Volvo Penta TAD1630G Workshop Manual
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Volvo Penta TAD1630G Workshop Manual

Volvo Penta TAD1630G Workshop Manual

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Workshop manual
TAD1630G/GE/P/V, TAD1631G/GE, TID162AP,
TWD1620G/GH, TWD1630G/GE/P/V,
TD164KAE

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Summary of Contents for Volvo Penta TAD1630G

  • Page 1 Workshop manual TAD1630G/GE/P/V, TAD1631G/GE, TID162AP, TWD1620G/GH, TWD1630G/GE/P/V, TD164KAE...

  • Page 3: Table Of Contents

    Workshop manual TAD1630G/GE/P/V, TAD1631G/GE, TID162AP, TWD1620G/GH, TWD1630G/GE/P/V, TD164KAE Contents Contents Cylinder liners and pistons, fitting ........ 45 General Information ............. 3 Sealant between the fuel injection pump bearing housing and the cylinder block: Tools ................11 TAD1630/TID162/TWD1620/TWD1630/TD164KAE ..48 Special tools ..............11 TAD1631 ..............
  • Page 4 Coolant pump, reconditioning ........130 TID162AP/TWD1620G/GH/TWD1630/GE ....91 Sleeve thermostats, replacing ........140 TAD1630P/V/TWD1630P/V/TD164KAE ....91 Sleeve thermostats, checking ........141 TAD1630G/GE y TAD1631G/GE ......92 Coolant manifold seals, replacing ......142 Smoke limiter TAD1630P/V ......... 94 Coolant ..............144 Feed pump ..............94 Anti-freeze ..............
  • Page 5 This Workshop manual contains descriptions and instruc- with hot surfaces (exhaust pipes, Turbocharger tions for the repair of the Volvo Penta products or product (TC), air intake pipe, starter heater etc.) and hot liq- types. Check that you have the correct Workshop manual uids in lines and hoses on an engine which is run- for your engine.
  • Page 6 Safety Precautions Always use protective glasses or goggles when car- Ensure that rags soaked in oil or fuel and used fuel rying out work where there is a risk of splinters, or oil filters are stored safely. Rags soaked in oil grinding sparks, acid splashes or where other can spontaneously ignite under certain circum- chemicals are used.
  • Page 7 WARNING! The components in the electrical system and in the fuel system on Volvo Penta products are de- signed and manufactured to minimize the risk of fire and explosion. The engine must not be run in areas where there are explosive materials.

  • Page 8: General Information

    Volvo Penta parts for the product in question will not be cov- ant. ered under any warranty or guarantee provided by AB Volvo Penta.
  • Page 9 ”Safety Pre- adjusted are correctly set up and that only Volvo Penta Orig- cautions”) inal Parts are used on the engine. The stated service inter- vals in the Maintenance Schedule must be followed.
  • Page 10 In this Volvo Penta Workshop manual the user will find that each section where these agents are applied in pro- duction states which type was used on the engine.
  • Page 11 Group 20 Service procedures Safety rules for fluorocarbon rubber Fluorocarbon rubber is a common material in seal rings for shafts, and in O-rings, for example. When fluorocarbon rubber is subjected to high temperatures (above 300°C/572°F), hydrofluoric acid can be formed, which is highly corrosive.
  • Page 12 General information Group 20 Location of identification plates Each engine is supplied with two identical identification plates, of which one is mounted on the cylinder block, see figure. The other identification plate should be mounted in a suitable location adjacent to the engine. Engine model Spec.

  • Page 13: Tools

    Group 20 Special tools Special tools The following special tools are used when working on the engine. The tools can be ordered from AB Volvo Penta by specifying the number shown. 999 1083 999 1819 999 2000 999 2269 999 2412...
  • Page 14 Special tools Group 20 999 6395 999 6433 999 6398 999 6400 999 6413 999 6419 999 6454 999 6478 999 6591 999 6626 999 6662 999 6645 999 6845 999 6848 999 6858 999 6863 999 6960 999 6963 999 6966 999 6942 999 6967...
  • Page 15 Group 20 Special tools 999 6997 999 6998 999 8000 999 8007 999 8009 999 8010 999 6978 999 6999 999 8011 999 8012 999 8017 999 8134 999 8140 999 8238 999 9179 999 9683 999 6962 999 9696 Tool Designation/use Tool...
  • Page 16 Special tools Group 20 884983 884995 884997 884994 884969 885232 885231 885184 885126 885341 Tool Designation/use Tool Designation/use 884969 Flange kit 885184 Flange kit 884983 Tool for seal and fitting wear ring 885231 Connection tool for leakage check 884994 Puller for polygon hub 885232 Sealing tool for leakage check 884995...

  • Page 17: Other Special Equipment

    Group 20 Special tools Other special equipment The following special tools are used when working on the engine. The tool can be ordered from AB Volvo Penta by specifying the appropriate Part number. 998 5423 998 8183 998 6981 (220V)

  • Page 18: Engine

    Design and Function Group 21 Engine Design and Function...

  • Page 19: Cylinder Head

    Group 21 Design and Function Cylinder head The engine has individual, cast iron cylinder heads each car- rying four valves. The injectors are centrally positioned in copper sleeves between the valves. Cylinder block The cast iron cylinder block has bearing caps of ductile cast iron.

  • Page 20: Valve Mechanism

    Design and Function Group 21 Valve mechanism Valve mechanism is carried from the camshaft by tappets of the roller type, short push rods, rocker arms and valve cali- pers. In each rocker arm is an oil drilling which due to the movement lubricates the valve caliper and ball cup of the push rod.

  • Page 21: Crankshaft/Pistons

    Group 21 Design and Function Crankshaft/pistons The crankshaft has 7 main bearings and is nitrocarburized. The oscillation damper is screw-attached to the polygon hub. The rear and front crankshaft seal consists of a liptype seal- ing ring. The front sealing ring seals against a wear ring on the pulley.

  • Page 22: Service Procedures

    Service procedures - engine Group 21 Service procedures The engine must always be washed before repairs are started Engine fixture, attaching Special tools: 998 6485, 999 6962 Remove the oil cooler as shown in ”oil cooler, replacing”. Cover the holes with rags or equivalent to prevent dirt or for- eign matter from entering the engine.

  • Page 23: Compression Test

    Group 21 Service procedures - engine Compression test Exposing engine body (Injectors removed) TAD1630/TAD1631 Special tools: 999 8009, 998 8539 Shut the fuel cocks. Disconnect the battery cables. Drain the coolant. Remove air filters and pipes for the turbo charger. Remove stays and brackets.

