1241 WS2
Contents
1. 1500 1620 1500 1620 2100 1000 ER HER O 1800 1920 1800 1920 Highest ful load engine speed rpm 1500 1800 1500 1800 2100 1800 Dry weight ko 1230 1230 1270 1230 RE EE RE TE 2706 lbs 2706 lbs 2794 Ibs 2706 Ibs Weight TAD engines without radiator assembly and air filter Engine block Cylinder head Ke One cylinder head for all cylinders with single overhead camshaft E UE 1078 mm 42 44 MI NEE 397 mm 15 63 elle ee 135 mm 5 32 Max surface unevenness bottom surface 0 1 mm 0 004 Cylinder head bolts Number of bolts per cylinder head 38 Bal RE M16 Rus E 200 mm 7 87 Group 20 Technical data Cylinder liners RK Wet replaceable Sealing surface height above block surface 0 15 0 20 mm 0 006 0 0079 Number of sealing rings per cylinder liner 4 0 15 0 20 mm a Pistons Height above cylinder block surface 0 05 0 45 mm 0 002 0 018 Diameter combustion chamber 89 mm 3 5 Depth piston bowl 18 55 mm 0 73 E 17 5 1 17 14 E 18 5 1 Number of ring grooves 3 Frontm rking sivi se see Arrow pointing forwards Gudgeon pin diameter 55 mm 2 17 Piston rings Compression rings NUMDOT si ane EE N EE Gates 2 Piston ring clearance in groove upper compr2. Axial clearance big end crankshaft max Big end bearing radial clearance makK 2 Straightness max deviation per 100 mm 3 94 measured length ee nee nana enene Warping max deviation per 100 mm 3 94 measured length RRE 1 Marking on same side 2 The measurements apply to oiled parts Flywheel fitted Max permissible axial runout test radius 150 mm 5 91 Number of teeth on starter ring Sensor grooves on flywheel 14 Forwards 55 mm 2 165 0 35 mm 0 014 0 10 mm 0 004 0 06 mm 0 002 0 15 mm 0 006 0 20 mm 0 008 Group 20 Group 20 Technical data Lubricating system Oil grade Fuel sulphur content in per cent by weight up to 0 5 0 5 1 0 more than 1 0 Oil change interval in operation whichever reached first VDS 3 600 hours or 12 months 300 hours or 12 months 150 thours or 12 months VDS 2 and ACEA E7 VDS 2 and ACEA ES VDS 2 and Global DHD 1 2 VDS 2 and API Cl 4 2 VDS 2 and API CH 4 2 VDS and ACEA E3 2 400 hours or 12 months 200 hours or 12 months 100 hours or 12 months ACEA E7 E5 E4 200 hours or 12 months 100 hours or 12 months 50 hours or 12 months API Cl 4 CH 4 CG 4 NOTE Mineral based oil either fully or semi synthetic can be used on condition that it complies with the quality requirements above
3. NOTE For 6 and 7 liter engines equipped with low profile type oil pans the oil change interval must be halved If the sulfur content is gt 1 0 by weight use oil with TBN gt 15 2 The engine oil must fullfil both requirements For markets outside Europe API CG 4 and CH 4 can be used instead of ACEA E3 VDS Volvo Drain Specification ACEA Association des Constructeurs Europ enne d Automobiles API American Petroleum Institute Global DHD Global Diesel Heavy Duty TBN Total Base Number Viscosity Ges SAE BOL The viscosity should be selected from the adjacent ane SAP TDA SD table Note the temperatures refer to constant outside SAF n tt air temperature oc SAE ANA Refers to synthetic or synthetic based oil l c SAE 30 103 SAE 40 2H Oil Change volume including changing three filters For horizontal installation 35 litres 9 2 US gal Oil pressure Operating engine speed 1100 rpm or higher 400 550 kPa 58 80 psi Idling speed minimum nn 175 kPa 25 psi Oil filters ME AO Or 3 Full flow filter tightened 1 2 3 4 turn after fitting 2 Bypass filter tightened 3 4 1 turn after fitting 1 Oil pump Ke Dear driven 15 Technical data Group 20 Oil valves 1 Safety valve MANKING OTT Yellow Safety valve opening pressure 700 kPa 101 psi 2 Delivery valve oil cooler MAKING ii awan ajana
4. NOTE Used to draw attention to important information for facilitating work operations or handling To provide an overview of the risks you should always be aware of and the precautionary measures that should always be adopted we have listed them here A Make it impossible for the engine to start Turn off the current by means of the main switch or switches and lock it them in the OFF position before starting service work Affix a warning sign in the driver s area A As a rule all service work should be carried out when the engine is stationary Some work including certain adjustments nonetheless reguires the engine to be running Approaching an engine that is running could be dangerous Bear in mind that loose fitting clothes or long hair may get caught in rotating parts and cause serious injury If work is carried out near an engine that is run ning an incautious movement or a dropped tool could in the worst case lead to bodily harm Be mindful of hot surfaces exhaust pipes the turbocharger charge air pipes starter elements etc and hot liquids in lines and hoses on an engine that is running or has just been stopped Before starting the engine refit all guards and protective elements that were removed in the course of carrying out service work Make sure that the warning and or information decals affixed to the product are always in plain sight Replace decals that are damaged or have been painted over Never
