Volvo Penta TAMD61A Workshop Manual Download Page 12

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Special tools

9996400-9

Impact hammer. Used with 9996419 or
9996657.

9996402-5

Mandrel for installing copper sleeves

9996419-9

Extractor for the steel ring above the
copper sleeve

9996420-7

Mandrel for installing copper sleeves and
steel rings, 7(x) series.

9996421-5

Mandrel for installing copper sleeves and
steel rings, 6(x) series.

9996433-0

Adapter (lid). Used with 6662

9996437-1

Tool for installing the rear crankcase seal

9996643-4

Injector extractor

9996645-9

Cylinder liner extractor. Used with
9996394 and 9992178 or 9996087

9996650-9

End cutter for cleaning the bed for the
copper cylinder (stage 1)

9996651-7

End cutter for cleaning the bed for the
copper cylinder (stage 2)

9996657-4

Extractor for copper cylinder

9996662-4

Pressure test equipment

9996772-1

Tool for checking camshaft wear. Used
with 9989876

9996841-4

Cutting tool for opening up sealant
grooves in cylinder head, 6(x) series*

9996842-2

Cutting tool for opening up sealant
grooves in cylinder head, 7(x) series*

9996847-1

Press tool (2 required). Used for measur-
ing lining collar height above block plane

* 9999745

Repair kit containing a cutter for cutting tools
9996841 and 9996847.

9996842

9996841

9996400

9996402

9996419

9996420

9996650

9996651

9996657

9996662

9996421

9996433

9996437

9996643

9996847

9996645

Summary of Contents for TAMD61A

Page 1: ...Engine Workshop Manual 2 0 D TAMD61A TAMD62A TAMD63L A TAMD63P A TAMD71A TAMD71B TAMD72A TAMD72P A TAMD72WJ A ...

Page 2: ......

Page 3: ...e assembly 50 Valves adjustment 52 Cylinder block renovation 53 Piston and con rod removal 53 Piston and con rod inspection 54 Piston removal gudgeon pin boss replacement 54 Piston assembly 55 Piston ring inspection and fit 56 Piston ring assembly 56 Cylinder liner inspection and measurement 57 Cylinder liner disassembly 57 Cylinder liner honing 58 Cylinder liner position renovation 59 Cylinder li...

Page 4: ...etc and liquids in supply lines and hoses when the engi ne is running or has been turned off immediately prior to starting work on it Reinstall all protecti ve parts removed during service operations be fore starting the engine Check that the warning or information decals on the product are always clearly visible Replace decals that have been damaged or painted over Engine with turbocharger Never ...

Page 5: ... deposited at an approved site for de struction together with used lubricating oil con taminated fuel paint remnants solvent degrea sing agents and waste from washing parts Never expose the batteries to a naked flame or electric sparks Never smoke in proximity to the batteries The batteries give off hydrogen gas during charging which when mixed with air can form an explosive gas oxyhydrogen This g...

Page 6: ...r jet at seals rubber hoses or electrical compo nents Never use a high pressure jet when washing the engine Never remove heavy components alone even where secure lifting equipment such as secured blocks are being used Even where lifting equip ment is being used it is best to carry out the work with two people one to operate the lifting equipment and the other to ensure that compo nents are not tra...

Page 7: ...e requirements No com pensation in respect of Volvo Penta guarantees will be given for any kind of damage or injury caused by the use of non original Volvo Penta spare parts on the product in question Certified engines On engines which are certified in accordance with na tional and regional regulations e g Bodensee the manufacturer guarantees that the requirements are met by both new engines and e...

Page 8: ...orten the repair service life Our joint responsibility Each engine consists of a large number of interactive systems and components The deviation of a component from the technical specification can dramatically increase the environmental impact from an otherwise first rate engine It is therefore of extreme importance to maintain the given wear tolerances that systems capable of adjustment receive ...

Page 9: ...ce work it is therefore important that the correct type of sealant and locking liquids are used for the unions where such are required In the Workshop Manual we have indicated in respective chapters the agents which are used in our engine production During service work the same agent or agent with similar properties but of other manufacture shall be used When using sealants and locking liquids it ...

