Workshop Manual I

Group 21-26 4(0)

TAD1250VE, TAD1251VE, TAD1252VE

 Workshop manual
Group 21-26

Industrial engines
TAD1250VE, TAD1251VE, TAD1252VE

Contents

Safety information ................................................. 4 Design and function ............................................ 19

Introduction .......................................................... 4 Group 21: Engine body ....................................... 19
Engine ............................................................... 19
General information .............................................. 7 Cylinder head ..................................................... 20
About this Workshop Manual ............................... 7 Engine block ...................................................... 21
Standard times (Flat Rate) ................................... 7 Cylinder liner ...................................................... 22
Spare parts .......................................................... 7 Pistons and con rods ......................................... 23
Certified engines .................................................. 7 Crankshaft ......................................................... 24
Camshaft ........................................................... 25
Repair instructions ................................................ 8 Valve mechanism .............................................. 26
Our common responsibility ................................... 8 Internal EGR ...................................................... 27
Torque ................................................................. 8 Transmission ..................................................... 29
Torque-angle tightening ........................................ 9 Group 22 Lubrication system ............................. 30
Lock nuts ............................................................. 9 Function description, lubrication system ............ 30
Strength classes .................................................. 9 Oil valves ........................................................... 31
Sealant ................................................................ 9 Group 23 Fuel system ......................................... 32
Safety rules for Fluorocarbon Rubber ................. 10 Function description, fuel system ...................... 32
When working with chemicals, Filter housing ..................................................... 33
fuel and lubricating oil ........................................ 10 Unit injector, summary ....................................... 34
Before lifting the engine ..................................... 11 Trim code, injector ............................................. 34
Actions after lifting the engine ............................ 11 Unit injector, working phases ............................. 35
Instructions for work on engines with Group 25 Inlet and exhaust system .................... 37
electronic fuel injection ...................................... 11 Turbocharger ...................................................... 38
Group 26: Cooling system .................................. 39
Special tools ....................................................... 12 Function description, cooling system ................. 39
Other special equipment .................................... 16 Intercooler .......................................................... 40
Group 30: Electrical system ............................... 41
EMS 2 ............................................................... 41
Introduction ......................................................... 17
Control unit ........................................................ 41
Identification numbers ........................................ 17 Electrical component diagram ............................ 42
Component location ........................................... 18
Fault tracing ........................................................
Symptoms and possible causes ........................
Malfunctions ......................................................
Blockage ............................................................
Tests and settings ...............................................
Charge pressure, fault tracing ............................
Turbocharger, inspection ....................................
Supply pressure .................................................
Service work ........................................................
Compression test ...............................................
Timing marks .....................................................
Adjustment, general ...........................................
Valves, adjustment ............................................
Double rocker arm, inspection (iEGR) ................
Double rocker arm, adjustment ..........................
Engine oil, changing ...........................................
Oil filter/By-pass filter, change ...........................
Fuel filter, change ..............................................
Primary fuel filter, change ..................................
Fuel system, draining .........................................
Draining condensate ..........................................
Venting the fuel system .....................................
Instructions for operating the starter motor .........
Exhaust system, inspection ...............................
Pressure drop indicator/air filter,
inspection/change ..............................................
Cooling system, draining ....................................
Cooling system, cleaning ...................................
Cooling system, pressure testing .......................
Cooling system, filling ........................................
Coolant filter, change .........................................
Alternator belt / Drive belt, inspection.................
Alternator belts, change .....................................
Drive belt, change ..............................................
Checking the pressure test unit ..........................
Installing the engine fixture ................................ 75
Overhaul / Change components ......................... 76
Group 21: Engine body ....................................... 76
Cylinder head, removing ..................................... 76
Cylinder head, installation .................................. 89
Cylinder liners and piston, inspection ................. 93
Cylinder liners and pistons, change (all) ............. 94
Cylinder liners, installation ................................. 96
Pistons, change ................................................. 98
Camshaft, inspection and overhaul ................... 100
Camshaft, wear check ...................................... 102
43 Bearing housing for camshaft, change .............. 103
43 Camshaft, installation ....................................... 104
44 Crankshaft, inspection and overhaul ................. 108
44 Main bearings, change (all) ............................... 110
Big end bearings, change (all) ........................... 113
45 Flywheel bearing, change .................................. 114
45 Flywheel, change .............................................. 115
47 Gear ring, change .............................................. 117
48 Flywheel, indication ........................................... 118
Crankshaft seal, front, change .......................... 119
49 Crankshaft seal rear, change ............................ 121
49 Con rod, inspection ........................................... 123
52 Gudgeon pin bushing, check measurement ....... 123
52 Valves, removing .............................................. 124
53 Valves, installation ............................................ 126
55 Valve seat, change ........................................... 127
57 Valve guides, inspection ................................... 129
58 Valve guides, replacing ..................................... 130
59 Valve stem seals, change ................................. 131
60 Valve seats, grinding ........................................ 133
61 Valves, grinding ................................................ 134
62 Cylinder head, pressure testing ......................... 135
62 Copper sleeve for injector, changing ................. 139
63 Timing gear, changing ....................................... 143
64 Group 22: Lubrication system ........................... 158
65 When working with chemicals,
fuel and lubrication oil ....................................... 158
65 Reduction valve, change ................................... 158
66 Safety valve, change ........................................ 159
67 Piston cooling valve, change ............................ 160
68 Bypass valve, oil filter, change ......................... 161
70 By-pass valve, by-pass filter, change ............... 162
71 Bypass valve, oil cooler, change ...................... 163
72 Sump gasket, change ....................................... 164
72 Piston cooling nozzle, change .......................... 166
73 Oil filter, change ................................................ 167
74 Lube oil pressure, check ................................... 170
Oil cooler, change ............................................. 171
Oil cooler, leakage test ..................................... 175
Group 23: Fuel system ....................................... 176
Control unit, change .......................................... 176
Feed pump, changing ........................................ 178
Feed pump, renovation ..................................... 179
Bypass valve, changing .................................... 181
Unit injector, change ......................................... 182
Group 25: Inlet / Exhaust systems .................... 186
Inlet pipe, gasket change .................................. 186
Manifold, gasket change ................................... 190
Turbo, replacing ................................................ 194
Group 26: Cooling system ................................. 198
Coolant pump, change ...................................... 198
Thermostat, function check............................... 203
Thermostat, change .......................................... 204
Charge air cooler, change ................................. 205
Charge air cooler, leakage test .......................... 206
Charge air cooler, cleaning ................................ 208
Radiator matrix, change .................................... 209

Technical data .................................................... 214

General ............................................................. 214
Torque .............................................................. 215

References to Service Bulletins ........................ 219

Alphabetical register .......................................... 220


Safety information
Introduction
The workshop manual contains descriptions and repair
instructions for products or product versions noted in
the table of contents, supplied by Volvo Penta. This
manual should be used together with the workshop
manual Technical data for each engine. Check that
you have the correct workshop manual for your en-
gine.
Read this safety information and the workshop manual
General information and Repair instructions care-
fully before service work is started.
Important
In this book and on the product you will find the follow-
ing special warning symbols.
WARNING! Warns for the risk of personal injury,
major damage to product or property, or serious
malfunctions if the instruction is ignored.
IMPORTANT! Is used to call attention to things
which could cause damage or malfunctions to
product or property.
NOTE! Is used to call attention to important informa-
tion, to facilitate work processes or operation.
To give you a perspective on the risks which always
need to be observed and precautions which always
have to be taken, we have noted them below.
Make it impossible to start the engine by cutting
system current with the main switch(es)and lock
it (them) in the off position before starting ser-
vice work. Set up a warning notice by the helm
station.
All service work should normally be done on a
stationary engine. Some work, such as adjust-
ments, need the engine to be running, however.
Approaching an engine which is operating is a
safety hazard. Remember that loose clothing or
long hair can fasten in rotating parts and cause
serious personal injury.
4
Safety information
If work is done adjacent to a running engine, a
careless movement or a dropped tool can lead
to personal injury in the worst case. Take care
to avoid contact with hot surfaces (exhaust
pipes, Turbocharger, air intake pipe, starter
heater etc.) and fluids in pipes and hoses in an
engine which is running or has just been
stopped. Reinstall all protective parts removed
during servicework before starting the engine.
Check that the warning or information labels on
the product are always clearly visible. Replace
labels which have been damaged or painted
over.
Never start the engine without installing the air
cleaner filter. The rotating compressor turbine in
the turbocharger can cause severe injury. For-
eign objects entering the intake ducts can also
cause mechanical damage.
Never use start spray or similar products as a
starting aid. They may cause an explosion in
the inlet manifold. Danger of personal injury.
Only start the engine in a well- ventilated area.
When operated in a confined space, exhaust
fumes and crankcase gases must be ventilated
from the engine bay or workshop area.
Avoid opening the coolant filling cap when the
engine is hot. Steam or hot coolant can spray
out and the system pressure will be lost. When
needed, open the filler cap slowly and release
the pressure in the system. Be extremely care-
ful if a tap, plug or coolant hose has to be re-
moved from a hot engine. Steam or hot coolant
might spray out in an unexpected direction.
Hot oil can cause burns. Avoid skin contact with
hot oil. Ensure that the lubrication system is not
under pressure before carrying out any work.
Never start or operate the engine with the oil fill-
er cap removed, otherwise oil could be ejected.
Stop the engine before carrying out operations
on the engine cooling system.

If other equipment connected to the engine has
altered its centre of gravity, special lifting devic-
es may be needed to obtain the correct balance
and safe handling.
Never do any work on an engine which just
hangs from a lifting device.
Never work alone when heavy components are
to be dismantled, even when safe lifting devices
such as lockable blocks & tackle are used.
When using a lifting device two people are usu-
ally required to do the work, one to take care of
the lifting device and another to ensure that
components are lifted clear and not damaged
during the lifting operations.
Always make sure that there is enough space
for disassembly where you are working, with no
risk for personal or material damage.
WARNING! Components in the electrical and
fuel systems on Volvo Penta products have
been designed to minimize the risks of explo-
sion and fire. The engine must not be run in ar-
eas where there are explosive materials.
Only use the fuels recommended by Volvo Pen-
ta. Refer to the Instruction Book. Use of fuels
that are of a lower quality can damage the en-
gine. On a diesel engine poor quality fuel can
cause the control rod to bind and the engine to
overrev with resulting risk of damage to the en-
gine and personal injury. Poor fuel can also lead
to higher maintenance costs.
Remember the following when washing with a
power washer: Never aim the water jet at seals,
rubber hoses, electrical components or radia-
tors. Never use a power washer for engine
cleaning.
Always use protective glasses or goggles when
carrying out work where there is a risk of splin-
ters, grinding sparks, acid splashes or where
other chemicals are used. Your eyes are ex-
tremely sensitive, injury could cause blindness!
Safety information
Avoid getting oil on your skin! Repeated expo-
sure to oil or exposure over a long period can re-
sult in the skin becoming dry. Irritation, dryness
and eczema and other skin problems can then
occur. Used oil is more dangerous than fresh oil
from a health aspect. Use protective gloves and
avoid oil-soaked clothes and rags. Wash regu-
larly, especially before eating. There are special
skin creams which counteract drying out of the
skin and make it easier to clean off dirt after
work is completed.
Most chemicals intended for the product (e.g.
engine and transmission oils, glycol, petrol (gas-
oline) and diesel oil) or chemicals for workshop
use (e.g. degreasers, paints and solvents) are
hazardous. Read the instructions on the product
packaging with care! Always follow the safety
precautions for the product (for example use of
protective mask, glasses, gloves etc.). Make
sure that other personnel are not inadvertently
exposed to hazardous chemicals, for example in
the air. Ensure good ventilation in the work
place. Follow the instructions provided when dis-
posing of used or leftover chemicals.
Exercise extreme care when leak detecting on
the fuel system and testing the fuel injector noz-
zles. Use eye protection. The jet from a fuel in-
jector is under very high pressure, and has con-
siderable penetration ability; fuel can force its
way deep into body tissues and cause serious
injury. Danger of blood poisoning (septicemia).
WARNING! Fuel delivery pipes on the engine
must not be bent or re-aligned under any circum-
stances. Damaged pipes must be replaced.
All fuels, and many chemicals, are flammable.
Do not allow naked flame or sparks in the vicini-
ty. Petrol (gasoline), some thinners and hydro-
gen gas from batteries are extremely flammable
and explosive when mixed with air in the correct
ratio. No Smoking! Ensure that the work area is
well ventilated and take the necessary safety
precautions before starting welding or grinding
work. Always ensure that there are fire extin-
guishers at hand when work is being carried out.
5

Make sure that oil and fuel soaked rags, and
used fuel and oil filters are stored in a safe
place. Rags soaked in oil can spontaneously ig-
nite under certain circumstances. Used fuel and
oil filters are polluting waste and must be hand-
ed to an approved waste management facility
for destruction, together with used lubrication oil,
contaminated fuel, paint residue, solvents, de-
greasers and wash residue.
Batteries must never be exposed to open
flames or electric sparks. Never smoke close to
the batteries. The batteries generate hydrogen
gas when charged, which forms an explosive
gas when mixed with air. This gas is easily ignit-
ed and highly volatile. A spark, which can be
formed if the batteries are wrongly connected, is
enough to make a battery explode and cause
damage. Do not shift the connections when at-
tempting to start the engine (spark risk) and do
not lean over any of the batteries.
Always ensure that the Plus (positive) and Mi-
nus (negative) battery cables are correctly in-
stalled on the corresponding terminal posts on
the batteries. Incorrect installation can result in
serious damage to the electrical equipment. Re-
fer to the wiring diagram.
6
Safety information
Always use protective goggles when charging
and handling the batteries. Battery electrolyte
contains sulfuric acid which is highly corrosive.
Should the battery electrolyte come into contact
with unprotected skin wash off immediately us-
ing plenty of water and soap. If you get battery
acid in your eyes, flush at once with a lot of wa-
ter, and get medical assistance at once.
Turn the engine off and turn off the power at the
main switch(es) before carrying out work on the
electrical system.
The clutch must be adjusted with the engine
shut off.
The existing lugs on the engine should be used
for lifting. Always check that the lifting devices
are in good condition and that they have the cor-
rect capacity for the lift (the weight of the engine
plus the gearbox and extra equipment).
The engine should be lifted with a customized or
adjustable lifting boom for safe handling and to
avoid damaging components on top of the en-
gine. All chains or cables must be parallel to
each other and should be as square as possible
to the top of the engine.

General information
About this workshop
manual
This workshop manual contains descriptions and re-
pair instructions for the standard versions of the
TAD1250VE, TAD1251VE and TAD1252VE engines.
The workshop manual can illustrate tasks done on
any of the engines noted above. This means that the
illustrations and photographs which clarify certain de-
tails might not entirely correspond. The repair meth-
ods are similar in all important respects, however. The
engine designation and number are noted on the type
plate (please refer to “Technical Data TAD1250VE,
TAD1251VE, TAD1252VE”).
The engine designation and number must always be
given in all correspondence about an engine.
The workshop manual is produced primarily for the
use of Volvo Penta workshops and service techni-
cians. For this reason the manual presupposes a cer-
tain basic knowledge and that the user can carry out
the mechanical/electrical work described to a general
standard of engineering competence.
Volvo Penta constantly improves its products, so we
reserve the right to make modifications without prior
notification. All information in this manual is based on
product data which was available up to the date on
which the manual was printed. Any material changes
introduced into the product or service methods after
this date are notified by means of Service Bulletins.
Standard times (Flat Rate)
In instructions where operation numbers are found in
the headings, this is a reference to the Volvo Penta
standard times list (“Flat Rate”).
Spare parts
Spare parts for electrical and fuel systems are subject
to various national safety requirements. Volvo Penta
Original Spare Parts meet these specifications. Any
kind of damage whatsoever, occasioned by use of
non-original Volvo Penta spares for the product in
question, will not be compensated by the warranty of-
fered by Volvo Penta.
General information
Certified engines
The manufacturer certifies that both new engines and
those in use, which are certified for national or region-
al legislation, comply with the environmental require-
ments. Each product must correspond with the unit
used for certification. The following requirements for
service and spare parts must be complied with, for
Volvo Penta as a manufacturer to be responsible for
ensuring that engines in use comply with the stipulat-
ed environmental requirements:
– Maintenance and service intervals recommended
by Volvo Penta must be complied with.
– Only Volvo Penta Original Spare Parts intended
for the certified engine version may be used.
– Service related to injection pumps, pump settings
or unit injectors must always be done by an au-
thorized Volvo Penta workshop.
– The engine must not be converted or modified in
any way, except for the accessories and service
kits which Volvo Penta has approved for the en-
gine.
– Installation changes to the exhaust pipe and the
engine bay air inlet ducts (ventilation ducts) must
not be done without further discussion, since this
could affect exhaust emissions. No seals on the
engine may be broken by unauthorized persons.
IMPORTANT! When spare parts are needed,
use only Volvo Penta Original Spares.
– The use of non-original spares means that AB
Volvo Penta ceases to be responsible for ensur-
ing that the engine corresponds with the certified
version.
– Any kind of damage whatsoever, occasioned by
use of non- original Volvo Penta spares for the
product, will not be compensated by the warranty
offered by Volvo Penta.
7
Repair instructions
Repair instructions
The working methods described in the workshop man-
ual apply to work carried out in a workshop. For this
reason, the engine is lifted out and mounted on an en-
gine support. Unless otherwise stated reconditioning
work which can be carried out with the engine in place
follows the same working method.
The warning signs which occur in the workshop manual
(for their meanings, please refer to Safety information)
WARNING!
IMPORTANT!
NOTE!
are not comprehensive in any way, since we can not
of course foresee everything, because service work
is done in highly varying circumstances. For this rea-
son, all we can do is to point out the risks which we
believe could occur due to incorrect work in a well-
equipped workshop, using work methods and tools
tested by us.
All operations described in the workshop manual for
which there are Volvo Penta Special Tools available
assume that these tools are used when carrying out
the repair. Volvo Penta Special Tools have been spe-
cifically developed to ensure the most safe and ratio-
nal working methods possible. It is therefore the re-
sponsibility of anyone using other tools or other work-
ing methods than we recommend to determine that
there is no risk of personal injury or mechanical dam-
age or malfunction as a result.
In some cases special safety precautions and user
instructions may be required in order to use the tools
and chemicals mentioned in the workshop manual.
These rules must always be observed, so there are
no special instructions about this in the workshop
manual.
By following these basic recommendations and using-
using common sense it is possible to avoid most of
the risks involved in the work. A clean workplace and
a clean engine will eliminate many risks of personal
injury and engine malfunction.
Above all, when work on fuel systems, lubrication
systems, inlet systems, turbocharger, bearing caps
and seals is done, it is extremely important that no
dirt or other kinds of foreign particles are able to get
in, since this would otherwise cause malfunctions or
shortened repair life.
8
Our common responsibility
Each engine consists of a large number of collaborat-
ing systems and components. Any deviation of a
component from its technical specification can dra-
matically increase the environmental impact of an oth-
erwise good engine. For this reason, it is extremely
important that specified wear tolerances are kept to,
that systems with adjustment facilities are correctly
adjusted and that Volvo Penta Original Spares are
used for the engine. The stated service intervals in
the Maintenance Schedule must be observed.
Some systems, such as the components in the fuel
system, require special expertise and special testing
equipment for service and maintenance. Some com-
ponents are sealed at the factory, for environmental
reasons etc. It is only permissible to work on sealed
components if you are authorized to do such work.
Remember that most chemical products, incorrectly used,
damage the environment. Volvo Penta recommends the
use of biodegradable degreasers whenever engine compo-
nents are de-greased, unless otherwise specified in the
workshop manual. Be careful to ensure that oils, wash
residue etc. are processed for destruction, and are not in-
advertently discharged to the environment.
Torque
The tightening torque for vital fasteners, which should
be tightened with a torque wrench, are listed in “Tech-
nical Data: Tightening torque” and noted in the job de-
scriptions in the book. All torque specifications apply
to clean screws, screw heads and mating faces.
Torque data stated apply to lightly oiled or dry
threads. If lubricants, locking fluids or sealants are
needed on a fastener, the type of preparation to be
used will be noted in the job description and in “Tight-
ening Torques”. Where a particular torque value is not
specified for any fastener, the general tightening
torques in the table below shall apply. The torque
specification is a target value and the fastener does
not need to be tightened with a torque wrench.
Dimension Torque
Nm
M5 ................................................. 6
M6 ................................................. 10
M8 ................................................. 25
M10 ............................................... 50
M12 ............................................... 80
M14 ............................................... 140
M16 ............................................... 220

Torque-angle tightening
In torque/angle tightening, the fastener is tightened to
the specified torque, and tightening then continues
through a pre-determined angle. Example; for 90° an-
gle tightening, the fastener is tightened a further 1/4
turn in one sequence, after the specified tightening
torque has been achieved.
Lock nuts
Disassembled locknuts shall not be re-used, they
shall be replaced by new ones, since the locking prop-
erties are impaired or lost when the nut is used sever-
al times. On locknuts with plastic inserts, such as Ny-
lock® the tightening torque specified in the table must
be reduced if the Nylock® nut has the same nut height
as a standard fully metallic hexagonal nut. Reduce the
torque by 25% for screw size 8 mm or larger. On Ny-
lock® nuts with higher nut height, where the fully me-
tallic thread is as high as on a standard hexagonal
nut, use the tightening torques in the table.
Strength classes
Screws and nuts are sub-divided into different
strength classes. Classification is indicated by mark-
ings on the screw head. A marking with higher number
indicates stronger material. For example, a screw
marked 10-9 is stronger than one marked 8-8. For this
reason, when fasteners are removed, it is important
that the screws are put back in the correct places
when they are re-installed. If a screw must be re-
placed check in the spare parts catalogue to make
sure the correct screw is used.
Repair instructions
Sealant
Several different types of sealant and locking fluids
are used on the engine. The properties of the prepara-
tions differ, and they are intended for different
strengths of fastener, temperature, resistance to oil
and other chemicals, and for the different materials
and gap thicknesses found in the engine.
It is therefore important that the correct types of seal-
ant and locking fluids are used on the fasteners where
needed, to give a fully acceptable service result.
In this Volvo Penta workshop manual the user will find
that each section where these agents are applied in
production states which type was used on the engine.
In service work, similar preparations, or preparations
of corresponding properties but of other makes, shall
be used.
When sealants and locking fluids are used, it is impor-
tant that the surfaces are free from oil, grease, paint
and rust-protection, and that they are dry. Always fol-
low the manufacturer’s instructions use regarding tem-
perature range, curing time and any other instructions
for the product.
Two different basic types of agent are used on the en-
gine. These are:
RTV preparations (Room Temperature Vulcanizing).
Used for gaskets, sealing gasket joints or coating
gaskets. RTV preparations are fully visible when the
component has been disassembled; old RTV com-
pound must be removed before the joint is sealed
again.
The following preparations are RTV-types: Loctite®
574, Volvo Penta 840879-1, Permatex® No. 3, Volvo
Penta 1161099-5, Permatex ® No 77. Remove old
sealant with denatured alcohol in each case.
Anaerobic agents. These agents cure in the absence
of air. These preparations are used when two solid
components, such as two cast components, are fitted
together without a gasket. Common uses are also to
lock and seal plugs, stud threads, taps, oil pressure
monitors etc. Hardened anaerobic preparations are
glassy and for this reason, the preparations are col-
ored to make them visible. Hardened anaerobic prepa-
rations are highly resistant to solvents, and old com-
pound can not be removed. On re-installation, de-
grease carefully and then apply new sealant.
The following preparations are anaerobic: Loctite ®
572 (white), Loctite ® 241 (blue).
Note. Loctite® is a registered trademark belonging to the Loctite
Corporation, Permatex® is a registered trademark belonging to
the Permatex Corporation.
9
Repair instructions

Safety rules for When working with chemicals,

Fluorocarbon Rubber fuel and lubricating oil
IMPORTANT! Apply barrier cream to your hands and
Fluorocarbon rubber is a common material in seal rings
always use protective gloves in work which involves
for shafts, and in O-rings, for example.
contact with oil, fuel etc. Continuous skin contact with
When fluorocarbon rubber is exposed to high tempera- engine oil dries your skin and can be hazardous.
tures (above 300°C), hydrofluoric acid which is highly
corrosive is formed. Contact with the skin can result in
severe chemical burns. Splashes in your eyes can re-
sult in severe chemical burns. If you breathe in the
fumes, your lungs can be permanently damaged.

