Workshop Manual Group 21-26 I 3(0) TD420VE, TAD420VE TAD620VE Workshop Manual Industrial engines TD420VE, TAD420VE, TAD620VE Contents Safety Precautions General information Service procedures Special tools Description of engine 12 Engine plate placement 12 Engine plate 12 Engine serial number 13 Cylinder numbering 13 Engine, component placement 14 Start motor side 14 Service side 15 Lubrication system 16 Fuel system 17 Cooling system 19 Technical data 20 Engine 20 Tables 24 Checks and adjustments 28 Compression test 28 Injectors, Checking/adjustment 29 Exposing engine 31 Installing fixture 32 Disassembly, complete engine 34 Crankshaft, measuring 89 Connecting rod, measuring 92 Piston 95 Camshaft 98 Camshaft bearing, Checking 100 Balance shaft bearing 102 Cylinder head 104 Valve seat, replacing 107 Valve seat, grinding 108 Valves, grinding 108 Rocker bridge 109 Control rod 110 Component repair 114 Group 21: Flywheel ring gear, replacing 114 Valve clearance, Checking/adjustment 116 Crankshaft seal, replacing (complete engine) 118 Crankshaft seal, front (front casing), replacing 120 Group 22: Pressure regulating and bypass valves, checking 122 Front casing, oil pump 124 Oil cooler 125 Group 23: Fuel pump 127 Injection pump, replacing 128 Group 25: Charge air pressure, checking 129 Group 26: Coolant pump, checking/replacing 130 Thermostat 132 Drive belts, replacing 133 Assembly, complete engine 49 Wiring diagram 134 Checking and measuring 87 Engine block 87 Index 136 Notes 137 Safety Precautions Group 20 Safety Precautions Introduction This Workshop Manual contains descriptions and instructions for the repair of the Volvo Penta products or product types Check that you have the correct Workshop Manual for your engine Before starting work on the engine, read these safety precautions with care as well as ”General information” and ”Service procedures” Important In this book and on the product you will find the following special warning symbols WARNING! Possible danger of personal injury, extensive damage to property or serious mechanical malfunction if the instructions are not followed IMPORTANT! Used to draw your attention to something that can cause damage or malfunctions on a product or damage to property NOTE: Used to draw your attention to important information that will facilitate the work or operation in progress Below is a summary of the risks involved and safety precautions you should always observe or carry out when operating or servicing the engine Immobilize the engine by turning off the power supply to the engine at the main switch (switches) and lock it (them) turned off before starting work Set up a warning notice at the main circuit breaker As a general rule all service operations must be carried out with the engine stopped However, some work, for example certain adjustments require that the engine is running when they are carried out Approaching an engine which is operating is a safety hazard Loose clothing or long hair can fasten in rotating parts and cause serious personal injury If working in proximity of an engine which is operating, careless movements or a dropped tool can result in personal injury Take care to avoid contact with hot surfaces (exhaust pipes, Turbocharger (TC), air intake pipe, starter heater etc.) and hot liquids in lines and hoses on an engine which is running or which has just been stopped Reinstall all protective parts removed during service operations before starting the engine Check that the warning or information labels on the product are always clearly visible Replace labels which have been damaged or painted over Never start the engine without installing the air cleaner (ACL) filter The rotating compressor in the Turbo can cause serious personal injury Foreign objects entering the intake ducts can also cause mechanical damage Never use start spray products or similar when starting the engine They may cause an explosion in the inlet manifold Danger of personal injury Only start the engine in a well-ventilated area If operating the engine in an enclosed area ensure that there is exhaust ventilation leading out of the engine compartment or workshop area Avoid opening the coolant filler cap when the engine is hot Steam or hot coolant can spray out and the system pressure will be lost When needed, open the filler cap slowly and release the pressure in the system Be very careful if a cock or plug or engine coolant line must be removed when the engine is hot It is difficult to anticipate in which direction steam or hot coolant can spray out Hot oil can cause burns Avoid getting hot oil on the skin Ensure that