Workshop Manual

Workshop Manual
Technical Data
TD630ME/VE, TWD630ME/VE, TD640VE
TD730ME/VE, TWD730ME/VE
TWD731ME/VE, TWD740VE
TD1030ME/VE, TWD1030ME/VE
TWD1031VE
Workshop Manual
Technical Data
Industrial Diesel Engines
TD730ME/VE, TWD730ME/VE, TWD731ME/VE
TWD740VE, TD1030ME/VE
TWD1030ME/VE, TWD1031VE
Contents
Safety precautions ................................................... 2 TD730ME/VE, TWD730ME/VE, TWD731ME/VE,
TWD740VE
General information ................................................. 5 General ..................................................................... 20
Engine ....................................................................... 21
Repair instructions .................................................. 6 Valve mechanism .................................................... 22
Camshaft .................................................................. 23
Location of identification plates ............................ 9 Timing gears ............................................................. 24
Crank mechanism .................................................... 25
TD630ME/VE, TWD630ME/VE, TD640VE Flywheel ................................................................... 27
General ..................................................................... 10 Lubricating system ................................................... 28
Engine ....................................................................... 11 Fuel system ............................................................. 30
Valve mechanism .................................................... 12 Intake and exhaust system, turbo .......................... 31
Camshaft .................................................................. 13 Cooling system ........................................................ 31
Timing gears ............................................................. 13 Wear tolerances ....................................................... 32
Crank mechanism .................................................... 14 Tightening torques .................................................... 32
Flywheel ................................................................... 15
Lubricating system ................................................... 16
Fuel system ............................................................. 17 TD1030ME/VE, TWD1030ME/VE, TWD1031VE
Intake and exhaust system, turbo .......................... 18 General ..................................................................... 33
Cooling system ........................................................ 18 Engine ....................................................................... 34
Wear tolerances ....................................................... 19 Valve mechanism .................................................... 35
Tightening torques .................................................... 19 Camshaft .................................................................. 36
Timing gears ............................................................. 36
Crank mechanism .................................................... 37
Flywheel ................................................................... 38
Lubricating system ................................................... 39
Fuel system ............................................................. 40
Intake and exhaust system, turbo .......................... 41
Cooling system ........................................................ 42
Wear tolerances ....................................................... 43
Tightening torques .................................................... 43
1
Safety Precautions
Introduction
This Workshop Manual contains technical specifica-
engine which is operating, careless movements
tions, descriptions and instructions for the repair of
or a dropped tool can result in personal injury.
the specified Volvo Penta products or product types.
Check that you have the correct Workshop Manual for
your engine. Take care to avoid contact with hot surfaces
(exhaust pipes, Turbocharger (TC), air intake
Before starting work on the engine read the “Safe- pipe, starter element etc.) and hot liquids in
ty Precautions”, “General Information” and “Rep- lines and hoses on an engine which is running or
air Instructions” sections of this Workshop Manual which has just been stopped. Reinstall all pro-
carefully. tective parts removed during service operations
before starting the engine.
Important Check that the warning or information labels on

In this book and on the product you will find the follo- the product are always clearly visible. Replace
wing special warning symbols. labels which have been damaged or painted
over.
WARNING! Possible danger of personal injury,
extensive damage to property or serious me-
chanical malfunction if the instructions are not
followed. Never start the engine without installing the air
cleaner (ACL) filter. The rotating compressor in
IMPORTANT! Used to draw your attention to the Turbo can cause serious personal injury.
something that can cause damage or malfunc- Foreign objects entering the intake ducts can
tions on a product or damage to property. also cause mechanical damage.
Note! Used to draw your attention to important infor-

mation that will facilitate the work or operation in
progress. Never use start spray products or similar when
starting the engine. They may cause an explo-
sion in the inlet manifold. Danger of personal in-
Below is a summary of the risks involved and safety
jury.
precautions you should always observe or carry out
when operating or servicing the engine.
Only start the engine in a well-ventilated area. If

Immobilize the engine by turning off the power
operating the engine in an enclosed area ensure
supply to the engine at the main switch (switch-
that there is exhaust ventilation leading out of
es) and lock it (them) in the OFF position before
the engine compartment or workshop area to
starting work. Set up a warning notice at the en-
remove exhaust gases and crankcase ventila-
gine control point.
tion emissions.
As a general rule all service operations must be
carried out with the engine stopped. However,
some work, for example certain adjustments re-
Avoid opening the coolant filler cap when the
quire that the engine is running when they are
engine is hot. Steam or hot coolant can spray
carried out. Approaching an engine which is op-
out as system pressure is lost. Open the filler
erating is a safety risk. Loose clothing or long
cap slowly and release the pressure in the sys-
hair can fasten in rotating parts and cause seri-
tem, if the filler cap or a drain cock/venting cock
ous personal injury. If working in proximity of an
must be opened, or if a plug or engine coolant
line must be removed on a hot engine.
It is difficult to anticipate in which direction

steam or hot coolant can spray out.
2
Safety Precautions
Hot oil can cause burns. Avoid getting hot oil on WARNING! The delivery pipes must under no
the skin. Ensure that the lubrication system is circumstances be bent. Damaged pipes should
not under pressure before carrying out any work. be replaced.
Never start or operate the engine with the oil
filler cap removed, otherwise oil could be eject-
ed. All fuels and many chemical substances are
flammable. Do not allow naked flame or sparks
in the vicinity. Fuel, certain thinner products
Stop the engine before carrying out operations and hydrogen from batteries can be extremely
on the engine cooling system. flammable and explosive when mixed with air.
Smoking is not to be permitted in the vicinity!
Ensure that the work area is well ventilated and
take the necessary safety precautions before
Always use protective glasses or goggles when starting welding or grinding work. Always en-
carrying out work where there is a risk of splin- sure that there are fire extinguishers at hand
ters, grinding sparks, acid splashes or where when work is being carried out.
other chemicals are used. The eyes are ex-
tremely sensitive, an injury could result in blind-
ness! Ensure that rags soaked in oil or fuel and used
fuel or oil filters are stored safely. Rags soaked
in oil can spontaneously ignite under certain
circumstances. Used fuel and oil filters are en-
Avoid getting oil on the skin! Repeated expo- vironmentally dangerous waste and must be
sure to oil or exposure over a long period can deposited at an approved site for destruction
result in the skin becoming dry. Irritation, dry- together with used lubricating oil, contaminated
ness and eczema and other skin problems can fuel, paint remnants, solvent, degreasing
then occur. Used oil is more dangerous than agents and waste from washing parts.
fresh oil from a health aspect. Use protective
gloves and avoid oil soaked clothes and shop
rags. Wash regularly, especially before eating. Never expose a battery to naked flame or elec-
There are special skin creams which counter- trical sparks. Never smoke in proximity to the
act drying out of the skin and make it easier to batteries. The batteries give off hydrogen gas
clean off dirt after work is completed. during charging which when mixed with air can
form an explosive gas – oxyhydrogen. This gas
is easily ignited and highly volatile. Incorrect
Many chemicals used on the product (for ex- connection of the battery can cause a single
ample engine and transmission oils, glycol, spark which is sufficient to cause an explosion
gasoline and diesel oil), or chemicals used in with resulting damage. Do not shift the connec-
the workshop (for example degreasing agents, tions when attempting to start the engine
paint and solvents) are dangerous to health. (spark risk) and do not lean over any of the bat-
Read the instructions on the product packaging teries.
carefully! Always follow the safety precautions
for the product (for example use of protective
mask, glasses, gloves etc.). Make sure that Always ensure that the Plus (positive) and Mi-
other personnel are not exposed to hazardous nus (negative) battery leads are correctly in-
chemicals, for example in the air. Ensure good stalled on the corresponding terminal posts on
ventilation in the work place. Follow the instruc- the batteries. Incorrect installation can result in
tions provided when disposing of used or lefto- serious damage to the electrical equipment.
ver chemicals. Refer to the wiring diagrams.
Always use protective goggles when charging

Excercise extreme care when leak detecting on and handling the batteries. Battery electrolyte
the fuel system and testing the fuel injector jets. contains sulfuric acid which is highly corrosive.
Use eye protection. The jet from a fuel injector Should the battery electrolyte come into contact
nozzle is under extremely high pressure and with unprotected skin wash off immediately us-
has great penetrative energy, so the fuel can ing plenty of water and soap. If battery acid
penetrate deep into the body tissue and cause comes in contact with the eyes, immediately
serious personal injury. Danger of blood poi- flush with plenty of water and obtain medical as-
soning. sistance at once.
3
Safety Precautions
Turn the engine off and turn off the power at the Never work alone when removing heavy engine
main switch(es) before carrying out work on the components, even when using lifting devices
electrical system. such as locking tackle lifts. When using a lifting
device two people are usually required to do the
work, one to take care of the lifting device and
another to ensure that components are lifted
Clutch adjustments must be carried out with the clear and not damaged during the lifting opera-
engine stopped. tions. Check before starting work if there is
enough room to carry out removal work without
risking personal injury or damage to the engine
or parts.
Use the lifting eyes fitted on the engine when
lifting the drive unit. Always check that the lift-
ing equipment used is in good condition and has
the load capacity to lift the engine (engine WARNING! The components in the electrical
weight including gearbox, if fitted, and any extra system and in the fuel system on Volvo Penta
equipment installed). products are designed and manufactured to min-
imize the risk of fire and explosion. The engine
Use an adjustable lifting beam or lifting beam must not be run in areas where there are
specifically for the engine to raise the engine to explosive materials.
ensure safe handling and to avoid damaging en-
gine parts installed on the top of the engine. All
chains and cables should run parallel to each
other and as perpendicular as possible in rela- Always use the fuels recommended by Volvo
tion to the top of the engine. Penta. Refer to the Instruction Book. Use of fu-
els that are of a lower quality can damage the
If extra equipment is installed on the engine engine. On a diesel engine poor quality fuel can
which alters its center of gravity a special lifting cause the control rod to seize and the engine to
device is required to obtain the correct balance overrev with resulting risk of damage to the en-
for safe handling. gine and personal injury. Poor fuel quality can
also lead to higher maintenance costs.
Never carry out work on an engine suspended
on a hoist without other supporting equipment
attached.
Observe the following rules when cleaning with
high-pressure water jets. Never direct the water
jet at seals, rubber hoses or electrical compo-
nents. Never use a high pressure jet when
washing the engine.
© 2004 AB VOLVO PENTA

All rights to changes or modifications reserved.
Printed on environmentally-friendly paper
4
General Information
About this Workshop Manual Certificated engines

This Workshop Manual contains descriptions and ins- Engines certificated to meet national and regional en-
tructions for the repair of the following engines in stan- vironmental legislation carry with them an undertaking
dard format: TD630ME/VE, TWD630ME/VE, from the manufacturer that both new and existing eng-
TD640VE, TD730ME/VE, TWD730ME/VE, ines in use meet the enviromental demands of the le-
TWD731ME/VE, TWD740VE, TD1030ME/VE, gislation. The product must correspond to the valida-
TWD1030ME/VE and TWD1031VE. ted example that was granted certification. In order for
Volvo Penta as the manufacturer to take responsibility
The Engine Designation and Engine Numbers can be
for engines in use, certain requirements regarding ser-
found on the product plate (see page 8). Please al-
vice and spare parts must be met by the user accor-
ways include both the engine designation and the eng-
ding to the following:
ine number in all correspondance.
• The Service Intervals and maintenance ope-
The Workshop Manual is produced primarily for the
rations recommended by Volvo Penta must
use of Volvo Penta workshops and service technici-
be followed.
ans. For this reason the manual presupposes a cer- • Only Volvo Penta Original Spare Parts inten-
tain basic knowledge and that the user can carry out ded for the certificated engine may be used.
the mechanical/electrical work described to a general • Service work on the injection pump and in-
standard of engineering competence. jectors must always be carried out by an
Volvo Penta products are under a continual process of authorized Volvo Penta workshop.
development and we therefore reserve all rights regar- • The engine may not be altered or modified in
ding changes and modifications. All the information in any way, with the exception of accessories
this manual is based on product specifications availa- and service kits developed by Volvo Penta
for that engine.
ble at the time the book was published. Any essential
• No modifications to the exhaust pipes and
changes or modifications introduced into production or
air supply ducts for the engine room (ventila-
updated or revised service methods introduced after
tion ducts) may be undertaken as this may
the date of publication will be provided in the form of
effect exhaust emissions.
Service Bulletins. • Any seals on the engine may not be broken
other than by authorized persons.
IMPORTANT! If replacement parts are required

