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1241 WS1

1. 15 Group 21 Engine Crankshaft The 7 bearing crankshaft is drop forged and induction hardened on bearing surfaces and fillets The crankshaft has front and rear sealing rings and is usu ally equipped with double vibration dampers depen ding on the engine variant Camshaft The engine has a single overhead camshaft carried in seven bearing housings bolted to the cylinder head There are two bearing housing versions a production housing and a spare part housing The bearing housings are numbered from the factory and should not be mixed up if the engine is reconditio ned Also note that bearing housings and bearing caps are machined together This applies both to production versions and spare parts versions The camshaft has three cams per cylinder one for the inlet valves one for the exhaust valves and one for the unit injectors 16 Design and operation Group 21 Engine Timing drive The timing drive on the TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE engines is located at the front of the engine on a 10 mm thick steel plate All gears are helical The intermediate gears 3 7 9 13 are carried in bushes and pressure lubricated Oth er lubrication is done via a nozzle 12 Design and operation Between the cylinder block and cylinder head is an adjustable intermediate gear 13 This gear must be adjusted after every
2. NOTE Do not use air assisted tools when fitting the valve cover as this could damage the studs and the Clean the threaded holes for the removed studs in the unit injector wiring harness cylinder head Clean the studs coat them with Volvo Penta locking fluid 1610532 and tighten them to NOTE It is important that the valve cover bolts are 40 3 Nm tightened to the torque specified in the diagram to pre Fit the wiring by means of straps round the studs vent cracks in the cover and loosening of the studs If any of the valve cover studs loosened from the cy A IMPORTANT Meticulously wipe off all surplus linder head when the bolts were removed the wiring locking fluid after tightening the studs harness to the unit injectors must be checked The wire holder on the stud may have followed in the rota tion and damaged the wiring harness 49 47 Apply a 2 mm thick bead of sealant part no 11612314 in the joint between the upper timing cover and the cylinder block NOTE The valve cover must be fitted within 20 minu tes of applying the sealant Fit the front engine lifting bracket 94 Group 21 Engine Repair instructions 50 52 Pull the hose between the pipes to the crankcase breather and secure the clamps 51 Fit the water pipe to the coolant pump and the radiator Mount the upper radiator hose connection on the cylin hose connection using a new seal der head with new seals 53 TWD Fit the front water
3. NOTE Fit protective sleeve 9998249 on the unit in jectors so that they will not be exposed to impurities or damage When performing a manual compression test on the engine use 6 adapters 9998248 to avoid repeated removal and refitting of the rocker arm bridge and unit injectors as well as valve adjustment ZX IMPORTANT Make sure that the area around the unit injectors is clean before removing them Special tools 9998248 9998249 Other special equipment 9988539 Use engine jig 9998648 to secure the engine in engine stand 9986485 2 The jig can be bolted to the left hand side of the engi ne as shown in the above illustration NOTE It is important to use the number of bolts indi cated to ensure that the engine is fastened securely in position Use the bolts supplied with the jig Fit all 6 adapters 9998248 in the cylinder head 20 Group 21 Engine 2 Oil the valve yokes camshaft cams and rocker arm bridge 3 Tighten the rocker arm bridge bolts successively so that the bridge does not bend or twist see tightening diagram Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE Then tighten the bolt until it fits against the camshaft cams Then tighten according to the tightening diagram 4 Check that the valve clearance of all valves is to spe cification 5 Connect a switch to the starter motor See Instruc tions for running the starter motor 6 999 8248
4. Check the dimensions of the crankpins in regard to maximum conicity and ovality If any values exceed the maximum permitted the crankshaft must be removed and remedied See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE If uncertain also check whether the crankshaft is standard or undersize Fit new bearing shells checking that they are of the right size Make sure that the bearing shell guide pins are correctly located in the connecting rod big end and that the oil holes in connecting rod and bearing shell coincide 6 Oil the bearing shells and crankpins Fit the bearing caps and tighten the bolts to 275 12 Nm 7 Rotate the flywheel until connecting rods no 5 and 2 are in position and repeat points 2 6 8 Rotate the flywheel until connecting rods no 3 and 4 are in position and repeat points 2 6 9 Check that no big end bearing binds 10 Remove turning tool 9993590 from the flywheel hous ing and refit the covers 99 Group 21 Engine Main bearings changing all This method describes changing main bearings with the crankshaft in situ Prior conditions Oil sump removed Special tool 9993590 1 Fit turning tool 9993590 2 Remove the oil suction pipe and oil delivery pipe NOTE The oil pump need not be removed 3 Remove one main bearing cap at a time 100 Repair instructions Remove the upper bearing shell Insert a dowel in the crankshaft oil hole and roll
5. Connect compression tester 9988539 to the first cylin der and perform the test using the switch 7 Turn the engine over by means of the switch until the compression tester needle stops Note the reading 8 Perform the same test on the other cylinders 9 If the results of the compression test are OK refit the unit injectors and rocker arm bridge Adjust the valve clearances and unit injectors 10 Perform leakage and functionality checks Repair instructions Cylinder head removing ZX IMPORTANT Strict cleanliness must be observed when working on the cylinder head Dirt particles in the fuel passages could cause breakdown or malfunction of the unit injectors Special tools 9993590 9996966 9998249 9998251 9998255 9998264 9998511 9998629 Prior conditions Fuel and coolant drained See instructions in the Ser vice Manual 1 Turn off the power by means of the main switch swit ches and check that no current is supplied to the engine Undo the clamp at the turbocharger and remove the air cleaner from the bracket 3 TAD Remove the lower charge air pipe by the turbocharger 21 Group 21 Engine 3 TWD Remove the charge air pipe from between the turbo charger and the charge air cooler Remove the oil pipes from the turbocharger NOTE Exercise care so that dirt particles do not en ter the connections to the turbocharger 22 Repair instructions Remove the turboch
6. gt s 9992013 9992269 9992955 n 9996645 9996662 Pin for hydraulic cylinder 9996161 Hydraulic cylinder for changing cylin der liner timing gear and valve gui des Foot pump Spindle for fitting polygon hub and crankshaft gear Spacer for removing cylinder liner Spacer for removing cylinder liner Adapter for hydraulic cylinder 9992671 Puller for cylinder liner Pressure gauge Group 21 Engine Tools Ue 9996965 9996966 9998238 9998246 9998248 9998249 9998251 9998258 9998260 9998261 9998262 9998263 9998264 9996965 Adapter for fitting polygon hub 9998258 Tool for securing cylinder head in engine 9996966 Press tool for cylinder liner stand 9998238 Drift for changing crankshaft seal 9998260 Press tool for removing and fitting valve springs and valve guides 9998261 Drift for fitting valve guide 9998262 Drift for fitting valve guide 9998246 Tool for removing and fitting valve spring 9998248 Adapter 9998249 Protective sleeve for unit injector 9998263 Drift for removing valve guide 9998251 Protective plug for cylinder head 9998264 Lifting yoke for camshaft 9998255 Lifting tool for rocker arm bridge Group 21 Engine Tools 9998266 9998267 rn a 9998511 9998531 9998583 9998599 9998601 9998602 9998619 9998624 9998628 9998629 9998266 Sealing washer for leakage check 9998599 Cleaning kit for unit injector 9998267 Guide pins for timing plate 9998601 Securing tool for cylinder hea
7. are correctly positioned relative to each other LA WARNING To avoid injury and material dama ge the rocker arm bridge should be lifted away by two persons if no lifting device is available The rocker arm bridge weighs about 27 kg 60 Ibs 91 Group 21 Engine 39 Fit the rocker arm bridge bolts and tighten them by hand Tighten the retaining bolts for the rocker arm bridge and camshaft bearing caps to the torque specified in the tightening diagram See Cylinder head fitting step 26 40 Mount the oil pipe for the rocker arm shaft Wipe all oil off the oil pipe making sure it is completely dry Oil the hole in the rocker arm bridge Use a 1 2 short extension bar and a 12 mm socket Insert the pipe in the socket and fit a new seal on the other end of the pipe Press the pipe into the rocker arm bridge Make sure that the sealing ring ends up in the right place 92 Repair instructions 41 Adjust the valves and unit injectors See Valves and unit injectors adjusting 42 Clean the upper timing cover and the contact surfaces 43 Apply a 2 mm thick bead see illustration of sealant part no 11612314 to the timing cover and in the cor ners between the lower timing cover and the timing plate NOTE The timing cover must be fitted within 20 minutes of applying the sealant Group 21 Engine Fit the upper timing cover Insert the bolts in the cov er s slotted holes Tighten the b
8. gradable degreasers for all cleaning of engine compo nents unless otherwise expressly stated in the Servi ce Manual Take care to ensure that oils and residual detergent etc are dispatched for destruction and do not inadvertently end up in the environment Tightening torques Tightening torques for vital bolted joints that should be tightened using a torque wrench are listed in Techni cal Data Tightening torques and are also given in the Service Manual s work descriptions All tightening tor ques refer to cleaned threads bolt heads and contact surfaces as well as lightly oiled or dry threads If lubri cants thread locking compounds or sealants are re quired for bolted joints the type concerned is stated in the work description and in Tightening torques The general tightening torques in the table below are appli cable to bolted joints for which no special tightening torque is specified The tightening torque is a guiding value and the joint need not in such case be tightened using a torque wrench Size Tightening torque Nm Ibf ft M5 6 4 4 M6 10 7 4 M8 25 18 4 M10 50 36 9 M12 80 59 0 M14 140 103 3 Group 21 Engine Torque angle tightening In torque angle tightening the bolted joint is tightened to a specified torque and then additionally tightened through a predetermined angle Example at 90 angle tightening the joint is tightened an additional 1 4 turn after the specified tightening torque has been re
9. 107 General information 0 ccccceeeseeeeesteeeeeeneeeeeeaes 5 l Instructions for running the starter motor 18 M Main bearings changing eeeeeeeeeseeeeereeern 100 oO Other special equipment ceeeeeeseeeeeteeeetees 12 P Piston changing seesi a 70 PISOS oir EA ET 15 R Repair instructions cccceecseeeeeeeeeesneeeeeeeeeenaees 6 Rocker arm mechanism Changing eeee 59 S Safety information seeeeeeeeeeseeerreerrereereesrrneee 2 Special tOO S iore ainei iiiaae iii aas 9 T TIMING OnE eea e a A a ed 17 Timing gear changing ccceeeeeeeeeeeeeeeeeeetneeeees 72 V Valve guides changing cceeeeseeeeeeeeeetneeeeees 56 Valve guides inspecting 0 0 0 0 eeeeeeeeeeeeeeeeteeeeeees 55 Valve seat changing ceeeeceeeeeeeeeeeeeeeteetteeeees 57 Valve seat grinding ecceeeeeeeeesseeeeeeeeeeetneeeeeeeeeed 58 Valves and unit injectors adjusting ee 60 Valves grinding 0 eeeeeeeeeeeeeeeneeeeeeeeeeneeeeeeeenea 59 W When work involves chemicals fuel and lubricating oil i e 19 109 Notes Report form Do you have any complaints or other comments about this manual Please make a copy of this page write your comments down and post it to us The address is at the bottom of the page We would prefer you to write in English or Swedish AB Volvo Penta Customer Support Dept 42200 SE 405 08 Gothenburg Sweden 9
10. 3 If grinding causes sharp edges to form at the inlet holes of the oil channels they can be removed with a grinding pin or emery cloth 4 Check that the shaft is free from grinding burns 5 Check the longitudinal curvature runout of the shaft see point C 6 Check for cracks see point D 7 Overlapping of bearing races Check that smoothness requirements for bearing races and radii are fulfilled See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE 8 After grinding the shaft including oil channels must be thoroughly cleaned from grindings and impurities For efficient cleaning of all oil channels the crank shaft is equipped with threaded plugs The plugs are removed during cleaning and refitted afterwards Group 21 Engine Big end bearings changing all Special tool 9993590 Prior conditions Cylinder head and oil sump removed 1 Fit turning tool 9993590 and rotate the flywheel until the big end cap on connecting rods no 1 and no 6 come into position for removing the bolts 2 Remove the big end caps on connecting rods no 1 and no 6 Remove the bearing shells and clean the bearing seat in the connecting rod and cap NOTE The bearing caps are numbered according to their respective connecting rod 3 Inspect the crankpins and bearing shells If any bearing has seized the cause must be deter mined before new bearing shells are fitted Repair instructions 4