WARNING! Be very careful when working on en-

gines which have been exposed to high tempera-
tures, such as overheating or fire. Seals must
never be cut with a flame torch during disassem-
bly, or burned in uncontrolled circumstances af-
terwards.

• Always use chloroprene rubber gloves (gloves for

chemicals handling) and goggles.
• Handle the removed seal in the same way as cor-
rosive acid. All residue, including ash, can be high-
ly corrosive. Never use compressed air to blow
anything clean.
• Put the remains in a plastic container, seal it and
apply a warning label. Wash the gloves under run-
ning water before removing them.
The following seals are most probably made from fluo-
rocarbon rubber:
Seal rings for crankshafts, camshafts, countershafts.
O-rings, regardless of where they are installed. O-rings
for cylinder liner sealing are almost always made of flu-
orocarbon rubber.

Please note that seals which have not been ex-

posed to high temperature can be handled normal-
ly.

10
Repair instructions

Before lifting the engine Instructions for work on

1. Turn the battery isolator off, undo the connections electronic fuel injection
on the starter motor.
• Never undo the control unit connectors or a cable
2. Remove the engine cable connector. from any of the sensors when the engine is run-
3. Remove the exhaust pipe. ning. The ignition key must be in position “0” and
the engine must be stopped.
4. Close the fuel taps.
• Never undo a battery cable when the engine is
5. Remove the fuel connections. running.
6. Undo the cable connectors from the engine. • Always remove the control unit connectors from
the control unit before doing any electric welding
7. Unscrew the engine mountings and lift the engine
work.
away.

NOTE! The main current must be disconnected

Actions after lifting the engine
1. Clean the engine.
WARNING! Remember the following when wash-
ing with a power washer: Be extremely careful
when cleaning, to avoid getting water inside en-
gine components. When a power washer is
used, the water jet must never be aimed at
seals, such as shaft seals, joints with gaskets,
rubber hoses or electrical components.
when the connectors are disconnected.
• Only batteries may be used for starting help.
Quick starting units can give excess voltages and
damage the electronics.
• Always undo the battery cables during quick
charging. (This does not apply to normal trickle
charging.)
• If a connector is undone, make sure that it is put
back correctly and that it is completely free from
oil and other contamination which could cause
poor contact.

2. Pump the engine oil out if necessary.

11
Special tools

Special tools

885231 885232 885316 3809090 3883671 3883672

9986173 99886177 9986179 9990006 99990013 9990176

9990185 9990210 9991801 9991821 9992000 9992013

9992269 9992412 9992479 9992564 9992584 992670

885231 Seal washer with junction nipple 9990185 Lifting tool, rocker bridge
885232 Seal washer 9990210 Tool, removing/installing valve springs
885316 Tool, for tilting the cylinder head 9991801 Mandrel, removal of gudgeon pin
3809090 Puller, polygon hub, vibration damper 9991821 Mandrel, removal of flywheel bearing
3883671 Installation sleeve, upper O-ring, injector 9992000 Extension, mandrel 9998238
3883672 Installation sleeve, lower O-ring, injector 9992013 Mandrel, removal and installation of gud-
9986173 Puller, flywheel bearing geon pin
9986177 Puller 9992269 Mandrel, installation of flywheel bearing
9986179 Puller, flywheel bearing 9992412 Pin
9990006 Puller, injector 9992479 Holder, dial gauge
9990013 Slide hammer 9992564 Mandrel, installation of flywheel bearing
9990176 Press tool, removing/installing valve 9992584 Adapter, hydraulic cylinder 9992671
springs and valve guides 9992670 Hand pump, used with 9996161, or with
9996222

12
 Special tools

9992671 9992873 9992955 9993590 9995028 9996159

9996161 9996222 9996315 9996394 9996395 9996398 9996441

9996626 9996645 9996662 9996845 9996958 9996965

9996966 9996998 9998238 9998246 9998248 9998249

9992671 Hydraulic cylinder 9996626 Adapter, hydraulic cylinder 9992671

9992873 Junction nipple 9996645 Puller, cylinder liner
9992955 Plate, removal of cylinder liners 9996662 Pressure gauge
9993590 Turning tool 9996845 Screw clamp
9995028 Mandrel 9996858 Tap, cooling system
9996159 Pin, for hydraulic cylinder 9996161 9996965 Adapter, for installing polygon hub
9996161 Hydraulic cylinder, for changing cylinder 9996966 Press tool, cylinder liner
liners, timing gear wheels and valve 9996998 Pin
guides
9998238 Mandrel, for changing crankshaft seal
9996222 Foot pump
9998246 Tool, removal and installation of valve
9996315 Spindle, installation of polygon hub and springs
crankshaft gear
9998248 Adapter, 6 pcs.
9996394 Spacer, removal of cylinder liners
9998249 Protective sleeve, unit injector
9996395 Spacer, removal of cylinder liners
9996398 Pressure gauge
9996441 Cap, leakage test, cooling system

13
Special tools

9998250 9998251 9998258 9998261 9998262

9998263 9998264 9998266 9998267

9998304 9998305 9998335 9998339 9998487

9998494 9998511 9998531 9998583 9998599

9998250 Seal ring, 2 pcs. 9998494 Junction nipple

9998251 Seal plug, cylinder head, 6 pcs. 9998511 Crowbar
9998258 Tool, fixing cylinder head in engine stand 9998531 Piston ring compressor
9998261 Mandrel, for pressing in valve guides 9998583 Gauge, setting unit injector pre-load
9998262 Mandrel, for pressing in valve guides 9998599 Cleaning kit for unit injector.
9998263 Mandrel, for removing valve guides Consists of:
959239 Screw M10
9998264 Lifting yoke, camshaft
9808570 Brush, white
9998266 Seal washer, leakage test 9998580 Sleeve with holder and O-ring
276948 O-ring kit
9998267 Guide pins, timing gear plate 9808634 Brush kit, consists of:
9998304 Measurement tool Storage box
Holder
9998305 Holder Holder
9998335 Guide sleeve, valve stem seal Handle
9808614 Brush, yellow, 10 pcs.
9998339 Pressure gauge 9808617 Steel brush, narrow
9998487 Puller, oil filter 9808618 Steel brush, coarse

14
 Special tools

9998601 9998602 9998619 9998624 9998628 9998629

9998648 88820003 88880003

9998601 Fixing tool, cylinder head 9998648 Engine fixture

9998602 Press tool 88820003 Gauges, for adjusting the double rocker arm
9998619 Mandrel, seal ring 88880003 Holder kit, used together with 9990185
9998624 Fixing tool, cylinder head, 2 pcs.
9998628 Press tool
9998629 Lifting lug

15
Special tools

Other special equipment

885633 885648 9812546 9986485 9988539

9989876 9998666 9998668

9999683 9999696

885633 Torque amplifier 9998666 Seal washers, kit: 9809696,

885648 Counterhold, used together with 885633 9809697, 9809699
9812546 Cleaning brush 9998668 Junction washers, kit: 9809698,
9809700, 9809701
9986485 Engine stand
9999683 Rocker dial gauge
9988539 Compression gauge
9999696 Magnetic stand
9989876 Dial gauge

16
 Introduction
TAD1250VE, TAD1251VE and TAD1252VE are in-line, direct injected, 6-cylinder industrial diesel engines with ad-
justable internal EGR (Exhaust Gas Recirculation).
They are equipped with electronically controlled fuel injection, turbochargers, intercoolers, thermostatically con-
trolled cooling systems and electronic speed control.

Identification numbers

The sign above shows:

1 Engine designation The sign above shows:
2 Serial number 1 Engine designation
3 Specification number 2 Serial number
3 Specification number, engine
block (six last figures)

The sign shows:

A Engine designation
B Engine power, net, (without fan)
C Max. engine speed
D Software
E Data set number
F Product number

The sign above shows:

(K) Engine family
(J) Cylinder volume
(A) Engine designation Explanation of engine designation:
(F1) Valve clearance, inlet E.g. TAD1250VE
(F2) Valve clearance, exhaust T – Turbo
(I) Exhaust control units A – Air to air intercooler
(P) Only constant rpm D – Diesel engine
(E) Part no. decal 12 – Cylinder volume, liter
(B) Engine code (in engine family) 5 – Generation
(C) Power / rpm 0 – Version
(D) Fuel quantity V – Stationary and mobile operation
(M) Engine speed E – Emission control
(H) Certification approval number (EU)

17
 Component location

1 2 3 4 5

6 7 8 9 10

1. Expansion tank 6. Radiator package

2. Alternator 7. Dipstick
3. Control unit, EMS 2 8. Oil filler
4. Starter motor 9. Fuel filter with fuel pressure monitor
5. Air filter 10. Secondary fuel filter with water monitor

18
Group 21 Engine Design and function

Design and function

Group 21: Engine

Engine
TAD1250VE, TAD1251VE are TAD1252VE in-line, 6- The unit injectors are centrally located above the pis-
cylinder, direct injected industrial diesel engines. The tons, and are controlled by the EMS2 control module
engines are equipped with adjustable, internal EGR, (Electronic Management System). The control module
electronically controlled fuel injection. The cylinder head is located on the left-hand side of the engine block.
is made in one piece, with a unit injector for each cylin-
der and an overhead camshaft.

19
Group 21 Engine
Cylinder head
The cylinder head is cast in one piece in cast iron,
and covers all the cylinders
It is equipped with an overhead camshaft and is fixed
with thirty eight M16 screws, which are evenly spaced
round the cylinders.
The cylinder head has separate inlet- and exhaust
ducts with so-called “cross-flow” for each cylinder.
The valve guides and valve seats are made from al-
loyed cast iron, and all valve guides have oil seals.
The valve seats are replaceable and made from steel.
20
Design and function
Four valve system, and the valves are displaced 12°
in relation to the cross section of the cylinder.
Valve diameter is 40 mm for both inlet and exhaust
valves. Valve seat angle is 45° on the exhaust side
and 30° on the induction side.
The engine is a low-emission engine, and no machin-
ing may be done which changes the position of the in-
jectors in relation to the combustion chamber, such as
planing the cylinder head or milling the copper sleeve
seats.
Group 21 Engine
Engine block
The engine block is made of alloyed cast iron and is
cast in one unit. It is provided with wet, replaceable
cylinder liners.
The sides of the engine block are arched around each
cylinder, for best stiffness and good sound damping.
A stiffening frame is mounted on the lower plane of
the engine block, to reduce vibration and thus reduce
engine noise.
The sump is made of aluminum, and is fixed by 18
spring-loaded screws at the foot of the engine block.
A seal is installed in a groove in the sump.
The main bearing caps in the engine block are made
from malleable iron, and are machined together with
the engine block. In order to prevent incorrect assem-
bly, bearing caps 1-3, 5 and 6 are numbered and pro-
vided with cast-in bosses on both the bearing cap and
block. The bearing caps are also located by sleeves
pressed into the screw holes in the block.
Design and function
The lube oil pump is fixed to the rearmost main bear-
ing cap, no. 7. The thrust bearing is fixed to the cen-
tral cap, no. 4.
The cylinder head gasket is made from solid steel, in
one piece for the entire engine. The gasket has rubber
seals vulcanized in, for oil and coolant transfer. The
gasket has also a number of convex dimples to pre-
vent the cylinder head from sliding on the gasket dur-
ing installation, and damaging the rubber rings in the
gasket.
The cylinder head is lowed down onto the guide pins
in the cylinder head, with a small gap against the tim-
ing gear plate. After this, the cylinder head is pulled
horizontally towards the timing gear plate. When this
is in place, it is screwed down to the engine block,
and the dimples are flattened out.
21
Group 21 Engine
Cylinder liner
The engine block is provided with wet, replaceable
cylinder liners. The coolant space round the cylinder
liner is sealed by four seal rings.
The upper section is sealed with one ring under the
liner collar. This ring is made from EPDM rubber. A
thin line of silicone sealer is applied between the liner
collars and the liner seats, before the liners are ap-
plied.
22
Design and function
The lower part of the cylinder liner is sealed by three
rubber rings, which are installed in grooves in the en-
gine block. The two upper rings are made from EPDM
rubber and seal out the coolant. The third ring seals
on the oil side, and is made from fluoride rubber (vio-
let).
The contact face of the liner against the steel gasket
is convex in shape. Its height above the edge of the
block is 0.15-0.21 mm.
Group 21 Engine Design and function

Pistons and con rods

The pistons are made of aluminum and are cooled by The con rods are made of forged steel. The big end
lube oil which is sprayed through piston cooling noz- bearing is “split”, i.e. divided by a plain, un-machined
zles in the engine block, into a gallery in the piston surface.
which leads to a cooling coil. The oil is drained via a The top of the con rod has machined sides and a trap-
duct between the piston and the con rod. ezoidal cross-section, which distributes forces from
The gudgeon pin bush is lubricated via an oil groove in the piston to the con rod in an optimum fashion.
the bush, and the piston rings are lubricated in the
usual manner.
The piston has three rings. At the top, there is a “key-
stone” type ring. The middle ring is a rectangular
cross-section compression ring and the lowest ring is
a spring-loaded oil scraper ring.

23
Group 21 Engine
Crankshaft
The crankshaft is drop forged in one piece, and the
bearing surfaces are induction hardened for increased
strength and reduced risk of cracking.
The crankshaft has 7 main bearings. Each big end
bearing has a main bearing on each side. The thrust
bearing is integrated into the center main bearing. Both
the main and big end bearings have steel shells which
are plated with lead/nickel and lined with lead bronze.
The crankshaft can be re-ground to five undersize di-
mensions.
Both at front and rear, the crankshaft is provided with
integrated hubs for fixing the timing gear wheels (rear)
and vibration damper/pulleys (front).
In the front cover, a Teflon seal seals the front end of
the crankshaft. The Teflon seal has an outer felt layer
which serves as a dust shield.
The vibration damper housing contains a freely rotat-
ing steel ring which serves as a flywheel. The space
between the steel ring and the damper housing is filled
with highly viscous silicone oil. Vibration is damped
out by the oil, which evens out the pulsating motion of
the crankshaft and the even movement of the steel
ring.
24
Design and function
The crankshaft timing gear is located at the rear of
the crankshaft. A guide pin in the crankshaft ensures
that the wheel can not be wrongly installed. A silicone
rubber seal ring is located at the end of the crank-
shaft, to seal between the crankshaft and the timing
gear wheel.
The combined timing gear housing / flywheel housing
is fixed round the crankshaft timing gear. A Teflon
seal seals between the flywheel housing and the
crankshaft timing gear wheel, with an outer felt layer
as a dust seal.
The crankshaft timing gear wheel has a guide dowel
at the rear which fits in the flywheel, so that it can not
be wrongly installed. The flywheel screws pass
through the flywheel, crankshaft timing gear and the
crankshaft.
There are a number of grooves milled into the periph-
ery of the flywheel, for the injection system speed
sensor.
Group 21 Engine
Camshaft
The camshaft is mounted on top of the cylinder head,
and is induction hardened. The bearing journals can
be ground down, and have replaceable bearing shells
as spare parts.
The camshaft is supported by seven bearing hous-
ings, which are machined together and are numbered
1-7, seen from the front of the engine. The bearing
housings and bearing caps are also machined togeth-
er. This applies to both production versions and spare
part housings.
The front bearing is a thrust bearing.
The camshaft has three lobes per cylinder. One for
the inlet valves, one for the exhaust valves, and a
lobe in the middle for the unit injector.
The camshaft drive gear is mounted on the front
flange of the camshaft, with an external hydraulic vi-
bration damper. Both the camshaft gear and the vibra-
tion damper have holes for a guide dowel mounted in
the camshaft, to prevent incorrect assembly. There
are teeth on the vibration damper, which generate sig-
nals in the camshaft sensor.
Design and function
In front of the front bearing housing, there is a flange
with the camshaft marking, the numbers 1-6 and TDC
(Top Dead Center). TDC is used for basic setting of
the camshaft, and must be between the two marks on
the bearing housing when the flywheel is at the 0°
mark. The number markings are used for adjusting the
valves and injectors.
A rocker arm bridge is screwed to the camshaft bear-
ing caps, which serves as the bearing journal for the
rocker arms with their pressed-in, surface-treated
steel bushings. A floating valve yoke transfers the
rocker arm movement to the valves. The rocker arm
has a roller in contact with the camshaft, and a ball
socket and adjuster screw in contact with the valve
yoke.
The valve guides are made of alloyed cast iron, the
valve seats are made of steel, and both are replace-
able as spare parts. All valve guides are equipped
with oil seals.
25
Group 21 Engine Design and function

2 3 1 4

6 5 8

7 9

Valve mechanism
The engines have a 4-valve system with overhead The valve yoke is floating, without a guide pin.
camshaft.
The exhaust valves have twin valve springs, whereas
A vibration damper (1), a spacer (2) and a gear wheel the inlet valves have single valve springs.
(3) for the position sensor are screwed to the front of
the camshaft, on the outside of the camshaft gear.
The vibration damper is a hydraulic type.
The rocker arms are mounted on the rocker arm shaft,
and have pressed in bushes (5). The rocker arm has a
roller (6) in contact with the camshaft, and a ball sock-
et (8) in contact with the valve yoke (7).

26
Group 21 Engine Design and function

7 2
6
4

3 1
5

1. Exhaust rocker arm 5. Drain nipple

2. Following arm 6. Lock nut
3. Stop nut 7. Piston
4. Socket

Internal EGR
The engines are equipped with internal EGR (Exhaust
Gas Recirculation). This means that the double rocker
arm has an extra following arm that makes the ex-
haust valve lift an extra time.
This extra lift allows exhaust gas to flow back into the
cylinder at the beginning of each filling phase. The
double rocker arm is controlled by the control unit, via
oil pressure from the iEGR valve. The iEGR valve is
located between the cylinder head and the rocker arm
shaft, and supplies the rocker arm shaft with oil.
The double rocker arm consists of two main sections,
the exhaust rocker arm (1) on which the following arm
(2) is mounted. The control valve in the rocker arm,
which is controlled by the iEGR valve, distributes oil
pressure to either the upper or the lower side of the
piston, and thus either activates or de-activates the
iEGR function.

27
Group 21 Engine Design and function

Inactive
Oil pressure presses the piston to its lower position.
The following arm follows it. The camshaft lobe now
only contacts the roller.

Active
Oil pressure presses the piston to its upper position.
The following arm follows it and the rocker is now acti-
vated twice by the camshaft lobe; first via the main
lobe and then via the following arm.
When the camshaft rotates, the lobe first activates
the roller to activate the exhaust valve. Then the lobe
comes into contact with the following arm contact sur-
face, which gives the exhaust valve a small lift.

28
Group 21 Engine Design and function

1. Gear, camshaft (z=76) 8. Gear, hydraulic oil pump (z=39)

2. Gear, compressor (z=29) 9. Idler wheel (z=71)
3. Idler wheel (z=83) 10. Gear for belts and fuel pump (z=27)
4. Gear, coolant pump (z=27) 11. Gear, servo pump (z=23)
5. Gear, crankshaft (z=38) 12. Nozzle, gear lubrication
6. Gear, lube oil pump (z=23) 13. Idler wheel, adjustable (z=97)
7. Idler wheel (z=44)

Timing gear
The timing gear is mounted on a 10 mm thick steel
plate, mounted on the front of the engine block. The
steel plate is mounted edge-to-edge against the front
of the cylinder head and has a reinforced rubber seal
against the cylinder head. The seal between the steel
plate and the engine block is made of silicone rubber.
All gear wheels have helical teeth. The idler wheels
(3, 7, 9, 13) rotate on pressure lubricated bushes.
Other lubrication is supplied via a spray nozzle (12).
Between the engine block and the cylinder head, there
is an adjustable idler wheel (13). The wheel must be
adjusted after all work that affects the timing gear. It
is important to ensure the correct flank clearance be-
tween the upper and lower gear wheels which engage
on the adjustable idler wheel.

29
Group 22: Lube oil system
Group 22: Lube oil system
The engine is pressure lubricated by means of a gear
wheel pump connected to the engine timing gear. The
oil flow is controlled by six valves.
Two oil galleries are drilled along the engine block.
The gallery on the left side of the engine is the lube oil
duct which provides all bearings in the valve mecha-
nism with oil.
The other duct on the right side of the engine is the
piston cooling duct, which provides the pistons with oil
for lubrication and cooling.
The oil cooler is a plate heat exchanger, located under
a cast iron cover on the right side of the engine block.
30
Design and function
The engine is pressure lubricated by means of a gear
wheel pump connected to the engine timing gear. The
pump forces the oil to the filter housing, via the oil
cooler. The oil is directed from the two full-flow filters
to the by-pass filter and then into the main duct. If the
oil is cold, the oil that should go to the oil cooler pass-
es through the by-pass valve, directly to the filter
housing.
Piston cooling oil is sprayed onto the inside of the pis-
tons via nozzles, one for each piston.
The camshaft and rocker mechanism is lubricated via
a duct through the engine block, cylinder head and
through the housing.
Three oil return holes are drilled through the cylinder
head and engine block.
Group 22: Lube oil system Design and function

1 Safety valve
2 By-pass valve for oil cooler
3 Bypass valve for oil filter
4 Piston cooling valve
5 Bypass valve for by-pass filter
(turbocharger)
6 Pressure limiting valve

Oil valves
1. Safety valve
When the oil pressure drop across the safety valve
exceeds 8.6 bar, the valve opens and leads oil back
to the oil pan
2. Bypass valve for oil cooler
When the pressure drop across the oil cooler is high,
such as just after starting when the oil temperature is
low, the bypass valve opens and oil passes through
the oil cooler’s bypass valve. When the oil tempera-
ture rises and pressure drop across the oil cooler falls
(< 3.0 bar), the bypass valve closes and oil passes
through the oil cooler before it is forced out into the lu-
brication system.
4. Piston cooling valve
The piston cooling valve opens (3.0 bar) when engine
speed increases just above idling.
Oil then flows through the piston cooling duct to the
six piston cooling nozzles. From here, the oil is
sprayed up underneath the pistons and into the piston
cooling ducts.
6. Pressure reduction valve
The pressure reduction valve controls the oil pressure
by opening at high pressure (5.7 bar) and directing
surplus oil back to the oil pan.

3, 5. By-pass valve for oil filter/by-pass (turbo-

charger)
The bypass valve opens (> 2.1 bar) if the filters be-
come blocked, which ensures lubrication, but with
contaminated oil.

