation damper is very sensitive

to shocks.

P0006886

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22 Remove the rocker arm bridge bolts alternately to

avoid uneven load.
23 Lift away the rocker arm bridge using tool
9990185 Lifting tool.

P0006887

24 Mark and remove the valve calipers.

P0006888

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25 Clean around the unit injectors and remove the

injector retainer bolts.
Remove the unit injectors, one at a time.
26 Pull out the injector with the aid of tool
9990006 Puller and 9990013 Slide hammer.

P0006889

27 Insert tool 9998251 Protection plug into the cyl-

inder head immediately after removal.
Mark the injectors and fit tool 9998249 Protective
sleeve to the injector.

NOTICE! Check that the tools are clean.

P0006890

28 Remove the camshaft bearing cap with the aid of

tool 9990192 Puller and 9996400 Slide hammer.

P0006891

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29 Lift the camshaft carefully using tool 9998264 Lift-

ing tool.
30 Loosen the bearing brackets by tapping them
carefully with a plastic faced mallet.
Remove the bearing brackets with the lower bear-
ing halves and put them in the right order together
with their respective camshaft bearing caps,
upper bearing halves and bolts.

NOTICE! The camshaft bearing brackets are

held by guide pins marked 1 through 7.

P0006892

31 Turn the engine so that the two the bolts (1) can
be accessed through the timing gear wheel.

P0006893

32 Place a rag in front of the gear to prevent bolts

from falling into the timing gear housing. Remove
the two bolts (1).

NOTICE! When the engine is cranked, the rag

must be removed.
33 Remove the remaining five bolts (2).
Remove the three upper bolts (3) from the timing
gear hub.

P0006894

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34 Remove the cylinder head bolts.

Use two lifting chains, tool 9996239 Lifting tool,
to carefully lift away the cylinder head. (Alterna-
999 6239 tively, lifting eyes and lifting straps may be used).

NOTICE! Place washers between the cylinder

head and lifting chains to protect the cylinder
head sealing surface.

P0006895

35 Remove the cylinder head gasket and clean the

contact surface on the cylinder block thoroughly.

NOTICE! Secure all cylinder liners using tool

9990157 Press tool.

P0006896

36 Remove the starter motor.

P0006897

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37 Remove the oil filters complete with bracket.

38 Remove the coolant filter with bracket and the
connection to the oil cooler cover.

P0006898

39 Remove the oil cooler cover. Remove the oil

cooler and seals.
40 Remove the two coolant pipes and the coolant
pump.

P0006899

41 Remove the fan bearing.

P0006900

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42 Remove the belt pulley/oscillation damper bolts.

Carefully tap and rock the hub and belt pulley to
loosen them.

NOTICE! Do not prize between the belt pulley

and oscillation damper.

Lift away the oscillation damper.

P0006901

43 Remove the bolts and the front crankshaft seal

fan bearing using a prybar at the reinforcement
illustrated.

P0006902

44 Remove the tensioning wheel and the front

engine mounts together with the belt tensioner on
the right side of the engine; 6 bolts (1).

P0006903

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45 Remove the alternator with its brackets together

with the belt tensioner and the bracket for the fan
bearing on the left side of the engine.

P0006904

46 Remove engine mounts, oil filler pipe and oil dip-

stick.

P0006905

47 Remove the fuel pump and servo pump com-

plete.
48 Remove the oil level sensor contact and remove
the oil pan.
49 Remove the oil strainer complete with pipe con-
nections.
50 Remove the bracing frame.

P0006906

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Timing Gear, Removal

9996239 Lifting tool
1 Remove the flywheel sensor, if not done previ-
ously.
2 Attach 9996239 Lifting tool to the flywheel with
two bolts.
Remove the bolts in the flywheel. Remove the
flywheel.

WARNING!
Pinch hazard.Keep fingers clear.

IMPORTANT!
The flywheel is heavy.

P0006907

3 Remove the bolts in the flywheel housing and

remove the flywheel housing using lifting eyes
and lifting straps.

P0006908

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4 Remove the lubricating oil pump together with the

drive gear.

P0006909

5 Remove the lower intermediate gear (4).

P0006837

1 Camshaft drive gear

2 upper intermediate gear
3 bull drive
4 lower intermediate gear
5 crankshaft gear
6 oil pump drive gear
7 fuel pump drive gear/servo pump

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6 Remove the two bolts on the crankshaft gear (5)

and remove the gear using a suitable puller.

NOTICE! To protect the puller thread, place a

thick washer between the threaded shaft and the
crankshaft.
7 Remove the six Allen bolts in the bull drive hub
(3) and remove it complete.
8 Remove the upper intermediate gear (2).

NOTICE! Save the spacer plate behind the gear

and note how it is installed.
9 Remove the timing gear plate and clean both
P0006909 sides.

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Pistons, Removal
9986485 Stand
9993590 Rotation tool
9996394 Support
9996645 Puller
9996963 Plate
1 Remove the piston cooling nozzle. Crank the
engine using 9993590 Rotation tool so that all
become accessible, two at a time.

IMPORTANT!
It is important that the piston cooling nozzles be
removed before the pistons are removed. Damaged
nozzles may cause extensive engine damage.
2 Remove big end bearing caps and bearing shells;
note any markings.
3 Turn the engine 90° if it is installed in
9986485 Stand.

P0006911

4 Press the piston so far out that the piston rings

are outside the edge of the cylinder liner. (Use a
hammer handle or other wooden object).
Lift the piston and connecting rod out.

IMPORTANT!
Replace the bearing cap on the connecting rod to avoid
damaging the split surface, as this is very sensitive.
5 Remove the retainer ring from the piston and
press out the piston pin. Disassemble the con-
necting rod and piston.

NOTICE! Mark the connecting rod and piston, if

they are to be installed in the same cylinder at
assembly.
6 Mark the cylinder liner position in the block before
it is removed to facilitate correct placement if rein-
stalled.

P0006912

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7 Fit 9996963 Plate and 9996394 Support to

9996645 Puller.
8 Move the plate down through the cylinder and
place it in the correct position below the cylinder
liner. Pull the cylinder liner out of the block, using
the puller. If necessary, extend the support legs
with 9996395.
9 Remove the cylinder liner sealing rings.

P0006913

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Crankshaft, Removal
1 Remove the main bearing caps, if not already
done.

P0006914

2 Lift the crankshaft out carefully.

NOTICE! The crankshaft weighs about 80 kg.

3 Before the engine block is washed, all plugs, bolts
and remaining brackets must be removed.
4 Clean the contact surfaces on parts to be rein-
stalled.

P0006915

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Crankshaft, Installation
1 Inspect the crankshaft; refer to Replacement of
Components page 98, Crankshaft, inspection.
2 Check the crankshaft ducts, the bearing shell
seats, the engine block and bearing caps.
3 Fit new main bearing shells.
4 Put the bearing shells in their correct places in the
engine block and bearing caps. Make sure that
bearing shells or caps are not damaged.

NOTICE! Make sure that the upper bearing shells

to be fitted into the cylinder block have oil holes.
5 Lubricate bearing journals and bearing shells with
engine oil and carefully lift the crankshaft into
position.
6 Install the thrust washers for the center main
bearing (thrust bearing). The thrust washers can
only be placed in one position.
7 Install the main bearing caps with the lower bear-
ing shells. The bearing caps are asymmetric and
can only be installed in one position. The center
bearing cap (by the thrust bearing) has a cutout,
which must be aligned to fit over the guide pin.

NOTICE! Note the markings on the bearing caps,

1 through 7.
8 Oil the main bearing screws. Let surplus oil run
off before installation.
Tighten according to the specifications in Special
Tightening Torques page 9.

NOTICE! Check that the crankshaft can be

cranked.
9 Install the front cover at the belt pulley and install
a new seal. Refer to Replacement of Compo-
nents page 98, Crankshaft seal, replace (front).

NOTICE! No lubrication. Must be installed com-

pletely dry.

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Cylinder Liner, Installation

9990157 Press tool
9996963 Plate
9998511 Lever
1 Inspect the cylinder liner and pistons; refer to
Replacement of Components page 98, Cylinder
liners and pistons, inspection.
2 Lubricate the sealing rings with the lubricant sup-
plied with the lining kit and install them on the
cylinder liners.

NOTICE! The purple seal ring must seat in the

lowest groove

P0006916

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3 When the cylinder liner is installed without shims,

an even bead 0.8 mm (0.0315") of sealing com-
pound (1161231) must be applied to the under-
side of the cylinder liner collar.

NOTICE! Do not put sealing compound around

the entire liner. Leave a 2 mm (0.8”) gap.

If the liner is installed with shims, the sealant bead

must be placed on the cylinder block liner seat.

NOTICE! Sealing compound must not be used

between the adjusting shims and the cylinder
liner collar.

NOTICE! The liner must be installed within 20

minutes of sealing compound application.

P0006917

P0006918

4 Screw one of the cylinder head bolts in place

(A).
Place 9996963 Plate above the cylinder liner
together with a suitable spacer (B).
Press the liner down using 9998511 Lever and
secure it with 9990157 Press tool.

P0006919

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Piston, Pre-installation
1 Install one of the retainer rings on the new piston.
2 Lubricate the piston pin, the piston bearing seat
and the connecting rod bearing with engine oil.

FRO
NT

P0006920

3 Install the connecting rod so that the arrow on the

piston and the connecting rod “Front” marking
face the same way.
Press in the piston pin.

NOTICE! It should be easy to press the piston pin

in; it must not be driven in.
4 Fit the second retainer ring.

P0006921

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5 Check that the piston pin does not move stiffly in

the small end, and that the piston can be moved
easily.

IMPORTANT!
Always use piston ring pliers to install/remove the piston
rings. The oil scraper rings are especially brittle and
easily damaged.

NOTICE! The two upper piston rings are marked

with letters or punch marks. The mark must face
upwards.
P0006825

P0006922

6 Align the piston ring gaps staggered about 120°

around the piston. However, the piston ring gaps
must not end up directly over the piston pin.

NOTICE! New cylinder liner kits are supplied

complete with pistons and piston rings.
7 Install the bearing shells in the engine block.

P0006923

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Pistons, Installation
9990157 Press tool
9990158 Piston ring compressor
1 Oil the cylinder liner, bearing shells and big end
bearing journals.
2 Temporarily remove 9990157 Press tool when
the piston is installed.
3 Use 9990158 Piston ring compressor and guide
the piston with piston rings down into the cylinder.
Ensure that the connecting rod does not damage
the crankshaft bearing journal.

NOTICE! Take great care. The oil scraper rings

are brittle and can easily be damaged.

NOTICE! The piston ring compressor may not be

opened when the piston has been placed in the
tool, the piston rings can be damaged. Press out
P0006924
the piston first, before opening the tool.
4 Re-install 9990157 Press tool. All cylinder liners
must be locked with the press tool in order to pre-
vent movement between the cylinder liner and
engine block when the engine is cranked.
5 Install the bearing caps with their bearing halves.
Torque according to the specifications in Special
Tightening Torques page 9.

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Piston Cooling Jet, Installation

1 Blow the piston cooling nozzle clean and check it
is undamaged and that the O-ring is fault free.

IMPORTANT!
Faulty piston cooling will cause the pistons to seize. If
piston cooling nozzle damage or deformation is sus-
pected, the nozzle must be replaced (also applies to
new nozzles).
2 Install the piston cooling nozzle.