11. 9696 980 9697 980 9698 980 9699 980 9700 980 9701 Fit the cylinder head in an engine stand 2 Remove the valve yoke NOTE Mark the yoke so that it can be refitted at the same place 3 Remove the exhaust manifold See Group 25 Gas ket exhaust manifold changing 4 Remove the thermostat housing and piston thermo stat See Group 26 Piston thermostat changing 5 Remove the cylinder head from the engine stand 6 Thoroughly wash and clean the cylinder head 7 Fit the cylinder head in the engine stand Repair instructions 980 9699 960 S696 80 D et 980 9700 Clean the contact surfaces of the cylinder head Fit sealing washers 9998266 and 980 9696 on the cy linder head with cylinder head bolts 13 bolts and 13 M16 nuts Fit sealing washer 980 9697 with plug 980 9701 in pla ce of the thermostat housing Fit sealing washer 980 9699 in the hole for the tempe rature sensor at the back edge of the cylinder head If the area in which the thermostat sits is to be check ed for leakage fit sealing washer 980 9698 and clamp 980 9700 Remove the pipe connections on the cylinder head and fit plugs A and B in the holes see illustration 49 Group 21 Engine Checking test equipment 9 Repair instructions Leakage check 11 Check that the cock on the reducing valve A is unscrewed and attach leakage check tool 9996662 to the pneumatic system Open the co
12. 9992564 Stationary engines 9992269 Mobile engines drift to pry out the bearing 1 2 Fit a new flywheel bearing using 9992269 and a plas tic mallet 2 Fit the new flywheel bearing with drift 9992564 and handle 9991801 105 Group 21 Engine Flywheel marking Checking axial runout Special tool 9993590 Other special equipment 9989876 9999696 1 998 9876 PRN Mount a dial indicator 9989876 in magnetic stand 9999696 and reset the dial to zero with the tip against the flywheel 106 Repair instructions Ji z EEERELUR 2 Fit turning tool 9993590 3 Rotate the flywheel with tool 9993590 and note the max value on the dial indicator 4 See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE for measurement values If the axial runout is excessive remove the flywheel and check to see if there is any dirt or unevenness between the flywheel and the contact surface of the crankshaft 5 NOTE Do not forget to remove turning tool 9993590 from the flywheel housing and refit the covers Group 21 Engine Repair instructions Gear ring changing 1 Heat the new gear ring with a welding torch or in an oven The gear ring must be heated evenly Heat the ring to 180 2002 C 365 3922 F stopping when the po lished surfaces become blue Be careful not to heat the gear ring too much as this will result in runout Check the heating by polishing the ri
13. A IMPORTANT To avoid injury and material dama ge the rocker arm bridge should be lifted away by two persons if no lifting device is available The rocker arm bridge weighs about 27 kg 60 Ibs 30 Repair instructions 35 Check that the camshaft bearing caps are factory marked 1 7 against the relevant bearing bracket Loo sen the camshaft bearing caps by tapping them care fully with a plastic mallet NOTE The camshaft bearing caps are held in place with guide pins 36 Lift the camshaft away using lifting tool 9998264 A WARNING Bear in mind that the camshaft cams are extremely sharp A IMPORTANT To avoid injury and material da mage the camshaft should be lifted away by at least two persons if no lifting device is available The camshaft weighs about 35 kg 77 Ibs Group 21 Engine 37 Take out the lower bearing halves by tapping the bea ring brackets carefully with a plastic mallet Remove the bearing brackets and place them in the right order together with their respective camshaft be aring caps bearing halves and bolts NOTE The camshaft bearing brackets are held in pla ce with guide pins 38 Lift away the valve yokes between the inlet valves and exhaust valves for all cylinders Place them in the right order for the respective cylinder 39 GAN Bii as fi ie o Detach the electrical connections from the unit injec tors and cut the straps on the wiring LA
14. Engine Fit the radiator fan six studs 47 Fit the protective plates round the drive belts 48 Fit the radiator assembly see Radiator element changing 49 Fit the thermostat and thermostat housing with new seals Tighten by hand Fit a bolt M8 x 20 with nut washer and spacer sleeve between the lug on the ex haust manifold and the machined surface on the ther mostat housing Tighten the bolt so that the sleeve presses the thermostat housing against the piston thermostat seal Secure the thermostat housing ac cording to the tightening diagram see illustration Remove the tensioning screw 48 Repair instructions Fit the coolant pipe between the thermostat housing and coolant pump 51 Fit the exhaust manifold and turbocharger See Group 25 Gasket exhaust manifold changing 512 TAD Fit the lower charge air pipe on the turbo charger 53 Fit the inlet manifold se Group 25 Inlet manifold changing 54 Fill up with the requisite quantities of oil and coolant 55 Bleed the fuel system See Group 23 Fuel system bleeding 56 Start the engine and perform functionality and integrity checks Group 21 Engine Cylinder head leakage check Prior conditions Cylinder head removed Special tools 9996662 9998258 9998266 9998511 9998619 9998666 9998668 9996485 Other special equipment 946173 945408 955894 949873 Inclu ded in 9998666 and 9998668 980
15. See Valves and unit injectors adjusting 29 1 35 3 Nm 2 g0 25 Fit the toothed wheel and tighten according to the tightening diagram above A IMPORTANT If the toothed wheel or any of its teeth are damaged or deformed the toothed wheel must be replaced The same applies if any of the holes for the toothed wheel retaining bolts are damaged Clean the lower timing cover and apply sealant part no 1161231 4 Fit the lower timing cover in place NOTE The timing cover must be fitted within 20 minutes of applying the sealant 31 Clean the upper timing cover and the contact surfa ces 44 Repair instructions 32 Apply a 2 mm thick bead see illustration of sealant part no 1161231 4 to the timing cover and in the cor ners between the lower timing cover and the timing plate NOTE The timing cover must be fitted within 20 minutes of applying the sealant Group 21 Engine Fit the upper timing cover in place Insert the bolts in the slotted holes in the cover Screw the bolts down but do not tighten them Fit press tools 9998602 and 9998628 Screw the tools down so that the sealing surface of the valve cover against the timing cover is level with the sealing surfa ce on the cylinder head Fit the other bolts and tighten to the specified torque NOTE Leave the press tools in place Allow the sea lant to solidify for about 30 minutes Do not forget tha
16. as the manufacturer to be answerable for ensuring that engi nes in use meet the stipulated environmental require ments the following requirements as regards 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 certified engine version may be used Service involving injection pumps pump settings or unit injectors must always be performed 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 compartment ventilation ducts must not be made indiscriminately as this could affect exhaust emissions Any security se als must not be broken by non authorized person nel A IMPORTANT When spare parts are required use only Volvo Penta Original Spare Parts If non original spare parts are used AB Volvo Penta will no longer be responsible for ensuring that the engine corresponds to the certified ver sion All types of injury damage or costs arising due to the use of non original Volvo Penta spare parts for the product in question will not be cove red under the terms of warranty as undertaken by Volvo Penta Group 21 Engine Repair instructions Repair instructions The work
17. cylinder liners that are not to be removed 2 Remove the piston cooling nozzle 1 Remove the connecting rod big end cap and bearing shells 2 Press the piston up until the piston rings come above the edge of the cylinder liner Use the handle of a hammer or other wooden object Lift out the piston and connecting rod A WARNING Incorrect piston cooling leads to pis ton shearing If you believe the piston cooling nozzle could be damaged or deformed it must be replaced This also applies to new nozzles Always check that the piston cooling nozzle sits correctly in the hole on the cylinder block and that the anchor plate lies flat against the cylinder block Mount turning tool 9993590 and rotate the flywheel un til the connecting rod that is to be removed comes into position NOTE Do not forget to remove turning tool 9993590 from the flywheel housing and refit the cover If the piston cooling nozzle is not correctly fit ted there is a risk that the engine will break down immediately upon start 64 Group 21 Engine 4 9996395 Mark the position of the cylinder liner in the block Mount the tools on the cylinder head see illustration Withdraw the cylinder liner 5 Remove all sealing rings 3 from the cylinder block Cylinder liners and pistons inspecting Cylinder liners and pistons must be thoroughly clea ned before inspection and measurement Cylinder liner wear can be measured wit
18. from the driver Use tool 884994 with two M12x60 bolts 5 Remove the lower timing cover A WARNING The timing cover is heavy and calls for two persons to handle it Remove the inner vibration damper Use tool 884994 with two M12x60 bolts Group 21 Engine Repair instructions 7 9 Use turning tool 9993590 with a ratchet wrench to stop flywheel rotation Secure the ratchet wrench to the engine block 10 Remove the polygon hub using puller 884994 and 6 pcs of M10x60 mm Rotate the flywheel until the piston in cylinder No 1 is at top dead center 0 on the flywheel and the cams haft marking TDC is between the marks on the bea ring cap Remove the toothed wheel 73 Group 21 Engine 12 The numbering of the gears in the illustration refers to the text 13 Remove the intermediate gears 3 and 9 from the ti ming plate and the cylinder head s intermediate gear 13 74 Repair instructions 14 Remove the crankshaft gear 5 with a suitable puller 15 Remove the intermediate gear 7 16 Make a punch mark in the center of an M12x20 mm bolt as a guide for the puller Then place it in the shaft for the oil pump gear 6 Pull the gear off with a puller Group 21 Engine Repair instructions Cleaning checking Timing plate removing fitting 17 Fitting removing the timing plate on an existing engine block is described in Alternative 1 NOTE The timing plate shou
19. methods described in the Service Manual apply to a workshop environment The engine is there fore lifted out of place and mounted on an engine stand Unless otherwise stated reconditioning work that does not require the engine to be removed can be performed in situ using the same work methods The warning symbols found in this Service Manual see Safety information for their meaning Lv WARNING L IMPORTANT Note are by no means all embracing as we cannot of cour se foresee everything that could happen as service work is performed under the most widely varying con ditions So we can only point out the risks we feel could arise as a result of incorrect handling when wor king in a well equipped workshop using methods and tools that have been tested by us All work operations for which there are Volvo Penta special tools are described in the Service Manual using these tools Special tools have been developed to ensure as safe and efficient methods of working as possible It is therefore the obligation of anyone using tools or work methods other than those recommended by us to ensure that there is no risk of injury or materi al damage and that such use does not result in mal function In a number of cases there may be special safety ru les and user instructions for the tools and chemicals mentioned in the Service Manual Such rules and ins tructions must always be followed and there are no special instructions for them in th
20. or cracked piston ring grooves are worn or snap ring grooves are damaged 65 Group 21 Engine Cylinder liner seat reconditioning A damaged cylinder liner seat is repaired by milling the liner shoulder Compensation is made for the ma terial removed through milling by using shims which are found in varying thickness Special tools 9992479 9996966 9998272 Other special equipment 9989876 1 Clean the liner seat and determine the extent of the damage Mount the cylinder liner without sealing rings and se cure the liner with press tool 9996966 3 x F FS ed Mount tools as shown in the illustration Measure the height of the cylinder liner at four different points and calculate the thickness of the shims Endeavor to use as few shims as possible NOTE Ensure that the measurements are always ta ken at the highest point of the seal face The height of the seal face must be 0 15 0 20 mm 66 Repair instructions 4 Remove the cylinder liner and roughen the cylinder li ner surface with an emery cloth 5 9989876 Secure milling tool 9998272 on the cylinder block and make sure that the feed sleeve does not press on the miller 6 Once the milling tool is secured tighten the feed bolt until it presses lightly against the miller and reset dial indicator 9989876 Group 21 Engine 7 Rotate the miller with even movements while rotating the feed sleeve NOTE Use a ratchet wrench an
21. out the bearing shell by ro tating the crankshaft in the direction of rotation using turning tool 9993590 5 Clean and inspect the bearing seat cap journal and shells If the bearing has seized the cause must be determi ned before a new bearing is fitted Group 21 Engine 6 Make sure that the right size is used when changing bearings NOTE If uncertain check the specifications to see which oversizes occur See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE Oil the journal and the new bearing shells 8 Fit the upper bearing shell by using turning tool 9993590 to rotate the crankshaft against the direction rotation with the dowel in the oil hole NOTE Check that the shoulder of the bearing shell fits correctly in the bearing seat Note that the upper bearing shells those that are to be fitted in the cylinder block incorporate oil holes 9 Fit the main bearing cap together with the lower bea ring shell Tighten in two stages Stage 1 150 20 Nm Stage 2 angle tighten to 120 5 Repair instructions 10 Change the other main bearings one at a time the same way as the first one After changing each main bearing check that the crankshaft does not bind This is done by rotating it with turning tool 9993590 11 Check the axial clearance of the crankshaft and change the axial bearing washers if the clearance is excessive or if the washers are damaged NOTE Measure th