31
Group 23 Fuel system
Group 23 Fuel system
13
5
14
11
2
10
1
7
There is an electronically controlled unit injector for
each cylinder, which opens at very high pressure. The
pressure is generated mechanically by the overhead
camshaft, via the rocker arms. The actual injection is
controlled electronically by the control unit.
Fuel is sucked from the fuel tank by the feed pump (1)
through the primary filter (3) with water trap (4),
through the cooling coil for the control unit and up to
the double banjo coupling, from where it passes, to-
gether with returned fuel, through the bypass valve (6)
to the suction side of the feed pump.
The pump forces the fuel through the filter housing (2)
and then through the main filter (7) to the long drilling
(8) in the cylinder head, which provides each unit in-
jector (9) with fuel via an annular space around each
unit injector. The bypass valve (6) maintains a con-
stant pressure to the injectors, by opening at 3.5 to
4.5 bar.
There are two valves in the feed pump. The pressure
limiting valve (10) allows fuel to flow back to the suc-
tion side when pressure becomes too high, such as
when the fuel filter is blocked. The non-return valve
(11) opens when the hand pump (12) is used. If air
has got into the system, it is automatically vented via
the valve (13) on the rear of the cylinder head and the
fuel return pipe (14) back to the tank. Venting of the
system after a filter change is automatically controlled
by valves in the filter housing. The valves also pre-
vent fuel spillage during filter changes. The filters
must be installed dry.
32
Design and function
9
8
12 15
3
4
16
The hand pump (12) in the filter housing is used to
pump fuel in a stationary engine, if the system has to
be completely drained. The non-return valve (15) for
the hand pump is located in the filter housing.
The water-in-fuel sensor is located in the transparent
body (4) under the primary filter. The sensor indicates
when it is time to manually empty the body by using
the drain valve (16).
The fuel pressure sensor is located in the filter hous-
ing, where the measurement point for manual pressure
measurement is also located.
IMPORTANT! Observe the greatest possible
cleanliness when working on the fuel system.
Always do an engine wash before you start
working. Protective plugs must always be in-
stalled when connections are removed, to pre-
vent contamination from entering the fuel sys-
tem. Removed components must be stored in a
sealed plastic bag until they are re-installed.
IMPORTANT! If the engine is turned with the
starter motor, such as during valve adjustment,
the cable in the terminal box for the engine man-
agement unit must be removed first, and the ig-
nition key must be in position “0”, to completely
remove the risk of starting the engine inadvert-
ently. Check the wiring diagram to ensure that
you remove the correct cable. Please refer to
“Instructions for operating the starter motor”.
Group 22: Lube oil system Design and function

1
4

3
2

1. In from tank to primary filter

2. Out from primary filter to fuel feed pump
3. In from fuel feed pump to secondary filter
4. Out from secondary filter to unit injectors
5. Ventilation pipe

Filter housing
Both the primary and secondary fuel filters are in- The hand pump is only used when the fuel system is
stalled in the filter housing. to be filled with fuel, such as after maintenance or if
The main components in the filter housing are: the engine has used up all the fuel.

• Hand pump The fuel pressure sensor is located downstream from

the secondary filter, and measures the fuel supply
• Fuel pressure sensor pressure for the unit injectors.
• Valve units (the valve units are located inside the Venting is not necessary when a filter is changed. The
filter nipples) fuel system is designed to manage the air in new fil-
ters, thanks to the three valves in the filter housings.
Filters should be installed dry.

33
Group 23 Fuel system Design and function

Unit injector, summary

The unit injectors are centrally located between the
four valves and are fixed with a yoke (1). The fuel
1 duct (2) is drilled through the cylinder head and forms
a ring around each injector. The lower part of the unit
2 injector is insulated from coolant by a copper sleeve
(3) which is belled out at its lower end and sealed with
an O-ring at the top end.
The injector has two integrated valves. A fuel valve
which controls the start and duration of injection, and
a valve which controls the actual needle.

4
3

Trim code, injector

There is also a code on the electrical connector which
is used in production. It contains the part number, se-
rial number, date, trim code type, manufacturer and
trim code.
When one or more injectors are changed, the control
unit must be programmed with the trim code(s) for the
new injector(s). The code consists of 9 digits.
Trim code programming is done with VODIA and only
needs to be done for the cylinder whose injector is
changed.

34
Group 23 Fuel system Design and function

Unit injector working phases

The working sequence of the unit injector can be di-

vided into four phases:
• Filling phase
• Spill phase
• Injection phase
• Pressure reduction phase

The pump piston always pumps the same volume of

fuel forwards and backwards through the injector. It is
only when the fuel valve is closed that pressure is
built up and injection takes place. The duration and
timing of the current impulse determines the volume
of fuel injected and its timing.

Filling phase
During the filling phase, the pump piston travels to-
wards its upper position.
The highest point on the camshaft lobe is passed and
the rocker is on the way down towards the camshaft
1 base circle.
The fuel valve is open, since the solenoid valve is not
2 powered. This means that fuel can be sucked from
the fuel duct, past the fuel valve, and into the pump
1. Pump piston cylinder.
2. Fuel gallery
Filling continues until the pump piston reaches its up-
3. Injector needle
per position.
3

Spill phase
The spill 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.
1 The spill phase continues for as long as the fuel valve
is open.
2

1. Pump piston
2. Fuel gallery
3. Injector needle
3

35
Group 23 Fuel system Design and function

Injection phase
The injection phase starts when the solenoid valve is
activated by the control unit, and the fuel valve clos-
es.
The camshaft lobe continues to press the pump pis-
ton down, via the rocker arm. Since the passage
1 through the fuel valve is closed, pressure quickly
builds up. The pressure lifts the injector needle and in-
jection takes place.
2 The injection phase continues for as long as the fuel
valve is closed.

1. Pump piston
2. Fuel gallery
3. Injector needle

Pressure reduction phase

The pressure reduction phase starts when the control
unit thinks that the engine has received the amount of
fuel it needs, and then cuts the current impulse to the
solenoid valve. The fuel valve opens and the fuel
1 flows back out into the fuel duct. The pressure falls
rapidly and the injector needle closes, so that injec-
tion is stopped.
1. Pump piston 2
2. Fuel gallery
3. Injector needle
3

36
Group 25 Inlet and exhaust system Design and function

Group 25 Inlet and exhaust system

37
Group 25 Inlet and exhaust system Design and function

Turbo
The turbocharger is driven by the exhaust gas which
passes through the turbine housing on its way out of
the exhaust system.
The stream of exhaust gas makes the turbine wheel in
the turbine housing rotate. The compressor wheel is
mounted on the same shaft as the turbine wheel. The
compressor turbine is located in a housing which is
connected between the air filter and the inlet manifold
on the engine.
When the compressor wheel rotates, air is sucked in
from the air filter. The air is compressed and is
pressed into the cylinders of the engine, after it has
first been cooled by its passage through the intercool-
er.

38
Group 26 Cooling system
Group 26 Cooling system
Thermostat
Radiator
When the
thermostat
is open
The coolant system is a sealed fresh water system,
with a piston thermostat which regulates the water
temperature.
Coolant is pumped directly into the engine by the
coolant pump, from the pump housing on the right
side of the engine block. The majority of the coolant
passes between the oil cooler plates, whereas part is
forced into the lower cooling housings surrounding the
cylinder liners.
After the oil cooler, the coolant is distributed to the
upper cylinder cooling housings via calibrated holes,
and to the cylinder head. The cylinder head also re-
ceives returned coolant from the cylinder cooling
housings.
Design and function
Venting Expansion tank
Circulation
pump Coolant filter
When the coolant is cold, the thermostat is closed and
coolant passes directly down through the thermostat
housing to the coolant pump and back into the engine
again.
When the coolant is hot, the coolant passes to the
front outlet on the thermostat housing, and to the up-
per radiator inlet. Coolant is forced down through the
duct at the same time as it is cooled down, and then it
is returned to the lower inlet of the pump. The coolant
pump then forces the coolant back into the engine
again.
39
Group 26 Cooling system Design and function

Intercooler
The intercooler is located beside the radiator and is air
cooled.
The purpose of the intercooler is to cool the induction
air, which means that the volume of the air falls and a
larger volume of air can be pressed into the combus-
tion chambers. This gives better combustion of the
fuel, and better fuel utilization.
Intercooling the engine gives a power increase of
about 10%. Engine torque increases and fuel con-
sumption falls.
A diesel engine with turbocharger and intercooler has
better specific efficiency than any other internal com-
bustion engine.

40
 Fault tracing

Group 30 Electrical system

EMS 2, Engine Management

System
EMS 2 is the electronic engine management system
The system consists of 6 unit injectors, a number of
sensors that supply the control module with measure-
ments, a socket for diagnosis (VODIA) and functional
checks.

The control unit

The central component in the injection system is the
control unit. This receives continual information from a
number of sensors on the engine, so that it can de-
cide the fuel volume and injection timing. Control sig-
nals to the unit injector fuel valves via electric cables.
The control unit stores any faults and non-conform-
ance which occurs in the system. Intermittent faults
are also stored so that they can be traced at a later
date.
The control unit is designed for installation directly on
the engine block, with four M8 screws. The control
unit has drain holes by the corners of the long sides,
to prevent water from collecting inside the unit. The
holes are also needed to obtain correct measurement
values from the internal atmospheric pressure sensor,
and must therefore never be covered over.
A coolant loop is fixed to the outside of the control
unit housing with six M6 screws.
The control unit has two, individually coded 62-pin
connectors. The connectors are locked with a catch
on the connector.
The control unit is also equipped with vibration damp-
ers, to resist engine vibration. The vibration dampers
also insulate the unit from the engine block.

41
 Fault tracing

Electrical component diagram

1 2 3 4 5 6 7

20

19

10
11

18 17 16 15 14 13 12

1. Coolant level sensor 11. Position sensor, flywheel

2. Position sensor, camshaft 12. Outlet for diagnostic tool, 6-pin
3. Unit injector (one for each cylinder) 13. 8-pin connector (Data bus)
4. Extra stop 14. Water in fuel, fuel filter
5. Charge pressure and temperature sensor 15. Control unit
6. Main relay 16. OiI temperature and level sensor
7. Fuel pressure alarm 17. Crankcase pressure
8. Coolant temperature sensor 18. Oil pressure sensor
9. Starter motor 19. Fuse 10 A
10. Starter motor relay 20. Alternator

42
 Fault tracing

Fault tracing
A number of symptoms and possible causes of engine malfunctions are described in the table below. Always con-
tact your Volvo Penta dealer if any problems occur which you can not solve by yourself.

WARNING! Read through the safety advice for care and maintenance work in the chapter entitled “Safety-
information” before you start work.

Symptoms and possible causes

The diagnosis button lamp flashes Please refer to the “Diagnostic information” chapter
Engine can not be stopped 2, 5
Starter motor does not rotate 1, 2, 3, 4, 5, 6, 7, 8, 25
Starter motor rotates slowly 1, 2
Starter motor rotates normally but engine does not start 9, 10, 11, 12,13
Engine starts but stops again 9, 10, 11, 12, 14
Engine does not reach correct operating speed at full throttle 10, 11, 12, 13, 14, 15, 22, 26, 27, 28
Engine runs roughly 11, 12,13
High fuel consumption 13, 14, 16, 26
Black exhaust smoke 13, 14
Blue or white exhaust smoke 15, 16, 23
Too low lubrication oil pressure 17
Excessive coolant temperature 18, 19, 20, 21
Too low coolant temperature 21
No, or poor charge 2, 24

1. Flat batteries 11. Air in the fuel system 19. Air in the fresh water cooling
2. Poor contact/broken cable 12. Water/contamination in the fuel system

3. Main switch turned off 13. Fault in one or several injectors 20. Fault in circulation pump

4. Burned fuse in junction box 14. Engine does not receive 21. Defective thermostat

5. Fault in ignition lock enough air: 22. Blocked intercooler

- blocked air filter 23. Too high oil level
6. Fault in main relay - air leakage between
7. Fault in starter motor relay turbocharger and engine 24. Alternator drive belt slips
plenum chamber 25. Water in engine
8. Fault in starter motor/solenoid
- contaminated compressor
9. Fuel used up: 26. High back pressure in
section in turbocharger
- fuel taps closed the exhaust system
- fault in turbocharger
- fuel tank empty/wrong tank - poor engine room ventilation 27. High oil temperature
connected 28. High charge air temperature
15. Excessive coolant temperature
10. Blocked secondary fuel filter/
16. Too low coolant temperature
primary filter (because of con-
tamination or fuel fractionation 17. Too low oil level
in fuel at low temperatures) 18. Low coolant level

43
Fault tracing
Malfunctions
Please refer to “Coolant temperature, fault tracing” for
more detailed information and more help in fault trac-
ing. If there is a malfunction, first check the following
points:
• Check that the coolant level is between the mark-
ings on the expansion tank (at 20°C). If the level
in the expansion tank is too low, top up and start
the engine. If the coolant disappears, there is in-
ner or outer leakage.
• Check that the coolant is not contaminated. If the
coolant is contaminated, this indicates inner leak-
age (oil) or that the cooling system is partially
blocked (deposits). Blockage in the cooling sys-
tem is caused by one or more of the following fac-
tors:
• The coolant has not been changed at the speci-
fied intervals.
• Incorrect mixture of coolant and water.
• Contaminated water has been used.
44
Blockage
Is often caused by high coolant temperature, inner or
outer blockage of the cooling system, or a combina-
tion of both. If the cooling system is blocked, it must
be cleaned. Please refer to “Radiator, cleaning, exter-
nal” and “Cooling system, flushing”
• External contamination: Check that the radiator
and/or intercooler are not blocked.
Check if there is any inner or outer leakage in the
cooling system.
• Inner contamination: Check that the radiator
and/or intercooler are not blocked.
• Inner or outer leakage in the cooling system:
Check if there is leakage in the system.
• Coolant circulation: Check that coolant circu-
lates by letting the engine run at high speed. Also
check the expansion tank to see that coolant cir-
culates. This can be a clue if there is a fault in the
cooling system.
• Thermostat: Check thermostat function. Drain
enough coolant to allow the thermostat to be re-
moved. Check the thermostat, please refer to
“Thermostat, testing”
 Tests and settings

Tests and settings

Charge pressure, fault tracing

25502
Charge air pressure, checking
Special tools:
Junction nipple .............................................. 9996666
Hose ............................................................. 9998493
Pressure gauge ............................................. 9998339

1. Connect the nipple with hose and pressure gauge

to the measurement connection on the inlet mani-
fold, please refer to “Location of measurement
connections”.

2. Compare the pressure with the pressure that can

be read with the VODIA tool, please 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

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 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 as in item 3 above.

5. Install the pressure drop indicator in the air filter

housing

45
Tests and settings

Intercooler, checking
1. Check the intercooler for damage to the cells and
connections.
If there is any damage, change the intercooler.

2. Check the intercooler and radiator for inner block-

age.
If there is any blockage, clean in accordance with
“Radiator, cleaning, internal”.

Inlet manifold, inspection

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

Charge air pipe, checking

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 en-
gine performance will be affected.
If the pipes are contaminated with oil on the in-
side, this indicates oil leakage in the turbocharger
turbine shaft seal. In this case, the turbocharger
should be changed as a unit.
NOTE! If there is any oil in the charge air pipes and
charge air hoses, the intercooler and all pipes and
hoses in the charge air system must be cleaned very
carefully before the engine is started.

46
 Tests and settings

Turbocharger, inspection
25507
1. Check that the turbocharger part number is cor-
rect for the engine variant. The wrong turbocharg-
er for the engine variant might not provide enough
charge pressure, which would reduce engine pow-
er.

2. Check that the turbocharger has the correct com-

pressor housing. If the wrong compressor housing
is installed on the turbocharger, the compressor
wheel might have been damaged or have too
much clearance between turbine wheel and hous-
ing. 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 tur-
bine 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 turbo-

charger and check the turbine wheel.

7. Check the turbine wheel for damage. If the turbine

wheel is damaged, the turbocharger must be
changed as a unit.

47
Tests and settings

Supply pressure, checking

Special tools:
Pressure gauge ............................................. 9998339
Junction nipple .............................................. 9998494

1. Clean the filter bracket carefully.

2. Remove vent nipple and install part no. 9998494.

Connect pressure gauge 9998339.

3. Start the engine and run it at 1000 rpm until feed

pressure on the pressure gauge has stabilized.

4. Compare the maximum feed pressure achieved

with the value in the table below.

Supply pressure
After fuel filter at 1000 rpm, min 350 kPa
After fuel filter at full load, min. 350 kPa

5. After you have completed the check, remove the

measurement equipment and vent the fuel sys-
tem. Please refer to “Venting the fuel system”.

48
 Service work

Service work
Compression test
21002
Fuel system empty and rocker arm bridge removed.
NOTE! Empty the fuel duct in the cylinder head.
Please refer to “Draining, fuel duct in cylinder head” in
the “ Overhaul / Change component” chapter.

Special tools:
Lifting device ................................................. 9990185
Adapter, 6 pcs .............................................. 9998248
Compression gauge ...................................... 9998539
Holder ......................................................... 88880003

1. Remove the unit injectors and clean the copper

sleeves as necessary.

IMPORTANT! Make sure that the area round the

unit injectors is clean before they are removed.

2. Install all 6 adapters, part no. 9998248 in the cyl-

inder head.

3. Oil the valve yoke, camshaft lobes and rocker

arm bridge.

4. Install the rocker arm bridge with lifting tool no.

9990185.
NOTE! The marks on the tool indicates the fastening
points for the rocker arm onto the engine.
Tighten the screws evenly along the rocker arm
bridge, to prevent the rocker arm bridge from
bending or being warped.
Make sure that the guide pins engage in the cam-
shaft support bearings.
Tighten the rocker arm bridge as in the tightening
schedule in “Technical data”. Use a torque
wrench.

5. Install the joining piece and the oil pipe for the
rocker arm bridge.

6. Tighten the valve clearance in all valves, as in

the specification in “Technical data”.

49
Service work

7. Undo both control cables from the starter motor

control connector (the two thin cables).
Now connect one of the free terminals on the con-
trol connector to an earthing point.

8. Connect the other terminal to a switch, which is

connected in its turn to the positive terminal on
the starter motor.

9. Connect compression gauge 9988539 to adapter

9998248 on the first cylinder.

10. Run the engine on the starter motor until the nee-
dle on the compression gauge has stopped mov-
ing (maximum compression value), and read off
the value.
Repeat the test on all the other cylinders.
NOTE! Do not run the starter motor for longer than 15
seconds at a time, with intervals of 60 seconds be-
tween each operation.

11. Remove the joining piece and the oil pipe for the
rocker arm bridge.

12. Undo the screws on the rocker arm shaft progres-

sively, equal amounts each time, to avoid bending
it.
Remove the screws and carefully lift the rocker
arm shaft away with lifting tool no. 9990185.
NOTE! The marks on the tool indicates the fastening
points for the rocker arm onto the engine.

50
 Service work

13. Empty the fuel duct in the cylinder head. Please

refer to “Draining, fuel duct in cylinder head” in the
“Overhaul / Change component” chapter.

14. Remove the adapters, part no. 9998248 from all

cylinders.

15. Install the unit injectors with new O-rings, please

refer to “Unit injectors, change”.
Install the rocker arm shaft.
NOTE! Tighten the screws evenly along the rocker
arm bridge, to prevent the rocker arm bridge from
bending or being warped.
Adjust the valves and unit injectors, please refer
to “Valves and unit injectors, adjustment”.

16. Vent the fuel system, please refer to “Fuel Sys-

tem, Venting”.

51
Service work

Timing marks
The camshaft has six markings, 1-6 for each cylinder,
for adjustment of the inlet and exhaust valves, double
rocker arm and unit injectors.
NOTE! It is important that the line marked on the
camshaft is centered between the two markings on
the bearing cap when adjustment is done.

Adjustment, general

NOTE! Inlet valves, exhaust valves, double rocker

arm and unit injectors are adjusted at the same time
for each cylinder.
This instruction covers adjustment of valves, double
rocker arm and unit injectors in the following order:
1. Inlet valves
2. Exhaust valves
3. Double rocker arm
4. Unit injector
Adjustment should be done in the order marked on the
camshaft when the engine is turned in the direction of
rotation.
By doing adjustments in this order, the crankshaft
does not need to be rotated more than two turns to ad-
just all valves and unit injectors.
It is a good idea to use a marker pen to mark the
rockers which have been checked or adjusted.

52
 Service work

Valves, adjustment
Special tools:
Turning tool ..................................................... 993590

1. Remove the protective cover from the flywheel

housing and install turning tool 9993590, an exten-
sion and a ratchet handle.

2. Inlet valve
Turn the flywheel with turning tool 9993590 until
the first marking on the camshaft is centered be-
tween the markings on the bearing cap.
NOTE! The figure corresponds with the cylinder for
which the inlet and exhaust valves are in the correct
positions for adjustment.
NOTE! Cylinder no 1 is closest to the engine trans-
mission.

3. Undo the locknut and adjust to give the correct

valve clearance. Tighten the lock nut.

1. Adjustment screw
2. Lock nut
3. Feeler gauge

53
Service work

4. Exhaust valve
Undo the locknut on the rocker arm and adjust to
give the correct valve clearance.
Tighten the lock nut.

5. Check the valve clearance again after the first

1000 hours and then check every 4000 hours.

1. Adjustment screw
2. Lock nut
3. Feeler gauge

54
 Service work

Double rocker arm, inspection

(iEGR)
Special tools:
Gauges ....................................................... 88820003

NOTE! The exhaust valve must be correctly adjusted.

1. Undo the drain nipple and drain the air and oil out
of the rocker arm.

2. Insert the “go” side of gauge no. 88820003 be-

tween the mating surface of the double rocker arm
and the camshaft base circle. The gauge must be
able to pass between. If it can not, the “iEGR” lift
is too great.

3. Insert the “stop” side of gauge no. 88820003 be-

tween the mating surface of the double rocker arm
and the camshaft base circle. The gauge must
not be able to pass between. If it can, the “iEGR”
lift is too small.

4. Correct clearance for double rocker arm (between

rocker arm mating surface and camshaft base cir-
cle) measured with gauge no. 88820003:
- ”go” side passes
- ”stop” side does not pass
If the clearance is not correct, please refer to
“Double rocker arm, adjustment”.

5. Tighten the drain nipple as in the specification in

“Technical data”.

55
Service work

6. Adjust the unit injectors, please refer to “Unit in-

jectors, adjustment” in the “Renovation/replace
components” chapter.

7. Turn the engine to the next timing mark, adjust

the other valves and check the double rocker arm
clearance in the same way.

56
 Service work

Double rocker arm, adjustment

Special tools:
Gauges ....................................................... 88820003
NOTE! The drain nipple on the double rocker arm
2 must be open during adjustment.
7
6
4 8. Keep the camshaft in the same position as for ad-
justing the valve clearance.
Undo the locknut and retain the piston with an
Allen key.

1
5
3
1. Exhaust rocker arm
2. Following arm
3. Stop nut
4. Socket
5. Drain nipple
6. Lock nut
7. Piston

9. Insert gauge no. 88820003 between the mating

surface of the double rocker arm and the cam-
shaft base circle.
Turn the piston with the Allen key to give zero
clearance between the double rocker arm, gauge
and camshaft.
NOTE! Zero clearance means that the gauge slides
slowly between the double rocker arm and the cam-
shaft.

10. Tighten the locknut at the same time as the pis-

ton is retained in its correct position. Please refer
to the “Technical Data” chapter for specifications.

11. Check, please refer to “Double rocker arm, check-

ing”.

57
Service work

Engine oil, changing

WARNING! Hot oil and hot surfaces can cause
burns.

NOTE! Oil changes must be done when the engine is

warm.

1. Connect the drain hose to the oil drain pump and

check that no leakage can occur.

2. Pump the oil out (or remove the bottom drain plug
and drain the engine oil).
NOTE! Collect all the old oil and old filters, and hand
them to a re-cycling station for destruction.

3. Remove the drain hose (or install the bottom drain

plug).

4. Fill up with engine oil.

Oil change volume, including changing three fil-
ters, for horizontal installation with standard oil
pan is 35 liter.

58
 Service work

Oil filter/By-pass filter, change

WARNING! Hot oil and hot surfaces can cause
burns.

1. Clean the oil filter housing.

2. Remove all oil filters with a suitable oil filter

puller (1).

3. Clean the mating surface of the oil filter housing.

Make sure that no pieces of old oil seal are left
behind.

4. Put a thin layer of engine oil on the seal rings of

the new fuel filters.

5. Install the new oil filters. Tighten the two full-flow

filters (on the right of the illustration) ½ - ¾ turns
after they just touch. Tighten the bypass filter ¾ -
1 turn after it just touches.

6. Top up with engine oil, start the engine and let it

run for 20-30 seconds.

7. Shut the engine off, check the oil level and top up
the engine oil as necessary.

8. Check sealing round the oil filters.

59
Service work

Fuel filter, change

NOTE! Do not fill the new fuel filter with fuel before
assembly. There is a risk that contamination could get
into the system and cause malfunctions or damage.

