Volvo Penta Tamd 63p Service Manual
. Workshop Manual Engine repair 2(0) MD22, TMD22, TAMD22. Engine repair Marine Engines MD22. TMD22. TAMD22 Contents General Information Crankshaft assembly Safety Information.3 General.43 General Information. 6 Repair Instructions Repair instructions.7 Crankshaft pulley, replacement (14A-01).
44 Special tools.10 Front sealing ring, replacement (14A-02). Engine settings Flywheel, flywheel cover General.71 General. 112 Repair Instructions Repair Instructions Setting the 1 piston at top dead center of Flywheel, replacement (21A-01).112 compression stroke (17A-01).72 Ring gear, replacement (21A-02). 112 Valve timings, checking and adjustment Flywheel cover, replacement (21A-03). Introduction This Workshop Manual contains descriptions and turned off immediately prior to starting work repair instructions for Volvo Penta products or prod- on it. Reinstall all protective parts removed during service operations before starting the uct versions contained in the contents list. Ensure engine.
General instructions Always use protective goggles where there is Store oil and fuel-soaked rags and fuel and oil a danger of pieces of metal, sparks from filters safely. In certain conditions, oil-soaked grinding, acid or other chemicals being thrown rags can spontaneously ignite. Replaced fuel into your eyes. (gasoline engines) and fuel system on Use an adjustable lifting beam or lifting beam Volvo Penta products are designed and con- specifically for the engine to raise the engine structed to minimize the risk of fire and explo- to ensure safe handling and to avoid damaging sion. This Workshop Manual has been developed primari- proved by Volvo Penta. Ly for Volvo Penta service workshops and qualified personnel. Personnel using this book are assumed.
No modifications to the exhaust pipes and air. Take special care when working on-board, that oil All procedures for which there are Volvo Penta spe- and waste is taken for destruction and is not acci- cial tools in this Workshop Manual are carried out dentally pumped into the environment with bilge wa- using these. In this Volvo Penta Service Manual the user will find ommended angle is added according to the protrac- that each section where these agents are applied in tor scale. General instructions.
Always used chloroprene rubber gloves (gloves Safety precautions for Fluorine for handling chemicals) and protective goggles. Rubber. Treat removed seals in the same way as corro- sive acid.
All remains, even the ash can be ex- Fluorine rubber is a common material in sealing tremely corrosive. Special tools Special tools In all cases where it is practical the tool number, except for the final digit, has been stamped on the tool, The final digit (after the hyphen) is a control number. 884 955 8858 018 885 019 885 021 885 020 885 022.
Volvo Tamd 74
Special tools 885 032 885 033 885 034 885 035 885 036 885 037 885 038 885 041 885 139 885032-3 Protective socket for front stuffing box, 885036-4 Belt tension gauge for timing belt. 885037-2 Adjustment drifts for the camshaft and 885033-1 Installation tool for front stuffing box, crankshaft. General information Identifying numbers Your engine and transmission has identification plates with identification numbers. This information should al- ways be quoted when ordering replacement parts. The appearance and location of identification plates is shown below. The figures in brackets refer to the location of the identification numbers on the identification plate. General information Engine presentation 1.
Coolant filler 2. Heat exchanger 3. Pipe for oil scavenging pump 4. Oil filter 5. Starter motor 6.
Injection pump 8. Fuel feed pump 9. Dipstick (engine) 10. Oil filler cap (engine) 11. Fuel filter 12. General information 12 13 14 15 18, 19 MD22P/MS25 12 13 14 15 TMD22/MS2 12 13 14 15 18, 19 TMD22P/HS25.
General information 12 13 14 15 TAMD22P/SX 1. Turbo (TMD, TAMD) 2. Coolant filler 3. Heat exchanger 4.
Oil cooler 5. Pipe for oil scavenging pump 6. Charge air cooler (CAC) (TAMD) 7. Oil filter 8.
Starter motor 9. Generator 10. Cylinder head Cylinder head General The carbon deposits in a diesel engine are small the valve lifters and the top of the valves so that ad- and therefore the number of operational hours do justment is possible. Not give an indication of when it is time to recondi- The cylinder head has two valves per cylinder. Cylinder head Repair Instructions Remove the engine lifting brackets.
If nothing is Camshaft cover, replacement driven from the rear end of the camshaft, remove (12A-01) the rear cover and install the camshaft lock 885025 (B1). This ensures that the camshaft does not tilt Special tools: 885025 when the camshaft cover is removed. Cylinder head Valve clearance, check (12A-02) Special tools: 885025, 885024 Check that the groove in the camshaft cover and the mating surfaces on the cylinder head and cover are clean. Apply a 2mm bead of silicon in the outer groove of the cover, but leave the inner groove empty as illustrated in illustration (C). Cylinder head Install the camshaft mountings 885024 (A1) to hold Valve clearance, adjustment the camshaft and mount the mountings with the rel- (12A–03) evant mounting screws for the cover. It is vital to move the rear camshaft stuffing box on the cam- Special tools: 885024, 885025, 885037 shaft to secure sufficient clearance between the rear mounting and the stuffing box.
Cylinder head Install the new front and rear stuffing box on the camshaft, operations 12A-04 and 12A-05. Install the camshaft pulley and the timing belt, see section 15. Remove the locking drifts from the fuel injection pump pulley and adjust the belt tension, operation 15A-03. Cylinder head Front sealing ring, replacement (12A-04) Special tools: 885026, 885018, 885037 Disconnect the battery Remove the screw from the adjustment hole on the top of the front end of the camshaft cover (12A.03/ A4). Turn the crankshaft until the adjustment hole in the front of the camshaft front bearing journal corre- sponds with the hole in the cover. Cylinder head Rear sealing ring, replacement (12A-05) Special tools: 885019, 885020, 885038 Remove the seawater pump and the drive housing and remove the drive adapter from the camshaft end, see section 20.
Ensure that the stuffing box and the camshaft are clean and undamaged. Cylinder head Camshaft, replacement Check the camshaft for wear and damage and re- (12A-06) place it if required. Special tools: 885037 Ensure that the camshaft is clean and lubricated Disconnect the battery with fresh engine oil.
Install the camshaft in position and check the valve clearance if necessary, see operation 12A-02. Cylinder head Cylinder head assembly, Check the fuel injection pump adjustment, opera- replacement (12A-07) tions 17A-03. Special tools: 885037 Install the cap of the timing cover, operation 15A- Disconnect the battery. Install the screw in the adjustment hole on top of the camshaft cover front section. Cylinder head Remove the injectors, operation 19A-02 and the glow plugs, operation 22C-01 to prevent any possi- ble damage to the tips. Remove the screw from the adjustment hole on the top of the front end of the camshaft cover 12A.03/ A4. Cylinder head If no tool is available make a suitable marking on each screw flange (C1).
Make other markings on Ensure that the two guide sleeves (12A.08/B1) is in the cylinder head (C2) with 90° clockwise offset in position in the cylinder block surface and install the relation to the markings on the screws. Cylinder head Check the fuel injection pump adjustment, opera- Fill the engine coolant system. See operation 20A- tions 17A-03 and remove the adjustment drifts.
Turn the crankshaft two revolutions to ensure that there is nothing preventing free movement. Connect the battery. Install the glow plugs, operation 22C-01. Cylinder head Press the valve springs together with the valve Valves and valve springs, spring tensioners (A1). Ensure that the spring is replacement (12A-08) pressed straight downwards so that the valve stem is not damaged. Remove the valve cotter (B1).
