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Workshop Manual: Group 21-26 I
Workshop Manual: Group 21-26 I
Industrial engines
TAD1250VE, TAD1251VE, TAD1252VE
Contents
Safety information
Introduction
The workshop manual contains descriptions and repair If work is done adjacent to a running engine, a
instructions for products or product versions noted in careless movement or a dropped tool can lead
the table of contents, supplied by Volvo Penta. This to personal injury in the worst case. Take care
manual should be used together with the workshop to avoid contact with hot surfaces (exhaust
manual Technical data for each engine. Check that pipes, Turbocharger, air intake pipe, starter
you have the correct workshop manual for your en- heater etc.) and fluids in pipes and hoses in an
gine. engine which is running or has just been
Read this safety information and the workshop manual stopped. Reinstall all protective parts removed
General information and Repair instructions care- during servicework before starting the engine.
fully before service work is started.
Check that the warning or information labels on
the product are always clearly visible. Replace
labels which have been damaged or painted
over.
Important
In this book and on the product you will find the follow- Never start the engine without installing the air
ing special warning symbols. cleaner filter. The rotating compressor turbine in
the turbocharger can cause severe injury. For-
WARNING! Warns for the risk of personal injury,
eign objects entering the intake ducts can also
major damage to product or property, or serious
cause mechanical damage.
malfunctions if the instruction is ignored.
IMPORTANT! Is used to call attention to things Never use start spray or similar products as a
which could cause damage or malfunctions to starting aid. They may cause an explosion in
product or property. the inlet manifold. Danger of personal injury.
4
Safety information
If other equipment connected to the engine has Avoid getting oil on your skin! Repeated expo-
altered its centre of gravity, special lifting devic- sure to oil or exposure over a long period can re-
es may be needed to obtain the correct balance sult in the skin becoming dry. Irritation, dryness
and safe handling. 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
Never do any work on an engine which just
hangs from a lifting device. avoid oil-soaked clothes and rags. Wash regu-
larly, especially before eating. There are special
skin creams which counteract drying out of the
Never work alone when heavy components are skin and make it easier to clean off dirt after
to be dismantled, even when safe lifting devices work is completed.
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 Most chemicals intended for the product (e.g.
the lifting device and another to ensure that engine and transmission oils, glycol, petrol (gas-
components are lifted clear and not damaged oline) and diesel oil) or chemicals for workshop
during the lifting operations. use (e.g. degreasers, paints and solvents) are
hazardous. Read the instructions on the product
packaging with care! Always follow the safety
Always make sure that there is enough space precautions for the product (for example use of
for disassembly where you are working, with no protective mask, glasses, gloves etc.). Make
risk for personal or material damage. sure that other personnel are not inadvertently
exposed to hazardous chemicals, for example in
WARNING! Components in the electrical and the air. Ensure good ventilation in the work
fuel systems on Volvo Penta products have place. Follow the instructions provided when dis-
been designed to minimize the risks of explo- posing of used or leftover chemicals.
sion and fire. The engine must not be run in ar-
eas where there are explosive materials. Exercise extreme care when leak detecting on
the fuel system and testing the fuel injector noz-
Only use the fuels recommended by Volvo Pen- zles. Use eye protection. The jet from a fuel in-
ta. Refer to the Instruction Book. Use of fuels jector is under very high pressure, and has con-
that are of a lower quality can damage the en- siderable penetration ability; fuel can force its
gine. On a diesel engine poor quality fuel can way deep into body tissues and cause serious
cause the control rod to bind and the engine to injury. Danger of blood poisoning (septicemia).
overrev with resulting risk of damage to the en-
gine and personal injury. Poor fuel can also lead WARNING! Fuel delivery pipes on the engine
to higher maintenance costs. must not be bent or re-aligned under any circum-
stances. Damaged pipes must be replaced.
Remember the following when washing with a
power washer: Never aim the water jet at seals, All fuels, and many chemicals, are flammable.
rubber hoses, electrical components or radia- Do not allow naked flame or sparks in the vicini-
tors. Never use a power washer for engine ty. Petrol (gasoline), some thinners and hydro-
cleaning. gen gas from batteries are extremely flammable
and explosive when mixed with air in the correct
Always use protective glasses or goggles when ratio. No Smoking! Ensure that the work area is
carrying out work where there is a risk of splin- well ventilated and take the necessary safety
ters, grinding sparks, acid splashes or where precautions before starting welding or grinding
other chemicals are used. Your eyes are ex- work. Always ensure that there are fire extin-
tremely sensitive, injury could cause blindness! guishers at hand when work is being carried out.
