Workshop Manual

Group 21-26

TAD164X GE/VE/VE-B
TAD165X GE/VE/VE-B
TAD166X VE, TAD167X VE
TWD164X GE, TWD165X GE
TWD166X GE, TWD167X GE
 Table of Content

General Information
00-0 General ............................................................................................. 3

Specifications
03-0 General Specifications ................................................................... 9
03-2 Specifications, Engine .................................................................. 11
03-21 Engine ....................................................................................... 28
03-22 Lubrication System ................................................................. 38
03-23 Fuel System .............................................................................. 40
03-25 Inlet and Exhaust System ....................................................... 41
03-26 Cooling System ........................................................................ 43
03-3 Specifications, Electrical .............................................................. 45

Safety and Other Instructions

05-1 Safety Instructions ........................................................................ 46

Special tools
08-2 Special Service Tools ................................................................... 50

General
20-0 Engine Information, General ........................................................ 59
Troubleshooting ................................................................................. 64
Test and Adjustments ....................................................................... 69

Engine
21-0 Engine Complete, General ........................................................... 80
Exposing the Engine ....................................................................... 126
Fitting the Fixture ............................................................................. 133
Engine Disassembly ........................................................................ 134
Engine Assembly ............................................................................. 178
21-4 Valve Mechanism ........................................................................ 180

Lubricating and Oil System

22-0 Lubricating and Oil System, General ........................................ 195
22-1 Oil pump and Line ....................................................................... 196
22-2 Oil filter ........................................................................................ 197
22-3 Oil cooler ..................................................................................... 204

Fuel System
23-0 Fuel System, General ................................................................. 207
23-3 Fuel Feed Pump and Filter ......................................................... 211
23-7 Injectors and Delivery Pipes ...................................................... 214
23-8 Control System, ECM, Data Sets ............................................... 225

Inlet and Exhaust System

25-1 Inlet and Exhaust Manifolds ...................................................... 227
25-2 Exhaust Pipe, Silencer ............................................................... 229
25-5 Turbo and supercharger ............................................................ 231
25-8 Emission After-Treatment .......................................................... 246

Cooling System
26-0 Cooling System, General ........................................................... 286
26-1 Radiator, Heat Exchanger .......................................................... 292

47702612 05-2018 © AB VOLVO PENTA 1

 26-2 Coolant Pump, Thermostat ........................................................ 295
26-5 Charge Air Cooler with Connections ........................................ 304

Alternator, Charge Regulator

32-1 Alternator ..................................................................................... 310

Starting System
33-1 Starter Motor ............................................................................... 314
Index ......................................................................................................... 317
References to Service Bulletins ............................................................ 319

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00-0 General
About this Workshop manual
General information Certified engines
This Service Manual contains technical data, When carrying out service and repair on
descriptions and maintenance and repair instructions emission-certified engines, it is important to be
for standard model Volvo Penta products. A list of aware of the following:
these products may be found in the section
Specifications. Certification means that an engine type has been
inspected and approved by the relevant authority.
The product designation and the serial number and The engine manufacturer guarantees that all engines
specification is indicated on the engine decal or type of the same type are manufactured to correspond to
plate. This information must be included in all the certified engine.
correspondence regarding the product. This places special demands on service and repair
work, namely:
The service manual is produced primarily for the use
of Volvo Penta workshops and their qualified • Maintenance and service intervals
personnel. It is assumed that any person using the recommended by Volvo Penta must be
Service Manual has a fundamental knowledge of the complied with.
product and is able to carry out mechanical and • Only spare parts approved by Volvo Penta may
electrical work to trade standard. be used.
Volvo Penta continually develops its products; we • Service on injection pumps, pump settings and
therefore reserve the right to make changes. All injectors must always be carried out by an
information in this manual is based on product data authorized Volvo Penta workshop.
which was available up to the date on which the
• The engine must not be converted or modified,
manual was printed. New working methods and
except with accessories and service kits which
significant changes introduced to the product after
Volvo Penta has approved for the engine.
this date are communicated in the form of Service
bulletins. • No changes to the exhaust pipe and engine air
inlet duct installations may be made.
Spare Parts
• No warranty seals (where present on the
Spare parts for the electrical and fuel systems are product) may be broken by unauthorized
subject to various national safety standards. Volvo persons.
Penta Original Spare Parts meet these standards. No
damage of any kind caused by the use of spare parts The general instructions in the Operator's Manual
not approved by Volvo Penta will be compensated by concerning operation, service and maintenance
any warranty undertaking. apply.

IMPORTANT!
Neglected or poorly-performed care/service and the
use of spare parts not approved by Volvo Penta, will
mean that AB Volvo Penta no longer guarantees that
the engine conforms to the certified model.

Volvo Penta accepts no responsibility for damage or

costs arising as a result of failure to follow the above
mentioned standards.

47702612 05-2018 © AB VOLVO PENTA 3

00-0 General

Repair instructions
Introduction Our Mutual Responsibility
The working methods described in this manual are Each product comprises a large number of interacting
based on a workshop scenario where the product is systems and components. A deviation from the
mounted in a workholding fixture. Maintenance work technical specification may dramatically increase the
is often carried out in situ, in which case - if nothing environmental impact of an otherwise reliable
else is indicated - using the same working methods system. It is therefore critical that the stated wear
as the workshop. tolerances be adhered to, that systems which can be
adjusted be correctly set up and that only Volvo Penta
Warning symbols that occur in the service manual. Original Parts are used. The intervals in the care and
For significance, refer to Safety Information. maintenance schedule must be followed.
Some systems, e.g. fuel systems, often require
DANGER! special expertise and test equipment. A number of
components are factory-sealed, for among other
WARNING! things environmental reasons. Warranty-sealed
components may not be worked on without
CAUTION! authorization to perform such work.
IMPORTANT!, NOTE! Remember that most chemical products, incorrectly
are by no means comprehensive since not everything used, are harmful to the environment. Volvo Penta
can be foreseen as service work is carried out in the recommends the use of biodegradable degreasers
most varied of circumstances. We call attention to whenever components are cleaned, unless otherwise
risks that may occur due to incorrect handling during specified in the Service Manual. When working
work in a well-equipped workshop using working outdoors, take especial care to ensure that oils and
methods and tools tried and tested by us. wash residues etc. are correctly properly for
destruction.
The service manual describes work operations
carried out with the aid of Volvo Penta Special Tools,
where such have been developed. Volvo Penta Tightening torque
Special Tools are designed to ensure the safest and Tightening torques for vital fasteners that must be
most rational working methods possible. It is applied using a torque wrench are indicated in the
therefore the responsibility of anyone using tools or Service Manual, chapter Tightening torques and in
working methods other than those we recommend to the Manual's work descriptions. All torque indications
ensure that no risk of personal injury or mechanical apply to clean threads, bolt heads and mating faces.
damage is present, or that malfunction can result. Indicated torque data apply to lightly-oiled or dry
threads. If lubricants, locking fluids or sealants are
In some cases, special safety regulations and user
required for fasteners, the correct type will be
instructions may be in force for the tools and
indicated in the job description.
chemicals mentioned in the Service Manual. These
rules must always be observed, so there are no
special instructions about this in the workshop
Torque, angle tightening
manual. When torque/angle tightening, the fastener is
tightened to a specified torque, and tightening then
By following these basic recommendations and using continues through a pre-determined angle.
common sense it is possible to avoid most of the risks
involved in the work. A clean workplace and a clean Example: For 90° angle tightening, the fastener is
product will eliminate many risks of personal injury turned an additional 1/4 turn in one sequence, after
and malfunction. the specified tightening torque has been achieved.
Above all, when working on fuel systems, hydraulic
systems, lubrication systems, turbochargers, inlet
systems, bearings and seals, it is of the utmost
importance that dirt and foreign objects are kept
away, as malfunctions or shortened service intervals
may otherwise result.

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 00-0 General

Lock nuts Anaerobic agents.

These agents cure in the absence of air. These
Removed lock nuts may not be re-used; they must be preparations are used when two solid components,
replaced by new ones, as locking properties are e.g. two cast components, are fitted together without
impaired or lost with re-use. a gasket. Common uses are also to lock and seal
In the case of lock nuts with plastic inserts, the plugs, stud threads, taps, oil pressure monitors etc.
tightening torque indicated must be reduced if the nut
has the same nut height as a standard, all-metal Hardened anaerobic preparations are vitreous and
hexagonal nut. for this reason, the preparations are colored to make
Reduce the torque by 25% for bolt sizes of 8 mm or them visible. Hardened anaerobic preparations are
larger. highly resistant to solvents, and old compound
In the case of lock nuts with plastic inserts with a high cannot be removed. On re-assembly, it is important
nut-height (where the all-metal thread is as high as a to carefully degrease and wipe dry components first,
standard hexagonal nut), the indicated torque before applying new sealant in accordance with the
applies. instructions.

Strength Classes Safety regulations for fluorocarbon

Nuts and bolts are grouped into different strength rubber
classes. Their classification is shown by a marking on Fluorocarbon rubber is a common material in seal
the bolt head. Markings of a higher number indicate rings for shafts, and in O-rings, for example.
stronger material. For example, a bolt marked 10-9 is
stronger than one marked 8-8. When fluorocarbon rubber is exposed to high
temperatures (above 300°C/572°F), hydrofluoric acid
For this reason, it is important that when bolted joints can form. This is highly corrosive. Contact with the
are removed they are returned to their original skin can result in severe chemical burns. Splashes in
locations on re-assembly. When replacing bolts, your eyes can result in corrosive wounds. If you
check the applicable Spare parts catalog to ensure breathe in the fumes, your lungs can be permanently
the correct bolt is used. damaged.

Sealing compounds etc. WARNING!

To ensure service work is correctly carried out, it is Seals must never be cut with a torch, or be burnt
important that the correct type of sealants and locking afterwards in an uncontrolled manner. Risk for
fluids are used on joints where such are required. poisonous gases.

In each service manual section concerned, the WARNING!

sealants used in product manufacture are indicated. Always use chloroprene rubber gloves (gloves for
The same sealants, or sealants with equivalent chemicals handling) and goggles. Handle the
properties, must be used for maintenance work. removed seal in the same way as corrosive acid. All
A service technician should have a basic knowledge residue, including ash, can be highly corrosive. Never
of how sealing compounds are handled, and are able use compressed air to blow clean.
to assess the condition of existing seals. Put the remains in a plastic container, seal it and
apply a warning label. Wash the gloves under running
Make sure that mating surfaces are dry and free from water before removing them.
oil, grease, paint and anti-corrosion agent before
applying sealant or locking fluid. Always follow the The following seals are most probably made from
manufacturer's instructions regarding applicable fluorocarbon rubber:
temperatures, hardening times and such.
Seal rings for the crankshaft, camshaft, idler shafts.
Two basic types of compound are used:
O-rings, regardless of where they are installed. O-
RTV preparations (Room Temperature rings for cylinder liner sealing are almost always
Vulcanizing). made of fluorocarbon rubber.
Used most often together with gaskets, e.g. sealing
gasket joints, or are brushed on gaskets. RTV Please note that seals which have not been
sealants are completely visible when the part has exposed to high temperature can be handled
been removed. Old RTV sealant must be removed normally.
before the component is sealed again. Use
denatured alcohol.

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00-0 General

Illustrations
A lot of illustrations contains standardized symbols and colors. Please refer to the following information to reduce
misunderstandings when working on an engine / transmission using this Workshop Manual.

Illustration colors Position

Most illustrations have a focused component which is
fastened by a bolt or such on a (light grey) engine /
transmission body.

P0015623

Focus arrows pointing at object. Sometimes it

contains number of items, e.g. three bolts.
When this symbol is used on a series of bolts it is
expected that the service technician tighten the bolts
in a logical sequence.

NOTICE! If an arrow with the text “x3” is pointing at

P0015699 only one item, e.g. a bolt, it still applies to the other
1 Focus two alike items (the two other bolts) highlighted in the
(blue) illustration.

2 Fastenings
(red)
3 Body
(light grey) P0015627

4 Background This symbol gives a positioning number to an object,

(white) e.g. 2, which is also mentioned in the supplied text
information.

P0015628

The symbol in the top left shows part no. of the

positioned special tool, e.g. 9991801.
The lower symbol is used when something needs to
be replaced by a new part / kit.
The symbol on the right side is used when a part
needs to be discarded.

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 00-0 General

Movement Tools

P0015622

Movement arrows are used to show which direction a P0015629

component is to be moved / rotated.

One of the following symbols is used when describing
the recommended type of screwdriver.

P0015625

Symbol is used in a corner of the illustration to show

how many degrees the object shall be turned and at
which direction.

P0015630

A symbol of a tool in a corner of the illustration is

shown when the tool is recommended to use, e.g. a
knife or a crowbar.
P0015626

Symbol is used to show how many revolutions the

object shall be turned and at which direction.

Measurements

P0015631

A drill in a specified size, duck tape and stripes may

also be shown as symbols.

P0022436

The symbols are used to show different types of

measurements.
Clearance is shown in this feeler gauge symbol.
This dial indicator symbol shows a MIN value.

47702612 05-2018 © AB VOLVO PENTA 7

00-0 General

Chemicals Units

P0015695
P0015696

Symbols can also describe when and how a chemical

Units are mentioned in the illustration when a specific
product is to be used.
value (e.g. pressure, weight or resistance etc.) is
expected.
Cleanliness
Important

P0015624

The scraper symbol suggests that a contact surface P0015005

needs to be scraped from sealant etc.
The cloth symbol suggests that the mechanic should The eye symbol is used when something needs close
clean the contact surface thoroughly or be prepared inspection or must be performed in a certain way.
for some oil spill or similar. The symbol to the right is used when several
mechanics are needed.

Sealant
Safety

P0015698

P0015697
The tube symbol shows how thick layer of sealant to
applicate. These symbols are used when a certain safety related
The clock symbol is used when something needs to equipment is needed.
be done within or after a certain time.

8 47702612 05-2018 © AB VOLVO PENTA

 03-0 General Specifications

03-0 General Specifications

General Tightening Torques
General Tightening Torques
M6 10 Nm (7.4 lbf ft)
M8 24 Nm (17.7 lbf ft)
M10 48 Nm (35.4 lbf ft)
M12 85 Nm (62.7 lbf ft)
M14 140 Nm (103.3 lbf ft)
M16 220 Nm (162.3 lbf ft)

IMPORTANT!
Check bolts which are to be re-installed. Damaged bolts,
e.g. with shear marks under heads must be scrapped.

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03-0 General Specifications

10 47702612 05-2018 © AB VOLVO PENTA

 03-2 Specifications, Engine

03-2 Specifications, Engine

Type designation TAD1640GE TAD1641GE TAD1642GE TWD1643GE
TWD1644GE
TWD1645GE
Power, Prime/Stand-by Refer to the sales literature
Torque, Prime/Stand-by Refer to the sales literature
Number of cylinders 6 6 6 6
Cylinder diameter mm (inches) 144 (5.67) 144 (5.67) 144 (5.67) 144 (5.67)
Stroke, mm (inches) 165 (6.50) 165 (6.50) 165 (6.50) 165 (6.50)
Cylinder volume, liters (inch3) 16.12 (983.9) 16.12 (983.9) 16.12 (983.9) 16.12 (983.9)
Weight dry, kg (lbs) 1440 (3175) 1440 (3175) 1480 (3263) 1700 (3748)
Weight wet, kg (lbs) 1510 (3329) 1510 (3329) 1550 (3417) 1770 (3902)
Firing order 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
Compression ratio 17.5:1 16.5:1 16.5:1 16.5:1
Low idle, rpm 900 900 900 900
High idle, rpm 1500/1800 1500/1800 1500/1800 1500/1800

Type designation TWD1652GE, TWD1663GE, TAD1650GE TAD1651GE

TWD1653GE TWD1672GE,
TWD1673GE
Power, Prime/Stand-by Refer to the sales literature
Torque, Prime/Stand-by Refer to the sales literature
Number of cylinders 6 6 6 6
Cylinder diameter mm (inches) 144 (5.67) 144 (5.67) 144 (5.67) 144 (5.67)
Stroke, mm (inches) 165 (6.50) 165 (6.50) 165 (6.50) 165 (6.50)
Cylinder volume, liters (inch3) 16.12 (983.9) 16.12 (983.9) 16.12 (983.9) 16.12 (983.9)
Weight dry, kg (lbs) 1700 (3748) 1700 (3748) 1440 (3175) 1440 (3175)
Weight wet, kg (lbs) 1770 (3902) 1770 (3902) 1510 (3329) 1510 (3329)
Firing order 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
Compression ratio 16.5:1 16.5:1 16.5:1 16.5:1
Low idle, rpm 900 900 900 900
High idle, rpm 1,500 1800 1500/1800 1500/1800

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03-2 Specifications, Engine

Type designation TAD1641VE TAD1642VE, TAD1650VE

TAD1643VE
Power, Prime/Stand-by Refer to the sales literature
Torque, Prime/Stand-by Refer to the sales literature
Number of cylinders 6 6 6
Cylinder diameter mm (inches) 144 (5.67) 144 (5.67) 144 (5.67)
Stroke, mm (inches) 165 (6.50) 165 (6.50) 165 (6.50)
Cylinder volume, liters (inch3) 16.12 (983.9) 16.12 (983.9) 16.12 (983.9)
Weight dry, kg (lbs) 1480 (3263) 1480 (3263) 1425 (3142)
Weight wet, kg (lbs) 1550 (3417) 1550 (3417) 1495 (3296)
Firing order 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
Compression ratio 17.5:1 17.5:1 18.0:1
Low idle, rpm 600 600 700
High idle, rpm 1800 1800 1800-2000

Type designation TAD1640-43VE-B, TAD1650VE-B, TAD1651VE, TAD1660-62VE,

TAD1670-72VE
Power, Prime/Stand-by Refer to the sales literature
Torque, Prime/Stand-by Refer to the sales literature
Number of cylinders 6
Cylinder diameter mm (inches) 144 (5.67)
Stroke, mm (inches) 165 (6.50)
Cylinder volume, liters (inch3) 16.12 (983.9)
Weight wet, kg (lbs) 1440 (3175)
Firing order 1-5-3-6-2-4
Compression ratio 16.8:1
Low idle, rpm 700
High idle, rpm 1900

Special Tightening Torques

Group 21: Engine

Front engine mounting, engine block 220 ± 35 Nm (162.3 ± 25.8 lbf ft)
Front engine mounting 220 ± 35 Nm (162.3 ± 25.8 lbf ft)
Rear engine mounting, flywheel housing 220 ± 35 Nm (162.3 ± 25.8 lbf ft)

Main bearing caps

step 1 300 ± 20 Nm (221.3 ± 14.75 lbf ft)
step 2 120° ± 5° angle tightening

Big end bearing cap

step 1 20 ± 3 Nm (14.75 ± 2.21 lbf ft)
step 2 60 ± 5 Nm (44.25 ± 3.69 lbf ft)
step 3 90° ± 5° angle tightening

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 03-2 Specifications, Engine

Stiffening Frame

P0007087

NOTICE! Tighten the bolts in the order illustrated.

step 1 65 ± 5 Nm (47.9 ± 3.69 lbf ft)

step 2 60° ± 5° angle tightening

Flywheel

P0007088

IMPORTANT!
Make sure the flange is clean and dry.
NOTICE! Tighten the bolts in the order illustrated.

step 1 60 ± 5 Nm (44.25 ± 3.69 lbf ft)

step 2 120° ± 10° angle tightening

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03-2 Specifications, Engine

Flywheel Housing

P0006930

NOTICE! Apply 2 mm (0.08”) silicone (part # 1161231 and 1161277) as illustrated.

stage 1: Torque all M14 screws to 160 ± 20 Nm (118.0 ± 14.75 lbf ft)
stage 2: Torque all M10 bolts to 48 ± 8 Nm (35.4 ± 5.9 lbf ft)
stage 3: Torque all M8 screws to 24 ± 4 Nm (17.7 ± 2.95 lbf ft)

Vibration Damper, Crankshaft

P0007089
P0007090

NOTICE! Tighten the bolts in the order illustrated. Single vibration dampers: 90 ± 10 Nm (66.38 ±
7.38 lbf ft)
Double vibration dampers:
Stage 1: 35 Nm (25.8 lbf ft)
Stage 2: 125 Nm (92.2 lbf ft)

NOTICE! The 8.8 bolts on the oscillation damper may not

be re-used.

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 03-2 Specifications, Engine

Cover, crankshaft seal

P0007091

NOTICE! Apply 2 mm (0.08”) silicone (part # 1161231 and

1161277) as illustrated.

stage 1: Tighten all bolts by hand.

stage 2: Tighten the bolts 2 and 7 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
stage 3: Torque the remaining bolts to 24 ± 4 Nm (17.7 ± 2.95 lbf ft)

Valve Cover

P0007092

NOTICE! Tighten the bolts in the order illustrated. 25 ± 3 Nm (18.44 ± 2.21 lbf ft)

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03-2 Specifications, Engine

Cylinder head

P0007093

NOTICE! Tighten the bolts in the order illustrated.

step 1 60 + 10 / – 0 Nm (44.25 + 7.38 / – 0 lbf ft)

step 2 90° ± 5° angle tightening
step 3 90° ± 5° angle tightening

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 03-2 Specifications, Engine

Bearing Caps, Camshaft/Rocker Arm

Shaft, thru engine no. 2016010024

P0007094

IMPORTANT!
Tighten the screws in stages to make sure the rocker arm
shaft is lowered without being bent.

stage 1: Tighten bolts 1-7. 15 ± 3 Nm (11.06 ± 2.21 lbf ft)

stage 2: Tighten bolts 1-7. 90° ± 5° angle tightening
stage 3: Torque screws 8-14. Start with screw 11 100 ± 10 Nm (73.76 ± 7.38 lbf ft)
stage 4: Tighten bolts 15-21. 50 ± 5 Nm (36.88 ± 3.69 lbf ft)
stage 5: Tighten bolts 15-21. 120° ± 5° angle tightening
stage 6: Loosen bolts 8 through 14. –
stage 7: Tighten bolts 8-14. 50 ± 5 Nm (36.88 ± 3.69 lbf ft)
stage 8: Tighten bolts 8-14. 120° ± 5° angle tightening

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03-2 Specifications, Engine

Bearing Caps, Camshaft/Rocker Arm

Shaft, as of engine no. 2016010025

1 1 2 3 4 5 6 7 6
15 ± 3 Nm 60 ± 5 Nm 20

2 7
100 ± 10 Nm 8 9 10 11 12 13 14 15 16 17 18 19
120º ± 5º

1 2 3 4 5 6 7
3 8
20
90º ± 5º 100º ± 5º

4 9
8 9 10 11 12 13 8 9 10 11 12 13
100 ± 10 Nm 50 ± 5 Nm

5 10
14 15 16 17 18 19 8 9 10 11 12 13
50 ± 5 Nm 120º ± 5º
P0008581

IMPORTANT! If the rocker arm shaft has been loosened or

Tighten the bolts in stages to ensure that the rocker arm removed, only the bolts that hold the shaft must
shaft bottoms against the bearing housing without bending. be tightened in accordance with the chart on re-
assembly.
Camshaft (camshaft and bearing caps in place).
Fit a drift to no. 7 bearing bracket (to protect the guide
sleeve).
stage 1: Tighten bolts 1-7 15 ± 3 Nm (11.06 ± 2.21 lbf ft)
stage 2: (with shorter extra bolts). Tighten bolts 8
through 13 100 ± 10 Nm (73.76 ± 7.38 lbf ft)
stage 3: Angle tighten screws 1 through 7 90° ± 5° angle tightening
Remove the extra bolts (8-13). Remove the drift from no. 7's
bearing seat.

Rocker arm shaft (rocker arm shaft in place)

stage 4: Tighten bolts 8 through 13 in stages in the order
11, 10, 12, 9, 13, and 8 100 ± 10 Nm (73.76 ± 7.38 lbf ft)
stage 5: Tighten bolts 14 through 19 50 ± 5 Nm (36.88 ± 3.69 lbf ft)
stage 6: Tighten bolt 20 60 ± 5 Nm (44.25 ± 3.69 lbf ft)
stage 7: Angle tighten screws 14-19 120° ± 5° angle tightening
stage 8: Angle tighten bolt 20 100° ± 5° angle tightening
Loosen bolts 8 through 13.
stage 9: Tighten bolts 8-13 50 ± 5 Nm (36.88 ± 3.69 lbf ft)
stage 10: Angle tighten bolts 8 through 13 120° ± 5° angle tightening

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 03-2 Specifications, Engine

Timing gear plate

P0007096

P0007097

NOTICE! Apply 2 mm (0.08”) silicone (part # 1161231 and

1161277) at the rear of the engine as illustrated.
NOTICE! Tighten the bolts in the order illustrated.

Bolts 1–27 28 ± 4 Nm (20.65 ± 2.95 lbf ft)

Bolt 28 60 ± 8 Nm (44.25 ± 5.90 lbf ft)

Timing gear cover, top

P0007098

NOTICE! Apply 2 mm (0.08”) silicone (part # 1161231 and

1161277) as illustrated.
Tightening torque 24 ± 4 Nm (17.7 ± 2.95 lbf ft)

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03-2 Specifications, Engine

Transmission

5 1

3 7

4
8
1
2 6
3
5
6
4
2
3 1

5 6

2 4

P0007099

1 Drive gear, crankshaft

step 1 60 ± 5 Nm (44.25 ± 3.69 lbf ft)
step 2 120° ± 10° angle tightening

2 Intermediate gear, bull drive, outer

Tighten the bolts in the order illustrated.
step 1 45 ± 5 Nm (33.19 ± 3.69 lbf ft)
step 2 90° ± 5° angle tightening

3 Intermediate gear, adjustable

Tighten the bolts in the order illustrated.
step 1 35 ± 4 Nm (25.81 ± 2.95 lbf ft)
step 2 120° ± 5° angle tightening

4 Drive gear, camshaft

Tighten the bolts in the order illustrated.
step 1 45 ± 5 Nm (33.19 ± 3.69 lbf ft)
step 2 90° ± 5° angle tightening

5 Drive gear, steering servo and fuel feed pump 100 ± 10 Nm (73.76 ± 7.38 lbf ft)

6 Drive gear, air compressor 200 + 50 / – 0 Nm (147.51 + 36.88 / – 0 lbf ft)

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 03-2 Specifications, Engine

Valve mechanism, VCB / EGR

Bolt, leaf spring (1) 25 Nm (18.4 lbf. ft.)
Adjustment, VCB/EGR rocker (2) 52 Nm (38.4 lbf. ft.)
Adjustment, exhaust tappet (3) 38 Nm (28.0 lbf. ft.)
Adjustment, exhaust (4) 38 Nm (28.0 lbf. ft.)
Pre-load, injector (5) 52 Nm (38.4 lbf. ft.)
Adjustment, inlet (6) 38 Nm (28.0 lbf. ft.)

P0016365

Valve mechanism, standard

Adjustment, exhaust (1) 38 Nm (28.0 lbf. ft.)
Adjustment, exhaust tappet (2) 38 Nm (28.0 lbf. ft.)
Pre-load, injector (3) 52 Nm (38.4 lbf. ft.)
Adjustment, inlet (4) 38 Nm (28.0 lbf. ft.)

P0016366

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03-2 Specifications, Engine

Group 22: Lubrication System

Oil Sump

P0007100

NOTICE! Tighten the bolts in sequence, as illustrated. 24 ± 4 Nm (17.7 ± 2.95 lbf ft)

Oil pump
stage 1 35 ± 3 Nm (25.81 ± 2.21 lbf ft)
stage 2 (not 17 and 18) 90° ± 5° angle tightening

Oil cooler, retaining bolts

P0007101

NOTICE! Tighten the bolts in sequence, as illustrated. 24 ± 4 Nm (19.91 ± 2.95 lbf ft)

Oil pressure pipe

stage 1 tighten to zero play
stage 2
pipe diameter Ø 12 80 ± 10 Nm (59.00 ± 7.38 lbf ft)
pipe diameter Ø 18 110 ± 10 Nm (81.13 ± 7.38 lbf ft)
pipe diameter Ø 20 130 ± 10 Nm (95.88 ± 7.38 lbf ft)
pipe diameter Ø 22 170 ± 10 Nm (125.39 ± 7.38 lbf ft)
pipe diameter Ø 28 200 ± 10 Nm (147.51 ± 7.38 lbf ft)

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 03-2 Specifications, Engine

Oil Valves
7
6

1 2

3 4

P0007023

1 Safety valve, lubricating oil pump 10 ± 2 Nm (7.39 ± 1.48 lbf ft)

2 Reducing valve 10 ± 2 Nm (7.39 ± 1.48 lbf ft)
3 Control valve, piston cooling 55 ± 5 Nm (40.57 ± 3.69 lbf ft)
4 Opening valve, piston cooling 55 ± 5 Nm (40.57 ± 3.69 lbf ft)
5 Overflow valve, oil cooler 10 ± 2 Nm (7.39 ± 1.48 lbf ft)
6 Overflow valve, bypass filter 12 ± 2 Nm (8.85 ± 1.48 lbf ft)
7 Overflow valve, full flow filter 55 ± 5 Nm (40.57 ± 3.69 lbf ft)

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03-2 Specifications, Engine

Group 23: Fuel System

Feed pump – steering servo pump 25 ± 2 Nm (18.44 ± 1.48 lbf ft)

1 Copper sleeve, earlier model

2 Copper sleeve, earlier model (only ever
available as factory fit, not as spare part)
3 Copper sleeve, new model

Fixing yoke, unit injector (new or re-used copper sleeve type 3)

IMPORTANT!
Always use a new steel gasket beneath the unit injector.
First tightening
stage 1 20 ± 5 Nm (14.75 ± 3.69 lbf ft)
stage 2 180° ± 5° angle tightening

NOTICE! Loosen the fixing yoke bolt before doing the second tightening.
Second tightening
stage 1 20 ± 5 Nm (14.75 ± 3.69 lbf ft)
stage 2 90° ± 5° angle tightening

Fixing yoke, unit injector (re-used copper sleeve, types 1 or 2)

NOTICE! The steel gasket must never be used under the unit injector.
stage 1 20 ± 5 Nm (14.75 ± 3.69 lbf ft)
stage 2 60° ± 5° angle tightening

Locknut for adjuster screw, unit injector

stage 1 tighten until it contacts
stage 2 45° ± 5° angle tightening

Lock nut, valve adjusting

stage 1 tighten until it contacts
stage 2 60° ± 5° angle tightening

Hollow bolt M16x1.5 50 ± 8 Nm (36.88 ± 5.90 lbf ft)

Hollow bolt M10x1 25 ± 4 Nm (18.44 ± 2.95 lbf ft)

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 03-2 Specifications, Engine

Group 25: Inlet and Exhaust System

Intake manifold
12 8 2 4 6 10

P0007102 11 7 1 3 5 9

Stage 1: Tighten the bolts 1-12 until contact max. 10 Nm (7.38 lbf ft)
Stage 2: Tighten the bolts 1-12 24 ± 4 Nm (17.7 ± 2.95 lbf ft)

NOTICE! Apply a 2 mm (approx 0.08") bead of sealing

compound 1161231-4, as illustrated.

Plug, M10 20 ± 3 Nm (14.75 ± 2.21 lbf ft)

Pressure/temperature sensor, charge air 12 ± 2 Nm (8.85 ± 1.48 lbf ft)

Exhaust Manifold

P0007103

Stage 1: Tighten the bolts (1-4-2-3) until contact max. 10 Nm (7.4 lbf ft)
Stage 2: Tighten the bolts (1-4-2-3) 40 Nm (29.5 lbf ft)
Stage 3: Tighten the bolts (1-4-2-3) 54 Nm (39.8 lbf ft)

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03-2 Specifications, Engine

Turbo

TWD1643GE, TWD1644GE, TWD1645GE, Other engines

TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672GE, TWD1673GE

P0018895

P0018887

Turbocharger – exhaust manifold

Stage 1: Tighten the nuts diagonally. 20 Nm (14.8 lbf ft)
Stage 2: Tighten the nuts diagonally. 55 Nm (40.6 lbf ft)

P0018906

Turbocharger – wastegate valve housing (TWD only)

Stage 1: Tighten the nuts diagonally. 20 Nm (14.8 lbf ft)
Stage 2: Tighten the nuts diagonally. 55 Nm (40.6 lbf ft)

TAD1670VE, TAD1671VE, TAD1672VE,

TWD1672GE, TWD1673GE

Dosing unit:
Tightening torque: 8 Nm (5.9 lbf. ft.)

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 03-2 Specifications, Engine

Group 26: Cooling System

Tightening sequence 1-6 24 Nm (17.7 lbf. ft.)