the lubrication system is not under pressure before carrying out any work Never start or operate the engine with the oil filler cap removed, otherwise oil could be ejected Stop the engine before carrying out operations on the engine cooling system Group 20 Always use protective glasses or goggles when carrying out work where there is a risk of splinters, grinding sparks, acid splashes or where other chemicals are used The eyes are extremely sensitive An injury could result in blindness! Avoid getting oil on the skin! Repeated exposure to oil or exposure over a long period can result in the skin becoming dry Irritation, dryness and eczema and other skin problems can then occur Used oil is more dangerous than fresh oil from a health aspect Use protective gloves and avoid oil soaked clothes and shop rags Wash regularly, especially before eating There are special skin creams which counteract drying out of the skin and make it easier to clean off dirt after work is completed Many chemicals used on the product (for example engine and transmission oils, glycol, gasoline and diesel oil), or chemicals used in the workshop (for example degreasing agents, paint and solvents) are dangerous to health Read the instructions on the product packaging with care! Always follow the safety precautions for the product (for example use of protective mask, glasses, gloves etc.) Make sure that other personnel are not exposed to hazardous chemicals, for example in the air Ensure good ventilation in the work place Follow the instructions provided when disposing of used or leftover chemicals Exercise extreme care when leak detecting on the fuel system and testing the fuel injector nozzles Use eye protection The jet from a fuel injector nozzle is under extremely high pressure and has great penetrative energy, so the fuel can penetrate deep into the body tissue and cause serious personal injury Danger of blood poisoning WARNING! The delivery pipes must under no circumstances be bent Damaged pipes should be replaced All fuels and many chemical substances are flammable Do not allow naked flame or sparks in the vicinity Certain thinner products and hydrogen from batteries can be extremely flammable and explosive when mixed with air in the right proportions No Smoking! Safety Precautions Ensure that the work area is well ventilated and take the necessary safety precautions before starting welding or grinding work Always ensure that there are fire extinguishers at hand when work is being carried out Ensure that rags soaked in oil or fuel and used fuel or oil filters are stored safely Rags soaked in oil can spontaneously ignite under certain circumstances Used fuel and oil filters are environmentally dangerous waste and must be deposited at an approved site for destruction together with used oil, contaminated fuel, paint remnants, solvent, degreasing agents and waste from washing parts Never expose a battery to naked flame or electrical sparks Do not smoke close to the batteries The batteries give off hydrogen gas during charging which when mixed with air can form an explosive gas - oxyhydrogen This gas is easily ignited and highly volatile A spark, which can be formed if the batteries are wrongly connected, is enough to make a battery explode and cause damage Do not shift the connections when attempting to start the engine (spark risk) and not lean over any of the batteries Always ensure that the Plus (positive) and Minus (negative) battery cables are correctly installed on the corresponding terminal posts on the batteries Incorrect installation can result in serious damage to the electrical equipment Refer to the wiring diagram Always use protective goggles when charging and handling the batteries Battery electrolyte contains sulfuric acid which is highly corrosive Should the battery electrolyte come into contact with unprotected skin wash off immediately using plenty of water and soap If battery acid comes in contact with the eyes, immediately flush with plenty of water and obtain medical assistance at once Turn the engine off and turn off the power at the main switch(es) before carrying out work on the electrical system Clutch adjustments must be carried out with the engine stopped Safety Precautions Group 20 Use the lifting eyes fitted on the engine when lifting the drive unit Always check that the lifting equipment used is in good condition and has the load capacity to lift the engine (engine weight including gearbox, if fitted, and any extra equipment installed) Use an adjustable lifting beam or lifting beam specifically for the engine to raise the engine to ensure safe