Volvo Penta TAD1240GE, TAD1241GEVE, TAD1242GEVE, TWD1240VE Group 21 Workshop Manual_336052407 – PDF

Volvo Penta TAD1240GE, TAD1241GEVE, TAD1242GEVE, TWD1240VE Group 21 Workshop Manual_336052407 – PDF Download

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Volvo Penta TAD1240GE, TAD1241GEVE, TAD1242GEVE, TWD1240VE Group 21 Workshop Manual_336052407 – PDF Download

TAD1240GE, TAD1241GE/VE
TAD1242GE/VE, TWD1240VE

Safety information
Introduction

This Service Manual contains descriptions and repair
instructions for the Volvo Penta products or product
versions listed in the table of contents. This manual
should be used together with the Service Manual
Technical data for the relevant engine. Be sure to
use the correct service literature.
Carefully read the safety information and General information
and Repair instructions in the Service
Manual before starting service work.
Important
This following special warning symbols are found in
the Service Manual and on the product.
WARNING! Warns for the risk of injury, damage
to the product or property or that serious malfunctions
could arise if the instructions are not
followed.
IMPORTANT! Used to draw attention to anything
that could cause injury or the malfunction of
a product or property.
NOTE:Used to draw attention to important information
to facilitate work operations or handling.
To provide an overview of the dangers of which you
should always be aware and the precautionary measures
that should always be taken, we have listed them
here.
Make it impossible for the engine to start. Turn
off the current by means of the main switch (or
switches) and lock it (them) in the off position
before starting service work. Affix a warning
sign in the driver’s area.
As a rule, all service work should be performed
when the engine is switched off. However, some
work, such as certain adjustments, requires the
engine to be running. Approaching a running
engine could be dangerous. Bear in mind that
loose-fitting clothes or long hair could get caught
in rotating parts and cause serious injury.
If work is performed near a running engine, an
incautious movement or dropped tool could in
the worst case lead to bodily harm. Be mindful
of hot surfaces (exhaust pipes, the turbocharger,
charge air pipes, starter elements, etc.) and
hot liquids in lines and hoses on an engine that
is running or has just been stopped. Before starting
the engine, refit all guards and protective
elements that were removed in the course of
performing service work.
Make sure that the warning and/or information
decals affixed to the product are always in plain
sight. Replace any decals that have been damaged
or painted over.
Never start the engine unless the air filter is fitted.
The rotating impeller in the turbocharger
could cause serious injuries. Foreign objects in
the inlet line could also cause machinery damage.
Never use starter spray or the like to help start
the engine. It could cause an explosion in the
inlet manifold. Danger of injury.
Start the engine in well-ventilated areas only. If
the engine is running in a confined space, exhaust
gases and crankcase gases should be
conducted away from the engine compartment
or workshop area.
Avoid opening the coolant filler cap when the
engine is still hot. Steam or hot coolant could
squirt out while the built-up pressure is lost. If
necessary, open the filler cap slowly and release
pressure in the cooling system. Be extremely
careful if a cock, plug or coolant line must be
removed while the engine is still hot. Steam or
hot coolant could squirt out in an unexpected direction.
Hot oil can cause burns. Avoid getting hot oil on
your skin. Make sure that the lubricating system
is depressurized before starting any work on it.
Never start or run the engine with the oil filler
cap removed as oil under pressure could then
escape.
Stop the engine before doing any work on the
cooling system.

TABLE OF CONTENTS:

Volvo Penta TAD1240GE, TAD1241GEVE, TAD1242GEVE, TWD1240VE Group 21 Workshop Manual_336052407 – PDF Download

Safety information ………………………………………… 2
General information ……………………………………… 5
Repair instructions……………………………………….. 6
Special tools ……………………………………………….. 9
Design and Operation
Engine ………………………………………………………. 13
Cylinder head ……………………………………………… 14
Cylinder block/cylinder liners …………………………. 15
Pistons ……………………………………………………… 15
Crankshaft …………………………………………………. 16
Camshaft …………………………………………………… 16
Timing drive ……………………………………………….. 17
Instructions for running the starter motor …………. 18
Repair instructions
When work involves chemicals, fuel
and lubricating oil ………………………………………… 19
Before/after lifting the engine ………………………… 19
Engine jig, attaching ……………………………………. 20
Compression test ………………………………………… 20
Cylinder head, removing ……………………………….. 21
Cylinder head, fitting/removing
jig 885316 ………………………………………………….. 35
Cylinder head, fitting ……………………………………. 37
Cylinder head, leakage check ……………………….. 49
Cylinder head, valves removing/fitting …………….. 53
Valve guides, inspecting ………………………………. 55
Valve guides, changing ……………………………….. 56
Valve seat, changing …………………………………… 57
Valve seat, grinding …………………………………….. 58
Valves, grinding ………………………………………….. 59
Rocker arm mechanism, changing ………………… 59
Valves and unit injectors, adjusting ………………… 60
Cylinder liners and pistons, removing …………….. 64
Cylinder liners and pistons, inspecting …………… 65
Cylinder liner seat, reconditioning ………………….. 66
Cylinder liners, fitting …………………………………… 67
Connecting rod small-end bush, checking
measurements……………………………………………. 69
Piston, changing …………………………………………. 70
Timing gears, changing ……………………………….. 72
Bearing housing for camshaft, changing …………. 84
Camshaft, changing…………………………………….. 84
Camshaft, inspecting and reconditioning ………… 98
Crankshaft, inspecting and reconditioning ………. 98
Big-end bearings, changing all ………………………. 99
Main bearings, changing all ………………………….. 100
Flywheel, changing ……………………………………… 103
Flywheel bearings, changing ………………………… 105
Flywheel, marking ………………………………………. 106
Ring gear, changing …………………………………….. 107
Crankshaft seal, rear, changing …………………….. 108
Index …………………………………………………………… 109

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