Related Manuals for Volvo Penta TAMD61A
Summary of Contents for Volvo Penta TAMD61A
- Page 1 Workshop Manual Engine 2(0) TAMD61A, TAMD62A, TAMD63L-A, TAMD63P-A TAMD71A, TAMD71B, TAMD72A, TAMD72P-A, TAMD72WJ-A...
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Page 3: Table Of Contents
Group 21 Engine body Marine engines TAMD61A • TAMD62A • TAMD63L-A • TAMD63P-A TAMD71A • TAMD71B • TAMD72A • TAMD72P-A TAMD72WJ-A Contents General instructions ..........2 Piston removal, gudgeon pin boss replacement ............54 Special tools ............9 Piston, assembly ..........55 Other special equipment ........ -
Page 4: General Instructions
This Workshop Manual contains technical data, des- liquids in supply lines and hoses when the engi- criptions and repair instructions for Volvo Penta pro- ne is running or has been turned off immediately ducts or product versions contained in the contents prior to starting work on it. - Page 5 Safety information Avoid skin contact with oil. Long-term or repea- Never expose the batteries to a naked flame or ted contact with oil can remove the natural oils electric sparks . Never smoke in proximity to from your skin. The result can be irritation, dry the batteries.
- Page 6 Components in the electrical system, ignition Observe the following rules when cleaning with system (gasoline engines) and fuel system on Volvo Penta products are designed and cons- high-pressure water jets: Never direct the water tructed to minimize the risk of fire and explosi- jet at seals, rubber hoses or electrical compo- on.
- Page 7 Volvo Penta for the mechanical/electrical nature which are associated with engine.
- Page 8 The warning symbols used in the Workshop Manual tolerances, that systems capable of adjustment (see Information on Safety for implication) receive the correct setting, and that Volvo Penta WARNING! Genuine Parts are used for the engine. The time intervals in the engine’s maintenance schedule must IMPORTANT! be followed.
- Page 9 The following RTV-agents are named in the Workshop Manual: Loctite® 574, Volvo Penta 840879-1, Strength classes Permatex®. No. 3, Volvo Penta 1161099-5, Permatex® No. 77. Old sealant is removed in each Screws and nuts are divided into different strength case with denatured spirit.
- Page 10 Safety information Always use gloves made of chloroprene rubber Safety rules for fluorocarbon (gloves for handling chemicals) and protective rubber goggles. Handle the removed seal in the same way as cor- Fluorocarbon rubber is a common material in seal rosive acid. All residue, including ash, can be rings for shafts, and in O-rings, for example.
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Page 11: Special Tools
Special tools In all cases where it is practical, tools have had their part number punched on, but not the last figure. The last fig- ure (after the dash) is a check sum figure. 884948 884949 9812546 9991084 9991459 9991801 9991867 9992000 9992071... - Page 12 Special tools 9996421 9996433 9996437 9996643 9996400 9996402 9996419 9996420 9996650 9996651 9996657 9996662 9996645 9996841 9996842 9996847 9996400-9 Impact hammer. Used with 9996419 or 9996651-7 End cutter for cleaning the bed for the 9996657. copper cylinder (stage 2) 9996402-5 Mandrel for installing copper sleeves 9996657-4 Extractor for copper cylinder...
- Page 13 Special tools 9998114 9996852 9996855 9996861 9996867 9998009 9998070 9998079 9998115 9999508 9996878 9999553 9996852-1 Connection washer for pressure testing 9998070-8 Tool for installing the copper sleeve and the cylinder block steel ring, 6(x) series. Used together with 9996406 and 9996421 9996855-4 Mandrel for installing the front crankshaft seal...
