Workshop Manual I

Group 20 Technical Data 1(0)

TAD1250VE, TAD1251VE,
TAD1252VE
 Technical data

Engine

TAD1250VE, TAD1251VE, TAD1252VE

Contents

Safety information ................................................ 2

Introduction ......................................................... 2
Important ............................................................ 2
General information ............................................. 5
About this Workshop Manual .............................. 5
Spare parts ......................................................... 5
Certified engines ................................................. 5
Technical data ...................................................... 6
General ............................................................... 6
Group 21: Engine body ....................................... 7
Group 22: Lubrication system ............................. 17
Group 23: Fuel system ....................................... 20
Group 25: Inlet and exhaust systems.................. 21
Group 26: Cooling system ................................... 21
Group 30: Electrical system ................................ 21
Torque .................................................................. 23
General ............................................................... 23
Group 21: Engine body ....................................... 23
Group 22: Lubrication system ............................. 29
Group 23: Fuel system ....................................... 30
Group 25: Exhaust system ................................. 33
Installing seals ..................................................... 34
References to Service Bulletins .......................... 37
Group 20
Safety information
This workshop manual contains technical data, de-
scriptions and repair instructions for the Volvo Penta
products or product versions noted in the table of con-
tents. Check that you have the correct Workshop
Manual for your engine.
Read the available safety information, “General in-
formation” and “Repair instructions” in the work-
shop manual before you start to do any service
work.
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 opera-
tion.
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.
2
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.
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. It is difficult to antici-
pate in which direction steam or hot coolant can
spray out.

Hot oil can cause burns. Avoid skin contact with
hot oil. Ensure that the lubrication system is not
under pressure before 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.
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!
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).
Group 20
WARNING! Fuel delivery pipes must not be bent
or straightened under any circumstances. Dam-
aged pipes must be replaced.
All fuels, and many chemicals, are flammable.
Do not allow naked flame or sparks in the vicini-
ty. Certain thinners and hydrogen from batteries
can be extremely flammable and explosive
when mixed with air in the right proportions. No
Smoking! Ensure that the work area is well ven-
tilated and take the necessary safety precau-
tions before starting welding or grinding work. Al-
ways ensure that there are fire extinguishers at
hand when work is being carried out.
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.
Group 20

Always use protective goggles when charging WARNING! Components in the electrical and
and handling the batteries. Battery electrolyte fuel systems on Volvo Penta products have
contains sulfuric acid which is highly corrosive. been designed to minimize the risks of explo-
Should the battery electrolyte come into contact sion and fire. The engine must not be run in ar-
with unprotected skin wash off immediately us- eas where there are explosive materials.
ing plenty of water and soap. If you get battery
acid in your eyes, flush at once with a generous Only use the fuels recommended by Volvo Pen-
amount of water, and get medical assistance at ta. Refer to the Instruction Book. Use of fuels
once. that are of a lower quality can damage the en-
gine. On a diesel engine poor quality fuel can
Turn the engine off and turn off the power at the cause the control rod to bind and the engine to
main switch(es) before carrying out work on the overrev with resulting risk of damage to the en-
electrical system. gine and personal injury. Poor fuel can also lead
to higher maintenance costs.
The clutch must be adjusted with the engine
shut off. Remember the following when washing with a
power washer: Never aim the water jet at seals,
The existing lugs on the engine should be used rubber hoses or electrical components. Never
for lifting. Always check that the lifting devices use a power washer for engine cleaning.
are in good condition and that they have the cor-
rect capacity for the lift (the weight of the engine
plus the reversing gear 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.
If other equipment connected to the engine has
altered its center 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.

4

General information
About this Workshop Manual
This workshop manual contains technical data for the
standard versions of TAD1250VE, TAD1251VE and
TAD1252VE engines.
It also contains all the references from the Workshop
Manuals that contain repair instructions for
TAD1250VE, TAD1251VE and TAD1252VE.
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.
Spare parts
Spare parts for electrical and fuel systems are subject
to various national safety requirements. Volvo Penta
Original Spares comply with these requirements. No
damage whatever, occasioned by use of non-original
Volvo Penta spares for the product, will be compen-
sated by the warranty offered by Volvo Penta.
Group 20
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
and injectors must always be done by an autho-
rized 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 unau-
thorized persons.
The general advice in the instruction book about oper-
ation, care and maintenance applies.
IMPORTANT! When spare parts are needed,
use only Volvo Penta Original Spares.
Use of non-original spareparts means that AB
Volvo Penta can no longer be responsible for
guaranteeing that the engine complies with the
certified version.
Any damage, injury and/or costs which arise due
to the use of non-original Volvo Penta spares for
the product in question will not be compensated
by Volvo Penta.
Technical data Group 20