Page 10: ... acetylene torch or be burned up afterwards in an uncontrolled manner l Always use gloves made of chloroprene rubber gloves for handling chemicals and protective goggles l Handle the removed seal in the same way as cor rosive acid All residue including ash can be highly corrosive Never use compressed air to blow anything clean l Put the remains in a plastic box which is sealed and provided with a ...

Page 11: ...mp 9992178 5 Extractor plate for lining extractor 7 x series 9992479 7 Holder for dial gauge for checking lining height above block plane 9996395 9996394 9996169 9996087 9992679 9992677 9992669 9992497 9992071 884948 884949 9992000 9991867 9991801 9991459 9991084 9992178 9992479 9812546 9992655 9992658 9992661 9992497 9 Drift for removal installing con rod bush 7 x series 9992655 2 Extractor for p...

Page 12: ...0 9 End cutter for cleaning the bed for the copper cylinder stage 1 9996651 7 End cutter for cleaning the bed for the copper cylinder stage 2 9996657 4 Extractor for copper cylinder 9996662 4 Pressure test equipment 9996772 1 Tool for checking camshaft wear Used with 9989876 9996841 4 Cutting tool for opening up sealant grooves in cylinder head 6 x series 9996842 2 Cutting tool for opening up seal...

Page 13: ...ng compression pres sure 9998070 8 Tool for installing the copper sleeve and steel ring 6 x series Used together with 9996406 and 9996421 9998079 9 Tool for lifting camshaft in and out 9998114 4 Seal plate 2 required for pressure test ing the cylinder block 6 x series 9998115 1 Seal plate 2 required for pressure test ing the cylinder block 7 x series 9999508 6 Cutter for renovating liner seat 7 x ...

Page 14: ...12 Other special equipment 885126 9988539 9989876 9999696 Other special equipment 885126 3 Piston ring compressor 9988539 4 Compression gauge 9989876 9 Dial gauge 0 20 mm 9999696 9 Magnetic stand ...

Page 15: ...be supplied to the en gine The additional air allows a further increase in the amount of fuel injected which increases engine pow er Since the induction air is cooled the combustion and exhaust temperatures are kept at a suitable level de spite the higher power output Intercooling also gives lower exhaust emissions since combustion becomes more complete thanks to the greater oxygen content of the ...

Page 16: ...eater and by pass valve are extra equipment not normally needed because of the higher compression l New external styling Design differences engine versions This workshop manual applies to all engines of the 6 x series TAMD61A TAMD62A TAMD63L A and TAMD63P A and from the 7 x series TAMD71A TAMD71B TAMD72A TAMD72P A and TAMD72WJ A The most important differences are TAMD61A TAMD62A TAMD62A has l High...

Page 17: ...ded located beside the rear fuel filter l Stop solenoid deleted the engine is stopped by the EDC system l New turbocharger with integrated wastegate valve l New rubber mounted junction box located by ex haust pipe l Sensor and monitor for engine oil pressure sep arately installed and rubber mounted l Reinforced insulation on engine cables convolut ed PA66 plastic hose with moisture proof con necto...

Page 18: ...12 Dipstick reverse gear MPM IRM 220A 13 Oil filler cap reverse gear Design and function 1 Junction box with circuit breakers 2 Coolant filler cap 3 Fuel filter 4 Oil filler cap also at front edge of engine 5 Injection pump 6 Stop solenoid 7 Turbocharger 8 Oil cooler reverse gear 9 Reverse gear MPM IRM 220A 10 Dipstick alternative location 11 Oil cooler engine 12 Smoke limiter 13 Circulation pump ...

Page 19: ...eather 4 Aftercooler 5 Heat exchanger 6 Expansion tank 7 Sea water pump 8 Lubrication oil filter alt location at left hand rear of engine as extra equipment 9 Flexible engine mountings extra equipment 10 Sump 11 Dipstick 12 Start motor 13 Reverse gear MPM IRM 220A 1 14 Dipstick reverse gear 2 3 4 5 1 7 14 13 12 11 10 9 8 6 ...

Page 20: ...e fuel shut off valve for engine stopping 13 Oil cooler engine 14 Flexible engine mounting extra equipment TAMD63L A TAMD63P A 1 Filter for crankcase breather 2 Air filter 3 Aftercooler 3 Relay for electric starting heater 4 Oil filler cap 5 Expansion tank 6 Coolant filler cap 7 Heat exchanger 8 Alternator 9 Sea water pump 10 By pass filter for lubrication oil 11 Lubrication oil filter engine 12 S...