P0020409

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03-2 Specifications, Engine

Engine
Technical Data

Engine body
Cylinder block
Length 1156 mm (45.512"),
Height, upper block plane - crankcase centerline 453 mm (17.835"),
Height lower block plane - crankcase centerline 120 mm (4.724"),
Crankcase pressure, normal value, irrespective of engine
speed max 0.5 kPa

Cylinder head
Type 6 cyl.
Length 1194 mm (47.008"),
Width 438 mm (17.244"),
Height 135 mm (5.315"),
Max. out-of-planeness (bottom plane) (1) 0.02 mm (0.000787"),
1) per 100 mm (3.937") measured length

Cylinder head bolts, Change

Number of bolts 38
Dimension, thread M18
Length 188 mm (7.402"),

Cylinder Liner
Type Wet, replaceable
Height, total 288 mm (11.339"),
Sealing surface height above block plane 0.15–0.21 mm (0.00591–0.00827”)
Quantity of seal rings per cylinder liner 3
Cylinder bore 144.00-144.02 mm (5.669-5.670”)

Piston
Type aluminum
Height above engine block plane 0.15-0.65 mm (0.00591-0.0256”)
Diameter, combustion chamber 98 mm (3.858"),
Depth, piston bowl:
TAD1640GE, TAD1641-43VE, TAD1650VE,
TAD1660-62VE, TAD1640-43VE-B, TAD1670-72VE,
TAD1650VE-B, TAD1651VE 19.35 mm (0.762"),
TAD1641-42GE, TAD1650-51GE, TWD1643GE,
TWD1644GE, TWD1645GE, TWD1652GE,
TWD1653GE, TWD1663GE, TWD1672-73GE 21.15 mm (0.883"),

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 03-2 Specifications, Engine

Number of piston ring grooves 3

Front marking Arrow towards front
Gudgeon pin diameter 63 mm (2.480"),

Piston rings
Compression Rings
Quantity 2
Piston ring clearance in groove:
upper compression ring –
0.07 mm (0.00276"),
lower compression ring wear tolerance 0.1 mm (0.00394")
Piston ring gap, measured at ring opening:
0.62 mm (0.0244"),
upper compression ring wear tolerance 0.85 mm (0.0335")
1.1 mm (0.0433"),
lower compression ring wear tolerance 1.35 mm (0.0531")
Oil ring
Quantity 1
Width, including spring 4.55 mm (0.179"),
0.04 mm (0.00157"),
Piston ring clearance in groove wear tolerance 0.1 mm (0.00394")
0.55 mm (0.0217"),
Piston ring gap, measured at ring opening wear tolerance 0.9 mm (0.0354")

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03-2 Specifications, Engine

Valve mechanism
Valves
Valve head, diameter:
Inlet 49 mm (1.929"),
Outlet 46 mm (1.811"),
Valve stem, diameter:
Inlet 10 mm (0.394"),
Outlet 10 mm (0.394"),

P0007076

Serial no: ≤ Serial no: ≥

Valve seat angle (A): 2016010024: 2016010025:
Inlet 19.5° 24.5°
Outlet 44.5° 44.5°

Serial no: ≤ Serial no: ≥

Seat angle in cylinder head (B): 2016010024: 2016010025:
Inlet 20° 25°
Outlet 45° 45°

Dimension between valve head and cylinder head plane:

Inlet 0.9-1.4 mm (0.0354-0.0551”)
Wear tolerance 1.5 mm (0.0591"),
Outlet 1.4-1.9 mm (0.0551-0.0748”)
Wear tolerance 2.0 mm (0.0787"),
NOTICE! When valve seats are changed, valves must
also be changed.
Valve clearance, cold engine, setting value:
Inlet (TWD1663GE, TWD1672-73GE) 0.4 mm (0.0157")
Inlet (other engines) 0.3 mm (0.0118"),
Outlet 0.6 mm (0.0236"),
Valve clearance, cold engine, check value:
Inlet (TWD1663GE, TWD1672-73GE) 0.35-0.45 mm (0.0138-0.0177")
Inlet (other engines) 0.25-0.35 mm (0.00984-0.0138”)
Outlet 0.55-0.65 mm (0.0217-0.0256”)

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 03-2 Specifications, Engine

Valve seats

P0007077

Outer diameter (A)

Standard:
Inlet 52.1 mm (2.051"),
Outlet 49.1 mm (1.933"),
Oversize:
Inlet 52.2 mm (2.055"),
Outlet 49.2 mm (1.937"),
Height (B):
Inlet 7.7 mm (0.303"),
Outlet 7.9 mm (0.311"),

Valve seat position

P0007078

Diameter (C) standard:

Inlet 52.0 mm (2.047"),
Outlet 49.0 mm (1.929"),
Diameter (C) oversize:
Inlet 52.2 mm (2.055"),
Outlet 49.2 mm (1.937"),
Depth (D):
Inlet 11.7 mm (0.461"),
Outlet 11.7 mm (0.461"),
Seat base radius (R):
Inlet max 0.8 mm (0.0315")
Outlet max 0.8 mm (0.0315")

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03-2 Specifications, Engine

Valve guides
Length:
Inlet 83.5 mm (3.287"),
Outlet 83.5 mm (3.287"),
Inner diameter:
Inlet 10 mm (0.394"),
Outlet 10 mm (0.394"),
Height above cylinder head spring plane:
Inlet 24.4 ± 1.0 mm (0.961 ± 0.0394")
Outlet 24.4 ± 1.0 mm (0.961 ± 0.0394")
Clearance, valve stem guide(1):
Inlet 0.025-0.054 mm (0.000984-0.00213”)
Wear tolerance max 0.4 mm (0.0157")
Outlet 0.058-0.87 mm (0.00228-0.0343”)
Wear tolerance max 0.4 mm (0.0157")
1) The dimensions are calculated for the measurement method described in the workshop manual (Group 21).

Rocker arms
Bearing clearance max 0.1 mm (0.00394")
Clearance rocker arm roller max 0.1 mm (0.00394")

Valve spring
Inlet
Uncompressed length 67.5 mm (2.657"),
With load 522 N (117.35 lbf) 57.0 mm (2.244"),
With load 1205 N (270.9 lbf) 43.3 mm (1.705"),
Coil bound length, max. 40.3 mm (1.587"),
Outlet
Outer valve springs:
Uncompressed length 69.3 mm (2.728"),
With load 930 N (209.1 lbf) 54.0 mm (2.126"),
With load 1813 N (430.1 lbf) 39.5 mm (1.555"),
Coil bound length, max. 37.0 mm (1.457"),
Inner valve spring:
Uncompressed length 67.0 mm (2.638"),
With load 465 N (104.5 lbf) 51.0 mm (2.008"),
With load 887 N (199.4 lbf) 36.5 mm (1.437"),
Coil bound length, max. 34.0 mm (1.339"),

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 03-2 Specifications, Engine

Engine Transmission
Timing gear wheels

P0006837

No. of teeth:
1 Drive gear, camshaft 84
2 Intermediate gear, adjustable 85
3 Intermediate gear, bull drive outer 84
Intermediate gear, bull drive, inner 56
4 Intermediate gear, servo pump 29
5 Drive gear, crankshaft 63
6 Drive gear, lubrication oil pump 37
7 Drive gear, steering servo and fuel feed pump 36

Gear lash 0.05–0.17 mm (0.00197–0.00669")

Shaft journal, intermediate gear, diameter Ø 99.97–99.99 mm (3.9358–3.9366")
Intermediate gear bush, diameter Ø 100.036–100.05 mm (3.9384–3.9390")
Radial clearance for intermediate gear max. 0.05 mm (0.00197")

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03-2 Specifications, Engine

Camshaft
Check camshaft setting, cold engine and valve
clearance =0.
At a flywheel position of 6° after TDC, the inlet valve must
be open 1.4 ± 0.3 mm (0.055 ± 0.012"). During this check,
the timing gear must be turned clockwise, seen from the
front, to take up all gear lash.
Drive gear wheel
No. of bearings 7
NOTICE! Only check values; not for machining.
Diameter, bearing journals, standard 69.97–70.00 mm (2.755–2.756")
Diameter, bearing journals, undersize dimension:
0.25 mm (0.00984") 69.72–69.78 mm (2.745–2.747")
0.50 mm (0.01968") 69.47–69.53 mm (2.735–2.737")
0.75 mm (0.02953") 69.22–69.28 mm (2.725–2.728")
Max. end float 0.35 mm (0.0138")
Max permissible ovality (with new bearings) 0.05 mm (0.00197")
Bearing, max. permissible wear on diameter 0.05 mm (0.00197")
Valve lift:
inlet 13.7 mm (0.539")
exhaust 14.5 mm (0.571")
Permitted wear between base circle and max lift max. 0.1 mm (0.00394")
Unit injector, stroke 18 mm (0.709")

Camshaft Bearings
Camshaft bearing thickness, standard 1.92 mm (0.0756")
Oversize dimension:
0.25 mm (0.00984") 2.05 mm (0.0807")
0.50 mm (0.01968") 2.17 mm (0.0854")
0.75 mm (0.02953") 2.30 mm (0.0906")

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Crank Mechanism
Crankshaft
Length 1,256 mm (49.449")
Crankshaft end float(1) 0.10–0.40 mm (0.0039–0.0157 in)
Ovality of main and big end bearings max. 0.01 mm (0.000394")
Taper on main and big end bearings max. 0.02 mm (0.000787")
Runout on center bearing 0.15 mm (0.00591")
1) Dimensions refer to oiled components.

Main bearing journal

C D
A
Ø

P0007079
R

NOTICE! Only check values; not for machining.

Diameter (Ø) standard 118 mm (4.646")
Undersize dimension:
0.25 mm (0.00984") 117.75 mm (4.636")
0.50 mm (0.0197”) 117.50 mm (4.626")
0.75 mm (0.030") 117.25 mm (4.616")
1.00 mm (0.0394") 117.00 mm (4.606")
1.25 mm (0.0492") 116.75 mm (4.596")
Surface finish, main bearing journal Ra 0.25 (9.84·10–6")
Surface finish, radius Ra 0.4 (1.575·10–5")
Width, thrust bearing journal (A) standard 49.0 mm (1.929")
Oversize dimension:
0.2 mm (0.00787"), thrust bearing 0.1 mm (0.00394") 49.2 mm (1.937")
0.4 mm (0.01575"), thrust bearing 0.2 mm (0.00787") 49.4 mm (1.945")
0.6 mm (0.02362"), thrust bearing 0.3 mm (0.0118") 49.6 mm (1.953")
Fillet radius (R) 4.5 mm (0.177")

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03-2 Specifications, Engine

Thrust washers (thrust bearings)

Width (B) standard 3.18 mm (0.1252")
Oversize dimension:
0.1 mm (0.00394") 3.28 mm (0.1291")
0.2 mm (0.00787") 3.38 mm (0.1331")
0.3 mm (0.0118") 3.48 mm (0.1370")
0.4 mm (0.016") 3.58 mm (0.1409")

Main bearing shells

Outer diameter (C) 123.12 mm (4.847")
Thickness (D) standard 2.51 mm (0.0988")
Oversize dimension:
0.25 mm (0.00984") 2.64 mm (0.104")
0.50 mm (0.0197”) 2.76 mm (0.109")
0.75 mm (0.0295") 2.89 mm (0.114 in)
1.00 mm (0.0394") 3.01 mm (0.119")
1.25 mm (0.0492") 3.14 mm (0.124")
Radial clearance, main bearings 0.07–0.14 mm (0.00276–0.00551")

Big-end bearing journal

P0007080

NOTICE! Only check values; not for machining.

Diameter (Ø) 112 mm (4.409")
Undersize dimension:
0.25 mm (0.00984") 111.75 mm (4.400")
0.50 mm (0.0197”) 111.50 mm (4.390")
0.75 mm (0.0295") 111.25 mm (4.380")
1.00 mm (0.0394") 111.00 mm (4.370")
1.25 mm (0.0492") 110.75 mm (4.360")

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 03-2 Specifications, Engine

Surface finish, big end bearing journal Ra 0.25 (9.84·10–6")

Surface finish, radius Ra 0.4 (1.575·10–5")
Width (A) 60 mm (2.362")
Fillet radius (R) 4.5 mm (0.177")

Big-end journal shells

Outer diameter (B) 116.8 mm (4.598")
Thickness (C) standard 2.35 mm (0.0925")
Oversize dimension:
0.25 mm (0.00984") 2.48 mm (0.0976")
0.50 mm (0.0197”) 2.60 mm (0.102")
0.75 mm (0.0295") 2.73 mm (0.107")
1.00 mm (0.0394") 2.85 mm (0.112")
1.25 mm (0.0492") 2.98 mm (0.117")
Diameter, bearing shell seat (D) 116.8 mm (4.598")

Connecting rod
Length, center - center (E) 280 mm (11.024")
Piston pin bush internal diameter (G) 63 mm (2.480")
End float, connecting rod - crankshaft(1) max. 0.35 mm (0.01378")
Big end bearing, radial clearance(1): max. 0.10 mm (0.00394")
Straightness, max. deviation on 100 mm (3.937") measured
length 0.06 mm (0.00236")
Twist, max. deviation on 100 mm (3.937") measured length 0.15 mm (0.00591")
1) Dimensions refer to oiled components.

P0007081

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

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03-2 Specifications, Engine

Flywheel, Installed
Runout, measured radius 150 mm (5.905") max. 0.1 mm (0.00394")
No. of teeth on starter gear ring 153
Sensor grooves in flywheel 54

Flywheel Cover, Installed

Runout for mating face against clutch bellhousing. max. 0.1 mm (0.00394")
Runout for alignment against clutch bellhousing. max. 0.05 mm (0.00197")

Lubrication System
Technical Data
Oil
Oil change volume, incl. filter:
TAD1650VE (optional for TAD1660-62VE, TAD1640–
43VE-B, TAD1670-72VE) 53 liter (14.0 US gals)
Other engines 48 liter (12.7 US gals)

Oil Pressure
Operating speed (above 1,100 rpm) 300–650 kPa (43.51–94.27 psi)
Low idle min 160 kPa (min 23.21 psi)

Oil temperature
Cold engine Ambient temperature
Hot engine max 125 °C (257 °F)

Lube oil pump

Typ Gear driven
No. of teeth, drive wheel 37
Gear lash 0,05–0,40 mm (0.00197–0.0157 in)

Oil filter
Full flow filters 2
Turbo filter (Bypass filter) 1

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 03-2 Specifications, Engine

Oil Valves

P0006839

A: Bypass valve, oil cooler

Spring, free length 69 mm (2.717 in)
Compressed 13–15 N (2.92–3.37 lbf) 40 mm (1.575 in)
B: Safety valve, lubricating oil pump
Marking Violet
C: Reduction valve, oil pressure
Marking Blue (not remote oil filter)
D: Control valve, piston cooling
Spring, free length 122 mm (4.803 in)
Compressed 60 N (13.49 lbf) 84 mm (3.307 in)
E: Opening valve, piston cooling
Spring, free length 122 mm (4.803 in)
Compressed 95 N (21.36 lbf) 63 mm (2.480 in)
F: Overflow valve, bypass filter
Spring, free length 69 mm (2.717 in)
Compressed 13–15 N (2.92–3.37 lbf) 40 mm (1.575 in)
G: Overflow valve, full flow filter
Spring, free length 69 mm (2.717 in)
Compressed 13–15 N (2.92–3.37 lbf) 40 mm (1.575 in)

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03-2 Specifications, Engine

Fuel System
Technical Data
Feed pump
Feed pressure at:
600 rpm min. 100 kPa (14.5 psi)
1,200 rpm min. 300 kPa (43.5 psi)
full load min. 300 kPa (43.5 psi)

Bypass valve
Opening pressure 400–550 kPa (58.0–79.8 psi)

Fuel amount

At low idle and with the engine unloaded, the fuel quantity
must be inside area B. The engine must be run in at least
600 h.

Unit injectors

P0007083

Pre-load 4 flats (0.85 mm (0.0335")); see illustration.

Tighten the adjuster screw to zero clearance against the
camshaft, then turn 4 flats.

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 03-2 Specifications, Engine

Inlet and Exhaust System

Technical Data
Turbo
TAD1640–1642GE, TAD1641–1643VE, TAD1660-62VE,
TAD1640-43VE-B, TAD1670-72VE, TAD1650VE-B,
TAD1651VE
Manufacturer/type I3K/K29
End float, turbine shaft max 0.13 mm (0.00512")

TAD1650VE, TAD1650-51GE
Manufacturer/type Holset/HE551
End float, turbine shaft max 0.127 mm (0.00500")

TWD1643GE, TWD1644GE, TWD1645GE,

TWD1652-53GE, TWD1663GE, TWD1672-73GE
HP Turbo:
Manufacturer/type Holset/HE551
End float, turbine shaft max 0.127 mm (0.00500")
LP Turbo:
Manufacturer/type Holset/HE82
End float, turbine shaft max 0.152 mm (0.00598")

Inlet temperature indicator

Cold engine Ambient temperature
Hot engine, coolant temperature 75–95 °C (167–203 °F) max. 30 °C (86 °F) above ambient temperature

Pressure drop indicator

Pressure drop indicator alarms at an underpressure of 5 kPa (37.5 mm VP) (0.725 psi)

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03-2 Specifications, Engine

Charge pressure
1500 rpm
TAD1640GE 232 kPa (33.65 psi)
TAD1641GE 240 kPa (34.81 psi)
TAD1643VE-B 335 kPa (48.59 psi)
TWD1644GE, TWD1645GE 426 kPa (61.79 psi)

1500 / 1800 rpm

TAD1642GE 268 kPa (38.87 psi)
TWD1643GE, TWD1663GE 462 kPa (67.01 psi)
TWD1652GE, TWD1653GE 480 kPa (69.62 psi)
TAD1650GE 320 kPa (46.41 psi)
TAD1651GE 264 kPa (38.29 psi)

1800 rpm
TAD1640GE 231 kPa (33.50 psi)
TAD1641GE 252 kPa (36.55 psi)
TAD1641VE 193 kPa (27.99 psi)
TAD1642VE 225 kPa (32.63 psi)
TAD1643VE 230 kPa (33.36 psi)
TAD1650VE 200 kPa (29.01 psi)
TWD1672GE, TWD1673GE 360 kPa (52.21 psi)
TAD1643VE-B 330 kPa (47.86 psi)
TWD1644GE 400 kPa (58.02 psi)
TWD1645GE 416 kPa (60.34 psi)

1900 rpm
TAD1640VE-B, TAD1660VE 170 kPa (24.66 psi)
TAD1641VE-B, TAD1661VE 180 kPa (26.11 psi)
TAD1642VE-B, TAD1662VE, TAD1650VE-B,
TAD1651VE 197 kPa (28.57 psi)
TAD1670VE, TAD1671VE 163 kPa (23.64 psi)
TAD1672VE 200 kPa (29.01 psi)

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 03-2 Specifications, Engine

Cooling System
Technical Data
General
Pressure valve opens at 75 kPa (10.88 psi)

Thermostat
Quantity 1
Opening temperature:
TAD1640–42GE, TAD1641–43VE, TAD1650VE,
TAD1650–51GE, TAD1660–62VE, TAD1640–
43VE-B, TAD1650VE-B, TAD1651VE,
TAD1670-72VE 82 °C (179.6 °F)
TWD1643GE (early model), TWD1663GE (early
model) 76 °C (168.8 °F)
TWD1643GE (late model), WD1644GE,
TWD1645GE, TWD1652GE, TWD1653GE,
TWD1663GE (late model), TWD1672-73GE 72 °C (161.6 °F)
Fully open:
TAD1640–42GE, TAD1641–43VE, TAD1650VE,
TAD1650–51GE, TAD1660–62VE, TAD1640–
43VE-B, TAD1650VE-B, TAD1651VE,
TAD1670-72VE 92 °C (197.6 °F)
TWD1643GE (early model), TWD1663GE (early
model) 86 °C (186.8 °F)
TWD1643GE (late model), WD1644GE,
TWD1645GE, TWD1652-53GE, TWD1663GE
(late model), TWD1672-73GE 82 °C (179.6 °F)

Coolant
There are two different types of coolant.

Type Volvo Penta Coolant

Color Green
Contains Ethylene glycol and anti-corrosion additives
Mix with Water (according to ASTM D4985)
Mixing proportions (conc coolant/water)(1) 40/60, freezing point -28 °C (-18.4 °F)

Type Volvo Penta Coolant VCS

Color Yellow
Contains Ethylene glycol and anti-corrosion additives
Mix with Water (according to ASTM D4985)
Mixing proportions (conc coolant/water)(1) 40/60, freezing point -24 °C (-11.2 °F)

1. Volvo Penta recommends ready mix coolant (Ready Mixed).

47702612 05-2018 © AB VOLVO PENTA 43

03-2 Specifications, Engine

IMPORTANT! IMPORTANT!
Under no circumstances mix VCS (yellow) with Volvo Industrial engines may not use coolant filters in
Penta Coolant (green) or any other coolant. combination with VCS (yellow); coolant filters will be
Engines filled with VCS (yellow) will have yellow omitted on new industrial engines filled with VCS
decals as external distinguishing features, e.g. the (yellow).
coolant filler cap will be surrounded by a yellow decal.

Refill quantity
Coolant quantity (engine, radiator and hoses):
TAD1640–42GE, TAD1641–43VE, TAD1650VE,
TAD1650–51GE, TAD1660–62VE, TAD1640–
43VE-B, TAD1670-72VE, TAD1650VE-B,
TAD1651VE 60 ± 2 liter (16 ± 0.5 US gallons)
TWD1643GE (early model), TWD1663GE (early
model) 95 liters (25 US gallons)
TWD1643GE (late model), WD1644GE,
TWD1645GE, TWD1652-53GE, TWD1663GE
(late model), TWD1672-73GE 65 liters (17 US gallons)

44 47702612 05-2018 © AB VOLVO PENTA

 03-3 Specifications, Electrical

03-3 Specifications, Electrical

Sensor
Charge air pressure sensor
TAD engines:
Check value 1.05–1.12 V at 100 kPa (14.50 PSI)
TWD engines:
Check value 0.81–0.91 V at 100 kPa (14.50 PSI)

Camshaft sensor
Distance to camshaft 1.1 ± 0.4 mm (0.0433 ± 0.0157")

Flywheel sensor
Distance to flywheel 1.1 ± 0.4 mm (0.0433 ± 0.0157")

Pressure drop indicator

Active V = 0.48 x Ubat
Inactive V = 0.12 x Ubat

Charge air temperature sensor

P0007084

Coolant temperature sensor Engine oil temperature sensor

P0007085
P0007086

47702612 05-2018 © AB VOLVO PENTA 45

05-1 Safety Instructions

05-1 Safety Instructions

Safety Information
This Service Manual contains repair instructions,
descriptions and technical data for products or product
designs from Volvo Penta. Ensure that you are using
the correct service manual.

Read the safety information below and the service manual section About this Workshop manual and Repair
instructions carefully before repair and service work is begun.

!
This symbol is used in the service manual and on the product, to call attention to the fact that this is safety
information. Always read such information very carefully.
Safety texts in the manual have the following order of priority:

DANGER!
Indicates a hazardous situation, which, if not avoided, result in death or serious injury.

WARNING!
Indicates a hazardous situation, which, if not avoided, could result in death or serious personal injury.

CAUTION!
Indicates a hazardous situation, which, if not avoided, could result in minor or moderate personal injury.

IMPORTANT!
Is used to draw your attention to something that may cause minor damage or a minor malfunction to the product
or property.

NOTICE! Is used to draw your attention to important information that will facilitate the work or operation in
progress.

This symbol is used on certain operations to indicate the following:

This operation requires prior theoretical and/or instructor led training before attempting. Contact your local training
organization for further information.

This symbol is used to inform that added information needs to be read. And where to find needed information.

This symbol is used where VODIA computer is needed,. either for fault tracing, testing or for programming.

A compilation of safety precautions that must be taken and risks which must be paid attention to is
presented in the following pages.

46 47702612 05-2018 © AB VOLVO PENTA

 05-1 Safety Instructions

Immobilize the engine by turning off the power Avoid opening the coolant filling cap when the
! supply to the engine at the main switch ! engine is hot. Steam or hot coolant can spray
(switches) and lock it (them) in the off position out and system pressure will be lost. Open the
before starting work. Post a warning notice at filler cap slowly, and release the pressure in the
the main circuit breaker. cooling system if the filler cap or valve has to be
opened, or if a plug or coolant hose has to be
removed when the engine is hot.

As a rule, all service operations must be carried Hot oil can cause burns. Avoid skin contact with
! out with the engine stopped. However, some ! hot oil. Ensure that the lubrication system is not
work, such as adjustments, will require the under pressure before any work is begun.
engine to be running. Approaching an engine Never start or operate the engine with the oil
which is running is a safety risk. Bear in mind filler cap removed, because of the risk of oil
that loose clothing or long hair can fasten in ejection.
rotating parts and cause serious personal
injury.

Be aware of hot surfaces (exhaust pipes, Never start the engine without installing the air
! turbos, charge air pipes, starting heaters etc.) ! filter. The rotating compressor turbine in the
and hot fluids in pipes and hoses on an engine turbocharger can cause severe injury. Foreign
that is running or has just stopped. objects entering the intake ducts can also cause
If work is done adjacent to a running engine, a mechanical damage. Install all protective
careless movement or a dropped tool may in the covers before the engine is started.
worst case lead to personal injury.

Ensure that the warning symbols or information Only start the engine in a well-ventilated space.
! decals on the product are always clearly visible. ! When running in a confined space, exhaust
Replace decals which have been damaged or fumes and crankcase gases must be led away
painted over. from the engine bay or workshop area.

Avoid getting oil on your skin! Protracted or The majority of chemicals e.g. engine and
! repeated exposure to oil can cause skin to ! transmission oils, glycol, gasoline, and diesel
become dry. Irritation, dryness, eczema and oil, together with chemicals for workshop use
other skin problems may then result. From a such as degreasing agents, paints and
health standpoint, used oil is more dangerous solvents, are injurious to health. Carefully read
than new. Use protective gloves and avoid oil- the instructions on the product packaging!
soaked clothes and rags. Wash regularly, Always follow a product's safety directions, e.g.
especially before eating. Use suitable barrier use of protective mask, glasses, gloves etc.
creams to counteract drying out of the skin and Ensure that other personnel are not exposed to
to aid dirt removal. substances that are injurious to health. Ensure
good ventilation. Handle used and leftover
chemicals in the prescribed manner.

Stop the engine and turn off the electrical supply Clutch adjustments must be carried out with the
! at the main switch(es) before carrying out work ! engine stopped.
on the electrical system.

47702612 05-2018 © AB VOLVO PENTA 47

05-1 Safety Instructions

Always use protective glasses or goggles when Never start the engine with the valve cover
! carrying out work where a risk of splinters, ! removed. There is a risk of personal injury.
grinding sparks, splashes from acid or other
chemicals is present. Your eyes are extremely
sensitive; injury may cause blindness!

Never use start gas or similar products as a Stop the engine before working on the cooling
! starting aid. They may cause an explosion in the ! system.
inlet manifold. Danger of personal injury. Marine engines: Close the sea cock / cooling
water inlet valve before work on the cooling
system is begun.

All fuels, as well as many chemicals, are Make sure that oil, fuel-soaked rags, and used
! flammable. Do not allow open flames or sparks ! fuel and oil filters are stored in a safe manner.
in their vicinity. Gasoline, some thinners, and Rags soaked in oil can spontaneously ignite
hydrogen gas from batteries are extremely under certain circumstances. Used fuel and oil
flammable and explosive when mixed with air in filters are environmentally hazardous waste
the correct proportions. No Smoking! Ensure and must be handed to an approved waste
that the work area is well ventilated and take the management facility for destruction, as must
necessary safety precautions before welding or any used lubrication oil, contaminated fuel,
grinding work is begun. Always ensure that paint residue, solvents, degreasers and wash
there are fire extinguishers close at hand in the residue.
work area.

Batteries must never be exposed to open Never work alone when removing heavy
! flames or electric sparks. Never smoke in the ! components, even when using lifting devices
vicinity of the batteries; they generate hydrogen such as locking tackle lifts. When using a lifting
gas when charged, which is explosive when device, two people are usually required to do
mixed with air. This gas is easily ignited and the work - one to take care of the lifting device
highly explosive. A spark, which can be caused and the other to ensure that components are
by incorrect battery connection, is sufficient to lifted clear and not damaged during the lifting
cause a battery to explode and cause damage. operations.

Do not touch the connections during start

attempts. Sparking hazard! Do not lean over
batteries.

Never transpose the positive (+) and negative The existing lugs on the engine should be used
! (-) battery posts when installing batteries. Such ! for lifting. Always check that the lifting
a transposition can result in serious damage to equipment used is in good condition and has the
electrical equipment. Refer to the wiring load capacity to lift the engine (engine weight
diagram. including gearbox or extra equipment). For safe
Always use protective goggles when charging handling and to avoid damaging components
and handling the batteries. Battery electrolyte fitted to the top of the engine, the engine must
contains sulfuric acid which is highly corrosive. be lifted with a correctly adjusted lifting boom.
Should the battery electrolyte come into contact All chains or wires must run parallel to each
with unprotected skin, wash it off immediately other and as perpendicular to the engine as
using soap and copious amounts of water. If you possible. If other equipment attached to the
get battery acid in your eyes, flush at once with engine has altered its center of gravity, special
copious amounts of water and seek medical lifting devices may be needed to obtain the
assistance immediately. correct balance for safe handling. Never
perform any work on an engine that is only
suspended from the lifting equipment.

48 47702612 05-2018 © AB VOLVO PENTA

 05-1 Safety Instructions

The components in the electrical and fuel Exercise extreme caution when leak-detecting
! systems on Volvo Penta products are designed ! on the fuel system and testing the fuel injector
and manufactured to minimize the risk of fire nozzles. Use eye protection. The jet from a fuel
and explosion. The engine must not be run in nozzle has very high pressure and great
areas where there are explosive materials. penetration power. Fuel can force its way deep
into body tissue and cause severe injury. There
is a risk of blood poisoning (septicemia).

Only use fuels and lubricating oils Never use a high-pressure washer for cleaning
! recommended by Volvo Penta. Refer to the ! the engine.
Operator's Manual for the product in question. Pay attention to the following when using a high-
Use of fuels that are of a lower grade may pressure washer on components other than the
damage the engine, the injection pump and the actual engine: Never direct the water jet at
injectors. On a diesel engine, low grade fuel can seals, rubber hoses or electrical components.
cause the control rod to bind and the engine to
over-rev, with the risk of engine damage and
personal injury as a result. Low fuel and oil
grades may result in high service, maintenance
and repair costs.

Fuel delivery pipes must not be bent or When working on the engine; perform leakage
! straightened under any circumstances. Cracks ! and function test as necessary.
may occur. Damaged pipes must be replaced.

47702612 05-2018 © AB VOLVO PENTA 49

08-2 Special Service Tools

08-2 Special Service Tools

The following special tools are used when working on
the engine. The tools can be ordered from AB Volvo
Penta by specifying the number indicated.

