Workshop Manual Engine D 2(0) TAMD61A, TAMD62A, TAMD63L-A, TAMD63P-A TAMD71A, TAMD71B, TAMD72A, TAMD72P-A, TAMD72WJ-A
Group 21 Engine body Marine engines TAMD61A • TAMD62A • TAMD63L-A • TAMD63P-A TAMD71A • TAMD71B • TAMD72A • TAMD72P-A TAMD72WJ-A Contents General instructions ............................................ 2 Special tools ........................................................ 9 Other special equipment ..................................... Design and function Engine, generally ................................................. Design differences, engine versions ................... Identification signs ....
Safety information Introduction This Workshop Manual contains technical data, descriptions and repair instructions for Volvo Penta products or product versions contained in the contents list. Ensure that the correct workshop literature is being used. Read the safety information and the Workshop Manual “General Information” and “Repair Instructions” carefully before starting work. personal injury. Avoid burns.
Safety information Avoid skin contact with oil. Long-term or repeated contact with oil can remove the natural oils from your skin. The result can be irritation, dry skin, eczema and other skin problems. Used oil is more dangerous to health than new oil. Use protective gloves and avoid oil soaked clothes and rags. Wash regularly, especially before meals. Use the correct barrier cream to prevent dry skin and to make cleaning your skin easier.
Safety information Never remove heavy components alone, even where secure lifting equipment such as secured blocks are being used. Even where lifting equipment is being used it is best to carry out the work with two people; one to operate the lifting equipment and the other to ensure that components are not trapped and damaged when being lifted. When working on-board ensure that there is sufficient space to remove components without danger of injury or damage.
General information About the service manual Certified engines This workshop manual contains technical data, descriptions and repair instructions for the standard versions of engine units TAMD61A, TAMD62A, TAMD63L-A, TAMD63P-A, TAMD71A, TAMD71B, TAMD72A, TAMD72P-A, TAMD72WJ-A. On engines which are certified in accordance with national and regional regulations (e.g. Bodensee), the manufacturer guarantees that the requirements are met by both new engines and engines in service.
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.
Safety information 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.
Safety information Safety rules for fluorocarbon rubber Fluorocarbon rubber is a common material in seal rings for shafts, and in O-rings, for example. When fluorocarbon rubber is subjected to high temperatures (above 300°C), hydrofluoric acid can be formed, which is highly corrosive. Skin contact can give severe chemical burns. Splashes in your eyes can give severe chemical burns. If you breathe in the fumes, your lungs can be permanently damaged.
Special tools In all cases where it is practical, tools have had their part number punched on, but not the last figure. The last figure (after the dash) is a check sum figure. 884948 884949 9812546 9992655 9992658 9991084 9991459 9992661 9991801 9992669 9991867 9992677 9992000 9992679 9992071 9992178 9996087 9996169 9992479 9996394 9992497 9996395 9992497-9 Drift for removal/installing con rod bush, 7(x) series.
Special tools 9996421 9996400 9996402 9996650 9996651 9996419 9996433 9996437 9996643 9996420 9996657 9996841 9996662 9996645 9996842 9996847 9996400-9 Impact hammer. Used with 9996419 or 9996657.
Special tools 9998114 9996852 9996855 9996861 9996867 9998009 9998070 9998079 9999508 9999553 9996878 9996852-1 Connection washer for pressure testing the cylinder block 9996855-4 Mandrel for installing the front crankshaft seal 9998115 9998070-8 Tool for installing the copper sleeve and steel ring, 6(x) series.
Other special equipment 885126 9988539 9989876 Other special equipment 885126-3 Piston ring compressor 9988539-4 Compression gauge 9989876-9 Dial gauge 0–20 mm 9999696-9 Magnetic stand 12 9999696
Design and function Engine, general The engines are straight 6-cylinder, 4-stroke diesel engines with overhead valves. They have direct fuel injection and turbocharging. Since the induction air is cooled, the combustion and exhaust temperatures are kept at a suitable level, despite the higher power output. The engines have wet, replaceable cylinder liners and two separate cylinder blocks, each of which contains three cylinders. The cylinder blocks are mutually interchangeable.