use only Volvo Penta Original Parts.
Use of replacement parts other than AB

Volvo Penta Original Parts will result in AB
Spare parts Volvo Penta being unable to assume any lia-
Spare parts for the electrical and fuel systems are bility that the engine corresponds to the cer-
subject to various national safety requirements. Volvo tificated engine variant.
Penta Original Spare Parts meet these specifications.
Any type of damage which is the result of using spare AB Volvo Penta excludes any liability for all and
parts that are not original Volvo Penta parts for the any type of damage or costs caused by the use
product in question will not be covered under any war- of replacement parts that are not Volvo Penta
ranty or guarantee provided by AB Volvo Penta. Original Parts for the product in question.
5
Repair Instructions
Repair Instructions
The working methods described in the Workshop Ma- Our joint responsibility
nual apply to work carried out in a workshop. The engi- Every engine consists of many systems and compo-
ne has been removed and is installed in an engine fix- nents that work together. If one component deviates
ture. Unless otherwise stated reconditioning work from the technical specifications this can have drama-
which can be carried out with the engine in place fol- tic consequences on the environmental impact of the
lows the same working method. engine even if it is otherwise in good running order. It
Warning symbols used in the Workshop Manual (for is therefore critical that the stated wear tolerances are
full explanation of the symbols refer to the section; observed, that systems which can be adjusted are
“Safety Precautions”) correctly set up and that only Volvo Penta Original
Parts are used on the engine. The stated service inter-
WARNING! vals in the Maintenance Schedule must be followed.
Some systems, such as the components in the fuel
IMPORTANT!
system, require special expertise and special testing
equipment for service and maintenance. Some com-
Note!
ponents are factory sealed for environmental and pro-
are not in any way comprehensive since it is impos- duct specific reasons. Under no circumstances at-
sible to predict every circumstance under which servi- tempt to service or repair a sealed component unless
ce work or repairs may be carried out. AB Volvo Penta the service technician carrying out the work is authori-
can only indicate the risks considered likely to occur zed to do so.
as a result of incorrect working methods in a well- Bear in mind that most chemical products, incorrectly
equipped workshop using working methods and tools used, are hazardous to the environment. Volvo Penta
tested by AB Volvo Penta. recommends the use of bio-degradable degreasing
All operations described in the Workshop Manual for agents for all cleaning of engine components unless
which there are Volvo Penta Special Tools available otherwise stated in the Workshop Manual. Pay special
assume that these tools are used by the service tech- attention to make sure that oils and washing residue
nician or person carrying out the repair. Volvo Penta are handled correctly for destruction, and do not unin-
Special Tools have been specifically developed to en- tentionally end up in the nature.
sure as safe and rational working methods as pos-
sible. It is therefore the responsibility of the person or
persons using other than Volvo Penta Special Tools or
approved Volvo Penta working methods (as described Tightening torques
in a Workshop Manual or Service Bulletin), to acquaint
The correct tightening torques for critical joints which
themselves of the risk of personal injury or actual
must be tightened using a torque wrench are listed un-
mechanical damage or malfunction that can result
der “Technical Data – Tightening Torques” and stated in
from failing to use the prescribed tools or working met-
the method descriptions in the Workshop Manual. All
hod.
tightening torques apply to cleaned threads, bolt
In some cases special safety precautions and user in- heads and mating surfaces. Tigthening torques stated
structions may be required in order to use the tools are for lightly oiled or dry threads. Where grease, lock-
and chemicals mentioned in the Workshop Manual. Al- ing or sealing agents are required for screwed joints
ways follow these precautions as there are no specific this is stated in both the operation description and in
instructions given in the Workshop Manual. “Tightening Torques”. Where no tightening torque is
stated for a joint use the general tightening torques
By following these basic recommendations and using
according to the table on the next page. The tightening
common sense it is possible to avoid most of the
torques stated are a guide and the joint does not have
risks involved in the work. A clean work place and a
to be tightened using a torque wrench.
clean engine will eliminate many risks of personal inju-
ry and engine malfunction. Dimension Tightening torque
Above all when working on the fuel system, engine Nm lbf.ft.
lubrication system, air intake system, Turbocharger M5 ..................................................... 6 4.4
unit, bearing seals and seals it is extremely important M6 ..................................................... 10 7.4
to observe the highest standards of cleanliness and M8 ..................................................... 25 18.4
avoid dirt or foreign objects entering the parts or sys- M10 ................................................... 50 36.9
tems, since this can result in reduced service life or M12 ................................................... 80 59.0
malfunctions. M14 ................................................... 140 103.3
6
Repair Instructions
Tightening torque with Protractor Sealant

tightening A number of sealants and locking liquids are used on
the engines. The agents have varying properties and
(angle tightening) are used for different types of jointing strengths, ope-
Tightening using both a torque setting and a protractor rating temperature ranges, resistance to oil and other
angle requires that first the recommended torque is chemicals and for the different materials and gap si-
applied using a torque wrench and then the recom- zes in the engines.
mended angle is added according to the protractor
scale. Example: a 90° protractor tightening means that To ensure service work is correctly carried out it is im-
the joint is tightened a further 1/4 turn in one operation portant that the correct sealant and locking fluid type
after the stated tightening torque has been applied. is used on the joint where the agents are required.
In the Volvo Penta Workshop Manuals the user will
Lock nuts find that each section where these agents are applied
Do not re-use lock nuts that have been removed in production states which type was used on the engi-
during dissassembly operations as these have redu- ne.
ced service life when re-used – use new nuts when During service operations use the same agent or an
assembling or reinstalling. For lock nuts with a plastic alternative from a different manufacturer.
insert such as Nylock® the tightening torque stated in
the table is reduced if the Nylock® nut has the same Make sure that mating surfaces are dry and free from
head height as a standard hexagonal nut without plas- oil, grease, paint and anti-corrosion agent before app-
tic insert. Reduce the tightening torque by 25% for lying sealant or locking fluid. Always follow the
bolt size 8 mm or larger. Where Nylock® nuts are hig- manufacturer’s instructions for use regarding tempera-
her, or of the same height as a standard hexagonal ture range, curing time and any other instructions for
nut, the tightening torques given in the table apply. the product.
Two different basic types of agent are used on the
engine and these are:
RTV agent (Room Temperature Vulcanizing). Used for
gaskets, sealing gasket joints or coating gaskets.
RTV is visible when a part has been disassembled;
Strength classes old RTV must be removed before resealing the joint.
Bolts and nuts are divided up into different classes of
The following RTV agents are mentioned in the Work-
strength; the class is indicated by the number on the
shop Manual: Loctite® 574, Volvo Penta part No.
bolt head. A high number indicates stronger material,
840879-1, Permatex® No. 3, Volvo Penta part No.
for example a bolt marked 10-9 indicates a higher
1161099-5, Permatex® No. 77. Old sealant can be
strength than one marked 8-8. It is therefore important
removed using methylated spirits in all cases.
that bolts removed during the disassembly of a bolted
joint must be reinstalled in their original position when Anaerobic agents. These agents cure in an absence of
assembling the joint. If a bolt must be replaced check air. They are used when two solid parts, for example
in the spare parts catalogue to make sure the correct cast components, are installed face-to-face without a
bolt is used. gasket. They are also commonly used to secure
plugs, threads in stud bolts, cocks, oil pressure swit-
ches and so on. The cured material is glass-like and it
is therefore colored to make it visible. Cured anaerobic
agents are extremely resistant to solvents and the old
agent cannot be removed. When reinstalling the part is
carefully degreased and then new sealant is applied.
The following anaerobic agents are mentioned in the
Workshop Manual: Loctite® 572 (white), Loctite® 241
(blue).
Note: Loctite® is the registered trademark of Loctite

Corparation, Permatex® the registered trademark of
the Permatex Corporation.
7
Repair Instructions
Safety rules for fluorocarbon

rubber
Fluorocarbon rubber is a common material in seal • Handle the removed seal in the same way
rings for shafts, and in O-rings, for example. as corrosive acid. All residue, including ash,
can be highly corrosive. Never use compres-
When fluorocarbon rubber is subjected to high tempe- sed air to blow anything clean.
ratures (above 300°C/572°F), hydrofluoric acid can • Put the remains in a plastic box which is
be formed, which is highly corrosive. Skin contact can sealed and provided with a warning label.
give severe chemical burns. Splashes in your eyes Wash the gloves under running water before
can give severe chemical burns. If you breathe in the removing them.
fumes, your lungs can be permanently damaged.
WARNING! Be very careful when working on en- The following seals are probably made from fluorocar-
gines which have been exposed to high temper- bon rubber:
atures, e.g. overheating during a seizure or fire. • Seal rings for the crankshaft, camshaft, in-
Seals must never be cut with an oxy-acetylene termediate shafts.
torch, or be burned up afterwards in an uncon- • O-rings irrespective of where they are instal-
trolled manner. led. O-rings for cylinder liner sealing are al-
most always made from fluorocarbon rubber.
• Always use gloves made of chloroprene rub-

ber (gloves for handling chemicals) and pro- Note! Seals which have not been subjected to high
tective goggles. temperature can be handled normally.
8
Location of Identification Plates
Each engine is supplied with two identical identifica-
tion plates, of which one is mounted on the cylinder
block, see fig.
The other identification plate should be mounted in a
suitable location adjacent to the engine.
T – Turbocharged
A – Air-to-air charge air cooler
W – Water-to-air charge air cooler
D – Diesel engine
7 – Displacement, liters
3 – Generation
0 – Version
P – Stationary engine (Power Pac)
G – Gen Set engine
V – Engine for stationary and mobile operation
M – Engine for mobile operation
E – Low emission engine
9
Technical Data
General
Type designation ........................................ TD630ME/VE TWD630ME/VE TD640VE
Number of cylinders ................................... 6 6 6
Bore ............................................................ 98.425 mm (3.875") 98.425 mm (3.875") 98.425 mm (3.875")
Stroke ......................................................... 120 mm (4.72") 120 mm (4.72") 120 mm (4.72")
Displacement ............................................. 5.48 dm³ (334.39 in3) 5.48 dm³ (334.39 in3) 5.48 dm³ (334.39 in3)
Compression ratio ...................................... 18.3:1 18.3:1 19.0:1
Firing sequence .......................................... 1–5–3–6–2–4 1–5–3–6–2–4 1–5–3–6–2–4
Rotation direction, viewed from the front .. Clockwise Clockwise Clockwise
Low idle ....................................................... 700 ± 25 rpm 725 ± 25 rpm 700 ± 10 rpm
High idle ...................................................... 2550 ± 25 rpm 2620 ± 25 rpm 2730 ± 25 rpm
Max. full load speed ................................... 2400 rpm 2500 rpm 2400 rpm
Weight, engine (dry) ................................... 655 kg (1444 lbs) 665 kg (1466 lbs) 655 kg (1444 lbs)
10
TD630, TWD630, TD640
Engine Pistons
Height, total ............................... 124.0 mm (4.88")
Cylinder heads Height above block face ........... max. 0.55 mm
(0.022")
Type ........................................... 3-cylinders/head
Number of ring grooves ............ 3
Length ........................................ 389 mm (15.32")
Front marking ............................ Arrow point forwards
Width ........................................ 213 mm (8.39")
Combustion chamber,
Diameter .................................... 53.0 mm (2.09")
Cylinder head bolts
Number/cylinder head ............... 20
Thread size ................................ M11
Length ........................................ 142 mm (5.59")
Cylinder block
Length ........................................ 796 mm (31.34") Depth ......................................... 20.4 mm (0.80")
Height, upper block face –
crankshaft centre (A), min. ....... 369 mm (14.53")
Piston rings
Height, lower block face – Compression rings
crankshaft centre (B), min. ....... 90 mm (3.54") Number ...................................... 2
Upper compression ring, height
TD630/TWD630 ....................... 3.1 mm (0.1220")
TD640 ...................................... 3.5 mm (0.1378")
Lower compression ring, height 2.5 mm (0.0984")
Piston ring gap measured in
ring opening ............................... 0.30 mm (0.0118")
Oil scraper ring

Number ...................................... 1
Height ........................................ 3.5 mm (0.1378")
Cylinder liners
Type ........................................... Wet, replaceable
Height, total ............................... 237.4 mm (9.35")
Height, cylinder liner above
block face .................................. 0,38–0,43 mm ring opening ............................... 0.25 mm (0.0098")
(0.0150–0.0169") Gudgeon pins
Max. difference in height
between cylinder liners 1, 2 and Clearance, gudgeon pin –
3 or 4, 5 and 6 ........................... 0.02 mm (0.0008") connecting rod bushing ............. 0.02 mm (0.0008")
Gudgeon pin diameter,
standard ..................................... 40.0 mm (1.575")
11
TD630, TWD630, TD640
Valve mechanism Valve seats

Outer diameter (meas. A),
Valves standard,
Inlet ......................................... 43.592 mm (1.7162")
Disc diameter,
Exhaust .................................. 41.592 mm (1.6375")
Inlet ......................................... 41 mm (1.61")
Oversize,
Exhaust .................................. 37 mm (1.46")
Inlet ......................................... 43.792 mm (1.7240")
Stem diameter,
Exhaust .................................. 41.792 mm (1.6454")
Inlet ......................................... 7.96 mm (0.313")
Height (meas. B),
Exhaust .................................. 7.97 mm (0.313")
Inlet ......................................... 6.90–7.00 mm
Valve seat angle,
(0.2717–0.2756")
Inlet ......................................... 29.5° min
Exhaust .................................. 8.55–8.65 mm
Exhaust .................................. 44.5° min
(0.3366–0.3406")
Seat angle in cylinder head,
Inlet ......................................... 30°
Exhaust .................................. 45°
Valve disc edge,
Inlet/Exhaust .......................... min. 1.2 mm (0.047")
Inlet Exhaust
Valve seat location

