Volvo TAD1640GE Workshop Manual
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Volvo TAD1640GE Workshop Manual

Volvo TAD1640GE Workshop Manual

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  • Page 1 Workshop and repair manual & & & & & & 7746012 – 7746022 - 7746032 33525071901_0_1 09/2004...

  • Page 3: Workshop Manual

    Workshop Manual Group 20 Technical Data 1(0) TAD1640GE, TAD1641GE, TAD1642GE TAD1641VE, TAD1642VE...

  • Page 5: Table Of Contents

    Technical data Engine TAD1640GE, TAD1641GE, TAD1642GE TAD1641VE, TAD1642VE Contents Safety information ..........2 General information ..........5 Technical data General ............... 6 Engine ..............6 Valve mechanism ..........8 Timing gear ............11 Reciprocating components ........13 Lubrication and oil systems......... 16 Fuel system ............

  • Page 6: Safety Information

    Safety information This workshop manual contains technical data, des- Read the available safety information, “General in- criptions and repair instructions for the Volvo Penta formation” and “Repair instructions” in the work- products or product versions noted in the table of con- shop manual before you start to do any service work.
  • Page 7 Group 20 General instructions Stop the engine before carrying out operations All fuels, and many chemicals, are flammable. on the engine cooling system. Do not allow naked flame or sparks in the vicini- ty. Certain thinner products and hydrogen from batteries are easily ignitable and are explosive when mixed with air in the right proportions.
  • Page 8 Allmänna anvisningar WARNING! The components in the electrical The clutch must be adjusted with the engine system and in the fuel system on Volvo Penta stationary. products are designed and manufactured to mi- nimize the risk of fire and explosion. The engine...

  • Page 9: General Information

    TAD1642VE engines. ments. The following requirements for service and spare parts must be complied with, for Volvo Penta as The workshop manual, Technical data section, con- a manufacturer to be responsible for ensuring that...

  • Page 10: General

    Technical data Group 20 Technical data General Designation TAD1640GE TAD1641GE TAD1642GE TAD1641VE TAD1642VE Power, Prime/Stand-by See sales literature Torque, Prime/Stand-by See sales literature No. of cylinders Bore Stroke, mm Cylinder volume, dm 16,12 16,12 16,12 16,12 16,12 Weight, dry (kg)

  • Page 11: Cylinder Head Bolts

    Height above engine block plane ......0.15 - 0.65 mm (0.00612 - 0.0256") Diameter, combustion chamber ......98 mm (3.86") Depth, piston bowl: TAD1640GE ............19.35 mm (0.76") TAD1641GE ............21.15 mm (0.83") TAD1642GE ............21.15 mm (0.83") TAD1641VE ............19.35 mm (0.76") TAD1642VE ............

  • Page 12: Valve Mechanism

    Technical data Group 20 Valve mechanism Valves Valve head, diameter: Inlet ..............49 mm (1.93") Exhaust .............. 46 mm (1.81") Valve stem, diameter: Inlet ..............10 mm (0.394") Exhaust .............. 10 mm (0.394") Valve seat angle (A): Inlet ..............19,5° Exhaust ..............

  • Page 13: Valve Seats

    Group 20 Technical data Valve seats Outer diameter (A) Standard: Inlet ..............52 mm (2.05") Exhaust .............. 49 mm (1.93") Oversize: Inlet ..............52.2 mm (2.06") Exhaust .............. 49.2 mm (1.94") Height (B): Inlet ..............7.7 mm (0.303") Exhaust .............. 7.9 mm (0.311") Valve seat bed Diameter (C) standard: Inlet ..............

  • Page 14: Valve Guides

    Technical data Group 20 Valve guides Length: Inlet ..............83.5 mm (3.29") Exhaust ............... 83.5 mm (3.29") Inner diameter: Inlet ..............10 mm (0.39") Exhaust ............... 10 mm (0.39") Height above cylinder head spring plane: Inlet ..............24.4 ± 1.0 mm (1.00 ± 0.157") Exhaust ...............

  • Page 15: Timing Gear

    Group 20 Technical data Timing gear Timing gear wheels No. of teeth: 1 Drive gear, camshaft ........... 84 2 Idler wheel, adjustable ......... 85 3 Idler wheel, bull gear outer ........84 Idler wheel, bull gear inner ........56 4 Idler wheel, servo pump ........29 5 Drive gear, crankshaft .........
  • Page 16 Technical data Group 20...

  • Page 17: Reciprocating Components

    Group 20 Technical data Reciprocating components Crankshaft Length ..............1256 mm (49.45") Crankshaft, end float* ..........0.15 mm (0.006") Ovality of main and big end bearings ..... max 0.01 mm (0.000394") Taper of main and big end bearings ....... max 0.02 mm (0.000787") Runout on center bearing ........
  • Page 18 Technical data Group 20 Thrust washers (thrust bearing) Width (B) standard ..........3.18 mm (0.125") Oversize: 0.1 mm (0.004") ..........3.28 mm (0.129") 0.2 mm (0.008") ..........3.38 mm (0.133") 0.3 mm (0.012") ..........3.48 mm (0.137") 0.4 mm (0.016") ..........3.58 mm (0.140") Main bearing shells Outer diameter (C) ..........

  • Page 19: Connecting Rod

    Group 20 Technical data Big end journal shells Outer diameter (B) ..........116,8 mm (4.598") Thickness (C) standard .......... 2.35 mm (0.092") Oversize: 0.25 mm (0.098") ..........2.48 mm (0.098") 0.50 mm (0.0197") ..........2.60 mm (0.102") 0.75 mm (0.029") ..........2.73 mm (0.107") 1.00 mm (0.039") ..........

  • Page 20: Lubrication And Oil Systems

    Technical data Group 20 Lubrication and oil systems Oil change volume, incl filters ........ 48 liter (50.7 US quart) Oil pressure Operating speed (above 1100 rpm) ......300 -650 kPa (43.5-94.25 psi) Low idle ..............min 160 kPa (23.2 psi) Oil temperature Cold engine ............

  • Page 21: Oil Valves

    Group 20 Technical data Oil valves A: Bypass valve, oil cooler Spring, free length ..........69 mm (2.72") Loaded 13-15 N (2.9-3.4 lbf) ......40 mm (1.57") B: Safety valve, lube oil pump Marking ............Violet C: Reduction valve, oil pressure Marking ............

  • Page 22: Fuel System

    Technical data Group 20 Fuel system Feed pump Feed pressure at: 600 rpm............... min 100 kPa (14.5 psi) 1200 rpm ............. min 300 kPa (43.5 psi) full load ............... min 300 kPa (43.5 psi) Bypass valve Opening pressure ........... 400 - 550 kPa (58 - 80 psi) Fuel quantity At low idle and with the engine unloaded, the fuel quantity should be inside area B.

  • Page 23: Inlet And Exhaust System

    Pressure drop indicator warns at a pressure drop of ..........5 kPa (37.5 mm VP) ( 0.725 psi) Boost pressure TAD1640GE ............231 kPa (33.1 psi) TAD1641GE ............265 kPa (38.3 psi) TAD1642GE ............273 kPa (39,6 psi) TAD1641VE ............193 kPa (28.0 psi)

  • Page 24: Cooling System

    Thermostat Quantity ..............1 Opening temperature ..........86°C (186.80°F) Fully open .............. 96°C (205°F) Coolant Type ..............Volvo Original Consists of ............Glycol and corrosion-inhibiting additives Color ..............Green Mix with ..............Tap water Corrosion protection Only used when anti-freeze is not needed.

  • Page 25: Engine Control System

    Group 20 Technical data Engine control system Engine control unit No. of pins ............. 2 x 36 Sensor Charge pressure sensor Check value ............1.05 - 1.30 V at 100 kPa (14.5 psi) Camshaft sensor Distance to camshaft ..........1.1 ±0.4 mm (0.0433 - 0.0157") Flywheel sensor Distance to flywheel ..........

  • Page 26: Tightening Torque

    Technical data Group 20 Tightening torque General tightening torques M6 standard screw 8.8 ........... 10 ± 1.5 Nm (7.4 ± 1 lbf ft) M8 standard screw 8.8 ........... 25 ± 4 Nm (18.5 ± 3 lbf ft) M10 standard screw 8.8 ......... 50 ± 8 Nm (37 ± 6 lbf ft) M12 standard screw 8.8 .........

  • Page 27: Flywheel Housing

    Group 20 Technical data Flywheel NOTE: Make sure that the flange is clean and dry. NOTE: Tighten the screws in number order, as in the illustration. stage 1 ..............60 ± 5 Nm (44 ± 4 lbf ft) stage 2 ..............120° ± 10° angle tightening Flywheel housing NOTE: Apply 2 mm (approx 1/8 inch) silicone sealer as in the illustration.
  • Page 28 Technical data Group 20 Vibration damper ......... 90 ±10 Nm (66 ± 7 lbf ft) NOTE: Tighten the screws in number order, as in the illustration. The 8.8 screws on the vibration damper must not be re-used. Housing, crankcase seal NOTE: Apply 2 mm (approx 1/8 inch) silicone sealer as in the illustration.
  • Page 29 Group 20 Technical data Valve cover ........... 25 ±3 Nm (18.5 ± 2 lbf ft) NOTE: Tighten the screws in number order, as in the illustration. Cylinder head NOTE: Tighten the screws in number order, as in the illustration. stage 1 ..............60 stage 2 ..............
  • Page 30 Technical data Group 20 Bearing caps, camshaft/rocker arm shaft Note! Tighten the screws in stages, to ensure that the rocker arm shaft comes down without being bent. Stage 1: Tighten screws 1-7 ......... 15 ± 3 Nm (11 ± 2 lbf ft) Stage 2: Torque screws 1-7 to ......
  • Page 31 Group 20 Technical data Timing gear plate NOTE: Apply 2 mm (approx 1/8") silicon to the rear edge of the engine block as shown in the illustration. NOTE: Tighten the screws in number order, as in the illustration. Screws 1-27 ............28 ± 4 Nm (20 ± 3 lbf ft) Screw 28 ..............
  • Page 32 Technical data Group 20 Timing gear 1 Driving gear, crankshaft stage 1 ..............60 ± 5 Nm (44 ± 4 lbf ft) stage 2 ..............120° ±10° angle tightening 2 Idler gear, bull gear, outer Tighten in order according to illustration stage 1 ..............
  • Page 33 Group 20 Technical data Tightening torque, group 22: Lubrication system Oil pan ............24 ±4 Nm (18 ± 3 lbf ft) NOTE: Tighten the screws in number order, as in the illustration. Oil pump stage 1 ..............35 ± 3 Nm (26 ± 2 lbf ft) stage 2 ..............
  • Page 34 Technical data Group 20 Tightening torque, group 23: Fuel system Feed pump - steering servo pump ......25 ± 2Nm (18.5 ± 1.5 lbf ft) Fixing yoke, unit injector (new copper sleeve) First tightening Stage 1 ............... 20 ± 5 Nm (15 ± 4 lbf ft) Stage 2 ...............