Technical data

General
Type designation .................................................... TAD1250VE TAD1251VE TAD1252VE
No. of cylinders ...................................................... 6
Bore (mm/inch) ...................................................... 131 mm (5.16")
Stroke .................................................................... 150 mm (5.91")
Cylinder volume ..................................................... 12.13 liter
No. of valves .......................................................... 24
Direction of rotation (seen from front) ..................... Clockwise
Compression ratio .................................................. 18.1:1
Injection sequence ................................................. 1-5-3-6-2-4
Low idle, adjustable (rpm) ...................................... 600-900
High idle, (rpm) ....................................................... 1900
Highest full load speed (rpm) .................................. 1900
Weight*, dry (kg) .................................................... 1220 (2680 lbs)
Weight*, wet (kg) .................................................... 1270 (2800 lbs)

* Only engine, without cooling system.

6
Group 20 Technical data

Group 21: Engine body

Cylinder head
Type ...................................................................... One cylinder head for all cylinders
Length .................................................................... 1078 mm (42.44")
Width ..................................................................... 397 mm (15.63")
Height .................................................................... 135 mm (5.32")
Max. flatness error (base plane) ............................. 0.1 mm (0.004")

Cylinder head screws

No. of screws per cylinder head ............................. 38
Dimension, thread .................................................. M16
Length .................................................................... 200 mm (7.87")

Cylinder liner
Type ...................................................................... Wet, replaceable
Sealing surface height above block plane .............. 0.15–0.20 mm (0.006–0.0079")
No. of seal rings per cylinder liner .......................... 3

Piston
Height above engine block plane ............................ 0.05–0.45 mm (0.002–0.018")
Diameter, combustion chamber .............................. 89 mm (3.5")
Depth, piston bowl ................................................. 17.14 (E=18.1:1)
No. of ring grooves ................................................. 3
Front marking ......................................................... Arrow towards front
Gudgeon pin diameter ............................................ 55 mm (2.17")

7
Technical data Group 20

Piston rings
Compression rings
Quantity ................................................................. 2
Piston ring clearance in groove:
upper compression ring ...................................... Trapezoidal profile, no clearance
lower compression ring, height ............................ 0.09–0.13 mm (0.0036-0-0051”)
Piston ring gap:
upper compression ring ...................................... 0.4–0.65 mm (0.0157-0.0256”)
wear tolerance .................................................. 1 mm (0.04")
lower compression ring ....................................... 0.1-1.3 mm (0.0039-0.051”)
wear tolerance .................................................. 1.6 mm (0.0630”)

Oil scraper ring

Quantity ................................................................. 1
Width, incl. spring .................................................. 4.32 mm (0.17")
Piston ring clearance, vertical ................................ 0.05–0.10 mm (0.0020-0.039”)
Piston ring gap ....................................................... 0.4–0.6 mm (00.0157-0.0236”)

8
Group 20 Technical data

Valve mechanism

Valves
Valve head diameter
Inlet .................................................................... 40 mm (1.58")
Exhaust .............................................................. 40 mm (1.58")
Valve stem diameter
Inlet .................................................................... 7.960–7.975 mm (0.3134–0.3140")
Exhaust .............................................................. 7.947–7.962 mm (0.3129–0.3135")
Valve seat angle
Inlet .................................................................... 29.5°
Exhaust .............................................................. 44.5°
Valve head edge (please refer to illustration)
Inlet (new valve) ................................................. Min 1.8 mm (0.07")
wear limit .......................................................... 1.4 mm (0.055")
Exhaust (new valve) ........................................... Min 1.6 mm (0.063")
wear limit .......................................................... 1.2 mm (0.0472")
Seat angle in cylinder head
Inlet .................................................................... 30°
Exhaust .............................................................. 45°
The valve seat must be ground down
until the distance from the valve head
(new valve) to the cylinder head plane is:
Inlet .................................................................... 0.9–1.4 mm (0.035–0.055")
wear limit .......................................................... Max 1.5 mm (0.06")
Exhaust .............................................................. 1.2–1.7 mm (0.047–0.067")
wear limit .......................................................... Max 1.8 mm (0.071")
If the distance is greater, the valve seat
must be changed.
Valve clearance, cold engine, setting value
Inlet .................................................................... 0.2 mm (0.008")
Exhaust .............................................................. 0.7 mm (0.020")
Valve clearance, cold engine, check value
Inlet .................................................................... 0.15–0.25 mm (0.006–0.010")
Exhaust .............................................................. 0.65–0.75 mm (0.026-0.030”)
Clearance, double rocker arm
– base circle on camshaft ...................................... using gauge tool