handling and to avoid damaging engine parts installed on the top of the engine All chains and cables should run parallel to each other and as perpendicular as possible in relation to the top of the engine If extra equipment is installed on the engine which alters its center of gravity a special lifting device is required to obtain the correct balance for safe handling Never carry out work on an engine suspended on a hoist Never work alone when removing heavy engine components, even when using lifting devices such as locking tackle lifts When using a lifting device two people are usually required to the work, one to take care of the lifting device and another to ensure that components are lifted cle- ar and not damaged during the lifting operations Always check before starting work if there is enough room to carry out disassembly work without risking personal injury or damage to the engine or parts WARNING! The components in the electrical system and in the fuel system on Volvo Penta products are designed and manufactured to minimize the risk of fire and explosion The engine must not be run in areas where there are explosive materials Always use the fuels recommended by Volvo Penta Refer to the Instruction Book Use of fuels that are of a lower quality can damage the engine On a diesel engine poor quality fuel can cause the control rod to seize and the engine to overrev with resulting risk of damage to the engine and personal injury Poor fuel quality can also lead to higher maintenance costs Remember the following when washing with a high pressure washer: Never direct the water jet at seals, rubber hoses, electrical components or the radiator Never use the high pressure feature when cleaning an engine © 2004 AB VOLVO PENTA We reserve the right to make changes Printed on environmentally-friendly paper Group 20 General information General information About this Workshop Manual Certified engines This Workshop Manual contains descriptions and instructions for the repair of standard engine versions TD/TAD 420 and 620 Manufacturer warrants that both new and currently operating engines that are certified to national and regional environmental regulations meet environmental requirements The product must correspond to the engine that was approved during certification In order that Volvo Penta, as manufacturer, will be able to warrant that engines in operation meet environmental requirements, the following requirements for service and spare parts must be met: The Engine Designation and Engine Numbers can be found on the product plate (see page 12) Please always include both the engine designation and the engine number in all correspondence The Workshop Manual is produced primarily for the use of Volvo Penta workshops and service technicians For this reason the manual presupposes a certain basic knowledge and that the user can carry out the mechanical/electrical work described to a general standard of engineering competence AB Volvo Penta products are under a continual process of development and we therefore reserve all rights regarding changes and modifications All the information in this manual is based on product specifications available at the time the book was published Any essential changes or modifications of the product or revised service methods introduced after the date of publication will be provided in the form of Service Bulletins Flat Rates Operation numbers that show in instruction headings refer to Volvo Penta Flat Rates Spare parts Spare parts for the electrical and fuel systems are subject to various national safety requirements Volvo Penta Original Spare Parts meet these specifications Any type of damage which is the result of using spare parts that are not original Volvo Penta parts for the product in question will not be covered under any warranty or guarantee provided by AB Volvo Penta • Service and maintenance intervals recommended by Volvo Penta must be followed • Only Volvo Penta Original Spare Parts intended for the certified engine version may be used • Service work that covers injection pumps, pump settings, and injectors must always be carried out by an authorized Volvo Penta workshop • The engine must not be altered or modified in any way, except for accessories and service kits developed by Volvo Penta for that engine • No modifications to the exhaust pipes and engine room air intake pipes are allowed • Any seals on the engine may not be broken by unauthorized persons IMPORTANT! When spare parts are required, use only Volvo Penta original parts Use of non-original parts will result in AB Volvo Penta being unable to warrant that