P0006764
P0006782

P0006792

885810 Fixture 9809726 Pneumatic hydraulic 9809729 Hydraulic cylinder

pump
For upper timing cover Used with 9809729 or Used with press tool 9990176
9992670. Replaces 9996222

P0006761 P0006763
P0006269

9986173 Puller 9986179 Puller 9990006 Puller

For flywheel bearings For flywheel bearings For unit injectors

p00006766
P0006765 P0006768

9990013 Slide hammer 9990107 Connection washer 9990114 Puller

Used for pressure testing Used for main bearing caps

P0006769 P0006770
P0004314

9990118 Cone 9990123 Pressure testing kit 9990124 Nipple

For installation of front
crankshaft seal

50 47702612 05-2018 © AB VOLVO PENTA

 08-2 Special Service Tools

P0006771

P0006772 P0006773

9990125 Nipple 9990143 Fixture 9990156 Adapter

For turbo pressure manometer Up to and including engine no. For sealing plug 9998251
2016010024

P0006776

P0006774 P0006775

9990157 Press tool 9990158 Piston ring 9990160 Fixture

compressor
For cylinder liner (7 pcs. For cylinder head
required)

P0006778
P0006777 P0006785

9990164 Fixture 9990165 Guide sleeve 9990166 Mounting tool

For pressure testing cylinder For valve spindle seal For rear crankshaft seal
head

P0006793
P0006795
P0006786

9990174 Drift 9990176 Press tool 9990185 Lifting tool

For removal/installation of valve For removal/installation of valve For rocker arm bridge
springs, outlet springs and valve guides

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08-2 Special Service Tools

P0006783
P0006779 P0006780

9990192 Puller 9990210 Valve spring 9991801 Standard handle

compressor
For rear crankshaft seal, used For e.g. changing flywheel
with 9996400 bearing
P0004328

P0006787
P0006791

9992000 Handle 9992269 Drift 9992479 Holder for dial

indicator
Standard handle For installation of flywheel
bearing

P0006794 P0006781 P0006784

9992670 Hand pump 9992873 Nipple 9993590 Rotation tool

Used with 9809729, alternative For pressure checking
to 9809726

P0006788
p0006802

9996049 Draining hose 9996159 Adapter 9996239 Lifting tool

For hydraulic cylinder 9809729 For removal/installation of
cylinder head and flywheel
housing, (2 pcs. required)

52 47702612 05-2018 © AB VOLVO PENTA

 08-2 Special Service Tools

p0004329

p0004330

P0002947

9996394 Support 9996395 Support 9996398 Manometer

P0004331

p0006800 P0004332

9996400 Slide hammer 9996441 Cover, with 9996645 Puller

connecting nipple
For cooling system leakage test
P0004333

P0006804 P0006807

9996662 Pressure testing kit 9996666 Nipple 9996845 Screw clamp

For pressure testing oil cooler
(2 pcs. required)

p0006798
p0006803
p0006801

9996963 Plate 9998246 Drift 9998248 Adapter

For removing/installing cylinder For removal/installation of valve For measuring cylinder
liners springs, inlet compression (6 pcs. required)

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08-2 Special Service Tools

P0006806

P0006808
P0006805

9998249 Protective sleeve 9998250 Sealing ring 9998251 Protection plug

For unit injectors (6 pcs. For fuel duct in cylinder head (2 For cylinder head (6 pcs.
required) pcs. required) required)

P0006813 P0004349

9998264 Lifting tool 9998339 Manometer

For camshaft

P0006816

P0006818 P0006820

9998487 Sleeve 9998494 Hose 9998502 Hose

For removal of oil filter For measuring fuel pressure For pressure testing cooling
(red), used with 9990123 and system (green), used with
9990124 9990123

P0006814
P0001859 P0006812

9998511 Lever 9998517 Adjustment tool 9998599 Cleaning kit

For checking/setting flywheel Complete kit for cleaning unit
and camshaft sensor injectors

54 47702612 05-2018 © AB VOLVO PENTA

 08-2 Special Service Tools

P00068115 P0001878
P0006817

9998601 Fixture 9998629 Lifting tool 9999179 Extractor oil filter

For upper timing cover Thread M10, 2 pcs. required

p0006797
P0006789

P0006767

88800003 Fixture 88800021 Drift 88800064 Drift

Used with 9986485 (from and For removal of front crankshaft For changing valve guides
including engine no. seal (inlet), installation
2016010025)

p0006799 P0006790

88800513 Drift 88800123 Plate 88800127 Drift

For removal of copper sleeve Used with 88800003 (from and For changing valve guides
including engine no. (exhaust), installation
2016010025)

P0006809

p0006796

88800147 Drift 88800151 Drift

For changing valve guides, For valve stem seal
removal

P00013450

88890105 Refractometer

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08-2 Special Service Tools

9998599 Cleaning kit

Cleaning kit for unit injector. Contains:

• 959239 Screw M10

• 9808570 Brush, white
• 9998580 Sleeve with holder and O-ring
• 276948 O-ring set
• 9808634 Brush kit, contains:
- Storage box
- Holder
- Holder
- Handle
- 9808614 Brush, yellow 10 pcs
- 9808617 Wire brush, narrow
- 9808618 Wire brush, coarse

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 08-2 Special Service Tools

Other Equipment
The following miscellaneous equipment is used when
working on the engine. The equipment can be ordered
from AB Volvo Penta by specifying the number
indicated.

P0002784

P0006821 P0002930

885531 Pressure testing kit 885633 Torque multiplier 885648 Counterhold

Cooling system
P0004342

P0006823 P0004344

885811 Timing tool 885812 Timing tool 1159794 Torque wrench

3/8", 10-100 Nm (7.4-73.8 lbf.
ft.)

P0006822

P0001875

9986485 Stand 9988539 Compression meter 9989876 Dial indicator

10
0

20
0
20

P0001881 P0004344
P0001879

9999683 Dial indicator (short 9999696 Magnetic stand 9999881 Torque wrench
probe)

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08-2 Special Service Tools

p0013448 P0013447

P0002793

88800083 Piston ring pliers 88890102 Nipple 88890104 Pump

58 47702612 05-2018 © AB VOLVO PENTA

 20-0 Engine Information, General

20-0 Engine Information, General

Placement of Instrument Socket(s)
TAD1640GE, TAD1640VE-B, TAD1641GE,
TAD1641VE, TAD1641VE-B, TAD1642GE,
TAD1642VE, TAD1642VE-B, TAD1643VE,
TAD1643VE-B, TAD1650GE, TAD1650VE,
TAD1650VE-B, TAD1651GE, TAD1651VE,
TAD1660VE, TAD1661VE, TAD1662VE,
TAD1670VE, TAD1671VE, TAD1672VE

The figures below show where measuring points may

be located on the engines.

6
P0006848 1 4 5 2 P0006849

1 Crankcase pressure 4 Fuel feed pressure (before filter)

2 Lubricating oil pressure 5 Fuel feed pressure (after filter)
3 Charge air pressure / temp. after charge air 6 Piston cooling oil pressure (not apply for
cooler. TAD1650/1651GE)

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20-0 Engine Information, General

Placement of Instrument Socket(s)

TWD1643GE, TWD1644GE, TWD1645GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672GE, TWD1673GE

The figures below show where measuring points may

be located on the engines.

4 5

P0006850

1 Crankcase pressure 4 Fuel feed pressure (before filter)

2 Lubricating oil pressure 5 Fuel feed pressure (after filter)
3 Charge air pressure / temp. after charge air 6 Piston cooling oil pressure
cooler.

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 20-0 Engine Information, General

Location of Sensors

P0020699

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20-0 Engine Information, General

Electrical Components
1 Under pressure sensor, air filter (only TWD engines)
2 Camshaft position sensor
3 Pre-NOx sensor (TAD1670-72VE)
4 Coolant temperature sensor
5 Flywheel position sensor
6 Air inlet pressure/intake manifold temperature sensor
7 Coolant level sensor
8 AUX-stop
9 Fuses
10 Crankcase pressure sensor
11 Fuel pressure sensor
12 Oil level/temp sensor
13 Water in fuel switch
14 Oil pressure sensor

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 20-0 Engine Information, General

AdBlue/DEF tank heating

TWD1663GE, TWD1672GE, TWD1673GE

Schematic connection stand-by AdBlue/DEF heating system using an independent

heater system Hotstart CSM 10302 for a standby heating system or similar.

AdBlue/DEF heating for standby engines NOTICE! The standard valve mounted on the AdBlue/
DEF tank is used only for continuous operation.
NOTICE! The freezing point of AdBlue/DEF is:
-11°C (12°F). The heater unit shall also ensure an acceptable start-
up temperature for stand-by operation.
AdBlue/DEF must be kept liquid all the time on
standby engines to allow immediate high engine load. 1 Power supply, valve (at engine running)
If the AdBlue/DEF is frozen, the AdBlue/DEF injector 2 Power supply, heater and pump unit
may be damaged due to overheating. In areas where
freezing may occur, a heating system for the engine 3 Relay (open at engine running)
cooling liquid is required. 4 Heater and pump unit. Thermostatically
The AdBlue/DEF should not be heated above 50 °C controlled. Max temperature 50 °C (122 °F)
(122 °F) during a longer period. 5 Hose, max 5m (16.4ft) total length
Description of operation 6 Valve, normally open (closed at engine running)
Using the connection points for the standard engine 7 AdBlue/DEF tank 200 l
heater system an independent heater system must be
installed (see picture above). 8 Engine

The system requires a heater with a pump unit (4) to If the pressure build-up in the AdBlue/DEF dosing
ensure a proper flow through the AdBlue/DEF tank system is not working correct, the engine is shut down
and a valve (6) that will stop the circulation when the within less than 1 hour.
engine is shut-down to prevent the AdBlue/DEF from
overheating.

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20-0 Engine Information, General

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

IMPORTANT!
Read through the safety advice for care and
maintenance work in the chapter Safety precautions
for boat operation before you start work.

Symptoms and possible causes

The diagnosis button lamp flashes
Please refer to Diagnostic Function
Engine can not be stopped
2, 5
Starter motor does not rotate
1, 2, 3, 4, 5, 6, 7, 24
Starter motor rotates slowly
1, 2
Starter motor rotates normally but engine does not start
8, 9, 10, 11,
Engine starts but stops again
8, 9, 10, 11, 13
Engine does not reach correct operating speed at full throttle
9, 10, 11, 12, 13, 21, 25, 26
Engine runs roughly
10, 11
High fuel consumption
12, 13, 15, 25
Black exhaust smoke
12, 13
Blue or white exhaust smoke
15, 22
Too low lubrication oil pressure
16
Excessive coolant temperature
17, 18, 19, 20, 28
Too low coolant temperature
20
No, or poor charge
2, 23
Too high exhaust temperature (only TWD engines)
13, 17, 18, 19, 21, 25, 27, 28, 29, 30

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 20-0 Engine Information, General

Reason code
1 Discharged batteries
2 Poor contact/open circuit in electrical wiring
3 Main switch turned off
4 Main fuse faulty
5 Faulty ignition lock
6 Faulty main relay
7 Faulty starter motor/-solenoid
8 No fuel:
– fuel cocks closed
– fuel tank empty/wrong tank connected
9 Blocked fuel fine-filter/pre-filter (due to contaminations, or stratification in the fuel at low temperature)
10 Air in the fuel system
11 Water/contamination in fuel
12 Faulty unit injectors
13 In sufficient air supply to the engine:
– blocked air filter
– air leakage between the turbo and the engine's intake manifold
– dirty compressor part in the turbocharger
– faulty turbo compressor
– poor engine room ventilation
14 Coolant temperature too high
15 Coolant temperature too low
16 Oil level too low
17 Coolant level too low
18 Air in the coolant system
19 Faulty circulation pump
20 Defective thermostat
21 Blocked charge air cooler
22 Oil level too high
23 Alternator drive belt slips
24 Water entry into engine
25 High back pressure in the exhaust system
26 Break in ”Pot+” cable to throttle
27 High temperature, charge air cooler
28 Blocked radiator
29 No pressure in cooling system
30 Check wastegate function

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20-0 Engine Information, General

Common Interference Causes

Suitable actions
Functional Disturbances External cleaning:
For more detailed information and further fault tracing 1 Remove guards as necessary, to access the
help, See Operator's Manual, group 30, “MID 128, radiator.
PID 110 Engine coolant temperature”. If there is a IMPORTANT!
malfunction, first check the following items: Take care that the radiator lamella are not
damaged.
• Check that the coolant level is between the
A high pressure washer may under no
markings on the expansion tank (at approx.
circumstances be used!
20°C) [68 °F]. If the level in the expansion tank
is too low, top up and start the engine. If the 2 Clean with water and a mild detergent.
coolant disappears, there is internal or external Use a soft brush.
leakage.
3 Re-install removed parts.
• Check that the coolant is not contaminated. If
the coolant is contaminated, this signifies Internal cleaning:
internal leakage (oil) or that the cooling system
has a blockage (deposits). Blockage in the • Refer to Cooling System, Cleaning.
cooling system is caused by one or more of the
following factors: Further checks
1 The coolant has not been changed at the • External and internal leakage in the cooling
specified intervals. system: Check if there is leakage in the system.

2 Incorrect mixture of coolant and water. • Coolant circulation: Check that coolant
circulates by letting the engine run at high
3 Contaminated water has been used. speed. Also check the expansion tank to see
that coolant circulates. This can be an indication
Clogging of a fault in the cooling system.
Is often caused by high coolant temperature, internal • Thermostat: Check thermostat function. Drain
or external blockage of the cooling system, or a enough coolant to allow the thermostat to be
combination of both. If the cooling system is blocked, removed. Check the thermostat; refer to
it must be cleaned. Thermostat, Function Check, page 302.
• External dirt: Check that the cooler and/or the
charge air cooler are not clogged. If you cannot
see light through at least one third, the cooler
should be removed and cleaned.
Check if there is any internal or external leakage
in the cooling system.
• Internal contamination: Check that the cooler
and/or the charge air cooler are not clogged.

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 20-0 Engine Information, General

Charge Pressure, Troubleshooting

Charge Air Pressure, Check

Tools:
9998339 Manometer
9998493 Hose
9996666 Nipple
1 Connect the nipple with hose and pressure gauge
to the measuring point on the inlet manifold; refer
to 20-0, Engine Placement.
2 Compare this pressure with the pressure that can
be read with the VODIA tool; refer to “Workshop
manual, EMS 2”
If the two measurements show different values,
the pressure sensor is faulty and must be
changed.

Pressure drop indicator, check

TAD1640-42GE, TAD1641-43VE, TAD1650-51GE,
TAD1640-43VE-B, TAD1650VE, TAD1660-62VE,
TAD1650VE-B, TAD1651VE, TAD1670-72VE

NOTICE! For TWD engines the pressure drop

indicator is electrical and provides a signal to the
engine management system.

1 Check that the air filter is clean and that there are
no obstructions to air entry.
2 Remove the pressure drop indicator from the air
filter housing
3 Check the pressure drop indicator by sucking out
air until the indicator shows red. Re-set by
pressing the yellow button.
4 When for example the air filter is blocked and
pressure drop occurs, the pressure drop indicator
shows this by indicating red. Change the indicator
if it does not function according to the checks in
the previous steps (shows red).
5 Install the pressure drop indicator on the air filter
housing.

Exhaust system, inspection

TAD1640-42GE, TAD1641-43VE, TAD1650-51GE,
TAD1640-43VE-B, TAD1650VE, TAD1660-62VE,
TAD1650VE-B, TAD1651VE, TAD1670-72VE
1 Check that the exhaust system is a Volvo Penta
original component.
2 Check whether the exhaust system has been
modified, has bends or damage that prevent
exhaust gas from flowing out.
If the exhaust system is not a Volvo Penta
original, has been modified, has bends or
damage, exhaust back pressure may be too high,
which will entail reduced engine power.

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20-0 Engine Information, General

Charge air cooler, checks

TAD1640-42GE, TAD1641-43VE, TAD1650-51GE,
TAD1640-43VE-B, TAD1650VE, TAD1660-62VE,
TAD1650VE-B, TAD1651VE, TAD1670-72VE
1 Check the charge air cooler for damage to the
cells and connections.
If there is any damage, change the charge air
cooler.
2 Check the charge air cooler and radiator for
internal blockage.
If there is any blockage, clean in accordance with
Charge Air Cooler, External
Cleaning, page 68.

Inlet manifold, checks

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

Charge air pipes, checks

1 Inspect the charge air pipes for visible cracks and
external damage.
2 Check that there is no oil in the charge air pipes.
If the pipes are damaged or the union seal rings
leak, the charge pressure will be too low and
engine performance will be impaired.
If the pipes are contaminated with oil on the
inside, this indicates oil leakage in the
turbocharger turbine shaft seal. In this case, the
turbocharger must be changed as a complete
unit.

IMPORTANT!
If there is oil in charge air pipes and charge air
hoses, the charge air cooler and all pipes and
hoses in the charge air system must be very
thoroughly cleaned inside, before the engine is
started.

Charge Air Cooler, External

Cleaning
Remove guards as necessary, to access the cooler.
Clean with water and a mild detergent. Use a soft
brush. Be careful not to damage the radiator matrix.
Re-install the components.

IMPORTANT!
Do not use a high pressure power washer.

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Test and Adjustments

Compression Test
The fuel system shall be emptied and the rocker bridge
removed, see Draining, Fuel Duct in Cylinder
Head, page 209.

Tools:
9988539 Compression meter
9990185 Lifting tool
9998248 Adapter
9998249 Protective sleeve
9998599 Cleaning kit

Removal
1 IMPORTANT!
9998248 Make sure that the area around the unit injectors
is clean before they are removed.
Remove the unit injectors, see Unit Injector,
Replace, page 214 and mount the unit injector
protection (9998249 Protective sleeve). Clean
the copper sleeves as needed with
9998599 Cleaning kit.
2 Fit all(1) adapters (6 pcs), tool 9998248 Adapter,
to the cylinder head and pull them on with the
P0004964 injector retainers.
3 Oil valve caliper, cam shaft ridges and the rocker
bridge.
4 Fit the rocker bridge with 9990185 Lifting tool.
Torque the screws evenly along the rocker arm to
avoid that the rocker arm bends or warps.
Make sure that guide pins fit in the camshaft
support bearing. Torque the rocker bridge as
specified in 03-2, Technical Data. Use torque
wrench.
5 Install the middle piece and the oil pipe to the
rocker bridge.
6 Check the valve clearance, see Valves and Unit
P0004965
Injectors, Adjustment, page 180, for all valves as
specified in 03-2, Technical Data.

1. This in order to avoid repeating removal/refitting of rocker bridge

and unit injector and performing valve adjustment six times.

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20-0 Engine Information, General

7 Remove both control wires from the starter motor

control connector (the two thin cables).
Connect one of the two free connectors on the
control connector to ground.

8 Connect the other connector to a switch, which in

turn is connected to the positive (plus) connection
on the starter motor.

9 Connect tool 9988539 Compression meter to

9998248 Adapter on the first cylinder.
998 8539 10 NOTICE! Do not run the engine for more than 15
seconds at a time with intervals of 60 seconds.

Run the engine with the starter motor until the

compression meter needle has stopped (max
compression reading).
Read the value.
Move the compression meter to the next cylinder.
P0004968 999 8248
Repeat the test on all cylinders.
11 Remove the middle piece and the oil pipe for the
rocker bridge.
12 Remove the rocker bridge screws equally in
stages so that it is not bent.
Remove the bolts and carefully lift off the rocker
bridge using 9990185 Lifting tool.

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13 Remove all adapters, tool 9998248 Adapter from

9998248 all cylinders.

P0004964

Installation
14 Mount the unit injectors and new o-rings, see the
Installation section in chapter Unit Injector,
Replace, page 214.
15 Fit the rocker bridge with 9990185 Lifting tool.
Torque the screws evenly along the rocker arm to
avoid that the rocker arm bends or warps.
Make sure that guide pins fit in the camshaft
support bearing. Torque the rocker bridge as
specified in 03-2, Technical Data. Use torque
wrench.
16 Install the middle piece and the oil pipe to the
rocker bridge.
17 Adjust valves and unit injectors, see Valves and
P0004965
Unit Injectors, Adjustment, page 180.
18 Check and if needed change the valve cover
bearing. Install the valve cover.
19 Re-install the fuel lines. Use new sealings.
20 Vent the fuel system, see Fuel system,
bleeding, page 207.

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Cooling System, Pressure Testing

Tools:
9996441 Cover, with connecting nipple
9996662 Pressure testing kit

Check the pressure testing device 9996662 Pressure

testing kit before using it. See Cylinder Head, Pressure
Testing, page 73.
1 Check that all hoses are free from defects.
2 Check that the cock on the pressure reduction
valve is fully opened.
3 Replace the coolant filler cap on the expansion
tank with cap 9996441 Cover, with connecting
nipple. Connect the pressure testing device to the
nipple on the lid.

P0006858

4 Connect the pressure-testing device to the

compressed air system and open the cock (B).
Adjust the pressure reduction valve (A) so that
pressure gauge shows a pressure of 70 kPa (10.2
PSI). Close cock (B).
5 The pressure must not drop during two
minutes for the cooling system to be considered
free from leaks.

NOTICE! Repeat the pressure testing if you are

uncertain whether the cooling system leaks or
not.
6 Close the compressed air after the pressure
testing. Eliminate the excess pressure in the
P0006859 cooling system by unscrewing the pressure
reduction valve and opening the cock (B).
7 Remove the testing device.
8 Check coolant level in the expansion tank. Install
the regular coolant filler cap.
9 Start the engine and check for leaks.

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Cylinder Head, Pressure Testing

Tools:
9990123 Pressure testing kit
9996239 Lifting tool
9986485 Stand
9990160 Fixture
9990107 Connection washer
9990164 Fixture

Checking the pressure test unit

Check pressure testing device 9990123 Pressure
testing kit before it is taken into service:
1 Connect the pressure testing device to the
compressed air mains.
2 Set the pressure gauge to 100 kPa (14.5 PSI)
using the reducing valve. The knob can be locked
with a retainer ring moved axially.

P0006858

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

pressure gauge must not fall for 2 minutes, for the
device to be regarded as reliable.
4 Unscrew the knob on the reducing valve and
open the tap.

P0007006

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Pressure Testing
Cylinder head removed.

For all lifts of the cylinder head use 2 lifting chains, tool
9996239 Lifting tool; refer to 21-1, Cylinder Head,
Removal.
1 Wash the cylinder head in a washing bath.
2 Fit the cylinder head to an assembly stand, tool
9986485 Stand with the aid of 9990160 Fixture
and 4 bolts, M8 x 25.
3 Clean the mating surfaces on the cylinder head.
4 Fit seal plates, tool 9990164 Fixture to the
cylinder head using the cylinder head bolts and
M18 nuts (14 pcs. required).
5 Fit connection washer, tool 9990107 Connection
washer onto the thermostat housing seat. Secure
the washer with a G-clamp; see illustration.
P0007007 Leave the side cover in place.
6 Leave the temperature sensor in place.
Plug any coolant connections for the compressor.
7 Connect the pressure gauge hose to connection
washer, tool 9990107 Connection washer.
8 Remove the cylinder head including fixture from
the assembly stand.
Remove the fixture.
9 Put the cylinder head in a water bath, +70 °C
(+158 °F).
10 Connect air to the pressure testing unit.
Open the shut-off valve.
11 Adjust the reducing valve knob so that pressure
gauge shows a pressure of 50 kPa (7.25 psi).
Maintain the pressure for 1 minute.
12 Raise the pressure to 150 kPa (21.76 PSI). Lock
P0007008 the reducing valve knob with the retainer ring.
Close the shut-off valve.
13 After 1 to 2 minutes, check whether the pressure
has dropped, or if bubbles of air can be seen in
the water bath.
If bubbles are visible, check seal plates and
inspect the cylinder head for any cracks.
14 Unscrew the knob on the reducing valve to relieve
the pressure in the cylinder head, and open the
tap.
15 Take the cylinder head out of the water bath.
Attach the fixture.
Secure the cylinder head in the assembly stand.

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16 Blow the cylinder head dry. Be extra thorough

with the fuel channels.

IMPORTANT!
Make sure no dirt gets into the fuel channels, as
this may cause damage to the unit injectors.
17 Remove all the sealing washers and any plugs
installed for the pressure testing.
18 Remove the cylinder head including fixture from
the assembly stand.
Remove the fixture.

P0006858

Charge Air Pipe, Leakage Check

1 Inspect the charge air pipes for visible cracks and
external damage.
2 Check that there is no oil in the charge air pipes.
If the pipes are damaged or the union seal rings
leak, the charge pressure will be too low and
engine performance will be affected. If the pipes
are contaminated with oil on the inside, this
indicates oil leakage in the turbocharger turbine
shaft seal. In this case, the turbocharger should
be changed as a unit.

NOTICE! If there is any oil in the charge air pipes and

charge air hoses, the charge air cooler and all pipes
and hoses in the charge air system must be cleaned
very carefully before the engine is started.

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20-0 Engine Information, General

Wastegate Valve, Adjustment

TWD1643GE (early mod.)

Localising
The wastegate valve link arm is on the side of the
wastegate housing.

Tools:
9990123 Pressure testing kit

P0006860

1 Connect manometer, tool 9990123 Pressure

testing kit to the waste gate actuator and to
compressed air.
Adjust the tool to 4 bar (400 kPa) [58.02 PSI].

P0006861

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 20-0 Engine Information, General

2 Remove the lock pin from the link arm.

P0006862

3 Lift the link arm so that the wastegate flap closes

completely.

IMPORTANT!
Hold the adjusting rod with a pair of pliers when
adjusting, so that the membrane in the pressure
actuator is not damaged by turning.
4 Adjust the rod so that the holes coincide.

P0006863

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20-0 Engine Information, General

5 Insert the lock pin and snap the lock into place on
the adjustment rod.
Tighten the lock nut.
6 Release the pressure from the tool and remove
it.
7 Reconnect the pressure hose to the wastegate
actuator.

P0006864

Drive Belt and Alternator Belt,

Inspection
Belts must be checked after operations while they are
still warm. The alternator belt and the drive belt must
be able to be depressed about 3–4 mm (0.12–0.16")
between the pulleys.
Both the alternator belt and the drive belt have
automatic belt tensioners and need not be adjusted.

Sensors, Adjustment
Sensor removed.

Tools:
88800031 Measuring tool
1 If the camshaft sensor needs to be adjusted,
rotate the crankshaft so that one tooth on the
camshaft vibration damper is centered in front of
the sensor hole.
2 Remove any shims beneath the sensor.
Clean the tool's contact surface on the engine.

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3 Insert 88800031 Measuring tool without

88800031 tightening the lock screw.
press in the tool firmly so that it is in contact with
the cover. Press in the center part of the tool until
it contacts the gearwheel and tighten the lock
screw.
Rove the tool and inspect the center section
position in its sleeve.

P0010198

4 Determine further actions according to the

following:

If the center section of the tool is entirely below

the sleeve's upper edge, no shims are required.

P0010219

If only the center section upper surface is above

the sleeve's top edge, one shim is required.

P0010218

If the two center section surfaces are above the

sleeve's top edge, two shims are required.

P0010220

5 Install the sensor with a new seal and any shims.

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21-0 Engine Complete, General

21-0 Engine Complete, General

Replacement of Components

Group 21: Engine

Cylinder Liner and Pistons,

Inspection
Clean the cylinder liners carefully before
inspection and measurement.

IMPORTANT!
Cylinder liners and pistons are classed together. This
means that cylinders and liners must not be mixed.

The piston and cylinder liner sets are only available as

a single, complete unit.

Cylinder Liner
Measurement of cylinder liner wear can be done with
the liner installed in the cylinder block.

NOTICE! The cylinder liners must be taken out of the

engine block, to do a careful crack check.

1 Measure the cylinder liners with a cylinder

indicator. In order to obtain the greatest possible
accuracy in the wear measurement, the cylinder
liner must first be set up with a gauge ring or
micrometer. Use the original diameter of the
cylinder liner as the base value.
2 Measure the cylinder liner at top and bottom dead
centers, and at several places vertically.
P0006962
At each measurement location, measurement
must be lengthwise and crosswise in relation to
the engine.
3 If wear is greater than 0.45–0.50 mm, a new
complete lining kit must be used (piston, liner,
piston rings, piston pin and seals).
Oil consumption also affects when cylinder liners
must be changed.
4 Remove the cylinder liner and do a crack check.
Be specially careful when checking the liner
collars.
The Magnaflux method may be used for this
check.

Pistons
5 Check for worn piston ring grooves, damaged
retainer ring grooves, cracks and other damage
to the pistons.
If the piston has deep scratches on its skirt, the
piston (liner kit) must be scrapped. The same
applies if the piston has one or more cracks in the

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 21-0 Engine Complete, General

piston pin hole or in the bottom of the combustion

chamber.
Crack tests must be done using the chalk powder
method.

Cylinder Liner and Pistons, Replace

(all)
Tools:
9989876 Dial indicator
9990157 Press tool
9990158 Piston ring compressor
9992479 Holder for dial indicator
9993590 Rotation tool
9996394 Support
9996395 Support
9996645 Puller
9996963 Plate
9998511 Lever
88800083 Piston ring pliers

Removal
Cylinder head, oil pan, bracing frame and piston
cooling nozzles removed.

IMPORTANT!
It is important that the piston cooling nozzles be
removed before the pistons are removed. Damaged
nozzles may cause extensive engine damage.
1 Remove the protective cover in the flywheel
housing and install tool 9993590 Rotation tool.
Turn the crankshaft until access is gained to the
bolts on the connecting rod that is to be removed.

P0006884

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2 Remove the big end bearing caps and bearing

cups.
3 Remove the piston together with the connecting
rod.

IMPORTANT!
Re-install the bearing cap on the connecting rod to avoid
damaging the split surface, as this is very sensitive.

P0006912

4 Pull the cylinder liner out of the block using tools

9996963 Plate, 9996645 Puller and
9996394 Support.
If necessary, extend using tool
9996395 Support.
5 Remove the cylinder liner sealing rings.

P0006913

6 Remove the retainer rings from the piston and

press out the piston pin.
Remove the piston from the connecting rod.
7 Clean the sealing surfaces in the cylinder block
and the grooves for the sealing rings. Do not use
scrapers or other tools that can damage the
sealing surfaces.

P0006963

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 21-0 Engine Complete, General

Installation
8 Check the cylinder block liner seat for damage. In
case of damage, the cylinder liner seat must be
reconditioned.
Fit the cylinder liner, without sealing rings.
Locate it using two tools9990157 Press tool.
9 Fit tool 9989876 Dial indicator into tool
9992479 Holder for dial indicator.
Place the holder with dial gauge across the
cylinder liner.
Zero the dial gauge with a couple of millimeters'
pre-load against the cylinder block plane.

P0006964

10 Measure the height between the cylinder liner

and the cylinder block plane.
Measure the height of the liner in two places,
diagonal to each other.
Calculate the average of the two measurements.
For correct liner height above block plane, see
specifications. If the liner height above block
plane is outside the specified tolerance, the liner
collar in the cylinder block must be milled.

NOTICE! Always measure at the highest point of

the sealing surface. Mark the liner position in the
cylinder block with an felt-tip pen, so that it is
replaced in the same position during installation.
Repeat the procedure for the remaining cylinder
liners.
P0006965
11 Remove the two tools 9990157 Press tool. Pull
the cylinder liner out of the block.
Place the cylinder liners in the same sequence
that they were installed, together with any
adjusting spacers.
12 Lubricate the sealing rings with the lubricant
supplied with the lining kit and install them on the
cylinder liners.

NOTICE! The purple seal ring must seat in the

lowest groove

P0006966

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13 When the cylinder liner is fitted without shims, an

even, thick bead of about 0.8 mm (0.03”) of
sealing compound must be placed on the
underside of the cylinder liner collar.

NOTICE! Do not put sealing compound around

the entire liner. Leave a 2 mm (0.08”) gap.

P0006917

14 If the liner is installed with shims, the sealant bead

must be placed on the cylinder block liner seat.

IMPORTANT!
Sealant must not be used between the adjusting
spacers and the cylinder liner collar.
15 NOTICE! After sealing compound has been
applied, the liner must be installed within 5
minutes and fixed in the engine block using two
tools 9990157 Press tool.

P0006918

16 Install one of the cylinder head bolts (A). Position

tool 9996963 Plate (D) above the cylinder liner
together with a suitable spacer (C) and press the
cylinder liner down using tool 9998511 Lever (B).

P0006967

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 21-0 Engine Complete, General

17 Lubricate the piston pin, the piston bearing seat

and the connecting rod bearing with engine oil.

FRO
NT

P0006920

18 Install the connecting rod in the piston with the

mark “FRONT” on the connecting rod and the
arrow on the piston facing the same direction.
Press in the piston pin.

NOTICE! It should be possible to press the piston

pin in without much force. If the resistance is too
great, the piston may need to be heated. The
connecting rod should turn freely on the piston
pin.

Install the retainer rings.

P0006921

19 Install the piston rings. Use tool 88800083 Piston

ring pliers. The piston ring openings must be
evenly spaced in relation to each other.
The oil scraper ring opening must be diametrically
opposite the opening in the spring.

NOTICE! The two upper piston rings are marked

with letters or dots. The markings must face
upward. The oil scraper ring is symmetrical and
may face either way.

P0006968

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20 Lubricate the piston and piston rings with engine

oil. Check that the piston ring openings are offset
120° in relation to each other.
21 Install the piston together with the connecting rod.

NOTICE! Connecting rods must be installed in

their original positions. The arrow on the piston
and the “FRONT” marking on the connecting rod
must face forwards. Use tool 9990158 Piston ring
compressor.

Temporarily remove the press tools when the

piston is installed. Put the press tools back when
the piston is in place.
22 Lubricate the bearing journal and bearing shells
with engine oil. Install the bearing shells. Check
P0006923
that they are correctly aligned in the connecting
rods and bearing caps. Install the main bearing
cap according to the markings and torque as
specified; refer to Technical Data, page 28.
23 Clean the piston cooling nozzle and check that it
is undamaged. Install the nozzle and torque
according to specifications; refer to Technical
Data, page 28.

NOTICE! Make sure that the nozzle is directed

toward the cutout in the piston.

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Crankshaft, Inspection
The crankshaft is induction hardened.