Design and function Design differences, engine versions This workshop manual applies to all engines of the 6(x) series; TAMD61A, TAMD62A, TAMD63L-A and TAMD63P-A, and from the 7(x) series; TAMD71A, TAMD71B, TAMD72A, TAMD72P-A and TAMD72WJ-A. l New sea water pump l Stop function with solenoid valve l New electrical system with sealed connectors and cables run in flexible hoses.
Design and function TAMD72A – TAMD72WJ-A l TAMD72WJ-A is a TAMD72A which has been modified for use with a water jet unit. TAMD72WJ-A has: Electronic box (EDC) added, located beside the rear fuel filter l Stop solenoid deleted (the engine is stopped by the EDC system) l New injection pump with changed settings.
Design and function Engine presentation TAMD61A 1 2 5 4 3 6 7 8 14 13 1 2 3 4 5 6 7 12 11 10 Junction box with circuit breakers Coolant filler cap Fuel filter Oil filler cap (also at front edge of engine) Injection pump Stop solenoid Turbocharger 1 2 9 8 9 10 11 12 13 14 3 Oil cooler, reverse gear Reverse gear, MPM IRM 220A Dipstick (alternative location) Oil cooler, engine Smoke limiter Circulation pump Alternator 4 5 6 7 9 13 1 2 3 4 5 6 7 16 12 2 Turbocharger Air filter Relay for
Design and function TAMD62A 2 3 4 5 6 1 7 14 1 2 3 4 5 6 7 13 12 Air filter By-pass valve (directs air flow through aftercooler) Filter for crankcase breather Aftercooler Heat exchanger Expansion tank Sea water pump 11 10 9 8 8 Lubrication oil filter (alt.
Design and function TAMD63L-A, TAMD63P-A 1 2 14 1 2 3 4 5 6 7 8 14 18 13 5 Filter for crankcase breather Air filter Aftercooler Relay for electric starting heater Oil filler cap Expansion tank Coolant filler cap Heat exchanger 2 3 6 12 11 Fuel filter, fine Smoke limiter Coolant filler cap Injection pump Oil filler cap Junction box with circuit breakers Turbocharger Water cooled exhaust riser (extra equipment) 1 1 2 3 3 4 5 6 7 3 4 7 8 10 9 9 10 11 12 Reverse gear, MPM IRM 220A-1 TAMD63P-A
Design and function TAMD71A 1 2 3 4 5 6 7 8 12 10 11 1 2 3 4 5 6 9 Junction box with circuit breakers Coolant filler cap Fuel filter Oil filler cap (also at front edge of engine) Injection pump Stop solenoid 7 8 9 10 11 12 1 2 3 Turbocharger Oil cooler, reverse gear Reverse gear, TD MG507 Oil cooler, engine Smoke limiter Circulation pump 4 5 9 14 1 2 3 4 5 6 7 8 13 2 12 Turbocharger Air filter Relay for electric starting heater By-pass valve (directs air flow through aftercooler) Expa
Design and function TAMD71B 1 2 3 4 5 6 7 14 8 13 12 1 2 3 4 5 6 7 20 Junction box with circuit breakers Coolant filler cap Fuel filter Oil filler cap Injection pump Stop solenoid Turbocharger 11 10 8 9 10 11 12 13 14 9 Oil cooler, reverse gear Reverse gear, TD MG507A Dipstick (alternative location) Oil cooler, engine Smoke limiter Circulation pump Alternator
Design and function TAMD72A 1 2 3 16 15 1 2 3 4 5 6 7 8 4 14 5 6 13 12 9 10 11 12 13 14 15 16 Junction box with circuit breakers Coolant filler cap Fuel filter Oil filler cap Injection pump Stop solenoid Wastegate valve (by-pass valve) Turbocharger 2 7 8 9 11 10 Water cooled exhaust riser (extra equipment) Reverse gear, TD MG5061SC Oil cooler, reverse gear Dipstick (alternative location) Oil cooler, engine Smoke limiter Circulation pump Alternator 3 4 5 1 6 11 1 2 3 4 5 6 Air filter F
Design and function TAMD72WJ-A 1 13 1 2 3 4 5 6 7 22 2 12 Junction box with circuit breakers Coolant filler cap Fuel filter, fine Smoke limiter Injection pump Oil filler cap Turbocharger 3 4 5 11 6 10 8 9 10 11 12 13 7 8 9 Water cooled exhaust riser (extra equipment) Stop solenoid Alt.
