Workshop Manual

Technical Data

TAD1030G, TAD1030GE, TAD1030P,

TAD1030V, TAD1031GE, TAD1032GE
 Workshop Manual
Technical Data

Industrial Diesel Engines

TAD1030G/GE • TAD1030P/V
TAD1031GE • TAD1032GE

Contents

Safety precautions ..................................................................... 2

General information ................................................................... 5

Identification plates .......................................................................... 8

Technical Data .............................................................................. 9

General ............................................................................................ 9
Electrical system .............................................................................. 9
Engine .............................................................................................. 10
Valve mechanism ............................................................................. 10
Crank mechanism ............................................................................ 13
Lubrication system ........................................................................... 15
Fuel system ..................................................................................... 17
Cooling system ................................................................................ 18
Intake and exhaust system .............................................................. 18
Wear tolerances ............................................................................... 19
Tightening torques ........................................................................... 19

1
 Safety Precautions
Introduction
The Workshop Manual contains technical data for the
Volvo Penta products or product versions noted in
the table of contents. Make sure that the correct
workshop literature is used.
Before starting work on the engine read the
“Safety Precautions”, “General Information” and
“Repair Instructions” sections of this service
manual carefully.
Important
In this book and on the product you will find the fol-
lowing special warning symbols.
WARNING! Possible danger of personal inju-
ry, extensive damage to property or serious
mechanical malfunction if the instructions are
not followed.
IMPORTANT! Used to draw your attention to
something that can cause damage or malfunc-
tions on a product or damage to property.
Note! Used to draw your attention to important infor-
mation that will facilitate the work or operation
in progress.
Below is a summary of the risks involved and safety
precautions you should always observe or carry out
when operating or servicing the engine.
Immobilize the engine by turning off the power
supply to the engine at the main switch (switch-
es) and lock it (them) in the OFF position be-
fore starting work. Set up a warning notice at
the engine control point.
2
As a general rule all service operations must be
carried out with the engine stopped. However,
some work, for example certain adjustments re-
quire that the engine is running when they are
carried out. Approaching an engine which is op-
erating is a safety risk. Loose clothing or long
hair can fasten in rotating parts and cause seri-
ous personal injury. If working in proximity of an
engine which is operating, careless movements
or a dropped tool can result in personal injury.
Take care to avoid contact with hot surfaces
(exhaust pipes, Turbocharger (TC), air intake
pipe, starter element etc.) and hot liquids in
lines and hoses on an engine which is running
or which has just been stopped. Reinstall all
protective parts removed during service opera-
tions before starting the engine.
Check that the warning or information labels on
the product are always clearly visible. Replace
labels which have been damaged or painted
over.
Never start the engine without installing the air
cleaner (ACL) filter. The rotating compressor in
the Turbo can cause serious personal injury.
Foreign objects entering the intake ducts can
also cause mechanical damage.
Never use start spray products or similar when
starting the engine. They may cause an explo-
sion in the inlet manifold. Danger of personal
injury.
Only start the engine in a well-ventilated area.
If operating the engine in an enclosed area en-
sure that there is exhaust ventilation leading
out of the engine compartment or workshop
area to remove exhaust gases and crankcase
ventilation emissions.
Avoid opening the coolant filler cap when the
engine is hot. Steam or hot coolant can spray
out as system pressure is lost. Open the filler
cap slowly and release the pressure in the sys-
tem, if the filler cap or a drain cock/venting cock
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.