  • Page 24: Tad1630/Tad1631/Tid162/Twd1630/Td164

    Service procedures - engine Group 21 TAD1630/TAD1631/TID162/TWD1620/ TWD1630/TD164 Remove the fuel delivery pipe and return fuel pipe together with the clamps and brackets from the injectors and the in- jection pump. On the cylinder heads which are to be removed, bend up the locking tabs on the exhaust manifold bolts.

  • Page 25: Cylinder Head, Removing

    Group 21 Service procedures - engine Cylinder head, removing Special tools: 999 3590, 999 6400, 999 6966, 999 8007 Remove the injectors. If an injector sticks in the copper sleeve, fit tool 999 6400 and 999 8007 to the injector and carefully knock out the injector.

  • Page 26: Cylinder Head, Disassembling

    Service procedures - engine Group 21 Cylinder head, disassembling Remove the valves and valve springs. Use a valve spring clamp to compress the springs for removal of the valve col- lets. Put the valves in a valve stand in the order they were fitted in the engine.

  • Page 27: Cylinder Head, Pressure Testing

    Group 21 Service procedures - engine Cylinder head, pressure testing (Cylinder head removed) Special tools: 999 6662, 999 6997 (2 ea) Before using the pressure testing equipment, check it for ac- curacy. Fit 999 6997 (two) to the cylinder head. Note: Tighten the wing nuts with care so as not do damage the rubber gaskets of the tool.

  • Page 28: Cylinder Head, Inspection

    Service procedures - engine Group 21 Cylinder head, inspection Unevenness of the cylinder head face must not exceed 0.02 mm (0.0008"). If the unevenness does exceed the maximum of 0.02 mm, or if any blow-by marks are observed, the cylin- der head must be face-ground or replaced.

  • Page 29: Valve Guides, Inspection

    Group 21 Service procedures - engine Valve guides, inspection Wear tolerances: Inlet valve max play 0.30 mm (0.0118") Special tools: 998 9876, 999 9696 Exhaust valve max play 0.45 mm (0.0177") To determine the degree of valve guide wear, fit a new valve If these amounts of play are exceeded, the valve guides into the guide and then measure the amount of play with a must be replaced.

  • Page 30: Valve Guides, Replacing

    Service procedures - engine Group 21 Valve guides, replacing Valve seats, replacing Special tools: 999 1083, 999 8336 Special tools: 999 2479, 998 9876 The valve seat must be replaced when measurement ”A”, measured with a new valve, exceeds 1.0 mm. This measurement applies to both the inlet and exhaust valves.

  • Page 31: Valve Seats, Grinding

    Group 21 Service procedures - engine Valve seats, grinding Valves, grinding Before grinding, check the valve guides and replace them if Valve sealing angles: the wear limits have been exceeded. Grind the valve seat just enough to give correct form and an- Inlet 29,5°...

  • Page 32: Cylinder Head, Assembling

    Service procedures - engine Group 21 Cylinder head, assembling Cylinder head, installation Special tools: 999 2479, 998 9876, 115 8959 Oil the valve stems and fit the valves into their guides. Fit the valve springs and the spring washers. Clamp the springs with a valve spring compressor and fit the collets.
  • Page 33 Group 21 Service procedures - engine Fit new greased sealing rings to the cylinder block. Fit the exhaust manifold bolts (two), locking tabs, washers and sleeves. Put the gasket onto the bolts. Lift the cylinder head carefully into position on the cylinder block.
  • Page 34 Service procedures - engine Group 21 Torque the exhaust manifold bolts to 48 Nm (35.4 ft-lb). Fit new O-rings to the inlet pipes of all cylinders. (On TWD1630, the delivery pipes to the injectors have to be fitted before the inlet manifold.) TAD1630P/V only Connect the smoke limiter hose to the inlet pipe.

  • Page 35: Rocker Arm Mechanism, Reconditioning

    Group 21 Service procedures - engine Rocker arm mechanism, reconditioning Special tools: 999 1801, 999 2000, 999 2457, 999 6225, 999 6352, 999 6478, 998 6173, 998 6175 Fit the new bushing using tools 999 1801 and 999 6478 Remove the locking plugs using tools 998 6173 and 998 making sure that the oil holes align with the oil channels 6175.

  • Page 36: Valves, Adjusting

    Service procedures - engine Group 21 Adjusting the valve caliper Valves, adjusting Special tools: 998,3590 Valves are adjusted with the engine cold. On no condition should the engine be running since the valves can strike against the piston and cause serious damage. Make sure that the stop control is pulled out and the starting key is turned off.
  • Page 37 Group 21 Service procedures - engine Crank the engine with the flywheel one more full turn in its direction of rotation until 6th cylinder piston is at top dead center after the compression stroke and both valve pairs of 1st cylinder are rocking. Turn it down a further 1/4 turn.

  • Page 38: Copper Sleeve For Injectors, Replacing

    Service procedures - engine Group 21 Copper sleeve for injectors, replacing Special tools: 999 1801, 999 1819, 998 3590, 999 6400, 999 6960, 999 6975, 999 8007, 999 8134, 999 8140, 981 2546 Drain the coolant and disconnect the batteries. Remove the delivery pipe and the fuel return pipe.
  • Page 39 Group 21 Service procedures - engine Remove the pin screw for the injector’s yoke. Check that the screw on tool 999 8140 extends about 22 mm (0.87") from the tool. Fit a new sealing ring to the cylinder head. Remove the reamer from tool 999 6960. Screw tool 999 8140 tight in the copper sleeve.
  • Page 40 Service procedures - engine Group 21 6975. Screw down the retainer nut until the copper sleeve bottoms in the cylinder head. Tap down the steel ring carefully until the drift bottoms against the cylinder head face. Insert a new sealing ring into the steel ring. Hold spindle 999 6960 and screw the nut down.

  • Page 41: Cylinder Liners And Pistons, Removing

    Group 21 Service procedures - engine Cylinder liners and pistons, Remove the big end cap. Tap up the connecting rod, with for removing example the handle of a hammer, so that the piston rings are released from the cylinder liner. Lift off the piston and con- necting rod.

  • Page 42: Cylinder Liners, Measurement And Inspection

    Service procedures - engine Group 21 Cylinder liners, measurement Cylinder liners, honing and inspection For good lubrication and sealing it is important that the liner walls retain the original honing pattern. See figure. Honing, to This check consists of measuring wear and checking for restore the pattern, is therefore to be carried out when: cracks.