5
Safety information
Make sure that oil and fuel soaked rags, and Always use protective goggles when charging
used fuel and oil filters are stored in a safe and handling the batteries. Battery electrolyte
place. Rags soaked in oil can spontaneously ig- contains sulfuric acid which is highly corrosive.
nite under certain circumstances. Used fuel and Should the battery electrolyte come into contact
oil filters are polluting waste and must be hand- with unprotected skin wash off immediately us-
ed to an approved waste management facility ing plenty of water and soap. If you get battery
for destruction, together with used lubrication oil, acid in your eyes, flush at once with a lot of wa-
contaminated fuel, paint residue, solvents, de- ter, and get medical assistance at once.
greasers and wash residue.
Turn the engine off and turn off the power at the
Batteries must never be exposed to open main switch(es) before carrying out work on the
flames or electric sparks. Never smoke close to electrical system.
the batteries. The batteries generate hydrogen
gas when charged, which forms an explosive
The clutch must be adjusted with the engine
gas when mixed with air. This gas is easily ignit- shut off.
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 The existing lugs on the engine should be used
damage. Do not shift the connections when at- for lifting. Always check that the lifting devices
tempting to start the engine (spark risk) and do are in good condition and that they have the cor-
not lean over any of the batteries. rect capacity for the lift (the weight of the engine
plus the gearbox and extra equipment).
Always ensure that the Plus (positive) and Mi-
nus (negative) battery cables are correctly in- The engine should be lifted with a customized or
stalled on the corresponding terminal posts on adjustable lifting boom for safe handling and to
the batteries. Incorrect installation can result in avoid damaging components on top of the en-
serious damage to the electrical equipment. Re- gine. All chains or cables must be parallel to
fer to the wiring diagram. each other and should be as square as possible
to the top of the engine.
6
General information
General information
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.
7
Repair instructions
Repair instructions
8
Repair instructions
9
Repair instructions
10
Repair instructions
11
Special tools
Special tools
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
13
Special tools
14
Special tools
15
Special tools
9999683 9999696
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
17
Component location
1 2 3 4 5
6 7 8 9 10
18
Group 21 Engine Design and function
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 Design and function
Cylinder head
The cylinder head is cast in one piece in cast iron, Four valve system, and the valves are displaced 12°
and covers all the cylinders in relation to the cross section of the cylinder.
It is equipped with an overhead camshaft and is fixed Valve diameter is 40 mm for both inlet and exhaust
with thirty eight M16 screws, which are evenly spaced valves. Valve seat angle is 45° on the exhaust side
round the cylinders. and 30° on the induction side.
The cylinder head has separate inlet- and exhaust The engine is a low-emission engine, and no machin-
ducts with so-called “cross-flow” for each cylinder. ing may be done which changes the position of the in-
jectors in relation to the combustion chamber, such as
The valve guides and valve seats are made from al-
planing the cylinder head or milling the copper sleeve
loyed cast iron, and all valve guides have oil seals.
seats.
The valve seats are replaceable and made from steel.
20
Group 21 Engine Design and function
Engine block
The engine block is made of alloyed cast iron and is The lube oil pump is fixed to the rearmost main bear-
cast in one unit. It is provided with wet, replaceable ing cap, no. 7. The thrust bearing is fixed to the cen-
cylinder liners. tral cap, no. 4.
The sides of the engine block are arched around each The cylinder head gasket is made from solid steel, in
cylinder, for best stiffness and good sound damping. one piece for the entire engine. The gasket has rubber
A stiffening frame is mounted on the lower plane of seals vulcanized in, for oil and coolant transfer. The
the engine block, to reduce vibration and thus reduce gasket has also a number of convex dimples to pre-
engine noise. vent the cylinder head from sliding on the gasket dur-
ing installation, and damaging the rubber rings in the
The sump is made of aluminum, and is fixed by 18 gasket.
spring-loaded screws at the foot of the engine block.
A seal is installed in a groove in the sump. The cylinder head is lowed down onto the guide pins
in the cylinder head, with a small gap against the tim-
The main bearing caps in the engine block are made ing gear plate. After this, the cylinder head is pulled
from malleable iron, and are machined together with horizontally towards the timing gear plate. When this
the engine block. In order to prevent incorrect assem- is in place, it is screwed down to the engine block,
bly, bearing caps 1-3, 5 and 6 are numbered and pro- and the dimples are flattened out.
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.
21
Group 21 Engine Design and function
Cylinder liner
The engine block is provided with wet, replaceable The lower part of the cylinder liner is sealed by three
cylinder liners. The coolant space round the cylinder rubber rings, which are installed in grooves in the en-
liner is sealed by four seal rings. gine block. The two upper rings are made from EPDM
The upper section is sealed with one ring under the rubber and seal out the coolant. The third ring seals
liner collar. This ring is made from EPDM rubber. A on the oil side, and is made from fluoride rubber (vio-
thin line of silicone sealer is applied between the liner let).
collars and the liner seats, before the liners are ap- The contact face of the liner against the steel gasket
plied. is convex in shape. Its height above the edge of the
block is 0.15-0.21 mm.
