Workshop Manual

Technical Data

TAD1630G/GE/P/V, TAD1631G/GE
TWD1620G/GH, TID162AP
TWD1630G/GE/P/V, TD164KAE
 Technical data

Group 20 Engine

TAD1630G/GE/P/V, TAD1631G/GE
TWD1620G/GH, TID162AP
TWD1630G/GE/P/V, TD164KAE

Contents

Safety information ................................................................ 2

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

Location of engine signs ..................................................... 9

Technical data ...................................................................... 10

General information ............................................................. 10
Electrical system ................................................................ 11
Short block ......................................................................... 11
Valve mechanism ............................................................... 13
Timing gear ......................................................................... 16
Reciprocating components .................................................. 17
Lubrication system .............................................................. 19
Fuel system ........................................................................ 22
Cooling system ................................................................... 24
Inlet and exhaust system .................................................... 25
Wear tolerances .................................................................. 27
Tightening torque ................................................................ 28
Safety Information
Safety information
Introduction
The workshop manual contains technical data, descrip-
tions and repair instructions for specified products or
product versions supplied by Volvo Penta. Make sure
that you use the correct workshop literature.
Read the available safety information, “General in-
formation” and “Repair instructions” in the work-
shop manual before you start to do any service
work.
Important
The following special warning signs are used in the
workshop manual and on the product.
WARNING! Warns for the risk of personal injury,
major damage to product or property, or serious
malfunctions if the instruction is ignored.
IMPORTANT! Is used to call attention to things
which could cause damage or malfunctions to
product or property.
NOTE! Is used to call attention to important informa-
tion, to facilitate work processes or operation.
2
Group 20
To give you a perspective on the risks which always
need to be observed and precautions which always
have to be taken, we have noted them below.
Make it impossible to start the engine by cutting
system current with the main switch(es) and lock
it (them) in the off position before starting service
work.
Fix a warning sign by the helmsman’s seat.
All service work should normally be done on a
stationary engine. Some work, such as adjust-
ments, need the engine to be running, however.
Going close to a running engine is a safety risk.
Remember that loose clothes, long hair etc. can
catch on rotating components and cause severe
injury.
If work is done adjacent to a running engine, a
careless movement or a dropped tool can lead to
personal injury in the worst case. Be careful with
hot surfaces such as exhaust pipes, turbos,
charge air pipes, starting heaters etc., and hot
fluids in pipes and hoses on an engine which is
running or which has just stopped.
Re-install all guards which have been removed
during service work, before re-starting the engine.
Make sure that the warning or information labels
on the product are always clearly visible. Replace
labels which have been damaged or painted over.
Never start an engine without the air filter in
place. The rotating compressor turbine in the tur-
bocharger can cause severe injury. Foreign bod-
ies in the inlet pipe can also cause severe me-
chanical damage.
Group 20
Never use start spray or similar products as a
starting aid. Explosions could occur in the inlet
manifold. Danger of personal injury.
Only start the engine in a well-ventilated area.
When operated in a confined space, exhaust
fumes and crankcase gases must be ventilated
from the engine bay or workshop area.
Avoid opening the coolant filling cap when the en-
gine is hot. Steam or hot coolant can spray out at
the same time as the pressure which has built up
is lost. Open the filler cap carefully if necessary,
and release the excess pressure in the cooling
system. Be extremely careful if a tap, plug or
coolant hose has to be removed from a hot en-
gine. Steam or hot coolant can stream out in an
unexpected direction.
Hot oil can cause burns. Avoid skin contact with
hot oil. Make sure that the oil system is de-pres-
surized before doing any work on it. Never start
or run the engine with the oil filler cap removed,
because of the risk of oil spillage.
Stop the engine before doing any work on the
cooling system.
Always use goggles when doing any work where
there is any risk of splinters, grinding sparks,
acid splash or other chemicals.
Your eyes are extremely sensitive.
Injury can cause blindness!
Avoid skin contact with oil!
Long-term or repeated skin contact with oil can
make your skin dry out. The consequence is irri-
tation, dry skin, eczema and other skin disorders.
Used oil is more hazardous to health than new
oil. Use protective gloves and avoid oil-soaked
clothes and rags.
Wash regularly, especially before meals. Use
special skin cream to avoid drying and facilitate
skin cleaning.
Most chemicals intended for the product, such as
engine and transmission oils, glycol, petrol (gaso-
line) and diesel oil, or chemicals for workshop
use, such as degreasers, paints and solvents are
hazardous. Read the instruction on the packages
carefully! Always observe the safety advice,
such as use of breathing protection, goggles,
gloves etc.
Make sure that other personnel are not inadvert-
ently exposed to hazardous substances, such as
via the air they breathe. Ensure good ventilation.
Handle used and surplus chemicals in the pre-
scribed manner.
Safety Information
Be very careful when searching for leaks in the
fuel system and testing fuel injectors.
Wear goggles.
The jet which comes from a fuel injector has very
high pressure and considerable penetration abil-
ity. Fuel can force its way deep into body tissue
and cause severe injury.
Risk of blood poisoning (septicemia).
WARNING! Fuel delivery pipes must not be bent
or straightened under any circumstances.
Damaged pipes must be replaced.
All fuels, and many chemicals, are flammable.
Make sure that open flames or sparks can not
set them alight. Petrol (gasoline), some thinners
and hydrogen gas from batteries are extremely
flammable and explosive when mixed with air in
the correct ratio. Do not smoke! Provide good
ventilation and take the necessary precautions
before you start welding or grinding in the vicinity.
Always have a fire extinguisher easily available
near the workplace.
Make sure that oil and fuel soaked rags, and
used fuel and oil filters are stored in a safe place.
Oil soaked rags can self-ignite in certain circum-
stances. Used fuel and oil filters are polluting
waste and must be handed to an approved waste
management facility for destruction, together with
used lubrication oil, contaminated fuel, paint resi-
due, solvents, degreasers and wash residue.
Batteries must never be exposed to open flames
or electric sparks. Do not smoke close to the bat-
teries. The batteries generate hydrogen gas when
charged, which forms an explosive gas when
mixed with air. This gas is very flammable and
highly explosive. A spark, which can be formed if
the batteries are wrongly connected, is enough to
make a battery explode and cause damage.
Do not move the connections during a start at-
tempt, since there is a risk of arcing.
Do not stand bent over any of the batteries either.
Never mix up the battery positive and negative
poles when the batteries are installed. If the bat-
teries are wrongly connected, this can cause se-
vere damage to the electrical equipment. Please
check the wiring diagram!
Always use goggles when charging and handling
batteries. Battery electrolyte contains highly cor-
rosive sulfuric acid. If this comes into contact
with your skin, wash at once with soap and a lot
of water. If you get battery acid in your eyes,
flush at once with a lot of water, and get medical
assistance at once.
3
Safety Information Group 20

Stop the engine and cut the system current with
the main switch(es) before doing any work on the
electrical system.
The clutch must be adjusted with the engine shut
off.
The existing lugs on the engine should be used for
lifting. Always check that all lifting devices are in
good condition and that they have the correct ca-
pacity for the lift. Engine weight together with a
marine gearbox and any auxiliaries, if fitted.
The engine should be lifted with a customized or
adjustable lifting boom for safe handling and to
avoid damaging components on top of the en-
gine. All chains or cables must be parallel to
each other and should be as square as possible
to the top of the engine.
If other equipment connected to the engine has
altered its centre of gravity, special lifting de-
vises may be needed to obtain the correct bal-
ance and safe handling.
Never do any work on an engine which just hangs
from a lifting devise.
WARNING! Components in the electrical and fuel
systems on Volvo Penta products have been de-
signed to minimize the risks of explosion and
fire. The engine must not be operated in environ-
ments with adjacent explosive media.
Only use the fuels recommended by Volvo Penta.
Please refer to the instruction book.
The use of fuel of inferior quality can damage the
engine.
In a diesel engine, poor fuel can cause the regu-
lation rod to bind and the engine will over-rev, en-
tailing a strong risk of personal injury and ma-
chinery damage.
Poor fuel can also lead to higher maintenance
costs.
Remember the following when washing with a
high pressure washer:
Never aim the water jet at seals, rubber hoses,
electrical components or the radiator.
Never use a high pressure washer for engine
cleaning.