  • Page 43: Cylinder Liner Seats, Reconditioning

    Group 21 Service procedures - engine Cylinder liner seats, reconditioning Special tools: 999 2479, 999 9942, 999 6966, 998 9876 Note: Due to tight fitting on some engines, it may be impos- sible to turn the lining in the cylinder block. Grinding with grinding paste under the liner collar can in such cases not be done.

  • Page 44: Cylinder Block, Face-Grinding

    Service procedures - engine Group 21 Cylinder block, face-grinding Fit the milling tool and yoke. The tool is bolted to the cylinder block. Place suitable flat washers under the bolt heads. The cylinder block must not be ground below the minimum, specified measurements.

  • Page 45: Pistons, Checking

    Group 21 Service procedures - engine Pistons, checking Check the pistons for cracks and other damage. If the piston has deep lines around the sleeve surface it (liner unit) must be scrapped. Similarly, if the piston has one or several cracks in the gudgeon pin hole or in the bottom of the com- bustion chamber it shall also be scrapped.

  • Page 46: Pistons, Piston Rings And Connecting Rods, Assembling

    Service procedures - engine Group 21 Pistons, piston rings and connecting rods, assembling Special tools: 999 1801, 999 2529, 998 3590, 885126 Fit one of the circlips to the piston. Oil the gudgeon pin and the connecting rod bushings. Heat the piston to about 100°C (212°F). Fit the piston and connecting rod with the arrow on the piston and the word Front on the connecting rod pointing in the same direction.

  • Page 47: Cylinder Liners And Pistons, Fitting

    Group 21 Service procedures - engine Cylinder liners and pistons, fitting Special tools: 999 2000, 999 2479, 998 3590, 999 6236, 999 6394, 999 6395, 999 6645, 999 6963, 999 6966, 999 6967, 998 9876, 885126 Carefully clean the liner seat in the cylinder block. Any rust or deposits on the sealing surfaces must be fully removed.
  • Page 48 Service procedures - engine Group 21 Fit the sealing ring under the liner collar and place the ring about 8 mm below the collar. Fit the sealing rings into the cylinder block. Note: Lubricate the three lower rings with the lubricant provided in the ring kit.
  • Page 49 Group 21 Service procedures - engine Oil the piston and put it into the liner with the marking (ar- Install the liner in the cylinder block aligning to the previ- row) pointing forward. ously made marks. Use standard handle 999 2000 and drift 999 6236.
  • Page 50 Service procedures - engine Group 21 Remove tool 3590 from the flywheel casing and fit the Install the bearing housing on the engine block. Tighten plug. the screws until the bearing housing is tight against the engine block. Remove the clamping tools from the cylinder liner when the cylinder head is to be refitted.
  • Page 51 Group 21 Service procedures - engine Sealant between the fuel Clean bearing housing as well as cylinder block and tim- injection pump bearing ing cover contact surfaces. housing and the cylinder Install a new locating pin and a new guide sleeve. block TAD1631 Note: The fuel pump bearing housing is co-machined with the engine block and therefore should not be replaced sepa-...

  • Page 52: Tad1630/Tid162/Twd1620/Twd1630/Td164Kae

    Service procedures - engine Group 21 Clean the bearing housing carefully. Lubricate bearing bushings and shaft. Install pivot shaft in bearing housing. Install thrust washer and torque to 24 Nm (17.7 ft-lb). Seal on output shaft from timing gear to injection pump, TAD/1630/ TID162/TWD1620/ Remove the pump coupling and the flange.

  • Page 53: Tad1631

    Group 21 Service procedures - engine Seal on output shaft from timing gear to injection pump TAD1631, replacing Special tools: 999 8011, 999 8012 To replace the sealing ring in the bearing housing the fuel in- jection pump and pump coupling must be removed. See ”Re- moving the injection pump”.
  • Page 54 Service procedures - engine Group 21 Locate seal ring on shaft and tap it in until the seal is level with the bearing housing. Use drift 999 8012. Install flange, pump coupling and injection pump. Check the injection angle, se ”Fitting and adjusting the injection pump”.

  • Page 55: Front Sealing Ring For Coolant Pump, Replacing

    Group 21 Service procedures - engine Front sealing ring for coolant pump, replacing Special tools: 999 2000, 999 2929 Press the new sealing ring into the holder using tools 999 2000 and 999 2929. Place a bead of sealant on the mating surface of the timing gear cover.

  • Page 56: Sealant, Timing Gear Cover, Replacement

    Service procedures - engine Group 21 Assembly Sealant, timing gear cover, replacement Remove the possible sealant residue from the timing gear cover and the timing gear housing. Disassembly Apply a new string of sealant the timing gear cover. See Set the electrical circuit breaker on 0 and drain off the cool- figure.

  • Page 57: Timing Gears, Removing

    Group 21 Service procedures - engine Install the coolant pump sealing ring retainer. See: Front sealing ring for coolant pump, replacing”. Fit the pulley and the outer torsional vibration damper (if any). Torque 48 Nm (44.3 ft-lb) Note: Check the condition of the sealing ring and the wear ring.

  • Page 58: Intermediate Gears, Replacing Bearing

    Service procedures - engine Group 21 Intermediate gears, replacing bearing Using a felt tip pen, mark the injection pump’s drive against the intermediate drive and the crankshaft drive. Thus the injection pump’s adjustment will be maintained Disconnect the hub to the intermediate gears, and thrust during work.

  • Page 59: Timing Gears, Fitting

    Group 21 Service procedures - engine Timing gears, fitting Heat the polygon hub to a temperature of 100°C (212°F). Special tools: 884995, 884997 Fit the hub using drift 884995. When the hub has cooled off, torque the crankshaft’s cen- tral screw to 640 Nm (472.3 ft-lb). Fit the crankshaft drive using a key.

  • Page 60: Polygon Hub, Replacing

    Service procedures - engine Group 21 Refitting Polygon hub, replacing (with the timing gear cover removed) Check the polygon hub and its contact face on the crank- Special tools: 999 3590, 884994, 884995 shaft. Any cutting marks are to be removed with fine emery cloth.

  • Page 61: Sealant, Transmission Gear Casing, Replacing

    Group 21 Service procedures - engine Sealant, timing gear casing, replacing (Timing gears, servo pump, air compressor and coolant pump removed) Remove the bolts and lift off the timing gear casing. Clean the contact surface on the cylinder block and on the timing gear casing carefully.
  • Page 62 Service procedures - engine Group 21 Remove the Plug from the flywheel casing. Fit cranking tool 999 3590. Put a steel ball in the bottom of no. 1 tappet. Put the magnetic stand on the front cylinder head. Start check-measuring at no. 1 valve tappet. Make sure that 999 6390 is on top of the steel ball.
  • Page 63 Group 21 Service procedures - engine Crank the engine around until the tip of the dial indicator is in its top position. Make a note of the dial indicator read- ing. The lifting height must not be less than. Min. inlet 7.80 mm (0.3073"). Min.