9
Technical data Group 20

Valve seats
Outer diameter (dimension A) Standard:
Inlet .................................................................... 43.0 mm (1.693")
Exhaust .............................................................. 43.0 mm (1.693")
Oversize dimension:
Inlet .................................................................... 43.2 mm (1.705")
Exhaust .............................................................. 43.2 mm (1.705")
Height (dimension B):
Inlet .................................................................... 7.15–7.35 mm (0.282–0.289")
Exhaust .............................................................. 7.9–8.1 mm (0.311–0.319")

Valve seat bed

Diameter (dimension C) standard:
Inlet .................................................................... 43 mm (1.69")
Exhaust .............................................................. 43 mm (1.69")
Diameter (dimension C) oversize dimension:
Inlet .................................................................... 43.200–43.225 mm (1.701–1.702")
Exhaust .............................................................. 43.200–43.225 mm (1.701–1.702")
Depth (dimension D):
Inlet .................................................................... 11.2±0.13 mm (0.441±0.005")
Exhaust .............................................................. 11.2±0.13 mm (0.441±0.005")
Seat base radius (dimension R):
Inlet, max. .......................................................... 0.8 mm (0.032")
Exhaust, max. .................................................... 0.8 mm (0.032")
Dimension between valve heads and
the cylinder head plane:
Inlet .................................................................... 0.9–1.4 mm (0.035–0.055")
Exhaust .............................................................. 1.2–1.7 mm (0.047–0.067")

10
Group 20 Technical data

Valve guides
Length:
Inlet .................................................................... 83.2–83.5 mm (3.28–3.29")
Exhaust .............................................................. 83.2–83.5 mm (3.28–3.29")
Inner diameter:
Inlet .................................................................... 8.0 mm (0.032")
Exhaust .............................................................. 8.0 mm (0.032")
Height above cylinder head spring plane:
Inlet .................................................................... 26.5±0.4 mm (1.04±0.016")
Exhaust .............................................................. 18.5±0.4 mm (0.73±0.016")
Clearance, valve stem - guide:
Inlet .................................................................... 0.03–0.05 mm (0.001–0.002")
Wear tolerance ................................................. 0.2 mm (0.008")1
Exhaust .............................................................. 0.04–0.07 mm (0.002–0.003")
Wear tolerance ................................................. 0.3 mm (0.012")1
1)
Max. permissible clearance between valve stem and valve guide:
(according to the “Valve guides, inspection” method in “Workshop Manual, Engine, Groups 21-26”).

Valve springs
Valve springs, inlet/exhaust
Valve springs:
Unloaded length .................................................. 72–73 mm (2.8-2.9")
with 600 N (61.2 kp) loading ................................ 56 mm (2.2")
with 1076 N (109.7 kp) loading ............................ 43 mm (1.7")
Coilbound length, max ........................................ 41 mm (1.6")
Inner valve spring (exhaust):
Unloaded length .................................................. 67–68 mm (2.6-2.7")
with 243 N (24.8 kp) loading ................................ 52 mm (2.1")
with 447 N (45.6 kp) loading ................................ 39 mm (1.5")
Coilbound length, max ........................................ 36 mm (1.4")

11
Technical data Group 20

Transmission

1. Gear, camshaft (z=76)

2. Gear, compressor (z=29)
3. Idler wheel (z=83)
4. Gear, coolant pump (z=27)
5. Gear, crankshaft (z=38)
6. Gear, lube oil pump (z=23)
7. Idler wheel (z=44)
8. Gear, hydraulic oil pump (z=39)
9. Idler wheel (z=71)
10. Gear for belts and fuel pump (z=27)
11. Gear, servo pump (z=23)
12. Nozzle, gear lubrication
13. Idler wheel, adjustable (z=97)

Flank clearance, adjustable intermediate gear (13) .. 0.05–0.17 mm (0.0020–0.0067")

Intermediate gear shaft journal, diameter ............... 99.99±0.01 mm (3.937±0.0004")
Intermediate gear bush, diameter ........................... 100.04±0.01 mm (3.939±0.0004")
Radial clearance for intermediate, max. diameter ... 0.03–0.07 mm (0.0012–0.0028")
Axial clearance for intermediate gear ..................... 0.07–0.17 mm (0.0028–0.0067")

12
Group 20 Technical data

Camshaft
Checking camshaft setting:
NOTE! The engine must be cold. During the check, the timing gear must be rotated in the correct direction, clock-
wise, seen from the front, to take up any tolerances.
Adjust cylinder 1 to valve clearance = 0. The inlet valve for cylinder 1 should have opened 1.6±0.3 mm at 6°
ATDC.