Special tools: 885023 Remove the cylinder head, operations 12A-07. Cylinder head Valves and valve springs, Use the valve spring tensioner to compress the inspection (12A-09) valve spring and the install the valve cotter (B1). Ensure that the valve spring is pressed straight down so that the valve stem is not damaged. Lubricate the shims and valve lifters.
Cylinder head Valve guides, inspection (12A-10) Special tools: 885021, 885022 Check the valve guides for wear. The maximum play between the valve stem and the hole in the guide is 0.13 mm. If the clearance is greater when a new valve is installed, a new valve guide must be installed. Cylinder head Cylinder head, inspection (12A-12) Remove the cylinder head assembly, operations 12A-07.
Remove the thermostat housing. Remove the seawater pump, operation 20A-06. Use a straight edged ruler and a feeler gauge to Remove the camshaft cover, operation 12A-01 and check the latitudinal, longitudinal and diagonal flat- the camshaft. Cylinder head Valve seat, grinding (12A-13) Valve seats with more serious damage can be cor- rected using a milling tool, operation 12A-13 or a new valve seats can be installed, operation 12A-14. If the valve guide is worn it should be replaced, op- eration 12A-11.
Cylinder head Valve seat, replacement (12A-14) Install a new valve guide, operation 12A-11. Work a small segment from the inside of one side of the valve seat to a depth of 8.25 mm from the sur- face of the cylinder head. Split the seat at the thin- nest point and remove it from the cylinder block. Piston and connecting rod General The combustion chamber on the upper side of the piston has a special ”swirl lip” to provide an effec- tive fuel – air mixture. On the high effects the upper side of the piston is turned to ensure clearance be- tween the valves and the glow plugs.
Repair Instructions Big ends, replacement (13A-01) Drain engine oil. Remove the oil pan, operation 18A-03 Remove the oil screen and extractor pipe, operation 18A-04. Turn the crankshaft until the relevant connecting rod is in its lowest position. Unscrew the nuts and remove the bearing cap. Remove the lower bearing shell from the bearing cap and put it together with the cap. Piston and connecting rod Piston and connecting rod as- Clean, lubricate and install the lower bearing shell in sembly, replacement (13A-03) the cap. Ensure that the guide lug is slid well into the cut out (A2).
Remove the protective hosing from the connecting rod screws and check that the Drain the engine oil and the engine coolant system. Piston and connecting rod Remove the big end bearing cap and the connecting Ensure that the piston, cylinder bore, big end jour- rod bearing caps, operation 13A-01. Keep the bear- nal and connecting rod big end are clean. Lubricate ing shells with the relevant caps so that they can be the piston and cylinder bore with fresh engine oil. Piston and connecting rod Slide the piston and connecting rod through the cyl- Install the oil screen and extractor pipe if required, inder bore and down to the big end journal. Turn the operation 18A-04.
Connecting rod so that the arrow on the upper side of the piston points towards the front end of the en- gine. Install the piston rings with an appropriate piston ring pliers Separate the ring gap just sufficiently that the ring ends do not damage the piston. MD22L, MD22, TMD22 Insert the expander ring for the oil scraper ring in TMD22P, TAMD22 the lower piston ring groove with the catch through both end of the rings (A). Piston and connecting rod Piston and connecting rod, assembly / dismantling (13A-05) Remove the piston rings, operation 13A-04. Remove the snap rings holding the piston pins in position.
Make a temporary marking on the piston to display the cylinder number as given on the connecting rod. If the original piston is used, ensure that it is in- Make the marking on the piston on the same side stalled on the correct connecting rod and the origi. Piston and connecting rod Remove the piston rings, operation 13A-04. Clean the piston ring and the piston ring grooves.
Place the connecting rod with piston upside down. The locating lug (B2) on the connecting rod must be on the same side as the arrow (B1) on the under- side of the piston. Piston and connecting rod Connecting rod, inspection Connecting rod bushing, (13A-07) replacement (13A-08) Check the connecting rods for deformation, see Workshop Manual “Technical Data”. Press out the old bushing with an appropriate drift. Check the connecting rod bushing for wear or other Clean the bearing recess in the connecting rod and damage and replace it as necessary. Crankshaft assembly General the rear stuffing box is located directly in the fly- The crankshaft is made of ductile cast iron.
It has wheel cover or the back plate. Integral balancing weights and five main bearing journals.
The crankshaft front end has two separate key- The axial play is controlled by two sectioned thrust grooves. Repair Instructions Slacken off the pulley center screw and remove the Crankshaft pulley, replacement pulley (C). Use a large screwdriver or similar tool (14A-01) as a counterhold at the flywheel ring gear. The belt pulley is locked to the front end of the crankshaft using Loctite 648 and can only be re- Disconnect the battery. Crankshaft assembly Front sealing ring, replacement (14A-02) Special tools: 885031, 885032, 885033, 885037 Disconnect the battery Remove the screw from the adjustment hole on the top of the front end of the camshaft cover (12A.03/ A4). Turn the crankshaft until the adjustment hole in the front of the camshaft front bearing journal corre- sponds with the hole in the cover. Crankshaft assembly Remove the adjustment drifts and the pulley drifts.
Check the fuel injection pump adjustment, opera- tions 17A-03. Turn the crankshaft two revolutions to ensure that there is nothing preventing free movement.
Install the cap for the timing cover, operation 15A- 01. Crankshaft assembly Rear sealing ring, replacement Clean the sealing ring housing and the flange on the (14A-03) crankshaft. Special tools: 885030, 885034, 885035 Lightly the sealing ring housing, the flange on the Disconnect the battery crankshaft and the sealing ring seal lip with fresh engine oil. Crankshaft assembly Locate the ring (C1) from tool 885035 on the crank- Crankshaft axial clearance, shaft flange with the correct side of the ring towards checking (14A-04) the sealing ring. If the sealing ring is to be installed in the front position (see paragraph 4), install the socket with the end with diameter markings turned to the sealing ring. Crankshaft assembly Check that the guide sleeves are correctly installed in the bearing cap or in the cylinder block. Check that the bearing shell is correctly installed in the cap and that the main bearing journals are clean.
Lubricate the bearing shell with fresh engine oil. Crankshaft assembly Clean the upper bearing shell and lubricate the Main bearings, replacement bearing surface with fresh engine oil. (14A-06) NOTE! There is only a lubrication hole in the upper bearing shell and it must therefore be placed (with crankshaft installed) against the cylinder block. Crankshaft assembly Crankshaft, replacement Check the mounting screws for wear and deforma- (14A-08) tion and replace them if required. Lightly lubricate the threads with engine oil.
Install the screws and washers and tighten the screws in stages and even- Drain the engine oil and the engine coolant system. Ly to 112 Nm. Crankshaft assembly Check that all the big end caps are marked with the Clean the main bearing housing and the bearing number of the relevant cylinder. Remove the caps shells.
Install the bearing shells with the lugs well and the lower big end shells, operation 13A-01. Into the cut outs. Crankshaft assembly Check the axial clearance of the crankshaft and re- Install the timing cover and the timing pulleys, see place the thrust washer if necessary.
Install the timing belt, operation 15A-04, with the temporary markings on the belt aligned to the marked teeth on the pulleys. Timing cover and sprocket General The drive pulleys are installed on the camshaft (A1) and the fuel injection pump (A2). These pulleys are driven by a toothed belt (A3) from one toothed pul- ley mounted on the crankshaft (A4). The pulleys are made of sintered iron with 2% copper and the belt is made of neoprene and glass fibre.
Repair Instructions Timing cover outer, replacement (15A-01) Check that the cap is clean and that all the spring clips are fastened at the timing cover. Disconnect the battery.
