Volvo TAD750 Workshop Manual

Workshop Manual I
Group 20-26 4(0)
TAD650VE, TAD660VE
TAD750VE, TAD760VE
Workshop manual
Industrial engines
TAD650VE, TAD660VE,
TAD750VE, TAD760VE
Contents
Safety Precautions ................................................. 2 Camshaft ............................................................. 74
Cylinder head ....................................................... 78
General information ............................................... 5 Valve seat, replacing ........................................... 81
Valve seat, grinding ............................................. 82
Valves, grinding ................................................... 82
Service procedures ................................................ 6
Rocker arm bridge ................................................ 83
Special tools .......................................................... 9

Repair of components .......................................... 84
Description of engine ........................................... 12 Group 21:

Engine plate, placement ...................................... 12 Ring gear, replace ................................................ 84
Engine serial number .......................................... 13 Valve clearance, adjustment ................................ 86
Cylinder numbering ............................................. 13 Cylinder head, removal/installation ....................... 89
Engine, component placement ............................ 14 Crankshaft seal, replacing (complete engine) ...... 100
Engine, sensor placement ................................... 16 Crankshaft seal, front (front casing), replacing .... 102
EMS 2 ................................................................ 17
Engine models .................................................... 18 Group 22:
Engine block ....................................................... 19 Sump/oil suction pipe, removal/installation ......... 104
Fuel system ........................................................ 20 Oil pump, disassembly ....................................... 106
Cooling System .................................................. 21 Oil cooler, checking ............................................ 107
Technical data ...................................................... 22 Group 23:

Engine ................................................................ 22 Fuel feed pressure, checking .............................. 113
Tightening torque ................................................ 24 Fuel feed pump, removal/installation ................... 114
Common Rail, removal/installation ...................... 116
Control valve, removal/installation ....................... 119
Checks and adjustments ..................................... 26
Fuel pump, removal/installation ........................... 120
Compression test ................................................ 26 Injector, removal/installation ............................... 123
Lube oil pressure ................................................. 27
Fuel pressure ...................................................... 27 Group 25:
Exposing engine ................................................. 28 Exhaust manifold, removal/installation ................ 126
Installing fixture .................................................. 29 Turbocharger, removal/installation ....................... 127
Inlet pipe, removal/installation ............................. 129
Disassembly, complete engine .......................... 31 IEGR, removal/installation .................................. 132
Solenoid valve, for IEGR (TAD660/760VE) ......... 135
Assembly, complete engine ............................... 42
Group 26:
Checking and measuring .................................... 63 Coolant pump, checking/replacing ....................... 137
Engine block ....................................................... 63 Thermostat, check .............................................. 139
Crankshaft, measuring ........................................ 65 Drive belts, replacing .......................................... 140
Connecting rod, measuring .................................. 68
Piston ................................................................. 71 Register ................................................................ 141
1
Safety Precautions Group 20
Safety Precautions
Introduction If work is done adjacent to a running engine, a

careless movement or a dropped tool can lead
This Workshop Manual contains descriptions and pro- to personal injury in the worst case.
cedures for the repair of the specified Volvo Penta Be careful with hot surfaces (exhaust pipes, tur-
products or product versions. Check that you have the bos, charge air pipes, starting heaters etc.) and
correct Workshop Manual for your engine. hot fluids in pipes and hoses on an engine which
Before starting work, read the safety precautions is running or which has just stopped. Reinstall
with care as well as “General information” and all protective parts removed during service
“Service procedures.” operations before starting the engine.
Check that the warning or information labels on

Important the product are always clearly visible. Replace
labels which have been damaged or painted
In this book and on the product you will find the follo- over.
wing special warning symbols.
Never start the engine without installing the air
WARNING! Possible danger of personal injury,
cleaner filter. The rotating compressor turbine in
extensive damage to property or serious me-
the turbocharger can cause severe injury. For-
chanical malfunction if the instructions are not
eign objects entering the intake ducts can also
followed.
cause mechanical damage.
Never use start spray or similar products as a

IMPORTANT! Used to draw your attention to starting aid. They may cause an explosion in
something that can cause damage or malfunc- the inlet manifold. Danger of personal injury.
tions on a product or damage to property.
Only start the engine in a well- ventilated area.