Page 21: ...Heat exchanger 10 Dipstick 11 Aftercooler 12 Start motor 13 Dipstick reverse gear TD MG507 14 Oil pump 1 Junction box with circuit breakers 2 Coolant filler cap 3 Fuel filter 4 Oil filler cap also at front edge of engine 5 Injection pump 6 Stop solenoid 1 2 3 4 5 6 7 9 12 10 8 7 Turbocharger 8 Oil cooler reverse gear 9 Reverse gear TD MG507 10 Oil cooler engine 11 Smoke limiter 12 Circulation pump...

Page 22: ... filler cap 3 Fuel filter 4 Oil filler cap 5 Injection pump 6 Stop solenoid 7 Turbocharger 8 Oil cooler reverse gear 9 Reverse gear TD MG507A 10 Dipstick alternative location 11 Oil cooler engine 12 Smoke limiter 13 Circulation pump 14 Alternator 1 3 4 5 6 7 8 12 11 10 9 2 14 13 ...

Page 23: ...e gear 12 Dipstick alternative location 13 Oil cooler engine 14 Smoke limiter 15 Circulation pump 16 Alternator 1 Air filter 2 Filter for crankcase breather 3 Aftercooler 4 Heat exchanger 5 Expansion tank 6 Sea water pump 7 Lubrication oil filter alt location at left hand rear of engine as extra equipment 8 Sump 9 Dipstick 10 Start motor 11 Dipstick reverse gear TD MG507A 1 Design and function TAM...

Page 24: ...er fine 4 Smoke limiter 5 Injection pump 6 Oil filler cap 7 Turbocharger 8 Water cooled exhaust riser extra equipment 9 Stop solenoid 10 Alt dipstick location 11 Oil cooler engine 12 Circulation pump 13 Alternator Design and function TAMD72WJ A 1 2 4 5 6 7 8 13 12 11 10 9 3 ...

Page 25: ...e breather 3 Aftercooler 4 Heat exchanger 5 Expansion tank 6 Sea water pump 7 Lubrication oil filter engine alt location at left hand rear of engine as extra equipment 8 Sump 9 Dipstick 10 Start motor 11 Dipstick reverse gear TD MG507 1 9 Reverse gear TD MG507 1 10 Oil cooler reverse gear 11 Wastegate valve by pass valve 12 Alt dipstick location 13 Oil cooler engine 14 Circulation pump 15 Alternat...

Page 26: ...eel the valve stems are chrome plated The exhaust valves for TAMD71 72 and the inlet valves for TAMD63 from Autumn 1995 have valve heads made from Nimonic 80 The exhaust valves on other engines of the 6 x series have Stellite coated sealing surfaces The valves are operated by rockers on a rocker bridge The engine has two rocker bridges one for each cylin der head The rockers are operated by the ca...

Page 27: ...d in turned grooves in the cylinder block These rings are made of different materials The lowest seal ring violet is made from fluorocarbon rubber FPM whereas the two upper rings in the lower liner seal are identical and are made of ethylene propylene rubber EPDM Note There have been two previous versions of the seal kit In the first version the two lower seal rings were identical and were made of...

Page 28: ...ons and cylinder liners are only stocked as com plete sets for spare part purposes Piston design A Combustion chamber diameter B Combustion chamber depth C Ring carrier Piston ring profiles TAMD 63 TAMD 61 TAMD62 Piston rings 6 x series Each piston has two compression rings and one oil scraper ring On the TAMD61 TAMD62 and TAMD63 the top com pression ring is of the Keystone type trapezoid The ring...

Page 29: ...ffect The second compression ring also has three Ferrox filled grooves and the third compression ring has a turned internal chamfer On the later version the second compression ring is chromed and has an internal chamfer the third com pression ring has been abolished The oil scraper ring is of the same type as on the 6 x series The pistons on the later version still have 4 piston ring grooves but t...

Page 30: ...g gear 1 Sea water pump drive 2 Camshaft gear 3 Idler 4 Injection pump drive 5 Coolant pump drive 6 Crankshaft drive 7 Idler for oil pump 8 Oil pump drive Big and small end bearings The big and small end bearings consist of indium plat ed lead bronze lined steel shells The bearings are precision made and are entirely ready for installation Five under dimensions can be obtained as spare parts The t...

