Volvo Penta TAMD70D Service Manual

EngineWorkshop Manual2(0)DTAMD61A, TAMD62A, TAMD63L-A, TAMD63P-ATAMD71A, TAMD71B, TAMD72A, TAMD72P-A,TAMD72WJ-A

8Safety informationSafety rules for fluorocarbonrubberFluorocarbon rubber is a common material in sealrings for shafts, and in O-rings, for example.Wh

9Special toolsIn all cases where it is practical, tools have had their part number punched on, but not the last figure. The last fig-ure (after the da

10Special tools9996400-9 Impact hammer. Used with 9996419 or9996657.9996402-5 Mandrel for installing copper sleeves9996419-9 Extractor for the steel r

11Special tools9996852-1 Connection washer for pressure testingthe cylinder block9996855-4 Mandrel for installing the front crankshaftseal9996861-2 To

12Other special equipment885126 9988539 9989876 9999696Other special equipment885126-3 Piston ring compressor9988539-4 Compression gauge9989876-9 Dial

13Design and functionEngine, generalThe engines are straight 6-cylinder, 4-stroke diesel en-gines with overhead valves. They have direct fuel in-jecti

14Design and functionNew sea water pumpStop function with solenoid valveNew electrical system with sealed connectorsand cables run in flexible hoses.

15TAMD72A – TAMD72WJ-ATAMD72WJ-A is a TAMD72A which has been modi-fied for use with a water jet unit. TAMD72WJ-A has:New injection pump with changed s

16Engine presentationTAMD61A1 Turbocharger2 Air filter3 Relay for electric starting heater4 By-pass valve (directs air flow through aftercooler)5 Expa

17TAMD62ADesign and function1 Air filter2 By-pass valve (directs air flow through aftercooler)3 Filter for crankcase breather4 Aftercooler5 Heat excha

18Design and function1 Fuel filter, fine2 Smoke limiter3 Coolant filler cap4 Injection pump5 Oil filler cap6 Junction box with circuit breakers7 Turbo

1911Design and functionTAMD71A1 Turbocharger2 Air filter3 Relay for electric starting heater4 By-pass valve (directs air flow through aftercooler)5 Ex

20Design and functionTAMD71B1 Junction box with circuit breakers2 Coolant filler cap3 Fuel filter4 Oil filler cap5 Injection pump6 Stop solenoid7 Turb

211 Junction box with circuit breakers2 Coolant filler cap3 Fuel filter4 Oil filler cap5 Injection pump6 Stop solenoid7 Wastegate valve (by-pass valve

221 Junction box with circuit breakers2 Coolant filler cap3 Fuel filter, fine4 Smoke limiter5 Injection pump6 Oil filler cap7 Turbocharger8 Water cool

23Design and functionTAMD72P-A (EDC)1 Coolant filler cap2 Fuel filter, fine3 Control unit (EDC)4 Oil filler cap5 Injection pump6 Junction box with cir

24Design and functionComponent descriptionCylinder headsThe engine has two (identical) cylinder heads, each ofwhich covers three cylinders. The cylind

25Cylinder blockThe cylinder block is cast in one piece and is made ofspecial cast iron alloy. The tension forces in the cyl-inder head screws, caused

26Design and functionPistonsThe pistons are made of light metal alloy. The topcompression ring, which transmits the majority of theheat which is trans

27TAMD71Each piston has three compression rings (early ver-sion), or two compression rings (later version)* andone oil scraper ring.The upper compress

Group 21 Engine bodyMarine enginesTAMD61A • TAMD62A • TAMD63L-A • TAMD63P-ATAMD71A • TAMD71B • TAMD72A • TAMD72P-ATAMD72WJ-AContentsGeneral instructio

28Design and functionTiming gearThe timing gear consists of cylindrical gear wheelswith spiral cut teeth.The injection pump and camshaft are driven fr

29Design and functionCon rodsThe con rods have an I section, and are drilled forpressure lubrication of the gudgeon pins. Since thecon rods have obliq

30Repair instructionsGeneralBefore every major service task, a condition testshould be carried out if possible, to determine the gen-eral condition of

31Repair instructionsEngine stand attachmentJig no. 9996787 is used to attach the engine to theengine stand. The jig is screwed to the right-hand side

32Repair instructionsCylinder head, renovationCondition test, engineCompression testSpecial tool 9998009A compression test is done in order to assess