NOTE! Re-set the valve clearance to the correct value after the test.

Drive ...................................................................... Gear wheel

No of bearings ........................................................ 7
Diameter, bearing journals, standard ...................... 70 mm (2.76 ")
Diameter, bearing journals, undersize dimension:
0.25 .................................................................... 69.720–69.780 mm (2.7449–2.7472")
0.50 .................................................................... 69.470–69.530 mm (2.7350–2.7374")
0.75 .................................................................... 69.220–69.280 mm (2.7252–2.7276")
Valve lift:
Inlet .................................................................... 13.1 mm (0.516")
Exhaust .............................................................. 13.1 mm (0.516")
Unit injector (stroke) ............................................... 17 mm (0.669")

Wear tolerances
End float, max ....................................................... 0.35 mm (0.0014")
Radial clearance, max ............................................ 0.01 mm (0.0004")
Valve lift:
Inlet .................................................................... 0.3 mm (0.012”)
Exhaust .............................................................. 0.3 mm (0.012”)

Camshaft bearings
Camshaft bearing thickness, standard: .................. 1.9 mm (0.075")
Oversize dimension:
0.25 .................................................................... 2.0 mm (0.079")
0.50 .................................................................... 2.2 mm (0.087")
0.75 .................................................................... 2.3 mm (0.091")
Diameter, camshaft bearing housing:
1st-7th bearing .................................................... 73.9 mm (2.91")

13
Technical data Group 20

Reciprocating components
Crankshaft
Length .................................................................... 1203 mm (47.36")
Crankshaft, end float1 ............................................. 0.10–0.40 mm (0.0039–0.0157")
Main bearings, radial clearance1 ............................. 0.01–0.15 mm (0.0004–0.0059")
Max permissible ovality on main- and
big end journals ...................................................... 0.08 mm (0.003")
Max permissible taper on main- and
big end journals ...................................................... 0.05 mm (0.002")
Max runout for middle bearing journal ..................... 0.15 mm (0.006")
1
Values apply to oiled components

Main bearing journals

Diameter (Ø) for machining, standard ..................... 108.0 mm (4.25")
Undersize dimension:
0.25 mm ............................................................. 107.73–107.75 mm (4.2413–4.2421")
0.50 mm ............................................................. 107.48–107.50 mm (4.2315–4.2323")
0.75 mm ............................................................. 107.23–107.25 mm (4.2216–4.2224")
1.00 mm ............................................................. 106.98–107.0 mm (4.2118–4.2126")
1.25 mm ............................................................. 106.73–106.75 mm (4.2020–4.2027")
Surface finish, main bearing journal ....................... Ra 0.25
Surface finish, radius ............................................. Ra 0.4
Width, main bearing journal (A) standard ................ 47.0 mm (1.85")
Oversize dimension:
0.2 mm (thrust bearing 0.1) ................................. 47.175–47.225 mm (1.8573–1.8592")
0.4 mm (thrust bearing 0.2) ................................. 47.375–47.425 mm (1.8652–1.8651")
0.6 mm (thrust bearing 0.3) ................................. 47.575–47.625 mm (1.8730–1.8750")
Fillet radius (R) ....................................................... 3.75–4.00 mm (0.148–0.158")

Thrust washers (thrust bearing)

Width (B) standard ................................................. 3.1–3.2 mm (0.122–0.126")
Oversize dimension:
0.1 mm ............................................................... 3.2–3.3 mm (0.126–0.130")
0.2 mm ............................................................... 3.3–3.4 mm (0.130–0.134")
0.3 mm ............................................................... 3.4–3.5 mm (0.134–0.138")

14
Group 20 Technical data

Main bearing shells

Type ...................................................................... Replaceable
Outer diameter (C) ................................................. 113.0 mm (4.45")
Thickness (D) standard .......................................... 2.5 mm (0.098")
Oversize dimension:
0.25 mm ............................................................. 2.6–2.7 mm (0.102–0.106")
0.50 mm ............................................................. 2.7–2.8 mm (0.106–0.110")
0.75 mm ............................................................. 2.8–2.9 mm (0.110–0.114")
1.00 mm ............................................................. 2.9–3.0 mm (0.114–0.118")
1.25 mm ............................................................. 3.1–3.2 mm (0.122–0.126")
Big end journals
Diameter (Ø) for machining, standard ..................... 92.0 mm (3.62")
Undersize dimension:
0.25 mm ............................................................. 91.73–91.75 mm (3.6114–3.612")
0.50 mm ............................................................. 91.48–91.50 mm (3.6016–3.6024")
0.75 mm ............................................................. 91.23–91.25 mm (3.5917–3.5925")
1.00 mm ............................................................. 90.98–91.00 mm (3.5819–3.5827")
1.25 mm ............................................................. 90.73–90.75 mm (3.5720–3.5728")
Surface finish, big end bearing journal .................... Ra 0.25
Surface finish, radius ............................................. Ra 0.4
Width (A) thrust bearing journal .............................. 56.9–57.0 mm (2.240–2.244")
Fillet radius (R) (5.25–5.5) ...................................... 3.75–4.00 mm (0.148–0.158")