22
Group 21 Engine Design and function
23
Group 21 Engine Design and function
Crankshaft
The crankshaft is drop forged in one piece, and the The crankshaft timing gear is located at the rear of
bearing surfaces are induction hardened for increased the crankshaft. A guide pin in the crankshaft ensures
strength and reduced risk of cracking. that the wheel can not be wrongly installed. A silicone
The crankshaft has 7 main bearings. Each big end rubber seal ring is located at the end of the crank-
bearing has a main bearing on each side. The thrust shaft, to seal between the crankshaft and the timing
bearing is integrated into the center main bearing. Both gear wheel.
the main and big end bearings have steel shells which The combined timing gear housing / flywheel housing
are plated with lead/nickel and lined with lead bronze. is fixed round the crankshaft timing gear. A Teflon
The crankshaft can be re-ground to five undersize di- seal seals between the flywheel housing and the
mensions. crankshaft timing gear wheel, with an outer felt layer
as a dust seal.
Both at front and rear, the crankshaft is provided with
integrated hubs for fixing the timing gear wheels (rear) The crankshaft timing gear wheel has a guide dowel
and vibration damper/pulleys (front). at the rear which fits in the flywheel, so that it can not
be wrongly installed. The flywheel screws pass
In the front cover, a Teflon seal seals the front end of through the flywheel, crankshaft timing gear and the
the crankshaft. The Teflon seal has an outer felt layer crankshaft.
which serves as a dust shield.
There are a number of grooves milled into the periph-
The vibration damper housing contains a freely rotat- ery of the flywheel, for the injection system speed
ing steel ring which serves as a flywheel. The space sensor.
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
Group 21 Engine Design and function
Camshaft
The camshaft is mounted on top of the cylinder head, In front of the front bearing housing, there is a flange
and is induction hardened. The bearing journals can with the camshaft marking, the numbers 1-6 and TDC
be ground down, and have replaceable bearing shells (Top Dead Center). TDC is used for basic setting of
as spare parts. the camshaft, and must be between the two marks on
The camshaft is supported by seven bearing hous- the bearing housing when the flywheel is at the 0°
ings, which are machined together and are numbered mark. The number markings are used for adjusting the
1-7, seen from the front of the engine. The bearing valves and injectors.
housings and bearing caps are also machined togeth- A rocker arm bridge is screwed to the camshaft bear-
er. This applies to both production versions and spare ing caps, which serves as the bearing journal for the
part housings. rocker arms with their pressed-in, surface-treated
The front bearing is a thrust bearing. steel bushings. A floating valve yoke transfers the
rocker arm movement to the valves. The rocker arm
The camshaft has three lobes per cylinder. One for has a roller in contact with the camshaft, and a ball
the inlet valves, one for the exhaust valves, and a socket and adjuster screw in contact with the valve
lobe in the middle for the unit injector. yoke.
The camshaft drive gear is mounted on the front The valve guides are made of alloyed cast iron, the
flange of the camshaft, with an external hydraulic vi- valve seats are made of steel, and both are replace-
bration damper. Both the camshaft gear and the vibra- able as spare parts. All valve guides are equipped
tion damper have holes for a guide dowel mounted in with oil seals.
the camshaft, to prevent incorrect assembly. There
are teeth on the vibration damper, which generate sig-
nals in the camshaft sensor.
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
Internal EGR
The engines are equipped with internal EGR (Exhaust The double rocker arm consists of two main sections,
Gas Recirculation). This means that the double rocker the exhaust rocker arm (1) on which the following arm
arm has an extra following arm that makes the ex- (2) is mounted. The control valve in the rocker arm,
haust valve lift an extra time. which is controlled by the iEGR valve, distributes oil
This extra lift allows exhaust gas to flow back into the pressure to either the upper or the lower side of the
cylinder at the beginning of each filling phase. The piston, and thus either activates or de-activates the
double rocker arm is controlled by the control unit, via iEGR function.
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.
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
Timing gear
The timing gear is mounted on a 10 mm thick steel Between the engine block and the cylinder head, there
plate, mounted on the front of the engine block. The is an adjustable idler wheel (13). The wheel must be
steel plate is mounted edge-to-edge against the front adjusted after all work that affects the timing gear. It
of the cylinder head and has a reinforced rubber seal is important to ensure the correct flank clearance be-
against the cylinder head. The seal between the steel tween the upper and lower gear wheels which engage
plate and the engine block is made of silicone rubber. on the adjustable idler wheel.
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).