Design and function TAMD72P-A (EDC) 1 2 3 15 14 1 2 3 4 5 6 7 8 5 13 2 11 Air filter Filter for crankcase breather Aftercooler Heat exchanger Expansion tank Sea water pump 6 11 10 9 10 11 12 13 14 15 4 9 9 Reverse gear, TD MG507-1 Oil cooler, reverse gear Wastegate valve (by-pass valve) Alt.
Design and function Component description Cylinder heads 1 4 The engine has two (identical) cylinder heads, each of which covers three cylinders. The cylinder heads are screwed to the cylinder block by 20 screws per head (M11). The cylinder head material is a special cast iron alloy. The cylinder head gasket is solid sheet steel. The cylinder head plane has lands, formed by two concentric wide grooves, recessed in the plane of the cylinder head, centred on the cylinder liner collars.
Design and function Cylinder block The cylinder block is cast in one piece and is made of special cast iron alloy. The tension forces in the cylinder head screws, caused by combustion pressures, are transmitted by stiffened sections in the interior walls of the cylinder block to the main bearings. The camshaft bearings are broached to the correct dimension after assembly. Cylinder block Cylinder liners The cylinder liners are of the wet type and are replaceable. They are made from centrifugal cast iron.
Design and function Pistons The pistons are made of light metal alloy. The top compression ring, which transmits the majority of the heat which is transferred via the pistons, is located in a ring carrier made of high alloy special cast iron, which is cast in to the piston. This gives the piston ring groove long service life despite the heat loading. The piston ring grooves for the other pistons are machined directly into the piston.
Design and function TAMD71 Each piston has three compression rings (early version), or two compression rings (later version)* and one oil scraper ring. The upper compression ring on the early version is chrome plated and has a turned internal chamfer, and on the later version it is molybdenum coated and must be fitted with the TOP marking** uppermost. The TAMD71B has a top ring of the “Keystone” type.
Design and function Timing gear The timing gear consists of cylindrical gear wheels with spiral cut teeth. The injection pump and camshaft are driven from the crankshaft gear via an idler gear. The engine oil pump is also driven from the crankshaft gear via an idler gear. In addition to the camshaft, the camshaft gear also drives the gear for the sea water pump (the sea water pump on the TAMD63 is driven by a Poly-Vee belt).
Design and function Con rods The con rods have an I section, and are drilled for pressure lubrication of the gudgeon pins. Since the con rods have obliquely split big ends, they can be pulled up through the cylinder bores during engine renovation. The gudgeon pin bushes are made of steel and have a bronze alloy lining. On the 71 and 72 series, the con rods have trapezoid small ends, to give a larger effective bearing area against the gudgeon pin. Con rods with trapezoid small end (71 and 72 series).
Repair instructions General Before every major service task, a condition test should be carried out if possible, to determine the general condition of the engine and to find any cooperating fault causes. It is necessary to operate the engine during a condition test, so this should be done before the engine or any engine components are removed. Please refer to condition test, engine, on page 32.
Repair instructions Engine stand attachment Jig no. 9996787 is used to attach the engine to the engine stand. The jig is screwed to the right-hand side of the engine, as in the illustration below. Before the engine jig can be fitted, and the engine attached to the engine stand, the following components must be removed from the engine: NOTE! It is important that the note about the numbers and dimensions of screws is observed, for safe attachment of the engine.
Repair instructions Condition test, engine Cylinder head, renovation Compression test Cylinder head, removal Special tool 9998009 Special tool nos. 9996643, 9996847* A compression test is done in order to assess the condition of the engine in a simple and reliable manner, this indicates the sealing ability of the piston rings and valves. TAMD61/62/63, TAMD 71/72 l Warm the engine up and stop it. l Remove all the injectors and test each of the cylinders in turn.
Repair instructions 9 19 Free the plastic pipe for the smoke limiter from the front edge of the induction manifold. Remove the induction manifold. If the engine has a stop solenoid, remove it and hang it up. Applies to all engines Applies to TAMD63 20 10 Shut off the fuel taps. Remove the fuel pipe leading to the fine filter, the supply pipes and the fuel leakage pipes. Remove the fuel filters.