22. pipe between the charge air cooler and the radiator hose connection 95 Group 21 Engine Repair instructions 54 55 Fit the pulley and spacer NOTE Center the holes for the studs with the pulley and spacer Fit the radiator fan drive NOTE The upper bolt also secures the upper timing cover Fit the radiator fan six studs and drive belt See Drive belts changing 96 Group 21 Engine Repair instructions 57 Fit the protective plates round the drive belts 58 Fit the radiator assembly see Radiator element changing 59 Fit the heat shield on the cylinder head 60 Fit the exhaust pipe on the turbocharger 61 Fill up with the requisite quantities of oil and coolant The coolant should be already mixed and of the cor rect quantity so that it will be known for certain that the cooling system is completely full 62 Bleed the fuel system See Fuel system bleeding 63 Start the engine and perform a functionality check 97 Group 21 Engine Camshaft inspecting and reconditioning See Crankshaft inspecting and reconditioning NOTE The axial bearing surface of the camshaft must not be grinded See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE regarding over sizes of camshaft bearings Crankshaft inspecting and reconditioning The crankshaft is induction hardened Inspecting Inspect the crankshaft very carefully to avoid unne
23. satisfactory it is important that the right types of sealants and locking fluids are used on the joints where such are required In the appropriate sections of the Service Manual we have indicated the agents used in the production of our engines Similar agents or agents with corresponding proper ties but from a different manufacturer should be used in connection with service work When using sealing agents and locking fluids it is im portant for the surfaces concerned to be free from oil grease paint and rust inhibitor They must also be dry Always follow the directions of the manufacturer regarding temperature hardening time and other ins tructions relating to the product Two different basic types of agent are used on the engine These are characterized by RTV agent Room Temperature Vulcanizing Used mostly on gaskets e g sealing gasket joints or coa ted on gaskets RTV agent is perfectly visible when the component has been dismantled and old RTV agent must be removed before the joint is sealed afresh The following agents are of RTV type Loctite 574 Volvo Penta 8408791 Permatex No 3 Volvo Penta 11610995 Permatex No 77 In all cases old sea lant can be removed with denatured alcohol Anaerobic agents These harden in the absence of air They are used when two solid parts like cast com ponents are fitted together without a gasket They are also commonly used to secure and seal plugs the th reads
24. scrat ched when the valves are fitted Group 21 Engine Valve guides inspecting Cylinder head removed Other special equipment 9989876 9999696 1 Remove the oil seal from the valve guide 2 Place the cylinder head horizontally in the stand Turn the cylinder head so that the valve heads face upwards LA IMPORTANT Do not lay the cylinder head in such a way that it rests on the valve guides see illustration point 4 3 Place a new valve in the valve guide so that the end of the valve stem is level with the edge of the guide Use a suitable counterstay for the valve stem Repair instructions 9999696 9989876 Place dial indicator 9989876 with magnetic stand 9999696 so that the tip of the dial indicator lies against the edge of the valve head Move the valve laterally in the direction of the inlet and exhaust port Note the reading on the dial indica tor 5 Check all valve guides If the reading values exceed those given in the specifications the valve guide must be replaced Clearance valve handle guide 0 04 0 07 mm 1 Max permissible clearance between valve handle and valve guide 0 03 0 05 mm 55 Group 21 Engine Valve guides changing Special tools 9996159 9996161 9996222 9998260 9998261 9998262 9998263 Removing Fit press tool 9998260 in the holes for the cylinder head retaining bolts NOTE Place washers between the nuts and the cylin der head surf
25. service measure that affects the timing It is important that the correct flank clearance is obtained between the upper and lower gears that mesh with the adjustable intermediate gear Gear camshaft z 76 Gear compressor z 29 Intermediate gear z 83 Gear coolant pump z 27 Gear crankshaft z 38 Gear oil pump z 23 Intermediate gear z 44 NOP OO Nem 8 Gear hydraulic pump z 39 9 Intermediate gear z 71 10 Gear for drive belt and fuel pump z 27 11 Gear servo pump z 23 12 Spray nozzle gear lubrication 13 Intermediate gear adjustable z 97 17 Group 21 Engine Instructions for running the starter motor A IMPORTANT Make sure that the engine cannot start when it is turned over with the starter mo tor 1 Make sure that the ignition switch is in the 0 posi tion If the ignition key is not used to start the engine ensure that the switch supplying the engine with the start signal is in the OFF position 2 Connect a switch between the ground terminal and the starter relay see illustration NOTE Do not run the starter motor for longer than 15 seconds at a time Allow the batteries and starter mo tor to rest for 1 minute before trying to start the engine again 3 Disconnect and remove the switch once you have finished running the starter motor 18 Design and operation Group 21 Engine Repair instructions Repair instructions When work i
26. the cylinder block See Group 23 Unit injectors changing 37 Group 21 Engine Repair instructions Fit four lifting eyes 9998629 and attach lifting straps Carefully lift the cylinder head into place A WARNING If no lifting device is available at 1999 bhil least four persons should carefully lift it and one Ban iil it person guide it into the correct position The cy ice z linder head weighs about 130 kg 287 Ibs Fit the securing tools as shown in the illustration A IMPORTANT Before fitting the tools Check the flatness of the tools by placing them on a flat surface If the tools do not lie flat against the cylinder head and cylinder block the cylinder head mounting will be faulty resulting in the risk of serious engine damage Clean off all paint and silicone from the contact surfaces of the tools 38 Group 21 Engine Repair instructions 6 7 Insert an M10x50 mm bolt in the upper hole of the se Check that the gasket between the cylinder head and curing tool at the timing plate to ensure that the cylin timing plate is correctly positioned der head abuts the tool Lower the cylinder head until the guide pins for the cy 8 linder head gasket in the block guide the cylinder head straight down Do not lower the cylinder head all the way down but leave it suspended a few inches above the surface of the block Press the cylinder head diagonally forward by hand so that it is fixed in pla
27. valve seat with four spot welds MAG welding A IMPORTANT Carefully cover other parts of the cylinder head so that welding spatter cannot ad here to it Repair instructions 3 Tap out the valve seat NOTE Be careful not to damage the cylinder head 4 Clean the valve seat meticulously and examine the cylinder head for cracks 5 A i y Measure the diameter of the valve seat posi tion Ascertain whether a seat of standard size or oversize is to be used Machine the seat po sition if necessary Height measurementB Inlet D12D 6 Chill the seat in dry ice to between 60 C and 70 C 76 F and 94 F and heat the cylinder head with hot water from a hose or in some other way Press the valve seat into place using a drift NOTE Turn the seat so that the seat angle faces the tool 7 Machine the seat to the correct angle and width 57 Group 21 Engine Repair instructions Valve seat grinding 1 Before grinding the valve seats check the valve guides and replace them if wear tolerances are exceeded 2 When grinding the valves seats do not take away too much material unnecessarily Take away just enough to give the valve seat the correct form and the valve head a good contact surface gaai ai Exhaust valve The new valve seat is grinded down so that the mea surement A between the cylinder head surface and the valve head surface measured with a new valv
28. 002 60 ysiibuy ZOLLYZZ
29. IMPORTANT Exercise care when handling the unit injectors as they can easily sustain damage if the nuts are cross threaded or tightened too hard Repair instructions Remove the wiring bracket on the cylinder head and carefully withdraw the unit injector wiring harness NOTE The wiring harness cannot be taken apart at the wiring bracket but must be carefully withdrawn as a complete unit 31 Group 21 Engine 41 Remove all studs 32 Repair instructions 42 43 Remove the unit injectors one at a time using tool 9998511 Carefully prise under the unit injector until it loosens Fit protective sleeve 9998249 on the unit in jectors A IMPORTANT Do NOT remove all unit injectors at the same time but remove them one by one as each protective plug is fitted in place Place the unit injectors where they cannot be dama ged Group 21 Engine Repair instructions 44 Fit protective plug 9998251 in the hole for the unit in jector in the cylinder head ZX IMPORTANT Utmost cleanliness is demanded 45 Remove all cylinder head bolts 46 Wipe up the engine oil that has collected in the bowls under the camshaft The oil could otherwise run down into the coolant passages when the cylinder head is lifted away 47 Fit four lifting eyes 9998629 and attach lifting straps Carefully lift away the cylinder head A WARNING At least four persons should careful ly lift it away if no lift
30. Insert pin 9996159 in the hydraulic cylinder Depress the valve disc using tool 9998246 Remove the valve collets Remove the valve disc the springs the valve yoke guide pins and the valves e Place the valves and springs in a marked stand so that they can be refitted in the same cylinder head places Remove the remaining valves the same way using the press tool e Remove the oil seals from the valve guides 53 Group 21 Engine Alternative removal M10 x 150 999 8506 Alternatively tool 9998506 can be used instead of the hydraulic cylinder NOTE Place the cylinder head on a clean level sur face NOTE Make sure that the cylinder head is not scrat ched when the valves are removed Valves fitting 3 Oil the valve stems and fit the valves 4 Fit the valve yoke guide pins 54 Repair instructions e Fit tool 9998335 and press the new oil seals down over the valve guides NOTE Make sure that the oil seals are firmly pressed down into place Fitthe spring or springs NOTE The exhaust valves have double springs e Fit the valve disc using the same tool as for dis mantling Carefully depress the spring springs and fit the valve collets Alternative fitting 6 M10 x 150 999 8506 Alternatively tool 9998506 can be used instead of the hydraulic cylinder NOTE Place the cylinder head on a clean level sur face NOTE Make sure that the cylinder head is not
31. Workshop Manual Group 21 TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE Workshop Manual Industrial Engines TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE Contents Safety information cccceeeeeseeeeeeneeeeteees 2 General information cccceeeeeeeeeteeeeeeees 5 Repair instructions ccc eeeeeeeeeeeeeeaees 6 Special tools ccccceceeeeeeeeeeeeeeeeeeeeeeeeseees 9 Design and Operation ENGNG aeii eet Geet E puna nee A 13 Cylinder head cccceeeceeeeeeseeeeeeneeeeeeseeeeeeneeeeee 14 Cylinder block cylinder liners ceeeeeeeeeees 15 PISTONS a aee ee e aeaa aar ETSE EAN 15 Grankshaft sis cedure idee eva aiina 16 Camshatt iesudihwntlitvicieelie aerea E 16 MUMUING ATIVE E EE E A 17 Instructions for running the starter motor 18 Repair instructions When work involves chemicals fuel and lubricating oil 2 19 Before after lifting the engine s e 19 Engine jig attaching eenen 20 Compression test cccecsceeeeeeeeeteseeeeeeeeeeeee 20 Cylinder head removing s s s 21 Cylinder head fitting removing jig 885310 eile ete rco Mines haste pelted niiat 35 Cylinder head fitting ccceeeeeeeeeteeeeeeteeeeeeee 37 Cylinder head leakage check n 49 Cylinder head valves removing fitting 53 Valve guides inspecting eeeeeeeeeeeeeeeneees 55 Valve guides Changing ceeeseeeeeeeeeennee
32. ace Tighten the nuts on the tool 2 Fit pin 9996159 in the hydraulic cylinder 3 Fit hydraulic cylinder 9996161 in tool 9998260 and press out the valve guide using drift 9998263 and foot pump 9996222 Press out the other valve guides in the same manner 56 Repair instructions Fitting 4 Oil the outside of the valve guides with engine oil be fore fitting them in place 5 6222 eT ia 8262 6161 Z malt zj 8260 ag eee TE ic F 6159 a 8262 NL aN Re 8261 a e on c o Ro Press in the valve guide for the inlet valve using tool 9998261 Press in the exhaust valve guide using tool 9998262 NOTE Tool 9998261 is marked Inl Tool 9998262 is marked Ex Keep pressing until the tool bottoms against the surfa ce of the cylinder head A IMPORTANT After changing the valve guides the cylinder head should be cleaned to prevent particles from entering the fuel chamber or oil passages Dirt particles in the fuel passages could cause a breakdown or malfunction of the unit injectors Group 21 Engine Valve seat changing Special tool 9992479 Other special equipment 9989876 9989876 9992479 The valve seats should be changed when the distance A measured with a new valve ex ceeds the value specified below Height measurement A 8 4 8 6 mm 7 9 8 1 mm Grind down the head of an old valve so that it comes about 1 3 mm further down in the seat Weld the old valve to the