NOTE: Used to draw your attention to important infor- When operated in a confined space, exhaust
mation that will facilitate the work or operation in fumes and crankcase gases must be ventilated
progress. from the engine bay or workshop area.
Below is a summary of the risks involved and safety
precautions you should always observe or carry out Avoid opening the coolant filler cap while the en-
when operating or servicing the engine. gine is hot. Steam or hot coolant can spray out
and the system pressure will be lost. When
needed, open the filler cap slowly and release
the pressure in the system. Be extremely care-
Immobilize the engine by turning off the power
ful if a tap, plug or coolant hose has to be re-
supply to the engine at the main switch
moved from a hot engine. Steam or hot coolant
(switches) and lock it (them) turned off before
might spray out in an unexpected direction.
starting work. Set up a warning notice at the
main circuit breaker.
Hot oil can cause burns. Avoid skin contact with
hot oil. Ensure that the lubrication system is not
under pressure before carrying out any work.
As a general rule all service operations must be Never start or operate the engine with the oil
carried out with the engine stopped. However, filler cap removed, otherwise oil could be
some work, for example certain adjustments re- ejected.
quire that the engine is running when they are
carried out. Approaching an engine which is run-
ning is a safety risk. Remember that loose Stop the engine before carrying out operations
clothing or long hair can fasten in rotating parts on the engine cooling system.
and cause serious personal injury.
2
Group 20 Safety Precautions
Always use protective glasses or goggles when Make sure that oil and fuel soaked rags, and
carrying out work where there is a risk of splin- used fuel and oil filters are stored in a safe
ters, grinding sparks, acid splashes or where place. Rags soaked in oil can spontaneously ig-
other chemicals are used. The eyes are ex- nite under certain circumstances. Used fuel and
tremely sensitive. An injury could result in blind- oil filters are polluting waste and must be
ness! handed to an approved waste management facil-
ity for destruction, together with used lubrication
oil, contaminated fuel, paint residue, solvents,
Avoid getting oil on your skin! Repeated expo-
degreasers and wash residue.
sure to oil or exposure over a long period can re-
sult in the skin becoming dry. Irritation, dryness
and eczema and other skin problems can then
occur. Used oil is more dangerous than fresh oil Batteries must never be exposed to open
from a health aspect. Use protective gloves and flames or electric sparks. Never smoke close to
avoid oil soaked clothes and rags. Wash regu- the batteries. The batteries generate hydrogen
larly, especially before eating. There are special gas when charged, which forms an explosive
skin creams which counteract drying out of the gas when mixed with air. This gas is easily ig-
skin and make it easier to clean off dirt after nited and highly explosive. A spark, which can
work is completed. be caused by incorrect battery connection, can
cause a single spark which is sufficient to
Many chemicals used on the product (such as cause an explosion with resulting damage. Do
engine and transmission oils, glycol, gasoline not shift the connections when attempting to
and diesel oil), or chemicals used in the work- start the engine (spark risk) and do not lean over
shop (such as degreasers, paint and solvents) any of the batteries.
are hazardous to health. Read the instructions
on the product packaging with care! Always fol-
low the safety precautions for the product (for
example use of protective mask, glasses, Always ensure that the Plus (positive) and Mi-
gloves etc.). Make sure that other personnel are nus (negative) battery cables are correctly in-
not inadvertently exposed to hazardous chemi- stalled on the corresponding terminal posts on
cals, for example in the air. Ensure good ventila- the batteries. Incorrect installation can result in
tion in the work place. Follow the instructions serious damage to the electrical equipment. Re-
provided when disposing of used or leftover fer to the wiring diagram.
chemicals.
Exercise extreme care when leak detecting on Always use protective goggles when charging
the fuel system and testing the fuel injector and handling the batteries. Battery electrolyte
nozzles. Use eye protection. The jet from a fuel contains sulfuric acid which is highly corrosive.
injector nozzle is under extremely high pressure Should the battery electrolyte come into contact
and has great penetrative energy, so the fuel with unprotected skin wash off immediately us-
can penetrate deep into the body tissue and ing plenty of water and soap. If you get battery
cause serious personal injury. Danger of blood acid in your eyes, flush at once with a lot of wa-
poisoning (septicemia). ter, and get medical assistance at once.
WARNING! The delivery pipes must under no

circumstances be bent. Damaged pipes must be Turn the engine off and turn off the power at the
replaced. main switch(es) before carrying out work on the
electrical system.
All fuels, and many chemicals, are flammable.
Do not allow naked flame or sparks in the vicin-
ity. Certain thinners and hydrogen from batteries
Clutch adjustments must be carried out with the
can be extremely flammable and explosive
engine stopped.
when mixed with air in the right proportions. No
Smoking! Ensure that the work area is well ven-
tilated and take the necessary safety precau-
tions before starting welding or grinding work. Al-
ways ensure that there are fire extinguishers at
hand when work is being carried out.
3
Safety Precautions Group 20
Use the lifting eyes fitted on the engine when WARNING! The components in the electrical
lifting the drive unit. Always check that the lift- system and in the fuel system on Volvo Penta
ing equipment used is in good condition and has products are designed and manufactured to
the load capacity to lift the engine (engine minimize the risk of fire and explosion. The en-
weight including gearbox, if fitted, and any extra gine must not be run in areas where there are
equipment installed). Use an adjustable lifting explosive materials.
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 Always use fuels recommended by Volvo
run parallel to each other and as perpendicular Penta. Refer to the Operator’s Manual. Use of
as possible in relation to the top of the engine. If fuels that are of a lower quality can damage the
other equipment connected to the engine has al- engine. On a diesel engine, poor quality fuel can
tered its centre of gravity, special lifting devices cause the control rod to bind and the engine to
may be needed to obtain the correct balance over-rev with resulting risk of damage to the en-
and safe handling. gine and personal injury. Poor fuel quality can
also lead to higher maintenance costs.
Never carry out work on an engine suspended
on a hoist.
Remember the following when washing with a

power washer: Never direct the water jet at
Never work alone when removing heavy engine seals, rubber hoses, electrical components or
components, even when using lifting devices the radiator. Never use the high pressure feature
such as locking tackle lifts. When using a lifting when cleaning an engine.
device two people are usually required to do the
work, one to take care of the lifting device and
another to ensure that components are lifted
clear and not damaged during the lifting opera-
tions.
Always check before starting work if there is

enough room to carry out disassembly work
without risking personal injury or damage to the
engine or parts.
© 2013 AB VOLVO PENTA