Big end journal shells

Outer diameter (B) ................................................. 96.85 mm (3.8130")
Thickness (C) standard .......................................... 2.39–2.40 mm (0.0941–0.0945")
Oversize dimension:
0.25 mm ............................................................. 2.51–2.52 mm (0.0988–0.0992")
0.50 mm ............................................................. 2.64–2.65 mm (0.1039–0.1043")
0.75 mm ............................................................. 2.76–2.77 mm (0.1087–0.1091")
1.00 mm ............................................................. 2.89–2.90 mm (0.1138–0.1142")
1.25 mm ............................................................. 3.01–3.02 mm (0.1185–0.1189")
Diameter, bearing shell seat (D) ............................. 96.84–96.85 mm (3.8126–3.8130")

15
Technical data Group 20

Con rods
Length, centre-centre (E) ........................................ 260 mm (10.236")
Big end bearing cap internal
diameter (G) ........................................................... 55 mm (2.165")
End float, con rod-crankshaft, max.1) ..................... 0.35 mm (0.014")
Big end bearings, radial clearance, max1) ............... 0.10 mm (0.004")
Straightness, max. deviation on 100 mm
measured length .................................................... 0.06 mm (0.002")
Twist, max. deviation on 100 mm
measured length .................................................... 0.15 mm (0.006")
1)
Values apply to oiled components

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

Flywheel, installed
Max permissible runout on measured
radius 150 mm ....................................................... 0.20 mm (0.008")
No. of teeth on starter gear ring .............................. 153
Sensor grooves on flywheel ................................... 3 × 18

16
Group 20 Technical data

Group 22: Lubrication system

Sulfur content in fuel, by weight

< 0.3 % 0.3 – 0.5 % > 0.5 %1)
Oil grade Oil change interval: Reached first in operation

VDS-3 600 hours / 12 month 300 hours / 12 month 150 hours / 12 month

VDS-2 and ACEA E7 2) 400 hours / 12 month 200 hours / 12 month 100 hours / 12 month
VDS-2 and ACEA E5 2)
VDS-2 and Global DHD-1 2)
VDS-2 and API CI-4 2)
VDS-2 and API CH-4 2)

VDS and ACEA E3 2) 200 hours / 12 month 100 hours / 12 month 50 hours / 12 month
ACEA: E7, E5, E4
API: CI-4, CH-4, CG-4
1)
If sulfur content is > 1.0% by weight, use oil with TBN > 15.
2)
The engine oil must comply with both quality requirements.

NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality
requirements above.

VDS = Volvo Drain Specification

ACEA = Association des Constructeurs Européenne d’Automobiles
Global DHD = Global Diesel Heavy Duty
API = American Petroleum Institute
TBN = Total Base Number

Viscosity
Viscosity should be selected from the adjacent table.
Note. The temperature values refer to stable ambient
temperatures.
* Refers to synthetic or semi-synthetic oils.

17
Technical data Group 20

Oil
Change volume, including changing three filters:
For horizontal installation ....................................... 35 liter (9.2 US gal)
Oil pressure
Operation speed 1100 rpm or higher ....................... 400-550 kPa (58–80 psi)
At idle, min. ........................................................... 175 kPa (25 psi)

Oil filter
Quantity ................................................................. 3
Full flow filter
(tighten 1/2–3/4 turn after it just touches) ............... 2
Bypass filter
(tighten 3/4–1 turn after it just touches) .................. 1

Lube oil pump

Type ...................................................................... Gear driven

18
Group 20 Technical data

Oil valves

1. Safety valve
Marking .................................................................. Yellow
Safety valve opening pressure ............................... 700 kPa (101 psi)

2. Pressure valve, oil cooler

Marking .................................................................. 124
Pressure valve, oil cooler, opening pressure .......... 300 kPa (43 psi)

3 and 5. By-pass valve, oil filter, full flow/by-pass

Marking on spring ................................................... Blue/yellow
By-pass valve for oil filter
opening pressure .................................................... 110 kPa (16 psi)
Free length ............................................................. 68.8 mm (2.71")
Loaded by 25–29 N (2.5–2.9 kp) ............................. 40.0 mm (1.58")