Install the cap on the timing cover and ensure that all the clips are in position. Remove the generator (GEN) drive belt, operation 22A-03. Timing cover and drive Timing belt, inspection (15A-02) Special tools: 885036 Press the ball end of the belt tension gauge and in- stall the gauge over the belt.
Ensure that the gauge foot is located under the belt and between two teeth (B). Timing cover and drive Unscrew the domed screws holding the belt ten- Timing belt, tension (15A-03) sioner roller. Adjust the belt tension using a hexago- nal key in the hexagonal socket in the roller (C). Special tools: 885036, 885037 The correct tension for a new belt is 425-465 N and for a used belt 340-370 N.
Timing cover and drive Timing belt, replacement Check the belt teeth for wear. Check the belt for oil (15A-04) contamination, cracks and other damage. Replace the belt if any fault is found.
Special tools: 885037 Install the timing belt over the crankshaft, camshaft Disconnect the battery. Timing cover and drive Fuel injection pump pulley, Install the cap of the timing cover, operation 15A-01 replacement (15A-05) and install the inspection hatch. Special tools: 885037, 885027, 885029 Install the mounting screw in the adjustment hole in the camshaft cover.
Disconnect the battery. There the camshaft cover. Are two keygrooves and two marked teeth, “A” and “B”, on the pulley. On engines types MD22 and MD22L use the keygroove lying on the same side as the tooth marked “A”. On engines types TMD22 Connect the battery.
Timing cover and drive Camshaft pulley, replacement (15A-06) Special tools: 885027, 885029, 885037 Disconnect the battery. Remove the screw over the adjustment hole in the camshaft cover.
Turn the crankshaft until the ad- justment hole in the front of the camshaft corre- sponds with the hole in the cover. Timing cover and drive Crankshaft pulley, replacement Turn the crankshaft two revolutions to ensure that (15A-07) there is nothing preventing free movement Special tools: 885029, 885027, 885037 Install the cap of the timing cover, operation 15A-01 Disconnect the battery.
And install the inspection hatch. Remove the screw over the adjustment hole in the Install the mounting screw in the adjustment hole in camshaft cover. Timing cover and drive Insert the thin end spacer piece in the crankshaft (A1). Install the main tool 885027 (B) on the pulley using the mounting screws and tighten the center Apply a bead of Loctite 648 (A3) in a complete cir- screws against the spacer piece to remove the pul- cle internally in the hole in the pulley (A4), 6.5 mm ley. Timing cover and drive Slide the (A8) into the keygroove to a depth of 5 mm Install the screw in the adjustment hole in the cam- measured from the pulley front end plate.
It is important that all excess Loctite is wiped off from the front end of the crankshaft and from the pulley before the pulley is installed. Timing cover and drive Timing cover inner, replace- ment (15A-08) Special tools: 885037, 885027, 885029 Disconnect the battery. Remove the screw over the adjustment hole in the camshaft cover.
Turn the crankshaft until the ad- justment hole in the front of the camshaft corre- sponds with the hole in the cover. Timing cover and drive Remove the fuel injection pump pulley, operation 15A-05 and the camshaft pulley, operation 15A-06. Install the crankshaft pulley if required, operation 14A-01A.
Install the timing belt, operation 15A-04. Remove the fixing pin for the fuel injection pump pulley and adjust the belt tension, operation 15A-03. Cylinder block General The cylinder block is made of cast iron with sides which extend below the crankshaft for maximum support. The cylinder bore is machined directly into the block and is specially honed to minimize wear and oil consumption. Repair instructions Cylinder block, replacement (16A.01). Cylinder block Remove the cylinder head assembly, operations 12A-07.
Remove the oil pump, operation 20A-11. Remove the oil filter/ separator unit. Remove the oil pan, operation 18A-03. Install the fuel injection pump bracket. Check that the guide pins (A1) is correctly installed. Tighten the mounting screws to 43 Nm. Cylinder block Cylinder block, inspection Install the cylinder head assembly, operation 12A- (16A-02) Clean the coolant and lubrication channels.
Install the fuel filter, injectors and fuel injection pump, see section 19. Check the cylinder block for cracks and other dam- age. Cylinder block If the cylinder bores are damaged or worn more than 0.15 mm, measured in the diameter, the bore A new Flex-Hone must be used on an old cylinder can be bored out and honed to 0.50 mm, diametri- bore first in order to remove any loose material and cally oversize, and oversized pistons can be in- sharp edges.
Engine settings General The installation holes for the adjustment drifts are in marks (A and B) and two keygrooves. The key- the flywheel and in the front camshaft bearing jour- groove on the same side as the relevant adjustment nal. When these holes are aligned to the adjustment mark must always be used. Repair Instructions Setting the 1 piston at top Valve timings, checking/ dead center of the compres- adjustment (17A-02) sion stroke (17A-01) Special tools: 885037 Special tools: 885037 Position the piston in cylinder 1 at TDC in the com- pression stroke, operation 17A-01 If both the adjust- ment drifts can be installed, the valve timing is cor- Disconnect the battery and remove the screw over rect.
Engine settings Injection timing, checking/ad- Check the fuel injection pump adjustment, opera- justment (17A-03) tions 17A-03. Special tools: 884955, 885139 (TMD22P, TAMD22), 885037 Remove the adjustment drifts and turn the engine two revolutions to ensure that there is nothing pre- venting free movement. Engine settings If the read out is not within 0.05 mm of the correct setting, disconnect the fuel delivery lines from the pump. Use a wrench to prevent the output terminals on the fuel pump (FP) from moving when the deliv- ery lines are removed or installed. Lubrication system General The oil pump is located around the front end of the From the pump the oil passes through a filter crankshaft, the pumps inner rotor is driven by a key mounted on the pump housing.
After the filter the oil in the crankshaft. Lubrication system Repair Instructions Oil filter, replacement (18A-01) Check that there is lubricating oil in the oil pan. Place a container under the filter to collect any Start the engine and check the filter for leaks.
Spilled fluid. Check the oil level on the dipstick when the engine has cooled and top up the oil in the oil pan if neces- sary. Lubrication system Oil pan, replacement (18A-03) Drain the oil. Remove the dip stick. Disconnect the crankcase ventilation return pipe.
Arrange a support for the oil pan if required. Re- move the screws holding the oil pan against the cyl- inder block. Lower the oil pan and remove the gas- ket. Lubrication system Oil screen and suction pipe, Oil screen and suction pipe, replacement inspection (18A-05) (18A-04) The oil screen is an integrated part of the suction pipe.
No regular service is required, but clean the Clean the unit in kerosene and dry it carefully. Oil screen when it is dismantled. Lubrication system Oil pump, replacement (18A-06) Special tools: 885032, 885037 Disconnect the battery Remove the screw from the adjustment hole on the top of the front end of the camshaft cover. Turn the crankshaft until the adjustment hole in the front of the camshaft front bearing journal corresponds with the hole in the cover. Lubrication system Install the front stuffing box in the pump if neces- sary, see operation 14A-02. Install a new front key on the crankshaft. Install the timing cover, operation 15A-08.
Remove the pulleys and timing belt, see section 15. Check the fuel injection pump adjustment, opera- tions 17A-03. Lubrication system Oil pump, inspection (18A-07) Check the rotor axial clearance using a ruler and a If the rotors are so damaged that it affects the oil feeler gauge (C).
For size and all clearances, see pump capacity, the whole oil pump must be re- Workshop Manual “Technical Data”. Lubrication system Relief valve, replacement Install the piston in the sleeve with the open end of (18A-08) the piston turned inwards.