Hot oil can cause burns. Avoid getting hot oil
on the skin. Ensure that the lubrication system
is not under pressure before carrying out any
work. Never start or operate the engine with
the oil filler cap removed, otherwise oil could be
ejected.
Stop the engine before carrying out operations
on the engine cooling system.
Always use protective glasses or goggles when
carrying out work where there is a risk of splin-
ters, grinding sparks, acid splashes or where
other chemicals are used. The eyes are ex-
tremely sensitive, an injury could result in blind-
ness!
Avoid getting oil on the skin! Repeated expo-
sure to oil or exposure over a long period can
result in the skin becoming dry. Irritation, dry-
ness and eczema and other skin problems can
then occur. Used oil is more dangerous than
fresh oil from a health aspect. Use protective
gloves and avoid oil soaked clothes and shop
rags. Wash regularly, especially before eating.
There are special skin creams which counter-
act drying out of the skin and make it easier to
clean off dirt after work is completed.
Many chemicals used on the product (for ex-
ample engine and transmission oils, glycol,
gasoline and diesel oil), or chemicals used in
the workshop (for example degreasing agents,
paint and solvents) are dangerous to health.
Read the instructions on the product packaging
carefully! Always follow the safety precautions
for the product (for example use of protective
mask, glasses, gloves etc.). Make sure that
other personnel are not exposed to hazardous
chemicals, for example in the air. Ensure good
ventilation in the work place. Follow the instruc-
tions provided when disposing of used or lefto-
ver chemicals.
Excercise extreme care when leak detecting on
the fuel system and testing the fuel injector jets.
Use eye protection. The jet from a fuel injector
nozzle is under extremely high pressure and
has great penetrative energy, so the fuel can
penetrate deep into the body tissue and cause
serious personal injury. Danger of blood poi-
soning.
Safety Precautions
WARNING! The delivery pipes must under no
circumstances be bent. Damaged pipes
should be replaced.
All fuels and many chemical substances are
flammable. Do not allow naked flame or sparks
in the vicinity. Fuel, certain thinner products
and hydrogen from batteries can be extremely
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
starting welding or grinding work. Always en-
sure that there are fire extinguishers at hand
when work is being carried out.
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-
vironmentally dangerous waste and must be
deposited at an approved site for destruction
together with used lubricating oil, contaminated
fuel, paint remnants, solvent, degreasing
agents and waste from washing parts.
Never expose a battery to naked flame or elec-
trical sparks. Never smoke in proximity to the
batteries. The batteries give off hydrogen gas
during charging which when mixed with air can
form an explosive gas – oxyhydrogen. This gas
is easily ignited and highly volatile. Incorrect
connection of the battery can cause a single
spark which is sufficient to cause an explosion
with resulting damage. Do not shift the connec-
tions when attempting to start the engine
(spark risk) and do not lean over any of the bat-
teries.
Always ensure that the Plus (positive) and Mi-
nus (negative) battery leads are correctly in-
stalled on the corresponding terminal posts on
the batteries. Incorrect installation can result in
serious damage to the electrical equipment.
Refer to the wiring diagrams.
Always use protective goggles when charging
and handling the batteries. Battery electrolyte
contains sulfuric acid which is highly corrosive.
Should the battery electrolyte come into con-
tact with unprotected skin wash off immediately
using plenty of water and soap. If battery acid
comes in contact with the eyes, immediately
flush with plenty of water and obtain medical
assistance at once.
3
Safety Precautions
Turn the engine off and turn off the power at the
main switch(es) before carrying out work on the
electrical system.
Clutch adjustments must be carried out with
the engine stopped.
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
weight including gearbox, if fitted, and any ex-
tra equipment installed).
Use an adjustable lifting beam or lifting beam
specifically for the engine to raise the engine to
ensure safe handling and to avoid damaging
engine parts installed on the top of the engine.
All chains and cables should run parallel to
each other and as perpendicular as possible in
relation to the top of the engine.
If extra equipment is installed on the engine
which alters its center of gravity a special lifting
device is required to obtain the correct balance
for safe handling.
Never carry out work on an engine suspended
on a hoist without other supporting equipment
attached.
Never work alone when removing heavy en-
gine components, even when using lifting de-
vices such as locking tackle lifts. When using a
© 2001 AB VOLVO PENTA
All rights to changes or modifications reserved.
Printed on environmentally-friendly paper
4
lifting device two people are usually required to
do the work, one to take care of the lifting de-
vice and another to ensure that components
are lifted clear and not damaged during the lift-
ing operations. 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.
WARNING! The components in the electrical
system and in the fuel system on Volvo Penta
products are designed and manufactured to
minimize the risk of fire and explosion. The en-
gine must not be run in areas where there are
explosive materials.
Always use the fuels recommended by Volvo
Penta. Refer to the Instruction Book. Use of fu-
els that are of a lower quality can damage the
engine. On a diesel engine poor quality fuel
can cause the control rod to seize and the en-
gine to overrev with resulting risk of damage to
the engine and personal injury. Poor fuel quali-
ty can also lead to higher maintenance costs.
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.
 General Information
About this Workshop Manual
This Workshop Manual contains technical data for the
repair of the following engines in standard format:
TAD1030G/GE, TAD1030P/V, TAD1031GE,
TAD1032GE.
The Engine Designation and Engine Numbers can be
found on the product plate (see page 8). Please al-
ways include both the engine designation and the en-
gine number in all correspondance.
The Workshop Manual is produced primarily for the
use of Volvo Penta workshops and service techni-
cians. For this reason the manual presupposes a
certain basic knowledge and that the user can carry
out the mechanical/electrical work described to a
general standard of engineering competence.
Volvo Penta products are under a continual process
of development and we therefore reserve all rights
regarding changes and modifications. All the infor-
mation in this manual is based on product specifica-
tions available at the time the book was published.
Any essential changes or modifications introduced
into production or updated or revised service meth-
ods introduced after the date of publication will be
provided in the form of Service Bulletins.
Spare parts
Spare parts for the electrical and fuel systems are
subject to various national safety requirements.
Volvo Penta Original Spare Parts meet these specifi-
cations. Any type of damage which is the result of
using spare parts that are not original Volvo Penta
parts for the product in question will not be covered
under any warranty or guarantee provided by AB
Volvo Penta.
Certificated engines
Engines certificated to meet national and regional en-
vironmental legislation carry with them an undertaking
from the manufacturer that both new and existing en-
gines in use meet the enviromental demands of the
legislation. The product must correspond to the vali-
dated example that was granted certification. In order
for Volvo Penta as the manufacturer to take responsi-
bility for engines in use, certain requirements regard-
ing service and spare parts must be met by the user
according to the following:
● The Service Intervals and maintenance operations
recommended by Volvo Penta must be followed.
● Only Volvo Penta Original Spare Parts intended for
the certificated engine may be used.
● Service work on the injection pump and injectors
must always be carried out by an authorized
Volvo Penta workshop.
● The engine may not be altered or modified in any
way, with the exception of accessories and ser-
vice kits developed by Volvo Penta for that en-
gine.
● No modifications to the exhaust pipes and air sup-
ply ducts for the engine room (ventilation ducts)
may be undertaken as this may effect exhaust
emissions.
● 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
Volvo Penta being unable to assume any li-
ability that the engine corresponds to the
certificated engine variant.
AB Volvo Penta excludes any liability for all and
any type of damage or costs caused by the use
of replacement parts that are not Volvo Penta
Original Parts for the product in question.
5
 Repair instructions
Our joint responsibility
Every engine consists of many systems and compo-
nents that work together. If one component deviates
from the technical specifications this can have dra-
matic consequences on the environmental impact of
the engine even if it is otherwise in good running or-
der. It is therefore critical that the stated wear toler-
ances are observed, that systems which can be ad-
justed are correctly set up and that only Volvo Penta
Original Parts are used on the engine. The stated
service intervals in the Maintenance Schedule must
be followed.
Some systems, such as the components in the fuel
system, require special expertise and special testing
equipment for service and maintenance. Some com-
ponents are factory sealed for environmental and
product specific reasons. Under no circumstances
attempt to service or repair a sealed component un-
less the service technician carrying out the work is
authorized to do so.
Bear in mind that most chemical products, incorrectly
used, are hazardous to the environment. Volvo
Penta recommends the use of bio-degradable de-
greasing agents for all cleaning of engine compo-
nents unless otherwise stated in the Workshop Man-
ual. Pay special attention to make sure that oils and
washing residue are handled correctly for destruc-
tion, and do not unintentionally end up in the nature.
Tightening torques
The correct tightening torques for critical joints which
must be tightened using a torque wrench are listed
under “Technical Data – Tightening Torques” and
stated in the method descriptions in the Workshop
Manual. All tightening torques apply to cleaned
threads, bolt heads and mating surfaces. Tigthening
torques stated are for lightly oiled or dry threads.
Where grease, locking or sealing agents are required
for screwed joints this is stated in both the operation
description and in “Tightening Torques”. Where no
tightening torque is stated for a joint use the general
tightening torques according to the table on the next
page. The tightening torques stated are a guide and
the joint does not have to be tightened using a torque
wrench.
6
Dimension Tightening torque
Nm lbf.ft.
M5 .................................................... 6 4.4
M6 .................................................... 10 7.4
M8 .................................................... 25 18.4
M10 .................................................. 50 36.9
M12 .................................................. 80 59.0
M14 .................................................. 140 103.3
Tightening torque with
Protractor tightening
(angle tightening)
Tightening using both a torque setting and a protrac-
tor angle requires that first the recommended torque
is applied using a torque wrench and then the recom-
mended angle is added according to the protractor
scale.
Example: a 90° protractor tightening means that the
joint is tightened a further 1/4 turn in one operation
after the stated tightening torque has been applied.
Lock nuts
Do not re-use lock nuts that have been removed dur-
ing dissassembly operations as these have reduced
service life when re-used – use new nuts when as-
sembling or reinstalling. For lock nuts with a plastic
insert such as Nylock® the tightening torque stated
in the table is reduced if the Nylock® nut has the
same head height as a standard hexagonal nut with-
out plastic insert. Reduce the tightening torque by
25% for bolt size 8 mm or larger. Where Nylock®
nuts are higher, or of the same height as a standard
hexagonal nut, the tightening torques given in the ta-
ble apply.