33. ached all in the same operation Lock nuts Lock nuts that have been removed must not be reu sed New ones must be fitted instead as the locking characteristics of the old nuts deteriorate or are lost if used several times For lock nuts with a plastic insert e g Nylock the tightening torques in the table should be reduced if the Nylock nut has the same height or thickness as a standard all metallic hex nut Reduce the tightening torque by 25 for 8 mm or larger bolt sizes For higher or thicker Nylock nuts where the all metallic thread is as high as that of a standard hex nut the tightening torques in the table are applicable Strength classes Nuts and bolts are divided into different strength clas ses the strength class is marked on the bolt head A higher number indicates a stronger material For ex ample a bolt marked 10 9 is stronger than one mar ked 8 8 When undoing bolted joints it is therefore im portant to make sure that the bolts are refitted in their original places When fitting new bolts check the spa re parts catalogue to ensure that the correct type is used Repair instructions Sealants Several different types of sealants and locking fluids are used on the engine Their properties differ and they are intended for joints of different strengths tem perature ranges resistance to oil and other chemi cals and for the various materials and clearances in the engine For service work to be fully
34. arger Remove the rear protective plate and front heat shield from the cylinder head Group 21 Engine Repair instructions Remove the thermostat housing and take out the ther mostat 10 TAD Remove the water pipe between the thermostat hous ing and coolant pump Remove the overflow valve and fuel connection 23 Group 21 Engine Repair instructions 10 TWD 11 TWD Remove the charge air temperature sensor charge pressure sensor from the inlet manifold Remove the overflow valve 11 TAD Remove the strap and remove the charge air tempera ture sensor charge pressure sensor from the inlet ma nifold 24 Group 21 Engine Repair instructions 12 TAD 14 Remove the charge air pipe between the inlet manifold Remove the intermediate bracket and charge air cooler 15 Remove the cover from the wiring box Remove the fuel connection and temperature sensor 25 Group 21 Engine Repair instructions 16 TAD 18 Remove the protective plates round the drive belts 19 Remove the inlet manifold NOTE The inlet manifold may be difficult to remove because the sealing compound may have hardened 3 TWD 16 TWD Remove the radiator fan six studs and the drive belt See Group 26 Drive belts changing ee pe Remove the inlet manifold Remove the spacer and pulley 17 Remove the radiator assembly see Group 26 Radia tor element changing 26 Group 21 Eng
35. aturated with oil and fuel used fuel and oil filters are kept in a safe place prior to their disposal Under certain conditions spontaneous combustion can occur in oil ingrai ned rags Used fuel and oil filters are environme ntally hazardous waste and together with used lubricating oil contaminated fuel residual paint solvents degreasers and residual detergents should be taken to a suitable plant for destruc tion Batteries should never be exposed to open fla mes 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 very explosive A spark which can occur if the batteries are connected incor rectly could cause a battery to explode resul ting in injury and damage Do not disturb the connections when attempting to start risk of sparks and do not lean over any of the batte ries Group 21 Engine A Never mistake the positive and negative termin als for each other when installing the batteries This could cause serious damage to the electri cal equipment Compare with the wiring dia gram A Always wear protective goggles when charging and handling batteries The battery electrolyte contains highly corrosive sulfuric acid If it gets on your skin wash the area with soap and plenty of water If the electrolyte gets in your eyes rinse them at once with plenty of water and seek m
36. c Camshaft suiii aae aea e ieaiaia 16 Camshaft changing ccccceseseeeeseteeeeeeteeeeesaeees 84 Camshaft inspecting and reconditioning 98 Compression test ccccceceseeeeeeneeeeesneeeeeeneeeessaes 20 Connecting rod small end bush checking measurements eesriie 69 Crankshaft seal rear changing ccccceeeseeees 108 Crankshaft ccccceceeesceeeeseneeeeeeeeeeseeneeeeseneeeeseaes 16 Crankshaft inspecting and reconditioning 98 Cylinder block cylinder liners cceeceeeeeeeees 15 Cylinder head sariini aaaeaii 14 Cylinder head fitting ceceeceeeeeeeeteeeeeeteeeeeeees 37 Cylinder head fitting removing jig 885316 35 Cylinder head leakage check 49 Cylinder head removing s s s 21 Cylinder head valves removing fitting 2 00 53 Cylinder liner seat reconditioning ceee 66 Cylinder liners and pistons inspecting 2 0 65 Cylinder liners and pistons removing 00 64 Cylinder liners fitting ceeceeeeeeeeeeseeeeeeteeeeeeees 67 E Engine jig attaching eee ceeeeeeeeeeesneeeeeeeeeenaees 20 ENGING aaisa EE E ied aiid 13 F Flywheel bearings Changing seese 105 Flywheel Changing cceeessseeeeeeeeeenneeeeeeeeeeaaees 103 Flywheel Marking cccceceeeseeeeeeeeeeesneeeeeeeeesaees 106 G Gear ring changing cceeeeeeeeeeeeeteeeeeeteeeteeaeees
37. c essary reconditioning The following is involved in determining the need for reconditioning A The crankshaft must be thoroughly cleaned Mea sure the ovality wear and conicity of the crankpins See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE B Examine the bearing races for external damage Any surface damage requires regrinding of the shaft C Measure the longitudinal curvature runout of the crankshaft The shaft is placed in a pair of V blocks under the main bearing journals of no 1 and no 7 Or mount the crankshaft between centers The measurement should be taken on the fourth main bearing See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE regarding max permissible values Straightening of the crankshaft is not allowed D Check for cracks both before and after grinding Use magnetic powder to perform the check i e fluo rescent powder that is visible in ultraviolet light 98 Repair instructions Reconditioning 1 Inspection as in A D 2 Grinding to undersize in accordance with specifica tions When grinding it is importance that hole fillet radii and transitions from hole fillet radii lie with given specifications A IMPORTANT Grinding of the center crankpin requires special attention as it concerns mea surement A See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE broad axial bearing journal
38. ce by the securing tools Lower the cylinder head onto the block NOTE Be careful when moving the cylinder head so that gaskets seals are not damaged a Check that a 0 10 mm feeler gauge cannot be inserted between the securing tool and the cylinder head 39 Group 21 Engine 9 Remove the lifting tools 10 Dip the cylinder head bolts in corrosion inhibitor part no 282036 Place them in a net or the like so that surplus corrosion inhibitor can run off 11 Fit the cylinder head bolts Tighten according to the tightening diagram 13 36 35 9 28 27 6 22 21 1 15 16 3 24 24 7 31 3211 Room Ae hE ee an eee ee ee K Ae fp i i y 4 i eal Nowe ee he oA l AA i i i ales t i oe D be mie ok te ot bbi b66166 d6 fod amp G fs o 9 o fs 9 Yee iS 4 A E NS op 1 i z i ee ee N N 14 38 37 10 30 2 4 18 17 2 19 20 5 25 26 8 33 34 12 60 10 Nm 6 0 1 0 Stage 2 control tightening 60 10 Nm 6 0 1 0 Stage 3 angle tightening 90 5 Stage 4 angle tightening Instructions are also available in Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE NOTE A useful tip is to write the order of tightening on the cylinder head with a marker pen 12 Carefully pull the wiring for the unit injectors into the cylinder head Tighten the wiring bracket on the cylin der head 40 Repair instructions 13 Take protective plugs 9998251 out of the un
39. ck A and set the reducing valve so that a pressure of 100 kPa shows on the pressure gauge OBS The knob on the reducing valve can be locked by turning the snap ring axially NOTE Always follow applicable safety regulations 10 Close the cock B For the test equipment to be con sidered reliable the pressure must not sink for two minutes 50 Check that the knob on the reducing valve A is unscrewed 12 Fit the hose from the pressure gauge onto the connec tion nipple 980 9697 13 Remove the cylinder head from the engine stand 14 Lower the cylinder head into a water bath 70 C 158 F 15 Connect the leakage check equipment to the pneuma tic system 16 Open the pneumatic system and set the reducing val ve A so that a pressure of 50 kPa shows on the pressure gauge Maintain the pressure for 1 minute Group 21 Engine 17 Raise the pressure to 150 kPa Lock the reducing val ve knob with the snap ring Close the cock of the pneumatic system After one or two minutes check that the air pressure does not sink and that no air bubbles come from the cylinder head 18 Release the air pressure from the cylinder head by unscrewing the reducing valve A 9996662 Move the test equipment to the connection nipple on the thermostat housing Perform a leakage check following steps 16 and 17 20 Remove the cylinder head from the water bath 21 Fit the cylinder head in th
40. contains descriptions and repair instructions for the Volvo Penta products or product versions listed in the table of contents This manual should be used together with the Service Manual Technical data for the relevant engine Be sure to use the correct service literature Carefully read the safety information and General in formation and Repair instructions in the Service Manual before starting service work Important This following special warning symbols are found in the Service Manual and on the product AN WARNING Warns for the risk of injury damage to the product or property or that serious mal functions could arise if the instructions are not followed A IMPORTANT Used to draw attention to anyth ing that could cause injury or the malfunction of a product or property NOTE Used to draw attention to important information to facilitate work operations or handling To provide an overview of the dangers of which you should always be aware and the precautionary measu res that should always be taken 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 performed when the engine is switched off However some work such as certain adjustments requires the engine to be running Approachin
41. d 9998272 Milling tool for cylinder liner seat 9998602 Press tool 9998335 Guide sleeve for valve stem seal 9998619 Drift for sealing ring 9998487 Puller for oil filter 9998624 Securing tool for cylinder head 9998506 Tool for removing and fitting valve spring 9998628 Press tool 9998511 Crowbar 9998629 Lifting eye 9998531 Piston ring guide 9998648 Engine jig 9998583 Gauge for setting unit injector prestress 3809090 Puller polygon hub vibration damper 11 Group 21 Engine Tools Other special equipment 9988539 9989876 9999683 9999696 YS 980 9696 980 9697 980 9698 980 9699 980 9700 980 9701 9986485 Engine stand 9998668 Connection washers kits 980 9698 9988539 Compression tester 980 9700 980 9701 9989876 Dial indicator 9999683 Lever type dial gauge 9999696 Magnetic stand 9998666 Sealing washers kits 980 9696 980 9697 980 9699 Group 21 Engine Design and operation Design and operation Engine The TAD1240GE TAD1241GE VE TAD1242GE VE The unit injectors are located in the center above the andTWD1240VE are 12 liter engines with cast iron cy pistons and are run by the control module The control linder blocks and wet cylinder liners The one piece module EDC III Electronic Diesel Control is located cylinder head has a single overhead camshaft and a on the left hand side of the cylinder block unit injector for each cylinder 13 Group 21 Engine Cylinder head The cylinder head which c
42. d caps as necessary Make sure that bearings of the correct size are used and that they are fitted correctly in their seats 17 Lubricate the bearing surfaces with engine oil 18 Carefully lift the camshaft into position using lifting tool 9998264 A WARNING Bear in mind that the camshaft cams are extremely sharp A IMPORTANT To avoid injury and material da mage the camshaft should be lifted away by at least two persons if no lifting device is available The camshaft weighs about 35 kg 77 Ibs 41 Group 21 Engine 20 Repair instructions 22 Insert 7 bolts M10 x 90 mm in the holes for the rock er arm bridge having no guide sleeves Tighten to M10 standard torque 21 1 15 5 Nm 90 5 Tighten as per stage 1 NOTE Tighten one bearing cap at a time checking that the camshaft can rotate freely If it offers resis tance check the bearing cap that was last tightened 42 Fit the camshaft gear 1 23 Check and adjust the flank clearance see Timing gear changing 24 Fit the valve yokes between the inlet valves and ex haust valves for all cylinders Group 21 Engine 25 Remove the extra bolts that were fitted instead of the rocker arm bridge bolts Oil the valve yokes and camshaft cams with engine oil Lift the rocker arm bridge into place using lifting tool 9998255 Check that the valve yokes and rocker arms are correctly positioned relative to each ot
43. d fire The engine must not be run in environments in which they will be surrounded by explosive media Always use fuel recommended by Volvo Penta See the Owner s Manual Use of a lower grade fuel could damage the engine On a diesel engi ne a poor grade of fuel could lead to binding of the control rod and overrevving of the engine causing risk of injury and damage Poor fuel can also give rise to higher maintenance costs Bear in mind the following when cleaning with high pressure equipment never direct the jet of water on seals rubber hoses electrical compo nents or the radiator Never use the high pressu re function when cleaning the engine Always use protective goggles when performing work in which splinters grinding sparks and splashes of acid or other chemicals could occur The eyes are especially sensitive and an injury could result in loss of sight Avoid getting oil on your skin Prolonged or re curring contact with oil can remove the skin s natural moisture resulting in irritation dehydra tion eczema and other skin disorders From a hygienic point of view used oil is more harmful than fresh oil Wear protective gloves and avoid clothes and rags ingrained with oil Wash regu larly particularly before mealtimes Use skin lo tion intended for this purpose to avoid dehydra tion and facilitate cleansing of the skin Safety information A Most chemicals intended for the product such as engine and transmi