the engine corresponds to the certificated engine version Any type of damages or costs which are the result of using spare parts that are not original Volvo Penta parts for the product in question will not be paid for by AB Volvo Penta Service procedures Group 20 Service procedures The working methods described in the Workshop Manual apply to work carried out in a workshop The engine has been removed and is installed in an engine fixture Unless otherwise stated reconditioning work which can be carried out with the engine in place follows the same working method Warning symbols used in this Workshop Manual (for full explanation of the symbols refer to the section; ”Safety Precautions” WARNING! IMPORTANT! NOTE: are not in any way comprehensive since it is impossible to predict every circumstance under which service work or repairs may be carried out AB Volvo Penta can only indicate the risks considered likely to occur as a result of incorrect working methods in a well equipped workshop using working methods and tools tested by AB Volvo Penta All operations described in the Workshop Manual for which there are Volvo Penta Special Tools available assume that these tools are used when carrying out the repair Volvo Penta Special Tools have been specifically developed to ensure as safe and rational working methods as possible It is therefore the responsibility of anyone using other tools or other working methods than we recommend to determine that there is no risk of personal injury or mechanical damage or malfunction as a result In some cases special safety precautions and user instructions may be required in order to use the tools and chemicals mentioned in the Workshop Manual Always follow these precautions There are no specific instructions given in the Workshop Manual By following these basic recommendations and using common sense it is possible to avoid most of the risks involved in the work A clean work place and a clean engine will eliminate many risks of personal injury and engine malfunction Especially when working on the fuel system, engine lubrication system, air intake system, turbocharger unit, bearing seals and seals, it is extremely important to avoid dirt or foreign objects entering the parts or systems, since this can result in reduced service life or malfunctions Our joint responsibility Every engine consists of many systems and components that work together If one component deviates from the technical specifications this can have dramatic consequences on the environmental impact of the engine even if it is otherwise in good running order It is therefore critical that the stated wear tolerances are observed, that systems which can be adjusted are correctly set up and that only Volvo Penta Original Parts are used on the engine The stated service intervals in the Maintenance Schedule must be followed Some systems, such as the components in the fuel system, require special expertise and special testing equipment for service and maintenance Some components are factory sealed for environmental and product specific reasons Under no circumstances attempt to service or repair a sealed component unless the service technician carrying out the work is authorized to so Bear in mind that most chemical products, incorrectly used, are hazardous to the environment Volvo Penta recommends the use of bio-degradable degreasing agents for all cleaning of engine components unless otherwise stated in the Workshop Manual Pay special attention to make sure that oils and washing residue etc are handled correctly for destruction, and not unintentionally end up in nature Torque Correct torque for critical joints which must be tightened using a torque wrench are listed under ”Technical Data - Torque” and stated in the method descriptions in the Workshop Manual All torque data apply to cleaned threads, bolt heads and mating surfaces Torque data stated apply to lightly oiled or dry threads Where grease, locking or sealing agents are required for screwed joints this is stated in both the operation description and in ”Torque” Where no torque is stated for a joint use the general torque shown in the following table The torques stated are a guide and the joint does not have to be tightened using a torque wrench Dimension Torque Nm M5 M6 10 M8 25 M10 50 M12 80 M14 140 Group 20 Torquing with Protractor tightening (angle tightening) When torquing with protractor (angle tightening), the fastener is tightened to a predetermined torque and then turned a predetermined angle Example: a 90° protractor tightening means that the joint is tightened a further 1/4 turn in one