IMPORTANT!
Check that the nozzle sits correctly in the hole in the
cylinder block and is directed towards the recess in the
piston and that the retaining plate lies flat against the
block. If the piston cooling nozzle is not correctly instal-
led, the engine will immediately break down under load.
3 Tighten according to the specifications in Special
Tightening Torques page 9.
P0006925
NOTICE! The piston cooling nozzle retaining
screw has a friction coating and may only be used
once.
4 Install the bracing frame and tighten according to
the tightening chart in Special Tightening Tor-
ques page 9.

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Timing Gear, Installation

1 Apply a 2 mm (0.08") thick bead of sealant on the
engine block as illustrated.
2 Install the timing gear plate. Use new bolts that
are pre-treated with locking compound. Tighten
according to the specifications in Special Tight-
ening Torques page 9.

NOTICE! Torque within 20 minutes of sealant

being applied.

P0006926

3 NOTICE! Lubricate the inside of the gears before

installation.

Oil the spacer plate and install it together with the

upper intermediate gear (2). Tighten with low tor-
que, max. 10 Nm (7.38 lbf ft).

P0006837

1 Camshaft drive gear

2 upper intermediate gear
3 bull drive
4 lower intermediate gear
5 crankshaft gear
6 oil pump drive gear
7 fuel pump drive gear/servo pump

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4 Install a new O-ring on the crankshaft.

5 Install the camshaft gear (5)and torque the bolts
according to the specification in Special Tighten-
ing Torques page 9.

NOTICE! Make sure that the mating surfaces on

crankshaft and gear are clean and fault free.

P0006927

6 Screw two bolts in the crankshaft gear for crowbar

grip, to allow the crankshaft to be turned when
necessary.

P0006928

7 Install the bull drive kit (3) with the hole marking
between the two hole markings on the crankshaft
gear.

NOTICE! The bull drive inner and outer gears

have different gear pitch. For the camshaft to be
set correctly, the markings must correspond.

Tighten the bolts according to the specification in

Special Tightening Torques page 9.
8 Install the lower intermediate gear (4) with a new
O-Ring.

P0006929

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9 Install the lubricating oil pump.

P0006909

10 Apply new sealing compound to the flywheel cas-

ing, towards the engine block.

P0006930

11 Remove the old crankshaft seal.

Install the flywheel housing. Check that the cas-
ing is aligned with the engine block plane.
Tighten according to the specifications in Special
Tightening Torques page 9.
Install the new crank shaft seal; refer to Replace-
ment of Components page 98, Crankshaft seal,
replace (rear).

P0006908

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12 Install the flywheel and tighten according to spec-

ifications in Special Tightening Torques page 9.
Also refer to Replacement of Compo-
nents page 98, Flywheel, indication.

P0006931

13 Remove the old crankshaft seal on the front the

casing; refer to Replacement of Compo-
nents page 98, Crankshaft seal, replace (front).
Apply sealing compound to the front casing.
Install the casing and make sure that the bottom
edge of the casing is aligned with the bottom edge
of the engine block.
Install a new crankshaft seal (if not already done).

NOTICE! No lubrication. The seal must be instal-

led completely dry.
14 Fit the oscillation damper and the belt pulley.
15 Install the oil suction strainer and pipe.
P0006932

16 Cut away any remaining sealing compound and

apply new sealant to the parting planes on the
front cover, flywheel housing and engine block
respectively.
17 Install the oil pan.

P0006933

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18 Install the oil filler pipe and oil dipstick with new
O-rings.

P0006934

19 Install the fuel feed pump/servo pump.

P0006935

20 Install the coolant pump.

21 Install the front engine mounts together with the
belt tensioner and the tensioning wheel on the
right side of the engine.
22 Install the alternator with brackets, the belt ten-
sioner and the fan bearing attachments on the left
side of the engine.

P0006936

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23 Install the fan bearing.

P0006900

24 Fit new sealing rings in the block and the rubber

seals on the sides of the radiator.
Install the oil cooler and tighten according to the
specifications in Special Tightening Tor-
ques page 9. Check that the side seals are placed
correctly in the block.
25 Install the oil cooler cover with a new o-ring and
tighten according to the specifications in Special
Tightening Torques page 9.

P0006899

26 Install the coolant filter with bracket and the con-

nection to the oil cooler cover.
27 Install the oil filter bracket with a new gasket and
new oil filters.

P0006898

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28 Fit the starter motor.

P0006897

29 Install the coolant pipes with new O-rings.

P0006937

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Cylinder Head, Installation

9990157 Press tool
1 Clean the cylinder head carefully both internally
and externally before fitting.

NOTICE! Dirt particles may cause the unit injec-

tors to fail.
2 Clean the unit injector copper sleeves. Refer to
Replacement of Components page 98, Copper
sleeve for unit injector, replacing.
Install the protection plugs immediately after
cleaning.
3 Remove 9990157 Press tool holding the cylinder
liners in place.
4 Carefully clean the cylinder head and the engine
block sealing surfaces and cut away excess seal-
ant.

NOTICE! Do not pull away dry sealant.

P0006896

5 Immerse the cylinder head bolts completely in a

rustproofing agent.
Then place the bolts on a net to allow the excess
to run off.

P0006938

6 Apply a 2 mm (0.080”) thick bead of sealant to the

back of the cylinder head.

NOTICE! The cylinder head bolts must be tor-

qued within 20 minutes of sealant application.
7 Fit a new cylinder head gasket.
P0006939
NOTICE! Convex embossments prevent damage
to the rubber seals.

NOTICE! Check that the coolant pipe is in place.

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8 Lower the cylinder head until it rests on the cylin-

der head gasket.
Maintain a distance to the timing gear plate of 5–
10 mm (0.2–0.4"). Locating pins ensure that the
cylinder head will be aligned with the engine
block.
9 Slide the cylinder head against the transmission
plate.
10 Place a rag in front of the gear to prevent bolts
from falling into the timing gear housing.

NOTICE! The rag must be removed before the

engine is cranked.

P0006940

11 Insert a bolt into the upper intermediate gear hub

(1) in the cylinder head, in order to pull the cylin-
der head towards the timing gear plate.
Screw in five M8 bolts into the timing plate (2).
12 Torque the bolts (1) and (2) as specified in Spe-
cial Tightening Torques page 9.
Unscrew all bolts (1) and (2) about one turn.

NOTICE! The cylinder head is now in the correct

position for fastening and must not be moved. If
the cylinder head is moved, the bolts must once
again be torqued and loosened as above.
13 Install the cylinder head bolts and tighten accord-
ing to the specifications in Special Tightening
Torques page 9. Use a torque amplifier for angle
tightening.
P0006941
14 Torque the four M8 bolts in the transmission plate
(2) according to the specifications in Special
Tightening Torques page 9.
15 Turn the engine so that the two M8 bolts (1) can
be installed through the upper intermediate gear.
Tighten according to the specifications in Special
Tightening Torques page 9.
16 Fit the remaining two M10 bolts (3) into the upper
intermediate gear, without tightening them.
17 Fasten the coolant pipe in the cylinder head.

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18 Clean sealant from the surface as illustrated.

NOTICE! Cut away the sealant.

P0006942

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Camshaft, Installation
1 Inspect the camshaft for wear. Refer to Replace-
ment of Components page 98, Camshaft, wear
check.
2 Clean the surfaces on the bearing brackets and
the cylinder head.
3 Install the camshaft bearing brackets as marked
on the cylinder head and make sure they abut the
cylinder head, no. 7 by the transmission.
4 Place the bearing shells in the bearing brackets
and lubricate the bearing shells with engine oil.
5 Turn the engine with the turning tool so that the
flywheel is set exactly to zero, according to the
marking on the flywheel housing.

P0006943

6 Carefully lift the camshaft in place. Make sure that

the hole for the guide pin on the camshaft gear
TDC
ends up straight up. The camshaft TDC marking
must be centered between the markings on the
no 7 bearing bracket.

! CAUTION!
The camshaft lobes are sharp.
C
TD

P0003112

P0006885

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7 Fit the camshaft gear without the oscillation

damper; use nuts as spacers.
Place the gear so that the reference hole in the
timing gear plate is between the gear markings.
If necessary, remove the bolts on the upper inter-
mediate gear.
Temporarily tighten two bolts with low torque,
max. 10 Nm (7.38 lbf ft).

P0006944

8 Clean the surfaces on the bearing caps and oil

the bearing shells.
Install the bearing caps on the respective bearing
brackets.

NOTICE! Use a suitable spacer on the rocker arm

side.

Torque the bolts 1 through 7 to 15 ± 3 Nm (11.06

± 2.21 lbf ft).
Torque the bolts 8, 11 and 14 (with spacers) to 50
± 5 Nm (36.88 ± 3.69 lbf ft).

P0006945

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Flank Clearance, Adjustment

885810 Fixture
9998601 Fixture
1 Undo the bolts (1) in the upper intermediate gear.
Check that the upper bolts are not tightened.

P0006946

2 Place a 0.1 mm (0.004") feeler gauge on the

pressure side. Turn the camshaft gear against the
feeler gauge.
Torque the upper intermediate gear according to
step 1 in Special Tightening Torques page 9.
Remove the feeler gauge.

P0006947

3 Check the clearance as follows:

Fix the adjustment wheel.
Place a dial indicator on the camshaft gear, as
illustrated.
Turn the gear back and forth and compare the
result against the gear lash specification in Spe-
cial Tightening Torques page 9.
4 If gear lash is correct; torque the intermediate
gear bolts (1) according to step 2 in Special Tight-
ening Torques page 9.
5 Install the oscillation damper and tighten accord-
ing to specifications in Special Tightening Tor-
ques page 9.

P0006948

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6 Apply a 2 mm (0.08") thick bead of sealant to the

upper timing gear casing contact surface, as illus-
trated.
7 Fit the rubber seals and install the upper timing
gear casing.

P0006949

8 Only install the bolts (1) and tighten by hand. (The

holes are oblong so that the casing can be
pressed down against the rubber seal).

P0006950

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9 Press the casing down using 885810 Fixture and

9998601 Fixture so that the cylinder head and the
upper timing gear casing sealing surfaces are
aligned.
Install the remaining bolts (2).
Tighten according to the specifications in Special
Tightening Torques page 9.

NOTICE! The timing gear casing must be instal-

led and torqued within 20 minutes of sealant
application.
10 Install the flywheel sensor and adjust it according
P0006951 to Flywheel Sensor Distance, Check page 96.

999 8601
P0006952

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Unit injector, Installation

9990156 Adapter
9996400 Slide hammer
9998251 Protection plug

NOTICE! Install one injector at a time.

1 Remove 9998251 Protection plug with

9990156 Adapter and 9996400 Slide hammer.
2 Fit new sealing rings to the unit injectors. Lubri-
cate the rings with diesel oil.
Install the injector and fixing yoke. Center the
injector so that it does not touch the valve springs.
Torque according to Special Tightening Tor-
ques page 9.

P0006890

3 Reinstall the valve calipers in their original posi-

tions.

