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1241 WS3

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1. 98 Group 20 Safety Information Safety Information Introduction The Service Manual contains descriptions and service instructions for the Volvo Penta products and versions of products listed in the list of contents This manual should be used in conjunction with the Service Manual Technical Data for the engine in question Make sure that the right service literature is used Read the available safety information and the General information and Repair instructions sections in the Service Manual carefully before starting service work Important The following special warning symbols occur in the Service Manual and on the products WARNING Warns of the danger of injury exten sive damage to the product or to property or that serious functional failure could happen if the instructions are not followed IMPORTANT Used to draw attention to any thing that could cause injury or malfunction of a product or damage to property NOTE Used to draw attention to important information that will facilitate repairs or other operations To provide an overview of the dangers you should al ways be aware of and the precautionary measures that should always be taken we have listed them here AN Make it impossible for the engine to start Turn off the power at the main switch or switches and lock it them in the OFF position before starting service work Place a warning sign in the operator s area AN As a rule
2. VON fa O Gm aa JONAA bja o T EM Install the new valve with new O rings in the oil filter bracket 5 1 o g Screw on the piston cooling valve cover 3am NOTRE aam ont 6 Start the engine and check for leaks Clean the oil filter bracket and remove the cover from the piston cooling valve take out the O ring 2 Take out the piston cooling valve clean it and check that the old O ring is not still in the oil filter bracket 3 Check that the new piston cooling valve is marked with an orange mark 16 Group 22 Lubricating System Bypass filter turbocharger bypass valve changing 1 Clean the oil filter bracket and remove the cover from the bypass valve 2 Remove the valve stem and spring 3 Clean and check the valve seat If the valve seat is damaged the entire bracket must be replaced 4 Install the new valve seat 1 and spring 2 Reinstall the bypass valve cover Use a new washer 3 5 Start the engine and check for leaks Repair instructions Bypass valve pressure valve oil cooler changing Clean the oil filter bracket and remove the bypass val ve cover take out the O ring 2 Take out the bypass valve clean it and check that the old O ring is not still in the oil filter bracket Check that the new bypass valve is marked 124 4 Install the new bypass valve with new O rings in the oil filter bracket and
3. Special tools 9990185 9993590 9998249 999 8250 999 8252 9998253 9998599 999 8688 Threading tool 9998252 includes thread tap 9809667 M9 and 9987009 M8 Cleaning kit 999 8599 includes 276948 959239 980 8570 999 8580 with holder and brush kit 9808634 1 Drain the coolant as appropriate Cooling system draining on page 49 2 Remove the unit injector when the copper sleeve is to be changed Please refer to Unit injector changing page 175 i i SSS LOSS B9 aed Eq TE M RASS LULL N W K AN T i Remove the valve yokes beside the copper sleeve to be changed NOTE Mark the valve yokes so that they can be put back in the right places Repair instructions 0 Hh 9998250 a gt E MAAN T Cro aE SS SSI Sy oe SYS ee SA oe wed f a ae Install two seal rings 999 8250 in the cylinder head fuel gallery as a protection against dirt O1 pas H BT ee a Be a a arial u f os a i A he eit Ee ies gt Sea F h TE 7 ig i _ is A i 9993590 CE IE Install turning tool 999 3590 6 Crank the engine until the piston is at TDC for the cyl inder where the copper cylinder is to be changed NOTE This must be done to prevent the drill from fall ing down into the cylinder when the sleeve diameter is chec
4. 3 TAD 4 Remove the turbo delivery pipe from the turbo 3 TWD weed i l ee Ol os I l Remove the oil pipe from the turbocharger Remove the turbo delivery pipe Remove the turbocharger 67 Group 25 Intake and Exhaust Systems Installation 6 Clean the contact surfaces carefully 7 Reinstall the oil pipe with new seals 68 Repair instructions 9 TAD Reinstall the turbo delivery pipe on the turbo 9 TWD ee a ri a t e Reinstall the turbo delivery pipe Group 25 Intake and Exhaust Systems 10 Reinstall the air filter and air duct 11 Check the oil level and if necessary add engine oil according to specifications See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE 12 Start the engine and perform a functional test and leak check Repair instructions Pressure drop indicator checking 1 Remove the pressure drop indicator Check the pres sure drop indicator by applying a vacuum reduced pressure until the indicator shows red Press the but ton on top of the pressure drop indicator to reset 2 When the air filter is clogged for example and the pres sure falls the pressure drop indicator indicates this by showing red If the pressure drop indicator is not wor king as described in step 1 it should be changed 3 Reinstall the pressure drop indicator 69 Group 26 Cooling System General Group 26 Cooli
5. General repair instructions The working methods described in the Service Manual apply to a shop environment where the engine is lifted out of place and mounted on an engine stand Unless otherwise stated reconditioning work that does not re quire the engine to be removed can be carried out onsite using the same work methods The warning symbols that are used in the Service Ma nual see Safety information for their meaning AN WARNING AN IMPORTANT NOTE are by no means comprehensive because we naturally cannot foresee everything that could happen when service work is being carried out under the most wide ly varying conditions So we can only point out the risks that we consider could arise as a result of incor rect handling when working in a well equipped shop using methods and tools that have been tested by us All work operations for which there are special Volvo Penta tools are described in the Service Manual using these tools Special tools have been developed to en sure working methods that are as safe and efficient as possible It is therefore the obligation of anyone using tools or working methods other than those recommen ded by us to make sure that no danger of injury or ma terial damage exists and that malfunctions cannot re sult from such use In a number of cases there may be special safety ru les and user instructions for the tools and chemicals mentioned in the Service Manual Such rules and ins truct
6. 11 Mount the guard washer 7 the spacer washer 8 and the clamp ring 9 Note The phase edge of the spacer washer and the heads of the clamp ring must be mounted facing the bearing Group 26 Cooling System 12 Mount the spacer washer 10 on the bearing axis 5A 13 Press the pulley 4 on the axle 5 use gauge pin 9992412 Place a pipe with a inner diameter of 27 mm and a outer diameter of 34 mm to support the bearing axis 5A from behind 14 Note The sealing ring 11 is delivered as one unit and not as the picture shows Press the new sealing ring 11 in to the coolant pump housing 2 use gauge pin 9996998 Repair instructions Put a piece of metall that is wider then the coolant pump housing 2 between the axle 5 and the mount ing tool When pressing in the axle 5 in the bearing axis 5A it will be mounted in line with the edges of the coolant pump housing 2 Apply bearing grease on the axle 5 and press it in the bearing axis 5A 16 Mount gauge pin 9996315 in the bearing axis 5A then tighten the nut with your hands Put a washer on the shovel wheel 12 so that the axle 5 will come out 2 mm from the shovel wheel The washer must be 2 mm thick and have a inner di ameter that is wider then the axle 5 Press the shovel wheel 12 on the axle 5 Note Let coolant pump rest on the nut on the gauge pin 9996315 during the entire mounting operation 17 Mount the ga
7. i 9993590 Crank the engine until the piston is in its lower posi tion in the cylinder Z N IMPORTANT This must be done so that tool No 999 8688 will not damage the piston due to its length when the copper sleeve is expanded 52 Repair instructions 17 Lubricate the new seal ring for the copper sleeve with soapy water and put it on the copper sleeve NOTE Always use a new O ring 18 Put the copper sleeve on expansion tool 999 8688 Lu bricate the expansion tool with oil 19 Carefully press the copper sleeve down so that the expansion tool locates against the area for the unit in jector edge in the cylinder head Install the unit injector yoke and tighten it Check that the copper sleeve bottoms in the cylinder head Group 23 Fuel System 20 E a lt 9998688 lt Y t t O Spread the copper sleeve by turning the nut at the same time as the spindle is kept still until the expan sion tool has been completely pulled through 21 Remove the expansion tool 22 Put the valve yoke back in accordance with the previ ous marking Repair instructions 23 Install the unit injector Please refer to Unit injector changing page 175 24 Install the rocker arm bridge and check the clearance of the valves and unit injectors Please refer to the in struction on the page 106 25 Install the valve cover Please refer to the torque sched ule in Tec
8. 3 TWD Remove the charge air temperature boost pressure sensor 4 TAD Cut the ties and remove the charge air temperature boost pressure sensor Remove the bypass valve from the intake manifold 58 Group 25 Intake and Exhaust Systems Repair instructions 5 8 TAD oD Te f n BE i Mi j Wa cee i ff A ij L k t l 1 i H _ 3 i a a L i C Es 5 M H 5 F pi i i 6 Remove intake manifold NOTE The intake manifold may be stuck tight if the sealing compound has hardened 8 TWD Pee iih a O oo mn i aS oe Remove the intermediate bracket Torx bolts 7 TWD Remove the intake manifold NOTE The intake manifold charge air cooler is heavy If no lifting device is available avoid injury and dama ge by having two persons ready to lift the intake mani fold charge air cooler Remove the water pipes on both ends of the charge air cooler 59 Group 25 Intake and Exhaust Systems Repair instructions Installation 11 TWD 9 Carefully clean the contact surfaces on the intake ma nifold and cylinder head TAD Scrape away the gasket with a wooden or plas tic scraper 10 TAD wormo 7 Reinstall the water pipes on both ends of the charge air cooler using new sealing rings 12 Apply a 2 mm 3 wide bead of sealant item no 1161231 4 on the intake manifold NOTE The intake manifold must be in
9. Step 2 Tighten through a further 120 5 12 Check the oil pressure tube for cracks in the flange at the bolt points 20 Snug up the oil pressure tube bolts then tighten th rough an additional 180 for a new tube or 60 fora used tube Group 22 Lubricating System 17 Install the oil pan with a new gasket See Oil sump gasket changing 18 Add engine oil according to specifications See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE 19 Run the engine with the starter according to instruc tions until oil pressure appears on the pressure gauge See Instructions for running on starter 20 Start the engine and check for leaks Repair instructions Oil pressure checking Special Tools 9992873 9996398 1 The lubricating oil pressure is checked by attaching pressure gauge 9996398 and nipple 9992873 to the rear plug M16 x 1 5 on the left hand side of the engine Carefully clean and remove the plug Install nipple 9992873 and connect pressure gauge 9996398 Ensure that the engine has reached operating tempe rature and measure the oil pressure at idle and at ope rating speed 3 Compare the oil pressure measured with that given in the table below 400 550 kPa 60 80 psi Oil pressure 175 kPa 25 psi 21 Group 22 Lubricating System Engine oil changing Note The oil should be changed with the engine warm 1 Connect the drain hose to t