Diameter (meas. C),
standard,
Inlet ......................................... 43.512 mm (1.7131")
Exhaust .................................. 41.512 mm (1.6343")
Diameter (meas. C),
oversize,
Inlet ......................................... 43.712 mm (1.7209")
Exhaust .................................. 41.712 mm (1.6422")
Depth (meas. D),
Inlet ......................................... 8.9–9.0 mm
Valve clearance, cold engine, (0.3504–0.3543")
Inlet ......................................... 0.40 mm (0.016") Exhaust .................................. 9.5–9.6 mm
Exhaust .................................. 0.55 mm (0.022") (0.3740–0.3780")
Seat bottom radius (meas. R),
Inlet/Exhaust .......................... 0.5–0.8 mm
The valves can be adjusted according to the two posi-
(0.0197–0.0315")
tion method.
Measurement between valve
When 1st cylinder piston is at T.D.C. after compression, disc and cylinder head face
adjust valves 1, 2, 3, 6, 7 and 10. Inlet/Exhaust .......................... 0–0.4 mm
When 6th cylinder piston is at T.D.C. after compression, (0–0.0157")
adjust valves 4, 5, 8, 9, 11 and 12.
Inlet
Exhaust
12
TD630, TWD630, TD640
Valve guides Camshaft bearings

Length, Diameter for machining,
Inlet/Exhaust .......................... 64.500 mm (2.5394") 1st bearing .............................. 69.050–69.075 mm
Exhaust (2.7185–2.7195")
Innder diameter, 2nd bearing ............................. 66.675–66.700 mm
Inlet/Exhaust .......................... 8.0–8.01 mm (2.6250–2.6260")
(0.3150–0.3153") 3rd bearing .............................. 64.287–64.312 mm
Height above cylinder head (2.5310–2.5320")
spring face, 4th bearing .............................. 63.500–63.525 mm
Inlet/Exhaust .......................... 23.0 mm (0.9055") (2.5000–2.5010")
Clearance, valve stem – guide 5th bearing .............................. 61.112–61.137 mm
Inlet ......................................... 0.025–0.049 mm (2.4060–2.4070")
(0.001–0.0019") 6th bearing .............................. 60.325–60.350 mm
Exhaust .................................. 0.050–0.075 mm (2.3750–2.3760")
(0.0020–0.0030") 7th bearing .............................. 56.350–56.375 mm
(2.2185–2.2195")
Injection timing adjuster, TWD630ME/VE

Drive ........................................... Gear
Valve springs
Number of bearings ................... 2
Type ........................................... Single Diameter, bearings .................... 67.050–67.075 mm
Length, unloaded ....................... 62.8 mm (2.472") (2.6398–2.6407")
Length, completely
compressed ............................... 34.8 mm (1.370")
Timing gears
Wire diameter ............................ 4.7 mm (0.185")
Backlash, max. ......................... 0.10 mm (0.0039")
Radial clearance for inter-
mediate gear, max. ................... 0.053 mm (0.0021")
Axial clearance for inter-
mediate gear, max. ................... 0.10 mm (0.0039")
Camshaft
Number of teeth, timing gears
Drive ........................................... Gear Drive gear, servo pump (1) ........ 19
Number of bearings ................... 7 Drive gear, compressor (2) ........ 33
Diameter, bearing journals, Camshaft gear (3) ...................... 60
1st bearing journal .................. 68.985–69.015 mm Intermediate gear (4) ................. 51
(2.7159–2.7171") Drive gear, injection pump (5) ... 60
2nd bearing journal ................. 66.610–66.640 mm Drive gear, coolant pump (6) ..... 23
(2.6224–2.6236") Crankshaft gear (7) .................... 30
3rd bearing journal .................. 64.222–64.252 mm Intermediate gear, lube oil
(2.5284–2.5296") pump (8) ..................................... 48
4th bearing journal .................. 63.435–63.465 mm Drive gear, lube oil pump (9) ..... 27
(2.4974–2.4986")
5th bearing journal .................. 61.047–61.077 mm
(2.4034–2.4046")
(2.3724–2.3736")
(2.2159–2.2171")
Axial clearance. ......................... 0.05–0.13 mm
(0.0020–0.0051")
Radial clearance. ....................... 0.035–0.080 mm
(0.0014–0.0031")
Check of camshaft setting (cold
engine and valve clearance = 0).
Inlet valve for No. 1 cylinder must with
flywheel position 10° A.T.D.C. have
opened ....................................... 1.95 ± 0.25 mm
(0.0768 ± 0.0098")
13
TD630, TWD630, TD640
Crank mechanism
Crankshaft
Length ........................................ 950 mm (37.40") Oversize,
Crankshaft axial clearance ........ 0.07–0.27 mm 0.2 mm (0.0079")
(0.0028–0.0106") (axial bear. 0.1 (0.0039") ........ 44.200 ± 0.025 mm
Main bearing, radial clearance .. 0.063–0.121 mm (1.7402 ± 0.0010")
(0.0025–0.0048") 0.4 mm (0.0157")
(axial bear. 0.2 (0.0079") ........ 44.400 ± 0.025 mm
The crankshaft is nitro-carburized.
(1.7480 ± 0.0010")
Note! A nitro-carburized crankshaft may be ground down 0.6 mm (0.0.236")
to max. 2nd undersize. If ground more, it must be (axial bear. 0.3 (0.0118") ........ 44.600 ± 0.025 mm
re-nitrocarburized. (1.7559 ± 0.0010")
Fillet radius (R) .......................... 4.300 ± 0.025 mm
(0.1693 ± 0.0010")
Main bearing journals

Thrust washers (axial bearing)
Diameter for machining,
standard ..................................... 76.149–76.162 mm Width (B), standard ................... 3.098 ± 0.025 mm
(3.9980–3.9985") (0.1220 ± 0.0010")
Undersize, Oversize,
0.25 mm (0.010") .................... 75.899–75.912 mm 0.1 mm (0.0039") .................... 3.198 ± 0.025 mm
(2.9881–2.9887") (0.1259 ± 0.0010")
0.50 mm (0.020") .................... 75.649–75.662 mm 0.2 mm (0.0079") .................... 3.298 ± 0.025 mm
(2.9483–2.9788") (0.1298 ± 0.0010")
0.75 mm (0.030") .................... 75.399–75.412 mm 0.3 mm (0.0118") .................... 3.398 ± 0.025 mm
(2.9685–2.9690") (0.1338 ± 0.0010")
1.00 mm (0.040") .................... 75.149–75.162 mm
(2.9586–2.9591") Main bearing shells
1.25 mm (0.050") .................... 74.899–74.912 mm
(2.9488–2.9493") Type ........................................... Replaceable
Main bearing journals Thickness (D), standard ............ 2.408 mm (0.0948")
out-of-round, max. .................. 0.08 mm (0.0031") Oversize,
taper, max. ............................. 0.05 mm (0.0020") 0.25 mm (0.0098") .................. 2.535 mm (0.0998")
Width, axial bearing journal (A), 0.50 mm (0.0197") .................. 2.662 mm (0.1048")
standard ..................................... 44.200 ± 0.025 mm 0.75 mm (0.0295") .................. 2.789 mm (0.1098")
(1.7402 ± 0.0010") 1.00 mm (0.0394") .................. 2.916 mm (0.1148")
1.25 mm (0.0492") .................. 3.043 mm (0.1198")
14
TD630, TWD630, TD640
Connecting rod bearing journals Connecting rods

Diameter (Ø) for machining, Length, centre – centre (E) ....... 230 mm (9.06")
standard ..................................... 63.449–63.462 mm Marking,
(2.4980–2.4985") Connecting rod resp. cap .......... 1 to 6
Undersize, “FRONT" on rod turned ............. Forwards
0.25 mm (0.010") .................... 63.195–63.208 mm Connecting rod bushing
(2.4880–2.4885") bore (G) ...................................... 40.018–40.022 mm
0.50 mm (0.020") .................... 62.941–62.954 mm (1.5755–1.5757")
(2.4780–2.4785") Axial clearance, connecting
0.75 mm (0.030") .................... 62.687–62.700 mm rod – crankshaft ......................... 0.250 mm (0.0098")
(2.4680–2.4685") Connecting rod bearing,
1.00 mm (0.040") .................... 62.433–62.446 mm radial clearance ......................... 0.080 mm (0.0031")
(2.4580–2.4585")
1.25 mm (0.050") .................... 62.179–62.192 mm
(2.4480–2.4485")
Width (A), axial bearing journal . 41.900–42.000 mm
(1.6496–1.6535")
Fillet radius (R) .......................... 4.2–4.4 mm
(0.1654–0.1732") Flywheel, installed
Connecting rod bearing journals, Max. permitted axial throw
out-of-round, max. .................. 0.08 mm (0.0031") measuring radius 150 mm
taper, max .............................. 0.05 mm (0.0020") (5.91") ........................................ 0.15 mm (0.0059")
Number of teeth on flywheel ..... 140
Connecting rod bearing shells

Flywheel casing, installed
Thickness (C), standard ............ 1.897 mm (0.0747")
Oversize, Max. permitted axial throw
0.25 mm (0.010") .................... 2.024 mm (0.0797") for contact surface against
0.50 mm (0.020") .................... 2.151 mm (0.0847") clutch casing ............................. 0.15 mm (0.0059")
0.75 mm (0.030") .................... 2.279 mm (0.0897") Max. permitted radial throw
1.00 mm (0.040") .................... 2.405 mm (0.0947") for positioning against clutch
1.25 mm (0.050") .................... 2.532 mm (0.0997") casing ........................................ 0.25 mm (0.0098")
15
TD630, TWD630, TD640
Lubricating system
Lubricating system, general

Oil pressure,
operating speed ...................... 300–500 kPa
(43.5–72.5 psi)
idling speed, min. ................... 150 kPa (21.8 psi)
Oil change quantity, std. sump
with oil filter ................................ 24 litres1) (6.34 US
gals)
Difference between
MIN. – MAX. on dipstick ........... 6 litres (1.58 US gals)
1)
Engine without by-pass filter
(earlier model) ........................... 22 litres (5.81 US gals)
Lubricanting oil, engine

Sulfur content in fuel, by weight
Oilgrade < 0,5 % 0,5 – 1,0 % > 1,0 %1)
Oil change interval, reached first in operation
VDS-3 400 h / 12 months 200 h / 12 months 100 h / 12 months
VDS-2 and ACEA: E7 2)
VDS-2 and Global DHD-1 2)
VDS-2 and API: CI-4 2)
VDS-2 and API: CH-4 2)
VDS and ACEA: E3 2) 300 h / 12 months 150 h / 12 months 75 h / 12 months
ACEA: E7, E5, E4 150 h / 12 months 75 h / 12 months 40 h / 12 months
API: CI-4, CH-4, CG-4
Viscosity is selected as per table below. Axial clearance,

The temperatures refer to stable ambient temperatures drive gear in pump .................. 0.07–0.15 mm
−30 −20 −10 ±0 +10 20 30 40 (0.0028–0.0059")
o
C intermediate gear .................... 0.10–0.18 mm
(0.0039–0.0071")
−15 Co
SAE 15W/40
Distance, drive gear – oil
o
−25 C SAE 10W/30 housing bracket ......................... 1.0–1.5 mm
✱ SAE 5W/30 (0.0394–0.0591")
−10oC SAE 20W/30
Oil filters
±0oC SAE 30 Number ...................................... 1 or 2
By-pass filter (later model only) Part No. 477556-5
+10oC SAE 40 Full flow filter ............................. Part No. 466634-3
o
−22 −4 +14 32 50 68 86 104 F Lubricating oil valves
* Concerns synthetic or semi-synthetic oil. 1. Overflow valve
Type ........................................... Pressure spring
Spring, length unloaded ............. 68.8 mm (2.709")
With load .................................... 29.1 mm (1.146")
2. Oil cooling valve (TD630)
Lube oil pump Piston cooling valve (other)
Marking ...................................... TD: White
Type ........................................... Gear driven
TWD: White
Number of teeth, drive gear ...... 27
3. Reduction valve
intermediate gear .................... 48
Marking ...................................... TD: Blue
Diameter, bearing sleeve,
TWD: Blue
intermediate gear .................... 63.985 mm (2.5191")
4. By-pass valve (TAD730)
bushing, intermediate gear ..... 64.045 mm (2.5215")
Marking ...................................... None
16
TD630, TWD630, TD640
Fuel system
Fuel specifications Injection timing adjuster, TWD630ME/VE

The fuel must be approved according to national and in- The injection timing adjuster gradually alters pump set-
ternational standards for commercial fuels, for exampel: ting between two speeds.
EN 590 (with environmental and sub-zero temperature Between 1560 rpm and
specifications according to national requirements) 2260 rpm pump setting
should alter ................................ 6° ± 1°
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulphur content: According to current legislation in the

respective country. Feed pump
Note. Fuels with extremely low sulfur contents (“Urban Designation, TD630 ................... FP/KG24MW200
diesel” in Sweden and “City diesel” in Finland) can TWD630, TD640 ... FP/KG24P200
cause a drop in power output of 5 % and an increase in Feed pressure ............................ 100–150 kPa
fuel consumption of 2–3 %. (14.50–21.75 psi)
Injection pump Overflow valve