Page 31: ...is determined by the cam shaft gear wheel the shoulder on the foremost cam shaft bearing journal and the thrust washer screwed to the front surface of the cylinder block Con rods with trapezoid small end 71 and 72 series Flywheel The flywheel is screwed to a flange on the rear of the crankshaft It is statically balanced and fully ma chined The flywheel ring gear is shrunk onto the fly wheel Torsio...

Page 32: ...he reverse gear Undo the engine pads from the bed and lift the engine out Measures after lifting out the engine 12 Clean the engine WARNING When you are clean the engine with a high pressure washer Be very careful when cleaning to avoid water entry into the engine When the high pressure function is engaged the water jet must never be aimed at seals e g shaft seals joints with gas kets rubber hoses...

Page 33: ... M12x40 mm Before the engine jig can be fitted and the engine at tached to the engine stand the following components must be removed from the engine TAMD61 62 Heat exchanger aftercooler start motor oil filter bracket front engine mounting and rear hatch for valve lifter TAMD63 Heat exchanger aftercooler start motor oil filter bracket front engine mounting rear hatch for valve lifter air filter and...

Page 34: ...ry cables 2 Close the sea cocks and drain the water in the fresh water and sea water systems If the engine has a hull cooling system close the valves for this system and drain the engine Applies to TAMD61 62 TAMD 71 72 3 Remove the shield over the heat exchanger and after cooler Remove the filter 4 Remove the pipe between the sea water pump and the heat exchanger and between the aftercooler and re...

Page 35: ...7 Remove all screws holding the induction manifold 18 Undo both the screws behind the aftercooler a few turns and lift the aftercooler off 19 If the engine has a stop solenoid remove it and hang it up Applies to all engines 20 Shut off the fuel taps Remove the fuel pipe leading to the fine filter the supply pipes and the fuel leakage pipes Remove the fuel filters Install protective covers 21 Remov...

Page 36: ...der head and cylinder block mating fac es 29 Install two press tools 9996487 to retain the cylinder liners1 1 Necessary if work is going to be done where the crankshaft is turned with the cylinder head detached The cylinder liners then have to be retained by 1 press tool no 9996487 per cylinder liner Cylinder head disassembly assembly Special tool 885128 Cylinder heads in the 6 x and 7 x series ha...

Page 37: ...ions 5 Install the valve spring s and valve collar and press the spring s together with the valve spring compres sor Install the collets and a new valve stem seal Cylinder head leakage check Special tools 9996662 9996852 6 x series 9998114 2 no 7 x series 9998115 2 no WARNING Before using proof testing equipment no 9996662 it must be checked Al ways observe the applicable safety instructions 1 Con...

Page 38: ... of 50 kPa 0 5 kp cm2 on the pressure gauge Main tain this pressure for 1 min 8 Then raise the pressure to 150 kPa 1 5 kp cm2 Lock the reduction valve knob with the lock ring and shut the tap off Check after one or two minutes whether the pressure has fallen and if any air bubbles come out of the water bath If there is any air leakage from the copper sleeves for the injectors this should be attend...

Page 39: ...iners are undamaged For sealing grooves please refer to Cylinder head milling the seal grooves on pages 39 42 Cracks When renovating engines with a large number of oper ation hours heat cracks may be found between the valve seats and the injector hole when the cylinder head is inspected The cylinder head does not need to be replaced be cause of heat cracks The crack starts by the copper sleeve for...

Page 40: ...ances Inlet valve max clearance 0 33 mm Exhaust valve max clearance 0 38 mm If these values are exceeded change the valve guides 2 Oil the new valve guides and press them in with man drel 9996169 6 x series or 9992661 7 x series The mandrel gives the guides the correct height 23 mm and 22 mm respectively above the spring plane of the cylinder head 3 Broach the valve guides up if necessary Valve gu...

Page 41: ...istance A between the cylinder head plane and valve head 6 x series 7 x series Inlet valve 0 7 1 1 mm 2 0 2 4 mm Exhaust valve 0 7 1 1 mm 1 0 1 4 mm TAMD72A 0 0 2 mm If the permitted distance A is not met after planing the valve seats must be milled out Milling tool 9996841 9996842 1 Nut 5 Spindle 2 Turning handle 6 Cutting head 3 Guide plate 7 Bit holder 4 Attachment screw 1 When new grooves are ...

