Volvo Penta TAD520GE Workshop Manual Download Page 7

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Group 20

General information

Fuel system

1 Fuel tank
2 Line to fuel pump
3 Fuel pump
4 Line to fuel filter
5 Fuel filter
6 Fuel line to fuel duct
7 Injection pump
8 Delivery pipe to injector
9 Injector

10 Fuel return line
11 Overflow valve with air ventilation screw
12 Return line to fuel tank
13 Fuel pipes

14 Pre-filter, water separating
15 Hand pump (accessory)

NOTE!

Minimum distance 300 mm.

NOTE!

Does not work laying down. Must be turned right (TOP).

Summary of Contents for TAD520GE

Page 1: ... check 122 Changing injection pump 123 Group 25 Boost pressure 124 Group 26 Coolant pump 125 Thermostat 127 Wiring diagrams 128 Index 133 Safety information 2 General information 5 Repair instructions 6 Special tools 9 Engine description 12 Location of the engine identification plate 12 Identification plates 12 Engine serial number 13 Cylinder numbering 13 Engine location of components 14 Starter ...

Page 2: ...cation adjacent to the engine 1 Engine model 2 Engine specific number 3 Engine serial number 10 digits 4 Engine output without fan 5 Rated engine speed 6 Injection timing and type of camshaft 7 Manufacturers identification code 8 Indication of standard and or regulation 9 Reference test conditions according to ISO 3046 10 Reference test conditions according to ISO 3046 11 Injection pump code EP co...

Page 3: ...gine serial number The engine serial number is stamped into the engine block and engine identification plate The serial number is a ten digit number Only the last eight digits are stamped into the engine block Cylinder numbering A flywheel ...

Page 4: ...ndividual This means that the governor can not be exchanged between different engines An incorrect adjusted governor can result in that the engine will not fulfill the regulations for emission and performance When ordering a governor as a spare part always state en gine types serial number and rated speed rpm Only trained personnel should make adjustments to the governor 1 Turbocharger 2 Lifting e...

Page 5: ...nlet pipe 3 Coolant pump 4 Alternator 5 Crankshaft pulley 6 Fuel pump 7 Fuel filter 8 Lubricating oil filter 9 Oil sump 10 Oil dipstick 11 Lubricating oil cooler 12 Power socket for hydraulic pump air compressor etc 13 Cylinder head 14 Stop solenoid Service side ...

Page 6: ... 7 Oil channel to piston cooling nozzle 8 Lubricating oil cooler 9 Lubricating oil pump 10 Safety valve pressure regulating valve 11 Reduction valve 12 Lubricating oil filter 13 Push rod oil feed to rocker arm lubrication 14 Oil sump 15 Connecting rod bearing 16 Crankshaft main bearing 17 Return flow from turbocharger to crankcase 18 Turbocharger 19 Return flow to oil sump 20 Oil line to turbochar...

Page 7: ...el line to fuel duct 7 Injection pump 8 Delivery pipe to injector 9 Injector 10 Fuel return line 11 Overflow valve with air ventilation screw 12 Return line to fuel tank 13 Fuel pipes1 14 Pre filter water separating 15 Hand pump accessory 2 1 NOTE Minimum distance 300 mm 2 NOTE Does not work laying down Must be turned right TOP ...

Page 8: ...and new EP code must also be calculated according to Calculation 2 and 3 in Technical data New EP code must also be is indicated on the identification plate in order for calculations during future replacement of injection pump to be correct Delivery pipes IMPORTANT The delivery pipes must be disposed of after disassembling The delivery pipes are deformed when tightened and all delivery pipes must ...

Page 9: ...oup 20 General information 19 Cooling system 1 Coolant connection inlet 2 Thermostat housing 3 Coolant pump 4 Lubricating oil cooler 5 Cylinder cooling 6 Cylinder head cooling 7 Coolant connection outlet ...

Page 10: ...l Four stroke diesel Combustion system Direct injection Direct injection Compression ratio 18 4 1 18 1 1 Firing order 1 3 4 2 1 3 4 2 Valve clearance inlet exhaust 0 35 0 55 mm 0 05 mm 0 35 0 55 mm 0 05 mm 0 014 0 022 0 0039 0 014 0 022 0 0039 Lubricating oil pressure at low idle temperature approx 120 C oil SAE 15W 40 Min 150 kPa 21 7 psi Min 80 kPa 11 6 psi Thermostat starts to open fully open 8...

Page 11: ...rder 1 5 3 6 2 4 1 5 3 6 2 4 Valve clearance inlet exhaust 0 35 0 55 mm 0 05 mm 0 35 0 55 mm 0 05 mm 0 014 0 022 0 0039 0 014 0 022 0 0039 Lubricating oil pressure at low idle emperature approx 120 C oil SAE 15W 40 Min 80 kPa 11 6 psi Min 80 kPa 11 6 psi Thermostat starts to open fully open 87 C 102 C 188 F 215 F 87 C 102 C 188 F 215 F TAD732GE Anti clockwise 6 108 4 25 130 5 12 7 15 436 12 18 0 1...

Page 12: ...mum idling speed 850 950 rpm 800 950 rpm Operating cycle Four stroke diesel Four stroke diesel Combustion system Direct injection Direct injection Compression ratio 18 4 1 18 4 1 stage 1 19 0 1 stage 2 Firing order 1 5 3 6 2 4 1 5 3 6 2 4 Valve clearance inlet exhaust 0 35 0 55 mm 0 05 mm 0 35 0 55 mm 0 05 mm 0 014 0 022 0 0039 0 014 0 022 0 0039 Lubricating oil pressure at low idle emperature app...

Page 13: ...0 720 721 722GE 732 733 200 kPa 29 psi 520 720 721 722 VE 530 531 730 731 532 50 kPa 7 psi Oil volume including filter TD520GE TAD520GE 10 litre 2 64 US gallon TD520VE TAD520VE 13 litre 3 43 US gallon TD TAD720 TAD721 722VE TAD730 731GE 20 litre 5 28 US gallon TAD721 722GE TAD732 733GE 34 litre 8 98 US gallon Coolant Manifold side TD TAD 720 722 TAD730 733 Volvo Penta glycol antifreeze mixed 45 55...