  • Page 35: Exhaust Header

    Group 20 Technical data Tightening torque, group 25: Inlet / exhaust system Inlet manifold ............24 ±4 Nm (18 ± 3 lbf ft) NOTE: Apply a 2 mm (approx 1/8") bead of sealing compound 1161231-4, as shown in illustration. Plug, M10 .............. 20 ± 3 Nm (15 ± 2 lbf ft) Pressure/temperature sensor, charge air ....
  • Page 36 Technical data Group 20 Notes ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________...

  • Page 37: Report Form

    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...

  • Page 39: Workshop Manual

    Workshop Manual Group 21-26 4(0) TAD1640GE, TAD1641GE, TAD1642GE TAD1641VE, TAD1642VE...
  • Page 41 Workshop Manual Group 21-26 Industrial engine TAD1640GE, TAD1641GE, TAD1642GE TAD1641VE, TAD1642VE Contents Safety information ........... 3 Boost pressure, troubleshooting ....... 39 Introduction ............... 3 Turbocharger, checking ..........41 General information ..........6 Exposing engine ............ 42 About this Workshop Manual ........6 Fixture fitting ............
  • Page 42 Valves, grinding ............113 Valve stem seals, replacing ........114 Cylinder head, pressure testing ....... 116 Copper sleeve for unit injector, replacing ....119 Camshaft, checking for wear ........123 Camshaft bearing housing, replacing ....... 124 Camshaft sensor distance, checking ...... 125 Transmission, replacing ..........

  • Page 43: Safety Information

    This Workshop Manual contains descriptions and ins- Take care to avoid contact with hot surfaces tructions for the repair of the Volvo Penta products or (exhaust pipes, Turbocharger (TC), air intake product versions. Check that you have the correct pipe, starter heater etc.) and hot liquids in lines...
  • Page 44 Safety information Always use protective glasses or goggles when Ensure that rags soaked in oil or fuel and used carrying out work where there is a risk of splint- fuel or oil filters are stored safely. Rags soaked ers, grinding sparks, acid splashes or where oth- in oil can spontaneously ignite under certain cir- er chemicals are used.
  • Page 45 Safety information WARNING! The components in the electrical Use the lifting eyes fitted on the engine when system and in the fuel system on Volvo Penta lifting the drive unit. Always check that the products are designed and manufactured to mi- lifting equipment used is in good condition and nimize the risk of fire and explosion.

  • Page 46: General Information

    Original Spare Parts meet these specifications. Any type of damage which is the result of using spare parts that are not original Volvo Penta parts for the product in ques- tion will not be covered under any warranty or guarantee...

  • Page 47: Repair Instructions

    Under no circumstances ce work or repairs may be carried out. AB Volvo Penta attempt to service or repair a sealed component unless can only indicate the risks considered likely to occur...

  • Page 48: Torque-Angle Tightening

    Lock nuts In this Volvo Penta Workshop Manual the user will find Do not re-use lock nuts that have been removed during that each section where these agents are applied in disassembly operations as these have reduced service production states which type was used on the engine.

  • Page 49: Safety Rules For Fluorocarbon Rubber

    Repair instructions Safety rules for fluorocarbon rubber Fluorocarbon rubber is a common material in seal rings The following seals are probably made from fluorocar- for shafts, and in O-rings, for example. bon rubber: When fluorocarbon rubber is subjected to high tempe- Seal rings for the crankshaft, camshaft, intermediate ratures (above 300°C/572°F), hydrofluoric acid can be shafts.

  • Page 50: Special Tools

    Special tools Special tools 885810 9986173 9986179 9990006 9990013 9990107 9990112 9990114 9990118 9990123 9990124 9990125 9990143 9990156 9990157 9990158 9990160 9990164 9990165 885810 Fixture for upper transmission gear casing 9990125 Nipple for checking of boost pressure gau- ge, with 4 mm (0.16") hose 9986173 Puller, flywheel bearing 9990143...
  • Page 51 Special tools 9990166 9990174 9990176 9990183 99990184 9990185 9990192 9990210 9991801 9992000 9992269 9992479 9992670 9992873 9993590 9996049 9996159 9996161 9996222 9990166 Tools for rear crankshaft seal 9992000 Standard handle 9990174 Drift, removal/refitting valve springs, outlet 9992269 Drift, installation of flywheel bearing 9990176 Press tool for removal/refitting of valve 9992479...
  • Page 52 Special tools 9996239 9996394 9996395 9996398 9996400 9996441 9996645 9996662 9996666 9996845 9996963 9998246 9998248 9998249 9998250 9998251 9996239 Lifting chain, removal/refitting of cylinder 9996666 Connecting nipple for pressure checking head and flywheel casing, (2 ea required) 9996845 Screw clamp for oil cooler pressure tes- 9996394 Spacer for removal of cylinder liner, 2 ea ting, (2 ea required)
  • Page 53 Special tools 9998252 9998253 9998264 9998339 9998487 9998494 9998502 9998511 9998517 9998599 9998601 9998629 9998688 9999179 9998252 Thread cutting tool for removal of copper 9998599 Unit injector cleaning kit. Consists of: sleeve. Consists of: 980 9667 (M9) and 998 7009 959239 Screw M10 (M8).

  • Page 54: Other Special Equipment

    Special tools Other special equipment 885531 885633 885811 885812 1159794 9986485 9988539 9989876 9999881 9999683 9999696 885531 Pressure-testing equipment, cooling system 885633 Torque amplifier 1/2" - 3/4" 885811 Angle gauge 3/4" 885812 Angle gauge 1/2" 1159794 Torque wrench 3/8, 10 - 100 Nm (7.4 - 74 lbf ft) 9986485 Assembly stand...

  • Page 55: Design And Function

    Design and function Design and function Group 21: Engine body Cylinder head The cylinder head is cast in one piece from a cast iron The oil pressure in the rocker arm mechanism is mea- alloy to provide a stable bearing for the overhead sured in a channel at plug (D).

  • Page 56: Engine Block

    Design and function Engine block The cylinder block is made of cast iron and cast in one The cylinder block main bearing caps is guided by piece. The cylinder block sides are cup-shaped around sockets pressed into the cylinder block (1). In order to each cylinder in order to obtain high rigidity and good avoid incorrect placement, the thrust bearing caps are sound proofing.

  • Page 57: Cylinder Liner

    Design and function Cylinder liner The cylinder block is equipped with wet, replaceable The lower part of cylinder liner is sealed using two rub- cylinder liners that are centrifugally cast of cast iron al- ber rings. The top one, closest to the coolant, is black loy.

  • Page 58: Pistons And Connecting Rods

    Design and function Pistons and connecting rods Pistons are made of aluminum and have three piston The upper end features a pressed-in bushing that is rings; on top is a “Keystone” compression ring, in the lubricated via a drilled channel in the connecting rod. middle a compression ring with rectangular cross-sec- tion and at the bottom a spring loaded oil wiper ring.

  • Page 59: Crankshaft

    Design and function Crankshaft The crankshaft is drop-forged in one piece and induc- The crankshaft transmission wheel is placed on the tion-hardened on the bearing surfaces for increased rear end of the crankshaft. A guide pin on the wheel in strength and decreased risk of cracks.

  • Page 60: Camshaft

    Design and function Camshaft The overhead camshaft is induction-hardened. The be- Screwed onto the camshaft cap is a rocker bridge. aring pins can be ground with replaceable bearing shel- Journalled on it are rocker arms with pressed-in surface ls as spare parts. treated steel bushings.

  • Page 61: Transmission

    Design and function 1. camshaft drive 2. upper intermediate gear 3. dual drive 4. lower intermediate gear 5. crankshaft drive 6. oil pump drive wheel 7. fuel pump drive wheel/servo pump Transmission The transmission is located at the rear edge of the Camshaft wheel (1) is screwed into the camshaft engine on a 6 mm thick steel plate, which is screwed flange and controlled by a guide pin.

  • Page 62: Group 22 Lubrication System

    Design and function Group 22: Lubrication system The engine is pressure lubricated by a gear wheel The oil pump housing is made of aluminum. The pump pump connect to the engine’s transmission. The oil is driven directly by the crankshaft drive. The oil pump flow is controlled by 7 valves.

  • Page 63: Piston Cooling

    Design and function Piston cooling The piston is cooled by oil using so called cavity coo- Oil for the piston cooling is filtered through the full-flow ling. The oil is sprayed vertically up in a channel in the filters, and is controlled by two spring loaded sleeve val- piston via the piston cooling nozzle in the cylinder ves.

  • Page 64: Overview, Valves

    Design and function Overview, valves A: Oil cooler bypass valve B: Safety valve C: Reduction valve D: Control valve for piston cooling E: Opening valve for piston cooling F: Bypass valve for bypass filter G: Bypass valve for full-flow filter...

  • Page 65: Group 23 Fuel System

    Design and function Group 23: Fuel system Each cylinder has an electronically controlled unit in- The feed pump has two valves. The safety valve (8) al- jector that works with very high pressure. The pressure lows the fuel to flow back to the suction side when the is created mechanically via the rocker arms from the pressure rises too high (such as when the fuel filter is overhead camshaft.
  • Page 66 Design and function The unit injectors are a combination of injection The control module is screwed to the engine with pump and injectors that works with much higher four vibration absorbing rubber blocks and is coo- pressure than an ordinary injector. The opening led by fuel through a cooling coil fastened on the pressure is about 320 bar (4,600 psi).

  • Page 67: Unit Injector, Work Phases

    Design and function Unit injector, work phases The unit injector function can be divided into four pha- ses; Filling phase • Spill phase • Injection phase • Pressure reduction phase • The pump piston always pumps the same amount of fuel back and forth through the injector.

  • Page 68: Injection Phase

    Design and function Injection phase The injection phase starts when the solenoid valve re- ceives a voltage from the control module and the fuel valve closes. The camshaft ridge continues to press the pump piston down via the rocker arm. Because the passage through the fuel valve is closed, pressure builds quickly.