Page 42: ... 0 1 0 2 mm Setting the cutters Set up the cutter head in a vice with the bits facing upwards 4 5 Slide the holder and dial gauge sideways so that the gauge tip rests on the highest point of one of the cut ters and read off the dial gauge Adjusting the bit 6 Undo lock screw A with a 4 mm Allen key and turn adjustment screw B a few turns with a 5 mm Allen key Attach the dial gauge 998976 in holder ...

Page 43: ...r can be removed from the cutter head 11 The bit holders are marked with a letter A A B C or D and the corresponding letter is punched on the cutter head where the bits are to be installed NOTE The two socket cap screws in the bit holder must not be touched 9999745 repair kit for cutting tool 9996481 and 9996482 12 Install the bit holders in the cutter head in accordance with the letters and with ...

Page 44: ...n below the edge of the seat Weld with a MIG MAG welder cover the area round the weld to avoid getting weld spatter stuck anywhere WARNING Be careful not to do any damage to the cylinder head 18 Clean the cylinder head carefully Then check the depth of the grooves by putting the cutting head back without the spring and nut and turn it a few times un der hand pressure If the tool cuts the grooves d...

Page 45: ...e head A measured with a new valve is TAMD61 62 TAMD63 TAMD71 72 Inlet 0 7 1 1 mm 0 0 4 mm 2 0 2 4 mm Exhaust 0 7 1 1 mm 0 0 4 mm 1 0 1 4 mm A used valve seat wear tolerance may be ground down so that the distance between the cylinder head plane and the valve head A measured with a new valve is max TAMD61 62 TAMD63 TAMD71 72 Inlet 1 5 mm 1 0 mm 3 0 mm Exhaust 1 5 mm 1 0 mm 2 0 mm If the distances ...

Page 46: ...a tor dye Check the distance A between the plane of the cylinder head and the valve head as in item 1 under the method for Valve seat replacement on page 42 Rocker mechanism renovation Special tools 6 x series 9991876 7 x series 9992677 Remove the circlips from the rocker shaft and remove the rockers bearing journals and springs 1 2 Clean the components Be especially careful with the oil duct in t...

Page 47: ... broach the bushing to give an accurately ad justed running fit on the shaft 22 020 22 041 mm for the 6 x series or 25 020 25 042 mm for the 7 x series Remove all swarf 7 Oil the rocker shaft and install all the components Note that the rockers on the 6 x series are installed in opposing pairs On the 7 x series all the rockers are identical and the location on the shaft is thus arbitrary Make sure...

Page 48: ... renovation on page 59 3 Dip the cylinder head screws including the screw heads in rust proofer part no 282036 3 and allow them to run off on a piece of netting The screws should have stopped dripping when installed oil could otherwise be forced up and be regarded as leakage WARNING The screws are phosphated and must not be cleaned with a steel brush If the cylinder head is painted the contact sur...

Page 49: ... the sleeve marking dis placed one spanner flat anti clockwise from the chalk mark Then carry out the angle tightening by turning until the sleeve marking coincides with the chalk mark on the top of the cylinder head Once all screws have been tightened 60 tighten ing is completed No subsequent torquing is nec essary 6 Install the push rods and rocker mechanism Tighten ing torque For the 61 series ...

Page 50: ...Remove all the pipes as a package i e all the pipes which are clamped together IMPORTANT No fuel pipe must be bent or deformed since cracks may occur which would lead to failure Turn the injector with a 15 mm open ended spanner and pull it upwards at the same time If the injector is stuck it must be removed with puller no 9996643 5 Pull out the steel ring above the copper sleeve Use extractor no 9...

Page 51: ...stalled or detached cylinder head Special tool 9812546 It is very important that all kinds of deposits on the mating surface in the cylinder head of the copper sleeve are removed before a new copper sleeve is in stalled IMPORTANT For TAMD63 cleaning with a plug brush is the only permitted method 1 Install plug brush 9812546 in an electric drill with ad justable speed The maximum speed for the plug...

Page 52: ...dicated by arrows please refer to the illustration 1 Then continue to clean up with cutter 9996650 until the cutter bottoms against the cone and stops cutting The cutter cuts on the surfaces indicated by arrows please refer to the illustration Check the seal surfaces If necessary repeat the cleaning process Also check that the upper seal seat is clean Blow the cylinder head clean of swarf 1 O ring...