WARNING! The fuel filter must be changed

when the engine is cold, to avoid the risk of fire
due to spilled fuel on hot surfaces.

1. Clean round the fuel filter.

2. Remove the filter with a suitable filter remover.

Collect any spilled fuel in a collection vessel.

3. Clean the filter mating surface on the filter brack-

et.

4. Lubricate the seal with diesel fuel and install the

new fuel filter. Tighten the fuel filter in accordance
with the instructions on the fuel filter.

5. If necessary, vent the fuel system, please refer to

“Fuel System, Venting”.
NOTE! If a water trap is installed: change the filter in
it at the same time as the fuel filter, and clean the wa-
ter trap in the plastic bowl under the filter with a soft
rag.

60
 Service work

Primary fuel filter, change

1. Undo the cable from the water trap sensor.

2. Remove the water trap filter from the filter brack-

et. Collect any spilled fuel in a collection vessel.

3. Remove the lower part of the water trap from the

filter.

4. Clean the lower part of the water trap with a soft

rag. Check that the drain hole in the lower part is
not blocked.

5. Install a new seal on the lower part and lubricate

the seal with diesel fuel. Re-install the lower part
of the filter.

6. Lubricate the seal with diesel fuel. Screw the filter

onto the filter bracket by hand until the rubber seal
just touches the mating surface. Then tighten a
further half turn, no more.

7. Connect the cable to the water trap sensor.

8. If necessary, vent the fuel system, please refer to

“Fuel System, Venting”.

61
Service work

Fuel system, draining

1. Carefully clean round the cylinder head vent nip-
ple and the fuel filter bracket drain nipple.

2. Connect a plastic hose to the fuel filter bracket

drain nipple (1) and open it.

3. Undo the vent nipple on the cylinder head. Let the

fuel run out into a suitable vessel.
NOTE! Fuel filter, changing. Only drain the fuel, as
in stages 1-3.

4. When the fuel has stopped flowing, undo the vent

nipple (2) on the fuel filter bracket and allow the
fuel to drain into a suitable vessel.
NOTE! Be careful to save this fuel and hand it to a re-
cycling station.

Draining condensate, fuel system

NOTE! Put a collection vessel under the fuel filter to
collect the condensate and fuel.
1. Open the drain nipple (1) in the base of the prima-
ry fuel filter.

2. Tighten the drain tap (1) when fuel without water

starts to run out.

62
 Service work

Venting the fuel system

NOTE! The system does not need to be vented un-
less it has been run completely dry. Venting is then
done with the hand pump on the fuel filter bracket.

1. Clean around the vent nipples on the cylinder

head and fuel filter bracket.

2. Vent the fuel system with fuel filter. Connect a

transparent plastic hose between the vent nipple
(2) and a suitable collection vessel.
Open the vent nipple on the fuel filter bracket.
Press the hand pump until air-free fuel flows out.
Tighten the venting nipple while fuel is flowing out.

3. Remove the hose and install a protective cap on

the vent nipple.
NOTE! No more venting is needed when the fuel filter
is changed.

4. Transfer the hose the vent nipple on the cylinder

head and vent in the same way as for the fuel fil-
ter bracket.

5. Run the engine at raised idle or with the power

take-off engaged for about 10 minutes to get any
remaining air out of the system.

6. Do a leakage- and function check.

63
Service work

Instructions for operating the

starter motor
IMPORTANT! Ensure that the engine can not
start when it is cranked with the starter motor.

1. Make sure that the starter key is in position “0”. If

a starter key is not used to start the engine, make
sure that the switch that starts the engine is in the
“OFF” position.

2. Undo both control cables from the starter motor

control connector (the two thin cables).
Now connect one of the free terminals on the con-
trol connector to an earthing point.

3. Connect the other terminal to a switch, which is

connected in its turn to the positive terminal on
the starter motor.
NOTE! Do not operate the starter motor for intervals
longer than 15 seconds. Then allow the batteries and
starter motor to rest for 1 minute before operation is
resumed.

4. After you have finished cranking with the starter

motor, remove the switch.

64
 Service work

Exhaust system, inspection

1. Check that the exhaust system is a Volvo Penta
original component.

2. Check whether the exhaust system has been

modified, has bends or damage that prevent ex-
haust gas from flowing out.
If the exhaust system is not Volvo Penta original,
has been modified, has bends or damage, the ex-
haust back pressure can be too high, which will
cut engine power.

3. If you suspect that the exhaust back pressure is

too high, check the pressure, please refer to “Ex-
haust back pressure, checking”.

Pressure drop indicator/air filter.

Check/change.
The engine is equipped with electronic air filter indica-
tion. If there is a pressure drop in the air filter, the
control unit gives a warning signal that is shown on
the instrument panel. The air filter must then be
checked, and may have to be changed.
NOTE! The old filter must be scrapped. No cleaning or
re-use is permissible.

IMPORTANT! In continuous operation, the filter

should be checked every 8 hours.
Driving in extremely contaminated environments
such as coal mines or rock crushers requires
special air filters (not stocked by Volvo Penta).

65
Service work

Cooling system, draining

WARNING! Do not open the filler cap (1) when
the engine is hot. Steam or hot coolant could
spray out.

1. Remove the filler cap (1).

2. Open all drain points. Drain the coolant from the

radiator. Use a drain hose which is ordered from
Volvo Penta. The drain tap (P) is located under-
neath the radiator.

3. Check that all coolant drains out. Deposits, which

may be found inside the drain plugs/taps, must be
cleared away. There is otherwise a risk that cool-
ant could remain and cause severe damage.
Check whether the installation has any further
taps or plugs at the lowest points of the cooling
water pipes.

4. Close the taps and install any plugs.

P = drain tap/plug for coolant

66
 Service work

Cooling system, cleaning

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

NOTE! If the cooling system is flushed regularly, for

example by draining and refilling with rust-preventative
fluid, a smaller amount of flushing additive or simple
rinsing with clean water can be sufficient.

1. Drain the cooling system, see “Draining, cooling

system”.
2. Rinse the cooling system clean with water.
3. Fill the cooling system with radiator flushing
agent, follow the instructions on the package.
4. Run the engine until normal operating temperature
has been reached and then for another 2 hours.

NOTE! As an alternative the cooling system can be

filled with 15–20% concentrated coolant which is
drained after 1–2 days of operation.

5. Carefully flush the system at once with hot water

to prevent any dirt from settling back on the inte-
rior surfaces, and to remove any traces of acid.
Make sure that any heater controls are set to full
heat during emptying.
NOTE! To prevent dissolved dirt etc. from settling in
the cooling system the emptying must be done quick-
ly, within 10 minutes, without leaving the engine sta-
tionary for a long time before emptying. Remove the
filler cap and the lower radiator hose, if fitted, to in-
crease the rate of emptying.
6. Fill the system with Volvo Penta neutralizing mix-
ture, follow the instructions on the package.
Neutralize the residual cleaner for 10-15 minutes
at normal working temperature.
7. Carefully flush the system at once with hot water.
8. When the cooling system is completely clean, fill
it with new coolant that is recommended by Volvo
Penta.

IMPORTANT! It is extremely important that the

correct concentration of coolant is added to the
system. Mix in a separate, clean vessel before
adding into the cooling system. Ensure that the
liquids mix properly.

67
Service work

Cooling system, pressure testing

Special tools:
Cap with junction nipple ................................ 9996441
Pressure testing device ................................ 9996662

WARNING! Open the pressure cap very careful-

ly if the engine is hot. Steam or hot coolant
could spray out.

Check pressure testing device 9996662 before it is

taken into service.

Alternative 1
1. Check that all hoses and clamps are undamaged.

2. Check that the tap on the reduction valve is

screwed out.

3. Unscrew the filler cap from the expansion tap and

screw cap no. 9996433 on. Make sure that the
evacuation pipe on the expansion tank is plugged
(1).
Connect the pressure test device to the nipple to
cover.

68
 Service work

B 4. Connect the pressure test device to the com-

pressed air system and open tap (B). Set reduc-
tion valve (A) so that a pressure of 0.7 bar is
shown on the pressure gauge. Close tap (B).

5. The pressure must not fall for two minutes if the

cooling system is to be regarded as being free
from leakage.
NOTE! Repeat the pressure test if there is any doubt
about whether the cooling system leaks or not.

6. Shut the compressed air off after pressure test-

ing. Eliminate excess pressure in the system by
unscrewing the valve on the reduction valve and
open tap (B).

7. Remove the pressure testing device.

Remove the plug from the evacuation pipe.

A
8. Check the coolant level in the expansion tank. In-
stall the ordinary filler cap.

9. Start the engine and check carefully that no leak-

age occurs.

Alternative 2
1. Check that all hoses and clamps are undamaged
and intact.

2. Check the coolant level in the expansion tank.

3. Replace the filler cap on the expansion tank by a

suitable tool from kit no. 885531.

4. Pump up a pressure of 0.7 bar.

5. The pressure must not fall during a two minute

test, for the cooling system to be regarded as be-
ing free from leakage.

6. Release the excess pressure and remove the

pressure testing tool.

7. Check the coolant level in the expansion tank. In-

stall the ordinary filler cap.

8. Start the engine and check carefully that no leak-

age occurs.

69
Service work

Cooling system, filling

WARNING! Do not open the filler cap (1) when
the engine is hot. Steam or hot coolant can
spray out and the system pressure will be lost.

1. Only open filler cap (1).

NOTE! Only use the coolant and mixture ratio recom-
mended by Volvo Penta.

2. Mix the correct volume of coolant in advance

(please refer to the table below), to ensure that
the system is filled. Filling must not be done so
fast that air locks are formed in the system. The
air should be allowed to flow out through the filling
opening and drain taps.
During filling: the coolant level must be between
the MAX and MIN markings.

3. Start the engine when it is completely filled. If a

heating unit is connected to the engine cooling
system, the heat control valve should be opened
and the installation vented during filling.

4. Stop the engine after about 1 hour. Check the

coolant level and top up with coolant as neces-
sary.

70
 Service work

Coolant filter, change

1. Turn the tap 90° to stop the flow through the cool-
ant filter.

1. Tap open
2. Tap closed

2. Remove the coolant filter with a suitable extractor.

Make sure that no residue from the old seal re-
mains in the housing.

3. Put a thin layer of engine oil on the new coolant

filter seal. Screw the coolant filter on by hand until
the seal comes into contact with the mating sur-
face of the filter bracket. Then tighten the coolant
filter a further 1/2 turn.

4. Turn the tap 90° to release the flow through the

coolant filter again.

5. Start the engine and do a leakage check.

6. Switch the engine off and check the coolant level.

71
Service work

Alternator belt / Drive belt,

inspection
Check the belts once the engine has been run and the
belts are warm.
The alternator belt has an automatic belt tensioner
and does not need to be adjusted.
Check the condition of the drive belts. It should be
possible to press the alternator drive belts down about
3-4 mm (0.118-0.157") between the pulleys.
Change as necessary. Please refer to “Alternator belt,
change” and “Drive belt, change”

Alternator belts, change

IMPORTANT! Change drive belts which are
worn or damaged.

1. Disconnect the main switches and check that the

engine is not connected to system voltage.

2. Remove the fan guard and fan ring round the cool-
ing fan.

3. Remove the belt cover.

4. Insert a 1/2" square socket wrench into the belt

tensioner. Turn the tensioner away with the
wrench and lift the alternator drive belt away.

5. Check that the pulleys are clean and undamaged.

6. Turn the tensioner away with the 1/2" square

socket wrench and install the new alternator drive
belt.

7. Install the belt guards.

8. Install the fan guard and fan ring round the cooling
fan.

9. Start the engine and do a function check.

72
 Service work

Drive belt, change

1. Disconnect the main switch(es) and check that
the engine is not connected to system voltage.

2. Remove the protective grating and the outer fan

ring round the cooling fan.

3. Remove the protective plates round the drive

belts.

4. Insert a 1/2" spanner in the belt tensioner. Lift the

wrench and remove the drive belt.

5. Check that the pulleys are clean and undamaged.

6. Lift the 1/2" wrench and install the new drive belt.

7. Install the protective plates round the drive belts.

8. Install the protective grating and the outer fan ring

round the cooling fan.

9. Start the engine and do a function check.

73
Service work

Checking the pressure test unit

Check pressure testing device 9990123 before it is

taken into service:
1. Connect the pressure testing device to the com-
pressed air mains.

2. Use the reduction valve to set the pressure gauge

to 100 kPa. The knob can be locked with a lock
ring that is moved axially.

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

pressure gauge must not fall during 2 minutes, for
the device to be regarded as being reliable.

4. Unscrew the knob on the reduction valve and

open the tap.

74
Checking the engine fixture

Checking the engine fixture

Special tools:
Engine fixture ................................................ 9998648
Other special equipment:
Engine stand ................................................. 9986485

1. When the engine is fixed in equipment stand

9986485, engine fixture 9998648 is used.

2. Screw the fixture to the left side of the engine, as

in the illustration above.

NOTE! It is important that the advice about the num-

ber of screws is followed, to fix the engine securely.
Use the screws supplied with the fixture.

75
Group 21 Engine Overhaul / change components

Overhaul / Change components

Group 21: Engine

Cylinder head, removing

IMPORTANT! Always observe the greatest pos-
sible cleanliness when working with the cylinder
head.

NOTE! Fuel and coolant drained.

Dirt particles in the fuel ducts can cause failure or
malfunction of the unit injectors.

Special tools:
Lifting device ................................................. 9990185
Turning tool ................................................... 9993590
Press tool ..................................................... 9996966
Protective sleeve .......................................... 9998249
Seal plug ....................................................... 9998251
Lifting yoke ................................................... 9998264
Crowbar ......................................................... 9998511
Lifting lug ...................................................... 9998629
Holder ......................................................... 88880003

1. Cut the current with the main switch (-es) and

check that the engine is not connected to system
voltage.

2. Undo the clamp by the turbocharger and remove

the air filter from the bracket.

3. Remove the lower charge air pipe from the turbo-

charger.

76
Group 21 Engine Overhaul / change components

4. Remove the oil pipes from the turbocharger.

NOTE! Be careful to ensure that no dirt particles get
into the unions on the turbocharger.

5. Remove the turbocharger.

6. Remove the rear protective panel and the front

heat shield from the cylinder head.

77
Group 21 Engine Overhaul / change components

7. Remove the exhaust manifold.

8. Remove the water pipe between the thermostat

and the coolant pump.

9. Remove the thermostat housing and take the ther-

mostat out.

78
Group 21 Engine Overhaul / change components

10. Remove the bypass valves and the fuel union.

11. Remove the tie wraps and remove the charge air
temperature/charge pressure sensor from the inlet
manifold.

12. Remove the charge air pipe between the inlet

manifold and the intercooler.

79
Group 21 Engine Overhaul / change components

13. Remove the covers from the cable chest.

14. Remove the intermediate bracket.

15. Remove the fuel union and temperature sensor.

80
Group 21 Engine Overhaul / change components

16. Remove the inlet pipe.

NOTE! The inlet pipe might be difficult to remove be-
cause the sealant has hardened.

17. Remove the radiator package. Please refer to “Ra-

diator matrix, change”.

18. Remove the protective plates round the drive

belts.

19. Remove the cooling fan (six studs) and remove

the drive belts. Please refer to “Drive belt,
change”.

20. Remove the spacer and pulley.

81
Group 21 Engine Overhaul / change components

21. Remove the clamps and camshaft sensor (1).

22. Remove the cooling fan drive.

23. Undo the clamps and pull away the hose between
the pipes for crankcase ventilation.

24. Remove the water pump from the coolant pump

and the radiator union.

82
Group 21 Engine Overhaul / change components

25. Remove the radiator top hose from the cylinder

head.

26. Remove the front lifting eye.

27. Remove the valve cover.

NOTE! Do not use air-driven tools when removing the
valve cover. This could damage the cable harness for
the unit injectors.

83
Group 21 Engine Overhaul / change components

28. Install turning tool 9993590 in the flywheel hous-

ing.
NOTE! Do not forget to remove turning tool 9993590
from the flywheel housing and put the covers back.

29. Turn the flywheel until the piston in cylinder 1 is at

top dead center, 0° on the flywheel and the cam-
shaft marking (TDC) is between the markings on
the bearing cap.

30. Remove the upper timing gear cover.

NOTE! One of the screws for the upper timing gear
cover is also used to hold the cooling fan drive.

84
Group 21 Engine Overhaul / change components

31. Remove the toothed wheel.

32. Remove the camshaft gear (1). If necessary, use

a puller

33. Remove the studs at the inlet side and the control
valve (IEGR-valve). Install a protective plug in the
oil hole of the cylinder head.
NOTE! Keep the valve dust free, e. g. in a plastic
bag.

85
Group 21 Engine Overhaul / change components

34. Undo the screws for the rocker arm bridge, evenly
across the entire bridge, to avoid uneven loading.
Lift off the rocker arm bridge with lifting tool 9998255.
NOTE! The marks on the tool indicates the fastening
points for the rocker arm to the engine.

IMPORTANT! At least two people should help to

remove the rocker arm bridge, to avoid personal
injury and material damage. The rocker arm
bridge weighs about 27 kg.

35. Check that the camshaft bearing caps are factory-

marked 1-7, to match the bearing caps. Loosen
the camshaft bearing caps by tapping them care-
fully with a plastic faced mallet.
NOTE! The camshaft bearing caps are located by
guide pins.

36. Lift off the camshaft with lifting tool 9998264.

WARNING! Please note that the camshaft lobes

are extremely sharp.

IMPORTANT! At least two people should help to

remove the camshaft, to avoid personal injury
and material damage, if a lifting device is not
available. The camshaft weighs about 35 kg.

37. Remove the lower bearing shells by carefully tap-

ping the bearing seats with a plastic-faced mallet.
Remove the bearing seats and put them in the
correct order together with the appropriate cam-
shaft bearing cap, bearing shells and screws.
NOTE! The camshaft bearing seats are located by
guide pins.

38. Lift the valve yokes between the inlet valves and
the exhaust valves for all cylinders. Put them in
the correct order for each cylinder.

86
Group 21 Engine Overhaul / change components

39. Undo the electric connectors on the unit injectors

and cut away the tie wraps on the cables.

IMPORTANT! Be careful in handling the unit in-

jectors, since these can easily be damaged if
the nuts are cross-threaded or tightened too
hard.

40. Remove the cable bracket on the cylinder head

and carefully pull out the cables for the unit injec-
tors.
NOTE! The cable harness can not be separated at the
cable bracket, it must be carefully pulled out as one
unit.

41. Remove the studs for the fixing brackets on all

unit injectors.

42. Undo the unit injectors one a time with tool no.
9998511. Carefully prise the unit injectors up un-
derneath to loosen them. Install protective sleeve
9998249 on the unit injectors.

IMPORTANT! Do NOT take all the unit injectors

out at once. Take out one at a time and put the
protective plug in at once.

Put the unit injectors in a place where they will not

be damaged.

87
Group 21 Engine Overhaul / change components

43. Install protective plugs no. 9998251 in the unit in-

jector holes in the cylinder head.

IMPORTANT! Very clean conditions are re-

quired.

44. Remove all the screws in the cylinder head.

45. Wipe up the engine oil that has collected in the

“dimples” under the camshaft. The oil could other-
wise run down into the coolant ducts when the
cylinder head is lifted off.

46. Install four lifting lugs no. 9998629 and thread a

lifting sling through. Carefully lift the cylinder head
away.

WARNING! If no lifting device is available, there

should be at least four people to help lift it care-
fully away. The cylinder head weighs about 130
kg.

47. Install press tools no. 9996966 on the cylinder lin-

ers to prevent them from being displaced if the
crankshaft is turned.

48. Remove the seals.

Clean the mating surface on the engine block
carefully.

IMPORTANT! Make sure that no sealant resi-

due or dirt particles can come down into the
coolant and oil ducts.

88
Group 21 Engine Overhaul / change components

Cylinder head, installation

Dirt particles and water must be sucked out of the
fuel ducts after cleaning.

IMPORTANT! The cylinder head must be

cleaned on both the outside and inside before it
is put back. Dirt particles in the fuel ducts can
cause failure or malfunction of the unit injectors.

Special tools:
Lifting device ................................................. 9990185
Turning tool ................................................... 9993590
Press tool, cylinder liner ................................ 9996966
Seal plug ....................................................... 9998251
Fixing tool, cylinder head .............................. 9998601
.................................................................. 9998624
Press tool ..................................................... 9998602
Cleaning kit ................................................... 9998599
Press tool. .................................................... 9998628
Lifting lug ...................................................... 9998629
Holder ......................................................... 88880003

Other special equipment:

Rocker dial gauge ......................................... 9999683
Magnetic stand ............................................. 9999696

1. If necessary, clean the copper sleeves for the unit

injectors with cleaning kit 9998599 (where the tool
in the figure is included in the cleaning kit) before
the cylinder head is lifted back into place on the
engine block. Please refer to “Group 23, Unit in-
jector, changing”.

2. Remove press tools no. 9996966 for the cylinder

liners.

89
Group 21 Engine Overhaul / change components

3. Install new seals and a cylinder head gasket.

Change the seal for the timing gear plate.
NOTE! Carefully check that all seal rings are correctly
installed in place and are not at an angle.

4. Install the fixing tool, as in the illustration.

IMPORTANT! Before the tools are installed:

Check the flatness of the tools by laying them
on a flat surface. If the tools are not flat against
the cylinder head or block, the cylinder head will
be incorrectly installed, which will risk an engine
failure. Clean off all traces of paint and silicone
sealant from the mating surfaces for the tools.

90
Group 21 Engine Overhaul / change components

5. Install four lifting lugs no. 9998629 and thread a

lifting sling through. Carefully lift the cylinder head
into place.

WARNING! If no lifting device is available, there

should be at least four people to help lift it care-
fully and one to guide it into the correct position.
The cylinder head weighs about 130 kg.

6. Check that the seal between the cylinder head

and timing gear plate is correctly installed.
Lower the cylinder head until the guide dowels for
the cylinder head gasket in the block guide the
cylinder head into alignment. Do not lower the cyl-
inder head down fully. Let it hang a few millime-
ters above the engine block plane.
Press the cylinder head obliquely down by hand
so that it is fixed against the fixing tools. Lower
the cylinder head down onto the engine block.
NOTE! Be careful when the cylinder head is moved,
to avoid damaging the gaskets/seals.

7. Use an M10 x 50 mm screw in the upper hole of

the fixing tool on the timing gear plate, to ensure
that the cylinder head rests against the tool.

91
Group 21 Engine Overhaul / change components

8. Check that it is not possible to put a 0.10 mm

feeler gauge between the fixing point and the cyl-
inder head.
9. Remove the lifting tools.

10. Dip the cylinder head screws in rust preventer,

part no. 282036. Put them on a piece of wire net
etc. to allow surplus rust preventer to run off.

11. Install the cylinder head screws as per the tight-

ening schedule.
Tighten the in the specification in “Technical
data”. Use a torque amplifier and counterhold.
NOTE! The screw heads and cylinder head should
preferably be marked with a felt tip pen.

12. Carefully pull the cables for the unit injectors into
the cylinder head. Tighten the cable anchorage on
the cylinder head.

Stage 1 60±10 Nm (6.0±1,0) 13. Install the unit injectors and connect the cables to
Stage 2 (check tightening) 60±10 Nm (6.0±1,0) the injectors. Install new tie wraps.
Stage 3 angle tightening 90°±5° IMPORTANT! Use Volvo Penta Original oil and
Stage 4 angle tightening 90°±5° heat resistant tie wraps (983472) and holders
(28429850).

14. Remove the fixing tools.

15. Install the camshaft, rocker arm bridge, manifold,

turbocharger and inlet manifold in the reverse or-
der to disassembly.