Never work alone when heavy components are to

be dismantled, even when safe lifting devises
such as lockable blocks & tackle are used. Even
when lifting devises are used, two people are
needed in most cases. One who operates the lift-
ing devise and other who makes sure that com-
ponents move freely and are not damaged during
lifting.
Always make sure that there is enough space for
disassembly where you are working, with no risk
for personal or material damage.

© 2001 AB VOLVO PENTA

We reserve the right to make modifications without prior notice.
Printed on environmentally compatible paper.

4
Group 20
General information
About the workshop manual
This workshop manual contains descriptions and re-
pair instructions for the standard versions of engines
with the following designations.
TAD1630G/GE/P/V, TAD1631G/GE
TWD1620G/GH, TID162AP
TWD1630G/GE/P/V, TD164KAE
The engine designation and number are noted on the
number plate.
In all correspondence with AB Volvo Penta about an
engine, the engine designation and serial number
must always be quoted.
The workshop manual has been primarily prepared for
Volvo Penta service workshops and their qualified per-
sonnel.
This assumes that people who use the manual have
basic skills and can do the tasks of a mechanical or
electrical nature associated with the trade.
Volvo Penta constantly improves its products, so we
reserve the right to make modifications without prior
notification.
All information in this manual is based on product data
which was available up to the date on which the
manual was printed.
Any material changes introduced into the product
or service methods after this date are notified by
means of Service Bulletins.
Spare parts
Spare parts for electrical and fuel systems are subject
to various national safety requirements.
Volvo Penta Original Spares comply with these re-
quirements.
No damage whatever, occasioned by use of non-origi-
nal Volvo Penta spares for the product, will be com-
pensated by the warranty offered by Volvo Penta.
General information
Certified engines
The manufacturer certifies that both new engines and
those in use, which are certified for national or regional
legislation, comply with the environmental require-
ments.
Each product must correspond with the unit used for
certification.
The following requirements for service and spare parts
must be complied with, for Volvo Penta as a manufac-
turer to be responsible for ensuring that engines in use
comply with the stipulated environmental requirements:
• Maintenance and service intervals recommended
by Volvo Penta must be complied with.
• Only Volvo Penta Original Spares, intended for the
certified engine variant, may be used.
• Service which includes injection pumps, pump set-
tings and injectors must always be done by an au-
thorized Volvo Penta workshop.
• The engine must not be converted or modified in
any way, except for the accessories and service
kits which Volvo Penta has approved for the en-
gine.
• Installation changes to the exhaust pipe and the
engine bay air inlet ducts (ventilation ducts) must
not be done without further discussion, since this
could affect exhaust emissions.
• No seals may be broken by unauthorized personnel.
IMPORTANT! When spare parts are needed,
use only Volvo Penta Original Spares. The
use of non-original spares means that AB
Volvo Penta ceases to be responsible for
ensuring that the engine corresponds with
the certified version.
Damage, injury and/or costs which arise due to the
use of non-original Volvo Penta spares for the product
in question will not be compensated by AB Volvo
Penta.
5
Repair instructions Group 20

Repair instructions

General information Our common responsibility

The work methods described in the workshop manual Each engine consists of a large number of collaborat-
apply to work in a workshop environment. ing systems and components. Any deviation of a com-
This is when the engine has been lifted out and ponent from its technical specification can dramatically
mounted on an engine support. Renovation work which increase the environmental impact of an otherwise
does not need the engine to be lifted out can be done good engine. For this reason, it is extremely important
in situ, with the same work methods, unless otherwise that specified wear tolerances are maintained, that sys-
specified. tems with adjustment facilities are correctly adjusted
The following warning signs occur in the workshop manual: and that Volvo Penta Original Spares are used for the
engine. The times noted in the engine maintenance
schedule must be observed.
WARNING! Some systems, such as components in the fuel sys-
tem, may require special competence and special test
IMPORTANT! equipment. For environmental reasons etc., some com-
ponents are sealed at the factory. It is only permissible
NOTE! to work on sealed components if you are authorized to
do such work.
The meaning of these warning signs is given in the
chapter entitled: “Safety information”. Remember that most chemical products, incorrectly
used, damage the environment.
One thing which must be pointed out are that they are
Volvo Penta recommends the use of biodegradable
not comprehensive in any way, since we can not of
degreasers whenever engine components are de-
course foresee everything, because service work is
greased, unless otherwise specified in the workshop
done in highly varying circumstances.
manual.
For this reason, all we can do is to point out the risks
Be careful to ensure that oils, wash residue etc. are
which we believe could occur due to incorrect work in a
processed for destruction, and are not inadvertently
well-equipped workshop, using work methods and tools
discharged to the environment.
tested by us.
In the workshop manual, all tasks for which there are
Volvo Penta special tools, are done using these tools.
Special tools are specially prepared to permit the saf-
est and most rational work methods possible. For this
reason, it is the responsibility of the person who uses
other tools or other work methods than those recom-
mended by us, to ensure that there is no risk of per-
sonal injury or material damage, and that they can not
cause any malfunctions.
In some cases, special safety regulations and user in-
structions are available for the tools and chemicals
mentioned in the workshop manual.
These rules must always be observed, so there are no
special instructions about this in the workshop manual.
The majority of risks can be prevented by taking cer-
tain elementary precautions and using common sense.
A clean workplace and a clean engine eliminate many
risks of both personal injury and malfunction.
This applies, above all, when work on fuel systems, lu-
brication systems, inlet systems, turbocharger, bearing
caps and seals is done, where it is extremely important
that no dirt or other kinds of foreign particles are able to
get in, since this would otherwise cause malfunctions
or shortened repair life.

6
Group 20 Repair instructions

Tightening torque Lock nuts

Tightening torques for important fasteners, which must Locknuts must not be re-used, they shall be replaced
be torqued to pre-determined levels, are found under: by new ones, since the locking properties are impaired
Technical data, chapter: “Tightening torque”. Tightening or lost when the nut is used several times.
torques are also specified in the workshop manual job On locknuts with plastic inserts, such as Nylock®, the
descriptions. tightening torque specified in the table must be reduced
All torque specifications apply to clean screws, screw if the Nylock® nut has the same nut height as a stan-
heads and mating faces. The torque specifications ap- dard fully metallic hexagonal nut. Reduce the tightening
ply to lightly oiled or clean screws. torque by 25% if the screw dimension is 8 mm (0.3”) or
If lubricants, locking fluids or sealants are needed on a greater.
fastener, this is noted in the job description and in On Nylock® nuts with higher nut height, where the fully
“Tightening Torques”. metallic thread is as high as on a standard hexagonal
Fasteners for which particular torque values are not nut, use the tightening torques in the table.
given can be tightened to the torques in the tables be-
low. The torque values are guidelines.
Thread dimension: Tightening torque:
M5 .................................................. 6 Nm (4.4 lbf-ft)
M6 .................................................. 10 Nm (7.4 lbf-ft)
M8 .................................................. 25 Nm (18.5 lbf-ft)
M10 ................................................ 50 Nm (37 lbf-ft)
M12 ................................................ 80 Nm (59 lbf-ft)
M14 ................................................ 140 Nm (104 lbf-ft)

Torque-angle tightening
In torque/angle tightening, the fastener is tightened to
the specified torque, and tightening then continues
through a pre-determined angle. Example: For 90°
angle tightening, the fastener is turned a further 1/4
turn in one sequence, after the specified tightening
torque has been achieved.

Strength classes
Screws and nuts are sub-divided into different strength
classes.
The classification is shown by a marking on the screw
head. Markings of a higher number indicate stronger
material.
For example a screw marked 10-9 is stronger than a
screw marked 8-8.
For this reason, it is important when screws are disas-
sembled that the screws are put back in their original
locations on re-assembly.
When you change screws, please check the spare
parts catalogue to ensure that the correct versions are
obtained.