Strength classes
Bolts and nuts are divided up into different classes of
strength; the class is indicated by the number on the
bolt head. A high number indicates stronger material,
for example a bolt marked 10-9 indicates a higher
strength than one marked 8-8. It is therefore important
that bolts removed during the disassembly of a bolted
joint must be reinstalled in their original position when
assembling the joint. If a bolt must be replaced check
in the spare parts catalogue to make sure the correct
bolt is used.
Sealant
A number of sealants and locking liquids are used on
the engines. The agents have varying properties and
are used for different types of jointing strengths, oper-
ating temperature ranges, resistance to oil and other
chemicals and for the different materials and gap siz-
es in the engines.
To ensure service work is correctly carried out it is im-
portant that the correct sealant and locking fluid type
is used on the joint where the agents are required.
In this Volvo Penta Workshop Manual the user will
find that each section where these agents are applied
in production states which type was used on the en-
gine.
Repair instructions
During service operations use the same agent or an
alternative from a different manufacturer.
Make sure that mating surfaces are dry and free from
oil, grease, paint and anti-corrosion agent before ap-
plying sealant or locking fluid. Always follow the man-
ufacturer’s instructions for use regarding temperature
range, curing time and any other instructions for the
product.
Two different basic types of agent are used on the en-
gine 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; old
RTV must be removed before resealing the joint.
The following RTV agents are mentioned in the Ser-
vice Manual: Loctite® 574, Volvo Penta part No.
840879-1, Permatex® No. 3, Volvo Penta part No.
1161099-5, Permatex® No. 77. Old sealant can be
removed using methylated spirits in all cases.
Anaerobic agents. These agents cure in an absence
of air. They are used when two solid parts, for exam-
ple cast components, are installed face-to-face with-
out a gasket. They are also commonly used to secure
plugs, threads in stud bolts, cocks, oil pressure
switches 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 reinstall-
ing the part is carefully degreased and then new seal-
ant 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

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.