We reserve the right to make modifications without prior notice.
Printed on environmentally compatible paper.
4
Group 20 General information
General information
About this Service Manual Certified Engines

This workshop manual contains descriptions and The manufacturer certifies that both new engines and
and repair instructions for standard versions of en- those in use, which are certified for national or re-
gines TAD650VE, TAD660VE, TAD750VE and gional legislation, comply with the environmental re-
TAD760VE. quirements. Each product must correspond with the
unit used for certification. In order that Volvo Penta,
The Engine Designation and Engine Numbers can be
as manufacturer, will be able to warrant that engines
found on the product plate (see page 12).
in operation meet environmental requirements, the fol-
Please always include both the engine designation
lowing requirements for service and spare parts must
and the engine number in all correspondence.
be met:
The Service Manual is produced primarily for the use
• Service and maintenance intervals recommended
of Volvo Penta workshops and service technicians.
by Volvo Penta must be followed.
For this reason the manual presupposes a certain ba-
sic knowledge and that the user can carry out the me- • Only Volvo Penta Original Spare Parts intended
chanical/electrical work described to a general stan- for the certified engine version may be used.
dard of engineering competence. • Service work that covers injection pumps, pump
AB Volvo Penta products are under a continual pro- settings, and injectors must always be carried out
cess of development and we therefore reserve all by an authorized Volvo Penta workshop.
rights regarding changes and modifications. All the in- • The engine must not be altered or modified in any
formation in this manual is based on product specifi- way, except for accessories and service kits de-
cations available at the time the book was published. veloped by Volvo Penta for that engine.
Any material changes introduced into the product or • No modifications to the exhaust pipes and engine
service methods after this date are notified by means room air intake pipes are allowed.
of Service Bulletins.
• No seals on the engine may be broken by unau-
thorized persons.
Standard times (Flat Rate) IMPORTANT! When spare parts are required,
use only Volvo Penta original parts.
Operation numbers that show in instruction headings
refer to Volvo Penta Flat Rates. Use of non-original parts will result in AB
Volvo Penta being unable to warrant that the
engine corresponds to the certificated engine
version.
Spare parts
Any type of damages or costs which are the re-
Spare parts for electrical and fuel systems are subject sult of using spare parts that are not original
to various national safety requirements. Volvo Penta Volvo Penta parts for the product in question will
Original Spare Parts meet these specifications. Any not be paid for by AB Volvo Penta.
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 war-
ranty or guarantee provided by AB Volvo Penta.
5
Repair Instructions Group 20
Repair procedures
The working methods described in the Service Manual

apply to work carried out in a workshop. For this rea-
Our common responsibility
son, the engine is lifted out and mounted on an engine Each engine consists of a large number of collabora-
support. Unless otherwise stated, reconditioning work ting systems and components. Any deviation of a
which can be carried out with the engine in place fol- component from its technical specification can drama-
lows the same working method. tically increase the environmental impact of an other-
Warning symbols used in this Workshop Manual (for wise good engine. It is therefore critical that the stated
full explanation of the symbols refer to the section; wear tolerances are observed, that systems which
“Safety Precautions”) can be adjusted are correctly set up and that only Vol-
vo Penta Original Parts are used on the engine. The
WARNING! stated service intervals in the Maintenance Schedule
must be observed.
IMPORTANT! Some systems, such as the components in the fuel
system, require special expertise and special testing
NOTE: equipment for service and maintenance. Some com-
ponents are sealed at the factory, for environmental
are not in any way comprehensive since it is impos- reasons etc. It is only permissible to work on sealed
sible to predict every circumstance under which service components if you are authorized to do such work.
work or repairs may be carried out. For this reason, all
Remember that most chemical products, incorrectly
we can do is to point out the risks which we believe
used, damage the environment. Volvo Penta recom-
could occur due to incorrect work in a well-equipped
mends the use of biodegradable degreasers whenever
workshop, using work methods and tools tested by us.
engine components are de-greased, unless otherwise
All operations described in the Service Manual for specified in the workshop manual. Be careful to ensu-
which there are Volvo Penta Special Tools available re that oils, wash residue etc. are processed for de-
assume that these tools are used when carrying out struction, and are not inadvertently discharged to the
the repair. Volvo Penta Special Tools have been spe- environment.
cifically developed to ensure the most safe and ratio-
nal working methods possible. It is therefore the re-
sponsibility of anyone using other tools or other wor-
Tightening torque
king methods than we recommend to determine that
there is no risk of personal injury or mechanical dama-
ge or malfunction as a result.
The correct torque for critical joints which must be
In some cases special safety precautions and user in- tightened using a torque wrench are listed under
structions may be required in order to use the tools “Technical Data: Torque” and stated in the method de-
and chemicals mentioned in the Service Manual. The- scriptions in the Workshop Manual work procedures.
se rules must always be observed, so there are no All torque specifications apply to clean screws, screw
special instructions about this in the Service Manual. heads and mating faces. Torque data stated apply to
By following these basic recommendations and using lightly oiled or dry threads. Where grease, locking or
common sense it is possible to avoid most of the sealing agents are required for screwed joints this is
risks involved in the work. A clean workplace and a stated in both the operation description and in “Tor-
clean engine will eliminate many risks of personal inju- que”. Where no torque is stated for a joint use the ge-
ry and engine malfunction. neral torque shown in the following table. The torque
specification is a target value and the fastener does
Above all, when work on fuel systems, lubrication not need to be tightened with a torque wrench.
systems, inlet systems, turbocharger, bearing caps
and seals is done, it is extremely important that no
dirt or other kinds of foreign particles are able to get Dimension Tightening torque
in, since this would otherwise cause malfunctions or
Nm
shortened repair life.
M5 ................................................ 6
M6 ................................................ 10
M8 ................................................ 25
M10 .............................................. 50
M12 .............................................. 80
M14 .............................................. 140
6
Group 20 Repair Instructions
Torque-angle tightening Sealant