7
Repair instructions
Sealants
Several different types of sealant and locking fluids
are used on the engine.
Their properties differ, since they are intended for dif-
ferent strengths of fastener, temperature, resistance
to oil and other chemicals, and for the different materi-
als and gap thicknesses found in an engine.
It is therefore important that the correct types of seal-
ant and locking fluids are used on the fasteners where
needed, to give a fully acceptable service result.
In the workshop manual, the relevant chapters contain
notes about the preparations used.
When sealants and locking fluids are used, it is impor-
tant that the surfaces are free from oil, grease, paint
and rust-protection, and that they are dry.
Always observe the manufacturer’s instructions about
application temperature and hardening time.
Two basic types of preparation are used.
Their characteristics are:
• RTV preparations
(Room Temperature Vulcanizing).
These are mostly used together with gaskets, such as
for sealing gasket joints, or are brushed on gaskets.
RTV preparations are fully visible once the component
has been disassembled. Old RTV material must be re-
moved before the joint is re-tightened.
Remove old sealant with denatured alcohol in all cases.
The following RTV preparations may be mentioned in
the workshop manual:
Loctite® 574, Permatex® No. 3, Permatex® No 77.
• Anaerobic preparations:
These preparations harden in the absence of air.
These preparations are used when two solid compo-
nents, such as two cast components, are fitted to-
gether without a gasket. Common uses are also to
lock and seal plugs, stud threads, taps, oil pressure
monitors etc. Hardened anaerobic preparations are
glassy and for this reason, the preparations are col-
ored to make them visible.
Hardened anaerobic preparations are highly resistant
to solvents, and old compound can not be removed.
On re-installation, degrease carefully and then apply
new sealant.
The following anaerobic preparations may be men-
tioned in the workshop manual: Loctite® 572 (color:
White), Loctite® 241 (Color: Blue).
NOTE! Loctite® is a registered trademark of the
Loctite Corporation.
Permatex® is a registered trademark of the Permatex
Corporation.
8
Group 20
Safety rules for Fluorocarbon
Rubber
Fluorocarbon rubbers are commonly used materials in
O-rings, seal rings on shafts etc.
Trade name: Viton®.
When flourocarbon rubber is exposed to high tempera-
tures (above 300°C) (572.7°F), hydrofluoric acid can
be formed.
Hydrofluoric acid is highly corrosive.
• Skin contact can cause severe chemical burns.
• If it splashes in your eyes, this can cause severe
chemical burns.
• If you breathe the fumes, you can suffer lung and
bronchial injury.
WARNING!
Be very careful when working on engines which
have been exposed to high temperatures, such
as overheating caused by a seizure or fire. Seals
must never be cut with a flame torch during dis-
assembly, or burned in uncontrolled circum-
stances afterwards.
Observe the following:
• Always use chloroprene rubber gloves (gloves for
chemicals handling) and goggles.
• Handle the removed seal in the same way as corro-
sive acid. All residues, including ash, can be
strongly corrosive. Never use compressed air to
blow components clean.
• Put the remains in a plastic container, seal it and
apply a warning label. Wash the gloves under run-
ning water before you take them off.
The following seals are most probably made from fluo-
rocarbon rubber:
• Seal rings for crankshafts, camshafts, counter-
shafts.
• O-rings, irrespective of where they are installed.
O-rings for cylinder liner seals are almost always
made of fluorocarbon rubber.
NOTE! Seals which have not been exposed to high
temperature can be handled normally.
Group 20 Repair instructions

Location of engine signs

Engines are delivered with two engine signs.
One is installed on the engine block, as in the illustration.
The other sign is supplied loose, for installation in a
suitable location close to the engine.

Engine type designations:

T – Turbocharged
A – Air to air intercooler
I – Intercooler (charge air cooler, industrial engines)
W – Water to air intercooler
D – Diesel engine
16 – Displacement, liter
Product sign:
3 – Generation figure
1. Engine designation
0 – Version or power level
2. Product number
K – Water to water intercooler
3. Serial number
A – Version A
4. Engine power, net, (without fan)
P – Stationary engine (Power Pac)
5. Engine power, net, (with fan)
G – Generator engine (Gen Set)
6. Max. engine speed
H – Higher power level (High Power)
7. Piston position/Injection advance (BTDC)
V – Engine for stationary and mobile operation
M – Mobile engine
E – Engine with emission control

9
Technical data Group 20

Technical data

General information
In-line four cycle diesel engine with direct injection.
Turbocharged, air-to-air charge air cooling (TAD, TID)
Turbocharged, water-to-air charge air cooling (TWD)

Type designations (please refer to page 9):

TAD1630G/GE/P/V, TAD1631G/GE
TWD1620G/GH, TID162AP
TWD1630G/GE/P/V, TD164KAE

No. of cylinders ...................................................... 6

Swept volume ........................................................ 16.2 litres
Injection sequence ................................................. 1–5–3–6–2–4
Direction of rotation (seen from front) ..................... Clockwise
Bore ....................................................................... 144 mm (5.7")
Stroke .................................................................... 165 mm (6.5")
Compression ratio .................................................. 15:1
Compression ratio TD164KAE ................................ 17.5:1
Compression pressure at starter motor speed ........ 2760 kPa (400.3 psi)
Weight, only engine, dry:
TID162AP ........................................................... 1,430 kg (3152.6 lb)
TWD1620G/GH ................................................... 1,885 kg (4155.7 lb)
TAD1630G/GE, TAD1631G/GE .......................... 1,538 kg (3390.7 lb)
TAD1630P/V ....................................................... 1,515 kg (3339.9 lb)
TWD1630G/GE ................................................... 1,428 kg (3148.1 lb)
TWD1630P/V ...................................................... 1,409 kg (3106.3 lb)
TD164KAE .......................................................... 1,456 kg (3209.9 lb)
Low idle. app.:
TID162AP ........................................................... 500 rpm.
TWD1620G/GH ................................................... 1300 rpm.
TAD1630G/GE, TAD1631G/GE .......................... 1300 rpm.
TAD1630P/V ....................................................... 500 rpm.
TWD1630G/GE ................................................... 1300 rpm.
TWD1630P/V ...................................................... 500 rpm.
TD164KAE .......................................................... 800–900 rpm.

Performance
Max. power ............................................................ See appropriate engine graph.
Max. torque ............................................................ See appropriate engine graph.

10
Group 20 Technical data

Electrical system
System voltage and type ....................................... 24 V, isolated from ground
Alternator, make .................................................... Valeo
Voltage/max. current density .............................. 28V/60A
Battery capacity:
Maximum ............................................................ 2 x 176 Ah
Minimum at >+5°C (41.1°F) ................................. 2 x 135 Ah
Battery electrolyte density at +25°C (77.7°F):
Fully charged battery .......................................... 1.28 g/cm3 (80 lb/cu ft)
Battery should be charged at .............................. 1.24 g/cm3 (77 lb/cu ft)
Starter motor, make ............................................... Bosch KE, 7.5 kW/24V
Starting heater ....................................................... 24V

Short block
Cylinder head
Type ...................................................................... 1 per cylinder
Length .................................................................... 285 mm (11.22")
Width ..................................................................... 235 mm (9.25")
Height (min.) .......................................................... 134.6 mm (5.29")
Valve yoke guide dowel:
Height above cylinder head plane,
applies to TD164KAE ............................................. 33.7–34.3 mm (1.33–1.36")

Cylinder head screws

No./cylinder head ................................................... 6
Dimension, thread .................................................. M16
Length .................................................................... 210 mm (8.26")

Engine block
Length .................................................................... 1.168 mm (45.98")
Height above upper block plane -
crankcase centerline (A), min ................................. 480 mm (18.89")
Height, lower block plane -
crankcase centerline (B) ........................................ 120 mm (4.72")

Cylinder liner
Type ...................................................................... Wet, replaceable
Cylinder diameter (no overbores) ............................ 144 mm (5.679")
Height, total. .......................................................... 314.83 mm (12.39")
Sealing surface above engine block plane. ............. 0.06–0.1 mm (0.0024")
Seal for cylinder liner, material, silicone ................. Part number 116 12 77–7
No. of O-rings, upper liner seal ............................... 2
No. of O-rings, lower liner seal ............................... 3
NOTE! In engine TD164KAE, only C-classed pistons must
be installed in E-classed liners.