Injection pump, Designation ................................ 1457413010
TD630 ..................................... PES6MW100/320RS
1132-1
TWD630 .................................. PE6P110A320RS
3266 Injectors
TD640 ..................................... PES6P110A320RS
Designation, nozzle holder ........ KBEL 98P 74
3410
Injector, TD630 .......................... DLLA 145P 478
Injection pump, setting,
TWD630, TD640 .......... DLLA 145P 328
TD630 ..................................... 12.0° ± 0.5° B.T.D.C.
Number marking (complete
TWD630 .................................. 13.5° ± 0.5° B.T.D.C.
injector) TD630 .......................... 645
TD640 ..................................... 13.0° ± 0.5° B.T.D.C.
TWD630 ....................... 328
Prelift, TD630 .......................... 2.95 ± 0.05 mm
TD640 .......................... 478
(0.1161 ± 0.0020")
Opening pressure ...................... 25.0 MPa (3625 psi)
TWD630 ....................... 2.45 ± 0,05 mm
Adjustment pressure
(0.0965 ± 0.0020")
(new spring) ............................... 26.0 + 0.8 MPa
TD640 .......................... 3.60 ± 0,05 mm
(3770 + 116 psi)
(0.1417 ± 0.0020")
Bore, TD630, TD640 .................. 6 x 0.236 mm
Governor, TD630 ....................... RSV 325–200MWOA
(0.00929")
359
TWD630 ........................... 6 x 0.226 mm
TWD630 .................... RSV 350–1250P0A
(0.00890")
TD640 ....................... RSV 325–1200P0A
Injection pump direction of
rotation viewed from front .......... Clockwise
Firing sequence ......................... 1–5–3–6–2–4 Fuel filters
Number ...................................... 2
17
TD630, TWD630, TD640
Intake- and exhaust system Cooling system
Turbocharger Cooling system, general

Make .......................................... Schwitzer Type ........................................... Pressurized, closed
Designation, TD630 ................... S2A61.12PAD/0.7W5 circuit
TWD630 ................ S2A69.18GAU/0.8W5 Pressure valve opens at ........... 50 kPa (7.25 psi)
TD640 ................... S2A69.18GAU/0.7W5 Capacity (VP std. radiator
Boost pressure, excl. expansion tank),
TD630 (2400 rpm) .................. Min. 130 kPa TD630 ..................................... approx. 21 litres
(18.85 psi) (5.55 US gals)
TWD630 (2500 rpm) ............... Min. 120 kPa TWD630, TD640 ..................... approx. 25 litres
(17.40 psi) (6.61 US gals)
TD640 (2400 rpm) .................. Min. 160 kPa
(23.21 psi) Coolant
Lube system .............................. Pressure lubrication
Max. permitted radial clearance Antifreeze (Glycol)
(compressor side) ...................... 0.82 mm (0.0323") Type ........................................... C
Max. permitted axial clearance . 0.14 mm (0.0055") Consists of ................................ Glycol and anticorro-
sion additives
Colour ......................................... Blue-green
Volvo Penta part Nos.,
5 litres (1.32 US gals) ............ 1141646-8
210 litres (55.48 US gals) ...... 1141647-6
Starting heater
Anti-corrosion agent
Starting heater ........................... 24V
Used ........................................... When there is no
chance of freezing
Mixed with .................................. Water (1:30)
Volvo Penta part No. ................. 1141526-2
Note! The anti-corrosion agent must not be mixed with

glycol or other types of anti-corrosion fluid as this could
result in negative consequences.
Coolant pump
Type ........................................... Gear-driven
Thermostat
Type ........................................... Sleeve thermostat
Number ...................................... 1
Marking ...................................... Blue
Beginns to open at .................... 75°C (167°F)
Fully open at .............................. 88°C (190°F)
18
TD630, TWD630, TD640
radial clearance ......................... 0.08 mm (0.0031")

Wear tolerances
Tightening torques
Cylinder liners
Tightening torques Nm (lbf.ft)
Cylinder liners (pistons and piston rings) should be re-
Main bearings ............................ 150 ± 10 (110.6 ± 7.4)
placed with a wear of 0.35–0.40 mm (0.0138–0.0157") or
Connecting rod bearings ........... 190 ± 10 (140 ± 7.4)
if oil consumption is abnormally high.
Axial bearing, camshaft ............ 65 ± 7 (48 ± 5.2)
Timing gear cover ...................... 33 ± 4 (24.3 ± 3.0)
Gear wheel, camshaft ............... 70 ± 7 (51.6 ± 5.2)
Gear wheel, injection pump
Crankshaft drive, TD630, TD640 ................. 35 ± 4 (25.8 ± 3.0)
Max. permitted out-of-round TWD630 ........................... 33 ± 4 (24.3 ± 3.0)
on main and connecting rod Intermediate gear journalling ..... 90 ± 9 (66.4 ± 6.6)
bearing pins ............................... 0.08 mm (0.0031") Bearing bracket, rocker arm
Max. permitted taper on main shaft ........................................... 50 ± 5 (36.9 ± 3.7)
and connecting rod bearing Oil sump,
pins ............................................ 0.05 mm (0.0020") gaskets with a string of
Max. axial clearance on silicone ................................... 16 ± 2 11.8 ± 1.5)
crankshaft .................................. 0.40 mm (0.0157") other gaskets .......................... 24 ± 3 17.7 ± 2.2)
(tightened in a specified order,
see fig. below)*
Drain plug, oil sump ................... 80 ± 8 (59 ± 5.9)
Bracket, oil pump ...................... 65 ± 7 (48 ± 5.2)
Connecting rods
Intermediate gear, oil pump ...... 33 ± 4 (24.4 ± 3.0)
Straightness, max. deviation Flywheel ..................................... 190 ± 10 (140.2 ± 7.4)
on a measuring length of Pulley, crankshaft ..................... 90 ± 9 (66.4 ± 6.6)
100 mm (3.94") .......................... 0.05 mm (0.0020") Flywheel casing ......................... 140 ± 14 (103.3 ±
Warp, max. deviation on a 10.3)
measuring length of Centre bolt, crankshaft .............. 260 ± 25 (191.9 ±
100 mm (3.94") .......................... 0.10 mm (0.0039") 18.5)
Nut for retainer, injector ............. 50 ± 5 (36.9 ± 3.7)
Clamp bolt, injection pump ........ 90 ± 9 (66.4 ± 6.6)
Cleaning plugs in cylinder
Valves block and cylinder heads .......... 70 ± 7 (51.7 ± 5.2)
Exhaust manifold ....................... 48 ± 5 (35.4 ± 3.7)
Valve stem, max. permitted
wear ........................................... 0.02 mm (0.0008") Tighten cylinder head screws in 4 stages:
Max. permitted clearance First tightening ........................... 30 (22.1)
between valve stem and Second tightening ...................... 85 (62.7)
valve guide Third tightening (check
Inlet ......................................... 0.33 mm (0.0130")
Exhaust .................................. 0.38 mm (0.0150")
Valve disc edge should be min.
Inlet/Exhaust .......................... 1.2 mm (0.0472")
The valve seat may be
ground down so far that the
distance from the valve disc
(new valve) to the cylinder
head face is max.,
Inlet/Exhaust .......................... 0.4 mm (0.0157")
tightening) .................................. 85 (62.7)
With a greater distance the valve seats must be re-
placed.
Final tightening (angle
Camshaft
Max. permitted out-of-round
(with new bearings) .................... 0.05 mm (0.0020")
Bearings, permitted wear .......... 0.05 mm (0.0020")
Lift height, min.,
Inlet/Exhaust .......................... 7.8 mm (0.3071")
Valve tappets, max. permitted
tightening) .................................. 60°
Angle tightening Tightening diagram
*
19
Oil sump tightening diagram
Technical Data
TD730ME/VE, TWD730ME/VE, TWD731ME/VE, TWD740VE
General
Designation ...................... TD730ME/VE TWD730ME/VE TWD731ME/VE TWE740VE
Number of cylinders ........ 6 6 6 6
Bore ................................. 104.77 mm (4.124") 104.77 mm (4.124") 104.77 mm (4.124") 107.00 mm (4.213")
Stroke .............................. 130 mm (5.12") 130 mm (5.12") 130 mm (5.12") 135 mm (5.31")
Displacement .................. 6.73 dm³ (410.7 in3) 6.73 dm³ (410.7 in3) 6.73 dm³ (410.7 in3) 7,28 dm³ (444.3 in³)
Compression ratio ........... 17.7:1 17.7:1 17.7:1 17.5:1
Firing sequence ............... 1–5–3–6–2–4 1–5–3–6–2–4 1–5–3–6–2–4 1–5–3–6–2–4
Rotation direction,
viewed from front ............. Clockwise Clockwise Clockwise Clockwise
Low idle ............................ 650 ± 25 rpm 675 ± 25 rpm 650 ± 25 rpm 600 ± 25 rpm
High idle ........................... 2570 ± 20 rpm 2620 ± 20 rpm 2570 ± 20 rpm 2520 ± 20 rpm
Max. full load speed ........ 2400 rpm 2400 rpm 2400 rpm 2400 rpm
Weight, engine (dry) ........ 745 kg (1641 lbs) 775 kg (1707 lbs) 770 kg (1696 lbs) 795 kg (1751 lbs)
20
TD730, TWD730, TWD731, TWD740
Engine Pistons
Cylinder heads Height, total ............................... 132.45 mm (5.21")
Centre gudgeon pin – piston
Type ........................................... 3-cylinders/head
upper edge ................................. 88.40–88.50 mm
Length ........................................ 421 mm (16.57")
(3.4803–3.4842")
Width .......................................... 233 mm (9.17")
Number of ring grooves ............. 3
Front marking ............................ Arrow pointing
forwards
Cylinder head bolts Combustion chamber,
Number/cylinder head ............... 20 diameter, TD730/TWD730/
Thread size ................................ M11 TWD731 ..................................... 61.00 mm (2.4016")
Length ........................................ 150 mm (5.91") diameter, TWD740 ..................... 66.00 mm (2.5984")
depth, TD730/TWD730/TWD731 20.1 mm (0.7913")
depth, TWD740 .......................... 20.2 mm (0.7953")
Cylinder block piston height above block
Length ........................................ 859 mm (33.82") face ............................................ 0.70 mm (0.0276")
crankshaft centre (A), min. ....... 403 mm (15.87")
Height, lower block face –
crankshaft centre (B), min. ....... 90 mm (3.54")
Piston rings
Compression rings
Number ...................................... 2
Upper compression ring, height
TD730/TWD730/TWD731 ....... 3.0 mm (0.1181")
TWD740 .................................. 3.5 mm (0.1378")
upper ring opening ..................... 0.3 mm (0.0118")
Lower compression ring, height 2.5 mm (0.0984")
lower ring opening
TD730/TWD730/TWD731 ....... 0.3 mm (0.0118")
TWD740 .................................. 0.6 mm (0.0236")
Oil scraper ring

Number ...................................... 1
Height
Cylinder liners TD730/TWD730/TWD731 ....... 4.0 mm (0.1575")
Type ........................................... Wet, replaceable TWD740 .................................. 3.5 mm (0.1378")
Height, total ............................... 259.7 mm (10.22") Piston ring gap measured in
Stepped edge in height above ring opening ............................... 0.3 mm (0.0118")
block face .................................. 0.38–0.43 mm
(0.0150–0.0169")
Max. difference in height
between cylinder liners 1, 2 and
3 or 4, 5 and 6 ........................... 0.02 mm (0.0008")
Gudgeon pins
Clearance, gudgeon pin –
connecting rod bushing ............. 0.020 mm (0.0008")
standard, TD730/TWD730/
TWD731 .................................. 45.00 mm (1.7717")
standard, TWD740 ................. 47.00 mm (1.8504")
21
TD730, TWD730, TWD731, TWD740

Valves Outer diameter (meas. A),
standard,
Disc diameter,
Inlet ......................................... 46.08 mm (1.8142")
Inlet ......................................... 43 mm (1.69")
Exhaust .................................. 42.07 mm (1.6563")
Exhaust .................................. 39 mm (1.54")
Oversize,
Stem diameter,
Inlet ......................................... 46.28 mm (1.8220")
Inlet ......................................... 7.965–7.975 mm
Exhaust .................................. 42.27 mm (1.6642")
(0.3136–0.3140")
Height (meas. B),
Exhaust .................................. 7.951–7.962 mm
Inlet ......................................... 8.15 mm (0.3209")
(0.3130–0.3135")
Exhaust .................................. 8.65 mm (0.3406")
Valve seat angle,
Inlet ......................................... 29.5°
Exhaust .................................. 44.5°
Seat angle in cylinder heads,
Inlet ......................................... 30°
Exhaust .................................. 45°
Valve disc edge,
Inlet ......................................... min. 2.0 mm (0.079")
Exhaust .................................. min. 1.0 mm (0.039")
Inlet Exhaust
Valve seat location

Diameter (meas. C),
standard,
Inlet ......................................... 46.000–46.025 mm
(1.8110–1.8120")
Exhaust .................................. 42.000–42.025 mm
(1.6535–1.6545")
Diameter (meas. C),
Valve clearance, cold engine, oversize,
Inlet ......................................... 0.40 mm (0.016") Inlet ......................................... 46.200–46.225 mm
Exhaust .................................. 0.55 mm (0.022") (1.8189–1.8199")
Exhaust .................................. 42.200–42.225 mm
The valves can be adjusted according to the two position (1.6614–1.6624")
method. Depth (meas. D)
When 1st cylinder piston is at T.D.C. after compression, Inlet ......................................... 9.95–10.05 mm
adjust valves 1, 2, 3, 6, 7 and 10. (0.3917–0.3957")
When 6th cylinder piston is at T.D.C. after compression, Exhaust .................................. 9.80–9.90 mm
adjust valves 4, 5, 8, 9, 11 and 12. (0.3868–0.3898")
Seat bottom radius (meas. R),
Inlet/Exhaust, max. ................ 0.5 mm (0.0197")
Measurement between valve
INLET disc and cylinder head face ...... 0–0.4 mm
EXHAUST (0–0.0157")
22
TD730, TWD730, TWD731, TWD740
Valve guides Diameter, bearing journals TWD740, min.