Page 14: ... up to 45 mm length Step 1 20 30 15 22 lbf ft Step 2 tighten angularly 60 Step 3 tighten angularly 60 C Flywheel with a screw length between 50 85 mm Step 1 30 40 22 30 lbf ft Step 2 tighten angularly 60 Step 3 tighten angularly 60 Flywheel housing M12 99 10 73 7 lbf ft M16 243 25 179 18 lbf ft Cylinder head See previous page V belt pulley Screws to V belt pulley are reusable only three times Step...

Page 15: ...7 1 5 12 5 1 lbf ft Flange screws Injection pump Step 1 Torque 5 3 7 lbf ft Step 2 Loosen screws for injection pump flange 60 counterclockwise Step 3 Turn injection pump to stop Counterclockwise Step 4 tighten angularly 60 Step 5 7 5 lbf ft Step 6 10 7 4lbf ft Step 7 30 22lbf ft Flange screw injector 19 2 14 1 5 lbf ft Injector cap nut 40 50 30 37lbf ft Delivery pipe NOTE Use a new delivery pipe a...

Page 16: ...P code for cylinder 3 from the engine identification plate in the EP column e g 397 Sequence from top row 1 cyl 1 row 2 cyl 2 etc Calculation 1 Explanation Factor Ex TD TAD 520 720 721 722 Cylinder no XXX Cyl 1 Cyl 2 Cyl 3 Cyl 4 Cyl 5 Cyl 6 Injection pump manufacturing number XXX EP code EP 397 Corrected fitting size see table 3 Ek 146 9 Basic meas of inj pump see table 1 L0 143 Manufacturing tole...

Page 17: ...n the injection valve opens Performed when replacing engine block camshaft or roller tappet Mathematical formula for the new shim thickness Ts L Fbakt Fbnom x Vhkorr Vhnom Lo A 100 The actual shim thickness can be found in Table 2 Ss Ts NOTE After determining the shim thickness a new EP code MUST ALWAYS be determined according to Calculation 3 in order for changing of pump to be correct at a later...

Page 18: ...L S3 Ek Ek 146 18 Ek rounded to nearest value in Table 3 Ek 146 175 EP code Ek Table 3 EP code EP 344 100 mm 3 937 Determination of the corrected fitting size Ek and EP code for an injection pump NOTE When you change the engine block camshaft or roller tappet you must determine the corrected fitting measurement Ek and change the relevant EP code on the engine identification plate Mathematical form...

Page 19: ...146 1 365 146 7 389 147 3 144 925 145 525 342 146 125 366 146 725 390 147 325 144 95 145 55 343 146 15 367 146 75 391 147 35 144 975 145 575 344 146 175 368 146 775 392 147 375 145 0 145 6 345 146 2 369 146 8 393 147 4 145 025 145 625 346 146 225 370 146 825 394 147 425 145 05 145 65 347 146 25 371 146 85 395 147 45 145 075 145 675 348 146 275 372 146 875 396 147 475 100 mm 3 937 0 95 1 049 1 0 3 ...

Page 20: ... compression depends on the engine speed during the measuring process and the ambient air pressure It is difficult to give an exact limit value due to the ambient air pressure We recommend that the com pression test is to compare the cylinders of the en gine If the pressure difference is greater than 15 the cylinder in question should be dismantled to determine the cause NOTE Refit the injector wi...

Page 21: ...Let an authorized workshop do the tests and adjustments The test requires equipment not sold by AB Volvo Penta WARNING Be very careful when working with the fuel injector nozzle The fuel pressure jet can penetrate deep into the skin tissue and cause blood poisoning 1 Connect the injector to the nozzle tester 2 Check the opening pressure For control value for the opening pressure see Technical data...

Page 22: ...ed 11 If the nozzle is leaking dismantle and clean the injector to prevent it from leaking If the nozzle still is leaking replace the injector Reuse is not permitted 12 Chatter characteristic and spray pattern tests NOTE Shut off the tester pressure gauge for this test The chatter test provides an audible check of how easily the nozzle needle is moving in the nozzle body New injectors give a diffe...

Page 23: ... crankcase ventilation hose 4 Remove the hose between the turbocharger and the air filter Disassembly complete engine Special tools Stand for mounting engine Unit stand 998 6485 Engine fixture 999 8671 Puller 999 6400 Socket for injector removal 999 8007 Filter wrench 999 9179 Pressure tool control rod 999 8682 Filter wrench 999 9179 The repair methods that are shown in this chapter apply to the s...

Page 24: ...2 Remove the mounting nuts and the turbo charger 1 Remove the oil pressure pipe oil return pipe and charger air pipe Turbo charger remove 5 Remove tha alternator as well as extra power sources alternator belt and bracket see Drive belts adjusting and replacing ...

Page 25: ...and tighten to 25 Nm 18 5 lbf ft NOTE Use the accompanying screws since their strength is higher than that of standard screws 5 Tighten the engine firmly in the engine repair stand 999 6845 3 Plug 1 the turbo and the connections for the oil return and the oil pressure pipes in the engine block ...

Page 26: ...and bracket Remove the fuel line between filter and fuel duct NOTE Plug the fuel system so that dirt can not enter 4 Remove the coolant outlet pipe 1 if required see picture 1 Remove the oil trap housing for the crankcase ven tilation see picture 2 Catch any remaining oil and dispose of it in accordance with the environmental regulations ...

Page 27: ... the engine by removing the hollow screw at the front of the engine block and the overflow valve and fuel return vent Remove the screw at the rear of the engine block Remove the fuel and oil filters using tool 999 9179 8 Remove the cooler housing 5 The starter motor can be removed at this stage but it is easier to leave it on and remove it together with the transmission cover ...