NOTICE! Make sure that the caliper is directly

above the valve stem.
4 Lubricate the valve caliper and camshaft.
5 Remove the temporary bolts and spacers on the
camshaft cap.
6 Install the rocker arm bridge using a hoist.
Make sure that the guide pins fit into the rocker
arm shaft.
Torque the screws alternately along the rocker
arm shaft according to specifications in Special
P0006953
Tightening Torques page 9.

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7 Slide new O-rings over the lubricating oil supply

pipe for the rocker arm bridge. Insert the pipe in
the joining piece and install the joining piece and
pipe. Check that the O-rings on the pipe and the
ring under the joining piece are correctly aligned.
Fit the cable holder.

P0006883

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Adjustment Markings
The camshaft has marks (1 through 6 for the respective
cylinders) for adjusting intake and outlet valves and the
unit injectors.

NOTICE! It is important that the line marked on the

camshaft is centered between the two marks on the
bearing cap when adjustment is carried out.

P0006954

Early model.

TDC 5
3
5
1
4

P0002568

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Valves and Unit Injectors,

Adjustment

Adjust valves and injectors for the respective cylinders

at the same time.
1 Crank the engine to the next camshaft marking.

P0006955

2 Screw the adjuster screw down until it abuts the

valve stem and then one additional flat (60°).
Tighten the locknut according to the specification
in Special Tightening Torques page 9.

NOTICE! When the adjuster screw is screwed

down, the caliper must simultaneously be
pressed down so it touches the valve stem. It is
very important that the pressure is brought to bear
as close to the adjuster screw as possible; see
illustration.

P0006956

3 Adjust the valve clearance between rocker arm

and valve caliper according to the specification in
Special Tightening Torques page 9.
Tighten the locknut according to the specification
in Special Tightening Torques page 9.
Check the valve clearance. Mark the rocker arm
when the valve has been adjusted.

P0006957

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4 Adjust the unit injector rocker arm to zero clear-

ance.
Tighten the adjuster screw a further 4 flats (240°).
Torque the adjuster bolt lock nut according to
Special Tightening Torques page 9.
5 Adjust the remaining valves and unit injectors
according to the above.

P0006958

6 Apply a 2 mm (0.080”) thick bead of sealant

(1161231-4) to the intake manifold.
Install the intake manifold and tighten according
P0006959 to the specifications in Special Tightening Tor-
ques page 9.

NOTICE! The intake manifold must be installed

within 20 minutes of sealant application.
7 Pull the cable harness to the unit injectors through
the cylinder head and connect the connectors.
8 Fit the rear lifting eye.
9 Install sensors for the flywheel, camshaft and oil
pressure and starter motor cables.
10 Connect the fuel lines to the cylinder head and
torque according to Special Tightening Tor-
ques page 9.
11 Apply a 2 mm (0.080”) thick bead of sealant to
parting plane (A) between the timing gear casing
and the cylinder head.
12 Install the valve cover. Tighten the bolts accord-
ing to the specification in Special Tightening Tor-
ques page 9.

NOTICE! The valve cover must be installed within

20 minutes of sealant application.

P0006960

200 7747722 01.2009

 21-0 Engine Complete, General

13 Place the gaskets on the exhaust manifold. Turn

the gasket so that the side with the text “Manifold
side” is facing the exhaust manifold. Thread the
bolts into the gaskets so that they are held in
place during installation of the exhaust manifold.
Install the exhaust manifold and tighten according
to the specifications in Special Tightening Tor-
ques page 9.

P0006961

14 Refit the turbo without tightening.

15 Fit the return oil pipe. Check that the old seal is
not remaining and that the new one ends up in
the correct position.
Install the pressure pipe between the oil filter
bracket and the turbo.
Tighten according to the specifications in Special
Tightening Torques page 9.
16 Install the heat shield plates.
17 Fit the thermostat housing and tighten alternately.
Remove the forward lifting eye.
18 Fit the new coolant pipe sealing rings and torque
alternately.
19 Remove fixture and replace the parts that were
P0006868
removed.
20 Install drive belts and fan.
21 Install the brackets for radiator fan safety cover/
grille. Install protection.
22 Install the alternator protection cover.
23 Install the pipe between charge air cooler and
inlet pipe.
24 Install the crankcase breather pipe and any addi-
tional oil separator.
25 Insert a new cartridge in the air filter housing and
install it with brackets and the pipe between the
air filter housing and the turbo.
26 Install the pipe between the turbo and the charge
air cooler.
27 Install the muffler with attachments. Connect the
exhaust pipe to the turbo.
28 Install the heat shield above the turbo, if fitted.
29 Install the belt cover on the right side of the
engine, if fitted. Install the hoses to expansion
tank and radiator.

7747722 01.2009 201

21-0 Engine Complete, General

30 Change the oil filter. Refill with engine oil; refer

toEngine oil and engine oil filter, chang-
ing page 212
31 Replace coolant filter. Refill with coolant; refer to
Coolant Level, Checking and Topping
Up page 251.
32 Change the fuel filter. Bleed the fuel system; refer
to Fuel system, bleeding page 218.
33 Start the engine and let it run until it reaches nor-
mal working temperature. Let it run an additional
5 to 10 minutes at idle. When the idle revolutions
are even, the cylinder balancing system has set
the correct amount of fuel for the unit injectors.

NOTICE! Do not connect any power consuming

device (e.g. power outlet) while cylinder balanc-
ing is under way.

Check that no leakage occurs.

202 7747722 01.2009

 21-4 Valve Mechanism

21-4 Valve Mechanism

Valves and Unit Injectors,
Adjustment
TAD1640GE, TAD1641GE, TAD1641VE,
TAD1642GE, TAD1642VE, TWD1643GE

Tools:
9993590 Rotation tool

Adjust valves and injectors for the respective cylinders

at the same time.
1 Remove the valve cover.
2 Crank the engine to the next camshaft marking
using 9993590 Rotation tool.

P0006955

3 Screw the adjuster screw down until it abuts the

valve stem and then one additional flat (60°).
Tighten the locknut according to the specification
in Special Tightening Torques page 9.

IMPORTANT!
When the adjuster screw is screwed down, the
caliper must simultaneously be pressed down so
it touches the valve stem. It is very important that
the pressure is brought to bear as close to the
adjuster screw as possible; see illustration.

P0006956

7747722 01.2009 203

21-4 Valve Mechanism

4 Adjust the valve clearance between rocker arm

and valve caliper as specified in Technical
Data page 22.
Tighten the locknut according to the specification
in Technical Data page 34.
Check the valve clearance using a feeler gauge.
Mark the rocker arm when the valve has been
adjusted.

P0006957

5 Adjust the unit injector rocker arm to zero clear-

ance.
Tighten the adjuster screw a further 4 flats (240°).
Torque the adjuster screw lock nut according to
Technical Data page 34.
6 Adjust the remaining valves and unit injectors
according to the above.

P0006958

Valve Guides, Inspection

9989876 Dial indicator
9999696 Magnetic stand

Cylinder head removed

Refer to removal in 21-1, Cylinder Head, Change.
1 Remove the valve stem seals from the valve
guides.
2
IMPORTANT!
The cylinder head must not be put down so its
entire weight rests on the valve guides (see illus-
tration).
Put the cylinder head on the bench with the valve
discs facing upwards.
3 Place a new valve in the valve guide with the
valve stem end in the same plane as the edge of

204 7747722 01.2009

 21-4 Valve Mechanism

the guide. Use a suitable counterhold under the

valve stem.
4 Place tool 9989876 Dial indicator and tool
999 9696
9999696 Magnetic stand, so that the dial indicator
tip is touching the valve disc edge.
998 9876 Move the valve sideways, in the direction of the
exhaust or inlet duct. Read off the value on the
dial gauge.
5 Check all valve guides.
If the measurement values exceed the values
noted in the specifications, the valve guide must
be changed; refer to Technical Data page 22.
p0005207

7747722 01.2009 205

22-0 Lubricating and Oil System, General

22-0 Lubricating and Oil System, General

When you work with Chemicals,
Fuel and Lubrication Oil, Change

! CAUTION!
Apply barrier cream to hands and always use protec-
tive gloves in work that involves the risk of contact with
oil and fuel and similar. Continuous skin contact with
engine oil dries the skin and can be hazardous.

P0007022

206 7747722 01.2009

 22-0 Lubricating and Oil System, General

Overview Control Valve

P0007023

A By-pass valve for oil cooler

B Safety valve
C Reduction valve
D Control valve for piston cooling
E Opening valve for piston cooling
F Overflow valve for bypass filter
G Overflow valve for full-flow filter

7747722 01.2009 207

22-1 Oil pump and Line

22-1 Oil pump and Line

Lubrication Oil Pump, Change
1 Drain the engine oil.
Remove the oil filler pipe.
Remove terminal to the oil level sensor.
Remove the oil dipstick tube from the bracket.
Remove the oil pan.
2 Remove bolts that fasten the oil pipes to the
engine.
Remove the oil pipes, the oil strainer and the
bracket together.
3 Remove the oil pump bolts and remove the pump.
4 Clean the oil suction pipe and the oil delivery pipe.
Check that there is no damage.
5 Remove and clean the oil strainer. Check that
there is no damage.
P0006969
6 Install the new oil pump.
Make sure that the teeth fit into the camshaft gear.
Tighten the bolts according to the specification in
Special Tightening Torques page 9.
7 Assemble the oil pipes and the oil strainer on the
bracket with new oil seals. The strainer must be
installed so that it faces to the engine front end.
Tighten the bolts according to the specification in
Special Tightening Torques page 9.
8 Assemble the oil pipes with the oil pump.
Tighten the bolts according to the specification in
Special Tightening Torques page 9.
9 Check if the seal needs to be changed.
Install the oil pan.
10 Attach the oil dipstick tube to the bracket.
Install oil filler pipe and the wiring to the oil level
sensor.
Top up with engine oil.
11 Start the engine. Check the oil pressure and
check for leakage.

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 22-2 Oil filter

22-2 Oil filter

Relief Valve, Replace
1 Clean the area around the reducing valve.
2 Remove the reducing valve.
3 Clean the valve contact surface in the oil filter
housing. Check that the old seal is not still in
place.
4 Check that the color marking on the new valve
matches the old.
5 Fit the new valve with a new seal ring. Check that
the internal seal does not come loose when the
valve is installed.
Tighten according to the specification in Special
Tightening Torques page 9.
6 Start the engine and check for leaks.
P0007024

Bypass Valve, Oil Filter Bypass,

Replace
1 Remove the pressure pipe to the turbo.
2 Clean the area around the overflow valve.
3 Remove the overflow valve.
4 Clean the valve contact surface in the oil filter
housing.
5 Fit the new the valve with a new seal ring and
tighten the nut as specified in Special Tightening
Torques page 9.
6 Tighten the turbo pressure pipe.
7 Start the engine and check for leaks.

P0007025

7747722 01.2009 209

22-2 Oil filter

Safety Valve, Oil Pressure, Replace

1 Clean the area around the valve and remove it.
2 Clean the valve contact surface.
3 Check that the color marking on the new valve
matches the old.
Install the new valve and tighten according to
specifications in Special Tightening Tor-
ques page 9.
4 Start the engine and check for leaks.
Check the oil pressure; refer to Oil Pressure Sen-
sor, Check page 212.