5. 29 5 AU 1 2 1 7 mm 0 047 0 067 Wear tolerance nenn Max 1 8 mm 0 071 If the distance is greater the valve seats must be changed Valve clearances cold engine setting value ll AE A A RE EE E 0 2 mm 0 008 07 1015 EE 0 5 mm 0 020 Valve clearance cold engine check value ll nenn anal 0 15 0 25 mm 0 006 0 010 EXNAUSTU ee ee eier 0 45 0 55 mm 0 018 0 022 Group 20 Technical data Valve seats Outer diameter dimension A Standard A Ma EE EE 43 1 mm 1 697 E EI RE AE 43 1 mm 1 697 Oversize OI al 43 3 mm 1 710 2 GES iia 43 3 mm 1 710 Height dimension B LO EE 8 4 8 6 mm 0 331 0 339 EE ei Seen DE ege Ee 7 9 8 1 mm 0 311 0 319 c Valve face seat Diameter dimension C standard Fi I Ad AE Ka 43 mm 1 691 a E Ed US EA AE RE EA N EE 43 mm 1 69 zv Diameter dimension C oversize 4 V IE EE A EO TER eg 43 200 43 225 mm 1 701 1 702 O AE EE EE ee 43 200 43 225 mm 1 701 1 702 Depth dimension D Net RR EE 11 2 0 1 mm 0 441 0 004 NET TEE 11 2 0 1 mm 0 441 0 004 Seat bottom radius dimension R Oe MAX nas OR EO 0 8 mm 0 032 Exhaust MEDE nenne 0 8 mm 0 032 Dimension between valve head and cylinder head surface Ja ergeet RE EE EE 0 9 1 4 mm 0 035 0 055 NI E 1 2 1 7 mm 0 047 0 067 Valve guides Length Idette ei 83 2 83 5 mm 3 28 3 29 ESE RE a EN 83 2 83 5 mm 3 28 3 29 Inner diameter lic EE a 8 0 mm 0 032 E EI E 8 0
6. 23 12 Spray nozzle drive lubrication 13 Idler adjustable z 97 oBNSaRUNA Flank clearance adjustable intermediate gear 13 0 05 0 17 mm 0 0020 0 0067 Intermediate gear shaft journal diameter 99 99 0 01 mm 3 937 0 0004 Intermediate gear bush diameter 100 04 0 01 mm 3 939 0 0004 Radial clearance for intermediate max diameter 0 03 0 07 mm 0 0012 0 0028 Axial clearance for intermediate gear 0 07 0 17 mm 0 0028 0 0067 10 Group 20 Technical data Camshaft Checking camshaft setting The engine should be cold and the No 1 cylinder valves should be adjusted to a clearance of 0 At a flywheel position of 6 ATDC the No 1 cylinder inlet valve should have opened 1 6 0 3 mm 0 063 0 012 When checking this the timing mechanism must be rotated in the right direction clockwise viewed from the front to take up any backlash NOTE Do not forget to adjust the valve clearance back to the correct value after the test BI VR ER N N Gears Number of bearings 7 Diameter of journals standard 70 mm 2 76 Diameter of journals undersize eege NE 69 720 69 780 mm 2 7449 2 7472 O50 NEEN 69 470 69 530 mm 2 7350 2 7374 eege ber TEO 69 220 69 280 mm 2 7252 2 7276 Wear tolerances Axial Clearance max ee Re nennen 0 35 mm 0 0014 Radial clearance Max e
7. A A General instructions WARNING Under no circumstances should the engine s pressure pipes be bent or reshaped Damaged pipes must be changed All fuels and many chemicals are flammable Make sure that they cannot be ignited by a naked flame or spark Petrol certain diluents and hydrogen from batteries when mixed with air in the right proportions are highly flammable and explosive No smoking Arrange for ad equate ventilation and take the necessary safety measures prior to the start of welding or grind ing work in the vicinity Always keep a fire ex tinguisher easily accessible at the workplace Ensure that rags saturated with oil and fuel as well as used fuel and oil filters are kept in a safe place prior to their disposal Under certain conditions spontaneous combustion can occur in oil ingrained rags Used fuel and oil filters comprise environmentally hazardous waste and together with used lubricating oil contaminated fuel residual paint solvents degreasants and residual detergents should be taken to a suit able plant for destruction Batteries should never be exposed to naked flames or electric sparks Never smoke near the batteries When the batteries are being charged they give off hydrogen which when mixed with air forms oxyhydrogen gas This gas is highly flammable and extremely explosive A spark which can occur if the batteries are connected incorrectly could cause a battery to explode with injury