Page 53: ...er sleeve and the correct clearance between the ring and sleeve The clearance should be 0 10 0 45 mm please refer to pos A on the illustration above 6x series and 7x series 6x series 7x series 3 6x series Remove the two fastening screws for the cylinder head one on each side of the copper sleeve Screw down press tool no 9998070 7x series Screw down press tool 9996861 with the injector attachment s...

Page 54: ...0 55 mm TAMD71 0 0157 0 0217 TAMD63 TAMD72 0 50 mm 0 65 mm TAMD73 TAMD74 0 0197 0 0256 1 Remove the valve covers When the valve clearance is checked the engine must only be cranked in its normal direction of rotation Cranking is done by turn ing the polygon hub on the crankshaft nose with a 21 mm ratchet spanner Firing sequence 1 5 3 6 2 4 Cylinder whose rockers tip 6 2 4 1 5 3 2 Crank the engine ...

Page 55: ...ners 9996847 for the cylinder liners before removing the pistons If a cylinder liner should slide up during piston re moval the cylinder liner must also be removed since there is a major risk that contamination will fall down between the lining and the block and cause leakage 2 1 Remove the piston cooling nozzle IMPORTANT The piston cooling nozzle must always be removed even if the work could theo...

Page 56: ...e must not be any noticeable slack The gudgeon should have a light interference fit in the piston when cold max 0 004 mm NOTE The cylinder liner wear must be checked be fore piston rings small end bushings etc are re placed Please refer to Cylinder liner inspection and mea surement on page 57 Removal of piston small end bush replacement Special tools 9991801 9992071 9992479 7x series 9992669 6x se...

Page 57: ...e correct fit is achieved an oiled gudgeon pin should slowly slide down through the bush under its own weight at room temperature Finish off by checking the con rod in the jig again to ensure that the oil hole is correctly aligned Piston assembly Special tool 9992071 1 Install one circlip on the piston Heat the piston up to about 100 C 3 Place the piston and con rod so that both the front marks ar...

Page 58: ... if there is any noticeable wear within the wear tolerances in the cylinders since the piston rings do not normally end up in the same positions as they had before removal Check the piston ring gap on new piston rings as well Please refer to Technical Data in the Workshop Man ual for measurements for each engine variant Note New cylinder liners are supplied complete with pistons and piston rings P...

Page 59: ...ack check ing Measurement 1 Measure the wear on the cylinder liner with a cylinder indicator To get the most accurate wear measure ment possible the cylinder indicator should first be set with a gauge ring or micrometer Use the original diameter of the cylinder liner as the starting value 2 3 If the wear is greater than 0 35 0 40 mm the cylinder liner with pistons and piston rings should be replac...

Page 60: ...n should be followed to safeguard lubrication The honing scratches must be applied regularly and cut evenly in both directions and over the entire cylin der NOTE You must maintain the correct speed on the honing tool to get the correct pattern 1 Clean the removed cylinder liner from sooty edges Set the liner up in a vice Use a heavy electric drill which can be operated at low speed 200 400 rpm Use...

Page 61: ...e ba sis of the measurements you have made Try to use the thinnest possible spacer preferably only one should be used The correct height above the block plane should be 0 38 0 43 mm 2 Remove the liner and roughen up the surface of the lining seat with an emery cloth Install the cylinder liner without sealing rings and press it down with holder 9996847 2 No Measure the height of the liner above the...

Page 62: ...height of the liner and estimate the thick ness of spacers required as in item 1 of the method described in Cylinder liner seat renovation on page 59 4 Lubricate the seal rings to be installed in the cylinder block with the lubricant provided in the seal ring pack age Install the rings in the grooves in accordance with the installation instruction provided on the package 5 Put any spacers required...

Page 63: ...stall the cap in accordance with the marking and install the screws 6 Make sure that the press tool is in place and turn the crankshaft until the piston comes to its lowest posi tion Torque the screws to 190 10 Nm 19 1 0 kpm 7 Install the piston cooling nozzle Oil the big end bearing shells and the gudgeon pin with engine oil Install the bearing shells and check that they are cor rectly aligned in...