4. Piston cooling valve

Marking .................................................................. Orange
Piston cooling valve, opening pressure .................. 200 kPa (29 psi)

6. Pressure reduction valve

Marking .................................................................. Blue
Reduction valve, opening pressure ......................... 480 kPa (70 psi)

19
Technical data Group 20

Group 23: Fuel system

Injection sequence
Injection sequence ................................................. 1-5-3-6-2-4

Feed pump
Supply pressure after fuel filter at
1000 rpm, min ........................................................ 350 kPa (51 psi)
Supply pressure after fuel filter at
full load, min .......................................................... 350 kPa (51 psi)

By - pass valve
Opening pressure ................................................... 400–450 kPa (58–65 psi)

Unit injector
Make ...................................................................... Delphi E3
Pre-load, please refer to the illustration .................. 3-4 spanner flats (180°–240°)
Tighten the adjustment screw to zero clearance against the camshaft, then turn 3-4 spanner flats.

20
Group 20 Technical data

Group 25: Inlet and exhaust system

Turbocharger
Make and type ....................................................... Holset HX55 D98K66 RAV / B86N 84PUI9QX
Lubrication system ................................................. Pressure lubrication
Max. permissible end float ..................................... 0.10 mm (0.004")
Max. permissible run out (compressor side) ........... 0.45 mm (0.0177")

Pressure drop indicator

Air filter
Level for indication (low pressure) .......................... 500 mm WP (19.7") w.g.

Exhaust back pressure

Exhaust back pressure, max ................................. 15 kPa (2.2 psi)

Cooling system
General
Type ...................................................................... Pressurized, sealed
Pressure cap opens at ........................................... 75 kPa (11 psi)
Volume (engine) ..................................................... 20 liter (5.3 US gal)
Volume (engine + radiator and hoses) .................... 44 liter (11.6 US gal)

Thermostat
Type ...................................................................... Piston thermostat
Quantity ................................................................. 1
Opening temperature .............................................. 82° C (187°F)

Coolant filter
Quantity ................................................................. 1

Coolant pump
Type ...................................................................... Gear wheel driven centrifugal pump

21
Technical data Group 20

Group 26: Cooling system

Coolant
Mix:
40% “Volvo Penta Coolant” (conc. coolant)
60% water
We recommend that you use “Volvo Penta Coolant, Ready Mixed”, or “Volvo Penta Coolant” (concentrated)
mixed with pure water acc. to the specification, please refer to “Water quality”. This grade of coolant is the only
one that is developed for and approved by Volvo Penta.
The coolant should contain a good grade of ethylene glycol and a suitable chemical formula for full engine protec-
tion. The use of only an anti-corrosion preparation is not permissible for use in Volvo Penta engines. Never use
water by itself as the coolant.

IMPORTANT! Coolant of a suitable chemical formula must be used all year round. This also applies in ar-
eas where there never is any risk of frost, to give the engine full corrosion protection.
Future warranty claims related to engine and accessories may be refused if an unsuitable coolant has been
used, or if the recommendation for coolant mixture has not been observed.

IMPORTANT! It is extremely important that the correct concentration of coolant is put in the system. Mix in
a separate clean vessel before filling the cooling system. Make sure that the liquids mix.

Water quality
ASTM D4985:
Total solid particles ............................................. < 340 ppm
Total hardness .................................................... < 9.5° dH
Chloride............................................................... < 40 ppm
Sulfate ................................................................ < 100 ppm
pH value ............................................................. 5.5–9
Silica (acc. to ASTM D859)................................. <20 mg SiO2/l
Iron (acc. to ASTM D1068) ................................. < 0.10 ppm
Manganese (acc. to ASTM D858) ....................... < 0.05 ppm
Conductivity (acc. to ASTM D1125) .................... < 500 µS/cm
Organic content, CODMn (acc. to ISO8467) ......... < 15 mg KMnO4/l

Group 30: Electrical system

Sensor distance
Camshaft ............................................................... 0.3–1.0 mm (0.018-0.039")
Flywheel ................................................................ 0.75–2.1 mm (0.029-0.0827")

22
Group 20 Torque

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.