44. d sleeve to rotate the miller 8 When the correct height has been reached disconti nue the feed and rotate the miller a few revolutions 9 Remove the milling tool and clean the liner seat tho roughly Repair instructions Cylinder liners fitting Special tools 9992479 9996966 Other special equipment 9989876 1 Make sure that the old sealing rings in the cylinder block have been removed and that the seal faces are thoroughly cleaned Use a brass wire brush and cleaning fluid part no 11614401 Scraping tools must not be used Fit the cylinder liner without sealing rings and secure it by means of two clamps 9996966 67 Group 21 Engine 3 9989876 Mount tools 9992479 and 9999876 as shown in the il lustration Measure the height of the cylinder liner at four different points and calculate the thickness of the shims Endeavor to use as few shims as possible NOTE Ensure that the measurements are always ta ken at the highest point of the seal face Regarding the height of the seal face see Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE Mark the position of the liner rela tive to the cylinder block so that it will be correctly po sitioned on assembly 4 Remove the cylinder liner and make sure that it and any shims are kept together 68 Repair instructions Lubricate the sealing rings with the lubricant supplied in the ring packaging NOTE The violet
45. djust the flank clearance as follows Undo the adjus table intermediate gear bolts 46 Insert two 0 10 mm feeler gauges in positions A and B and rotate the camshaft in the direction of the ar row 44 Tighten the bolts on the adjustable intermediate gear lightly and check that both feeler gauges meet with the same resistance Then remove the feeler gauges Tighten the adjustable gear to the specified torque ac cording to the tightening diagram See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE Turn the adjustable intermediate gear clockwise Check the flank clearance of the intermediate gear by turning the lower gear back and forth Note the reading 81 Group 21 Engine 47 Transfer the lever type dial indicator to the camshaft gear Secure the adjustable intermediate gear by me ans of a screwdriver Check the clearance to the ad justable gear by turning the camshaft gear back and forth Compare the flank clearances with those given in the specification See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE 82 Repair instructions Remove bolts and sleeves from the camshaft gear Fit the toothed wheel on the camshaft gear Tighten the vibration damper to 35 3 Nm and then angle tigh ten to 90 5 A IMPORTANT If the toothed wheel or any of its teeth are damaged or deformed it must be changed The same applies if any of the holes for the toothed wheel
46. e meets specifications See Valve seat changing 4 The valve seat angle is checked with a valve seat gauge after a thin layer of marking paint is applied to the seat s contact surface Inlet valve 58 Group 21 Engine Valves grinding Valves sealing angles Inlet 29 5 Exhaust 44 5 1 Grind the seal face as little as possible but enough to grind away all damage 2 Check the measurement A of the valve head s edge If the measurement is less than the wear tolerance below the valve must be replaced Inlet new valve Min Exhaust new valve Min Wear limit Always replace valves with crooked valve stems 3 Check the integrity of the valves with marking paint If there is leakage grind the valve seat again but not the valve Then perform another check Repair instructions Rocker arm mechanism changing The following components are replaceable rocker arm bridge expansion plugs complete rocker arms and adjusting screws 1 Remove the rocker arms from the rocker arm bridge Mark the rocker arms so that they can be refitted in the right order 2 Clean the parts Pay particular attention to the oil pas sage in the bearing housing and the oil holes in the rocker arm bridge and rocker arms 3 Check the rocker arm bridge and ball studs for wear The threads on ball studs and lock nuts should be un damaged If the bush of any rocker arm is worn oval t
47. e Service Manual The majority of risks can be avoided by taking certain elementary precautions and using common sense A clean workplace and a clean engine eliminate many risks of injury and faulty operation It is extremely important especially in connection with work on fuel systems lubrication systems inlet sys tems turbochargers bearings and seals to keep out dirt and foreign particles of other kinds If this is not done malfunction or a shorter repair life could be the result Our common responsibility Every engine consists of numerous interacting sys tems and components The deviation of a component from its technical specification could dramatically in crease the environmental impact of an otherwise good engine It is therefore extremely important for speci fied wear tolerances to be maintained for systems with facilities for adjustment to be correctly set and for Volvo Penta Original engine spare parts to be used The intervals in the engine maintenance schedule must be followed Certain systems such as fuel system components may require special competence and special testing equipment For environmental and other reasons cer tain components are sealed at the factory Work on these components must not be performed by persons not authorized for such work Bear in mind that the majority of chemical products if incorrectly used are hazardous to the environment Volvo Penta recommends the use of biologically de
48. e axial clearance using a dial indi cator In regard to axial clearance see Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE 12 The crankshaft axial bearing is located in the center main bearing seat NOTE The axial bearing washers are available in a number of oversizes see Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE 101 Group 21 Engine 13 Use a thin plastic or wood stick to remove the axial bearing washers in the cylinder block bearing seats NOTE The axial bearing washers are fitted in grooves in the main bearing cap 102 Repair instructions 14 Once all main bearing caps have been tightened to the specified torque check the axial clearance of the crankshaft See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE 15 Fit the oil suction pipe and oil delivery pipe See the instructions in the Service Manual 16 Remove turning tool 9993590 from the flywheel hous ing and refit the covers Group 21 Engine Repair instructions Flywheel changing 3 Special tool 9998629 Attach 2 lifting eyes 9998629 and lift away the fly wheel see illustration with a lifting strap threaded th rough the lifting eyes NOTE The flywheel weighs about 60 kg 132 Ibs 4 Thoroughly clean the crankshaft flange s contact sur face against the flywheel 5 Thoroughly clean the flywheel s contact surface against the cran
49. e engine stand 22 Dry the cylinder head with compressed air Be especi ally careful to ensure that the fuel passages are clean and dry NOTE Dirt or foreign particles in the fuel passages could damage the unit injectors Repair instructions 23 Remove all sealing washers 24 Remove the plugs for the thermostat housing and fit the pipe connections on the cylinder head 25 Fit the exhaust manifold see Group 25 Gasket ex haust manifold changing 26 Remove the seal for the piston thermostat in the cylin der head Use a suitable drift 27 x s 9998619 Clean all seal surfaces and fit a new seal on drift 9998619 NOTE Turn the sealing rind with the broad edge against the shoulder of drift 9998619 Press drift 9998619 into the cylinder head with crowbar 999851 1until drift 9998619 bottoms against the cylin der head Remove the drift and check that the seal sits correctly 51 Group 21 Engine Repair instructions 28 32 Check the seal on the piston thermostat Replace as Fit the last two bolts on the exhaust manifold necessary See Group 26 Piston thermostat chang 33 ing i Oil the handles of the valve yokes and fit them 34 Fit the new piston thermostat in the cylinder housing f f aar 30 Fit the cylinder head see Cylinder head fitting coal 8 ee Fit the thermostat housing with new seals Tighten the bolts by hand 31 Fit a bolt M8
50. e illustration re fers to the text 31 9996965 Fit adapter 9996965 and spindle 9996315 in the crankshaft journal 78 Repair instructions 32 9996222 NOTE Heat the crankshaft gear to approx 100 C 212 F Place the new heated crankshaft gear 5 on the spin dle Fit adapters 9992584 and 9996626 Fit hydraulic cylinder 9992671 Fit the nut on the spindle and tight en it Connect foot pump 9996222 to the hydraulic cyl inder and press on the heated crankshaft gear 33 Heat the oil pump gear to approx 180 C 356 F and tap it onto the oil pump using a plastic mallet Group 21 Engine 34 Oil the plain bearing fit the intermediate gear 7 and tighten to 24 4 Nm Oil the plain bearings for intermediate gears 3 and 9 Fit and tighten to 15 3 Nm Then angle tighten to 120 5 NOTE Use new bolts when refitting the intermediate gears 35 Fit the cylinder head s adjustable intermediate gears 13 Tighten the bolts by hand until they bottom against the bearing bracket 9996222 r a z T o T Fi 9996625 a Place the heated polygon hub on spindle 9996315 Fit adapter 9996626 and hydraulic cylinder 9992671 Fit the nut on the spindle and connect foot pump 9996222 to the hydraulic cylinder Press on the polygon hub NOTE Heat the polygon hub to approx 100 C 212 F 37 Secure turning tool 9993590 to the engine block with a ratchet w
51. edical attention immediately A Stop the engine and cut off the current with the main switch or switches before starting work on the electrical system A The clutch should be adjusted with the engine switched off Safety information A 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 transmission and extra equipment if any To ensure safe handling and avoid damaging components mounted on the top of the engine it should be lifted using an adjustable lifting beam or one 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 Group 21 Engine General General information About the Service Manual This Service Manual contains descriptions and repair instructions for the standard versions of the TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE engines The Service Manual may show work operations per formed on any of the engines listed above Conse quently the illustrations and photographs showing certain details may not be completely accurate in a number of cases The repair methods however are in all essentials the same The engine designation and number are given on the type plate see Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE The engine designation and number s
52. eeees 56 Valve seat changing 0 eee ceeeeeeeeeesneeeeeeeeenaeees 57 Valve seat grinding seeen 58 Valves grinding 0 0 eee eeeeeeeeeeeeeeeneeeeeeeeenaeeeeees 59 Rocker arm mechanism changing eee 59 Valves and unit injectors adjusting 0 60 Cylinder liners and pistons removing 64 Cylinder liners and pistons inspecting 65 Cylinder liner seat reconditioning 00 66 Cylinder liners fitting ccceeeeeeeeseeeeeeteeeeeee 67 Connecting rod small end bush checking Measurement cece eee eee teen ee eeeeee 69 Piston changing cceeeeeeeeeeeeeeeeeteetneeeeeeeeeeee 70 Timing gears changing seeen 72 Bearing housing for camshaft changing 84 Camshaft Changing ccccceesceeeeeseeeeteteeeteaes 84 Camshaft inspecting and reconditioning 98 Crankshaft inspecting and reconditioning 98 Big end bearings changing all scene 99 Main bearings changing all n 100 Flywheel Changing cecesscceeeeeeeeseeeeeeeeeesaes 103 Flywheel bearings Changing seese 105 Flywheel Marking cceeesseeeeeeeeeeeteeeeeeeeenaaes 106 Ring gear CHANGING eee seeeeeeeeeeetteeeeeeeeeeaes 107 Crankshaft seal rear changing cseeeeees 108 INdOX fiend ates dla aed araia a dee n 109 Group 21 Engine Safety information Safety information Introduction This Service Manual
53. ether in E rockera Daa WENS ADONE Er KONG a suitable place with the bolts in the order they were removed and will later be refitted A WARNING To avoid injury and material dama ge the rocker arm bridge should be lifted away NOTE The camshaft bearing caps are held in place with guide pins 88 Group 21 Engine 25 Lift the camshaft away using lifting tool 9998264 A WARNING Bear in mind that the camshaft cams are extremely sharp A WARNING To avoid injury and material dama ge the camshaft should be lifted away by at least two persons if no lifting device is available The camshaft weighs about 35 kg 77 Ibs 26 Remove the lower bearing halves Repair instructions 27 Fit new camshaft bearing shells in the bearing brack ets and caps as necessary Make sure that bearings of the correct size are used and that they are fitted correctly in their seats 28 Lubricate the bearing surfaces with engine oil 29 Carefully lift the camshaft into position using lifting tool 9998264 A WARNING Bear in mind that the camshaft cams are extremely sharp A WARNING To prevent injury and material dam age the camshaft should be lifted into place by at least two persons if no lifting device is avail able The camshaft weighs about 35 kg 77 Ibs 89 Group 21 Engine Repair instructions 30 33 9999520 A liti A Liia NOTE See the location of the bearing cap bolts at far right Fit
54. g a running engine could be dangerous Bear in mind that loose fitting clothes or long hair could get caught in rotating parts and cause serious injury A If work is performed near a running engine an incautious movement or dropped tool could in the worst case lead to bodily harm Be mindful of hot surfaces exhaust pipes the turbochar ger 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 star ting the engine refit all guards and protective elements that were removed in the course of performing service work A Make sure that the warning and or information decals affixed to the product are always in plain sight Replace any decals that have been dama ged or painted over A Never start the engine unless the air filter is fit ted The rotating impeller in the turbocharger could cause serious injuries Foreign objects in the inlet line could also cause machinery dama ge A Never use starter spray or the like to help start the engine It could cause an explosion in the inlet manifold Danger of injury A Start the engine in well ventilated areas only If the engine is running in a confined space ex haust gases and crankcase gases should be conducted away from the engine compartment or workshop area A Avoid opening the coolant filler cap when the engine is still hot Steam or hot coolant could squirt out while the built up pressure is l