P0007026

Piston Cooling Valves, Replace

1 Clean around the oil filter bracket and the piston
cooling valves.
2 Remove the filter bracket.
3 Remove the two piston cooling valves: control
valve and opening valve.
4 Clean valve seats in the oil filter bracket.
5 Fit new valves with new seal rings; tighten
according to specification in Special Tightening
Torques page 9.
6 Re-install the oil filter bracket, with new gasket
and new seal rings.
7 Start the engine and check for leaks.

P0007027

210 7747722 01.2009

 22-2 Oil filter

Bypass Valve Oil Filter, Change

1 Clean the area around the overflow valve.
2 Remove the valve and clean the valve seat in the
oil filter bracket.
3 Fit a new valve with a new seal ring. Tighten
according to the specifications in Special Tight-
ening Torques page 9.
4 Start the engine and check for leaks.

P0007028

Oil Filter, Check

1 Check that the oil filters are not faulty or blocked.
If the filters have external damage, oil flow
through the filters may be restricted. This may
cause the oil pressure to deteriorate.

7747722 01.2009 211

22-2 Oil filter

Oil Pressure Sensor, Check

If you suspect that the oil pressure sensor reads incor-
rectly, check the oil pressure with a external pressure
sensor.
The pressure sensor is located behind the control unit;
refer to Placement of Instrument Socket(s) page 76.

9992873 Nipple
9996398 Manometer
9998493 Hose
1 Check the oil pressure with an external pressure
gauge and compare values with the specification
in Technical Data page 32.
2 Remove the pressure sensor.
3 Fit tool 9998493 Hose, 9992873 Nipple and
9996398 Manometer.
4 Start the engine and check the oil pressure.
If the oil pressure measurement shows that the
pressure is below the minimum value as speci-
fied, continue troubleshooting by checking the oil
filters.
If the oil pressure measurement using an external
pressure sensor shows that the pressure is within
tolerance, but the regular engine pressure sensor
does not, replace the pressure sensor.
5 Remove the hose, nipple and pressure gauge.
6 Install the oil pressure sensor. Connect the sen-
sor to the wiring.

Engine oil and engine oil filter,

changing
9998487 Sleeve
9999179 Extractor oil filter
1 Remove the drain plug and drain engine oil into
an appropriate container immediately after run-
ning when the oil is hot and flows more easily.

WARNING!
Hot oil and hot surfaces can cause burns.
2 Clean around the filter bracket and remove the
filters. Use 9998487 Sleeve or 9999179 Extractor
oil filter.

P0007029

212 7747722 01.2009

 22-2 Oil filter

3 Fill the new filters with engine oil and apply some
to the gaskets (1).
4 Tighten the filters by hand until they touch the
bracket contact surface (2).
Tighten them by hand another 3/4 to one full turn
(3).
5 Re-install the drain plug. Add engine oil to correct
level.
6 Connect a switch to the starter motor and use it
to crank the engine until the oil pressure is regis-
tered by the oil pressure gauge. This means that
the oil filters are full.

NOTICE! Refer to Compression Test page 85 for

connection of starter motor.
7 Start the engine and check for any leakage
around filter bracket and filter.
8 Check the oil level. Add oil as needed.

P0007030

7747722 01.2009 213

22-2 Oil filter

Relief Valve, Check

1 Check that the reducing valve has a blue color
marking.

NOTICE! In installations with remote oil filters the

reducing valve must have a blackcolor marking.
2 Check that the valve is not damaged, which would
impair its function.
Press in the valve poppet (1) with a blunt object
and check that it does not seize and that it seals
against the seat (2).

P0007031

214 7747722 01.2009

 22-3 Oil cooler

22-3 Oil cooler

Oil Cooler, Replace
Removal
1 Clean around the oil cooler cover.
2 Drain the coolant; refer to Draining the Cooling
System page 247.
Remove the coolant filter with attachment.
3 Remove the cover bolts and lift away the cover.
4 Remove the oil cooler from the engine block.

P0006899

Installation
5 Clean the cover contact surface on the engine
block.
6 Install the oil cooler on the block with new rubber
gaskets. Tighten the bolts according to the spec-
ification in Special Tightening Torques page 9.
7 Install new gaskets in the cover.
8 Lift the cover into position. Check that the rubber
cover gasket remains in its groove.
9 Install the cover bolts and torque according to
specifications in Special Tightening Tor-
ques page 9.
Install the coolant filter and its bracket.
10 Add coolant. Refer to Coolant Level, Checking
and Topping Up page 251.

IMPORTANT!
If the oil cooler has leaked engine oil to the cooling
system, the coolant filter must be replaced and the
cooling system cleaned. Refer to Cooling System,
Cleaning page 249.
11 Start the engine and check for leakage when it
has reached normal temperature.
Check coolant level.

7747722 01.2009 215

22-3 Oil cooler

Oil Cooler, Pressure Testing

9996662 Pressure testing kit
9996845 Screw clamp
1 Remove the oil cooler. Refer to Oil Cooler,
Replace page 215.
2 Clean the oil cooler coolant side with water solu-
ble degreaser.
Clean the oil side of the oil cooler with degreaser.
3 Check 9996662 Pressure testing kit before it is
taken into service. See Cylinder Head, Pressure
Testing page 90 in the Checking pressure testing
equipment section.

999 6845 4 Install 9996845 Screw clamp and check that they
are placed correctly.

P0007032

5 Check that the pressure reducing valve knob on

9996662 Pressure testing kit is fully opened and
that the manometer shows “0”.
Connect the pressure testing device to
9996845 Screw clamp.
6 Lower the oil cooler into a vessel containing water
at room temperature.
Increase the pressure to 250 kPa (2.5 bar) [36.26
PSI] with the knob on the reducing valve.
Wait at least one minute.
P0007033

IMPORTANT!
If an even stream of air bubbles comes from the oil
cooler matrix, there is leakage and the oil cooler
must be changed.

216 7747722 01.2009

 22-3 Oil cooler

Bypass Valve, Oil Cooler, Replace

1 Clean the area around the overflow valve and
remove it.
Clean the valve seat.
2 Fit the new valve with a new seal ring.
Tighten according to the specifications in Special
Tightening Torques page 9.
3 Start the engine and check for leaks.

P0007034

7747722 01.2009 217

23-0 Fuel System, General

23-0 Fuel System, General

Fuel system, bleeding
TAD1640GE, TAD1641GE, TAD1641VE,
TAD1642GE, TAD1642VE, TAD1643VE,
TAD1650VE
1 Check that there is sufficient fuel in the tank, and
that any fuel taps are open.
2 Twist the hand pump free from the fuel filter
bracket.
3 Vent the fuel system by pumping with the hand
pump.
Air is vented to the tank via the fuel return pipe.
No venting nipples need be opened.
4 Start the engine and allow it to idle fast for about
10 minutes.
5 Perform a leakage and function check.

P0007042

Fuel system, bleeding

TWD1643GE
1 Check that there is sufficient fuel in the tank, and
that any fuel taps are open.

218 7747722 01.2009

 23-0 Fuel System, General

2 Twist the hand pump free from the fuel filter

bracket.

P0004969

3 Open the nipple on the front fuel connection. Con-

nect a drain hose.
4 Purge the fuel system by pumping with the hand
pump until fuel flows. Close the nipple and secure
the hand pump.
5 Start the engine and allow it to idle fast for about
10 minutes.
6 Perform a leakage and function check.

P0004970

Draining, Fuel Duct in Cylinder Head

TAD1640GE, TAD1641GE, TAD1641VE,
TAD1642GE, TAD1642VE, TAD1643VE,
TAD1650VE

IMPORTANT!
Take great care to ensure that dirt does not enter the
fuel channel.
1 Clean around the fuel unions on the cylinder head
and fuel filter bracket.

7747722 01.2009 219

23-0 Fuel System, General

2 Undo the hose from the outlet of the fuel filter

bracket and bend it down into a suitable recepta-
cle.
3 Undo the return fuel line from the front edge of the
cylinder head.
4 Use a suitable hose and blow fuel through the fuel
channel in the cylinder head, so that it runs out
into the receptacle.

Draining, Fuel Duct in Cylinder Head

TWD1643GE

IMPORTANT!
Make sure that dirt does not enter the fuel channels
and hoses.
1 Clean around the fuel connections at the cylinder
head rear end.
2 Remove the purging hose screw.
Remove the two clamps.

P0005062

220 7747722 01.2009

 23-0 Fuel System, General

3 Remove the fuel supply line on the engine topside

(coming from the filter bracket).
Remove the two clamps

NOTICE! Do not remove the lower union at the

filter bracket.

P0005061

4 Allow the hoses to hang into a receptacle.

P0005059

7747722 01.2009 221

23-0 Fuel System, General

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 NOTICE! If a compression test must be carried
out, do not connect the fuel lines until the test has
been completed. Otherwise the cylinder head fuel
channels will fill with fuel again.
7 When installing the fuel hoses, use new seals.
P0005060

222 7747722 01.2009

 23-3 Fuel Feed Pump and Filter

23-3 Fuel Feed Pump and Filter

Fuel Feed Pump, Change
Removal
1 Close any fuel cocks between the tank and feed
pump, to avoid unnecessary fuel spills.
2 Clean thoroughly around the feed pump and its
connections.
3 Remove fuel connections to the fuel pump and
allow the fuel to flow out into a suitable container.

NOTICE! Plug the lines! Mark the suction and

pressure lines.
4 Remove the fuel feed pump together with the
servo pump.
5 Remove the three Torx bolts and separate the
feed pump from the servo pump.
6 Remove the feed pump by carefully pulling it
straight out.

NOTICE! Ensure that the intermediate connector

on the servo pump shaft does not follow it out.

P0004961

Installation
7 Replace the O-ring on the servo pump flange.
Check that the intermediate connector slots into
its groove on the servo pump shaft.
8 Fit the feed pump and the servo pump together.
Facilitate assembly by turning the pump shaft so
that it slots into the groove in the intermediate
connector.
Torque the bolts according to specifications:
Refer to General Tightening Torques page 8.
9 Install the feed pump and servo pump on the
engine.

NOTICE! Use a new O-ring.

10 Replace the sealing washers.
Remove the plugs and attach the fuel lines.
11 Open the fuel taps and purge the fuel system:
Refer to Fuel system, bleeding page 218.
12 Start the engine.
Perform a function and leakage check.

7747722 01.2009 223

23-3 Fuel Feed Pump and Filter

Engine Fuel Filter Replacement

IMPORTANT!
Do not fill the new filter with fuel before installation.
There is a risk that contaminants will enter the system
and cause operational disruptions or damage.

! WARNING!
The fuel filter should be replaced when the engine is
cold, to prevent any fire hazard from fuel being spilled
onto hot surfaces.
1 Clean round the fuel filter.
2 Remove the fuel filter with the aid of a suitable
filter puller.
Collect any spilled fuel in a collection vessel.
3 Clean around the filter housing sealing surface.
4 Lubricate the seal with diesel fuel and install the
new fuel filter. Torque the filter according to the
instructions on the filter.
5 Bleed the fuel system; refer to Fuel system,
bleeding page 218.