N T
R O
F

1
2
3
4
5
6

T – Turbo charged
A – Air-to-air charge air cooler
W – Water-to-air charge air cooler
D – Diesel engine
10 – 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

8
 Technical Data

Technical Data

General
Designation ....................................................................................... TAD1030G/GE/P/V, TAD1031GE, TAD1032GE
In line four stroke diesel engine with direct injection.
Turbocharged and air-to-air intercooled (TAD).
Numbers of cylinders .......................................................................... 6
Displacement, total ............................................................................. 9.60 litres/586 in³
Firing order ......................................................................................... 1–5–3–6–2–4
Rotation direction, viewed towards front ............................................ Clockwise
Bore ................................................................................................... 120.65 mm (4.750")
Stroke .................................................................................................. 140 mm (5.512") in
Compression ratio ............................................................................. 15:1, TAD1031GE: 17:1
Compression pressure, starter speed ................................................ 2600 kPa (377psi)
Dry weight,
TAD1030G/GE, TAD1031GE engine only ..................................... 1107 kg (2441 lbs)
TAD1030P/V, engine only ............................................................... 1062 kg (2342 lbs)
Idling speed, low (approx.),
TAD1030G/GE ................................................................................ 1300 rpm
TAD1030P/V ................................................................................... 600 rpm
TAD1031GE .................................................................................... 1300 r/min

Performance
Max output: See applicable engine diagram
Max torque: See applicable engine diagram

Electrical system
Volyage and type ................................................................................ 24V, insulated from earth
Alternator,
output ............................................................................................... 60A
voltage ............................................................................................. 28V
rating ................................................................................................ 1700 W
make ................................................................................................ Valeo
Starter motor battery capacity,
maximum ......................................................................................... 2 x 152 Ah
minimum at > +5°C (41°F) .............................................................. 2 x 110 Ah
Density of battery electrolyte at +25°C (77°F),
fully charged .................................................................................... 1.28 g/cm³ (1.24 g/cm³)*
battery needs recharging at ............................................................ 1.24 g/cm³ (1.20 g/cm³)*
Starter motor,
type .................................................................................................. Bosch 5.4 kW/24V
Starting heater .................................................................................... 24V

* Note: Refers to batteries with tropic acid.

9
Technical Data

Engine Pistons
Piston clearance ..................................... 0.15–0.18 mm
Cylinder heads (0.006–0.007")
Type ........................................................ One per cylinder Height above block face (max) .............. 0.55 mm (0.022")
Length ..................................................... 157 mm (6.18") Number of ring grooves .......................... 3
Width ....................................................... 240 mm (9.45") Front marking ......................................... Arrow pointing
Height, min ............................................. 114.65 mm (4.514") forwards

Piston rings
Compression rings
Cylinder head bolts Number .................................................... 2
Number/cylinder head ............................ 4 Piston ring gap measured in ring
Thread size ............................................. 3/4" – 10 UNC opening, 1st ring ..................................... 0.40–0.60 mm
Length ..................................................... 200 mm (7.874") (0.016–0.024")
2nd ring ................................... 0.35–0.65 mm
(0.014–0.026")
TAD1032GE: opening, 1st ring ................ 0.45–0.60 mm
(0.018–0.024")
Cylinder block 2nd ring .................................... 0.45–0.60 mm
(0.018–0.024")
Length ..................................................... 990 mm (38.976") Oil scraper ring
Height, upper block face – crankshaft Number .................................................... 1
centre (A), min ........................................ 438.8 mm (17.276") Piston ring gap measured in ring
Height, lower block face – crankshaft opening ................................................... 0.35–0.65 mm
centre (B) ................................................ 120 mm (4.724") (0.014–0.026")
TAD1031GE/TAD1032GE: Piston ring gap
measured in ring opening ........................ 0.60–0.80 mm
(0.024–0.031")
Gudgeon pins
Clearance, gudgeon pin – connecting
rod bushing ............................................. 0.018–0.026 mm
(0.0007–0.0010")
Gudgeon pin diameter, standard ........... 51.998–52.004 mm
(2.0472–2.0474")
Gudgeon pin hole in piston .................... 52.000–52.008 mm
(2.0472–2.0476")

Valve mechanism
Valves
Disc diameter,
Inlet ..................................................... 50 mm (1.97")
Exhaust ............................................... 46 mm (1.81")
Stem diameter,
Inlet ..................................................... 10.982–11.000 mm
(0.4324–0.4331")
Exhaust ............................................... 10.966–10.984 mm
(0.4317–0.4324")
Valve seat angle,
Inlet ..................................................... 29.5° min
Exhaust ............................................... 44.5° min
Seat angle in cylinder head,
Cylinder liners Inlet ..................................................... 30°
Exhaust ............................................... 45°
Type ........................................................ Wet, replaceable Valve disc edge, min.,
Height, total ............................................ 287 mm (11.299") Inlet ..................................................... 1.2 mm (0.047")
Stepped edge height above block face . 0.15–0.20 mm Exhaust ............................................... 1.4 mm 0.055")
(0.006–0.008")
Cylinder diameter ................................... 120.65 mm (4.750")
INLET EXHAUST

10
 Technical Data

Valve clearance, cold engine or at Measurement between valve disc and

operating temperature, cylinder head face,
Inlet ..................................................... 0.40 mm (0.016") Inlet/Exhaust ....................................... 1.2–1.7 mm
Exhaust ............................................... 0.70 mm (0.028") (0.047–0.067")

The valves can be adjusted according to the two-position

method.
When 1st cylinder piston is at T.D.C. after compression, adjust
valves 1, 2, 4, 5, 8 and 9.
When 6th cylinder piston is at T.D.C. after compression, adjust
valves 3, 6, 7, 10, 11 and 12.