  • Page 69: Group 25: Inlet And Exhaust System

    Design and function Group 25: Inlet and exhaust system Turbocharger As the compressor wheel rotates, air is sucked in from The turbocharger is powered by the exhaust gases the air filter. Air is compressed and pressed into the which pass through the compressor turbine housing on engine cylinders after it first has been cooled while pas- their way to the exhaust system.

  • Page 70: Group 26 Cooling System

    Design and function Group 26: Cooling system The coolant is pumped directly into the engine by the When the coolant becomes warm it expands and the coolant pump from the pump housing on the right- excess is pressed up to the expansion tank. Any air in hand side of the cylinder block.

  • Page 71: Troubleshooting / Tests And Adjustments

    A number of symptoms and possible causes of engine malfunctions are described in the table below. Always con- tact your Volvo Penta dealer if any problems occur which you can not solve by yourself. WARNING! Read the safety instructions for handling and service in the chapter “Safetyinformation” before starting work.

  • Page 72: Operational Disturbances

    Troubleshooting / Tests and adjustments Operational disturbances Clogging For additional information and more troubleshooting High coolant temperature is most often due to internal help, see “Coolant temperature, troubleshooting.” In or external clogging of the cooling system or a combi- case of an operational disturbance, check the following nation of both.

  • Page 73: Placement Of Instrument Socket

    Troubleshooting / Tests and adjustments Placement of instrument socket The figures below show where instrument sockets may be placed on the engines. 1. Crankcase pressure 2. Oil pressure 3. Charge air pressure or charge air temperature after charge air cooler. 4.

  • Page 74: Sensor Overview

    Troubleshooting / Tests and adjustments Sensor overview 1. Coolant level sensor, in the expansion tank 8. Solenoid valve, drainage, water trap (optional), not shown in illustration 2. Crankcase pressure sensor 9. Oil level sensor 3. Charge air pressure sensor, air filter 10.

  • Page 75: Compression Test

    Troubleshooting / Tests and adjustments Compression test 21002 The fuel system is emptied and the rocker bridge re- moved. NOTE! Empty the fuel channel in the cylinder head, see “Draining, fuel channel cylinder head” in chapter “Reconditioning / replacing components”. Special tools: Lifting tool .........
  • Page 76 Troubleshooting / Tests and adjustments Remove both control wires from the starter motor control connector (the two thin cables). Connect one of the two free connectors on the control connector to ground. Connect the other connector to a switch, which in turn is connected to the positive (plus) connection on the starter motor.
  • Page 77 Troubleshooting / Tests and adjustments 13. Empty the fuel channel in the cylinder head, see “Draining, fuel channel cylinder head” in chapter “Reconditioning / replacing components”. 14. Remove adapters 9998248 from all cylinders. 15. Fit unit injectors, with new o-rings. See “Unit injec- tor, replacing.”...

  • Page 78: Cooling System, Pressure-Testing

    Troubleshooting / Tests and adjustments Cooling system, pressure-testing Special tools: Cover with connecting nipple ..9996441 Pressure testing device .... 9996662 Check the pressure testing device 9996662 before using it. See “Cylinder head, pressure testing.” Check that all hoses are free from defects. Check that the cock on the pressure reduction valve is fully opened.

  • Page 79: Boost Pressure, Troubleshooting

    Check if exhaust system has been rebuilt, is bent or has damage that prevents the exhaust from getting out. If the exhaust system is not a Volvo Penta origi- nal, has been rebuilt or damaged, the exhaust backpressure may be too high, which leads to less engine output.
  • Page 80 Troubleshooting / Tests and adjustments Charge air cooler, checking Check the charge air cooler for damaged cells or connections. If it is damaged, replace the charge air cooler. Check the charge air cooler and radiator for external clogging. In case of clogging, clean per “Radiator, outside cleaning.”...

  • Page 81: Turbocharger, Checking

    Troubleshooting / Tests and adjustments Turbocharger, checking 25507 Check that the turbo unit item number is matches the engine version. The wrong turbo unit for the engine version may provide charging pressure that is too low and thus reduce the engine’s output.

  • Page 82: Exposing Engine

    Exposing engine Exposing engine Drain the coolant, see “Cooling system, draining.” Drain engine oil. Remove fuel connections to the fuel pump and al- low the fuel to flow out into a suitable container. Remove the hoses from the radiator and the ex- pansion tank.
  • Page 83 Exposing engine Remove the air filter sensor. Remove the pipe between the air filter and the tur- bo. Cover all openings. Remove the air filter housing and mounting brack- Remove muffler and brackets, if any. Remove the turbo from the exhaust pipe and the two the oil pipes.

  • Page 84: Fixture Fitting

    Fixture fitting Fixture fitting Remove distributor above the control module Remove cable harness and fuel lines to the con- trol module. Cover all openings. Remove the control module. Remove fuel and electrical connections. Lift the fuel filter bracket together with the filters. Cover all fuel connections.

  • Page 85: Engine Body, General Overhaul

    Engine body, general overhaul Engine body, general overhaul Cylinder head, removal The engine exposed and installed on stand, coolant and fuel drained. Remove the rear lifting eye/mounting bracket. Remove the heat shields above the turbo, if this was not done when the engine was exposed. Remove the oil pipes between the turbo and the oil filter bracket and the engine block, respective- Cover all openings.
  • Page 86 Engine body, general overhaul Remove the exhaust manifold. Remove the camshaft sensor (1), the flywheel sensor (2) and the sensor on the oil filter bracket (3). Remove the cable harness from sensor and star- ter motor. Remove the fuel lines to the cylinder head (1) and plug connections.
  • Page 87 Engine body, general overhaul 10. Remove the screw for the cable bushing (1) and carefully pull out the cable harness through the cylinder head. IMPORTANT! Remove on the screw, do not split the cable bushing. 11. Remove the contact to the coolant sensor, the ho- ses to the expansion tank and the rest of the ca- ble harness and lift it away.
  • Page 88 Engine body, general overhaul 17. Remove the upper transmission gear casing and remove the rubber seals. 18. Remove the middle piece for lubrication of the rocker bridge, together with the delivery pipe. 19. Remove the cover lid in the flywheel casing and attach turning tool 9993590.
  • Page 89 Engine body, general overhaul 20. Turn the engine to TDC on the camshaft, check that the mark on the flywheel is at “0.” 21. Remove the camshaft drive together with the vi- bration damper. NOTE: The vibration damper is very sensitive to shocks.
  • Page 90 Engine body, general overhaul 24. Mark and remove the valve calipers. 25. Clean around the unit injectors and unscrew the screws for the injector retainers. Remove the unit injectors, one at a time. 26. Pull up the injector using puller 9990006 and slide hammer 9990013.
  • Page 91 Engine body, general overhaul 28. Remove the camshaft cap using tools 9990192 and 9996400. 29. Lift the camshaft carefully using tool 9998264. 30. Remove bearing blocks by carefully tapping them with a plastic hammer. Remove the bearing blocks with the lower bearing halves and put them in the right order together with their respective camshaft bearing caps, upper bearing halves and screws.
  • Page 92 Engine body, general overhaul 32. Place a rag in front of the drive to prevent screws from falling into the transmission housing. Remove the two screws (1). NOTE: When the engine is turned, the rag must be removed. 33. Remove the remaining five screws (2). Remove the three upper screws (3) from the trans- mission wheel hub.
  • Page 93 Engine body, general overhaul 36. Remove the starter motor. 37. Remove the oil filters complete with bracket. 38. Remove the coolant filter with bracket and the connection to the oil cooler casing. 39. Remove the oil cooler casing and the oil cooler. Remove the seals.
  • Page 94 Engine body, general overhaul 40. Remove the two coolant pipes and the coolant pump. 41. Remove the fan bearing. 42. Remove the screws for belt pulley/vibration dam- per. Carefully tap and rock the hub and belt pulley to get them loose. NOTE: Do not disconnect between belt pulley and vi- bration damper.
  • Page 95 Engine body, general overhaul 45. Remove alternator with its brackets together with the belt tensioner and the bracket for the fan bea- ring on the left side of the engine. 46. Remove engine mounts, oil filler pipe and dipstick. 47. Remove fuel pump and servo pump complete. 48.

  • Page 96: Transmission, Removal

    Engine body, general overhaul Transmission, removal 51. Remove the flywheel sensor, if not already done. 52. Secure lifting chain 9996239 in the flywheel with two screws. Remove the screws in the flywheel. Remove the flywheel. WARNING! Pinching hazard. The flywheel is heavy. 53.
  • Page 97 Engine body, general overhaul 1. camshaft drive 2. upper intermediate gear 3. dual drive 4. lower intermediate gear 5. crankshaft drive 6. oil pump drive wheel 7. fuel pump drive wheel/servo pump 55. Remove the lower intermediate gear (4). 56. Remove the two screws on the crankshaft drive (5) and remove the drive using a suitable puller.

  • Page 98: Pistons, Removal

    Engine body, general overhaul Pistons, removal 60. Remove the piston cooling nozzle. Turn the engi- ne using tool 9993590 so that all become acces- sible, two at a time. WARNING! It is important to remove the piston cooling nozzles before the pistons are remo- ved.

  • Page 99: Crankshaft, Removal

    Engine body, general overhaul 65. Mark the cylinder liner position in the block before it is removed to facilitate correct placement if reinstalled. 66. Install puller plate 9996963 and support 9996394 on the puller 9996645. 67. Move plate down through the cylinder and place it in correct position under the cylinder liner.

  • Page 100: Crankshaft, Refitting

    Engine body, general overhaul Crankshaft, refitting 73. Inspect the crankshaft, see “Crankshaft, inspec- tion” 74. Check the oil channels of crankshaft and its con- tact surfaces with the bearing shells, cylinder block and caps. 75. Install new main bearing shells. 76.

  • Page 101: Cylinder Liner, Fitting

    Engine body, general overhaul Cylinder liner, fitting 82. Inspect cylinder liner and pistons, see “Cylinder liner and pistons, inspection” 83. Lubricate the sealing rings, using the lubricant supplied with the lining kit, and install them on the cylinder liner. NOTE: The purple seal ring belongs in the lowest groo- 84.

  • Page 102: Piston, Pre-Fitting

    Engine body, general overhaul 85. Secure one of the cylinder head screws (A). Place tool 9996963 above the cylinder liner to- gether with appropriate spacer (B). Press the liner down with crowbar 9998511 and secure it using tool 9990157. Piston, pre-fitting 86.
  • Page 103 Engine body, general overhaul IMPORTANT! Always use piston ring pliers during installation/removal of the piston rings. The oil scraper rings, especially, are brittle and are easily damaged. NOTE: The two upper piston rings are marked with lett- ers or point marks. The mark shall be turned up. 91.