With torque/angle tightening, the fastener is tightened A number of sealants and locking liquids are used on
to the specified torque, and tightening then continues the engines. The properties of the preparations differ,
through a pre-determined angle. Example: for 90° ang- and they are intended for different strengths of faste-
le tightening, the fastener is turned a further 1/4 turn in ner, temperature, resistance to oil and other chemi-
one sequence, after the specified tightening torque cals, and for the different materials and gap thicknes-
has been achieved. ses found in the engine.
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 Service Manual the user will find
that each section where these agents are applied in
production states which type was used on the engine.
Lock nuts In service work, the same preparations or preparations
Do not re-use lock nuts that have been removed of corresponding properties, but of other makes, shall
during disassembly operations as these have reduced be used.
service life when re-used. For lock nuts with a plastic Make sure that mating surfaces are dry and free from
insert such as Nylock® the torque stated in the table oil, grease, paint and anti-corrosion agent before app-
is reduced if the Nylock® nut has the same head lying sealant or locking fluid.
height as a standard hexagonal nut without plastic in-
Always follow the manufacturer’s instructions for use
sert. Reduce the torque by 25% for screw size 8 mm
regarding temperature range, curing time and any oth-
or larger. Where Nylock® nuts are higher, where the
er instructions for the product.
metallic thread is of the same height as a standard
hexagonal nut, the torques given in the as shown in Two different basic types of agent are used on the
table apply. engine. These are:
RTV preparations (Room Temperature Vulcanizing).
Used for gaskets, sealing gasket joints or coating
gaskets. RTV is visible when a part has been disas-
sembled; old RTV must be removed before resealing
the joint.
Strength Classes The following RTV agents are mentioned in the Work-
shop Manual: Loctite® 574, Permatex® No. 3, Perma-
Screws and nuts are sub-divided into different tex® No 77. Old sealant can be removed using denatu-
strength classes. Classification is indicated by mar- red alcohol in all cases.
kings on the screw head. A higher number indicates a Anaerobic agents. These agents cure in the absence
material with greater strength. For example, a bolt of air. They are used when two solid parts, for ex-
marked 10-9 indicates a higher strength than one mar- ample cast components, are installed face-to-face wit-
ked 8-8. It is therefore important that bolts removed hout a gasket. Common uses are also to lock and
during the disassembly of a bolted joint must be seal plugs, stud threads, taps, oil pressure monitors
reinstalled in their original position when assembling etc. Hardened anaerobic preparations are glassy and
the joint. If a screw must be replaced, check in the for this reason, the preparations are colored to make
spare parts catalogue to make sure the correct screw them visible. Hardened anaerobic preparations are
is used. highly resistant to solvents, and old compound can
not be removed. When reinstalling the part, degrease
it carefully and then apply new sealant.
The following anaerobic agents are mentioned in the
Workshop Manual: Loctite® 572 (white), Loctite® 241
(blue).
NOTE: Loctite® is a registered trademark of Loctite Corporation,