Valve guides
Inner diameter (spare part)
Inlet/Exhaust ....................................... 11.032–11.059 mm
(0.4343–0.4354")
Height above cylinder head spring face
INLET (outer spring)
EXHAUST Inlet ..................................................... 19 mm (0.748")
Exhaust ............................................... 21 mm (0.827")

Valve springs
Valve seats Outer valve spring
Outer diameter (meas. A), standard, Length, unloaded .......................... min 61 mm (2.40")
Inlet ..................................................... 54 mm (2.126") With load of 300–390 N (67.5–87.8 lbf) 49.6 mm (1.95")
Exhaust ............................................... 49 mm (1.929")
Oversize, Inner valve spring
Inlet ..................................................... 54.2 mm (2.134") Length, unloaded .......................... min 53 mm (2.087")
Exhaust ............................................... 49.2 mm (1.937") With load of 80–170 N (18–38.3 lbf) .. 42.6 mm (1.677")
Height (meas. B),
Inlet ..................................................... 6.8 mm (0.268")
Exhaust ............................................... 9.5 mm (0.374")
Camshaft
Diameter, front bearing journal, min. ..... 68.985–69.015 mm
(2.7159–2.7171")
2nd bearing journal, min. ...... 66.610–66.640 mm
(2.6224–2.6236")
3rd bearing journal, min. ....... 64.222–64.252 mm
(2.5284–2.5296")
4th bearing journal, min. ....... 63.435–63.465 mm
(2.4974–2.4986")
5th bearing journal, min. ....... 61.047–61.077 mm
(2.4034–2.4046")
6th bearing journal, min. ....... 60.260–60.290 mm
(2.3724–2.3736")
Valve seat location 7th bearing journal, min. ....... 56.285–56.315 mm
Diameter (meas. C), standard, (2.2159–2.2171")
Inlet ..................................................... 54.000–54.030 mm Axial clearance ....................................... 0.05–0.18 mm
(2.1260–2.1272") (0.0020–0.0071")
Exhaust ............................................... 49.000–49.025 mm Radial clearance ..................................... 0.03–0.08 mm
(1.9291–1.9301") (0.0012–0.0031")
Diameter (meas. C), oversize, Check of camshaft setting (cold engine
Inlet ..................................................... 54.200–54.230 mm and valve clearance = 0)
(2.1339–2.1350") Inlet valve for no. 1 cylinder must
Exhaust ............................................... 49.200–49.225 mm with flywheel position 10° A.T.D.C.
(1.9370–1.9380") have opened ........................................... 4.5 ±0.3 mm
Depth (meas. D), (0.177±0.012")
Inlet ..................................................... 9.8–9.9 mm Lift height,
(0.386–0.390") Inlet ..................................................... 8.6 mm (0.339")
Exhaust ............................................... 11.8–11.9 mm Exhaust ............................................... 9.2 mm (0.362")
(0.465–0.469") Max. valve lift, inlet ................................. 13.3 mm (0.524")
Seat bottom radius (meas. R), exhaust .......................... 14.3 mm (0.563)
Inlet/Exhaust ....................................... 0.5–0.8 mm Min. valve lift, inlet ................................. 13.0 mm (0.512")
(0.020–0.031") exhaust ........................... 14.0 mm (0.551")

11
Technical Data

Camshaft bearings
Diameter,
front bearing ........................................ 69.050–69.075 mm
(2.7185–2.7195")
2nd bearing ......................................... 66.675–66.700 mm
(2.6250–2.6260")
3rd bearing .......................................... 64.287–64.312 mm
(2.5310–2.5320")
4th bearing .......................................... 63.500–63.525 mm
(2.5000–2.5010")
5th bearing .......................................... 61.112–61.137 mm
(2.4060–2.4070")
6th bearing .......................................... 60.325–60.350 mm
(2.3750–2.3760")
7th bearing .......................................... 56.350–56.375 mm
(2.2185–2.2195")
wear ............................................ max. 0.050 mm (0.0020")

Timing gears
Number of teeth,
drive gear for compressor (1) ............. 33
camshaft gear (2) ................................ 60
intermediate gear (3) .......................... 53
drive gear for injection pump (4) ........ 60
intermediate gear for coolant pump (5) 31
drive gear for coolant pump (6) .......... 19
crankshaft gear (7) .............................. 30
intermediate gear for oil pump (8) ...... 48
drive gear for oil pump (9) .................. 21
drive gear for servo pump (10) ........... 19

Backlash ................................................. 0.03–0.17 mm

(0.0012–0.0067")
Axle journal for intermediate gear,
diameter .................................................. 92.084–92.106 mm
(3.6253–3.6262") 1. Drive gear for compressor (optional)
Bushing for intermediate gear,
2. Camshaft gear
diameter .................................................. 92.131–92,166 mm
(3.6272–3,6286") 3. Intermediate gear
Radial clearance for intermediate 4. Drive gear for injection pump
gear ......................................................... 0.03–0.09 mm 5. Intermediate gear for coolant pump
(0.0012–0.0035") 6. Drive gear for coolant pump
Axial clearance for intermediate 7. Crankshaft gear
gear ......................................................... 0.05–0.15 mm 8. Intermediate gear for oil pump
(0.0020–0.0060") 9. Drive gear for oil pump
10. Drive gear for servo pump

12
 Technical Data

Crank mechanism

Crankshaft
Crankshaft, axial clearance ................... 0.06–0.27 mm Oversize,
(0.0024–0.0106") 0.2 mm (0.008"),
max. axial clearance .......... 0.40 mm (0.0157") (axial bearing 0.1mm/0.004") ............. 46.175–46.225 mm
Main bearing, radial clearance ............... 0.07–0.14 mm (1.8179–1.8199")
(0.0028–0.0055") 0.4 mm (0.016"),
(axial bearing 0.2mm/0.008") ............. 46.375–46.425 mm
The crankshaft is nitro carburized.
(1.8258–1.8278")
Note: A nitro carburized crankshaft may be ground down to
0.6 mm (0.024"),
maximum the 2nd undersize. If ground additionally, the
(axial bearing 0.3mm/0.012") ............. 46.575–46.625 mm
crankshaft must be nitro carburized again.
(1.8337–1.8356")
Fillet radius (R) ....................................... 3.75–4.0 mm
(0.148–0.157")

