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TAD1630G
Volvo Penta TAD1630G User Manual
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W
orkshop manual
T
AD1630G
/G
E
/
P/V
, T
AD1631G
/G
E, TI
D162AP
,
T
W
D1620G
/G
H, T
W
D1630G
/G
E
/
P/V
,
TD164KAE
2
Table of Contents
Default Chapter
3
Table of Contents
3
Contents
8
General Information
8
Tools
13
Special Tools
13
Other Special Equipment
17
Engine
18
Design and Function
18
Cylinder Head
19
Cylinder Block
19
Seals
19
Valve Mechanism
20
Camshaft
20
Timing Gears
20
Crankshaft/Pistons
21
Service Procedures
22
Engine Fixture, Attaching
22
Compression Test
23
Exposing Engine Body
23
Tad1630/Tad1631
23
Tid162/Twd1620/Twd1630/Td164
23
Tad1630/Tad1631/Tid162/Twd1630/Td164
24
Cylinder Head, Removing
25
Cylinder Head, Disassembling
26
Cylinder Head, Pressure Testing
27
Cylinder Head, Inspection
28
Cylinder Head, Face-Grinding
28
Valve Guides, Inspection
29
Valve Guides, Replacing
30
Valve Seats, Replacing
30
Valve Seats, Grinding
31
Valves, Grinding
31
Cylinder Head, Assembling
32
Cylinder Head, Installation
32
Rocker Arm Mechanism, Reconditioning
35
Valves, Adjusting
36
Copper Sleeve for Injectors, Replacing
38
Cylinder Liners and Pistons, Removing
41
Cylinder Liners, Measurement and Inspection
42
Cylinder Liners, Honing
42
Cylinder Liner Seats, Reconditioning
43
Cylinder Block, Face-Grinding
44
Pistons, Checking
45
Pistons, Fitting
45
Piston Rings, Inspection
45
Connecting Rods, Inspection
45
Pistons, Piston Rings and Connecting Rods, Assembling
46
Cylinder Liners and Pistons, Fitting
47
Tad1630/Tid162/Twd1620/Twd1630/Td164Kae
52
Tad1631
53
Seal on Output Shaft from Timing Gear to Injection Pump, Re- Placing:
53
Front Sealing Ring for Coolant Pump, Replacing
55
Sealant, Timing Gear Cover, Replacement
56
Timing Gears, Removing
57
Intermediate Gears, Replacing Bearing
58
Timing Gears, Fitting
59
Polygon Hub, Replacing
60
Sealant, Transmission Gear Casing, Replacing
61
Camshaft, Checking for Wear
61
Camshaft, Replacing
64
Camshaft Bearings, Replacing
66
Main Bearings, Replacing, All
68
Crank Bearings, Checking for Wear or Replacing, All
69
Crankshaft, Replacing
70
Crankshaft
71
Inspection
71
Reconditioning
73
Flywheel, Checking for Warp
73
Flywheel, Replacing
74
Ring Gear, Replacing
75
Flywheel Casing, Checking for Warp
75
Flywheel Bearing, Replacing
76
Crankshaft Seal, Rear, Replacing
77
Crankshaft Seal, Front, Replacing
78
Sealant, Flywheel Casing, Replacing
79
Lubrication System
81
Design and Function
81
General
81
Oil Cooler
83
Service Procedures
84
Lubricating Oil Pressure, Checking
84
Oil Filters, Replacing
84
Oil Cooler, Replacing
85
Oil Cooler, Leakage Test
86
Oil Pump, Replacing
87
Oil Pump, Reconditioning
89
Fuel System
92
Design and Function
92
General
92
Fuel Filters
92
Injection Pump
93
Tid162Ap/Twd1620G/Gh/Twd1630/Ge
93
Tad1630P/V/Twd1630P/V/Td164Kae
93
TAD1630G/GE y TAD1631G/GE
94
Smoke Limiter TAD1630P/V
96
Feed Pump
96
Manual Pump
96
Instrucciones de Reparación
97
Service Procedures
97
Injection Pump, Removal
97
Fitting and Adjusting the Injection Pump
97
Injection Pump, Setting with Measuring Tool 998 7057
100
Pump Coupling Shaft, Removing
103
Checking and Replacing Pump Coupling Laminates
103
Injectors
103
Injectors, Replacing
104
Injectors, Reconditioning
105
Opening Pressure, Adjusting
106
Fuel Feed Pressure, Checking
106
Fuel Filters, Replacing
107
Feed Pump, Replacing
107
Feed Pump, Reconditioning
108
Smoke Limiter, TAD1630P/V
109
Replacing the Diaphragm
109
Fuel System, Bleeding
110
Intake and Exhaust Systems
111
Design and Function
111
Charge Air Cooler
111
Turbocharger
111
Air Filter
112
Starter Heater
112
Exhaust Manifold
112
Service Procedures
113
Boost Pressure, Checking
113
Rectifying Low Boost Pressure
114
Checking Exhaust Back Pressure
115
Turbocharger, Checking Bearing Clearance
115
Schwitzer S4T and Holset H3B
115
Turbocharger, Reconditioning
117
Schwitzer S4T y TAD1630/1631
117
Holset, TID162/TWD1620/TWD1630
122
Measures in Case of Turbo Failure on TAD- Engines
125
Turbocharger, Replacing/Refitting on Engine
125
Charge Air Cooler, Checking for Leakage, TAD-Engines
126
Cooling System
127
Design and Function
127
General
127
Service Procedures
130
Coolant Pump, Replacing
130
Coolant Pump, Reconditioning
132
Sleeve Thermostats, Replacing
142
Sleeve Thermostats, Checking
143
Coolant Manifold Seals, Replacing
144
Coolant
146
Anti-Freeze
146
Volume
146
Anti-Corrosion Additives
146
Checking Coolant Level
146
Draining the Coolant
146
Coolant, Filling
147
Coolant Temperature too High
147
Coolant Temperature too Low
147
Temperature Gauge, Checking
147
Level Switch, Checking
147
Coolant Leakage
148
Radiator and Charge Air Cooler, Checking
148
Drive Belts, Adjusting
148
Cooling System, Cleaning
148
Cooling System, Pressure-Testing
149
Checking Pressure-Testing Device 999 6662
149
Pressure Testing
149
Pressure Valve, Checking
150
Electrical System
151
Important
151
Arc Welding
151
Starting with Auxiliary Battery
151
Electronic Speed Governor, Wiring
152
Wiring Diagrams
153
Troubleshooting
158
5
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Volvo Penta TAD1630G Specifications
General
Engine Model
TAD1630G
Number of Cylinders
6
Fuel System
Common rail
Displacement
16.1 L
Aspiration
Turbocharged
Cylinder Arrangement
Inline
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