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Page 14: Other Special Equipment
Other special equipment 885126 9988539 9989876 9999696 Other special equipment 885126-3 Piston ring compressor 9988539-4 Compression gauge 9989876-9 Dial gauge 0–20 mm 9999696-9 Magnetic stand... -
Page 15: Design And Function
Design and function Engine, general The engines are straight 6-cylinder, 4-stroke diesel en- Since the induction air is cooled, the combustion and gines with overhead valves. They have direct fuel in- exhaust temperatures are kept at a suitable level, de- jection and turbocharging. -
Page 16: Design Differences, Engine Versions
Junction boxes, This workshop manual applies to all engines of the monitors and sensors have rubber mountings (vi- 6(x) series; TAMD61A, TAMD62A, TAMD63L-A bration reducing) and TAMD63P-A, and from the 7(x) series; TAMD71A, TAMD71B, TAMD72A, TAMD72P-A New alternator (engines with 24V electrical sys- and TAMD72WJ-A. -
Page 17: Identification Signs
Design and function TAMD72A – TAMD72WJ-A Electronic box (EDC) added, located beside the rear fuel filter TAMD72WJ-A is a TAMD72A which has been modi- fied for use with a water jet unit. TAMD72WJ-A has: Stop solenoid deleted (the engine is stopped by the EDC system) New injection pump with changed settings. - Page 18 Design and function Engine presentation TAMD61A 14 13 1 Junction box with circuit breakers 8 Oil cooler, reverse gear 2 Coolant filler cap 9 Reverse gear, MPM IRM 220A 3 Fuel filter 10 Dipstick (alternative location) 4 Oil filler cap (also at front edge of engine)
- Page 19 Design and function TAMD62A 1 Air filter 8 Lubrication oil filter (alt. location at left-hand rear 2 By-pass valve (directs air flow through aftercooler) of engine as extra equipment) 3 Filter for crankcase breather 9 Flexible engine mountings (extra equipment) 4 Aftercooler 10 Sump 5 Heat exchanger...
- Page 20 Design and function TAMD63L-A, TAMD63P-A 12 11 1 Fuel filter, fine 9 Reverse gear, MPM IRM 220A-1 2 Smoke limiter 10 TAMD63P-A: Wastegate valve (by-pass valve) 3 Coolant filler cap 11 Dipstick, engine 4 Injection pump 12 Solenoid valve (fuel shut-off valve) for engine 5 Oil filler cap stopping 6 Junction box with circuit breakers...
- Page 21 Design and function TAMD71A 1 Junction box with circuit breakers 7 Turbocharger 2 Coolant filler cap 8 Oil cooler, reverse gear 3 Fuel filter 9 Reverse gear, TD MG507 4 Oil filler cap (also at front edge of engine) 10 Oil cooler, engine 5 Injection pump 11 Smoke limiter 6 Stop solenoid...
- Page 22 Design and function TAMD71B 1 Junction box with circuit breakers 8 Oil cooler, reverse gear 2 Coolant filler cap 9 Reverse gear, TD MG507A 3 Fuel filter 10 Dipstick (alternative location) 4 Oil filler cap 11 Oil cooler, engine 5 Injection pump 12 Smoke limiter 6 Stop solenoid 13 Circulation pump...
- Page 23 Design and function TAMD72A 16 15 11 10 9 Water cooled exhaust riser (extra equipment) 1 Junction box with circuit breakers 10 Reverse gear, TD MG5061SC 2 Coolant filler cap 11 Oil cooler, reverse gear 3 Fuel filter 12 Dipstick (alternative location) 4 Oil filler cap 13 Oil cooler, engine 5 Injection pump...
- Page 24 Design and function TAMD72WJ-A 8 Water cooled exhaust riser (extra equipment) 1 Junction box with circuit breakers 9 Stop solenoid 2 Coolant filler cap 10 Alt. dipstick location 3 Fuel filter, fine 11 Oil cooler, engine 4 Smoke limiter 12 Circulation pump 5 Injection pump 13 Alternator 6 Oil filler cap...
- Page 25 Design and function TAMD72P-A (EDC) 15 14 11 10 1 Coolant filler cap 9 Reverse gear, TD MG507-1 2 Fuel filter, fine 10 Oil cooler, reverse gear 3 Control unit (EDC) 11 Wastegate valve (by-pass valve) 4 Oil filler cap 12 Alt.