29
Group 22: Lube oil system Design and function
The engine is pressure lubricated by means of a gear The engine is pressure lubricated by means of a gear
wheel pump connected to the engine timing gear. The wheel pump connected to the engine timing gear. The
oil flow is controlled by six valves. pump forces the oil to the filter housing, via the oil
Two oil galleries are drilled along the engine block. cooler. The oil is directed from the two full-flow filters
The gallery on the left side of the engine is the lube oil to the by-pass filter and then into the main duct. If the
duct which provides all bearings in the valve mecha- oil is cold, the oil that should go to the oil cooler pass-
nism with oil. es through the by-pass valve, directly to the filter
housing.
The other duct on the right side of the engine is the
piston cooling duct, which provides the pistons with oil Piston cooling oil is sprayed onto the inside of the pis-
for lubrication and cooling. tons via nozzles, one for each piston.
The oil cooler is a plate heat exchanger, located under The camshaft and rocker mechanism is lubricated via
a cast iron cover on the right side of the engine block. 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.
30
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 4. Piston cooling valve
When the oil pressure drop across the safety valve The piston cooling valve opens (3.0 bar) when engine
exceeds 8.6 bar, the valve opens and leads oil back speed increases just above idling.
to the oil pan Oil then flows through the piston cooling duct to the
six piston cooling nozzles. From here, the oil is
2. Bypass valve for oil cooler sprayed up underneath the pistons and into the piston
cooling ducts.
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 6. Pressure reduction valve
the oil cooler’s bypass valve. When the oil tempera- The pressure reduction valve controls the oil pressure
ture rises and pressure drop across the oil cooler falls by opening at high pressure (5.7 bar) and directing
(< 3.0 bar), the bypass valve closes and oil passes surplus oil back to the oil pan.
through the oil cooler before it is forced out into the lu-
brication system.
31
Group 23 Fuel system Design and function
8
5
14
12 15
11
2
10 3
1
4
7
16
There is an electronically controlled unit injector for The hand pump (12) in the filter housing is used to
each cylinder, which opens at very high pressure. The pump fuel in a stationary engine, if the system has to
pressure is generated mechanically by the overhead be completely drained. The non-return valve (15) for
camshaft, via the rocker arms. The actual injection is the hand pump is located in the filter housing.
controlled electronically by the control unit. The water-in-fuel sensor is located in the transparent
Fuel is sucked from the fuel tank by the feed pump (1) body (4) under the primary filter. The sensor indicates
through the primary filter (3) with water trap (4), when it is time to manually empty the body by using
through the cooling coil for the control unit and up to the drain valve (16).
the double banjo coupling, from where it passes, to- The fuel pressure sensor is located in the filter hous-
gether with returned fuel, through the bypass valve (6) ing, where the measurement point for manual pressure
to the suction side of the feed pump. measurement is also located.
The pump forces the fuel through the filter housing (2)
and then through the main filter (7) to the long drilling IMPORTANT! Observe the greatest possible
(8) in the cylinder head, which provides each unit in- cleanliness when working on the fuel system.
jector (9) with fuel via an annular space around each Always do an engine wash before you start
unit injector. The bypass valve (6) maintains a con- working. Protective plugs must always be in-
stant pressure to the injectors, by opening at 3.5 to stalled when connections are removed, to pre-
4.5 bar. vent contamination from entering the fuel sys-
There are two valves in the feed pump. The pressure tem. Removed components must be stored in a
limiting valve (10) allows fuel to flow back to the suc- sealed plastic bag until they are re-installed.
tion side when pressure becomes too high, such as
when the fuel filter is blocked. The non-return valve IMPORTANT! If the engine is turned with the
(11) opens when the hand pump (12) is used. If air starter motor, such as during valve adjustment,
has got into the system, it is automatically vented via the cable in the terminal box for the engine man-
the valve (13) on the rear of the cylinder head and the agement unit must be removed first, and the ig-
fuel return pipe (14) back to the tank. Venting of the nition key must be in position “0”, to completely
system after a filter change is automatically controlled remove the risk of starting the engine inadvert-
by valves in the filter housing. The valves also pre- ently. Check the wiring diagram to ensure that
vent fuel spillage during filter changes. The filters you remove the correct cable. Please refer to
must be installed dry. “Instructions for operating the starter motor”.
32
Group 22: Lube oil system Design and function
1
4
3
2
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.