33Repair instructions9Free the plastic pipe for the smoke limiter from thefront edge of the induction manifold. Remove the in-duction manifold.Applies

34Repair instructions24Free the exhaust pipe from the turbocharger.Remove the coolant pipe between the turbo and thecylinder block.Remove the oil pipe

35Repair instructions2Clean all components, be especially careful with theoil and coolant galleries.Remove any remaining soot and contamination fromth

36Repair instructions46Lower the cylinder head into a bath of water at 70°Cand open the tap.Check that the knob on the reduction valve of theproof tes

37Repair instructionsCylinder head, inspectionWarpageThe warpage of the cylinder head must not exceed0.03 mm.The check is made with a feeler gauge and

2Safety informationIntroductionThis Workshop Manual contains technical data, des-criptions and repair instructions for Volvo Penta pro-ducts or produc

38Repair instructions2Place dial gauge 9989876, with magnetic stand9999696, so that the tip of the dial gauge rests uponthe edge of the valve head. Mo

39Repair instructionsCylinder head, planingSpecial tools: 9992479, 998976.The warpage on the cylinder head must not exceed0.03 mm.If the warpage excee

40Repair instructions2The remaining bits (marked C-D) are intended to workthe sealing plane, and should be adjusted to ±0.02mm.Sealing grooves in cyli

41Milling the grooves13Set the cylinder head up in a vice.WARNING! Use protective jaw pads to avoiddamaging any sealing surfaces.Make sure that the cy

42Repair instructions16Install the spring and nut. Tighten the nut loosely.Valve seat, replacementSpecial tools: 9992479, 99897617Turn the tool clockw

43Repair instructions3Clean the valve seat location carefully, and check thatthere are no cracks. Measure the diameter of thevalve seat location. Use

44Repair instructionsValves, grinding(does not apply to engines with Nimonicvalves)** Note. Nimonic valves must not be ground.Valve sealing angles:Inl

45Repair instructions4Press out the rocker bushing with mandrel no.9991967 for the 6(x) series, or 9992677 for the 7(x)series.5Turn the mandrel over a

46Repair instructionsChecking the valve springs Cylinder head, assemblySpecial tools: 9992479, 99968471Clean the mating planes of the cylinder head an

47Repair instructions5Torque the cylinder head screws in the numbered se-quence in the tightening schedule, four times.1st tightening: 30 Nm (3 kpm)2n

3Safety informationAvoid skin contact with oil. Long-term or repea-ted contact with oil can remove the natural oilsfrom your skin. The result can be i

48Repair instructionsCopper sleeve for injectorsSpecial tools, 6(x) series: 9812546, 9996400,9996402, 9996419, 9996421, 9996643, 9996650,9996651, 9996

49Repair instructions7Injector and copper sleeve1 O-ring 4 Steel ring2 Copper sleeve 5 Protective ring3 Seal ring 6 Yoke8Check that the O-ring has com

50Repair instructionsMethod 2 – with a cutter (detachedcylinder head)Special tool: 9996650, 9996651Cleaning up with a cutter is done in two stages.NOT

51Repair instructions6x-series7x-seriesClearance between the copper sleeve and steel ring.5Install mandrel 9996402 and then re-install the presstool (

52Repair instructions6Remove the press tool and mandrel.(6x series): Install the cylinder head screws andtorque them. Please refer to “Cylinder head,

53Cylinder block, renovationPiston and connecting rod,removal(Cylinder head and sump removed)Special tool: 9996847.Please refer to “Cylinder head, rem

54Repair instructionsPiston and con. rod, inspectionChecking piston wearCheck the pistons for cracks, damaged piston ringdowels and worn piston ring g

55Repair instructions35Press in the new bush, using the same tool as wasused for extracting the old one. Make sure that the oilhole in the new bush co

56Repair instructions4Press the gudgeon pin in carefully with mandrel no.992071 and install the second circlip.NOTE! It should be possible to press th

57Repair instructionsMeasure the upper and lower turning points in the cyl-inder liner, and at several points along the height ofthe liner. At each me

4Safety informationAlways use fuels recommended by Volvo Pen-ta. Refer to the Instruction Book. The use of lo-wer quality fuels can damage the engine.