P0007037

224 7747722 01.2009

 23-3 Fuel Feed Pump and Filter

Fuel Pre-filter, Change

1 Disconnect the cable harness at the water sepa-
rator sensor.
2 Remove the water separator filter from the filter
housing. Collect any spilled fuel in a collection
vessel.
3 Remove the lower section of the water separator
from the filter.
4 Clean the lower section of the water separator
with a soft rag. Check that the strainer and drain
hole in the lower section are not clogged.
5 Install a new seal on the lower section and lubri-
cate the seal with diesel fuel.
Re-install the lower section of the filter.
6 Lubricate the seal with diesel fuel.
Screw the filter onto the filter bracket by hand until
the rubber seal bottoms on the mating surface.
Then tighten a further half turn, no more.
7 Connect the cable to the water separator sensor.
8 Bleed the fuel system; refer to Fuel system,
P0007038 bleeding page 218.

7747722 01.2009 225

23-7 Injectors and Delivery Pipes

23-7 Injectors and Delivery Pipes

Unit Injector, Replace
9988539 Compression meter
9990006 Puller
9990013 Slide hammer
9990185 Lifting tool
9998248 Adapter
9998249 Protective sleeve
9998251 Protection plug
9998599 Cleaning kit

The tool kit 9998599 Cleaning kit includes:

– 9808570 Brush
– 9808616 Extender
– 9998580 Protective sleeve

For adjusting valves and unit injectors, refer to Valves

and Unit Injectors, Adjustment page 203.

NOTICE! When reinstalling, use new seals.

NOTICE! If a new unit injector is fitted, a new injector

code must programmed into the control unit, see “Serv-
ice manual EMS 2”. The injector code is stamped on
the unit injector.

Removal
1 Remove the valve cover.
2 Disconnect the electric connectors on the unit
injectors.
Cut the cable ties holding the cable harness and
fold it to one side.
3 Remove the fuel supply pipe and the rocker arm
bridge lubrication oil supply union.
4 Undo the rocker arm bridge bolts in stages, equal
amounts each time, to avoid bending the rocker
shaft.
Carefully lift the rocker arm bridge using tool
9990185 Lifting tool.
5 Mark and remove the valve calipers.
6 Empty the cylinder head fuel channels; refer to
Draining, Fuel Duct in Cylinder Head page 219.

P0004965

226 7747722 01.2009

 23-7 Injectors and Delivery Pipes

7 Remove the bolts for the unit injector fixing yoke.

Place the tool 9990006 Puller on the injector.
Put the puller fork in the groove in the injector and
lock the arm with the screw on the side. Fasten
the puller by turning the screw down against the
injector ball seat.
Attach tool 9990013 Slide hammer and remove
the injector.
8 Attach tool 9998249 Protective sleeve to the
removed injector.

9 Install tool 9998580 Protective sleeve and clean

thoroughly using tool 9808570 Brush and tool
9808616 Extender from the toolkit
9998599 Cleaning kit.

P0005063

7747722 01.2009 227

23-7 Injectors and Delivery Pipes

Installation
9990185 Lifting tool
10 Install new O-rings on the unit injector.
Upper O-ring – large diameter
Lower ring – small diameter

P0005064

11 If the copper sleeve has a smooth upper edge

(1) or one groove (2) a steel gasket must never
be used.
If the copper sleeve has two grooves (3) a steel
gasket must always be used. Always use a new
steel gasket.
The steel gasket is installed on the injector tip and
is held in place by the gasket spines.

1 2 3

228 7747722 01.2009

 23-7 Injectors and Delivery Pipes

12 Attach the fixing yoke to the unit injector and cen-

ter it between the valve springs.
Torque the bolts according to specifications; refer
to Technical Data page 34.
13 Attach the connector; press it in until a clear “click”
is heard.
Attach new cable ties.
14 Install the valve caliper.
15 Lubricate the valve caliper and camshaft lobes
with engine oil.

P0005066

16 Lift the rocker arm bridge into place with the aid
of tool 9990185 Lifting tool.
Check that the guide pins position correctly in the
bearing caps.

IMPORTANT!
Tighten alternately, to avoid bending the rocker
shaft.
Torque the rocker arm bridge bolts according to
specifications: refer to 03-2, Technical Data, so
P0004965
that the shaft abuts the bearing caps.
17 Clean the cylinder head where the union is instal-
led, and check that there is no foreign material in
the cylinder head oil channel.
Install new seal rings on the oil supply pipe and
union.
Put a thin layer of petroleum jelly on the pipe seal
rings and install the pipe in the union.
18 Install the union and torque according to specifi-
cations; refer to 03-2, Technical Data.
19 Adjust the valves and unit injectors; refer to
Valves and Unit Injectors, Adjustment page 203.
20 Connect the wiring to the unit injectors.
21 Install the valve cover. Replace gasket as neces-
sary.
22 Purge the fuel system; refer to Fuel system,
bleeding page 218.

7747722 01.2009 229

23-8 Control System, ECM, Data Sets

23-8 Control System, ECM, Data Sets

Control Unit, Replace
NOTICE! Before the control unit is replaced and any
warranty claim made, all checks in the check list must
be performed, to exclude any defect in the engine con-
trol system. If the measurements of the cable harness
show defects, it is highly likely that the control unit is
fault free. Refer to the “Service Manual, EMS 2”.

! WARNING!
Faulty individual control unit settings may result in
injury to persons or damage to the engine. For infor-
mation about reprogramming and reading of software,
refer to “Service manual, EMS 2”

IMPORTANT!
Exchange of control units between engines, during
fault tracing or repair, must never be performed under
any circumstances.
1 Clean thoroughly around the control unit fuel con-
nections.
2 Disconnect power from the engine by disconnect-
ing the negative battery terminal.
3 Remove the lower part of the crankcase breather
pipe.
4 Remove the upper and lower cable harness
clamps.
5 Remove the control unit cable harness by moving
the connector block retaining clips outwards.
6 Remove the upper and lower fuel connections to
the cooling element; plug the fuel lines.
7 Remove the control unit retaining bolts and
remove the control unit.
P0007035

230 7747722 01.2009

 23-8 Control System, ECM, Data Sets

8 Transfer the cooling element to the new control

unit. Make sure that the surface between the
cooling element and the control unit is clean.
9 Install the new control unit. Torque according to
specifications in Special Tightening Tor-
ques page 9.
10 Connect the upper and lower fuel connections to
the cooling element with new sealing washers.
11 Install the harness and clamps.
12 Install the crank case breather lower pipe.

P0007036

13 Bleed the fuel system. Refer to Fuel system,

bleeding page 218.
Start the engine and check for error codes. Refer
to the “Service Manual, EMS 2”.

P0007035

7747722 01.2009 231

25-2 Exhaust Pipe, Silencer

25-2 Exhaust Pipe, Silencer

Exhaust Pipe (Y-pipe), Replace
TWD1643GE

Removal
1 Remove the heat shield and any exhaust tem-
perature sensor. Refer also to Heat Protec-
tion page 153.
2 Remove the two exhaust clamps.
3 Remove the four nuts and the Y pipe spacers.
4 Remove the pipe.

Installation
5 Check the seal surface condition and check that
the flange joint surfaces are clean.
Install a new gasket.
6 Install the new exhaust pipe.
Torque the nuts according to specifications in
Special Tightening Torques page 9.

232 7747722 01.2009

 25-2 Exhaust Pipe, Silencer

7 Make sure the flange joint positions correctly.

Adjust as necessary.
Tighten the clamps.
8 Install the heat shield.
Refer to Heat Protection page 153.
9 Install the exhaust temperature sensor, where fit-
ted.

7747722 01.2009 233

25-5 Turbocharger

25-5 Turbocharger
Turbo, Change
Always determine and rectify the reasons why the tur-
bocharger has failed, before a new turbocharger is
installed.
A prerequisite for the turbocharger to work satisfacto-
rily is that the engine lubrication and intake systems
are kept in good condition, i.e. that oil and oil filter
changes are completed as scheduled, that the right
grade of oil is used and that the air filter is maintained
correctly.
Therefore the first action should be to check the engine
oil and replace the oil filters if needed, and preferably
to run the engine for a few minutes with the new oil
before the new turbo unit is installed.
Blow any rust and soot flakes out of the exhaust mani-
fold when the turbocharger is changed. The soot flakes
could damage the turbine wheel on the new unit.
It is also important to clean the intake line from the air
filter. Debris from a failed turbine wheel may remain in
place and cause instant breakdown of the new turbo-
charger.

Removal
TAD1640GE, TAD1641GE, TAD1641VE,
TAD1642GE, TAD1642VE, TAD1643VE,
TAD1650VE

Variants with single turbo

1 Remove the air hose between the turbo and the
air filter housing.
2 Remove the bolts and remove the exhaust pipe
from the turbo.
3 Remove the oil delivery pipe and return oil pipe.

P0006875

234 7747722 01.2009

 25-5 Turbocharger

4 Remove the nuts and the spacer sleeves.

5 Remove the turbo.

P0006868

Installation
TAD1640GE, TAD1641GE, TAD1641VE,
TAD1642GE, TAD1642VE, TAD1643VE,
TAD1650VE

Variants with single turbo

1 Clean the turbo contact surface on the exhaust
manifold.
2 Fit the return oil pipe with a new seal ring against
the engine block.
3 Place a new gasket on the exhaust manifold and
install the turbo.
Tighten the nuts according to the specification in
Special Tightening Torques page 9.

P0006868

7747722 01.2009 235

25-5 Turbocharger

4 Connect return oil pipe using a new gasket

against the turbo.
5 Fill the turbo with clean engine oil through the oil
delivery pipe connection.

IMPORTANT!
Make sure no dirt gets into the connection. Use a
strainer when filling oil.
6 Fit the oil delivery pipe with a new gasket.
7 Fit the exhaust pipe to the turbo.
8 Fit the hose between air filter and turbo.
9 Start the engine and check for leaks.

P0006875

236 7747722 01.2009

 25-5 Turbocharger

Turbo, Change
Always determine and rectify the reasons why the tur-
bocharger has failed, before a new turbocharger is
installed.
A prerequisite for the turbocharger to work satisfacto-
rily is that the engine lubrication and intake systems
are kept in good condition, i.e. that oil and oil filter
changes are completed as scheduled, that the right
grade of oil is used and that the air filter is maintained
correctly.
Therefore the first action should be to check the engine
oil and replace the oil filters if needed, and preferably
to run the engine for a few minutes with the new oil
before the new turbo unit is installed.
Blow any rust and soot flakes out of the exhaust mani-
fold when the turbocharger is changed. The soot flakes
could damage the turbine wheel on the new unit.
It is also important to clean the intake line from the air
filter. Debris from a failed turbine wheel may remain in
place and cause instant breakdown of the new turbo-
charger.

Removal
TWD1643GE

Low Pressure Turbo

Variants with twin turbo
1 Remove the heat shield, if fitted.
Refer to Heat Protection page 153.
2 Undo the connector for the air filter sensor.

P0003625

7747722 01.2009 237

25-5 Turbocharger

3 Remove the inlet pipe (1).

4 Remove the exhaust system (2).
5 Undo the upper clamp (3) between the turbo and
the charge air cooler.
6 Remove the oil supply hose (4).
7 Remove the bolts for the oil return pipe (5) on the
turbo. Allow the other end to remain in the engine
block.