Install the spring over the lug on the end of the piston. Install the end plug with The relief valve is installed on the left side of the the sprung end inserted in the cutout in the plug.
Fuel system General The supply pump is the membrane type and is me- All engines are equipped with Bosch fuel injection pump. These pumps have mechanical engine speed chanically driven. It is mounted on the right side of regulator. The camshaft cover and is driven by an eccentric cam on the camshaft. Bleed the air from the fuel filter, see operation 19A- NOTE! It is extremely important that only original Volvo Penta filter holders are used.
Using the wrong type of holder can damage the fuel injection pump. Fuel injection system Injectors, fault-tracing Check the holder unit for wear and deformation and A faulty injector can cause engine misfires. Replace the unit if required. Replace the injector seat gasket. To find the faulty injector, run the engine at high idling speed. Fuel injection system Feed pump, replacement Slacken off the bleed screw in the fuel filter head. (19A-03) Hand pump with the lever on the supply pump to eliminate any air between the supply ball and the fuel filter.
Pump with the lever until air free fuel comes out of the bleed screw. Fuel injection system Feed pump, reconditioning The valves (B4) are jammed in the housing and can (19A-04) be removed with a suitable jimmy tool. Part of the flattened metal must be removed before the valves can be removed. Clean the outside of the supply pump. Disconnecting the control arm: secure the rocker (B12) with a vise and hit the pump housing with a soft faced hammer to release the two holders (B11).
Fuel injection system Fuel supply pressure, Install the diaphragm in position above the bottom checking (19A-05) pump half with the connecting arm fin upwards to- wards the slit in the control arm. Ensure that the If there is fuel leakage through the hole in the pump small bulge in the edge of the diaphragm (19A.04/ housing (19A.04/C3), it means that the diaphragm is C1) is at a 90°. Fuel injection system Fuel injection pump, replace- ment (19A-06) Special tools: 885027, 885029, 885037 Disconnect the battery. Position the piston in cylinder 1 at TDC in the com- pression stroke, operation 17A-01 and install the adjustment drifts 885037. Remove the locknuts and remove the pump (B) – Remove the cap for the timing cover, the timing belt ensure that the key does not fall out of the drive and the fuel injection pump pulley, see section 15. Fuel injection system Check that the key is correctly installed on the Check that the adjustment drifts are removed. Install the fuel injection pump in posi- tion with the locknuts sufficiently tightened to hold the pump secure, but not so much that it prevents radial movement in the housing.
Fuel injection system Idling speed, adjustment Run the engine and check for any leakage. Check (19A-07) that the idle speed is correct, operation 19A-07. If a new fuel injection pump has been installed, check that maximum idling speed, operation 19A- Run the engine to operating temperature and check the idling speed. Fuel injection system Fuel injection system, bleeding (19A-08) If air has entered the fuel injection system it must be removed before the engine is started. Air can enter the fuel injection system if:.
The fuel tank is run dry during normal opera- tion. Cooling system General When the coolant temperature increases, the ther- The engine has two cooling circuits. The closed cir- mostat valve opens, the by-pass connection closes cuit is filled with coolant which is used for cooling and the coolant passes through the heat exchanger. The cylinder block and cylinder head. Cooling system MD22L-B, MD22P-B, TMD22-B, TMD22P-C, TAMD22P-B Cylinder block Freshwater pump Thermostat Sea water pump The combined coolant tank, heat exchanger Outlet bend and exhaust manifold Charge air cooler (only TAMD22) Engine oil cooler (MD22P, TMD22, TAMD22). Cooling system Repair Instructions Coolant, draining (20A-01) Coolant, draining (20A-01) Applies to MD22A, MD22L-A, TMD22A Applies to MD22L-B, MD22P-B, TMD22-B, TMD22P-C, TAMD22P-B WARNING!
Do not drain coolant when the en- gine is still warm and the system is pressu- WARNING! Do not drain coolant when the en- rized, as dangerous hot coolant may spray out. Cooling system Coolant, filling (20A-2) Coolant, filling (20A-2) Applies to MD22A, MD22L-A, TMD22A Applies to MD22L-B, MD22P-B, TMD22-B, TMD22P-C, TAMD22P-B Remove the bleed plug from the hot water connec- Remove the bleed plug from the outlet connection tion (B1) or the plug (B2) on the heat exchanger. For the coolant (B2).
Cooling system Sea water circuit, draining Sea water circuit, draining (20A-03) (20A-03) Applies to MD22A, MD22L-A, TMD22A Applies to MD22L-B, MD22P-B, TMD22-B, TMD22P-C, TAMD22P-B Check that the seacock is closed. Check that the seacock is closed. Disconnect both hoses from the sea water pump. Disconnect both hoses from the sea water pump. Cooling system Thermostat, replacement Thermostat, checking (20A-04) Suspend the thermostat in a suitable container filled with water.
Drain the cooing system so that the coolant level is below the position of the thermostat and disconnect the upper hose from the coolant outlet connection. Warm the water slowly. Cooling system Circulation pump, replacement Check that the mating surfaces of the circulation (20A-05) pump and cylinder block are clean.
Disconnect the battery. Drain the coolant circuit, operation 20A-01. Disconnect the suction pipe at the circulation pump and, if necessary, the by-pass connection. Position the piston in cylinder 1 at TDC in the com- pression stroke, operation 17A-01 and install the adjustment drifts. Cooling system Sea water pump, replacement (20A-06) Applies to MD22A, MD22L-A, TMD22A NOTE!
If the installation plate and adapter plate for the sea water pump are removed, they must be aligned (using alignment tool 885038) before the pump is installed, see operation 20A-08. Drain the sea water circuit, operation 20A-03. Cooling system Sea water pump, replacement Install the pump on the engine with two screws (A1) (20A-06) and (A2) and install the belt.
At the correct tension it should be possible to press in the belt approxi- Applies to MD22L-B, MD22P-B, TMD22-B, mately 5 mm between the pulleys. Cooling system Remove the end cover (B13) and the gasket (B14). Press stuffing box (B4) into position in the bearing housing with the lip against the side of the bearing.
Lubricate the sealing lip a little. Remove the rubber plug (B12) from the end of the impeller (B11). Cooling system Sea water pump, recondition- Remove the stuffing box (A7) from the housing. Ing (20A-07) Applies to MD22L-B, MD22P-B, TMD22-B, TMD22P-C, TAMD22P-B Check the components for wear or other damage and replace as necessary. Check that all the components are clean.
Press the bearing (A9) on the shaft (A11). Cooling system Installation and adapter plate for sea water pump, replace- ment (20A-08) Special tools: 885038 Applies to MD22A, MD22L-A, TMD22A Remove the sea water pump, operation 20A-06 and remove the adapter plate. Disconnect the fuel pipe from the fuel filter and, if necessary, remove the filter. Cooling system Oil cooler, replacement If the oil cooler and suspension bracket have been (20A-09) removed: Hold the unit in position and install the two front mounting screws. Install the rear mounting Applies to MD22A, MD22L-A, TMD22A screw through the bracket to the main oil pump and The pipes in the oil cooler do not usually need the spacer sleeve into the cylinder block. Cooling system Oil cooler, replacement (20A-09) Applies to MD22P-B, TMD22-B, TMD22P-C, TAMD22P-B The oil cooler may need cleaning because the cool- ant which passes through it comes from the sea water circuit.
Remove the oil pipes / hose from the cooler. Make a mark on the flanges (A1) and the coolant tank, so that the flanges can be reinstalled in the same position. Cooling system Heat exchanger / manifold / Remove the gaskets and clean the mating surfaces coolant tank, replacement on the unit, the cylinder head and the coolant pipes. Check the components for signs of damage and re- (20A-10) place if necessary. If the heat exchanger insert needs replacing, see operation 20A-11.