  • Page 64: Camshaft, Replacing

    Service procedures - engine Group 21 Camshaft, replacing (with the timing gear cover removed) Special tools: 999 3590, 999 6454, 999 6970 Remove all delivery pipes, return pipes and valve covers. Fit protection plugs to the injectors and the injection pump. Lift up all of the tappets.
  • Page 65 Group 21 Service procedures - engine Push 999 6970 onto the camshaft. If the pop markings on the camshaft and idler do not coin- cide, the gear must be marked. Note: These markings must be made with a felt tipped pen. Remove the camshaft drive bolts.

  • Page 66: Camshaft Bearings, Replacing

    Service procedures - engine Group 21 Camshaft bearings, replacing (Camshaft removed) Special tools: 999 2000, 999 6062, 999 6071, 999 6626, 999 6969, 999 6971, 999 6974 Removal Expose and remove the camshaft inspection covers. Remove 999 6970 from the camshaft. Fit the cover. Check the tappet rollers.
  • Page 67 Group 21 Service procedures - engine Refitting Only the front edges of the bearing seats are bevelled. For this reason, all the bearings must be fitted from the front. New camshaft bearings are ready-machined and do not need to be reamed after fitting. Turn the spindle and press in bearing 7.

  • Page 68: Main Bearings, Replacing, All

    Service procedures - engine Group 21 Main bearings, all, replacing Remove the upper bearing shells by inserting a pin into the oil hole of the crankshaft. Special tools: 999 3590 Turn the crankshaft so that the pin carries the upper bearing shell with it.

  • Page 69: Crank Bearings, Checking For Wear Or Replacing, All

    Group 21 Service procedures - engine Crank bearings, wear check or Fit the oil pump and delivery pipe. replacement, all Note: When refitting the oil pump, check the delivery pipe at its union with the block with regard to flattening of the pipe. (Pan removed) Push the delivery pipe in until it bottoms in the blocks, thread Special tools: 999 3590...

  • Page 70: Crankshaft, Replacing

    Service procedures - engine Group 21 Crankshaft, replacing Check the oil channels of the new crankshaft and its contact surfaces with the bearing shells, cylinder block and caps. (Engine removed) Special tools: 999 3590 Examine the bearing shells. Worn or damaged shells must be replaced.

  • Page 71: Crankshaft

    Group 21 Service procedures - engine Crankshaft Check the axial play of the crankshaft. Max play 0.19 mm (0.0075"). The crankshaft is nitro-carburized. A nitro-carburized crankshaft has a greater resistance to fa- tigue and wear than an induction-hardened crankshaft. Fit the flywheel and the flywheel casing. Inspection Torque: Flywheel casing 140 Nm (103.3 ft-lb)
  • Page 72 Service procedures - engine Group 21 Check for cracks Checking must be carried out after alignment and before and after grinding. To check, use a magnetic powder test of type Magnaglo, i.e. fluorescent powder which can be seen under ultraviolet light. Refer to manufacturer’s instructions on the method to be adopted.

  • Page 73: Reconditioning

    Group 21 Service procedures - engine Reconditioning Flywheel, checking for warp Special tools: 998 9876, 999 9696, 999 3590 When reconditioning, keep to the following routines: Alignment (only as required). Check for cracks. Measure the bearing pins. See ”Workshop manual, Tech- nical Data”.

  • Page 74: Flywheel, Replacing

    Service procedures - engine Group 21 Flywheel, replacing Fit the flywheel and the bolts. (Clutch removed) Torque the flywheel to 260 Nm (191.8 ft-lb). Remove the flywheel bolts. Screw two bolts into the flywheel. Using the bolts, lift off the flywheel. Clean the crankshaft flange contact surface.

  • Page 75: Ring Gear, Replacing

    Group 21 Service procedures - engine Ring gear, replacing Flywheel casing, checking for warp (Flywheel removed) Special tools: 998 9876, 999 9683, 999 9696, 999 3590 Clean the flywheel and flywheel casing. Drill one or more holes in the ring gear and crack it with a chisel.

  • Page 76: Flywheel Bearing, Replacing

    Service procedures - engine Group 21 Flywheel bearing, replacing Special tools: 999 2269 Due to a hard fit the flywheel must be removed to allow the flywheel bearing to be removed using a suitable drift. Mount the magnetic stand on the flywheel with the probe of the dial indicator against the inner edge of the flywheel cas- ing.

  • Page 77: Crankshaft Seal, Rear, Replacing

    Group 21 Service procedures - engine Crankshaft seal, rear, replacing Special tools: 999 2000, 999 3590, 999 8010, 999 8238 Knock out the crankshaft seal using tool 999 8010. Clean the seat of the sealing ring in the flywheel casing. Apply sealant to the outer edge of the sealing ring and oil the inner edge of the sealing ring before fitting it with tool 999 Remove the flywheel bolts.

  • Page 78: Crankshaft Seal, Front, Replacing

    Service procedures - engine Group 21 Crankshaft seal, front, replacing Special tools: 884983 A new vibration damper with a narrower hub entered produc- tion as of serial no xxxx/35550. At the same time, a spacing washer was introduced, part number 877303, installed in front of the vibration damper.

  • Page 79: Sealant, Flywheel Casing, Replacing

    Group 21 Service procedures - engine Sealant, flywheel casing, replacing (Flywheel removed) Remove the flywheel casing from the cylinder block. Remove the old sealant from the cylinder block and on the flywheel casing. A = Outer vibration damper (Generating set engines) Fit the pulley and the outer vibration damper (if any).
  • Page 80 Service procedures - engine Group 21 Application of sealant to cylinder block...

  • Page 81: Lubrication System

    Group 22 Lubrication system Lubrication system Design and Function General The engine is pressure lubricated by a gear wheel pump. The system incorporates five valves: Safety valve Bypass valve for oil cooler By-pass valve for oil filter Reduction valve Piston cooling valve The lubricating oil is cleaned by two full-flow filters and one bypass filter.
  • Page 82 Lubrication system Group 22 (Notice.The engine outline shows a TAD-engine. The lu- brication system is the same for both TAD and T(I)(W)D engines. The oil pump forces the oil through the oil cooler to the Safety valve two full-flow filters. From these filters the oil is led to the Bypass valve for oil cooler engine block where it is distributed through ducts and By-pass valve for oil filter...

