Volvo Penta TD164KAE Manuals

Manuals and User Guides for Volvo Penta TD164KAE. We have 1 Volvo Penta TD164KAE manual available for free PDF download: Workshop Manual

Volvo Penta TD164KAE Workshop Manual

Volvo Penta TD164KAE Workshop Manual (164 pages)

Brand: Volvo Penta | Category: Engine | Size: 1.95 MB

Table of Contents

Table of Contents
3
Contents

8
General Information

8
Tools

13
- Special Tools
  13
- Other Special Equipment
  17
Engine

18
Design and Function

18
- Cylinder Head
  19
- Cylinder Block
  19
- Seals
  19
- Valve Mechanism
  20
- Camshaft
  20
- Timing Gears
  20
- Crankshaft/Pistons
  21
Service Procedures

22
- Engine Fixture, Attaching
  22
- Compression Test
  23
- Exposing Engine Body
  23
- Tad1630/Tad1631
  23
- Tid162/Twd1620/Twd1630/Td164
  23
- Tad1630/Tad1631/Tid162/Twd1630/Td164
  24
- Cylinder Head, Removing
  25
- Cylinder Head, Disassembling
  26
- Cylinder Head, Pressure Testing
  27
- Cylinder Head, Inspection
  28
- Cylinder Head, Face-Grinding
  28
- Valve Guides, Inspection
  29
- Valve Guides, Replacing
  30
- Valve Seats, Replacing
  30
- Valve Seats, Grinding
  31
- Valves, Grinding
  31
- Cylinder Head, Assembling
  32
- Cylinder Head, Installation
  32
- Rocker Arm Mechanism, Reconditioning
  35
- Valves, Adjusting
  36
- Copper Sleeve for Injectors, Replacing
  38
- Cylinder Liners and Pistons, Removing
  41
- Cylinder Liners, Measurement and Inspection
  42
- Cylinder Liners, Honing
  42
- Cylinder Liner Seats, Reconditioning
  43
- Cylinder Block, Face-Grinding
  44
- Pistons, Checking
  45
- Pistons, Fitting
  45
- Piston Rings, Inspection
  45
- Connecting Rods, Inspection
  45
- Pistons, Piston Rings and Connecting Rods, Assembling
  46
- Cylinder Liners and Pistons, Fitting
  47
- Tad1630/Tid162/Twd1620/Twd1630/Td164Kae
  52
- Tad1631
  53
- Seal on Output Shaft from Timing Gear to Injection Pump, Re- Placing:
  53
- Front Sealing Ring for Coolant Pump, Replacing
  55
- Sealant, Timing Gear Cover, Replacement
  56
- Timing Gears, Removing
  57
- Intermediate Gears, Replacing Bearing
  58
- Timing Gears, Fitting
  59
- Polygon Hub, Replacing
  60
- Sealant, Transmission Gear Casing, Replacing
  61
- Camshaft, Checking for Wear
  61
- Camshaft, Replacing
  64
- Camshaft Bearings, Replacing
  66
- Main Bearings, Replacing, All
  68
- Crank Bearings, Checking for Wear or Replacing, All
  69
- Crankshaft, Replacing
  70
- Crankshaft
  71
  - Inspection
    71
  - Reconditioning
    73
- Flywheel, Checking for Warp
  73
- Flywheel, Replacing
  74
- Ring Gear, Replacing
  75
- Flywheel Casing, Checking for Warp
  75
- Flywheel Bearing, Replacing
  76
- Crankshaft Seal, Rear, Replacing
  77
- Crankshaft Seal, Front, Replacing
  78
- Sealant, Flywheel Casing, Replacing
  79
Lubrication System

81
Design and Function

81
- General
  81
- Oil Cooler
  83
Service Procedures

84
- Lubricating Oil Pressure, Checking
  84
- Oil Filters, Replacing
  84
- Oil Cooler, Replacing
  85
- Oil Cooler, Leakage Test
  86
- Oil Pump, Replacing
  87
- Oil Pump, Reconditioning
  89
Fuel System

92
Design and Function

92
- General
  92
- Fuel Filters
  92
- Injection Pump
  93
- Smoke Limiter TAD1630P/V
  96
- Feed Pump
  96
- Manual Pump
  96
Instrucciones de Reparación

97
Service Procedures

97
- Injection Pump, Removal
  97
- Fitting and Adjusting the Injection Pump
  97
- Injection Pump, Setting with Measuring Tool 998 7057
  100
- Pump Coupling Shaft, Removing
  103
- Checking and Replacing Pump Coupling Laminates
  103
- Injectors
  103
- Injectors, Replacing
  104
- Injectors, Reconditioning
  105
- Opening Pressure, Adjusting
  106
- Fuel Feed Pressure, Checking
  106
- Fuel Filters, Replacing
  107
- Feed Pump, Replacing
  107
- Feed Pump, Reconditioning
  108
- Smoke Limiter, TAD1630P/V
  109
  - Replacing the Diaphragm
    109
- Fuel System, Bleeding
  110
Intake and Exhaust Systems

111
Design and Function

111
- Charge Air Cooler
  111
- Turbocharger
  111
- Air Filter
  112
- Starter Heater
  112
- Exhaust Manifold
  112
Service Procedures

113
Cooling System

127
Design and Function

127
- General
  127
Service Procedures

130
- Coolant Pump, Replacing
  130
- Coolant Pump, Reconditioning
  132
- Sleeve Thermostats, Replacing
  142
- Sleeve Thermostats, Checking
  143
- Coolant Manifold Seals, Replacing
  144
- Coolant
  146
- Anti-Freeze
  146
- Volume
  146
- Anti-Corrosion Additives
  146
- Checking Coolant Level
  146
- Draining the Coolant
  146
- Coolant, Filling
  147
- Coolant Temperature too High
  147
- Coolant Temperature too Low
  147
- Temperature Gauge, Checking
  147
- Level Switch, Checking
  147
- Coolant Leakage
  148
- Radiator and Charge Air Cooler, Checking
  148
- Drive Belts, Adjusting
  148
- Cooling System, Cleaning
  148
  - Cooling System, Pressure-Testing
    149
  - Checking Pressure-Testing Device 999 6662
    149
  - Pressure Testing
    149
  - Pressure Valve, Checking
    150
Electrical System

151
- Important
  151
- Arc Welding
  151
- Starting with Auxiliary Battery
  151
- Electronic Speed Governor, Wiring
  152
Wiring Diagrams

153
Troubleshooting

158

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