55. ged or deformed it must be replaced This also applies to new nozzles Always check that the piston cooling nozzle sits correctly in the hole on the cylinder block and that the anchor plate lies flat against the cylinder block If the piston cooling nozzle is not correctly fit ted there is a risk that the engine will break down immediately upon start 71 Group 21 Engine Timing gears changing Prior conditions Oil sump removed front engine mountings removed valve cover removed upper timing cover removed and coolant pump removed Gear camshaft Gear compressor Intermediate gear Gear coolant pump Gear crankshaft Gear lubricating oil pump Intermediate gear Gear hydraulic pump Intermediate gear 10 Gear for drive belt and fuel pump 11 Gear servo pump 12 Nozzle gear lubrication 13 Intermediate gear adjustable OONOAPWN gt A IMPORTANT Never rotate the crankshaft or camshaft when the timing gear has been remo ved Pistons and valves could then strike each other and sustain damage Special tools 884994 9992584 9992671 9993590 9996222 9996315 9996626 9996965 9998511 9999683 9999696 Removing gears and wheels 1 Remove the outer vibration damper 2 Remove the dust excluders and holder for the crankshaft sealing ring 72 Repair instructions 3 Remove the drive take off the generator and the fuel pump Remove the seal and the two socket cap screws
56. ghtness of the connecting rod in a jig 69 Group 21 Engine Repair instructions 2 Piston changing Special tools 9991801 9992013 Measure the degree of warping of the connecting rod 1 Remove the snap rings from the old piston and tap out the piston pin using tools 9991801 and 9992013 Rem ove the connecting rod 2 Remove one of the snap rings from the new piston 70 Group 21 Engine 3 th Oil the piston pin the piston bosses and the connec ting rod small end bearing with engine oil 4 FRONT Fit the connecting rod so that the piston s arrow and the connecting rod s Front marking face the same di rection Press the piston pin in place using drift 9992013 and handle 9991801 NOTE It should be easy to press the piston pin in place It must not be driven in by force 5 Fit the other snap ring 6 Check that the top and bottom of the piston can move easily in relation to each other and that the piston pin is not a tight fit in the connecting rod small end bush Repair instructions Always use piston ring pliers when fitting removing the piston rings NOTE The two upper piston rings are marked with letters or dots The marking should face upwards NOTE New cylinder liners are delivered complete with pistons and piston rings A WARNING Incorrect piston cooling leads to pis ton shearing If you believe the piston cooling nozzle could be dama
57. h the liner mounted in the cylinder block NOTE To thoroughly check for cracks the cylinder liner must be removed from the cylinder block Mark the position of the cylinder liner with a felt tip pen before removing it so that it can be refitting in the correct position Cylinder liners 1 Check for cracks being especially thorough when checking the liner flange The magnaflux method can be used when checking for cracks Repair instructions Measure the wear of the cylinder liner with a cylinder indicator To get as precise a wear measurement as possible the cylinder indicator should first be set with a gauge ring or micrometer Use the original diameter of the cylinder liner as the base value 3 Measure the cylinder liner from both the top and bot tom and several places vertically At each measurement spot the measurement must be taken both along the engine and across it 4 If wear is greater than 0 45 0 50 mm a new complete liner kit must be used piston liner piston rings pis ton pin and seals Oil consumption is also of importance for when cylin der liners should be replaced NOTE Cylinder liners and pistons are classed to gether This means that pistons and liners must not be mixed together Pistons and cylinder liners are delivered as spare parts only in complete units Pistons 1 Pistons must be replaced if there are deep scratches in the casing surface piston ring stops are damaged
58. he entire rocker arm should be changed 4 Oil the rocker arm bridge and refit the rocker arms in the right order A IMPORTANT It is extremely important that the rocker arms and rocker arm bridge are thorough ly cleaned and lubricated with engine oil before the rocker arms and shafts are assembled 59 Group 21 Engine Repair instructions Valves and unit injectors adjusting Special tools 9993590 9998583 9999696 Other special equipment 9989876 Setting marks Setting marks for valves and unit injectors The engine is marked with numbers 1 6 for valves and unit injectors cylinder no 6 is nearest the fly wheel Each number applies to the adjustment of inlet valves exhaust valves and unit injectors for the re spective cylinders NOTE When adjusting it is important to ensure that the line marked on the camshaft is midway between the marks on the bearing cap 60 Setting mark bearing cap Adjusting general 3 The instructions cover adjustment of valves and unit injectors in the following order Exhaust valves Inlet valves Unit injectors NOTE Exhaust valves inlet valves and unit injectors are to be adjusted at the same time for each cylinder Valves and unit injectors should be adjusted in the or der as marked on the camshaft when the engine is turned over in the direction of rotation By following this order the crankshaft need not be ro tated more than two revolut
59. her A IMPORTANT To avoid injury and material da mage the rocker arm bridge should be lifted away by at least two persons if no lifting device is available The rocker arm bridge weighs about 27 kg 60 Ibs 26 NOTE Remove all adjusting screws for the valves and unit injector before fitting the rocker arm bridge Tighten the rocker arm bridge bolts by hand Tighten the retaining bolts for the rocker arm bridge and camshaft bearing caps to the torque specified in the tightening diagram NOTE The tightening in stage 2 must be done gradu ally to ensure that the rocker arm shaft bottoms against the bearing housing without the shaft bending Repair instructions NOTE In stage 4 the marked bolts are removed be fore stage 5 is performed If the rocker arm shaft has been loosened or removed only the bolts holding the shaft should be tightened as in the diagram when refit ting 1 15 5 Nm 90 5 60 gt 0 Nm 15 5 Nm 120 5 27 Mount the oil pipe for the rocker arm shaft Wipe all oil off the oil pipe making sure it is completely dry Oil the hole in the rocker arm bridge Use a 1 2 short extension bar and a 12 mm socket Insert the pipe in the socket and fit a new seal on the other end of the pipe Press the pipe into the rocker arm bridge Check that the sealing ring is correctly po sitioned 43 Group 21 Engine 28 Adjust the valves and unit injectors
60. hould always be quoted in all correspondence concerning any of the engines 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 perform work of a mechanical electrical nature that oc curs in their profession Volvo Penta is continuously developing its products and we therefore reserve the right to introduce chan ges and modifications All the information in this ma nual is based on product data available up to the time of printing Any vitally important changes to the pro duct or service methods that are introduced after that date are announced in the form of Service Bulletins Spare parts Spare parts for the electrical and fuel systems are subject to different national safety requirements Vol vo Penta Original Spare Parts meet these require ments All types of damage occurring as a result of using non original Volvo Penta spare parts for the pro duct in question will not be covered under the terms of the warranty as undertaken by Volvo Penta Certified engines For engines certified for nation and regional environ mental legislation the manufacturer undertakes to en sure that the environmental requirements are fulfilled both in new engines and those already in use The pro duct must correspond to the specimen product that was approved for certification For Volvo Penta
61. ine Repair instructions 21 23 Undo the clamps and pull away the hose between the pipes to the crankcase breather 24 Detach the water pipe from the coolant pump and radi ator hose connection Remove the radiator fan drive 27 Group 21 Engine Repair instructions 25 27 Remove the upper radiator hose connection from the cylinder head 26 Remove the valve cover NOTE Do not use air assisted tools when removing the valve cover as this could damage the unit injector wiring harness 28 Remove the front engine lifting bracket Fit turning tool 9993590 in the flywheel housing NOTE Do not forget to remove turning tool 9993590 from the flywheel housing and refit the cover 28 Group 21 Engine Repair instructions 29 31 Rotate the flywheel until the piston in cylinder 1 is at Remove the toothed wheel top dead center 0 on the flywheel and the camshaft 32 marking TDC is between the marks on the bearing cap Remove the camshaft gear 1 Use a puller if neces sary Remove the upper timing cover NOTE One of the upper timing cover retaining bolts also secures the radiator fan drive 29 Group 21 Engine Ni a Remove the supply of lubricating oil for the rocker arm bridge 34 Undo the rocker arm bridge retaining bolts evenly over the entire bridge to avoid uneven stress Lift away the rocker arm bridge using lifting tool 9998255
62. ing device is available The cylinder head weighs about 130 kg 287 Ibs 33 Group 21 Engine Repair instructions Fit press tool 9996966 on the cylinder liners so that they are not dislodged from their positions if the crankshaft is rotated 49 Remove the seals Thoroughly clean the contact surface on the cylinder block ZX IMPORTANT Make sure that no residual sea lant or dirt particles can enter the coolant and oil passages 34 Group 21 Engine Cylinder head fitting removing jig 885316 When work does not include servicing of the cylinder head or cylinder block jig 885316 can be used when replacing valves pistons cylinder head gaskets etc When performing this work the inlet manifold and camshaft can remain in place Special tools 885316 9998629 1 Remove the engine components necessary to be able to fit the jig See Cylinder head removing for instructions m i So Er a iC Remove the five bolts on the cover of the oil cooler Repair instructions Secure the bottom of jig 885316 on the oil cooler co ver 5 Secure the top of jig 885316 to the exhaust ports on cylinders 2 and 4 4 Fit the bolts and brackets on both sides of the jig NOTE The brackets work as a stop so it is important that they are fitted correctly 35 Group 21 Engine Repair instructions 6 8 Pull back the catch on the jig and carefully lower the cylinder head 9 Remove jig 885316 and
63. ings are oval so that the center bearing hous ing can be adjusted radially and the front and rear hou sings axially If the cylinder head is already fitted with exchange housings a damaged bearing housing can be changed without changing the other housings The exchange housings are recognizable by their oval holes for the guide sleeves If exchange housings are fitted mark them with num bers so that they can be refitted in the same place if they have been removed 84 See Cylinder head fitting removing Repair instructions Camshaft changing Special tools 9993590 9998255 9998264 9998602 9998628 Prior conditions Radiator assembly removed See Radiator element changing 1 Turn off the power by means of the main switch swit ches and check that no current is supplied to the engine 2 Remove the protective plates round the drive belts Remove the radiator fan six studs and remove the drive belt See Drive belts changing Group 21 Engine Repair instructions 5 7 Undo the clamps on the hose between the pipes to the crankcase breather and pull the hose to the left Detach the water pipe from the coolant pump and radi ator hose connection Remove the radiator fan drive 85 Group 21 Engine Repair instructions 9 12 Remove the upper radiator hose connection from the Remove the exhaust pipe at the turbocharger cylinder head 13 10 Remove the heat shield three b
64. ions for the adjustment of all valves and unit injectors A colored pencil can be used to mark the rocker arms that have been checked or adjusted Group 21 Engine 4 Mount turning tool 9993590 5 Check that the line marked on the camshaft is mid way between the marks on the bearing cap The num bers indicate the cylinder for which the valves can be adjusted Repair instructions Valve yoke adjusting exhaust valves Adjust the valve yoke by slackening the adjusting screw until it is clear of the valve stem 7 Screw in the adjusting screw until it reaches the valve stem and then an additional hexagon side 60 Tighten the lock nut to 38 4 Nm ZX IMPORTANT When screwing down the adjus ting screw the valve yoke must be pressed down at the same time so that it reaches the valve stems It is extremely important that pressure is applied as close as possible to the adjusting screw see arrow in illustration Incor rect adjustment of the valve yoke could lead to a breakdown 61 Group 21 Engine Setting valve clearances 8 Adjust the valve clearances correctly and tighten the lock nut to 3844 Nm Check the valve clearance 9 Adjust the inlet valves the same way as the exhaust valves but with a different clearance Unit injectors adjusting prestress 10 Check that the line marked on the camshaft for adjus ting the inlet valves and unit injectors is midway bet ween the