Inspect the crankshaft very carefully to avoid

unnecessary overhaul.
The following applies when the need for overhaul is
checked:
1 Clean the crankshaft carefully.
Measure the bearing journals' out-of-round, wear
and taper. Refer to Technical Data, page 28 for
specifications.
2 Check whether there is any surface damage on
the bearing journals. If there is any damage on
the surface layer, the shaft must be re-ground.
3 Place the shaft pair of V-blocks, under 1st and 7th
main bearing journals. Alternatively, hold the
crankshaft between the two centers.
4 Measure crankshaft axial displacement (throw)
on the 4th main bearing.
For maximum permissible values, refer to
Technical Data, page 28.

IMPORTANT!
Crankshaft straightening is not permitted.
5 Check for cracks before and after any grinding.
Magnetic powder testing is used for this test, i.e.
fluorescent powder which is viewed under ultra-
violet light.

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Main bearing, Change

Oil pan removed

The method describes replacement of main bearings

with the crankshaft in place in the engine

Tools:
9990013 Slide hammer
9990114 Puller
9993590 Rotation tool

Removal
1 Fit tool 9993590 Rotation tool.

P0006884

2 Remove the oil suction pipe and oil pump.

Remove the bracing frame.

P0006969

3 Remove one bearing cap.

P0006970

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4 Remove the upper main bearing shell by putting

a pin in the crankshaft oil hole and rolling the
bearing shell out by turning the crankshaft in the
direction of rotation with tool 9993590 Rotation
tool.
5 Clean and check the bearing seat, bearing cap,
shaft journal and bearing shell.
If the bearing has seized, the reason must be
determined before a new bearing is installed.
6 Check that the correct bearing dimension is used
when the bearing shells are changed.

NOTICE! If case of uncertainty, check in

Technical Data, page 28 which oversize
P0006971
dimensions are available.

Installation
7 Lubricate the shaft journal and the new bearing
shells with engine oil.
8 Install the upper bearing shell by turning the
crankshaft using tool 9993590 Rotation tool
against the direction of rotation with the pin in the
oil hole.

NOTICE! Check that the pressed-out bearing

shell heel is correctly aligned in the bearing seat
cutout.

Make sure that the upper bearing shells (those to

be located in the engine block) are equipped with
oil holes.

P0006972
NOTICE! Remove the pin when done.

9 Fit the main bearing cap together with the lower

bearing shell.

NOTICE! The main bearing caps are asymmetric

and can only be installed in one position. Note the
main bearing cap numbers showing their
locations if several caps are removed
simultaneously.

Torque the caps in two steps as specified; refer

to Technical Data, page 28.
10 Change the other bearing shells, one a time, in
the same way as the first one. Each time a
P0006973
changed is made, check that the crankshaft does
not seize by turning it using tool 9993590 Rotation
tool.

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11 Check crankshaft end float and replace the thrust

washers if the clearance is too great or if the thrust
washers are damaged.

NOTICE! Measure the end float with a dial gauge.

Thrust bearings are available in a number of
oversize dimensions. Refer to Technical
Data, page 28 for oversize dimensions and axial
play.

The crankshaft thrust bearing is located in the

center main bearing.
12 Use a narrow plastic or wood stick to remove the
thrust bearing washers from the cylinder block
bearing seat.

NOTICE! The thrust washers can only be placed

in one position.

P0006974

13 Check the axial play of the crankshaft when all

main bearing caps have been torqued; refer to
Technical Data, page 28 for specification.
14 Install the bracing frame and torque according to
the tightening chart; refer to Technical
Data, page 28.
15 Install the oil pump and oil suction pipe.
16 Remove tool 9993590 Rotation tool from the
flywheel housing and install the cover.
17 Install the oil pan.
P0006975 Add oil and change the oil filter.
Check the oil pressure.

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Big end bearing, Change (all)

Oil pan, oil suction pipe and bracing frame
removed.

Tools:
9993590 Rotation tool

Removal
1 Fit tool 9993590 Rotation tool and turn the
flywheel until the bearing caps on connecting
rods 1 and 6 are in a position that allows the bolts
to be removed.
2 Mark and remove the bearing caps on connecting
rods 1 and 6.

IMPORTANT!
Be careful not to damage the surfaces.
3 Remove the bearing shells and clean the
P0006884
connecting rod and cap bearing seats.

NOTICE! Make sure the bearing caps are

installed on the same connecting rod.
4 Check the bearing journals and bearing caps.
5 Measure the shaft journals; if any value exceeds
the maximum allowed, the crankshaft must be
removed and remedied.

Installation
6 Fit the new the bearing shells and check that the
bearing size is correct. Make sure the bearing
shell guide pins is aligned with the connecting rod
recess.
7 Lubricate the bearing shells and the big end
journals. Fit the bearing caps and torque the bolts
as specified; refer to Technical Data, page 28.
8 Turn the flywheel so that connecting rods 5 and
2 are in position for bolt removal and repeat steps
2-7.
P0006976
9 Turn the flywheel so that connecting rods 3 and
4 are in position for bolt removal and repeat steps
2-7.
10 Check that no big end bearing binds.
11 Remove the turning tool from the flywheel
housing and install the cover.
12 Install the bracing frame, oil suction pipe and oil
pan.
Add oil and change the oil filter.
Check the oil pressure.

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Flywheel Bearing, Change

Tools:
9986173 Puller
9986179 Puller
9991801 Standard handle
9992269 Drift
1 Measure the bearing position on the flywheel.
2 Remove the old bearing using tool
9986173 Puller and 9986179 Puller.

P0006977

3 Tap the new bearing into the measured position,

using tool 9991801 Standard handle and
9992269 Drift.

P0006978

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Flywheel, Change
Tools:
9993590 Rotation tool
9996239 Lifting tool
1 Remove the flywheel sensor.
2 Fit tool 9993590 Rotation tool.
3 Bolt tool 9996239 Lifting tool onto the flywheel
with two bolts.
Remove the flywheel retaining bolts. Use as the
turning tool as a counterhold.
Lift the flywheel away.
4 Clean the flywheel contact surface on the
crankshaft.
5 Clean the flywheel. Check that the tracking
surfaces for the flywheel sensor are clean.
6 Check that the flywheel guide pin is correctly
inserted into the crankshaft.
Check that there is no damage.
7 Lift the flywheel into position and install the
retaining bolts.
8 Torque the retaining bolts according to the
tightening chart; refer to Technical
Data, page 28. Use tool 9993590 Rotation tool as
P0006931
a counterhold.
9 Remove the cranking tool and re-install the cover.
10 Check the flywheel sensor clearance; refer to
Sensors, Adjustment, page 78.
Install the flywheel sensor.

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Gear Ring, Fywheel: Replace

Flywheel removed.
1 Drill 1–2 holes between teeth on the ring gear.
Split the gear ring at the drilled hole, using a cold
chisel. Lift the gear ring away from the flywheel.
2 Brush the flywheel contact surface clean with a
steel wire brush.

P0006979

3 Heat the new gear ring up to 180–200°C (356–

392 °F) with a welding torch or in an oven. The
gear ring must be evenly heated. Be careful not
to heat the gear ring up far with annealing as a
result.
Check the heat by polishing the ring bright at
several places. Stop heating when the polished
surfaces become blued.

P0006980

4 Put the heated gear ring onto the flywheel and tap
it into place with a soft mandrel and hammer.
Leave the gear ring to cool.

P0006981

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Flywheel, Indication
Pressure plate removed.

Tools:
9989876 Dial indicator
9993590 Rotation tool
9999696 Magnetic stand
1 Install tool 9989876 Dial indicator and
9999696 Magnetic stand with the measuring tip
against the flywheel.
2 Remove the cover from the engine flywheel
housing. Fit tool 9993590 Rotation tool.
3 Set the dial gauge to zero. Turn the flywheel and
observe the maximum value measured on the
dial gauge. This must not exceed 0.20 mm
(0.0079") on a measurement radius of 150 mm
(5.91").
If the runout is greater, remove the flywheel and
investigate whether there is any dirt or
unevenness between the flywheel and the
crankshaft flange.

P0006985 4 Remove tool 9993590 Rotation tool and install

the cover.

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Crankshaft Seal, Change (front)

Option 1

Tools:
9990118 Cone
9992000 Handle
88800021 Drift

Option 2

Tools:
9990118 Cone
9990192 Puller
9992000 Handle
9996400 Slide hammer
88800021 Drift

Removal, alternative 1
1 Remove the crankshaft pulley and oscillation
damper (12 bolts).
2 Drill 2 holes Ø 3.5 mm (0.14") in the seal with the
aid of the guide holes in tool 88800021 Drift.
Brush grease on the drill to prevent dirt from
getting into the engine.
3 Screw two 5 mm self-tapping screws (1) 5 mm
(0.2") into the seal.
4 Screw in two long thread M10 x 60 bolts (2) into
the tool and pull the seal out. Remove the seal
and bolts from the tool.
5 Clean the seal area in the cover and the sealing
P0004789 surface on the crankshaft.

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Removal, alternative 2

Tools:
9990192 Puller
9996400 Slide hammer
1 Hammer out the seal with tool 9990192 Puller
together with 9996400 Slide hammer.

9990192 IMPORTANT!
Incline the tool to ensure that the crankshaft is not
damaged.

999 6400

P0006989

Installation

Tools:
9992000 Handle
88800021 Drift
1 Check that the plastic ring is correctly in place in
the new seal.

NOTICE! If the plastic ring is not in place in the

new seal, the seal ring may be damaged and
must not be used.
2 Clean the crankshaft sealing surface and cover.
Check that these are damage free.

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3 Install the new sealing ring and plastic ring onto

the crankshaft journal.

P0004791

4 Press home the seal toward the cover by hand.

P0004792

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5 Remove the plastic ring.

P0004793

6 Carefully tap in the new seal until it bottoms

against the crankshaft journal. Remove the tool.
7 Ensure that the crankshaft, belt pulleys and hub
mating surfaces are clean and damage free.
8 Install the oscillation damper and pulley. Torque
according to specifications; refer to Special
Tightening Torques, page 12.

P0004794

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Crankshaft Seal, Change (rear)

Tools:
9990166 Mounting tool
9990192 Puller
9992000 Handle
9996400 Slide hammer

Removal
1 Fit tool 9996400 Slide hammer and
9990192 Puller on the old seal by pressing it in or
tapping it in the with a slide hammer.

IMPORTANT!
Be careful not to damage the crankshaft. Incline
the tool inwards to ensure a good grip in the seal.
Hammer out the seal with 9990166 Mounting
tool.
2 Clean the seal area in the flywheel housing (the
timing gear cover) and the sealing surface on the
crankshaft (sealing surfaces must be completely
clean and dry).
P0006990

Installation
3 Install the tool on the crankshaft and fasten it with
the bolts. Make sure that the plate on the tool is
touching the crankshaft before tightening it. The
washer must be placed on the center bolt as a
spacer. It determines how far the seal is pressed
into the cover.

P0006991

4 Install the plastic ring that the new seal is

mounted on and install the cover together with the
screw handle.

P0006992

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5 Press in the seal using the tool; when the cover

bottoms against the tool, the seal will be in the
correct position.

IMPORTANT!
No lubricants may be used and surfaces must be
clean.
6 Remove 9990166 Mounting tool.

P0006993

Connecting Rod, Check

Important consideration when removing/installing
fracture-split connecting rods.

Installing a NEW connecting rod:

Carefully fix the connecting rod in a vise with soft jaw
pads.

Undo the connecting rod bolts a few turns and carefully

tap the bearing cap with a plastic faced hammer until
it loosens.

The split line can be difficult to find when the

connecting rod is assembled.

When the cap is separated from the connecting rod, it

may occur that a chip is missing or comes loose. This
does not affect the function of the connecting rod
adversely.

Handle the connecting rod and bearing cap carefully.

If any strike marks occur on the split line, this may
affect strength after torquing.

IMPORTANT!
If the connecting rod or bearing cap are damaged,
change the connecting rod.

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Connecting Rod Bushing, Check up

1 Check the connecting rods for cracking,
straightness and twist before any piston pin bush
replacement. Scrap the connecting rod if it is
cracked, bent or twisted.
When the piston pin bush is changed, the bush
must be machined (trapezoid piston pin end).
When the clearance is correct, an oiled piston pin
should slowly slide through the bush under its
own weight.

3 IMPORTANT!
2 Regarding max. allowed straightness and twist
deviations, refer to Technical Data, page 28.

P0006994 P0006995

2 Use a new piston pin and measure the

straightness of the connecting rod, using a fixture.
3 Measure connecting rod twist.

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Valves, Removal

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

equipment stand using tool 9990160 Fixture. Use 4
pcs. bolts M8 x 25.

NOTICE! It is important that the greatest possible

cleanliness is observed during work on the cylinder
head. Dirt particles in the fuel ducts can cause failure
or malfunction of the unit injectors.

Alternative 1

Tools:
9809726 Pneumatic hydraulic pump
9809729 Hydraulic cylinder
P0006996 9990160 Fixture
9990174 Drift
9992670 Hand pump
9996159 Adapter
9998246 Drift

Note: 9992670 Hand pump is alternative to

9809726 Pneumatic hydraulic pump .

Alternative 2

Tools:
9990210 Valve spring compressor

Alternative 1
1 Fit tool 9809729 Hydraulic cylinder into tool
9990176 Press tool.
2 Install tool 9996159 Adapter and tool
9998246 Drift (inlet) or tool 9990174 Drift (outlet)
on the hydraulic cylinder. Place the tool in the
holes for the cylinder head retaining bolts.
Tighten the tool nuts.
3 Connect tool 9809726 Pneumatic hydraulic pump
(alternatively 9992670 Hand pump).
4 Press the valve spring washer down and remove
the collets.

NOTICE! Check that the tool does not damage

the unit injector electrical connector, if the injector
is left in place.

NOTICE! Put the valves and springs in a marked

stand, to facilitate putting components back in the
same places in the cylinder head.
5 Remove the remaining valves in the same way as
above, using the press tool.
6 Remove the oil seals from the valve guides.

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Alternative 2

Tools:
9990210 Valve spring compressor
1 Lay the cylinder head on a flat, clean surface.
Make sure the cylinder head is not damaged
when the valves are to be removed.
2 Fit tool 9990210 Valve spring compressor in the
unit injector hole. Fix the tool in the bolt hole for
the unit injector yoke, M10 x 30.
3 Place the moving part of the tool over the valve
spring to be removed. Screw down the “wing nut”
on the tool until the valve washer has been
pressed down so far that the collets can be
removed.

NOTICE! Put the valves and springs in a marked

P0006997
stand, to facilitate putting components back in the
same places in the cylinder head.
4 Remove the remaining valves in the same way as
above.
5 Remove the oil seals from the valve guides.

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Valves, Installation
Alternative 1

Tools:
9809726 Pneumatic hydraulic pump
9990165 Guide sleeve
9990174 Drift
9990176 Press tool
9990210 Valve spring compressor
9992670 Hand pump
9996159 Adapter
9998246 Drift

Note: 9992670 Hand pump is alternative to

9809726 Pneumatic hydraulic pump .

Alternative 2

Tools:
9990210 Valve spring compressor

Alternative 1
Not TAD670–672VE

IMPORTANT!
1 Blue valve stem sealing.
2 Brown valve stem sealing.

P0021295

1 Oil the valve stems and install the valves.

Oil the oil seals.
2 Install tool 9990165 Guide sleeve on the valve
stem and press the new oil seals down over the
valve guides.

NOTICE! Check that the oil seals are pressed

down properly.
3 Install the valve caliper guide pins.
Install the springs and valve spring washers.
Carefully press down the valve spring washer and
install the collets. Use tool 9990176 Press tool
together with 9809726 Pneumatic hydraulic
pump , 9996159 Adapter and 9998246 Drift (inlet)
P0006998 or 9990174 Drift (outlet), in the same way as for
Valves, Removal.

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Alternative 2

Tools:
9990210 Valve spring compressor
1 Alternatively, tool 9990210 Valve spring
compressor may be used instead of the hydraulic
cylinder, in the same way as for Valves, Removal.

P0006997

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Valve Seat, Change

Cylinder head and valves removed.

Tools:
9989876 Dial indicator
9992479 Holder for dial indicator
1 The valve seats must be changed if a satisfactory
seal cannot be obtained or when the distance (A)
exceeds the value stated in the specification;
refer to Technical Data, page 28.

P0007000

2 Grind the head off an old valve and weld it onto

the valve seat. Use a MAG welder, or a
conventional arc welder (with a stainless welding
electrode).

IMPORTANT!
Carefully cover the other surfaces on the cylinder head
to prevent any weld spatter from fastening.
P0007001

P0007002

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3 Place a suitable socket over the valve/valve guide

and carefully tap the valve seat out.

IMPORTANT!
Be careful not to damage the cylinder head.
CAUTION!
Risk of eye injury. Eye protection required.
4 Clean the seat bed carefully and check the
cylinder head for cracks.
5 Measure the diameter of the valve seat bed in the
cylinder head. Determine whether a standard or
oversize dimension valve seat must be used.
Carry out any necessary machining to the valve
P0007003 seat bed; refer to Technical Data, page 28.

6 Cool the seat in carbon dioxide snow between –

60 °C (–76 °F) and –70 °C (–94 °F) and heat the
cylinder head by flushing with hot water, or by
some other method.
Install the new valve seat using a drift.

NOTICE! Align the seat with the seat angle facing

the tool. Check sealing against the valve.

P0007004

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Valve Guides, Inspection

Refer to Valve Guides, Inspection, page 194.

Valve Guides, Replacing

Cylinder head removed.

NOTICE! If the valve seats must also be changed, this

must be done before the valve guides are removed.

CAUTION!
Risk of eye injury. Eye protection required.

Option 1

Tools:
9809726 Pneumatic hydraulic pump
9809729 Hydraulic cylinder
9990176 Press tool
9996159 Adapter
88800064 Drift
88800127 Drift
88800147 Drift

Optional tools

Tools:
9992670 Hand pump

Note: 9992670 is alternative to 9809726.

Removal
999 2670 980 9729 1 Install tool 9990176 Press toolinto the cylinder
980 9726 head retaining bolt holes.

NOTICE! Put washers between the nuts and the

cylinder head plane.
999 0176 2 Tighten the tool nuts.
999 6159 3 Install tool 9996159 Adapter in the hydraulic
888 00147 cylinder.
4 Fit tool 9809729 Hydraulic cylinder into tool
9990176 Press tool and press out the valve guide
using tool 88800147 Drift
and9809726 Pneumatic hydraulic pump ,
alternatively 9992670 Hand pump.
5 Press the other valve guides out in the same way.

p0003637

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Installation
6 Heat the cylinder head with hot water while
cooling the valve guides with e.g. carbon dioxide
snow.
Lubricate the cylinder head valve guides with
engine oil.

IMPORTANT!
Wear protective goggles when pressing.
7 Press in the valve guide for the inlet valve using
tool 88800064 Drift. Press in the exhaust valve
guide using tool 88800127 Drift.
8 Press until the tool bottoms against the cylinder
head plane.
9 Remove the tool from the cylinder head.

IMPORTANT!
After the valve guides have been changed, the cylinder
head must be cleaned carefully to prevent dirt particles
from getting into the fuel and oil ducts. Contamination
may cause failure or malfunction of the unit injectors.

Option 2

Tools:
9992000 Handle
88800064 Drift
88800127 Drift
88800147 Drift

NOTICE! If the valve seats must also be changed, this

must be done before the valve guides are removed.

CAUTION!
Risk of eye injury. Eye protection required.

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Removal
NOTICE! Take out the valve guides from beneath the
cylinder head.

1 Tap out the valve guides with tool 88800147 Drift

together with 9992000 Handle.
2 Tap the other valve guides out in the same way.

Installation
3 Heat the cylinder head with hot water while
cooling the valve guides with e.g. carbon dioxide
snow.
Lubricate the cylinder head valve guides with
engine oil.
CAUTION!
Risk of eye injury. Eye protection required.
4 Tap in the valve guide for the inlet valve using
tool88800064 Drift. Tap in the exhaust valve
guide using tool 88800127 Drift.
5 Tap until the tool bottoms against the cylinder
999 2000 head plane.
6 Repeat the procedure for the remaining valve
guides.

IMPORTANT!
After the valve guides have been changed, the cylinder
head must be cleaned carefully to prevent dirt particles
from getting into the fuel and oil ducts. Contamination
may cause failure or malfunction of the unit injectors.
888 00064
P0003640 888 00127

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Valve Seats and Valve, Grinding

For valve sealing angles, refer to Technical

Data, page 28.

NOTICE! Spare part valve seats are already

machined, and do not need further grinding.

P0007076

P0008416

Inlet valve

P0008417

Exhaust valve

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Valve seat, grinding

1 Before the valve seats are ground, the valve
guides must be checked and changed if wear
tolerances have been exceeded.
2 When grinding valve seats, do not remove an
unnecessary amount of material; only remove
enough material to give the valve seat the correct
shape and a good mating surface.
3 Grind new seats down so far that the dimension
between the cylinder head plane and the valve
disc surface, is in accordance with specifications;
refer also to Technical Data, page 28.
4 Check the valve seat angle with a valve seat
gauge, once the seat mating surface has been
coated with a thin layer of marker dye.

NOTICE! Spare part valves are already machined, and

do not need further grinding.

NOTICE! The sealing surface must be ground as little

as possible; however, enough to grind away all
damage.

Valves, grinding
1 Check dimension (A). If the dimension is greater
than the wear tolerance as specified in Technical
Data, page 28, the valve must be changed.

NOTICE! Always change a valve with a bent

valve stem.
2 Check valve sealing with marker dye. If there is
any leakage, grind the valve seat again; refer to
Valve Seat, Grinding, then do a new check.
Once the results of grinding are acceptable, the
valve and seat may be lapped in with fine grinding
P0007000 paste.

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Valve Stem Sealings, Replace

Tools:
9990165 Guide sleeve
9990210 Valve spring compressor
9993590 Rotation tool

Removal
1 Switch off all electrical power to the engine at the
main switch.
2 Remove the unit injectors; refer to the section in
Unit Injector, Replace, page 214.
3 NOTICE! The piston must be at top dead center
when the valves are removed. This is to prevent
the valves from falling down into the cylinder. Use
tool 9993590 Rotation tool.
4 Compress the valve springs for # 1 cylinder. Use
tool 9990210 Valve spring compressor .
5 Remove the valve washers, valve springs and
collets.
6 Remove the old valve stem seals.

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Installation
Not TAD1670-1672VE

IMPORTANT!
• Blue valve stem seal (1)
• Brown valve stem seal (2)

P0021295

7 Lubricate the valve stem with engine oil.

Install tool 9990165 Guide sleeve on the valve
stem. Fit the new seal and slide it over the drift.
8 Install the valve springs, valve spring washers
and collets. To ensure the collets arrive in the
correct positions, carefully tap with a plastic
mallet.
9 Transfer the valve spring compressor to cylinder
# 6 and repeat the above procedure. Then crank
the engine so that cylinders 3 and 4 are at TDC.
Repeat the procedure. Then continue with
cylinders 2 and 5.

NOTICE! The piston must be at top dead center

when the valves are removed. This is to prevent
the valves from falling down into the cylinder. Use
tool 9993590 Rotation tool.
10 Install the unit injectors; refer to the section in Unit
Injector, Replace, page 214.
11 Adjust valves and unit injectors; refer to Valves
and Unit Injectors, Adjustment, page 180.
12 Purge the fuel system; refer to Fuel system,
bleeding, page 207. Perform function and
leakage checks.

Cylinder Head, Pressure Testing

Refer to Cylinder Head, Pressure Testing, page 73.

Sleeve for unit injector, replace

See Sleeve for unit injector, replace, page 217.

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Camshaft, Wear Check

Rocker bridge removed

Put a steel rule across the camshaft lobes, parallel with

the camshaft axis, to check whether the cam profiles
show signs of wear.

Measure the wear with a feeler gauge or wire gauge.

Alternatively, a digital caliper gauge may be used.

Compare the measured values with those specified in

Technical Data, page 28.

P0007013

Guidlines for replacement

In normal conditions, unevenness may occur on the
surface of engine camshaft lobes. This does not mean
that the camshaft must be changed. These marks do
not have any negative influence on either engine
performance or the durability of the engine and its
components.

Examples of acceptable wear and unacceptable wear

are shown below.

Acceptable wear: Unacceptable wear:

The camshaft need not be changed. IMPORTANT!
The camshaft and associated rocker arms must be
changed.

P0003896 P0003899

P0003898 P0003897

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Camshaft Bearing Housing,

Replace
The factory-installed bearing housings are machined
together with the cylinder head, and may therefore not
be moved from one cylinder head to another.

Therefore, the first time one or more bearing housings

are replaced, all bearing housings must be replaced so
that the positions of the bearing housings can be
aligned. Bearing housings may then be replaced
individually.

P0007018

The holes for the guide sleeves are oval in the

replacement housings, which allows radial adjustment
of the center bearing housing and axial adjustment of
the front and rear bearing housings.

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 need to be removed.

P0007019

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Timing Gear, Replace

Valve cover, cable harness, upper timing gear
cover, camshaft sensor, oil pan, and oil pump
removed.

Tools:
885810 Fixture
9993590 Rotation tool
9996239 Lifting tool
9998601 Fixture

Removal
1 Remove the flywheel sensor.
2 Install 9993590 Rotation tool.
3 Turn the engine to TDC on the camshaft and
check that the mark on the flywheel is at “0”.

P0006884

4 Bolt lifting chain tool 9996239 Lifting toolonto the

flywheel. Remove the flywheel.
WARNING!
Pinch hazard.Keep fingers clear.

IMPORTANT!
The flywheel weighs about 40 kg (88.2 lbs).
5 Remove the starter motor, rear lifting eye and fuel
pump together with servo pump, the cover and
any rear engine mounts.

P0006931

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6 Remove flywheel housing bolts. Remove the

housing using lifting eyes and lifting strap.
7 Remove the lower intermediate gear (4).
8 Remove the camshaft gear (1).
9 Remove the two bolts on the crankshaft gear (5)
and remove the gear using a suitable puller.

NOTICE! To protect the puller thread, place a

thick washer between the threaded shaft and the
crankshaft.

P0006908

10 Remove the six Allen bolts in the bull drive hub (3)
and remove it complete.
11 Remove the upper intermediate gear (2).

NOTICE! Save the spacer plate behind the gear

and note how it is installed.
12 Remove the timing gear plate and clean both
sides.

P0006837

1 Camshaft gear
2 Upper intermediate gear
3 Bull drive
4 Lower intermediate gear
5 Crankshaft gear
6 Drive gear, lubricating oil pump
7 Drive gear for fuel feed pump/servo pump

Installation
NOTICE! Lubricate the inside of the gears before
installation.

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13 Apply a 2 mm (0.08") thick bead of sealant on the

engine block and the cylinder head, as illustrated.
14 Install the timing gear plate. Use new bolts that
are pre-treated with locking compound. Tighten
according to the specifications in Special
Tightening Torques, page 12.

NOTICE! Torque within 20 minutes of sealant

being applied.

P0006926

15 Oil the spacer plate and install it together with the

upper intermediate gear (2). Tighten with low
torque, max. 10 Nm (2.25 lbf).

P0006837

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16 Install a new O-ring on the crankshaft.

17 Install the camshaft gear (5)and torque the Allen
bolts according to the specification in Special
Tightening Torques, page 12.

P0006927

18 Install the bull drive kit (3) with the hole marking
between the two hole markings on the crankshaft
gear.

NOTICE! The bull drive inner and outer gears

have different gear pitch. For the camshaft to be
set correctly, the markings must correspond.

Tighten the bolts according to the specification in

Special Tightening Torques, page 12.

P0006929

19 Install the lower intermediate gear (4) with a new

O-Ring.
20 Install the lubricating oil pump.
21 Screw two bolts in the crankshaft gear for crowbar
grip, to allow the crankshaft to be turned when
necessary.
22 Fit the camshaft gear (5) without the oscillation
damper; use nuts as spacers.

P0006928

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23 Place the gear so that the reference hole in the

timing gear plate is between the gear markings.
Temporarily tighten two bolts with low torque,
max. 10 Nm (2.25 lbf).
24 Remove the 2 lower bolts (1) in the adjustment
wheel. Check that the upper bolts are not
tightened.

P0006944

25 Place a 0.1 mm (0.004") feeler gauge on the

pressure side. Turn the camshaft gear against the
feeler gauge.
Torque the upper intermediate gear according to
step 1 in Special Tightening Torques, page 12.
Remove the feeler gauge.

P0006947

26 Check the clearance as follows:

Fix the adjustment wheel.
Place a dial indicator on the camshaft gear, as
illustrated.
Turn the gear back and forth and compare the
result against the gear lash specification. Refer to
the Engine Transmission section in Technical
Data, page 28.
27 If gear lash is correct; torque the intermediate
gear bolts (1) according to step 2 in Special
Tightening Torques, page 12.

P0006948

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28 Remove the crankshaft seal and apply new

sealing compound to the flywheel housing, facing
the engine block.

P0006930

29 Install the flywheel housing. Check that the

housing is aligned with the bottom edge of the
engine block.
30 Install a new crankshaft seal. See “Crankshaft
seal, front, replacing.” Replacement of
Components, page 80.

IMPORTANT!
No lubrication. Must be installed completely dry.

P0007020

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31 Install the flywheel and tighten according to

specifications in Special Tightening
Torques, page 12. Refer to “Flywheel, indication”
Replacement of Components, page 80.
Install the flywheel sensor and adjust it; refer to
Sensors, Adjustment, page 78.
32 Install the camshaft oscillation damper and
tighten according to specifications in Special
Tightening Torques, page 12.
33 Apply a 2 mm (0.08") thick bead of sealant to the
upper timing gear casing contact surface, as
illustrated.

P0006907

34 Fit the rubber seals and install the upper timing

gear casing.

P0006949

35 Only install the bolts (1) and tighten by hand. (The

holes are oblong so that the casing can be
pressed down against the rubber seal).

P0006950

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36 Press the casing down using tools 885810 Fixture

and 9998601 Fixture so that the cylinder head
and the upper timing gear casing sealing surfaces
are aligned.
Install the remaining bolts (2).
Tighten according to the specifications in Special
Tightening Torques, page 12.

NOTICE! The timing gear casing must be

installed and torqued within 20 minutes of sealant
application.
37 Install the flywheel sensor and adjust it according
to Sensors, Adjustment, page 78.
38 Install the remaining removed components.
P0007021

999 8601
P0006952

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Exposing the Engine

Exposing
TAD1640GE, TAD1640VE-B, TAD1641GE,
TAD1641VE, TAD1641VE-B, TAD1642GE,
TAD1642VE, TAD1642VE-B, TAD1643VE,
TAD1643VE-B, TAD1650GE, TAD1650VE,
TAD1650VE-B, TAD1651GE, TAD1651VE,
TAD1660VE, TAD1661VE, TAD1662VE,
TAD1670VE, TAD1671VE, TAD1672VE
1 Drain the coolant; refer to Draining the Cooling
System, page 286.
Drain the engine oil.

P0006865

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2 Remove fuel connections to the fuel pump and

allow the fuel to run out into a suitable container.
Also loosen the upper connection on the cooling
coil and water drain.
3 Remove the hoses from the radiator and the
expansion tank.
4 Remove the heat shield above the turbo, if fitted.

P0006866

5 Remove the air filter sensor.

6 Remove the pipe between the air filter and
turbocharger. Cover all openings.
Remove the air filter housing and mounting
bracket.

P0006867

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7 Remove muffler and attachments, if fitted.

Remove the turbo from the exhaust pipe, plus the
two the oil pipes.
Cover the turbo opening.
8 Remove the crankcase breather with its bracket
and oil separator.
9 Remove the pipe between the inlet manifold and
the charge air cooler. Cover all openings.
10 Remove the safety cover above the alternator, if
fitted.
11 Remove the radiator fan safety cover/grille and
remove the fan, the hub and its brackets to the
cylinder head.
12 Remove the coolant pipe from the thermostat.
P0006868 13 Remove the belt guard and drive belts.

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Exposing
TWD1643GE, TWD1644GE, TWD1645GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672GE, TWD1673GE
1 Drain the coolant; refer to Draining the Cooling
System, page 286.
Drain the engine oil.
2 Remove the radiator assembly.
Refer to removal for 26-1, Radiator Assembly
(Complete Unit), Change.

P0006865

3 Remove fuel connections to the fuel pump and

allow the fuel to run out into a suitable container.
Also loosen the upper connection on the cooling
coil and water drain.
4 Remove the heat shield above the turbo, if fitted.

P0006866

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5 Remove the air filter sensor.