operation after the stated torque has been applied Lock nuts Do not re-use lock nuts that have been removed during disassembly operations as these have reduced service life when re-used For lock nuts with a plastic insert such as Nylok® the torque stated in the table is reduced if the Nylok® nut has the same head height as a standard hexagonal nut without plastic insert Reduce the torque by 25% for bolt size mm or larger Where Nylok® nuts are higher, where the metallic thread is of the same height as a standard hexagonal nut, the torques given in the as shown in table apply Service procedures Sealant A number of sealants and locking liquids are used on the engines The agents have varying properties and are used for different types of jointing strengths, operating temperature ranges, resistance to oil and other chemicals and for the different materials and gap sizes in the engines To ensure service work is correctly carried out it is important that the correct sealant and locking fluid type is used on the joint where the agents are required In this Volvo Penta Workshop Manual the user will find that each section where these agents are applied in production states which type was used on the engine During service operations, use the same agent or an alternative from a different manufacturer Make sure that mating surfaces are dry and free from oil, grease, paint and anti-corrosion agent before applying sealant or locking fluid always follow the manufacturer’s instructions for use regarding temperature range, curing time and any other instructions for the product Two different basic types of agent are used on the engine and these are: RTV agent (Room temperature vulcanizing) Used for gaskets, sealing gasket joints or coating gaskets RTV is visible when a part has been disassembled; old RTV must be removed before resealing the joint Strength classes Bolts and nuts are divided up into different classes of strength; the class is indicated by the number on the bolt head A higher number indicates a material with greater strength For example, a bolt marked 10-9 indicates a higher strength than one marked 8-8 It is therefore important that bolts removed during the disassembly of a bolted joint must be reinstalled in their original position when assembling the joint If a bolt must be replaced check in the spare parts catalogue to make sure the correct bolt is used The following RTV agents are mentioned in the Workshop Manual: Loctite® 574, Permatex® No 3, Permatex® No 77 Old sealant can be removed using denatured alcohol in all cases Anaerobic agents These agents cure in an absence of air They are used when two solid parts, for example cast components, are installed face-to-face without a gasket They are also commonly used to secure plugs, threads in stud bolts, cocks, oil pressure switches etc The cured material is glass-like and it is therefore colored to make it visible Cured anaerobic agents are extremely resistant to solvents and the old agent cannot be removed When reinstalling the part, degrease it carefully and then apply new sealant The following anaerobic agents are mentioned in the Workshop Manual: Loctite® 572 (white), Loctite® 241 (blue) NOTE: Loctite® is a registered trademark of Loctite Corporation, Permatex® is a registered trademark of the Permatex Corporation Service procedures Safety rules for fluorocarbon rubber Fluorocarbon rubber is a common material in seal rings for shafts, and in O-rings, for example When fluorocarbon rubber is subjected to high temperatures (above 300 °C/572°F), hydrofluoric acid can be formed, which is highly corrosive Skin contact can result in severe chemical burns Splashes in your eyes can result in severe chemical burns If you breathe in the fumes, your lungs can be permanently damaged WARNING! Be very careful when working on engines which have been exposed to high temperatures, e.g overheating during a seizure or fire Seals must never be cut with an oxyacetylene torch, or be burned up afterwards in an uncontrolled manner Group 20 • Always use gloves made of chloroprene rubber (gloves for handling chemicals) and protective goggles • Handle the removed seal in the same way as corrosive acid All residue, including ash, can be highly corrosive Never use compressed air to blow anything clean • Put the remains in a plastic jar which is sealed and provided with a warning label Wash the gloves under running water before removing them The following seals are probably made from fluorocarbon rubber: Seal rings for the crankshaft, camshaft, intermediate shafts O-rings, irrespective of where they are installed Orings for