65. it injector holes A IMPORTANT Do NOTE remove all protective plugs at the same time but remove them one by one as each unit injector is fitted in place 14 Fit new sealing rings on the unit injectors Lubricate the sealing rings with engine oil Fit the unit injectors and press them down forcefully until they reach the bottom center them so that they do not touch the val ve springs Tighten the unit injectors to the specified torque See Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE Note Unit injector tightening torques are different de pending on whether or not the copper sleeve is new 15 27 ru i ts O AN Connect the electric leads to the unit injectors NOTE Tighten the nuts to a torque of max 1 5 Nm A IMPORTANT Exercise great care when hand ling the unit injectors as they can easily sustain damage if the nuts are cross threaded or tighte ned too hard If the bolts break the entire unit injector will have to be replaced Group 21 Engine Repair instructions 16 19 E NOTE See the location of the bearing cap bolts at l far right Fit the remaining bolts as on the bearing cap NOTE If a new cylinder head is fitted the bearing to the left see illustration brackets supplied with it must be used Fit the bearing caps on the respective bearing brack Fit new camshaft bearing shells in the bearing brack ets Screw in the bolts but do not tighten them ets an
66. kshaft flange and check that the sur face at the location of the sensor grooves is comple tely free from impurities 6 Check that the flywheel s guide pin in the crankshaft sits correctly in place and is free from damage Remove the flywheel 103 Group 21 Engine Repair instructions 7 9 A clearance mm Attach 2 lifting eyes 9998629 and lift in the new fly B shim wheel see illustration with a lifting strap threaded th rough the lifting eyes NOTE The flywheel weighs about 60 kg 132 Ibs P Quantty 0 2 1 0 mm 0 3 till 0 3 mm 1 1677894 0 6 till 0 3 mm 2 1677894 Rotate the flywheel until a tooth on the camshaft s toothed wheel is opposite the sensor s hole in the fly wheel housing Fit the flywheel sensor and measure the distance A between the sensor s tip and the flywheel Permissible clearance A 0 6 0 4 mm To obtain a correct signal from the flywheel sensor the clearance between the sensor and the flywheel must lie within these limits Adjust the sensor by means of shims in accordance with the above table Mount the flywheel and tighten the bolts to 245 0 2 5 Nm in accordance with the tightening diagram 104 Group 21 Engine Repair instructions Flywheel bearings changing Stationary engines 1 Due to the tight fit the flywheel must be removed to be able to remove the flywheel bearing Use a suitable Special tools Mobile engines 9991801 9991821
67. ld not be removed unless absolutely necessary New engine blocks supplied as a spare part are ship ped without a timing plate The method in Alternative 2 describes mounting of the timing plate on a new engine block ALT 1 20 Clean the timing plate and the front of the cylinder head NOTE The timing plate should not be removed unless absolutely necessary 18 Mount two guide pins 9998267 so that they are secu red in the engine block through the timing plate Rem ove the timing plate The guide pins should remain in place Remove the oil nozzle from the timing plate and check that the holes are not clogged Refit the oil nozzle 19 Check that the keyway in the crankshaft is undama ged Make sure that the key is correctly positioned in the groove 75 Group 21 Engine 21 The sealant should be applied 4 mm from the edge of the engine block Where no hole radius is specified the sealant should be applied with a radius of 8 mm from the center Apply a 1 mm thick bead of sealant part no 1161231 4 at 1 on the engine block Apply a 2 mm thick bead of sealant all round the engine block 2 and at the hole 3 NOTE The timing plate must be fitted within 20 minu tes as the sealant will then harden 22 Fit the timing plate which is guided into position by the previously fitted guide pins 9998267 Tighten to 34 4 Nm 76 Repair instructions ALT 2 23 Fit the
68. lifting eye 9998629 from the cylinder head Refit all removed engine components in reverse order See instructions Cylinder head fitting re f a Fit lifting eye 9998629 to the center of the cylinder head 7 Put a crowbar or the like in lifting eye 9998629 Use the crowbar as a lever to carefully lift up the cylinder head A WARNING Risk of getting pinched Carefully check that the safety catch works so the cylin der head cannot fall back The cylinder head weighs about 130 kg 287 Ibs 36 Group 21 Engine Repair instructions Cylinder head fitting i Remove press tool 9996966 for the cylinder liners Dirt particles and water should be sucked out of the fuel passages after cleaning A IMPORTANT The cylinder head must be tho roughly cleaned inside and out before it is fitted back in place Dirt particles in the fuel passages could cause a breakdown or malfunction of the unit injectors Special tools 9993590 9998251 9998255 9998601 9998602 9998624 9998264 9998599 9998628 9998629 9996966 9999683 9999696 Fit new seals and a new cylinder gasket Change the timing plate gasket NOTE Carefully check that all sealing rings are pro perly fitted and not skewed or out of position If necessary clean the copper sleeves of the unit in jectors using cleaning kit 9998599 the tools in the il lustration are included in the cleaning kit before lifting the cylinder head into position on
69. marks on the bearing cap The numbers indi cate which unit injector can be adjusted 62 Repair instructions 11 Mount gauge 9998583 on dial indicator 9989876 with magnetic stand 9999696 Position the dial indicator so that the flange of the gauge rests against the unit injector s spring disc and the tip points towards the plane between the spring seat and the fuel valve Group 21 Engine 12 Prestress the dial indicator 2 3 mm Prestress the unit injector by screwing down the ad justing screw until the gauge bottoms against the pla ne surface and the dial indicator s pointer stops Tighten the lock nut to 5244 Nm NOTE If adjustment is incorrect the unit injector could bottom resulting in damage to the camshaft and unit injectors Repair instructions Functionality check 13 Perform a functionality check by starting the engine and running it until normal operating temperature is attained Then run the engine another 4 10 minutes at idling speed Once idling speed is steady the cylinder balan cing system will have set the correct amount of fuel for the unit injectors 13 NOTE Do not forget to remove turning tool 9993590 from the flywheel housing and refit the cover 63 Group 21 Engine Repair instructions Cylinder liners and pistons 3 removing 9996966 Special tools 9992955 9993590 9996394 9996395 9996645 9996966 t Fit press tool 9996966 on the
70. ng until glossy at some spots 4 Drill 1 2 holes in a tooth gap on the gear ring Use a chisel to split the gear ring at the drilled hole and lift the gear ring from the flywheel 2 Clean the contact surface of the flywheel with a steel brush Place the warmed gear ring on the flywheel and tap it into position with a soft drift and hammer Allow the gear ring to cool 107 Group 21 Engine Crankshaft seal rear changing Special tools 9992000 9998238 Fit tool 9998238 in the seal by turning the tool while pressing it inwards Drill two 4 mm holes in the metal edge of the seal by using the tool s locating holes as a template 2 Screw two self tapping screws M5x35 in the seal through the tool s locating holes Fit two screws M10x60 with a long thread in the tool s threaded holes and withdraw the seal 108 Repair instructions Remove the seal and the screws from the tool 4 Clean the seal s place in the flywheel housing and the seal face against the crankshaft 5 SE K SHS Spread sealant part no 11612314 on the outer sur face of the new seal and oil the seal lip Carefully tap in the new seal with tool 9998238 and handle 9992000 until the tool bottoms against the fly wheel housing Index B Bearing housing for camshaft changing 84 Before after lifting the engine s e 19 Big end bearings Changing ceeseeeeeeeeeenees 99 C
71. nvolves chemicals fuel and lubricating oil Important Apply barrier cream to your hands and always use protective gloves when work involves oil fuel and the like Continuous skin contact with engine oil dries out the skin and could be harmful Before lifting the engine 1 Turn off the battery current remove the starter motor connections 2 Unplug the engine wiring connectors 3 Remove the exhaust pipe 4 Close the fuel cocks 5 Detach the fuel connections 6 Disconnect the cables from the engine 7 Undo the engine mounts and lift out the engine After lifting the engine 1 Clean the engine A WARNING Observe the following when using high pressure equipment to clean the engine Take great care to ensure that water does not enter engine components When the high pres sure function is engaged never direct the water at sealing arrangements like shaft seals joints with gaskets rubber hoses etc nor at electrical components 2 Pump out the engine oil as needed 19 Group 21 Engine Repair instructions Engine jig attaching Compression test Special tool 9998648 Unit injectors removed and fuel drained Other special equipment 9986485 Compression test can be performed two different ways 1 either using the diagnostics tool or manually employing the method described below To perform a manual compression test first drain the fuel system and then remove the rocker arm bridge and unit injectors
72. of studs cocks oil pressure monitors etc Hardened anaerobic agents are glass like they are therefore colored to make them more visible Harde ned anaerobic agents are highly resistant to solvents and old agent cannot be removed When refitting a component thorough degreasing is required followed by application of fresh sealant The following agents are anaerobic Loctite 572 white Loctite 241 blue Note Loctite is a registered trademark of the Loctite Corpora tion Permatex is a registered trademark of the Permatex Cor poration General Group 21 Engine Group 21 Engine Group 21 Engine Tools Special tools 884994 885316 9991801 9991821 9992000 Ih l a lt a 9992564 9992479 9992671 00 9996161 9996222 9996315 9996394 9996395 884994 Puller for polygon hub vibration damper 9996159 885316 Tool for tilting of cylinder head 9996161 9991801 Drift for removing piston pin 9991821 Drift for removing flywheel bearing 9996222 9992000 Handle for drift 9998238 Bp 9996315 9992013 Drift for removing and fitting piston pin 22 Drift for fitti i 9992269 rift for fitting flywheel bearing 9996394 9992479 Holder for dial indicator 2990395 2564 Drift for fitti i 999256 rift for fitting flywheel bearlng 9996626 9992584 Adapter for hydraulic cylinder 9992671 9996645 9992671 Hydraulic cylinder 9996662 9992955 Plate for removing cylinder liner 9993590 Turning tool 9996626 Tools
73. olts from the cylinder Remove the front engine lifting bracket head at the turbocharger 11 TWD 14 Remove the front water pipe between the charge air cooler and the radiator hose connection Remove the camshaft position sensor 1 and the clamps 86 Group 21 Engine Repair instructions 15 17 Remove the toothed wheel 18 Remove the valve cover nuts using an ordinary rat chet wrench and remove the valve cover NOTE Do not use air assisted tools when removing the valve cover as this could damage the unit injector wiring harness and the studs 16 Remove the camshaft gear 1 Use a suitable puller if necessary Remove the upper timing cover 87 Group 21 Engine Repair instructions TM amp Remove the oil pipe connected to the rocker arm bridge 20 Undo the rocker arm bridge retaining bolts evenly over the entire bridge to avoid uneven stress 21 Rotate the flywheel until the piston in cylinder no 1 is at top dead center 0 on the flywheel and the cam shaft marking is midway between the marks on the bearing cap Lift away the rocker arm bridge using lifting tool 9998255 24 Check that the camshaft bearing caps are factory marked 1 7 in accordance with the relevant bearing bracket Remove the camshaft bearing caps by tap by two persons if no lifting device is available ping them care ully wile Tupper malet Keep tie f camshaft bearing caps and bearing halves tog
74. olts finger tight but not to the specified torque Fit press tools 9998602 and 9998628 Screw the tools down so that the seal face of the timing cover against the valve cover is level with the seal face on the cylin der head Fit the other bolts and tighten to the speci fied torque See Cylinder head fitting step 33 NOTE Leave the press tools in place Allow the seal ant to solidify for about 30 minutes Do not forget that one of the bolts also secures the radiator fan drive Repair instructions D A X C toothed wheel D camshaft position sensor A clearance mm B shim Rotate the flywheel until a tooth on the camshaft s toothed wheel is opposite the sensor s hole in the tim ing cover Fit the camshaft position sensor and mea sure the distance A using a feeler gauge between the sensor s tip and the toothed wheel Permissible clear ance A 0 6 0 4 mm To obtain a correct signal from the camshaft position sensor the clearance between the sensor and toothed wheel must lie within these limits Adjust the sensor by means of shims in accor dance with the table below a p a 0 2 1 0 mm 0 3 till 0 3 mm 0 6 till 0 3 mm 1 1677894 2 1677894 NOTE Do not forget to fit the two clamps on the camshaft position sensor wiring 93 Group 21 Engine Repair instructions Fit the valve cover and tighten the bolts to 202 Nm according to the tightening diagram
