Volvo Penta TAD1250VE, TAD1251VE, TAD1252VE Group 21-26 Workshop Manual_441403095 – PDF DOWNLOAD

Volvo Penta TAD1250VE, TAD1251VE, TAD1252VE Group 21-26 Workshop Manual_441403095 – PDF DOWNLOAD

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Volvo Penta TAD1250VE, TAD1251VE, TAD1252VE Group 21-26 Workshop Manual_441403095 – PDF DOWNLOAD

TAD1250VE, TAD1251VE, TAD1252VE

Safety information
Introduction
The workshop manual contains descriptions and repair
instructions for products or product versions noted in
the table of contents, supplied by Volvo Penta. This
manual should be used together with the workshop
manual Technical data for each engine. Check that
you have the correct workshop manual for your engine.
Read this safety information and the workshop manual
General information and Repair instructions carefully
before service work is started.
Important
In this book and on the product you will find the following
special warning symbols.
WARNING! Warns for the risk of personal injury,
major damage to product or property, or serious
malfunctions if the instruction is ignored.
IMPORTANT! Is used to call attention to things
which could cause damage or malfunctions to
product or property.
NOTE! Is used to call attention to important information,
to facilitate work processes or operation.
To give you a perspective on the risks which always
need to be observed and precautions which always
have to be taken, we have noted them below.
Make it impossible to start the engine by cutting
system current with the main switch(es)and lock
it (them) in the off position before starting service
work. Set up a warning notice by the helm
station.
All service work should normally be done on a
stationary engine. Some work, such as adjustments,
need the engine to be running, however.
Approaching an engine which is operating is a
safety hazard. Remember that loose clothing or
long hair can fasten in rotating parts and cause
serious personal injury.
If work is done adjacent to a running engine, a
careless movement or a dropped tool can lead
to personal injury in the worst case. Take care
to avoid contact with hot surfaces (exhaust
pipes, Turbocharger, air intake pipe, starter
heater etc.) and fluids in pipes and hoses in an
engine which is running or has just been
stopped. Reinstall all protective parts removed
during servicework before starting the engine.
Check that the warning or information labels on
the product are always clearly visible. Replace
labels which have been damaged or painted
over.
Never start the engine without installing the air
cleaner filter. The rotating compressor turbine in
the turbocharger can cause severe injury. Foreign
objects entering the intake ducts can also
cause mechanical damage.
Never use start spray or similar products as a
starting aid. They may cause an explosion in
the inlet manifold. Danger of personal injury.
Only start the engine in a well- ventilated area.
When operated in a confined space, exhaust
fumes and crankcase gases must be ventilated
from the engine bay or workshop area.
Avoid opening the coolant filling cap when the
engine is hot. Steam or hot coolant can spray
out and the system pressure will be lost. When
needed, open the filler cap slowly and release
the pressure in the system. Be extremely careful
if a tap, plug or coolant hose has to be removed
from a hot engine. Steam or hot coolant
might spray out in an unexpected direction.
Hot oil can cause burns. Avoid skin contact with
hot oil. Ensure that the lubrication system is not
under pressure before carrying out any work.
Never start or operate the engine with the oil filler
cap removed, otherwise oil could be ejected.
Stop the engine before carrying out operations
on the engine cooling system.

TABLE OF CONTENTS:

Volvo Penta TAD1250VE, TAD1251VE, TAD1252VE Group 21-26 Workshop Manual_441403095 – PDF DOWNLOAD