Cooling system Heat exchanger / manifold / Connect the sea water intake and outlet pipes to the coolant tank, replacement heat exchanger. The output pipe must be pushed in so that the end of the pipe is in the center of rubber (20A-10) end of the heat exchanger. Cooling system Heat exchanger, reconditioning Place a new manifold gasket in position over the (20A-11) guide pins in the cylinder head (A1).
You do not need to use any sealing compound. Check that the Applies to MD22A, MD22L-A, TMD22A gasket is correctly installed. The heat exchanger insert can be removed (with the heat exchanger installed on the engine) if the space behind or in front of the heat exchanger is at least. Cooling system Check the components for signs of damage and re- place if necessary. Slide the sleeve (A1) on the end of the insert until the insert is in contact with the reduced diameter of the sleeve. Press a rubber end (A2) over the other end of the insert until the protrusion inside the rubber end touches the end of the sleeve. Cooling system Heat exchanger, reconditioning Charge air cooler (CAC), re- (20A-11) conditioning (20A-12) Applies to MD22L-B, MD22P-B, TMD22-B, Applies to TAMD22P-B TMD22P-C, TAMD22P-B Drain the sea water circuit, operation 20A-03.
Drain the sea water circuit, operation 20A-03. Remove the cover and press the insert out of the Remove the charge air cooler assembly from the heat exchanger. Flywheel, flywheel cover General The motor may be equipped with a back plate of The steel flywheel has a hardened ring gear which aluminum or soft carbon steel or a flywheel cover of is installed by the process of shrinking-on. The ring cast iron.
Flywheel, flywheel cover Ring gear, replacement (21A-01) WARNING! Protective goggles must be worn for this operation. Check the position of the chamfering on the teeth before removing the ring gear. Removing The ring gear can be removed using a hammer and chisel to break off the collar.
Flywheel, flywheel cover Flywheel cover, replacement (21A-3) Special tools: 885030 Remove the drive components from the rear end of the engine. Remove the starter motor, operation 22B-01. En- gines with reverse gear: Remove the adapter hous- ing for the reverse gear.
Apply a continuous 1.5 mm line of sealant on the front surface of the cover, as shown in illustration Remove the flywheel, operation 21A-01. Flywheel, flywheel cover Install the flywheel and the drive adapter for the re- verse gear, operation 21A-01. Check that the guide pins are correctly installed in the housing. Install the adapter housing for the reverse gear and tighten the mounting screws to 43 Nm. Check the concen- tricity of the housing (C) and the axial run-out (D) in the same way as in points 5 and 7 above.
Electrical system Component description Generator Glow plugs The Valeo A13N 147M generator is driven from the The starting aid for these engines consists of a set crankshaft pulley with a single drive belt. The gen- of glow plugs, one for each cylinder. Erator has a capacity of 60 A (early version 50 A). Electrical system Repair Instructions Generator, replacement (22A-01) To prevent damage to the diodes and resistance, the following instructions must be followed.
Do not disconnect the battery when the engine is running. This causes an increase in voltage in the generator charging system, which may cause damage to the diodes or transistors. Electrical system Generator, maintenance Connect a good-quality voltmeter with a range of 0- 50 V across the generator and the negative termi- nals. If an ammeter is not connected in the circuit: Con- Check that the drive belt is not worn and that the nect a good-quality ammeter with a range of 0-100 belt tension is correct. Electrical system Starter motor, replacement Starter motor, maintenance (22B-01) (22B-02) The starter motor must be removed from the en- gine.
The brush unit can be removed from the rotor unit Disconnect the battery. The back plate has been removed. Inspect the brushes to ensure that they move freely in their guides and that the cable connectors move Disconnect the starter motor cables. Electrical system Starter motor, checking Glow plugs, replacement (22B-03) (22C-01) Check that the battery is charged. Switch on the lamps and engage the ignition switch. If no lamps are connected to the engine, connect a Disconnect the electrical connections for the glow voltmeter across the battery poles and engage the plugs.
Electrical system Glow plugs, checking power Glow plugs, function check supply/continuity Disconnect the power supply cable and the cables at the glow plug connectors. Connect a 12 V test lamp between the battery posi- tive pole and ground to check that the lamp oper- ates. Electrical system Wiring Diagram Instrument panel Cable color Printed circuit board GR =gray Switch for instrument lighting SB =black Tachometer BN =brown Starter button LBN =light brown Button =red Alarm connector PU =purple GN =green W =white BL =blue LBL =light blue OR =orange Unless otherwise stated, cable cross sections = 1.5. Electrical system Instrument panel Voltmeter Button Oil pressure gauge Switch for instrument lighting Engine coolant temperature Tachometer gauge Ignition switch Printed circuit board Alarm. Electrical system Engine Cable color Engine coolant temperature GR =gray sensor SB =black Coolant temperature switch BN =brown Oil pressure sensor LBN =light brown Pre-heating =red Relay PU =purple Ground fuse GN =green Fuses W =white BL =blue LBL =light blue OR =orange Unless otherwise stated, cable cross sections = 1.5. Intake and exhaust system Turbocharger, replacement Remove the nuts at the turbocharger flange and re- (only TMD, TAMD) move the turbocharger (TC) (A) and the gasket.
Re- move the exhaust elbow and its joint from the turbo- Removing and installing charger (TC) if installed. Intake and exhaust system Boost pressure control valve, Install the exhaust elbow for the turbocharger (TC) checking if required. Check that the mating surfaces on the elbow and the turbocharger (TC) are clean. Install a new gasket. Tighten the nuts to 22 Nm.
Connect the oil return line and the boost pressure line to the turbocharger (TC). Notes. Notes. We would prefer you to write in English or Swedish.
From.Refers to publication. Publication no.Issued.Suggestion/reasons.Date.Name.AB Volvo Penta Customer Support Dept. 42200 SE-405 08 Gothenburg Sweden.
Boatinfo requires FlashPlayer 9 or newer to display this document! Workshop Manual Fuel System 2(0) D TAMD61A, TAMD62A, TAMD63L-A, TAMD63P-A TAMD71A, TAMD71B, TAMD72A, TAMD72P-A, TAMD72WJ-A Group 23 Fuel System Marine engines TAMD61A. TAMD62A. TAMD63P-A. TAMD63L-A TAMD71A. TAMD71B. TAMD72A.
TAMD72WJ-A TAMD72P-A Contents General instructions. 2 Special tools. 9 Other special equipment.
9 Design and function General. 10 Injection pump. 11 Regulator.
12 Pressure variable full load stop. 15 Feed pump. 15 Overflow valve. 16 Fuel injector. 16 Fuel shut-off valve (TAMD 63). 17 Fuel filter. 17 Repair instructions.
18 Injection pump, removal. 18 Injection pump, installation and adjustment (TAMD61, -62.), -71, 72.). 20 Injection pump, installation and adjustment (TAMD63.) and TAMD72P-A).
24. Not applicable for TAMD63P-A which is equipped with stroke position sensor, and TAMD72P-A. Not applicable for TAMD63P-A which lacks stroke position sensor. Idle speed, adjustment. 27 Feed pump, replacement.
28 Feed pump, renovation. 29 Fuel supply pressure, checking. 30 Fuel shut-off valve, trouble shooting.
31 Fuel shut-off valve, renovation. 31 Seal in pump drive, replacement (TAMD61, -62, -71). 32 Seal in pump drive, replacement (TAMD63, -72). 33 Injector, replacement. 35 Injector, renovation.