  • Page 83: Oil Cooler

    Group 22 Lubrication system The piston cooling valve opens when engine revs have The oil cooler maintains the temperature of the lubricating increased to slightly above idling speed. Oil flows through oil at a relatively low level which is advantageous from the the piston cooling duct to the nozzles for the pistons.

  • Page 84: Service Procedures

    Service procedures - lubrication system Group 22 Service procedures The engine must always be washed prior to starting repairs. Oil filters, replacing Lubricating oil pressure, checking Special tools: 999 9179 Special tools: 999 6591, 999 6398 Clean around the filter bracket and remove the 3 filters us- ing tool 999 9179.

  • Page 85: Oil Cooler, Replacing

    Group 22 Service procedures - lubrication system Oil cooler, replacing Disconnect the oil cooler from the front coolant pipe. Drain the coolant. Fit new sealing rings to the engine block and to both coolant pipes. Push the new oil cooler onto the front coolant pipe. Bolt the oil cooler to the spacer plate and engine block.

  • Page 86: Oil Cooler, Leakage Test

    Service procedures - lubrication system Group 22 Oil cooler, leakage test Connect leak detection equipment 999 6662 to 999 6845. (Oil cooler removed) Special tools: 999 6662, 999 6845 Flush the coolant side of the oil cooler with water- soluble de- greasing fluid.

  • Page 87: Oil Pump, Replacing

    Group 22 Service procedures - lubrication system Oil pump, replacing (Pan removed) Special tools: 999 6413, 999 8012 Removal Remove the idler gear from the bracket. Remove the delivery oil pipe. Remove the suction oil pipe. Remove the pump housing from the bracket. Push the shaft out of the drive gear.
  • Page 88 Service procedures - lubrication system Group 22 Refitting Fit the new pump to the bracket. Heat up the pump drive gear to 180° ±20°C (356° ± 36°F). Fit a new sealing ring to the delivery pipe. Fit the delivery pipe. Note: When refitting the oil pump, check the delivery pipe at its union with the block with regard to flattening of the pipe.

  • Page 89: Oil Pump, Reconditioning

    Group 22 Service procedures - lubrication system The illustration numbers above refer to the relevant point in the text below. Oil pump, reconditioning (Safety valve removed) Special tools: 999 2677, 999 6413, 999 8012 Remove the flange screws, the bearing end plate, the thrust Remove the gear wheel from the pump housing.
  • Page 90 Service procedures - lubrication system Group 22 The illustration numbers above refer to the relevant point in the text below. Check the housing for scoring and wear, and also check for Check the axial play of the pump using a feeler gauge. leakage between the bracket and pump housing.
  • Page 91 Group 22 Service procedures - lubrication system The illustration numbers above refer to the relevant point in the text below. Note: The clearance between the drive gear and the Place the gear wheels in the pump housing. bracket should be 0.4-1.0 mm (0.0157-0.0394"). Fit the thrust washers, the hub, the idler gear and the bearing Fit the pump housing to the bracket.

  • Page 92: Fuel System

    Fuel system Group 22 Fuel system Design and Function General The injection system consists of the injection pump, fuel fil- ters (2 ea), feed pump, injectors and pipes. The injection pump is mounted on the ”cold” side of the en- gine (right-hand side of engine).

  • Page 93: Injection Pump

    Group 22 Fuel system Injection pump Feed pump Manual pump Smoke limiter (TAD1630P/V) Injection pump TWD1620G/GH, TID162AG, TWD1630G/GE The pump does not have a separate bottom plate. The pump These engines have an RQ-governor. The RQ- governor is body and flange are of integral design. The smoke limiter is mechanical and works by means of speed sensitive gover- mounted on top of the governor housing (TAD1630P/V only).

  • Page 94: Tad1630G/Ge Y Tad1631G/Ge

    Fuel system Group 22 TAD1630G/GE, TAD1631G/GE The injection pump on TAD1630G/GE, TAD1631G/ GE is fitted with an electronic speed governor. The electronic gov- ernor system is a control unit which controls the engine speed. Its task is to: – maintain the idling speed at the set value.
  • Page 95 Group 22 Fuel system New seal screws (two different ones) have a pre-installed, pre-stressed nut on the conical thread. During assembly, you turn the nut until it releases (the screw has left-hand threads). This provides correct torque. Screws apply to en- gines as follows: Press hard on the top of the tool and remove it.

  • Page 96: Smoke Limiter Tad1630P/V

    Fuel system Group 22 Smoke limiter, TAD1630P/V The task of the smoke control device is to limit the quantity of fuel from the injection pump at low boost pressure. The diaphragm in the smoke control device is activated via a pipe by the pressure in the inlet pipe. The diaphragm’s movement operates an angle lever via a link system.

  • Page 97: Instrucciones De Reparación

    Group 22 Service procedures - fuel system Service procedures The engine must always be washed prior to starting repairs. Injection pump, removal Carefully clean the injection pump, pipes and the engine near the pump. Remove the protection plate for the pump cou- pling.
  • Page 98 Service procedures - fuel system Group 22 Screw the injection pump securely to the engine. Screw the carrier securely to the pump coupling (do not tighten the clamping screws). Fit tool 999 6848 and dial indicator 998 9876. Adjust the measurement tip so that it rests on the lifter.
  • Page 99 Group 22 Service procedures - fuel system Continue to rotate until the lifter has moved up until the value of the lift from basic circle is shown on the dial indicator. See ”Workshop manual, Technical Data” for each engine type. Further rotate the pump coupling until the dial test indicator shows about 1-2 mm (0.04-0,08”) more than the figure specified.

  • Page 100: Injection Pump, Setting With Measuring Tool 998 7057

    Service procedures - fuel system Group 22 Crank the flywheel in the direction of rotation until 1st Bleed the fuel system and test run the engine. See ”Fuel cylinder is on compression, 0° on the flywheel and the system, bleeding”. camshaft’s marking hole pointing upwards.
  • Page 101 Group 22 Service procedures - fuel system tation. Remove the plug in the governor housing and fit the measuring instrument sensor. Ground the measuring in- strument ground cable to a suitable place on the injection pump. Crank the flywheel in the direction of rotation until the correct degree marking immediately behind the needle on the flywheel housing.
  • Page 102 Service procedures - fuel system Group 22 Carefully turn the pump coupling against the direction of rotation until both light emitting diodes on the instrument light up. The injection pump is now in position for the in- jection cycle to commence on No.1 cylinder. Note: The measuring instrument is very sensitive, which en- sures that the setting will be exact.