33
Group 23 Fuel system Design and function
4
3
34
Group 23 Fuel system Design and function
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
36
Group 25 Inlet and exhaust system Design and function
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 Design and function
Thermostat Circulation
pump Coolant filter
Radiator
When the
thermostat
is open
The coolant system is a sealed fresh water system, When the coolant is cold, the thermostat is closed and
with a piston thermostat which regulates the water coolant passes directly down through the thermostat
temperature. housing to the coolant pump and back into the engine
Coolant is pumped directly into the engine by the again.
coolant pump, from the pump housing on the right When the coolant is hot, the coolant passes to the
side of the engine block. The majority of the coolant front outlet on the thermostat housing, and to the up-
passes between the oil cooler plates, whereas part is per radiator inlet. Coolant is forced down through the
forced into the lower cooling housings surrounding the duct at the same time as it is cooled down, and then it
cylinder liners. is returned to the lower inlet of the pump. The coolant
After the oil cooler, the coolant is distributed to the pump then forces the coolant back into the engine
upper cylinder cooling housings via calibrated holes, again.
and to the cylinder head. The cylinder head also re-
ceives returned coolant from the cylinder cooling
housings.
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
41
Fault tracing
1 2 3 4 5 6 7
20
19
10
11
18 17 16 15 14 13 12
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.
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
43
Fault tracing
Malfunctions Blockage
Please refer to “Coolant temperature, fault tracing” for Is often caused by high coolant temperature, inner or
more detailed information and more help in fault trac- outer blockage of the cooling system, or a combina-
ing. If there is a malfunction, first check the following tion of both. If the cooling system is blocked, it must
points: be cleaned. Please refer to “Radiator, cleaning, exter-
• Check that the coolant level is between the mark- nal” and “Cooling system, flushing”
ings on the expansion tank (at 20°C). If the level • External contamination: Check that the radiator
in the expansion tank is too low, top up and start and/or intercooler are not blocked.
the engine. If the coolant disappears, there is in- Check if there is any inner or outer leakage in the
ner or outer leakage. cooling system.
• Check that the coolant is not contaminated. If the • Inner contamination: Check that the radiator
coolant is contaminated, this indicates inner leak- and/or intercooler are not blocked.
age (oil) or that the cooling system is partially
blocked (deposits). Blockage in the cooling sys- • Inner or outer leakage in the cooling system:
tem is caused by one or more of the following fac- Check if there is leakage in the system.
tors: • Coolant circulation: Check that coolant circu-
• The coolant has not been changed at the speci- lates by letting the engine run at high speed. Also
fied intervals. check the expansion tank to see that coolant cir-
culates. This can be a clue if there is a fault in the
• Incorrect mixture of coolant and water. cooling system.
• Contaminated water has been used. • Thermostat: Check thermostat function. Drain
enough coolant to allow the thermostat to be re-
moved. Check the thermostat, please refer to
“Thermostat, testing”
44
Tests and settings
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.
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.
47
Tests and settings
Supply pressure
After fuel filter at 1000 rpm, min 350 kPa
After fuel filter at full load, min. 350 kPa
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
5. Install the joining piece and the oil pipe for the
rocker arm bridge.
49
Service work
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.
50
Service work
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
52
Service work
Valves, adjustment
Special tools:
Turning tool ..................................................... 993590
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.
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.
1. Adjustment screw
2. Lock nut
3. Feeler gauge
54
Service work
55
Service work
56
Service work
1
5
3
1. Exhaust rocker arm
2. Following arm
3. Stop nut
4. Socket
5. Drain nipple
6. Lock nut
7. Piston
57
Service work
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.
58
Service work
7. Shut the engine off, check the oil level and top up
the engine oil as necessary.
59
Service work
60
Service work
61
Service work
62
Service work
63
Service work
64
Service work
65
Service work
66
Service work
67
Service work
Alternative 1
1. Check that all hoses and clamps are undamaged.
68
Service work
A
8. Check the coolant level in the expansion tank. In-
stall the ordinary filler cap.
Alternative 2
1. Check that all hoses and clamps are undamaged
and intact.
69
Service work
70
Service work
1. Tap open
2. Tap closed
71
Service work
2. Remove the fan guard and fan ring round the cool-
ing fan.
8. Install the fan guard and fan ring round the cooling
fan.
72
Service work
6. Lift the 1/2" wrench and install the new drive belt.
73
Service work
74
Checking the engine fixture
75
Group 21 Engine Overhaul / change components
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
76
Group 21 Engine Overhaul / change components
77
Group 21 Engine Overhaul / change components
78
Group 21 Engine Overhaul / change components
11. Remove the tie wraps and remove the charge air
temperature/charge pressure sensor from the inlet
manifold.
79
Group 21 Engine Overhaul / change components
80
Group 21 Engine Overhaul / change components
81
Group 21 Engine Overhaul / change components
23. Undo the clamps and pull away the hose between
the pipes for crankcase ventilation.
82
Group 21 Engine Overhaul / change components
83
Group 21 Engine Overhaul / change components
84
Group 21 Engine Overhaul / change components
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.
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
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.