8 Remove the four nuts and spacers to the turbo.

9 Lift away the turbocharger.
10 Transfer any oil supply pipe extension to the new
turbo.

P0007044

Installation
TWD1643GE

Low Pressure Turbo

Variants with twin turbo
1 Install the studs if they were removed from the
fixture.
2 Fit the gasket.
3 Lift the turbo into place and align it with the hose
on the charge air cooler.

238 7747722 01.2009

 25-5 Turbocharger

4 Fit the spacers and nuts to the turbo.

Torque the nuts according to specifications in
Special Tightening Torques page 9.

P0007044

5 Install the oil return pipe (5) and a new gasket.

Tighten the bolts.
6 Fill the turbo with clean engine oil through the oil
delivery pipe connection.

IMPORTANT!
Make sure no dirt gets into the connection. Use a
strainer when filling oil.
7 Install the oil supply hose (4).
Tighten the nut.
8 Tighten the hose clamp (3) on the turbo.
9 Check the condition of the rubber connectors.
Install the inlet pipe (1).
Tighten the hose clamps.
10 Install the exhaust system (2).
Tighten the clamp.

11 Install the air filter sensor connector.

12 Install the heat shield, where fitted.
Refer to Heat Protection page 153.

P0003625

7747722 01.2009 239

25-5 Turbocharger

Turbo, Change
Always determine and rectify the reasons why the tur-
bocharger has failed, before a new turbocharger is
installed.
A prerequisite for the turbocharger to work satisfacto-
rily is that the engine lubrication and intake systems
are kept in good condition, i.e. that oil and oil filter
changes are completed as scheduled, that the right
grade of oil is used and that the air filter is maintained
correctly.
Therefore the first action should be to check the engine
oil and replace the oil filters if needed, and preferably
to run the engine for a few minutes with the new oil
before the new turbo unit is installed.
Blow any rust and soot flakes out of the exhaust mani-
fold when the turbocharger is changed. The soot flakes
could damage the turbine wheel on the new unit.
It is also important to clean the intake line from the air
filter. Debris from a failed turbine wheel may remain in
place and cause instant breakdown of the new turbo-
charger.

240 7747722 01.2009

 25-5 Turbocharger

Removal
TWD1643GE

High Pressure Turbo

Variants with twin turbo
1 Remove the heat shield, if fitted.
Refer to Heat Protection page 153.
2 Remove the charge air pipe (1) from the turbo-
1 charger.

4 NOTICE! Note the O-ring.

3 Remove the charge air pipe (2) from the turbo-
charger.
4 Cover the opening (3) on the charge air cooler.
5 Remove the oil supply line (4).
6 Remove the bolts for the oil return pipe (5) on the
turbo. Allow the other end to remain in the engine
block.
6 7 Undo the clamp (6) for the flex-pipe on the
exhaust side.

3
P0003627

7747722 01.2009 241

25-5 Turbocharger

8 Remove the nuts from the turbo attachment to the

wastegate valve.

2X

2X

P0003630

9 Separate the flange, so the sealing surfaces are

free. Leave the clamp on the flex-pipe.
Lift away the turbocharger.

P0007045

Installation
TWD1643GE

High Pressure Turbo

Variants with twin turbo
1 Make sure the clamp is on the flex-pipe.

P0007046

242 7747722 01.2009

 25-5 Turbocharger

2 Install the high pressure turbo and a new gasket

3 Tighten the nuts on the turbo according to speci-
fications in Special Tightening Torques page 9.
4 Tighten the flex-pipe clamp.

P0007047

5 Install the turbo oil return pipe with a new gasket.

Tighten the bolts.
6 Fill the turbo with clean engine oil through the oil
delivery pipe connection.

IMPORTANT!
Make sure no dirt gets into the connection. Use a
strainer when filling oil.
7 Install the oil supply line to the turbo with a new
gasket.
Tighten the bolts.
8 Check the condition of the rubber connector.
Check that the flange joint sealing surfaces are
clean and correctly aligned.

P0007048

7747722 01.2009 243

25-5 Turbocharger

9 Install the charge air pipe (2) on the turbo with a

new O-ring.

1 10 Fit the clamp and tighten it.

11 Tighten the clamp on the rubber connector.
12 Check the condition of the rubber connector.
Fit new O-rings.

NOTICE! Make sure the O-rings fit properly in

their grooves.
13 Install the charge air pipe (1) from the turbo-
charger.
14 Tighten the flange joint. The lower clamp must be
tightened first.

NOTICE! Adjust the wastegate valve; refer to

Wastegate Valve, Adjustment page 94.
15 Install the heat shield, where fitted.
Refer to Heat Protection page 153.
2

P0003631

244 7747722 01.2009

 25-5 Turbocharger

Wastegate Valve, Replace

TWD1643GE

Removal
1 Remove the high pressure turbo in accordance
with Turbo, Change page 240.
2 Remove the wastegate valve connection.

P0007049

3 Remove the clamp under the wastegate housing.

4 Remove the nuts and spacers.
5 Lift the wastegate valve away.

P0007050

7747722 01.2009 245

25-5 Turbocharger

Installation
6 Check the condition of the rubber connector.
7 Install the wastegate housing and a new gasket
8 Tighten the nuts.

9 Install the clamp under the wastegate housing

and tighten until it touches.
10 Install the high pressure turbo in accordance with
Turbo, Change page 240.
11 Tighten the clamp below the wastegate housing.

P0007050

12 Install the wastegate valve connector.

NOTICE! Adjust the wastegate valve in accord-

ance with Wastegate Valve, Adjust-
ment page 94.

P0007051

246 7747722 01.2009

 26-0 Cooling System, General

26-0 Cooling System, General

Draining the Cooling System
NOTICE! The installation implementation for
TAD1650VE may vary. The pictures do not always
correspond.

WARNING!
Do not open the coolant filler cap when the engine is
warm, except in emergencies, this could cause serious
personal injury. Steam or hot fluid could spray out.

IMPORTANT!
On engines which are to be laid up or put in storage,
the engine cooling system must not be drained. The
coolant contains corrosion-inhibiting additives.

9996049 Draining hose

NOTICE! Do not open the pressure cap (2).

7747722 01.2009 247

26-0 Cooling System, General

1 1 Remove the filler cap (1).

2
NOTICE! Open both the pressure cap on the
expansion tank (1) and the filler cap on the radi-
ator (2) on TWD1643GE.

P0002095

TAD1640GE, TAD1641GE, TAD1642GE TAD1641VE,

TAD1642VE, TAD1643VE

2
1

P0002097

TWD1643GE

2 Open all drain points. Drain the coolant from the

radiator and engine block, using tool
9996049 Draining hose. The drain nipples are sit-
uated under the radiator on the right side of the
engine block.
3 Check that all coolant drains out. Deposits may
be found inside the drain tap/plug that need to be
cleaned away. There is otherwise a risk that cool-
ant could remain and cause freeze bursting.
Check whether the installation has any further
taps or plugs at the lowest points of the cooling
water lines.
4 Shut any taps and check that the spring-loaded
covers on the nipples close completely. Install the
rubber plugs.

P0006865

248 7747722 01.2009

 26-0 Cooling System, General

Cooling System, Cleaning

NOTICE! The installation implementation for
TAD1650VE may vary. The pictures do not always
correspond.

WARNING!
All coolant is hazardous and harmful to the environ-
ment. Do not consume. Coolant is flammable.

Cooling performance is reduced by deposits in the

radiator and cooling galleries. The cooling system
should be cleaned out when the coolant is changed.

IMPORTANT!
Cleaning must not be done if there is any risk of the
cooling system freezing, since the cleaning solution
does not have antifreeze properties.

IMPORTANT!
It is extremely important that the correct concentration
and volume of coolant is added to the system. Mix in a
separate clean vessel before filling the cooling system.
Make sure that the liquids mix.
1 Drain the cooling system. Refer to Draining the
Cooling System page 247.
2 Put a hose into the expansion tank filling hole and
flush with clean water, according to specifications
in Technical Data page 36, until the water drain-
ing out is completely clear.
3 Should there still be some contamination left after
flushing for a long time, cleaning may be done
with coolant. Otherwise, continue as in stage 8
below.
4 Fill the cooling system with 15-20% mixture of
concentrated coolant. Use only Volvo Penta rec-
ommended concentrated coolant mixed with
clean water.
5 Drain the coolant after 1–2 days of operation.
Remove the filler cap and the lower radiator hose
if necessary to increase emptying speed.
To prevent suspended material from settling back
in the system, emptying should be done rapidly,
within 10 minutes, without the engine having
been at a standstill for a long time.
6 Flush the system immediately and thoroughly
with clean hot water to prevent dirt from settling
on the inner surfaces. Flush until the water run-
ning out is completely clean. Make sure that any
heater controls are set to full heating during emp-
tying.
7 Should contamination still remain after a long
period of flushing, a clean-out may be done using
Volvo Penta radiator cleaner, followed by treat-

7747722 01.2009 249

26-0 Cooling System, General

ment with Volvo Penta neutralizer. Carefully fol-

low the instructions on the package. Otherwise,
continue as in stage 8 below.
8 When the cooling system is completely free from
contamination, close the drain taps and plugs.
9 Refill with new, Volvo Penta-recommended cool-
ing fluid. Refer to Technical Data page 36 and
Coolant Level, Checking and Topping
Up page 251.

Cooling System, Pressure Testing

9996441 Cover, with connecting nipple
9996662 Pressure testing kit

NOTICE! The installation implementation for

TAD1650VE may vary. The pictures do not always
correspond.

Check pressure testing device 9996662 Pressure test-

ing kit before it is taken into service. Refer to Cylinder
Head, Pressure Testing page 90.
1 Check that all hoses and clamps are undamaged.
2 Check that the tap on the reducing valve is
screwed out.
3 Replace the filler cap on the expansion tank with
cover 9996441 Cover, with connecting nipple.
Connect the pressure test device to the nipple on
the cover.

P0006858

4 Connect the pressure test device to the com-

pressed air system and open tap (B). Adjust the
reducing valve (A) so that the manometer shows
a pressure of 70 kPa (10.2 PSI). Close the cock
(B).
5 The pressure must not drop for two minutes for
the cooling system to be considered free from
leaks.

NOTICE! Repeat the pressure test if there is any

doubt about whether the cooling system leaks or
not.
6 Shut off the compressed air after pressure test-
ing. Release excess pressure in the system by
P0006858 unscrewing the valve on the reducing valve and
opening tap (B).
7 Remove the pressure testing device.

250 7747722 01.2009

 26-0 Cooling System, General

8 Check the coolant level in the expansion tank.

Install the regular filler cap.
9 Start the engine and check that no leakage
occurs.

Coolant Level, Checking and

Topping Up
NOTICE! The installation implementation for
TAD1650VE may vary. The pictures do not always
correspond.

WARNING!
Do not open the coolant filler cap when the engine is
warm, except in emergencies, this could cause serious
personal injury. Steam or hot fluid could spray out.

IMPORTANT!
Coolant filling must be performed with the engine stop-
ped. Fill slowly, to allow air to flow out.

Coolant Level, Checking and Topping Up

IMPORTANT!
Only use coolant recommended by Volvo Penta.

7747722 01.2009 251

26-0 Cooling System, General

1 1 NOTICE! Open only the filler cap (1). Do not open

2 the pressure cap (2).