  • Page 103: Pump Coupling Shaft, Removing

    Group 22 Service procedures - fuel system Pump coupling shaft, removing Injectors Checking and replacing the laminates on the pump cou- The injectors are placed vertically in the middle of the cylin- pling der through the valve cover. The injectors’ task is to: Check that the laminates on the pump coupling for the injec- –...

  • Page 104: Injectors, Replacing

    Service procedures - fuel system Group 22 Injectors, replacing Remove the injector retainers. Remove all injectors. (All) Note: If it is difficult to remove the injectors, tap gently on them using tools 999 6400 and 999 8007. Special tools: 981 2546, 999 6400, 999 8007 Clean up around all fuel return and delivery pipes as well as Remove the sealing rings from the steel rings.

  • Page 105: Injectors, Reconditioning

    Group 22 Service procedures - fuel system Injectors, reconditioning Clean the outside of the injector. Dismantle the injector. Pull the injector needle out of the dif- fuser and place the items in gasoline. If several diffusers are cleaned at the same time, make sure that the prematched needles and diffuser sleeves are not mixed up with others.

  • Page 106: Opening Pressure, Adjusting

    Service procedures - fuel system Group 22 Spray pattern Opening pressure, adjusting At a pump speed of 4-6 strokes per second, the spray pat- tern should be uniform and the fuel finely atomized. Two different pressures apply: On completion of the test, plug the pipe connections and pro- tect the diffuser tips with caps.

  • Page 107: Fuel Filters, Replacing

    Group 22 Service procedures - fuel system Fuel filters, replacing Clean and fit new gasket on the injection pump. Fit the feed Special tools: 999 9179 pump. Note: If lubricating oil has run out of the injection pump, an equal quantity should be replaced afterwards through the regulator’s level plug, at the rear of the regulator.

  • Page 108: Feed Pump, Reconditioning

    Service procedures - fuel system Group 22 Inspection Feed pump, reconditioning Inspect all other parts and replace those that are damaged or worn. (Pump removed) Disassembly Assembly Observe the greatest of cleanliness and rinse the parts in clean diesel fuel before fitting together. If the pump is not to be installed immediately, fit protection plugs to the connec- tions.

  • Page 109: Smoke Limiter, Tad1630P/V

    Group 22 Service procedures - fuel system Replacing the diaphragm Fit the union (3) and the O-ring (4) to the feed pump housing. (Can be carried out with the pump fitted to the engine) Fit the hand primer pump (5) and the seal (6). Note: The seals may only be broken by authorized staff.

  • Page 110: Fuel System, Bleeding

    Service procedures - fuel system Group 22 Fuel system, bleeding The fuel system must be vented after the fuel filters or the in- jection pump have been replaced Make sure that the engine is in operating mode. Open the bleed nipple (1) on the fuel filter. Press the primer pump (2), until fuel free from bubbles of air starts to flow out.

  • Page 111: Intake And Exhaust Systems

    Group 22 Intake and exhaust systems Intake and exhaust systems Design and Function Charge air cooler The TAD1630 and TAD1631 are equipped with an air to air charge air cooler. The purpose of the cooler is to lower the temperature of the intake air before it is blown into the engine cylinders.

  • Page 112: Air Filter

    Intake and exhaust systems Group 22 Air filter The disposable air filter is of the dry type with a paper filter element. There is a pressure drop indicator which shows a red indicator when the filter is clogged and needs replacing. Starter heater The pre-heating and post-heating times are a factor of engine temperature.

  • Page 113: Service Procedures

    Group 22 Service procedures - intake and exhaust systems Service procedures The engine must always be washed prior to starting repairs. The charging pressure should not fall below these levels. Note: For this test to give a true picture of the situation, it is Boost pressure, checking essential that the full load condition is maintained a sufficient- ly long period of time for the pressure to stabilize.

  • Page 114: Rectifying Low Boost Pressure

    Service procedures - intake and exhaust systems Group 22 In the event of daily operation in dusty or oily air, regular Rectifying low boost pressure cleaning of the compressor housing and compressor wheel is recommended. Fouled compressor parts can result in low boost pressure.

  • Page 115: Checking Exhaust Back Pressure

    Group 22 Service procedures - intake and exhaust systems Checking exhaust back Turbocharger, checking pressure bearing clearance Special tools: 884969 (flange kit) TWD1620/-1630, TID162 Schwitzer S4T/Holset H3B/Holset 885184 (flange kit) TAD1630/-1631 HSB870/B36 Remove the exhaust pipe from the turbocharger’s exhaust Checking axial and radial clearance is normally done only in outlet.
  • Page 116 Service procedures - intake and exhaust systems Group 22 Measuring radial clearance Place a rocking arm dial indicator with its measuring point on the compressor wheel hub. Press down the wheel at the same time as the rotor on the opposite end of the shaft is pushed upwards.

  • Page 117: Turbocharger, Reconditioning

    Group 22 Service procedures - intake and exhaust systems Turbocharger, reconditioning Schwitzer S4T (TAD1630, TAD1631) Compressor Wheel Bearing housing (complete) Lock nut V-clamp Compressor Cover Circlips Piston ring holder Heat Shield Shim (optional) Piston ring Piston ring Turbine housing Cover Shaft and wheel (complete) Screws Snap ring...
  • Page 118 Service procedures - intake and exhaust systems Group 22 Gently remove the turbine shaft and wheel by tap- ping with a small soft faced mallet on the compressor end of the shaft. Be careful not to bend or damage the shaft. Place the bearing housing (13) on the turbine backplate (16) (if fitted) on the bench and remove the insert retaining snap ring (20).
  • Page 119 Group 22 Service procedures - intake and exhaust systems 3 Shaft and wheel assembly 6 Turbine heat shield (16) Soak in solvent to remove oily residue. Mask entire shaft Replace if cracked or warped. section and totally clean wheel and hub using steam. Avoid concentrating on piston ring seal groove.
  • Page 120 Service procedures - intake and exhaust systems Group 22 Fit the shaft and wheel etc. into the bearing housing after lu- Fit the compressor wheel (1) and lock nut (2). On models bricating both shaft and piston ring. Take care not to damage that have shims (5) under the compressor wheel, ensure the piston ring when inserting the sealing bore.
  • Page 121 Group 22 Service procedures - intake and exhaust systems Torque the compressor lock nut with a T-handle torque wrench to 13.6 Nm (10 ft-lb) and then rotate to an additional 90°-95° and apply 2 drops of Loctite 601 to the threads. Note: Use a T-handle torque wrench together with a univer- sal joint to avoid side-loading the turbine wheel shaft.