Repair instructions 24 Free the exhaust pipe from the turbocharger. Remove the coolant pipe between the turbo and the cylinder block. Cylinder head disassembly/ assembly Special tool: 885128 Remove the oil pipes for the turbocharger. Install protective covers. 25 Remove the turbocharger and exhaust manifold. Cover the turbo inlet and outlet with clean paper or use some other method, to prevent dirt and other foreign matter from entering the turbocharger. 26 Remove the valve covers.
Repair instructions 2 1 Clean all components, be especially careful with the oil and coolant galleries. Remove any remaining soot and contamination from the cylinder head mating surfaces. Clean the sealing grooves with a suitable scraper (shaped to conform with the contours of the grooves). NOTE! Never pass a rotating steel brush or other tool across the sealing grooves. The lands would then be broken down and ruined.
Repair instructions 4 7 Check that the knob on the reduction valve of the proof testing equipment is screwed out. Screw in the reduction valve knob to give a pressure of 50 kPa (0.5 kp/cm2) on the pressure gauge. Maintain this pressure for 1 min. 5 Connect the hose from the proof testing equipment to the air connection plate. 8 Then raise the pressure to 150 kPa (1.5 kp/cm2). Lock the reduction valve knob with the lock ring and shut the tap off.
Repair instructions Cylinder head, inspection Warpage The warpage of the cylinder head must not exceed 0.03 mm. The check is made with a feeler gauge and steel ruler, whose sides has been shaved to an accuracy corresponding to DIN 874/Normal. If the cylinder head is found to be warped more than the permitted value, the cylinder head must be planed or replaced.
Repair instructions Valve guides, inspection Valve guides, replacement Special tools: 9999876 and 9999696. Special tools: 6(x) series: 9991459, 9996169, 7(x) series: 9991084, 9992661. 1 Put the cylinder head on a flat surface and put new valves in the guides. The valve spindles should rest on the flat surface. If necessary, remove the injector fastening studs to get good contact. 1 2 Press out the valve guides with mandrel 9991459 6(x) series, or 9991084 7(x) series.
Repair instructions Cylinder head, planing Special tools: 9992479, 998976. The warpage on the cylinder head must not exceed 0.03 mm. Cylinder head, milling the seal groove Special tools: 998976 and 9992479 + 9996841, 6(x) series; 9996842, 7(x) series If the warpage exceeds this value, or if blow-by lines occur, the cylinder head must be planed or replaced. Please refer to the “Technical Data” section of the workshop manual for the minimum height of the cylinder head.
Repair instructions 2 Setting the cutters Set up the cutter head in a vice, with the bits facing upwards. 4 The grooving tool has five bits. Three of them (Marked A-A*-B) are intended to work the flame edge groove. These should be adjusted to 2.8 mm +0.1, –0.2 mm. Attach the dial gauge (998976) in holder 9992479 and put this on the ring-shaped land on the cutting tool. Zero the dial gauge against the land.
Repair instructions 7 12 Press down the bit holder and tighten the lock screw enough to press against the holder. Install the bit holders in the cutter head, in accordance with the letters, and with the grooves aligned towards the lock screws. Adjust the bit height as instructed. 8 Put the dial gauge tip on the highest point of the bit and turn the adjustment screw upwards until the correct value of bit height is obtained. Tighten the lock screw.
Repair instructions 16 Valve seat, replacement Special tools: 9992479, 998976 1 Install the spring and nut. Tighten the nut loosely. 17 Turn the tool clockwise, using even movements, and without pressing. The cutters are fed automatically. Turn the tool until the cutter bits stop cutting. The valve seat should be replaced when distance (A), measured with a new valve, exceeds Remove the nut and lift off the cutting head. TAMD61/62 TAMD63 TAMD71/72 Inlet .......... 1.5 mm 1.0 mm 3.0 mm Exhaust ..
Repair instructions 3 Clean the valve seat location carefully, and check that there are no cracks. Measure the diameter of the valve seat location. Use the measurement to determine whether a STD or OD dimension seat should be used. Do any machining on the valve seat location. Cool the new valve seat down in carbon dioxide snow to –60 to –70°C, and possibly heat the cylinder head by hosing it with hot water or other means. Press the valve seat in with a mandrel.
Repair instructions Valves, grinding (does not apply to engines with Nimonic valves)* * Note. Nimonic valves must not be ground. Rocker mechanism, renovation Special tools: 6(x) series 9991876, 7(x) series 9992677. Valve sealing angles: Inlet: 29.5° Exhaust: 44.5° 1 Check the valves before grinding them. Cracks and damage to the valve head or bent valve stems always mean that the valve must be replaced. Grind the sealing surface as little as possible, just enough to make it clean all the way round.