Page 28: ... 7 screws First remove the bearing bracket for the intermediate pulley 11 Remove the fuel return lines together with the overflow valve and air vent screw 10 Loosen the screws and remove the rocker cover and the gasket NOTE Make sure that dirt trapped between the inlet manifold and the rocker cover does not fall down into the engine Clean thoroughly before removing the rocker cover ...

Page 29: ...the cylinder head NOTE To prevent dirt and water coming in the injec tor hole make sure to clean well around the injector before removing it 12 Remove the delivery pipes complete with the rub ber seals NOTE Cover the injector and injector pump openings 13 Remove the stop solenoid alternatively the plug if the governor is electronic NOTE Be careful not to damage the control rod In stall 999 8682 to...

Page 30: ...ifold and gasket 16 Remove and mark up the push rods 18 Remove the exhaust manifold 1 19 Loosen the screws to the cylinder head using the torx socket E18 Connect lifting wires to the lifting eye bolts and remove the cylinder head NOTE Weight is approx 80 kg 720 722 ...

Page 31: ...ect position 20 Remove the injection pumps Start with the screw closest to the flywheel Put them in a stand to protect them from dirt NOTE Be careful with the loose shim 21 Using pliers or a pen magnet lift out and mark the roller tappets together with the shim NOTE Attach the shim firmly to its respective injec tion pump 22 Pull out the dipstick NOTE The oil sump is mounted with a fluid gasket an...

Page 32: ...lete engine Group 21 42 24 Remove the oil suction pipe 25 Remove the crankshaft pulley and damper if in stalled Use a Torx socket E20 26 Remove the oil pump front cover 27 Remove the cover plate on the flywheel housing ...

Page 33: ...ery heavy 28 Remove the flywheel housing Use Torx sockets E20 and E14 29 Turn the engine through 90 Remove the plastic plugs between every second screw which are a locking device for the flywheel screws Loosen the screws on the flywheel but let them stay in place Use 999 8681 to block the flywheel 31 Remove the transmission housing if this has not been removed before ...

Page 34: ... the cylinderliners Measure at three different levels according to the picture both in the longitudinal and in the transverse axis Diameter 108 0 02 mm 4 252 0 001 Wear limit 108 1 mm 4 256 34 Turn the engine through 90 Set the dial gauge to 108 mm 4 25 32 Turn the engine through 90 Mark up the the bearing caps of the connecting rods and loosen the screws Remove the bearing caps and the bearing ha...

Page 35: ...o that the crankshaft is directed upwards Make sure that the camshaft and crankshaft gears are marked 39 Lift the crankshaft out of the engine block NOTE The crankshaft is heavy approx 75 kg 720 722 730 733 Use a soft strap to lift it out 37 Make sure that the crankshaft bearing caps are marked Remove the securing screws and remove the bearing caps and the main bearing halves ...

Page 36: ...oving the camshaft to prevent damaging the bearings 42 Remove the idler gear NOTE Does not apply to electronic governor 41 Press the piston cooling nozzles out 40 Remove the thrust washers and bearing shells at main bearing cap 2 NOTE Mark up the bearing halves if they are to be used again ...

Page 37: ... 6645 and supports 999 6395 and 999 6394 NOTE Mark up the liners if they are to be used again WARNING When fluorocarbon rubber is subjected to high temperatures highly corrosive hydrofluoric acid can be produced Skin contact can cause severe burning Be very careful and see Safetyinstructions for fluorocarbon rubber 44 Remove the valve tappets and mark them if they are to be used again ...

Page 38: ... and cylinder liner in the areas marked X in the diagram Fit new O rings NOTE Make sure the cylinder liner is correct mount ed in the engine block compare the liners height com pare to the engine block see Technical data NOTE Before insertion IMPORTANT Fit it without sealer well cleaned and dry 3 Fit the cylinder liner in to the correct position in the engine block Drive it in as far as possible E...

Page 39: ...ooling nozzles in the correct position in the engine block Press the piston cooling noz zles in as far as they will go Cams camshaft 5 Insert the valve tappets lightly oiled 6 Fit the camshaft NOTE Be careful when fitting the camshaft to prevent damaging the bearings 7 Fit the main bearing shells into the engine block ...

Page 40: ... the half thrust bearing without lug NOTE The thrust bearing running face must be towards the crankshaft 9 Mark the camshaft if necessary and put it in place 10 Insert the crankshaft The marks must line up Use a ruler and make sure that the marks line up through the centre of the crankshaft and cam shaft ...

Page 41: ...Tighten the main bearing cap screws as follows Initial torque 50 Nm 37 lbf ft 1st tightening angle 60 2nd tightening angle 60 NOTE You can use the bolts three times if you know how many times they have been used Make a punch mark for each of the following usages 13 Fit the bearing shells into the main bearing caps and lightly oil them 12 Fasten the half thrust bearing with lug to the thrust bearin...

Page 42: ...dler gear 16 Fit the govenor idler complete with bearing jour nal 17 Using locking compound insert the screw and tighten it using thread sealer 1161053 2 to 21 Nm 15 lbf ft Control rod 18 Fit the control rod complete with guide sleeve 19 Put thread sealer 1161053 2 on the screw and tighten to 10 2 Nm 7 4 1 5 lbf ft 0 0 ...

Page 43: ...face 22 Tighten the screws to 21 2 Nm 15 1 5 lbf ft Oil pump cover 23 Lightly oil the oil pump rotor Transmission housing NOTE The transmission cover and starter motor can be installed together 20 Apply silicon sealing compound 1161231 4 as shown in the diagram to the sealing surface for the transmission housing Lightly oil the crankshaft seal ...

Page 44: ... without tightening the bolts IMPORTANT Push the cover upwards and align it with the oil sump sealing surface 27 Tighten the oil pump cover screws to 21 2 Nm 15 1 5 lbf ft 24 Attach the gasket to the oil pump cover with a lit tle grease Piston complete with connecting rod 28 Fit the bearing shells into the connecting rod and cap Lightly oil ...