92
Group 21 Engine Overhaul / change components

Cylinder liners and piston,

inspection

The cylinder liners and pistons must be carefully

cleaned before inspection and measurement.
Measurement of cylinder liner wear can be done with
the liner installed in the engine block.
NOTE! The cylinder liners must be taken out of the
engine block, to do a careful crack check.
The position of the cylinder liner must be marked with
a marker pen before it is removed, so that it will be
put back in the correct position if re-installed.

Cylinder liner
1. Do a crack check. Be specially careful when
checking the liner collars. The Magnaflux method
can be used for crack checking.
2. Measure the cylinder liners with a cylinder indica-
tor. In order to obtain the greatest possible accu-
racy in the wear measurement, the cylinder liner
must first be set with a gauge ring or micrometer.
Use the original diameter of the cylinder liner as
the base value.
3. Measure the cylinder liner at the end of travel of
the top piston ring, and at several places along its
travel.
At each measurement point, measurements
should be done along the length of the engine-
and across it.
4. If wear is greater than 0.45–0.50 mm, a complete
new kit should be used (pistons, liners, piston
rings, gudgeon pins and seals).
Oil consumption also has a bearing on when the
cylinder liners should be changed.
NOTE! Cylinder liners and pistons are classed togeth-
er. This means that cylinders and liners must not be
mixed. Pistons and cylinder liners are only supplied
as complete units for spare part purposes.

Pistons
Pistons should be changed if there are deep scratch-
es on the skirt surface, cracked or damaged piston
ring lands, worn piston ring grooves or missing circlip
grooves.

93
Group 21 Engine Overhaul / change components

Cylinder liners and pistons,

change (all)

Special tools:
Plate ............................................................. 9992955
Turning tool ................................................... 9993590
Spacer .......................................................... 9996394
Spacer .......................................................... 9996395
Puller ............................................................ 9996645
Press tool ..................................................... 9996966

1. Install press tool 9996966 on the cylinder liners

that will not be removed.

2. Install turning tool 9993590 and turn the flywheel

until the con rod to be removed comes into posi-
tion.
NOTE! Do not forget to remove turning tool 9993590
from the flywheel housing and put the covers back.

94
Group 21 Engine Overhaul / change components

3. Remove the piston cooling nozzle (1).

Remove the big end bearing cap and bearing
shells (2).
Press the piston up so far that the piston rings
come above the edge of the cylinder liner. (Use a
hammer handle or other wooden object.)
Lift the piston and con rod out.

WARNING! Faulty piston cooling will cause the

pistons to seize.
If you suspect that the piston cooling nozzle
may be damaged or deformed, it must be re-
placed. This also applies to new nozzles. Al-
ways check that the piston cooling nozzle is
correctly located in the hole in the engine block
and that the fixing plate rests flat against the en-
gine block.

If the piston cooling nozzle is not correctly in-

stalled, there is a risk that the engine will imme-
diately seize when loaded.

4. Mark the position of the cylinder liner in the block.

Install the tools on the cylinder head, please refer
to the illustration. Pull the cylinder liner out.
5. Remove all seal rings (3 pcs.) from the engine
block.

95
Group 21 Engine Overhaul / change components

Cylinder liners, installation

Special tools:
Holder, dial gauge ......................................... 9992479
Press tool ..................................................... 9996966
Other special equipment:
Dial gauge ..................................................... 9989876

1. Make sure that the old seals in the engine block

have been removed, and that the sealing surfaces
are carefully cleaned. Use a brass brush and
cleaning fluid no. 1161440-1.
NOTE! Scraping tools must not be used.
2. Install the cylinder liner without seal rings and
screw it down with two clamping tools no.
9996966.

3. Install tools nos. 9992479 and 9999876 as in the

figure. Measure the cylinder liner height at four
places and calculate the thickness of the adjust-
ment shims. Aim to use the least possible num-
ber of shims.
NOTE! Make sure that measurements are always
done on the highest point of the sealing surface.
For sealing surface height, please refer to “Tech-
nical Data”. Mark the position of the liner against
the engine block so that it is put in the correct po-
sition during installation.

4. Take out the cylinder liner and make sure that the
liner and any shims are kept together.

96
Group 21 Engine Overhaul / change components

5. Lubricate the seal rings with the lubricant included

in the ring package.
NOTE! The purple ring must be put in the lowest
groove in the engine block.

6. If shims are used, the sealant must be put on the

liner shelf in the engine block.
NOTE! No sealant must be put between the shims
and the liner collar.
Apply a thin, even line of sealant part no.
1161231-4.
NOTE! The line of sealant must not be larger than
0.8 mm.

7. After application of the sealant, the cylinder liner

must be installed within 20 minutes.

8. Carefully press the cylinder liner down into the en-

gine block. Install press tools no. 9996966 to lock
the cylinder liner in the engine block.
NOTE! Always install press tool no. 9996966 on the
cylinder liners, to ensure that the sealant hardens in
the correct position.

97
Group 21 Engine Overhaul / change components

Pistons, change
Special tools:
Mandrel ......................................................... 9991801
Mandrel ......................................................... 9992031
Piston ring compressor ................................. 9998531

1. Remove the circlips on the old piston and tap the

gudgeon pin out with tool nos. 9991801 and
9992013. Remove the con rod.

2. Remove one of the circlips from the new piston.

3. Oil the gudgeon pin, the piston bearing seat and

the con rod bearing with engine oil.

4. Install the con rod so that the arrow on the piston

and the con rod’s “Front” marking face the same
way. Press the gudgeon pin in with mandrel
9992013 and extension 9991801.
NOTE! It should be easy to press the gudgeon pin in,
it must not be driven in.

5. Install the other circlip.

6. Check that the piston’s upper and lower sections

can move freely in relation to each other and that
the gudgeon pin does not move stiffly in the gud-
geon pin bush.

98
Group 21 Engine Overhaul / change components

7. Install the piston rings. Use piston ring pliers. The

piston ring openings must be evenly spaced in re-
lation to each other.
The opening in the oil scraper ring must be dia-
metrically opposite the opening in the spring un-
derneath.
NOTE! Both the upper piston rings are marked with
letters or dots. The markings must face upwards.
The oil scraper ring is symmetrical and can face either
way.

8. Lubricate the piston and piston rings with engine

oil. Check that the piston ring openings are dis-
placed in relation to each other.

9. Install the piston together with the con rod.

NOTE! The con rods must be re-installed in their origi-
nal positions. The arrow on the pistons and the
“FRONT” marking on the con rod must face forwards.
Use piston ring compressor 9998531.
Temporarily remove the press tools when the pis-
ton is installed. Put the press tools back when the
piston is in place.

10. Oil the bearing journal and bearing shells with en-
gine oil. Install the big end bearing shells. Check
that they are correctly aligned in the con rods and
bearing caps.
Install the big end bearing caps in accordance
with the markings, and tighten to the specified
torque.

11. Clean the piston cooling nozzle and check that it

is undamaged. Install the nozzle and tighten to
the specified torque.
NOTE! Make sure that the nozzle is aimed at the cut-
out in the piston.

99
Group 21 Engine Overhaul / change components

Camshaft, inspection and

overhaul
The camshaft is induction hardened.

Inspection
Inspect the camshaft very carefully to avoid unneces-
sary renovation.
The following applies when the need for renovation is
checked:
A. Clean the camshaft carefully. Measure the bearing
journals’ out-of-round, wear and taper.
Please refer to “Technical Data TAD1250VE,
TAD1251VE, TAD1252VE”.

B. Check whether there is any surface damage on the

bearing journals. If there is any damage on the sur-
face layer, the shaft must be re-ground. Please refer
to “Camshaft, wear check”.

C. Measure lengthwise crookedness in the camshaft

(runout).
Put the shaft on a pair of V-blocks under no.1 and
no.7 bearing journals, or set the camshaft up between
pins.
Measurement should be done on the 4:th bearing.
Please refer to the “Technical Data” chapter for per-
missible values.
It is not permissible to straighten the camshaft.

D. A crack test must be done before and after any

grinding. Magnetic powder testing is used for this test,
i.e. fluorescent powder which is viewed under ultra-vi-
olet light.

100
Group 21 Engine Overhaul / change components

Renovation
1. Inspection as in: A–D

2. Grinding to undersize dimension as specified.

When grinding is done, it is important that fillet ra-
dii and transitions from fillet radii are kept within
the specified dimensions.

IMPORTANT! Grinding of the center main bear-

ing requires special attention to dimension “A”,
please refer to “Width of thrust bearing journal”
in the “Technical Data” chapter.

3. If sharp edges are formed at the oil duct inlet

holes during grinding, the edges must be removed
with a small grindstone or emery cloth.

4. Check that there are no grinding burns on the

shaft.

5. Check lengthwise crookedness of the shaft

(runout), please refer to item C.

6. Do the crack test, please refer to item D.

7. Lapping the bearing journals. Check that the sur-

face finish requirements for bearing journals and
radii has been complied with, please refer to
“Technical data TAD1250VE, TAD1251VE,
TAD1252VE”.

8. After grinding, any grinding swarf and contamina-

tion must be carefully cleaned off the shaft, in-
cluding the oil ducts. The camshaft is equipped
with tapped plugs, for effective cleaning of all oil
ducts. The plugs must be removed during clean-
ing and put back afterwards.

101
Group 21 Engine Overhaul / change components

Camshaft, wear check

Rocker arm bridge removed

Put a steel ruler across the camshaft lobes, parallel

with the camshaft axis, to check whether the cam pro-
files have been worn.
Measure the wear with a feeler gauge or wire gauge.
Alternatively, a digital caliper gauge can be used.
Compare the measured values with those specified in
“Technical Data”.

Guidelines for replacement

In normal conditions, un-evenness may occur on the
camshaft lobes in the engine. This does not mean
that the camshaft has to be changed. These marks do
not have any negative influence on either engine per-
formance or durability of the engine and its compo-
nents.
Examples are shown below, of acceptable and not ac-
ceptable wear.

Acceptable wear. Not acceptable wear.

The camshaft does not need to be changed. NOTE! The camshaft and associated rocker arms
must be changed.

102
Group 21 Engine Overhaul / change components

Bearing housing for camshaft,

change

The production-installed bearing housings are ma-

chined together with the cylinder head, and can there-
fore not be moved from one cylinder head to another
one.
If a bearing housing is damaged, a replacement hous-
ing can be installed. All bearing housings must
then be changed, so that the bearing housing po-
sitions can be aligned.
The holes in the replacement housings are oval, which
allows the center bearing housings to be adjusted radi-
ally, and the front and rear housings to be adjusted
axially.
If the cylinder head is already equipped with replace-
ment housings, a damaged housing can be changed
without needing to change the other housings.

Replacement housings can be recognized since they

have oval holes for the guide sleeves.
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 have been removed.

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Group 21 Engine Overhaul / change components

Camshaft, installation

Special tools:
Lifting device ................................................. 9990185
Turning tool ................................................... 9993590
Lifting yoke ................................................... 9998264
Holder ......................................................... 88880003

1. Install new camshaft bearing shells in the bearing

supports and caps as necessary. Make sure that
bearing shells of the correct dimensions are in-
stalled, and that they are correctly located in their
seats.

2. Lubricate the bearing surfaces with engine oil.

3. Carefully lift the new camshaft into place with lift-

ing brace 9998264.

WARNING! Please note that the camshaft lobes

are extremely sharp.

WARNING! At least two people should help to

remove the camshaft, to avoid personal injury
and material damage, if a lifting device is not
available. The camshaft weighs about 35 kg.

4. Install the bearing caps on each bearing support.

Install the screws but do not torque them.
NOTE! Pleas refer to screw positioning on the bearing
cap, furthest right. The other screws are installed as
on the cap on the left.

6. Torque as in the figure.

104
Group 21 Engine Overhaul / change components

5. Install screws (M10 x 90, 7pcs.) in the holes for

the rocker arm bridge that do not have guide
sleeves.
Tighten these screws to M10 standard torque.

NOTE! Torque one bearing cap at a time and make

sure that the camshaft can be turned round easily. If
the camshaft is stiff to turn, check the last tightened
bearing cap.

7. Turn the flywheel with turning tool 9993590 until

the 0° marking is centered against the arrow.
NOTE! Do not forget to remove turning tool 9993590
from the flywheel housing and put the covers back.

105
Group 21 Engine Overhaul / change components

8. Check that the marking for top dead center (TDC)

on the camshaft is between the markings on the
bearing cap.

9. Install the camshaft gear and use sockets to be

able to tighten the screws properly.

10. Check or adjust the gear flank clearance in accor-

dance with the instructions under the “Timing gear
wheel, change” instructions.

11. Install the toothed wheel and torque it in accor-

dance with the tightening schedule in the figure.

IMPORTANT! If there is any damage to, or de-

formation of the toothed wheel or any of the
teeth on the toothed wheel, the toothed wheel
must be changed. The same applies if any of
the holes for the toothed wheel fixing screws is
damaged.

106
Group 21 Engine Overhaul / change components

12. Oil the valve yoke and camshaft lobes with en-
gine oil. Lift the rocker arm bridge into place with
9990185. Check that the valve yokes and rockers
are correctly aligned with each other.
NOTE! Loosen all adjustment screws for valves and
unit injectors before the rocker arm bridge is installed.
NOTE! The marks on the tool indicates the fastening
points for the rocker arm onto the engine.

WARNING! At least two people should help to

install the rocker arm bridge, to avoid personal
injury and material damage, if a lifting device is
not available. The rocker arm bridge weighs
about 27 kg.

13. Install and tighten the rocker arm bridge screws

by hand.
Torque the screws on the rocker arm bridge and
camshaft bearing caps in accordance with the
tightening schedule. Please refer to “Cylinder
head, installation”.

107
Group 21 Engine Overhaul / change components

Crankshaft, inspection and

overhaul
The crankshaft is induction hardened.

Inspection
Inspect the crankshaft very carefully to avoid unnec-
essary renovation.
The following applies when the need for renovation is
checked:
A. Clean the crankshaft carefully. Measure the bear-
ing journals’ out-of-round, wear and taper.
Please refer to “Technical Data TAD1250VE,
TAD1251VE, TAD1252VE”.

B. Check whether there is any surface damage on the

bearing journals. If there is any damage on the sur-
face layer, the shaft must be re-ground.

C. Measure lengthwise crookedness in the crankshaft

(runout).
Put the shaft on a pair of V-block under no.1 and no.7
main bearing journals or set the crankshaft up be-
tween pins.
Measurement should be done on the 4:th main bear-
ing.
Please refer to the “Technical Data” chapter for maxi-
mum permissible values,.
It is not permissible to straighten the crankshaft.

D. A crack test must be done before and after any

grinding. Magnetic powder testing is used for this test,
i.e. fluorescent powder which is viewed under ultra-vi-
olet light.

108
Group 21 Engine Overhaul / change components

Renovation
1. Inspection as in: A–D

2. Grinding to undersize dimension as specified.

When grinding is done, it is important that fillet ra-
dii and transitions from fillet radii are kept within
the specified dimensions.

IMPORTANT! Grinding of the center main bear-

ing requires special attention to “dimension”A”,
please refer to “Width of thrust bearing journal”
in the “Technical Data” chapter.

3. If sharp edges are formed at the oil duct inlet

holes during grinding, the edges must be removed
with a small grindstone or emery cloth.

4. Check that there are no grinding burns on the

shaft.

5. Check lengthwise crookedness of the shaft

(runout), please refer to item C.

6. Do the crack test, please refer to item D.

7. Lapping the bearing journals. Check that the sur-

face finish requirements for bearing journals and
radii has been complied with, please refer to
“Technical data TAD1250VE, TAD1251VE,
TAD1252VE”.

8. After grinding, any grinding swarf and contamina-

tion must be carefully cleaned off the shaft, in-
cluding the oil ducts. The crankshaft is equipped
with tapped plugs, for effective cleaning of all oil
ducts. The plugs must be removed during clean-
ing and put back afterwards.

109
Group 21 Engine Overhaul / change components

Main bearings, change (all)

This method describes how the main bearings are
changed with the crankshaft left in the engine.
Oil pan removed.

Special tools:
Turning tool ................................................... 9993590

1. Install turning tool 9993590.

2. Remove the oil scavenge and supply pipes.
NOTE! The oil pump does not need to be removed.
3. Remove one main bearing cap at a time.

4. Remove the upper main bearing shell by putting a

pin in the crankshaft oil hole and roll the bearing
shell out by turning the crankshaft in the direction
of rotation with turning tool 9993590.

5. Clean and check the bearing seat, bearing cap,

shaft journal and bearing shell.
If the bearing has seized, the reason must be dis-
covered before a new bearing is installed.

110
Group 21 Engine Overhaul / change components

6. Check that the correct bearing dimension is used

when the bearing shells are changed.
NOTE! If there is any doubt, check the oversize di-
mensions used in the specification. Please refer to
“Technical Data”.

7. Oil the bearing journal and the new bearing shells.

8. The upper bearing shell is installed by rotating the

crankshaft with tool no. 9993590, against the di-
rection of rotation, with the pin in the oil hole.
NOTE! Check that the pressed out heel in the bearing
shell is correctly aligned in the bearing seat cutout.
Be careful to make sure that the upper bearing
shells (the ones that should be put in the engine
block) are the ones with oil holes.

9. Install the main bearing cap together with the low-

er bearing shell.
Torque in two stages.

10. Change the other bearing shells, one a time, in

the same way as the first one. After each bearing
shell is changed, check that the crankshaft does
not bind, by rotating it with turning tool no.
9993590.

11. Check the crankshaft end float and change the

thrust washers if the end float is too large, or the
washers are damaged.
NOTE! Measure the end float with a dial gauge. For
end float, please refer to “Technical Data”.

12. The crankshaft thrust bearing is located in the

center main bearing.
NOTE! There is a number of oversize thrust washers.
Please refer to “Technical Data”.

111
Group 21 Short block Overhaul / change components

13. Use a small plastic- or wood pin to remove the

thrust washers from the engine block bearing
seat.
NOTE! The thrust washers are located in grooves in
the main bearing cap.

14. When all main bearing caps have been torqued to

the specified values, do a check of the crankshaft
end float. Please refer to “Technical data”.

15. Install the oil suction pipe and oil supply pipe.
Please refer to the instructions in the workshop
manual.

16. Remove turning tool 9993590 from the flywheel

housing and put the covers back.

112
Group 21 Short block Overhaul / change components

Big end bearings, change (all)

Special tools:
Turning tool ................................................... 9993590

Oil pan removed.

1. Install turning tool 9993590 and turn the flywheel

until the bearing caps on con rods 1 and 6 come
into position to remove the screws.
2. Remove the bearing caps on con rods 1 and 6.
Remove the bearing shells and clean the bearing
seat on the con rod and bearing cap.
NOTE! The bearing caps are numbered for each con
rod.
3. Check the bearing journals and bearing caps.
If a bearing has seized, the reason must be dis-
covered before new bearing shells are installed.
4. Check the measurements of the bearing journal
for taper and ovality. If any of the values exceed
the maximum permissible values, the crankshaft
must be removed and renovated or changed.
Please refer to “Technical data” for the tolerances.
Also check if the crankshaft has standard- or un-
derdimension, if you are not sure.

5. Install new bearing shells and check that the cor-

rect bearing dimension has been used. Make sure
that the bearing shell guide pin is correctly located
in the con rod cutout, and that the oil holes in the
con rod and bearing shell line up.
6. Oil the bearing shells and big end bearing jour-
nals. Put the bearing caps in place and torque the
screws to 275±12 Nm.
7. Turn the flywheel until con rod nos. 5 and 2 come
into place, and repeat items 2-6.
8. Turn the flywheel until con rod nos. 3 and 4 come
into place, and repeat items 2-6.
9. Check that no big end bearing binds.
10. Remove turning tool 9993590 from the flywheel
housing and put the covers back.

113
Group 21 Short block Overhaul / change components

Flywheel bearing, change

Special tools:
Handle .......................................................... 9991801
Puller ............................................................ 9986173
Puller ............................................................ 9986179
Mandrel ......................................................... 9992269

1. Measure the bearing position on the flywheel.

2. Remove the old bearing with the aid of tools nos.

9986173 and 9986179.

3. Drive the new bearing into the measured position,

using tools nos. 9991801 and 9992269.

114
Group 21 Short block Overhaul / change components

Flywheel, change
Special tools:
Lifting lug ...................................................... 9998629

1. Remove the flywheel sensor.

2. Remove the flywheel.

3. Install 2 lifting lugs no. 9998629 and lift the fly-

wheel away with a lifting sling (see figure) which is
threaded through the lifting lugs.
NOTE! The flywheel weighs about 60 kg.
4. Clean the mating face of the crankshaft against
the flywheel very carefully.
5. Clean the mating face of the flywheel against the
crankshaft very carefully and check that the sur-
face where the sensor grooves are located is
completely free from contamination.
6. Check that the flywheel guide pin in the crank-
shaft is in position and is undamaged.

115
Group 21 Short block Overhaul / change components

7. Install 2 lifting lugs no. 9998629 and lift the new

flywheel with a lifting sling (see figure) which is
threaded through the lifting lugs.
NOTE! The flywheel weighs about 60 kg.

8. Install the flywheel and torque the screws to the

value specified on the torque table in the “Techni-
cal Data”.

9. Turn the flywheel round until one tooth on the fly-

wheel is exactly centered on the sensor hole in
the flywheel housing.
Install the flywheel sensor and measure the dis-
tance A between the flywheel tip and the flywheel.
Permissible clearance A: 0.6 ±0.4 mm
The clearance between the sensor and the fly-
wheel must be within the specified tolerance, to
get the correct signal from the flywheel sensor.
Adjust the sensor with spacers.

A = clearance mm
B = adjustment shim

116
Group 21 Short block Overhaul / change components

Gear ring, change

21687
Flywheel removed.

1. Drill 1-2 holes in a gap between two teeth on the

gear ring.
Split the gear ring at the drilled hole, using a cold
chisel. Lift the gear ring away from the flywheel.

2. Brush the flywheel bed clean with a steel wire

brush.

3. Heat the new gear ring up to 180-200°C with a

welding torch or in an oven. The gear ring must be
evenly heated. Be careful not to heat the gear ring
up too far and anneal it.
Check the heat by polishing the ring bright at sev-
eral places. Stop heating when the polished sur-
faces have become blued.

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.

117
Group 21 Short block Overhaul / change components

Flywheel, indication
Special tools:
Turning tool ................................................... 9999696

Pressure plate/clutch removed

1. Put dial gauge 9989876 with magnetic holder
9999696 with the measurement tip on the fly-
wheel.

2. Remove the cover from the engine’s flywheel

housing. Install turning tool 9993590.

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 on a mea-
surement radius of 150 mm.
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.

4. Remove turning tool 9993590 and install the cov-

er.

118
Group 21 Short block Overhaul / change components

Crankshaft seal, front, change

21672
Special tools:
Alt 1
Cone ............................................................. 9990118
Mandrel ......................................................... 9990112
Mandrel ......................................................... 9992000
Alt 2
Slide hammer ................................................ 9996400
Puller ............................................................ 9990192
Cone ............................................................. 9990118
Mandrel ......................................................... 9990112
Mandrel ......................................................... 9992000

Alternative 1
1. Remove the crankshaft pulley and vibration damp-
er (12 screws).

2. Drill two ∅ 3.5 mm holes in the seal, using the

guide holes in mandrel 9990112. Wipe grease on
the drill to prevent dirt from getting into the en-
gine.

3. Screw two 5 mm self-tapping screws into the

seal.

4. Screw in two M10x60 screws with long thread into

the mandrel and pull the seal out. Remove the
seal and screws from the tool.

119
Group 21 Short block Overhaul / change components

5. Clean the seal seat in the housing and the mating

surface on the crankshaft.

6. Check that the tools are undamaged, to prevent

damage to the seal.

7. Install cone 9990118 on the tool.

NOTE! No lubrication. This should be installed com-

pletely dry.

8. Install the seal on tool 9990112 via 9990118.

Remove tool 9990118.

9. Then install extension 9992000 on 9990112 and

carefully tap the new seal in until the tool bottoms
against the crankshaft.
Remove the tool and check that the seal is cor-
rectly installed.