Repair instructions 4 Press out the rocker bushing with mandrel no. 9991967 for the 6(x) series, or 9992677 for the 7(x) series. 7 Oil the rocker shaft and install all the components. Note that the rockers on the 6(x) series are installed in opposing pairs. On the 7(x) series, all the rockers are identical and the location on the shaft is thus arbitrary. Make sure that the circlips on the rocker shaft ends have seated securely in their grooves. 5 Turn the mandrel over and press in a new bushing.
Repair instructions Checking the valve springs Cylinder head, assembly Special tools: 9992479, 9996847 1 Clean the mating planes of the cylinder head and cylinder block. Remove any rust or carbon from screw holes and from the threads for the cylinder head fastening holes. Clean the holes with a tap (M11 x 1.5). Remove all loosened dirt with a vacuum cleaner or compressed air. 2 Check the lining heights. Please refer to the values noted in “Technical Data” in the workshop manual.
Repair instructions 5 Torque the cylinder head screws in the numbered sequence in the tightening schedule, four times. 6 1st tightening: 30 Nm (3 kpm) 2nd tightening: 6(x) series: 85 Nm (8.5 kpm) 7(x) series: 90 Nm (9 kpm) 3rd tightening: 6(x) series: 85 Nm (8.5 kpm) 7(x) series: 90 Nm (9 kpm) Install the push rods and rocker mechanism. Tightening torque: For the 61 series with steel bearing caps, use 65 Nm (6.
Repair instructions Copper sleeve for injectors 5 Special tools, 6(x) series: 9812546, 9996400, 9996402, 9996419, 9996421, 9996643, 9996650, 9996651, 9996657, 9996867, 9998070 7(x) series: 9812546, 9996400, 9996402, 9996419, 9996420, 9996643, 9996657, 9996861, 9996867 The copper sleeve can be changed with the cylinder head either installed or detached. The seat for the copper sleeve must never be cleaned up with a cutting tool, with the cylinder head still installed on the engine.
Repair instructions 7 Cleaning the seat for the copper sleeve Method 1 – with a plug brush (installed or detached cylinder head) Special tool 9812546 It is very important that all kinds of deposits on the mating surface in the cylinder head, of the copper sleeve are removed before a new copper sleeve is installed. IMPORTANT! For TAMD63, cleaning with a plug brush is the only permitted method.
Repair instructions Method 2 – with a cutter (detached cylinder head) Copper sleeve, assembly Special tool: 9996650, 9996651 Special tools, 6(x) series: 9996402, 9996421, 9998070 7(x) series: 9996402, 9996420, 9996861 Cleaning up with a cutter is done in two stages. Injector and copper sleeve NOTE! Only use a cutter if absolutely necessary, since the location of the injector in the cylinder head is changed each time the seat is re-cut.
Repair instructions 6x-series 6x-series 7x-series 7x-series 3 (6x series): Remove the two fastening screws for the cylinder head (one on each side of the copper sleeve). Screw down press tool no. 9998070. (7x series): Screw down press tool 9996861 with the injector attachment screws. Clearance between the copper sleeve and steel ring. 4 Screw down the press tool screw against the mandrel, and press the steel ring and copper sleeve down by torquing to 58 Nm (5.8 kpm) with a torque wrench.
Repair instructions 6 Remove the press tool and mandrel. (6x series): Install the cylinder head screws and torque them. Please refer to “Cylinder head, installation” on pages 46 and 47. 7 ❍ Exhaust ● Inlet Valve location and cylinder numbering Valve clearance, Inlet Install the injectors with dust covers and yokes. Tightening torque is 50 Nm (5.0 kpm/37 lbf.ft). Install the valve covers and oil leakage pipes. 8 TAMD61, TAMD62, ............. 0.40 mm TAMD71 (0.0157”) 0.55 mm (0.
Repair instructions Cylinder block, renovation 3 Turn the engine round until the relevant piston is at BDC. Remove the big end bearing cap with the lower bearing shell. Piston and connecting rod, removal (Cylinder head and sump removed) 4 Special tool: 9996847. Please refer to “Cylinder head, removal” on pages 32 and 33 for the method of removing the cylinder head. 1 Carefully tap the con rod and piston up until the piston rings come free of the cylinder liner.