36 Copper sleeve, cleaning. 36 Recommendations for adjustment of opening pressure, adjustment pressure and replacement of fuel injectors. 37 Opening pressure, adjustment. 38 Fuel filter, replacement. 39 Fuel system, venting.
39 Information on Safety Introduction The Workshop Manual contains technical data, descriptions and repair instructions for the products or product versions from Volvo Penta indicated in the contents. Make sure that the correct literature is used. Read the following Information on Safety and the Workshop Manual’s “General Information” and “Repair Instructions” carefully before service work is begun. Important The following special warning signs are used in the Workshop Manual and on the products. Failure to follow the instructions can result in personal injury, extensive damage to the product or property, or serious malfunctioning.
Used to attract attention to what can cause injury, malfunction, or damage to property. Used to attract attention to important information for the simplification of work processes or handling. To provide a general understanding of the risks and precautions to which attention should always be given we have made the following list. Prevent starting the engine by switching off the power with the main switch(s) and locking it (them) before service work is begun.
Attach a warning label on the instrument panel. All service work should as a rule be conducted with an idle engine. Some work, e.g.
Certain adjustments, require the engine to be running. Approaching an engine which is running is a safety risk. Remember that loose clothes or long hair can fasten in rotating parts and cause severe personal injuries. If work is conducted in the vicinity of an engine which is running, an unintentional movement or dropped tool can lead to personal injury. Observe care with hot surfaces (exhaust pipe, turbo, air pressure pipe, starter element, etc.) and hot liquids in pipes and hoses on an engine which is running or has just been switched off.
Refit all guards dismantled during service work before starting the engine. Make sure that the warning or information labels on the product are always clearly visible.
Replace labels which have been damaged or painted over. Engines with turbo compressor: Never start the engine unless the air filter is fitted. The rotating compressor wheel in the turbo can result in serious personal injuries.
Foreign objects in the intake can also result in damage to the engine. Never use start spray or the like to assist starting. This can cause explosion in the intake pipe. Risk of personal injury. Avoid opening the filler cap for coolant (fresh water cooled engines) when the engine is hot. Steam or hot coolant can spray out.
Volvo Penta Service Manual
Open the filler cap slowly and release the overpressure in the cooling system. Observe great care if the tap, plug or coolant pipe must be dismantled when the engine is hot.
Steam or hot coolant can flow out unexpectedly. Hot oil can cause burn injuries. Avoid skin contact with hot oil. Make sure that the oil system is pressureless before staring work. Never start or run the engine with the oil fill cap removed in view of the risk of oil splash. Stop the engine and close the bottom valve before working on the cooling system.
Only start the engine in a well ventilated area. When running the engine in enclosed areas the exhaust fumes and crankcase gases shall be led out of the engine compartment or workshop area. Always use protective goggles when working where this is risk of splinters, sparks, splashing acid or other chemicals. The eyes are extremely sensitive, an injury can result is the loss of sight! Avoid skin contact with oil! Prolonged or repeated skin contact with oil can lead to degreasing of the skin, resulting in irritation, drying out, eczema and other skin complaints.
From the health aspect used oil is more dangerous than new. Use protective gloves and avoid oil drenched clothes and rags. Wash regularly, especially before meals. Use skin cream for this purpose to counteract drying out and to simplify cleaning of the skin. The majority of chemicals intended for the product (e.g.
Engine and transmission oils, glycol, petrol and diesel) or chemicals for workshop use (e.g. Degreasing agents, varnishes and solvents) are hazardous to health. Read the instructions on the pack carefully! Always follow prescribed safety instructions (e.g.
The use of breathing protection, protective goggles and gloves, etc.) Ensure that other personnel are not unintentionally exposed to hazardous substances, e.g. Via breathing the air. Ensure good ventilation. Handle consumed and excess chemicals in the prescribed manner. Observe great care when looking for leaks in the fuel system and testing fuel injectors.
Wear protective goggles. The jet from a fuel injector has a very high pressure and high penetration capacity; the fuel can penetrate deeply into body tissue and cause severe injuries. Risk of blood poisoning. All fuel, in similarity with many chemicals, is inflammable.
Make sure that naked flames or sparks cannot cause ignition. Petrol, certain thinners and hydrogen gas from batteries, are in the right proportions with air extremely inflammable and explosive. Smoking prohibited! Ventilate well and take the necessary safety precautions before welding or grinding work is begun in the vicinity. Always have a fire extinguisher easily accessible at the workplace. Make sure that oil and fuel drenched rags, fuel and lubricant filters, are stored safely.
Oil drenched rags can in certain circumstances self-ignite. Old fuel and oil filters are environmentally hazardous waste and should together with consumed lubricant, contaminated fuel, paint residue, solvent, degreasing agent and washing residue, be handed in to an environmental station for destruction. Batteries must never be exposed to naked flames or electric sparks. Never smoke in the vicinity of batteries. Hydrogen gas develops during the charging of batteries, which in combination with air forms detonating gas. This gas is highly inflammable and very explosive. A spark, which can result from an incorrectly connected battery, is sufficient to cause the battery to explode and cause personal injury.
Do not move the connection when starting (spark risk) and do not lean over the batteries. Never confuse the plus and minus terminals when fitting the batteries. This can cause serious damage to ths can cause serious damage to thwith the wiring diagram. Always use protective goggles during the charging and handling of batteries. The battery electrolyte contains strongly corrosive sulphuric acid.
In the event of skin contact wash with soap and plenty of water. If battery acid has come in contact with the eyes, rinse immediately with water and contact a doctor without delay. Stop the engine and switch of the power with the main switch(s) before working on the electrical system. Adjustment of the clutch should be conducted on an idle engine.
Use the lifting hooks mounted on the engine/ reversing gear when lifting the drive unit. Always check that all lifting tackle is in good condition and has the correct lifting capacity (weight of engine with reversing gear and extra equipment). For safe handling, and to avoid damaging components fitted on the top of the engine, the engine should be lifted with a lift-bar adjusted to the engine. All chains or wires should run parallel to each other and as far as possible at rightangles to the top of the engine.
Special lifting tackle may be necessary if other equipment connected to the engine changes its centre of gravity, in order to achieve the correct balance and safe handling. Never work on an engine hanging in lifting tackle. Never work alone when heavy components are to be dismantled, even when secure lifting tackle in the form of lockable pulleys are used. Two persons are normally required even when lifting tackle is used, one to manage the lifting tackle and another to ensure that all components are unobstructed and not damaged during the lifting. When working on board a boat always make sure in advance that there is sufficient space available to facilitate dismantling in situ, without risk of personal injury or damage to materials. Components in the electrical system, in the ignition system (petrol engines), and in the fuel system on Volvo Penta products are designed and manufactured to minimise the risk of explosion and fire.
The engine must not be run in environments containing explosive media. Always use fuel recommended by Volvo Penta. See the Instruction Manual.
The use of inferior fuel can damage the engine. On a diesel engine the use of inferior fuel can lead to jamming of the control rod and over-revving of the engine, with the risk of both damage to the machine and personal injury.
Inferior fuel can also lead to high maintenance costs. General information About the Workshop Manual Certified engines This Workshop Manual contains technical data, descriptions and repair instructions for the standard version of engine units TAMD61A, TAMD62A, TAMD63P-A, TAMD63L-A, TAMD71A, TAMD71B, TAMD72A, TAMD72WJ-A, and TAMD72P-A. The Workshop Manual shows the work procedure conducted on an optional engine as per the above specification, and therefore the illustrations and photographs of certain details may not fully correspond with other engines.