75. ost If necessary open the filler cap slowly and relea se pressure in the cooling system Be extremely careful if a cock plug or coolant line must be removed while the engine is still hot Steam or hot coolant could squirt out in an unexpected di rection 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 Group 21 Engine A If other equipment connected to the engine changes its center of gravity special lifting devi ces may be needed to obtain the right balance and ensure safe handling Never perform any work on an engine that is suspended solely from a lifting device Never work alone when heavy components are to be removed even if a safe lifting device such as a lockable block and tackle is used Even if a lifting device is used two people are generally required one to handle the lifting device and the other to make sure that the components go cle ar and are not damaged when lifting Always ensure in advance that there is suffi cient space for dismantling to be done without risk of injury or material damage WARNING Electrical system and fuel system components of Volvo Penta products are desig ned and manufactured to minimize the risk of explosion an
76. overs all cylinders has a single overhead camshaft The cylinder head is held in place with 38 bolts spa ced evenly round the cylinders The cylinder head has separate inlet and exhaust ports arranged for crossflow in each cylinder The val ve guides are of alloyed cast iron the steel valve se ats are replaceable All valve guides have oil seals The unit injectors are centrally positioned and sur rounded by four valves per cylinder which ensures uniform combustion chamber geometry The lower part of the injectoris placed in a copper sleeve and the fuel passage for the injectors is machined directly in the cylinder head Design and operation Top Injectors Center Exhaust valves with double springs Bottom Inlet valves Group 21 Engine Cylinder block cylinder liners The TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE engines have a cylinder block with wet replaceable cylinder liners The coolant space water jacket round the cylinder liners is sealed against the lower part of the cylinder block by means of three sealing rings me oe a k ee ar ee Aor i gir Sea ere Pistons The pistons are of aluminum and are cooled by lubri cating oil sprayed from below by piston cooling nozz les and in the oil passage RI Design and operation i pl T jy WAM nn O K To N ANA rm a j GF ca me roy A
77. rench Fit the crankshaft bolt together with the washer and tighten to 645 25 Nm NOTE Allow the parts to cool to room temperature before tightening Repair instructions 39 Make sure that the camshaft marking for top dead cen ter TDC is between the markings on the bearing cap rio M bee Fit the camshaft gear without the vibration damper Use suitable sockets see illustration so that the bolts can be tightened down hard 79 Group 21 Engine Repair instructions 41 The illustration shows checking on a removed timing Check that the camshaft gear is correctly mounted by cover inserting a 7 mm dowel in the hole see illustration Make sure that the dowel is between the two marks on the camshaft gear 42 Check the adjustable intermediate gear s flank clea rance in mesh with the two gears A and B See Tech nical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE Use two feeler gauges to check the flank clearance Checking with the lower timing cover fitted is done th rough the inspection hole 80 Group 21 Engine Repair instructions i a F he F f p 9999683 Checking method with lever type dial indicator Place lever type dial indicator 9999683 in magnetic stand 9999696 and bring the tip of the indicator up against a tooth on the adjustable intermediate gear NOTE The tip of the lever type dial indicator should be at right angles to the tooth A
78. retaining bolts are dam aged 49 Fit the inner vibration damper the O ring on the hub and the driver Tighten the two socket cap screws to 60 5 Nm and then angle tighten to 90 5 50 Fit the dust excluders and holder for the crankshaft sealing ring Group 21 Engine Repair instructions 51 52 Fit the drive take off generator and fuel pump 53 Apply an even bead 2 mm of sealant part no 11612777 in the marked area see illustration The lower timing cover must be fitted within 20 min utes as the sealant will harden A WARNING The lower timing cover is heavy Two persons will be necessary to fit it in place Fit the outer vibration damper Tighten to 60 5 Nm and then angle tighten to 90 5 as specified in the tightening diagram 54 NOTE Do not forget to remove turning tool 9993590 from the flywheel housing and refit the cover 83 Group 21 Engine Bearing housing for camshaft changing ae Ue aT Sa a f r AN SSA ox x A if f G Sif A The production fitted bearing housings are machined together with the cylinder head and therefore cannot be transferred from one cylinder head to another If a bearing housing is damaged an exchange hous ing can be fitted in its place All bearing housings should then be changed to ensure that the bearing housing seats can be aligned The holes for the guide sleeves in the exchange bea ring hous
79. ring should be fitted in the lowest groove in the cylinder block 6 If shims are used the bead of sealant should be app lied to the liner shoulder in the cylinder block NOTE Apply no sealant between the shim and liner flange Apply a thin even bead of sealant part no 11612314 NOTE The bead of sealant should be max 0 8 mm Group 21 Engine 7 The cylinder liner must be fitted within 20 minutes of applying the sealant Carefully press the cylinder liner down into the cylin der block Fit press tool 9996966 to secure the cylin der liner in the block NOTE Always fit press tool 9996966 on the cylinder liners to ensure that the sealant hardens in the right position Repair instructions Connecting rod small end bush checking measurements Before the connecting rod small end bush is changed the connecting rod should be checked for cracks straightness and warping A cracked bent or warped connecting rod must be scrapped When changing connecting rod small end bushes on connecting rods with trapezoidal piston pin ends the bush must be machined The bush should be reamed In a correct fit an oiled piston pin should slowly slide through the bush by its own weight A IMPORTANT Concerning the maximum permis sible deviation in respect of straightness and warping see Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE Use a new piston pin and measure the strai
80. ssion oils glycol gasoline and diesel oil or chemicals for workshop use such as degreasers paints and solvents are injurious to health Read the instructions on the package carefully Always follow prescribed sa fety rules such as the use of respirators pro tective goggles gloves etc Make sure that other personnel are not unknowingly exposed to substances that are injurious to health such as through the air they breathe Make provision for good ventilation Deal with used and surplus chemicals in the prescribed manner 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 pene trative power the fuel can penetrate deep into body tissues and cause serious injury Risk of blood poisoning WARNING The engine s pressure pipes should not be bent or reshaped under any circumstanc es Damaged pipes must be replaced All fuels and many chemicals are flammable Make sure that they cannot be ignited by an open flame or spark Gasoline certain dilutants and hydrogen from batteries when mixed with air in the right proportions are highly flammable and explosive No smoking Provide for adequa te ventilation and take the necessary safety me asures prior to the start of welding or grinding work in the vicinity Always keep a fire ext inguisher easily accessible at the workplace Ensure that rags s
81. t one of the bolts also secures the radiator fan drive ME x 130 mm 9 ER wna cere i 8 M10x 100 mm MBxSdrnm Z St G M10 x 75 mm 2 M18 80 mm Ac 4 M10 x 80 mm Repair instructions 34 gt ae PKK A clearance mm B shim C toothed wheel D camshaft position sensor Rotate the flywheel until a tooth on the camshaft s toothed wheel is opposite the sensor s hole in the ti ming cover Fit the camshaft position sensor and me asure the distance A using a feeler gauge between the sensor s tip and the toothed wheel Permissible clearance A 0 6 0 4 mm To obtain a correct signal from the camshaft position sensor the clearance bet ween sensor and toothed wheel must lie within these limits Adjust the sensor by means of shims in accor dance with the table below E 0 2 1 0 mm 0 3 till 0 3 mm 0 6 till 0 3 mm 1 1677894 2 1677894 NOTE Do not forget to fit the two clamps on the camshaft position sensor wiring 35 Clean the threaded holes for the studs in the cylinder head Clean the studs coat them with Volvo Penta locking fluid part no 161053 2 and tigh ten them to 40 3 Nm Attach the wiring to the unit injectors by means of straps round the studs NOTE Meticulously wipe off all surplus locking fluid after tightening the studs 45 Group 21 Engine Fit the front engine lifting bracket 37 Attach
82. the remaining bolts as on the bearing cap to Rotate the flywheel using turning tool 9993590 until the left the 0 mark is opposite the arrow Fit the caps on the relevant bearing brackets Fit the NOTE Do not forget to remove turning tool 9993590 bolts but do not tighten them from the flywheel housing and refit the covers 31 si Check that the camshaft marking for top dead center TDC is midway between the markings on the bearing Insert 7 bolts M10 x 90 in the holes for the rocker cap arm bridge having no guide sleeves Tighten these bolts to M10 standard torque 32 1 15 5 Nm 90 45 90 Group 21 Engine Repair instructions Fit the camshaft gear and use suitable sockets so that the bolts can be tightened down hard 36 Check or adjust the flank clearance according to the in structions under the heading Timing gear changing 37 Fit the toothed wheel and tighten according to the tightening diagram below A IMPORTANT If the toothed wheel or any of its teeth are damaged or deformed it must be chan ged The same applies if any of the holes for the toothed wheel retaining bolts are damaged 1 35 3 Nm 2 g0 5 NOTE Loosen all adjusting screws for the valves and unit injector before fitting the rocker arm Oil the valve yokes and camshaft cams with engine oil Lift the rocker arm bridge into place using 9998255 Check that the valve yokes and rocker arms
83. the temperature sensor and fuel connections to the cylinder head with new gaskets Tighten the fuel lines to 55 5 Nm 46 Repair instructions 38 Apply a 2 mm thick bead of sealant part no 1161231 4 in the joint between the upper timing co ver and the cylinder block NOTE The valve cover must be fitted within 20 minu tes of applying the sealant Fit the valve cover and tighten the bolts to 202 Nm according to the tightening diagram NOTE It is important that the valve cover bolts are tightened to the torque specified in the diagram to pre vent cracks in the cover and loosening of the studs If any of the valve cover studs loosened from the cy linder head when the bolts were removed the wiring harness to the unit injectors must be checked The wire holder on the stud may have followed in the rota tion and damaged the wiring harness Group 21 Engine Repair instructions 40 43 Fit the hose between the crankcase breather pipes in place and tighten the clamps 41 Fit the upper radiator hose connection on the cylinder head with new seals 42 Fit the radiator fan drive NOTE The upper bolt also secures the upper timing cover Attach the water pipe to the coolant pump and radiator hose connection Fit the pulley and spacer NOTE Center the holes for the studs with the pulley and spacer 45 Fit the drive belt see Group 26 Drive belts chang ing 47 Group 21
84. timing plate loosely on the new engine block Adjust the timing plate so that it is level with the bot tom of the engine block NOTE Do not apply sealant at this stage 24 Fit the two fixed intermediate gears on the timing plate 25 Adjust the timing plate laterally so that the backlash to the crankshaft gear is the same for both intermedia te gears Fit dial indicator 9999683 in magnetic stand 9999696 Adjust and check until the backlash is the same for both intermediate gears 26 9 co D a o O Q a o a Secure the timing plate with a few bolts Insert two guide pins 9998267 so that they are secured in the engine block through the timing plate 27 Remove the timing plate Group 21 Engine Repair instructions 28 29 Fit the timing plate which is guided into position by the previously fitted guide pins 9998267 Tighten to 34 4 Nm The sealant should be applied 4 mm from the edge of the engine block Where no hole radius is specified the sealant should be applied with a radius of 8 mm from the center Apply a 1 mm thick bead of sealant part no 1161231 4 at 1 on the engine block Apply a 2 mm thick bead of sealant all round the engine block 2 and at the hole 8 NOTE The timing plate must be fitted within 20 minutes as the sealant will harden 77 Group 21 Engine Fitting the timing gears 30 The numbering of the gears in th
85. x 20 with nut washer and spacer sleeve between the lug on the exhaust manifold and the machined surface on the thermostat housing Tighten the bolt so that the sleeve presses the ther mostat housing against the piston thermostat seal Secure the thermostat housing according to the tight ening diagram see illustration Remove the tensio ning screw 52 Group 21 Engine Cylinder head valves removing fitting There are two methods of removing fitting valves Fastening the cylinder head in an engine stand Work on the cylinder head will be facilitated if it is fas tened in an engine stand In order to fasten tool 9998258 to the cylinder head it will first be necessary to remove the inlet manifold Also remove the exhaust manifold if the cylinder head is to be removed Bolt tool 9998258 to the cylinder head using 4 M8x50 bolts NOTE It is extremely important to observe the strict est cleanliness when working on the cylinder head Dirt particles in the fuel passages could cause a breakdown or malfunction of the unit injectors Repair instructions Removing valves Special tools 9996159 9996161 9996222 9998246 9998258 9998260 9998335 9998506 HATAR j 6222 8246 a vhn om 1 Pa Cro NN NUES ee NW EEE C I r N oo e Fit press tool 9998260 together with the valves counterstay e Fit hydraulic cylinder 9996161 in press tool 9998260 and connect foot pump 9996222 e

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