Group 21: Engine body

Front engine mounting, cross member (M14) ......... 180±15 Nm (18.4±1.5 kpm)
Front engine mounting (M16) .................................. 220±35 Nm (22.4±3.6kpm)
Rear engine mounting, flywheel housing (M16) ....... 220±35 Nm (22.4±3.6 kpm)

Main bearing
Stage 1 .................................................................. 150±20 Nm (15.3±2.0 kpm)
Stage 2, angle tightening ........................................ 120°±5°

Big end bearing cap ............................................... 275±12 Nm (28.0±1.2 kpm)

23
Torque Group 20

Stiffening frame
Stage 1: Tighten screws 1-6 in number order ......... 48±8 Nm (4.9±0.8 kpm)
Stage 2: Tighten screws 7-26 in number order ....... 15 Nm (1.5 kpm)
Stage 3: 7-26 angle tightening ................................ 90°±5°

Flywheel
-0 -0
Tighten in number order ......................................... 245 +25 Nm (25.0 +2.5 kpm)

Inner vibration damper (2 socket cap screws)

Stage 1 .................................................................. 60±5 Nm (6.1±0.5 kpm)
Stage 2, angle tightening ........................................ 90°±5°

24
Group 20 Torque

Outer vibration damper

10 screws, tighten in number order
Stage 1 .................................................................. 60±5 Nm (6.1±0.5 kpm)
Stage 2, angle tightening ........................................ 90°±5°

Flywheel housing
Tighten in number order ......................................... 140±14 Nm (14.3±1.4 kpm)

25
Torque Group 20

Valve cover
Stud, valve housing ............................................... 40±3 Nm (4.1±0.3 kpm)
Tighten in number order, nuts ................................. 20±2 Nm (2.0±0.2 kpm)

Cylinder head
Tighten in number order.
Stage 1 .................................................................. 60±10 Nm (6.1±1.0 kpm)
Stage 2 (check tightening) ..................................... 60±10 Nm (6.1±1.0 kpm)
Stage 3, angle tightening ........................................ 90°±5°
Stage 4, angle tightening ........................................ 90°±5°
Core plugs, cylinder head ....................................... 60±10 Nm (6.1±1.0 kpm)
Drain nipple, double rocker arm .............................. 6±1Nm (0.6±0.01kpm)
Lock nuts, double rocker arm ................................. 25±3 Nm (2.5±0.3 kpm)

26
Group 20 Torque

Bearing caps, camshaft

Tighten the screws in stages, to ensure that the rocker arm shaft comes down without being bent.
Stage 1: ................................................................. 15±5 Nm (1.3±0.5 kpm)
angle tightening ................................................... + 90°±5°
Stage 2: ................................................................. 60±5 Nm (6.1±0.51 kpm)
Stage 3: ................................................................. 15±5 Nm (1.5±0.5 kpm)
angle tightening ................................................... 120°±5°
Stage 4: ................................................................. undo the screws
Stage 5: ................................................................. 15±5 Nm (1.5±0.5 kpm)
angle tightening ................................................... 120°±5°

Timing gear cover, upper

Tighten the screws in number order.

27
Torque Group 20

Timing gear wheel, including toothed wheel

Apply a string of silicone sealant between the flywheel

housing and the engine block, as in the illustration.
Thickness 2 mm (0.08"). Max 20 minutes before in-
stallation.

Timing gear plate

Center with tool no. 9998267 .................................. 34±4 Nm (3.5±0.4 kpm)

28
Group 20 Torque

Group 22: Lubrication system

Oil nozzle in timing gear
(please refer to “Timing gear”) ................................ 34±4 Nm (3.5±0.4 kpm)
Oil cooler, retaining screws .................................... 27±4 Nm (2.7±0.4 kpm)
Oil supply pipe
Tighten to “0-clearance”, then angle tightening ....... 180°, new pipe 60°, used pipe
Oil pump
Stage 1 ............................................................... 24±4 Nm (2.4±0.4 kpm)
stage 2, angle tightening ..................................... 90°

Oil strainer – oil pump ............................................ 27±4 Nm (2.7±0.4 kpm)

Cover, lubrication oil cooler

Always use guide dowels when the cylinder head is installed on the engine.
Tighten the screws in number order ....................... 24±4 Nm (2.4±0.3 kpm)
1 Install screws A and B, for alignment
2 Tighten screws C and D.
3 Install all screws, tighten the screws in number order from the center and outwards, as in the illustration (1-4).
4 Check tighten screws C and D

29
Torque Group 20

Sump
Tighten the screws in number order ....................... 24±3 Nm (2.4±0.3 kpm)

Piston cooling nozzles

Screw, piston cooling nozzle
(always use new screws) ....................................... 24±4 Nm (2.4±0.4 kpm)

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

IMPORTANT! Incorrect piston cooling always

leads to piston siezure! If you suspect that the
piston cooling nozzle may be damaged or de-
formed, it must be replaced. This also applies to
new nozzles. Always check that the piston cool-
ing nozzle is correctly located in the hole in the
engine block and that the fixing plate rests flat
against the engine block. If the piston cooling
nozzle is not correctly installed, the engine will
immediately seize when loaded.