6 Remove the pipe between the air filter and
turbocharger. Cover all openings.
Remove the air filter housing and mounting
bracket.
7 Remove muffler and attachments, if fitted.
8 Remove the crankcase breather with its bracket
and oil separator.

P0006867

9 Remove both belt guards, right and left.

Leave the cover on the right guard.

P0006869

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10 Fit a 1/2” socket drive to the belt tensioner (1).

Lift the square wrench and unhook the drive belt.
11 Thread the drive belt round the fan and remove
it.
Remove the alternator belt.
12 Remove the cooling fan and fan hub.
13 Remove the upper radiator attachment and
bracket.

P0006870

14 Undo the connector and remove the control

panel.

P0006871

15 Remove both turbochargers, charge air cooler

and associated pipes and hoses.
Refer to removal for Turbo, Change, page 231
and 26-5, Charge Air Cooler, Removal.

P0006872

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Heat Protection
TWD1643GE, TWD1644GE, TWD1645GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672GE, TWD1673GE

The heat shield is an option and may be removed for

increased accessibility for certain types of repair work.
Re-install the heat shield carefully after completion of
work.

P0003624

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Fitting the Fixture

Engine Fixture, Installation
Applies to engine nos. through 2016010024

Tools:
9990143 Fixture
1 Remove electrical distributor above the control
unit.
2 Remove cable harness and fuel lines to the
control unit. Cover all openings.
Remove the control unit.
3 Remove fuel and electrical connections. Lift away
the fuel filter bracket together with the filter.
Cover all fuel connections.
4 Attach tool 9990143 Fixture using 7 bolts.

P0006873

Engine Fixture, Installation

Applies from, and including, engine no. 2016010025.

Tools:
88800003 Fixture
88800123 Plate
1 Remove the crank case breather.
2 Remove the cover for the alternator cables.
3 Remove the electrical cover bolts.
4 Remove all connection cables.
5 Remove the valve cover.
6 Remove the electrical cover including cable
harnesses.
7 Remove the electronics unit and fuel hoses.
8 Fit tool 88800003 Fixture and 88800123 Plate.
9 Hoist the engine onto the stand.

P0006874

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Engine Disassembly
Cylinder Head, Removal
NOTICE! The illustrations in the manual conform in all
essential parts, but due to differences in models cannot
always be shown in greater detail.

Engine exposed and installed on stand, coolant

and fuel drained.

Tools:
9990006 Puller
9990013 Slide hammer
9990157 Press tool
9990160 Fixture
9990185 Lifting tool
9990192 Puller
9993590 Rotation tool
9996239 Lifting tool
9996400 Slide hammer
9998249 Protective sleeve
9998251 Protection plug
9998264 Lifting tool
9998511 Lever
1 Remove the rear lifting eye/mounting bracket.
2 Remove the heat shields above the turbo, if this
was not done when the engine was exposed.
3 Remove the oil pipes between the turbo and the
oil filter bracket and the engine block.
Cover all openings.

P0006875

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4 Cover the turbo exhaust port and remove the

turbo.

P0006868

5 Remove the exhaust manifold.

P0006876

6 Remove camshaft sensor (1), the flywheel sensor

(2) and the sensor on the oil filter bracket (3).
Remove the cable harness from sensors and
starter motor.

P0006877

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7 Remove the fuel lines to the cylinder head (1) and

plug the connections.
8 Remove the valve cover and the crankcase
breather.

P0006878

9 Clean around the unit injectors and remove the

unit injector contacts. Remove cable holders
together with cable harness.
Cut off cable ties and remove the cable harness
from the cable holder.

P0006879

10 Remove the bolt (1) from the cable bushing and

carefully extract the harness from the cylinder
head.

IMPORTANT!
Remove the bolt, do not split the cable bushing.
11 Remove the contact to the coolant sensor, the
hoses to the expansion tank and the rest of the
cable harness and lift it away.

P0006878 12 Remove the return fuel lines on the cylinder head

front edge and plug the connections.

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13 Remove cables from any preheater on the intake

manifold.
14 The intake manifold must be removed if the
cylinder head fixture, tool 9990160 Fixture, is to
be used. Remove all bolts and remove the intake
manifold using tool 9998511 Lever against the
reinforcement bosses.

P0006880

15 Remove the thermostat housing and thermostat,

and the front lifting eye.
16 Remove the bolts from the coolant pipe and the
hose clamp from the coolant hose.

P0006881

17 Remove the upper timing gear casing and

remove the rubber seals.

P0006882

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18 Remove the center piece for lubrication of the

rocker arm bridge, together with the delivery pipe.

P0006883

19 Remove the cover in the flywheel housing and

install tool 9993590 Rotation tool.

P0006884

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20 Turn the engine to TDC on the camshaft and

check that the mark on the flywheel is at “0”.
TDC

C
TD

P0003112

Early model.

P0006885

Late model.

21 Remove the camshaft gear together with the

oscillation damper.

NOTICE! The oscillation damper is very sensitive

to shocks.

P0006886

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22 Remove the rocker arm bridge bolts alternately to

avoid uneven load.
D9 23 Lift away the rocker arm bridge using tool
D11 9990185 Lifting tool.
D16 D9 D9
D11 D11 D9
D16 D16 D11
D16

P0006887

24 Mark and remove the valve calipers.

P0006888

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25 Clean around the unit injectors and remove the

injector retainer bolts.
Remove the unit injectors, one at a time.
26 Pull out the injector with the aid of tool
9990006 Puller and 9990013 Slide hammer.

P0006889

27 Insert tool 9998251 Protection plug into the

cylinder head immediately after removal.
Mark the injectors and fit tool 9998249 Protective
sleeve to the injector.

NOTICE! Check that the tools are clean.

P0006890

28 Remove the camshaft bearing cap with the aid of

tool 9990192 Puller and 9996400 Slide hammer.

P0006891

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29 Lift the camshaft carefully using tool

9998264 Lifting tool.
30 Loosen the bearing brackets by tapping them
carefully with a plastic faced mallet.
Remove the bearing brackets with the lower
bearing halves and put them in the right order
together with their respective camshaft bearing
caps, upper bearing halves and bolts.

NOTICE! The camshaft bearing brackets are

held by guide pins marked 1 through 7.

P0006892

31 Turn the engine so that the two the bolts (1) can
be accessed through the timing gear wheel.

P0006893

32 Place a rag in front of the gear to prevent bolts

from falling into the timing gear housing. Remove
the two bolts (1).

NOTICE! When the engine is cranked, the rag

must be removed.
33 Remove the remaining bolts (2).
Remove the three upper bolts (3) from the timing
gear hub.

P0006894

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34 Remove the cylinder head bolts.

Use two lifting chains, tool 9996239 Lifting tool,
to carefully lift away the cylinder head.
999 6239 (Alternatively, lifting eyes and lifting straps may
be used).

NOTICE! Place washers between the cylinder

head and lifting chains to protect the cylinder
head sealing surface.

P0006895

35 Remove the cylinder head gasket and clean the

contact surface on the cylinder block thoroughly.

NOTICE! Secure all cylinder liners using tool

9990157 Press tool.

P0006896

36 Remove the starter motor.

P0006897

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37 Remove the oil filters complete with bracket.

38 Remove the coolant filter with bracket and the
connection to the oil cooler cover.

NOTICE! Industrial engines may not use coolant

filters in combination with Coolant VCS (yellow);
coolant filters will be omitted on new industrial
engines filled with Coolant VCS (yellow).

P0006898

39 Remove the oil cooler cover. Remove the oil

cooler and seals.
40 Remove the two coolant pipes and the coolant
pump.

P0006899

41 Remove the fan bearing.

P0006900

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42 Remove the belt pulley/oscillation damper bolts.

Carefully tap and rock the hub and belt pulley to
loosen them.

NOTICE! Do not prize between the belt pulley

and oscillation damper.

Lift away the oscillation damper.

P0006901

43 Remove the bolts and the front crankshaft seal

fan bearing using a prybar at the reinforcement
illustrated.

P0006902

44 Remove the tensioning wheel and the front

engine mounts together with the belt tensioner on
the right side of the engine; 6 bolts (1).

P0006903

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45 Remove the alternator with its brackets together

with the belt tensioner and the bracket for the fan
bearing on the left side of the engine.

P0006904

46 Remove engine mounts, oil filler pipe and oil

dipstick.

P0006905

47 Remove the fuel pump and servo pump

complete.
48 Remove the oil level sensor contact and remove
the oil pan.
49 Remove the oil strainer complete with pipe
connections.
50 Remove the bracing frame.

P0006906

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Timing Gear, Removal

Tools:
9996239 Lifting tool
1 Remove the flywheel sensor, if not done
previously.
2 Attach 9996239 Lifting tool to the flywheel with
two bolts.
Remove the bolts in the flywheel. Remove the
flywheel.
WARNING!
Pinch hazard.Keep fingers clear.

IMPORTANT!
The flywheel is heavy.

P0006907

3 Remove the bolts in the flywheel housing and

remove the flywheel housing using lifting eyes
and lifting straps.

P0006908

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4 Remove the lubricating oil pump together with the

drive gear.

P0006909

5 Remove the lower intermediate gear (4).

1 Camshaft drive gear

2 upper intermediate gear
3 bull drive
4 lower intermediate gear
5 crankshaft gear
6 oil pump drive gear
7 fuel pump drive gear/servo pump

P0006837

6 Remove the two bolts on the crankshaft gear (5)

and remove the gear using a suitable puller.

NOTICE! To protect the puller thread, place a

thick washer between the threaded shaft and the
crankshaft.
7 Remove the six Allen bolts in the bull drive hub (3)
and remove it complete.
8 Remove the upper intermediate gear (2).

NOTICE! Save the spacer plate behind the gear

and note how it is installed.
9 Remove the timing gear plate and clean both
P0006909 sides.

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Pistons, Removal
Tools:
9986485 Stand
9993590 Rotation tool
9996394 Support
9996645 Puller
9996963 Plate
1 Remove the piston cooling nozzle. Crank the
engine using 9993590 Rotation tool so that all
become accessible, two at a time.

IMPORTANT!
It is important that the piston cooling nozzles be
removed before the pistons are removed. Damaged
nozzles may cause extensive engine damage.
2 Remove big end bearing caps and bearing shells;
note any markings.
3 Turn the engine 90° if it is installed in
9986485 Stand.

P0006911

4 Press the piston so far out that the piston rings

are outside the edge of the cylinder liner. (Use a
hammer handle or other wooden object).
Lift the piston and connecting rod out.

IMPORTANT!
Replace the bearing cap on the connecting rod to avoid
damaging the split surface, as this is very sensitive.
5 Remove the retainer ring from the piston and
press out the piston pin. Disassemble the
connecting rod and piston.

NOTICE! Mark the connecting rod and piston, if

they are to be installed in the same cylinder at
assembly.
6 Mark the cylinder liner position in the block before
it is removed to facilitate correct placement if
reinstalled.

P0006912

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7 Fit 9996963 Plate and 9996394 Support to

9996645 Puller.
8 Move the plate down through the cylinder and
place it in the correct position below the cylinder
liner. Pull the cylinder liner out of the block, using
the puller. If necessary, extend the support legs
with 9996395.
9 Remove the cylinder liner sealing rings.

P0006913

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Crankshaft, Removal
Tools:
9990013 Slide hammer
9990114 Puller
1 Remove the main bearing caps, if not already
done.
Use 9990114 Puller and 9990013 Slide hammer.

P0006914

2 Lift the crankshaft out carefully.

NOTICE! The crankshaft weighs about 80 kg

(176 lbs).
3 Before the engine block is washed, all plugs, bolts
and remaining brackets must be removed.
4 Clean the contact surfaces on parts to be
reinstalled.

P0006915

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Crankshaft, Installation
1 Inspect the crankshaft; refer to Replacement of
Components, page 80, Crankshaft, inspection.
2 Check the crankshaft ducts, the bearing shell
seats, the engine block and bearing caps.
3 Fit new main bearing shells.
4 Put the bearing shells in their correct places in the
engine block and bearing caps. Make sure that
bearing shells or caps are not damaged.

NOTICE! Make sure that the upper bearing shells

to be fitted into the cylinder block have oil holes.
5 Lubricate bearing journals and bearing shells with
engine oil and carefully lift the crankshaft into
position.
6 Install the thrust washers for the center main
bearing (thrust bearing). The thrust washers can
only be placed in one position.
7 Install the main bearing caps with the lower
bearing shells. The bearing caps are asymmetric
and can only be installed in one position. The
center bearing cap (by the thrust bearing) has a
cutout, which must be aligned to fit over the guide
pin.

NOTICE! Note the markings on the bearing caps,

1 through 7.
8 Oil the main bearing screws. Let surplus oil run
off before installation.
Tighten according to the specifications in Special
Tightening Torques, page 12.

NOTICE! Check that the crankshaft can be

cranked.
9 Install the front cover at the belt pulley and install
a new seal. Refer to Replacement of
Components, page 80, Crankshaft seal, replace
(front).

NOTICE! No lubrication. Must be installed

completely dry.

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Cylinder Liner, Installation

Tools:
9990157 Press tool
9996963 Plate
9998511 Lever
1 Inspect the cylinder liner and pistons; refer to
Replacement of Components, page 80, Cylinder
liners and pistons, inspection.
2 Lubricate the sealing rings with the lubricant
supplied with the lining kit and install them on the
cylinder liners.

NOTICE! The purple seal ring must seat in the

lowest groove

P0006916

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3 When the cylinder liner is installed without shims,

an even bead 0.8 mm (0.0315") of sealing
compound (part no. 1161231) must be applied to
the underside of the cylinder liner collar.

NOTICE! Do not put sealing compound around

the entire liner. Leave a 2 mm (0.8”) gap.

If the liner is installed with shims, the sealant bead

must be placed on the cylinder block liner seat.

NOTICE! Sealing compound must not be used

between the adjusting shims and the cylinder
liner collar.

NOTICE! The liner must be installed within 20

minutes of sealing compound application.

P0006917

P0006918

4 Screw one of the cylinder head bolts in place (A).

Place 9996963 Plate above the cylinder liner
together with a suitable spacer (B).
Press the liner down using 9998511 Lever and
secure it with 9990157 Press tool.

P0006919

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Piston, Pre-installation
1 Install one of the retainer rings on the new piston.
2 Lubricate the piston pin, the piston bearing seat
and the connecting rod bearing with engine oil.

FRO
NT

P0006920

3 Install the connecting rod so that the arrow on the

piston and the connecting rod “Front” marking
face the same way.
Press in the piston pin.

NOTICE! It should be easy to press the piston pin

in; it must not be driven in.
4 Fit the second retainer ring.

P0006921

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5 Check that the piston pin does not move stiffly in

the small end, and that the piston can be moved
easily.

IMPORTANT!
Always use piston ring pliers to install/remove the piston
rings. The oil scraper rings are especially brittle and
easily damaged.

NOTICE! The two upper piston rings are marked

with letters or punch marks. The mark must face
upwards.
P0006825

P0006922

6 Align the piston ring gaps staggered about 120°

around the piston. However, the piston ring gaps
must not end up directly over the piston pin.

NOTICE! New cylinder liner kits are supplied

complete with pistons and piston rings.
7 Install the bearing shells in the engine block.

P0006923

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Pistons, Installation
Tools:
9990157 Press tool
9990158 Piston ring compressor
1 Oil the cylinder liner, bearing shells and big end
bearing journals.
2 Temporarily remove 9990157 Press tool when
the piston is installed.
3 Use 9990158 Piston ring compressor and guide
the piston with piston rings down into the cylinder.
Ensure that the connecting rod does not damage
the crankshaft bearing journal.

NOTICE! Take great care. The oil scraper rings

are brittle and can easily be damaged.

NOTICE! The piston ring compressor may not be

opened when the piston has been placed in the
tool, the piston rings can be damaged. Press out
P0006924
the piston first, before opening the tool.
4 Re-install 9990157 Press tool. All cylinder liners
must be locked with the press tool in order to
prevent movement between the cylinder liner and
engine block when the engine is cranked.
5 Install the bearing caps with their bearing halves.
Torque according to the specifications in Special
Tightening Torques, page 12.

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Piston Cooling Jet, Installation

1 Blow the piston cooling nozzle clean and check it
is undamaged and that the O-ring is fault free.

IMPORTANT!
Faulty piston cooling will cause the pistons to seize. If
piston cooling nozzle damage or deformation is
suspected, the nozzle must be replaced (also applies to
new nozzles).
2 Install the piston cooling nozzle.

IMPORTANT!
Check that the nozzle sits correctly in the hole in the
cylinder block and is directed towards the recess in the
piston and that the retaining plate lies flat against the
block. If the piston cooling nozzle is not correctly
installed, the engine will immediately break down under
load.
3 Tighten according to the specifications in Special
P0006925 Tightening Torques, page 12.

NOTICE! The piston cooling nozzle retaining

screw has a friction coating and may only be used
once.
4 Install the bracing frame and tighten according to
the tightening chart in Special Tightening
Torques, page 12.

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Timing Gear, Installation

1 Apply a 2 mm (0.08") thick bead of sealant on the
engine block as illustrated.
2 Install the timing gear plate. Use new bolts that
are pre-treated with locking compound. Tighten
according to the specifications in Special
Tightening Torques, page 12.

NOTICE! Torque within 20 minutes of sealant

being applied.

P0006926

3 NOTICE! Lubricate the inside of the gears before

installation.

Oil the spacer plate and install it together with the

upper intermediate gear (2). Tighten with low
torque, max. 10 Nm (7.38 lbf ft).

P0006837

1 Camshaft drive gear

2 upper intermediate gear
3 bull drive
4 lower intermediate gear
5 crankshaft gear
6 oil pump drive gear
7 fuel pump drive gear/servo pump

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4 Install a new O-ring on the crankshaft.

5 Install the camshaft gear (5)and torque the bolts
according to the specification in Special
Tightening Torques, page 12.

NOTICE! Make sure that the mating surfaces on

crankshaft and gear are clean and fault free.

P0006927

6 Screw two bolts in the crankshaft gear for crowbar

grip, to allow the crankshaft to be turned when
necessary.

P0006928

7 Install the bull drive kit (3) with the hole marking
between the two hole markings on the crankshaft
gear.

NOTICE! The bull drive inner and outer gears

have different gear pitch. For the camshaft to be
set correctly, the markings must correspond.

Tighten the bolts according to the specification in

Special Tightening Torques, page 12.
8 Install the lower intermediate gear (4) with a new
O-Ring.

P0006929

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9 Install the lubricating oil pump.

P0006909

10 Apply new sealing compound to the flywheel

casing, towards the engine block.

P0006930

11 Remove the old crankshaft seal.

Install the flywheel housing. Check that the
casing is aligned with the engine block plane.
Tighten according to the specifications in Special
Tightening Torques, page 12.
Install the new crank shaft seal; refer to
Replacement of Components, page 80,
Crankshaft seal, replace (rear).

P0006908

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12 Install the flywheel and tighten according to

specifications in Special Tightening
Torques, page 12. Also refer to Replacement of
Components, page 80, Flywheel, indication.

P0006931

13 Remove the old crankshaft seal on the front the

casing; refer to Replacement of
Components, page 80, Crankshaft seal, replace
(front).
Apply sealing compound to the front casing.
Install the casing and make sure that the bottom
edge of the casing is aligned with the bottom edge
of the engine block.
Install a new crankshaft seal (if not already done).

NOTICE! No lubrication. The seal must be

installed completely dry.
14 Fit the oscillation damper and the belt pulley.
P0006932
15 Install the oil suction strainer and pipe.

16 Cut away any remaining sealing compound and

apply new sealant to the parting planes on the
front cover, flywheel housing and engine block
respectively.
17 Install the oil pan.

P0006933

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 21-0 Engine Complete, General

18 Install the oil filler pipe and oil dipstick with new
O-rings.

P0006934

19 Install the fuel feed pump/servo pump.

P0006935

20 Install the coolant pump.

21 Install the front engine mounts together with the
belt tensioner and the tensioning wheel on the
right side of the engine.
22 Install the alternator with brackets, the belt
tensioner and the fan bearing attachments on the
left side of the engine.

P0006936

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23 Install the fan bearing.

P0006900

24 Fit new sealing rings in the block and the rubber

seals on the sides of the radiator.
Install the oil cooler and tighten according to the
specifications in Special Tightening
Torques, page 12. Check that the side seals are
placed correctly in the block.
25 Install the oil cooler cover with a new o-ring and
tighten according to the specifications in Special
Tightening Torques, page 12.

P0006899

26 Install the coolant filter with bracket and the

connection to the oil cooler cover.

NOTICE! Industrial engines may not use coolant

filters in combination with Coolant VCS (yellow);
coolant filters will be omitted on new industrial
engines filled with Coolant VCS (yellow).
27 Install the oil filter bracket with a new gasket and
new oil filters.

P0006898

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28 Fit the starter motor.

P0006897

29 Install the coolant pipes with new O-rings.

P0006937

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Cylinder Head, Installation

Tools:
9990157 Press tool
1 Clean the cylinder head carefully both internally
and externally before fitting.

NOTICE! Dirt particles may cause the unit

injectors to fail.
2 Clean the unit injector copper sleeves. Refer to
Replacement of Components, page 80, Copper
sleeve for unit injector, replacing.
Install the protection plugs immediately after
cleaning.
3 Remove 9990157 Press tool holding the cylinder
liners in place.
4 Carefully clean the cylinder head and the engine
block sealing surfaces and cut away excess
sealant.

NOTICE! Do not pull away dry sealant.

P0006896

5 Immerse the cylinder head bolts completely in a

rustproofing agent.
Then place the bolts on a net to allow the excess
to run off.

P0006938

6 Apply a 2 mm (0.080”) thick bead of sealant to the

back of the cylinder head.

NOTICE! The cylinder head bolts must be

torqued within 20 minutes of sealant application.
7 Fit a new cylinder head gasket.
P0006939
NOTICE! Convex embossments prevent damage
to the rubber seals.

NOTICE! Check that the coolant pipe is in place.

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8 Lower the cylinder head until it rests on the

cylinder head gasket.
Maintain a distance to the timing gear plate of 5–
10 mm (0.2–0.4"). Locating pins ensure that the
cylinder head will be aligned with the engine
block.
9 Slide the cylinder head against the transmission
plate.
10 Place a rag in front of the gear to prevent bolts
from falling into the timing gear housing.

NOTICE! The rag must be removed before the

engine is cranked.

P0006940

11 Insert a bolt into the upper intermediate gear hub

(1) in the cylinder head, in order to pull the
cylinder head towards the timing gear plate.
Screw in five M8 bolts into the timing plate (2).
12 Torque the bolts (1) and (2) as specified in
Special Tightening Torques, page 12.
Unscrew all bolts (1) and (2) about one turn.

NOTICE! The cylinder head is now in the correct

position for fastening and must not be moved. If
the cylinder head is moved, the bolts must once
again be torqued and loosened as above.
13 Install the cylinder head bolts and tighten
according to the specifications in Special
Tightening Torques, page 12. Use a torque
amplifier for angle tightening.
P0006941
14 Torque the four M8 bolts in the transmission plate
(2) according to the specifications in Special
Tightening Torques, page 12.
15 Turn the engine so that the two M8 bolts (1) can
be installed through the upper intermediate gear.
Tighten according to the specifications in Special
Tightening Torques, page 12.
16 Fit the remaining two M10 bolts (3) into the upper
intermediate gear, without tightening them.
17 Fasten the coolant pipe in the cylinder head.

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18 Clean sealant from the surface as illustrated.

NOTICE! Cut away the sealant.

P0006942

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Camshaft, Installation
Tools:
9993590 Rotation tool
1 Inspect the camshaft for wear. Refer to Camshaft,
Wear Check, page 116.
2 Clean the surfaces on the bearing brackets and
the cylinder head.
3 Install the camshaft bearing brackets as marked
on the cylinder head and make sure they abut the
cylinder head, no. 7 by the transmission.
4 Place the bearing shells in the bearing brackets
and lubricate the bearing shells with engine oil.
5 Turn the engine with 9993590 Rotation tool so
that the flywheel is set exactly to zero, according
to the marking on the flywheel housing.

P0006943

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6 Carefully lift the camshaft in place. Make sure that

the hole for the guide pin on the camshaft gear
TDC
ends up straight up. The camshaft TDC marking
must be centered between the markings on the
no 7 bearing bracket.

! CAUTION!
The camshaft lobes are sharp.
C
TD

P0003112

P0006885

7 Fit the camshaft gear without the oscillation

damper; use nuts as spacers.
Place the gear so that the reference hole in the
timing gear plate is between the gear markings.
If necessary, remove the bolts on the upper
intermediate gear.
Temporarily tighten two bolts with low torque,
max. 10 Nm (7.38 lbf ft).

P0006944

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8 Clean the surfaces on the bearing caps and oil

the bearing shells.
Install the bearing caps on the respective bearing
brackets.

NOTICE! Use a suitable spacer on the rocker arm

side.

Torque the bolts 1 through 7 to 15 ± 3 Nm (11.06

± 2.21 lbf ft).
Torque the bolts 8, 11 and 14 (with spacers) to 50
± 5 Nm (36.88 ± 3.69 lbf ft).

P0006945

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Flank Clearance, Adjustment

Tools:
885810 Fixture
9998601 Fixture
1 Undo the bolts (1) in the upper intermediate gear.
Check that the upper bolts are not tightened.

P0006946

2 Place a 0.1 mm (0.004") feeler gauge on the

pressure side. Turn the camshaft gear against the
feeler gauge.
Torque the upper intermediate gear according to
step 1 in Special Tightening Torques, page 12.
Remove the feeler gauge.

P0006947

3 Check the clearance as follows:

Fix the adjustment wheel.
Place a dial indicator on the camshaft gear, as
illustrated.
Turn the gear back and forth and compare the
result against the gear lash specification in
Special Tightening Torques, page 12.
4 If gear lash is correct; torque the intermediate
gear bolts (1) according to step 2 in Special
Tightening Torques, page 12.
5 Install the oscillation damper and tighten
according to specifications in Special Tightening
Torques, page 12.

P0006948

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 21-0 Engine Complete, General

6 Apply a 2 mm (0.08") thick bead of sealant to the

upper timing gear casing contact surface, as
illustrated.
7 Fit the rubber seals and install the upper timing
gear casing.

P0006949

8 Only install the bolts (1) and tighten by hand. (The

holes are oblong so that the casing can be
pressed down against the rubber seal).

P0006950

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9 Press the casing down using 885810 Fixture and

9998601 Fixture so that the cylinder head and the
upper timing gear casing sealing surfaces are
aligned.
Install the remaining bolts (2).
Tighten according to the specifications in Special
Tightening Torques, page 12.

NOTICE! The timing gear casing must be

installed and torqued within 20 minutes of sealant
application.
10 Install the flywheel sensor and adjust it according
P0006951 to Sensors, Adjustment, page 78.

999 8601
P0006952

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Unit injector, Installation

Tools:
9990156 Adapter
9996400 Slide hammer
9998251 Protection plug

NOTICE! Install one injector at a time.

1 Remove 9998251 Protection plug with

9990156 Adapter and 9996400 Slide hammer.
2 Fit new sealing rings to the unit injectors.
Lubricate the rings with diesel oil.
Install the injector and fixing yoke. Center the
injector so that it does not touch the valve springs.
Torque according to Special Tightening
Torques, page 12.

P0006890

3 Reinstall the valve calipers in their original

positions.

NOTICE! Make sure that the caliper is directly

above the valve stem.
4 Lubricate the valve caliper and camshaft.
5 Remove the temporary bolts and spacers on the
camshaft cap.
6 Install the rocker arm bridge using a hoist.
Make sure that the guide pins fit into the rocker
arm shaft.
Torque the screws alternately along the rocker
arm shaft according to specifications in Special
P0006953
Tightening Torques, page 12.

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7 Slide new O-rings over the lubricating oil supply

pipe for the rocker arm bridge. Insert the pipe in
the joining piece and install the joining piece and
pipe. Check that the O-rings on the pipe and the
ring under the joining piece are correctly aligned.
Fit the cable holder.

P0006883

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Adjustment Markings
The camshaft has marks (1 through 6 for the respective
cylinders) for adjusting intake and outlet valves and the
unit injectors.

NOTICE! It is important that the line marked on the

camshaft is centered between the two marks on the
bearing cap when adjustment is carried out.

P0006954

Early model.

TDC 5
3
5
1
4

P0002568

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Engine Assembly
1 Adjusting valves and injectors; refer to Valves
and Unit Injectors, Adjustment, page 180.
2 NOTICE! The inlet manifold must be installed
within 20 minutes of sealant application.

Apply a 2 mm (0.0787") bead of sealant

P0006959
(1161231-4) to the inlet manifold.
Install the inlet manifold and torque according to
the specifications in Special Tightening
Torques, page 12.
3 Pull the cable harness to the unit injectors through
the cylinder head and connect.
4 Install the rear lifting eye.
5 Install the sensors for the flywheel, camshaft and
oil pressure and starter motor cables.
6 Connect the fuel lines to the cylinder head and
torque according to Special Tightening
Torques, page 12.
7 Apply a 2 mm (0.0787") bead of sealant to parting
plane (A) between the timing gear casing and the
cylinder head.
8 Install the valve cover. Tighten the bolts
according to the specifications in Special
Tightening Torques, page 12.

NOTICE! The valve cover must be installed within

20 minutes of sealant application.

P0006960

9 Place the gaskets on the exhaust manifold. Turn

the gasket so that the side with the text “Manifold
side” is facing the exhaust manifold. Thread the
bolts into the gaskets so that they are held in
place during installation of the exhaust manifold.
Install the exhaust manifold and torque according
to the specifications in Special Tightening
Torques, page 12.

P0006961

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 21-0 Engine Complete, General

10 Fit the turbocharger without tightening.

11 Fit the return oil pipe. Check that the old seal is
removed and that the new seal ends up in correct
position. Install the pressure pipe between the oil
filter bracket and the turbocharger. Tighten
according to the specifications in Special
Tightening Torques, page 12.
12 Install the heat shield plates.
13 Fit the thermostat housing and torque alternately.
Remove the forward lifting eye.
14 Fit the new coolant pipe sealing rings and torque
alternately.
15 Remove fixture and replace the parts that were
removed.
P0006868 16 Install drive belts and fan.
17 Install the brackets for the radiator fan safety
cover/grille. Install protection.
18 Install the alternator protection cover.
19 Install the pipe between charge air cooler and
inlet pipe.
20 Install the crankcase breather pipe and any
additional oil separator.
21 Insert a new cartridge in the air filter housing and
install it with brackets and the pipe between the
air filter housing and the turbocharger.
22 Install the pipe between the turbocharger and the
charge air cooler.
23 Install the muffler with attachments. Connect the
exhaust pipe to the turbocharger.
24 Install the heat shield above the turbocharger, if
fitted.
25 Install the belt cover on the right side of the
engine, if fitted. Install the hoses to expansion
tank and radiator.
26 Replace oil filter. Fill with engine oil; refer to
Engine oil and engine oil filter,
changing, page 201.
27 Replace coolant filter. Fill with coolant; refer to
Coolant Level, Checking and Topping
Up, page 288.
28 Change the fuel filter. Bleed the fuel system; refer
to Fuel system, bleeding, page 207.
29 Start the engine and let it run until it reaches
normal working temperature. Let it run an
additional 5–10 minutes at idle. When the idle is
even, the cylinder balancing system has set the
correct amount of fuel for the unit injectors.

NOTICE! Do not connect any power consuming

device (e.g. power outlet) while cylinder
balancing is under way.

Check that no leakage is present.

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21-4 Valve Mechanism

21-4 Valve Mechanism

Valves and Unit Injectors,
Adjustment
Identifying the valve system
Depending on their specification engines are equipped
with different valve mechanisms. It is extremely
important that correct valve adjustment is performed
according to the mechanism.

Timing marks
The camshaft has marks (1–6 for the respective
cylinders) for adjusting inlet and exhaust valves and
the unit injectors.

P0006954

Early model.

NOTICE! It is important that the line marking on the

camshaft is centred between the marks on the bearing
TDC 5
3 cap when adjustment is carried out.
5
1
4

P0002568

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 21-4 Valve Mechanism

NOTICE! There are several valve mechanism versions

on the engines.

Check the version according to the below.

Standard valve mechanism

For adjustment of valve mechanism as illustrated, refer
to Standard valve mechanism, page 183.

P0016503
TAD1640-42GE, TAD1641-43VE, TAD1640VE-B, TAD1641VE-B,
TAD1642VE-B, TAD1660-62VE, TAD1670-72VE, TWD1643GE,
TWD1644GE, TWD1645GE, TWD1652-53GE, TWD1663GE,
TWD1672-73GE.