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Page 26: Component Description
Design and function Component description Cylinder heads The engine has two (identical) cylinder heads, each of which covers three cylinders. The cylinder heads are screwed to the cylinder block by 20 screws per head (M11). The cylinder head material is a special cast iron alloy. The cylinder head gasket is solid sheet steel. - Page 27 Design and function Cylinder block The cylinder block is cast in one piece and is made of special cast iron alloy. The tension forces in the cyl- inder head screws, caused by combustion pressures, are transmitted by stiffened sections in the interior walls of the cylinder block to the main bearings.
- Page 28 Design and function Pistons The pistons are made of light metal alloy. The top compression ring, which transmits the majority of the heat which is transferred via the pistons, is located in a ring carrier made of high alloy special cast iron, which is cast in to the piston.
- Page 29 Design and function TAMD71 Each piston has three compression rings (early ver- sion), or two compression rings (later version)* and one oil scraper ring. The upper compression ring on the early version is chrome plated and has a turned internal chamfer, and on the later version it is molybdenum coated and must be fitted with the TOP marking** uppermost.
- Page 30 Design and function Timing gear The timing gear consists of cylindrical gear wheels with spiral cut teeth. The injection pump and camshaft are driven from the crankshaft gear via an idler gear. The engine oil pump is also driven from the crankshaft gear via an idler gear.
- Page 31 Design and function Con rods The con rods have an I section, and are drilled for pressure lubrication of the gudgeon pins. Since the con rods have obliquely split big ends, they can be pulled up through the cylinder bores during engine ren- ovation.
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Page 32: General
Repair instructions Measures before renovation outside the General boat Before every major service task, a condition test 4 Lift the boat up onto land should be carried out if possible, to determine the gen- eral condition of the engine and to find any co- 5 Turn off the battery isolator, remove the battery operating fault causes. -
Page 33: Engine Jig Attachment
Repair instructions Engine stand attachment Jig no. 9996787 is used to attach the engine to the Before the engine jig can be fitted, and the engine at- engine stand. The jig is screwed to the right-hand side tached to the engine stand, the following components of the engine, as in the illustration below. -
Page 34: Condition Test, Engine
Repair instructions Condition test, engine Cylinder head, renovation Compression test Cylinder head, removal Special tool 9998009 Special tool nos. 9996643, 9996847* A compression test is done in order to assess the TAMD61/62/63, TAMD 71/72 condition of the engine in a simple and reliable man- ner, this indicates the sealing ability of the piston Remove both battery cables rings and valves. - Page 35 Repair instructions Free the plastic pipe for the smoke limiter from the If the engine has a stop solenoid, remove it and hang front edge of the induction manifold. Remove the in- it up. duction manifold. Applies to all engines Applies to TAMD63 Shut off the fuel taps.
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Page 36: Cylinder Head, Stripping/Assembly
Repair instructions Cylinder head disassembly/ Free the exhaust pipe from the turbocharger. assembly Remove the coolant pipe between the turbo and the cylinder block. Special tool: 885128 Remove the oil pipes for the turbocharger. Install pro- tective covers. Remove the turbocharger and exhaust manifold. Cov- er the turbo inlet and outlet with clean paper or use some other method, to prevent dirt and other foreign matter from entering the turbocharger. -
Page 37: Cylinder Head, Leakage Test
Clean the core plugs if they have been removed. lock ring which is moved along the spindle. Clean the core plug seats. Use Permatex® No. 3 or Volvo Penta 1161099-5 seal- ant. Install the plug by means of a mandrel or sleeve. - Page 38 Repair instructions Check that the knob on the reduction valve of the Screw in the reduction valve knob to give a pressure proof testing equipment is screwed out. of 50 kPa (0.5 kp/cm ) on the pressure gauge. Main- tain this pressure for 1 min. Connect the hose from the proof testing equipment to the air connection plate.