30
Group 20 Torque

Group 23: Fuel system

Screw, fixing yoke, unit injector
(new copper sleeve)
First tightening
Stage 1 .................................................................. 20±5 Nm (2.0±0.5 kpm)
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 Nm (2.0±0.5 kpm)
Stage 2, angle tightening ........................................ 60°±5°
Screw, fixing yoke, unit injector
(old copper sleeve)
Stage 1 .................................................................. 20±5 Nm (2.0±0.5 kpm)
Stage 2, angle tightening ........................................ 60°±5°
Locknut for adjuster screw, unit injector ................. 52±4 Nm (5.3±0.4 kpm)
Bypass valve, hollow screw ................................... 55±5 Nm (5.6±0.5 kpm)

Clamping and tightening torque for fuel pipes, please refer to “Fuel pipes” on the next page.

IMPORTANT! Be careful, do NOT tighten the nuts on the electrical connections to greater torque values
than specified above.

31
Torque Group 20

Fuel pipes

A. Hollow screw 34±4 Nm (3.5±0.4 kpm)

B. Nipple 14±3 Nm (1.4±0.3 kpm)
C. Bypass valve 55±5 Nm (5.6±0.5 kpm)
D. Hollow screw 35±4 Nm (3.6±0.4 kpm)
E. Nut 65±5 Nm (6.7±0.5 kpm)
F. Nut 65±5 Nm (6.7± 0.5 kpm)
G. Hollow screw 15±2.5 Nm (1.5±0.25 kpm)
H. Screw 55±5 Nm (5.6±0.5 kpm)

32
Group 20 Torque

Group 25: Exhaust system

Exhaust collector pipe

Stage 1. Tighten screws 1 ..................................... max 10 Nm (1.0 kpm)
Stage 2. Tighten screws 2 ..................................... max 10 Nm (1.0 kpm)
Stage 3. Tighten screws 3 ..................................... 52±4 Nm (5.3 ±0.5 kpm)
Stage 4. Tighten screws 2 ..................................... 52±4 Nm (5.3 ±0.5 kpm)
Stage 5. Tighten screws 4 ..................................... 52±4 Nm (5.3 ±0.5 kpm)
Stage 6. Tighten screws 1 ..................................... 52±4 Nm (5.3 ±0.5 kpm)

33
Installing seals Group 20

Installing seals
Engine block, front

Put an app. 1 mm (0.04") thick line of sealant, part no. 1161231*, at 1 (broken line).
Put a 2 mm (0.08") thick line of sealant all round the engine block and round the three marked holes.
* Note. Sealant 1161231 (cartridge 0.31 l), or 1161277 (tube 20 g).

Engine block, rear Flywheel housing, aluminum, front

Apply a string of sealant, part no. 1161231 and with a diameter of about 2 mm (0.08").
Note. Engines with aluminum flywheel housings. Apply the seal in the flywheel housing groove instead.

34
Group 20 Installing seals

Timing gear cover, upper

Apply a string of sealant, part no. 1161231* and with a diameter of about 2 mm (0.08").
Note. On late model engines, one end of the timing cover has a rubber seal molding. Put the sealant on top of the
seal molding.
* Note. Sealant 1161231 (cartridge 0.31 l), or 1161277 (tube 20 g).

Timing gear cover, lower

Apply a string of sealant, part no. 1161231 and with a diameter of about 2 mm (0.08").

35
Installing seals Group 20

Engine block, underneath

A. Apply an even, 1mm (0.04") thick string of sealant to the joints.

The illustration shows the joint between the engine block and timing gear cover, or flywheel housing, where
sealant 1161231 should be applied.

Sump

B. Apply a 1 mm (0.04") thick and 15–20 mm (0.59-0.79")long string of sealant 1161231 under and over the
ends of the oil sump seal (rubber molding).

Valve cover

C. Apply a 2 mm (0.08") thick string of sealant 1161231 in the joints between the upper timing gear cover and
the cylinder head 2.

36
 Group 20

References to Service Bulletins

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 Report form

Do you have any complaints or other comments about this manual.

Please make a copy of this page, write your comments down and send
them to us. The address is at the bottom. We would prefer you to write in
English or Swedish.

From: ......................................................................

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Refers to publication: ................................................................................................................................

Publication No.: .................................. Date of issue: ................................................................................

Proposal/motivation: .................................................................................................................................

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Date: ..................................................................................

Signed: ..............................................................................

AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Göteborg
Sweden
7745332 English 03–2006