10. all service work should be carried out when the engine is not running However some tasks such as certain adjustments need the engine to be running Approaching a running engine can be dangerous Keep in mind that loo se fitting clothes or long hair may get caught in rotating parts and cause severe injury AN When working near a running engine remember that a careless movement or a dropped tool could in the worst case lead to bodily harm Be careful of hot surfaces exhaust pipes the tur bocharger turoocharger air ducts starter etc and hot liquids in lines and hoses on a running engine or one that has just been stopped Before starting the engine replace all guards and protections that were removed during servi ce work AN Make sure that the warning and information dec als on the product are always in plain sight Re place decals that are damaged or that have been painted over AN Never start the engine unless the air filter is in place The rotating impeller in the turbocharger could cause serious injuries Foreign objects in the intake could also damage the machinery AN Never use a starter spray or the like to help start the engine It could cause an explosion in the intake manifold with the danger of injury AN Start the engine in well ventilated spaces only If the engine is run in a confined space exhaust gases and crankcase gases should be vented away from the engine room or shop area AN Avoid opening the
11. changing ccccseeeeeeeeeees 22 Oil cooler element leakage test 0ccee 26 GROUP 23 FUEL SYSTEM OMEN E E 28 Instructions for working with electronic fuel injection lt crctesstnacmeac aria cencct saacinvsaccertaventnteserss 28 no 8218 8 8 een ne eee eee eee eee 29 Design and Operation Unit injectors OVerviewW ccceeceseeeeseeeeeeeeeeees 31 Unit injectors working phases 0 cceeeeeees 32 Repair instructions Control module EDC Ill changing 34 Fuel system draining cccccsseccseeeceeeeeseeeeens 36 UCI TITEL CHANGING sssini 37 Fuel pump changing siuticwmscntnonertonacisinucderanest nines 38 Fuel pump rebuilding cccceecceeseeeeeeeeeeeeeaees 39 Fuel system bleeding ccceceeeceeeeseeeeeeeees 41 Bypass valve changing cccsscccseeeeeeeeeseeeeess 42 Fuel pressure checking cccceeeceeeseeeeeeeens 43 Unit injectors CHANGING xiencuecesshnicsdnceectsebeneseenesst 44 Draining condensate water ccccssseesseeeees 48 Fuel pre filter with water monitor changing 48 Copper sleeve for unit injector change 49 GROUP 25 INTAKE AND EXHAUST SYSTEMS General seepran a aa 55 Design and Operation Turbocharger see cescasncecetenntenechecaneoadvectereeanateeenocsces 56 Repair instructions Working with chemicals fuel and Welgisclila s O eee et nent renner E 57 Intake manif
12. inside the valve plug which must be cleaned out Otherwise there is a risk that water can be trapped and cause serious damage Check whether the system has any other valves or plugs on the lowest points of the coolant lines 3 Close the valves and reinstall plugs Cooling system filling 1 Z WARNING Open the filler cap very carefully when the engine is hot Steam or hot coolant can spray out NOTE Only use Volvo Penta recommended coolant and mixtures 2 NOTE Fill the system only with the engine shut down Mix the correct volume of coolant in advance to be sure that the system is filled Fill slowly to avoid the formation of air locks in the system The air must be allowed to flow out through the filler opening and vent valves 3 When filling an empty system or if the coolant level has for some reason fallen so low that it is not visible through the filler opening open the vent valves on the turbocharger and the valves on the front of the heat exchanger during filling 4 NOTE The engine must not be started until the sys tem has been bled and completely filled If a space heater is connected to the engine cooling system the heater control valve should be opened and the system vented during filling 5 Fill with coolant to approx 50 mm 2 below the seal ing surface of the filler cap 6 Start the engine and let it run for about 1 hour Switch off the engine check the coolant level and add coola
13. manifold and the finished surface of the thermostat housing Tighten the nut so that the spacer braces the thermostat hou sing against the gasket for the piston thermostat Then tighten the thermostat housing bolts in the order shown in the picture Remove the brace bolt 80 Group 26 Cooling System 6 Reinstall the two bolts on the exhaust manifold 7 Add coolant according to specifications See Techni cal data TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE NOTE Mix the correct volume in advance to be sure that the system is filled 8 Start the engine and perform functional and leakage checks Repair instructions Piston thermostat functional check 1 Drain the cooling system see Cooling system drain ing 2 Remove the piston thermostat see Piston thermo stat changing 3 Closed thermostat 81 Group 26 Cooling System Open thermostat Place the piston thermostat in a large pan of water and heat it to the temperature at which it should open TAD 1240 42GE TAD1241 42VE at 82 C 187 F and TWD 1240VE at 75 C 165 F 4 If the piston thermostat does not open at the proper temperature replace it with a new one 82 Repair instructions Drive belts changing Special tools 9998304 9998305 1 Open the main switch es and check that there is no power to the engine 2 Remove the protective grille around the cooling fan 3 Remove the protective p
14. on Volvo Penta products are designed and manufactured to minimize the risk of explosion and fire The engine must not be run in an envi ronment where it will be exposed to explosive liquids or vapors AN Always use the fuel recommended by Volvo Penta See the Owner s Manual The use of a poorer grade of fuel could damage the engine On a diesel engine a poor grade of fuel could lead to binding of the control rod and overrev ving of the engine with a consequent risk of inju ry and damage Poor fuel can also cause higher maintenance costs AN When cleaning with high pressure equipment re member never direct the jet of water on seals rubber hoses electrical components or the radi ator Never use the high pressure function when cleaning the engine AN Always use protective goggles when working where splinters grinder sparks or splashes of acid or other chemicals could occur Eyes are especially sensitive and an injury could result in loss of sight AN Avoid getting oil on your skin Prolonged or re curring contact with oil can remove the skin s natural moisture with irritation dehydration ec zema and other skin disorders as a result Used oil is more harmful than fresh oil Wear protecti ve gloves and avoid clothes and rags contami nated with oil Wash regularly particularly before meals Use skin lotion intended for this purpose to avoid dehydration and to help cleanse the skin Safety Information AN Most chemi
15. screw on the cover 5 Start the engine and check for leaks Group 22 Lubricating System Piston cooling nozzle changing Special tool 9993590 1 Remove the oil pan See Oil pan gasket replacing 9993590 me a Turn the crankshaft so that the piston cooling nozzle that is to be replaced is accessible Repair instructions 4 Remove the piston cooling nozzle 5 Install the new piston cooling nozzle with a new screw NOTE The setscrew for the piston cooling nozzle is provided with a friction coating and can be used only once AN WARNING Faulty piston cooling means piston damage If there is any suspicion that a piston cooling nozzle may be damaged or deformed it must be replaced even if it is a new nozzle Always check that the piston cooling nozzle is seated properly in the engine block and that the se curing plate lies flat against the engine block If the piston cooling nozzle is not properly instal led the engine can be wrecked immediately upon starting 6 Remove the twist tool and replace the cover 7 Make a thorough check of the installation before the oil pan is replaced 8 Replace the oil pan with a new gasket See Oil pan gasket replacement 9 Start the engine and check for leaks Group 22 Lubricating System Oil pump changing 1 Pump out the engine oil See Engine oil changing 2 Remove the oil pan See Oil sump gasket changing 3 Remov
16. 6662 885231 885232 Checking test equipment 1 Pi ii H a CRORE Remove the charge air pipe between the turbo com pressor and the connector Install pressure plug 995232 and tighten the clamp 4 Check that the knob on the reducing valve A is tur ned all the way counter clockwise and connect 9996662 to a compressed air source Open valve B and adjust the reducing valve A until the pressure gauge shows a pressure of 100 kPa 14 5 psi NOTE The knob on the reducing valve can be locked by pressing in on the knob NOTE Always follow the applicable safety rules 2 Pi i E Remove the charge air pipe between the intake pipe and the connector Install pressure plug 885231 on the Close valve B If the pressure does not fall within connector and tighten the clamp two minutes the equipment is considered reliable Check that the valve on the reducing valve A is tur ned all the way counter clockwise and connect 9996662 to the nipple on pressure plug 885231 90 Group 26 Cooling System 6 Connect 999662 to a compressed air source Open valve B and adjust the reducing valve A until the pressure gauge shows a pressure of 100 kPa 14 5 psi Close valve B 7 If the pressure does not fall within two minutes the charge air cooler and the connections are tight NOTE If the pressure falls check that there is no le akage at the connections to the charge air pipe Spray or brus
17. 8250 9998251 9998255 9998511 9998251 9998255 9998339 9998494 9998511 Protective plug Lifting bar Pressure gauge Connector nipple Pry bar 29 Group 23 Fuel System Tools Other special tools _ E r E E E E 7 2 r I ER ns al 981 2546 998 6173 998 6177 9812546 Cleaning brush 9986177 Extractor 9986173 Puller 30 Group 23 Fuel System Design and Operation Design and Operation Unit injectors overview E a _ i m i PIENI ID i Lie Ig BANETA i Au Wl lead ib i H k TY pT Camshaft Rocker arm Electrical connection for injector unit Fuel passage ae oa AE 31 Group 23 Fuel System Unit injectors working phases Filling phase During the filling phase the pump piston 2 is moving up to its top position The camshaft high point is passed and the cam follo wer is moving towards the base of the cam The fuel valve 1 is open and fuel can flow into the pump cylinder from the lower fuel passage in the cy linder head and into the injector unit pump cylinder Filling continues until the pump piston reaches its top position Spill phase The spill phase begins when the camshaft is turned to the position where the cam via the rocker arm begins to press the piston 2 down Fuel can now flow through the fuel valve 1 throu