Length, 1st bearing journal .................. 68.985–69.015 mm
Inlet/Exhaust .......................... 64.5 mm (2.539") (2.7160–2.7171")
Inner diameter, 2nd bearing journal ................. 68.420–68.450 mm
Inlet/Exhaust .......................... 8.000–8.015 mm (2.6937–2.6949")
(0.3150–0.3156") 3rd bearing journal .................. 67.835–67.865 mm
Height above cylinder head (2.6707–2.6719")
spring face, 4th bearing journal .................. 67.235–67.265 mm
Inlet/Exhaust .......................... 19.5 mm (0.768") (2.6470–2.6482")
Clearance, valve stem – guide, 5th bearing journal .................. 66.610–66.640 mm
Inlet ......................................... 0.025–0.050 mm (2.6224–2.6236")
(0.0010–0.0020") 6th bearing journal .................. 66.010–66.040 mm
Exhaust .................................. 0.038–0.064 mm (2.5988–2.6000")
(0.0015–0.0025") 7th bearing journal .................. 56.285–56.315 mm
(2.2159–2.2171")
Axial clearance .......................... 0.05–0.13 mm
(0.0020–0.0051")
Radial clearance ........................ 0.035–0.079 mm
(0.0014–0.0031")
Valve springs Check of camshaft setting(cold

Outer valve spring, engine and valve clearance =
Length, unloaded .................... 64.1 mm (2.524") 0),
With load of 230–330 N Inlet valve for no. 1 cylinder
(51.75–74.25 lbf) .................... 48.6 mm (1.913") must with flywheel position 10°
Inner valve spring, A.T.D.C. have opened, TD730/
Length, unloaded .................... 60.1 mm (2.366") TWD730/TWD731 ...................... 4.5 mm (0.1772")
With load of 90–150 N TWD740 ..................................... 3.0 mm (0.1181”)
(20.25–3.38 lbf) ...................... 44.6 mm (1.756")
Camshaft
Drive ........................................... Gear
Diameter, bearing journals,
TD730/TWD730/TWD731, min.
1st bearing journal .................. 68.985–69.015 mm
(2.7160–2.7171")
2nd bearing journal ................. 66.610–66.640 mm
(2.6224–2.6236")
3rd bearing journal .................. 64.222–64.252 mm
(2.5284–2.5296")
(2.4974–2.4986")
(2.4034–2.4046")
(2.3724–2.3736")
(2.2159–2.2171")
(0.0020–0.0051")
Radial clearance ........................ 0.035–0.080 mm
(0.0014–0.0031")
23
TD730, TWD730, TWD731, TWD740
Camshaft bearings Timing gears

Diameter for machining, TD730/ Backlash .................................... 0.03–0.17 mm
TWD730/TWD731, (0.0012–0.0067")
1st bearing .............................. 69.050–69.075 mm Radial clearance for inter-
(2.7185–2.7195") mediate gear .............................. 0.03–0.09 mm
2nd bearing ............................. 66.675–66.700 mm (0.0012–0.0035")
(2.6250–2.6260") Axial clearance for intermediate
3rd bearing .............................. 64.287–64.312 mm gear ............................................ 0.05–0.15 mm
(2.5310–2.5320") (0.0020–0.0059")
4th bearing .............................. 63.500–63.525 mm
(2.5000–2.5010")
5th bearing .............................. 61.112–61.137 mm Number of teeth, timing gears
(2.4060–2.4070") Drive gear, servo pump (1) ........ 19
6th bearing .............................. 60.325–60.350 mm Drive gear, compressor (2) ........ 33
(2.3750–2.3760") Camshaft gear (3) ...................... 60
7th bearing .............................. 56.350–56.375 mm Intermediate gear (4) ................. 51
Drive gear, coolant pump (6) ..... 23
Diameter for machining, TWD740, Crankshaft gear (7) .................... 30
1st bearing .............................. 69.050–69.075 mm Intermediate gear, lube oil
(2.7185–2.7195") pump (8) ..................................... 48
2nd bearing ............................. 68.485–68.510 mm Drive gear, lube oil pump (9) ..... 27
(2.6963–2.6972")
3rd bearing .............................. 67.900–67.925 mm
(2.6732–2.6742")
4th bearing .............................. 67.300–67.325 mm
(2.6496–2.6506")
5th bearing .............................. 66.675–66.700 mm
(2.6250–2.6260")
6th bearing .............................. 66.075–66.100 mm
(2.6014–2.6024")
7th bearing .............................. 56.350–56.375 mm
(2.2185–2.2195")
Injection timing adjuster, (TWD730ME)

Drive ........................................... Gear
Diameter, bearings .................... 67.050–67.075 mm
(2.6398–2.6407")
24
TD730, TWD730, TWD731, TWD740
Crank mechanism
Crankshaft
Length, TD730/TWD730/TWD731 950 mm (37.40") (3.5141–3.5150")
Length, TWD740 ........................ 1013 mm (39.88") Main bearing journal,
Crankshaft axial clearance ........ 0.068–0.268 mm out-of-round, max. .................. 0.08 mm (0.0031")
(0.0027–0.0106") taper, max. ............................. 0.05 mm (0.0020")
Main bearing, radial clearance .. 0.065–0.119 mm
Width, axial bearing journal (A),
(0.0026–0.0047")
standard ..................................... 45.975–46.025 mm
(1.8100–1.8120")
Note! A nitro-carburized crankshaft may be ground down
to max. 2nd undersize. If ground more, it must be re-ni- Oversize,
tro- 0.2 mm (0.0079"),
carburized. (axial bear. 0.1 (0.0039") ........ 46.175–46.225 mm
(1.8179–1.8199")
Main bearing journals Diameter for machining, 0.4 mm (0.0157"),
TD730/TWD730/TWD731 (-SN 20711097292) (axial bear. 0.2 (0.0079") ........ 46.375–46.425 mm
standard ..................................... 82.535–82.550 mm (1.8258–1.8278")
(3.2494–3.2500") 0.6 mm (0.0236"),
Undersize, (axial bear. 0.3 (0.0118") ........ 46.575–46.625 mm
0.25 mm (0.010") .................... 82.281–82.296 mm (1.8337–1.8356")
(3.2394–3.2400") Fillet radius (R) .......................... 3.75–4.00 mm
0.50 mm (0.020") .................... 82.027–82.042 mm (0.1476–0.1575")
(3.2294–3.2300")
0.75 mm (0.030") .................... 81.773–81.788 mm Thrust washers (axial bearing)
(3.2194–3.2200") Width (B), standard ................... 2.312–2.362 mm
1.00 mm (0.040") .................... 81.519–81.534 mm (0.0910–0.0930")
(3.2094–3.2100") Oversize,
1.25 mm (0.050") .................... 81.265–81.280 mm 0.1 mm (0.0039") .................... 2.412–2.462 mm
(3.2002–3.2000") (0.0950–0.0969")
0.2 mm (0.0079") .................... 2.512–2.562 mm
TWD 731 (SN 20711098793-), TWD 740 (0.0989–0.1009")
standard ..................................... 90.528–90.550 mm 0.3 mm (0.0118") .................... 2.612–2.662 mm
Undersize, (3.5640–3.5650") (0.1028–0.1048")
0.25 mm (0.010") .................... 90.274–90.296 mm Main bearing shells
(3.5541–3.5550") Thickness (D), standard ............ 2.931 mm (0.1154")
0.50 mm (0.020") .................... 90.020–90.042 mm Oversize,
(3.5441–3.5450") 0.25 mm (0.0098") .................. 3.058 mm (0.1204")
0.75 mm (0.030") .................... 89.766–89.788 mm 0.50 mm (0.0197") .................. 3.185 mm (0.1254")
(3.5341–3.5350") 0.75 mm (0.0295") .................. 3.312 mm (0.1304")
1.00 mm (0.040") .................... 89.512–89.534 mm 1.00 mm (0.0394") .................. 3.439 mm (0.1354")
(3.5241–3.5250") 1.25 mm (0.0492") .................. 3.566 mm (0.1404")
1.25 mm (0.050") .................... 89.258–89.280 mm
25
TD730, TWD730, TWD731, TWD740
Connecting rod bearing journals Connecting rod bearing shells

Diameter (Ø) for machining, Thickness (C), standard, TD730/
standard, TD730/TWD730/ TWD730/TWD731 ................... 1.908 mm (0.0751")
TWD731 ..................................... 69.837–69.850 mm Oversize,
(2.7495–2.7500") 0.25 mm (0.0098") .................. 2.035 mm (0.0800")
Undersize, 0.50 mm (0.0197") .................. 2.162 mm (0.0851")
0.25 mm (0.0098") .................. 69.583–69.596 mm 0.75 mm (0.0295") .................. 2.289 mm (0.0901")
(2.7395–2.7400") 1.00 mm (0.0394") .................. 2.416 mm (0.0951")
0.50 mm (0.0197") .................. 69.329–69.342 mm 1.25 mm (0.0492") .................. 2.543 mm (0.1001")
(2.7295–2.7300")
0.75 mm (0.0295") .................. 69.075–69.088 mm Thickness (C), standard,
(2.7195–2.7200") TWD740 ................................... 1.917 mm (0.0755")
1.00 mm (0.0394") .................. 68.821–68.834 mm Oversize,
(2.7095–2.7100") 0.25 mm (0.0098") .................. 2.044 mm (0.0805")
1.25 mm (0.0492") .................. 68.567–68.580 mm 0.50 mm (0.0197") .................. 2.171 mm (0.0855")
(2.7015–2.6995") 0.75 mm (0.0295") .................. 2.298 mm (0.0905")
standard, TWD740 ..................... 73.831–73.850 mm 1.00 mm (0.0394") .................. 2.425 mm (0.0955")
(2.9067–2.9075") 1.25 mm (0.0492") .................. 2.552 mm (0.1005")
Undersize,
0.25 mm (0.0098") .................. 73.577–73.596 mm
(2.8967–2.8975")
0.50 mm (0.0197") .................. 73.323–73.342 mm
(2.8867–2.8875")
0.75 mm (0.0295") .................. 73.069–73.088 mm
(2.8767–2.8775")
1.00 mm (0.0394") .................. 72.815–72.834 mm
(2.8667–2.8675")
1.25 mm (0.0492") .................. 72.561–72.580 mm
(2.8567–2.8575")
Width (A), axial bearing journal 43.900–44.000 mm
(1.7283–1.7323")
(0.1339–0.1417")
Connecting rod bearing journals,
out-of-round, max. ................... 0.08 mm (0.0031")
taper, max. .............................. 0.05 mm (0.0020")
26
TD730, TWD730, TWD731, TWD740
Connecting rods Flywheel, installed

Length, centre – centre (E) Max. permitted axial throw
TD730/TWD730/TWD731 ....... 230.0 mm (9.0551") measuring radius 150 mm (5.9") 0.15 mm (0.0059")
TWD740 ................................... 247.5 mm (9.7441") Number of teeth on flywheel ..... 153
Marking,
Connecting rod resp. cap .......... 1 to 6
“FRONT” on rod turned ............. Forwards
Connecting rod bushing

bore (G),
TD730/TWD730/TWD731 ....... 45.020–45.024 mm Flywheel casing, installed
(1.7724–1.7726") Max. permitted axial throw
TWD740 ................................... 47.020–47.026 mm for contact surface against
(1.8512–1.8514") clutch casing ............................. 0.15 mm (0.0059")
Axial clearance, connecting Max. permitted radial throw
rod – crankshaft, max. for positioning against clutch
TD730/TWD730/TWD731 ....... 0.250 mm (0.0098") casing ........................................ 0.25 mm
TWD740 ................................... 0.350 mm (0.0138") (0.0098")
Connecting rod bearing,
radial clearance, max
TD730/TWD730/TWD731. ...... 0.087 mm (0.0034")
TWD740 ................................... 0.098 mm (0.0039")
27
TD730, TWD730, TWD731, TWD740
Lubricating system