8. M10x80 mm Timing 35 3 Nm BO EE 1 1548 Nm 1 1543 Nm 2 1207 EE 2 120 45 15 48 Nm 1207 5 645 25 Nm 24 4 Nm 25 Technical data Piston cooling nozzle NOTE The piston cooling nozzle retaining bolt has a friction coating and can be used only once N IMPORTANT Incorrect piston cooling always leads to seizing of the piston or pistons If it is suspected that the piston cooling nozzle could be damaged or deformed it must be changed This applies to new nozzles also Always check that the piston cooling nozzle is correctly loca ted in the hole in the cylinder block and that the retaining plate lies flat against the cylinder block If the piston cooling nozzle is not correctly fit ted engine breakdown when under load will be the immediate result Delivery oil pipe Tighten to O clearance and then angle tighten 60 for a used delivery oil pipe and 180 for a new delivery oil pipe 26 Group 20 Group 20 Technical data Cover oil cooler Always use locating pins when positioning the cover on the engine 1 Insert screws A and B to align the cover Tighten screws C and D Insert all screws tighten the screws in numerical order from the center outwards in accordance with the diagram 1 4 4 Check screws C and D for tightness 27 Technical data Group 20 Fuel l
9. camshaft rocker arm shaft page 23 Timing cover upper see tightening diagram Timing cover upper page 25 Timing gear incl toothed wheel see tightening diagram Timing gear page 25 Timing plate see Timing plate page 24 Group 22 Oil nozzle in timing gear see Timing gear page 25 Oil cooler retaining bolts Cover oil cooler see tightening diagram Cover oil cooler page 27 Delivery oil pipe see Delivery oil pipe page 26 Bolt piston cooling nozzle see Piston cooling nozzle page 26 Drain plug oil SUMP c cee ee ee Re nennen Group 23 Bolt retaining yoke unit injector new copper sleeve First tightening Undo the bolt for the unit injector retaining yoke before the second tightening Second tightening SAGE Lanasan e aa iia Bolt retaining yoke unit injector old copper sleeve Lock nut for adjusting screw unit injector Nut connection unit injector Clamping and tightening torques for fuel lines see Fuel lines page 28 IMPORTANT Pay attention and do NOT tighten the nut for the electrical Nm 34 4 3444 2744 24 44 180 new pipe 2444 60 10 20 5 20 5 20 5 52 4 1 5 0 5 kgfm Angle tightening 3 4 0 4 3 4 0 4 2 7 0 4 60
10. mm 0 032 Height above cylinder head spring plane vi 26 5 0 4 mm 1 04 0 016 EXNAUSE EE EE EE 18 5 0 4 mm 0 73 0 016 Clearance valve stem guide has AA ER OR rea ee 0 03 0 05 mm 0 001 0 002 Wear tolerance AA 0 2 mm 0 008 EXMAUSU OE RE UE PET EP RAT 0 04 0 07 mm 0 002 0 003 Wear tolerance 0 3 mm 0 012 1 Max permissible clearance between valve stem and valve guide according to the method described in Service Manual Engine Group 21 valve guides inspection Technical data Group 20 Valve springs Valve springs exhaustinlet Valve springs Length without load 72 73 mm 2 8 2 9 With 600 N 61 2 kgfm 134 6 Ibs load 56 mm 2 2 With 1076 N 109 7 kgfm 241 3 Ibs load 43 mm 1 7 Rigid length max 41 mm 1 6 Inner valve spring exhaust Length without load 67 68 mm 2 6 2 7 With 243 N 24 8 kgfm 54 6 Ibs load 52 mm 2 1 With 447 N 45 6 kgfm 100 3 Ibs load 39 mm 1 5 Rigid let UC EE 36 mm 1 4 Timing Drive camshaft z 76 Drive compressor z 29 Idler z 83 Drive coolant pump z 27 Drive crankshaft z 38 Drive lubricating oil pump z 23 Idler z 44 Drive hydraulic pump z 39 Idler z 71 10 Drive to belt and fuel pump z 27 11 Drive servo pump z
11. 24 20 DCAYD 27 20 DCAYD Lubrication system Force feed lubrication Max permissible axial clearance 0 16 mm 0 0063 Max permissible radial clearance turbocharger side 0 45 mm 0 0177 Pressure drop indicator Air filter TAD1240 42GE TAD1241 42VE TWD1240VE Level for indication VACUUM 500 mm 19 7 w g Exhaust back pressure Exhaust back pressure Ma esse ee 10 kPa 15 kPa 1 5 psi 2 2 psi Cooling system General ea EE EE EE GENEE Overpressure closed Pressure cap valve opens at 75 kPa 11 psi Capacity engine swasa adasa knea 20 litres 5 3 US gal Capacity engine radiator and hoses 44 litres 11 6 US gal Thermostat TAD1240 42GE TWD1240VE TAD1241 42VE BKL Piston thermostat Elle 1 Opening temperature 82 C 75 C 187 F 167 F Coolant filter Number 1 Coolant pump KEE Geared centrifugal pump 18 Group 20 Technical data Coolant ke Volvo Penta Coolant Consisting of Ethylene glycol corrosion inhibiting additives Colour EE EE EE dE Blue green MP Geb een Pure water A IMPORTANT Coolant must be mixed with pure water use distilled de ionized water The water must ful fill the reguirements specified by Volvo Penta see Water guali