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Page 39: Cylinder Head, Inspection
Repair instructions Warpage Cylinder head, inspection The warpage of the cylinder head must not exceed 0.03 mm. The check is made with a feeler gauge and steel ruler, whose sides has been shaved to an accuracy corresponding to DIN 874/Normal. If the cylinder head is found to be warped more than the permitted value, the cylinder head must be planed or replaced. -
Page 40: Valve Guides, Inspection
Repair instructions Valve guides, inspection Valve guides, replacement Special tools: 9999876 and 9999696. Special tools: 6(x) series: 9991459, 9996169, 7(x) series: 9991084, 9992661. Put the cylinder head on a flat surface and put new valves in the guides. The valve spindles should rest on the flat surface. If necessary, remove the injector fastening studs to get good contact. -
Page 41: Cylinder Head, Planing
Repair instructions Cylinder head, planing Cylinder head, milling the seal groove Special tools: 9992479, 998976. Special tools: 998976 and 9992479 + 9996841, 6(x) The warpage on the cylinder head must not exceed series; 9996842, 7(x) series 0.03 mm. If the warpage exceeds this value, or if blow-by lines occur, the cylinder head must be planed or replaced. - Page 42 Repair instructions Setting the cutters Set up the cutter head in a vice, with the bits facing upwards. The grooving tool has five bits. Three of them (Marked A-A*-B) are intended to work the flame edge groove. These should be adjusted to 2.8 mm +0.1, –0.2 mm. Attach the dial gauge (998976) in holder 9992479 and put this on the ring-shaped land on the cutting tool.
- Page 43 Repair instructions Press down the bit holder and tighten the lock screw Install the bit holders in the cutter head, in accordance enough to press against the holder. with the letters, and with the grooves aligned towards the lock screws. Adjust the bit height as instructed. Put the dial gauge tip on the highest point of the bit and turn the adjustment screw upwards until the cor- rect value of bit height is obtained.
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Page 44: Valve Seat, Replacement
Repair instructions Valve seat, replacement Special tools: 9992479, 998976 Install the spring and nut. Tighten the nut loosely. The valve seat should be replaced when distance (A), Turn the tool clockwise, using even movements, and measured with a new valve, exceeds without pressing. -
Page 45: Valve Seat, Grinding
Repair instructions Mill or grind the valve seats. A new valve seat must be ground down so that the distance between the cyl- Clean the valve seat location carefully, and check that inder head plane and the valve head (A), measured there are no cracks. -
Page 46: Valves, Grinding
Repair instructions Valves, grinding Rocker mechanism, renovation (does not apply to engines with Nimonic valves)* Special tools: 6(x) series 9991876, 7(x) series 9992677. * Note. Nimonic valves must not be ground. Valve sealing angles: Inlet: 29.5° Exhaust: 44.5° Check the valves before grinding them. Cracks and damage to the valve head or bent valve stems always mean that the valve must be replaced. - Page 47 Repair instructions Oil the rocker shaft and install all the components. Note that the rockers on the 6(x) series are installed in opposing pairs. On the 7(x) series, all the rockers are identical and the location on the shaft is thus arbitrary. Make sure that the circlips on the rocker shaft ends Press out the rocker bushing with mandrel no.
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Page 48: Checking The Valve Springs
Repair instructions Checking the valve springs Cylinder head, assembly Special tools: 9992479, 9996847 Clean the mating planes of the cylinder head and cyl- inder block. Remove any rust or carbon from screw holes and from the threads for the cylinder head fast- ening holes. - Page 49 Repair instructions Torque the cylinder head screws in the numbered se- quence in the tightening schedule, four times. Install the push rods and rocker mechanism. Tighten- 1st tightening: 30 Nm (3 kpm) ing torque: For the 61 series with steel bearing caps, 2nd tightening: use 65 Nm (6.5 kpm) 6(x) series: 85 Nm (8.5 kpm)
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Page 50: Copper Injector Sleeve, Replacement
Repair instructions Copper sleeve for injectors Special tools, 6(x) series: 9812546, 9996400, 9996402, 9996419, 9996421, 9996643, 9996650, 9996651, 9996657, 9996867, 9998070 7(x) series: 9812546, 9996400, 9996402, 9996419, 9996420, 9996643, 9996657, 9996861, 9996867 The copper sleeve can be changed with the cylinder head either installed or detached. -
Page 51: Cleaning Seat For Copper Sleeve
Repair instructions Cleaning the seat for the copper sleeve Method 1 – with a plug brush (installed or detached cylinder head) Special tool 9812546 It is very important that all kinds of deposits on the mating surface in the cylinder head, of the copper sleeve are removed before a new copper sleeve is in- stalled. -
Page 52: Copper Sleeve, Assembly
Repair instructions Copper sleeve, assembly Method 2 – with a cutter (detached cylinder head) Special tools, 6(x) series: 9996402, 9996421, 9998070 Special tool: 9996650, 9996651 7(x) series: 9996402, 9996420, 9996861 Cleaning up with a cutter is done in two stages. Injector and copper sleeve NOTE! Only use a cutter if absolutely necessary, since the location of the injector in the cylinder head... - Page 53 Repair instructions 6x-series 6x-series 7x-series 7x-series (6x series): Remove the two fastening screws for the cylinder head (one on each side of the copper sleeve). Screw down press tool no. 9998070. (7x series): Screw down press tool 9996861 with the injector attachment screws.