  • Page 104: Pistons, Fitting

    Engine body, general overhaul Pistons, fitting 93. Oil the cylinder liner, the bearing shells and the crank bearing pins. 94. Remove press tool 9990157 temporarily while in- stalling the piston. 95. Use tool 9990158 and guide the piston with piston rings down into the cylinder.

  • Page 105: Transmission, Fitting

    Engine body, general overhaul Transmission, fitting 102. Apply a 2 mm (0.080”) thick string of sealant on the engine block as shown. 103. Install the transmission plate. Use new screws that are pre-treated with locking compound. Tor- que as specified in “Technical data.” NOTE: Torque within 20 minutes after sealant has been applied.
  • Page 106 Engine body, general overhaul 1. camshaft drive 2. upper intermediate gear 3. dual drive 4. lower intermediate gear 5. crankshaft drive 6. oil pump drive wheel 7. fuel pump drive wheel/servo pump 107. Place two screws in the crankshaft drive so you can attach a crowbar and thus be able to turn the crankshaft as needed.
  • Page 107 Engine body, general overhaul 110. Install the lubricating oil pump. 111. Apply new sealing compound to the flywheel ca- sing, towards the engine block. 112. Remove the old crankshaft seal. Install the flywheel casing. Check that the casing is aligned with the engine block plane. Torque as specified in “Technical data.”...
  • Page 108 Engine body, general overhaul 113. Install the flywheel and torque as specified in “Technical data.” See also “Flywheel, checking for warp.” 114. Remove the old crankshaft seal on the front the casing. See “Crankshaft seal, front, replacing.” Apply sealing compound to the front casing. In- stall the casing and make sure that the bottom edge of the casing is lined up with the bottom edge of the engine block.
  • Page 109 Engine body, general overhaul 118. Fit the oil pan. 119. Install oil filler pipe and dipstick with new o-rings. 120. Install fuel feed pump/servo pump. 121. Fit the coolant pump. 122. Fit the front engine mounts together with the belt tensioner and the tensioning wheel on the right side of the engine.
  • Page 110 Engine body, general overhaul 124. Install the fan bearing. 125. Fit new sealing rings in the block and the rubber seals on the sides of the radiator. Install the oil cooler and torque as specified in “Technical data.” Check that the side seals are placed correctly in the block.

  • Page 111: Cylinder Head, Refitting

    Engine body, general overhaul 129. Fit the starter motor. 130. Install the coolant pipes with new o-rings. Cylinder head, refitting 131. Clean the cylinder head thoroughly inside and out before installing. NOTE: Dirt particles can destroy the unit injectors. 132. Clean the unit injector copper sleeves. See “Re- conditioning/Replacing: Copper sleeve for unit in- jector, replacing.”...
  • Page 112 Engine body, general overhaul 135. Dip the cylinder head bolts completely into a rust- proofing agent. Then place the screws on a net to remove ex- cess. 136. Apply a 2 mm (0.080”) thick string of sealant on the back side of the engine block. NOTE: The cylinder head screws must be torqued wit- hin 20 minutes after sealant application.
  • Page 113 Engine body, general overhaul 141. Place a screw in the upper intermediate gear hub (1) into the cylinder head, so you can pull the cy- linder head towards the transmission plate. Screw in five M8 screws in the transmission plate (2).

  • Page 114: Camshaft, Refitting

    Engine body, general overhaul Camshaft, refitting 149. Check the camshaft for wear. See “Camshaft, checking for wear.” 150. Clean surfaces on bearing blocks and the cylinder head. 151. Install the camshaft bearing blocks as marked on the cylinder head, make sure that they rest on the cylinder head no.

  • Page 115: Gear Backlash, Adjusting

    Engine body, general overhaul 156. Clean surfaces on the bearing caps and oil the be- aring shells. Install the bearing caps on the respective bearing block. NOTE: Use a suitable spacer on the rocker arm side. Torque screws 1-7 per step 1 in “Technical data.” Torque screws 8, 11, 14 (with spacers) per step 2 in “Technical data.”...
  • Page 116 Engine body, general overhaul 159. Check the clearance as follows: Fix the adjustment wheel. Place a dial indicator on the camshaft drive, as shown. Turn the drive back and forth and compare the re- sult against the specification for gear backlash in “Technical data.”...

  • Page 117: Unit Injector, Refitting

    Engine body, general overhaul 165. Press the casing down with the tools 885810 and 9998601 so that the cylinder head and the upper transmission gear casing sealing surfaces are aligned. Refit the other bolts (2). Torque as specified in “Technical data.” NOTE: The transmission gear casing must be installed and torqued within 20 minutes after sealant application.
  • Page 118 Engine body, general overhaul 169. Reinstall the valve calipers in their original posi- tions. NOTE: Make sure that the yoke is directly above the valve stem. 170. Lubricate valve caliper and camshaft. 171. Remove the temporary screws with spacers on the camshaft cap.

  • Page 119: Adjustment Markings

    Engine body, general overhaul Adjustment markings The camshaft has markings (1-6 for the respective cy- linders) for adjusting inlet and outlet valves and the unit injectors. NOTE: It is important that the line on the camshaft is right between the marks on thrust bearing cap when making the adjustment.
  • Page 120 Engine body, general overhaul 177. Adjust the unit injector rocker arm to zero clearan- Tighten the adjustment screw nut another 180 to 240 degrees. Torque the adjustment screw nut as specified in “Technical data.” 178. Adjust remaining valves and unit injector per the above.
  • Page 121 Engine body, general overhaul 186. Place the gaskets on the exhaust manifold. Turn the gasket so that the side with the text “Manifold side” is facing the exhaust manifold. ”Thread in” the screws in the gaskets so that they are held in place during installation of the exhaust manifold.
  • Page 122 Engine body, general overhaul 195. Install safety cover above alternator 196. Install the pipe between charge air cooler and inlet pipe. 197. Install the crankcase ventilation pipe and any ex- tra oil separator. 198. Place a new insert in the air filter housing and in- stall it with brackets and the pipe between the air filter housing and the turbo.

  • Page 123: Reconditioning / Replacing Components

    Reconditioning / replacing: Engine body Reconditioning / replacing components Group 21: Engine body Cylinder liner and pistons, inspection Clean cylinder liner and pistons carefully before inspec- tion and measurement. NOTE: Cylinder liner and pistons are classified to- gether. This means that pistons and liners must not be mixed.

  • Page 124: Cylinder Liner And Pistons, Replacing (All)

    Reconditioning / replacing: Engine body Cylinder liner and pistons, replacing (all) Special tools: Turning tool ......9993590 Puller ........9996645 Spacer ........9996394 Spacer ........9996395 Puller plate ......9996963 Press tool, 7 ea ....9990157 Drift ........9996599 Prying tool ......9998511 Piston ring compressor ..9990158 Other special equipment: Torque wrench, 10-100 Nm (7.38 - 73.8 lbf ft) ....1159794...
  • Page 125 Reconditioning / replacing: Engine body Remove main bearing cap and bearing shells. Remove the piston together with the connecting rod. IMPORTANT! Reinstall the bearing caps on the connecting rod to avoid damage to the parting sur- face, since this is very delicate. Pull the cylinder liners from the block using puller plate 9996963, puller 9996645 and spacer 9996394.
  • Page 126 Reconditioning / replacing: Engine body Fitting Check the cylinder block liner collar for damage. In case of damage, the cylinder liner seat must be reconditioned. Fit cylinder liner, without seal rings. Hold it using two press tools, 9990157. Fit dial indicator 9989876 in holder 9992479. Place the container with the dial indicator across the cylinder liners.
  • Page 127 Reconditioning / replacing: Engine body When the cylinder liner is fitted without shims, an even, about 0.8 mm (0.003”) thick bead of sealing compound should be placed on the underside of the cylinder liner collar. NOTE: Do not put the seal around the entire liner. Lea- ve a 2 mm opening.
  • Page 128 Reconditioning / replacing: Engine body Install the connecting rod in the piston with the mark “FRONT” on the connecting rod and the arrow on the piston turned in the same direction. Press in the piston pin. NOTE: You should be able to press the piston pin in without much force.
  • Page 129 Reconditioning / replacing: Engine body Lubricate main bearing caps and the crank bearing pin with engine oil. Fit the big-end bearing shells. Check that they are a correct fit to the connecting rod and caps. Install the main bearing cap per the markings and torque as specified in “Technical data.”...

  • Page 130: Crankshaft, Inspection

    Reconditioning / replacing: Engine body Crankshaft, inspection The crankshaft has been induction-hardened. Inspect the crankshaft thoroughly to avoid unnecessary reconditioning. To determine reconditioning requirements, the following applies: Thoroughly clean the crankshaft. Measure the bearing journals for out-of roundness, wear and taper. See specifications in “Technical data.”...

  • Page 131: Main Bearings, Replacing

    Reconditioning / replacing: Engine body Main bearings, replacing Pan removed. The method describes replacement of main bearings with the crankshaft in place in the engine. Special tools: Turning tool ............ 9993590 Puller ............. 9990114 Slide hammer ..........9996400 Removal Install turning tool 9993590. Remove the oil suction pipe and oil pump.
  • Page 132 Reconditioning / replacing: Engine body Remove the upper bearing shell by placing a pin in the crankshaft oil hole and roll the bearing shell out by turning the crankshaft in the direction of ro- tation using turning tool 9993590. Clean and check the bearing seat, caps, shaft pi- vot and bearing shells.
  • Page 133 Reconditioning / replacing: Engine body 11. Check the crankshaft axial play and replace the thrust washers if the clearance is too big or if the thrust washers are damaged. NOTE: Axial play is measured using a dial indicator. The thrust washers are available in a number of oversi- ze dimensions.

  • Page 134: Crank Bearing, Replacing (All)

    Reconditioning / replacing: Engine body Crank bearings, replacing (all) Oil pan, oil suction pipe and bracing frame remo- ved. Special tools: Turning tool ......9993590 Removal Fit turning tool 9993590 and turn the flywheel until the bearing caps on connecting rod 1 and 6 are in a position where you can remove the screws.