Oil pressure,
(43.50–72.50 psi)
piston cooling ......................... 80–120 kPa
(11.60–17.40 psi)
with oil filter ................................ 29 litres (7.66 US
gals)
Difference between

Oilgrade < 0,5 % 0,5 – 1,0 % > 1,0 %1)
Lube oil pump

Viscosity is selected as per table below. Type ........................................... Gear driven
Number of teeth,
The temperatures refer to stable ambient temperatures. drive gear ................................ 27
intermediate gear .................... 48
−30 −20 −10 ±0 +10 20 30 40 Diameter, bearing sleeve,
o
C intermediate gear .................... 63.99 mm (2.5193")
bushing, intermediate gear ..... 64.05 mm (2.5266")
−15 Co
SAE 15W/40 Axial clearance,
−25oC SAE 10W/30 drive gear in pump .................. 0.07–0.15 mm
(0.0028–0.0059")
✱ SAE 5W/30
intermediate gear .................... 0.10–0.18 mm
−10oC SAE 20W/30 (0.0039–0.0071")
Distance, drive gear – oil
±0oC SAE 30
housing bracket ......................... 1.0–1.5 mm
+10oC SAE 40 (0.039–0.059")
o
Oil filters
−22 −4 +14 32 50 68 86 104 F Number ...................................... 2
By-pass ...................................... Part No. 477556-5
Full-flow ...................................... Part No. 466634-3
* Concerns synthetic or semi-synthetic oil.
28
TD730, TWD730, TWD731, TWD740
Lubricating oil valves (TD730/TWD730/ Lubricating oil valves (TWD740VE)

TWD731) A. Overflow valve
A. Overflow valve Type ........................................... Pressure spring
Type ........................................... Pressure spring Spring, length unloaded ............. 68.8 mm (2.709")
Spring, length unloaded ............. 68.8 mm (2.709") loaded, max. .................. 30.0 mm (1.181")
loaded, max. .................. 30.0 mm (1.181")
B. Piston cooling valve B. Piston cooling valve

Marking ...................................... White Marking ...................................... White
C. Reduction valve
Marking ...................................... Blue C. Reduction valve
Marking ...................................... Yellow
D. Reduction valve
Marking ...................................... Braun
29
TD730, TWD730, TWD731, TWD740
Fuel system
TD730, TWD730, TWD731 TWD740
Fuel specifications Injection timing adjuster (TWD730ME)

The fuel must be approved according to national and in- The injection timing adjuster gradually alters pump set-
ternational standards for commercial fuels, for exampel: ting between two speeds.
EN 590 (with environmental and sub-zero temperature Between 1400 rpm and1800 rpm
specifications according to national requirements) pump setting should alter .......... 6° ± 1°
ASTM D 975 No 1-D and 2-D
JIS KK 2204 Feed pump
Designation, TD730/TWD730 .... 5–291
Sulphur content: According to current legislation, in the
TWD731/TWD740 FP/KG24P200
respective country.
Feed pressure ............................ 100–150 kPa
Note! Fuels with extremely low sulfur contents (“Urban (14.50–21.75 psi)
diesel" in Sweden and “City diesel" in Finland) can Overflow valve
cause a drop in power output of 5 % and an increase in
fuel consumption of 2–3 %. Designation, TD730/TWD730 .... 090310 – 0210
TWD731/TWD740 2 417 413 077
Injector
Injection pump Design. Nozzle holder,
Pump designation, TD730/TWD730 ...................... 093100 – 5150
TD730 ..................................... PE6P120A320RS TWD731/TWD740 .................. KBEL98P74
3359 Nozzle, TD730/TWD730 ........... DLLA–148 P99
TWD730 .................................. NDPE6NB120C320 TWD731 ....................... DLLA–148 P586
TWD731 .................................. PE6P120A320RS TWD740 ....................... DLLA–145 P961
3355 Number marking (complete
TWD740 .................................. PES6P120B320RS injector), TD730/TWD730 .......... 093500 – 5150
3415 TWD731 ..................... 600
Pump setting,TD730 ................. 8° ± 0.5° B.T.D.C. TWD740 ..................... 3826446
TWD730 .............. 10° ± 0.5° B.T.D.C. Opening pressure,
TWD731/TWD740 12° ± 0.5° B.T.D.C. TD730/TWD730 ...................... 25.5 MPa (3698 psi)
Preelift, TD730 ........................... 3.35 ± 0.05 mm TWD731 .................................. 25.0 MPa (3626 psi)
(0.1319 ± 0.0020") TWD740 .................................. 29.0 Mpa (4206 psi)
TWD730 ........................ 2,85 ± 0.05 mm Adjustment press. (new spring) 26.0 (± 0.8) MPa
(0.1122 ± 0.0020") (3770 (± 116) psi)
TWD731 ........................ 3,45 ± 0.05 mm TWD740 .................................. 29.0 (± 0.8) Mpa
(0.1358 ± 0.0020") (4206 (± 116) psi)
TWD740 ........................ 3,55 ± 0.05 mm Bore, TD730/TWD730 ............... 7 x 0.235 mm
(0.1400 ± 0.0020") (0.0093")
Governor, TD730 ....................... RSV325–1200 TWD731 ........................... 7 x 0,258 mm
P1A615 (0.0102")
TWD730 ................... R901 TWD740 ........................... 6 x 0,256 mm
TWD731 ................... RSV325–1200 (0.0101")
P1A605
TWD740 ................... EDC RE30
Injection pump, direction of
rotation viewed from front .......... Clockwise Fuel filters
Firing sequence ......................... 1–5–3–6–2–4 Number ...................................... 2
30
TD730, TWD730, TWD731, TWD740
Intake- and exhaust systems Cooling system
Turbocharger Cooling system, general

Designation, TWD730, TWD731/ Type ........................................... Pressurized
TWD740 ..................................... Holset H1E8264AE Pressure valve opens at ........... 50 kPa (7.25 psi)
H14JA8 Capacity (VP std. radiator
Designation, TWD740 ............... S200/80H27BEDAM/ excl. expansion tank),
0.76DA7 TD730 ..................................... approx. 27 litres
Boost pressure at engine (7.13 US gals)
speed 2400 rpm, TWD730, TWD731/TWD740 .. approx. 28 litres
TD730 ..................................... Min. 190 kPa (7.40 US gals)
(24.65 psi)
TWD730 .................................. Min. 170 kPa
(24.65 psi) Coolant
TWD731/TWD740 .................. Min. 180 kPa Antifreeze (Glycol)
(26.10 psi)
Type ........................................... C
Consists of ................................ Glycol and anticorro-
sion additives
(0.0039–0.0059")
Radial clearance
Volvo Penta part Nos.:
(compressor side) ...................... 0.30–0.45 mm
5 litres (1.32 US gals) ............ 1141646-8
(0.0118–0.0177")
210 litres (55.48 US gals) ...... 1141647-6
Anti-corrosion additive
chance of freezing
Mixed with .................................. Water (1:30)
Starting heater
Starting heater ........................... 24V Note! The anti-corrosion agent must not be mixed with
anti-freeze, coolant or any other type of anti-corrosion
fluid, as this could result in negative consequences.
Coolant pump
Type ........................................... Gear-driven
Thermostat
Number ...................................... 1
Marking ...................................... Blue
Beginns to open at .................... 75°C (167°F)
Fully open at .............................. 88°C (190°F)
31
TD730, TWD730, TWD731, TWD740
Wear tolerances TD/TWD730, TWD731 ........... 190 ± 10 (140.2 ± 7.4)

TWD740 ..................................
Cylinder liners step 1 ..................................... 35 ± 5 (25.8 ± 3.7)
Cylinder liners (pistons and piston rings) should be re- step 2(angle tightening) ......... 90°
placed with a wear of 0.35 – 0.40 mm (0.0138–0.0157") Axial bearing, camshaft ............ 65 ± 7 (48.0 ± 5.2)
or if oil consumption is abnormally high. Timing gear cover ...................... 33 ± 4 (24.4 ± 3.0)
Gear wheel, camshaft ............... 70 ± 7 (51.7 ± 5.2)
Crankshaft Gear wheel, injection pump drive,
Max. permitted out-of-round TD730, TWD730, 731, 740 ...... 60 ± 6 (44.3 ± 4.4)
on main and connecting rod TAD730 .................................... 33 ± 4 (24.4 ± 2.9)
bearing pins ............................... 0.08 mm (0.0031") Intermediate gear journalling ..... 90 ± 9 (66.4 ± 6.6)
Max. permitted taper on main Bearing bracket, rocker arm
and connecting rod bearing shaft ........................................... 65 ± 7 (48.0 ± 5.2)
pins ............................................ 0.05 mm (0.0020") Oil sump,
Max. axial clearance on gaskets with a string of
crankshaft .................................. 0.40 mm (0.0157") silicone ................................... 16 ± 2 11.8 ± 1.5
other gaskets ............................. 24 ± 3 17.7 ± 2.2
Connecting rods (tightened in a specified order,
Straightness, max. deviation see fig. below)*
on a measuring length of Drain plug, oil sump ................... 80 ± 8 (59.0 ± 5.9)
100 mm (3.94") .......................... 0.05 mm (0.0020") Bracket, oil pump ...................... 65 ± 7 (48.0 ± 5.2)
Warp, max. deviation on a Intermediate gear, oil pump ...... 33 ± 4 (24.4 ± 2.9)
measuring length of Flywheel ..................................... 190 ± 10 (140.2 ± 7.4)
100 mm (3.94") .......................... 0.10 mm (0.0039") Pulley, crankshaft ..................... 90 ± 9 (66.4 ± 6.6)
Flywheel casing ......................... 140 ± 14 (103 ± 10.3)
Centre bolt, crankshaft .............. 260 ± 25 (191.8 ± 18.4)
Valves
Nut for retainer, injectors ........... 50 ± 5 (36.9 ± 3.7)
wear ........................................... 0.02 mm (0.0008")
Cleaning plugs in cylinder
Max. permitted clearance
block and cylinder heads .......... 70 ± 7 (51.7 ± 5.2)
between valve stem and
Exhaust manifold ....................... 48 ± 5 (35.4 ± 3.7)
valve guide,
Inlet ......................................... 0.33 mm (0.0130") Tightening cylinder head in 4 stages:
Exhaust .................................. 0.38 mm (0.0150")
First tightening ........................... 30 (22.1)
Valve disc edge should be min.,
Second tightening ...................... 90 (66.4)
Inlet ......................................... 2.0 mm (0.0787")
Third tightening (check
Exhaust .................................. 1.0 mm (0.0394")
tightening) .................................. 90 (66.4)
The valve seat may be ground
down so far that the distance
tightening) .................................. 60°
from the valve disc (new valve)
Angle tightening Tightening diagram
to the cylinder head face is max.
*
Inlet/Exhaust .......................... 0.4 mm (0.0157")
With a greater distance, the vlaves seats must be
replaced.
Camshaft
Bearings, max. permitted
wear ........................................... 0.05 mm (0.0020")
Lift height, min.,
Inlet/Exhaust .......................... 8.33 mm (0.328")
Valve tappets, max. permitted
Tightening torques
Tightening torques Nm (lbf.ft)
Main bearings ............................ 150 ± 10 (110.7 ±7.4)
As from engine No. xxxx/097293:
step 1 ...................................... 150 ±15 (111 lbf.ft)
step 2, angle tightening ......... 90° ±5°
Connecting rod bearings
32
Technical Data
TD1030ME/VE, TWD1030ME/VE, TWD1031VE
General
Type designation ........................................................ TD1030ME TWD1030ME/VE TWD1031VE
Number of cylinders ................................................... 6 6 6
Bore ............................................................................ 120.65 mm (4.75") 120.65 mm (4.75") 120.65 mm (4.75")
Stroke ......................................................................... 140 mm (5.51") 140 mm (5.51") 140 mm (5.51")
Displacement ............................................................. 9.6 dm³ (585.8 in3) 9.6 dm³ (585.8 in3) 9.6 dm³ (585.8 in3)
Compression ratio ...................................................... 18.0:1 18.0:1 18.0:1
Compression pressure at 220 rpm ............................ 2600 kPa (377 psi) 2600 kPa (377 psi) 2600 kPa (377 psi)
Firing sequence .......................................................... 1–5–3–6–2–4 1–5–3–6–2–4 1–5–3–6–2–4
Rotation direction, viewed from the front .................. Clockwise Clockwise Clockwise
Low idle ....................................................................... 600 ± 25 rpm 675 ± 25 rpm 675 ± 25 rpm
High idle ...................................................................... 2390 ± 20 rpm 2420 ± 20 rpm 2250 ± 20 rpm
Engine cut-off speed commences at ......................... 2200 rpm 2200 rpm 2100 rpm
Weight, engine (dry) ................................................... 945 kg (2084 lbs) 975 kg (2150 lbs) 975 kg (2150 lbs)
33
TD1030, TWD1030, TWD1031
Engine Pistons
Cylinder heads Height above block face ........... max. 0.6 mm
(0.0236")
Type ........................................... One cylinder head per
Number of ring grooves ............. 3
cylinder
Front marking ............................ Arrow pointing
Length ........................................ 157 mm (6.18")
forwards
Width .......................................... 240 mm (9.45")
Height ......................................... 114.65 mm (4.51")
Piston rings
Compression rings
Cylinder head bolts
Number per cylinder head ......... 4 Number ...................................... 2
Thread size ................................ 3/4"–10 UNC Upper compression ring, height 3.5 mm (0.1378")
Length ........................................ 200 mm (7.87") Lower compression ring, height 3.1 mm (0.1220")
ring opening,
upper ring ................................ 0.5 mm (0.0197")
lower ring ................................ 0.4 mm (0.0157")
Cylinder block
Length ........................................ 990 mm (39.01") Oil scraper ring
crankshaft centre (A), min. ....... 438.8 mm (17.28") Number ...................................... 1
Height, lower block face – Height ..................................... 4.7 mm (0.1850")
crankshaft centre (B), min. ....... 120 mm (4.72") Piston ring gap measured in
ring opening,
TD1030, TWD1030 ................. 0.5 mm (0.0197")
TWD1031 ................................ 0.4 mm (0.0157")
Gudgeon pins
Clearance, gudgeon pin –

connecting rod bushing ............. 0.03 mm (0.0012")
standard ..................................... 51.998–52.004 mm
(2.0472–2.0474")
Cylinder liners
Type ........................................... Wet, replaceable
Height, total ............................... 287 mm (11.30")
Stepped edge height above
block face .................................. 0.15–0.20 mm
(0.006–0.008")
34
TD1030, TWD1030, TWD1031