Valve mechanism equipped with VCB (Volvo

Compression Brake)
For adjustment of the valve mechanism and camshaft
marking as illustrated, refer to valve adjustment Valve
mechanism equipped with VCB (Volvo Compression
Brake), page 185.

P0016504
Options for TAD1660-62VE, TAD1670-72VE, TAD1640VE-B,
TAD1641VE-B, TAD1642VE-B.

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21-4 Valve Mechanism

Valve mechanism equipped with Internal EGR

(Exhaust Gas Recirculation)
For adjustment of the valve mechanism and camshaft
marking as illustrated, refer to Valve mechanism
equipped with Internal EGR (Exhaust Gas
Recirculation).

P0016505
TAD1650GE, TAD1650VE, TAD1651GE, TAD1650VE-B,
TAD1651VE.

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 21-4 Valve Mechanism

Standard valve mechanism

TAD1640GE, TAD1640VE-B, TAD1641GE,
TAD1641VE, TAD1641VE-B, TAD1642GE,
TAD1642VE, TAD1642VE-B, TAD1643VE,
TAD1660VE, TAD1661VE, TAD1662VE,
TAD1670VE, TAD1671VE, TAD1672VE,
TWD1643GE, TWD1644GE, TWD1645GE,
TWD1663GE, TWD1672GE, TWD1673GE

Tools:
9993590 Rotation tool

Valves and Unit Injectors, Adjustment

1 Adjust valves and injectors for the respective
cylinders at the same time.
5 Turn the engine to the next camshaft marking.
TDC
3 Use 9993590 Rotation tool.
5
1
4

P0002568

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21-4 Valve Mechanism

2 Screw out the yoke adjuster screw around 1 turn.

NOTICE! Before the adjuster screw is screwed in,

the yoke must be pressed down simultaneously
until it touches the valve stem. It is extremely
important that the pressure is brought to bear as
close to the adjuster screw as possible; see
illustration.

Screw the adjuster screw down until it rests

against the valve stem and then turn one
additional flat (60°).
Tighten the locking nut according to the
specifications in Special Tightening
Torques, page 12.

NOTICE! Use a wrench on the yoke as a

counterhold also when tightening.
P0006956

3 Adjust the valve clearance between the rocker

arm and valve yoke as specified in the Valve
mechanism section in the Technical
Data, page 28 chapter.
Tighten according to the specifications in Special
Tightening Torques, page 12.
Check the valve clearance. Mark the rocker arm
once the valve has been adjusted.
Adjust clearances for the inlet and exhaust
valves.

P0006957

4 Adjust the unit injector preload by loosening the

adjuster screw until a clearance is obtained on the
injector.
Adjust the screw until the clearance disappears
(by feel until the roller can no longer be rotated).
Tighten the adjuster screw a further 240° (4 flats).
Tighten the nut on the adjuster screw according
to Special Tightening Torques, page 12.
5 Adjust the remaining valves and unit injectors as
described above.
6 Remove 9993590 Rotation tool from the gear
ring.
Install the valve cover.

P0006958

P0006958

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 21-4 Valve Mechanism

Valve mechanism equipped with

VCB (Volvo Compression Brake)
TAD1640VE-B, TAD1641VE-B, TAD1642VE-B,
TAD1643VE-B, TAD1660VE, TAD1661VE,
TAD1662VE, TAD1670VE, TAD1671VE, TAD1672VE

Valves and Unit Injectors, Adjustment

1 Remove all VCB rocker arm springs.

P0016506

2 Turn the engine to the next camshaft marking.

Use 9993590 Rotation tool.

In this case camshaft position indicates

adjustment of:
5 = Inlet and injector rocker arm, cylinder 5.
E6 = Exhaust and VCB rocker arm, cylinder
6

P0016507

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21-4 Valve Mechanism

3 Adjust the valve clearance for the inlet valves to

0.30 mm (0.0118") with the aid of a feeler gauge.
Tighten the locking nut according to the
specifications in Special Tightening
Torques, page 12.

P0016508

4 Adjust the unit injector preload by loosening the

adjuster screw until a clearance is obtained on the
injector.
Adjust the screw until the clearance disappears
(by feel until the roller can no longer be rotated).
Tighten the adjuster screw a further 240° (4 flats).
Tighten the nut on the adjuster screw according
to Special Tightening Torques, page 12.

P0016509

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 21-4 Valve Mechanism

5 IMPORTANT!
Adjust the exhaust and VCB rocker arm on the
cylinder which is indicated by the camshaft E
marking.

Example: E6 = Exhaust and VCB rocker arm,

cylinder 6

P0016507

6 Adjust the exhaust valve yokes by first checking

that there is no clearance between the yoke and
the rocker arm.
Undo the yoke locking nut while holding the yoke
secure with a wrench so that the valves are not
bent.

P0016510

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21-4 Valve Mechanism

7 Screw out the yoke adjuster screw around 1 turn.

NOTICE! Before the adjuster screw is screwed in,

the yoke must be pressed down simultaneously
until it touches the valve stem. It is extremely
important that the pressure is brought to bear as
close to the adjuster screw as possible; see
illustration.

Screw the adjuster screw down until it rests

against the valve stem and then turn one
additional flat (60°).
Tighten the locking nut according to the
specifications in Special Tightening
Torques, page 12.

NOTICE! Use a wrench on the yoke as a

counterhold also when tightening.
P0006956

8 Adjust the valve clearance for the exhaust valves

to 0.60 mm (0.0236") with the aid of a feeler
gauge.
Tighten the locking nut according to the
specifications in Special Tightening
Torques, page 12.

P0016511

9 Allow the feeler gauge (A) to remain after

adjustment. Adjust the clearance between the
VCB rocker arm roller and the camshaft to
3.50 mm (0.138") with the aid of feeler gauge (B).
Tighten the locking nut according to the
specifications in Special Tightening
Torques, page 12.

P0016512

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 21-4 Valve Mechanism

10 Where necessary, check the VCB rocker arm

adjustment with a feeler gauge.
Check the clearance between the camshaft and
the roller on the VCB rocker arm.
The clearance must be between
3.70-4.00 mm (0.146-0.157").
Adjust the remaining valves and unit injectors as
described above.

P0016513

11 Tighten the retaining screws to the VCB rocker

arm springs.
Tightening torque: 25 Nm (18.4 lbf. ft.)

NOTICE! Ensure that the springs position

correctly on the pressure points.

Remove 9993590 Rotation tool from the gear

ring.
Install the valve cover.

P0016506

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21-4 Valve Mechanism

Valve mechanism equipped with

Internal EGR (Exhaust Gas
Recirculation)
TAD1650GE, TAD1650VE, TAD1650VE-B,
TAD1651GE, TAD1651VE, TWD1652GE,
TWD1653GE

Valves and Unit Injectors, Adjustment

1 Adjust valves and injectors for the respective
cylinders at the same time.
2 Remove all EGR rocker arm springs.

P0016506

3 Turn the engine to the next camshaft marking.

Use 9993590 Rotation tool.
TDC 5
3
5
1
4

P0002568

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 21-4 Valve Mechanism

4 Adjust the valve clearance for the inlet valves to

0.30 mm (0.0118") with the aid of a feeler gauge.
Tighten the locking nut according to the
specifications in Special Tightening
Torques, page 12.

P0016508

5 Adjust the unit injector preload by loosening the

adjuster screw until a clearance is obtained on the
injector.
Adjust the screw until the clearance disappears
(by feel until the roller can no longer be rotated).
Tighten the adjuster screw a further 240° (4 flats).
Tighten the nut on the adjuster screw according
to Special Tightening Torques, page 12.

P0016509

6 Adjust the exhaust valve yokes by first checking

that there is no clearance between the yoke and
the rocker arm.
Undo the yoke locking nut while holding the yoke
secure with a wrench so that the valves are not
bent.

P0016510

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21-4 Valve Mechanism

7 Screw out the yoke adjuster screw around 1 turn.

NOTICE! Before the adjuster screw is screwed in,

the yoke must be pressed down simultaneously
until it touches the valve stem. It is extremely
important that the pressure is brought to bear as
close to the adjuster screw as possible; see
illustration.

Screw the adjuster screw down until it rests

against the valve stem and then turn one
additional flat (60°).
Tighten the locking nut according to the
specifications in Special Tightening
Torques, page 12.

NOTICE! Use a wrench on the yoke as a

counterhold also when tightening.
P0006956

8 Adjust the valve clearance for the exhaust valves

to 0.60 mm (0.0236") with the aid of a feeler
gauge.
Tighten the locking nut according to the
specifications in Special Tightening
Torques, page 12.

P0016511

9 Allow the feeler gauge to remain in place after

adjustment and adjust the EGR rocker arm by
loosening the locking nut and adjusting the screw
until zero clearance is attained (check by rotating
the rocker arm roller against the camshaft).

P0016514

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 21-4 Valve Mechanism

10 Loosen the adjuster screw 660°(1 turn and five

flats).
Tighten the locking nut according to the
specifications in Special Tightening
Torques, page 12.
Remove the feeler gauge from the exhaust valve.
P0004808

11 Where necessary, check the EGR rocker arm

adjustment with a feeler gauge.
Check the clearance between the camshaft and
the roller on the EGR rocker arm.
The clearance must be between
4.05-4.35 mm (0.159-0.171").
Adjust the remaining valves and unit injectors as
described above.

P0016513

12 Tighten the retaining screws to the EGR rocker

arm springs.
Tightening torque: 25 Nm (18.4 lbf. ft.)

NOTICE! Ensure that the springs position

correctly on the pressure points.

Remove 9993590 Rotation tool from the gear

ring.
Install the valve cover.

P0016506

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21-4 Valve Mechanism

Valve Guides, Inspection

Tools:
9989876 Dial indicator
9999696 Magnetic stand

Cylinder head removed

Refer to removal in 21-1, Cylinder Head, Change.
1 Remove the valve stem seals from the valve
guides.
2
IMPORTANT!
The cylinder head must not be put down so its
entire weight rests on the valve guides (see
illustration).
Put the cylinder head on the bench with the valve
discs facing upwards.
3 Place a new valve in the valve guide with the
valve stem end in the same plane as the edge of
the guide. Use a suitable counterhold under the
valve stem.
4 Place tool 9989876 Dial indicator and tool
999 9696
9999696 Magnetic stand, so that the dial indicator
tip is touching the valve disc edge.
998 9876 Move the valve sideways, in the direction of the
exhaust or inlet duct. Read off the value on the
dial gauge.
5 Check all valve guides.
If the measurement values exceed the values
noted in the specifications, the valve guide must
be changed; refer to Technical Data, page 28.
p0005207

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 22-0 Lubricating and Oil System, General

22-0 Lubricating and Oil System, General

When you work with Chemicals,
Fuel and Lubrication Oil, Change

! CAUTION!
Apply barrier cream to hands and always use
protective gloves in work that involves the risk of
contact with oil and fuel and similar. Continuous skin
contact with engine oil dries the skin and can be
hazardous.

P0007022

Overview Control Valve

A By-pass valve for oil cooler
B Safety valve
C Reduction valve
D Control valve for piston cooling
E Opening valve for piston cooling
F Overflow valve for bypass filter
G Overflow valve for full-flow filter

P0007023

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22-1 Oil pump and Line

22-1 Oil pump and Line

Lubrication Oil Pump, Change
1 Drain the engine oil.
Remove the oil filler pipe.
Remove terminal to the oil level sensor.
Remove the oil dipstick tube from the bracket.
Remove the oil pan.
2 Remove bolts that fasten the oil pipes to the
engine.
Remove the oil pipes, the oil strainer and the
bracket together.
3 Remove the oil pump bolts and remove the pump.
4 Clean the oil suction pipe and the oil delivery pipe.
Check that there is no damage.
5 Remove and clean the oil strainer. Check that
there is no damage.
P0006969
6 Install the new oil pump.
Make sure that the teeth fit into the camshaft gear.
Tighten the bolts according to the specification in
Special Tightening Torques, page 12.
7 Assemble the oil pipes and the oil strainer on the
bracket with new oil seals. The strainer must be
installed so that it faces to the engine front end.
Tighten the bolts according to the specification in
Special Tightening Torques, page 12.
8 Assemble the oil pipes with the oil pump.
Tighten the bolts according to the specification in
Special Tightening Torques, page 12.
9 Check if the seal needs to be changed.
Install the oil pan.
10 Attach the oil dipstick tube to the bracket.
Install oil filler pipe and the wiring to the oil level
sensor.
Top up with engine oil.
11 Start the engine. Check the oil pressure and
check for leakage.

Oil Pump, Check

1 Remove the oil pump. Refer to Lubrication Oil
Pump, Change, page 196.
2 Check the pump gear.

NOTICE! If the reason for the fault is traced to

poor oil quality, clean the oil system thoroughly
before new oil is filled.

P0006969

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 22-2 Oil filter

22-2 Oil filter

Relief Valve, Replace
1 Clean the area around the reducing valve.
2 Remove the reducing valve.
3 Clean the valve contact surface in the oil filter
housing. Check that the old seal is not still in
place.
4 Check that the color marking on the new valve
matches the old.
5 Fit the new valve with a new seal ring. Check that
the internal seal does not come loose when the
valve is installed.
Tighten according to the specification in Special
Tightening Torques, page 12.
6 Start the engine and check for leaks.
P0007024

Bypass Valve, Oil Filter Bypass,

Replace
1 Remove the pressure pipe to the turbo.
2 Clean the area around the overflow valve.
3 Remove the overflow valve.
4 Clean the valve contact surface in the oil filter
housing.
5 Fit the new the valve with a new seal ring and
tighten the nut as specified in Special Tightening
Torques, page 12.
6 Tighten the turbo pressure pipe.
7 Start the engine and check for leaks.

P0007025

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22-2 Oil filter

Safety Valve, Oil Pressure, Replace

1 Clean the area around the valve and remove it.
2 Clean the valve contact surface.
3 Check that the color marking on the new valve
matches the old.
Install the new valve and tighten according to
specifications in Special Tightening
Torques, page 12.
4 Start the engine and check for leaks.
Check the oil pressure; refer to Oil Pressure
Sensor, Check, page 200.

P0007026

Piston Cooling Valves, Replace

1 Clean around the oil filter bracket and the piston
cooling valves.
2 Remove the filter bracket.
3 Remove the two piston cooling valves: control
valve and opening valve.
4 Clean valve seats in the oil filter bracket.
5 Fit new valves with new seal rings; tighten
according to specification in Special Tightening
Torques, page 12.
6 Re-install the oil filter bracket, with new gasket
and new seal rings.
7 Start the engine and check for leaks.

P0007027

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 22-2 Oil filter

Bypass Valve Oil Filter, Change

1 Clean the area around the overflow valve.
2 Remove the valve and clean the valve seat in the
oil filter bracket.
3 Fit a new valve with a new seal ring. Tighten
according to the specifications in Special
Tightening Torques, page 12.
4 Start the engine and check for leaks.

P0007028

Oil Filter, Check

1 Check that the oil filters are not faulty or blocked.
If the filters have external damage, oil flow
through the filters may be restricted. This may
cause the oil pressure to deteriorate.

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22-2 Oil filter

Oil Pressure Sensor, Check

If you suspect that the oil pressure sensor reads
incorrectly, check the oil pressure with a external
pressure sensor.
The pressure sensor is located behind the control unit;
refer to 20-0, Engine Placement.

Tools:
9992873 Nipple
9996398 Manometer
9998493 Hose
1 Check the oil pressure with an external pressure
gauge and compare values with the specification
in Technical Data, page 38.
2 Remove the pressure sensor.
3 Fit tool 9998493 Hose, 9992873 Nipple and
9996398 Manometer.
4 Start the engine and check the oil pressure.
If the oil pressure measurement shows that the
pressure is below the minimum value as
specified, continue troubleshooting by checking
the oil filters.
If the oil pressure measurement using an external
pressure sensor shows that the pressure is within
tolerance, but the regular engine pressure sensor
does not, replace the pressure sensor.
5 Remove the hose, nipple and pressure gauge.
6 Install the oil pressure sensor. Connect the
sensor to the wiring.

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 22-2 Oil filter

Engine oil and engine oil filter,

changing
Tools:
9998487 Sleeve
9999179 Extractor oil filter
1 Remove the drain plug and drain engine oil into
an appropriate container immediately after
running when the oil is hot and flows more easily.
WARNING!
Hot oil and hot surfaces can cause burns.
2 Clean around the filter bracket and remove the
filters. Use 9998487 Sleeve or 9999179 Extractor
oil filter.

P0007029

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22-2 Oil filter

3 Fill the new filters with engine oil and apply some
to the gaskets (1).
4 Tighten the filters by hand until they touch the
bracket contact surface (2).
Tighten them by hand another 3/4 to one full turn
(3).
5 Re-install the drain plug. Add engine oil to correct
level.
6 Connect a switch to the starter motor and use it
to crank the engine until the oil pressure is
registered by the oil pressure gauge. This means
that the oil filters are full.

NOTICE! Refer to Compression Test, page 69 for

connection of starter motor.
7 Start the engine and check for any leakage
around filter bracket and filter.
8 Check the oil level. Add oil as needed.

P0007030

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 22-2 Oil filter

Relief Valve, Check

1 Check that the reducing valve has a blue color
marking.

NOTICE! In installations with remote oil filters the

reducing valve must have a blackcolor marking.
2 Check that the valve is not damaged, which would
impair its function.
Press in the valve poppet (1) with a blunt object
and check that it does not seize and that it seals
against the seat (2).

P0007031

Safety Valve, Check

1 Check that the safety valve has a purple color
marking.

NOTICE! In installations with remote oil filters the

safety valve must have a blackcolor marking.
2 Check that the valve is not damaged, which would
impair its function.
Press in the valve poppet (1) with a blunt object
and check that it does not seize and that it seals
against the seat (2).

P0007031

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22-3 Oil cooler

22-3 Oil cooler

Oil Cooler, Replace
Removal
1 Clean around the oil cooler cover.
2 Drain the coolant; refer to Draining the Cooling
System, page 286.
Remove the coolant filter with attachment(1).
3 Remove the cover bolts and lift away the cover.
4 Remove the oil cooler from the engine block.

P0006899

Installation
5 Clean the cover contact surface on the engine
block.
6 Install the oil cooler on the block with new rubber
gaskets. Tighten the bolts according to the
specification in Special Tightening
Torques, page 12.
7 Install new gaskets in the cover.
8 Lift the cover into position. Check that the rubber
cover gasket remains in its groove.
9 Install the cover bolts and torque according to
specifications in Special Tightening
Torques, page 12.
Install the coolant filter and its bracket(1).
10 Add coolant. Refer to Coolant Level, Checking
and Topping Up, page 288.

IMPORTANT!
If the oil cooler has leaked engine oil to the cooling
system, the coolant filter must be replaced and the
cooling system cleaned. Refer to Cooling System,
Cleaning, page 287.
11 Start the engine and check for leakage when it
has reached normal temperature.
Check coolant level.

1. Only “Volvo Penta Coolant” (green).

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 22-3 Oil cooler

Oil Cooler, Pressure Testing

Tools:
9996662 Pressure testing kit
9996845 Screw clamp
1 Remove the oil cooler. Refer to Oil Cooler,
Replace, page 204.
2 Clean the oil cooler coolant side with water
soluble degreaser.
Clean the oil side of the oil cooler with degreaser.
3 Check 9996662 Pressure testing kit before it is
taken into service. See Cylinder Head, Pressure
Testing, page 73 in the Checking pressure testing
equipment section.

999 6845 4 Install 9996845 Screw clamp and check that they
are placed correctly.

P0007032

5 Check that the pressure reducing valve knob on

9996662 Pressure testing kit is fully opened and
that the manometer shows “0”.
Connect the pressure testing device to
9996845 Screw clamp.
6 Lower the oil cooler into a vessel containing water
at room temperature.
Increase the pressure to 250 kPa (2.5 bar) [36.26
PSI] with the knob on the reducing valve.
Wait at least one minute.
P0007033

IMPORTANT!
If an even stream of air bubbles comes from the oil
cooler matrix, there is leakage and the oil cooler
must be changed.

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22-3 Oil cooler

Bypass Valve, Oil Cooler, Replace

1 Clean the area around the overflow valve and
remove it.
Clean the valve seat.
2 Fit the new valve with a new seal ring.
Tighten according to the specifications in Special
Tightening Torques, page 12.
3 Start the engine and check for leaks.

P0007034

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 23-0 Fuel System, General

23-0 Fuel System, General

Fuel system, bleeding
TAD1640GE, TAD1640VE-B, TAD1641GE,
TAD1641VE, TAD1641VE-B, TAD1642GE,
TAD1642VE, TAD1642VE-B, TAD1643VE,
TAD1643VE-B, TAD1650GE, TAD1650VE,
TAD1650VE-B, TAD1651GE, TAD1651VE,
TAD1660VE, TAD1661VE, TAD1662VE,
TAD1670VE, TAD1671VE, TAD1672VE
1 Check that there is sufficient fuel in the tank, and
that any fuel taps are open.
2 Twist the hand pump free from the fuel filter
bracket.
3 Vent the fuel system by pumping with the hand
pump.
Air is vented to the tank via the fuel return pipe.
No venting nipples need be opened.
4 Start the engine and allow it to idle fast for about
10 minutes.
5 Perform a leakage and function check.

P0007042

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23-0 Fuel System, General

Fuel system, bleeding

TWD1643GE, TWD1644GE, TWD1645GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672GE, TWD1673GE
1 Check that there is sufficient fuel in the tank, and
that any fuel taps are open.
2 Twist the hand pump free from the fuel filter
bracket.

P0004969

3 Open the nipple on the front fuel connection.

Connect a drain hose.
4 Purge the fuel system by pumping with the hand
pump until fuel flows. Close the nipple and secure
the hand pump.
5 Start the engine and allow it to idle fast for about
10 minutes.
6 Perform a leakage and function check.

P0004970

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 23-0 Fuel System, General

Draining, Fuel Duct in Cylinder Head

TWD1643GE, TWD1644GE, TWD1645GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672GE, TWD1673GE

IMPORTANT!
Make sure that dirt does not enter the fuel channels
and hoses.
1 Clean around the fuel connections at the cylinder
head rear end.
2 Remove the purging hose screw.
Remove the two clamps.

P0005062

3 Remove the fuel supply line on the engine topside

(coming from the filter bracket).
Remove the two clamps

NOTICE! Do not remove the lower union at the

filter bracket.

P0005061

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23-0 Fuel System, General

4 Allow the hoses to hang into a receptacle.

P0005059

5
IMPORTANT!
Take great care to ensure that dirt does not enter
the fuel channel.
Use a suitable hose and blow the fuel through the
fuel channel in the cylinder head, so that it runs
out into the receptacle.
6 NOTICE! If a compression test must be carried
out, do not connect the fuel lines until the test has
been completed. Otherwise the cylinder head fuel
channels will fill with fuel again.
7 When installing the fuel hoses, use new seals.
P0005060

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 23-3 Fuel Feed Pump and Filter

23-3 Fuel Feed Pump and Filter

Engine Fuel Filter Replacement
IMPORTANT!
Do not fill the new filter with fuel before installation.
There is a risk that contaminants will enter the system
and cause operational disruptions or damage.

! WARNING!
The fuel filter should be replaced when the engine is
cold, to prevent any fire hazard from fuel being spilled
onto hot surfaces.
1 Clean round the fuel filter.
2 Remove the fuel filter with the aid of a suitable
filter puller.
Collect any spilled fuel in a collection vessel.
3 Clean around the filter housing sealing surface.
4 Lubricate the seal with diesel fuel and install the
new fuel filter. Torque the filter according to the
instructions on the filter.
5 Bleed the fuel system; refer to Fuel system,
bleeding, page 207.

P0007037

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23-3 Fuel Feed Pump and Filter

Fuel Feed Pump, Change

Removal
1 Close any fuel cocks between the tank and feed
pump, to avoid unnecessary fuel spills.
2 Clean thoroughly around the feed pump and its
connections.
3 Remove fuel connections to the fuel pump and
allow the fuel to flow out into a suitable container.

NOTICE! Plug the lines! Mark the suction and

pressure lines.
4 Remove the fuel feed pump together with the
servo pump.
5 Remove the three Torx bolts and separate the
feed pump from the servo pump.
6 Remove the feed pump by carefully pulling it
straight out.

NOTICE! Ensure that the intermediate connector

on the servo pump shaft does not follow it out.

P0004300

Installation
7 Replace the O-ring on the servo pump flange.
Check that the intermediate connector slots into
its groove on the servo pump shaft.
8 Fit the feed pump and the servo pump together.
Facilitate assembly by turning the pump shaft so
that it slots into the groove in the intermediate
connector.
Torque the bolts according to specifications:
Refer to General Tightening Torques, page 9.
9 Install the feed pump and servo pump on the
engine.

NOTICE! Use a new O-ring.

10 Replace the sealing washers.
Remove the plugs and attach the fuel lines.
11 Open the fuel taps and purge the fuel system:
Refer to Fuel system, bleeding, page 207.
12 Start the engine.
Perform a function and leakage check.

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 23-3 Fuel Feed Pump and Filter

Fuel Pre-filter, Change

1 Disconnect the cable harness at the water
separator sensor.
2 Remove the water separator filter from the filter
housing. Collect any spilled fuel in a collection
vessel.
3 Remove the lower section of the water separator
from the filter.
4 Clean the lower section of the water separator
with a soft rag. Check that the strainer and drain
hole in the lower section are not clogged.
5 Install a new seal on the lower section and
lubricate the seal with diesel fuel.
Re-install the lower section of the filter.
6 Lubricate the seal with diesel fuel.
Screw the filter onto the filter bracket by hand until
the rubber seal bottoms on the mating surface.
Then tighten a further half turn, no more.
7 Connect the cable to the water separator sensor.
8 Bleed the fuel system; refer to Fuel system,
P0007038 bleeding, page 207.

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23-7 Injectors and Delivery Pipes

23-7 Injectors and Delivery Pipes

Unit Injector, Replace
Tools:
9990006 Puller
9990013 Slide hammer
9990185 Lifting tool
9998249 Protective sleeve
9998599 Cleaning kit

The tool kit 9998599 Cleaning kit includes:

– 9808570 Brush
– 9808616 Extender
– 9998580 Protective sleeve

For adjusting valves and unit injectors, refer to Valves

and Unit Injectors, Adjustment, page 180.

NOTICE! When reinstalling, use new seals.

NOTICE! If a new unit injector is fitted, a new injector

code must programmed into the control unit, see
“Service manual EMS 2”. The injector code is stamped
on the unit injector.

Removal
1 Remove the valve cover.
2 Disconnect the electric connectors on the unit
injectors.
Cut the cable ties holding the cable harness and
fold it to one side.
3 Remove the fuel supply pipe and the rocker arm
bridge lubrication oil supply union.
4 Undo the rocker arm bridge bolts in stages, equal
amounts each time, to avoid bending the rocker
shaft.
Carefully lift the rocker arm bridge using
9990185 Lifting tool.
5 Mark and remove the valve calipers.
6 Empty the cylinder head fuel channels; refer to
Draining, Fuel Duct in Cylinder Head, page 209.

P0004965

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 23-7 Injectors and Delivery Pipes

7 Remove the bolts for the unit injector fixing yoke.

9990013 Place the tool 9990006 Puller on the injector.
Put the puller fork in the groove in the injector and
lock the arm with the screw on the side. Fasten
the puller by turning the screw down against the
injector ball seat.
9990006 Attach tool 9990013 Slide hammer and remove
the injector.
8 Attach tool 9998249 Protective sleeve to the
removed injector.

P0001370

9 Install tool 9998580 Protective sleeve and clean

thoroughly using tool 9808570 Brush and tool
9808616 Extender from the toolkit
9998599 Cleaning kit.

P0005063

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23-7 Injectors and Delivery Pipes

Installation

10 Install new O-rings on the unit injector.

Upper O-ring – large diameter
Lower ring – small diameter

P0005064

11 If the copper sleeve has a smooth upper edge (1)

or one groove (2) a steel gasket must never be
used.
If the copper sleeve has two grooves (3) a steel
gasket must always be used. Always use a new
steel gasket.
The steel gasket is installed on the injector tip and
is held in place by the gasket spines.

1 2 3

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 23-7 Injectors and Delivery Pipes

12 Attach the fixing yoke to the unit injector and

center it between the valve springs.
Torque the bolts according to specifications; refer
to Technical Data, page 40.
13 Attach the connector; press it in until a clear “click”
is heard.
Attach new cable ties.
14 Install the valve caliper.
15 Lubricate the valve caliper and camshaft lobes
with engine oil.

P0005066

16 Lift the rocker arm bridge into place with the aid
of 9990185 Lifting tool.
Check that the guide pins position correctly in the
bearing caps.

IMPORTANT!
Tighten alternately, to avoid bending the rocker
shaft.
Torque the rocker arm bridge bolts according to
specifications: refer to 03-2, Technical Data, so
that the shaft abuts the bearing caps.
P0004965
17 Clean the cylinder head where the union is
installed, and check that there is no foreign
material in the cylinder head oil channel.
Install new seal rings on the oil supply pipe and
union.
Put a thin layer of petroleum jelly on the pipe seal
rings and install the pipe in the union.
18 Install the union and torque according to
specifications; refer to 03-2, Technical Data.
19 Adjust the valves and unit injectors; refer to
Valves and Unit Injectors, Adjustment, page 180.
20 Connect the wiring to the unit injectors.
21 Install the valve cover. Replace gasket as
necessary.
22 Purge the fuel system; refer to Fuel system,
bleeding, page 207.

Sleeve for unit injector, replace

Unit injector removed

Tools:
9998251 Protection plug
9998250 Sealing ring
9998580 Protective sleeve
9998599 Cleaning kit
9996049 Draining hose
88800513 Drift
9986173 Puller
88800196 Drift

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23-7 Injectors and Delivery Pipes

88800387 Puller
88800460 Sleeve

IMPORTANT!Working with the fuel system requests

special cleanliness.
1 Drain the coolant with the aid of 9996049 Draining
hose; refer to Draining the Cooling
System, page 286. Mark and remove the valve
yokes.
2 Remove the protective plug.

P0019120

3 Clean carefully around the sleeve.

Install 2 seal rings to prevent dirt from entering the
fuel ducts when the sleeve is removed.

P0019121

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 23-7 Injectors and Delivery Pipes

4 The puller marking (A) should be visible when the

support ring (2) is fitted. If the marking is not
visible it may be difficult to remove the sleeve.
Press the puller (1) down to the sleeve bottom;
see arrow marking.
Install the support ring (2).
- 9998250 Seal ring, 2 pcs (3)
- Expander (4)
- Sleeve (5)
- Nut (6)

P0019122

5 Push the tool down to the bottom of the sleeve.

Tighten the nut (1) sufficiently hard to hold the
puller in place; apply moderate force and use the
tool (2) as a counterhold.

P0019123

6 Alternative 1
Remove the sleeve from 88800387 Puller and fit
88800460 Sleeve.

P0021199

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23-7 Injectors and Delivery Pipes

7 NOTICE! Tighten the bolt moderately.

Install the sleeve with bolt (1).

Screw down to the end position towards the puller
(2).

P0021200

8 Counterhold the screw puller (2) and screw the

sleeve nut (1) until the sleeve releases.

P0021202

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 23-7 Injectors and Delivery Pipes

9 Pull up the puller and sleeve.

A misshapen sleeve can be difficult to remove. If
this is the case, remove the puller and find a new
grip for the expander.
Install the support ring and make a new attempt.

P0021201

10 Alternative 2
Install the puller.
Screw down until the puller lugs meet the support
ring.

P0019124

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23-7 Injectors and Delivery Pipes

11 Screw until the sleeve releases and the puller and

sleeve can be removed.
A misshapen sleeve can be difficult to remove. If
this is the case, remove the puller and find a new
grip for the expander.
Install the support ring and make a new attempt.

P0019125

12 Use tool 9998599 Cleaning kit and a power drill

before fitting the new sleeve.
Install tool 9998580 Protective sleeve in the
injector hole and secure it with a holder.
IMPORTANT! Tool no. 9998580 Protective
sleeve must be used to prevent dirt from entering
the fuel duct.
13 Clean the cylinder head walls using 9808618.

P0007010

P0007010

14 Clean the sleeve seat using Brush 9808614

together with the handle and holders.

P0007011
P0007011

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 23-7 Injectors and Delivery Pipes

15 Clean the cylinder head hole with Brush 9808617.

999 8580 16 Remove tool 9998580 Protective sleeve. Make
980 8617 sure the O-ring is removed.
17 Check that the piston is at BDC.
IMPORTANT! This must be done so that tool no.
9808617, due to its length, does not damage the
piston.