  • Page 135: Flywheel Bearing, Replacing

    Reconditioning / replacing: Engine body Flywheel bearing, replacing Special tools: Handle ........9991801 Puller ........9986173 Puller ........9986179 Drift ........9992269 Measure the bearing position in the flywheel. Remove the old bearing using tool 9986173 and 9986179. Drive in the new bearing to the measured posi- tion using tools 9991801 and 9992269.

  • Page 136: Flywheel, Replacing

    Reconditioning / replacing: Engine body Flywheel, replacing 21661 Special tools: Turning tool ......9993590 Lifting chain ......9996239 Remove the flywheel sensor. Install turning tool 9993590. Secure lifting chain, 9996239, to the flywheel with two screws. Remove the flywheel retaining screws, Use the turning tool as an anvil.

  • Page 137: Ring Gear, Replacing

    Reconditioning / replacing: Engine body Ring gear, replacing 21687 Flywheel removed. Drill 1–2 holes between teeth on ring gear. Crack the ring gear at the drilled the hole using a chisel. Lift the ring gear away from the flywheel. Brush the flywheel bed clean with a steel wire brush.

  • Page 138: Flywheel Sensor Distance, Checking

    Reconditioning / replacing: Engine body Flywheel sensor distance, checking Special tools: Turning tool ..........9993590 Measuring instrument ........9998517 Install turning tool 9993590 and turn the engine’s flywheel to 0°. Remove the flywheel sensor. Slide the installation tool circlip so that it is placed around the tool’s middle.
  • Page 139 Reconditioning / replacing: Engine body Flywheel, indication Special tools: Turning tool ............ 9993590 Dial indicator ..........9989876 Magnet holder ..........9999696 Pressure plate removed Place the dial indicator 9989876 with magnetic stand 9999696 with the probe towards the flywheel. Remove the cover from the engine’s flywheel casing.

  • Page 140: Crankshaft Seal, Front, Replacing

    Reconditioning / replacing: Engine body Crankshaft seal, front, replacing 21672 Special tools: Alt 1 Cone ............9990118 Drift ............9990112 Drift ............9992000 Alt 2 Slide hammer ..........9996400 Puller ............9990192 Cone ............9990118 Drift ............9990112 Drift ............9992000 Alternative 1 Remove crankshaft belt pulley and the vibration damper (12 screws).
  • Page 141 Reconditioning / replacing: Engine body Check that the tools are flawless, so you don’t de- stroy the seal. Fit cone 9990118 on drift. NOTE: No lubrication. Should be installed completely dry. Install the seal on tool 9990112 via 9990118. Remove tool 9990118. Install handle 9992000 on 9990112 and carefully tap in the new seal until the tool bottoms against the crankshaft.

  • Page 142: Crankshaft Seal, Rear, Replacing

    Reconditioning / replacing: Engine body Crankshaft seal, rear, replacing Flywheel removed. Special tools: Slide hammer ..........9996400 Tool ............9990166 Puller ............9990192 Drift ............9992000 Fit tool 9996400 and 9990192 on the old seal by pressing it in or tap it in the with slide hammer. NOTE: Protect the crankshaft by leaning the tool inward and so that you get a good grip of the seal.
  • Page 143 Reconditioning / replacing: Engine body Fit the plastic ring that holds the new seal and fit the cover with the screw handle. Press in the seal using the tool. When the lid bottoms against the tool, the seal will be in the correct position.

  • Page 144: Connecting Rod, Checking

    Reconditioning / replacing: Engine body Connecting rod, checking Important consideration when removing/installing “cracked” connecting rod. Fitting NEW connecting rod: Carefully clamp the connecting rod in a vise equipped with soft jaws. Unscrew the connecting rod screws a few turns and tap carefully on the bearing cap with a plastic hammer until it comes loose.

  • Page 145: Valves, Removal

    Reconditioning / replacing: Engine body Valves, removal Special tools: Fixture ........9990160 Hydraulic cylinder ....9996161 Press tool ......9990176 Adapter ......... 9996159 Drift, inlet ......9998246 Drift, outlet ......9990174 Hydraulic pump ..... 9996222 alt........9992670 Valve spring compressor ..9990210 The work will be facilitated if the cylinder head is held in an assembly stand with fixture 9990160.
  • Page 146 Reconditioning / replacing: Engine body Alternative 2 Place the cylinder head on a flat and clean surfa- ce. Make sure that the cylinder head is not scrat- ched when the valves are removed. Install press tool 9990210 in the unit injector hole. Secure the tool in the unit injector retainer screw hole, M10 x 30.

  • Page 147: Valves, Fitting

    Reconditioning / replacing: Engine body Valves, fitting Special tools: Hydraulic cylinder ....9996161 Press tool ......9990176 Adapter ......... 9996159 Drift, inlet ......9998246 Drift, outlet ......9990174 Hydraulic pump ..... 9992670 alt........9996222 Valve spring compressor ..9990210 Guide sleeve ......
  • Page 148 Reconditioning / replacing: Engine body Valve seat, changing Cylinder head and valves removed The valve seats should be replaced if you cannot get perfect sealing or when the distance “A” ex- ceeds the value shown in the specification. Plea- se refer to the “Technical Data”. Grind the disc on an old valve and weld it to the valve seat.
  • Page 149 Reconditioning / replacing: Engine body Thoroughly clean the seat location and check the cylinder head for cracks. Measure the diameter of the valve seat location in the cylinder head. With this measurement as a ba- sis, check whether a standard size seat or an oversize seat is required.

  • Page 150: Valve Guides, Inspection

    Reconditioning / replacing: Engine body Valve guides, inspection Cylinder head removed Special tools: Dial indicator ......9989876 Magnetic stand ..... 9999696 Remove the valve shaft seals from the valve gui- des. Place the cylinder head on the workbench with the valve discs facing up.

  • Page 151: Valve Guides, Replacing

    Reconditioning / replacing: Engine body Valve guides, replacing Cylinder head removed NOTE: If the valve seats too will be replaced, this should be done before the valve guides are removed. IMPORTANT! Use protective goggles when pres- sing the valve guides out or in. Special tools: Adapter .........

  • Page 152: Valve Seat, Grinding

    Reconditioning / replacing: Engine body Valve seat, grinding NOTE: As spare parts, the valve seats are fully machi- ned and should not need additional grinding. Before grinding, check the valve guides and 20° replace them if the wear limits have been exceeded.

  • Page 153: Valves, Grinding

    Reconditioning / replacing: Engine body Valves, grinding Regarding valve sealing angles, See “Technical data.” NOTE: As spare parts, the valves are fully machined and should not need additional grinding. NOTE: Grind the sealing surface as little as possible. But enough that you remove all damage. Check the dimension (A).

  • Page 154: Valve Stem Seals, Replacing

    Reconditioning / replacing: Engine body Valve stem seals, replacing Special tools: Drift ........9990165 Valve spring compressor ..9990210 Turning tool ......9993590 Remove electricity from the engine by turning off the main circuit breaker. Remove unit injector, see “Unit injector, replacing.”...
  • Page 155 Reconditioning / replacing: Engine body Install unit injectors, see “Unit injector, replacing.” Adjust valves and unit injectors, see “Valves and unit injectors, adjusting.” Vent the fuel system. Check for function and leakage.

  • Page 156: Cylinder Head, Pressure Testing

    Reconditioning / replacing: Engine body Cylinder head, pressure testing Special tools: Pressure testing device ..9990123 Lifting chain, 2 ea ....9996239 Assembly stand ....9986485 Fixture ........9990160 Connection washer ....9990107 Seal plates ......9990164 Checking pressure testing device Check the pressure testing device 9990123 before using it: Connect the pressure testing device to an air...

  • Page 157: Pressure Testing

    Reconditioning / replacing: Engine body Pressure testing 21111 Cylinder head removed. For all lifts of the cylinder head; use 2 lifting chains 9996239, see “Cylinder head, removal” Wash the cylinder head. Attach the cylinder head in assembly stand 9986485 using fixture 9990160 and 4 screws, M8x25.
  • Page 158 Reconditioning / replacing: Engine body 13. After 1-2 minutes, check whether the pressure has dropped, or if bubbles of air can be seen in the water bath. If you see bubbles, check seal plates and inspect the cylinder head for any cracks. 14.

  • Page 159: Copper Sleeve For Unit Injector, Replacing

    Reconditioning / replacing: Engine body Copper sleeve for unit injector, replacing Unit injector removed Special tools: Thread cutting tool ....9809667 Turning tool ......9993590 Protective sleeve ....9998251 Sealing ring ......9998250 Thread cutting tool ....9998252 Puller ........9998253 Cleaning kit ......
  • Page 160 Reconditioning / replacing: Engine body Lubricate thread cutting tool, 9809667, with grease in order to prevent chips from falling into the cylinder. Screw in thread cutting tool at least 20 mm (0.8") in the copper sleeve with tool 9998252. NOTE: Use thread cutting tool 9809667. Remove tool 9998252 and thread cutting tool.
  • Page 161 Reconditioning / replacing: Engine body Clean the copper sleeve seat with brush 9808614 together with handle 9808616 and the holders 9808613 and 9808615. Clean the cylinder head hole with brush 9808617. Remove the tools 11 980580 and 9808607. Check that the piston is located in its lower posi- tion in the cylinder.
  • Page 162 Reconditioning / replacing: Engine body Oil the pin on tool 9998688. Lubricate between nut and tool. Press the copper sleeve down carefully so that the drifts are guided towards the unit injector space (the edge) in the cylinder head. Check that copper sleeve bottoms in the cylinder head.

  • Page 163: Camshaft, Checking For Wear

    Reconditioning / replacing: Engine body Camshaft, checking for wear Rocker bridge removed Place a steel ruler above the ridges in the camshaft’s lengthwise direction in order to check if the cam profi- les are worn. Measure wear using a feeler gauge or wire gauge. As an alternative you can use a digital depth slide gauge.

  • Page 164: Camshaft Bearing Housing, Replacing

    Reconditioning / replacing: Engine body Camshaft bearing housing, replacing Factory installed bearing housings have been machi- ned with the cylinder head and must not be moved from one cylinder head to another. Therefore, the first time one or more bearing housings are replaced, all bearing housings must be replaced so that the positions of the bearing housings can be inscribed.

  • Page 165: Camshaft Sensor Distance, Checking

    Reconditioning / replacing: Engine body Camshaft sensor distance, checking Turn the engine so that a tooth on the camshaft drive is aligned with the cam shaft sensor hole on the upper transmission gear casing. Slide the installation tool circlip so that it is placed in the middle of the tool.