Repair instructions Piston and con. rod, inspection Removal of piston, small end bush replacement Special tools: 9991801, 9992071, 9992479 (7x series), 9992669 (6x series) Before the small end bush is replaced, the con rod must be checked for cracking, straightness and twist. A cracked, bent or twisted con rod must be scrapped. 1 Checking piston wear Check the pistons for cracks, damaged piston ring dowels and worn piston ring grooves.
Repair instructions 3 Piston assembly Special tool: 9992071 1 Press the old bush out, using mandrel no. 9992669 (6x series) or 9992479 (7x series). and shaft no. 9991801. 4 Heat the con rod up to about 100°C. 5 Press in the new bush, using the same tool as was used for extracting the old one. Make sure that the oil hole in the new bush coincides with the oil duct in the con rod. Draw a guide line on the bushing hole and the con rod with a felt tip pen.
Repair instructions 4 During measurement, the ring should be pressed down below the Bottom Turning point using a piston. Replace the piston rings if the gap is 1.5 mm or greater. In general, piston rings should be replaced if there is any noticeable wear (within the wear tolerances) in the cylinders, since the piston rings do not normally end up in the same positions as they had before removal. Check the piston ring gap on new piston rings as well.
Repair instructions Cylinder liner, inspection and measurement Inspection The cylinder liner should be carefully cleaned before inspection and measurement. The cylinder liner must be removed from the cylinder block to permit accurate crack checking. 3 If the wear is greater than 0.35–0.40 mm, the cylinder liner with pistons and piston rings should be replaced. NOTE! The piston and cylinder liner are only supplied as a complete set as spare parts.
Repair instructions Cylinder liner, honing Clean the removed cylinder liner from sooty edges. Set the liner up in a vice. Use a heavy electric drill which can be operated at low speed, 200–400 rpm. Honing pattern on cylinder liner bore It is important that the cylinder liner should retain its original honing pattern, for good lubrication and sealing. The liner should therefore be honed if it has surface scratches because of a ring seizure or dirt, or has bright spots (polishing).
Repair instructions Cylinder liner seat, renovation Special tools: 9989876, 9992479, 9996847 (2 No.), 9999508 (7x series), 9999514 (7x series), 9999538 (6x series), 9999553 (6x series) A damaged cylinder liner seat is repaired by milling the lining shelf. Check the mating face of the upper lining seat with marking dye if there is any doubt about the extent of the damage. The material which is removed during milling should be compensated by spacers which are available in thicknesses of 1.
Repair instructions Cylinder liner, installation 5 Special tools: 9989876, 9992000, 9992479, 9996847 (2 No.), 9996854 Put any spacers required on the cylinder liner seat. Lubricate the new seal ring and install it beneath the liner collar. 1 Remove the old seal rings from the cylinder block and make sure that the sealing surfaces are carefully cleaned. 6 Use cleaning fluid and a brass brush. NOTE! Scraping tools must not be used.
Repair instructions Piston assembly Special tool: 885126 NOTE! The cylinder liner press tool must be removed temporarily when tool no. 885126 is used. When the piston is in place, the press tool must be put back again. 1 Oil the piston with engine oil. 5 Check that the bearing shells are correctly aligned in the con rod. Install the cap in accordance with the marking, and install the screws.
Repair instructions Timing gear, disassembly l Remove the shield plates above the heat exchanger and remove the aftercooler. Remove the two plastic pipes from the expansion tank. l Remove the lid at the front of the thermostat housing and the connection pipe to the coolant pump. l Remove the coolant pump. l Turn the engine round in its normal direction of rotation until the no. 1 piston is at TDC after the compression stroke (0° on the flywheel).
Repair instructions 2 5 Remove the idler gear (pos 4)* together with the bearing pin and thrust washer. 6 Remove the polygon hub centre screw, remove the washer and pull the hub off with tool no. 9992655. 3 Remove the camshaft gear (pos 7)* with extractor no. 999279. Use the same procedure as for the injector pump drive wheel (pos 5)*. Remove the timing gear cover. 4 8 Remove the crankshaft gear (pos 1)* with extractor no. 9992658.