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Page 54: Valves, Adjustment
Repair instructions Remove the press tool and mandrel. (6x series): Install the cylinder head screws and torque them. Please refer to “Cylinder head, installa- tion” on pages 46 and 47. Inlet Exhaust Valve location and cylinder numbering Valve clearance, Inlet Exhaust TAMD61, TAMD62, ..... -
Page 55: Cylinder Block, Renovation
Repair instructions Cylinder block, renovation Turn the engine round until the relevant piston is at BDC. Remove the big end bearing cap with the lower bearing shell. Piston and connecting rod, removal (Cylinder head and sump removed) Special tool: 9996847. Please refer to “Cylinder head, removal”... -
Page 56: Piston And Con Rod, Inspection
Repair instructions Piston and con. rod, inspection Removal of piston, small end bush replacement Special tools: 9991801, 9992071, 9992479 (7x series), 9992669 (6x series) Before the small end bush is replaced, the con rod must be checked for cracking, straightness and twist. A cracked, bent or twisted con rod must be scrapped. -
Page 57: Piston Assembly
Repair instructions Piston assembly Special tool: 9992071 Press the old bush out, using mandrel no. 9992669 (6x series) or 9992479 (7x series). and shaft no. 9991801. Install one circlip on the piston. Heat the piston up to about 100°C. Heat the con rod up to about 100°C. Press in the new bush, using the same tool as was used for extracting the old one. -
Page 58: Piston Ring Inspection And Fit
Repair instructions During measurement, the ring should be pressed down below the Bottom Turning point using a piston. Replace the piston rings if the gap is 1.5 mm or great- In general, piston rings should be replaced if there is any noticeable wear (within the wear tolerances) in the cylinders, since the piston rings do not normally end up in the same positions as they had before removal. -
Page 59: Cylinder Liner, Inspection And Measurement
Repair instructions Cylinder liner, inspection and If the wear is greater than 0.35–0.40 mm, the cylinder measurement liner with pistons and piston rings should be replaced. NOTE! The piston and cylinder liner are only supplied as a complete set as spare parts. The pistons and Inspection cylinder liners are classified and marked with a letter, C, D or E. -
Page 60: Cylinder Liner, Honing
Repair instructions Clean the removed cylinder liner from sooty edges. Cylinder liner, honing Set the liner up in a vice. Use a heavy electric drill which can be operated at low speed, 200–400 rpm. Use a Flex-Hone® tool with no. 80 grit. Honing pattern on cylinder liner bore NOTE! Do not use a honing tool with grinding stones, It is important that the cylinder liner should retain its... -
Page 61: Cylinder Liner Position, Renovation
Repair instructions Calculate the thickness of spacers needed, on the ba- Cylinder liner seat, renovation sis of the measurements you have made. Try to use the thinnest possible spacer, preferably only one Special tools: 9989876, 9992479, 9996847 (2 No.), should be used. The correct height above the block 9999508 (7x series), 9999514 (7x series), 9999538 plane should be 0.38–0.43 mm. -
Page 62: Cylinder Liner, Assembly
Repair instructions Cylinder liner, installation Put any spacers required on the cylinder liner seat. Special tools: 9989876, 9992000, 9992479, 9996847 Lubricate the new seal ring and install it beneath the (2 No.), 9996854 liner collar. Remove the old seal rings from the cylinder block and make sure that the sealing surfaces are carefully cleaned. -
Page 63: Piston Assembly
Repair instructions NOTE! The cylinder liner press tool must be removed Piston assembly temporarily when tool no. 885126 is used. When the piston is in place, the press tool must be put back Special tool: 885126 again. Oil the piston with engine oil. Check that the bearing shells are correctly aligned in the con rod. -
Page 64: Timing Gears, Disassembly
Repair instructions Remove the shield plates above the heat ex- Timing gear, disassembly changer and remove the aftercooler. Remove the two plastic pipes from the expansion tank. Special tools: 9992655, 9992 58, 9992697 Remove the lid at the front of the thermostat housing and the connection pipe to the coolant pump. - Page 65 Repair instructions Remove the idler gear (pos 4)* together with the bear- ing pin and thrust washer. Remove the polygon hub centre screw, remove the washer and pull the hub off with tool no. 9992655. Remove the camshaft gear (pos 7)* with extractor no. 999279.