Page 45: ...out the piston before the tool is opened NOTE The flywheel symbol punched into the top of the piston and the guide pins on the connecting rod must point towards the flywheel 32 Tighten the new big end bearing screws as fol lows Initial torque 30 Nm 22 lbf ft 1st tightening angle 60 2nd tightening angle 60 NOTE You should renew the big end screws every time you remove them 33 Turn the crankshaft to...

Page 46: ...hten the oil suction pipe to the oil pump housing Tighten to 21 2 Nm 15 1 5 lbf ft 36 Cut off the protruding gasket NOTE Do not pull away protruding dried silicone Fill the joints in the oil sump sealing surface with silicone part no 1161231 37 Position the new gasket on the engine block 38 Fill the indentations in the gasket with silicon part no 1161231 ...

Page 47: ...57 Group 21 Assembly complete engine 39 Fit the oil sump Tighten to 21 2 Nm 15 5 1 5 lbf ft ...

Page 48: ...th gauge 998 5471 42 Measure from the measuring fixture to the control rod fuel rack start position Use rule depth gauge 998 5471 The difference between the start and stop posi tions is the control rod fuel rack travel Stated measurement 17 0 mm 17 5 mm 0 67 0 69 Example Stop position 30 7 mm 1 21 Start position 13 4 mm 0 53 Control rod travel 17 3 mm 0 68 Control rod measuring 43 Turn the measuri...

Page 49: ...rotation until the dial gauge has reached its turning point Set the dial gauge to 0 IMPORTANT The dial gauge must be placed in the center of the gudgeon pin direction Determining the injection angle shim thickness and fitting of injection pumps NOTE The injection angle and type of camshaft is stated on the engine identification plate To follow the procedure described below is only required if the ...

Page 50: ... Turn the crankshaft through 350 in the opposite engine rotation direction until 8 mm 0 32 before top dead center dial gauge turning point Read the value Example 50 49 Turn the crankshaft until you reach half of the value you have determined on the protractor Example 0 50 2 25 ACTUAL value This is the same as the top dead centre and should correspond with the top dead center on the dial gauge 50 S...

Page 51: ...8 9876 52 Position the roller tappet without shims for the injector pump in question on the base circle of the camshaft Insert the depth gauge carefully in the injection pump hole NOTE Make sure that the guide on the roller tappet ends up in the groove in the material 54 Take measurement L and enter it in Calculation 1 in Technical data Depth gauge 150 mm 5 9 Dial gauge X mm 2 18 mm 0 086 L 150 2 ...

Page 52: ...in Technical data Enter both values in calculations 2 1 and 3 1 in Technical data Example Fbnom injection angle 6 0 Camshaft A Vhnom pre stroke 6 11 57 Turn the crankshaft in the direction of engine rota tion until the dial gauge shows Vhnom Example 7 6 11 0 89 The dial gauge was zeroed at 7 mm pre stroke and when it shows 0 89 in the example you have reached Vhnom 58 You can now on the protractor...

Page 53: ... calculations for shim thickness in Calculation 2 2 in Technical data NOTE Don t forget to change the EP code on the engine identification plate 61 Slide the shim in place along a scewdriver into the roller tappet NOTE Perform the measurement procedure in steps 51 61 above for each injection pump ...

Page 54: ...ake sure that the control rod is still in the stop position held in place with the tools 999 8682 or 999 8684 66 Put the pump flange in place with the camfered hole side facing the pump Oil the screws lightly and tighten the screws evenly to 5 Nm 3 7 lbf ft Back she screws off 60 1 Fuelrack 2 Shim for pump element 3 Roller tappet for pump element 65 Lightly oil the O rings using lubricant 1141699 ...

Page 55: ...11668403 Stop turning when the pump has reached its stop position and the torque is increased by1Nm 0 74 lbf ft Observe the torque required on the torque wrench gauge to turn the injection pump e g 3 5 Nm 2 6 lbf ft Example 3 5 1 4 5 Nm 68 Tighten the screws 60 clockwise then alternately with a torque of 7 10 and 30 Nm 5 2 7 4 and 22 2 lbf ft NOTE Start with the screw furthest away from the flywhe...

Page 56: ...using a governor test bench 75 Install the flywheel housing NOTE Make sure the guiding sleeves are in place Tighten the screws as specified M12 screws 99 10 Nm 73 3 7 4 lbf ft M16 screws 243 25 Nm 179 9 18 5 lbf ft NOTE Use Torx sockets E14 and E20 74 Fit the flywheel Tighten the srews by hand WARNING The flywheel is heavy approx 55 kg 720 722 72 Measure from the measuring fixture to the control r...

Page 57: ...ata NOTE There are several screw lengths Screws may be used 5 times Fit the plastic plugs that are used as a locking device for the flywheel screws 79 Fit the crankshaft pulley and vibration damper and tighten the screws as specified below NOTE Use tool 999 8681 to block the flywheel Initial torque 40 5 Nm 33 3 7 lbf ft 1 st tightening angle 60 2 nd tightening angle 60 NOTE Use Torx socket E 20 NO...

Page 58: ...etermine the greatest piston height NOTE You need to measure all pistons at T D C NOTE Take note of the measuring points since the surface of the piston is spherical Use for example a steel ruler to find the highest point in the direction of the gudgeon pin 82 Compare the largest values with the table and de termine a suitable cylinder head gasket Piston height Marking on cylinder head gasket 0 28...

Page 59: ... head bolts as specified below NOTE Follow the tightening sequence for the cylinder head see Tightening sequence for cylinder head screws Tighten the bolts in three stages 1st stage 50 Nm 37 lbf ft 2nd stage 130 Nm 96 lbf ft 3d stage tightening angle 90 83 Position the cylinder head gasket correctly with the numbers facing upwards and the marking holes towards the flywheel NOTE The cylinder sealin...

Page 60: ...overnor fit the plug with a new O ring NOTE Lightly oil the O ring 87 Install the rocker arm brackets according to the markings and align them with the push rods valves 88 Tighten the screws to 21 Nm 15 lbf ft 89 Set the valve clearance see Valve clearance adjusting in the Repairing components chapter Inlet 0 35 0 05 mm 0 01 0 002 Exhaust 0 55 0 05 mm 0 02 0 002 90 Remove the cranking tool 1 2 ...