P0007012

P0007012

18 Lubricate the tap with graphite paste 85134750.

P0025230

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23-7 Injectors and Delivery Pipes

19 1 Fit the sleeve to the expander tool.

Lubricate the O-rings with soapy water.
2 Use the unit injector yoke to steady the tool.
Tightening torque: 80 Nm (59 lbf ft)
3 Run the tap down through the tip of the
sleeve.
20 Remove the expander tool.

P0025231

21 Remove the seal ring, (2 pcs).

22 Install the unit injectors with washer; refer to Unit
Injector, Replace, page 214.
23 Reinstall the valve yokes according to the
markings.
24 Install the rocker arm bridge. Check play on
valves and unit injectors.
25 Install the valve cover.
26 Fill up with coolant and check that no leakage
occurs.

9998250

P0003619
P0003619

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 23-8 Control System, ECM, Data Sets

23-8 Control System, ECM, Data Sets

Engine Control Unit (ECU), Replace
NOTICE! Before the control unit is replaced and any
warranty claim made, all checks in the check list must
be performed, to exclude any defect in the engine
control system. If the measurements of the cable
harness show defects, it is highly likely that the control
unit is fault free. Refer to the “Service Manual, EMS 2”.

! WARNING!
Faulty individual control unit settings may result in
injury to persons or damage to the engine. For
information about reprogramming and reading of
software, refer to “Service manual, EMS 2”

IMPORTANT!
Exchange of control units between engines, during
fault tracing or repair, must never be performed under
any circumstances.
1 Clean thoroughly around the control unit fuel
connections.
2 Disconnect power from the engine by
disconnecting the negative battery terminal.
3 Remove the lower part of the crankcase breather
pipe.
4 Remove the upper and lower cable harness
clamps.
5 Remove the control unit cable harness by moving
the connector block retaining clips outwards.
6 Remove the upper and lower fuel connections to
the cooling element; plug the fuel lines.
7 Remove the control unit retaining bolts and
remove the control unit.
P0007035

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23-8 Control System, ECM, Data Sets

8 Transfer the cooling element to the new control

unit. Make sure that the surface between the
cooling element and the control unit is clean.
9 Install the new control unit. Torque according to
specifications in Special Tightening
Torques, page 12.
10 Connect the upper and lower fuel connections to
the cooling element with new sealing washers.
11 Install the harness and clamps.
12 Install the crank case breather lower pipe.

P0007036

13 Bleed the fuel system. Refer to Fuel system,

bleeding, page 207.
Start the engine and check for error codes. Refer
to the “Service Manual, EMS 2”.

P0007035

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 25-1 Inlet and Exhaust Manifolds

25-1 Inlet and Exhaust Manifolds

Exhaust Manifold, Change
Removal
1 Remove the turbocharger as per: Turbo,
Change, page 231.
2 Remove the heat shield, if fitted.
3 TAD1670-72VE only
Undo e-EGR connection.

P0022360

4 Remove the exhaust manifold.

P0022355

Exhaust manifold inspection

5 In case of inspection:
Dismantle the exhaust manifold.
Check that the components have no cracks or
damage.

P0022356

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25-1 Inlet and Exhaust Manifolds

6 Clean the mating surfaces and install the gaskets

as illustrated.

NOTICE! Apply assembly paste (part # 1161929)

around the exhaust manifold insertion surfaces at
the connections.

Assemble the exhaust manifold.

P0022357

Installation
7 Apply assembly paste (part # 1161929) for
fasteners.
8 Place the gaskets on the sealing surface.
Install the exhaust manifold.

P0022358

9 Torque the exhaust manifold in the following

stages:
1 Tighten the bolts (1-2-3-4) until contact.
Tightening torque: (10 Nm) 7.4 lbf. ft.
2 Tighten the bolts (1-2-3-4).
Tightening torque: (40 Nm) 29.5 lbf. ft.
3 Tighten the bolts (1-2-3-4).
Tightening torque: (54 Nm) 39.8 lbf. ft.
P0022359 10 Install the heat shield, where fitted.
11 Install the turbocharger as per: Turbo,
Change, page 231.
12 Start the engine and perform a function check.

228 47702612 05-2018 © AB VOLVO PENTA

 25-2 Exhaust Pipe, Silencer

25-2 Exhaust Pipe, Silencer

Exhaust Pipe (Y-pipe), Replace
TWD1643GE, TWD1644GE, TWD1645GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672GE, TWD1673GE

Removal
1 Remove the heat shield and any exhaust
temperature sensor. Refer also to Heat
Protection, page 132.
2 Remove the two exhaust clamps.
3 Remove the four nuts and the Y pipe spacers.
4 Remove the pipe.

Installation
5 Check the seal surface condition and check that
the flange joint surfaces are clean.
Install a new gasket.
6 Install the new exhaust pipe.
Torque the nuts according to specifications in
Special Tightening Torques, page 12.

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25-2 Exhaust Pipe, Silencer

7 Make sure the flange joint positions correctly.

Adjust as necessary.
Tighten the clamps.
8 Install the heat shield.
Refer to Heat Protection, page 132.
9 Install the exhaust temperature sensor, where
fitted.

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 25-5 Turbo and supercharger

25-5 Turbo and supercharger

Turbocharger, Inspection
1 Check that the turbocharger part number is
correct for the engine variant. The wrong
turbocharger for the engine variant might not
provide enough charge pressure, which would
reduce engine power.
2 Check that the turbocharger has the correct
compressor housing. If the wrong compressor
housing is installed on the turbocharger, the
compressor wheel might have been damaged or
have too much clearance between wheel and
housing. In both cases, charge air pressure will
be too low.
3 Remove the inlet manifold from the turbocharger.
4 Check the turbocharger for damage to the
compressor wheel and excessive end float on the
turbine shaft.
5 If there is any damage on the compressor wheel
or excessive end float on the turbine shaft, the
turbocharger must be changed as a unit.
6 Remove the exhaust pipe (muffler) from the
turbocharger and check the turbine disc.
7 Check the turbine wheel for damage. If the turbine
wheel is damaged, the turbocharger must be
changed as a unit.

Turbo, Change
Always determine and rectify the reasons why the
turbocharger has failed, before a new turbocharger is
installed.
A prerequisite for the turbocharger to work
satisfactorily is that the engine lubrication and intake
systems are kept in good condition, i.e. that oil and oil
filter changes are completed as scheduled, that the
right grade of oil is used and that the air filter is
maintained correctly.
Therefore the first action should be to check the engine
oil and replace the oil filters if needed, and preferably
to run the engine for a few minutes with the new oil
before the new turbo unit is installed.
Blow any rust and soot flakes out of the exhaust
manifold when the turbocharger is changed. The soot
flakes could damage the turbine wheel on the new unit.
It is also important to clean the intake line from the air
filter. Debris from a failed turbine wheel may remain in
place and cause instant breakdown of the new
turbocharger.

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25-5 Turbo and supercharger

Removal
TAD1640GE, TAD1640VE-B, TAD1641GE,
TAD1641VE, TAD1641VE-B, TAD1642GE,
TAD1642VE, TAD1642VE-B, TAD1643VE,
TAD1643VE-B, TAD1650GE, TAD1650VE,
TAD1650VE-B, TAD1651GE, TAD1651VE,
TAD1660VE, TAD1661VE, TAD1662VE,
TAD1670VE, TAD1671VE, TAD1672VE

Variants with single turbo

1 Remove the air hose between the turbo and the
air filter housing.
2 Remove the bolts and remove the exhaust pipe
from the turbo.
3 Remove the oil delivery pipe and return oil pipe.

P0006875

4 Remove the nuts and the spacer sleeves.

5 Remove the turbo.

P0006868

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 25-5 Turbo and supercharger

Installation
TAD1640GE, TAD1640VE-B, TAD1641GE,
TAD1641VE, TAD1641VE-B, TAD1642GE,
TAD1642VE, TAD1642VE-B, TAD1643VE,
TAD1643VE-B, TAD1650GE, TAD1650VE,
TAD1650VE-B, TAD1651GE, TAD1651VE,
TAD1660VE, TAD1661VE, TAD1662VE,
TAD1670VE, TAD1671VE, TAD1672VE

Variants with single turbo

1 Clean the turbo contact surface on the exhaust
manifold.
2 Fit the return oil pipe with a new seal ring against
the engine block.
3 Place a new gasket on the exhaust manifold and
install the turbo.
Tighten the nuts according to the specification in
Special Tightening Torques, page 12.

P0006868

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25-5 Turbo and supercharger

4 Connect return oil pipe using a new gasket

against the turbo.
5 Fill the turbo with clean engine oil through the oil
delivery pipe connection.

IMPORTANT!
Make sure no dirt gets into the connection. Use a
strainer when filling oil.
6 Fit the oil delivery pipe with a new gasket.
7 Fit the exhaust pipe to the turbo.
8 Fit the hose between air filter and turbo.
9 Start the engine and check for leaks.

P0006875

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 25-5 Turbo and supercharger

Low-Pressure Turbo, Change

Always determine and rectify the reasons why the
turbocharger has failed, before a new turbocharger is
installed.
A prerequisite for the turbocharger to work
satisfactorily is that the engine lubrication and intake
systems are kept in good condition, i.e. that oil and oil
filter changes are completed as scheduled, that the
right grade of oil is used and that the air filter is
maintained correctly.
Therefore the first action should be to check the engine
oil and replace the oil filters if needed, and preferably
to run the engine for a few minutes with the new oil
before the new turbo unit is installed.
Blow any rust and soot flakes out of the exhaust
manifold when the turbocharger is changed. The soot
flakes could damage the turbine wheel on the new unit.
It is also important to clean the intake line from the air
filter. Debris from a failed turbine wheel may remain in
place and cause instant breakdown of the new
turbocharger.

Removal
TWD1643GE, TWD1644GE, TWD1645GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672GE, TWD1673GE

Low-Pressure Turbo
Variants with twin turbo
1 Remove the heat shield, if fitted.
Refer to Heat Protection, page 132.
2 Undo the connector for the air filter sensor.

P0003625

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25-5 Turbo and supercharger

3 Remove the inlet pipe (1).

4 Remove the exhaust system (2).
5 Undo the upper clamp (3) between the turbo and
the charge air cooler.
6 Remove the oil supply hose (4).
7 Remove the bolts for the oil return pipe (5) on the
turbo. Allow the other end to remain in the engine
block.

8 Remove the four nuts and spacers to the turbo.

9 Lift away the turbocharger.
10 Transfer any oil supply pipe extension to the new
turbo.

P0007044

Installation
TWD1643GE, TWD1644GE, TWD1645GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672GE, TWD1673GE

Low-Pressure Turbo
Variants with twin turbo
1 Install the studs if they were removed from the
fixture.
2 Fit the gasket.
3 Lift the turbo into place and align it with the hose
on the charge air cooler.

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 25-5 Turbo and supercharger

4 Fit the spacers and nuts to the turbo.

Torque the nuts according to specifications in
Special Tightening Torques, page 12.

P0007044

5 Install the oil return pipe (5) and a new gasket.

Tighten the bolts.
6 Fill the turbo with clean engine oil through the oil
delivery pipe connection.

IMPORTANT!
Make sure no dirt gets into the connection. Use a
strainer when filling oil.
7 Install the oil supply hose (4).
Tighten the nut.
8 Tighten the hose clamp (3) on the turbo.
9 Check the condition of the rubber connectors.
Install the inlet pipe (1).
Tighten the hose clamps.
10 Install the exhaust system (2).
Tighten the clamp.

11 Install the air filter sensor connector.

12 Install the heat shield, where fitted.
Refer to Heat Protection, page 132.

P0003625

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25-5 Turbo and supercharger

High-Pressure Turbo, Change

Always determine and rectify the reasons why the
turbocharger has failed, before a new turbocharger is
installed.
A prerequisite for the turbocharger to work
satisfactorily is that the engine lubrication and intake
systems are kept in good condition, i.e. that oil and oil
filter changes are completed as scheduled, that the
right grade of oil is used and that the air filter is
maintained correctly.
Therefore the first action should be to check the engine
oil and replace the oil filters if needed, and preferably
to run the engine for a few minutes with the new oil
before the new turbo unit is installed.
Blow any rust and soot flakes out of the exhaust
manifold when the turbocharger is changed. The soot
flakes could damage the turbine wheel on the new unit.
It is also important to clean the intake line from the air
filter. Debris from a failed turbine wheel may remain in
place and cause instant breakdown of the new
turbocharger.

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 25-5 Turbo and supercharger

Removal
TWD1643GE, TWD1644GE, TWD1645GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672GE, TWD1673GE

High-Pressure Turbo
Variants with twin turbo
1 Remove the heat shield, if fitted.
Refer to Heat Protection, page 132.
2 Remove the charge air pipe (1) from the
1 turbocharger.

4 NOTICE! Note the O-ring.

3 Remove the charge air pipe (2) from the
turbocharger.
4 Cover the opening (3) on the charge air cooler.
5 Remove the oil supply line (4).
6 Remove the bolts for the oil return pipe (5) on the
turbo. Allow the other end to remain in the engine
block.
6 7 Undo the clamp (6) for the flex-pipe on the
exhaust side.

3
P0003627

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25-5 Turbo and supercharger

8 Remove the nuts from the turbo attachment to the

wastegate valve.

2X

2X

P0003630

9 Separate the flange, so the sealing surfaces are

free. Leave the clamp on the flex-pipe.
Lift away the turbocharger.

P0007045

Installation
TWD1643GE, TWD1644GE, TWD1645GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672GE, TWD1673GE

High-Pressure Turbo
Variants with twin turbo
1 Make sure the clamp is on the flex-pipe.

P0007046

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 25-5 Turbo and supercharger

2 Install the high pressure turbo and a new gasket

3 Tighten the nuts on the turbo according to
specifications in Special Tightening
Torques, page 12.
4 Tighten the flex-pipe clamp.

P0007047

The picture shows TWD1643GE, TWD1652-53GE.

5 Install the turbo oil return pipe with a new gasket.

Tighten the bolts.
6 Fill the turbo with clean engine oil through the oil
delivery pipe connection.

IMPORTANT!
Make sure no dirt gets into the connection. Use a
strainer when filling oil.
7 Install the oil supply line to the turbo with a new
gasket.
Tighten the bolts.
8 Check the condition of the rubber connector.
Check that the flange joint sealing surfaces are
clean and correctly aligned.

P0007048

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25-5 Turbo and supercharger

9 Install the charge air pipe (2) on the turbo with a

new O-ring.

1 10 Fit the clamp and tighten it.

11 Tighten the clamp on the rubber connector.
12 Check the condition of the rubber connector.
Fit new O-rings.

NOTICE! Make sure the O-rings fit properly in

their grooves.
13 Install the charge air pipe (1) from the
turbocharger.
14 Tighten the flange joint. The lower clamp must be
tightened first.

NOTICE! TWD1643GE (early mod.): Adjust the

wastegate valve; refer to Wastegate Valve,
Adjustment, page 76.
15 Install the heat shield, where fitted.
2 Refer to Heat Protection, page 132.

P0003631

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 25-5 Turbo and supercharger

Wastegate Valve, Replace

TWD1643GE, TWD1644GE, TWD1645GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672GE, TWD1673GE

Removal
1 Remove the high pressure turbo in accordance
with High-Pressure Turbo, Change, page 238.
2 Remove the wastegate valve connection.

P0007049

The picture shows TWD1643GE, TWD1652-53GE.

P0018880
The picture shows TWD1663GE, TWD1672-73GE.

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25-5 Turbo and supercharger

3 Remove the clamp under the wastegate housing.

4 Remove the nuts and spacers.
5 Lift the wastegate valve away.

P0007050

The picture shows TWD1643GE, TWD1652-53GE.

P0018881
The picture shows TWD1663GE, TWD1672-73GE.

244 47702612 05-2018 © AB VOLVO PENTA

 25-5 Turbo and supercharger

Installation
6 Check the condition of the rubber connector.
7 Install the wastegate housing and a new gasket.
8 Tighten the nuts.

9 Install the clamp under the wastegate housing

and tighten until it touches.
10 Install the high pressure turbo in accordance with
High-Pressure Turbo, Change, page 238.
11 Tighten the clamp below the wastegate housing.

P0007050

12 Install the wastegate valve connector.

NOTICE! TWD1643GE (early mod.): Adjust the

wastegate valve in accordance with Wastegate
Valve, Adjustment, page 76.

P0007051

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25-8 Emission After-Treatment

25-8 Emission After-Treatment

Repair instructions
TAD1660VE, TAD1661VE, TAD1662VE,
TAD1670VE, TAD1671VE, TAD1672VE,
TWD1644GE, TWD1645GE, TWD1663GE,
TWD1672GE, TWD1673GE

NOTICE! Because the illustrations in the maintenance

literature are used for different engine variants, certain
details may vary compared to the actual model
concerned. The essential information in the
illustrations is always correct, however.

IMPORTANT!
AdBlue/DEF and urea solutions cause corrosion
damage. Do not remove AdBlue/DEF hoses, urea
hoses or electrical wiring during normal service or
when moving a component. Tools that have come into
contact with AdBlue/DEF or urea solution must be
cleaned.
CAUTION!
Gloves must be changed. Take off contaminated
clothes.

WARNING!
In the case of any contact with eyes or skin the affected
area must be thoroughly rinsed with lukewarm water.
If you inhale any fumes, make sure you breathe fresh
air.

NOTICE! Always plug AdBlue/DEF and urea hoses in

order to avoid dirt in the AdBlue/DEF system, and any
crystallization of AdBlue/DEF.

NOTICE! Clean the AdBlue/DEF system before any

type of work is done to avoid dirt.

IMPORTANT!
Fluids other than AdBlue/DEF (such as diesel) and that
are not approved by Volvo, will cause a breakdown of
the exhaust aftertreatment system.

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 25-8 Emission After-Treatment

Electrically Heated AdBlue/DEF

Hose, Change
TAD1660VE, TAD1661VE, TAD1662VE,
TAD1670VE, TAD1671VE, TAD1672VE,
TWD1663GE, TWD1672GE, TWD1673GE

1 NOTICE! Wait at least 2 minutes after engine

stop so that the automatic drainage function is
depressurized before beginning to remove
components.
2 Remove the hose.
3 Install a new hose.

P0025276

4 Run the Urea pressure build up test.

Check that there are no leaks.

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25-8 Emission After-Treatment

AdBlue/DEF Tank, Change

TAD1660VE, TAD1661VE, TAD1662VE,
TWD1663GE

Tools:
1158957 Pliers
1159794 Torque wrench
1 Switch off the engine.

NOTICE! Wait at least two minutes before

removing the AdBlue hoses so that automatic
drainage of the AdBlue system can proceed and
for the AdBlue system to de-pressurize.
2 Cut power to the engine by disconnecting the
negative battery terminal.
Assemble the necessary equipment and place a
recovery container under the AdBlue tank.

NOTICE! Use protective equipment and an

approved recovery container.
3 Remove the AdBlue tank filler cap. Remove the
drain plug. Empty the AdBlue tank.

4 Remove the electrical connection from the tank

fitting.
Protect the connector by enclosing it in a plastic
bag and moving it to one side.

p0013232

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 25-8 Emission After-Treatment

1158957 5 Clamp hose pinch-off pliers 1158957 on each

coolant hose. Remove the coolant hoses.

p0013226

6 Remove the AdBlue hoses by pressing in the

latches.

7 Install the new AdBlue tank.

8 Install the AdBlue tank.
Torque-tighten the nuts.
9 Install the electrical connection to the tank fitting.
Install the AdBlue hoses. Check that the
connection locks securely.
10 Install the coolant hoses. Unclamp both hose
pinch-off pliers from the coolant hoses.
11 Install cable ties around hoses and electrical
wiring.
12 Install the filler cap on the new AdBlue tank.
Affix a new adhesive decal to the new AdBlue
tank.

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25-8 Emission After-Treatment

13 Connect the battery negative terminal.

14 Fill with clean AdBlue solution.
Start the engine and check for any leaks.

p0013223

IMPORTANT!
Fluids other than clean AdBlue solution approved by
Volvo (ISO 22241–1) will cause a breakdown of the
exhaust aftertreatment system.

NOTICE! Top up with coolant as necessary.

15
NOTICE! Gather up equipment and surplus
AdBlue solution.

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 25-8 Emission After-Treatment

AdBlue/DEF Tank, Change

TAD1670VE, TAD1671VE, TAD1672VE,
TWD1672GE, TWD1673GE

Tools:
1 NOTICE! Wait at least 2 minutes after engine
stop to give the automatic drainage function time
to complete operations. Make sure the system is
depressurized before beginning to remove
components.
2 Unscrew the hexagonal cover (1).
Remove the drain screw (2) and empty the tank.
3 Remove the tank fittings; refer to Combined Tank
Unit, AdBlue/DEF Tank, Change, page 278.

P0019366

4 Hold the tank securely and remove the bolts.

P0025278

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25-8 Emission After-Treatment

5 Lift the tank module and pull it carefully out of the

locating pins on the bracket.

P0019369

6 Remove the bolts.

P0019370

7 Remove the bolts.

P0019372

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 25-8 Emission After-Treatment

8 Remove the bolts and hose holder.

P0019373

9 Carefully pry the tank sides (1) apart and then pull
out the tank (2). Be aware that the venting hose
is attached.
10 Install the new tank in reverse order.

P0019374

11 Run the Urea pressure build up test.

Check that there are no leaks.

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25-8 Emission After-Treatment

AdBlue/DEF Tank, Cleaning

TAD1660VE, TAD1661VE, TAD1662VE,
TWD1663GE
CAUTION!
Gloves must be changed. Take off contaminated
clothes.

1 Remove the drain plug (1) from the bottom of the

tank and empty any remaining AdBlue solution
and coolant into a suitable recovery container.
Change the plug gasket and remount the plug (1).

P0013268 1

2 Remove the filler cap and undo the filler

assembly.

3 Immerse the filler cap and filler assembly in a

water bath for at least 2 minutes.

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 25-8 Emission After-Treatment

4 Undo and remove the tank fittings.

5 Check the strainer on the fittings: clean as

necessary.

NOTICE! Always replace a damaged strainer.

6 Flush the tank with hot water for at least 10

minutes.
Make sure the AdBlue tank is completely drained
of water afterwards.

p0013237

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25-8 Emission After-Treatment

7 Reinstall the tank fittings.

8 Install the filler assembly.

9 Fill the tank with AdBlue solution; refer to Filling
AdBlue®/DEF . Install the filler cap.

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 25-8 Emission After-Treatment

AdBlue/DEF Tank, Cleaning

TAD1670VE, TAD1671VE, TAD1672VE,
TWD1672GE, TWD1673GE

AdBlue/DEF contamination
If a fluid other than AdBlue/DEF is used in the system, or if the AdBlue/DEF tank is contaminated with other
material, the AdBlue/DEF system must be assessed, cleaned and tested to ensure it is functioning correctly.
This information provides general guidelines for the inspections that must be carried out and the actions that
must be taken if the AdBlue/DEF tank is contaminated.
The technician is expected to be acquainted with the SCR system and be able to judge of components can be
cleaned or must be replaced.

Inspection
Action: Checking for diesel or oil in the AdBlue/DEF solution, page 284.

Cleaning / replacement
If the tank has been contaminated by diesel, biodiesel, oil/grease, solvents or alkaline cleaning agents, the
tank fittings must be replaced and all hoses thoroughly cleaned with warm water.

Contamination < 20% Contamination > 20%

Change Change
• Pump unit • Pump unit
• Dosing unit • Dosing unit
• Tank fittings • Tank fittings
• All filters • AdBlue/DEF tank

Clean • All AdBlue/DEF hoses

• Use hot water to clean the AdBlue/DEF tank and • All filters
all AdBlue/DEF hoses.

NOTICE! Operations with contaminated AdBlue/DEF over extended periods can damage the SCR silencer. High
emissions following a complete cleaning as described above indicate a replacement of the SCR silencer may be
necessary.

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25-8 Emission After-Treatment

1 Remove the tank module and tank fittings; refer

to steps 1–5 AdBlue/DEF Tank,
Change, page 248.
2 Flush through the tank fitting with warm water.
Replace the tank fitting filter.

P0019379

3 Remove the filler filter.

Place the cover and the unit in warm water for at
least 2 minutes.

P0019380

4 Flush the tank with hot water for at least 10

minutes.
5 Install in reverse order with a new filler filter and
breather filter.

NOTICE! Fit the drain screw.

P0019381

6 Run the Urea pressure build up test.

Check that there are no leaks.

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 25-8 Emission After-Treatment

Exhaust Temperature Sensor,

Change
TAD1660VE, TAD1661VE, TAD1662VE,
TAD1670VE, TAD1671VE, TAD1672VE,
TWD1663GE, TWD1672GE, TWD1673GE
1 Disconnect the battery negative terminal.
2 Remove the cable ties.
3 Disconnect the connector.
4 Disconnect and remove the temperature sensor.
5 Screw in a new temperature sensor.
6 Connect the connector. Attach new cable ties.
7 Reconnect the battery negative terminal.
8 Start the engine. Check operation and inspect for
leaks.
9 Delete any fault codes.
P0019383

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25-8 Emission After-Treatment

Dosing unit, change

TAD1660VE, TAD1661VE, TAD1662VE,
TAD1670VE, TAD1671VE, TAD1672VE,
TWD1663GE, TWD1672GE, TWD1673GE

1 NOTICE! Wait at least 2 minutes after engine

stop to give the automatic drainage function time
to complete operations. Make sure the system is
depressurized before beginning to remove
components.
2 Disconnect the connector.

P0025288

3 Remove the hoses.

P0025276

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 25-8 Emission After-Treatment

4 Remove the dosing valve.

5 Clean the contact surfaces.
6 Install the dosage valve.
Tightening torque: 8Nm (5.9 Ibf ft)

P0025289

7 Run the Urea pressure build up test.

Check that there are no leaks.

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25-8 Emission After-Treatment

AdBlue/DEF-Pump Filter, Change

TAD1660VE, TAD1661VE, TAD1662VE,
TWD1663GE

Tools:
1159794 Torque wrench
1 Switch off the engine.

NOTICE! Wait at least two minutes before

removing the AdBlue/DEF hoses so that
automatic drainage of the AdBlue/DEF system
can proceed and for the AdBlue/DEF system to
de-pressurize.
2 Cut power to the engine by disconnecting the
negative battery terminal.
Assemble the necessary equipment and place a
recovery container under the pump unit.

NOTICE! Use protective equipment and an

approved recovery container.

3 Remove the heater element from the filter cover

and move the coil to one side.

NOTICE! Pull the heater element out straight.

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 25-8 Emission After-Treatment

4 Expose the AdBlue/DEF hoses connections to

gain access to the latches. Remove the
AdBlue/DEF hose from the filter cover by
pressing in the latches.

5 Remove the filter cover from the pump unit.

Remove the AdBlue/DEF filter.

p0013241

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25-8 Emission After-Treatment

6 Install a new seal ring in the filter cover.

Install a new AdBlue/DEF filter by tighten the filter
on to the filter cover first, and then mount the filter
cover into the filter house.
Tighten the filter cover with: 20 (+5) Nm (14 +3.68
Ibf ft)
7 Install the AdBlue/DEF hose. Make sure that the
connection locks securely.

p0013242

8 Insert the heater element.

NOTICE! Make sure that the connection locks

securely.

9 Connect the battery negative terminal.

10 Start the engine and check that there are no
leaks.
11 Delete any fault codes.
12 NOTICE! Gather up equipment and surplus
AdBlue/DEF solution.

p0013223

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 25-8 Emission After-Treatment

AdBlue/DEF-Pump Filter, Change

TAD1670VE, TAD1671VE, TAD1672VE,
TWD1672GE, TWD1673GE

1 NOTICE! Wait at least 2 minutes after engine

stop to give the automatic drainage function time
to complete operations. Make sure the system is
depressurized before beginning to remove
components.
2 Unscrew the filter cover.

P0019389

3 Remove the rubber gasket.

Pull out the filter. Use the puller (supplied with the
filter kit).

P0019390

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25-8 Emission After-Treatment

4 Install as illustrated.
Filter cover:
Tightening torque: 20 Nm (14 Ibf ft).

P0019391

5 Run the Urea pressure build up test.

Check that there are no leaks.

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 25-8 Emission After-Treatment

Solenoid Valve, AdBlue/DEF Tank,

Change
TAD1660VE, TAD1661VE, TAD1662VE,
TAD1670VE, TAD1671VE, TAD1672VE,
TWD1663GE, TWD1672GE, TWD1673GE

Tools:
1158957 Pliers
1 Pinch off the coolant hoses.
Remove the hoses.

A
p0013271

2 NOTICE! When installing the valve. Check valve

installation direction. Arrow toward tank.

P0025292

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25-8 Emission After-Treatment

Pressure Sensor, Change

TAD1660VE, TAD1661VE, TAD1662VE,
TWD1663GE

Tools:
88890102 Nipple
88890104 Pump
1 Install an M8 X 100 bolt with a non-locking nut in
each of the 4 holes beneath the pump. Adjust the
bolts so that the pump is held stably.

p0013258

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 25-8 Emission After-Treatment

2 Clean around the pump cover.

Remove the pump cover.

p0013259

3 Remove the connector and the sensor.

p0013263

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25-8 Emission After-Treatment

4 Install the new sensor. Use soapy water on the

O-ring.
IMPORTANT!
Do not touch the sensor! The sensor is easily
damaged so check thoroughly to ensure the
pressure surface is undamaged and free of
defects. Do not touch the surface either!
5 Check the cover seal; if the seal is damaged the
cover must be changed. Install the pump cover.
6 Remove all M8 X 100 bolts.

p0013262

7 Remove the valve underneath the pump.

p0013264

8 Install pressure test nipple A = 88890102.

A
Pressure test using B = 88890104 to 0.2–0.3 bar
Spray soapy water around the cover and the
valve connections that protrude from the housing
and check for any leaks.
9 Remove the pressure test tool and install a new
valve.

B
p0013265

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 25-8 Emission After-Treatment

Pump Unit, Change

TAD1660VE, TAD1661VE, TAD1662VE,
TWD1663GE

1 + 1 = OK
1 1

2 + 2 = OK

1 + 2 = OK
2
2

2 2 2 + 1 = OK
p0013266
IMPORTANT!
The dosing unit and pump unit are available in
different versions.
Before changing, check that any component markings
correspond to one another.

IMPORTANT!
Make sure that the new pump is intended for the
engine concerned. Check the part number underneath
the pump.

p0013255

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25-8 Emission After-Treatment

1 Switch off the engine.

NOTICE! Wait at least two minutes before

removing the AdBlue hoses so that automatic
drainage of the AdBlue system can proceed and
for the AdBlue system to de-pressurize.
2 Cut power to the engine by disconnecting the
negative battery terminal.
Assemble the necessary equipment and place a
recovery container under the pump unit.

NOTICE! Use protective equipment and an

approved recovery container.

3 Remove the cable ties from around the AdBlue

hoses and wiring.

4 Mark the hose so that they cannot be transposed.

D
A

B C

P0013273

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 25-8 Emission After-Treatment

5 Remove the heater element from the filter.

NOTICE! Pull the heater element out straight.

p0013257

6 Expose the AdBlue hose connections to gain

access to the lock catches. Remove the AdBlue
hoses from the pump unit by pressing in the lock
catches.

p0013250

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25-8 Emission After-Treatment

7 Wipe the electrical connections dry using a rag or

paper. Remove the clamp. Remove the electrical
connection from the pump unit. Protect the
connector by enclosing it in a plastic bag and
moving it to one side.

p0013232

8 Place a protective cover on the pump unit

connectors.
9 Remove the pump unit bolts. Remove the pump
unit from the bracket.

p0013047

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 25-8 Emission After-Treatment

10 Transfer the plugs from the old pump unit to the

new one.

NOTICE! It is extremely important that the inlet

and outlet connections be plugged.
11 Install the new pump unit on the bracket; tighten
the bolts.

NOTICE! Allow the protective cover to remain to

protect the connectors.
12 Remove the protective cover. Connect the
electrical connectors. Install a new drive clamp.

p0013251

13 Install the AdBlue hoses on the pump unit

according to the markings. Check that the
connection locks securely.
14 Install cable ties around the AdBlue hoses and
electrical wiring.

D
A
B C

p0013252

15 Insert the heater element into the filter cover.

Make sure that the connection locks securely.

p0013254

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25-8 Emission After-Treatment

16 Connect the battery negative terminal.

17 Program the new pump unit with the aid of
VODIA.
18 Start the engine and check that there are no
leaks. Carry out a function test.
19 Delete any fault codes.
20
NOTICE! Gather up equipment and surplus
AdBlue solution.

p0013223

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 25-8 Emission After-Treatment

Pump Unit, Change

TAD1670VE, TAD1671VE, TAD1672VE,
TWD1672GE, TWD1673GE

1 NOTICE! Wait at least 2 minutes after engine

stop to give the automatic drainage function time
to complete operations. Make sure the system is
depressurized before beginning to remove
components.
2 Disconnect the connector.