87
Group 21 Engine Overhaul / change components
88
Group 21 Engine Overhaul / change components
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
89
Group 21 Engine Overhaul / change components
90
Group 21 Engine Overhaul / change components
91
Group 21 Engine Overhaul / change components
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).
92
Group 21 Engine Overhaul / change components
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
Special tools:
Plate ............................................................. 9992955
Turning tool ................................................... 9993590
Spacer .......................................................... 9996394
Spacer .......................................................... 9996395
Puller ............................................................ 9996645
Press tool ..................................................... 9996966
94
Group 21 Engine Overhaul / change components
95
Group 21 Engine Overhaul / change components
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
97
Group 21 Engine Overhaul / change components
Pistons, change
Special tools:
Mandrel ......................................................... 9991801
Mandrel ......................................................... 9992031
Piston ring compressor ................................. 9998531
98
Group 21 Engine Overhaul / change components
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.
99
Group 21 Engine Overhaul / change components
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”.
100
Group 21 Engine Overhaul / change components
Renovation
1. Inspection as in: A–D
101
Group 21 Engine Overhaul / change components
102
Group 21 Engine Overhaul / change components
103
Group 21 Engine Overhaul / change components
Camshaft, installation
Special tools:
Lifting device ................................................. 9990185
Turning tool ................................................... 9993590
Lifting yoke ................................................... 9998264
Holder ......................................................... 88880003
104
Group 21 Engine Overhaul / change components
105
Group 21 Engine Overhaul / change components
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.
107
Group 21 Engine Overhaul / change components
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”.
108
Group 21 Engine Overhaul / change components
Renovation
1. Inspection as in: A–D
109
Group 21 Engine Overhaul / change components
Special tools:
Turning tool ................................................... 9993590
110
Group 21 Engine Overhaul / change components
111
Group 21 Short block Overhaul / change components
15. Install the oil suction pipe and oil supply pipe.
Please refer to the instructions in the workshop
manual.
112
Group 21 Short block Overhaul / change components
113
Group 21 Short block Overhaul / change components
Special tools:
Handle .......................................................... 9991801
Puller ............................................................ 9986173
Puller ............................................................ 9986179
Mandrel ......................................................... 9992269
114
Group 21 Short block Overhaul / change components
Flywheel, change
Special tools:
Lifting lug ...................................................... 9998629
115
Group 21 Short block Overhaul / change components
A = clearance mm
B = adjustment shim
116
Group 21 Short block Overhaul / change components
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
118
Group 21 Short block Overhaul / change components
Alternative 1
1. Remove the crankshaft pulley and vibration damp-
er (12 screws).
119
Group 21 Short block Overhaul / change components
Alternative 2
120
Group 21 Short block Overhaul / change components
121
Group 21 Short block Overhaul / change components
122
Group 21 Short block Overhaul / change components
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
Alternative 1
1. Install hydraulic cylinder 9996161 in press tool
9990176.
NOTE! Check that the tool does not damage the unit
injector connector, if the injector is left in place.
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.
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
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
127
Group 21 Short block Overhaul / change components
128
Group 21 Short block Overhaul / change components
129
Group 21 Short block Overhaul / change components
Removal
1. Install hydraulic cylinder 9996161 in tool 9990176.
Fitting
3. Oil the valve guides on the outside with engine oil
before installation.
130
Group 21 Short block Overhaul / change components
131
Group 21 Short block Overhaul / change components
132
Group 21 Short block Overhaul / change components
Exhaust valve
133
Group 21 Short block Overhaul / change components
Valves, grinding
Valve sealing angles:
Inlet .................................................................. 29.5°
Exhaust ............................................................ 44.5°
134
Group 21 Short block Overhaul / change components
135
Group 21 Short block Overhaul / change components
136
Group 21 Short block Overhaul / change components
137
Group 21 Short block Overhaul / change components
33. Oil the shafts for the valve yokes and install
them.
138
Group 21 Short block Overhaul / change components
139
Group 21 Short block Overhaul / change components
140
Group 21 Short block Overhaul / change components
141
Group 21 Short block Overhaul / change components
21. Install the rocker arm bridge and check the clear-
ance of the valves and unit injectors.
142
Group 21 Short block Overhaul / change components
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
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
143
Group 21 Short block Overhaul / change components
144
Group 21 Short block Overhaul / change components
145
Group 21 Short block Overhaul / change components
14. Remove the crankshaft gear (5). Pull the gear off
with a suitable puller.
146
Group 21 Short block Overhaul / change components
Cleaning, inspection
17. Clean the timing gear plate and the front of the
cylinder head.
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.
147
Group 21 Short block Overhaul / change components
Alternative 1
148
Group 21 Short block Overhaul / change components
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.
149
Group 21 Short block Overhaul / change components
150
Group 21 Short block Overhaul / change components
151
Group 21 Short block Overhaul / change components
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.