10. Install the vibration damper and pulley.

Tighten it as in the specification in “Technical
data”.

Alternative 2

1. Drive the seal out with extractor 9990192 together

with slide hammer 9996400.

2. Install the new seal. Please refer to items 6-11 in

“Alternative 1”.

120
Group 21 Short block Overhaul / change components

Crankcase seal rear, change

Special tools:
Handle .......................................................... 9992000
Mandrel ......................................................... 9998238

1. Install tool no. 9998238 in the seal by turning the

tool at the same time as it is pressed in.
Drill 2 Ø 4 mm holes in the metal edge of the
seal, using the holes in the tool as drill templates.

2. Screw 2 self-tapping screws (M5x35) into the

seal, through the tool holes. Screw in two screws
(M10x60) with long thread into the tapped holes in
the tool and pull the seal out.

3. Remove the seal and screws from the tool.

4. Clean the seal seat in the flywheel housing and

the mating surface on the crankshaft.

121
Group 21 Short block Overhaul / change components

5. Wipe sealant, part no. 1161231-4 onto the edge of

the new seal and oil the seal lip.
Carefully tap in the new seal with tool no. 9998238
and handle no. 9992000 until the tool bottoms
against the flywheel housing.

122
Group 21 Short block Overhaul / change components

Con rod, inspection

Important to remember when removing/installing
a “split” con rod.
Installing a NEW con rod:
Carefully fix the con rod in a vise with soft jaw pads.
Undo the con rod screws a few turns and carefully
tap the bearing cap with a plastic faced hammer until
it loosens.
The parting line can be difficult to find when the con
rod is assembled.
When the cap is separated from the con rod, it may
occur that a chip is missing or comes loose. This
does not affect the function of the con rod at all.
Handle the con rod and bearing cap carefully. If any
dents occur on the parting line, this can affect
strength after torquing.

IMPORTANT! If the con rod or bearing cap are

damaged, change the con rod.

Gudgeon pin bushing,

check measurement
1. Check the con rods for cracking, straightness and
twist before considering changing the gudgeon pin
bush. Discard the connecting rod if it is cracked,
bent or twisted.
When the gudgeon pin bush has been changed,
the bush must be machined (trapezoid shaped
gudgeon pin end).
When the clearance is correct, an oiled gudgeon
pin should slowly slide through the bush under its
2 3 own weight.

IMPORTANT! Please refer to “Technical data”

for maximum permissible twist and crooked-
ness.

2. Use a new gudgeon pin and measure the straight-

ness of the con rod, using a fixture.

3. Measure con rod twist.

123
Group 21 Short block Overhaul / change components

Valves, removing

Special tools:
Fixture .......................................................... 9990160
Hydraulic cylinder .......................................... 9996161
Press tool ..................................................... 9990176
Adapter ......................................................... 9996159
Mandrel, inlet ................................................ 9998246
Mandrel, exhaust .......................................... 9990174
Hydraulic pump ............................................. 9996222
or ............................................................... 9992670
Valve spring compressor ............................... 9990210

Cylinder head removed.

Work is made easier if the cylinder head is fixed in an

equipment stand with fixture no. 9990160. Use four
M8x25 screws.
NOTE! It is very 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
1. Install hydraulic cylinder 9996161 in press tool
9990176.

2. Install pin 9996159 and mandrel 9998246 (inlet) or

9990174 (exhaust) on the hydraulic cylinder. Put
the tool in the holes for the cylinder head fixing
screws.
Tighten the nuts of the tool.

3. Connect a hydraulic pump, 9996222 (or 9992670).

4. Press the valve spring washer down and remove

the collets.

NOTE! Check that the tool does not damage the unit
injector connector, if the injector is left in place.

NOTE! Put the valves and springs in a marked stand,

to make it easier to put 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.

124
Group 21 Short block Overhaul / change components

Alternative 2
1. Put the cylinder head down on a soft, clean sur-
face. Make sure that the cylinder head is not
damaged when the valves are to be removed.

2. Install press tool 9990210 in the unit injector hole.

Fix the tool in the screw hole for the unit injector
fixing yoke, M10 x 30.

3. Put 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 re-
moved.
NOTE! Put the valves and springs in a marked stand,
to make it easier to put 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.

125
Group 21 Short block Overhaul / change components

Valves, installation
Special tools:
Hydraulic cylinder .......................................... 9996161
Press tool ..................................................... 9990176
Adapter ......................................................... 9996159
Mandrel, inlet ................................................ 9998246
Mandrel, exhaust .......................................... 9990174
Hydraulic pump ............................................. 9992670
or ............................................................... 9996222
Valve spring compressor ............................... 9990210
Guide sleeve ................................................. 9998335

1. Oil the valve stems and install the valves.

Oil the oil seals.

2. Install tool no. 9998335 on the valve stem and

press the new oil seals down over the valve
guides.
NOTE! Check that the oil seals are pressed down
properly.

3. Install the guide pins for the valve yokes.

Install the springs and valve spring washers.

Alternative 1
4. Carefully press down the valve spring washer and
install the collets. Use 9990176 together with hy-
draulic cylinder 9996161, pin 9996159 and man-
drel 9998246 (inlet) or 9990174 (exhaust), in the
same way as for disassembly.

Alternative 2
5. Alternatively, tool no. 99900210 can be used in-
stead of the hydraulic cylinder, in the same way
as for disassembly.

126
Group 21 Short block Overhaul / change components

Valve seat, change

Cylinder head and valves removed

1. The valve seats must be changed if full sealing

can not be obtained, or if distance “A” exceeds
the value given in the specification. Please refer
to the “Technical Data” chapter.

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 stop any weld spatter
from fastening.

3. Place a suitable socket over the valve/valve

guide and carefully tap the valve seat out.
NOTE! Be careful not to damage the cylinder head.
NOTE! Wear goggles.

127
Group 21 Short block Overhaul / change components

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. Investigate whether a standard or
oversize dimension valve seat should be used.
Do any machining needed on the valve seat bed.
Please refer to the “Technical Data” chapter.

6. Cool the seat in carbon dioxide snow between –

60°C and –70°C and warm the cylinder head by
flushing with hot water, or some other method.
Install the valve seat with a mandrel.
NOTE! Align the seat with the seat angle facing the
tool.
Check sealing against the valve.

128
Group 21 Short block Overhaul / change components

Valve guides, inspection

Special tools:
Dial gauge ..................................................... 9989876
Magnetic stand ............................................. 9999696

Cylinder head, removed

1. Remove the valve stem seals from the valve

guides.

2. Put the cylinder head on the bench with the valve

discs facing upwards.

IMPORTANT! The cylinder head must not be

laid down so that its entire weight bears on the
valve guides.

3. Put a new valve in the valve guide, with the valve

spindle end level with the edge of the valve guide.
Use a suitable counterhold under the valve stem.

4. Place dial gauge 9989876 with magnetic stand

9999696, so that the tip of the dial gauge rests on
the edge of the valve.
Move the valve sideways. Read off the value on
the dial gauge.

5. Check all valve guides. If the measurement val-

ues exceed the values noted in the specifications,
the valve guide must be changed. Please refer to
the “Technical Data” chapter.

129
Group 21 Short block Overhaul / change components

Valve guides, replacing

Special tools:
Adapter ......................................................... 9996159
Hydraulic cylinder .......................................... 9996161
Press tool ..................................................... 9990176
Mandrel, assembly ........................................ 9990183
Mandrel, for disassembly .............................. 9990184
Hydraulic pump ............................................. 9996222

Cylinder head, removed

NOTE! If the valve seats are also going to be
changed, this must be done before the valve guides
are removed.

IMPORTANT! Use protective goggles when

pressing the valve guides in or out.

Removal
1. Install hydraulic cylinder 9996161 in tool 9990176.

2. Install pin 9996159 in the hydraulic cylinder and

press the valve guide out with mandrel 9990184
and hydraulic pump 9996222.
Press the other valve guides out in the same way.

Fitting
3. Oil the valve guides on the outside with engine oil
before installation.

4. Cool the valve guides.

Press the valve guide in with tool no. 9990183.
Press until the tool bottoms against the cylinder
head plane.

IMPORTANT! After valve guides have been

changed, the cylinder head has to be cleaned to
prevent particles from coming into the fuel and
oil ducts. Contamination can cause failure or
malfunction of the unit injectors.

130
Group 21 Short block Overhaul / change components

Valve stem seals, change

Special tools:
Valve spring compressor ............................... 9990210
Turning tool ................................................... 9993590
Mandrel ......................................................... 9998335

1. Disconnect all current to the engine, by switching

off the main switch.

2. Remove the unit injectors, please refer to “Unit in-

jector, changing”.

3. NOTE! The piston must be at its upper dead cen-

tre when the valve are undone. This is to prevent
the valves from falling down into the cylinder. Use
turning tool 9993590.

4. Compress the valve springs for no. 1 cylinder.

Use tool no. 9990210.

5. Remove the collets, valves washers and valve

springs.

6. Remove the old valve spring seals.

7. Lubricate the valve stem with engine oil.

Install mandrel no. 9998335 on the valve stem.
Thread the new seal on and put it over the man-
drel.

8. Install valve springs, valve spring washers and

collets. Carefully tap with a plastic faced mallet to
put the collets in the correct positions.

131
Group 21 Short block Overhaul / change components

9. Transfer the valve spring compressor to no. 6 cyl-

inder and repeat the tasks as above. Then crank
the engine so that no.3 and no.4 cylinder are at
upper dead center.
Repeat the tasks. Then continue with cylinders 2
and 5.
NOTE! The piston must be at its upper dead centre
when the valve are undone. This is to prevent the
valves from falling down into the cylinder. Use turning
tool 9993590.

10. Install the unit injectors, please refer to “Unit in-

jector, changing”.

11. Adjust the valves and unit injectors, please refer

to “Valves and unit injectors, adjustment”.

12. Vent the fuel system. Do a function and leakage

check.

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Group 21 Short block Overhaul / change components

Valve seats, grinding

NOTE! Spare part valve seats are already machined,
and do not need further grinding.

30° 1. Before the valve seats are ground, the valve

guides should be checked and changed if the
29.5° wear tolerances have been exceeded.

2. When the valve seats are ground, 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.
Inlet valve

3. Grind new seats down so far that the dimension

between the cylinder head plane and the valve
disc surface, measured with a new valve, is in ac-
cordance with the specification.
45°
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.
44.5°

Exhaust valve

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Group 21 Short block Overhaul / change components

Valves, grinding
Valve sealing angles:
Inlet .................................................................. 29.5°
Exhaust ............................................................ 44.5°

A 1. The sealing surface should be ground as little as

possible, just enough to grind away all damage.

2. Check dimension (A) on the valve disc edge. If

the dimension is less than the wear tolerance, the
valve must be changed.
Inlet (new valve) Min 1.8 mm
wear limit 1.4 mm
Exhaust (new valve) Min 1.6 mm
wear limit 1.2 mm

Always change a valve with a bent valve stem.

3. Check valve sealing with marker dye.

If there is any leakage, grind the valve seat again,
but not the valve, then do a new check.

134
Group 21 Short block Overhaul / change components

Cylinder head, pressure

testing
Special tools:
Pressure gauge ............................................. 9996662
Fixing, cylinder head ..................................... 9998258
Seal washer .................................................. 9998266
Crowbar ......................................................... 9998511
Mandrel ......................................................... 9998619

Other special equipment:

Seal washers ................................................ 9998666
Junction washers .......................................... 9998668
Equipment stand ........................................... 9996485
Puller ............................................................ 9996173
(9998666 and 9998668 include: 9809696, 9809697,
9809698, 9809699, 9809700, 9809701)

Check the pressure test unit, please refer to “Check-

ing the pressure test device”.
1. Install the cylinder head in an equipment stand.

2. Remove the valve yokes.

NOTE! Mark the yokes so they can be put back in the
same positions.

3. Remove the exhaust manifold. Please refer to

“Group 25, Exhaust manifold gaskets, changing”.

4. Remove the thermostat housing and thermostat.

Please refer to “Group 26, Thermostat, changing”.

5. Remove the cylinder head from the equipment

stand.

6. Clean and clean the cylinder head carefully.

7. Install the cylinder head in the equipment stand.

135
Group 21 Short block Overhaul / change components

8. Clean the mating surfaces of the cylinder head.

Install seal washers 9998266 and 980 9696 on the
cylinder head, using the cylinder head screws (13
screws and 13 x M16 nuts).
Install seal washer 980 9697 with plug 980 9701
on the thermostat housing seat.
Install seal washer 980 9699 in the hole for the
temperature sensor (at the rear of the cylinder
head).
If the area where the thermostat housing is in-
stalled is to be leakage tested, install seal washer
980 9698 and clamp 980 9700.
Remove the pipe unions on the cylinder head and
install plugs A and B in the holes (please refer to
the figure).

11. Check that the knob on reduction valve (A) is

screwed out.

12. Install the hose from the pressure gauge to the

junction nipple (980 9697).

13. Remove the cylinder head from the equipment

stand.

14. Put the cylinder head in a water bath (70° C).

15. Connect a leakage test unit to the compressed air

system.

16. Open the compressed air system and set reduc-

tion valve (A) so that a pressure of 50 kPa is
shown on the pressure gauge. Retain the pressure
for 1 minute.

17. Raise the pressure to 150 kPa. Lock the reduction

valve knob with the locking ring. Close the tap for
the compressed air system.
Check after one or two minutes that the air pres-
sure has not dropped and that no air bubbles
come out of the cylinder head.

18. Empty the compressed air from the cylinder head

by undoing the reduction valve (A).

136
Group 21 Short block Overhaul / change components

19. Transfer the test equipment to the junction nipple

on the thermostat housing.
Do the leakage test as in stages 16 and 17.

20. Take the cylinder head up out of the water bath.

21. Install the cylinder head in the equipment stand.

22. Dry the cylinder head with compressed air. Be ex-

tra careful to ensure that the fuel ducts are clean
and dry.
NOTE! Dirt or foreign bodies in the fuel ducts can
cause failure in the unit injectors.

23. Remove all seal washers.

24. Remove the plugs for the thermostat housing and

install the pipe unions on the cylinder head.

25. Install the exhaust manifold. Please refer to

“Group 25, Exhaust manifold gaskets, changing”.

26. Remove the seal for the piston thermostat in the

cylinder head. Use a suitable punch.

137
Group 21 Short block Overhaul / change components

27. Clean all sealing surfaces and install a new seal

on mandrel 9998619.
NOTE! Align the seal ring with the wide edge against
the land on mandrel 9998619.
Press mandrel 9998619 into the cylinder head
with crowbar 9998511, until mandrel 9998619 bot-
toms in the cylinder head.
Remove the mandrel and check that the seal is
correctly installed.

28. Check the seal on the piston thermostat, change

if necessary. Please refer to “Group 26, Piston
thermostat, changing”.

29. Install the new piston thermostat in the cylinder

housing.

30. Install the thermostat housing with new seals.

Torque the screws by hand.

31. Install a screw (M8 x 20) with nut, washer and

spacer sleeve between the heel on the exhaust
manifold and the machined surfaces on the ther-
mostat housing. Tighten the nut so that the
sleeve presses the thermostat housing against
the piston thermostat seal. Tighten the thermostat
housing as in the tightening schedule (see the il-
lustration). Remove the tension screw.

32. Install the last two screws on the exhaust mani-

fold.

33. Oil the shafts for the valve yokes and install
them.

34. Install the cylinder head, please refer to “Cylinder

head, installation”.

138
Group 21 Short block Overhaul / change components

Copper sleeve for unit injector,

change
Special tools:
Thread tap ..................................................... 9809667
Turning tool ................................................... 9993590
Protective sleeve .......................................... 9998251
Seal ring ....................................................... 9998250
Thread tap ..................................................... 9998252
Puller ............................................................ 9998253
Cleaning kit ................................................... 9998599
Injector sleeve expander ............................... 9998688

Unit injector removed

1. Drain the coolant using a hose, 9996049. Please

refer to “Cooling system, draining”.

2. Remove protective plug 9998581.

3. Install 2 seal rings, 9998250, to prevent dirt from

coming down into the fuel ducts when the copper
sleeve is removed.

NOTE! Ensure that the piston is in its lower position.

4. Grease the thread tap, 9809667, using grease to

prevent swarf from falling down into the cylinder.
Screw the thread tap at least 20 mm into the cop-
per sleeve, using tool no. 9998252.
NOTE! Use thread tap 9809667.

139
Group 21 Short block Overhaul / change components

5. Remove tool no. 9998252 and the thread tap.

6. Check that the pin 9809668 is installed on nipple

9998253.
Screw the tap onto threading tool 9998253 at
least 15 mm into the copper sleeve. Remove the
copper sleeve by turning the nut at the same time
as the pin is held tight.

7. Use cleaning kit 9998599 and an electric drill be-

fore the new copper sleeve is installed.
Install cleaning sleeve 999 8580 in the injector
well and fix it with the holder (the “ears” must be
cut off to get the tool to fit).
NOTE! Tool no. 9808580 must be used to prevent dirt
from coming down into the fuel duct.

8. Clean the cylinder head walls for the copper

sleeve with part no. 9808618.

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Group 21 Short block Overhaul / change components

9. Clean the copper sleeve seat with brush no.

9808614 together with the handle and holders.

10. Clean the cylinder head hole with brush no.

9808617.

11. Remove tool 980580.

12. Check that the piston is in its lower position in

the cylinder.
NOTE! This must be done so that tool no. 9998688
does not damage the piston because of its length.

13. Lubricate the new seal ring on the copper sleeve

with soapy water.

141
Group 21 Short block Overhaul / change components

14. Put the copper sleeve on tool no. 9998688

15. Oil the nose of tool no. 9998688. Lubricate be-

tween the nut and the tool.

16. Press carefully down on the copper sleeve so

that the mandrel locates against the fuel chamber
(edge) in the cylinder head. Check that the copper
sleeve “bottoms” in the cylinder head.
Install the unit injector yoke and tighten.

17. Spread the copper sleeve with the mandrel by

turning the nut at the same time as the spindle is
kept still, until the mandrel has been completely
pulled through.
NOTE! Once the copper sleeve has been installed,
follow the instructions for “tightening the unit injector
yoke” in “Technical Data”.

18. Remove seal rings 9998250.

19. Install the unit injector. Please refer to “Unit injec-

tor, change”.

20. Put the valve yoke back in accordance with the

marking.

21. Install the rocker arm bridge and check the clear-
ance of the valves and unit injectors.

22. Install the valve cover.

23. Fill up with coolant and check that no leakage oc-

curs.

142
Group 21 Short block Overhaul / change components

Timing grear, changing

IMPORTANT! Never turn the crankshaft or cam-
shaft when the timing gear wheels have been re-
moved. Pistons and valves might come into
contact with each other and be damaged.

Special tools:
Adapter ......................................................... 9992584
Hydraulic cylinder .......................................... 9992671
Turning tool ................................................... 9993590
Foot pump ..................................................... 9996222
Spindle .......................................................... 9996315
Adapter ......................................................... 9996626
Adapter ......................................................... 9996965
Crowbar ......................................................... 9998511
Puller ............................................................ 9998849
Dial gauge ..................................................... 9999683
Magnetic stand ............................................. 9999696

Oil pan, front engine mountings, valve cover, up-

per timing gear cover and coolant pump all re-
moved.

1. Gear, camshaft
2. Gear, compressor
3. Idler gear
4. Gear, coolant pump
5. Gear, crankshaft
6. Gear, lube oil pump
7. Idler gear
8. Gear, hydraulic pump
9. Idler gear Removing drives and pulleys
10. Gear for drive belts and fuel pump
11. Drive gear, servo pump
12. Nozzle, gear lubrication 1. Remove the outer vibration damper.
13. Idler wheel, adjustable

2. Remove the dust shield and holder for the crank-

shaft seal.

3. Remove the drive connection, alternator and fuel

pump.

4. Remove the seal and the two socket cap screws

from the flange. Use tool no. 9998849 and two
M12x60 screws.

5. Remove the lower timing gear cover.

WARNING! The timing gear cover is heavy.

This task requires two people.

6. Remove the inner vibration damper. Use tool no.

9998849 and two M12x60 screws.

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Group 21 Short block Overhaul / change components

7. Install turning tool 9993590.

8. Turn the flywheel until the piston in cylinder no. 1

is at top dead center 0º on the flywheel and the
camshaft marking (TDC) is between the markings
on the bearing cap.

9. Use turning tool 9993590 with a ratchet wrench to

stop the flywheel rotation. Lock the ratchet
wrench against the engine block.

144
Group 21 Short block Overhaul / change components

10. Remove the polygon hub. Use puller no. 9998849

and 66 x M10x60 mm screws.

11. Remove the toothed wheel.

12. Remove the camshaft drive gear (1) with a puller.

145
Group 21 Short block Overhaul / change components

The gear wheel numbering in the illustration refer

to the text
13. Remove the idler wheels (3) and (9) from the tim-
ing gear plate and the cylinder head idler wheel
(13).

14. Remove the crankshaft gear (5). Pull the gear off
with a suitable puller.

15. Remove the idler wheel (7).

16. Put a center punch mark in the center of an

M12x20 screw to locate the puller. Then put it in
the shaft for the lube oil pump drive (6). Pull the
shaft off with a puller.

146
Group 21 Short block Overhaul / change components

Cleaning, inspection

17. Clean the timing gear plate and the front of the
cylinder head.

NOTE! The timing gear plate should only be removed

if absolutely necessary.

18. Remove the lube oil nozzle from the timing gear
plate and check that the holes have not become
blocked. Put the lube oil nozzle back.

19. Check that the Woodruff key groove in the crank-

shaft is not damaged. Make sure that the Woo-
druff key is securely seated in the groove.

147
Group 21 Short block Overhaul / change components

Timing gear plate,

disassembly / assembly
Disassembly / assembly of the timing gear plate is
described in the Alt. method. 1.
NOTE! The timing gear plate should only be removed
if absolutely necessary!

New spare part engine blocks are supplied without the

timing gear plate. Method ALT. 2 describes installa-
tion of the timing gear plate on a new engine block.

Alternative 1

20. Install the two guide dowels 9998267 so that they

are fixed to the engine block through the timing
gear plate. Remove the timing gear plate. The
guide dowels should be left in place.

21. Install a 1 mm thick string of sealant, part number

1161231-4 to (1) the engine block. Apply a 2 mm
wide line of sealant all round the engine block (2)
and around the hole (3).

NOTE! The timing gear plate must be installed within

20 minutes, since the sealant hardens.

Sealant should be put 4 mm in from the edge of the engine block.

When no hole radius is specified, the sealant should be applied
with a radius of 8 mm from the center.

148
Group 21 Short block Overhaul / change components

22. Install the transmission plate, which is located by

the previously installed guide pins 9998267.
Toque to 34±4 Nm.

Alternative 2

23. Install the timing gear plate lightly in the new en-
gine block. Adjust the timing gear plate so that it
lines up with the lower edge of the engine block.
NOTE! Do not apply sealant at this point.

24. Install the two (fixed) idler wheels on the timing

gear plate.

25. Adjust the timing gear plate so as to give the

same gear flank clearance to the crankshaft gear
for both idler wheels. Install dial gauge 9999683 in
magnetic stand 9999696. Adjust and check until
there is the same gear flank clearance for both
idler wheels.

26. Tighten the timing gear plate with a few screws.

Install the two guide dowels 9998267 so that they
are fixed to the engine block through the timing
gear plate.

27. Remove the timing gear plate.

149
Group 21 Short block Overhaul / change components

28. Apply a 1 mm thick line of sealant no. 1161231-4

at (1) on the engine block. Apply a 2 mm wide line
of sealant all round the engine block (2) and
around the hole (3).

NOTE! The timing gear plate must be installed within

20 min since the sealant hardens.

Sealant should be put 4 mm in from the edge of the engine block.

When no hole radius is specified, the sealant should be applied
with a radius of 8 mm from the center.