  • Page 166: Transmission, Replacing

    Reconditioning / replacing: Engine body Transmission, replacing Valve cover, cable harness, upper transmission casing, camshaft sensor, oil pan, and oil pump have been removed. Removal Remove the flywheel sensor. Turn the engine to TDC on the camshaft, check that the mark on the flywheel is at “0.” Secure lifting chain 9996239 in the flywheel.
  • Page 167 Reconditioning / replacing: Engine body Remove the lower intermediate gear (4). Remove the camshaft drive (1). Remove the two screws on the crankshaft drive (5) and remove the drive using a suitable puller. NOTE: To protect the puller thread, place a thick was- her between the piston ring tool and the crankshaft.
  • Page 168 Reconditioning / replacing: Engine body Fitting NOTE: Lubricate the inside of the gears before you pla- ce them. Apply a 2 mm (0.080") thick string of sealant on the engine block and the cylinder head, as shown. Install the transmission plate. Use new screws that are pre-treated with locking compound.
  • Page 169 Reconditioning / replacing: Engine body Install the bottom intermediate gear (4) with a new O-ring. Install the lubricating oil pump. Place two screws in the crankshaft drive so you can attach a crowbar and thus be able to turn the crankshaft as needed.
  • Page 170 Reconditioning / replacing: Engine body 16. Remove the crankshaft seal and apply new seal- ing compound to the flywheel casing, against the engine block. 17. Install the flywheel casing. Check that the casing is aligned with the bottom edge of the engine block.
  • Page 171 Reconditioning / replacing: Engine body 23. Only fit the screws (1) and tighten by hand. (The holes are oblong so that you can press the casing down towards the rubber seal.) 24. Press the casing down with the tools 885810 and 9998601 so that the cylinder head and the upper transmission gear casing sealing surfaces are aligned.

  • Page 172: Group 22: Lubrication System

    Reconditioning / replacing: Lubrication system Group 22: Lubrication system When working with chemicals, fuel and lubricating oil Important! Lubricate hands with a barrier cream and always use protective gloves during work where you risk contact with oil, fuel, etc. Continu- ous skin contact with engine oil dries the skin and can be damaging.

  • Page 173: Pressure Reduction Valve, Replacing

    Reconditioning / replacing: Lubrication system Pressure reduction valve, replacing Clean the area around the reducing valve. Remove the pressure reduction valve. Clean the valve contact surface in the oil filter housing. Check that the old seal is not left. Check that the color marking on the new valve matches the old.

  • Page 174: Oil Pressure Safety Valve, Replacing

    Reconditioning / replacing: Lubrication system Oil pressure safety valve, replacing Clean the area around the valve and remove it. Clean the valve contact surface. Check that the color marking on the new valve matches the old. Fit the new valve and torque as specified in “Technical data.”...

  • Page 175: Bypass Valve Oil Filters, Full Flow, Replacing

    Reconditioning / replacing: Lubrication system Bypass valve oil filters, full flow, replacing Clean the area around the bypass valve. Remove the valve and clean the valve seat in the oil filter bracket. Fit a new valve with a new seal ring. Torque as specified in “Technical data.”...

  • Page 176: Oil Filters, Checking

    Reconditioning / replacing: Lubrication system Oil filters, checking Check that the oil filters are not faulty or blocked. If the filters have outside damage, oil flow through the filters may be prevented. This may cause the oil pressure to deteriorate. Oil pressure sensor, checking Special tools: Oil hose ........

  • Page 177: Engine Oil And Oil Filters, Replacing

    Reconditioning / replacing: Lubrication system Engine oil and oil filters, replacing 22231 Special tools: Socket ........9998487 Filter pliers ......9999179 Remove the drain plug and drain engine oil into an appropriate container immediately after running when the oil is warm and flows more easily. WARNING! Warm oil and hot surfaces can burn your skin! Clean around the filter bracket and remove the filt-...

  • Page 178: Pressure Reduction Valve, Checking

    Reconditioning / replacing: Lubrication system Pressure reduction valve, checking Check that the pressure reduction valve features a blue color marking. Check that the valve is not damaged, which would hurt its function. Press in the valve cone (1) with a blunt object and check that it does not seize and that it seals against the seat (2).

  • Page 179: Oil Pump, Replacing

    Reconditioning / replacing: Lubrication system Oil pump, replacing 22111 Drain engine oil. Remove the oil filler pipe. Remove terminal to the oil level sensor. Remove the dip stick pipe from the bracket. Remove the pan. Remove screws that hold the oil pipes to the engi- Remove the oil pipes, the oil strainer and the bracket together.

  • Page 180: Oil Pump, Checking

    Reconditioning / replacing: Lubrication system Oil pump, checking Remove the oil pump. See “Oil pump, replacing” Check the pump drives. NOTE: If the reason for the error can be traced to poor oil quality, clean the oil system thoroughly before new oil is filled.

  • Page 181: Oil Cooler

    Reconditioning / replacing: Lubrication system Oil cooler 22311 Removal Clean around the oil cooler casing. Drain the coolant, see “Cooling system, draining” Remove the coolant filter and its bracket. Remove the casing screws and lift away the ca- sing. Remove the oil cooler from the engine block. Fitting Clean the casing contact surface on the engine block.

  • Page 182: Oil Cooler, Leakage Test

    Reconditioning / replacing: Lubrication system Oil cooler, leakage test 22312 Remove the oil cooler. See “Oil cooler, removal/ refitting.” Clean the oil cooler coolant fluid side with water soluble degreaser. Clean the oil side of the oil cooler with degreaser. Check the pressure testing device 9996662 before using it.

  • Page 183: Bypass Valve Oil Cooler, Replacing

    Reconditioning / replacing: Lubrication system Bypass valve oil cooler, replacing Clean the area around the bypass valve and remo- ve it. Clean the valve seat. Fit the new the valve with a new seal ring. Torque as specified in “Technical data.” Start the engine and check for leaks.

  • Page 184: Group 23: Fuel System

    Reconditioning / replacing: Fuel system Group 23: Fuel system Draining, fuel channel in cylinder head Clean around the fuel connections on the cylin- der head and the fuel filter bracket. Loosen the hose from the outlet on the fuel filter bracket and bend down the hose in a suitably vessel.

  • Page 185: Control Module, Replacing

    Reconditioning / replacing: Fuel system Control module, replacing NOTE: Before the control module is replaced and any warranty claim made, all checks in the check list should be performed, to exclude any defect in engine control system. If the measurements of the flat cables show defects, it is highly likely that the control module is OK.
  • Page 186 Reconditioning / replacing: Fuel system Transfer the cooling element to the new control module. Make sure that the surface between the cooling element and the control module is clean. Install the new control module. Torque as specified in “Technical data.” Install upper and lower fuel connections to the cooling element with new sealing washers.

  • Page 187: Fuel Filters, Replacing

    Reconditioning / replacing: Fuel system Fuel filters, replacing 23341 NOTE: Do not fill the new filter with fuel before installa- tion. There is a risk that contamination enters the sys- tem and cause operational disturbances or damage. WARNING! The fuel filter should be replaced when the engine is cold, to prevent any fire hazard if fuel is spilled on hot surfaces.

  • Page 188: Primary Fuel Filter, Change

    Reconditioning / replacing: Fuel system Primary fuel filter, change 23341 Disconnect cable harness at the water trap sen- sor. Remove the water trap filter from the filter hous- ing. Collect any spilled fuel in a container. Remove the lower part of the water trap from the filter.

  • Page 189: Fuel Feed Pump, Replacing

    Reconditioning / replacing: Fuel system Fuel feed pump, replacing 23311 Removal Close any fuel cocks between tank and feed pump, to avoid unnecessary fuel spills. Remove fuel connections to the fuel pump and al- low the fuel to flow out into a suitable container. Clean thoroughly around the feed pump and its connections.

  • Page 190: Unit Injector, Replacing

    Reconditioning / replacing: Fuel system Unit injector, replacing 23710 Special tools: Puller ........9990006 Slide hammer ......9990013 Protective sleeve ....9998249 Socket * ........ 9998580 Handle* ......... 9807616 * included in cleaning kit 9998599 NOTE: If a new unit injector is fitted, a new injector code must programmed into the control unit, see “Workshop manual EMS 2.”...
  • Page 191 Reconditioning / replacing: Fuel system Install protective sleeve 9998580 and clean tho- roughly with brush 9808570 and extender 9808616. Fitting 10. Install new o-rings on unit injector. Upper ring - large diameter Lower ring - Small diameter 11. Install the retainer on unit injector and center it between the valve springs.
  • Page 192 Reconditioning / replacing: Fuel system 12. Connect the contact, press in until you hear a “click.” Install new cable ties. 13. Install the valve calipers. 14. Oil valve calipers and cam shaft ridges with engi- ne oil. 15. Lift the rocker bridge in place using lifting tool 9990185.

  • Page 193: Venting The Fuel System

    Reconditioning / replacing: Fuel system Venting the fuel system Check whether there is enough fuel in the tank, and that any fuel taps are open. Remove the hand pump on the fuel filter bracket by turning it. The fuel system is vented by pumping with the hand pump.

  • Page 194: Group 25: Inlet / Exhaust Systems

    Reconditioning / replacing: Inlet and exhaust systems Group 25: Inlet and exhaust systems Turbo, replacing 25512 Always determine and remedy the reasons why the tur- bocharger has been wrecked before a new turbocharger is installed. One condition for the turbocharger to work satisfactorily is that the engine’s lubrication and inlet systems are kept in good condition, i.e.
  • Page 195 Reconditioning / replacing: Inlet and exhaust systems Fitting Clean the turbo contact surface on the exhaust manifold. Fit the return oil pipe with a new seal ring against the engine block. Place a new gasket on the exhaust manifold and install the turbo.

  • Page 196: Group 26: Cooling System

    Reconditioning / replacing: Cooling system Group 26: Cooling system Cooling system, draining WARNING! Be careful when opening the coolant filler cap when the engine is hot. Steam or hot coolant can spray out. NOTE: Before draining the cooling system, remove the expansion tank cover.

  • Page 197: Cooling System, Cleaning

    Reconditioning / replacing: Inlet and exhaust systems Cooling system, cleaning Warning! Chemicals for the cooling system are a health hazard (do not ingest). Empty the cooling system, see “Cooling system, draining,” and flush with clean water. Close all open cocks and fill the cooling system with a mix of radiator cleaner and pure water.