Repair instructions Inspecting the timing gears Clean the gear wheels and other components in the timing gear, and inspect them carefully. Replace any gear wheels which are heavily worn or damaged. During assembly, all clearances must be checked. Max. permitted gear flank clearance is 0.17 mm. Check the radial clearance and end float of the idler wheel. End float .................................... 0.05–0.15 mm Radial clearance ........................ 0.025–0.
Repair instructions Timing gear, assembly 2 Special tools: 884948, 884949 Check that the camshaft drive gear dowel is installed. Install the camshaft drive gear. Tightening torque is 70 Nm (7 kpm) IMPORTANT! All gear wheels in the timing gear which are important for timing are marked with a centre punch mark on the relevant gear tooth or tooth gap. Also, please note the instructions for installing nitrocarburised gears on page 64. 3 Tightening torque for timing gear. 90 ±9 Nm (9 ±0.
Repair instructions Application of sealant, timing gear cover Seal ring, polygon hub, replacement (With polygon hub removed) Special tool: 9996855 1 Remove the old seal ring by means of a screwdriver. Clean the seal ring mating surface in the lid. Note. On early model engines, the seal consists of an inner rubber ring and an outer felt ring. These have been replaced as spare parts by a rubber seal which is used on late model engines, i.e. 1 rubber seal is installed.
Repair instructions Polygon hub, installation Camshaft, wear check Special tool: 884949 Special tools: 998976, 9996772 1 Preparatory work l Remove the valve covers. Remove the screws holding the rocker shaft bearing caps and remove the rocker mechanism. Lift the push rods out. Mark the push rods so that they end up in the same place during re-assembly. Valve location and cylinder numbering Lubricate the crankshaft nose with molybdenum disulphide compound. Install the centring section of mandrel no.
Repair instructions 2 4 Install the push rods in the correct order, install the rocker support bridges and torque the screws. Tightening torque: for the 61 series with steel bearing caps*, torque to 65 Nm (6.5 kpm). Later models of the 61 series and all engines in the 62 and 63 series have aluminium bearing caps. Tightening torque is 50 Nm (5.0 kpm). On the 71 and 72 series, the torque used is 65 Nm (6.5 kpm). Valve adjustment, please refer to page 52.
Repair instructions 3 Inspection of valve lifters and camshaft 3 Remove the valve lifter access hatches (3). NOTE! The centre hatch does not need to be removed. Inspection of valve lifters 4 4 Use a steel rule to check that the surface of the valve lifter in contact with the camshaft is spherical (convex). It may even be flat, but it must absolutely not be concave. If there is visible light showing through the lifting surface between the ruler and the valve lifter, the lifter must be replaced.
Repair instructions It has been found that the damage only gets worse in very rare cases. Check the camshaft bearing surface and cam profiles for wear. The cams can be worn obliquely in the lengthwise direction, for example. This can be adjusted in milder cases by stoning the cam profile. Replace the camshaft if there is any other damage or wear. Camshaft bearing, replacement The bearings are pressed into their locations and must be bored after pressing in.
Repair instructions Camshaft installation 6 1 Install the valve lifter inspection hatches with new gaskets. Oil the camshaft bearing surfaces and cam profiles. Carefully slide the camshaft into place, so as to avoid damaging the bearings. Use tool no. 9998079. 2 Install the camshaft flange. Torque the screws to 65 Nm (6.5 kpm). Tightening torque is 24 Nm (2.4 kpm). NOTE! Put the oil guide plate on the rear hatch. 7 Install the crankcase breather pipe.
Repair instructions 6 2 Assess any surface damage. The following applies to nitrocarburised shafts: Features which would be classed as dirt scratches on an induction hardened crankshaft may be normal surface finish on a nitrocarburised crankshaft in some cases, as on a new crankshaft. On a used crankshaft, this is emphasized very clearly, because of the extremely smooth bearing surface. After a long period of operation, very small particles may loosen from the surface layer (spalling).
Repair instructions Crack checking Seizure damage can cause overheating cracks which can only be discovered with special equipment. Any cracks and notches are most reliably found by magnetic powder testing such as Magnaglo, i.e. fluorescent powder which is observed in ultra-violet light. Please refer to the instructions provided by the manufacturers of the equipment. After such a test, the crankshaft must be de-fluxed.