Permatex® is a registered trademark of the Permatex Corporation.
7
Repair Instructions Group 20
Safety rules for • Always use gloves made of chloroprene rubber
Fluorocarbon rubber
(gloves for handling chemicals) and protective
goggles.
Fluorocarbon rubber is a common material in sealing • Handle the removed seal in the same way as cor-
rings for shafts, and in O-rings, for example. rosive acid. All residue, including ash, can be high-
When fluorocarbon rubber is subjected to high ly corrosive. Never use compressed air to blow
temperatures (above 300 °C), hydrofluoric acid can anything clean.
be formed, which is highly corrosive. Contact with the • Put the remains in a plastic container, seal it and
skin can result in severe chemical burns. Splashes in apply a warning label. Wash the gloves under run-
your eyes can result in severe chemical burns. If you ning water before removing them.
breathe in the fumes, your lungs can be permanently
damaged. The following seals are most probably made from fluo-
rocarbon rubber:
WARNING! Be very careful when working on
Seal rings for crankshafts, camshafts, countershafts.
engines which have been exposed to high
temperatures, e.g. overheating during a fire. Se- O-rings, regardless of where they are installed. O-
als must never be cut with an oxy-acetylene rings for cylinder liner sealing are almost always made
torch, or be burned up afterwards in an uncon- of fluorocarbon rubber.
trolled manner.
Note that seals which have not been subjected to
high temperature can be handled normally.
8
Group 20 Special Tools
Special Tools
The following special tools are used when working on the engine. The tools can be ordered from AB Volvo Penta by speci-
fying the number shown.
999 0124 999 0145 (660) 999 0192 999 1821
999 2000 999 6394 1) 999 6395 1) 999 6398
999 6400 999 6645 999 6666 999 6845
1) Sold individually
Tool Designation – use
999 0124 Banjo nipple, used together with 9996398 999 6395 Support leg, for 999 6645
999 0145 Piston ring compressor, installation of 999 6398 Manometer
pistons in block (660) 999 6400 Puller
999 1821 Extractor, removal of roller lifter 999 6645 Puller, for cylinder liner
999 2000 Standard handle 999 6666 Nipple, used together with 999 6398
999 0192 Extractor 999 6845 Pressure testing clamp, for lube oil cooler
999 6394 Support, for 999 6645
9
Special Tools Group 20
888 00050 888 00070 888 00129 999 8676
999 8678 888 20025 888 20026 888 20027
999 8511 999 8681 999 8687 (750/760) 999 8694
999 9179 11 668 400 (650/660) 11 668 401 (650/660) 11 668 402
88820043 (750/760) 11 668 406 (750/760)
88800050 Engine fixture, for mounting stand 999 6485 999 8681 Cranking tool, flywheel. Attach 4 M10-nuts
88800070 Wrench (17mm), supply pipe 999 8687 piston ring compressor, installation of
88800083 Piston ring pliers, piston rings pistons in block (TAD750/760)
88800129 Press tool, cylinder liner (TAD750/760) 999 8694 Adapter, for compression test
88820025 Tool, for glowplug 999 9179 Filter extractor, remove filter
88820026 Gauge, check of upper piston ring 11 668 400 Install/removal tool, front
88820027 Press tool, cylinder liner (TAD660) crankshaft seal (TAD650/660)
999 8511 Lever, removal/install injector 11 668 401 Install/removal tool, rear
999 8676 Cranking tool, crankshaft crankshaft seal (TAD650/660)
999 8678 Gauge rod, with spacing washers for 11 668 402 Installtion tool, camshaft bearing
determining cylinder head gasket 11 668 406 Install/removal tool, rear
88820043 Install/removal tool, front crankshaft seal (TAD750/760)
crankshaft seal (TAD750/760)
10
Group 20 Special Tools
Other special equipment
998 5423 998 5468 998 6485 8889 0080
998 8539 998 9876 999 8494
998 5423 Piston ring tool, remove/install piston rings 998 8539 Compression tester
998 5468 Valve spring compressor, remove/install 998 9876 Dial indicator
valve collet 999 8494 Hose
998 6485 Rotatable assembly fixture for engines
88890080 Pressure meter, check fuel pressure
Other special equipment
885 510 885 633 885 509 942 352 167 8297
885 510 Plug, fuel delivery pipe (kit)

885 633 Torque multiplier
885 509 Torx tool (E20)
942 352 Plug, pressure testing of oil cooler (750/760)
167 8297 Spacer, check of lube oil pressure. Used
together with 969 299
11
Description of engine Group 20
Description of engine
Engine plate placement
Each engine is supplied with two identification plates,
of which one is mounted on the right side of the cylin-
der block.
The other engine plate is located upon the valve cover.
Engine plate
1. Engine model 7. Rated power, standard (peak power according to
2. Engine specification number Tier III)
3. Engine serial number (10 digit) 8. Air temperature in °C (°F), in accordance with
4. Engine stall power, without fan ISO 3046
5. Engine rpm 9. Altitude above mean sea level, in accordance with
6. Engine code (linked to EPA/EU Tier III approval) ISO 3046
10. EU Tier III, approval number
12
Group 20 Description of engine
Engine serial number

Engine serial number is stamped on the engine block
and on the product plate. The serial number comprises
10 numbers. Only the last eight numbers are stamped
on the block.
Cylinder numbering
A = flywheel
13
Engine, component placement
TAD650/660VE
1. Oil filler cap