  • Page 198: Cooling System, Pressure-Testing

    Reconditioning / replacing: Cooling system Cooling system, pressure-testing Special tools: Pressure-testing equipment ... 885531 WARNING! Be careful when opening the coolant filler cap when the engine is hot. Steam or hot coolant can spray out. Check that all hoses are free from defects. Check coolant level in the expansion tank.

  • Page 199: Cooling System, Filling

    Air should be able to flow out through the fill ope- ning and the vent cocks. Use only of Volvo Penta re- commended coolant and mix.

  • Page 200: Coolant Pump, Replacing

    Reconditioning / replacing: Cooling system Coolant pump, replacing 26211 Removal IMPORTANT! Break the current or use some oth- er means to prevent the engine from starting during the work. Drain the coolant into a suitable container. see “Cooling system, draining” Remove the drive belt shield that is installed abo- ve the coolant pump.

  • Page 201: Thermostat, Functional Check

    Reconditioning / replacing: Cooling system Thermostat, functional check 26273 Remove the thermostat, see “Thermostat, repla- cing.” Place the thermostat in a big pot with water and heat it to the opening temperature as specified in “Technical data, Thermostat.” If the thermostat does not open at specified tem- Closed thermostat perature, replace it.

  • Page 202: Coolant Filter, Changing

    Reconditioning / replacing: Cooling system Coolant filter, changing NOTE: The coolant filter should be replaced at stated intervals, if this is not done, the engine may last a lot less. When working on an engine where more a five li- ters (5.3 quarts) new coolant are being added, a new coolant filter should always be installed.

  • Page 203: Drive Belt, Changing

    Reconditioning / replacing: Cooling system Drive belt/Alternator belt, inspection Check belts after running when they are warm. You should be able to depress the alternator belt and the drive belt about 3-4 mm (0.118-0.158") between the pul- leys. Both the alternator belt and the drive belt has an auto- matic belt tensioner and need not be adjusted.

  • Page 204: Alternator Belts, Changing

    Reconditioning / replacing: Cooling system Alternator belts, changing IMPORTANT! Always replace a drive belt that seems worn or is cracked. 1. Disconnect the main switch(es) and check that the engine is not connected to system voltage. 2. Remove the belt guard. 3.
  • Page 205 Notes ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________...
  • Page 206 Notes ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________...

  • Page 207: Report Form

    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...
  • Page 209 Workshop Manual Group 23 EMS2 4(0) TAD1640GE, TAD1641GE, TAD1642GE TAD1641VE, TAD1642VE...
  • Page 211 EMS 2 TAD1640GE, TAD1641GE, TAD1642GE, TAD1641VE, TAD1642VE Contents Service procedures ..........27 Safety Precautions ..........2 When working with EMS 2 ......... 27 Introduction ............2 Control module (EMS 2), replace ....... 28 Unit injector, replacing ......... 29 General information ..........5 Starting with auxiliary batteries ......

  • Page 212: Introduction

    This workshop manual contains descriptions and re- with hot surfaces (exhaust pipes, turbos, charge pair instructions for the Volvo Penta products or prod- air pipes, starting heaters etc.) and hot fluids in uct versions noted in the table of contents. This work-...
  • Page 213 All fuels and many chemical substances are WARNING! The components in the electrical flammable. Do not allow naked flame or sparks system and in the fuel system on Volvo Penta in the vicinity. Petrol (gasoline), some thinners products are designed and manufactured to min- and hydrogen gas from batteries are extremely imize the risk of fire and explosion.
  • Page 214 Turn the engine off and turn off the power at the main switch(es) before carrying out work on the electrical system. © 2004 AB VOLVO PENTA We reserve the right to make modifications without prior notice. Printed on environmentally-friendly paper.

  • Page 215: General Information

    Any type of damage which is the result of using spare Any damage, injury and/or costs which arise parts that are not original Volvo Penta parts for the due to the use of non-original Volvo Penta product in question will not be covered under any war- spares for the product in question will not be ranty or guarantee provided by AB Volvo Penta.

  • Page 216: Repair Instructions

    Volvo Penta Special Tools have been spe- unintentionally end up in nature. cifically developed to ensure the most safe and ratio- nal working methods possible.

  • Page 217: Torque-Angle Tightening

    Lock nuts In this Volvo Penta Workshop Manual the user will find that each section where these agents are applied Disassembled locknuts shall not be re-used, they...

  • Page 218: General

    Group 23 EMS 2 General General Location of engine signs The sign above shows: Engine designation Serial number Specification number The sign above shows: A Engine designation B Engine power, net (without fan) C Max. engine speed D Main software E Data set 1 F Data set 2 G Product number...

  • Page 219: Tools

    Group 23 EMS 2 Tools Tools Special tools The following special tools are used when working on the engine. The special tools can be ordered from AB Volvo Penta by specifying the number shown. 951 2636 999 8482 999 8534...

  • Page 220: Technical Data

    Group 23 EMS 2 Technical data Technical data Control unit Voltage ..............24 V Connector .............. 2 x 62-pin Working temperature range ........-40°C to +90°C (-40°F to +194°F) Cooling ..............External fuel cooling Sensor, water in fuel Voltage ..............24 V Connector ..............
  • Page 221 Group 23 EMS 2 Technical data Sensor, coolant temperature Voltage ..............5 V Connector .............. 2-pin Working temperature range ........-40°C to +140°C (-40°F to +284°F) Type ..............NTC Max tightening torque ..........20-24 Nm (14.75 - 17.7 lbf-ft) Sensor, coolant level Connector ..............

  • Page 222: Design And Function

    EMS 2 stands for ”Engine Management System” and is an electronic system with CAN communications (Control- ler Area Network) for control of diesel engines. The system has been developed by Volvo Penta and includes fuel control and diagnostic function. The system consists of a control module, six unit injectors, a number of sensors that supply the control module with measurements, sockets for diagnosis and functional checks.
  • Page 223 Group 23 EMS 2 Design and function Input signals Output signals The control module receives input signals about the Based on the input signals the control module controls engines operating conditions and other things from the the following components: following components: –...

  • Page 224: Fuel Control

    Fault codes can also be read tion to the cylinder stops. by Volvo’s VODIA tool at authorized Volvo Penta In order to determine when the fuel valve shall open or workshops.

  • Page 225: Component Description

    Group 23 EMS 2 Design and function Component description The numbers after the heading refer to ”component lo- cation” on page. 20. Sensor, water in fuel (11) The sensor is located in the lower part of the fuel pre- filter. It’s purpose is to detect water in the fuel system.

  • Page 226: Coolant Temperature Sensor

    Group 23 EMS 2 Design and function Charge air pressure/charge air sensor (3) The charge air pressure and temperature are mea- sured via a combined sensor positioned on the inlet pipe. The charge air pressure sensor measures absolute pressure, which is the sum of charge air pressure and atmospheric pressure.
  • Page 227 Group 23 EMS 2 Design and function Oil level sensor / oil temperature sensor (12) The sensor is located in the oil sump. The purpose of the level sensor is to detect if the oil level becomes too low. A current is passed through the sensor and the voltage measured across it is then proportional to the oil level.

  • Page 228: Control Module (Ems 2)

    Group 23 EMS 2 Design and function Control module EMS 2 The control module checks and controls the unit injec- tors so that the correct amount of fuel is injected into each cylinder. It calculates and sets the injection an- gle.

  • Page 229: Unit Injector

    Group 23 EMS 2 Design and function Unit injector The unit injectors are located under the valve cover, mounted in the cylinder head. The engine’s fuel requirement is analyzed up to 100 times per second (depending on engine rpm). The amount of fuel injected into the engine and the injec- tion timing are electronically controlled via the unit in- jector’s solenoid controlled fuel valves.

  • Page 230: Component Location

    Group 23 EMS 2 Design and function Component location 1. Coolant level sensor (in the expansion tank) 2. Extra stop 3. Charge pressure / charge temperature sensor 4. Air filter pressure sensor and air temperature sen- 5. Main circuit breaker 10 A 6.

  • Page 231: Limit Values

    Group 23 EMS 2 Limit values Limit values Limit values, control module (EMS 2) TAD1640–1642GE Oil temperature NOTE: The engine protection can be turned off. Preset alarm limit Adjustable between Alarm lamp is lit Engine cut off 125 °C (257 °F) 120 - 130 °C at alarm limit +5 °C (+41 °F)

  • Page 232: Fuel Pressure

    Group 23 EMS 2 Limit values Fuel pressure Preset alarm limit Adjustable between Alarm lamp is lit Engine cut off See diagram, fuel not adjustable at alarm limit pressure below Fuel pressure Water in fuel Preset alarm limit Adjustable between Alarm lamp is lit Engine cut off water in fuel...

  • Page 233: Limit Values, Control Module (Ems 2) Tad1641-1642Ve

    Group 23 EMS 2 Limit values Limit values, control module (EMS 2) TAD1641–1642VE Oil temperature NOTE: The engine protection can be turned off. Preset alarm limit Adjustable between Alarm lamp is lit Torque limitation Engine cut off 125 °C (257 °F) 120 - 130 °C at alarm limit +5 °C (+41 °F)

  • Page 234: Coolant Level

    Group 23 EMS 2 Limit values Coolant level NOTE: The engine protection can be turned off. Preset alarm limit Adjustable between Alarm lamp is lit Torque limitation Engine cut off low coolant level not adjustable low coolant level Fuel pressure Preset alarm limit Adjustable between Alarm lamp is lit Torque limitation Engine cut off...
  • Page 235 Group 23 EMS 2 Limit values Boost air temperature NOTE: The engine protection can be turned off. Preset alarm limit Adjustable between Alarm lamp is lit Torque limitation Engine cut off 80 °C (176 °F) not adjustable at alarm limit +5 °C (+41 °F) Boost air pressure NOTE: The engine protection can be turned off.
  • Page 236 Group 23 EMS 2 Limit values Limp-home value (emergency regulation value) The basic value is used by the control unit in order to continue running the engine when a technical fault oc- curs in the system or it’s peripherals, sensors etc. The following value (Limp home-value) is stored in the control unit: Boost air temperature...
  • Page 237 Group 23 EMS 2 Repair instructions Repair instructions When working with EMS 2 system Follow the instructions below so as not to damage the EMS 2-system control unit: • Never switch off main power while the engine is running. • Never disconnect a battery cable while the engine is running.
  • Page 238 Group 23 EMS 2 Repair instructions Control module (EMS 2), replace WARNING! Exchange of control units between engines, during fault tracing or repair, must nev- er be performed under any circumstances.. Clean thoroughly around the control module fuel connections. Remove electricity from the engine by discon- necting the negative battery terminal.