18. 996662 9996845 4 Remove the oil cooler element see Oil cooler ele n ment changing s OE Mer 0 2 5 Rinse off the coolant side and the oil side of the oil cooler with degreaser 3 tel F A NEAT T F Check that the knob on the reduction valve on the pressure gauge is turned all the way counter clock wise and that the gauge is at 0 Connect the pressure gauge to clamp 9996845 to test the oil cooler element for leaks Immerse the oil cooler element in a room temperature water bath Turn the knob to increase the pressure to 250 kPa 35 psi Wait at least one minute If a steady stream of bubbles comes out of the oil cooler element it leaks and must be replaced Tighten clamp 9996845 to test the oil cooler element for leaks and check that it seals properly 26 Group 23 Fuel System General Group 23 Fuel System ai Group 23 Fuel System General General N IMPORTANT Ensure maximum cleanliness when working with the fuel system Always cle an the engine before starting repair work To pre vent contamination of the fuel system always install protective plugs when connections are removed Parts removed should be kept ina closed plastic bag until they are reinstalled Z N IMPORTANT If the engine is turned over using the starter for valve adjustment for example first disconnect the cables at the junction boxes for the engine control system and turn the igni tio
19. D 1 Open the main switch es and check that there is no power to the engine 2 Drain the cooling system see Cooling system drain ing 3 Remove the radiator assembly see Radiator chang ing 4 Remove the fan cowling 10 bolts from the charge air cooler 6 Install the fan cowling 10 bolts on the new charge air cooler 7 Install the charge air cooler on the radiator 8 Install the radiator see Radiator changing 9 Add coolant according to specifications See Techni cal data TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE NOTE Mix the correct volume in advance to be sure that the system is filled Release the charge air cooler from the left and right sides of the radiator assembly Charge air cooler TAD1241VE 86 Group 26 Cooling System Repair instructions Charge air cooler changing j TWD 1 Open the main switch es and check that there is no power to the engine 2 Drain the cooling system see Cooling system drain ing Remove the charge air pipe Remove the water pipes on the ends of the charge air cooler 87 Group 26 Cooling System 5 Remove the water pipe connectors on the ends of the charge air cooler 6 F a F 2 P ee a w es ey aseti TE A Remove the cover from the charge air cooler 88 Repair instructions 7 Lift out the charge air cooler element NOTE The charge air cooler ele
20. TWD1240VE The engine mo del and serial number should always be given in all correspondence concerning any of the engines The Service Manual is primarily produced for Volvo Penta service facilities and their qualified personnel It is therefore assumed that persons using the manual have the necessary basic knowledge and can carry out the mechanical and electrical tasks that occur in their profession Volvo Penta is continuously developing its products and we therefore reserve the right to introduce chan ges and modifications All the information in this ma nual is based on product data available at press time Any significant changes that have been introduced in the product or service methods after that date will be announced in the form of Service Bulletins Spare parts Spare parts for the electrical and fuel systems are subject to different national safety requirements Volvo Penta Original Spare Parts meet these require ments All types of damage occurring as a result of using non original Volvo Penta spare parts for the pro duct in question will not be covered under the terms of warranty as provided by Volvo Penta Certificated engines For engines that are certificated for national and regi onal environmental legislation the manufacturer un dertakes to ensure that the environmental require ments are met both in new engines and in those al ready in use The product must correspond to the sample product that was appro
21. Workshop Manual Group 22 26 TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE Industrial Engines TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE Contents GROUP 20 GENERAL INFORMATION Safety Information ccccceeeecceeeeeseeeeeeaeeeeeeeeaes 2 General Information ccccccccccsesseeeeeseeeeeeeeeeeeees 5 General repair instructions ccccceeeeeeeeeeeeeees 6 GROUP 22 LUBRICATING SYSTEM General sasaaa 8 Special tools sencan EE EA 9 Design and Operation Lubrication system snannnnennneaneeennnnennnneennnne 10 Repair instructions Working with chemicals fuel and lubricating oil nannnnnnnnnnannnnennnnnnnnnnnnnnnnnnnnnnnnnne 12 Oil filter changing ccccsseeceeseeeeeeeeeeseseeeeseeeees 12 Oil sump gasket ChANGING cccceeeeeeeeeeees 13 Oil filter bypass valve replacing ccceee 14 Safety valve changing cccccsseeeeeeeeeeeeeeeeeees 15 Reducing valve changing ccccsseeeeeeeeeeeeaees 15 Piston cooling valve changing ccceeeeeeeeees 16 Bypass filter turbocharger bypass valve Sea S EAE E E E TT 17 Bypass valve pressure valve oil cooler enan cae AE 17 Piston cooling nozzle Changing cceseeeee 18 QOilpump changing eee etree een enet meen eens 19 Oil pressure checking cccceeeeeeeeeeeeeeeeeeeaes 21 Engine oil CHANGING wichentaticoenstriemnsiwecacwnanswniviart 22 Oil cooler element
22. aerobic agents are highly resistant to solvents and old agent cannot be removed When reinstalling a component thorough degreasing Is required followed by application of fresh sealant The following agents are anaerobic Loctite 572 white Loctite 241 blue Note Loctite is a registered trademark of the Loctite Corporation Permatex is a registered trademark of the Permatex Corporation Group 22 Lubricating System General Group 22 Lubricating System Group 22 Lubricating System Tools Tools Special tools 9990185 9992873 9993590 9996398 9996662 oo CJ 9809667 LO E a ED oe 998 7009 SS 9996845 9998249 9998250 9998252 9808618 980 8617 276948 999 8580 p 980 8570 980 9668 m 9809746 p a 959239 9998253 9998487 999 8599 999 8688 9990185 Lifting tool for rocker bridge 9998487 Filter wrench 9992873 Connector nipple 9998599 Cleaning kit for unit injector Consists of 9993590 Twist tool sn sae ils i 9996398 Pressure gauge 9808570 Brush white 9996662 Leakage tester 9998580 Socket 9996845 Clamp Holder 9808634 Brush kit Consists of 9808614 Brush yellow 10 pcs Holder 2 pcs Handle 999 8249 Protective sleeve for unit injector 6 pcs needed 9998250 Seal ring for fuel duct in cylinder head 2 pcs needed 47 or 9998252 Thread tap Consists of aeh sine a e 9809667 Threading tool M9 for removing the 999 8688 Expansion tool 7 8 m
23. ages separately as requi red 4 Rinse out the charge air cooler with neutralizer part no 1141658 3 and blow dry with compressed air or allow to stand and drain 5 Reinstall the charge air element cooler 6 TWD Fill with coolant as specified See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE NOTE Mix the correct volume in advance to be sure that the system is filled 7 Start engine and perform functional and leakage checks 91 Group 26 Cooling System Repair instructions Radiator core changing 1 Open the main switch es and check that there is no power to the engine 2 Drain the cooling system see Cooling system drain ing 3 Disconnect the coolant level sensor from the outlet 1 and remove the expansion tank Place the expan Remove the protective grille around the fan sion tank on the engine NOTE The protective grille is mounted with the outer 4 fan shroud Remove the upper coolant hose and the hose to the 7 TAD expansion tank from the radiator 5 TAD Remove the upper turbo delivery pipe from the char ge air cooler Remove the lower turbo delivery pipe from the charge air cooler 92 Group 26 Cooling System Repair instructions 8 12 Remove the lower coolant hose from the radiator Iii IN Hi HII WH WT Wii Remove the radiator assembly from the engine sup port 10 Carefully lift the radiator assembly forward ensur
24. ay out to the exhaust system The exhaust gas flow causes the turbine wheel in the housing to rotate The compressor wheel is mounted on the same shaft as the turbine wheel The compres sor wheel is placed in a housing which is connected between the air filter and the engine intake manifold When the compressor wheel rotates air is drawn from the air filter The air is compressed and forced into the engine cylinders after first being cooled while passing through the charge air cooler 56 Group 25 Intake and Exhaust Systems Repair instructions Repair instructions Working with chemicals fuel and Intake manifold gasket lubricating oil changing TWD Drain the cooling system see Cooling system IMPORTANT Apply barrier cream to hands and al draining ways wear protective gloves for work where there is a risk of contact with oil fuel or the like Continual skin 1 contact with engine oil dries out the skin and can be harmful Turn off the main switch es and check that there is no power to the engine 2 TAD Release the clamps and remove the turbo delivery pipe 2 TWD Release the turbo delivery pipe from the charge air cooler 57 Group 25 Intake and Exhaust Systems Repair instructions 3 TAD 4 TWD Remove the bypass valve from the intake manifold NOTE If the fuel connections to the cylinder head must be removed the fuel system must first be drai ned See Fuel system draining
25. bearing blocks Then tighten the bolts on the rocker arm bridge to the torque specified in the tightening instructions See Technical Data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE Repair instructions 16 Adjust the valves and injectors See Valves and unit injectors adjustment 17 Install the valve cover and torque the nuts to 20 2 Nm 15 2 ft lbf in the order shown in the diagram NOTE It is important to torque the valve cover nuts as shown in the diagram to avoid cracking the cover and to prevent the studs from loosening in the cylinder head If any stud in the valve cover came loose from the cy linder head when the nuts were removed check the wiring insulation by the injectors There is a risk that the cable holder on the stud will twist and damage the wiring insulation 47 Group 23 Fuel System 18 If any stud has come loose it must be removed clea ned and coated with locking compound item no 1610532 before being replaced and tightened Do not loosen the stud bolts or nuts until the locking compound has set NOTE Install the studs within 20 minutes after apply ing the locking fluid 19 Bleed the fuel system See Fuel system bleeding 20 Run the engine at fast idle for about 10 minutes to evacuate any remaining air from the system 21 Perform a leakage and function check Draining condensate water NOTE Place a container under the fuel pre
26. ble 3 with a new O ring 13 99 100 Notes 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 post it to us The address Is at the bottom of the page We would prefer you to write in English or Swedish AB Volvo Penta Customer Support Dept 42200 SE 405 08 Gothenburg Sweden 600G S0 ysibuy 6 GOSLPLL
27. cals intended for the products such as engine and transmission oils glycol gasoline and diesel fuel or chemicals for shop use such as degreasers paints and solvents are dangerous to your health Carefully read the ins tructions on the container Always follow the prescribed safety rules for the use of respira tors protective goggles gloves etc Make sure that other personnel are not accidentally exposed to substances that are dangerous to health by breathing vapors for example Make provision for good ventilation Dispose of used and surplus chemicals in the prescribed way Take great care when looking for leaks in the fuel system or testing fuel nozzles Wear pro tective goggles The jets from a fuel nozzle are under very high pressure and have great pene trating power the fuel can penetrate deep into body tissues and cause serious injury including the risk of blood poisoning WARNING Under no circumstances should the engine s high pressure tubing be bent or resha ped Damaged tubing must be replaced All fuels and many chemicals are flammable Make sure that they cannot be ignited by an open flame or spark Gasoline certain solvents and hydrogen from batteries when mixed with air in the right proportions are highly flammable and explosive No smoking Arrange for adequa te ventilation and take the necessary safety pre cautions before starting welding or grinding in the vicinity Always keep a fire extingu