Page 64: ...stic pipes from the expansion tank l Remove the lid at the front of the thermostat housing and the connection pipe to the coolant pump l Remove the coolant pump l Turn the engine round in its normal direction of ro tation until the no 1 piston is at TDC after the compression stroke 0 on the flywheel TAMD63 l Remove the belt tensioner free the alternator and hang it up l Remove the alternator brack...

Page 65: ...s on the gears coincide Adjust if necessary by turning the crankshaft round 5 Remove the idler gear pos 4 together with the bear ing pin and thrust washer 6 Remove the crankshaft gear pos 1 with extractor no 9992658 Please refer to the overview of the timing gears on page 62 Remove the camshaft gear pos 7 with extractor no 999279 Use the same procedure as for the injector pump drive wheel pos 5 8 ...

Page 66: ... timing cover Nitrocarburised timing gear wheels Since some of the timing gear wheels are more heavi ly loaded in some engine versions than in other ver sions the timing gear wheels on these engines are made to withstand heavier loading by nitrocarburising them WARNING Nitrocarburised gears must not be installed in contact with quenched and tempered gears Always observe the spare part catalogue wh...

Page 67: ...e that the teeth are correctly engaged in the oil pump drive gear 1 33 4 Nm 3 3 0 4 Nm 70 7 Nm 7 0 7 Nm 90 9 Nm 9 0 9 Nm 3 Set the crankshaft up with the no 1 piston at TDC crankshaft key straight up Install the idler gear in accordance with the markings The thrust washer is positioned as in illustration A 4 Check that the dowel is installed in the injector pump shaft not TAMD63 TAMD72 and install...

Page 68: ... and an outer felt ring These have been replaced as spare parts by a rubber seal which is used on late model engines i e 1 rubber seal is in stalled 2 Install a new seal ring on mandrel 9996855 Oil in the seal ring and tap it in until the mandrel bottoms Application of sealant timing gear cover Apply an even 2 mm wide string of sealant on the timing gear cover Use sealant no 1161231 4 NOTE The tim...

Page 69: ...and torque the screw to 260 Nm 26 kpm 2 Install the torsional damper and crankshaft pulley Torque the screws to 90 Nm 9 kpm Camshaft wear check Special tools 998976 9996772 Preparatory work l Remove the valve covers Remove the screws holding the rocker shaft bearing caps and remove the rocker mechanism Lift the push rods out Mark the push rods so that they end up in the same place during re assemb...

Page 70: ...e below Lift heights camshaft 4 Install the push rods in the correct order install the rocker support bridges and torque the screws Tightening torque for the 61 series with steel bearing caps torque to 65 Nm 6 5 kpm Later models of the 61 series and all engines in the 62 and 63 series have aluminium bearing caps Tighten ing torque is 50 Nm 5 0 kpm On the 71 and 72 series the torque used is 65 Nm 6...

Page 71: ...outside of the valve lifter shows that the surface has not been worn down Investigate the reason why the valve lifter has not ro tated before installing a new valve lifter Minor pitting damage on valve lifter A camshaft B Check the valve lifters for pitting damage Pitting damage can occur for various reasons The damage is caused by small particles of metal which come away from the hardened surface...

Page 72: ...in relation to the end bearings is 0 04 mm Measure the lift height cam height with a calliper gauge as in the illustration above Lift height C A B The lift height can also be mea sured by the Camshaft wear check method on page 67 Please refer to Technical Data for the measurements of the camshaft and camshaft bearings Also please refer to the table on page 68 for the lift height Camshaft bearing r...

Page 73: ...nism Tightening torque for the 61 series with steel bearing caps the torque is 65 Nm 6 5 kpm Late model versions of the 61 series and all engines in the 62 and 63 series have aluminium bearing caps These should be torqued to 50 Nm 5 0 kpm The 71 and 72 series should be torqued to 65 Nm 6 5 kpm The steel bearing cap has been replaced by an aluminium bear ing cap as a spare part 6 Install the valve ...

Page 74: ... crankshaft in some cases as on a new crankshaft On a used crankshaft this is emphasized very clearly because of the extremely smooth bearing surface After a long period of operation very small particles may loosen from the surface layer spalling This phenomenon can be confused with dirt scratches but differs since the marks do not go round the entire bearing journal and they have uneven edges The...