12. 3 62 Undersize 025 mm 0 010 WEE 91 73 91 75 mm 3 6114 3 612 0 50 mm 0 020 u A era 91 48 91 50 mm 3 6016 3 6024 0 75 mm 0 030 91 23 91 25 mm 3 5917 3 5925 1 00 mm 00407 90 98 91 00 mm 3 5819 3 5827 1 25 mm 0 007 90 73 90 75 mm 3 5720 3 5728 Surface finish crankpin Ra 0 25 Surface finish radius Ra 0 4 Width A thrust bearing journal 56 9 57 0 mm 2 240 2 244 Fillet radius R 5 25 5 B 3 75 4 00 mm 0 148 0 158 Big end bearing shells Outside diameter B 96 85 mm 3 8130 Thickness C standard 2 39 2 40 mm 0 0941 0 0945 Oversize 0 25 mm 0 010 2 51 2 52 mm 0 0988 0 0992 0 50 mm 0 0207 2 64 2 65 mm 0 1039 0 1043 0 75 mm 0 030 zen 2 76 2 77 mm 0 1087 0 1091 a peiores nie 2 89 2 90 mm 0 1138 0 1142 A 3 01 3 02 mm 0 1185 0 1189 Diameter bearing shell seat D 96 84 96 85 mm 3 8126 3 8130 Technical data 13 Technical data Connecting rod Length centre to centre E Marking Connecting rod and cap FRONT on the shank to face Connecting rod bush inside diameter G
13. Workshop Manual Technical Data TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE Technical data Engine TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE Contents Safety information 2 IntrodueHOn NEE 2 palen pa EE 2 General information 5 About the Service Manual 5 Spare parts ese Re RA ke ee eke ee 5 Certificated engines 5 Technical data 6 References to Service Bulletins 31 Group 20 Safety information The Service Manual contains technical data descriptions and repair instructions relating to the Volvo Penta products or product versions included in the list of contents Make sure you use the right workshop literature Read the safety information General information and Repair instructions carefully before starting any service work Important The following special warning symbols occur in the Service Manual and on the product ZN WARNING Warns of the risk of injury and extensive damage to the product or property or that serious functional faults could arise if the instructions are not followed IMPORTANT Used to draw attention to any thing that could cause damage to the product or property or functional disorders in the same
14. and damage as a result Do not dis turb the connections when attempting to start risk of sparks and do not lean over any of the batteries Never mistake the positive and negative ter minals for each other when installing the bat teries If this happens it could cause serious damage to the electrical equipment Compare with the wiring diagram General instructions A A A A Always wear protective goggles when charging and handling batteries The battery electrolyte contains highly corrosive sulphuric acid If it gets on your skin wash the affected area with soap and plenty of water If the electrolyte gets in your eyes rinse them at once with plenty of water and see a doctor as soon as possible Stop the engine and cut off the current with the main switch or switches before starting to work on the electrical system The clutch should be adjusted with the engine switched off Use the lifting eyes mounted on the engine when lifting it Always check that all lifting equipment is in good condition and that it has the right capacity for the job engine weight plus reversing gear and extra equipment if any To ensure safe handling and to avoid damaging components mounted on the top of the engine it should be lifted using an adjustable lifting beam or one suitably adapted to the engine All chains or cables should run parallel to each other and as perpendicular as possible to the top of the engine If other equipmen
15. done in two stages in accordance with the tightening diagram Stage 1 Insert all of the screws screw them down until they touch the surface Stage 2 Tighten the screws in accordance with the tightening diagram to a torque of 20 2 Nm 14 7 1 5 Ib ft 30 Group 20 References to Service Bulletins Group No Date Concerning 31 Group 20 32 Group 20 Notes 33 Group 20 Report form Do you have any complaints or other comments about this manual Please make a copy of this page write your comments down and send them to us The address is at the bottom We would prefer you to write in English or Swedish AB Volvo Penta Technical Information Dept 42200 SE 405 08 G teborg Sweden 9003 50 USIBU3 3111722