Page 61: ...a new gasket Tighten the screws to 11 1 Nm 8 1 0 7 lbf ft Fitting of injectors delivery pipes 94 Using a little high temperature paste 1161035 fit a new copper gasket 1 on the injector and fit the injector NOTE The connection for the fuel return line must be towards the exhaust side 95 Put the injector yokes 1 in place and tighten the screws lightly Use Torx socket E10 2 ...

Page 62: ... nuts in two stages 1 Tighten to 5 Nm 3 7 lbf ft 2 Tighten to 25 3 5 Nm 22 2 6 lbf ft 99 Fit the fuel leakage line and push it through the rubber seal NOTE Always replace the leakage line NOTE The delivery pipes are deformed when tightened and all delivery pipes must be tightened with the same tightening torque If they are tightened with different tightening torque the cylinders may take different...

Page 63: ...o 1 141 699 on the O rings Oil cooler 103 Fit the oil cooler with a new gasket Tighten the screws to 21 2 Nm 15 5 1 5 lbf ft Coolant pump 104 Fit the O rings to the intermediate pipe NOTE To make it easier to fit put some lubricant part no 1 141 699 on the O rings 105 Press the intermediate pipe into the thermostat housing and coolant pump ...

Page 64: ...he screws alternately to 21 2 Nm 15 1 5 lbf ft Alternative assembly depending on coolant pump model 109 Fit the plug for the control rod Apply sealing compound 1 1161277 or 1161231 and new O rings 2 on the cooling pump house 110 Fit the coolant housing with the coolant pump Tighten the screws to 21 2 Nm 15 1 5 lbf ft 1 2 ...

Page 65: ...ntil it touches the contact surface Turn another half a turn no more 113 Lightly oil the fuel filter gasket Tighten the fuel filter by hand until it touches the contact surface Turn another half a turn no more 112 Fit the fuel lines Tighten the hollow screws to 34 Nm 25 lbf ft Fuel pump 111 Fit the fuel pump ...

Page 66: ...over and lightly oil it Speed govenor 118 Apply silicone sealing compound 1161231 to the govenor Sealant bead diameter Ø 1 5 0 5 mm 0 06 0 02 NOTE The sealing surface must be free from oil and grease 116 Fit the cover 117 Tighten the screw to 21 2 Nm 15 1 5 lbf ft 0 0 ...

Page 67: ...s not unique with a calibrated x measurement 121 For electronic governors the following applies for the 5 M8 screws 1 2 70 mm 3 5 55 mm Tighten the screws to 24 Nm 123 Fit the cable and fixing clips 119 Install the speed governor IMPORTANT The governor is uniquely prepared for each engine This means that the governor can not be exchanged between different en gines An incorrect adjusted governor ca...

Page 68: ...ealant Tighten the screws to 21 2 Nm 15 5 1 5 lbf ft Oil dipstick 125 Slide on the new O ring Exhaust manifold 127 Fit the exhaust manifold with new gaskets The gasket flange should be directed towards the cylinder head Tighten the exhaust manifold nuts with a torque to 25 2 5 Nm 18 1 8 lbf ft NOTE Use high temperature paste 1161035 on the screws ...

Page 69: ... arrow until you obtain the correct belt tension 2 Tighten the screws to 21 2 Nm 15 5 1 5 lbf ft Alternator 128 Fit the alternator bracket and alternator Fit the V belt Adjust the position of the alternator by pushing it in the direction of the arrow until you obtain the correct belt tension Tighten the screws to 30 Nm 22 lbf ft NOTE The belt is correctly tensioned when you can press it down 10 mm...

Page 70: ... filter and crank case ventilation hose Oil pressure pipe oil return pipe 135 Fit the oil pressure pipe with a new gasket 136 Tighten the screws to 21 2 Nm 515 5 1 5 lbf ft 133 Remove the engine from the engine repair stand then loosen the engine fixture 134 Install the turbo ...

Page 71: ...up 21 Checks and adjustments 81 140 Fit the clamping yoke 139 Tighten the screws to 21 2 Nm 15 5 1 5 lbf ft 138 Fit the oil return pipe with a new gasket 137 Fit a new O ring to the return pipe Oil lightly ...

Page 72: ...ents Engine block Special tools Cylinder liner extractor with support 999 6645 999 6395 Fitting tool for camshaft bearings 999 8695 Fitting tool for control rod sleeves 999 8696 Cylinder extractor plate 999 8675 Standard shaft 999 2000 TD TAD520 TD TAD720 ...

Page 73: ...tween the liner collar seat and sealing surface in the engine block Measure in several places at each cylinder Max depth 8 92 0 03 mm 0 35 0 002 NOTE Liner collar height or collar seat depth can not be re machined Replace liner and engine block if required 4 Inspect the liner collar and measure the height of the collar in several spots on the circumference NOTE Min collar height 9 0 02 mm 0 354 0 ...

Page 74: ... bearing journals at planes 1 and 2 in points a and b Bearing main diameter 85 00 0 02 mm 3 35 0 008 Undersize 0 25 mm 84 75 0 02 mm 3 337 0 001 0 50 mm 84 50 0 02 mm 3 327 0 001 Wear limit Bearing journal oval 0 01 mm 0 0004 Conicity 0 01 mm 0 0004 3 Fit the bearing shells into the main bearing caps and fit the main bearing caps in the engine block Main bearing caps ...

Page 75: ... bearing diameter at points 1 and 2 in planes a and b Inner diameter Ø 85 03 0 036 mm 3 347 0 001 Oversize 0 25 mm 84 78 0 036 mm 3 338 0 001 0 50 mm 84 53 0 036 mm 3 328 0 001 8 Locate the half thrust bearings on the main bear ing cap Measure and note the width measure ment b 9 Determine the axial clearance Example Measurement a 38 02 mm 1 5 Measurement b 37 90 mm 1 49 a b axial clearance 0 12 mm...

