Volvo Penta Engine TAD 1640 & 1641 & 1642 GE TAD 1641 & 1642 VE Repair Manual PDF

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Volvo Penta Engine TAD 1640 & 1641 & 1642 GE TAD 1641 & 1642 VE Repair Manual – PDF DOWNLOAD

FILE DETAILS:

Volvo Penta Engine TAD 1640 & 1641 & 1642 GE TAD 1641 & 1642 VE Repair Manual – PDF DOWNLOAD

Language : English
Pages : 276
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Volvo Penta Engine TAD 1640 & 1641 & 1642 GE TAD 1641 & 1642 VE Repair Manual – PDF DOWNLOAD

Safety information 3
Introduction 3
General information 6
About this Workshop Manual 6
Flat Rates 6
Spare parts 6
Certified engines 6
Repair instructions 7
Our joint responsibility 7
Torque 7
Torque-angle tightening 8
Lock nuts 8
Strength classes 8
Sealant 8
Safety rules for
fluorocarbon rubber 9
Special tools 10
Other special equipment 14
Design and function 15
Group 21: Engine body 15
Cylinder head 15
Engine block 16
Cylinder liner 17
Pistons and connecting rods 18
Crankshaft 19
Camshaft 20
Transmission 21
Group 22 Lubrication system 22
Piston cooling 23
Overview, valves 24
Group 23 Fuel system 25
Unit injector, work phases 27
Group 25 Intake and exhaust system 29
Turbocharger 29
Group 26 Cooling system 30
Troubleshooting / Tests and adjustments 31
Symptoms and possible causes 31
Operational disturbances 32
Clogging 32
Placement of instrument socket 33
Sensor overview 34
Compression test 35
Cooling system, pressure-testing 38
Boost pressure, troubleshooting 39
Turbocharger, checking 41
Exposing engine 42
Fixture fitting 44
Engine body, general overhaul 45
Cylinder head, removal 45
Transmission, removal 56
Pistons, removal 58
Crankshaft, removal 59
Crankshaft, refitting 60
Cylinder liner, fitting 61
Piston, pre-fitting 62
Pistons, fitting 64
Piston cooling nozzle, fitting 64
Transmission, fitting 65
Cylinder head, refitting 71
Camshaft, refitting 74
Gear backlash, adjusting 75
Unit injector, refitting 77
Adjustment markings 79
Valves and injectors, adjusting 79
Reconditioning / replacing components 83
Group 21: Engine body 83
Cylinder liner and pistons, inspection 83
Cylinder liner and pistons, replacing (all) 84
Crankshaft, inspection 90
Main bearings, replacing 91
Crank bearing, replacing (all) 94
Flywheel bearing, replacing 95
Flywheel, replacing 96
Ring gear, replacing 97
Flywheel sensor distance, checking 98
Flywheel, checking for warp 99
Crankshaft seal, front, replacing 100
Crankshaft seal, rear, replacing 102
Connecting rod, checking 104
Connecting rod bushing, check measurement 104
Valves, removal 105
Valves, fitting 107
Valve seat, replacing 108
Valve guides, inspection 110
Valve guides, replacing 111
Valve seat, grinding 112
2
Valves, grinding 113
Valve stem seals, replacing 114
Cylinder head, pressure testing 116
Copper sleeve for unit injector, replacing 119
Camshaft, checking for wear 123
Camshaft bearing housing, replacing 124
Camshaft sensor distance, checking 125
Transmission, replacing 126
Group 22: Lubrication system 132
When working with chemicals, fuel and lubricating oil 132
Overview, control valves 132
Pressure reduction valve, replacing 133
Bypass valve, oil filter, replacing 133
Oil pressure safety valve, replacing 134
Piston cooling valves, replacing 134
Bypass valve oil filters, full flow, replacing 135
Oil filters, checking 136
Oil pressure sensor, checking 136
Engine oil and oil filters, replacing 137
Pressure reduction valve, checking 138
Safety valve, checking 138
Oil pump, replacing 139
Oil pump, checking 140
Oil cooler 141
Oil cooler, leakage test 142
Bypass valve oil cooler, replacing 143
Group 23: Fuel system 144
Draining, fuel channel in cylinder head 144
Control module, replacing 145
Fuel filters, replacing 147
Primary fuel filter, change 148
Fuel feed pump, replacing 149
Unit injector, replacing 150
Venting the fuel system 153
Group 25: Inlet / exhaust systems 154
Turbo, replacing 154
Group 26: Cooling system 156
Cooling system, draining 156
Cooling system, cleaning 157
Cooling system, pressure-testing 158
Cooling system, filling 159
Coolant pump, replacing 160
Thermostat, functional check 161
Thermostat, replacing 161
Coolant filter, changing 162
Alternator belt/ Drive belt, checking 163
Drive belt, changing 163
Alternator belts, changing 164

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