16. ect the jet of water on seals rubber hoses or electrical com ponents Never use the high pressure function when cleaning the engine Group 20 General information About the Service Manual This Service Manual contains technical data for the standard versions of the TAD1240GE TAD1241GE VE TA1242GE VE and TWD1240VE engines All references from the service manuals containing repair instructions for the TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE engines will be found in the Technical data Service Manual The Service Manual is primarily produced for Volvo Penta s service workshops and their qualified person nel It is therefore assumed that persons using the manual have the necessary basic knowledge and can carry out work of a mechanical electrical nature that forms part of their occupational duties Volvo Penta is continuously developing its products and we therefore reserve the right to introduce changes and modifications All the information in this manual is based on product data available up to the time of going to press Any changes of vital import ance that have been introduced in product or service methods after that date will be announced in the form of Service Bulletins Spare parts Spare parts for the electrical and fuel systems are subject to different national safety requirements Volvo Penta Original Spare Parts meet these require ments All types of damage occurring as a result of using non ori
17. ee ech Delivery valve oil cooler opening pressure 3 5 Overflow valve oil filter full flow by pass Marking on spimg ANANA ee nennen Blue yellow Overflow valve oil filter opening pressure 110 kPa 16 psi Ane RE EE N 68 8 mm 2 71 Loaded with 25 29 N 2 5 2 9 kgf 5 5 6 4 Ibs 40 0 mm 1 58 4 Piston cooling valve Marking RE ER RE nad Orange Piston cooling valve opening pressure 200 kPa 29 psi 6 Pressure reducing valve M rking E Blue Pressure reducing valve opening pressure 480 kPa 70 psi 16 Group 20 Technical data Fuel system titty Em al P 1 E Injection order Injection Order Dee EE ESE aa 1 5 3 6 2 4 Feed pump Feed pressure after fuel filter at 1000 rpm min 350 kPa 51 psi Feed pressure after fuel filter at full load min 350 kPa 51 psi Overflow valve Opening pressure ee ee ee RR Re ee ee 400 450 kPa 58 65 psi Sensor spacing SURE N EE EE 0 3 1 0 mm 0 012 0 040 A riian 0 75 2 1 mm 0 030 0 083 Unit injectors Prestress setting with gauge 68 9 0 1 mm 2 7 120 004 17 Technical data Group 20 Inlet and exhaust system ENGINE E TAD1240GE TAD1241GE VE TWD1240VE TAD1242GE VE Turbocharger Manufacturer and type 3K Warner K31 3971 OXAKB K31 3971 QXAKB
18. el In other respects the general instructions for driving operation and maintenance given in the Owner s Man ual are applicable N IMPORTANT When spare parts are required use only Volvo Penta Original Spare Parts If non original spare parts are used AB Volvo Penta will no longer be responsible for ensur ing that the engine corresponds to the cer tificated version All types of injury damage and or costs arising due to the use of non original Volvo Penta Original Spare Parts for the product in question will not be covered under the terms of warranty as under taken by Volvo Penta Group 20 Technical data Ranra B REID SEED E ME D Di E Ke E General ees al Type designation 4 asasaran aga kawa KANEKA Kuda kt Aia An TAD1240GE TAD1241 42GE TWD1240VE TAD1241 42VE Number of cylinders asarana saka san ee ee EN NA AKAN Re ee 6 Cylinder Dore EE ng AGA Da kaga 131 mm 5 16 SU OKE EE TR ajah PG Ka 150 mm 5 91 SWeptVOlUMe deeg nee 12 13 dm 740 20 inch Number of valves 24 Direction of rotation viewed from front Clockwise Compression ratio saa saa aane aaa RA eaaa kae 18 5 1 17 5 1 18 5 1 17 5 1 lA 1 5 3 6 2 4 Slow idling speed rpm 600 1200 600 1200 600 900 600 900 Fast idling speed rpm