The repair methods, however, remain the same in all their critical parts. If this should not be the case important differences will be reported separately. The engine designation and number is indicated on the rating plate (see Workshop Manual Group 21 Engine page 15). The engine designation and number should be stated on all correspondence concerning an engine. The Workshop Manual is primarily produced for Volvo Penta service workshops and their qualified personnel.
It is therefore assumed that persons using this manual have basic competence on marine drive systems and can conduct work of a mechanical/electrical nature attendant to this profession. Volvo Penta continuously develops its products, and therefore we reserve the right to change technical specifications without prior notice. All information in this manual is based on product data available prior to press. Any modifications of critical importance introduced on the product or service methods after this date are confirmed in the form of Service Bulletins.
Spare parts Spare parts for the electrical and fuel systems are subject to different national safety regulations, e.g. US Coast Guard Safety Regulations. Volvo Penta Genuine Parts comply with these regulations.
All types of damage occurring as a result of the use of non genuine Volvo Penta parts for the product in question will not be regulated by the warranty undertakings of Volvo Penta. For engines which are certified for national and regional environmental legislation the manufacturer undertakes to ensure compliance with environmental regulations both for new engines and those in use. The product must comply with the approved example on certification.
In order for Volvo Penta as manufacturer to ensure that engines in use comply with the set environmental regulations the following requirements for service and spare parts must be fulfilled:. Service intervals and maintenance procedures recommended by Volvo Penta must be followed.
Only Volvo Penta Genuine Parts, intended for the certified engine version, must be used. Service which includes the ignition system, ignition adjustment and fuel injection system (petrol) or injection pumps, pump adjustment and injectors (diesel) shall always be conducted by an authorised Volvo Penta workshop. The engine must not be rebuilt or modified in any way, with the exception of the accessories and service sets which Volvo Penta has developed for the engine.
Installation modifications on exhaust pipes and air intake channels for engine chambers(ventilation channels) must not be made, since this can influence exhaust emissions. Seals must not be broken by unauthorised personnel. When spare parts are required use only Volvo Penta Genuine Parts. The use of non genuine parts implies that AB Volvo Penta no longer assumes responsibility for the compliance of the engine with the certified version.
All types of damage or costs occurring as a result of the use of non genuine Volvo Penta parts for the product in question will not be regulated by Volvo Penta. Repair instructions The work methods described in the Workshop Manual are applicable for a workshop environment. The engine is therefore removed from the boat and mounted in an engine block.
Renovation work which does not require removal of the engine is conducted in situ with the same work methods, unless otherwise stated. The warning symbols used in the Workshop Manual (see Information on Safety for implication) WARNING! These are in no way comprehensive, since we obviously cannot foresee everything, in that service work is conducted under the most various conditions. We can therefore only point out the risks which we consider can arise as a result of incorrect handling during work in a well-equipped workshop with work methods and tools which are proven by us.
In the Workshop Manual all the work procedures for which there are special Volvo Penta tools are conducted with these. The special tools are specially produced to facilitate the most safe and rational work method possible. It is therefore the responsibility of persons using other tools or another work method than that which we recommend to ensure that no risk of personal injury, material damage or malfunction can occur. In some cases there may be special safety instructions and user instructions for the tools and chemicals named in the Workshop Manual. These instructions shall always be followed and there are no special instructions for this in the Workshop Manual.
By means of taking certain elementary procedures and using a modicum of common sense, most risk factors can be prevented. A clean workplace and a clean engine eliminate many risks both of personal injury and malfunction. Especially during work on the fuel system, lubrication system, induction system, turbo, bearing unions and sealing unions, it is of the greatest importance that dirt or foreign particles do not get in, since this can result in malfunctioning or shorten 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 the correct setting, and that Volvo Penta Genuine Parts are used for the engine. The time intervals in the engine’s maintenance schedule must be followed. Certain systems, e.g. Components in the fuel system, may require special competence and special test equipment. Certain components are sealed at the factory for environmental reasons.
Work on sealed components must not be conducted unless authorisation for such work is held. Remember that most chemical products, incorrectly used, are hazardous to the environment. Volvo Penta recommends the use of biologically decomposing de- greasing agents for all cleaning of engine components, unless otherwise stated in the Workshop Manual. When working on board a boat pay special attention to make sure that oils and washing residue are handled correctly for destruction, and do not unintentionally end up in the nature, e.g. In the bilge-water. Tightening torque Tightening torque for vital unions, which should be tightened with dynamometric wrenches, is listed in “Specifications: Tightening torque” and indicated in the manual’s work descriptions. All torque indications are applicable for cleaned threads, screw heads and mating surfaces.
The torque indications refer to lightly oiled or dry threads. If lubricants, locking liquids or sealants are required for the screw union, the type is indicated in the work description and in “Tightening torques”. General tightening torque as per the table below is applicable for unions where special torque indications are not given. The torque indication is a standard value and the union does not require tightening with a dynamometric wrench. Size Tightening torque Nm ft.Ib M5 64.4 M6 10 7.4 M8 25 18.4 M10 50 36.9 M12 80 59.0 M14 140 103.3 Angular tightening torque For angular tightening torque the screw union is tightened with a given torque, thereafter further tightening with a predetermined angle. Example: at 90° angular tightening the union is tightened and an additional 1/4 turn is made in a work procedure after the given tightening torque has been reached. Lock nuts Dismantled lock nuts shall not be reused but replaced with new items, since the locking properties diminish or are lost with repeated use.
For lock nuts with plastic inserts, e.g. Nylock®, the tightening torque given in the table shall be reduced if the Nylock ® nut has the same nut height as a standard full- metal hexagonal nut. The tightening torque is reduced by 25% for screw size 8 mm or larger. For Nylock ® nuts with higher nut heights, where the full- metal thread is equally high as a standard hexagonal nut, the tightening torque as per the table are applicable. Strength classes Screws and nuts are divided into different strength classes; affiliation is indicated by the marking on the screw head. A higher number on the marking represents a stronger material, e.g. A screw marked 10–9 has a higher strength than a screw marked 8–8.
It is therefore important when dismantling screw unions that the screws are refitted in their original places. For replacement of screws see the Parts Catalogue to ensure that the correct version is obtained. Sealants A number of different sealants and locking liquids are used on the engine.
The properties of the mediums differ, and they are intended for different union strengths, temperature ranges, resistance to oils and other chemicals, and for the different materials and column sizes in the engine. In order to conduct satisfactory service 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 is important that the surfaces are free from oil, grease, paint and anti-rust agent, and that they are dry.
Always follow the instructions of the manufacturer concerning application temperature, hardening time and other instructions for the product. Two different basic types of agents are used on the engine, and these are characterised by: RTV-agent (Room temperature vulcanising). Most often used with gaskets, e.g. Sealing of gasket joints or applied on gaskets. RTV-agent is fully visible when the part has been dismantled: old RTV-agent must be removed before the union is sealed again.
The following RTV-agents are named in the Workshop Manual: Loctite® 574, Volvo Penta 840879-1, Permatex®. 3, Volvo Penta 1161099-5, Permatex® No. Old sealant is removed in each case with denatured spirit. Anaerobic agents. These agents harden on the absence of air. The agent is used when two solid parts, e.g.
Cast components, are fitted together without gasket. A common application is also to secure and seal plugs, threads on pin bolts, taps, oil pressure relays, etc. Hardened anaerobic agents are transparent and therefore they are coloured to make them visible. Hardened anaerobic agents are very resistant to solvents and old agent cannot be removed. Careful de- greasing is conducted prior to refitting, and new sealant is applied. The following anaerobic agents are named in the Workshop Manual: Loctite® 572 (white), Loctite® 241 (blue).