cylinder liner sealing are almost always made from fluorocarbon rubber Note that seals which have not been subjected to high temperature can be handled normally Component repair Group 22 Front casing, oil pump (Operation number 22111) Tap out the crankshaft seal using a drift To clean the front the casing: remove the oil pump and the pressure regulating valve Press the compression spring down and remove the stop washer Remove the spring and the valve for checking Also check the valve seat in the casing NOTE: Be careful The valve spring force is very big A high quality spring compressor is required Remove drive kit and check that no abnormal wear has occurred When needed, replace oil pump Torque the screws to 8-9 Nm (5.90-6.64 lbf ft) WARNING! Make sure that correct oil pump is used for the respective engine The pumps for the 420 and 620 engines are different See ”Spare parts catalog” Refitting Fit pressure regulating valve and spring Press the compression spring down and fit the spring’s stop washer NOTE: Make sure that the spring’s stop washer is secure Lubricate with a thin layer of oil before refitting Regarding refitting the seal ring, see section ”crankshaft seal, front (front casing), replacing” The crankshaft seal should be placed after refitting of the front casing 124 Group 22 Component repair Oil cooler Oil cooler, Leakage check (Operation number 22312) Special tools: Pressure-testing device 999 6662 C-clamp, ea 999 6845 Sealing pieces, ea NOTE: The oil cooler element should be as dry as possible inside during the check, since residual water may have a sealing effect on any cracks Water may not leak into the oil cooler element during the check NOTE: Avoid starting or stopping fan systems or letting air into or out of the room, since air pressure in the room may change and this may be misinterpreted as leakage NOTE: During the test, the oil cooler element should have ambient temperature The oil cooler element must not be repaired Use a piece of rubber or packaging material, 35 x 35 mm (1.38 x 1.38 ”) with a 22 mm (0.8661 ”) hole in the center Fit clamp (2), 999 6845 (with rubber original, 3) together with the sealing piece (1) with a hole to one of the cooling element’s oil connections as illustrated Make sure that it seals properly 125 Component repair Group 22 Turn the second clamp 999 6845 (1) the other way to seal the second oil connection Connect pressure gauge 999 6662 Immerse the oil cooler element in a tub of water Set the air pressure to 100 kPa (1.0 kp/cm² = 14.5 psi) Check for air bubbles from the element Let the pressure stay on for one minute The pressure must not drop Increase the pressure to 500 kPa (5.0 kp/cm² = 73 psi) Let the pressure stay on for one minute The pressure must not drop NOTE: If the pressure drops during this check, there is a leak Replace the oil cooler element NOTE: If there are bubbles from the water connections, there is an internal leak Replace the oil cooler element 126 Move the clamp 999 6845 to one of the water connections Fit a screw clamp to the second connection and pressure test as above Make sure that the oil side of the cooler is free from water before reinstalling Group 23 Component repair Group 23 Fuel system Fuel pump (Operation number 23315) Fuel feed pressure, checking Special tools: Pressure gauge 999 6398 Nipple 999 6666 Alternative: Electronic pressure gauge 999 8496 together with hose 999 8494 Together with both alternatives Hollow screw 969 299 Copper washer 969 011 Nipple 947 899 IMPORTANT! Clean nipple and hose carefully before they are connected to the fuel system Measure fuel feed pressure before (1) hollow screw 969 299 and after (2) nipple 947 899 fuel filter Use pressure gauge 999 6398 or electronic pressure gauge 999 8496 together with hose 999 8494 Feed pressure: after pump (before filter): 0.5 MPa / bar after filter: at 1,500 rpm: 0.28 MPa / 2.8 bar Fuel feed pressure before fuel filter Fuel feed pressure after fuel filter 127 Component repair Grupp 23 Injection pump, replacing (Operation number 23611) Before refitting the new injection pump: See ”Injection pump, refitting” NOTE: Before the injection pump is replaced, check that power loss is due to an injection pump and not due to a damaged delivery pipe Check inner diameter of the pipe It should be 1.8 mm (0.0709 ”) for all 420 and 620 engines When refitting a new injection pump, the shim thickness under the pump must be calculated so that correct injection time is achieved Follow the following steps: Clean the engine carefully before the casing over therocker arm is removed Normally, lots of dirt lies embedded between