19. ession ing Trapezoidal section no clearance lower compression ring vertical 0 05 0 08 mm 0 002 0 0031 Piston ring gap upper compression ing 0 425 0 575 mm 0 0167 0 0226 wear tolerance ee ee ee ee 1 mm 0 04 lower Compression ring 0 8 mm 0 032 wear tolerance 1 3 mm 0 051 Oil control ring NUDO E 1 Width incl spring esse ee ee ee ee 4 3 mm 0 17 Piston ring clearance vertical 0 03 0 08 mm 0 0012 0 0031 PISTONTINO Qap ER EE Eko 0 35 0 75 mm 0 014 0 03 Technical data Group 20 Valve mechanism Valves Valve head diameter la EE OE EE ee 40 mm 1 58 EEXIMGUSE E 40 mm 1 58 Stem diameter el GE 7 960 7 975 mm 0 3134 0 3140 BXxhaust neueste net ita 7 947 7 962 mm 0 3129 0 3135 Valve face angle Mt ee namen 29 5 ER ui 44 5 Valve head face see illustration below Inlet new valve Min 1 8 mm 0 07 Weal tolerance A 1 4 mm 0 055 Exhaust new valve a s daana ada walaa dag Min 1 6 mm 0 063 Weal TOlETA NGE ese ek 1 2 mm 0 0472 Seat angle in cylinder head Net rasen A OT 30 EXNaUS Eunice 45 The valve seat should be ground down until the distance from the valve head new valve to the cylinder head surface is EE 0 9 1 4 mm 0 035 0 055 wear tolerance ee ee ee ee Ge ee ee Max 1 5 mm 0 06 1 8 mm 1 6 mm o
20. et 0 01 mm 0 0004 Valve lift A canes Sakae ege seen die eerie een 13 1 mm 0 516 EXMAUST EE 13 1 mm 0 516 Unit injector stroke 17 mm 0 669 Camshaft bearings Camshaft bearing thickness standard 1 9 mm 0 075 Oversize ORE EE teed 2 0 mm 0 079 O50 EE N EE GE aa eba 2 2 mm 0 087 ONO MAR ER kan na ORE Ee RE ERGER aan 2 3 mm 0 091 Diameter camshaft bearing housings Bearings EE 73 9 mm 2 91 11 Technical data Crank movement Crankshaft LONO sas aswatan O RA TI 1203 mm 47 36 Crankshaft axial clearance 0 10 0 40 mm 0 0039 0 0157 Main bearing radial clearance 0 01 0 15 mm 0 0004 0 0059 Max permissible ovality of main bearing journals and crankpins 0 08 mm 0 003 Max permissible conicity of main bearing journals and crankpins 0 05 mm 0 002 Max runout of centre bearing 0 15 mm 0 006 1 The dimensions apply to oiled parts Main bearing journals Diameter for machining standard 108 0 mm 4 25 Undersize 0 25 mm 0 010 107 73 107 75 mm 4 2413 4 2421 0 50 mm 0 020 sia aa ina aan jeda apan a Taek 107 48 107 50 mm 4 2315 4 2323 0 75 mm 0090 107 23 107 25 mm 4 2216 4 2224 1 00 mMM d EE 106 98 107 0 mm 4 2118 4 2126 1 25 mm 0 0503 a
21. ginal Volvo Penta spare parts for the pro duct in question will not be covered under the terms of warranty as undertaken by Volvo Penta Certificated engines For engines that are certificated in compliance with national and regional environmental legislation the manufacturer undertakes to ensure that the environ mental requirements are fulfilled both in new engines and those already in use The product must corres pond to the specimen product that was approved for certification For Volvo Penta as the manufacturer to be answerable for ensuring that engines in use meet the stipulated environmental requirements the follow ing requirements in regard to service and spare parts must be fulfilled The service intervals and maintenance measures recommended by Volvo Penta must be followed Only Volvo Penta Original Spare Parts intended for the certificated engine version may be used Service embracing injection pumps pump set tings and injectors must always be carried out by an authorized Volvo Penta workshop The engine must not be rebuilt or modified in any way except for the accessories and service kits that Volvo Penta has developed for the engine in question Installation changes to exhaust pipes and supply air ducts for the engine bay ventilation ducts must not be made indiscriminately as this could affect exhaust emission levels Security seals if any must not be broken by non authorized personn
22. ines TAD TAD A B C iN E i j N d z 5 Wi Ed e J o A Ma EZ Tu er E G IL ms El gt W a A i T F oP ft a 1 S E E d Banjo bolt 34 4 Nm 2543 Ibf ft Nipple 14 3 Nm 10 2 2 Ibf ft Overflow valve 55 5 Nm 41 3 7 Ibf ft Banjo bolt 35 4 Nm 2643 Ibf ft Nut 65 5 Nm 48 3 7 Ibf ft Nut 65 5 Nm 48 3 7 Ibf ft Banjo bolt 1542 5 Nm 11 1 8 Ibf ft H Bolt 5545 Nm 41 3 7 Ibf ft onmoou gt 28 Group 20 Fuel lines TWD 90 0 u gt E Overflow valve 55 5 Nm 41 3 7 Ibf ft Banjo bolt 35 5 Nm 26 3 7 Ibf ft Nut 65 5 Nm 48 3 7 Ibf ft Nut 65 5 Nm 48 3 7 Ibf ft Banjo bolt 15 2 Nm 11 1 5 Ibf ft 1 F Banjo bolt 34 4 Nm 2543 Ibf ft 2 G Hose connection 55 5 Nm 41 3 7 Ibf ft Technical data 29 Group 20 Exhaust manifold Stage 1 Tighten bolts 1 to 10 Nm 0 7 to 7 4 Ibf ft max Stage 2 Tighten bolts 2 to 10 Nm 1 5 to 7 4 Ibf ft max Stage 5 Tighten bolts 4 to 52 4 Nm 3 0 to 38 3 Ibf ft Stage 3 Tighten bolts 3 to 52 4 Nm 2 2 to 38 3 Ibf ft Stage 6 Tighten bolts 1 to 52 4 Nm 0 7 to 38 3 Ibf ft Stage 4 Tighten bolts 2 to 52 4 Nm 1 5 to 38 3 Ibf ft Intercooler TWD 25 Sg 24 23 22 21 120 MS Tightening diagram Tightening is