Valves Outer diameter (meas. A),
standard,
Disc diameter,
Inlet ......................................... 54 mm (2.126")
Inlet ......................................... 50 mm (1.97")
Exhaust .................................. 49 mm (1.929")
Exhaust .................................. 46 mm (1.81")
Oversize,
Stem diameter,
Inlet ......................................... 54.2 mm (2.134")
Inlet ......................................... 10.91 mm (0.4295")
Exhaust .................................. 49.2 mm (1.937")
Exhaust .................................. 10.90 mm (0.4291")
Height (meas. B),
Valve seat angle,
Inlet ......................................... 6.8 mm (0.268")
Inlet ......................................... 29.5°
Exhaust .................................. 9.5 mm (0.374")
Exhaust .................................. 44.5°
Seat angle in cylinder head,
Inlet ......................................... 30°
Exhaust .................................. 45°
Valve disc edge, min.,
Inlet ......................................... 1.9 mm (0.075")
Exhaust .................................. 1.4 mm (0.055")
Inlet Exhaust
Valve seat location

Diameter (meas. C), standard,
Inlet ......................................... 54.000–54.030 mm
(2.1260–2.1272")
Exhaust .................................. 49.000–49.025 mm
(1.99291–1.9301")
Diameter (meas. C),oversize,
Inlet ......................................... 54.200–54.230 mm
(2.1339–2.1350")
Exhaust .................................. 49.200–49.225 mm
Valve clearance, cold engine,
(1.9370–1.9380")
Inlet ......................................... 0.40 mm (0.016")
Depth (meas. D),
Exhaust .................................. 0.70 mm (0.028")
Inlet ......................................... 9.8–9.9 mm
(0.386–0.390")
The valves can be adjusted according to the two position
Exhaust .................................. 11.8–11.9 mm
method.
(0.465–0.469")
When 1st cylinder piston is at T.D.C. after compression, Seat bottom radius (meas. R),
adjust valves 1, 2, 4, 5, 8 and 9. Inlet/Exhaust .......................... 0.5–0.8 mm
When 6th cylinder piston is at T.D.C. after compression, (0.020–0.031")
adjust valves 3, 6, 7, 10, 11 and 12. Measurement between valve
disc and cylinder head face,
Inlet/Exhaust .......................... 1.2/1.7 mm
(0.05/0.07")
INLET
EXHAUST
35
TD1030, TWD1030, TWD1031
Valve guides 3rd bearing .............................. 64.287–64.312 mm

Inner diameter, (2.5310–2.5320")
Inlet ......................................... 11.05 mm (0.435") 4th bearing .............................. 63.500–63.525 mm
Exhaust .................................. 11.15 mm (0.439") (2.5000–2.5010")
Height above cylinder head 5th bearing .............................. 61.112–61.137 mm
spring face (outer spring), (2.4060–2.4070")
Inlet ......................................... 19 mm (0.75") 6th bearing .............................. 60.325–60.350 mm
Exhaust .................................. 21 mm (0.83") (2.3750–2.3760")
7th bearing .............................. 56.350–56.375 mm
(2.2185–2.2195")
Wear, max. ................................ 0.050 mm (0.0020")
Valve springs
Outer valve spring,
Length, unloaded, min. ........... 61 mm (2.40") Injection timing adjuster (TWD1030ME)
With load of 300–390 N
Drive ........................................... Gear
(67.50–87.75 lbf) .................... 49.6 mm (1.953")
Inner valve spring,
Diameter, bearings .................... 67.050–67.075 mm
Length, unloaded .................... 53 mm (2.09")
(2.6418–2.6428")
With load of 80–170 N
(18.00–38.25 lbf) .................... 42.6 mm (1.68") Timing gears
Backlash .................................... 0.03 – 0.17 mm
(0.0012–0.0067")
Camshaft Axle journal for intermediate
Drive ........................................... Gear gear, diameter ............................ 92.084 – 92.106 mm
Number of bearings ................... 7 (3.6253–3.6221")
Diameter, bearing journals, min., Bushing for intermediate
1st bearing journal .................. 68.985–69.015 mm gear, diameter, max. ................. 92.131–92,166 mm
(2.7159–2.7171") (3.6272–3,6286")
2nd bearing journal ................. 66.610–66.640 mm Radial clearance for intermediate
(2.6224–2.6236") gear ............................................ 0.03 – 0.09 mm
3rd bearing journal .................. 64.222–64.252 mm (0.0012–0.0035")
(2.5284–2.5296") Axial clearance for intermediate
4th bearing journal .................. 63.435–63.465 mm gear ............................................ 0.05 – 0.15 mm
(2.4974–2.4986") (0.0020–0.0059")
(2.4034–2.4046") Number of teeth, timing gears
6th bearing journal .................. 60.260–60.290 mm Drive gear, compressor (1) ........ 33
(2.3724–2.3736") Drive gear, camshaft gear (2) ... 60
7th bearing journal .................. 56.285–56.315 mm Intermediate gear (3) ................. 53
Axial clearance .......................... 0.05–18 mm Intermediate gear, coolant
(0.002–0.007") pump (5) ..................................... 31
Radial clearance ........................ 0.03–0.08 mm Drive gear, coolant pump (6) ..... 19
(0.001–0.003") Crankshaft gear (7) .................... 30
Check of camshaft setting (cold Intermediate gear, lube oil
engine and valve clearance = 0), pump (8) ..................................... 48
Inlet valve for No. 1 cylinder Drive gear, oil pump (9) ............. 21
must with flywheel position 10° Drive gear, servo pump (10) ...... 19
A.T.D.C. have opened ............... 4.2–4.8 mm
(0.165–0.189")
Valve lift, max.,
Inlet ......................................... 13.3 mm (0.524")
Exhaust .................................. 14.3 mm (0.563")
Valve lift, min.,
Inlet ......................................... 13.0 mm (0.512")
Exhaust .................................. 14.0 mm (0.551")
Camshaft bearings
1st bearing .............................. 69.050–69.075 mm
(2.7185–2.7195")
2nd bearing ............................. 66.675–66.700 mm
(2.6250–2.6260")
36
TD1030, TWD1030, TWD1031
Crank mechanism
Crankshaft Oversize,
Length ........................................ 1154 mm (45.43") 0.2 mm (0.008"),
Crankshaft axial clearance ........ 0.06–0.27 mm (axial bear. 0.1 (0.004") .......... 46.175–46.225 mm
(0.0024–0.0106") (1.8179–1.8199")
Main bearings, radial 0.4 mm (0.016"),
clearance ................................... 0.07–0.14 mm (axial bear. 0.2 (0.008") .......... 46.375–46.425 mm
(0.0028–0.0055") (1.8258–1.8278")
0.6 mm (0.024"),
(axial bear. 0.3 (0.012") .......... 46.575–46.625 mm
Note! A nitro-carburized crankshaft may be ground down (1.8336–1.8356")
to max. 2nd undersize. If ground more, it must be Fillet radius (R) .......................... 3.75–4.00 mm
re-nitro-carburized. (0.1476–0.1575")
Main bearing journals

standard ..................................... 99.978–100.000 mm Thrust washers (axial bearing)
(3.9361–3.9370") Width (B), standard ................... 2.312–2.362 mm
Undersize, (0.0910–0.0930")
0.25 mm (0.010") .................... 99.724–99.746 mm Oversize,
(3.9261–3.9270") 0.1 mm (0.004") ...................... 2.412–2.462 mm
0.50 mm (0.020") .................... 99.470–99.492 mm (0.0950–0.0969")
(3.9161–3.9170") 0.2 mm (0.008") ...................... 2.512–2.562 mm
0.75 mm (0.030") .................... 99.216–99.238 mm (0.0989–0.1009")
(3.9061–3.9070") 0.3 mm (0.012") ...................... 2.612–2.662 mm
1.00 mm (0.040") .................... 98.962–98.984 mm (0.1028–0.1048")
(3.8961–3.8970")
1.25 mm (0.050") .................... 98.708–98.730 mm
(3.8861–3.8870")
Main bearing journal, Main bearing shells
wear, out-of-round, max. ........ 0.08 mm (0.003")
Thickness (D), standard ............ 2.447 mm (0.0963")
taper, max. ............................. 0.05 mm (0.002")
Oversize,
Width, axial bearing journal (A),
0.25 mm (0.010") .................... 2.574 mm (0.1013")
standard ..................................... 45.975–46.025 mm
0.50 mm (0.020") .................... 2.701 mm (0.1063")
(1.8100–1.8120")
0.75 mm (0.030") .................... 2.828 mm (0.1113")
1.00 mm (0.040") .................... 2.955 mm (0.1163")
1.25 mm (0.050") .................... 3.082 mm (0.1213")
37
TD1030, TWD1030, TWD1031
Connecting rod bearing pin Connecting rods

Diameter (Ø) for machining, Length, centre – centre (E) ....... 277 mm (10.91")
standard ..................................... 86.003–86.025 mm Marking,
(3.3859–3.3868") Connecting rod resp. cap .......... 1 to 6
Undersize, “FRONT" on rod turned ............. Forwards
0.25 mm (0.0098") .................. 85.753–85.775 mm Connecting rod bushing
(3.3761–3.3770") bore (G) ...................................... 52.022–52.028 mm
0.50 mm (0.0197") .................. 85.503–85.525 mm (2.0481–2.0483")
(3.3663–3.3671") Axial clearance, connecting
0.75 mm (0.0295") .................. 85.253–85.275 mm rod – crankshaft ......................... 0.15–0.35 mm
(3.3564–3.3573") (0.0059–0.0138")
1.00 mm (0.0394") .................. 85.003–85.025 mm Connecting rod bearing,
(3.3466–3.3474") radial clearance ......................... 0.08–0.12 mm
1.25 mm (0.0492") .................. 84.753–84.775 mm (0.0032–0.0047")
(3.3367–3.3376")
Width (A), axial bearing journal . 53.90–54.00 mm
(2.1220–2.1260")
(0.1476–0.1575") Flywheel, installed
Connecting rod bearing journal, Max. permitted axial throw,
out-of-round, max. .................. 0.08 mm (0.0031") measuring radius 150 mm
taper, max .............................. 0.05 mm (0.0020") (5.91") ........................................ 0.15 mm (0.0059")
Number of teeth on flywheel ..... 156
Connecting rod bearing shells

Thickness (C), standard ............ 2.413 mm (0.0950") Flywheel casing, installed
Oversize, Max. permitted axial throw
0.25 mm (0.010") .................... 2.540 mm (0.0900") for contact surface against
0.50 mm (0.020") .................... 2.667 mm (0.1050") clutch casing ............................. 0.15 mm (0.0059")
0.75 mm (0.030") .................... 2.794 mm (0.1100") Max. permitted radial throw
1.00 mm (0.040") .................... 2.921 mm (0.1150") for positioning against clutch
1.25 mm (0.050") .................... 3.048 mm (0.1200") casing ........................................ 0.25 mm (0.0098")
38
TD1030, TWD1030, TWD1031
Lubricating system

Oil pressure,
(43.50–72.50 psi)
with oil filter ................................ 36 litres (9.5 US gals)
Difference between

Oilgrade < 0,5 % 0,5 – 1,0 % > 1,0 %1)
Viscosity is selected as per table below.