28. coolant filler cap while the engine is still hot Steam or hot coolant could boil out when the cooling system s pressure is lost If necessary open the filler cap slowly and release the pressure in the cooling system Be extremely careful if a valve plug or coolant line has to be removed while the engine is still hot Steam or hot coolant could squirt out in an un expected direction AN Hot oil can cause burns Avoid getting hot oil on your skin Make sure that pressure in the lubri cating system is released before starting any work on it Never start or run the engine with the oil filler cap removed because oil under pressure could then escape A Stop the engine before doing any work on the cooling system Group 20 AN If other equipment attached to the engine chan ges its center of gravity special lifting devices may be needed to obtain the right balance and ensure safe handling Never work on an engine that is only suspended from a lifting device AN Never work alone when heavy components are to be removed not even when a safe lifting de vice like a lockable block and tackle is used Two people will generally be required one to handle the lifting device and the other to make sure that the components are clear and are not damaged during the lift Always make sure in advance that there is enough room to work in with no danger of cau sing injury or material damage AN WARNING The electrical system and fuel sys tem
29. ctive grille and outer fan shrouds around the fan 14 Start the engine and perform a functional check 84 Group 26 Cooling System Cooling system cleaning Part no 1141658 3 1 Drain the cooling system see Cooling system drain ing 2 NOTE If the cooling system is cleaned regularly by draining and refilling with a rust protection fluid less cleaning additive or simply flushing with pure water may be sufficient 3 Flush the cooling system with fresh water 4 Fill the cooling system with radiator cleaner item no 1141658 3 see instructions on package Then run the engine up to normal working temperatu re and allow it to run for at least another 2 hours NOTE Alternatively fill the system with 15 20 con centrated coolant and drain it out after 1 2 days ope ration 5 Drain the cooling system and then flush it out with a mixture of neutralizer part no 1141658 3 see instruc tions on package Repair instructions 6 If any contamination remains repeat the cleaning until the system is free from contamination 7 When the cooling system is completely free from con tamination fill with fresh coolant In areas where Volvo Penta concentrated coolant is not available use water with a corrosion protection additive NOTE Mix the correct volume in advance to be sure that the system is filled 85 Group 26 Cooling System Repair instructions Charge air cooler changing gt TA
30. e the bolts for the front main bearing cap and lift down the lubricating oil pump together with the main bearing cap 4 Remove the lubricating oil pump from the main bea ring cap Repair instructions Remove the idler gear from the oil pump housing 6 Clean the oil strainer Check that the strainer is not damaged 7 Clean and inspect the bearing and teeth on the idler gear 8 Oil the bearing with engine oil and install the idler gear on the new oil pump Torque the bolts to 24 4 Nm 18 3 ft lbf 19 Group 22 Lubricating System 9 Install the new lubricating oil pump on the main bea ring cap and tighten the bolts to 25 Nm 20 ft llbf and then tighten a further 90 NOTE Remember to install the main bearing cap bolts before the lubricating oil pump is tightened onto the cap 10 Clean the main bearing shell and oil it with engine oil 11 Repair instructions 13 Install new O rings for the oil strainer and oil pressure tube NOTE Check that there are no cracks on the oil strai ner 14 Attach the oil strainer to the lubricating oil pump and install the associated clamp Tighten the bolts on the lubricating oil pump to 27 4 Nm 20 3 ft lbf Install the oil pressure tube 16 Install the lubricating oil pump and check that the te eth on the idler gear mesh with the crankshaft gear te eth Tighten the main bearing cap Step 1 150 20 Nm 110 15 ft lbf
31. emove the bypass valve 42 Group 23 Fuel System Fuel pressure checking Special tools 9998339 9998494 i Clean the fuel filter bracket carefully 2 Remove the bleed nipple and install connector nipple 9998494 Connect pressure gauge 9998339 3 Start the engine and run it at 1000 RPM until the fuel pressure on the pressure gauge has stabilized 4 Compare the measured pressure with the fuel pressu re given in the table below Fuel pressure After fuel filter at 1000 RPM min 350 kPa 50 psi 350 kPa 50 psi After fuel filter at full load min Repair instructions 5 When the check is completed remove the measure ment equipment and bleed the fuel system See Fuel system bleeding 43 Group 23 Fuel System Unit injectors changing Special tools 9998249 9998250 9998251 9998255 9998511 Other special equipment 9812546 1 Remove valve cover NOTE Do not use air tools as the studs can come loose and the injector wiring insulation can be dama ged 2 Remove all the adjustment bolts for the rocker arms and the valves Remove all the bolts on the rocker arm bridge NOTE Loosen the bolts on the rocker arm bridge evenly along the entire bridge to avoid distortion 44 Repair instructions 9998255 T ao hy re PE I Pee eee Se ATENTAN Ais a Lift out the rocker arm bridge using lifting bar 9998255 NOTE If no lifting bar is available the rock
32. er arm bridge should be lifted by two persons to avoid injury and damage 4 Drain the fuel from the cylinder head as instructed See Fuel system draining 5 Clean very carefully around the injectors to be repla ced Repair instructions Group 23 Fuel System 9998250 i DII aaa of M g J Mss il 9 CLD i DD AV Ne i D j aad ih Prers S 2D M o Install 2 ea ring seals 9998250 in the cylinder head fuel groove NOTE Be sure that the sealing rings are well cleaned and correctly seated Disconnect electrical wires from the injector N L gt f M SZA Clean the copper sleeve Use a hand drill and clea lt N D Ml Bs 00 g J E O Q a Fo P o PE n 2 Cc 5 3 2 4 BY 22 Z LO Se D pE 22 LL WS 8 Ear Ss wm p cn WIAA Z ED S A L z D O S ec ao a 5 5 J an 2 red Check that no contamination gets down into the fuel chamber in the cylinder head Install protective sleeve 9998249 onto the injector 45 Group 23 Fuel System 10 Clean the injector hole in the cylinder head very care fully and remove sealing rings 9998250 11 E 4 Deanne Tin X d CEESTI r N a a H H tl A es 4 N m V iB od ee F vy fles q l Install ne
33. et must be replaced 4 Install the new valve stem 1 and spring 2 Use a new sealing washer 3 install and tighten the bypass valve cover 5 Start the engine and check for leaks Group 22 Lubricating System Safety valve changing Special tool 9998487 Remove the right hand oil filter with the filter wrench 9998487 2 t eb OP ia t p onia MO Vg all WHO Halo ac amcan hA Clean around the cover on the engine block Remove the cover and take out the safety valve NOTE The safety valve cover takes a 50 mm wrench 3 Clean and check that the old O ring is not still in pla ce 4 Check that the new safety valve is marked with a yel low mark 5 Install the new safety valve with new O rings onto the engine block 6 Install a new oil filter see oil filter installation instruc tions 7 Start the engine and check for leaks Repair instructions Reducing valve changing EA Clean around the cover on the engine block Remove the cover and take out the reducing valve NOTE The safety valve cover takes a 50 mm wrench 2 Clean and check that the old O ring is not still in pla ce 3 Check that the new reducing valve is marked with a blue mark 4 Install the new reducing valve with new O rings onto the engine block 5 Start the engine and check for leaks 15 Group 22 Lubricating System Repair instructions Piston cooling valve changing
34. filter to collect the condensate water and fuel Open the drain nipple at the bottom of the fuel pre fil ter and let the condensate water run out 2 Tighten the drain nipple when water free fuel runs out 3 Start the engine and let the engine fill the water sepa rator with fuel Let the engine run for 10 minutes at idle so that any air remaining is forced out of the fuel system 4 Shut down the engine and check for leaks 48 Repair instructions Fuel pre filter with water monitor changing 1 Clean around the fuel filter Disconnect the water monitor 3 Drain the fuel filter see Fuel system draining 4 Remove the fuel filter with an appropriate filter wrench NOTE Unless the entire filter unit with water monitor is to be replaced the water monitor should be trans ferred to the new fuel filter 5 Clean the filter contact surface on the filter housing 6 Spread a thin layer of engine oil onto the sealing ring and install the new fuel filter according to the instruc tions on the filter 7 Connect the water monitor 8 Start the engine and check for leaks Group 23 Fuel System 21191 Copper sleeve for unit injector change NOTE Two different variants of copper sleeve can occur on the D12C Always check the variant of copper sleeve that is installed in the cylinder head before work starts to ensure that the correct speci al tool is used Please refer to item 7 on the next page
35. for ex ample when the oil temperature is low immediately af ter start up the bypass valve opens and the oil by passes the cooler When the oil temperature rises and the pressure drop across the oil cooler falls lt 3 0 bar 45 psi the valve closes and the oil flows through the oil cooler before being pumped into the lubrication system 3 5 Bypass valve for oil filter bypass turbo charger The bypass valve opens gt 2 1 bar 30 psi to maintain lubrication when the filter is clogged 4 Piston cooling valve The piston cooling valve opens 3 0 bar 45 psi when the engine speed reaches just above idle The oil flows through the piston cooling passages to the six piston cooling nozzles where oil is sprayed onto the underside of the pistons 6 Reducing valve The reducing valve controls the oil pressure by ope ning at high pressure 5 7 bar 80 psi and returns the excess oil to the oil pan 11 Group 22 Lubricating System Repair instructions Repair instructions Working with chemicals fuel and lubricating oil Important Apply barrier cream to hands and always wear protective gloves for work where there is a risk of contact with oil fuel or the like Continual skin con tact with engine oil dries out the skin and can be harmful Oil filter changing Special Tool 9998487 1 Clean the oil filter canister Remove all oil filters with filter wrench 9998487 3 Clean the sealing surface check that
36. gh the hole in the injector and out through the fuel passage The spill phase continues as long as the fuel valve 1 is Open 32 Design and Operation 1 Fuel valve 2 Pump piston 1 Fuel valve 2 Pump piston Group 23 Fuel System Injection phase The injection phase begins when the fuel valve 1 clo ses The cam on the camshaft continues to press the piston 2 down via the rocker arm and injection takes place as the passage through the fuel valve is closed The injection phase continues as long as the fuel val ve 1 is closed Pressure release phase Injection stops when the fuel valve opens and the pressure in the injector falls below the opening pressu re of the atomizer The fuel flows through the open valve through the in jector hole and out through the fuel passage Note that it is the position of the fuel valve closed or open which determines when injection begins and ends The duration for which the fuel valve is closed deter mines the quantity of fuel injected on each pump stro ke 1 Fuel valve 2 Pump piston Design and Operation 33 Group 23 Fuel System Repair instructions Repair instructions Control module EDC III i changing 1 Disconnect power to engine 2 Remove the control unit 5 Transfer the four rubber mounts to the new control module Remove the fuel cooling loop and the clamps on the fuel lines from the control module Fold the cooling loo