Main bearing journals

Diameter (Ø), Thrust washers (axial bearing)
standard .............................................. 99.978–100.000 mm
(3.9361–3.9370") Width (B), standard ................................... 2.312–2.362 mm
undersize 0.25 mm (0.010") .................. 99.724–99.746 mm (0.0910–0.0930")
(3.9261–3.9270") oversize 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")1) ................ 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")1) ................ 98.962–98.984 mm (0.1028–0.1048")
(3.8961–3.8970")
1.25 mm (0.050")1) ................ 98.708–98.730 mm
(3.8861–3.8870")
1)
Note! The crankshaft must once more be nitro carburized.
Main bearing shells
Type ........................................................ Replaceable
Main bearing journals, Thickness (D), standard ......................... 2.447 mm (0.0963")
out-of-round ................................ max. 0.006 mm (0.0002") oversize 0.25 mm(0.010") .................. 2.574 mm (0.1013")
wear, out-of-round ...................... max. 0.08 mm (0.0031") 0.50 mm(0.020") .................. 2.701 mm (0.1063")
taper ............................................ max. 0.05 mm (0.0020") 0.75 mm(0.030") .................. 2.828 mm (0.1113")
Width, axial bearing journal (A), standard 45.975–46.025 mm 1.00 mm(0.040") .................. 2.955 mm (0.1163")
(1.8100–1.8120") 1.25 mm(0.050") .................. 3.082 mm (0.1213")

13
Technical Data

Connecting rod bearing journals Connecting rods

Diameter (Ø), standard ........................... 86.003–86.025 mm Length, centre – centre (E) ..................... 260 mm (10.24")
(3.3859–3.3868") Marking:
undersize 0.25 mm(0.010") ................ 85.753–85.775 mm Connecting rod resp. cap ....................... 1 to 6
(3.3761–3.3770") “FRONT” on rod turned .......................... Forwards
0.50 mm(0.020") ................. 85.503–85.525 mm Connecting rod bushing bore (G) .......... 52.022–52.026 mm
(3.3663–3.3671") (2.0481–2.0483")
0.75 mm(0.030")1) ............... 85.253–85.275 mm Axial clearance, connecting rod –
(3.3564–3.3573") crankshaft ...............................................
0.15–0.35 mm
1.00 mm(0.040")1) ............... 85.003–85.025 mm (0.006–0.014")
(3.3466–3.3474") Connecting rod bearing, radial clearance 0.08–0.12 mm
1.25 mm(0.050")1) ............... 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")
Fillet radius (R) ....................................... 3.75–4.0 mm
(0.1476–0.1575")
Connecting rod bearing journal,
out-of-round ................................ max. 0.004 mm(0.0002") Flywheel, installed
wear, out-of-round ...................... max. 0.08 mm (0.0031")
Max permitted axial throw measuring
taper ............................................ max. 0.05 mm (0.0020")
radius 150 mm ........................................ 0.15 mm (0.0060")
1)
Note! The crankshaft must once more be nitro carburized. Ring gear on flywheel ............................ 156 teeth

Connecting rod bearing shells

Thickness (C), standard ......................... 2.413 mm
(0.0950")
undersize 0.25 mm(0.010") ................ 2.540 mm (0.1000")
Flywheel casing, installed
0.50 mm(0.020") ................. 2.667 mm (0.1050") Max permitted axial throw for rear
0.75 mm(0.030") ................. 2.794 mm (0.1100") contact surface ....................................... 0.20 mm (0.0079")
1.00 mm(0.040") ................. 2.921 mm (0.1150") Max permitted radial throw for inner
1.25 mm(0.050") ................. 3.048 mm (0.1200") edge guide .............................................. 0.25 mm (0.0098")

14
 Technical Data

Lubrication system

3
2

96091301

Lubrication system, general

Oil system capacity,
incl. filter .......................................................................................... 38 litres (10.04 US gals)
excl. filter ......................................................................................... 34 litres (8.98 US gals)
Difference in volume between MIN. – MAX. ...................................... 9 litres (2.38 US gals)
Oil pressure,
rated speed ..................................................................................... 300–500 kPa (43.5–72.5 psi)
idling speed (min.) ........................................................................... 150 kPa/1,5 kp (21.75 psi)
Oil temperature,
normal .............................................................................................. 105°C (221°F)
max. ................................................................................................. 120°C (248°F)
Oil filter, micron size ........................................................................... 0.040 mm (0.0016")

Oil valves
1. Reduction valve
Marking ......................................................................................... Yellow

2. By-pass valve, oil cooler

Type ............................................................................................... Pressure spring
Spring length
off-load ....................................................................................... 46.0 mm (1.81")
loaded 54 ±1 N (12.15 ±0.23 lbf) .............................................. 30.0 mm (1.18")

3. Overflow valve, filter

Type ............................................................................................... Pressure spring
Spring length
off-load ....................................................................................... 68.8 mm (2.71")
loaded 18 ±1 N (4.05 ±0.23 lbf) ................................................ 32.0 mm (1.26")

4. Piston cooling valve

Marking ......................................................................................... –

15
Technical Data

Lubricanting oil, engine Viscosity is selected as per table below.