11
Technical data Group 20

Pistons
Height, total. .......................................................... 163.5 mm
No. of grooves ....................................................... 3
Front marking ......................................................... Arrow. Must face forwards.
Piston height below engine block plane .................. 0.9–1.5 mm (0.035–0.59")
Piston height below engine block plane: TD164KAE min. 0.7 mm (0.028")
Diameter, combustion chamber .............................. 80 mm (3.15")
Diameter, combustion chamber: Engine 162, 1620 82 mm (3.23")
Depth, combustion chamber .................................. 28.8 mm (1.14")
Depth, combustion chamber: Engine 162 ............... 32.8 mm (1.53")
Depth, combustion chamber: Engine 1620 ............. 32.25 mm (1.27")

Piston rings
Compression rings:
Quantity ................................................................. 2
Upper compression ring, molybdenum coated
Height A: Engine 1620, 1630 .................................. 4 mm (0.16")
Height A: Engine 1631 ........................................... 4.5 mm (0.18")
Height A: Engine: 162 ............................................ 2.944 mm (0.115")
2:nd compression ring
Height B ................................................................. 3.5 mm (0.14")
Height B: Engine: 162 ............................................ 3.444 mm (0.135")
Piston ring gap, measured at ring opening:
Upper ..................................................................... max. 0.65 mm (0.026")
Upper: Engine: 162 ................................................ max. 0.75 mm (0.030")
Lower ..................................................................... max. 0.45 mm (0.018")
Lower: Engine: 1631 ............................................... max. 1 mm (0.04")
Lower: Engine: 164 ................................................ max. 1 mm (0.04")
Piston ring clearance in groove
Upper compression ring: Engine: 164 ..................... 0.135–0.185 mm (0.005–0.007")
Upper compression ring: Engine: 162 ..................... 0.15–0.182 mm (0.006–0.007")
Lower compression ring: Engine: 164, 1620 ........... 0.07–0.102 mm (0.003–0.004")
Lower compression ring: Engine: 162 ..................... 0.11–0.142 mm (0.004–0.006")

Oil scraper ring:

Quantity ................................................................. 1
Height C ................................................................. 4.984 mm (0.196")
Piston ring gap, measured at ring opening .............. max. 0.65 mm (0.026")
Piston ring clearance in groove, oil scraper ring ..... max. 0.072 mm (0.003")

Gudgeon pins
Gudgeon pin diameter ............................................ min. 59.998 mm (2.362")
Gudgeon pin hole diameter in piston ...................... max. 60.011 mm (2.361")
Small end bushing, internal diameter ...................... max. 60.026 mm (2.363")

12
Group 20 Technical data

Valve mechanism
Valves

Inlet Exhaust

Valve head diameter:

Inlet .................................................................... 47 ± 0.1 mm (1.85 ± 0.004")
Exhaust .............................................................. 45 ± 0.1 mm (1.77 ± 0.004")
Valve stem diameter:
Inlet .................................................................... 9.485-9.5 mm (0.373-0.374")
Exhaust .............................................................. 9.472-9.487 mm (0.372-0.373")
Valve seat angle:
Inlet .................................................................... 29.5°
Exhaust .............................................................. 44.5°
Seat angle in cylinder head:
Inlet .................................................................... 30°
Exhaust .............................................................. 45° INLET 0.3 mm
Valve head edge: EXHAUST 0.6 mm
Inlet .................................................................... min. 1.4 mm (0.055")
Exhaust .............................................................. min. 1.55 mm (0.061")
Valve clearance, cold engine or at operating temperature:
Inlet .................................................................... 0.3 mm (0.011")
Exhaust .............................................................. 0.6 mm (0.023")

Valve seats
Outer diameter A, standard:
Inlet .................................................................... 50.07 mm (1.971")
Exhaust .............................................................. 48.062 mm (1.892")
Oversize dimension:
Inlet .................................................................... 50.27 mm (1.979")
Exhaust .............................................................. 48.262 mm (1.900")
Height B:
Inlet .................................................................... 7.55 mm (0.297")
Exhaust .............................................................. 12.4 mm (0.488")
Inlet: Engine 162 ................................................. 6.15 mm (0.242")
Exhaust: Engine 1620 ......................................... 10.95 mm (0.431")

13
Technical data Group 20

Valve seat bed

Diameter C, standard
Inlet .................................................................... 50.012 mm (1.968")
Exhaust .............................................................. 48.012 mm (1.890")
Diameter C, oversize:
Inlet .................................................................... 50.212 mm (1.976")
Exhaust .............................................................. 48.212 mm (1.898")
Depth D:
Inlet .................................................................... 9.5 mm (0.374")
Exhaust .............................................................. 14.05 mm (0.553")
Seat base radius R:
Inlet/Exhaust ...................................................... 0.65 mm (0.025")
Inlet: Engine 164 ................................................. 0.66 mm (0.025")
Dimension between valve head and cylinder head plane:
Inlet/Exhaust (0–0.4 mm ) ................................... 0.2 mm (0.007")
Inlet: Engine 162, 1620 (1.47–1.9 mm ) ............... 1.68 mm (0.066")
Exhaust: Engine 162, 1620 (1.43–1.85 mm ) ....... 1.64 mm (0.064")

Valve guides
Length:
Inlet .................................................................... 87 mm (3.425")
Exhaust .............................................................. 76 mm (2.992")
Inlet: Engine 164 ................................................. 82 mm (3.228")
Exhaust: Engine 164 ........................................... 71 mm (2.795")
Inner diameter:
Inlet .................................................................... 9.525–9.54 mm (0.375–0.3756")
Exhaust .............................................................. 9.525–9.54 mm (0.375–0.3756")
Height above cylinder head spring plane:
Inlet .................................................................... 23.5 ± 0.35 mm (0.925–0.013")
Exhaust .............................................................. 25 ± 0.35 mm (0.985–0.013")
Inlet: Engine 164 ................................................. 19.1 ± 0.35 mm (0.752–0.013")
Exhaust: Engine 164 ........................................... 20.6 ± 0.35 mm (0.811–0.013")
Clearance, valve stem - guide:
Inlet .................................................................... 0.04 mm (0.001")
Exhaust .............................................................. 0.052 mm (0.002")

Rocker arms
Bearing clearance .................................................. 0.041 mm (0.001")

Valve lifters
Clearance:
Shaft – bushing ................................................... 0.036 mm (0.001")
Shaft – shank ..................................................... 0.026 mm (0.001")

14
Group 20 Technical data

Valve springs, exhaust

Unloaded length ..................................................... 68.1 mm (2.681")
Loaded by 598 N (61 kp) ..................................... 49.5 mm (1.948")
Loaded by 1022 N (104 kp) ................................. 36.3 mm (1.429")
Coilbound length, max ......................................... 33.5 mm (1.318")
Engine TD164KAE:
Inner valve spring, unloaded length ........................ 63.7 mm (2.507")
Loaded by 275 N (28 kp) ..................................... 44 mm (1.732")
Loaded by 468 N (47.7 kp) .................................. 31.8 mm (1.251")
Coilbound length, max ......................................... 28.8 mm (1.133")

Valve springs, inlet

Unloaded length ..................................................... 61.3 mm (2.413")
Loaded by 304 N (31 kp) ..................................... 48 mm (1.889")
Loaded by 624 N (63.5 kp) .................................. 34 mm (1.338")
Coilbound length, max ......................................... 31.5 mm (1.240")

Camshaft
Drive ...................................................................... Gearwheel
No of bearings ........................................................ 7
Diameter: Front bearing journal .............................. 68.946–68.965 mm (2.714–2.715")
2:nd–7:th bearing journal ........................ 64.94–64.965 mm (2.557–2.557")
End float ................................................................ 0.115 mm (0.004")
Radial clearance 1:st ............................................. 0.074 mm (0.002")
2:nd–7:th .................................... 0.078 mm (0.003")
Checking camshaft setting:
Cold engine and valve clearance = 0, inlet valve
for cylinder 1 at flywheel position 10° ATDC should
have opened .......................................................... 1.8–2.6 mm (0.071–0.102")
Max. valve lift: Inlet ............................................... 14 mm (0.551")
Exhaust ......................................... 13.2 mm (0.519")

Camshaft bearings
Diameter, camshaft bearing, standard
1:st bearing, inner diameter ................................. 69–69.06 mm (2.716–2.718")
1:st bearing, outer diameter ................................. 72–72.025 mm (2.835–2.835")
2:nd–7:th bearing inner diameter ......................... 65–65.06 mm (2.560–2.557")
2:nd–7:th bearing ................................................ 68–68.025 mm (2.677–2.678")
Note. Outer diameter of camshaft bearing is equal to diameter of bearing seat.