Page 76: ...0 0 02 mm 2 68 0 001 Undersize 0 25 mm 67 75 0 02 mm 2 67 0 001 0 50 mm 67 50 0 02 mm 2 66 0 001 Wear limit Crankshaft journal oval 0 01 mm 0 0004 Conicity 0 01 mm 0 0004 11 Check that the crankshaft runs evenly use a dial gauge Max deviation 520 0 07 mm 0 0027 720 721 722 0 10 mm 0 0039 Crankshaft journals ...

Page 77: ...pper connecting rod end 45 50 0 02 mm 1 79 0 001 Outside diameter for the bushing in the upper connecting rod end 45 50 0 04 mm 1 79 0 002 5 Press the bushing into the upper connecting rod end so that it is level with the surface Use tool 999 8692 NOTE The lubricating oil holes in the bushing and the connecting rod must be aligned with one another 6 After you have pressed the bushing in ream it to...

Page 78: ...es are just a little out take additional measurements when new bearing shells have been fitted 10 Remove the bearing cap and fit new bearing shells Replace the bearing cap Tighten the screws according to specification Initial torque 30 Nm 22 lb ft NOTE Only when measuring 11 Set the dial gauge Measure the bearing shells at planes 1 and 2 in points a and b Big end bearing shells Inside diameter 68 ...

Page 79: ... connecting rod tester NOTE Check the connecting rods without bearing shells 12 Use a gudgeon pin to measure the connecting rod for straightness Max deviation a 0 05 mm 0 002 over a dis tance x of 100 mm 3 9 13 Use a gudgeon pin to measure the connecting rod for torsion Max deviation a 0 05 mm 0 002 over a dis tance x of 100 mm 3 9 ...

Page 80: ...nts Group 21 90 Pistons 1 Remove the circlip Remove the gudgeon pin 2 Remove the piston rings using the piston ring pli ers 998 5423 NOTE Clean and inspect piston and ring grooves Special tool Piston ring pliers 998 5423 ...

Page 81: ... rings 5 Fit the oil control ring c 6 Fit the tapered compression ring b with text Top towards combustion chamber 7 Fit the conical compression ring a with text Top towards combustion chamber 8 Fit the piston rings as the instructions in step 5 shows and then make sure that the ring gap is 120 between them NOTE The joint of the inside spring of the oil control rings should be moved 180 in relation...

Page 82: ...of the piston 11 Insert one of the circlips 12 Put the piston onto the connecting rod The fly wheel symbol on the piston and the cylindrical pegs on the connecting rod 1 must be on the same side 13 Insert the other circlip in the right position 10 Check the gudgeon pin for wear Gudgeon pin diameter 42 0 006 mm 1 654 0 002 ...

Page 83: ...e checked for wear or not Make sure that the lifting surfaces on the camshaft and the valve tappets do not have great pitting damage Pitting damage can appear for different reasons The damage consists of small metal pieces being broken off the hardened surface Tappets and camshaft with minor pitting damages can be used Pitting damages are rarely worsened Make sure that the bearing race and cam cur...

Page 84: ...ans that the camshaft must be replaced These markings have no negative effect neither on the engine prestanda nor on the strength of the engine or its components Below you can see examples of acceptable wear and unacceptable wear Acceptable wear The camshaft does not need to be replaced Unacceptable wear NOTE The camshaft and its belonging rocker arms must be replaced ...

Page 85: ...9 8695 1 Set the internal dial gauge to 65 mm 2 56 2 Procedure for measuring the bushes at planes 1 and 2 in points a and b see figure 3 Measure the bushes replace if necessary Inside diameter 65 00 0 054 mm 2 56 0 002 Wear limit 65 08 mm 2 562 Camshaft bearings Special tools Dial gauge 998 9876 Fitting tool camshaft bearings 999 8695 ...

Page 86: ...the new bearing NOTE The widest bearing 27 mm 1 06 should be palced at the flywheel end 1 Styrhylsa 2 Lagerbussning 3 Presshylsa 6 Fit the bearings Use tool 999 8695 999 8695 NOTE The lubrication holes must fit the oil duct in the bearing positions ...

Page 87: ...arance in the valve guide Wear limits Inlet valve 0 10 mm 0 004 Exhaust valve 0 13 mm 0 005 Cylinder head 1 Put the cylinder head in a vice 2 Remove valve retainers valve discs valve springs and valves using valve spring compressor 998 5468 Special tool Valve spring compressor 998 5468 NOTE Measured with a new valve Replace valve guide if worn The valve guides are different as a spare part compare...

Page 88: ...t valve 2 1 mm 0 08 Exhaust valve 1 8 mm 0 07 C Valve head diameter Inlet valve 48 0 0 1 mm 1 89 0 004 Exhaust valve 42 0 0 1 mm 1 65 0 004 8 Check the valve seats rings and wear limits Wear limit for valve seat width Inlet valve 2 8 mm 0 11 Exhaust valve 2 2 mm 0 09 Design 1 without flange Design 1 with flange Design 2 On later designs the o ring is exchanged for a valve rod seal according to the...

Page 89: ...ter of the valve head and the cylinder head mating surface Depth of valve in cylinder head Measurement between valve disc and cylinder head face Inlet Exhaust Max 1 5 mm 0 06 10 Measure the length of the valve spring using a sliding caliper and with the spring unloaded Unloaded length standard 64 70 1 3 mm 2 55 0 05 11 Use the grinding tool to grind the valves into their seats and correct the seat...

Page 90: ...o that possible welding sparks can not stick 3 Place a suitable socket over the valve valve guide and carefully knock out the valve seat NOTE Be careful so that the cylinder head is not damaged 4 Clean the location of the seat carefully and check the cylinder head for cracks 5 Measure the diameter of the valve seat location Check whether a seat of standard size or an oversize seat should be used P...

Page 91: ... coated with a thin layer of indelible ink Valves grinding 21401 21402 For valve tightening angles see Technical data NOTE As a spare part the valves are finish machined and should not need further grinding 1 The faying surface should be grinded as little as possible however so much that all the damages are removed 2 Check the measuremant A on the edge of the valve disc If the measurement is small...