the intake pipe and the casing above the rocker arm Remove stop solenoid between 1st and 2nd injection pump and install special tool 999 8684 Set the control rod to the stop position Check that the roller pin for the current pump is located on the camshaft’s base circle Loosen the screws that hold the pump, a few turns and tap the pump in with care to see if it pops up NOTE: The pump is spring loaded, which means that if the roller pin not is located on the base circle, the force from the pump’s spring can damage the threads in the engine block when the screws are removed Remove the shim in the roller pin Cover the hole in order to prevent dirt from entering into the engine Read the EP code on the engine plate for the current cylinder Enter the value in ”Calculation 1, Technical data” Read the corresponding corrected install dimension, Ek, from Table Enter the value in ”Calculation 1, Technical data” Read the pump’s length, basic dimension, L0, from Table Enter the value in ”Calculation 1, Technical data” Read the pump’s mfg tolerance, A, on the injection pump Enter the value A/100 in ”Calculation 1, Technical data” 10 Calculate the theoretical shim thickness, Ts, according to the formula Ts = Ek – (L0 + A/100) See ”Calculation 1, Technical data” 11 Read the actual shim thickness, Ss, fromTable 12 Let the shim slide in, along a screw driver, for example NOTE: Use only one shim 13 Check that the roller pin for the current pump is located on the camshaft’s base circle 14 Turn the pump’s lever arm to the mid-point, oil the O-rings on the pump and fit the pump NOTE: Check that the pump’s lever arm is entered correctly in the slot for the fuel control before the pump is pressed down 15 Fit the pump flange with the chamfer aimed towards the pump and pretorque the screws to Nm (3.68 lbf ft) Then loosen the screws 60° 16 Turn the injection pump carefully counterclockwise, use ratchet sleeve 11668403 and a torque wrench Note the torque required to turnthe injection pump, e.g 3.5 Nm (2.58 lbf ft) Stop turning when the pump has reached its stop position and the torque has increased by Nm (0.74 lbf ft) Ex 3.5 + = 4.5 Nm 17 Torque the screws on the pump flange 60° Then torque them alternately Start with the screw farthest away from the flywheel, at Nm (5.16 lbf ft) – 10 Nm (7.38 lbf ft) – 30 Nm (22.139 lbf ft) 18 After refitting the pump, remove special tool- 999 8684 and check that the control rod can move freely 19 Pre-load the delivery pipe in two steps: Nm (3.69 lbf ft) 25 ±3.5 Nm (18.44 ±2.581 lbf ft) NOTE: A delivery pipe that has been removed must be discarded and replaced with a new one 20 Fit a new valve cover gasket and the valve casing Torque the screws to 11 ±1 Nm(8.11 ±0.74 lbf ft) 128 Group 25 Component repair Group 25 Intake and exhaust system Charge air pressure, checking (Operation number 25502) Special tools Pressure gauge 999 6398 or electronic pressure gauge 999 8496 and hose 999 8494 Nipple 999 6666 Spacer item no 912130 Charge air pressure, see Workshop Manual, Technical data 129 Component repair Grupp 26 Group 26 Cooling system Coolant pump, checking/replacing (Operation number 26211) Remove coolant pump from the housing Remove the V-belt sheave Check coolant pump and seal with regard to leakage, replace coolant pump when needed 130 Fit the V-belt sheave Torque the screws to 21 Nm (15.49 lbf ft) Group 26 Component repair Refit coolant pump in housing with a new gasket 131 Component repair Grupp 26 Thermostat (Operation number 26273) Measure dimension ”a” on thermostat Note:”a”= thermostat starts opening 87°C ±2°C (188.6 ±35.6 °F) (T1) ”b”= thermostat fully open 102°C (215.6 °F) (T2) Heat thermostat in water NOTE: To obtain an exact opening temperature, measure as close to thermostat as possible without touching it Stir the water at all times to get an even temperature distribution The temperature shall not rise more than 1°C/min Otherwise, the opening time will be delayed Measure dimension ”b” on thermostat At opening temperature (102°C (215.6 °F)): ”a”-”b”= mini mm (0.3150 ”) 132 Group 26 Component repair Drive belts, replacing (Operation number 26341) IMPORTANT! Check/tension or replace the V-belt only when the engine is shut down, refit the V-belt protective shield NOTE: Replace belts which have become oily, worn or damaged in any way Relax the belt by turning the spring loaded belt tension device clockwise with a 11.2 mm (0.44094 ”) square pin Fit a new belt NOTE: It may be necessary to remove the fan to access the belt 133 Wiring diagram Group 30 Wiring diagram NOTE: Wiring diagram on this page is an example of wiring diagrams