15
Technical data Group 20

Timing gear

Gear wheel designation No. of teeth:

1. Drive gear, crankshaft ...................................... 37
2. Idler gear, oil pump .......................................... 58
3. Drive gear, oil pump ......................................... 25
4. Idler gear, left ................................................... 86
5. Power take-off .................................................. 33
6. Drive gear, injection pump ................................ 74
7. Drive gear, servo pump .................................... 22
8. Drive gear, camshaft ........................................ 74
9. Idler gear, upper ............................................... 85
10. Drive gear, coolant pump ................................. 25
11. Idler gear, right ................................................. 86

Flank clearance ..................................................... 0.115 mm (0.004")

Hub for idler wheel, diameter .................................. 99.99 ±0.011 mm (3.937–0.0004")
Bushing for idler wheel, diameter ............................ 100.04 ±0.018 mm (3.939–0.0007")
Radial clearance for idler wheel .............................. 0.054 mm (0.002")
End float for idler wheel .......................................... 0.1 mm (0.003")

Applies to engines 162, 1620 and 164:

Gear wheel designation No. of teeth:
1. Drive gear, crankshaft ...................................... 37
2. Idler gear, oil pump .......................................... 58
3. Drive gear, oil pump ......................................... 25
4. Idler gear, left ................................................... 25
5. Power take-off .................................................. 86
6. Drive gear, injection pump ................................ 85
7. Drive gear, servo pump .................................... 74
8. Drive gear, camshaft ........................................ 74
9. Idler gear, upper ............................................... 86

Flank clearance ..................................................... 0.05–0.17 mm (0.002–0.006")

Hub for idler wheel, diameter .................................. 99.88–100 mm (3.932–3.937")
Bushing for idler wheel, diameter ............................ 100.026–100.062 mm (3.938–3.939")
Radial clearance for idler wheel .............................. 0.054 mm (0.002")
End float for idler wheel .......................................... 0.1 mm (0.003")

16
Group 20 Technical data

Reciprocating components

Crankshaft
Nitrocarburized crankshaft. Note. A nitrocarburized crankshaft must not be ground down past the 2:nd undersi-
ze dimension.
If it is ground down further, it must be nitrocarburized again.

Length .................................................................... 1,323 mm (52.086")

Crankshaft, end float .............................................. 0.19 mm (0.007")
Main bearings, radial clearance .............................. 0.12 mm (0.004")

Main bearing journals

Diameter ∅: Standard ............................................ 117.989 ± 0.011 mm (4.645±0.0004")
Undersize dimension 0.25 mm ............................ 117.739 ± 0.011 mm (4.635±0.0004")
Undersize dimension 0.5 mm .............................. 117.489 ± 0.011 mm (4.626±0.0004")
Undersize dimension 0.75 mm ............................ 117.239 ± 0.011 mm (4.616±0.0004")
Width, thrust bearing journal A: Standard ............... 51 ± 0.025 mm (2.008±0.0001")
Oversize dimension 0.2 mm
(thrust bearing 0.1 mm ) ...................................... 51.2 ± 0.025 mm (2.016±0.0001")
Oversize dimension 0.4 mm
(thrust bearing 0.2 mm ) ...................................... 51.4 ± 0.025 mm (2.024±0.0001")
Oversize dimension 0.6 mm
(thrust bearing 0.3 mm ) ...................................... 51.6 ± 0.025 mm (2.31±0.0001")
Fillet radius R ......................................................... 5.38 ± 0.125 mm (0.212±0.004")

Thrust washers, thrust bearing

Width B: Standard .................................................. 3.175 ± 0.038 mm (0.125±1.496")
Oversize dimension: 0.1 mm (0.003”) .................. 3.275 ± 0.038 mm (0.128±1.496")
0.2 mm (0.007”) .................. 3.375 ± 0.038 mm (0.133±1.496")
0.3 mm (0.011”) .................. 3.475 ± 0.038 mm (0.137±1.496")

Main bearing shells

Type ...................................................................... Replaceable
Outer diameter C .................................................... 123.135 mm (4.847")
Thickness D: Standard........................................... 2.506 ± 0.009 mm (0.099±0.0004")
Oversize dimension: 0.25 mm (0.009”) ................ 2.632 ± 0.009 mm (0.104±0.0004")
0.5 mm (0.019”) .................. 2.756 ± 0.009 mm (0.108±0.0004")
0.75 mm (0.029”) ................ 2.882 ± 0.009 mm (0.113±0.0004")

17
Technical data Group 20

Big end journals

Diameter ∅: Standard ............................................ 99.992 ± 0.008 mm (3.937±0.0003")
Undersize dimension: 0.25 mm (0.009”) .............. 99.742 ± 0.008 mm (3.927±0.0003")
0.5 mm (0.019”) ................ 99.492 ± 0.008 mm (3.917±0.0003")
0.75 mm (0.029”) .............. 99.242 ± 0.008 mm (3.907±0.0003")
Width, A: Big end bearing journal ........................... 59.95 ± 0.05 mm (2.360±0.001")
Fillet radius R (5.25–5.5 mm) (0.207–0.216”) .......... 5.38 mm (0.211")

Big end journal shells

Outer diameter B .................................................... 104.807 mm (4.126")
Thickness C: Standard........................................... 2.354 ± 0.008 mm (0.093±0.0003")
Oversize dimension: 0.25 mm (0.009”) ................ 2.48 ± 0.008 mm (0.098±0.0003")
0.5 mm (0.019”) .................. 2.604 ± 0.008 mm (0.103±0.0003")
0.75 mm (0.029”) ................ 2.73 ± 0.008 mm (0.107±0.0003")
Diameter D: Bearing shell seat ............................... 104.8 mm (4.125")

Con rods
Marking: Con rod and cap ...................................... 1 to 6
“FRONT” marking on shaft must face forwards
Length E: Centre - centre ....................................... 286 mm (11.259")
Diameter F: Small end bushing seat ...................... 65.3–65.346 mm (2.571–2.572")
Small end bushing, internal diameter G .................. 59.978–60.028 mm (2.361–2.363")
End float, con rod - crankshaft ............................... 0.15–0.35 mm (0.006–0.013")
Big end bearings, radial clearance .......................... Max 0.128 mm (0.005")

Flywheel
Max. permissible run out for installed flywheel:
Measurement radius 150 mm (5.905”) .................... 0.15 mm (0.005")
Gear ring on flywheel ............................................. 153 teeth

Bell housing
Max. permissible run out for installed bell housing:
Rear mating plane .................................................. 0.2 mm (0.007")
Max. permissible run out applies to:
Inner guide edge on bell housing ............................ 0.25 mm (0.009")

18
Group 20 Technical data

Lubrication system

Lubrication system, general

Oil volume: Incl. filter ............................................. 64 liters (67.6 US quart)
Excl. filter ............................................ 57 liters (60.2 US quart)
Difference between MIN – MAX ............................. 17 liters (17.9 US quart)
Oil pressure: At operating speed ............................. 300–500 kPa (43.5–72.5 psi)
At idle (min.) ...................................... 150 kPa (21.7 psi)
Oil temperature: Normal ......................................... 105°C (221.2°F)
Max ............................................. 120°C (248.4°F)
Oil filter, mesh size ................................................ 0.04 mm (0.0015")

Viscosity at various ambient temperatures

Lubrication oil, engine Bar diagram temperature values refer to stable ambient
temperatures.
Oil grade Standard
VDS-2, VDS Volvo Drain Specification
ACEA E3–96, E2–96 ACEA
CD, CE, CF API
CF-4, CG-4 API

SAE5W/30 refers to synthetic or semi-synthetic oils.