2. Inlet, after charge air cooler
3. Lifting lug
4. Alternator
5. Fan hub
6. Fuel pump
7. Drive gear, crankshaft
8. Drive belt
9. Tensioner pulley
10. Coolant pump
11. Oil filter
12. Drain plug, oil pan
13. Dipstick
14. Oil Cooler
15. Fuel filter
16. Outlet for hydraulic pump or super-
charger (optional)
17. Oil filler (option)
18. Electrical connection for EMS 2
19. Crankcase ventilation, (sealed crank-
case ventilation optional)
20. High pressure pumps
21. Common Rail unit, with safety valve
and rail pressure sensor
22. Injector
23. Crankcase breather
24. Inlet pipe
25. Solenoid valve for EGR
26. Flywheel housing
27. Oil pan
28. Guard for starter motor
29. Oil pipe, from turbo
30. Turbo
31. Charge air to cooler
32. Coolant inlet, to engine
33. Coolant outlet, from thermostat housing
34. Exhaust manifold
35. Valve cover
14
TAD750/760VE
1. Inlet, after charge air cooler

2. Oil filler
3. Lifting lug
4. Alternator
5. Coolant pump
6. Oil filter
7. Fuel filter
8. Oil pan
9. Dipstick
10. Oil drain plug
11. Return oil, from separator
12. Engine mounting
13. Flywheel housing
14. Electrical connection for EMS 2
15. High pressure pumps
16. Common Rail unit, with safety
valve and rail pressure sensor
17. Crankcase breather
18. Injector
19. Turbo
20. Exhaust manifold
21. Starter motor
22. Lube oil pipe, to turbo
23. Cooling system, draining
24. Coolant inlet
25. Drive belt
26. Fan (optional)
27. Tensioner pulley
28. Coolant filling
29. Air bleed screw
30. Coolant from engine to radia-
tor, after thermostat
31. Pre-heating of air, after inter-
cooler (optional)
32. Fuel pump
15
Location of sensors
Note! Location can differ, depending on engine model.
1. Speed sensor, camshaft

2. Connection, EMS 2
3. Solenoid controlled proportional
valve, high pressure pump – fuel
(MPROP)
4. Fuel pressure
5. Fuel pressure in distributor manifold
6. Pre-heating (optional)
7. Oil pressure sensor
8. Charge air pressure and temperature
(optional)
9. Solenoid valve, EGR
10. Coolant temperature
11. RPM sensor, crankshaft
12. Water in fuel (not shown, mounted
on primary fuel filter)
16
EMS 2
EMS 2 (Engine Management System) is an electronic system with CAN communication (Controller Area Network) for
diesel engine control. The system has been developed by Volvo and includes fuel control and diagnostic function.
Summary Fuel control

The system comprises, amongst other things, of a The engine fuel requirement is analyzed up to 100 times
control unit, sensors and injectors. The sensors send per second. The amount of fuel injected into the engine
input signals to the control unit, which in turn controls and the injection advance are fully electronically con-
the injectors. trolled, via fuel valves and the unit injectors.
The information from the sensors give exact data This means that the engine always receives the cor-
about prevailing operating conditions and allows the rect volume of fuel in all operating conditions, which
processor in the control module to, among other offers lower fuel consumption, minimal exhaust emis-
things, calculate correct injection amount, injection sions etc.
timing and check the engine’s condition.
Diagnostic function
Input signals The task of the diagnostic function is to discover and
The control unit receives input signals about engine localize any malfunctions in the EMS 2 system, to
operating conditions from the following components: protect the engine and to inform about any problems
that occur.
– coolant temperature sensor
If a malfunction is discovered, this is announced by
– charge air pressure and temperature sensor warning lamps, a flashing diagnostic lamp or in plain
language on the instrument panel, depending on the
– speed sensor, camshaft equipment used. If a fault code is obtained as a flash-
ing code or in plain language, this is used for guidance
– speed sensor, flywheel
in any fault tracing. Fault codes can also be read by
– coolant level sensor Volvo’s VODIA tool at authorized Volvo Penta work-
shops.
– oil pressure sensor
If there is a serious malfunction, the engine will be
– fuel pressure sensor shut down altogether, or the control unit will reduce
the power delivered (depending on application). Once
– water in fuel indicator again, a fault code is set for guidance in any fault
tracing.
– fuel pressure in distributor manifold
Output signals
Based on the input signals the control module controls
the following components:
– unit injectors
– starter motor
– main relay
– pre-heating relay
– solenoid valve, EGR
– MPROP, high pressure fuel pump
17
Engine models
Three different cylinder types Fixed or selectable, internal EGR

The two six liter engines 650 and 660, have different There are two different types of EGR (fixed or select-
cylinder volumes. This is due to the 660 having dry able), both are internal.
cylinder liners (2), which are pressed into the cylinder
block. The fixed version (fixcam) has an extra lobe on the
exhaust camshaft to open the exhaust valve slightly
Different solutions have been used when it comes to during the inlet phase. This causes a small amount of
the cylinder liners. The 650 has no cylinder liners, the exhaust gas to enter the combustion chamber and
cylinder bore is machined directly in the cylinder improve the emission level.
block (3).
The system is always active and cannot be shut off.
The 660 has dry cylinder liners that are mounted in
the machined and honed cylinder block. Due to this, The selectable EGR consists of a hydraulic system
the cylinder volume is about 0.3 liter less. where engine oil is used to control the exhaust valves
via an extra rocker arm in the cylinder head. The
The 750 and 760 have wet cylinder liners (1), with a system can be turned off or on via a solenoid valve in
cooling mantel directly around the liner. the oil feed channel.
18
Cylinder Block
Cylinder block and crankshaft