Page 75: ...the instructions provided by the manufacturers of the equipment After such a test the crankshaft must be de fluxed Cracks of the following types and locations mean that the crankshaft has to be replaced C Cracks longer than 5 mm adjacent to oil duct holes Cracks which are shorter than 5 mm can be ground off D Cracks longer than 5 mm adjacent to the marked area Single cracks shorter than 10 mm can ...

Page 76: ...has been ground to the 3rd underdimension or more Nitrocarburisation can be done with gas or salt the experience and methods of every heat treatment craftsman are applicable The following two stages are only applicable if the crankshaft has been nitrocarburised l Check the runout of the crankshaft again l Do a new crack test Finish off renovation by l Buffing the crankshaft carefully after any gri...

Page 77: ...side of the engine above the rear connection on the block for the flat oil cooler Note The plug on early model TAMD61 and TAMD71 By pass valve on TAMD62 TAMD72 and late model versions of TAMD61 and TAMD71 Cylinder block inspection Clean the cylinder block carefully and check the bearing journals con rods and bearing caps for damage Check that all oil ways are free from deposits and that the block ...

Page 78: ...r and on the idler gear coincide 7 Install thrust washers for the centre main bearing thrust bearing Thanks to the fixing cutouts the thrust washers can only be installed one way round 8 Install the main bearing caps and note the markings carefully The markings indicate the bearing cap positions 9 Oil and install the main bearing cap screws Torque the screws to 150 10 Nm 15 1 0 kpm Check the end f...

Page 79: ...s and adjust if necessary Big end bearing replacement Crankshaft not removed Preparatory work l Drain or pump out the engine oil l Remove the sump l Remove the supply and suction pipes for the oil pump plus the baffle l Remove the injectors to make it easier to crank the engine 1 Turn the crankshaft round until the bearing caps for cylinders 1 and 6 come into the positions where the screws can be ...

Page 80: ...all the big end bearing shells turn the crankcase and check that no bearings run stiff Main bearings replacement Crankshaft not removed Preparatory work l Drain or pump out the engine oil l Remove the sump l Remove the supply and suction pipes for the oil pump plus the baffle l Remove the injectors to make it easier to crank the engine 1 Remove the main bearing cap screws for the front main bearin...

Page 81: ...t one After you have changed each main bearing check that the crank shaft turns easily by cranking the shaft The upper bearing shell is installed by turning the crankcase the opposite way to the normal direc tion of rotation with the pin in the hole Check that the pressed out heel in the bearing shell engages correctly in the cutout in the bearing seat Remove the pin from the oil hole and install ...

Page 82: ... flywheel away Flywheel inspection Check the flywheel for cracks and other damage Also check that the gear ring is not worn or dam aged Replace the flywheel and gear ring as neces sary 2 Clean the mating surface of the crankshaft flange against the flywheel 3 Clean the mating surface of the flywheel against the crankshaft flange 4 Check that the flywheel location dowel in the crank shaft is in pla...

Page 83: ...at care to ensure that the gear ring is evenly heated and not spot heated which would cause annealing To check the heating process polish the gear ring bright at several places before heating it Stop heating when these surfaces become blued 4 Put the heated gear ring on the flywheel and tap it into place with a soft punch and hammer Allow the gear ring to air cool 5 Clean the mating surfaces on th...

Page 84: ...dial gauge on the outer edge of the flywheel housing see illustration Read off the value and move the dial gauge with base round to the opposite side of the flywheel The value of these measurements must not exceed 0 15 mm Put the magnetic base of the dial gauge on the fly wheel and put the tip of the dial gauge on the inner edge of the flywheel housing see illustration Pull the flywheel round and ...

Page 85: ... 9996437 and shaft 9992000 Install the flywheel Tightening torque is 190 10 Nm 19 1 0 kpm Flange seal flywheel housing replacement Flywheel removed 1 Remove the four rear screws from the sump and the screws which hold the flywheel housing to the cylin der block 10 no Tap the flywheel housing loose using a plastic faced hammer by tapping alternately on the right and left hand sides 2 Clean the mati...

Page 86: ...84 References to Service Bulletins Group No Date Concerning ...

Page 87: ... this page write your comments down and send them to us The ad dress is at the bottom We would prefer you to write in English or Swedish 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 88: ...7735718 4 English 08 1996 ...

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Volvo Penta TAMD61A, Workshop Manual

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