NOTE! Only SAE5W/30 may be used.

19
Technical data Group 20

Lubrication oil pump

Type ...................................................................... Gear wheel pump
No. of teeth: Drive gear .......................................... 25
Idler gear ............................................................. 58
Diameter:
Idler gear journal ................................................. 99.99 ± 0.011 mm (3.937±0.0004")
Bushing, idler wheel ............................................ 100.044 ± 0.018 mm (3.939±0.0007")
End float: ............................................................... Pump gears 0.095 mm (0.003")
Idler gear ............................................................. 0.1 mm (0.0039")
Flank clearance ..................................................... 0.115 mm (0.004")

Clearance between drive gear –

oil pump bracket .................................................... 0.4–1 mm (0.0016–0.039")

Oil filter
By-pass ................................................................. 1
Full flow ................................................................. 2
Mesh size .............................................................. 0.04 mm (0.001")

Oil valve spring lengths, please refer to the illustration on page 19

1. Safety valve:
Unloaded ............................................................ 121.6 mm (4.787")
Loaded by 178–200 N (18–20.4 kp) .................... 59.6 mm (2.346")
Loaded by 215 N (22 kp) .................................... 51 mm (2.007")

2. By-pass valve, oil cooler:

Unloaded ............................................................ 91.2 mm (3.590")
Loaded by 41.4–47.4 N (4.2–4.8 kp) ................... 59.6 mm (2.346")
Loaded by 56.5 N (5.6 kp) .................................. 51 mm (2.007")

3. By-pass valve, oil cooler:

Unloaded ............................................................ 68.8 mm (2.708")
Fully loaded ....................................................... 30 mm (1.181")

4. Reduction valve:
Unloaded ............................................................ 93 mm (3.661")
Loaded by 96–108 N (9.8–11 kp) ........................ 59.6 mm (2.346")
Loaded by 128.3 N (13.1 kp) .............................. 51 mm (2.007")

5. Piston cooling valve:

Unloaded ............................................................ 68.8 mm (2.708")
Loaded by 18.6–20.6 N (1.9–2.1 kp) ................... 40.5 mm (1.594")
Loaded by 28.9 N (2.9 kp) .................................. 32 mm (1.259")
Fully compressed .............................................. 30 mm (1.181")

20
Group 20 Technical data

Applies to engines 162, 1620 and 164:

Oil filter
By-pass ................................................................. 1
Full flow ................................................................. 2

Oil valves, spring lengths

1. Safety valve:
Unloaded ........................................................... 121.6 mm (4.787")
Loaded by 178–200 N (18–20.4 kp) ................... 59.6 mm (2.346")
Loaded by 215 N (22 kp) ................................... 51 mm (2.007")
2. By-pass valve:
Free length ........................................................ 68.8 mm (2.708")
Fully compressed length ................................... 30 mm (1.181")
3. Reduction valve:
Unloaded ........................................................... 93 mm (3.661")
Loaded by 96–108 N (9.8–11 kp) ....................... 59.6 mm (2.346")
Loaded by 128.3 N (13.1 kp) ............................. 51 mm (2.007")
4. Piston cooling valve:
Unloaded ........................................................... 58.4 mm (2.299")
Loaded by 18.6–20.6 N (1.9–2.1 kp) .................. 40.5 mm (1.594")
Loaded by 28.9 N (2.9 kp) ................................. 32 mm (1.259")
Fully compressed ............................................. 30 mm (1.181")

21
Technical data Group 20

Fuel system
The fuel must comply with national and international standards for commercially supplied fuels, such as:
EN 590 (with nationally adapted environmental and cold requirements)
ASTM D 975 No 1-D and 2-D.
JIS KK 2204.
Sulfur content: Complying with legal requirements in each country. Extremely low sulfur content fuel (urban die-
sel in Sweden and city diesel in Finland) can cause a loss of up to 5% of power and an increase in fuel consump-
tion of about 2–3%.

Fuel filter
Quantity ................................................................. 1 or 2
Part number ........................................................... 466 987–5

Feed pump
Engines 162, 1620 and 1630 .................................. Bosch FP/KG 24 P307
Engine 1631 ........................................................... Bosch FP/KP22 P78
Pump pressure ....................................................... 100–150 kPa (14.5–21.7 psi)
Supply pump, max. suction height ......................... 2 m
Applies to engine 164: Supply pressure ................. 100–400 kPa (14.5–58.0 psi)

By-pass valve
Make, type ............................................................. Bosch PVE 53S 5Z
Applies to engine 164: Make/designation ............... Bosch 2 417 413 078
Part number ........................................................ 119 963 09–8
Opening pressure ................................................ 150 kPa (21.7 psi)

Injection advance adjuster

Drive ...................................................................... Gearwheel
No of bearings ........................................................ 2
Diameter, bearing journal:
Front bearing ....................................................... 69.006–70.015 mm (2.717–2.756")
Rear bearing ........................................................ 66.006–67.015 mm (2.599–2.638")
End float ................................................................ 0.08–0.23 mm (0.003–0.009")
Radial clearance
Front and rear bearings ....................................... 0.075 mm (0.002")
Bearing diameter:
Front bearing ....................................................... 70.05–70.11 mm (2.758–2.760")
Rear bearing ........................................................ 67.077–67.083 mm (2.641–2.641")
The injection advance adjuster changes pump settings successively between two engine speeds.
Pump adjustment between 16.6 r/s (1,000 rpm) and 25.8 r/s (1,550 rpm) = 5°± 1°.

22
Group 20 Technical data

Injection pump
Injection pump, direction of rotation ....................... Clockwise
Injection sequence ................................................. 1–5–3–6–2–4

Make, type:
TID162AP ........................................................... Bosch PE 6P 130A 760 RS 7140
TWD1620G/GH ................................................... Bosch PE 6P 130A 720 RS 7137
TAD1630G/GE .................................................... Bosch PE6P 130A700 RS7272
TAD1631G/GE .................................................... Bosch PE6 130/720 RS1511
TAD1630P/V ....................................................... Bosch PE6P 130A720 RS7273
TWD1630G/GE ................................................... Bosch PE6P 130A720 RS7137
TWD1630P/V ...................................................... Bosch PE6P 130A720 RS7140
TD164KAE .......................................................... Bosch PE6R 120 720 RS 1507

Regulator, make and type:

TID162AP ........................................................... Bosch RQV 250–900 PA 869
TWD1620G/GH ................................................... Bosch RQ 750 PA 865
TAD1630G/GE, TAD1631G/GE .......................... Electronic, GAC
TAD1630P/V ....................................................... RQV250–900PA881–2
TWD1630G/GE ................................................... RQ750PA865–2 separate or in comb. with GAC225
TWD1630P/V ...................................................... RQV250–900PA869
TD164KAE .......................................................... RQV300–950 R 5 K

Pump impeller, diameter ........................................ 13 mm (0.512")

Setting:
TID162AP ........................................................... 21°/ 25° BTDC.
TWD1620G/GH ................................................... 21°/ 25° BTDC.
TAD1630G, 1500/1800 rpm. ................................ 19°/ 21° ±0.5 BTDC.
TAD1630GE, 1500/1800 rpm. ............................. 18°/ 21° ±0.5 BTDC.
TAD1631G/GE, 1500/1800 rpm. .......................... 17°/ 21° ±0.5 BTDC.
TAD1630P/V ....................................................... 21° ± 0.5 BTDC.
TWD1630G, 1500/1800 rpm. ............................... 21°/ 25° ±0.5 BTDC.
TWD1630GE, 1500/1800 rpm. ............................ 18°/ 20° ±0.5 BTDC.
TWD1630P/V ...................................................... 25° ±0.5 BTDC.
TD164KAE .......................................................... 11.5°–13° BTDC.