NOTICE! TWD1643GE: The cap (2) is both filler

cap and pressure cap.
2 Check that the coolant level is above the MIN
mark on the expansion tank.
3 Top up with coolant as required, so that the level
is between the MIN and MAX marks.
TWD1643GE: Fill the expansion tank to the MAX
P0002095 mark on the sight glass.

TAD1640GE, TAD1641GE, TAD1642GE TAD1641VE,

TAD1642VE, TAD1643VE, TAD1650VE

P0002096

TWD1643GE

252 7747722 01.2009

 26-0 Cooling System, General

Filling a completely empty system

NOTICE! Mix the correct amount of coolant in
advance, to ensure that the cooling system is com-
pletely filled. Refer to Technical Data page 36 for the
correct coolant volume.

IMPORTANT!
Do not start the engine until the system is vented and
completely filled.
1 Check that all drain points are closed.
1 2 Open the filler cap (1). Do not open the pressure
2 cap (2).
3 Fill with coolant, so that the level is between the
MIN and MAX marks.
4 Start the engine when the cooling system has
been completely filled and vented. Open any
venting taps a short while after starting, to allow
trapped air to escape.
If a heating unit is connected to the engine cooling
system, the heat control valve should be opened
P0002095
and the installation vented during filling.

TAD1640GE, TAD1641GE, TAD1642GE TAD1641VE, 5 Stop the engine after about an hour and check
TAD1642VE, TAD1643VE, TAD1650VE the coolant level. Top up as necessary.

TWD1643GE
2 1 Open the caps to both the expansion tank (1) and
radiator (2).
1
2 Fill coolant into the expansion tank until it is com-
pletely full.

P0002097

TWD1643GE

7747722 01.2009 253

26-0 Cooling System, General

3 Fill the radiator. Vent via the venting nipple (3).

4 Top up until the system is completely full. Refer
to Technical Data page 36 for the correct coolant
volume.

P0002098

IMPORTANT!
Do not start the engine until the system is vented and
completely filled.

254 7747722 01.2009

 26-1 Radiator, Heat Exchanger

26-1 Radiator, Heat Exchanger

Radiator Assembly, Change
TWD1643GE

Removal
1 Drain the coolant; refer to “Cooling system, drain-
ing”
2 Remove the coolant pipes.
3 Remove the cable ties. Disconnect the level sen-
sor connector.
4 Remove the protective grille from the fan.
5 Attach a lifting strap to the lifting eyes.

P0007057

7747722 01.2009 255

26-1 Radiator, Heat Exchanger

6 Remove the fixing stay bolts.

7 NOTICE! Start by only lifting high enough to
release the guide pins.

Lift away the radiator assembly.

NOTICE! Mind the fan.

P0007058

P0007059

256 7747722 01.2009

 26-1 Radiator, Heat Exchanger

Installation
8 Carefully lift the radiator assembly with a strap
through the lifting eyes (2) so that the guide pins
(3) are in the correct position.
Lower the radiator assembly.

NOTICE! Mind the fan.

9 Install the fixing stay bolts (1).

P0007060

7747722 01.2009 257

26-1 Radiator, Heat Exchanger

10 Install the protective grille for the fan

11 Install the coolant hoses.
12 Fit a new cable tie so that the hoses do not chafe.
13 Install the level sensor connector.
14 Add coolant. Vent the cooling system.
Refer to Coolant Level, Checking and Topping
Up page 251, section Refill of completely empty
system.

P0007057

258 7747722 01.2009

 26-2 Coolant Pump, Thermostat

26-2 Coolant Pump, Thermostat

Coolant Pump, Change
Removal

! CAUTION!
Disconnect power or use some other means to prevent
the engine from starting during the work.
1 Drain the coolant into a suitable container. Refer
to Draining the Cooling System page 247.
2 Remove the drive belt shield that is installed
above the coolant pump.
3 Remove the coolant pump drive belt by placing a
pulling handle in the belt tensioner and easing the
belt tension.
Remove the drive belt from the coolant pump.
4 Remove the coolant pump and its seal.
Press the belt tensioner down so it is easier to
access the lower bolt in the coolant pump. Allow
the bolt (1) to remain in the housing.

P0007061

7747722 01.2009 259

26-2 Coolant Pump, Thermostat

Installation
5 Install the coolant pump with a new seal. Use
petroleum jelly to hold the seal in place during
installation.
The screw (1) must remain in place in the housing
during installation. Tighten the bolts according to
the specification in Special Tightening Tor-
ques page 9.
6 Install the coolant pump drive belt.
7 Install the engine drive belt guard.
8 Refill with coolant; refer to Coolant Level, Check-
ing and Topping Up page 251, section Refill of
completely empty system.
9 Start the engine and let it run until it reaches nor-
mal operating temperature.
P0007062
Check that no leakage occurs. Top up with cool-
ant as necessary.

Thermostat, Change
9996049 Draining hose

Removal
1 Drain the cooling system; refer to Draining the
Cooling System page 247.
Drain off coolant sufficient for its level to drop
below the thermostat housing.
2 Remove the upper belt guard; refer to 26-3, Belt
Protector.
3 Remove the thermostat housing cover.

P0004690

260 7747722 01.2009

 26-2 Coolant Pump, Thermostat

4 Remove the thermostat.

P0004691

Installation
5 Clean and inspect the mating surfaces for both
the thermostat and the thermostat housing cover.

P0005071

6 Install the new thermostat and a new gasket.

P0004691

7747722 01.2009 261

26-2 Coolant Pump, Thermostat

7 Install the thermostat housing cover and the bolts.

8 Install the upper belt guard: Refer to 26-3, Belt
Protector.

IMPORTANT!
Ensure that engine wiring is not pinched.
9 Refill with new coolant; refer to Coolant Level,
Checking and Topping Up page 251.
10 Start the engine and check for leaks. Pressurize
the cooling system; refer to Cooling System,
Pressure Testing page 89.

P0004690

262 7747722 01.2009

 26-2 Coolant Pump, Thermostat

Drive Belt, Change

TAD1640GE, TAD1641GE, TAD1641VE,
TAD1642GE, TAD1642VE, TAD1643VE,
TAD1650VE
1 Switch off at the main switch(es) and check that
the engine is not connected to voltage.
2 Remove the fan guard and fan ring round the
cooling fan.
3 Remove the belt covers.
4 Fit a 1/2” socket drive to the belt tensioner (1). Lift
the socket drive and remove the drive belt.
5 Thread the drive belt round the fan and remove
it.
6 Check that the pulleys are clean and undamaged.
7 Thread the new drive belt over the fan.
8 Lift the socket drive and install the new drive belt.
9 Install the belt guard.
10 Install the fan guard and fan ring round the cooling
fan.
11 Start the engine and perform a function check.

7747722 01.2009 263

26-2 Coolant Pump, Thermostat

Drive Belt, Change

TWD1643GE
1 Switch off at the main switch(es) and check that
the engine is not connected to voltage.
2 Remove both protective grilles, the upper and the
lower, behind the cooling fan.

P0007073

264 7747722 01.2009

 26-2 Coolant Pump, Thermostat

3 Remove both belt guards, right and left.

Leave the cover on the right guard.

P0006869

4 Fit a 1/2” socket drive to the belt tensioner (1).

Lift the square wrench and unhook the drive belt.
5 Thread the drive belt round the fan and remove
it.
6 Check that the pulleys and idler and tensioner
rollers are clean and undamaged, especially
regarding bearings and condition.
7 Thread the new drive belt over the fan.
8 Lift the socket drive and install the new drive belt.
Check that the belt is correctly aligned on all the
pulleys.
P0006870
9 Fit the belt guards and fan cage.
10 Start the engine and perform a function check.

7747722 01.2009 265

26-2 Coolant Pump, Thermostat

Thermostat, Function Check

Remove the thermostat, see Thermostat,
Change page 260.
1 Place the thermostat in a big pot with water and
heat it to the opening temperature as specified in
03-2, Technical Data.

P0005072

Closed thermostat.

2 If the thermostat does not open at specified tem-

perature, it should be replaced.
3 Install the thermostat, see Thermostat,
Change page 260.

NOTICE! Always use a new seal, even if the ther-

mostat is not replaced.

P0005073

Open thermostat.

266 7747722 01.2009

 26-2 Coolant Pump, Thermostat

Coolant Filter, Change

IMPORTANT!
The coolant filter must be changed at the prescribed
intervals. Failure to follow these intervals may result in
significantly reduced engine life. When working on an
engine where more than five liters (5.3 quarts) of new
coolant are being added, a new coolant filter must
always be installed.
1 Shut the filter housing tap.
2 Clean around the filter and remove it using filter
pliers.
3 Lubricate the filter gasket with petroleum jelly, or
soapy water, and fit the new filter.
Screw the filter down until the gasket just touches
the sealing surface. Then turn a further ½ turn.
4 Open the tap on the filter housing.
5 Start the engine and check for leaks.

P0007065

1 Tap open
2 Tap closed

7747722 01.2009 267

26-5 Charge Air Cooler with Connections

26-5 Charge Air Cooler with Connections

Lower Charge Air Cooler, Replace
TWD1643GE

Removal
1 Remove the heat shield, if fitted.
2 Drain the cooling water.
3 Remove the venting hose (1).
4 Remove the screws for the flange joint (2).
5 Remove the connection pipe (3) to the charge air
cooler
6 Undo the clamp (4) to the charge air cooler.
6 5 3
7 Undo the clamp (5) to the turbocharger.
7 2 8 Remove the connection pipe (6) from the turbo-
4x charger.
1
4

P0003633

9 Remove the upper attachment (7).

P0007066

The upper attachment (7) removed.

268 7747722 01.2009

 26-5 Charge Air Cooler with Connections

10 Remove the nuts (2) under the charge air cooler

bracket.
11 Undo the hoses under the charge air cooler (1).
12 Lift away the charge air cooler.

P0007067

Installation
13 Install the charge air cooler and align the hoses
underneath (1).
14 Tighten the hose clamps.
15 Install the nuts (2) under the bracket.

P0007067

16 Install the upper attachment (7).

17 Clean and check that the mating surfaces are
unmarked (4, 5).
18 Install a new O-ring on the charge air cooler
flange joint (4).

P0007069

7747722 01.2009 269

26-5 Charge Air Cooler with Connections

19 Remove the connection pipe (6) from the turbo-

charger.
20 Tighten the clamps (4, 5).
21 Fit a new O-ring on the connection pipe (3) to the
charge air cooler.
6 Install the pipe.
5 3
22 Tighten the flange joint (2) and clamp.
7 2
4x
1
4

P0003633

23 Install the venting hose.

24 Install the heat shield.
25 Add coolant.
Vent the cooling system.
Refer to Coolant Level, Checking and Topping
Up page 251, section Refill of completely empty
system.
26 Check seals.

P0007068

270 7747722 01.2009

 26-5 Charge Air Cooler with Connections

Upper Charge Air Cooler, Replace

TWD1643GE

Removal
1 Remove the heat shield, if fitted.
2 Drain the cooling water.
3 Undo the connector (1) for the air filter sensor.
4 Remove the air filter housing and attachment
bracket (2) including inlet pipe (3) to the turbo-
charger.