Page 92: ...ly checking assembly 1 Disassemble the rocker arm and rocker arm bracket 2 Check for wear 1 Shaft pivots 2 Adjusting screw 3 Rocker arm contact surfaces 4 Diameter Replace if the wear is abnormal 3 Check that the oilways are clear 4 Assemble the rocker arm and rocker arm bracket Fit the circlips ...

Page 93: ...hen you have changed the control rod A trained specialist should perform the setting on a governor test bench NOTE With an electronic governor the new x measurement must be entered into the trigger unit Dismantling 2 Drill out the tension pin on the guide sleeve and remove it NOTE Always renew the guide sleeve and the ten sion pin when you dismantle the control rod ...

Page 94: ...uence 1 Control rod 2 Compression spring 3 Washer 4 Guide sleeve 5 Tension pin 4 Pay attention to the alignment of the control rod in relation to the guide sleeve 5 Insert the tension pin according to fig 6 Press the tension pin in as far as it will go ...

Page 95: ...rive out the guide sleeve at the flywheel end 3 Put the fitting tool 999 8696 and the drift against the engine block and lock it in place with a screw 999 8696 999 8696 2 Position the guide sleeve on the drift with the chamfer towards the crankcase Control rod guide sleeves Special tools Fitting tool control rod sleeves 999 8696 Standard shaft drifts 999 2000 ...

Page 96: ...ments Group 21 106 999 8696 5 For engines 720 721 722 drive in guide sleeve from flywheel end Repeat the procedure as above Use the longer drift 4 Drive in the guide sleeve until the drift 999 8696 bottoms in the socket ...

Page 97: ...ven or gas torch If you use an oven put in the new ring gear in advance If you use a gas torch heat the ring gear immediately before you install it 2 Drill a hole between two teeth Use a 10 mm 0 4 drill Drill a 9 mm 0 35 deep hole IMPORTANT Be careful not to drill on the fly wheel if you do it will loose its balance Repairing components ...

Page 98: ...e ring gear using a screwdriver If nec essary split the ring gear at the drilled hole Clean the contact surfaces of the flywheel 4 Fit the new ring gear Check the temperature Position the ring gear so that it meets the flywheel flange If necessary tap the ring gear down to the bottom Use a brass drift Let the ring gear cool ...

Page 99: ...l flywheel 999 8681 NOTE The normal valve clearance is set when the engine is cold or has cooled down for at least half an hour Oil temperature 80 C 176 F NOTE The valve clearance should be at the highest permissible variation when the cylinder head gasket is changed and at the lowest permissible variation after 50 hours running 1 Rotate the crankshaft until the valves for no 1 cylinder overlap NO...

Page 100: ...e 4 Rotate the crankshaft another revolution 360 Set the valve clearance for each cylinder using a feeler gauge according to the black markings Mark up the rocker arm on each set cylinder using a chalk 5 Tighten the locknut to 20 2 Nm 15 lbf ft Recheck the setting with the feeler gauge 6 Fit a new rocker cover gasket ...

Page 101: ...e pre drilled holes in the tool NOTE Max depth 8 mm 0 31 Special tools Standard shaft drifts 999 2000 Fitting Removal tool rear 999 8672 Fitting tool Removal front 999 8673 Transmission housing flywheel end Rear crankshaft seal changing 21671 4 Screw two self tapping screws in the drilled holes NOTE Max screw length 40 mm 1 6 5 Pull out the seal using the screws in the tool 999 6400 885341 Alterna...

Page 102: ...and put it on the tool 999 6872 with the lip facing the crankshaft NOTE The seal is originally installed in position 1 see fig The tool s installation position 2 is when the crankshaft has a measurable wear in position 1 Use a drift and gently knock the seal into required position ...

Page 103: ...two 3 5 mm 0 14 holes in the seal through the predrilled holes in the tool NOTE Max depth 7 5 mm 0 3 3 Screw two self tapping screws in the drilled holes NOTE Max length of screws 32 mm 1 28 999 6400 885341 Alternatively Use extractor 885341 together with slide hammer 999 6400 4 Pull out the seal using the screws in the tool Front crankshaft seal changing Front housing 21672 ...

Page 104: ...73 The sealing lip to face the crankshaft Use standard shaft 999 2000 and carefully nock the seal in place NOTE The seal is originally installed in position 1 see fig The tool s installation position 2 is when the crankshaft has a measurable wear in position 1 Use a drift and gently knock the seal into required position ...

Page 105: ...ction of the arrow until you obtain the correct belt tension 3 Retighten the screws 1 2 and 3 Drive belts replacing 1 Loosen the screws 1 2 and 3 2 Remove the old drive belt 3 Fit the new belt 4 Adjust the alternator until you obtain the correct belt tension 5 Retighten the screws 1 2 and 3 NOTE The belt tension is correct when you can press them down 10 mm 0 4 between the pulleys Drive belts repl...

Page 106: ...ting 3 Apply locking compound part no 1161351 0 to the new reduction valve Group 22 Oil System 22020 Reduction valve Special tools Adapter oil pressure valve 999 8674 Slide hammer 999 6400 2 Use tool 999 6400 together with adapter 999 8674 Pull out the reduction valve 4 Drive in the reduction valve using a brass drift Ø 20 mm 0 8 ...

Page 107: ...ng components Group 22 117 Front housing oil pump 22111 Removing 1 Use a drift to drive out the crankshaft seal Special tools Standard shaft drifts 999 2000 Fitting removal tool front crankshaft seal 999 8673 ...

Page 108: ...ar assembly and check for abnor mal wear Fit a new gear assembly if necessary and oil lightly Tighten the screws to 8 9 Nm 6 6 6 lb Fitting 5 Insert the reduction valve and spring 6 Press down the compression spring and insert the spring retaining washer NOTE Make sure the retaining washer is firmly in place Lubricate with a thin coating of oil before fitting 7 Insert the crankshaft seal using fit...