152
Group 21 Short block Overhaul / change components
39. Make sure that the marking for top dead center
(TDC) on the camshaft is between the markings
on the bearing cap.
153
Group 21 Short block Overhaul / change components
154
Group 21 Short block Overhaul / change components
155
Group 21 Short block Overhaul / change components
156
Group 21 Short block Overhaul / change components
50. Install the dust shield and holder for the crank-
shaft seal.
54.
157
Group 22 Lubrication system Overhaul / change components
2. Clean it and make sure that the old seal ring does
not remain.
158
Group 22 Lubrication system Overhaul / change components
3. Clean it and make sure that the old seal ring does
not remain.
159
Group 22 Lubrication system Overhaul / change components
160
Group 22 Lubrication system Overhaul / change components
161
Group 22 Lubrication system Overhaul / change components
162
Group 22 Lubrication system Overhaul / change components
163
Group 22 Lubrication system Overhaul / change components
2. Remove the oil filler pipe and pull the dipstick out
of the oil pan.
164
Group 22 Lubrication system Overhaul / change components
7. Install the oil filler pipe and put the dipstick back.
165
Group 22 Lubrication system Overhaul / change components
166
Group 22 Lubrication system Overhaul / change components
167
Group 22 Lubrication system Overhaul / change components
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.
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”.
17. Install the oil pan with a new seal. Please refer to
“Oil pan seal, changing”.
169
Group 22 Lubrication system Overhaul / change components
Oil pressure:
Operation speed 1100 rpm or higher: 400–550 kPa
At idle, min: 175 kPa
170
Group 22 Lubrication system Overhaul / change components
2. Turn off the main switch (-es) and check that the
engine is not connected to system voltage.
171
Group 22 Lubrication system Overhaul / change components
172
Group 22 Lubrication system Overhaul / change components
11. Remove the seal rings in the engine block and re-
move the seal in the cover. Clean all mating sur-
faces.
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
15. Install the water pipe between the cover over the
oil cooler matrix and the coolant pump, using new
seals.
174
Group 22 Lubrication system Overhaul / change components
2. Flush the oil cooler’s coolant side and oil side with
detergent/degreaser.
175
Group 23 Fuel system Overhaul / change components
176
Group 23 Fuel system Overhaul / change components
177
Group 23 Fuel system Overhaul / change components
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.
178
Group 23 Fuel system Overhaul / change components
Special tools:
Adapter ......................................................... 9996626
Mandrel ......................................................... 9995028
Puller ............................................................ 9986173
Other special equipment:
Puller ............................................................ 9986177
179
Group 23 Fuel system Overhaul / change components
10. Install the valves (4 and 7). Use new seal wash-
ers.
180
Group 23 Fuel system Overhaul / change components
7. Do a leakage check.
181
Group 23 Fuel system Overhaul / change components
182
Group 23 Fuel system Overhaul / change components
183
Group 23 Fuel system Overhaul / change components
12. Clean the hole in the cylinder head for the unit in-
jector very carefully, and remove seal rings
9998250.
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”.
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.
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.
185
Group 25 Inlet and exhaust system Overhaul / change components
1. Turn off the main switch (-es) and check that the
engine is not connected to system voltage.
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.
187
Group 25 Inlet and exhaust system Overhaul / change components
Fitting
188
Group 25 Inlet and exhaust system Overhaul / change components
189
Group 25 Inlet and exhaust system Overhaul / change components
1. Turn off the main switch (-es) and check that the
engine is not connected to system voltage.
190
Group 25 Inlet and exhaust system Overhaul / change components
191
Group 25 Inlet and exhaust system Overhaul / change components
Fitting
11. Install the rear protective panel and the front heat
shield.
192
Group 25 Inlet and exhaust system Overhaul / change components
16. Check the oil level and top the engine oil up as
specified.
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.
1. Turn off the main switch (-es) and check that the
engine is not connected to system voltage.
194
Group 25 Inlet and exhaust system Overhaul / change components
195
Group 25 Inlet and exhaust system Overhaul / change components
Fitting
196
Group 25 Inlet and exhaust system Overhaul / change components
11. Check the oil level and top the engine oil up as
specified.
197
Group 26 Cooling system Overhaul / change components
1. Turn off the main switch (-es) and check that the
engine is not connected to system voltage.
198
Group 26 Cooling system Overhaul / change components
199
Group 26 Cooling system Overhaul / change components
200
Group 26 Cooling system Overhaul / change components
14. Install the water pipe between the oil cooler matrix
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.
202
Group 26 Cooling system Overhaul / change components
Open thermostat
203
Group 26 Cooling system Overhaul / change components
Thermostat, change
204
Group 26 Cooling system Overhaul / change components
1. Turn off the main switch (-es) and check that the
engine is not connected to system voltage.