  • Page 239: Unit Injector, Replacing

    Repair instructions Unit injector, replacing For replacement of unit injectors see: ”Workshop Manual Group 21-26 Industrial engine TAD1640GE, TAD1641GE, TAD1642GE, TAD1641VE,TAD1642VE” When a unit injector has been replaced, a new injector code must be programmed into the EMS 2-control unit. This is done with the VODIA tool.

  • Page 240: Starting With Auxiliary Batteries

    Group 23 EMS 2 Repair instructions Starting with auxiliary batteries WARNING! Ventilate well. Batteries can gener- ate oxy-hydrogen, which is very flammable and highly explosive. A short circuit, open flame or spark could cause a violent explosion. WARNING! Never mix up the battery cables po- sitions on the battery.

  • Page 241: Function Check

    • User information is included with the program. • To order the program, contact your Volvo Penta retailer. • The task of the diagnostic function is to discover and locate any malfunctions in the EMS 2 system, to protect the engine and to ensure operation in the event of serious malfunction.

  • Page 242: Fault Tracing

    A number of symptoms and possible causes of engine malfunctions are described in the table below. Always con- tact your Volvo Penta dealer if any problems occur which you can not solve by yourself. WARNING! Read the safety instructions for handling and service in the chapter ”Safetyinformation” before starting work.

  • Page 243: Diagnostic Function

    For reading fault codes, see chapter Operation on page 34. All fault codes are found in the fault code list with in- formation about cause, reaction and actions, see chapter on ”Fault codes.” NOTE: The indicated flashing codes apply only if the Volvo Penta CIU is used.
  • Page 244 Group 23 EMS 2 Diagnostic function Operation Reading fault codes via Display Control unit (DCU) When a disturbance has occurred and the diagnosis system has generated one or more fault codes, these When a fault code has been set, the text ”!! ENGINE can be read either via: WARNING !!”...
  • Page 245 Group 23 EMS 2 Diagnostic function Reading fault codes via the diagnosis lamp on instrument panel (CIU) If the diagnosis knob is depressed and then released, a fault code will flash. The fault code consists of two groups of flashes, sep- arated by a pause of two seconds.
  • Page 246 Group 23 EMS 2 Diagnostic function Fault codes EMS 2 WARNING! Read the safety instructions for handling and service in chapter ”Safety information” before star- ting work. NOTE: Reading the fault codes below, such as PID 97, Code 2.1 means that PID 97 is read using the diagnostic tool VODIA.
  • Page 247 Group 23 EMS 2 Diagnostic function PPID 132, Code 2.8 RPM-potentiometer SID22, Code 2.5 Speed sensor, camshaft wheel connected to CIU Cause: Reason: No signal. • Shorted to plus (+) or minus (-). • Abnormal frequency. • Potentiometer faulty. • Sensor faulty.
  • Page 248 Group 23 EMS 2 Diagnostic function PID 105, Code 3.2 Charge air temperature sensor PID106/102, Code 3.4 Boost pressure sensor Reason: Reason: Shorted to plus (+) or minus (-). Shorted to plus (+) or minus (-). • • Break. Break. •...
  • Page 249 Group 23 EMS 2 Diagnostic function PID175, Code 3.7 Oil temperature sensor PPID 4, Code 5.2 Start input, CIU Reason: Reason: Shorted to plus (+) or minus (-). Shorted to minus (-). • • Break. Activated for too long. • •...
  • Page 250 Group 23 EMS 2 Diagnostic function PID 107, Code 5.5 Pressure drop, air filter PID 98, Code 5.9 Oil level sensor Reason: Reason: Blocked air filter. Shorted to plus (+) or minus (-). • • Reaction: Break. • Warning indicator. Reaction: •...
  • Page 251 Group 23 EMS 2 Diagnostic function PID 105, Code 6.2 Charge air temperature SID 231, Code 6.5 Data link (CAN), EMS 2 Reason: Reason: Charge air temperature too high. Internal fault in the control module. • • Reaction: Reaction: VE engines: The engine control module limits en- Engine not operating: engine can not be started.
  • Page 252 Group 23 EMS 2 Diagnostic function PPID 8, Code 6.7 Piston cooling pressure PID 158, Code 6.9 Battery voltage, CIU Reason: Reason: Piston cooling pressure is too low. Shorted to minus (-). • • Reaction: Faulty alternator • Engine stopped, applies to both GE and VE en- Battery, battery cables faulty.
  • Page 253 Group 23 EMS 2 Diagnostic function SID 2, Code 7.2 Unit injector cylinder 2# SID 4, Code 7.4 Unit injector cylinder 4# Reason: Reason: Electric fault. Electric fault. • • Compression or unit injector faulty. Compression or unit injector faulty. •...
  • Page 254 Group 23 EMS 2 Diagnostic function PID 153, Code 7.8 Crankcase ventilation pressure SID 6, Code 7.6 Unit injector cylinder 6# sensor Reason: Reason: Electric fault. • Shorted to plus (+) or minus (-). • Compression or unit injector faulty. •...
  • Page 255 Group 23 EMS 2 Diagnostic function SID250, Code 9.2 Data link faulty (J1708/J1587) SID 254, Code 9.8 Control module fault, CIU Reason: Reason: Data link faulty. EEPROM, CIU, faulty • • Reaction: Flash memory, CIU faulty. • Warning indicator. Fault in control module, CIU •...

  • Page 256: General

    Group 23 EMS 2 Electrical fault tracing Electrical fault tracing General Functional check of wiring and connector blocks Before performing electrical fault tracing, the following should be checked: • Fault codes Connection problems • Fuel level and filter Loose connectors or occasionally recurring faults can •...

  • Page 257: Functional Check Of Wiring And Connector Blocks

    Group 23 EMS 2 Electrical fault tracing Functional check of wiring and connector blocks Check connections visually Connector resistance and oxidation. Check the following: The resistance in connectors, wiring and connections should be 0 Ω. • Look for oxidation that can worsen connector con- A certain resistance is always present however, due tact in the connections to oxidation of connections.

  • Page 258: Splicing Cables For Cable Connectors

    Group 23 EMS 2 Electrical fault tracing Splicing cables for cable connectors Special tools: 951 2636, 9999324 Repair kit: 1078054 1. Disconnect the connector block from the control unit, see ”Control unit, replace”. Dismantle the connector block so that the pin/socket to be re- placed is accessible.
  • Page 259 Group 23 EMS 2 Electrical fault tracing Check of combination sensor, Check of sensor, coolant charge air pressure/charge air temperature temperature Check, charge air pressure 1. Turn off engine 1. Turn off engine 2. Disconnect connector A on the control unit and 2.
  • Page 260 Group 23 EMS 2 Electrical fault tracing Check of sensor, water in fuel Temperature Resistance -20 °C (-4 °F) 15462 Ω -10 °C (14 °F) 9397 Ω 0 °C (32 °F) 5896 Ω 10 °C (50 °F) 3792 Ω 20 °C (68 °F) 2500 Ω...
  • Page 261 Group 23 EMS 2 Electrical fault tracing Check of sensors, camshaft Checking sensor, oil pressure and flywheel Check of oil pressure function The speed sensors for the camshaft and flywheel are 1. Turn off engine identical. For visual checking, first remove the sensor from the engine.
  • Page 262 Group 23 EMS 2 Electrical fault tracing Check of sensor, Checking combined sensor, coolant level oil level/oil temperature Check of oil level function Empty the expansion tank from coolant. 1. Remove connector block from the oil level sensor. WARNING! NEVER open the expansion tank 2.
  • Page 263 Group 23 EMS 2 Electrical fault tracing Check of sensor, fuel pressure Check of sensor, crankcase pressure 1. Turn off engine 1. Turn off engine 2. Disconnect the oil pressure sensor connector 2. Disconnect the charge air pressure sensor con- block and connect the 7-pin adapter 9998567 be- nector block and connect the 4-pin adapter tween the oil pressure sensor’s connector unit and...
  • Page 264 Group 23 EMS 2 Electrical fault tracing Checking combined sensor, air filter pressure/air temperature Checking air filter pressure function 1. Remove the connector from the sensor. 2. Connect the 4-pin adapter 9998534 between the oil pressure sensor connector and engine har- ness.
  • Page 265 Group 23 EMS 2 Electrical fault tracing Fault tracing unit injectors Fault tracing starter motor and cabling General If the voltage level measured across the battery is less than 24.7V, the starter motor will not be able to crank the engine at normal speed. Voltage measurement check 1.
  • Page 266 Group 23 EMS 2 Electrical fault tracing Functional check of relay Multimeter 9510060 is used during the fault tracing procedure. Two different symbols visualize conductor status. Symbol 1 indicates open circuit or very high resis- tance (~). The multimeter does not sound. Symbol 2 indicates connection or very low resistance.

  • Page 267: Electrical System

    For simultaneous charging of Electric welding two independent battery circuits, a Volvo Penta Remove the positive and negative cables from the charging separator can be fitted to the standard batteries.

  • Page 268: Electrical System, Overview

    Group 23 EMS 2 Electrical system Electrical system, overview TAD1640-1642GE with CIU, CAN based SAE J1939 TAD1640-1642GE with DCU, CAN based SAE J1939...
  • Page 269 Group 23 EMS 2 Electrical system TAD1641-1642VE with CIU, CAN based SAE J1939 TAD1631641-1642VE with DCU, CAN based SAE J1939...
  • Page 270 Group 23 EMS 2 Electrical system Electrical diagram EMS2 Cable colors BL = Blue LBL = Light blue BN = Brown LBN = Light brown GN = Green GR = Grey OR = Orange = Pink = Red SB = Black VO = Purple = White = Yellow...

  • Page 271: Wiring Diagram Ciu

    Group 23 EMS 2 Electrical system Key switch running power (15+) Wiring diagram CIU RPM-potentiometer Tachometer (code 14) Oil pressure, instrument Oil temperature, instrument Coolant temperature, instrument Cable colors Instrument illumination Blue = Pink Idle switch, two-position LBL = Light blue R = Red 1500/1800 switch, two-position Brown...

  • Page 272: Wiring Diagram Dcu

    Group 23 EMS 2 Electrical system Wiring diagram DCU Cable colors BL = Blue LBL = Light blue BN = Brown LBN = Light brown GN = Green GR = Grey OR = Orange = Pink = Red SB = Black VO = Purple Start contact Stop contact...
  • Page 273 Notes ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 274 Notes ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 275 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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