23. nne ae 106 73 106 75 mm 4 2020 4 2027 Surface finish main bearing journal Ra 0 25 Surface finish radius Ra 0 4 Width thrust bearing journal A standard 47 0 mm 1 85 Oversize 0 2 mm 0 008 thrust bearing 0 1 47 175 47 225 mm 1 8573 1 8592 0 4 mm 0 016 thrust bearing 0 2 47 375 47 425 mm 1 8652 1 8651 0 6 mm 0 024 thrust bearing 0 3 47 575 47 625 mm 1 8730 1 8750 Fillet radius A nn 3 75 4 00 mm 0 148 0 158 Thrust washers thrust bearing Width B standard 3 1 3 2 mm 0 122 0 126 Oversize OM BAR RR N ee 3 2 3 3 mm 0 126 0 130 O 2 MM 0008 Han da 3 3 3 4 mm 0 130 0 134 0 3 mm 0 012 3 4 3 5 mm 0 134 0 138 12 Group 20 Group 20 Main bearing shells Kier replaceable Outer diameter C aanaaaranen anane nenn nennen 113 0 mm 4 45 Thickness D standard 2 5 mm 0 098 Oversize 0 25 mmi 0 010 an een 2 6 2 7 mm 0 102 0 106 0 50 mmi 0 020 u a nee 2 7 2 8 mm 0 106 0 110 0 75 MI O OBO urn ea 2 8 2 9 mm 0 110 0 114 1 00 mm 0 040 ana ee 2 9 3 0 mm 0 114 0 118 1 25 mm 0 050 J ern ea 3 1 3 2 mm 0 122 0 126 Crankpins Diameter for machining standard 92 0 mm
24. result in loss of sight A Avoid getting oil on your skin Prolonged or re curring contact with oil can remove the skin s natural moisture with irritation dehydration ec zema and other skin disorders as a result From a hygienic point of view used oil is more harm ful than fresh oil Wear protective gloves and avoid clothes and rags ingrained with oil Wash yourself regularly particularly before mealtimes Use skin lotion intended for this purpose to avoid dehydration and to facilitate cleansing of the skin A Most chemicals intended for the product such as engine and transmission oils glycol petrol and diesel oil or chemicals for workshop use such as degreasants paints and solvents are injurious to the health Carefully read the ins tructions on the package Always follow the prescribed safety rules such as the use of res pirators protective goggles gloves etc Make sure that other personnel are not exposed with out their knowledge to substances that are in jurous to health such as through the air they breathe Make provision for good ventilation Deal with used and surplus chemicals in the pre scribed manner A Exercise great care when detecting leaks in the fuel system and testing fuel nozzles Wear pro tective goggles The jets from a fuel nozzle are under very high pressure and have great pen etrative power the fuel can penetrate deep into body tissues and cause serious injury Risk of blood poisoning
25. smember M14 Front engine mounting M16 Rear engine mounting flywheel housing M16 Main bearings Flywheel see tightening diagram Flywheel page 22 Flywheel housing Vibration damper inner 2 socket cap screws Stage EE Vibration damper outer or Pulley 10 bolts see tightening diagram Outer vibration damper page 24 Rocker cover see tightening diagram Rocker cover page 22 Stud rocker COVED ee ee ese ee ee Cylinder head see tightening diagram Cylinder head page 23 Stage EA RE len Stage 2 check tightening ole EE EE EE Stage 4 seine EE whan Clean out plugs cylinder head Lock nut valve adjustment bolt 20 Nm 10 1 5 24 4 48 8 85 15 140 25 Nm 180 15 220 35 220 35 150 20 120 5 275 12 245 25 140414 60245 6045 2042 4043 60 10 60 10 60 10 38 4 kgfm Angle tightening 18 0 1 5 22 0 3 5 22 0 3 5 15 0 2 0 27 5 1 2 24 5 425 14 0 1 4 6 0 0 5 90 5 6 0 0 5 90 5 2 0 0 2 4 0 0 3 6 0 1 0 6 0 1 0 90 5 90 5 6 0 1 0 3 8 0 4 Group 20 Group 20 Special tightening torques Technical data Bolts for camshaft bearing caps should be tightened in 5 stages see tightening diagram Bearing caps
26. start the engine unless the air filter is fitted The rotating impeller in the turbo could cause serious injuries Foreign objects in the in let line could additionally cause machinery dam age Never use a starter spray or the like to help start the engine It could cause an explosion in the in let manifold Danger of injury Start the engine in well ventilated premises only If the engine is run in a confined space exhaust gases and crankcase gases should be conduc ted away from the engine bay or workshop area Avoid opening the coolant filler cap when the engine is still hot Steam or hot coolant could squirt out while the built up pressure will be lost If necessary open the filler cap slowly and re lease the pressure in the cooling system Be extremely careful if a cock plug or coolant line has to be removed while the engine is still hot Steam or hot coolant could squirt out in an un expected direction Group 20 A Hot oil can cause burns Avoid getting hot oil on your skin Make sure that the lubricating system is depressurized before starting any work on it Never start or run the engine with the oil filler cap removed as oil under pressure could then escape A Stop the engine before doing any work on the cooling system A Always use protective goggles when carrying out work where splinters grinding sparks and splashes of acid or other chemicals could occur The eyes are especially sensitive and an injury could