  • Page 122: Holset, Tid162/Twd1620/Twd1630

    Service procedures - intake and exhaust systems Group 22 Holset H3B/HSB 0870/B36, TWD1620, TID162, TWD1630 36. Thrust flange 4. Bearing Housing 37. Oil Control Ring 5. Turbine housing 38. Heat Shield 6. Shaft and Wheel 43. Insert 7. Compressor Wheel 51.
  • Page 123 Group 22 Service procedures - intake and exhaust systems Disassembly Remove the compressor nut and pull the compressor wheel (7) from the turbine’s shaft. If the compressor wheel is stick- ing it may be heated with a hot air pistol to max 130°C Clamp the turbine inlet flange and mark the relative positions (266°F).
  • Page 124 Service procedures - intake and exhaust systems Group 22 Gently slide the shaft and wheel into the bearing housing. Fit the insert assembly into the bearing housing. Apply mod- Apply moderate pressure and a slight rotation to allow the erate pressure to correctly seat the insert (43). piston ring to centralize and enter the chamfered bore of the Note: It may be necessary to use a small, soft mallet.

  • Page 125: Measures In Case Of Turbo Failure On Tad- Engines

    Group 22 Service procedures - intake and exhaust systems Note: As an extra precaution to prevent contaminated oil Measures in case of turbo from reaching the turbocharger, a strainer can be mounted failure on TAD- engines temporarily in the compressor inlet connection. The engine must then be run for at least half an hour.

  • Page 126: Charge Air Cooler, Checking For Leakage, Tad-Engines

    Service procedures - intake and exhaust systems Group 22 Charge air cooler, checking for leakage, TAD-engines Special tools: 999 6662, 885231, 885232 Check the pressure tester before use. Fit connection tool 885231 and sealing tool 884232 together with new hoses (if needed) on the charge air cooler. Un- screw the pressure tester reduction valve.

  • Page 127: Cooling System

    Group 22 Cooling system Cooling system Design and Function (These illustrations are only examples of the design and function in the cooling systems for various engines) Radiator Thermostats Distributor pipe for coolant Coolant pump Coolant filter Oil cooler Charge air cooler...
  • Page 128 Cooling system Group 22 Cooling system The coolant is circulated by an gear-driven pump (4) and is led in the cylinder block and from there through channels and openings to the cylinder heads, liner jackets and oil cooler (6). On TWD, TID and TD (7), the return flow of fluid from the cylinder blocks and from the charge air cooler is led via an outer pipe (3) from the cylinder head to the thermostat hous- ing (2), which contains two thermostats.
  • Page 129 Group 22 Cooling system the situation with the engine warm. Both thermostats have The filter consists of a filter insert made of pleated paper and the same opening temperature and they work in parallel. containing a dosage of corrosion-inhibiting additive. When a new filter is fitted, the anti- corrosion additive is quickly Between the distribution gallery of the engine and the return leached out by the passing fluid.

  • Page 130: Service Procedures

    Service procedures - cooling system Group 22 Service procedures Remove the belt pulley. Remove the holder for the coolant pump’s sealing ring. Coolant pump, replacing Special tools: 999 2000, 999 2929, 999 6860 Removal Remove the central screw. Remove the flange for the belt Switch off the main circuit breaker/disconnect batteries.
  • Page 131 Group 22 Service procedures - cooling system Fitting the coolant pump Replace the sealing ring in the sealing ring holder, using tool 999 2000 and 999 2929. Scrape the mating surfaces clean. Apply a bead of sealant and fit the holder for the sealing ring. Screw the belt pulley tight.

  • Page 132: Coolant Pump, Reconditioning

    Service procedures - cooling system Group 22 Coolant pump, reconditioning Special tools: 999 1801, 999 2061, 999 2412, 999 2852, 999 6019, 999 6858, 999 6998, 999 6999 999 8000, 998 9876 Put the coolant pump in a vise with the impeller facing up- wards.
  • Page 133 Group 22 Service procedures - cooling system Press out the pump shaft together with the ball bearing, the roller bearing race and the gear wheel. Use drift 999 6858. Turn the pump around in the press to bring the drive side facing up.
  • Page 134 Service procedures - cooling system Group 22 Press the ball bearing and stop ring off the pump shaft. Heat the stop ring to +160°C (+320°F). Press the ring onto the pump shaft until it stops against the inner race of the bearing.
  • Page 135 Group 22 Service procedures - cooling system Grease the edge of the seal. Put the seal into the pump with the metal edge facing upwards. Oil the pump shaft and press the inner race of the roller bearing into position. Press until its stops. Put the pump housing in the press.
  • Page 136 Service procedures - cooling system Group 22 Turn the pump over to bring the drive side facing upward. Oil the seat of the ball bearing in the pump housing. Press in the pump shaft until the ball bearing is about 2 mm (0.080") from the circlip groove in the pump housing.
  • Page 137 Group 22 Service procedures - cooling system that the pump shaft is free and the walls of the pump shaft take up the pressing force. Continue to press in the shaft carefully until the outer race Mount the deflector ring onto the pump shaft with the edge of the ball bearing stops against the circlip in the pump facing down.
  • Page 138 Service procedures - cooling system Group 22 Fit the seal into the pump housing. Mount dial indicator 998 9876 on tool 999 6999. Set the dial indicator so that it shows 20.0mm (0.8") against a flat surface. Press in the seal with tool 999 6998. Position the pump in the press so that the pump stands on its shaft with the drive side facing down.
  • Page 139 Group 22 Service procedures - cooling system Dip the rubber ring in soapy water. Place the rubber and ceramic rings in the center of the impeller. Put the impeller onto the pump shaft. Remove 999 6998 from the pump. Check that the center of the impeller is 4.8 mm (0.1890") above the edge of the pump housing.
  • Page 140 Service procedures - cooling system Group 22 Extra coolant pump, reconditioning (TD164KAE) Special tools: 999 2412, 999 6315, 999 6858, 999 6998 Press out bearing (6) and bearing shaft (5A) with punch 999 Note: All numbers in parenthesis refer to the illustration 6858.
  • Page 141 Group 22 Service procedures - cooling system Install spacer ring (10) on the bearing shaft (5A). Screw 999 6315 into the bearing journal (5A) where the belt pulley (4) is located, until it bottoms. Place a washer between the impeller and the press tool so Press the belt pulley (4) in place with punch 999 2412.