- Page 66 Repair instructions Inspecting the timing gears Clean the gear wheels and other components in the timing gear, and inspect them carefully. Replace any gear wheels which are heavily worn or damaged. During assembly, all clearances must be checked. Max. permitted gear flank clearance is 0.17 mm. Check the radial clearance and end float of the idler wheel.
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Page 67: Timing Gears, Assembly
Repair instructions Timing gear, assembly Check that the camshaft drive gear dowel is installed. Special tools: 884948, 884949 Install the camshaft drive gear. Tightening torque is 70 Nm (7 kpm) IMPORTANT! All gear wheels in the timing gear Tightening torque for timing gears. which are important for timing are marked with a centre punch mark on the relevant gear tooth or tooth gap. -
Page 68: Sealant Application, Timing Gear Lid
Repair instructions Application of sealant, timing Seal ring, polygon hub, gear cover replacement (With polygon hub removed) Special tool: 9996855 Remove the old seal ring by means of a screwdriver. Clean the seal ring mating surface in the lid. Note. On early model engines, the seal consists of an inner rubber ring and an outer felt ring. -
Page 69: Polygon Hub, Assembly
Repair instructions Polygon hub, installation Camshaft, wear check Special tool: 884949 Special tools: 998976, 9996772 Preparatory work Remove the valve covers. Remove the screws holding the rocker shaft bearing caps and remove the rocker mechanism. Lift the push rods out. Mark the push rods so that they end up in the same place during re-assembly. -
Page 70: Camshaft, Disassembly
Repair instructions Install the push rods in the correct order, install the rocker support bridges and torque the screws. Tightening torque: for the 61 series with steel bearing caps*, torque to 65 Nm (6.5 kpm). Later models of the 61 series and all engines in the 62 and 63 series have aluminium bearing caps. -
Page 71: Inspection Of Valve Lifters And Camshaft
Repair instructions Inspection of valve lifters and camshaft Remove the valve lifter access hatches (3). NOTE! The centre hatch does not need to be re- moved. Inspection of valve lifters Use a steel rule to check that the surface of the valve lifter in contact with the camshaft is spherical (con- vex). -
Page 72: Camshaft Measurement
Repair instructions It has been found that the damage only gets worse in Camshaft bearing, very rare cases. replacement Check the camshaft bearing surface and cam profiles for wear. The cams can be worn obliquely in the The bearings are pressed into their locations and must lengthwise direction, for example. -
Page 73: Camshaft, Assembly
Repair instructions Camshaft installation Install the valve lifter inspection hatches with new gaskets. Oil the camshaft bearing surfaces and cam profiles. Tightening torque is 24 Nm (2.4 kpm). Carefully slide the camshaft into place, so as to avoid NOTE! Put the oil guide plate on the rear hatch. damaging the bearings. -
Page 74: Inspection, Crankshaft And Bearings
Repair instructions Assess any surface damage. The following applies to nitrocarburised shafts: Features which would be classed as dirt scratches on an induction hardened crankshaft may be normal surface finish on a nitrocarburised crankshaft in some cases, as on a new crankshaft. On a used crankshaft, this is emphasized very clearly, because of the extremely smooth bearing surface. - Page 75 Repair instructions Crack checking Seizure damage can cause overheating cracks which can only be discovered with special equipment. Any cracks and notches are most reliably found by magnetic powder testing such as Magnaglo, i.e. fluorescent powder which is observed in ultra-violet light. Please refer to the instructions provided by the manufacturers of the equipment.