37. h water with a little detergent added around the connections to determine if they are leaking 8 If the pressure falls and the connections are not lea king the charge air cooler should be replaced with a new one Repeat the leakage test to be sure that the charge air cooler is leaking 9 After the leakage test is complete shut of the com pressed air supply turn the knob on the reducing val ve A fully counter clockwise and release the com pressed air 10 Remove the leakage tester 9996662 and the pressure plug 885231 Reinstall the charge air pipe on the inta ke pipe using new gaskets and tighten the clamp 11 Remove the pressure plug 885232 Reinstall the char ge air pipe between the turbo compressor and the con nection and tighten the clamp 12 Start the engine and perform a leakage check Repair instructions Charge air cooler cleaning Part no 1141658 3 1 TWD Drain the cooling system see Cooling system drain ing 2 Remove the charge air cooler see Charge air cooler changing 3 Clean the charge air element cooler on the outside Rinse the air passages with fresh water Clean the in side with cleaner part no 1141658 3 and blow dry with compressed air or allow to stand and drain TWD Alternatively the entire cooling system can be filled with 15 20 concentrated coolant and drained after 1 2 days of operation Then remove the charge air ele ment and clean the air pass
38. he oil pump and make sure there are no leaks AN WARNING Hot oil can cause burns 2 Pump out the oil NOTE Collect all old oil and hold it for recycling 3 Remove the drain hose 4 Add engine oil according to specifications See Tech nical data TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE 22 Repair instructions Oil cooler element changing 1 Drain the cooling system see Cooling system Draining 2 Open the main switch es and check that power to the engine is off Remove the pipe between the coolant pump and the cover of the oil cooler element NOTE Cover the hole to the coolant pump Release the clamp on the turbocharger and remove the air filter from the bracket Remove the air filter and air hose Group 22 Lubricating System Repair instructions 5 TAD Engine 6 Remove the turbo intake duct at the turbo 5 TWD Engine Remove the oil pipe from the turbocharger 7 Remove the turbo intake duct Remove the turbocharger 23 Group 22 Lubricating System Repair instructions 7 12 fo Fil Remove the rear cover plate four bolts Two of the Remove the sealing rings on the engine block and re se are installed on the cover of the oil cooler element move the seals in the cover Clean all contact sur 9 faces 12 Clean and install new sealing rings in the engine block Tighten the oil cooler element to 27 4 Nm 20 2 ft lbf Loosen the
39. hnical Data Tightening torque 20 2 Nm 15 1 5 Ibf ft 26 Fill up with coolant and do a leakage test if the work has not been done on a loose cylinder head 53 Group 23 Fuel System Bearing housing for camshaft change The production installed bearing housings are machined together with the cylinder head and can therefore not be moved from one cylinder head to another one If a bearing housing is damaged a replacement hous ing can be installed All bearing housings must then be changed so that the bearing housing po sitions can be aligned The holes in the replacement housings are oval which allows the center bearing housings to be adjusted radi ally and the front and rear housings to be adjusted axially If the cylinder head is already equipped with replace ment housings a damaged housing can be changed without needing to change the other housings 54 Repair instructions Replacement housings can be recognized since they have oval holes for the guide sleeves If a replacement housings are installed mark them with their numbers so they can be put back in the same place as before if they have to be removed Group 25 Intake and Exhaust Systems General Group 25 Intake and Exhaust Systems 95 Group 25 Intake and Exhaust Systems Design and Operation Design and Operation Turbocharger The turbocharger is driven by exhaust gases which pass through the turbine housing on their w
40. ing that it does not catch Then lift the radiator assembly out to a place where the radiator core can be changed 11 TAD Remove the frames and lift away the cover Remove the radiator core Loosen the charge air cooler at the left and right sides of the radiator 93 Group 26 Cooling System Repair instructions 13 14 TAD Install the new radiator core reinstall the frames and Reinstall the charge air cooler and tighten on the left cover tighten the bolts 16x and right sides 94 Group 26 Cooling System Repair instructions 15 18 TAD Carefully lift the radiator assembly onto the engine support NOTE Do not forget the outer fan shroud Clamp the lower turbo delivery pipe to the charge air cooler NOTE Fit the lower radiator hose and turbo delivery 19 pipe in before attaching the radiator to the engine sup port 16 Tighten the lower radiator hose clamp 17 Reinstall the expansion tank on the radiator connect the coolant level sensor 1 and clamp the hose to the expansion tank Reinstall the protective grille and outer fan shroud 95 Group 26 Cooling System 20 TAD Clamp the upper turbo delivery pipe to the charge air cooler 21 Add coolant according to specifications See Techni cal data TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE NOTE Mix the correct volume in advance to be sure that the system is filled 22 Start the engine and check for
41. ing running problems or damage 1 Clean around the fuel filter 2 Drain the fuel filter see Fuel filter draining 3 Remove the filter using an appropriate filter wrench 4 Clean the filter contact surface on the filter housing Repair instructions 5 Spread a thin layer of engine oil onto the gasket and install the new fuel filter Tighten the fuel filter accor ding to the instructions on the filter 6 Bleed the fuel system at the filter see Fuel system bleeding 7 Run the engine at fast idle for about 10 minutes to evacuate any remaining air from the system Perform a leakage and functional check 37 Group 23 Fuel System Fuel pump changing Clean around the fuel pump Disconnect fuel lines 1 2 and 3 Remove the fuel pump 3 Clean the contact surface on the transmission plate 38 Repair instructions NOTE Spread a thin layer of graphite grease around the O ring on the drive shaft before installing the fuel pump Check that the new fuel pump drive shaft fits into the transmission Install the fuel pump with a new gasket and apply thread tape to the bolt 1 NOTE The bolt 1 comes with thread tape see fuel pump packaging Connect fuel lines 1 2 and 3 with new gaskets 6 Bleed the fuel system and filter see Fuel system bleeding 7 Run the engine at high idle for about 10 minutes to evacuate any remaining air from the system 8 Carry out a
42. ions must always be followed and no special ins tructions for this are given in the Service Manual The majority of risks can be avoided by taking certain elementary precautions and using common sense A clean workplace and a clean engine eliminate many risks of injury and malfunction It is extremely important especially in working on fuel systems lubrication systems intake systems tur bos bearings and seals to keep out dirt and other kinds of foreign particles If this is not done malfunc tions or a shortened repair life could result Our common responsibility Every engine consists of numerous interacting sys tems and components The deviation of a component from its technical specification could dramatically in crease the environmental impact of an otherwise good engine It is therefore extremely important for speci fied wear tolerances to be maintained for systems with provisions for adjustment to be correctly set and for Volvo Penta Original Spare Parts to be used The service intervals in the engine maintenance schedule must be followed Certain systems such as fuel system components may require special competence and special testing equipment For environmental and other reasons cer tain components are sealed at the factory Work on these components must not be done by persons who are not authorized for such work Keep in mind that most chemical products if incorrectly used are ha zardous to the environment V
43. ir filter and air hose 16 Check the oil level and if necessary add engine oil ac cording to specifications See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE 17 Start the engine and perform a functional test and leak check 66 Repair instructions Turbocharger changing Always troubleshoot and repair any cause of damage to the turbo before installing a new unit The engine s lubrication system and intake system must be maintained properly for the turbo to work well the oil and the oil filter must be changed at the speci fied intervals the correct type of oil must be used and the air filter must be maintained correctly The first step in installing a new turbo should therefore be be to check the engine oil and change the filter if necessa ry then run the engine for a few minutes before instal ling a new turbo When changing the turbo blow out any flakes of rust or soot from the exhaust manifold as these flakes can damage the turbine on the new unit lt is also important to clean out the intake duct from the air filter Fragments from a damaged compressor wheel for example can remain and cause immediate damage to the new turbo 1 Open the main switch es and check that there is no power to the engine 2 Release the clamp on the turbocharger and remove the air filter from the bracket Remove the air filter and air duct Group 25 Intake and Exhaust Systems Repair instructions
44. isher ea sily accessible at the workplace Make sure that rags contaminated with oil or fuel as well as used fuel or oil filters are kept in a safe place prior to their disposal Under certain conditions spontaneous combustion can occur in oily rags Used fuel and oil filters along with used lubricating oil contaminated fuel left over paint solvents degreasers and detergents are all environmentally hazardous waste and should be taken to a recycling facility for proper treat ment Group 20 AN Batteries should never be exposed to open fla mes or electric sparks Never smoke near batte ries When batteries are being charged they give off hydrogen gas which combines with air to form a mixture that is highly flammable and ex tremely explosive If batteries are connected in correctly a spark can occur that could cause a battery to explode with injury and damage as a result Do not disturb the connections when at tempting to start an engine risk of sparks and do not lean over a battery AN Never mix up the positive and negative termin als when installing batteries A wrong connec tion could cause serious damage to the electri cal equipment Check against the wiring dia gram AN Always wear protective goggles when charging and handling batteries The battery electrolyte contains highly corrosive sulfuric acid If it gets on your skin wash the area with soap and plenty of water If the electrolyte gets in your eyes ri