The cylinder block is manufactured in one piece from Removable thrust washers are fitted to main bearing
cast iron alloy. no. 2. Oversizes are available.
The timing gears are located at the rear of the engine. Oversize big end bearings are also available.
The cylinders are numbered from the flywheel/timing Versions without cylinder liners can be machined to
gear end with cylinder 1 at the flywheel and cylinder 6 oversize.
at the front of the engine.
Versions with cylinder liners can have new liner kits
The crankshaft is manufactured from forged steel and fitted.
is re-grindable. Oversize bearings are available as
spare parts.
19
Fuel System
1. Fuel tank 8. Fuel pump

2. Manual pump (accessory) 9. Fuel delivery pipe
3. Fuel feed pump line 10. Injectors
4. Fuel feed pump 11. Control valve “M-plug”
5. Fuel filter 12. By-pass valve
6. Line to fuel filter 13. Return line to fuel tank. A = Fuel pipe,
7. Common Rail unit min distance 300 mm.
20
Cooling System
1. Radiator 4. Circulation pump

2. Thermostat 5. Oil Cooler
3. Expansion tank
21
Technical data Group 20
Technical data
See also separate Workshop Manual, Technical data.
Engine
Type designation TAD650VE TAD660VE TAD750VE TAD760VE
Power Please refer to the sales literature
Torque Please refer to the sales literature
No. of cylinders 6 6 6 6
Bore 101 98 108 108
Stroke (mm/inch) 126 126 130 130
Cylinder volume, dm3 6.07 5.70 7.15 7.15
Weight*, app. (kg/lb) 565 565 650 650
Weight*, wet (kg/lb) 585 585 681 681
Firing order 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
Compression-
ratio 18.4:1 18.4:1 18:1 18:1
Low idle, rpm 600-800 600-800 600-800 600-800
High idle, rpm 2400 2400 2400 2400
* only engine, excluding cooling system
22
Group 20 Technical data
Coolant
Volvo Penta anti-freeze, mixed 40/60 % with water. See specification below
Water specification:
To avoid any risk of clogging the cooling system, coolant should be mixed with pure water per ASTM D4985.
If there is any doubt about water purity, use distilled water or premixed coolant.
Lubrication
Lube oil pump ....................................................... Gear driven
Oil SAE ................................................................. 15W 40
Oil temperature in oil pan ...................................... Normal 80°C Max. 125 °C
Oil pressure at rated rpm:

TD650/660VE ....................................................... 450 kPa
TAD750/760VE ...................................................... 450 kPa
Adjustment, oil pressure monitor ........................... 50 kPa
Oil volume, including filter:

TAD650/660VE (standard oil pan) ............................... 15.5 Liter
TAD650/660 (optional oil pan) ..................................... 19.5 Liter
TAD750/760VE (standard oil pan) ............................... 21.5 Liter
TAD750/760VE (optional oil pan) ................................ 17.5 Liter
Torque sequence for cylinder head bolts

Inlet pipe side:
NOTE: Cylinder head bolts can only be re-used five times.
Tightening torque, TAD650/660VE

Stage 1 .................................................................. 30 Nm
Stage 2 .................................................................. 80 Nm
Stage 3 .................................................................. 90° angle tightening
Tightening torque, TAD750/760VE

Stage 1 .................................................................. 50 Nm
Stage 2 .................................................................. 130 Nm
Stage 3 .................................................................. 90° angle tightening
23
Technical data Group 20
Tightening torque
Torque applies to oiled screws and nuts. Degreased (washed) parts should be oiled prior to assembly.
Special torques Nm/angle tightening
Group 21 Engine
Engine mount ......................................................... 260
Starter motor .......................................................... 70
Transmission gear casing ...................................... 21 (±2)
Main bearing
NOTE: Bolts for main bearing caps can only be re-used three times.
TAD650VE-TAD660VE:
Stage 1 .................................................................. 50
Stage 2 .................................................................. angle tighten 90°
TAD750VE-TAD760VE:
Stage 1 .................................................................. 50
Big-end bearings
NOTE: New bolts for each installation.
Stage 1 .................................................................. 30
Flywheel
A) Flywheel with 30 mm long bolts
Stage 1: ................................................................. 20-30
Stage 2: ................................................................. angle tighten 60°
B) Flywheel with bolts between 35 and 45 mm long
Stage 1: ................................................................. 20-30
C) Flywheel with bolts between 50 and 85 mm long
Stage 1: ................................................................. 30-40
Flywheel casing
M12 ....................................................................... 99 (±10)
M16 ....................................................................... 243 (±25)
Cylinder head
See previous page
Pulley
NOTE: Bolts for the belt pulley shall be replaced when they have been re-used three times.
Stage 1: ................................................................. 45 (±5)
Oscillation damper ................................................. 70
24
Group 20 Technical data
Nm/angle tightening
Valve cover
Bolt, valve cover...................................................... 13
Rocker arm, locknut................................................. 30
Crankcase ventilation bolt....................................... 9 (±1)
Group 22 Lubrication System