Loctite® is a registered trade-mark for Loctite Corporation, Permatex® is a registered trade-mark for Permatex Corporation. Safety instructions for fluorocarbon rubber Fluorocarbon rubber is a common material used in seals for shafts and O-rings.
When fluorocarbon rubber is exposed to high temperatures (over 300° C) hydrofluoric acid can be formed, which is strongly corrosive. Contact with the skin can result in serious burn injuries. Contact with the eyes can result in malignant ulcers. Inhalation of fumes can injure the respiratory passages. Observe great care during work on engines which can have been exposed to high temperatures, e.g. Overheating during seizing or fire.
Seals must never be burned loose during dismantling or subsequently burned in an uncontrolled manner. Always wear gloves of chloroprene rubber (gloves for handling chemicals) and protective goggles. Handle the removed seal in the same way as corrosive acid. All residue, including ash, can be strongly corrosive.
Never use compressed air to blow clean. Place the residue in a sealed plastic tin provided with a label. Gloves are washes under running water before taking them off. The following seals are in all probability manufactured of fluorocarbon rubber: Seals for crankshafts, camshafts, intermediate shafts. O-rings irrespective of where they are fitted. O-rings for cylinder lining sealing are almost always of fluorocarbon rubber. Note that seals which have not been exposed to high temperatures can be handled as normal.
Special tools In all cases where it has been practically possible the tools have been stamped with a tool number, excluding the last digit. The last digit (after the hyphen) is a control number. 990 996 998 99065-0 Pressure gauge for checking of charging 9996779-6 Extractor for seal in pump drive, pressure. TAMD61, -62, -71.
9996066-8 Nipple for checking of supply pressure. 9996848-9 Adjusting tool for injection pump.
9996640-0 Mandrel, used together with extractor 9998011-2 Extractor for seal in pump drive, 99968011. 9996643-4 Extractor for injectors. 9998012-0 Mandrel for positioning of seal in pump drive, TAMD63, -72. 9996670-7 Filter key for fuel filter. 9996778-8 Tool for pressing in seal for pump drive, TAMD61, -62, -71. Other special equipment 9812546-1 Tap brush for cleaning of injector’s copper sleeve.
9987057-8 Adjusting tool for fuel pump’s injection angle. 9989876-9 Dial gauge 0.8 in.
6 Design and function General The main parts of the fuel system are the fuel tank with fitting, feed pump, two fuel filters, injection pump, fuel injectors and pipelines. The fuel is induced by the feed pump from the fuel tank and pressed through the fine filter to the injection pump. Excess fuel returns through the overflow valve (placed on the injection pump) back to the tank. This implies that return fuel flushes through (cools) the injection pump’s fuel chamber. The temperature of the fuel is thus equalised (and becomes the same for all the engine cylinders) while gas bubbles in the fuel are avoided. The injection pump then presses at high pressure a fuel volume corresponding to the power requirement through the delivery pipe to the injectors, which atomises the fuel in the engine’s combustion chambers. Return fuel from the fuel injectors is led through the leak-off pipe via the overflow valve and return pipe back to the tank.
Note: Certain of the illustrations in this chapter have been kindly put at our disposal by Robert Bosch AB. Fuel system 1 Fuel fine filter 2 Venting screw 3 Delivery pipe from intake pipe (charging pressure) 4 Injection pump 5 Delivery pipe 6 Fuel injector 7 Leak-off pipe 8 Pressure equaliser 9 Centrifugal regulator 10 Overflow valve 11 Return pipe, lubricant 12 Return pipe to fuel tank 13 Fuel pipe, intake 14 Feed pump 15 Hand pump 16 Lubricant pipe, intake 17 Smoke limiter Injection pump The injection pump is placed on the left-hand side of the engine and is driven from the timing gears. The pump, which is of the piston type, is equipped with 6 pump elements (6), one for each engine cylinder, which pump the fuel under high pressure to the engine’s combustion chambers. Each pump element consists of piston and cylinder, where the piston is pressed up by the pump’s camshaft (11) by means of a lifter (10), and pressed back by the piston spring (9). The piston has a constant stroke length and is actuated by the regulator, via a control rod (7), which turns the piston during operation, whereby the injected fuel volume can be modified. The injection pump is lubricated by means of the engine’s lubricating system. The pump element’s pump function A.
When the piston is in its lower position the pressure chamber over the piston is filled with fuel from the fuel pump. When the piston moves up in the cylinder the fuel supply is shut off. The fuel above the piston is compressed, the pressure increased, and the pressure valve (1) opens. When the piston has reached a certain height in its upward going movement the relief hole (2) is exposed (also designated inlet hole when the piston is in its lower position).
The fuel flows back via the zero channel (3) and the piston’s spiral shaped channel (4). The pressure above the piston reduces and the pressure valve (1) is closed. The excess fuel is returned back to the fuel tank. The pump element’s control function The pump element’s control function is controlled by the regulator, which via the control rod turns the pump piston. Depending on the position of the piston in the cylinder the length of the injection time and injection volume can vary in that the piston’s spiral shaped channel (4) opens the connection with the relief hole.
If the piston is turned so that the vertical channel (3) (zero channel) on the pump piston comes opposite the relief hole (2) the fuel will flow back during the full piston stroke to the pump’s fuel chamber and the engine will stop. Injection pump 1 Delivery valve retainer 7 Control rod 2 Thrust plate 8 Control sleeve 3 Sealing ring 9 Piston spring 4 Delivery valve 10 Lifter 5 Flange bushing 11 Camshaft 6 Pump element AB C The pump element’s pump and control function Regulator The regulator has the purpose of controlling the fuel volume to the engine’s combustion chambers by means of activating the throttle control. The regulator is available in two versions:.
Centrifugal regulator which is mechanical and is used on engine versions TAMD61A, -62A, -63P-A, -63L-A, -71A, -71B, -72A, and -72WJ-A. Electromagnetic actuator which is electronic and is used on the engine version TAMD72P-A. The mechanical regulator works with speed sensing regulator weights. The speed is controlled over the full speed range of the engine, from low idle to high idle. The electromagnetic actuator is controlled from an electronic control unit which collects information from a number of sensors placed on the engine and control. The control unit calculates with the help of this information the injection volume for each load case.
The illustrations below show the differences between a mechanical regulator and an electromagnetic actuator. Principle diagram of injection pump with Centrifugal regulator 1 Max. Fuel volume 2 Min.
Fuel volume 3 Full throttle 4 Idle A Control rod B The injection pump’s camshaft C Lever D Centrifugal regulator Principle diagram of injection pump with electromagnetic actuator 1 Max. Fuel volume 2 Min. Fuel volume 3 Full throttle 4 Idle 5 Position sensor for control rod 6 Actuator 7 Speed sensor A Control unit B Actuator Two different basic types of centrifugal regulator are used, RSV and RQV. The RQV regulator is available in two versions, RQV and RQV-L. The electromagnetic actuator is designated RE. The main difference between RQV and RQV-K is that the RQV-K regulator can both increase and decrease the fuel volume during equalising at full load, while the RQV regulator’s equalising only gives a reduction of the fuel volume. The following list shows which regulator type is used for the different engine versions: – TAMD61A, -62A, -63L-A and -71A/B have a regulator of the RSV type.
– TAMD 63-P-A has an RQV regulator. – TAMD72A and -72WJ-A have an RQV-K regulator.
– TAMD72P-A (EDC) has an RE regulator.