205
Group 26 Cooling system Overhaul / change components
206
Group 26 Cooling system Overhaul / change components
207
Group 26 Cooling system Overhaul / change components
208
Group 26 Cooling system Overhaul / change components
1. Turn off the main switch (-es) and check that the
engine is not connected to system voltage.
209
Group 26 Cooling system Overhaul / change components
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.
14. Install the charge air cooler, and tighten the right
and left sides.
211
Group 26 Cooling system Overhaul / change components
18. Tighten the lower charge air pipe to the charge air
cooler.
212
Group 26 Cooling system Overhaul / change components
20. Tighten the upper charge air pipe to the charge air
cooler.
213
Technical data
Technical data
General
Type designation TAD1250VE TAD1251VE TAD1252VE
No. of cylinders 6 6 6
Compression
ratio 18.1:1 18.1:1 18.1:1
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)
IMPORTANT! Check screws which are to be re-installed. Damaged screws, with marks of seizure etc. un-
der the heads, must be scrapped.
Main bearing
stage 1 ................................................................... 150±20 (15.0±2.0)
stage 2, angle tightening ........................................ 120°±5°
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)
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)
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°
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.
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)
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°
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
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219
Contents
Contents
A E
Adjustment, general .............................................. 52 Engine oil, changing .............................................. 58
Alternator belts, change ........................................ 72 Exhaust system, inspection ................................. 65
Alternator belts, inspection ................................... 72
F
B Fault tracing .......................................................... 43
Bearing housing for camshaft, change ................ 103 Feed pump, changing ......................................... 178
Big end bearings, change (all) ............................. 113 Feed pump, renovation ....................................... 179
By-pass valve, by-pass filter, change ................. 162 Flywheel bearing, change ................................... 114
Bypass valve, changing ...................................... 181 Flywheel, change ................................................ 115
Bypass valve, oil cooler, change ........................ 163 Flywheel, indication ............................................ 118
Bypass valve, oil filter, change ........................... 161 Fuel filter, change ................................................. 60
Fuel system, draining ........................................... 62
C
Camshaft, inspection and overhaul ..................... 100 G
Camshaft, installation ......................................... 104 Gear ring, change ............................................... 117
Camshaft, wear check ........................................ 102 General information ................................................. 7
Charge air cooler, change ................................... 205 Gudgeon pin bushing, check measurement ........ 123
Charge air cooler, cleaning ................................. 208
I
Charge air cooler, leakage test ........................... 206 Identification numbers ........................................... 17
Charge pressure, fault tracing ............................... 45 Inlet pipe, gasket change ................................... 186
Checking the engine fixture .................................. 75 Instructions for operating the starter motor ........... 64
Checking the pressure test unit ............................ 74 Introduction ........................................................... 17
Component location .............................................. 18
Compression test .................................................. 49 L
Con rod, inspection ............................................. 123 Lube oil pressure, check ..................................... 170
Control unit, change ............................................ 176 M
Coolant filter, change ............................................ 71 Main bearings, change (all) ................................. 110
Coolant pump, change ........................................ 198 Manifold, gasket change ..................................... 190
Cooling system, cleaning ...................................... 67
O
Cooling system, draining ....................................... 66 Oil cooler, change ............................................... 171
Cooling system, filling ........................................... 70 Oil cooler, leakage test ....................................... 175
Cooling system, pressure testing ......................... 68 Oil filter, change ................................................. 167
Copper sleeve for injector, changing ................... 139 Oil filter/By-pass filter, change ............................. 59
Crankcase seal rear, change .............................. 121 Overhaul / Change components ............................ 76
Crankshaft seal, front, change ............................ 119
Crankshaft, inspection and overhaul ................... 108 P
Cylinder head, installation ..................................... 89 Piston cooling nozzle, change ............................ 168
Cylinder head, pressure testing .......................... 135 Piston cooling valve, change .............................. 160
Cylinder head, removing ....................................... 76 Pistons, removal ................................................... 98
Cylinder liners and piston, inspection .................... 93 Pressure drop indicator/air filter,
inspection/change ................................................. 65
Cylinder liners and pistons, change (all) ............... 94
Primary fuel filter, change ..................................... 61
Cylinder liners, installation .................................... 96
R
D
Radiator matrix, change ...................................... 209
Design and function .............................................. 19
Reduction valve, change ..................................... 158
Double rocker arm, adjustment ............................. 57
References to Service Bulletins .......................... 219
Double rocker arm, inspection (iEGR) ................... 55
Repair instructions .................................................. 8
Draining condensate ............................................. 62
220
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
Notes
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Report form
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Date: ..................................................................................
Signed: ..............................................................................
AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Göteborg
Sweden
7745282 English 09–2006