The engines are not equipped with electrical systems from the factory Wire area 10 11 Temperature sensor - cooling Battery water Starter motor 12 Oil pressure switch - engine Alternator 13 Oil pressure sensor - engine Start relay 14 Speed sensor Fuse 15 Temperature switch - governor Pressure sensor - reversing gear 16 Cold start regulator Pressure sensor - turbo 17 Union Stop magnet Temperature switch- cooling water 18 Main switch 19 Stop relay Level switch - cooling water POLE 134 Area not specified mm (0.0393 ”)2 Dashed line not supplied by Volvo Penta All switches normally open Index Index A Adjustment of injection angle, Fb 18 Assembly, complete engine 49 B Balance shaft bearing, checking 102 Balance shafts, refitting 54 C Cams / camshaft, refitting 50 Camshaft bearing, checking and measuring 100 Camshaft, checking and measuring 98 Charge air pressure, checking 129 Checking and measuring 87 Checks and adjustments 28 Component placement, service side 15 Component placement, start motor side 14 Component repair 114 Compression test 28 Connecting rod, measuring 92 Control rod, checking and measuring 110 Control rod, refitting 53 Coolant 21 Coolant pump, checking / replacing 130 Cooling system 19 Crankshaft 45 Crankshaft seal, front, replacing 120 Crankshaft seal, rear, replacing 118 Crankshaft, measuring 89 Crankshaft, refitting 51 Cylinder head gasket, refitting 75 Cylinder head with valve guides, refitting 76 Cylinder head, Checking and measuring 104 Cylinder head, removal 34 Cylinder liner, refitting 49 Cylinder numbering 13 D Delivery pipes, removal 35 Determining corrected install dimension, Ek, and EP code for injection pump 26 Determining injection angle 67 Determining injection angle, shim thickness and refitting of injection pumps 67 Determining shim thickness when injection valve shall open 25 Determining shim thickness when replacing injection pump 24 Disassembly, complete engine 34 Drive belts, replacing 133 E Engine block, checking and measuring 87 Engine fixture, refitting 32 Engine plate 12 Engine plate placement Engine plate, placement Engine serial number Engine, component placement Engine, removal from engine fixture Exposing engine 12 12 13 14 85 31 F Flywheel ring gear, replacing 114 Front casing with oil pump, refitting 62 Front casing, oil pump, repair 124 Fuel delivery pipe 18 Fuel pump, checking of feed pressure 127 Fuel system 17 G General information Governor intermediate gear, refitting 53 Governor lever, measuring 65 Guide sleeves for control rod 112 I Injection pump 39 Injection pump, refitting 71 Injection pump, replacing 128 Injectors and fuel lines, refitting 78 Injectors, checking/adjustment 29 Installing fixture 32 L Lubrication 21 Lubrication system 16 M Manifold, air intake pipe and valve cover, refitting 79 Measuring tolerance deviation, engine block 69 Measuring tolerance deviation, roller pin and camshaft 70 O Oil cooler, oil filters and oil cooler housing, removal 37 Oil cooler, repair 125 Oil filter housing and oil cooler, refitting 82 Oil pressure 113 Oil suction pipe / oil pan, refitting 64 Oil trap, refitting 81 P Piston and connecting rod, assembling, 59 Piston, checking and measuring 95 Pistons and connecting rod, removal 43 Pistons and connecting rods, refitting 60 Pressure regulating and bypass valves, checking 122 135 Index R Rocker bridge, checking and measuring 109 S Safety Precautions Service procedures Special tools Speed governor, refitting 80 Starter motor and turbo unit, refitting 85 T Technical data 20 Thermostat, repair 132 Torque 22 Torque order for cylinder head screws 21 Transmission gear casing, refitting 61 V Valve clearance, checking/adjustment 115 Valve seat, grinding 108 Valve seat, replacing 107 Valves, grinding 108 W Wiring diagram 134 136 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 From: Refers to publication: Publication no.: Issued: Suggestion/reasons: Date: Name: AB Volvo Penta Customer Support Dept 42200 SE-405 08 Gothenburg Sweden 7745222 English 09-2004 ... 282 283 284 121, 125 121, 15 121, 175 121, 2 121, 225 305 306 307 308 309 119,375 119,4 119,425 119,45 119,475 235 236 237 238 239 120,0 120,025 120,05 120,075 120,1 260 261 262 263 264 120,625 120,65... 287 288 289 121, 25 121, 275 121, 3 121, 325 121, 35 310 311 312 313 314 119,5 119,525 119,55 119,575 119,6 240 241 242 243 244 120,125 120,115 120,175 120,2 120,225 265 266 267 268 269 120,75 120,775... 120,475 275 276 277 278 279 121, 0 121, 025 121, 05 121, 075 121, 1 300 301 302 303 304 27 Checks and adjustments Group 20 Checks and adjustments Compression test (Operation number 210 02) Special tools: