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Workshop Ma

Group

TAD1640-42GE, TAD1641-43
TAD1640-42VE-B, TAD165
TAD1651VE, TAD1660-6
TWD1643GE, TWD1652
Content

General Information
00-0 General ...........................

Specifications
03-2 Specifications, Engine ..
03-21 Engine ..........................
03-22 Lubrication System .....
03-23 Fuel System .................
03-25 Inlet and Exhaust Syste
03-26 Cooling System ...........
03-3 Specifications, Electrica

Safety and Other Instructio


05-1 Safety Instructions ........

Special tools
08-2 Special Service Tools ...

General
20-0 Engine Information, Gen
Troubleshooting ....................
Test and Adjustments ...........

Engine
21-0 Engine Complete, Gener
Exposing the Engine .............
Fitting the Fixture ..................
Engine Disassembly .............
Engine Assembly ..................
26-5 Charge Air Cooler with C

Alternator, Charge Regula


32-1 Alternator .......................

Starting System
33-1 Starter Motor .................
Alphabetical index ................
References to Service Bulleti
00-0 General
Ab
General information Ce
This Service Manual contains technical data, descrip- Wh
tions and maintenance and repair instructions for sio
standard model Volvo Penta products. A list of these of t
products may be found in the section Specifica-
tions. Cer
insp
The product designation and the serial number and The
specification is indicated on the engine decal or type of th
plate. This information must be included in all corre- the
spondence regarding the product. This
wor
The service manual is produced primarily for the use
of Volvo Penta workshops and their qualified person- •
nel. 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 infor-
mation 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
00-0 General

Repa
Introduction Our m
The working methods described in this manual are Each p
based on a workshop scenario where the product is system
mounted in a holding fixture. Maintenance work is nical sp
often carried out on site, in which case – if nothing environ
else is indicated – using the same working methods tem. It
as the workshop. ances
adjuste
Warning symbols that occur in the service manual. Origina
For significance, refer to Safety Information . mainte
! DANGER! Some
cial exp
! WARNING! ponent
environ
! CAUTION!
nents m
perform
IMPORTANT!, NOTICE!
are by no means comprehensive since not everything Remem
can be foreseen as service work is carried out in the used, a
most varied of circumstances. We call attention to recomm
risks that may occur due to incorrect handling during whene
work in a well-equipped workshop using working specifie
methods and tools tried and tested by us. doors,
residue
The service manual describes work operations car-
ried out with the aid of Volvo Penta Special Tools,
where such have been developed. Volvo Penta Spe-
Tight
cial Tools are designed to ensure the safest and most Tighten
rational working methods possible. It is therefore the applied
responsibility of anyone using tools or working meth- Service
ods other than those we recommend to ensure that the Ma
no risk of personal injury or mechanical damage is apply t
present, or that malfunction can result. Indicat
Lock nuts Ana
The
Removed locknuts may not be re-used; they must be The
replaced by new ones, as locking properties are nen
impaired or lost with re-use. with
In the case of lock nuts with plastic inserts the tight- sea
ening torque indicated must be reduced if the nut has etc.
the same nut height as a standard, all-metal hexag-
onal nut. Har
Reduce the torque by 25% for bolt sizes of 8 mm or this
larger. them
In the case of lock nuts with plastic inserts with a high high
nut-height (where the all-metal thread is as high as a not
standard hexagonal nut), the indicated torque care
applies. befo
inst
Strength classes
Saf
Nuts and bolts are subdivided into different strength
classes. The classification is shown by a marking on rub
the bolt head. Markings of a higher number indicate Fluo
stronger material. For example, a bolt marked 10-9 is ring
stronger than one marked 8-8.
Wh
For this reason, it is important that when bolts are pera
removed they are returned to their original locations can
on re-assembly. When replacing bolts check the skin
applicable Spare parts catalogue to ensure the cor- you
rect bolt is used. brea
dam
Sealing compounds etc.
To ensure service work is correctly carried out it is
important that the correct type of sealants and locking Sea
fluids are used on joints where such are required. afte
pois
In each service manual section concerned the seal-
00-0 General

Illust
A lot of illustrations contains standardized symbols and colors. Plea
misunderstandings when working on an engine / transmission usin

Illustration colors Positio


Most illustrations have a focused component (blue)
which is fastened by a (red) bolt or such on a (light
grey) engine / transmission body.

P0015623

Focus a
tains nu

NOTICE
only one
two alike
P0015699
illustrati
1 Focus
(blue)
2 Fastenings
(red)
3 Body
(light grey)
4 Background
P0015627
(white)
This sym
e.g. 2, w
Movement Too

P0015622

Movement arrows are used to show which direction a


component is to be moved / rotated.

P0015625

Symbol is used in a corner of the illustration to show


how many degrees the object shall be turned and at
P00156
which direction.
A sy
show
knife
00-0 General

Chemicals Units

P0015695

Symbols can also describe when and how a chemical


product is to be used.

Cleanliness

P0015696

Units ar
value (e
expecte

Impor
P0015624

The scraper symbol suggests that a contact surface


needs to be scraped from sealant etc.
The cloth symbol suggests that the mechanic should
03-2 Specifications, Engine
Engine designation TAD1640GE TA
Power, Prime/Stand-by Refer to the sales li
Torque, Prime/Stand-by Refer to the sales li
No. of cylinders 6 6
Bore, mm (inch) 144 (5.67) 14
Stroke, mm (inch) 165 (6.50) 16
Cylinder volume, liter (inch 3) 16,12 (983.9) 16
Weight dry, kg (lbs) 1440 (3175) 14
Weight wet, kg (lbs) 1510 (3329) 15
Firing order 1-5-3-6-2-4 1-5
Compression ratio 17,5:1 16
Low idle, rpm 900 90
High idle, rpm 1500/1800 15

Engine designation TWD1652GE, TW


TWD1653GE TW
TW
Power, Prime/Stand-by Refer to the sales li
Torque, Prime/Stand-by Refer to the sales li
No. of cylindersl 6 6
Bore, mm (inch) 144 (5.67) 14
Stroke, mm (inch) 165 (6.50) 16
Cylinder volume, liter (inch 3) 16,12 (983.9) 16
Weight dry, kg (lbs) 1700 (3748) 17
03-2 Specifications, Engine

Engine designation TAD1641VE

Power, Prime/Stand-by Refer to the sales literature


Torque, Prime/Stand-by Refer to the sales literature
No. of cylinders 6
Bore, mm (inch) 144 (5.67)
Stroke, mm (inch) 165 (6.50)
Cylinder volume, liter (inch 3) 16,12 (983.9)
Weight dry, kg (ibs) 1480 (3263)
Weight wet, kg (ibs) 1550 (3417)
Firing order 1-5-3-6-2-4
Compression ratio 17,5:1
Low idle, rpm 600
High idle, rpm 1800

Engine designation TAD1640-43VE-B, TAD16


TAD1670-72VE
Power, Prime/Stand-by Refer to the sales literature
Torque, Prime/Stand-by Refer to the sales literature
No. of cylinders 6
Bore, mm (inch) 144 (5.67)
Stroke, mm (inch) 165 (6.50)
Cylinder volume, liter (inch 3) 16,12 (983.9)
Weight wet, kg (ibs) 1440 (3175)
Firing order 1-5-3-6-2-4
Compression ratio 16 8:1
Spe

Gro
Front engine mounting, engine block
Front engine mounting
Rear engine mounting, flywheel housing

Main bearing caps


stage 1
stage 2

Big end bearing cap


stage 1
stage 2
stage 3

Stif
03-2 Specifications, Engine

Flywh

P0007088

IMPORTANT!
Make sure the flange is clean and dry.
NOTICE! Tighten the bolts in sequence, as illustrated.

stage 1 60
stage 2 12

Flywh
Vib

P0007089

NOTICE! Tighten the bolts in sequence, as illustrated.

NOTICE! The 8.8 bolts on the oscillation damper may not


be re-used.

Cov
03-2 Specifications, Engine

Valve

P0007092

NOTICE! Tighten the bolts in sequence, as illustrated. 25

Cylind
Bea
Sha

P0007094

IMPORTANT!
Tighten the bolts in stages to ensure that the rocker arm
shaft lowers without being bent.
03-2 Specifications, Engine

Bearin
Shaft,
20160

1 1 2 3 4 5 6 7 6
15 ± 3 Nm 60 ± 5 Nm

2 7
100 ± 10 Nm 8 9 10 11 12 13
120º ± 5º

1 2 3 4 5 6 7
3 8
90º ± 5º 100º ± 5º

4 9
8 9 10 11 12 13
100 ± 10 Nm 50 ± 5 Nm

5 10
14 15 16 17 18 19
50 ± 5 Nm 120º ± 5º
P0008581

IMPORTANT! If t
Ti ht th b lt i t t th t th k rem
stage 9: Tighten bolts 8 through 13
stage 10: Angle tighten bolts 8 through 13

Tim

P0007096

NOTICE! Apply 2 mm (0.08") silicone (part nos. 1161231


and 1161277) to the back of the engine block as illustrated.
NOTICE! Tighten the bolts in sequence, as illustrated.

Bolts 1–27
Bolt 28
03-2 Specifications, Engine

Trans

5 1

3 7

4
8
1
2 6

3
5
6
4
2
3 1

5 6

2 4

P0007099

1 Drive gear, crankshaft


stage 1 60
stage 2 12

2 Intermediate gear, bull drive, outer


Ti ht th b lt i ill t t d
Valv
Bolt,
Adju
Adju
Adju
Pre-
Adju

P0016365

Valv
Adju
Adju
Pre-
Adju
03-2 Specifications, Engine

Grou

Oil Su

P0007100

NOTICE! Tighten the bolts in sequence, as illustrated. 24

Oil pu
stage 1 35
stage 2 (not 17 and 18) 90

Oil co
Oil
7
6

1 2

3 4

P0007023

1 Safety valve, lubricating oil pump


2 Reducing valve
3 Control valve, piston cooling
4 Opening valve, piston cooling
5 Overflow valve, oil cooler
6 Overflow valve, bypass filter
7 Overflow valve, full flow filter
03-2 Specifications, Engine

Grou
Feed pump – steering servo pump 25

Fixing yoke, unit injector (new or re-used copper sleeve type 3)


IMPORTANT!
Always use a new steel gasket beneath the unit injector.
First tightening
stage 1 20
stage 2 18

NOTICE! Loosen the fixing yoke bolt before doing the second tigh
Second tightening
stage 1 20
stage 2 90

Fixing yoke, unit injector (re-used copper sleeve, types 1 or 2)


Gro

Inta
12 8 2 4 6 10

P0007102 11 7 1 3 5 9

Stage 1: Tighten the bolts 1-12 until contact


Stage 2: Tighten the bolts 1-12

NOTICE! Apply a 2 mm (approx 0.08") bead of sealing com-


pound 1161231-4, as illustrated.

Plug, M10
Pressure/temperature sensor, charge air

Exh

P0007103
03-2 Specifications, Engine

Turbo
TWD1643GE, TWD1652GE, TWD1653GE, Other e
TWD1663GE, TWD1672GE, TWD1673GE

P0018895

P0018887

Turbo – exhaust manifold


Stage 1: Tighten nuts in the sequence illustrated
Stage 2: Tighten nuts in the sequence illustrated
Gro
Tigh

P0020409
03-2 Specifications, Engine

Eng

Tech

Engin
Cylind
Length 11
Height, upper block plane - crankcase centerline 45
Height lower block plane - crankcase centerline 12
Crankcase pressure, normal value, irrespective of engine
speed ma

Cylind
Type 6c
Length 11
Width 43
Height 13
Max. out-of-planeness (bottom plane) (1)
0.0
1) per 100 mm (3.937") measured length

Cylind
Number of bolts 38
Dimension, thread M1
Pist
Type
Height above engine block plane
Diameter, combustion chamber
Depth, piston bowl:
TAD1640GE, TAD1641-43VE, TAD1650VE,
TAD1660-62VE, TAD1640-43VE-B, TAD1670-72VE,
TAD1650VE-B, TAD1651VE
TAD1641-42GE, TAD1650-51GE, TWD1643GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672-73GE
No. of ring grooves
Front marking
Piston pin diameter

Pist
Compression Rings
Quantity
Piston ring clearance in groove:
upper compression ring

lower compression ring


Piston ring gap, measured at ring opening:

upper compression ring

lower compression ring


Oil ring
03-2 Specifications, Engine

Valve

Valves
Valve head, diameter:
Inlet 49
Exhaust 46
Valve stem, diameter:
Inlet 10
Exhaust 10

P0007076

Se
Valve seat angle (A): 20
Inlet 19
Exhaust 44

Se
Seat angle in cylinder head (B): 20
Valv

P0007077

Outer diameter (A)


Standard:
Inlet
Exhaust
Oversize dimension:
Inlet
Exhaust
Height (B):
Inlet
Exhaust

Valv

P0007078

Diameter (C) standard:


I l t
03-2 Specifications, Engine

Valve
Length:
Inlet 83
Exhaust 83
Inner diameter:
Inlet 10
Exhaust 10
Height above cylinder head spring plane:
Inlet 24
Exhaust 24
Clearance, valve stem guide(1) :
Inlet 0
Wear tolerance m
Exhaust 0
Wear tolerance m
1) The dimensions are calculated for the measurement method described

Rocke
Bearing clearance ma
Clearance rocker arm roller ma

Valve
Inlet
Uncompressed length 67
With 522 N (117.35 lbf) load 57
With 1205 N (270 9 lbf) load 43
En

Tim

P0006837

No. of teeth:
1 Drive gear, camshaft
2 Intermediate gear, adjustable
3 Intermediate gear, bull drive outer
Intermediate gear, bull drive, inner
03-2 Specifications, Engine

Cams
Check camshaft setting, cold engine and valve clear-
ance =0.
At a flywheel position of 6° after TDC, the inlet valve must
be open 1.4 ± 0.3 mm (0.055 ± 0.012"). During this check,
the timing gear must be turned clockwise, seen from the
front, to take up all gear lash.
Drive ge
No. of bearings 7
NOTICE! Only check values; not for machining.
Diameter, bearing journals, standard 69
Diameter, bearing journals, undersize dimension:
0.25 mm (0.00984") 69
0.50 mm (0.01968") 69
0.75 mm (0.02953") 69
Max. end float 0.3
Max permissible ovality (with new bearings) 0.0
Bearing, max. permissible wear on diameter 0.0
Valve lift:
inlet 13
exhaust 14
Permitted wear between base circle and max lift ma
Unit injector, stroke 18

Cams
Camshaft bearing thickness, standard 1.9
Oversize dimension:
Cra

Cra
Length
Crankshaft end float(1)
Ovality of main and big end bearings
Taper on main and big end bearings
Runout on center bearing
1) Dimensions refer to oiled components.

Mai

C D
A
Ø

P0007079
R
03-2 Specifications, Engine

Thrus
Width (B) standard 3.1
Oversize dimension:
0.1 mm (0.00394") 3.2
0.2 mm (0.00787") 3.3
0.3 mm (0.0118") 3.4
0.4 mm (0.016") 3.5

Main b
Outer diameter (C) 12
Thickness (D) standard 2.5
Oversize dimension:
0.25 mm (0.00984") 2.6
0.50 mm (0.0197”) 2.7
0.75 mm (0.0295") 2.8
1.00 mm (0.0394") 3.0
1.25 mm (0.0492") 3.1
Radial clearance, main bearings 0.0

Big en
Surface finish, big end bearing journal
Surface finish, radius
Width (A)
Fillet radius (R)

Big
Outer diameter (B)
Thickness (C) standard
Oversize dimension:
0.25 mm (0.00984")
0.50 mm (0.0197”)
0.75 mm (0.0295")
1.00 mm (0.0394")
1.25 mm (0.0492")
Diameter, bearing shell seat (D)

Con
Length, center - center (E)
Piston pin bush internal diameter (G)
End float, connecting rod - crankshaft (1)
Big end bearing, radial clearance (1):
Straightness, max. deviation on 100 mm (3.937") measured
length
Twist, max. deviation on 100 mm (3.937") measured length
1) Dimensions refer to oiled components.
03-2 Specifications, Engine

Flywh
Runout, measured radius 150 mm (5.905") ma
No. of teeth on starter gear ring 15
Sensor grooves in flywheel 54

Flywh
Runout for mating face against clutch bellhousing. ma
Runout for alignment against clutch bellhousing. ma

Lub

Tech

Oil
Oil change volume, incl. filter:
TAD1650VE (optional for TAD1660-62VE, TAD1640–
43VE-B, TAD1670-72VE) 53
Other engines 48

Oil Pre
Operating speed (above 1,100 rpm) 30
Low idle mi

Oil tem
Oil

P0006839

A: Bypass valve, oil cooler


03-2 Specifications, Engine

Fuel

Tech

Feed p
Feed pressure at:
600 rpm mi
1,200 rpm mi
full load mi

Bypas
Opening pressure 40

Fuel a
Inl

Tec

Tur
TAD1640–1642GE, TAD1641–1643VE, TAD1660-62VE,
TAD1640-43VE-B, TAD1670-72VE, TAD1650VE-B,
TAD1651VE
Manufacturer/type
End float, turbine shaft

TAD1650VE, TAD1650-51GE
Manufacturer/type
End float, turbine shaft

TWD1643GE, TWD1652-53GE, TWD1663GE,


TWD1672-73GE
HP Turbo:
Manufacturer/type
End float, turbine shaft
LP Turbo:
Manufacturer/type
End float, turbine shaft

Inle
Cold engine
Hot engine coolant temperature 75 95 °C (167 203 °F)
03-2 Specifications, Engine

Charg
1500 rpm
TAD1640GE 23
TAD1641GE 24
TAD1643VE-B 33

1500 / 1800 rpm


TAD1642GE 26
TWD1643GE, TWD1663GE 46
TWD1652GE, TWD1653GE 48
TAD1650GE 32
TAD1651GE 26

1800 rpm
TAD1640GE 23
TAD1641GE 25
TAD1641VE 19
TAD1642VE 22
TAD1643VE 23
TAD1650VE 20
TWD1672GE, TWD1673GE 36
TAD1643VE-B 33

1900 rpm
TAD1640VE-B, TAD1660VE 17
TAD1641VE-B, TAD1661VE 18
TAD1642VE B TAD1662VE TAD1650VE B
Co

Tec

Gen
Pressure cap opens at 75 k

The
Quantity 1
Opening temperature:
TAD1640–42GE, TAD1641–43VE, TAD1650VE,
TAD1650–51GE, TAD1660–62VE,
TAD1640-43VE-B, TAD1650VE-B, TAD1651VE,
TAD1670-72VE 82 °
TWD1643GE (early mod.), TWD1663GE (early
mod.) 76 °
TWD1643GE (later mod.), TWD1652GE,
TWD1653GE, TWD1663GE (later mod.),
TWD1672-73GE 72 °
Fully open:
TAD1640–42GE, TAD1641–43VE, TAD1650VE,
TAD1650–51GE, TAD1660–62VE, TAD1640–
43VE-B, TAD1650VE-B, TAD1651VE,
TAD1670-72VE 92 °
TWD1643GE (early mod.), TWD1663GE (early
mod.) 86 °
TWD1643GE (later mod.), TWD1652GE,
03-2 Specifications, Engine

IMPORTANT! IMPORT
Under no circumstances mix VCS (yellow) with Volvo Industria
Penta Coolant (green) or any other coolant. bination
Engines filled with VCS (yellow) will have yellow dec- ted on n
als as external distinguishing features, e.g. the cool-
ant filler cap will be surrounded by a yellow decal.

Refill q
Coolant quantity (engine, radiator and hoses):
TAD1640–42GE, TAD1641–43VE, TAD1650VE,
TAD1650–51GE, TAD1660–62VE, TAD1640–
43VE-B, TAD1670-72VE, TAD1650VE-B,
TAD1651VE 60 ±2 l
TWD1643GE (early mod.), TWD1663GE (early
mod.) 95 liter
TWD1643GE (later mod.), TWD1652-53GE,
TWD1663GE (later mod.), TWD1672-73GE 65 liter
03-3 Specifications, Electrical
Sen
Charge air pressure sensor
TAD engines:
Check value
TWD engines:
Check value

Camshaft sensor
Distance to camshaft

Flywheel sensor
Distance to flywheel

Pressure drop indicator


Active
Inactive

Charge air temperature sensor


05-1 Safety Instructions

05-1 Safety Instructions


Safet
This Se
descript
designs
the corr

Read the safety information below and the service manual section
instructions carefully before repair and service work is begun.

!
This symbol is used in the service manual and on the
fact that this is safety information. Always read such
Safety texts in the manual have the following ord

DANGER!
Indicates a hazardous situation which, if not avoided,
injury.

WARNING!
Indicates a hazardous situation which, if not avoided,
personal injury.

CAUTION!
I di t h d it ti hi h if t id d
Immobilize the engine by turning off the power
! supply to the engine at the main switch !
(switches) and lock it (them) in the off position
before starting work. Post a warning notice at
the main circuit breaker.

As a rule, all service operations must be carried


! out with the engine stopped. However, some !
work, such as adjustments, will require the
engine to be running. Approaching an engine
which is running is a safety risk. Bear in mind
that loose clothing or long hair can fasten in
rotating parts and cause serious personal
injury.

Be aware of hot surfaces (exhaust pipes, tur-


! bos, charge air pipes, starting heaters etc.) and !
hot fluids in pipes and hoses on an engine that
is running or has just stopped.
If work is done adjacent to a running engine, a
careless movement or a dropped tool may in the
worst case lead to personal injury.

Ensure that the warning symbols or information


! decals on the product are always clearly visible. !
Replace decals which have been damaged or
painted over.

Avoid getting oil on your skin! Protracted or


! repeated exposure to oil can cause skin to !
become dry. Irritation, dryness, eczema and
other skin problems may then result From a
05-1 Safety Instructions

Always use protective glasses or goggles when N


! carrying out work where a risk of splinters, ! re
grinding sparks, splashes from acid or other
chemicals is present. Your eyes are extremely
sensitive; injury may cause blindness!

Never use start gas or similar products as a S


! starting aid. They may cause an explosion in the ! s
inlet manifold. Danger of personal injury. M
w
te

All fuels, as well as many chemicals, are flam- M


! mable. Do not allow open flames or sparks in ! fu
their vicinity. Gasoline, some thinners, and R
hydrogen gas from batteries are extremely u
flammable and explosive when mixed with air in fi
the correct proportions. No Smoking! Ensure a
that the work area is well ventilated and take the m
necessary safety precautions before welding or a
grinding work is begun. Always ensure that p
there are fire extinguishers close at hand in the re
work area.

Batteries must never be exposed to open N


! flames or electric sparks. Never smoke in the ! p
vicinity of the batteries; they generate hydrogen a
gas when charged, which is explosive when d
mixed with air. This gas is easily ignited and th
highly explosive. A spark, which can be caused a
by incorrect battery connection, is sufficient to li
cause a battery to explode and cause damage. o

Do not touch the connections during start


The components in the electrical and fuel sys-
! tems on Volvo Penta products are designed and !
manufactured to minimize the risk of fire and
explosion. The engine must not be run in areas
where there are explosive materials.

Only use fuels and lubricating oils recom-


! mended by Volvo Penta. Refer to the Operator's !
Manual for the product in question. Use of fuels
that are of a lower grade may damage the
engine, the injection pump and the injectors. On
a diesel engine, low grade fuel can cause the
control rod to bind and the engine to over-rev,
with the risk of engine damage and personal
injury as a result. Low fuel and oil grades may
result in high service, maintenance and repair
costs.

Fuel delivery pipes must not be bent or straight-


! ened under any circumstances. Cracks may
occur. Damaged pipes must be replaced.
08-2 Special Service Tools

08-2 Special Service Tools


The follo
the eng
Penta b

P0006764
P0006782

885810 Fixture 9809726 Pneumatic hydr


pump
For upper timing cover Used with 9809729 or
9992670. Replaces 99962

P0006761 P0006763

9986173 Puller 9986179 Puller


For flywheel bearings For flywheel bearings
P0006771

P0006772

9990125 Nipple 9990143 Fixture


For turbo pressure manometer Up to and including eng
2016010024

P0006774 P0006775

9990157 Press tool 9990158 Piston ring c


pressor
For cylinder liner (7 pcs.
required)

P0006778
P0006777

9990164 Fixture 9990165 Guide sleeve


For pressure testing cylinder For valve spindle seal
head
08-2 Special Service Tools

P0006779 P0006780

9990192 Puller 9990210 Valve spring co


pressor
For rear crankshaft seal, used
with 9996400
P0004328

P0006787

9992000 Handle 9992269 Drift

Standard handle For installation of flywheel


ing

P0006794 P0006781

9992670 Hand pump 9992873 Nipple


Used with 9809729, alternative For pressure checking
to 9809726
p0004329

p0004330

9996394 Support 9996395 Support


P0004331

p0006800

9996400 Slide hammer 9996441 Cover, with c


ing nipple
For cooling system leak
P0004333

P0006804

9996662 Pressure testing kit 9996666 Nipple


08-2 Special Service Tools

P0006806

P0006805

9998249 Protective sleeve 9998250 Sealing ring


For unit injectors (6 pcs. For fuel duct in cylinder he
required) pcs. required)

P0006810

P0006813

9998252 Thread cutting tool 9998264 Lifting tool


For removal of copper sleeve For camshaft

P0006816

P0006818

9998487 Sleeve 9998494 Hose


For removal of oil filter For measuring fuel pressu
(red), used with 9990123 a
9990124
P00068115
P0006817

9998601 Fixture 9998629 Lifting tool


For upper timing cover Thread M10, 2 pcs. req

p0006797

P0006767

88800003 Fixture 88800021 Drift


Used with 9986485 (from and For removal of front cra
including engine no. seal
2016010025)

p0006799

P0006819

88800196 Drift 88800123 Plate


For removal of copper sleeve Used with 88800003 (fr
including engine no.
2016010025)
08-2 Special Service Tools

Other
The follo
working
from AB
cated.

P0006821 P0002930

885531 Pressure testing kit 885633 Torque multiplier


Cooling system
P0004342

P0006823

885811 Timing tool 885812 Timing tool


p0013448

P0002793

88800083 Piston ring pliers 88890102 Nipple


20-0 Engine Information, General

20-0 Engine Information, Gener


Place
TAD164
TAD164
TAD164
TAD164
TAD165
TAD166
TAD167

The figu
be locat

P0006848 1 4 5 2 P0006849
Pla
TWD
TWD

The
be lo

4 5

6
20-0 Engine Information, General

Locat
Electrical Components
1 Under pressure sensor, air filter (only TWD engines)
2 Camshaft position sensor
3 Pre-NOx sensor (TAD1670-72VE)
4 Coolant temperature sensor
5 Flywheel position sensor
6 Air inlet pressure/intake manifold temperature sensor
7 Coolant level sensor
8 Aux stop
9 Fuses
10 Crankcase pressure sensor
11 Fuel pressure sensor
12 Oil level/temp sensor
13 Water in fuel switch
14 Oil pressure sensor
20-0 Engine Information, General

AdBl
TWD16

Schematic connection stand-by AdBlue/DEF heating


heater system Hotstart CSM 10302 for a standby he
Tr
A nu
malf
cont
whic

IMP
Rea
nanc
oper

Symptoms and possible causes


The diagnosis button lamp flashes
Please refer to Diagnostic Function
Engine can not be stopped
2, 5
Starter motor does not rotate
1, 2, 3, 4, 5, 6, 7, 24
Starter motor rotates slowly
1, 2
Starter motor rotates normally but engine does not start
8, 9, 10, 11,
Engine starts but stops again
8, 9, 10, 11, 13
Engine does not reach correct operating speed at full throttle
9, 10, 11, 12, 13, 21, 25, 26
Engine runs roughly
10, 11
High fuel consumption
20-0 Engine Information, General

Reason code
1 Discharged batteries
2 Poor contact/open circuit in electrical wiring
3 Main switch turned off
4 Main fuse faulty
5 Faulty ignition lock
6 Faulty main relay
7 Faulty starter motor/-solenoid
8 No fuel:
– fuel cocks closed
– fuel tank empty/wrong tank connected
9 Blocked fuel fine-filter/pre-filter (due to contaminations, or stra
10 Air in the fuel system
11 Water/contamination in fuel
12 Faulty unit injectors
13 In sufficient air supply to the engine:
– blocked air filter
– air leakage between the turbo and the engine's intake man
– dirty compressor part in the turbocharger
– faulty turbo compressor
– poor engine room ventilation
14 Coolant temperature too high
15 Coolant temperature too low
16 Oil level too low
17 Coolant level too low
18 Air in the coolant system
Co
Su
Functional Disturbances Ext
For more detailed information and further fault tracing 1
help, See Operator's Manual, group 30, “MID 128,
PID 110 Engine coolant temperature”. If there is a
malfunction, first check the following items:
• Check that the coolant level is between the
markings on the expansion tank (at approx.
20°C) [68 °F]. If the level in the expansion tank
is too low, top up and start the engine. If the 2
coolant disappears, there is internal or external
leakage.
3
• Check that the coolant is not contaminated. If
the coolant is contaminated, this signifies inter- Int
nal leakage (oil) or that the cooling system has
a blockage (deposits). Blockage in the cooling •
system is caused by one or more of the follow-
ing factors: Fu
1 The coolant has not been changed at the •
specified intervals.
2 Incorrect mixture of coolant and water. •
3 Contaminated water has been used.

Clogging
Is often caused by high coolant temperature, internal •
or external blockage of the cooling system, or a com-
bination of both. If the cooling system is blocked, it
must be cleaned.
20-0 Engine Information, General

Charg
Charg

Tools:
999833
999849
999666
1 Co
to
to
2 Co
be
ma
If t
the
ch

Press
TAD164
TAD164
TAD165

NOTICE
tor is ele
manage

1 Ch
no
2 Re
filt
Cha
TAD
TAD
TAD
1

Inle
1

Cha
1

2
20-0 Engine Information, General

Test

Comp
The fue
remove
Head pa

Tools:
998853
999018
999824
999824
999859

Remo
1 IM
9998248 Ma
is
Re
Re
pro
the
99
2 Fit
to
P0004964 inj
3 Oil
bri
4 Fit
7

9
20-0 Engine Information, General

13 Re
9998248 all

P0004964

Install
14 Mo
Ins
Re
15 Fit
To
av
Ma
po
fie
16 Ins
roc
17 Ad
Un
P0004965 18 Ch
be
19 Re
20 Ve
Co
Too
9996
9996

Che
testi
Test
1
2

P0006858

5
20-0 Engine Information, General

Cylin
Tools:
999012
999623
998648
999016
999010
999016

Check
Check p
ing kit b
1 Co
pre
2 Se
us
wit

P0006858

3 Clo
pre
de
4 Un
op
Pre
Cyli
For a
9996
Rem
1
2

3
4

P0007007

10
20-0 Engine Information, General

16 Blo
wit

IM
Ma
thi
17 Re
ins
18 Re
the
Re

P0006858

Charg
1 Ins
ex
2 Ch
If t
lea
en
are
ca
se
ch

NOTICE
charge
and hos
very car
7
20-0 Engine Information, General

Wast
TWD16

Locali
The was
wastega

Tools:
999012

P0006860

1 Co
ing
pre
Ad
2

P0006862

4
20-0 Engine Information, General

5 Ins
the
Tig
6 Re
it.
7 Re
ac

P0006864

Drive
Inspe
Belts m
still war
be able
between
Both the
matic be

Sens
Sensor
3
88800031

P0010198

P0010219
20-0 Engine Information, General

Therm
Remov
Change
1 Pla
he
03

P0005072

Closed thermostat.

2 If t
pe
3 Ins
Ch

NO
mo
21-0 Engine Complete, Gener
Re

Gro

Cy
Ins
Clea
tion

IMPO
Cylin
mea

The
a sin

Cyl
Mea
the l

NOT
engi

1
21-0 Engine Complete, General

pis
ch
Cr
me

Cylin
(all)
Tools:
998987
999015
999015
999247
999359
999639
999639
999664
999696
999851
888000

Remo
Cylinde
cooling

IMPORT
It is imp
remove
nozzles
1 Re
ho
Tu
bo
2

IMPO
Re-i
dam

P0006912

5
21-0 Engine Complete, General

Install
8 Ch
ca
rec
Fit
Lo
9 Fit
99
Pla
ind
Ze
pre

P0006964

10 Me
an
Me
dia
Ca
Fo
sp
pla
co

NO
the
cy
rep
13

P0006917

14

15
21-0 Engine Complete, General

17 Lu
an

FRO
NT

P0006920

18 Ins
ma
arr
Pr

NO
pin
gre
co
pin

Ins
20

21

22

P0006923

23
21-0 Engine Complete, General

Crank
The cra

Inspect
essary o
The follo
checked
1 Cle
Me
an
sp
2 Ch
the
the
3 Pla
ma
cra
4 Me
on
Fo
nic

IM
Cr
5 Ch
Ma
flu
vio
Ma
Oil p

The
with

Too
9990
9990
9993

Rem
1

P0006884

2
21-0 Engine Complete, General

4 Re
ap
be
dir
too
5 Cle
sh
If t
de
6 Ch
wh

NO
ca
P0006971
av

Install
7 Lu
sh
8 Ins
cra
ag
oil

NO
sh
cu

Ma
be
oil

NO
11

12

P0006974

13

14
21-0 Engine Complete, General

Big e
Oil pan
remove

Tools:
999359

Remo
1 Fit
wh
1a
be
2 Ma
rod

IM
Be
3 Re
P0006884
ne

NO
led
4 Ch
5 Me
the
rem

Install
6 Fit
be
sh
Fly
Too
9986
9986
9991
9992
1
2

P0006977

3
21-0 Engine Complete, General

Flywh
Tools:
999359
999623
1 Re
2 Fit
3 Bo
wit
Re
tur
Lif
4 Cle
sh
5 Cle
fac
6 Ch
ins
Ch
7 Lif
ing
8 To
en
P0006931
too
9 Re
10 Ch
Se
Ins
Ge
Flyw
1

P0006979

P0006980
21-0 Engine Complete, General

Flywh
Pressu

Tools:
998987
999359
999969
1 Ins
99
ag
2 Re
ing
3 Se
ob
dia
(0
(5
If t
inv
ne
fla

P0006985
4 Re
the
Cra
Opti

Too
9990
9992
8880

Opti

Too
9990
9990
9992
9996
8880

Rem
1

5
21-0 Engine Complete, General

Remo
Tools:
999019
999640
1 Ha
tog

9990192 IM
Inc
da

999 6400

P0006989

Install
Tools:
999200
888000
1 Ch
3

P0004791

4
21-0 Engine Complete, General

5 Re

P0004793

6 Ca
ag
7 En
ma
8 Ins
ac
en
Cra
Too
9990
9990
9992
9996

Rem
1

P0006990

Inst
3
21-0 Engine Complete, General

5 Pre
bo
co

IM
No
cle
6 Re

P0006993

Conn
Importa
fracture

Install
Carefull
pads.

Undo th
tap the
it loosen

The spl
ing rod

When th
may occ
does no
adverse
Co
1

3 IMPOR
2 Regard
tions, r

P0006994 P0006995

3
21-0 Engine Complete, General

Valve

Work is
equipme
pcs. bol

NOTICE
cleanlin
head. D
or malfu

Alterna

Tools:
980972
980972
P0006996 999016
999017
999267
999615
999824

Note: 99
980972

Alterna

Tools:
999021

Altern
1 Fit
99
Alte
Too
9990
1

P0006997

5
21-0 Engine Complete, General

Valve
Alterna

Tools:
980972
999016
999017
999017
999021
999267
999615
999824

Note: 99
980972

Alterna

Tools:
999021

Altern

IMPORT
1 Blue
2 Brow
Alte
Too
9990
1

P0006997
21-0 Engine Complete, General

Valve
Cylinde

Tools:
998987
999247
1 Th
se
ex
ref

P0007000

2 Gr
the
tio
tro

IMPORT
Carefull
to preve
P0007001
3

P0007003

6
21-0 Engine Complete, General

Valve
Refer to

Valve
Cylinde

NOTICE
must be

CA
Risk of

Option

Tools:
980972
980972
999017
999615
888000
888001
888001

Optiona

Tools:
999267

Note: 99

Remo
999 2670 980 9729 1 Ins
Inst
6

IMPO
Wea
7

IMPO
After
head
from
may

Opti

Too
9992
8880
8880
8880
21-0 Engine Complete, General

Remo
NOTICE
cylinder

1 Ta
tog
2 Ta

Install
3 He
ing
sn
Lu
en
Val

For
Data

NOT
mac

P0007076

P0008416

Inlet valve
21-0 Engine Complete, General

Valve
1 Be
gu
era
2 Wh
un
en
sh
3 Gr
be
dis
ref
4 Ch
ga
co

NOTICE
do not n

NOTICE
as poss
age.

Valves
1 Ch
tha
Da

NO
va
2 Ch
an
Val
Too
9990
9990
9993

Rem
1

6
21-0 Engine Complete, General

Install
IMPORT
1 Blue
2 Brow

P0021295

7 Lu
Fit
Sli
dre
8 Ins
an
co
ma
9 Tra
ind
en
top
Re
de
9996
9998
9998
9998
9998
8880
8880
1

P0006890

5
21-0 Engine Complete, General

7 Us
an
sle
Ins
tor
mu

NO
be
du
8 Cle
P0007010 sle

9 Cle
98

P0007011

10 Cle
999 8580 98

980 8617 11 Re
12 Ch

NO
13

P0003615

1, 2. Older versions of the copper sleeve.


3. New version copper sleeve.

14

88800196
21-0 Engine Complete, General

88800196 16 By
dra
sle
Re

P0003618

17 Re
99
18 Ins
tio
19 Pu
ma
20 Ins
an
21 Ins
22 Fil
oc
an
9998250
Ca
Roc

Put a
the c
show

Mea
Alter

Com
Tech

P0007013

Gui
In no
surfa
that
not h
form
pone
Exam
are s

Acceptable wear: Una


The camshaft need not be changed. IMPO
The
chan
21-0 Engine Complete, General

Cams
Repla
The fac
togethe
be move

Therefo
are repla
that the
aligned.
vidually

P0007018

The hole
ment ho
center b
front an

If a repla
their nu
place as

P0007019
Tim
Valv
cove
rem

Too
8858
9993
9996
9998

Rem
1
2
3

P0006884

4
21-0 Engine Complete, General

6 Re
ho
7 Re
8 Re
9 Re
an

NO
thi
cra

P0006908

10 Re
an
11 Re

NO
an
12 Re
sid
13

14

P0006926

15
21-0 Engine Complete, General

16 Ins
17 Ins
bo
Tig

P0006927

18 Ins
be
ge

NO
ha
se

Tig
Sp

P0006929
23

24

P0006944

25

P0006947
21-0 Engine Complete, General

28 Re
ing
en

P0006930

29 Ins
ing
blo
30 Ins
se
ne

IM
No
31

32

33

P0006907

34
21-0 Engine Complete, General

36 Pre
tur
he
su
Ins
Tig
Tig

NO
led
ap
37 Ins
to
38 Ins
P0007021

999 8601
P0006952
Ex

Exp
TAD
TAD
TAD
TAD
TAD
TAD
TAD
1

P0006865
21-0 Engine Complete, General

2 Re
all
Als
co
3 Re
ex
4 Re

P0006866

5 Re
6 Re
ch
Re
bra
7

10

11

12
P0006868 13
21-0 Engine Complete, General

Expo
TWD16
TWD16
1 Dr
Sy
Dr
2 Re
Re
(C

P0006865

3 Re
all
Als
co
4 Re
5
6

7
8

P0006867

9
21-0 Engine Complete, General

10 Fit
Lif
11 Th
it.
Re
12 Re
13 Re
bra

P0006870

14 Un
pa
Hea
TWD
TWD

The
incre
Re-i
work
21-0 Engine Complete, General

Fitti

Engin
Applies

Tools:
999014
1 Re
un
2 Re
tro
Re
3 Re
the
Co
4 Att

P0006873

Engin
Applies
En

Cy
NOT
esse
alwa

Eng
and

Too
9990
9990
9990
9990
9990
9990
9993
9996
9996
9998
9998
9998
9998
1
2

3
21-0 Engine Complete, General

4 Co
tur

P0006868

5 Re

P0006876
7

P0006878

P0006879

10
21-0 Engine Complete, General

13 Re
ma
14 Th
ind
us
ma
rei

P0006880

15 Re
an
16 Re
ho

P0006881
18

P0006883

19
21-0 Engine Complete, General

20 Tu
ch
TDC

C
TD

P0003112

Early model.
22

D9 23
D11
D16
D9 D9
D11 D11 D9
D16 D16 D11
D16

P0006887

24
21-0 Engine Complete, General

25 Cle
inj
Re
26 Pu
99

P0006889

27 Ins
ind
Ma
sle

NO
29

30

P0006892

31

P0006893

32
21-0 Engine Complete, General

34 Re
Us
to
999 6239 tiv

NO
he
he

P0006895

35 Re
co
NO
99

P0006896

36 Re
37
38

P0006898

39

40

P0006899
21-0 Engine Complete, General

42 Re
Ca
loo

NO
an

Lif

P0006901

43 Re
fan
illu

P0006902
45

P0006904

46

P0006905

47
21-0 Engine Complete, General

Timin
Tools:
999623
1 Re
ou
2 Att
tw
Re
fly

Pin

IM
Th

P0006907

3 Re
rem
an
4

P0006909

7
21-0 Engine Complete, General

Pisto
Tools:
998648
999359
999639
999664
999696
1 Re
en
be

IMPORT
It is imp
remove
nozzles
2 Re
no
3 Tu
99

P0006911

4 Pre
are
ha
Lif

IMPORT
Replace
7

P0006913
21-0 Engine Complete, General

Crank
Tools:
999001
999011
1 Re
do
Us

P0006914

2 Lif

NO
(17
Cra
1

3
4

8
21-0 Engine Complete, General

Cylin
Tools:
999015
999696
999851
1 Ins
Re
lin
2 Lu
pli
ind

NO
low

P0006916
3

P0006917
21-0 Engine Complete, General

Pisto
1 Ins
2 Lu
an

FRO
NT

P0006920

3 Ins
pis
fac
Pr

NO
in;
4 Fit
5

IMPO
Alwa
rings
easi

P0006825

P0006922

6
21-0 Engine Complete, General

Pisto
Tools:
999015
999015
1 Oil
be
2 Te
the
3 Us
the
En
the

NO
are

NO
op
too
P0006924
the
4 Re
mu
ve
en
5 Ins
To
Tig
Pis
1

IMPO
Faul
pisto
pect
new
2

IMPO
Che
cylin
pisto
bloc
led,
3

P0006925

4
21-0 Engine Complete, General

Timin
1 Ap
en
2 Ins
are
ac
en

NO
be

P0006926

3 NO
ins

Oi
up
qu
4
5

P0006927

6
21-0 Engine Complete, General

9 Ins

P0006909

10 Ap
ing

P0006930
12

P0006931

13

14
21-0 Engine Complete, General

18 Ins
O-

P0006934

19 Ins
23

P0006900

24

25

P0006899

26
21-0 Engine Complete, General

28 Fit

P0006897

29 Ins
Cy
Too
9990
1

P0006896

5
21-0 Engine Complete, General

8 Lo
de
Ma
10
cy
blo
9 Sli
pla
10 Pla
fro

NO
en

P0006940

11 Ins
(1)
de
Sc
12 To
cia
Un

NO
po
the
ag
13 Ins
ing
18

P0006942
21-0 Engine Complete, General

Cams
Tools:
999359
1 Ins
W
2 Cle
the
3 Ins
on
cy
4 Pla
an
5 Tu
tha
to

P0006943
6
TDC

C
TD

P0003112

P0006885
21-0 Engine Complete, General

8 Cle
the
Ins
bra

NO
sid

To
±2
To
±5

P0006945
Fla
Too
8858
9998
1

P0006946

P0006947
21-0 Engine Complete, General

6 Ap
up
tra
7 Fit
ge

P0006949

8 On
ho
pre

P0006950
9

10
P0006951

999 8601
P0006952
21-0 Engine Complete, General

Unit i
Tools:
999015
999640
999825

NOTICE

1 Re
99
2 Fit
ca
Ins
inj
To
qu

P0006890

3 Re
tio

NO
ab
4 Lu
5 Re
ca
6 Ins
Ma
7

P0006883
21-0 Engine Complete, General

Adjus
The cam
cylinder
unit inje

NOTICE
camsha
bearing

P0006954

Early model.

TDC 5
3
En
1

P0006959

4
5

8
21-0 Engine Complete, General

10 Fit
11 Fit
rem
po
filt
ac
en
12 Ins
13 Fit
Re
14 Fit
alt
15 Re
rem
P0006868 16 Ins
17 Ins
co
18 Ins
19 Ins
inl
20 Ins
tio
21 Ins
ins
air
22 Ins
ch
23 Ins
ex
21-4 Valve Mechanism
Val
Adj
Iden
Dep
with
tant
acco

Tim
The
ders
injec

P0006954

Early model.

NOT
cam
TDC 5
3 bear
21-4 Valve Mechanism

NOTICE
on the e

Check t

Standa
For adju
illustrati
mechan

P0016503
TAD1640-42GE, TAD1641-43VE, TAD1640VE-B, TAD1641VE-B,
TAD1642VE-B, TAD1660-62VE, TAD1670-72VE, TWD1643GE,
TWD1652-53GE, TWD1663GE, TWD1672-73GE.

Valve m
Compre
For adju
marking
anism e
Brake) p
Valv
(Exh
For a
mark
anis
Reci

P0016505
TAD1650GE, TAD1650VE, TAD1651GE TAD1650VE-B,
TAD1651VE.
21-4 Valve Mechanism

Stand
TAD164
TAD164
TAD164
TAD166
TAD167
TWD16
TWD16

Tools:
999359

Valves
1 Ad
ind
5 Tu
TDC
3 Us
5
1
2

P0006956

3
21-4 Valve Mechanism

Valve
VCB
TAD164
TAD166
TAD167

Valves
1 Re

P0016506

2 Tu
Us

In
me
3

P0016508

P0016509
21-4 Valve Mechanism

5 IM
Ad
cy
ma

Ex
ind

P0016507

6 Ad
tha
the
Un
se
be
7

P0006956

8
21-4 Valve Mechanism

10 Wh
ad
Ch
the
Th
3.7
Ad
de

P0016513

11 Tig
arm
Tig

NO
rec

Re
rin
Ins

P0016506
Val
Inte
Re
TAD
TAD
TWD

Valv
1

P0016506

TDC 5
3
21-4 Valve Mechanism

4 Ad
0.3
Tig
ca

P0016508

5 Ad
ad
inj
Ad
(by
Tig
Tig
to

P0016509
7

P0006956

8
21-4 Valve Mechanism

10 Lo
fla
Tig
ca
Re

P0004808

11 Wh
ad
Ch
the
Th
4.0
Ad
de

P0016513

12 Tig
arm
Tig

NO
rec

Re
i
Val
Too
9989
9999

Cyli
Refe
1

4
999 9696

998 9876

5
22-0 Lubricating and Oil System, General

22-0 Lubricating and Oil System


When
Fuel a

! CA
Apply b
tive glov
oil and f
engine o

P0007022

Overv
A By-pa
B Safet
C Redu
D Contr
E Open
22-1 Oil pump and Line
Lub
1

3
4

P0006969
6

9
22-2 Oil filter

22-2 Oil filter


Relie
1 Cle
2 Re
3 Cle
ho
pla
4 Ch
ma
5 Fit
the
va
Tig
Tig
6 Sta
P0007024

Bypa
Repla
1 Re
2 Cle
3 Re
4 Cle
ho
5 Fit
tig
Saf
1
2
3

P0007026

Pis
1

2
3

4
5
22-2 Oil filter

Bypa
1 Cle
2 Re
oil
3 Fit
ac
en
4 Sta

P0007028

Oil Fi
1 Ch
If t
thr
ca
Oil
If yo
rectl
sens
The
refer

Too
9992
9996
9998
1

2
3

5
6
22-2 Oil filter

Engin
chang
Tools:
999848
999917
1 Re
an
nin

Ho
2 Cle
filte
oil

P0007029
3

8
22-2 Oil filter

Relie
1 Ch
ma

NO
red
2 Ch
im
Pre
an
ag

P0007031

Safet
1 Ch
ma

NO
sa
2 Ch
im
Pre
an
ag

P0007031
22-3 Oil cooler
Oil

Rem
1
2

3
4

P0006899

Inst
5

6
22-3 Oil cooler

Oil Co
Tools:
999666
999684
1 Re
Re
2 Cle
ble
Cle
3 Ch
tak
Te
eq

999 6845 4 Ins


are

P0007032

5 Ch
99
tha
By
1

P0007034
23-0 Fuel System, General

23-0 Fuel System, General


Fuel s
TAD164
TAD164
TAD164
TAD164
TAD165
TAD166
TAD167
1 Ch
tha
2 Tw
bra
3 Ve
pu
Air
No
4 Sta
10
5 Pe

P0007042
Fue
TWD
TWD
1

P0004969
23-0 Fuel System, General

Drain
TWD16
TWD16

IMPORT
Make su
and hos
1 Cle
he
2 Re
Re

P0005062

3 Re
(co
Re

NO
filte
4

P0005059

5
23-3 Fuel Feed Pump and Filter

23-3 Fuel Feed Pump and Filter


Engin
IMPORT
Do not f
There is
and cau

! W
The fue
cold, to
onto ho
1 Cle
2 Re
filte
Co
3 Cle
4 Lu
ne
ins
5 Ble
ble
Fue
Rem
1

P0004300

Inst
7
23-3 Fuel Feed Pump and Filter

Fuel
1 Dis
rat
2 Re
ho
ve
3 Re
fro
4 Cle
wit
ho
5 Ins
ca
Re
6 Lu
Sc
the
Th
7 Co
8 Ble
P0007038 ble
23-7 Injectors and Delivery Pi
Un
Too
9990
9990
9990
9998
9998

The
– 98
– 98
– 99

For a
and

NOT

NOT
code
ice m
the u

Rem
1
2

3
23-7 Injectors and Delivery Pipes

7 Re
9990013 Pla
Pu
loc
the
inje
9990006 Att
the
8 Att
rem

P0001370

9 Ins
tho
98
99
Inst

10

P0005064

11
23-7 Injectors and Delivery Pipes

12 Att
ter
To
to
13 Att
is
Att
14 Ins
15 Lu
wit

P0005066

16 Lift
of
Ch
be

IM
Tig
sh
To
sp
tha
P0004965
17 Cle
led
the
Ins
un
Pu
rin
Sle
Unit
Rep

Too
1159
9986
9996
9998
9998
9998
9998
8880
8880
8880

IMPO
Wor
ness
1

2
23-7 Injectors and Delivery Pipes

4 Th
su
ble

Pre
Re
Ins

Mi

P0019122

5 Pre
sle
Tig
pu
too
P0021200
23-7 Injectors and Delivery Pipes

Pu

Am
If t
ne
Ins

P0021202

7 Alt

Ins
Sc
po
8

P0007010

10

P0007011

11
999 8580

980 8617 12

13
23-7 Injectors and Delivery Pipes

15 Fit
Th
the
the
Oi

NO
sle
88800196

P0003616

88800196 16 Fit
cy
the
Ins
Us
sle
88800196 17

P0003618

18
19

20

21

22
23

9998250
23-8 Control System, ECM, Data Sets

23-8 Control System, ECM, Dat


Engin
NOTICE
warrant
be perfo
trol syst
show de
fault fre

! W
Faulty in
injury to
mation a
refer to

IMPORT
Exchan
fault tra
any circ
1 Cle
ne
2 Dis
ing
3 Re
pip
4 Re
cla
5 Re
the
8

10

11
12

P0007036

13
25-0 Inlet and Exhaust System, General

25-0 Inlet and Exhaust System,


Charg
1 Ins
ex
2 Ch
If t
lea
en
are
ca
se
ch

NOTICE
charge
and hos
very car
25-2 Exhaust Pipe, Silencer
Exh
TWD
TWD

Rem
1

2
3
4
25-2 Exhaust Pipe, Silencer

7 Ma
Ad
Tig
8 Ins
Re
9 Ins
ted
25-5 Turbo and supercharger
Tur
1

3
4

Tur
Alwa
25-5 Turbo and supercharger

Remo
TAD164
TAD164
TAD164
TAD164
TAD165
TAD166
TAD167

Variant
1 Re
air
2 Re
fro
3 Re
Ins
TAD
TAD
TAD
TAD
TAD
TAD
TAD

Vari
1

P0006868
25-5 Turbo and supercharger

4 Co
ag
5 Fil
de

IM
Ma
str
6 Fit
7 Fit
8 Fit
9 Sta

P0006875
Low
Alwa
boch
insta
A pr
rily is
are k
chan
grad
corre
Ther
oil a
to ru
befo
Blow
fold w
coul
It is
filter
plac
char

Re
TWD
TWD

Low
Vari
1

2
25-5 Turbo and supercharger

3 Re
4 Re
5 Un
the
6 Re
7 Re
tur
blo

8 Re
9 Lif
10 Tra
tur
4

P0007044

8
9

10
25-5 Turbo and supercharger

High
Always
bocharg
installed
A prereq
rily is th
are kep
changes
grade o
correctly
Therefo
oil and r
to run th
before t
Blow an
fold whe
could da
It is also
filter. De
place an
charger
Re
TWD
TWD

High
Vari
1

2
1

4
3

4
5
6

6 7

3
25-5 Turbo and supercharger

8 Re
wa

2X

2X

P0003630

9 Se
fre
Lif

P0007045

Insta
2
3

P0007047

The picture shows TWD1643GE, TWD1652-53GE.

8
25-5 Turbo and supercharger

9 Ins
ne

1 10 Fit
11 Tig
12 Ch
Fit

NO
the
13 Ins
ch
14 Tig
tig

NO
wa
Ad
15 Ins
2 Re

1
Wa
TWD
TWD

Rem
1

P0007049

The picture shows TWD1643GE, TWD1652-53GE.


25-5 Turbo and supercharger

3 Re
4 Re
5 Lif

P0007050

The picture shows TWD1643GE, TWD1652-53GE.

P0018881
The picture shows TWD1663GE, TWD1672-73GE.
Inst
6
7
8

10

11
25-8 Emission After-Treatment

25-8 Emission After-Treatment


Repa
TAD166
TAD167
TWD16

NOTICE
literatur
details m
cerned.
always

IMPORT
AdBlue/
age. Do
electrica
a compo
AdBlue/

CA
Gloves
clothes.

WA
In the ca
area mu
If you in
air.

NOTICE
order to
crystalli
Ele
Ho
TAD
TAD
TWD
1

P0019364

3
25-8 Emission After-Treatment

8 Re
9 Sw
up
oc
10 Pe
co

P0019365
Ad
TAD
TWD

Too
1158
1159
1

4
25-8 Emission After-Treatment

1158957 5 Cla
co

p0013226

6 Re
lat

7 Ins
8 Ins
To
9 Ins
Ins
tio
13
14

p0013223

IMPO
Fluid
Volv
exha

NOT

15
25-8 Emission After-Treatment

AdBl
TAD167
TWD16

Tools:
115895

Remo
1 Sto

NO
run
ing
2 Dis
3 Pla

NO
rec

P0019364

4 Un
(2)
Em
5

P0019367

p0013226

p0013222

7
25-8 Emission After-Treatment

8 Lif
pin

P0019369

9 Un
sh

P0019370
11

P0019372

12

P0019373

13
25-8 Emission After-Treatment

Install
14 Ca
the

P0019375

15 Ins

P0019373

16 I
17

P0019376

18

P0019370
25-8 Emission After-Treatment

20 Ins

P0019368

21 Ins
Ch
an
22 Re
23 Fil
24 To

P0019378

25 Re
Ad
TAD
TWD

Glov
cloth

P0013268 1

2
25-8 Emission After-Treatment

3 Im
wa

4 Un
6

p0013237

7
25-8 Emission After-Treatment

AdBl
TAD167
TWD16

Tools:
115895

CA
Gloves
clothes.

1 Sto

NO
run
ing

2 Dis

P0019364

3 Pla

NO
rec
5

P0019367

p0013226

p0013222

7
25-8 Emission After-Treatment

8 Su
loc

P0019369

9 Re
ho
Ca

P0019371
11

P0019380

12
25-8 Emission After-Treatment

14 Ins

P0019382

15 Ins

P0019376
17

P0019368

18

19
20
21
22

P0019378

23
25-8 Emission After-Treatment

Exha
Chan
TAD166
TAD167
TWD16
1 Dis

P0019364

2 Re
3 Un
4 Un
5 Sc
6 Ins
Do
TAD
TAD
TWD

Rem
1

P0019364

3
25-8 Emission After-Treatment

4 Re

NO
be

P0019385

5 Re
6 Re

P0019386
Inst
7
8

P0019387

10

P0019388
25-8 Emission After-Treatment

12 Re
13 Sta
14 De

P0019365

NOTICE
AdBlue®

p0013225
Ad
TAD
TWD

Too
1159
1

3
25-8 Emission After-Treatment

4 Ex
ga
Ad
ing

5 Re
Re
6

p0013242

8
25-8 Emission After-Treatment

AdBl
TAD167
TWD16
1 Sto

NO
run
ing
2 Dis

P0019364

3 Pla
4 Un

NO
rec
5

P0019390

7
25-8 Emission After-Treatment

8 Tig
Tig
ft.)

P0019392

9 Re
10 Sta
11 De

P0019365

NOTICE
AdBlue®
So
Ch
TAD
TAD
TWD

Too
1158

Rem
1

P0019364

A
25-8 Emission After-Treatment

Install
6 Ins
Ins
7 Ins
8 Ins
cla

P0013270

9 Re
ho

A
p0013271

10 Re
Pre
TAD
TWD

Too
8889
8889
1

p0013258
25-8 Emission After-Treatment

2 Cle
Re

p0013259

3 Re
4

p0013262

p0013264
25-8 Emission After-Treatment

Pump
TAD166
TWD16

1 1

2
2

2 2
p0013266
IMPORT
The dos
ent vers
Before c
corresp

IMPORT
Make su
1

4
25-8 Emission After-Treatment

5 Re

NO

p0013257

6 Ex
ac
ho
ca
7

p0013232

9
25-8 Emission After-Treatment

10 Tra
ne

NO
an
11 Ins
the

NO
pro
12 Re
tric

p0013251

13 Ins
ing
loc
14 Ins
ele

D
16
17

18

19
20

p0013223
25-8 Emission After-Treatment

Pump
TAD167
TWD16

Remo
1 Sto

NO
run
ing
2 Dis

P0019364

3 Re
4

P0019394

p0013222

5
25-8 Emission After-Treatment

Install
6 Ins
bo

P0019395

7 Ins
9
10
11

P0019365

NOT
AdB

p0013225

Co
Tan
TAD
TWD
1
25-8 Emission After-Treatment

Comb
Tank
TAD167
TWD16

Tools:
115895

Remo
1 Sto

NO
run
ing
2 Dis

P0019364
3

P0019367

115895

p0013226

p0013222

5
25-8 Emission After-Treatment

Install
6 Ins

P0019376

7 Ins
Ch
an
8 Re

P0019378
Tem
TAD
TWD

Too
8889
8889
1

p0013258
25-8 Emission After-Treatment

2 Cle
co

p0013259

3 Re
4

p0013261

7
25-8 Emission After-Treatment

Chec
AdBl
TAD166
TAD167
TWD16

1 Rem
ibility

P0019380

2 Dip t
in th
3 Attac
reac

Evaluat
• If the
the p
Ch
flui
TAD
TAD
TWD

Too
8889

NOT
tilled

1 R
ib
2 D
fa
U
le

P0019380

3 A
(8
26-0 Cooling System, General

26-0 Cooling System, General


Drain
NOTICE
TAD165
corresp

WA
Do not o
hot, exc
persona

IMPORT
On eng
the eng
coolant

Tools:
999604

NOTICE

1 Re

NO
ex
ato
2

P0006865

Co
NOT
TAD
corre

All c
men

Coo
radia
shou
26-0 Cooling System, General

om
cle
5 Dr
Re
if n
To
in
wit
be
6 Flu
wit
on
nin
he
tyi
7 Sh
pe
Vo
me
low
co
8 Wh
co
9 Re
ing
Co
Up

Coola
Topp
NOTICE
TAD165
1

TAD engines

P0002096

TWD engines
26-0 Cooling System, General

Filling
NOTICE
advance
pletely f
correct

IMPORT
Do not s
complet
1 Ch
2 Op
ca
3 Fil
MI
4 Sta
be
ve
tra
If a
sys
an
TAD engines 5 Sto
the

TWD e
2 1 Op
rad
1
2 Fil
ple
3
4

IMPO
Do n
3 com

P0002098

Co
Too
9996
9996

NOT
TAD
corre

Che
ing k
Hea
1
2

3
26-0 Cooling System, General

4 Co
pre
red
ap
(B
5 Th
the
lea

NO
do
no
6 Sh
ing
P0006859 un
op
7 Re
8 Ch
Ins
9 Sta
oc
26-1 Radiator, Heat Exchange
Ra
TWD
TWD

Rem
1

2
3

4
5
26-1 Radiator, Heat Exchanger

6 Re
7 NO
rel

Lif

NO

P0007058

P0007059
Inst
8

P0007060

10
11
12
26-2 Coolant Pump, Thermostat

26-2 Coolant Pump, Thermosta


Coola

Remo

! CA
Disconn
the eng
1 Dr
to
2 Re
ab
3 Re
pu
be
Re
4 Re
Pre
ac
the
The
Too
9996

Rem
1

P0004690

4
26-2 Coolant Pump, Thermostat

Install
5 Cle
the

P0005071

6 Ins

P0004691
Dri
TAD
TAD
TAD
TAD
TAD
TAD
TAD
1

3
4

6
7
8
9
10

11
26-2 Coolant Pump, Thermostat

Drive
TWD16
TWD16
1 Sw
the
2 Re
low

P0007073
3

P0006869

6
26-2 Coolant Pump, Thermostat

Belt T
Right b
tector.

Drive b
Change

Remo
1 Un
an
2 Un
the
The
Rem
Cha
1

P0005072

Closed thermostat.

3
26-2 Coolant Pump, Thermostat

Coola
IMPORT
The coo
intervals
significa
engine w
coolant
always
1 Sh
2 Cle
plie
3 Lu
so
Sc
the
4 Op
5 Sta

P0007065

1 Tap open
2 Tap closed
26-5 Charge Air Cooler with C
Low
TWD
TWD

Rem
1
2
3
4
5

6
6 5 3
7
7 2 8
4x
1
4

P0003633

9
26-5 Charge Air Cooler with Connections

10 Re
bra
11 Un
12 Lift

P0007067

Install
13 Ins
un
14 Tig
15 Ins

P0007067
19

20
21

6 5 3
22
7 2
4x
1
4

P0003633

23
24
25

26

P0007068
26-5 Charge Air Cooler with Connections

Uppe
TWD16
TWD16

Remo
1 Re
2 Dr
3 Un
4 Re
bra
ch

P0007070
7

8
9

P0007071

Inst
10

P0007072

11
26-5 Charge Air Cooler with Connections

14 Ins
bra
15 Ch
Fit
air
16 Ins

17 Ins
bra
ch
Tig
18 Ins
19 Ins
20 Ad
Re
Up
21 Ch
32-1 Alternator
Alt
TAD
TAD
TAD
TAD
TAD
TAD
TAD

Left

Coo
Cha

Rem
1
32-1 Alternator

2 De

Pin

Wi

P0004688

Altern
TWD16
TWD16

IMPORT
Always
cracked
1 Sw
the
2

P0007073
32-1 Alternator

3 Fit
Lif
dri
4 Fit
(2)
Pre
alt
5 Ch
rol
reg
6 Pre
do
7 Lif
ins
8 Ins
P0007074 9 Fit
10 Sta
33-1 Starter Motor
Sta

Rem
1
2
3

P0007066

5
33-1 Starter Motor

7 Ins
Tig

P0007075

8 On
Ins
co
9 Ins
10 Ch
Alphabetical index
A E
About this Workshop manual..................................... 3 Electrica
AdBlue/DEF tank heating......................................... 60 Emission
AdBlue/DEF Tank, Change............................ 251, 254 Engine...
AdBlue/DEF Tank, Cleaning.......................... 261, 264 Engine A
AdBlue/DEF-Pump Filter, Change................. 275, 278 Engine b
Adjustment Markings.............................................. 180 Engine C
Alternator................................................................ 329 Engine C
Alternator Belt, Change.................................. 329, 330 Engine D
B Engine F
Belt Tensioner, Change.......................................... 320 Engine F
Big end bearing, Change (all)................................... 90 Engine In
Bypass Valve Oil Filter, Change............................. 202 Engine o
Bypass Valve, Oil Cooler, Replace........................ 209 Engine T
Bypass Valve, Oil Filter Bypass, Replace.............. 200 Exhaust
Exhaust
C Exhaust
Camshaft Bearing Housing, Replace..................... 120 Exposing
Camshaft, Installation............................................. 172 Exposing
Camshaft, Wear Check.......................................... 119
Charge Air Cooler with Connections...................... 323 F
Charge Air Cooler, External Cleaning...................... 65 Fitting th
Charge Air Pipe, Leakage Check..................... 72, 230 Flank Cle
Charge Pressure, Troubleshooting.......................... 64 Flywhee
Checking for diesel or oil in the AdBlue/DEF Flywhee
solution................................................................... 302 Flywhee
Checking urea concentration in the fluid................ 303 Fuel Fee
Combined Tank Unit, AdBlue/DEF Tank, Fuel Fee
Change........................................................... 295, 296 Fuel Pre
Common Interference Causes................................. 63 Fuel Sys
Compression Test.................................................... 66 Fuel syst
Connecting Rod Bushing, Check up...................... 101 Fuel Sys
Connecting Rod, Check......................................... 100 G
O V
Oil cooler................................................................ 207 Valve Gu
Oil Cooler, Pressure Testing.................................. 208 Valve Gu
Oil Cooler, Replace................................................ 207 Valve Me
Oil Filter, Check...................................................... 202 Valve me
Oil Pressure Sensor, Check................................... 203 Valve Se
Oil pump and Line.................................................. 199 Valve Se
Oil Pump, Check.................................................... 199 Valve Ste
Other Equipment...................................................... 54 Valves a
Overview Control Valve.......................................... 198 Valves, I
P Valves, R
Piston Cooling Jet, Installation............................... 161 W
Piston Cooling Valves, Replace............................. 201 Wastega
Piston, Pre-installation............................................ 158 Wastega
Pistons, Installation................................................ 160 When yo
Pistons, Removal................................................... 152 cation O
Placement of Instrument Socket(s).................... 56, 57
Pressure Sensor, Change...................................... 283
Pump Unit, Change........................................ 286, 292
R
Radiator Assembly, Change .................................. 311
Radiator, Heat Exchanger...................................... 311
Relief Valve, Check................................................ 206
Relief Valve, Replace............................................. 200
Repair instructions.............................................. 4, 248
Replacement of Components................................... 79
S
Safety Instructions.................................................... 44
Safety Valve, Check............................................... 206
Safety Valve, Oil Pressure, Replace...................... 201
Sensors, Adjustment................................................ 76
Sleeve for unit injector replace 114 221
References to Servi

Group No. Date

....................................................................................................

....................................................................................................

....................................................................................................

....................................................................................................

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....................................................................................................

....................................................................................................

....................................................................................................

....................................................................................................

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....................................................................................................

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Proposal/Motivation: ...................................................................
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