27. t that has been connected to the engine changes its centre of gravity special lifting devices may be needed to obtain the right balance and ensure safe handling Never carry out any work on an engine that is suspended solely from a lifting device hoist etc Group 20 N Never work alone when heavy components are to be removed not even when a safe lifting dev ice like a lockable block and tackle is used Even when a lifting device is used two people will generally be required one to handle the lif ting device and the other to make sure that the components go clear and are not damaged when lifted away Always make sure in advance that there is suf ficient space for dismantling to be carried out in the area with no danger of it causing injury or material damage WARNING Electrical system and fuel system components on Volvo Penta products are de signed and manufactured to minimize the risk of explosion and fire The engine must not be run in environments where they will be surrounded by explosive media Always use fuel recommended by Volvo Penta See the Owner s Manual The use of a poorer grade of fuel could damage the engine Ona diesel engine a poor grade of fuel could lead to binding of the control rod and overrevving of the engine with a consequent risk of injury and dam age Poor fuel can also give rise to higher main tenance costs Bear in mind the following when cleaning with high pressure equipment never dir
28. ty N IMPORTANT Coolant must be used all year round This applies even if there is never any risk for frost to ensure that the engine has an adequate protection against corrosion Using anti corrosion aditive exclusively is not permitted in Volvo Penta s engines Never use water by itself as coolant Future warranty claims on the engine and additional equipment may be rejected if an unsuitable coolant has been used or if the instructions concerning coolant mixing have not been followed Water quality ASTM D4985 Total solid particles cocinan lt 340 ppm Be Re lt 9 5 dH Chloride Zi lt 40 ppm Sulfate sasa akan akanang ee ee Re Re ee ee ee ee ee lt 100 ppm PH ER AE EE naa ka era aaa 5 5 9 Silica acc ASTM D859 lt 20 mg SiO Iron acc ASTM D1068 lt 0 10 ppm Manganese acc ASTM D858 lt 0 05 ppm Conductivity acc ASTM D1125 lt 500 uS cm Organic content COD acc ISO8467 lt 15 mg KMnO l 19 Technical data Tightening torques General tightening torques M6 standard bolt 8 8 MB standard bolt 8 8 M10 standard bolt 8 8 M12 standard bolt 8 8 M14 standard bolt 8 8 Special tightening torgues Group 21 Front engine mounting cros
29. used pipe 2 4 0 4 6 0 1 0 2 0 0 5 180 5 2 0 0 5 60 5 2 0 0 5 60 5 5 20 4 0 15 0 05 connections on the unit injector to a higher torque than specified above 21 Group 20 Technical data Tightening diagram Flywheel y y LO Ze AH An N 2 Ve Rocker cover S ES S g Ss e 22 Group 20 Cylinder head 13 36 35 9 28 27 6 22 21 NH 1 Technical data BABA od EES SN 14 38 37 10 30 29 4 18 17 2 19 20 TA 8 33 34 12 Bearing caps camshaft rocker arm shaft 15 5 Nm 90 5 2 60 5 Nm 15 5 Nm 120 5 NOTE Tightening in stage 2 should be carried out gradually to ensure that the rocker arm shaft bottoms against the bearing housings without bending NOTE In stage 4 undo the marked bolts before continuing to stage 5 Ifthe rocker arm shaft has been loosened or removed only the bolts retaining the shaft should be tightened according to the diagram on refitting 23 Technical data Group 20 Timing plate Centre the plate using tool 9998267 No special tightening sequence for marked bolts Outer vibration damper 24 Group 20 Technical data Timing cover upper YYYYDUZ 9998628 M8 x 120 mm 9 E gt 8 M10x 100 mm M8 x 80 mm 7 iji 5 M10x 75 mm M8 x BO mm 5 2 M10x80 mm M8 x 80 mm 1 M8 x 90 mm 3 N A
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