58Repair instructionsCylinder liner, honingHoning pattern on cylinder liner boreIt is important that the cylinder liner should retain itsoriginal honi

59Repair instructionsCylinder liner seat, renovationSpecial tools: 9989876, 9992479, 9996847 (2 No.),9999508 (7x series), 9999514 (7x series), 9999538

60Repair instructionsCylinder liner, installationSpecial tools: 9989876, 9992000, 9992479, 9996847(2 No.), 99968541Remove the old seal rings from the

61Repair instructionsPiston assemblySpecial tool: 8851261Oil the piston with engine oil.2Make sure that the piston ring openings point in differ-ent d

62Repair instructionsTiming gear, disassemblySpecial tools: 9992655, 9992658, 9992697Timing gear1 Crankshaft gear 5 Injection pump drive gear2 Idler

63Repair instructions2Remove the polygon hub centre screw, remove thewasher and pull the hub off with tool no. 9992655.3Remove the timing gear cover.4

64Repair instructionsInspecting the timing gearsClean the gear wheels and other components in thetiming gear, and inspect them carefully. Replace anyg

6570 ± 7 Nm(7 ± 0.7 Nm)33 ±4 Nm(3.3 ±0.4 Nm)Repair instructionsTiming gear, assemblySpecial tools: 884948, 884949IMPORTANT! All gear wheels in the tim

66Repair instructionsSeal ring, polygon hub,replacement(With polygon hub removed)Special tool: 99968551Remove the old seal ring by means of a screwdri

67Polygon hub, installationSpecial tool: 8849491Lubricate the crankshaft nose with molybdenum disul-phide compound. Install the centring section of ma

5General informationAbout the service manualThis workshop manual contains technical data, de-scriptions and repair instructions for the standardversio

686(x) series ... 8.000 8.000 7.8 7.87(x) series ... 8.006 8.268 7.8 7.8Camshaft lift Min lift heightin mm in mm inlet exhaust inlet exhaust

69Inspection of valve lifters andcamshaftRepair instructionsInspection of valve liftersUse a steel rule to check that the surface of the valvelifter i

70It has been found that the damage only gets worse invery rare cases.Check the camshaft bearing surface and cam profilesfor wear. The cams can be wor

71Repair instructionsCamshaft installation1Oil the camshaft bearing surfaces and cam profiles.Carefully slide the camshaft into place, so as to avoidd

726Carefully lift the crankshaft out with lifting strops anda block and tackle.Inspection, crankshaft andbearingsThe crankshaft is nitrocarburised. A

73Repair instructionsCrack checkingSeizure damage can cause overheating crackswhich can only be discovered with specialequipment. Any cracks and notch

74Repair instructionsCrankshaft, renovationIn general, both re-grinding and trueing reduce thefatigue resistance. So do not re-grind bearingjournals (

75Repair instructionsThe surface finish (profile depth) of bearing surfacesand fillets is 2 mm, medium surface deviation 5 mm.This surface finish is a

76Repair instructionsCrankshaft, assembly1Place the bearing shells in their places.Make sure that bearing shells of the correctdimensions are installe

77Repair instructions12Install a new rear crankshaft seal. Please refer toitems 2 and 3 in the “Crankshaft seal, rear” methodon page 83.13Clean the ma

6Repair instructionsThe work methods described in the Workshop Manualare applicable for a workshop environment. Theengine is therefore removed from th

78Repair instructions6Install new bearing shells. Make sure that the guidepin on the bearing shell is correctly located in thecutouts in the con rod a

79Repair instructions3Clean and check the bearing seat, bearing cap,bearing journal and bearing shells for damage. Ifthe bearing shells have seized, t

80Repair instructions9Use a narrow wood or plastic pin to remove thethrust washers.10When all the main bearing caps have been torqued,check the cranks

81Repair instructionsGear ring, replacement(Flywheel removed)1Drill 1–2 holes in the gap between two teeth on thegear ring.Split the gear ring across

82Repair instructionsFlywheel, indicationSpecial tools: 9999696, 99898761Place a dial indicator with its tip on the flywheel.2Zero the dial gauge. Tur

83Repair instructionsCrankshaft seal, rear,replacement(Flywheel removed)Special tools: 9992000, 99964371Tap in one side of the oil seal with a narrow

84References to Service BulletinsGroup No. Date Concerning...

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7735718-4 English 08–1996

7Safety informationAngular tightening torqueFor angular tightening torque the screw union istightened with a given torque, thereafter furthertightenin