Safety information …………………………………………. 4
Introduction …………………………………………………. 4
General information ………………………………………. 7
About this Workshop Manual …………………………. 7
Standard times (Flat Rate) …………………………….. 7
Spare parts …………………………………………………. 7
Certified engines ………………………………………….. 7
Repair instructions ………………………………………… 8
Our common responsibility …………………………….. 8
Torque ……………………………………………………….. 8
Torque-angle tightening …………………………………. 9
Lock nuts ……………………………………………………. 9
Strength classes ………………………………………….. 9
Sealant ………………………………………………………. 9
Safety rules for Fluorocarbon Rubber …………….. 10
When working with chemicals,
fuel and lubricating oil …………………………………. 10
Before lifting the engine ………………………………. 11
Actions after lifting the engine ………………………. 11
Instructions for work on engines with
electronic fuel injection ……………………………….. 11
Special tools ………………………………………………. 12
Other special equipment ……………………………… 16
Introduction ………………………………………………… 17
Identification numbers …………………………………. 17
Component location ……………………………………. 18
Design and function …………………………………….. 19
Group 21: Engine body………………………………… 19
Engine ……………………………………………………… 19
Cylinder head …………………………………………….. 20
Engine block ……………………………………………… 21
Cylinder liner ……………………………………………… 22
Pistons and con rods ………………………………….. 23
Crankshaft ………………………………………………… 24
Camshaft ………………………………………………….. 25
Valve mechanism ………………………………………. 26
Internal EGR ……………………………………………… 27
Transmission …………………………………………….. 29
Group 22 Lubrication system ……………………….. 30
Function description, lubrication system ………… 30
Oil valves ………………………………………………….. 31
Group 23 Fuel system ………………………………….. 32
Function description, fuel system …………………. 32
Filter housing …………………………………………….. 33
Unit injector, summary ………………………………… 34
Trim code, injector ……………………………………… 34
Unit injector, working phases ……………………….. 35
Group 25 Inlet and exhaust system……………….. 37
Turbocharger ……………………………………………… 38
Group 26: Cooling system ……………………………. 39
Function description, cooling system …………….. 39
Intercooler …………………………………………………. 40
Group 30: Electrical system …………………………. 41
EMS 2 ……………………………………………………… 41
Control unit ……………………………………………….. 41
Electrical component diagram ………………………. 42
Fault tracing ……………………………………………….. 43
Symptoms and possible causes …………………… 43
Malfunctions ……………………………………………… 44
Blockage …………………………………………………… 44
Tests and settings ……………………………………….. 45
Charge pressure, fault tracing ………………………. 45
Turbocharger, inspection ……………………………… 47
Supply pressure …………………………………………. 48
Service work ……………………………………………….. 49
Compression test ……………………………………….. 49
Timing marks …………………………………………….. 52
Adjustment, general ……………………………………. 52
Valves, adjustment …………………………………….. 53
Double rocker arm, inspection (iEGR) ……………. 55
Double rocker arm, adjustment …………………….. 57
Engine oil, changing ……………………………………. 58
Oil filter/By-pass filter, change ……………………… 59
Fuel filter, change ………………………………………. 60
Primary fuel filter, change ……………………………. 61
Fuel system, draining ………………………………….. 62
Draining condensate …………………………………… 62
Venting the fuel system ………………………………. 63
Instructions for operating the starter motor ……… 64
Exhaust system, inspection …………………………. 65
Pressure drop indicator/air filter,
inspection/change ………………………………………. 65
Cooling system, draining ……………………………… 66
Cooling system, cleaning …………………………….. 67
Cooling system, pressure testing ………………….. 68
Cooling system, filling …………………………………. 70
Coolant filter, change ………………………………….. 71
Alternator belt / Drive belt, inspection…………….. 72
Alternator belts, change ………………………………. 72
Drive belt, change ………………………………………. 73
Checking the pressure test unit …………………….. 74
Installing the engine fixture ………………………….. 75
Overhaul / Change components ……………………. 76
Group 21: Engine body………………………………… 76
Cylinder head, removing ………………………………. 76
Cylinder head, installation ……………………………. 89
Cylinder liners and piston, inspection …………….. 93
Cylinder liners and pistons, change (all) …………. 94
Cylinder liners, installation …………………………… 96
Pistons, change …………………………………………. 98
Camshaft, inspection and overhaul ……………….100
Camshaft, wear check ………………………………..102
Bearing housing for camshaft, change …………..103
Camshaft, installation …………………………………104
Crankshaft, inspection and overhaul ……………..108
Main bearings, change (all) ………………………….110
Big end bearings, change (all) ………………………113
Flywheel bearing, change …………………………….114
Flywheel, change ……………………………………….115
Gear ring, change……………………………………….117
Flywheel, indication …………………………………….118
Crankshaft seal, front, change ……………………..119
Crankshaft seal rear, change ……………………….121
Con rod, inspection …………………………………….123
Gudgeon pin bushing, check measurement …….123
Valves, removing ……………………………………….124
Valves, installation ……………………………………..126
Valve seat, change …………………………………….127
Valve guides, inspection ……………………………..129
Valve guides, replacing ……………………………….130
Valve stem seals, change ……………………………131
Valve seats, grinding ………………………………….133
Valves, grinding …………………………………………134
Cylinder head, pressure testing …………………….135
Copper sleeve for injector, changing ……………..139
Timing gear, changing …………………………………143
Group 22: Lubrication system ………………………158
When working with chemicals,
fuel and lubrication oil …………………………………158
Reduction valve, change ……………………………..158
Safety valve, change ………………………………….159
Piston cooling valve, change ……………………….160
Bypass valve, oil filter, change …………………….161
By-pass valve, by-pass filter, change ……………162
Bypass valve, oil cooler, change ………………….163
Sump gasket, change …………………………………164
Piston cooling nozzle, change ……………………..166
Oil filter, change …………………………………………167
Lube oil pressure, check ……………………………..170
Oil cooler, change ………………………………………171
Oil cooler, leakage test ……………………………….175
Group 23: Fuel system …………………………………176
Control unit, change ……………………………………176
Feed pump, changing ………………………………….178
Feed pump, renovation ……………………………….179
Bypass valve, changing ………………………………181
Unit injector, change …………………………………..182
Group 25: Inlet / Exhaust systems ………………..186
Inlet pipe, gasket change …………………………….186
Manifold, gasket change ……………………………..190
Turbo, replacing …………………………………………194
Group 26: Cooling system ……………………………198
Coolant pump, change ………………………………..198
Thermostat, function check………………………….203
Thermostat, change ……………………………………204
Charge air cooler, change ……………………………205
Charge air cooler, leakage test ……………………..206
Charge air cooler, cleaning …………………………..208
Radiator matrix, change ………………………………209
Technical data …………………………………………….214
General …………………………………………………….214
Torque ……………………………………………………..215
References to Service Bulletins ……………………219
Alphabetical register ……………………………………220

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