Lift from base circle (stroke position):

TID162AP, TWD1620 .......................................... 3.6 +0.1 mm (0.141+0.003")
TAD1630G/GE, TAD1631G/GE .......................... 4.55 ±0.05 mm (0.179±0.001")
TAD1630P/V ....................................................... 4.55 ±0.05 mm (0.179±0.001")
TWD1630G/GE. Inj. pump Bosch
no. 0 402 646 652 ............................................... 3.65 ±0.05 mm (0.144±0.001")
TWD1630G. Inj. pump Bosch
no. 0 402 646 962 ............................................... 3.45 ±0.05 mm (0.136±0.001")
TWD1630P/V ...................................................... 3.45 ±0.05 mm (0.136±0.001")

23
Technical data Group 20

Injectors
Designation:
Injector holder, 162, 1620 .................................... KBAL 116 S 66
Injector holder, 1630, 1631, TD164KAE .............. KBAL 116 S 75
Injector 162, 1620 ............................................... DLLA 140 S 1054
Injector: 1630 ...................................................... DLLA 148 S 1263
Injector: 1631 ...................................................... DLLA 148 S 1298
Injector: TD164KAE ............................................ DLLA 148 S 1272
Marking, complete injector
162, 1620 ............................................................ 635
1630 .................................................................... 531
1631 .................................................................... 545
Opening pressure:
162, 1620, 1630 .................................................. 26 MPa (3770.9 psi)
1631 .................................................................... 28.5 MPa (4133.5 psi)
TD164KAE .......................................................... 23.5 MPa (3408.3 psi)
Setting pressure, new spring:
162, 1620 ............................................................ 26.5–27.3 MPa (3843.5-3959.5 psi)
1630 .................................................................... 26.5 (+0.2) MPa (3843.5 + 29 psi)
1631 .................................................................... 29 (+0.2) MPa (4206 + 29 psi)
TD164KAE .......................................................... 24 MPa (3480.9 psi)
Hole diameter:
162, 1620 ............................................................ 5 pcs. 0.4 mm (0.015")
1630 .................................................................... 7 pcs. 0.31 mm (0.012")
1631 .................................................................... 7 pcs. 0.35 mm (0.013")
TD164KAE .......................................................... 7 pcs. 0.27 mm (0.010")

Cooling system
Recommended coolant:
Volvo Penta ethylene glycol or Volvo Penta anti-corrosion compound together with clean fresh water.
Cooling system, type ............................................. Pressurized, sealed
Pressure valve in radiator opens at ........................ 70 kPa (10152.6 psi)
Engine TD164KAE:
Pressure valve opens at ........................................ 50 kPa (7251.8 psi)

Coolant volume:
Engine: TID162AP, TWD1620G/GH .................... 38 litres (40.1 US quart)
Engine: TAD1630, TAD1631 ............................... 29 litres (30.6 US quart)
Engine: TWD1630: .............................................. 32 litres (33.8 US quart)
Engine: TD164KAE ............................................. 57 litres (60.2 US quart)
Engine incl. standard radiator and hoses:
TID162AP, TWD1620G/GH ................................. 70 litres (73.9 US quart)
TAD1630 ............................................................. 52 litres (54.9 US quart)
TAD1631 ............................................................. 56 litres (59.1 US quart)
TWD1630 ............................................................ 59 litres (62.3 US quart)
TD164KAE .......................................................... 59 litres (62.3 US quart)

Thermostat: TAD1630, TAD1631

Marking ............................................................... Red
Starts to open/fully open at ................................. 82°C (179.7°F)/95°C (203.0°F)
Thermostat: TID162AP, TWD1620G/GH, TWD1630
Marking ............................................................... Blue
Starts to open/fully open at ................................. 76°C (168.6°F)/88°C (190.9°F)
Thermostat: TD164KAE
Type/quantity ...................................................... Piston thermostat/2 pcs.
Starts to open/fully open at ................................. 82°C (179.7°F)/95°C (203.0°F)

24
Group 20 Technical data

Inlet and exhaust system

Turbocharger:
Make, type:
TID162 and TWD1620G/GH ................................... Holset HSB 0870/B36
TAD1630G/GE ....................................................... Schwitzer S4T/122.61/BE1.30L1
TAD1631G/GE ....................................................... Schwitzer S4T/122.61/BE1.45L1
TAD1630PV ........................................................... Schwitzer S4T/122.58/EE1.30L1
TWD1630G/GE ...................................................... Holset H3B 0980AR–B36S1
TWD1630P/V ......................................................... Holset H3B 08070–B36S1
TD164KAE ............................................................. TV75/56–PS–BCI18B/126–3BI
Applies to engine TD164KAE:
Measurement of charge pressure and regulator
setting, please refer to service bulletin: .................. L258 WLO–1

Lubrication system ................................................. Pressure lubrication

Pre-charge pressure:
1500 rpm. 1800 rpm.
TID162AP, TWD1620G/GH Prime power ............... 125 kPa (18.1 psi) 130 kPa (18.8 psi)
TID162AP, TWD1620G/GH Stand-by power ........... 170 kPa (24.6 psi) 150 kPa (21.7 psi)
TAD1630G/GE: Prime power ................................. 201 kPa (29.1 psi) 216 kPa (31.3 psi)
TAD1631G/GE: Prime power ................................. 180 kPa (26.1 psi) 190 kPa (27.5 psi)
TWD1630G/GE: Prime power ................................. 170 kPa (24.6 psi) 175 kPa (25.3 psi)

1200 rpm. 1500 rpm. 1600 rpm. 1800 rpm.

TAD1630P/V: Continuous rating ............................. 151 kPa 180 kPa 187 kPa 195 kPa
(21.9 psi) (26.1 psi) (27.1 psi) (28.2 psi)
TID162AP, TWD1620G/GH Continuous rating ........ 90 kPa 116 kPa 122 kPa 125 kPa
(13.0 psi) (16.8 psi) (17.6 psi) (18.1 psi)
TWD1630P/V: Continuous rating ............................ 136 kPa 158 kPa 161 kPa 163 kPa
(19.7 psi) (22.9 psi) (23.3 psi) (23.6 psi)
TD164KAE: Continuous rating ................................ 120 kPa 136 kPa 150 kPa 160 kPa
(17.4 psi) (19.7 psi) (21.7 psi) (23.2 psi)

25
Technical data Group 20

Exhaust system
1500 rpm. 1800 rpm.
Exhaust temperature after turbine wheel, engine
TAD1630G/GE:
Prime power without fan ......................................... 490°C (914.1°F) 455°C (851.5°F)
Stand-by power without fan .................................... 510°C (950.5°F) 490°C (914.1°F)
Max. permissible back pressure in exhaust pipe .... 5 kPa (0.7 psi) 7 kPa (1 psi)
Exhaust temperature after turbine wheel, engine
TAD1630P/V:
Prime power without fan ...................................... 490°C (914.1°F) 455°C (851.5°F)
Stand-by power without fan ................................. 510°C (950.5°F) 490°C (914.1°F)
Continuous rating ................................................ 490°C (914.1°F) 475°C (887.8°F)
Max. permissible back pressure in exhaust pipe . 8.3 kPa (1.2 psi) 12 kPa (1.7 psi)
Exhaust temperature after turbine wheel, engine
TAD1631G/GE:
Prime power without fan ...................................... 550°C (1022.0°F) 520°C (968.6°F)
Stand-by power without fan ................................. 565°C (1049.0°F) 560°C (1040.0°F)
Max. permissible back pressure in exhaust pipe . 5 kPa (0.7 psi) 7 kPa (1.0 psi)
Exhaust temperature after turbine wheel, engine
TWD1630G/GE:
Prime power without fan ...................................... 520°C (968.6°F) 530°C (986.8°F)
Stand-by power without fan ................................. 540°C (1004.0°F) 605°C (1121.1°F)
Continuous rating, applies to
engine TWD1630P/V: .......................................... 500°C (932.3°F) 505°C (941.4°F)
Max. permissible back pressure in exhaust pipe . 5 kPa (0.7 psi) 7 kPa (1.0 psi)
Max combustion pressure, engine: TAD1630G/G:
Prime power ........................................................ 15 MPa (2175.5 psi) 15.5 MPa (2248.0 psi)
Max combustion pressure, engine: TAD1631G/GE:
Prime power ........................................................ 14.4 MPa (2088.5 psi) 15.2 MPa (2204.5 psi)
Max combustion pressure, engine: TAD1630P/V:
Continuous rating ................................................ 16.3 MPa (2364.1 psi) 15.4 MPa (2233.5 psi)
Max combustion pressure, engine TWD1630G/GE:
Prime power ........................................................ 13.6 MPa (1972.5 psi) 12.5 MPa (1812.9 psi)
Max combustion pressure, engine TWD1630P/V:
Continuous rating ................................................ 15.1 MPa (2190.0 psi) 14.5 MPa (2103.0 psi)