29. Install the transmission plate, which is located by

the previously installed guide pins 9998267.
Torque as in the specification in “Technical data”.

150
Group 21 Short block Overhaul / change components

Installing the timing gear wheels

The gear wheel numbering in the illustration refers

to the text.

31. Install adapter 9996965 and spindle 9996315 in

the crankshaft nose.

32. NOTE! Warm the crankshaft gear to about 100°C.

Put the new, heated gear wheel (5) on the spindle.
Install adapter 9992584 and 9996626. Install hy-
draulic cylinder 9992671. Install the nut on the
spindle and tighten it. Connect foot pump 9996222
to the hydraulic cylinder and press the heated
crankshaft gear on.

151
Group 21 Short block Overhaul / change components

33. Heat up the lube oil pump gear to about 180°C

and tap it onto the lube oil pump with a plastic-
faced mallet.

34. Oil the plain bearing, install idler wheel (7) and
torque it to 34±4 Nm.
Oil the plain bearings for the idler wheels (3) and
(9). Install and torque to 15±3 Nm, then angle
tighten to 120° ±5°.
NOTE! Use new screws when re-installing the idler
wheels.

35. Install the adjustable idler wheel (13) on the cylin-

der head. Just tighten the screws by hand until
they bottom against the bearing shield.

36. Put the heated polygon hub on spindle 9996315.

Install adapter 9996626 and hydraulic cylinder
9992671. Install the nut on the spindle and con-
nect foot pump 9996222 to the hydraulic cylinder.
Press the polygon hub on.

NOTE! Heat the polygon hub up to about 100°C.

152
Group 21 Short block Overhaul / change components

37. Lock turning tool 9993590 to the engine block with

a ratchet wrench. Install the crankshaft screw to-
gether with the washer and torque to 645±25 Nm.

NOTE! The components must cool to room tempera-

ture before they are torqued.

38. Check that the flywheel marking 0° is centered on

the arrow on the flywheel housing.

39. Make sure that the marking for top dead center
(TDC) on the camshaft is between the markings
on the bearing cap.

40. Install the camshaft drive gear without the vibra-

tion damper. Use suitable sockets (please refer to
the figure) to be able to tighten the screws proper-
ly.

153
Group 21 Short block Overhaul / change components

41. Check that the camshaft gear is correctly in-

stalled by inserting a 7 mm pin into the hole
(please refer to the figure). Make sure that the pin
is between the markings on the camshaft drive.

42. Check the flank clearance of the adjustable idler

wheel in the two engagements A and B. Please
refer to the specification in “Technical Data”. The
flank clearance is checked with two feeler gaug-
es.

154
Group 21 Short block Overhaul / change components

The figure shows inspection with the timing gear

cover removed.
Checking is done through the inspection hole
when the lower timing gear cover is installed.

43. Adjust the flank clearance as follows: Undo the

adjustable idler gear screws.
Put two 0.10 mm feeler gauges in positions A and
B and turn the camshaft in the direction of the ar-
row.

44. Tighten the screws on the adjustable idler wheel

lightly and check that the two feeler gauges are
equally stiff to move. Then remove the feeler
gauges. Torque the adjustable gear wheel as in
the tightening schedule, please refer to “Technical
data”.

155
Group 21 Short block Overhaul / change components

Inspection method and dial gauge.

45. Install dial gauge 9999683 on the magnetic stand
9999696 and put the dial gauge tip against a tooth
on the adjustable idler wheel.
NOTE! The tip of the dial gauge must be at right
angles to the gear tooth.

46. Turn the adjustable idler wheel clockwise. Check

the idler wheel gear flank clearance by turning the
lower gear back and forwards. Read the value.

47. Move the dial gauge to the camshaft gear. Lock

the adjustable idler gear with a screwdriver. Check
the clearance to the adjustable wheel by turning
the camshaft gear back and forwards. Compare
the flank clearance with the specification in “Tech-
nical Data”.

156
Group 21 Short block Overhaul / change components

48. Remove the screws and sockets from the cam-

shaft gear. Install the toothed wheel on the cam-
shaft gear. Torque to 35±3 Nm and then angle
tighten to 90° ±5°.

IMPORTANT! If there is any damage to, or de-

formation of the toothed wheel or any of the
teeth on the toothed wheel, the toothed wheel
must be changed. The same applies if any of
the holes for the toothed wheel fixing screws is
damaged.

49. Install the inner vibration damper O-ring on the

hub and the flange. Then torque the two socket
cap screws to 60±5 Nm, and angle tighten them
to 90° ±5°.

50. Install the dust shield and holder for the crank-
shaft seal.

51. Apply an even string of sealant (2 mm thick), part

no. 1161277-7 to marked areas (please refer to
the figure).
Install the lower timing gear cover within 20 min-
utes, since the sealant hardens.

WARNING! The lower timing gear cover is

heavy. Two people should help each other to in-
stall it.

52. Install the drive connection, alternator and fuel

pump.

53. Install the outer vibration damper. Torque as in

the tightening schedule to 60±5 Nm, then angle
tighten to 90° ±5°

54.

NOTE! Do not forget to remove turning tool 9993590

from the flywheel housing and put the covers back.

157
Group 22 Lubrication system Overhaul / change components

Group 22: Lubrication system

When working with chemicals,

fuel and lubricating oil
IMPORTANT! Apply barrier cream to your hands
and always use protective gloves in work which
involves contact with oil, fuel etc. Continuous
skin contact with engine oil dries your skin and
can be hazardous.

Reduction valve, change

1. Clean round the cover on the engine block. Disas-

semble and take the reduction valve out.
NOTE! The cover over the reduction valve has 50 mm
spanner flats.

2. Clean it and make sure that the old seal ring does
not remain.

3. Check that the new reduction valve is marked

with blue paint.

4. Install the new reduction valve in the engine

block, using new seals.

5. Start the engine and do a leakage check.

158
Group 22 Lubrication system Overhaul / change components

Safety valve, change

Special tools:
Puller ............................................................ 9998487

1. Remove the right-hand oil filter with filter puller

9998487.

2. Clean round the cover on the engine block.

Disassemble the cover and take the safety valve
out.
NOTE! The cover over the safety valve has 50 mm
spanner flats.

3. Clean it and make sure that the old seal ring does
not remain.

4. Check that the new safety valve is marked with

yellow paint.

5. Install the new safety valve in the engine block,

using new seal rings.

6. Install a new oil filter. Please refer to the installa-

tion instructions on the oil filter.

7. Start the engine and do a leakage check.

159
Group 22 Lubrication system Overhaul / change components

Piston cooling valve, change

1. Clean the oil filter bracket and remove the cover

over the piston cooling valve. Remove the seal
ring.

2. Remove the piston cleaning valve, clean it and

make sure that the old seal ring does not remain
in the oil filter bracket.

3. Check that the new piston cooling valve is

marked with orange paint.
Install the new valve in the engine block, using
new seals in the oil filter bracket.

4. Screw the cover down for the piston cooling

valve.

5. Start the engine and do a leakage check.

160
Group 22 Lubrication system Overhaul / change components

Bypass valve, oil filter, change

1. Clean the oil filter bracket and remove the cover

for the bypass valve.

2. Remove the ball and spring.

3. Clean and check the valve seat. If the valve seat

is damaged, the entire bracket must be changed.

4. Install the new ball (1) and spring (2).

Use a new seal washer (3) and tighten the cover
over the bypass valve.

5. Start the engine and do a leakage check.

161
Group 22 Lubrication system Overhaul / change components

By-pass valve, by-pass filter

(turbo), change

1. Clean the oil filter bracket and remove the cover

for the bypass valve.

2. Remove the ball and spring.

3. Clean and check the valve seat. If the valve seat

is damaged, the entire bracket must be changed.

4. Install the new ball (1) and spring (2).

Use a new seal washer (3) and install the cover
over the bypass valve.

5. Start the engine and do a leakage check.

162
Group 22 Lubrication system Overhaul / change components

Bypass valve (delivery valve),

oil cooler, change

1. Clean the oil filter bracket and remove the cover

over the bypass valve. Remove the seal ring.

2. Remove the bypass valve, clean it and make sure

that the old seal ring does not remain in the oil fil-
ter bracket.

3. Check that the new bypass valve is marked “124”.

4. Install the new bypass valve in the engine block,

using new seals in the oil filter bracket, and screw
the cover down.

5. Start the engine and do a leakage check.

163
Group 22 Lubrication system Overhaul / change components

Sump gasket, change

Special tools:
Puller ............................................................ 9998487

1. Pump the engine oil out, please refer to “Engine

oil, change”.

2. Remove the oil filler pipe and pull the dipstick out
of the oil pan.

3. Remove the oil pan.

4. Remove the old seal. Clean the seal groove in the

oil pan, and the mating surface on the engine
block carefully.

164
Group 22 Lubrication system Overhaul / change components

5. Install the new seal in the groove in the oil pan.

Apply sealant above and below the joint. Also re-
fer to “Installing seals” in “Technical Data”.

6. Install the oil pan.

7. Install the oil filler pipe and put the dipstick back.

8. Add engine oil, as specified in “Technical Data”.

9. Start the engine and do a leakage check.

165
Group 22 Lubrication system Overhaul / change components

Piston cooling nozzle, change

Special tools:
Turning tool ................................................... 9993590

1. Remove the oil pan. Please refer to “Oil pan seal,

changing”.

2. Install turning tool 9993590

3. Turn the crankshaft round so that the piston cool-

ing nozzle to be changed becomes accessible.

4. Remove the piston cooling nozzle.

5. Install the new piston cooling nozzle with new

screws.
NOTE! The piston cooling nozzle fixing screw is pro-
vided with a friction coating, and can only be used
once.

WARNING! Faulty piston cooling will cause the

pistons to seize.
If you suspect that the piston cooling nozzle
may be damaged or deformed, it must be re-
placed. This also applies to new nozzles. Al-
ways check that the piston cooling nozzle is
correctly located in the hole in the engine block
and that the fixing plate rests flat against the en-
gine block.
If the piston cooling nozzle is not correctly in-
stalled, there is a risk that the engine will imme-
diately seize when loaded.

6. Remove the turning tool and put the cover back.

7. Do a thorough installation check before the oil pan

is installed.

8. Install the oil pan with a new seal. Please refer to

“Oil pan seal, changing”.

9. Start the engine and do a leakage check.

166
Group 22 Lubrication system Overhaul / change components

Oil filter, change

1. Pump the engine oil out.

Please refer to “Engine oil, changing”.

2. Remove the oil pan. Please refer to “Oil pan seal,

changing”.

3. Remove the screws for the front main bearing cap

and lift the lube oil pump down together with the
main bearing cap.

4. Remove the lube oil pump from the main bearing

cap.

5. Remove the idler gear from the oil pump housing.

6. Clean the oil strainer. Check that the net in oil

strainer is not damaged.

7. Clean and check the plain bearings and gear teeth

in the idler gear.

167
Group 22 Lubrication system Overhaul / change components

8. Oil the plain bearings with engine oil and install

the idler gear with the new oil pump.
Torque the screws as in the specification in
“Technical data”.

9. Install the new lube oil pump on the main bearing

cap and torque the screws as in the specification
in “Technical data”.
NOTE! Remember to install the screws for the main
bearing cap before the lube oil pump is screwed to the
bearing cap.

10. Clean the main bearing cap and oil it with engine
oil.

11. Install the lube oil pump and make sure that the
teeth on the idler gear engage with the teeth on
the crankshaft gear.
Torque the main bearing cap as in the specifica-
tion in “Technical data”.

12. Check the oil supply pipe for cracks in the flange
against the fitting.

168
Group 22 Lubrication system Overhaul / change components

13. Install new seal rings for the oil strainer and oil
supply pipe.

NOTE! Check that there are no cracks in the oil

strainer.

14. Screw the oil strainer to the lube oil pump and in-
stall the associated clamp. Torque the screws for
the lube oil pump as in the specification in “Tech-
nical data”.

15. Install the oil supply pipe.

16. Angle tighten the oil supply pipe when it contacts

the casting. 180° for a new pipe and 60° for a pre-
used pipe.

17. Install the oil pan with a new seal. Please refer to
“Oil pan seal, changing”.

18. Top the engine oil up as specified. Please refer to

“Technical Data, Lubrication system”.

19. Crank the engine with the starter motor as in the

instructions, until oil pressure is shown on the
pressure gauge. Please refer to “Instructions for
operating the starter motor”.

20. Start the engine and do a leakage check.

169
Group 22 Lubrication system Overhaul / change components

Lube oil pressure, check

Special tools:
Junction nipple .............................................. 9992873
Pressure gauge ............................................. 9996398

1. Check the lube oil pressure by installing pressure

gauge 9996398 and nipple 9992873 on the rear
plug (M16 x 1.5) on the left side of the engine.
2. Carefully clean and unscrew the plug. Install nip-
ple 9992873 and connect pressure gauge
9996398.
Make sure that the engine is warmed up to operat-
ing temperature and measure the oil pressure at
idling- and operating speeds.

3. Compare the measured feed pressure with the

value in the table below.

Oil pressure:
Operation speed 1100 rpm or higher: 400–550 kPa
At idle, min: 175 kPa

170
Group 22 Lubrication system Overhaul / change components

Oil cooler, change

1. Empty the cooling system, please refer to “Drain-

ing, cooling system”.

2. Turn off the main switch (-es) and check that the
engine is not connected to system voltage.

3. Remove the pipe between the coolant pump and

the cover of the oil cooler matrix.
NOTE! Cover over the hole for the coolant pump.

4. Undo the clamp by the turbocharger and remove

the air filter from the bracket. Lift away the air fil-
ter and air hose.

5. Remove the air pipe from the turbocharger.

171
Group 22 Lubrication system Overhaul / change components

6. Remove the oil pipes from the turbocharger.

7. Remove the turbocharger.

8. Remove the rear shield panel (four screws). Two

of these are installed together with the cover over
the oil cooler matrix.

172
Group 22 Lubrication system Overhaul / change components

9. Undo the other four screws and remove the cover

over the oil cooler matrix.

10. Remove the oil cooler matrix.

11. Remove the seal rings in the engine block and re-
move the seal in the cover. Clean all mating sur-
faces.

12. Clean and install new seal rings in the engine

block. Torque the oil cooler matrix
as in the specification in “Technical Data”.

13. Install and torque the cover for the oil cooler as in
the tightening torque table in “Technical data”.
NOTE! The rear shield panel is installed together with
the cover over the oil cooler matrix.

173
Group 22 Lubrication system Overhaul / change components

14. Install the rear shield panel (four screws). Two of

these are installed together with the cover over
the oil cooler matrix.

15. Install the water pipe between the cover over the
oil cooler matrix and the coolant pump, using new
seals.

16. Install the turbocharger, please refer to “Turbo-

charger, change”.
Install the charge air pipe, air filter and hoses.

17. Top the engine oil up as specified. Please refer to

“Technical Data, Lubrication system”.

18. Add coolant as in Volvo Penta’s recommenda-

tions, please refer to “Operator’s manual
TAD1250-1252VE”.
NOTE! Mix the correct volume in advance, to ensure
that the system is filled.

19. Start the engine and do a leakage check.

174
Group 22 Lubrication system Overhaul / change components

Oil cooler, leakage test

Special tools:
Pressure gauge ............................................. 9996662
Screw clamp ................................................. 9996845

1. Disassemble the oil cooler matrix, please refer to

“Oil cooler, change”.

2. Flush the oil cooler’s coolant side and oil side with
detergent/degreaser.

3. Screw on clamps 9996845 to leak test the oil

cooler matrix and check that they seal properly.

4. Check that the reduction valve knob on pressure

gauge 9996662 is fully screwed out and that the
pressure gauge shows 0. Connect the pressure
gauge to clamp 9996845 to leak test the oil cooler
matrix. Lower the oil cooler matrix down into a wa-
ter bath at room temperature.
Increase the pressure to 250 kPa with the knob
on the reduction valve.
Wait for at least one minute.
If an even stream of bubbles comes from the oil
cooler matrix, there is leakage and the oil cooler
matrix should then be changed.

175
Group 23 Fuel system Overhaul / change components

Group 23: Fuel system

Control unit, change

1. Disconnect system voltage from the engine.

2. Undo the fuel cooling loop and clamps for fuel

pipes from the control unit. Fold the cooling loop
to one side.

3. Disconnect the cable connector from the control

unit. Press the catch (1) in and move the cable
connector (2) upwards.

4. Remove the control unit.

176
Group 23 Fuel system Overhaul / change components

5. Transfer the four rubber pads to the new control

unit.

6. Install the new control unit.

7. Install the fuel cooling loop and clamps for fuel

pipes on the control unit.
NOTE! The fuel cooling coil fixing screws are self-tap-
ping since there are no tapped threads in the control
unit.

8. Connect the cable connector to the control unit.

Move the cable connector (2) into the control unit
so that the safety catch (1) engages.

9. Start the engine and do a leakage- and function

check.

177
Group 23 Fuel system Overhaul / change components

Feed pump, changing

1. Clean around the fuel pump. Undo fuel pipes 1, 2
and 3.

2. Remove the feed pump.

3. Clean the mating surface on the timing gear plate.

4.
NOTE! Put a thin layer of graphite grease around the
O-ring on the drive shaft before the feed pump is in-
stalled.
Check that the new feed pump drive fits the tim-
ing gear. Install the feed pump with a new seal,
and put thread sealing tape on the screw (1).
NOTE! The screw (1) has accompanying thread seal-
ing tape, please refer to the feed pump packaging.

5. Connect fuel pipes 1, 2 and 3 with new seals.

6. Vent the fuel system at the fuel filter, please refer

to “Fuel System, Venting”.

7. Run the engine at raised idle for 10 minutes to get

any remaining air out of the system.

8. Do a leakage and function check.

178
Group 23 Fuel system Overhaul / change components

Feed pump, renovation

The position figures in the illustration are referred to in
the instruction below.
Check all components for wear and damage.
Damaged or worn components must always be
changed.
Components which are not changed must be checked
very carefully.

Special tools:
Adapter ......................................................... 9996626
Mandrel ......................................................... 9995028
Puller ............................................................ 9986173
Other special equipment:
Puller ............................................................ 9986177

1. Remove the valves (4 and 7).

2. Remove the screws (1) and take the housing

apart.

3. Remove the pump gears (6 and 7) and the seal

(5).

4. Remove the seal rings from each end of the pump

impeller shaft (2 and 3) with 9986173 and extrac-
tor 9986177. Use sleeve drift 9996626.

179
Group 23 Fuel system Overhaul / change components

5. The position figures in the illustration are referred

to in the instruction above.

6. Press the pump shaft inner and outer seals (3 and

2) with mandrel 9995028.
Press the inner seal as far as it goes, and press
the outer seal ring to be flush with the housing.
NOTE! The seal rings must be aligned with the
sealing lips away from each other.

7. Install a new seal (5).

8. Dip the pump impellers (6 and 8) in diesel oil and

insert them into the housing.

9. Check that the seal (5) is correctly aligned in the

groove, and screw the housing together.

10. Install the valves (4 and 7). Use new seal wash-
ers.

11. Insert protective plugs in the fuel pipe connec-

tions.

180
Group 23 Fuel system Overhaul / change components

Bypass valve, changing

1. Clean carefully round the bypass valve.

2. Drain the fuel filer, please refer to “Fuel system,

draining”.

3. Remove the bypass valve.

4. Clean the fuel hose connections.

Install a new bypass valve and seals. Torque to
55±5 Nm.

5. Vent the fuel system. Please refer to “Venting the

fuel system”.

6. Run the engine at raised idle for 10 minutes to get

any remaining air out of the system.

7. Do a leakage check.

181
Group 23 Fuel system Overhaul / change components

Unit injector, change

Special tools:
Lifting device ................................................. 9990185
Protective sleeve .......................................... 9998249
Seal ring ....................................................... 9998250
Seal ring ....................................................... 9998251
Crowbar ......................................................... 9998511
Other special equipment:
Cleaning brush .............................................. 9812546

1. Remove the valve cover.

NOTE! Do not use air powered tools, since the studs
can come loose, which would damage the unit injector
cable harnesses.

2. Undo the electric connectors for the unit injectors.

Cut off the tie wraps that hold the cable harness
and fold it to one side.

3. Remove the fuel supply pipe and the joining piece

that supplies oil to the rocker arm bridge.

4. Undo the rocker arm bridge screws progressively,

equal amounts each time, to avoid bending the
rocker shaft.
Carefully lift off the rocker arm bridge with lifting
tool 9990185.
NOTE! The marks on the tool indicates the fastening
points for the rocker arm onto the engine.

5. Remove the valve yoke.

6. Empty the fuel duct in the cylinder head. Please

refer to “Draining, fuel duct in cylinder head” in the
“Overhaul / Change component” chapter.

182
Group 23 Fuel system Overhaul / change components

7. Clean carefully round the unit injector to be

changed.

8. Remove the screws for the unit injector fixing

yoke.
Install puller 9990006 on the injector.
Put the puller fork in the groove in the injector
and lock the arm with the screw on the side. Fix
the puller by screwing the screw down towards
the ball hole in the injector.
Install a slide hammer no. 9990013 and remove
the injector.

9. Install protective sleeve no. 9998249 on the in-

jector which has been removed.

10. Install two seal rings 9998250 in the cylinder head

fuel gallery.
NOTE! Make sure that the seal rings are properly
cleaned and are correctly located.

183
Group 23 Fuel system Overhaul / change components

11. Install protective sleeve 9998580 and clean care-

fully with brush 9808570 and extension 9808616.

12. Clean the hole in the cylinder head for the unit in-
jector very carefully, and remove seal rings
9998250.

13. Install new O-rings on the propeller unit injector.

Upper ring - large diameter - violet
Lower ring - small diameter - violet
NOTE! Use installation sleeves 3883671 and 3883672
to avoid damaging the O-rings.

14. Install the fixing yoke on the unit injector and cen-
ter it between the valve springs.
Torque the screw as in the specification in “Tech-
nical data”.

15. Join up the connector. Press it in until a clear

“click” is heard.
Install new tie wraps.

IMPORTANT! Use Volvo Penta Original oil and

heat resistant tie wraps (983472) and holders
(28429850).

16. Install the valve yokes.

17. If the unit injector is not to be replaced at once,

install a protective plug 9998251 in the hole in the
cylinder head.

184
Group 23 Fuel system Overhaul / change components

18. Oil the valve yoke and camshaft lobes with en-
gine oil.

19. Lift the rocker arm bridge into place with lifting
tool 9990185. Check that the guide pins are in the
correct positions on the bearing caps.
Tighten the rocker arm screws to the values spec-
ified in “Technical data”, so that the shaft rests on
the bearing supports.

NOTE! Tighten alternately, to avoid bending the rock-

er shaft.

20. Clean the cylinder head where the joining piece is

installed, and check that there is no rubbish in the
cylinder head oil duct.
Install new seal rings on the oil supply pipe and
joining piece. Put a thin layer of Vaseline on the
seal rings for the pipe and install the pipe in the
joining piece.

17. Install the joining piece and tighten as specified in

“Technical data”.

18. Adjust the valves and unit injectors, please refer

to “Valves and injectors, adjustment”.

19. Install the cables for the unit injectors and install
the valve housing as specified in “Technical data”.
If any stud has come loose, it must be removed
and coated with thread-locking fluid, part no.
161053-2 before it is re-installed and tightened.
Do not loosen the stud or the nut before the
thread locking fluid has hardened.
NOTE! Install the studs within 20 min. after
application of thread-locking fluid.

20. Vent the fuel system, please refer to “Fuel Sys-

tem, Venting”.

21. Run the engine at raised idle for 10 minutes to get

any remaining air out of the system.

22. Do a leakage- and function check.

185
Group 25 Inlet and exhaust system Overhaul / change components

Group 25: Inlet / Exhaust systems

Inlet pipe, gasket change

1. Turn off the main switch (-es) and check that the
engine is not connected to system voltage.

2. Undo the clamps and remove the charge air pipe.

3. Remove the bypass valve from the inlet pipe.

NOTE! If the fuel connection to the cylinder head has
to be removed, the fuel system must be drained be-
fore this is done. Please refer to “Fuel system, drain-
ing”.

