VolvoPenta TAD1630G-GE-P-V TAD1631G-GE TID162AP TWD1620G-GH TWD1630G-GE-P-V TD164KAE Workshop Manual

Volvo Penta TAD1630G-GE-P-V, TAD1631G-GE, TID162AP, TWD1620G-GH, TWD1630G-GE-P-V, TD164KAE Workshop Manual_319900372 – PDF DOWNLOAD

FILE DETAILS:

Volvo Penta TAD1630G-GE-P-V, TAD1631G-GE, TID162AP, TWD1620G-GH, TWD1630G-GE-P-V, TD164KAE Workshop Manual_319900372 – PDF DOWNLOAD

Language : English
Pages : 164
Downloadable : Yes
File Type : PDF
Size: 1.86 MB

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Volvo Penta TAD1630G-GE-P-V, TAD1631G-GE, TID162AP, TWD1620G-GH, TWD1630G-GE-P-V, TD164KAE Workshop Manual_319900372 – PDF DOWNLOAD

TAD1630G/GE/P/V, TAD1631G/GE, TID162AP,
TWD1620G/GH, TWD1630G/GE/P/V,
TD164KAE

General information:This Service Manual contains technical data, descriptions and maintenance and repair instructions for standard model Volvo Penta products. A list of these products may be found in the section Specifications. The product designation and the serial number and specification is indicated on the engine decal or type plate.

• This information must be included in all correspondence regarding the product. The service manual is produced primarily for the use of Volvo Penta workshops and their qualified personnel. It is assumed that any person using the Service Manual has a fundamental knowledge of the product and is able to carry out mechanical and electrical work to trade standard.
• Volvo Penta continually develops its products; we therefore reserve the right to make changes. All information in this manual is based on product data which was available up to the date on which the manual was printed. New working methods and significant changes introduced to the product after this date are communicated in the form of Service bulletins.

Spare Parts:

Spare parts for the electrical and fuel systems are subject to various national safety standards. Volvo Penta Original Spare Parts meet these standards. No damage of any kind caused by the use of spare parts not approved by Volvo Penta will be compensated by any warranty undertaking.

About this Workshop manual:

Certification means that an engine type has been inspected and approved by the relevant authority. The engine manufacturer guarantees that all engines of the same type are manufactured to correspond to the certified engine.

This places special demands on service and repair work, namely:
• Maintenance and service intervals recommended by Volvo Penta must be complied with.• Only spare parts approved by Volvo Penta may be used.• Service on injection pumps, pump settings and injectors must always be carried out by an authorized Volvo Penta workshop.• The engine must not be converted or modified, except with accessories and service kits which Volvo Penta has approved for the engine.• No changes to the exhaust pipe and engine air inlet duct installations may be made.• No warranty seals (where present on the product) may be broken by unauthorized persons.The general instructions in the Operator’s Manual concerning operation, service and maintenance apply.

TABLE OF CONTENTS:

Volvo Penta TAD1630G-GE-P-V, TAD1631G-GE, TID162AP, TWD1620G-GH, TWD1630G-GE-P-V, TD164KAE Workshop Manual_319900372 – PDF DOWNLOAD