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Page 76: Crankshaft, Renovation
Repair instructions Grinding the crankshaft Crankshaft, renovation It is essential for a satisfactory result from grinding, In general, both re-grinding and trueing reduce the that the correct method has been used. The following fatigue resistance. So do not re-grind bearing grinding data are recommended. -
Page 77: Cylinder Block, Inspection
Repair instructions The surface finish (profile depth) of bearing surfaces For piston cooling, a plug* (C) must be installed and fillets is 2 mm, medium surface deviation 5 mm. underneath the engine block in addition to the This surface finish is achieved by buffing. Buffing is requisite nozzles, centred on the 5:th main bearing, done in the opposite direction of rotation to grinding. -
Page 78: Crankshaft, Assembly
Repair instructions Crankshaft, assembly Place the bearing shells in their places. Make sure that bearing shells of the correct dimensions are installed and that they are correctly seated in their places. Lubricate the bearing surfaces with engine oil. Lubricate the crankshaft journals with engine oil and carefully lift the crankshaft into place, using two lifting Check the crankshaft ducts and bearing surfaces. -
Page 79: Big End Bearings, Replacement
Repair instructions Big end bearing replacement Install a new rear crankshaft seal. Please refer to items 2 and 3 in the “Crankshaft seal, rear” method (Crankshaft not removed) on page 83. Preparatory work Drain or pump out the engine oil. Remove the sump. -
Page 80: Main Bearings, Replacement
Repair instructions Main bearings, replacement (Crankshaft not removed) Preparatory work Drain or pump out the engine oil. Remove the sump. Remove the supply and suction pipes for the oil pump, plus the baffle. Remove the injectors, to make it easier to crank the engine. - Page 81 Repair instructions Clean and check the bearing seat, bearing cap, Change the other main bearing shells, one at a time, bearing journal and bearing shells for damage. If in the same way as the first one. After you have the bearing shells have seized, the reason must be changed each main bearing, check that the crank- investigated before new bearing shells are installed.
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Page 82: Flywheel, Replacement
Repair instructions Flywheel, replacement Use a narrow wood or plastic pin to remove the Remove the screws and lift the flywheel away. thrust washers. Flywheel, inspection Check the flywheel for cracks and other damage. When all the main bearing caps have been torqued, Also check that the gear ring is not worn or dam- check the crankshaft end float. -
Page 83: Gear Ring, Replacement
Repair instructions Gear ring, replacement (Flywheel removed) Put the heated gear ring on the flywheel and tap it into place with a soft punch and hammer. Drill 1–2 holes in the gap between two teeth on the Allow the gear ring to air cool. gear ring. -
Page 84: Flywheel, Indication
Repair instructions Flywheel, indication Read off the value, and move the dial gauge with base round to the opposite side of the flywheel. Special tools: 9999696, 9989876 The value of these measurements must not exceed 0.15 mm. Place a dial indicator with its tip on the flywheel. Zero the dial gauge. -
Page 85: Crankshaft Seal, Rear, Replacement
Repair instructions Crankshaft seal, rear, Flange seal, flywheel housing, replacement replacement (Flywheel removed) (Flywheel removed) Special tools: 9992000, 9996437 Remove the four rear screws from the sump, and the screws which hold the flywheel housing to the cylin- der block (10 no.) Tap the flywheel housing loose, using a plastic faced hammer, by tapping alternately on the right and left hand sides. - Page 86 References to Service Bulletins Group Date Concerning ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
- Page 87 From: ....................................................................Refers to publication: ............................. Publication No.: ............. Date of issue: ..............Proposal/motivation: ....................................................................................................................................................................................................................................................................................................................Date: ..............Signed: ............. AB Volvo Penta Technical Information Dept. 42200 SE-405 08 Göteborg Sweden...
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Questions and answers
What is the speed limit of the engine
The speed limit of the Volvo Penta TAMD61A engine is a maximum of 2,800 rpm.
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