P0025290

3 Remove the hoses.

P0019394

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25-8 Emission After-Treatment

4 Remove the pump.

5 Install the new pump in reverse order.

P0025291

6 Run the Urea pressure build up test.

Check that there are no leaks.

Combined Tank Unit, AdBlue/DEF

Tank, Change
TAD1660VE, TAD1661VE, TAD1662VE,
TWD1663GE
1 Remove the tank fitting by turning it 1/4 turn
counter clockwise. Lift the tank fitting out
carefully.
Empty the remaining AdBlue solution and
coolant.

NOTICE! Use protective equipment and an

approved recovery container.
2 Install a new seal ring in the tank fitting. Install the
new tank fitting in the AdBlue tank by twisting it
1/4 turn clockwise.
3
NOTICE! Gather up protective equipment and
surplus AdBlue solution.

p0013228

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 25-8 Emission After-Treatment

Combined Tank Unit, AdBlue/DEF

Tank, Change
TAD1670VE, TAD1671VE, TAD1672VE,
TWD1672GE, TWD1673GE

Tools:
1158957 Pliers

1158957 1 NOTICE! Wait at least 2 minutes after engine

stop to give the automatic drainage function time
to complete operations. Make sure the system is
depressurized before beginning to remove
components.

p0013226
P0013226

2 Pinch off the coolant hoses (B).

3 Remove the hoses. Seal the connectors (A) in a
plastic bag.

P0019367

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25-8 Emission After-Treatment

4 Remove the hose clamp.

Lift out the tank fitting.
5 Install the new tank fitting in reverse order.

P0025293

6 Run the Urea pressure build up test.

Check that there are no leaks.

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 25-8 Emission After-Treatment

Temperature Sensor, Change

TAD1660VE, TAD1661VE, TAD1662VE,
TWD1663GE

Tools:
88890102 Nipple
88890104 Pump
1 Install an M8 X 100 bolt with a non-locking nut in
each of the 4 holes beneath the pump.
Adjust the bolts so that the pump is held stably.

p0013258

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25-8 Emission After-Treatment

2 Clean around the pump cover. Remove the pump

cover.

p0013259

3 Remove the connector and the sensor.

p0013260

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 25-8 Emission After-Treatment

4 Install the new sensor. Use soapy water on the

O-ring.
IMPORTANT!
Do not touch the sensor! The sensor is easily
damaged so check thoroughly to ensure the
pressure surface is undamaged and free of
defects. Do not touch the surface either!
5 Check the cover seal; if the seal is damaged the
cover must be changed.
6 Remove all M8 X 100 bolts.

p0013261

7 Remove the valve underneath the pump.

p0013264

8 Install pressure test nipple A = 88890102.

A
Pressure test using B = 88890104 to 0.2–0.3
bar. Check for any leaks by spraying soapy water
around the cover and valve connections that
protrude from the housing.
9 Remove the pressure test tool and install a new
valve.

B
p0013265

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25-8 Emission After-Treatment

Checking for diesel or oil in the

AdBlue/DEF solution
TAD1660VE, TAD1661VE, TAD1662VE,
TAD1670VE, TAD1671VE, TAD1672VE,
TWD1663GE, TWD1672GE, TWD1673GE

1 Remove the insertion in the tank inlet for better

visibility and access to the fluid.

P0019380

2 Dip the indicating paper in the AdBlue/DEF solution

in the tank by halves.
3 Attach the indicating paper to a suitable stick to
reach down to the surface.

Evaluation
• If there is diesel or oil in the fluid, the dipped part of
the paper will turn dark blue.
• As small amount of diesel as down to 0,5 % can be
detected.
• Most of the diesel will stay on the surface of the
P0020548 AdBlue/DEF solution, but traces of diesel can be
found throughout the entire tank.
• The system is very sensitive for incorrect
AdBlue/DEF solution.

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 25-8 Emission After-Treatment

Checking urea concentration in the

fluid
TAD1660VE, TAD1661VE, TAD1662VE,
TAD1670VE, TAD1671VE, TAD1672VE,
TWD1663GE, TWD1672GE, TWD1673GE

Tools:
88890105 Refractometer

NOTICE! Rinse the test equipment carefully with

distilled water before use.

1 Remove the insertion in the tank inlet for better

visibility and access to the fluid.
2 Draw in a small amount of the liquid from the
surface using the pipette.
Use a clean hose as extension to the pipette if tank
level is low.

P0019380

3 Apply a drop on the viewer of the instrument

(88890105 Refractometer).

Evaluation
• The level must be exactly on the line for correct
concentration.
• The system is very sensitive for incorrect urea
solution.
• If no level is shown in the instrument it may indicate
chemical residue, such as pure water or diesel.

P0020549

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26-0 Cooling System, General

26-0 Cooling System, General

Draining the Cooling System
NOTICE! The installation implementation for
TAD1650VE may vary. The pictures do not always
correspond.

WARNING!
Do not open the coolant filler cap when the engine is
hot, except in emergencies as this could cause serious
personal injury. Steam or hot fluid could spray out.

IMPORTANT!
On engines which are to be laid up or put in storage,
the engine cooling system must not be drained. The
coolant contains corrosion-inhibiting additives.

Tools:
9996049 Draining hose

NOTICE! Do not open the pressure cap (2).

1 Remove the filler cap (1).

NOTICE! Open both the pressure cap on the

expansion tank (1) and the filler cap on the
radiator (2) on TWD engines.

TAD engines

2
1

P0002097

TWD engines

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 26-0 Cooling System, General

2 Open all drain points. Drain the coolant from the

radiator and engine block, using tool
9996049 Draining hose. The drain nipples are
situated under the radiator on the right side of the
engine block.
3 Check that all coolant drains out. Deposits may
be found inside the drain tap/plug that need to be
cleaned away. There is otherwise a risk that
coolant could remain and cause freeze bursting.
Check whether the installation has any further
taps or plugs at the lowest points of the cooling
water lines.
4 Shut any taps and check that the spring-loaded
covers on the nipples close completely. Install the
rubber plugs.

P0006865

Cooling System, Cleaning

NOTICE! The installation implementation for
TAD1650VE may vary. The pictures do not always
correspond.

WARNING!
All coolant is hazardous and harmful to the
environment. Do not consume. Coolant is flammable.

Cooling performance is reduced by deposits in the

radiator and cooling galleries. The cooling system
should be cleaned out when the coolant is changed.

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

IMPORTANT!
It is extremely important that the correct concentration
and volume of coolant is added to the system. Mix in a
separate clean vessel before filling the cooling system.
Make sure that the liquids mix.
1 Drain the cooling system. Refer to Draining the
Cooling System, page 286.
2 Put a hose into the expansion tank filling hole and
flush with clean water, according to specifications
in Technical Data, page 43, until the water
draining out is completely clear.
3 Should there still be some contamination left after
flushing for a long time, cleaning may be done
with coolant. Otherwise, continue as in stage 8
below.
4 Fill the cooling system with 15-20% mixture of
concentrated coolant. Use only Volvo Penta

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26-0 Cooling System, General

recommended concentrated coolant mixed with

clean water.
5 Drain the coolant after 1–2 days of operation.
Remove the filler cap and the lower radiator hose
if necessary to increase emptying speed.
To prevent suspended material from settling back
in the system, emptying should be done rapidly,
within 10 minutes, without the engine having
been at a standstill for a long time.
6 Flush the system immediately and thoroughly
with clean hot water to prevent dirt from settling
on the inner surfaces. Flush until the water
running out is completely clean. Make sure that
any heater controls are set to full heating during
emptying.
7 Should contamination still remain after a long
period of flushing, a clean-out may be done using
Volvo Penta radiator cleaner, followed by
treatment with Volvo Penta neutralizer. Carefully
follow the instructions on the package.
Otherwise, continue as in stage 8 below.
8 When the cooling system is completely free from
contamination, close the drain taps and plugs.
9 Refill with new, Volvo Penta-recommended
cooling fluid. Refer to Technical Data, page 43
and Coolant Level, Checking and Topping
Up, page 288.

Coolant Level, Checking and

Topping Up
NOTICE! The installation implementation for
TAD1650VE may vary. The pictures do not always
correspond.

WARNING!
Do not open the coolant filler cap when the engine is
hot, except in emergencies as this could cause serious
personal injury. Steam or hot fluid could spray out.

IMPORTANT!
Coolant filling must be performed with the engine
stopped. Fill slowly, to allow air to flow out.

Coolant Level, Checking and Topping Up

IMPORTANT!
Only use coolant recommended by Volvo Penta.

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 26-0 Cooling System, General

1 NOTICE! Open only the filler cap (1). Do not open

the pressure cap (2).

NOTICE! TWD:
The cap (2) is both filler cap and pressure cap.
2 Check that the coolant level is above the MIN
mark on the expansion tank.
3 Top up with coolant as required, so that the level
is between the MIN and MAX marks.
TWD:
Fill the expansion tank to the MAX mark on the
sight glass.
TAD engines

P0002096

TWD engines

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26-0 Cooling System, General

Filling a completely empty system

NOTICE! Mix the correct amount of coolant in
advance, to ensure that the cooling system is
completely filled. Refer to Technical Data, page 43 for
the correct coolant volume.

IMPORTANT!
Do not start the engine until the system is vented and
completely filled.
1 Check that all drain points are closed.
2 Open the filler cap (1). Do not open the pressure
cap (2).
3 Fill with coolant, so that the level is between the
MIN and MAX marks.
4 Start the engine when the cooling system has
been completely filled and vented. Open any
venting taps a short while after starting, to allow
trapped air to escape.
If a heating unit is connected to the engine cooling
system, the heat control valve should be opened
and the installation vented during filling.
TAD engines 5 Stop the engine after about an hour and check
the coolant level. Top up as necessary.

TWD engines
2 1 Open the caps to both the expansion tank (1) and
radiator (2).
1
2 Fill coolant into the expansion tank until it is
completely full.

P0002097

TWD engines

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 26-0 Cooling System, General

3 Fill the radiator. Vent via the venting nipple (3).

4 Top up until the system is completely full. Refer
to Technical Data, page 43 for the correct coolant
volume.

IMPORTANT!
Do not start the engine until the system is vented and
3 completely filled.

P0002098

Cooling System, Pressure Testing

See Cooling System, Pressure Testing, page 72.

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26-1 Radiator, Heat Exchanger

26-1 Radiator, Heat Exchanger

Radiator Assembly, Change
TWD1643GE, TWD1644GE, TWD1645GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672GE, TWD1673GE

Removal
1 Drain the coolant; refer to “Cooling system,
draining”
2 Remove the coolant pipes.
3 Remove the cable ties. Disconnect the level
sensor connector.
4 Remove the protective grille from the fan.
5 Attach a lifting strap to the lifting eyes.

P0007057

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 26-1 Radiator, Heat Exchanger

6 Remove the fixing stay bolts.

7 NOTICE! Start by only lifting high enough to
release the guide pins.

Lift away the radiator assembly.

NOTICE! Mind the fan.

P0007058

P0007059

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26-1 Radiator, Heat Exchanger

Installation
8 Carefully lift the radiator assembly with a strap
through the lifting eyes (2) so that the guide pins
(3) are in the correct position.
Lower the radiator assembly.

NOTICE! Mind the fan.

9 Install the fixing stay bolts (1).

P0007060

10 Install the protective grille for the fan

11 Install the coolant hoses.
12 Fit a new cable tie so that the hoses do not chafe.
13 Install the level sensor connector.
14 Add coolant. Vent the cooling system.
Refer to Coolant Level, Checking and Topping
Up, page 288, section Refill of empty system.

P0007057

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 26-2 Coolant Pump, Thermostat

26-2 Coolant Pump, Thermostat

Coolant Pump, Change
Removal

! CAUTION!
Disconnect power or use some other means to prevent
the engine from starting during the work.
1 Drain the coolant into a suitable container. Refer
to Draining the Cooling System, page 286.
2 Remove the drive belt shield that is installed
above the coolant pump.
3 Remove the coolant pump drive belt by placing a
pulling handle in the belt tensioner and easing the
belt tension.
Remove the drive belt from the coolant pump.
4 Remove the coolant pump and its seal.
Press the belt tensioner down so it is easier to
access the lower bolt in the coolant pump. Allow
the bolt (1) to remain in the housing.

P0007061

Installation
5 Install the coolant pump with a new seal. Use
petroleum jelly to hold the seal in place during
installation.
The screw (1) must remain in place in the housing
during installation. Tighten the bolts according to
the specification in Special Tightening
Torques, page 12.
6 Install the coolant pump drive belt.
7 Install the engine drive belt guard.
8 Refill with coolant; refer to Coolant Level,
Checking and Topping Up, page 288, section
Refill of empty system.
9 Start the engine and let it run until it reaches
normal operating temperature.
P0007062
Check that no leakage occurs. Top up with
coolant as necessary.

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26-2 Coolant Pump, Thermostat

Thermostat, Change
Tools:
9996049 Draining hose

Removal
1 Drain the cooling system; refer to Draining the
Cooling System, page 286.
Drain off coolant sufficient for its level to drop
below the thermostat housing.
2 Remove the upper belt guard; refer to 26-3, Belt
Guard.
3 Remove the thermostat housing cover.

P0004690

4 Remove the thermostat.

P0004691

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 26-2 Coolant Pump, Thermostat

Installation
5 Clean and inspect the mating surfaces for both
the thermostat and the thermostat housing cover.

P0005071

6 Install the new thermostat and a new gasket.

P0004691

7 Install the thermostat housing cover and the bolts.

8 Install the upper belt guard: Refer to 26-3, Belt
Guard.

IMPORTANT!
Ensure that engine wiring is not pinched.
9 Refill with new coolant; refer to Coolant Level,
Checking and Topping Up, page 288.
10 Start the engine and check for leaks. Pressurize
the cooling system; refer to Cooling System,
Pressure Testing, page 72.

P0004690

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26-2 Coolant Pump, Thermostat

Drive belt, change

TAD1640GE, TAD1640VE-B, TAD1641GE,
TAD1641VE, TAD1641VE-B, TAD1642GE,
TAD1642VE, TAD1642VE-B, TAD1643VE,
TAD1643VE-B, TAD1650GE, TAD1650VE,
TAD1650VE-B, TAD1651GE, TAD1651VE,
TAD1660VE, TAD1661VE, TAD1662VE,
TAD1670VE, TAD1671VE, TAD1672VE
1 Switch off at the main switch(es) and check that
the engine is not connected to voltage.
2 Remove the fan guard and fan ring round the
cooling fan.
3 Remove the belt covers.
4 Fit a 1/2” socket drive to the belt tensioner (1). Lift
the socket drive and remove the drive belt.
5 Thread the drive belt round the fan and remove
it.
6 Check that the pulleys are clean and undamaged.
7 Thread the new drive belt over the fan.
8 Lift the socket drive and install the new drive belt.
9 Install the belt guard.
10 Install the fan guard and fan ring round the cooling
fan.
11 Start the engine and perform a function check.

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 26-2 Coolant Pump, Thermostat

Drive belt, change

TWD1643GE, TWD1644GE, TWD1645GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672GE, TWD1673GE
1 Switch off at the main switch(es) and check that
the engine is not connected to voltage.
2 Remove both protective grilles, the upper and the
lower, behind the cooling fan.

P0007073

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26-2 Coolant Pump, Thermostat

3 Remove both belt guards, right and left.

Leave the cover on the right guard.

P0006869

4 Fit a 1/2” socket drive to the belt tensioner (1).

Lift the square wrench and unhook the drive belt.
5 Thread the drive belt round the fan and remove
it.
6 Check that the pulleys and idler and tensioner
rollers are clean and undamaged, especially
regarding bearings and condition.
7 Thread the new drive belt over the fan.
8 Lift the socket drive and install the new drive belt.
Check that the belt is correctly aligned on all the
pulleys.
P0006870
9 Fit the belt guards and fan cage.
10 Start the engine and perform a function check.

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 26-2 Coolant Pump, Thermostat

Belt Tensioner, Change

Right belt guard removed; refer to 26-3, Belt
Guard.

Drive belt removed; refer to Drive belt,

change, page 298.

Removal
1 Undo the three bolts that retain the belt tensioner
and return wheel. Remove the unit.
2 Unbolt the return wheel or tensioner, or replace
the complete unit.

P0004682

Installation
3 Install the tensioner complete with attachment.
Align the guide pin on the attachment to the
installation hole and tighten the bolts.
Check the condition of the drive belts.
4 Re-install the belts; refer to Drive belt,
change, page 298.

P0009982

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26-2 Coolant Pump, Thermostat

Thermostat, Function Check

Remove the thermostat, see Thermostat,
Change, page 296.
1 Place the thermostat in a big pot with water and
heat it to the opening temperature as specified in
03-2, Technical Data.

P0005072

Closed thermostat.

2 If the thermostat does not open at specified

temperature, it should be replaced.
3 Install the thermostat, see Thermostat,
Change, page 296.

NOTICE! Always use a new seal, even if the

thermostat is not replaced.

P0005073

Open thermostat.

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 26-2 Coolant Pump, Thermostat

Coolant Filter, Change

IMPORTANT!
The coolant filter must be changed at the prescribed
intervals. Failure to follow these intervals may result in
significantly reduced engine life. When working on an
engine where more than five liters (5.3 quarts) of new
coolant are being added, a new coolant filter must
always be installed.
1 Shut the filter housing tap.
2 Clean around the filter and remove it using filter
pliers.
3 Lubricate the filter gasket with petroleum jelly, or
soapy water, and fit the new filter.
Screw the filter down until the gasket just touches
the sealing surface. Then turn a further ½ turn.
4 Open the tap on the filter housing.
5 Start the engine and check for leaks.

P0007065

1 Tap open
2 Tap closed

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26-5 Charge Air Cooler with Connections

26-5 Charge Air Cooler with Connections

Lower Charge Air Cooler, Replace
TWD1643GE, TWD1644GE, TWD1645GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672GE, TWD1673GE

Removal
1 Remove the heat shield, if fitted.
2 Drain the cooling water.
3 Remove the venting hose (1).
4 Remove the screws for the flange joint (2).
5 Remove the connection pipe (3) to the charge air
cooler
6 Undo the clamp (4) to the charge air cooler.
6 5 3
7 Undo the clamp (5) to the turbocharger.
7 2 8 Remove the connection pipe (6) from the
4x turbocharger.
1
4

P0003633

9 Remove the upper attachment (7).

P0007066

The upper attachment (7) removed.

304 47702612 05-2018 © AB VOLVO PENTA

 26-5 Charge Air Cooler with Connections

10 Remove the nuts (2) under the charge air cooler

bracket.
11 Undo the hoses under the charge air cooler (1).
12 Lift away the charge air cooler.

P0007067

Installation
13 Install the charge air cooler and align the hoses
underneath (1).
14 Tighten the hose clamps.
15 Install the nuts (2) under the bracket.

P0007067

16 Install the upper attachment (7).

17 Clean and check that the mating surfaces are
unmarked (4, 5).
18 Install a new O-ring on the charge air cooler
flange joint (4).

P0007069

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26-5 Charge Air Cooler with Connections

19 Remove the connection pipe (6) from the

turbocharger.
20 Tighten the clamps (4, 5).
21 Fit a new O-ring on the connection pipe (3) to the
charge air cooler.
6 Install the pipe.
5 3
22 Tighten the flange joint (2) and clamp.
7 2
4x
1
4

P0003633

23 Install the venting hose.

24 Install the heat shield.
25 Add coolant.
Vent the cooling system.
Refer to Coolant Level, Checking and Topping
Up, page 288, section Refill of empty system.
26 Check seals.

P0007068

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 26-5 Charge Air Cooler with Connections

Upper Charge Air Cooler, Replace

TWD1643GE, TWD1644GE, TWD1645GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672GE, TWD1673GE

Removal
1 Remove the heat shield, if fitted.
2 Drain the cooling water.
3 Undo the connector (1) for the air filter sensor.
4 Remove the air filter housing and attachment
bracket (2) including inlet pipe (3) to the
turbocharger.

P0007070

5 Remove the intake manifold (4) for the charge air

cooler.
Alternatively, remove the clamp by the
turbocharger if the pipe is difficult to remove.
6 Remove the bolts to the charge air cooler side
bracket (6) and upper attachment.

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26-5 Charge Air Cooler with Connections

7 Remove the hoses (7) under the charge air

cooler.
Remove the venting hose on the charge air cooler
upper side.
8 Remove the bolts (8) below the charge air cooler.
9 Lift up and pull the charge air cooler backwards.
Remove the charge air cooler.

IMPORTANT!
The charge air cooler may not be taken apart.
Leakage risk.

P0007071

Installation
10 Check the condition of the rubber connector.
Install a new O-ring to the inlet pipe sealing
surface.

P0007072

11 Install the charge air cooler.

Install the bolts (8) underneath.
12 Install the hoses (7) under the charge air cooler.
Tighten the clamps.
13 Install the venting hose on the charge air cooler
upper side.

P0007071

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 26-5 Charge Air Cooler with Connections

14 Install the bolts to the charge air cooler side

bracket (6) and upper attachment.
15 Check the condition of the rubber connector.
Fit a new O-ring on the inlet pipe (4) to the charge
air cooler.
16 Install the inlet pipe and tighten the flange joint.

17 Install the air filter housing and attachment

bracket (2) including inlet pipe (3) to the
turbocharger.
Tighten the clamp on the turbocharger.
18 Install the air filter sensor connector (1).
19 Install the heat shield, where fitted.
20 Add coolant. Vent the cooling system.
Refer to Coolant Level, Checking and Topping
Up, page 288, Refill of empty system.
21 Check seals.

P0007070

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32-1 Alternator

32-1 Alternator
Alternator Belt, Replace
TAD1640GE, TAD1640VE-B, TAD1641GE,
TAD1641VE, TAD1641VE-B, TAD1642GE,
TAD1642VE, TAD1642VE-B, TAD1643VE,
TAD1643VE-B, TAD1650GE, TAD1650VE,
TAD1650VE-B, TAD1651GE, TAD1651VE,
TAD1660VE, TAD1661VE, TAD1662VE,
TAD1670VE, TAD1671VE, TAD1672VE

Left belt guard removed: Refer to 26-3, Belt Guard.

Coolant pump belt removed: Refer to Drive belt,

change, page 298.

Removal
1 Depress the lever.
CAUTION!
Pinch hazard. Keep fingers clear.

Wind off the belt.

P0004688

Installation
1 Check the belt tensioner pulleys.

P0004687

310 47702612 05-2018 © AB VOLVO PENTA

 32-1 Alternator

2 Depress the lever.

CAUTION!
Pinch hazard. Keep fingers clear.

Wind on the belt.

P0004688

Alternator Belt, Replace

TWD1643GE, TWD1644GE, TWD1645GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672GE, TWD1673GE

IMPORTANT!
Always replace a drive belt that appears worn or is
cracked.
1 Switch off at the main switch(es) and check that
the engine is not connected to voltage.

47702612 05-2018 © AB VOLVO PENTA 311

32-1 Alternator

2 Remove the fan cage and belt guards.

Refer to Heat Protection, page 132, exposure
section.

P0007073

P0006869

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 32-1 Alternator

3 Fit a 1/2” socket drive to the belt tensioner (1).

Lift the socket drive and hook the water pump
drive belt off.
4 Fit a 1/2” socket drive to the left belt tensioner
(2).
Press the socket drive down and remove the
alternator belt.
5 Check that the pulleys and idler and tensioner
rollers are clean and undamaged, especially
regarding bearings and condition.
6 Press the socket drive to the belt tensioner (2)
down and install the new alternator drive belt.
7 Lift the socket drive in the belt tensioner (1) and
install the water pump drive belt.
8 Install the belt guard.
P0007074 9 Fit the fan cage.
10 Start the engine and perform a function check.

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33-1 Starter Motor

33-1 Starter Motor

Starter Motor, Change
Removal
1 Disconnect system voltage from the engine.
2 Remove the heat shield, if fitted.
3 Only TWD
Remove the support plate from the lower charge
air cooler.

P0007066

4 Undo the nuts.

Remove the starter motor harness.
5 Undo the nuts.
Remove the starter motor.

P0007075

Installation
6 Fit the new ring starter motor.
Tighten the nuts.

314 47702612 05-2018 © AB VOLVO PENTA

 33-1 Starter Motor

7 Install the harness.

Tighten the nuts.

P0007075

8 Only TWD
Install the support plate for the lower charge air
cooler.
9 Install the heat shield, where fitted.
10 Check functions.

P0007066

47702612 05-2018 © AB VOLVO PENTA 315

Index
A Drive belt, change.......................................... 298, 299
About this Workshop manual..................................... 3 E
AdBlue/DEF tank heating......................................... 63 Electrically Heated AdBlue/DEF Hose, Change..... 247
AdBlue/DEF Tank, Change............................ 248, 251 Emission After-Treatment....................................... 246
AdBlue/DEF Tank, Cleaning.......................... 254, 257 Engine................................................................ 28, 80
AdBlue/DEF-Pump Filter, Change................. 262, 265 Engine Assembly.................................................... 178
Adjustment Markings.............................................. 177 Engine body............................................................. 28
Alternator................................................................ 310 Engine Complete, General....................................... 80
Alternator Belt, Replace................................. 310, 311 Engine Control Unit (ECU), Replace...................... 225
B Engine Disassembly............................................... 134
Belt Tensioner, Change.......................................... 301 Engine Fixture, Installation..................................... 133
Big end bearing, Change (all)................................... 91 Engine Fuel Filter Replacement............................. 211
Bypass Valve Oil Filter, Change............................. 199 Engine Information, General.................................... 59
Bypass Valve, Oil Cooler, Replace........................ 206 Engine oil and engine oil filter, changing................ 201
Bypass Valve, Oil Filter Bypass, Replace.............. 197 Engine Transmission................................................ 33
Exhaust Manifold, Change..................................... 227
C Exhaust Pipe (Y-pipe), Replace............................. 229
Camshaft Bearing Housing, Replace..................... 117 Exhaust Pipe, Silencer........................................... 229
Camshaft, Installation............................................. 169 Exhaust Temperature Sensor, Change.................. 259
Camshaft, Wear Check.......................................... 116 Exposing......................................................... 126, 129
Charge Air Cooler with Connections...................... 304 Exposing the Engine.............................................. 126
Charge Air Cooler, External Cleaning...................... 68
Charge Air Pipe, Leakage Check............................. 75 F
Charge Pressure, Troubleshooting.......................... 67 Fitting the Fixture.................................................... 133
Checking for diesel or oil in the AdBlue/DEF Flank Clearance, Adjustment................................. 172
solution................................................................... 284 Flywheel Bearing, Change....................................... 92
Checking urea concentration in the fluid................ 285 Flywheel, Change..................................................... 93
Combined Tank Unit, AdBlue/DEF Tank, Flywheel, Indication.................................................. 95
Change........................................................... 278, 279 Fuel Feed Pump and Filter..................................... 211
Common Interference Causes................................. 66 Fuel Feed Pump, Change...................................... 212
Compression Test.................................................... 69 Fuel Pre-filter, Change........................................... 213
Connecting Rod Bushing, Check up...................... 102 Fuel System..................................................... 40, 207
Connecting Rod, Check......................................... 101 Fuel system, bleeding.................................... 207, 208
Control System, ECM, Data Sets........................... 225 Fuel System, General............................................. 207
Coolant Filter, Change........................................... 303 G
Coolant Level, Checking and Topping Up.............. 288 Gear Ring, Fywheel: Replace.................................. 94
Coolant Pump, Change.......................................... 295 General................................................................. 3, 59
Coolant Pump, Thermostat.................................... 295 General Specifications............................................... 9
Cooling System................................................ 43, 286 General Tightening Torques....................................... 9
Cooling System, Cleaning...................................... 287 Group 21: Engine............................................... 12, 80
Cooling System, General....................................... 286 Group 22: Lubrication System.................................. 22
Cooling System, Pressure Testing................... 72, 291 Group 23: Fuel System............................................ 24
Crank Mechanism.................................................... 35 Group 25: Inlet and Exhaust System........................ 25
Crankshaft Seal, Change (front)............................... 96 Group 26: Cooling System....................................... 27
Crankshaft Seal, Change (rear)............................. 100 H
Crankshaft, Inspection.............................................. 87 Heat Protection....................................................... 132
Crankshaft, Installation........................................... 152 High-Pressure Turbo, Change............................... 238
Crankshaft, Removal.............................................. 151
Cylinder Head, Installation..................................... 166 I
Cylinder Head, Pressure Testing..................... 73, 115 Illustrations................................................................. 6
Cylinder Head, Removal........................................ 134 Injectors and Delivery Pipes................................... 214
Cylinder Liner and Pistons, Inspection..................... 80 Inlet and Exhaust Manifolds................................... 227
Cylinder Liner and Pistons, Replace (all)................. 81 Inlet and Exhaust System................................. 41, 227
Cylinder Liner, Installation...................................... 153 Installation.............................................. 233, 236, 240
D L
Dosing unit, change................................................ 260 Location of Sensors.................................................. 61
Draining the Cooling System.................................. 286 Lower Charge Air Cooler, Replace......................... 304
Draining, Fuel Duct in Cylinder Head..................... 209 Low-Pressure Turbo, Change................................ 235
Drive Belt and Alternator Belt, Inspection................. 78 Lubricating and Oil System, General...................... 195

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Lubrication Oil Pump, Change............................... 196 U
Lubrication System................................................... 38 Unit injector, Installation......................................... 175
M Unit Injector, Replace............................................. 214
Main bearing, Change.............................................. 88 Upper Charge Air Cooler, Replace......................... 307
O V
Oil cooler................................................................ 204 Valve Guides, Inspection................................ 109, 194
Oil Cooler, Pressure Testing.................................. 205 Valve Guides, Replacing........................................ 109
Oil Cooler, Replace................................................ 204 Valve Mechanism................................................... 180
Oil filter................................................................... 197 Valve mechanism..................................................... 30
Oil Filter, Check...................................................... 199 Valve Seat, Change............................................... 107
Oil Pressure Sensor, Check................................... 200 Valve Seats and Valve, Grinding............................ 112
Oil pump and Line.................................................. 196 Valve Stem Sealings, Replace............................... 114
Oil Pump, Check.................................................... 196 Valves and Unit Injectors, Adjustment.................... 180
Other Equipment...................................................... 57 Valves, Installation................................................. 105
Overview Control Valve.......................................... 195 Valves, Removal.................................................... 103
P W
Piston Cooling Jet, Installation............................... 158 Wastegate Valve, Adjustment.................................. 76
Piston Cooling Valves, Replace............................. 198 Wastegate Valve, Replace..................................... 243
Piston, Pre-installation............................................ 155 When you work with Chemicals, Fuel and
Pistons, Installation................................................ 157 Lubrication Oil, Change.......................................... 195
Pistons, Removal................................................... 149
Placement of Instrument Socket(s).................... 59, 60
Pressure Sensor, Change...................................... 268
Pump Unit, Change........................................ 271, 277
R
Radiator Assembly, Change .................................. 292
Radiator, Heat Exchanger...................................... 292
Relief Valve, Check................................................ 203
Relief Valve, Replace............................................. 197
Removal................................................. 232, 235, 239
Repair instructions.............................................. 4, 246
Replacement of Components................................... 80
S
Safety Information.................................................... 46
Safety Instructions.................................................... 46
Safety Valve, Check............................................... 203
Safety Valve, Oil Pressure, Replace...................... 198
Sensors, Adjustment................................................ 78
Sleeve for unit injector, replace...................... 115, 217
Solenoid Valve, AdBlue/DEF Tank, Change.......... 267
Special Service Tools............................................... 50
Special Tightening Torques...................................... 12
Specifications, Electrical........................................... 45
Specifications, Engine ............................................. 11
Starter Motor.......................................................... 314
Starter Motor, Change............................................ 314
T
Technical Data................................. 28, 38, 40, 41, 43
Temperature Sensor, Change................................ 281
Test and Adjustments............................................... 69
Thermostat, Change............................................... 296
Thermostat, Function Check.................................. 302
Timing Gear, Installation........................................ 159
Timing Gear, Removal........................................... 147
Timing Gear, Replace............................................ 118
Troubleshooting........................................................ 64
Turbo and supercharger......................................... 231
Turbo, Change....................................................... 231
Turbocharger, Inspection....................................... 231

318
 References to Service Bulletins

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AB Volvo Penta
Service Communication
Dept. CB22000
SE-405 08 Gothenburg
Sweden
47702612 English 05-2018