45. ked next task 49 Group 23 Fuel System 7 A Check diameter A of the copper sleeve to be chan ged using a drill 7 5 mm 0 295 NOTE The copper sleeve must be free from soot If the drill can be passed through the hole this means that the copper sleeve has a diameter A 7 8 mm 0 307 If the drill does not pass through the hole or only with some resistance the copper sleeve diameter A 7 4mm 0 291 Z N IMPORTANT Turn the piston away from TDC once the correct diameter has been found to prevent the tools from touching the piston crown 8 Put tap No 980 9667 M9 in tool 999 8252 if diameter A was measured as 7 8 mm 0 307 Use tap No 998 7009 M8 if the diameter is 7 4 mm 0 291 The tip of the tap should project 20 mm 0 8 beyond the tip of the tool rod 50 Repair instructions 9998252 W oE Min 20 mm Carefully tap a thread in the copper sleeve using tool 999 8252 and a suitable tap as in point 8 NOTE Grease the thread tap to prevent swarf from falling down into the cylinder Screw the tap in at least 20 mm 0 8 past the tip of the copper sleeve 10 Remove the tap Group 23 Fuel System 11 999 8253 If o H A ral 3 CDA S A SJ TA NOTE Screw the nose of extractor 999 8253 in at least 15 mm 0 6 into the copper sleeve Remove the copper sleeve by carefully turning the nut a
46. lates around the drive belts Group 26 Cooling System 4 TAD Loosen the inner mounting bolt 1 a few turns Loosen the locking bolt 2 so that the tensioning bolt 3 can operate freely Screw down the tensioning bolt and remove the drive belt Repair instructions 5 Install the new drive belt and tension the drive belt with the tensioning screw 3 so that the slack is about 5 mm 0 2 6 Checking belt slack 9998305 Place holder 9998305 with the hole halfway between the pulleys where the drive belt is longest 7 Push down the O ring on the gauge 9998304 so that it lies below the graduated scale 8 Keeping the holder in position insert the gauge into the hole and push it in so that the end of the pin is flush with the upper part of the gauge push with thumb or finger Remove the gauge carefully and read it The slack should be 3 mm 0 1 for a new belt 3 4 mm 0 10 0 15 for an old belt NOTE Tighten the tensioner before making the mea surement because the belt will become tighter when the tensioner is snugged up 83 Group 26 Cooling System Repair instructions 9 Fit a 1 2 socket wrench handle in the belt tensioner Pull up on the handle and remove the drive belt 10 Check that the belt pulleys are clean and undamaged 11 Pull up on the 1 2 wrench handle and install the new drive belt 12 Reinstall the protective plates around the drive belts 13 Reinstall the prote
47. leakage and functional check Group 23 Fuel System Repair instructions Fuel pump rebuilding 4 The instructions below refer to the parts locations numbers shown in the figures Check all parts for damage and wear Always replace any parts that are damaged or worn Parts that are not replaced must be cleaned very tho roughly Special tools 9996626 9995028 Other special equipment 9986173 9986177 Remove the seals 2 and 3 from the impeller shafts with puller 9986173 and extractor 9986177 Use sleeve pin 9996626 1 Remove the valves 4 and 7 2 Remove the bolts 1 and take apart the housing 3 Remove the pump impellers 6 and 8 and the gas ket 5 The instructions below refer to the parts locations numbers shown in the figures above 39 Group 23 Fuel System 6 9995028 Press in the inner and outer seals 3 and 2 for the pump drive shaft with pin 9995028 The inner seal should be pressed down to the bottom and the outer seal flush with the housing NOTE The seals should be positioned with their seal ing lips away from one another 40 Repair instructions Install a new gasket 5 8 Dip the pump impellers 6 and 8 in diesel oil and in sert them into the housing 9 Check that the gasket 5 is seated properly in its groove and bolt the housing back together 10 Install the valves 4 and 7 Use new sealing washers 11 Insert protective plugs into the opening
48. leaks 96 Repair instructions Cooling system leakage testing Special tools 9996441 9996662 Checking test equipment 1 Check that the knob on the reducing valve A is tur ned all the way counter clockwise and connect 9996662 to a compressed air source 999 6662 9996441 Open valve B and adjust the reducing valve A until the pressure gauge shows a pressure of 100 kPa 14 5 psi NOTE The knob on the reducing valve A can be locked by pressing in on the knob NOTE Always follow the applicable safety rules 2 999 6662 9996441 Close valve B If the pressure does not fall within two minutes the equipment is considered reliable Group 26 Cooling System Leakage test 3 9996441 a a i Screw off the filler cap on the expansion tank and screw on cap 9996441 Check that the drain opening 1 on the expansion tank is plugged 4 Check all hoses and clamps for damage 5 Connect the leak tester 9996662 to a source of com pressed air and check that the knob on the reducing valve A is turned fully counter clockwise Repair instructions 6 Connect leak tester 9996662 to the air nipple on cap 9996433 7 9996662 Turn the knob on the reducing valve A clockwise un til the pressure gauge shows a pressure of 50 kPa 7 psi Close valve B The pressure should not show any decrease for two minutes if the system has no le aks NOTE If there is any doubt
49. m 0 307 for copper sleeve for the unit injector copper cleave forimnit imiector 9987009 Threading tool M8 for removing the Ri J copper sleeve for the unit injector 999 8253 Puller for copper sleeve for unit injector Consists of 9809668 Puller for copper sleeve for unit injector M9 9809746 Puller for copper sleeve for unit injector M8 2 Supplied individually Group 22 Lubricating System Design and Operation Design and Operation Lubrication system The engine is pressure lubricated via a gear pump coupled to the engine transmission The oil flow is re gulated by six valves The oil pump pumps the oil to two full flow filters and one by pass filter where the oil to the turbocharger is also filtered by about 5 From the full flow filter the 1 Safety valve 2 Bypass valve for oil cooler 3 Bypass valve for oil filter oil is passed to the engine block and distributed th rough passages to the engine lubrication points The oil cooler is of the plate type and is located under a cast iron cover on the right hand side of the engine block 4 Piston cooling valve 5 Bypass valve for bypass filter turbocharger 6 Reducing valve Group 22 Lubricating System Design and Operation 1 Safety valve When the oil pressure across the safety valve ex ceeds 8 6 bar 125 psi the valve opens and returns the oil to the oil pan 2 Bypass valve for oil cooler When the pressure across the oil cooler is low
50. ment is heavy If no lifting device is available avoid injury and damage by having two persons ready to lift the charge air cooler element Carefully clean the contact surfaces Install a new gasket on the charge air cooler and install the new charge air cooler element NOTE The charge air cooler element is heavy If no lifting device is available avoid injury and damage by having two persons ready to lift the charge air cooler element Reinstall the cover on the charge air cooler Use a new gasket Torque the bolts in two steps as described below Step 1 Insert all bolts and screw then down into con tact with the surface Step 2 Torque the bolts to 20 2 Nm 15 2 ft lbf in the order shown in the diagram Group 26 Cooling System Repair instructions 10 12 Reinstall the water pipe connectors on the ends of the charge air cooler using new sealing rings 11 Reinstall the turbo delivery pipe Use new sealing rings 13 Add coolant according to specifications See Techni cal data TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE NOTE Mix the correct volume in advance to be sure that the system is filled 14 Start the engine and perform leakage and functional checks Reinstall the water pipes on the ends of the charge air cooler using new sealing rings 89 Group 26 Cooling System Repair instructions Charge air cooler leakage test Lakage test TAD i Special tools 999
51. n key to 0 to avoid any risk of accidentally starting the engine Check the wiring diagram to be sure that the correct cables are disconnec ted See Instructions for running on starter NOTE For specifications see Technical Data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE Instructions for working with electronic fuel injection 28 Never remove the control module connectors or any electrical cable from the sensors when the engine is running The ignition key should be in the 0 position and the engine stopped Never disconnect any battery cables when the engine is running Disconnect the control module connector from the control module when doing any electrical welding work on the engine NOTE The main power must be turned off before the connectors are disconnected Only batteries should be used for starting Starter packs can cause voltage surges and damage the electronics For quick battery charging disconnect the battery cables This does not apply to normal maintenan ce charging If any connectors are disconnected be sure that they are reconnected properly and that they are free from oil and other contamination which can Cause poor contact Group 23 Fuel System Special Tools 9995028 9998339 Tool 9995028 9996626 9998249 9998250 9996626 9998249 9998494 Name use Drift pin Sleeve pin Protective sleeve Ring seal Tools Tools 999
52. ng System 70 Group 26 Cooling System Tools Tools Special tools 885231 885232 9996315 9996441 9996662 9996858 9998304 9998305 885231 Pressure plug with connection nipple 9996858 Gauge pin 885232 Pressure plug 9996998 Gauge pin 9992412 Gauge pin 9998304 Gauge 9996315 Gauge pin 9998305 Holder 9996441 Cap leak testing 9996662 Leak testing equipment 71 Group 26 Cooling System Design and Operation Design and Operation Cooling system TAD The cooling system is a closed fresh water system with a piston thermostat which controls the water tem perature _ f 4 ab 3 Conn ee ar P i 1 Expansion tank 4 Thermostat housing 2 Coolant pump 5 Radiator 3 Coolant filter 72 Group 26 Cooling System Cooling system TWD The cooling system is a closed fresh water system with a piston thermostat which controls the water tem perature The TWD engine has a water cooled charge air cooler that is integrated into the engine cooling system Design and Operation An extra coolant pump supplies the charge air cooler and is installed on the generator 1 Expansion tank 2 Coolant pump 3 Coolant filter O90990 4 Charge air cooler water cooled 5 Thermostat housing 6 Radiator 73 Group 26 Cooling System Charge air cooler On TAD engines the charge air cooler is located with
53. no gasket resi due remains 4 Spread a thin layer of engine oil onto the gasket of the new oil filter and install filter 5 Install the new oil filters see oil filter installation ins tructions 6 Top up engine oil and run the engine with the starter until the lubricating oil pressure appears on the pres sure gauge See Instructions for running the starter motor 7 Start the engine and check for leaks around the oil filters Group 22 Lubricating System Repair instructions Oil sump gasket changing j 1 Pump out the engine oil See Engine oil changing 2 Remove the old gasket Carefully clean the sealing groove on the lip of the oil pan and the contact surfa ce on the engine block Install the new gasket in the groove on the lip of the oil pan Remove the oil filler pipe and pull out the dipstick from the oil pan Reinstall the oil pan Remove the oil pan 13 Group 22 Lubricating System 6 Install the oil filler tube and replace the dipstick 7 Add engine oil according to specifications See Tech nical data TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE 8 Start the engine and check for leaks Repair instructions Oil filter bypass valve replacing Clean the oil filter bracket and remove the cover from the bypass valve 2 Remove the valve stem and spring 3 Clean and check the valve seat If the valve seat is damaged the entire brack
54. nse them at once with plenty of water and see a doctor as soon as possible A A A Safety Information Stop the engine and cut off the power at the main switch or switches before starting to work on the electrical system The clutch should be adjusted with the engine switched off Use the lifting eyes mounted on the engine when lifting it Always check that all lifting equipment is in good condition and that it has the right capacity for the job weight of engine plus gearbox and extra equipment if any To ensure safe handling and to avoid damaging components mounted on the top of the engine the engine should be lifted using a special pur pose fixture or an adjustable one set up for the engine All chains or cables should run parallel to each other and be as perpendicular as pos sible to the top of the engine Group 20 General General Information About the Service Manual This Service Manual contains descriptions of and repair instructions for the standard versions of the TAD1240GE TAD1241GE VE TA1242GE VE and TWD1240VE model engines The Service Manual may show procedures performed on any of the engines listed above so the illustrations and photographs showing certain details may not be completely accurate in some cases However the rep air methods are all essentially the same The engine model and serial number are given on the data plate see Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and
55. nt if required 19 Group 26 Cooling System Repair instructions Coolant pump changing i 1 Open the main switch es and check that there is no power to the engine 2 Drain the cooling system see Cooling system drain ing 3 Remove the water pipe between the coolant pump and thermostat housing Remove the water pipe from the coolant pump and from the radiator hose connection Remove the water pipe between the oil cooler ele ment and the coolant pump 76 Group 26 Cooling System Repair instructions Remove the coolant filter with a suitable wrench 7 TAD Remove the coolant pump 9 Remove the radiator hose at the coolant pump 7 TWD Remove the gear unit from the coolant pump Remove the water pipe from the coolant pump 11 Group 26 Cooling System Repair instructions 10 12 Lubricate the sealing rings with a thin layer of engine oil and install the new coolant filter See installation instructions on the filter canister Install the new gear unit in the coolant pump with new sealing rings NOTE Lubricate the sealing rings to make it easier to 13 TAD fit the gear unit in the coolant pump Reinstall the radiator hose between the coolant pump 11 and the radiator 13 TWD Reinstall the water pipe to the coolant pump using a new gasket 3 f t k 4 Vy E H i Install the coolant pump NOTE Be sure that the coolant pump is correc
56. old gasket changing 00 57 Exhaust manifold gasket changing 005 63 Turbocharger changing cccsssseeessseeeeseeeeeeens 66 Pressure drop indicator checking cce 69 GROUP 26 COOLING SYSTEM Ea E E E E E 70 Special 100 S trragantestencivgepateondtetganeuspmaneeiterrraes 71 Design and Operation Cooling system TAD ccccceseceeeeeeeeeeeeeeeees 72 Cooling system TWD ccccseeeeeeeeeeeeeeeeeeees 73 Charge air CODEN cc seteersercccsoecersctce tebeeceoreencteee 74 Repair instructions Cooling system draining ccccceceseeeeeeeeeeeees 75 Cooling system filling ccccceeeceeeeeeeeeeeeeeeees 75 Coolant pump changing ceccceceeeeeeeeeeeeees 76 Coolant filter changing cccsecceeeeeeeeeeeeeeeees 79 Piston thermostat changing ccsssceseeeeeees 80 Piston thermostat functional check 005 81 Drive belts changing sscccpesionscznnuncznewbdommectondedaes 82 Cooling system cleaning cccceeeeeeeeeeeeeeees 85 Charge air cooler changing TAD 008 86 Charge air cooler changing TWD 068 87 Charge air cooler leakage test TAD 90 Charge air cooler cleaning ccccseeeeeeeeeeeees 91 Radiator core changing ceccceeeeeeeeeeeeeeeees 92 Cooling system leakage testing 00ce 96 Extra coolant pump changing TWD
57. olvo Penta recommen ds the use of biologically degradable degreasers for all cleaning of engine components unless otherwise ex pressly stated in the Service Manual Take care to en sure that oils and residual detergent etc are properly destroyed and do not inadvertently end up in the envi ronment Tightening torques Tightening torques for vital fasteners that should be tightened using a torque wrench are listed in Techni cal Data Tightening torques and are also given in the Service Manual s work descriptions All tightening tor ques refer to clean threads bolt heads and contact surfaces and lightly oiled or dry threads If lubricants thread locking compounds or sealants are required for certain fasteners the type to be used is stated in the work description and in Tightening torques The tor ques in the table below are applicable to fasteners for which no special torque is specified These torques are for guidance only and the fastener in this case need not be tightened with a torque wrench Size Tightening torque Nm Ibf ft M5 6 4 4 M6 10 7 4 M8 25 18 4 M10 50 36 9 M12 80 59 0 M14 140 103 3 Group 20 Torque angle tightening In torque angle tightening the fastener is tightened to a specified torque and then further tightened through a specified angle Example for 90 angle tightening the fastener is tightened an additional 1 4 turn after the specified torque has been reached all in the same operati
58. on Lock nuts Lock nuts that have been removed must not be reu sed New ones must be used because the locking characteristics of the old nuts deteriorate if they are used again For lock nuts with a plastic insert Nylock for example the tightening torques in the table should be reduced if the Nylock nut has the same depth as a standard all metal hex nut Reduce the tightening torque by 25 for 8 mm or larger thread sizes For deeper Nylock nuts where the all metal thread is as deep as that of a standard hex nut the tightening torques in the table are applicable Strength classes Nuts and bolts are divided into different strength clas ses the strength class is marked on the bolt head A higher number indicates a stronger material For ex ample a bolt marked 10 9 is stronger than one mar ked 8 8 When reassembling components it is therefore important to make sure that bolts are reinstalled in their original places When installing new fasteners check the spare parts catalog to make sure that the correct type is used General repair instructions Sealants Several different types of sealants and locking fluids are used on the engines Their properties differ and they are intended for fasteners of different strengths temperature ranges resistance to oil and other chemi cals and for the various materials and clearances in the engine For service work to be fully satisfactory it is therefore important that the righ
59. p to one side 3 Disconnect the wiring connector from the control mo dule Push out on the latch 1 and pull the connector 2 upward 34 Group 23 Fuel System Repair instructions Connect the fuel cooling loop and the clamps for the fuel lines on the control module NOTE The mounting screws for the fuel cooling loop are self tapping there are no threads in the control module Connect the connector to the control module Plug the connector 2 into the control module so that the safe ty latch 1 can be engaged 9 Start the engine and perform a leakage and functional check 35 Group 23 Fuel System Repair instructions Fuel system draining Open the vent nipple on the cylinder head Allow fuel 1 to drain into a container Clean carefully around the cylinder head vent nipple NOTE For fuel filter changing Only perform steps and fuel filter bracket draining nipple 1 3 in the fuel draining procedure 2 4 Connect a plastic hose to the fuel filter bracket drain When the fuel has finished flowing out open the vent ing nipple and open the nipple 2 nipple 1 on the fuel filter bracket and allow the fuel to drain into a container NOTE Be careful when handling fuel and make sure that it is disposed of properly 36 Group 23 Fuel System Fuel filter changing NOTE Do not fill the new filter with fuel before instal ling as there is a risk of contamination entering the system and caus
60. remaining bolts and remove the cover of the oil cooler element 10 Remove the oil cooler element 24 Group 22 Lubricating System Repair instructions 13 15 NOTE The rear cover plate is mounted together with the cover of the oil cooler element 1 Install a new seal in the cover lift it into place and tighten the bolts to 24 4 Nm 188 ft lof as specified in the torque table Always use new drift pins when in Stalling the cover on the engine Install the water pipe between the cover of the oil coo ler element and the coolant pump Use new seals 16 Install the turbocharger see Turbocharger changing 17 Add engine oil to specification See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE 18 Add coolant to specification See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and 1 Install bolts A and B for alignment TWD1240VE 2 Tighten bolts C and D 3 Install all bolts tighten them in numerical order from NOTE Mix the correct volume in advance to ensure the center outwards as shown in the figure 1 4 that the system is filled 4 Check the torque on bolts C and D 14 19 Start the engine and check for leaks Install the rear cover plate four bolts Two of these are mounted together with the cover for the oil cooler element 25 Group 22 Lubricating System Repair instructions Oil cooler element leakage h test 9996662 Special tools 9
61. s of the fuel pipes Group 23 Fuel System Repair instructions Fuel system bleeding a 1 Clean the vent nipples on the cylinder head and on the fuel filter bracket 2 Transfer the hose to the cylinder head bleeder nipple and bleed in the same way as at the fuel filter bracket 5 Run the engine at fast idle for about 10 minutes to evacuate any remaining air from the system 6 Perform a leakage and functional check Bleed the fuel system and filter Connect a transpa rent plastic hose from the bleeder nipple 1 to a con tainer Open the bleeder nipple on the fuel filter bracket Pump with the manual pump until fuel flows without air bubbles Tighten the bleeder nipple while fuel is flo wing 3 Remove the hose and replace the protective cap on the bleeder nipple NOTE When changing the fuel filter only no further bleeding is necessary 41 Group 23 Fuel System Repair instructions Bypass valve changing 4 1 Clean the connectors on the fuel hoses Install a new bypass valve and gaskets Torque to lean thoroughl h Ive Clean thoroughly around the bypass valve 55 5 Nm 40 4 ft lbf 2 5 Drain the fuel Fuel ining a Bebe e a iegee a Hebe yee Chalnlng Bleed the fuel system See Fuel system bleeding 6 Run the engine at fast idle for about 10 minutes to evacuate any remaining air from the system 7 Perform a leakage check Remove the bypass valve 3 TWD R
62. stalled and tor qued within 20 minutes from applying the sealant NOTE Sealant should be applied as shown in the pic ture above 3 mm 114 from the inside edge of the in take manifold contact surface 10 TWD Reinstall the intermediate bracket Torx bolts Reinstall the intake manifold charge air cooler with a new gasket NOTE The intake manifold charge air cooler is heavy If no lifting device is available avoid injury and dama ge by having two persons ready to lift the intake mani fold charge air cooler 60 Group 25 Intake and Exhaust Systems Repair instructions 13 14 TAD Replace the cover on the wiring box Torx bolts 14 TWD Reinstall the bypass valve on the intake manifold 15 TWD Reinstall the bypass valve on the intake manifold Reinstall the charge air temperature boost pressure sensor on the intake manifold 61 Group 25 Intake and Exhaust Systems Repair instructions 15 TAD 16 TAD Reinstall the charge air temperature boost pressure sensor on the intake manifold and attach the wiring Reinstall the turbo delivery pipe with new ties 7 16 TWD ses E engine and perform a functional test and leak check me Reinstall the turbo delivery pipe on the charge air coo ler with a new gasket 62 Group 25 Intake and Exhaust Systems Repair instructions Exhaust manifold gasket 3 TWD changing Say 7 z PAANAN Turn off the main switch es and check tha
63. t sealants and locking fluids are used on the fasteners where they are needed In the appropriate sections of the Service Manual we have indicated the agents used in the assembly of our engines The same agents or agents with equivalent properties but from a different manufacturer should be used in service work When using sealing agents and locking fluids it is im portant for the mating surfaces to be free of oil grea se paint and rust inhibitor They must also be dry Al ways follow the manufacturer s directions regarding temperature hardening time and other instructions for the product Two different basic types of agent are used on the engines RTV agents Room Temperature Vulcanizing Used mostly as a sealant coating dope on gaskets RTV agents are easily visible when the gasket is removed and the old RTV agent must be cleaned off before the new gasket is installed The following agents are of RTV type Loctite 574 Volvo Penta 8408791 Permatex No 3 Volvo Penta 11610995 Permatex No 77 Old sealant can be removed in all cases with denatured alcohol Anaerobic agents These harden in the absence of air They are used when two solid parts like castings are fitted together without a gasket They are also com monly used to secure and seal plugs the threads of studs valves oil pressure monitors etc Hardened anaerobic agents are glassy they are usu ally colored to make them more visible Hardened an
64. t the same time as the spindle is held tight NOTE Use 980 9668 M9 or 980 9746 M8 depend ing on the diameter of the hole in the copper sleeve 12 999 8580 9808618 gt Carefully clean the sealing surface in contact with the O ring on the copper sleeve Use cleaning kit 999 8599 and an electric drill NOTE Install sleeve 999 8580 with holder into the in jector well to prevent dirt from coming down into the fuel duct Note The lugs must be cut off the holder to get the tool to fit Repair instructions 13 9998580 ER 9808614 SS Carefully clean the seat for the copper sleeve in the cylinder head Use brush 980 8614 together with a shaft and holder NOTE Install sleeve 999 8580 with holder must re main in the injector well to prevent dirt from coming down into the fuel duct 14 99985380 9808617 gt Carefully clean the seat for the copper sleeve tip with brush No 9808617 NOTE Sleeve 999 8580 with holder must remain in the injector well to prevent dirt from coming down into the fuel duct 51 Group 23 Fuel System 15 Check that there is no contamination left in the cylin der head Remove sleeve 9998580 and holder Undo the two seal rings 999 8250 from the fuel gallery in the cylinder head 16 Mrs Te eile mgit P 72 n b ig an ee i 1 ch ea ae d TLE Wh Vo ne ni i x i A i y rf im 1 lt sake r
65. t there is no power to the engine Release the clamp on the turbocharger and remove the air filter from the bracket Remove the air filter and air duct 3 TAD Remove the oil pipe from the turbocharger Remove the turbo delivery pipe at the turbo 63 Group 25 Intake and Exhaust Systems 5 Remove the rear protective plate and the front heat shield Remove the exhaust manifold 64 Repair instructions Installation 9 Carefully clean the contact surfaces on the exhaust manifold and cylinder head 10 Install the exhaust manifold using new gaskets and torque as shown below Step 1 Torque bolts 1 to 10 Nm 7 ft lbf max to 10 Nm 7 ft lbf max to 52 4 Nm 38 3 ft lof to 54 4 Nm 38 3 ft lof to 54 4 Nm 38 3 ft lof to 54 4 Nm 38 3 ft lbf SN Step 2 Torque bolts 2 3 2 Step 5 Torque bolts 4 Step 3 Torque bolts Step 4 Torque bolts S SA SAN SA SA SAN Step 6 Torque bolts 1 11 Replace the rear protective plate and the front heat shield Group 25 Intake and Exhaust Systems Repair instructions 12 14 TAD Install the turbocharger using a new gasket Reinstall the turbo delivery pipe on the turbo 13 14 TWD Reinstall the turbo delivery pipe Reinstall the oil pipe with new seals 65 Group 25 Intake and Exhaust Systems 15 a p yy D 5 A i Reinstall the a
66. that the cooling system is not leaking repeat the leak test until the test gives a clear result 8 Remove the leak tester and open the drain on the ex pansion tank Check the coolant level in the expansion tank 10 Start the engine and perform a leak check 97 Group 26 Cooling System Extra coolant pump overhaul TWD Special tools 9992412 9996315 9996858 9996998 Note All numbers in parenthesis refers to the picture above 1 Note Mark the fitting position of the gable 3 on the coolant pump housing 2 before removing Remove the gable 3 and the O ring 13 2 Press out the shovel wheel 12 together with the axle 5 use gauge pin 9996858 3 Remove the pulley 4 use a suitable puller Remove the spacer washer 10 4 Remove the clamp washer 9 spacer washer 8 and the guard ring 7 5 Remove the sealing washer 11 6 Press out the bearing 6 together with the bearing axis 5A use gauge pin 9996858 98 Repair instructions 5A 7 Remove the plugs 16 check that the draining holes are clean and not blocked should be 7 mm 8 Clean all the coolant pumps parts well and check for damages and wear 9 Apply bearing grease on the bearing axis 5A and press on the new bearing 6 use gauge pin 9992412 10 Apply bearing grease in the bearing housing Press the new bearing 6 and the bearing axis 5A in the bearing housing use gauge pin 9992412
67. the radiator and is air cooled On TWD engines the charge air cooler is located at the intake manifold on the left hand side of the engine and is water cooled The purpose of the charge air cooler is to cool the in take air which means that the specific volume of the air is reduced so that larger quantities of air can be forced into the combustion chamber This means bet ter combustion of fuel and hence better fuel efficien cy Cooling the engine charge air gives a power increase of about 10 increased torque and reduced fuel con sumption A diesel engine with turbocharger and charge air coo ler has the best efficiency of all internal combustion engines 74 Design and Operation Charge air cooler TAD1240GE TAD1241GE TAD1242GE s SS tA OINO EAr a Charge air cooler TAD1241VE Group 26 Cooling System Repair instructions Repair instructions Cooling system draining Z N WARNING Open the filler cap very carefully when the engine is hot Steam or hot coolant can spray out NOTE Before draining the cooling system remove the expansion tank cap TAD a fiifini int iis m it a Gear 4 sair ac T P fresh water drainage valve plug 1 Open all drain locations Drain the coolant from the ra diator using drain hoses The drain nipple is located under the radiator 2 Check that all coolant runs out There may be depo sits
68. tly se ated and that all bolts are screwed in before being tightened 78 Group 26 Cooling System Repair instructions 15 17 Reinstall the water pipe to the coolant pump and to the radiator connection 18 Reinstall the water pipe between the oil cooler ele Add coolant according to specifications See Tech ment and the coolant pump Use new gaskets nical data TAD1240GE TAD1241GE VE 16 TAD1242GE VE TWD1240VE NOTE Mix the correct volume in advance to be sure that the system is filled 19 Start the engine and check for leaks Coolant filter changing NOTE Turn the valve at the coolant pump 90 degrees before removing the coolant filter Do not forget to turn the valve back after the new coolant filter has been in Stalled See Coolant pump changing steps 6 and 12 Reinstall the water pipe between the oil cooler ele ment and thermostat housing Use new gaskets 79 Group 26 Cooling System Repair instructions Piston thermostat changing h 1 Drain the cooling system see Cooling system drain Install the new piston thermostat with a new sealing ring and hand tighten the bolts 5 Remove the thermostat housing and take out the thermostat NOTE Two bolts must be removed from the exhaust manifold in order to be able to remove the thermostat housing 3 Clean all contact surfaces Install a bolt M8 x 20 with nut washer and spacer between the flange of the exhaust
69. ved for certification For Volvo Penta to be answerable as the manufactu rer for ensuring that engines in use meet the stipula ted environmental requirements the following require ments regarding service and spare parts must be ful filled The service intervals and maintenance measures recommended by Volvo Penta must be followed Only Volvo Penta Original Spare Parts intended for the certificated version of the engine may be used Service affecting injection pumps pump settings or unit injectors must always be carried out by an authorized Volvo Penta facility The engine must not be rebuilt or modified in any way except for the accessories and service kits that Volvo Penta has developed for the engine in question Modifications made to exhaust pipes and air inta ke ducts to install an engine in an engine room ventilation ducts must not be made indiscrimina tely as this could affect exhaust emissions Secu rity seals if present must not be broken by unauthorized personnel Z N IMPORTANT When spare parts are required use only Volvo Penta Original Spare Parts If non original spare parts are used AB Volvo Penta will no longer be responsible for ensuring that the engine corresponds to the certificated version All types of injury damages or costs arising from the use of non original Volvo Penta spare parts for the product in question will not be co vered by Volvo Penta Group 20 General repair instructions
70. w sealing rings on the injector and check that they are correctly seated Lubricate the rings with engine oil Install the injector forcing it down until it seats and center it between the valve springs Tighten the injector to the torque and angle specified See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE NOTE Different tightening torques apply depending on whether or not the injector s copper sleeve has been replaced 46 Repair instructions 12 a ATUA LL 0 If the injector is not installed immediately insert a pro tective plug 9998251 into the cylinder head hole 13 Connect the electrical wires to the injector and tighten the nuts to max torque 1 5 Nm 1 ft lbf NOTE If the nuts are overtightened the solenoid val ve can be damaged and the entire injector will have to be replaced Group 23 Fuel System 14 Oil the valve yokes and cams with engine oil Lift the rocker arm bridge into position using lifting bar 9998255 Be sure that the valves and rocker arms mate correctly NOTE If no lifting bar is available the rocker arm bridge should be lifted by two persons to avoid injury and damage 15 Tighten the bolts on the rocker arm bridge evenly along the entire bridge to avoid distortion Be sure that the rocker arm shaft fits correctly into the guide sleeves on the camshaft bearing blocks and tighten the bolts so that the shaft is snug against the

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