186
Group 25 Inlet and exhaust system Overhaul / change components

4. Cut off the tie wraps and remove the charge air
temperature/charge pressure sensor.

5. Remove the cover from the cable chest (Torx

screws).

6. Remove the intermediate bracket (Torx screws).

7. Remove the inlet manifold.

NOTE! The inlet manifold might be difficult to remove
because the sealant has hardened.

187
Group 25 Inlet and exhaust system Overhaul / change components

Fitting

8. Clean the mating surfaces on the inlet pipe and

the cylinder head carefully.
Scrape the seal off with a wood or plastic scraper.

9. Apply a 2 mm wide string of sealant, part no.

1161231-4 to the inlet pipe.
NOTE! The inlet pipe must be installed and tightened
within 20 minutes after applying the sealant.
NOTE! The sealant must be applied as in the upper
figure, 3 mm from the inner edge of the inlet pipe mat-
ing surface.
Install the inlet pipe and tighten as specified in
“Technical data”.

10. Install the intermediate bracket (Torx screws).

11. Install the cover on the cable chest (Torx screws).

188
Group 25 Inlet and exhaust system Overhaul / change components

12. Install the bypass valve on the inlet pipe.

13. Install the charge air temperature/charge air pres-

sure sensor on the inlet pipe and fix the cables
with new tie wraps.

14. Install the inlet pipe.

15. Start the engine and do a function and sealing

check.

189
Group 25 Inlet and exhaust system Overhaul / change components

Manifold, gasket change

1. Turn off the main switch (-es) and check that the
engine is not connected to system voltage.

2. Undo the clamp by the turbocharger and remove

the air filter from the bracket. Lift away the air fil-
ter and air hose.

3. Remove the air pipe from the turbocharger.

4. Remove the oil pipes from the turbocharger.

190
Group 25 Inlet and exhaust system Overhaul / change components

5. Remove the turbocharger.

6. Remove the rear protective panel and the front

heat shield.

7. Remove the exhaust manifold.

191
Group 25 Inlet and exhaust system Overhaul / change components

Fitting

9. Clean the mating surfaces on the exhaust mani-

fold and the cylinder head carefully.

10. Install the exhaust manifold with new gaskets and

torque it as specified in “Technical data”.

11. Install the rear protective panel and the front heat
shield.

12. Install the turbocharger with a new gasket.

192
Group 25 Inlet and exhaust system Overhaul / change components

13. Install the oil pipes with new seals.

14. Install the charge air pipe on the turbocharger.

15. Install the air filter and air hoses.

16. Check the oil level and top the engine oil up as
specified.

17. Start the engine and do a function and sealing

check.

193
Group 25 Inlet and exhaust system Overhaul / change components

Turbo, replacing
Always find out and rectify the reasons for why the
turbocharger has failed, before a new turbocharger is
installed.

One condition for satisfactory functioning of the turbo-

charger is that the engines oil system and inlet sys-
tem are kept in good condition, i.e. that oil changes
and filter change are done at specified times, the right
grade of oil is used, and the air filter is correctly at-
tended to. The first action should therefore be to
check the engine oil, and if necessary, change the oil
filter and preferably run the engine for a few minutes
before the new oil filter is installed.

When the turbocharger is changed, blow out any rust

and soot flakes from the exhaust manifold. The flakes
can damage the turbine of the new unit.

It is important that the inlet pipe from the air filter is

also cleaned. Pieces from a failed turbine wheel can
remain in place and cause instant destruction of the
new turbocharger.

1. Turn off the main switch (-es) and check that the
engine is not connected to system voltage.

2. Undo the clamp by the turbocharger and remove

the air filter from the bracket. Lift away the air fil-
ter and air hose.

194
Group 25 Inlet and exhaust system Overhaul / change components

3. Remove the air pipe from the turbocharger.

4. Remove the oil pipes from the turbocharger.

5. Remove the turbocharger.

195
Group 25 Inlet and exhaust system Overhaul / change components

Fitting

6. Clean the mating surfaces carefully.

7. Install the turbocharger with a new gasket.

8. Install the oil pipes with new seals.

9. Install the charge air pipe on the turbocharger.

196
Group 25 Inlet and exhaust system Overhaul / change components

10. Install the air filter and air hoses.

11. Check the oil level and top the engine oil up as
specified.

12. Start the engine and do a function and sealing

check.

197
Group 26 Cooling system Overhaul / change components

Group 26: Cooling system

Coolant pump, change

1. Turn off the main switch (-es) and check that the
engine is not connected to system voltage.

2. Empty the cooling system, please refer to “Drain-

ing, cooling system”.

3. Remove the water pipe from the coolant pump

and the radiator union.

4. Remove the water pipe between the thermostat

and the coolant pump.

5. Remove the water pipe between the oil cooler ma-

trix and the coolant pump.

198
Group 26 Cooling system Overhaul / change components

6. Remove the coolant filter with a suitable extrac-

tor.

7. Remove the coolant hose from the coolant pump.

8. Remove the coolant pump.

199
Group 26 Cooling system Overhaul / change components

9. Remove the gear package from the coolant pump.

10. Install the new gear package in the coolant pump,

using new seal rings.
NOTE! Oil the seal rings to make it easier to install
the gear package in the coolant pump.

11. Install the coolant pump.

NOTE! Be careful to ensure that the coolant pump is
put in the correct position, and that all screws have
been inserted before they are tightened.

200
Group 26 Cooling system Overhaul / change components

12. Lubricate the seal ring with a thin layer of engine

oil, and install a new coolant filter. Please refer to
the installation instructions on the filter.

13. Install the coolant hose between the coolant pump

and the radiator.

14. Install the water pipe between the oil cooler matrix
and the coolant pump, using new seals.

15. Install the water pipe between the thermostat

housing and the coolant pump, using new seals.

201
Group 26 Cooling system Overhaul / change components

16. Install the water pipe on the coolant pump and the
radiator union.

17. Add coolant, as specified in “Technical Data”.

NOTE! Mix the correct volume in advance, to ensure
that the system is filled.

18. Start the engine and do a sealing check.

202
Group 26 Cooling system Overhaul / change components

Thermostat, function check

1. Empty the cooling system, please refer to “Cool-

ing system, draining”.

2. Remove the piston thermostat. Please refer to

“Piston thermostat, changing”.

3. Put the thermostat in a large saucepan full of wa-

ter and heat up to the temperature when it should
open. Please refer to “Technical data”.
Closed thermostat

4. If the thermostat does not open at the specified

temperature it should be changed.

Open thermostat

203
Group 26 Cooling system Overhaul / change components

Thermostat, change

1. Empty the cooling system, please refer to“Cooling

system, draining”.

2. Remove the thermostat housing and take the ther-

mostat out.
NOTE! To remove the thermostat housing, two
screws must be removed from the exhaust manifold.

3. Clean all mating surfaces.

4. Install the new piston thermostat with new seal

ring and tighten all screws by hand.

5. Install a screw (M8 x 20) with nut, washer and

spacer sleeve between the heel on the exhaust
manifold and the machined surfaces on the ther-
mostat housing. Tighten the nut so that the
sleeve presses the thermostat housing against
the piston thermostat seal. Tighten the thermostat
housing as in the tightening schedule (see the il-
lustration). Remove the tension screw.

6. Install the two screws on the exhaust manifold.

7. Top the coolant up as specified.

NOTE! Mix the correct volume in advance, to ensure
that the system is filled.

8. Start the engine and do a leakage and function

check.

204
Group 26 Cooling system Overhaul / change components

Charge air cooler, change

1. Turn off the main switch (-es) and check that the
engine is not connected to system voltage.

2. Empty the cooling system, please refer to “Cool-

ing system, draining”.

3. Remove the radiator package. Please refer to “Ra-

diator matrix, change”.

4. Undo the charge air cooler on the left and right

sides of the radiator package.

5. Remove the fan shroud (10 screws) from the

charge air cooler.

6. Install the fan shroud (10 screws) on the new

charge air cooler.

7. Install the charge air cooler on the radiator pack-

age.

8. Install the radiator package. Please refer to “Radi-

ator matrix, change”.

9. Add coolant, as specified in “Technical Data”.

NOTE! Mix the correct volume in advance, to ensure
that the system is filled.

205
Group 26 Cooling system Overhaul / change components

Charge air cooler, leakage test

Special tools:
Pressure gauge ............................................. 9996662
Seal washer .................................................... 885231
Seal washer .................................................... 885232

1. Check the pressure test unit, please refer to

“Checking the pressure test device” under “Ser-
vice measures”.

2. Remove the charge air pipe between the turbo-

charger and the union. Install pressure plate
885232 and tighten the clamp.

3. Remove the charge air pipe between the turbo-

charger and the union. Install pressure plate
885231 to the junction and tighten the clamp.
Check that the tap on reduction valve (A) is and
connect part no. 9996662 to the nipple on pres-
sure plate 885231.

206
Group 26 Cooling system Overhaul / change components

4. Connect part no. 9996662 to the compressed air

system and open tap (B). Set reduction valve (A)
so that a pressure of 100 kPa is shown on the
pressure gauge. Close tap (B).

5. The pressure must not fall for two minutes, to en-

sure that the charge air cooler and unions seal
correctly.
NOTE! If the pressure falls, check that no leakage oc-
curs at the charge air pipe unions. Spray or brush wa-
ter and washing up liquid on the unions to ensure that
there is no leakage.

6. If the pressure falls and you have proved that the

unions do not leak, the charge air cooler must be
changed. Repeat the leakage test to check wheth-
er the charge air cooler leaks.

7. After the leakage test, close the compressed air

system, screw the reduction valve (A) out and
empty the compressed air.

8. Remove leakage test tool 9996662 and pressure

plate 885231. Install the charge air pipe on the in-
let manifold with new seals, and tighten the
clamp.

9. Remove pressure plate 885232. Install the charge

air pipe between the turbocharger and the junction
and tighten the clamp.

10. Start the engine and do a sealing check.

207
Group 26 Cooling system Overhaul / change components

Charge air cooler, cleaning

1. Disassemble the charge air cooler, please refer to

“Charge air cooler, change”.

2. Clean the charge air cooler matrix/radiator on the

outside. Flush the air ducts with fresh water.
Clean the inside with radiator cleaner part no.
1141658-3 and blow it clean with compressed air
(or leave it to drain off).

3. Flush through the charge air cooler with neutraliz-

er, part no. 1141658-3 and blow it clean with com-
pressed air (or leave it to drain off).

4. Install the charge air cooler matrix/radiator.

5. Start the engine and do a leakage and function

check.

208
Group 26 Cooling system Overhaul / change components

Radiator matrix, change

1. Turn off the main switch (-es) and check that the
engine is not connected to system voltage.

2. Empty the cooling system, please refer to “Cool-

ing system, draining”.

3. Disconnect the coolant level sensor from the out-

let (1) and remove the expansion tank. Put the ex-
pansion tank on the engine.

4. Remove the upper coolant hose and the hose for

the expansion tank from the radiator.

5. Remove the lower charge air pipe from the charge

air cooler.

6. Remove the protective grating round the radiator

fan.
NOTE! The protective grating is installed together with
the outer fan ring.

209
Group 26 Cooling system Overhaul / change components

7. Remove the upper charge air pipe on the charge

air cooler.

8. Remove the lower coolant hose from the radiator.

9. Remove the radiator package from the engine

stand.

10. Carefully lift the radiator package forwards, and be

careful to ensure that it does not get caught on
anything. Then lift the radiator package away to
the place where the radiator matrix is to be
changed.

11. Undo the charge air cooler on the left and right
sides of the radiator package.

210
Group 26 Cooling system Overhaul / change components

12. Remove the frames and lift the cover off. Remove
the radiator matrix.

13. Install the new radiator matrix, lift the frames in

place together with the cover, and tighten the
screws (16 pcs).

14. Install the charge air cooler, and tighten the right
and left sides.

211
Group 26 Cooling system Overhaul / change components

15. Carefully lift the radiator package up onto the en-

gine stand.
NOTE! Do not forget the outer fan ring!
NOTE! Line up the lower radiator hose and charge air
pipe before the radiator package is fixed in place
on the engine stand.

16. Tighten the lower radiator hose.

17. Install the protective gratings and the outer fan

ring.

18. Tighten the lower charge air pipe to the charge air
cooler.

212
Group 26 Cooling system Overhaul / change components

19. Install the expansion tank on the radiator pack-

age, connect the coolant level sensor (1) and
hose to the expansion tank.

20. Tighten the upper charge air pipe to the charge air
cooler.

21. Add coolant, as specified in “Technical Data”.

NOTE! Mix the correct volume in advance, to ensure
that the system is filled.

22. Start the engine and do a leakage check.

213
Technical data

Technical data

General
Type designation TAD1250VE TAD1251VE TAD1252VE

Power Please refer to the sales literature

Torque Please refer to the sales literature

No. of cylinders 6 6 6

Bore (mm/inch) 131 131 131

Stroke (mm/inch) 150 150 150

Cylinder volume, dm3 12.13 12.13 12.13

Weight, app. kg 1220 1220 1220

Weight, wet kg 1270 1270 1270

Injection sequence 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4

Compression
ratio 18.1:1 18.1:1 18.1:1

Low idle, rpm 700 700 700

High idle, rpm 1900 1900 1900

214
 Technical data

Torque
General tightening torque values
Nm (kpm)
M6 standard screw 8.8 .............................................. 10±1.5 (1.0±0.15)
M8 standard screw 8.8 .............................................. 25±4 (2.5±0.4)
M10 standard screw 8.8 ............................................ 50±8 (5.1±0.8)
M12 standard screw 8.8 ............................................ 85±15 (8.7±1.5)
M14 standard screw 8.8 ............................................ 140±25 (14.3±2.5)

Only torqued screws can be re-installed.

Torque and angle tightened / plastic limit tightened screws:
8.8 .................................. should not be re-installed
10.9 ........................................... can be re-installed
12.9 ........................................... can be re-installed

IMPORTANT! Check screws which are to be re-installed. Damaged screws, with marks of seizure etc. un-
der the heads, must be scrapped.

Special tightening torques

NOTE! Please refer to “Technical data” for TAD2150VE, TA1251VE, TA1252VE” for tightening torques.
Nm (kpm)
Group 21: Engine
Front engine mounting, cross member (M14) ............ 180±15 (18.4±1.5)

Front engine mounting (M16) ..................................... 220±35 (22.4±3.5)

Rear engine mounting, flywheel housing (M16) .......... 220±35 (22.4±3.5)

Main bearing
stage 1 ................................................................... 150±20 (15.0±2.0)
stage 2, angle tightening ........................................ 120°±5°

Big end bearing cap .................................................. 275±12 (27.5±1.2)

Stiffening frame
(please refer to tightening schedule, “ Stiffening Frame”)
stage 1: Tighten screws 1-6 in number order .......... 48±8 (4.9±0.8)
stage 2: Tighten screws 7-26 in number order ........ 15 (1.5)
Stage 3: 7-26 angle tightening ................................ 90°±5°

Flywheel
-0 -0
(please refer to tightening schedule, “ Flywheel”) ....... 245+25 (25.0+2.5)

Flywheel housing ...................................................... 140±14 (14.3±1.4)

Vibration damper, inner (2 socket cap screws)

stage 1 ................................................................... 60±5 (6.1±0.5)
stage 2, angle tightening ........................................ 90°±5°

215
Technical data

Nm kpm
Vibration damper, outer, or Fan pulley
(10 screws please refer to “Outer vibration damper” tightening schedule)
stage 1 ................................................................... 60±5 (6.1±0.5)
stage 2, angle tightening ........................................ 90°±5°

Valve cover
(please refer to “Flywheel” tightening schedule) ......... 20±2 (2.0±0.2)

Stud, valve housing .................................................. 40±3 (4.1±0.3)

Cylinder head
(please refer to “Flywheel” tightening schedule)
stage 1 ................................................................... 60±10 (6.1±1.0)
stage 2 (check tightening) ...................................... 60±10 (6.1±1.0)
stage 3, angle tightening ........................................ 90°±5°
stage 4, angle tightening ........................................ 90°±5°

Core plugs, cylinder head .......................................... 60±10 (6.1±1.0)

Drain nipple, double rocker arm ................................. 6±1 (0.6±0.01)

Lock nuts, double rocker arm .................................... 25±3 (2.5±0.3)

Bearing cap
(Please refer to “camshaft bearing cap/rocker shaft” tightening schedule)
Stage 1: .................................................................... 15±5 (1.3±0.5)
angle tightening ...................................................... 90°±5°
Stage 2: .................................................................... 60±5 (6.1±0.51)
Stage 3: .................................................................... 15±5 (1.3±0.5)
angle tightening ...................................................... 120°±5°
Stage 4: .................................................................... undo the screws
Stage 5: .................................................................... 15±5 (1.3±0.5)
angle tightening ...................................................... 120°±5°

Timing gear cover, upper, please refer to “Timing gear cover, upper” tightening schedule.

Timing gear wheels, incl. toothed wheel, please refer to “Timing gear” tightening schedule.

Timing gear plate ...................................................... 34±4 (3.5±0.4)

(centered with 9998267, please refer to “Timing gear plate” in “Technical data”)

(please refer to “Timing gear plate”) ........................... 34±4 (3.5±0.4)

216
 Technical data

Nm kpm
Group 22: Lubrication system
Oil nozzle in timing gear
(please refer to “Timing gear”) ................................... 34±4 (3.5±0.4)

Oil cooler, retaining screws ....................................... 27±4 (2.7±0.4)

Cover, lubrication oil cooler (please refer to

“Cover, lubrication oil cooler” tightening schedule) ..... 24±4 (2.4±0.4)

Oil supply pipe

tighten to “0 clearance”, then angle tightening ........ 180° new pipe 60°, used pipe

Screw, piston cooling nozzle ..................................... 24±4 (2.4±0.4)

NOTE! Always use new screws, also refer to “Piston cooling nozzle” in “Technical data”.

Sump ........................................................................ 24±3 (2.4±0.3)

Oil strainer – oil pump ............................................... 27±4 (2.7±0.4)

217
Technical data

Nm kpm
Group 23: Fuel system
Screw, fixing yoke, unit injector (new copper sleeve)
First tightening
stage 1 ................................................................... 20±5 (2.0±0.5)
stage 2, angle tightening ........................................ 180°±5°
NOTE! Undo the screw for the unit injector fixing yoke before doing the second tightening
Second tightening
stage 1 ................................................................... 20±5 (2.0±0.5)
stage 2, angle tightening ........................................ 60°±5°

Screw, fixing yoke, unit injector (old copper sleeve)

stage 1 ................................................................... 20±5 (2.0±0.5)
stage 2, angle tightening ........................................ 60°±5°

Locknut for adjuster screw, unit injector .................... 52±4 (5.3±0.4)

Bypass valve, hollow screw ...................................... 55±5 (5.6±0.5)

Fuel pipes, please refer to the “Fuel pipes” in “Technical Data”.

Exhaust manifold
(please refer to “Exhaust manifold” tightening schedule)
stage 1. Tighten screws 1 ...................................... max 10 (1.0)
stage 2. Tighten screws 2 ...................................... max 10 (1.0)
stage 3. Tighten screws 3 ...................................... 52 ±4 (5.3 ±0.5)
stage 4. Tighten screws 2 ...................................... 52 ±4 (5.3 ±0.5)
stage 5. Tighten screws 4 ...................................... 52 ±4 (5.3 ±0.5)
stage 1. Tighten screws 1 ...................................... max 10 (1.0)

218
 References to service bulletins

References to Service Bulletins

Group No. Date Refers to

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219
Contents
Contents
A E
Adjustment, general .............................................. 52
Alternator belts, change ........................................ 72
Alternator belts, inspection ................................... 72
B Fault tracing .......................................................... 43
Bearing housing for camshaft, change ................ 103
Big end bearings, change (all) ............................. 113
By-pass valve, by-pass filter, change ................. 162
Bypass valve, changing ...................................... 181
Bypass valve, oil cooler, change ........................ 163
Bypass valve, oil filter, change ........................... 161
C
Camshaft, inspection and overhaul ..................... 100
Camshaft, installation ......................................... 104
Camshaft, wear check ........................................ 102
Charge air cooler, change ................................... 205
Charge air cooler, cleaning ................................. 208
Charge air cooler, leakage test ........................... 206
Charge pressure, fault tracing ............................... 45
Checking the engine fixture .................................. 75
Checking the pressure test unit ............................ 74
Component location .............................................. 18
Compression test .................................................. 49
Con rod, inspection ............................................. 123
Control unit, change ............................................ 176
Coolant filter, change ............................................ 71
Coolant pump, change ........................................ 198
Cooling system, cleaning ...................................... 67
Cooling system, draining ....................................... 66
Cooling system, filling ........................................... 70
Cooling system, pressure testing ......................... 68
Copper sleeve for injector, changing ................... 139
Crankcase seal rear, change .............................. 121
Crankshaft seal, front, change ............................ 119
Crankshaft, inspection and overhaul ................... 108
Cylinder head, installation ..................................... 89
Cylinder head, pressure testing .......................... 135
Cylinder head, removing ....................................... 76
Cylinder liners and piston, inspection .................... 93
Cylinder liners and pistons, change (all) ............... 94
Cylinder liners, installation .................................... 96
D
Design and function .............................................. 19
Double rocker arm, adjustment ............................. 57
Double rocker arm, inspection (iEGR) ................... 55
Draining condensate ............................................. 62
220
Engine oil, changing .............................................. 58
Exhaust system, inspection ................................. 65
F
Feed pump, changing ......................................... 178
Feed pump, renovation ....................................... 179
Flywheel bearing, change ................................... 114
Flywheel, change ................................................ 115
Flywheel, indication ............................................ 118
Fuel filter, change ................................................. 60
Fuel system, draining ........................................... 62
G
Gear ring, change ............................................... 117
General information ................................................. 7
Gudgeon pin bushing, check measurement ........ 123
I
Identification numbers ........................................... 17
Inlet pipe, gasket change ................................... 186
Instructions for operating the starter motor ........... 64
Introduction ........................................................... 17
L
Lube oil pressure, check ..................................... 170
M
Main bearings, change (all) ................................. 110
Manifold, gasket change ..................................... 190
O
Oil cooler, change ............................................... 171
Oil cooler, leakage test ....................................... 175
Oil filter, change ................................................. 167
Oil filter/By-pass filter, change ............................. 59
Overhaul / Change components ............................ 76
P
Piston cooling nozzle, change ............................ 168
Piston cooling valve, change .............................. 160
Pistons, removal ................................................... 98
Pressure drop indicator/air filter,
inspection/change ................................................. 65
Primary fuel filter, change ..................................... 61
R
Radiator matrix, change ...................................... 209
Reduction valve, change ..................................... 158
References to Service Bulletins .......................... 219
Repair instructions .................................................. 8
 Contents

S V
Safety information .................................................. 4 Valve guides, inspection ..................................... 129
Safety valve, change .......................................... 159 Valve guides, replacing ....................................... 130
Service work ......................................................... 49 Valve seat, change ............................................. 127
Special tools ......................................................... 12 Valve seats, grinding .......................................... 133
Sump gasket, change ......................................... 164 Valve stem seals, change .................................. 131
Supply pressure .................................................... 48 Valves, adjustment ............................................... 53
Valves, grinding .................................................. 134
T
Technical data .................................................... 214 Valves, installation ............................................. 126
Tests and settings ................................................ 45 Valves, removing ................................................ 124
Thermostat, change ............................................ 204 Venting the fuel system ........................................ 63
Thermostat, function check ................................ 203
Timing gear, changing ......................................... 143
Timing marks ........................................................ 52
Torque ................................................................ 215
Turbo, replacing .................................................. 195
Turbocharger, check ............................................. 47
Unit injector, change ........................................... 182

221
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AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Göteborg
Sweden
7745282 English 09–2006