Page 109: ...cooler housing Engine oil cooler 1 Remove the Allen key plugs 17 mm 2 Remove the hollow Allen key screws 17 mm that hold the oil cooler 3 Check all individual parts If you suspect a leak pressure test the oil cooler and change if neces sary Oil cooler check replace 22311 Check ...

Page 110: ... It may not be repaired 1 Place a clamp 2 on the oil cooler 3 as shown in the picture Make sure that it is properly tighte ned 2 Plug the other connection 1 3 Connect the pressure testing equipment 4 Place the oil cooler in a tub of water 5 Set the air pressure to 100 kPa 14 5 psi Check if there are air bubbles coming from the oil cooler 6 Increase the pressure to 500 kPa 72 5 psi Hold the pressur...

Page 111: ...cal pressure gauge 999 8496 together with hose 999 8493 1 Measure the lubricating oil pressure on the start motor side of the engine as in picture using the manometer together with nipple and spacer Minimum oil pressure at operation temperature and idle speed 520 530 532 90 kPa 13 1 psi 720 721 722 730 733 80 kPa 11 6 psi At rated speed se Technical Data ...

Page 112: ...the fuel pump and replace if necessary 2 Measure the supply pressure before 1 and after 2 the fuel filter Use manometer 999 6398 nipple 999 6066 with a long hollow screw art no 180211 and new cop per washers 969011 Supply pressure 1 after pump 0 5 MPa 5 bar 2 after filter at 1500 rpm 0 28 MPa 2 8 bar Special tools Nipple 999 6066 Manometer 999 6398 Hollow screw art no 180211 Copper washer art no 9...

Page 113: ...s on the camshaft base circle 14 Turn the pump likage lever into middle position oil the O rings on the pump and insert the pump NOTE make sure the pump linkage lever is intro duced properly in the slot of the control rod before pushing the pump down 15 Install the pump flange with the chamfered hole side facing the pump and pre load the screws to 5 Nm 3 7 lfb ft Thereafter slacken the screws 60 1...

Page 114: ...Special tools Manometer 999 6398 Nipple 999 6066 Spacer art nr 1678297 Alternately Electrical pressure gauge 999 8496 together with hose 999 8493 1 Measure the turbocharger boost pressure as in picture using the manometer together with nipple and spacer For boost pressure see Technical Data ...

Page 115: ...ll 1 1 Remove the coolant pump from the housing 2 Remove the V belt pulley 3 Check coolant pump and sealing for leaks re place the coolant pump if necessary 4 Fit the V belt pulley Tighten the bolts to 21 Nm 15 lbf ft 5 Fit the coolant pump in the housing with a new gasket Model 2 1 Loosen the coolant pump from the house Coolant pump check replace 26211 ...

Page 116: ...heck coolant pump and sealing for leaks re place the coolant pump if necessary Make sure that the overflow hole for the spindle seal is not filled up 4 Fit the V belt pulley Tighten the bolts to 21 Nm 15 lbf ft 5 Fit the coolant pump in the housing with a new gasket ...

Page 117: ...re the measurement a on the thermostat a the thermostat starts to open 83 C b the thermostat is completely open 93 C 2 Heaten the thermostat in a water bath NOTE To get the exact opening temperature measure as close to the thermostat as possible without touching it Stir the water unceasingly to get an even temperature distribution The temperature should not rise more than 1 C min or the time of op...

Page 118: ... connector 15 Temperature sender engine connector 16 Relay 17 Stop solenoid 18 Horn 46 Water level connector 720 models 52 Start connector 52a Start relay 53 Interlock button 54 Stop button 57 Charge warning lamp 58 Oil pressure gauge 59 Water temperature gauge 61 Hour counter 65 Instrument illumination connector 66 Instrument illumination 84 Holding relay Conductor area 12V 24V A 90 mm2 0 140 in2...

Page 119: ...lamp 19 Temp switch excessfuel solenoid 20 Excessfuel solenoid 21 Stop solenoid 22 Signal horn 23 Water temperature gauge 24 Temp sender switch engine 25 Alarm lamp cool water 26 Oil pressure gauge 27 Oil pressure sender switch 28 Alarm lamp oil pressure 29 Alarm lamp water level 30 Water level switch 31 Relay 32 Diode 33 Supply button Conductor area 12V 24V A 90 mm2 0 140 in2 70 mm2 0 109 in2 B 1...

Page 120: ...17 Excessfuel solenoid 18 Stop solenoid 19 Signal horn 20 Water temperature gauge 21 Temp sender switch engine 22 Alarm lamp cool water 23 Oil pressure gauge 24 Oil pressure sender switch 25 Alarm lamp oil pressure 26 Water level switch 27 Alarm lamp water level 28 Relay 29 Diode 30 Tachometer sender Conductor area 12V 24V A 90 mm2 0 140 in2 70 mm2 0 109 in2 B 10 1 mm2 0 016 in2 6 2 mm2 0 009 in2 ...

Page 121: ...NTC 18 Temp switch excessfuel solenoid 19 Excessfuel solenoid 20 Stop solenoid 21 Signal horn 22 Water temperature gauge 23 Temp sender switch engine 24 Alarm lamp cool water 25 Oil pressure gauge 26 Alarm lamp oil pressure 27 Oil pressure sender switch 28 Water level switch 29 Alarm lamp water level 30 Relay 31 Preheating button 31 Diode 32 Tachometer sender Conductor area 12V 24V A 90 mm2 0 140 ...

Page 122: ...tor NTC 19 Preheater lamp 20 Preheating button 21 Temp switch excessfuel solenoid 22 Excessfuel solenoid 23 Stop solenoid 24 Signal horn 25 Water temperature gauge 26 Temp sender switch engine 27 Alarm lamp cool water 28 Oil pressure gauge 29 Oil pressure sender switch 30 Alarm lamp oil pressure 31 Alarm lamp water level 32 Water level switch 33 Relay 34 Diode 35 Tachometer sender 36 Supply button...

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Volvo Penta TAD520GE, Workshop Manual

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