Temperatures refer to stable ambient temperature.
Oil grade Standard
VDS-2, VDS Volvo Drain Specification −30 −20 −10 ±0 +10 20 30 40 o
C
ACEA E3–96, E2–96 ACEA
CD, CE, CF API −15oC SAE 15W/40
CF-4, CG-4 API −25 C
o
SAE 10W/30
✱ SAE 5W/30
−10oC SAE 20W/30
±0oC SAE 30
+10oC SAE 40
o
−22 −4 +14 32 50 68 86 104 F

* Concerns synthetic or semi-synthetic oil.

Note! Only SAE 5W/30 may be used.

Lube oil pump

Type .................................................................................................... Gear
Diameter,
bearing sleeve, intermediate gear .................................................. 92.084–92.106 mm (3.6253–3.6262")
intermediate gear, bushing .............................................................. 92.131–92.166 mm (3.6272–3.6286")
Axial clearance,
drive gear ........................................................................................ 0.11 mm (0.0043")
intermediate gear ............................................................................ 0.14 mm (0.0055")

Oil filters
Full-flow .............................................................................................. 2
Micron size .......................................................................................... 0.04 mm (0.0016")

16
 Technical Data

Fuel system

Fuel specifications
The fuel must be approved according to national and international standards for commercial fuels, for example:
EN 590 (With environmental and sub-zero temperature specifications according to national requirements)
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulphur content: According to current legislation in respective country.
Note. Fuels with extremely low sulfur contents (“Urban diesel" in Sweden and “City diesel" in Finland) can cause a
drop in power output of 5% and an increase in fuel consumption of 2–3%.

Feed pump
Type ................................................................................................... FP/KG 24 P200
Feed pump pressure .......................................................................... 100–150 kPa (14.50–21.75 psi)
Feed pump, max. suction height ....................................................... 2.0 m (78.74")

Injection pump
Pump type,
TAD1032GE .................................................................................... Bosch PE6P 120A 300 RS7502
TAD1030G/GE/TAD1031GE ........................................................... Bosch PE6P 120A 300 RS7289
TAD1030P/V ................................................................................... Bosch PE6P 120A 320 RS7288
Govenor type,
TAD1030G/GE ................................................................................ GAC 175 D
TAD1031GE/TAD1032GE .............................................................. GAC275D
TAD1030P/V ................................................................................... RQV250 – 900PA1069
Pump element diameter .................................................................... 12 mm (0.47")
Setting,
TAD1030G, 1500/1800 rpm ........................................................... 15°/15° ±0.5° B.T.D.C.
TAD1030GE, 1500/1800 rpm ......................................................... 12°/15° ±0.5° B.T.D.C.
TAD1030P/V ................................................................................... 15° ±0.5° B.T.D.C.
TAD1031GE .................................................................................... 9° ±0.5° B.T.D.C.
TAD1032GE, 1500/1800 rpm ......................................................... 11° ±0.5°/12° ±0.5° B.T.D.C.
Lift from basic circle (stroke position),
TAD1030G/GE/TAD1031GE/1032GE ............................................ 3.45 (±0.05) mm (0.1358" ± 0.0020")
TAD1030P/V ................................................................................... 3.45 (±0.05) mm (0.1358" ± 0.0020")

Injectors
Designation, nozzle holder ............................................................... KBEL117P73, TAD1031GE: KBEL 117
TAD1032GE: KBEL 117 P237
nozzle ........................................................................... DLLA 150 P429, TAD1031GE: DLLA 152 P571
TAD1032GE: DSLA 152 P1184
Marking, complete injector ................................................................ 670, TAD1031GE: 8194094
Opening pressure .............................................................................. 25.5 MPa (3698 psi)
Adjustment pressure, new spring ...................................................... 26.0 (+0.8) MPa (3770 psi (+ 116) psi)
Bore .................................................................................................... 5 x 0.30 mm (5 x 0.0118"), TAD1031GE: 6 x 0,24 mm
TAD1032GE: 6 x 0,27 mm

17
Technical Data

Cooling system
Type ................................................................................................... Pressurized, closed circuit
Pressure valve opens at .................................................................... 70 kPa (10.15 psi)
Recommended coolant,
Volvo Penta ethylen glycol or Volvo Penta
anticorrosion additive together with clean fresh water
Coolant capacity,
engine ............................................................................................. 16 litres (4.23 US gals)
engine incl standard radiator with hoses ...................................... 37.3 litres (9.78 US gals)
Thermostat,
marked ............................................................................................ Green
starts to open .................................................................................. 86°C (187°F)
fully open ........................................................................................ 96°C (205°F)

Intake and exhaust system

Turbocharger
Designation ........................................................................................ Schwitzer S3B
Lube system ....................................................................................... Pressure lubrication

Boost pressure
TAD1030G/GE/1032GE 1500 rpm 1800 rpm
Prime power, kPa (psi) ........................................... 145 (21.0) 165 (23.9)
Stand by power, kPa (psi) ...................................... 190 (27.6) 200 (29.0)
TAD1031GE: Prime power, kPa (psi) .................... 210 (30.5)
TAD1031GE: Stand by power, kPa (psi) ................ 230 (33.4)
TAD1032GE: Prime power, kPa (psi) .................... 185 (26.8) 180 (26.1)
TAD1032GE: Stand by power, kPa (psi) ................ 215 (31.1) 210 (30.5)

Boost pressure
TAD1030P/V 1500 rpm 1800 rpm 2000 rpm
Continuous power, kPa (psi) .................................. 143 (20.7) 155 (22.5) 160 (23.2)