26
Group 20 Technical data

Wear tolerances
Cylinder head
Height, min. ........................................................... 134.6 mm (5.299")

Cylinder liner
Should be changed if oil consumption is
abnormally high.
Wear tolerance ....................................................... 0.45–0.5 mm (0.0178–0.019")
Change pistons and piston rings at the same time.

Engine block
Height block plane – crankshaft centerline ............. min. 479.8 mm (18.889")

Crankshaft
Max. permissible ovality in main and big end
bearings ................................................................. 0.08 mm (0.003")
Max. permissible taper in main and big end
bearings ................................................................. 0.05 mm (0.001")
Max. crankshaft end float ...................................... 0.4 mm (0.015")

Con rods
Straightness, max. deviation on 100 mm (3.937”)
measured length .................................................... 0.05 mm (0.001")
Twist, max. deviation on 100 mm (3.937”)
measured length .................................................... 0.4 mm (0.015")

Valves
Valve stem, max. permissible wear ....................... 0.02 mm (0.0001")
Max. permissible clearance between valve stem and valve guide.
Inlet .................................................................... 0.3 mm (0.011")
Exhaust .............................................................. 0.45 mm (0.017")
Valve head edge shall be at least:
Inlet .................................................................... 1.4 mm (0.055")
Exhaust .............................................................. 1.55 mm (0.061")
Valve seat may be ground down so far that
distance from valve head to cyl. head plan is max:
Inlet, applies to new valve ................................... 1 mm (0.039")
Exhaust, applies to new valve ............................ 1 mm (0.039")
Engine 162, 1620: Inlet, new valve ...................... 2.5 mm (0.098")
Engine 162, 1620: Exhaust, new valve ............... 2.5 mm (0.098")

Camshaft
Max permissible ovality (with new bearings) ........... 0.05 mm (0.001")
Bearings, max. permissible wear ............................ 0.05 mm (0.001")
Lift height, min:
Inlet .................................................................... 7.8 mm (0.307")
Exhaust .............................................................. 7.35 mm (0.289")

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Technical data Group 20

Tightening torque

Nm:
Cylinder head, tighten screws in four or five stages:
Stage 1 ............................................................... 50 (36.8 lbf-ft)
Stage 2 ............................................................... 125 (92.1 lbf-ft)
Stage 3 ............................................................... 200 (147.5 lbf-ft)
Stage 4 ............................................................... Angle tightening: 180°
For TD164KAE: Stage 4 ..................................... Angle tightening: 90°
For TID162AP/ TWD1620G/GH:
Stage 4 .............................................................. Angle tightening: 90°
Stage 5 .............................................................. Angle tightening: 90°
Main bearing .......................................................... 440 (324.5 lbf-ft)
Main bearing plates, engine block .......................... 85± 7 (62.7±5.1 lbf-ft)
Big end bearing ...................................................... 240 (177.0 lbf-ft)
Thrust bearing, camshaft ....................................... 24 (17.7 lbf-ft)
Timing cover .......................................................... M8 = 24 ± 3 (17.7 ± 2.2 lbf-ft)
Timing cover .......................................................... M10 = 48± 5 (35.4 ± 3.6 lbf-ft)
Timing cover .......................................................... M14 = 140± 10 (103.3 ± 7.3 lbf-ft)
Timing cover .......................................................... 35± 5 (25.8 ± 3.6 lbf-ft)
Timing cover, engine 162, 1620 ............................. 24 (17.7 lbf-ft)
Camshaft gear ....................................................... 58± 6 (44.7 ± 4.4 lbf-ft)
Camshaft gear, engine 162, 1620 ........................... 48 (35.4 lbf-ft)
Gear wheel, injection pump drive,
engines 162, 1620, 1630 ........................................ 58 (42.7 lbf-ft)
Gear wheel, injection pump drive, engine 1631 ....... 65 (47.9 lbf-ft)
Applies to TD164KAE: Injection pump
Fixing screws ...................................................... 48 (35.4 lbf-ft)
Screws, laminations, pump coupling ................... 63 (46.4 lbf-ft)
Nuts, flange, pump coupling ................................ 340 (250.7 lbf-ft)
Clamping screw .................................................. 114 (84.0 lbf-ft)
Idler wheel bearing for left, right and upper
idler gears .............................................................. 65 (47.9 lbf-ft)
Bearing cap, rocker arm shaft ................................ 65 (47.9 lbf-ft)

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Group 20 Technical data

Nm:
Bearing block, rocker arm shaft,
engines 162, 1620 .................................................. 48 (35.4 lbf-ft)
Sump, tighten to special schedule,
see illustration above ............................................. 16± 2 (11.8 ± 1.4 lbf-ft)
Sump, engines 162, 1620, 164, tighten to
special schedule, see illustration above ................. 24± 3 (17.7 ± 2.2 lbf-ft)
Drain plug, sump .................................................... 80 (59.0 lbf-ft)
Bracket, oil pump ................................................... 48 (35.4 lbf-ft)
Idler gear, oil pump ................................................ 48 (35.4 lbf-ft)
Flywheel ................................................................ 260 (191.7 lbf-ft)
Bell housing ........................................................... 140 (103.2 lbf-ft)
Centre screw, crankshaft ....................................... 642 (473.5 lbf-ft)
Pressure valve retainer, injection pump.
Grease threads with special grease,
part no: 5 963 340 110 ........................................... 115 (84.8 lbf-ft)
Nut for retaining yoke, injectors .............................. 50 (36.8 lbf-ft)
Stud for retaining yoke, injectors ............................ 65 (47.9 lbf-ft)
Clamp screw, injector pump coupling ..................... 85 (62.6 lbf-ft)
Centre screw for hub, coolant pump shaft .............. 60 (44.2 lbf-ft)
Valve housing. ....................................................... 20± 5 (14.8 ± 3.6 lbf-ft)
Engine mounting, front, engine block ..................... 200± 20 (147 ± 14.7 lbf-ft)
Exhaust collector pipe ............................................ 48 (35.4 lbf-ft)
Center screw for fan hub ........................................ 65± 7 (48 ± 5.1 lbf-ft)
Vibration damper .................................................... 60 (44.2 lbf-ft)
Applies to TD164KAE: Vibration damper ................ 48 (35.4 lbf-ft)
Nut, piston cooling nozzle ...................................... 24± 5 (17.7 ± 3.6 lbf-ft)
Stud, piston cooling nozzle .................................... 23 (16.9 lbf-ft)
Core plug, diameter in engine block: 1 3/4” ............. 60 (44.2 lbf-ft)
Core plug, diameter in engine block: 1/2” ............... 80 (59.0 lbf-ft)
Core plug, diameter in cylinder head: M30 .............. 60 (44.2 lbf-ft)
Core plug, diameter in engine block: 3/4” ............... 80 (59.0 lbf-ft)

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AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Göteborg
Sweden
7742312-7 English 05–2002