Repair instructions Crankshaft, renovation In general, both re-grinding and trueing reduce the fatigue resistance. So do not re-grind bearing journals (nitrocarburised in particular) unless there are strong reasons for doing so. E.g. measurement faults (wear, ovality, taper) or so serious surface damage that buffing is not sufficient. If the crankshaft does not need to be re-aligned before it is re-ground, it can be ground down to the second under-dimension before it has to be nitrocarburised again.
Repair instructions The surface finish (profile depth) of bearing surfaces and fillets is 2 mm, medium surface deviation 5 mm. This surface finish is achieved by buffing. Buffing is done in the opposite direction of rotation to grinding. l l Grinding must be done in a crankcase grinding machine to an underdimension specified in the “Technical Data” in the workshop manual.
Repair instructions Crankshaft, assembly 6 1 Place the bearing shells in their places. Make sure that bearing shells of the correct dimensions are installed and that they are correctly seated in their places. 2 Lubricate the bearing surfaces with engine oil. 3 Check the crankshaft ducts and bearing surfaces. Lubricate the crankshaft journals with engine oil and carefully lift the crankshaft into place, using two lifting strops.
Repair instructions 12 Big end bearing replacement Install a new rear crankshaft seal. Please refer to items 2 and 3 in the “Crankshaft seal, rear” method on page 83. (Crankshaft not removed) Preparatory work l Drain or pump out the engine oil. l Remove the sump. 13 l Clean the mating surface of the flywheel against the crankshaft flange and install the flywheel. Torque the screws to 190 ± 10 Nm (19 ± 1.0 kpm). Remove the supply and suction pipes for the oil pump, plus the baffle.
Repair instructions 6 Main bearings, replacement (Crankshaft not removed) Preparatory work l Drain or pump out the engine oil. l Remove the sump. l Remove the supply and suction pipes for the oil pump, plus the baffle. l Remove the injectors, to make it easier to crank the engine. 1 Install new bearing shells. Make sure that the guide pin on the bearing shell is correctly located in the cutouts in the con rod and bearing cap, and that the oil holes in the con rods and bearing shells line up.
Repair instructions 3 7 Clean and check the bearing seat, bearing cap, bearing journal and bearing shells for damage. If the bearing shells have seized, the reason must be investigated before new bearing shells are installed. Change the other main bearing shells, one at a time, in the same way as the first one. After you have changed each main bearing, check that the crankshaft turns easily, by cranking the shaft.
Repair instructions 9 Flywheel, replacement 1 Use a narrow wood or plastic pin to remove the thrust washers. Remove the screws and lift the flywheel away. Flywheel, inspection 10 When all the main bearing caps have been torqued, check the crankshaft end float. The end float, measured with a dial gauge, must be 0.16–0.40 mm. 11 Install the oil pump and injectors. Check the flywheel for cracks and other damage. Also check that the gear ring is not worn or damaged.
Repair instructions Gear ring, replacement 4 (Flywheel removed) 1 Drill 1–2 holes in the gap between two teeth on the gear ring. Split the gear ring across the drilled holes, using a hammer and cold chisel. Put the heated gear ring on the flywheel and tap it into place with a soft punch and hammer. Allow the gear ring to air cool. 2 5 Brush the mating surface of the flywheel with a wire brush. Clean the mating surfaces on the flywheel and crankshaft.
Repair instructions Flywheel, indication Read off the value, and move the dial gauge with base round to the opposite side of the flywheel. Special tools: 9999696, 9989876 The value of these measurements must not exceed 0.15 mm. 1 2 Place a dial indicator with its tip on the flywheel. 2 Zero the dial gauge. Turn the flywheel round and read off the greatest value. The measured value must not exceed 0.15 mm, at a measurement radius of 150 mm.
Repair instructions Crankshaft seal, rear, replacement Flange seal, flywheel housing, replacement (Flywheel removed) (Flywheel removed) Special tools: 9992000, 9996437 1 1 Remove the four rear screws from the sump, and the screws which hold the flywheel housing to the cylinder block (10 no.) Tap the flywheel housing loose, using a plastic faced hammer, by tapping alternately on the right and left hand sides. Tap in one side of the oil seal with a narrow punch.
References to Service Bulletins Group No. Date Concerning ......................................................................................................................................................................................... ......................................................................................................................................................................................... ..............................................................................
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7735718-4 English 08–1996