The temperatures refer to stable ambient temperatures.
−30 −20 −10 ±0 +10 20 30 40 o

Axial clearance,
C drive gear in pump .................. 0.11 mm (0.0043")
intermediate gear .................... 0.14 mm (0.0055")
−15 Co
SAE 15W/40
o
−25 C SAE 10W/30
Lubricating oil valves
✱ SAE 5W/30 1. Overflow valve, filter
−10oC SAE 20W/30 Type ........................................... Thrust spring
Spring, length,
±0oC SAE 30 unloaded ................................. 68.8 mm (2.709")
+10oC SAE 40 with load of 18 ± 1 N
(4.05 ± 0.23 lbf) ...................... 32 mm (1.26")
o
−22 −4 +14 32 50 68 86 104 F
2. By-pass valve, oil cooler
* Concerns synthetic or semi-synthetic oil.
Type ........................................... Thrust spring
Spring, length,
Oil filters unloaded ................................. 46 mm (1.81")
Number ...................................... 2 with load of 54 ± 1 N
(12.15 ± 0.23 lbf) .................... 30 mm (1.18")
Lube oil pump
Type ........................................... Gear driven 3. Reduction valve
Diameter, Marking ...................................... Yellow
bearing sleeve, intermediate
gear ......................................... 92.084–92.186 mm 4. Piston cooling valve
(3.6253–3.6294") Marking ...................................... None
bushing intermediate gear ...... 92.131–92.166 mm
(3.6272–3.6286")
39
TD1030, TWD1030, TWD1031
Fuel system
Fuel specifications Delivery pipes

The fuel must be approved according to national and in- Delivery pipes
ternational standards for commercial fuels, for exampel: Type ........................................... Prestressed
Inner diameter ............................ 2.0 mm (0.0787")
EN 590 (with environmental and sub-zero temperature
specifications according to national requirements)
ASTM D 975 No 1-D och 2-D
JIS KK 2204 Injection timing adjuster (TWD1030ME)
The injection timing adjuster gradually alters pump set-
Sulphur content: According to current legislation, in the
ting between two speeds.
respective country.
Note. Fuels with extremely low sulfur contents (“Urban Between 1200 rpm and 1800 rpm
diesel" in Sweden and “City diesel" in Finland) can pump setting should alter .......... 6° ± 1°
cause a drop in power output of 5 % and an increase in
fuel consumption of 2–3 %.
Feed pump
Injection pump Designation, TD1030 ................. FP/KG 24P 200
TWD1030 .............. FP/KG 24P 307
Pump designation,
TWD1031 .............. FP/KG 24P 307
TD1030 ................................... PE6P120A320RS
Feed pressure ............................ 100–150 kPa
3355
(14.50–21.75 psi)
TWD1030 ................................ PE6P120A320RS
8017
TWD1031 ................................ PE6P120A320RS Injectors
7426 Designation, nozzle holder ........ KBEL 117 P73
Pump setting, Nozzle, TD1030 ......................... DLLA 152P 335
TD1030 ................................... 11° (± 0.5°) B.T.D.C TWD1030 ...................... DLLA 152P 313
TWD1030 ................................ 10° (± 0.5°) B.T.D.C TWD1031 ...................... DLLA 152P 313
TWD1031 ................................ 10° (± 0.5°) B.T.D.C Number marking (complete
Preelift, injector), TD1030 ....................... 721
TD1030 ................................... 3.45 ± 0.05 mm TWD1030 ................... 730
(0.1358 ± 0.0020") TWD1031 ................... 730
TWD1030 ................................ 4.15 ± 0.05 mm Opening pressure ...................... 25.0 MPa (3625 psi)
(0.1634 ± 0.0020") Adjustment pressure
TWD1030 ................................ 4.45 ± 0.05 mm (new spring) ............................... 26.0 (+ 0.8) MPa
(0.1752 ± 0.0020") (3770 (+ 116) psi)
Governor, Bore, TD1030 ............................ 6 x 0.27 mm (0.0106")
TD1030 ................................... RSV300–1100P1A TWD1030 ......................... 6 x 0.25 mm (0.0098")
604 TWD1031 ......................... 6 x 0.25 mm (0.0098")
TWD1030 ................................ RQV300–1100PA
1017
TWD1031 ................................ RSV300–1100P1A
650 Fuel filters
Injection pump direction of Number ...................................... 2
rotation viewed from front .......... Clockwise
Firing sequence ......................... 1–5–3–6–2–4
40
TD1030, TWD1030, TWD1031
Intake- and exhaust systems
Turbocharger Starting heater

Designation, Starting heater ........................... 24V
TD1030, TWD1030 ................. Garret TA45564
1.22/69SJA
TWD1031 ................................ Schwitzer S3B 91
H39 BJ AQM 1
Boost pressure at engine speed
2200 rpm,
TD1030 ................................... min. 160 kPa
(23.2 psi)
TWD1030 ................................ min. 130 kPa
(18.85 psi)
2100 rpm,
TWD1031 ................................ min. 170 kPa
(24.66 psi)
Axial clearance,
Garret ...................................... 0.5–0.8 mm
(0.0197–0.0315")
Schwitzer ................................ max. 0,170 mm
(0.007")
Radial clearance,
Garret ...................................... 0.12–0.17 mm
(0.0047–0.0067")
Schwitzer ................................ max. 0.70 mm
(0.028")
41
TD1030, TWD1030, TWD1031
Cooling system
Cooling system, general Coolant pump

Type ........................................... Pressurized Type ........................................... Gear-driven
Pressure valve opens at ........... 75 kPa (10.88 psi)
Capacity (VP std. radiator excl.
expansion tank),
TD1030 ................................... approx. 29 litres
(7.66 US gals)
TWD1030, TWD1031 ............. approx. 32 litres
(8.45 US gals)
Coolant
Antifreeze (Glycol) Thermostat
Type ........................................... C
Number ...................................... 1
Consists of ................................ Glycol and anti-
Marking (TWD1031) ................... Blue
corrosion additives
(TD1030/TWD1030) ................... Green
Volvo Penta part Nos.,
Beginns to open at (TWD1031) . 75°C (167°F)
5 litres (1.32 US gals) ............ 1141646-8
(TD1030/TWD1030) ................... 86°C (187°F)
210 litres (55.48 US gals) ...... 1141647-6
Fully open at (TWD1031) .......... 88°C (190°F)
(TD1030/TWD1030) ................... 96°C (205°F)
Anti-corrosion agent
chance of freezing
Mixed with .................................. Water (1:30)
Note! The anti-corrosion agent must not be mixed with

anti-freeze or any other type of anti-corrosion fluid as
this could result in negative consequences.
42
TD1030, TWD1030, TWD1031
Wear tolerances Tightening torques

Cylinder heads Nm (lbf.ft)
Height, min. ............................... 114.65 mm (4.5138") Main bearings ............................ 340 ± 25 (250.8 ±18.5)
Connecting rod bearings,
Cylinder liners First tightening ........................ 40 (29.5)
Second tightening .................. 75 (55.4)
The cylinder liner (pistons and piston rings) should be re-
placed with a wear of 0.40 – 0.45 mm (0.058–0.0177") or
tightening) ............................... 90°
if oil consumption is abnormally high. Axial bearing, camshaft ............ 40 ± 4 (29.5 ± 3.0)
Timing gear cover ...................... 40 ± 4 (29.5 ± 3.0)
Gear, camshaft ......................... 60 ± 6 (44.3 ± 4.4)
Crankshaft Gear, injection pump drive,
Max. permitted out-of-round TD1030, TWD1031 ................. 60 ± 6 (44.3 ± 4.4)
on main and connecting rod TWD1030 ................................ 45 ± 5 (33.2 ± 3.7)
bearing pins ............................... 0.08 mm (0.0032") Intermediate gear journal ........... 60 (44.3)
Max. permitted taper on main Bearing bracket, rocker arm
and connecting rod bearing shaft ........................................... 40 ± 4 (29.5 ± 3.0)
pins ............................................ 0.05 mm (0.0020") Drain plug, oil sump ................... 60 ± 15 (44.3 ± 11.1)
Max. axial clearance on Oil sump,
crankshaft .................................. 0.40 mm (0.0157") gaskets with a string of
silicone ................................... 16 ± 2 (11.8 ± 1.5)
Connecting rods other gaskets ............................. 24 ± 3 (17.7 ± 2.2)
Straightness, max. deviation (tightened in a specified order,
on a measuring length of see fig. below)*
100 mm (3.94") .......................... 0.05 mm (0.0020") Bracket, oil pump ...................... 40 ± 4 (29.5 ± 3.0)
Warp, max. deviation on a Intermediate gear, oil pump ...... 17 ± 2 (12.5 ± 1.5)
measuring length of 100 mm Intermediate gear, coolant
(3.94") ........................................ 0.10 mm (0.0039") pump .......................................... 120 (88.5)
Flywheel ..................................... 175 (129.1)
Pulley, crankshaft ..................... 60 (44.3)
Valves
Flywheel casing ......................... 140 ± 15 (103.3 ± 11.1)
Centre bolt, crankshaft .............. 550 (406)
wear ........................................... 0.07 mm (0.0028")
Nut for retainers, injectors ......... 50 ± 5 (36.9 ± 3.7)
Max. permitted clearance
between valve stem and
Discs, pump coupling ................ 62 ± 5 (45.8 ± 3.7)
valve guide,
Cleaning plugs in cylinder block
Inlet ......................................... 0.2 mm (0.0079")
and cylinder heads .................... 60 ±10 (44.3 ± 7.3)
Exhaust .................................. 0.3 mm (0.0118")
Valve disc edge should be min., Tightening cylinder head in 4 stages:
Inlet ......................................... 1.9 mm (0.0748")
First tightening ........................... 50 (36.9)
Exhaust .................................. 1.4 mm (0.0551")
Second tightening ...................... 200 (147.6)
The valve seat may be ground
Third tightening .......................... 370 (273)
down so far that the distance
Final tightening (angle tightening) 90°
from the valve disc (new valve)
to the cylinder head face is
max.,
Inlet/Exhaust .......................... 2.5 mm (0.0984")
With greater distance, the valve seats must be replaced.
Camshaft
Bearings, max. permitted
Cylinder head tightening diagram
wear ........................................... 0.05 mm (0.0020")
Lift height, min., *
Inlet ......................................... 8.4 mm (0.3307")
Exhaust .................................. 9.0 mm (0.3543")
Valve tappet, max. permitted
43
TD1030, TWD1030, TWD1031
Notes
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44
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Publication No.: ............................................................. Date of issue: .................................................................
Proposal/motivation: ..............................................................................................................................................
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Date: ................................................................
Signed: .............................................................
AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Göteborg
Sweden
7738348 English 07–2005

Workshop Manual

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Important Check that the warning or information labels on

Note! Used to draw your attention to important infor-

Only start the engine in a well-ventilated area. If

It is difficult to anticipate in which direction

Always use protective goggles when charging

© 2004 AB VOLVO PENTA

About this Workshop Manual Certificated engines

IMPORTANT! If replacement parts are required

Use of replacement parts other than AB

Tightening torque with Protractor Sealant

Note: Loctite® is the registered trademark of Loctite

Safety rules for fluorocarbon

• Always use gloves made of chloroprene rub-

Oil scraper ring

Valve mechanism Valve seats

Valve seat location

Valve guides Camshaft bearings

Injection timing adjuster, TWD630ME/VE

Main bearing journals

Connecting rod bearing journals Connecting rods

Connecting rod bearing shells

Lubricating system, general

Lubricanting oil, engine

Viscosity is selected as per table below. Axial clearance,

Fuel specifications Injection timing adjuster, TWD630ME/VE

Sulphur content: According to current legislation in the

Injection pump Overflow valve

Intake- and exhaust system Cooling system

Turbocharger Cooling system, general

Note! The anti-corrosion agent must not be mixed with

radial clearance ......................... 0.08 mm (0.0031")

Oil scraper ring

Valve mechanism Valve seats

Valve seat location

Valve guides Diameter, bearing journals TWD740, min.

Valve springs Check of camshaft setting(cold

Camshaft bearings Timing gears

Injection timing adjuster, (TWD730ME)

Connecting rod bearing journals Connecting rod bearing shells

Connecting rods Flywheel, installed

Connecting rod bushing

Lubricating system, general

Lubricanting oil, engine

Lube oil pump

Lubricating oil valves (TD730/TWD730/ Lubricating oil valves (TWD740VE)

B. Piston cooling valve B. Piston cooling valve

Fuel specifications Injection timing adjuster (TWD730ME)

Intake- and exhaust systems Cooling system

Turbocharger Cooling system, general

Wear tolerances TD/TWD730, TWD731 ........... 190 ± 10 (140.2 ± 7.4)

Clearance, gudgeon pin –

Valve mechanism Valve seats

Valve seat location

Valve guides 3rd bearing .............................. 64.287–64.312 mm

Main bearing journals

Connecting rod bearing pin Connecting rods

Connecting rod bearing shells

Lubricating system, general

Lubricanting oil, engine

Viscosity is selected as per table below.

−30 −20 −10 ±0 +10 20 30 40 o

Fuel specifications Delivery pipes