Contents
General Information 3
Tools 11
Special tools 11
Other special equipment 15
Engine 16
Design and Function 16
Cylinder head 17
Cylinder block 17
Seals 17
Valve mechanism 18
Camshaft 18
Timing gears 18
Crankshaft/pistons 19
Service procedures 20
Engine fixture, attaching 20
Compression test 21
Exposing engine body 21
TAD1630/TAD1631 21
TID162/TWD1620/TWD1630/TD164 21
TAD1630/TAD1631/TID162/TWD1630/TD164 22
Cylinder head, removing 23
Cylinder head, disassembling 24
Cylinder head, pressure testing 25
Cylinder head, inspection 26
Cylinder head, face-grinding 26
Valve guides, inspection 27
Valve guides, replacing 28
Valve seats, replacing 28
Valve seats, grinding 29
Valves, grinding 29
Cylinder head, assembling 30
Cylinder head, installation 30
Rocker arm mechanism, reconditioning 33
Valves, adjusting 34
Copper sleeve for injectors, replacing 36
Cylinder liners and pistons, removing 37
Cylinder liners, measurement and inspection 40
Cylinder liners, honing 40
Cylinder liner seats, reconditioning 41
Cylinder block, face-grinding 42
Pistons, checking 43
Pistons, fitting 43
Piston rings, inspection 43
Connecting rods, inspection 43
Pistons, piston rings and connecting rods,
assembling 44
Cylinder liners and pistons, fitting 45
Sealant between the fuel injection pump bearing housing
and the cylinder block:
TAD1630/TID162/TWD1620/TWD1630/TD164KAE 48
TAD1631 49
Seal on output shaft from timing gear to injection pump, replacing:
TAD1630/TID162/TWD1620/TWD1630/TD164KAE 50
TAD1631 51
Front sealing ring for coolant pump, replacing 53
Sealant, timing gear cover, replacement 54
Timing gears, removing 55
Intermediate gears, replacing bearing 56
Timing gears, fitting 57
Polygon hub, replacing 58
Sealant, transmission gear casing, replacing 59
Camshaft, checking for wear 59
Camshaft, replacing 62
Camshaft bearings, replacing 64
Main bearings, replacing, all 66
Crank bearings, checking for wear or replacing, all 67
Crankshaft, replacing 68
Crankshaft 69
Inspection 69
Reconditioning 71
Flywheel, checking for warp 71
Flywheel, replacing 72
Ring gear, replacing 73
Flywheel casing, checking for warp 73
Flywheel bearing, replacing 74
Crankshaft seal, rear, replacing 75
Crankshaft seal, front, replacing 76
Sealant, flywheel casing, replacing 77
Lubrication system 79
Design and Function 79
General 79
Oil cooler 81
Service procedures 82
Lubricating oil pressure, checking 82
Oil filters, replacing 82
Oil cooler, replacing 83
Oil cooler, leakage test 84
Oil pump, replacing 85
Oil pump, reconditioning 87
Fuel system 90
Design and Function 90
General 90
Fuel filters 90
Injection pump 91
TID162AP/TWD1620G/GH/TWD1630/GE 91
TAD1630P/V/TWD1630P/V/TD164KAE 91
TAD1630G/GE y TAD1631G/GE 92
Smoke limiter TAD1630P/V 94
Feed pump 94
Manual pump 94
Instrucciones de reparación 95
Service procedures 95
Injection pump, removal 95
Fitting and adjusting the injection pump 95
Injection pump, setting with measuring tool 998 7057 98
Pump coupling shaft, removing 101
Checking and replacing pump coupling laminates 101
Injectors 101
Injectors, replacing 102
Injectors, reconditioning 103
Opening pressure, adjusting 104
Fuel feed pressure, checking 104
Fuel filters, replacing 105
Feed pump, replacing 105
Feed pump, reconditioning 106
Smoke limiter, TAD1630P/V 107
Replacing the diaphragm 107
Fuel system, bleeding 108
Intake and exhaust systems 109
Design and Function 109
Charge air cooler 109
Turbocharger 109
Air filter 110
Starter heater 110
Exhaust manifold 110
Service procedures 111
Boost pressure, checking 111
Rectifying low boost pressure 112
Checking exhaust back pressure 113
Turbocharger, checking bearing clearance 113
Schwitzer S4T and Holset H3B 113
Turbocharger, reconditioning 115
Schwitzer S4T y TAD1630/1631 115
Holset, TID162/TWD1620/TWD1630 120
Measures in case of turbo failure on TAD- engines 123
Turbocharger, replacing/refitting on engine 123
Charge air cooler, checking for leakage,
TAD-engines 124
Cooling system 125
Design and Function 125
General 125
Service procedures 128
Coolant pump, replacing 128
Coolant pump, reconditioning 130
Sleeve thermostats, replacing 140
Sleeve thermostats, checking 141
Coolant manifold seals, replacing 142
Coolant 144
Anti-freeze 144
Volume 144
Anti-corrosion additives 144
Checking coolant level 144
Draining the coolant 144
Coolant, filling 145
Coolant temperature too high 145
Coolant temperature too low 145
Temperature gauge, checking 145
Level switch, checking 145
Coolant leakage 146
Radiator and charge air cooler, checking 146
Drive belts, adjusting 146
Cooling system, cleaning 146
Cooling system, pressure-testing 147
Checking pressure-testing device 999 6662 147
Pressure testing 147
Pressure valve, checking 148
Electrical system 149
Important 149
Arc welding 149
Starting with auxiliary battery 149
Electronic speed governor, wiring 150
Wiring diagrams 151
Troubleshooting 156