  • Page 142: Sleeve Thermostats, Replacing

    Service procedures - cooling system Group 22 Sleeve thermostats, replacing Special tools: 999 6863 Drain the coolant. Remove the pipe between the thermostat housing and the upper radiator hose. Push the pipe to one side. Remove the old sealing rings by tapping them down with a suitable drift.

  • Page 143: Sleeve Thermostats, Checking

    If the thermostat does not close properly, replace it. Tap the sealing ring in with the drift until the drift bottoms against the thermostat housing. Fit the thermostats and O-rings. Heat water in a receptacle to: TAD1630G, TAD1631G, TD164KAE 75°C (167°F) Fit the thermostat housing. Others 70°C (158°F) Immerse the thermostat in the receptacle as illustrated.

  • Page 144: Coolant Manifold Seals, Replacing

    Service procedures - cooling system Group 22 Coolant manifold seals, Remove connections and pipes as one unit. replacing Special tools: 999 6662 Removal Switch off at main circuit breaker/disconnect batteries. Drain the coolant. Disconnect electrical cables and engine temperature sen- sor.
  • Page 145 Group 22 Service procedures - cooling system Refitting Fit the rear coolant pipe to the oil cooler together with the new sealing rings. Fit the new seals to the coolant manifold. Fit new sealing rings (4) to the coolant pipe. Fit the manifold as one unit.

  • Page 146: Coolant

    WARNING! Do NOT open the pressure cap (bleed Note: Volvo Penta anti-freeze must not be mixed with any cock) when the engine is hot. Steam or hot coolant other kind of anti-freeze.

  • Page 147: Coolant, Filling

    Group 22 Service procedures - cooling system On engines with a separate expansion tank (optional Coolant, filling equipment), the filling of large volumes is done directly through the filler opening on the radiator, until the system To ensure excellent cooling of the engine, it is vital to check is vented and completely filled.

  • Page 148: Coolant Leakage

    * Not marketed by Volvo Penta, can be purchased from chemical stores. pressure valve. The fault can be in the compressed air com- Chemical formula for oxalic acid: C pressor, it fitted, or leakage at the cylinder head gaskets.

  • Page 149: Cooling System, Pressure-Testing

    Replace if necessary. Note: Always follow applicable safety regulations. Fill the system with a coolant recommended by Volvo Penta. See section “Coolant”. Check to make sure that there are no leaks. Close cock (B). The pressure must not drop during two min- utes if the test device is to be considered reliable.

  • Page 150: Pressure Valve, Checking

    Service procedures - cooling system Group 22 Tighten the lock ring for the knob on the relief valve. In- crease the pressure by tightening the knob until the pressure gauge reads 70 kPa (10.15 psi).Lock the knob by pressing in the lock ring and close the cock (B). Check during one minute that the pressure does not drop.

  • Page 151: Electrical System

    Group 22 Electrical system Electrical system The engines are equipped with a 2-pole electrical system Starting with auxiliary battery with an alternator. System voltage is 24 volts. Important WARNING! The batteries (especially auxiliary batter- ies) contain an oxyhydrogen gas mixture which is For engines with alternators the following is applicable: very explosive.

  • Page 152: Electronic Speed Governor, Wiring

    9. Engine speed pickup for overspeed protection 2. Actuator 6. Main switch 10. Engine speed switch (rpm switch) 3. Pickup 7. Transient protection 11. Relay 4. Multi-turn potentiometer* 8. Stop solenoid/Fuel shut off valve 12. Battery * Not from Volvo Penta...

  • Page 153: Wiring Diagrams

    Wiring diagrams Instrument panel and engine (except TWD1620 and TID162) (equipped with stop sole- noid). Position key for diagram 1 and 2 1. Oil pressure gauge 2. Coolant temperature gauge 3. Rev. counter with built-in hour counter 4. Warning lamp, charging 5.
  • Page 154 TID162) (equipped with fuel shut-off valve). Instrument panel and engine (except TWD1620 and Cable areas in mm² (see color code in wiring diagram). 1.5 mm² applies when no other area is shown Color code Blue Orange LBL = Light blue Violet Brown LBN =...
  • Page 155 Cable areas in mm (see color code in wiring diagram). 1.5 mm² applies when no other area is shown Instrument panel and engine for TWD1620 and TID162. Color code Blue Orange LBL = Light blue Violet Brown LBN = Light brown Black Green White...
  • Page 156 Connection of alarm separator (option) to instrument pan- 1. Relay for coolant level switch (option) 2. Relay for coolant temp. switch, oil pressure switch 3. Holding current relay (operating current and instrument) 4. Alarm separator 5. Connection 6. Terminal block (extra receptacle fused for 16A. Receptacle for automatic stop, shutdown in case of fault).
  • Page 157 Dotted line represents existing cable Connection of time relay kit (accessory) for connection of starter heater. Time relay Contact piece, 8-pole. Ignition switch Temperature switch (option) Starter heater Indicator lamp (starter heater connected) Battery High output relay for starter heater Fuse, 8A)

  • Page 158: Troubleshooting

    Troubleshooting Group 22 Troubleshooting 1. Engine does not start Starter motor does not turn engine CAUSE REMEDY • Discharged batteries Charge/replace the batteries (or connect auxiliary batteries as described in section “Starting with auxiliary battery”). • Main switches off Turn on the main switches. •...
  • Page 159 Group 22 Troubleshooting Starter motor turns over as usual but engine does not start CAUSE REMEDY • Air in fuel system Bleed the fuel system, see “Fuel system, bleeding”. • No fuel – fuel cocks closed Open the fuel cocks –...
  • Page 160 Troubleshooting Group 22 • Insufficient air flow to engine – air filter blocked Fit new air filter or clean the air filter. Check ventilation to engine room. • Faulty injectors Check/replace injector(s). 3. Coolant temperature too high CAUSE REMEDY • Coolant level in engine too low (air in system) Fill the engine with coolant and vent the system See “Cool- ant, filling”.
  • Page 161 Group 22 Troubleshooting • Faulty setting of injection pump Adjust pump setting. • Faulty smoke limiter – smoke limiter seizing Overhaul smoke limiter. – pressure pipe between inlet manifold and smoke Fit new pressure line limiter leaking – faulty diaphragm in smoke limiter Replace diaphragm in smoke limiter.
  • Page 163 From: ......................................................................Refers to publication: .................................. Publication No: ................Date of issue: ................. Proposal/Justification: ......................................................................................................................................................................................................................................................................................................................... Date: ................. Signed: ..............AB Volvo Penta Teknisk Information Avd. 42200 SE-405 08 Göteborg Sweden...

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