Exhaust system
TAD1030P/V 1500 rpm 1800 rpm
Exhaust gas temperature after turbine °C (°F),
continuous power ............................................... 540 (1000) 530 (990)

TAD1030G/GE/1031GE/1032GE 1500 rpm 1800 rpm

Exhaust gas temperature after turbine °C (°F),
Prime power ........................................................ 485 (910) 445 (830)
Standby power .................................................... 510 (950) 495 (920)
TAD1031GE: Prime power ................................. 490 (914)
TAD1031GE: Standby power ............................. 530 (990)
TAD1032GE: Prime power ................................. 510 (950) 475 (887)
TAD1032GE: Standby power ............................. 520 (968) 490 (914)

TAD1031GE, TAD1030G/GE TAD1030P/V

TAD1032GE
1500 rpm 1800 rpm 1500 rpm 1800 rpm
Max. allowable back-pressure in exhaust
line kPa (inwc) ........................................................ 5 (20.1) 7 (28.1) 6.8 (27.3) 9.7 (39.0)

TAD1030P/V
1800 rpm 2000 rpm
Max. combustion pressure MPa (psi),
continuous power ............................................... 12.0 (1740) 11.3 (1639)

TAD1030G/GE
1500 rpm 1800 rpm
Max. combustion pressure MPa (psi),
Prime power ........................................................ 12.4 (1800) 11.0 (1600)
TAD1031GE: Prime power ................................. 14,5 (2103)
TAD1032GE: Prime power ................................. 15,3 (2219) 14,9 (2161)

18
 Technical Data

Wear tolerances Tightening torques

Nm lbf.ft
Cylinder heads Cylinder heads 1)
Height, min. ........................................... 114.65 mm (4.5138") Main bearings ......................................... 340 ±25 251 ±18
Connecting rod bearings,
First tightening .................................... 40 30
Second tightening ............................... 75 55
Final tightening (angle tightening) ...... 90°
Axial bearing, camshaft .......................... 40 ±4 30 ±3
Cylinder liners Timing gear cover ................................... 40 ±4 30 ±3
Gear, camshaft ....................................... 60 ±5 44 ±3.7
Cylinder liner (pistons and piston rings) should be replaced
Gear, injection pump drive ..................... 33 24
with wear of 0.40–0.45 mm (0.0157–0.0177") or if oil con-
Intermediate gear journal ....................... 60 44
sumption is abnormally high.
Bearing bracket rocker arm shaft ........... 40 ±4 30 ±3
Drain plug, oil sump ............................... 60 ±15 44 ±11
Oil sump, .................................................
gaskets with a string of silicone ........ 16 ±2 11.8±1.5
other gaskets ...................................... 24 ±3 17.7±2.2
Crankshaft (tighten in a specified order, see figure
below) 2)
Max. permitted out-of-round on main Bracket, oil pump .................................... 40 ±4 30 ±3
and connecting rod bearing journals ..... 0.08 mm (0.003") Intermediate gear, oil pump ................... 17 ±2 12.5±1.5
Max. permitted taper on main and Intermediate gear, coolant pump ........... 120 189
connecting rod bearing journals ............ 0.05 mm (0.002") Flywheel ................................................. 175 129
Max. axial clearance on crankshaft ....... 0.40 mm (0.016") Crankshaft pulley .................................... 60 ±6 44 ±4.4
Flywheel casing ...................................... 140 ±15 103 ±11
Centre bolt, crankshaft ........................... 550 406
Delivery valve holder, injection pump .... 85 ±5 67 ±3.7
Nut for retainers, injectors ...................... 50 ±5 37 ±3.7
Clamp bolt, injection pump .................... 90 ±9 66 ±6.6
Connecting rods Pump coupling, carrier flange ................ 62 ±5 46 ±3.7
Straightness, max. deviation on 100 mm Cleaning plugs in cylinder block and
(3.94") measuring lenght ........................ 0.05 mm (0.002") cylinder heads ........................................ 60 ±10 44 ±7.4
Warp, max. deviation on 100 mm 1)
(3.94") measuring lenght ........................ 0.1 mm (0.004") Tighten the cylinder head bolts in 4 stages.
First tightening 50 Nm (37 lbf.ft).
Second tightening 200 Nm (148 lbf.ft).
Third tightening 370 Nm (273 lbf.ft).
Final tightening, angle tightening 90°.
Valves
Valve stem, max. permitted wear ........... 0.07 mm (0.003")
Max. permitted clearance between valve
stem and valve guides,
Inlet ..................................................... 0.2 mm (0.008")
Exhaust ............................................... 0.3 mm (0.012")
Valve disc edge should be min.,
Inlet ..................................................... 1.9 mm (0.075")
Exhaust ............................................... 1.4 mm (0.055")
Valve seat may be ground down so far
that distance from valve disc (new
valve) to cylinder head face is max.,
Inlet/Exhaust ....................................... 2.5 mm* (0.098")* Tightening torque diagram

* With greater values, the seats must be replaced.

2)

Camshaft
Max. permitted out-of-round (with new
bearings) ................................................. 0.05 mm (0.002")
Bearings, max. permitted wear .............. 0.05 mm (0.002")
Lift height, min.,
Inlet ..................................................... 8.4 mm (0.331")
Exhaust ............................................... 9.0 mm (0.354")
Valve tappet, max. permitted radial
clearance ................................................ 0.08 mm (0.003") Tightening torque diagram, oil sump

19
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AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Göteborg
Sweden
7738335-4 English 11–2001