P0007070

5 Remove the intake manifold (4) for the charge air

cooler.
Alternatively, remove the clamp by the turbo-
charger if the pipe is difficult to remove.
6 Remove the bolts to the charge air cooler side
bracket (6) and upper attachment.

7747722 01.2009 271

26-5 Charge Air Cooler with Connections

7 Remove the hoses (7) under the charge air

cooler.
Remove the venting hose on the charge air cooler
upper side.
8 Remove the bolts (8) below the charge air cooler.
9 Lift up and pull the charge air cooler backwards.
Remove the charge air cooler.

IMPORTANT!
The charge air cooler may not be taken apart.
Leakage risk.

P0007071

Installation
10 Check the condition of the rubber connector.
Install a new O-ring to the inlet pipe sealing sur-
face.

P0007072

11 Install the charge air cooler.

Install the bolts (8) underneath.
12 Install the hoses (7) under the charge air cooler.
Tighten the clamps.
13 Install the venting hose on the charge air cooler
upper side.

P0007071

272 7747722 01.2009

 26-5 Charge Air Cooler with Connections

14 Install the bolts to the charge air cooler side

bracket (6) and upper attachment.
15 Check the condition of the rubber connector.
Fit a new O-ring on the inlet pipe (4) to the charge
air cooler.
16 Install the inlet pipe and tighten the flange joint.

17 Install the air filter housing and attachment

bracket (2) including inlet pipe (3) to the turbo-
charger.
Tighten the clamp on the turbocharger.
18 Install the air filter sensor connector (1).
19 Install the heat shield, where fitted.
20 Add coolant. Vent the cooling system.
Refer to Coolant Level, Checking and Topping
Up page 251, Refill of completely empty system.
21 Check seals.

P0007070

7747722 01.2009 273

32-1 Alternator

32-1 Alternator
Alternator Belts, Change
TAD1640GE, TAD1641GE, TAD1641VE,
TAD1642GE, TAD1642VE, TAD1643VE,
TAD1650VE

Left belt guard removed: Refer to 26-3, Belt Protec-

tor.

Coolant pump belt removed: Refer to Drive Belt,

Change page 263.

Removal
1 Depress the lever.

NOTICE! Pinch risk!

Wind off the belt.

P0004688

274 7747722 01.2009

 32-1 Alternator

Installation
1 Check the belt tensioner pulleys.

P0004687

2 Depress the lever.

NOTICE! Pinch risk!

Wind on the belt.

P0004688

Alternator Belts, Change

TWD1643GE

IMPORTANT!
Always replace a drive belt that appears worn or is
cracked.
1 Switch off at the main switch(es) and check that
the engine is not connected to voltage.

7747722 01.2009 275

32-1 Alternator

2 Remove the fan cage and belt guards.

Refer to Heat Protection page 153, exposure sec-
tion.

P0007073

P0006869

276 7747722 01.2009

 32-1 Alternator

3 Fit a 1/2” socket drive to the belt tensioner (1).

Lift the socket drive and hook the water pump
drive belt off.
4 Fit a 1/2” socket drive to the left belt tensioner
(2).
Press the socket drive down and remove the
alternator belt.
5 Check that the pulleys and idler and tensioner
rollers are clean and undamaged, especially
regarding bearings and condition.
6 Press the socket drive to the belt tensioner (2)
down and install the new alternator drive belt.
7 Lift the socket drive in the belt tensioner (1) and
install the water pump drive belt.
8 Install the belt guard.
P0007074 9 Fit the fan cage.
10 Start the engine and perform a function check.

7747722 01.2009 277

33-1 Starter Motor

33-1 Starter Motor

Starter Motor, Change
TWD1643GE

Removal
1 Disconnect system voltage from the engine.
2 Remove the heat shield, if fitted.
3 Remove the support plate from the lower charge
air cooler.

P0007066

4 Undo the nuts.

Remove the starter motor harness.
5 Undo the nuts.
Remove the starter motor.

P0007075

Installation
6 Fit the new ring starter motor.

278 7747722 01.2009

 33-1 Starter Motor

Tighten the nuts.

7 Install the harness.
Tighten the nuts.

P0007075

8 Install the support plate for the lower charge air

cooler.
9 Install the heat shield, where fitted.
10 Check functions.

P0007066

7747722 01.2009 279

Alphabetical index
About this Workshop manual................................ 2 Engine Transmission......................................... 27, 59
Adjustment Markings............................................. 198 Exhaust Pipe (Y-pipe), Replace............................ 232
Alternator............................................................... 274 Exhaust Pipe, Silencer.......................................... 232
Alternator Belts, Change............................... 274, 275 Exposing........................................................ 148, 150
Exposing the Engine............................................. 148
Big end bearing, Change (all)............................. 110
Bypass Valve Oil Filter, Change............................ 211 Fitting the Fixture................................................ 154
Bypass Valve, Oil Cooler, Replace....................... 217 Flank Clearance, Adjustment................................ 193
Bypass Valve, Oil Filter Bypass, Replace............. 209 Flywheel Bearing, Change.................................... 111
Flywheel Sensor Distance, Check........................... 96
Camshaft Bearing Housing, Replace................ 139 Flywheel, Change.................................................. 112
Camshaft Sensor Distance, Check......................... 96 Flywheel, Indication............................................... 114
Camshaft, Installation............................................ 191 Fuel Feed Pump and Filter.................................... 223
Camshaft, Wear Check......................................... 138 Fuel Feed Pump, Change..................................... 223
Charge Air Cooler with Connections..................... 268 Fuel Pre-filter, Change.......................................... 225
Charge Air Cooler, External Cleaning..................... 85 Fuel System................................................... 34, 0
Charge Pressure, Troubleshooting......................... 84 Fuel system, bleeding........................................... 218
Closed crankcase venting....................................... 72 Fuel System, General............................................ 218
Common Interference Causes................................ 83
Compression Test................................................... 85 Gear Ring, Fywheel: Replace............................. 113
Connecting Rod Bushing, Check up..................... 121 General....................................................... 2, 0 , 74
Connecting Rod, Check........................................ 120 General Specifications.............................................. 6
Control System, ECM, Data Sets.......................... 230 General Tightening Torques...................................... 8
Control Unit, Replace............................................ 230 Group 21: Engine.......................................... 9, 53, 98
Coolant Filter, Change.......................................... 267 Group 22: Lubrication System........................... 17, 60
Coolant Level, Checking and Topping Up............. 251 Group 23: Fuel System..................................... 19, 64
Coolant Pump, Change......................................... 259 Group 25: Inlet and Exhaust System................. 21, 70
Coolant Pump, Thermostat................................... 259 Group 26: Cooling System...................................... 73
Cooling System.............................................. 36, 0 Heat Protection.................................................... 153
Cooling System, General...................................... 247 Identification Numbers......................................... 52
Cooling System, Pressure Testing.................. 89, 250 Injectors and Delivery Pipes.................................. 226
Copper sleeve for unit injector, replace................. 134 Inlet and Exhaust System............................... 35, 0
Crank Mechanism................................................... 29
Crankshaft seal, replace (front)............................. 115 Location of Sensors.................................. 78, 79, 80
Crankshaft Sealing, Change (rear)........................ 119 Lower Charge Air Cooler, Replace........................ 268
Crankshaft, Inspection........................................... 106 Lubricating and Oil System, General..................... 206
Crankshaft, Installation.......................................... 174 Lubrication Oil Pump, Change.............................. 208
Crankshaft, Removal............................................. 173 Lubrication System.................................................. 32
Crankshaft, vibration damper, flywheel................... 57 Main bearing, Change......................................... 107
Cylinder Head, Installation.................................... 188 Maintenance Service............................................... 50
Cylinder Head, Pressure Testing.................... 90, 133
Oil cooler.............................................................. 215
Cylinder Head, Removal....................................... 154
Oil Cooler, Pressure Testing................................. 216
Cylinder Liner and Pistons, Inspection.................... 98
Oil Cooler, Replace............................................... 215
Cylinder Liner and Pistons, Replace (all).............. 100
Oil filter.................................................................. 209
Cylinder Liner, Installation..................................... 175
Oil Filter, Check..................................................... 211
Design and Function............................................. 52 Oil Pressure Sensor, Check.................................. 212
Draining the Cooling System................................. 247 Oil pump and Line................................................. 208
Draining, Fuel Duct in Cylinder Head............ 219, 220 Overview Control Valve......................................... 207
Drive Belt and Alternator Belt, Inspection................ 97
Piston Cooling Jet, Installation.......................... 180
Drive Belt, Change........................................ 263, 264
Piston cooling system.............................................. 61
Engine........................................................... 22, 0 Piston Cooling Valves, Replace............................ 210
Engine body............................................................ 22 Piston, cylinder lining, connecting rod..................... 55
Engine Complete, General...................................... 98 Piston, Pre-installation........................................... 177
Engine Disassembly.............................................. 154 Pistons, Installation............................................... 179
Engine Fixture, Installation.................................... 154 Pistons, Removal.................................................. 171
Engine Fuel Filter Replacement............................ 224 Placement of Instrument Socket(s)................... 76, 77
Engine Information, General................................... 52
Radiator Assembly, Change .............................. 255
Engine oil and engine oil filter, changing............... 212
Radiator, Heat Exchanger..................................... 255

7747722 01.2009 281

Relief Valve, Check............................................... 214
Relief Valve, Replace............................................ 209
Repair instructions..................................................... 3
Replacement of Components.................................. 98
Safety Instructions................................................ 38
Safety Valve, Oil Pressure, Replace..................... 210
Special Service Tools.............................................. 44
Special Tightening Torques....................................... 9
Specifications, Electrical.......................................... 37
Specifications, Engine .............................................. 8
Starter Motor......................................................... 278
Starter Motor, Change........................................... 278
Steering System...................................................... 37
Test and Adjustments........................................... 85
Thermostat, Change.............................................. 260
Thermostat, Function Check................................. 266
Timing Gear, Installation....................................... 181
Timing Gear, Removal.......................................... 168
Timing Gear, Replace........................................... 140
Troubleshooting....................................................... 81
Turbo, Change...................................... 234, 237, 240
Turbocharger, Inspection........................................ 93
Twin Turbochargers................................................ 71
Unit injector, Installation.................................... 196
Unit Injector, Replace............................................ 226
Universal Tools........................................................ 42
Upper Charge Air Cooler, Replace........................ 271
Valve Guides, Inspection............................ 127, 204
Valve Guides, Replacing....................................... 127
Valve Mechanism.................................................. 203
Valve mechanism.................................................... 24
Valve Seat, Change.............................................. 125
Valve Seats and Valve, Grinding........................... 130
Valve Stem Sealings, Replace.............................. 133
Valves and Unit Injectors, Adjustment........... 199, 203
Valves, Installation................................................ 124
Valves, Overview..................................................... 62
Valves, Removal................................................... 122
Wastegate Valve, Adjustment.............................. 94
Wastegate Valve, Replace.................................... 245
When you work with Chemicals, Fuel and Lubri-
cation Oil, Change................................................. 206

282 7747722 01.2009

 References to Service Bulletins

Group No. Date Subject

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AB Volvo Penta
Customer Support
Dept. 42200
SE-405 08 Gothenburg
Sweden
7747722 English 01-2009