Oil cooler, retaining bolts......................................... 30
Oil cooler plugs (750/760)....................................... 80
Front casing/oil pump case...................................... 30
Oil suction pipe........................................................ 30
Oil pan..................................................................... 30
Oil pressure monitor................................................ 18 (±2)
Oil pressure pipe, turbo........................................... 39
Oil return pipe, turbo................................................ 20
Group 23 Fuel System

Injector yoke............................................................ 16 (+5)
Fuel inlet pipe.......................................................... 22 (±2)
Fuel outlet pipe........................................................ 22 (±2)
Fuel pump
Stage 1: .................................................................. 10
Stage 2: .................................................................. 50
Common Rail, complete unit................................... 30
Common Rail, fuel hose.......................................... 39
Common Rail, safety valve...................................... 100
Common Rail, rail pressure sensor......................... 70
Delivery pipes
NOTE: Replace with new delivery pipes after each disassembly.
Fuel delivery pipe....................................................... 25 (±3.5)
Group 25 Inlet and Exhaust System

IEGR, bridge............................................................ 30
IEGR, solenoid valve............................................... 24
Inlet pipe.................................................................. 13
Exhaust manifold..................................................... 25 (±2.5)
Turbocharger (to exhaust manifold)......................... 42
Group 26 Cooling System

Thermostat housing................................................. 30
Temperature sensor................................................. 21 (±2)
Coolant pump.......................................................... 21 (±2)
Air compressor
Knorr compressor LK39.
1 ............................................................................. 30
2 ............................................................................. 22
3 ............................................................................. 200
25
Checks and adjustments Group 20
Checks and adjustments
Compression test
(Operation number 21035)
Special tools:
Adapter for compression test ...................... 999 8694
Compression gauge .................................... 998 8539
Injectors have been removed.

Valve clearance has been checked
1. Undo electrical connection, from “M-plug”.
2. Fit adapter (1), 999 8694.
3. Use existing injector holder (2).
Tighten the bolt (3) to ........................... 16+5 Nm
4. Connect compression tester, 998 8539. Crank the

engine with the starter motor.
Compression: ...................................... 30-38 bar
NOTE: The measured compression is dependant on

the starter motor rpm during the measurement pro-
cess and on the ambient air pressure.
It is difficult to indicate exact limit values due to the in-
fluence of ambient air pressure. We recommend that
the measurement of compression pressure is used to
compare the compression pressure in the cylinders of
one engine. If the pressure difference exceeds 15 %,
the cylinder in question should be disassembled to
No.
Kompression in bar determine the cause.
Compression value in bar
Pression en bar
Dat. ± ± ± ± ± ± ± ±
Install the injector with a new copper washer.
10 15 20 25 30 35 40 45
5.
Zyl.
Install a new fuel delivery pipe.

1
2
3
4
Tighten the injector to: ........................... 16+5 Nm
5
6
Tighten the fuel delivery pipe in two stages, with
7 5 and then 25+3.5 Nm.
8 Best.Nr.51341 250 00
DBGM MADE IN GERMANY
MOTOMETER 7250 Leonberg Connec the cable, to “M-plug”.

Install the protective cover and clamp the cabling.
26
Group 20 Checks and adjustments
Lubricating oil pressure

Special tools:
Pressure gauge ........................................... 999 6398
Nipple ......................................................... 999 6666
Nipple ......................................................... 999 0124
Spacer ............................................ part no. 1678297
Lube oil pressure, check

1. Measure the lubricating oil pressure, as illus-
trated, with pressure gauge together with nipple
and spacer.
Min oil pressure when hot at idle:
650/660, 750/760: ...................... 80 kPa (0.8 bar)
At rated rpm, see Technical Data.
Fuel pressure
Special tools: ............................................ 8889 0080
Fuel pressure, check

(From high pressure pumps “common rail”)
1. Clean all fuel pipes, pumps and rails.

Remove pipe between pumps and rail (2 pcs).
Connect pressuregauge (8889 0080) with two

hoses, between one of pumps (1) and the rail (2)
(nipples needed on the rail and on pump).
Plug the open connection (3) of the rail, but with the
plug which is for teh pressure gauge (adapter
needed for plug).
Fit a pipe “leak pipe” (4) on the pump that is not be-
ing tested. Connect a hose and feed it to a vessel.
Crank the engine with the starter motor and purge
the measurement equipment.
Crank the engine with thestarter motor or start the

engine and read off pressure.
2. Move the pressure testing equipment to the other

high pressure pump and repeat the same test on this
pump.
Compare the results to determine if either of the

pumps are defective.
27
Disassembly, complete engine Group 21
Exposing the engine
1. Loosen all cable harnesses and junction boxes.

Mark as needed.
Drain the engine oil.
Remove the plug (arrow) to drain the coolant.
Drain and collect remaining oil and coolant and
discard these per applicable environmental regula-
tions.
TAD650/660VE
2. Replace the drain plugs.
TAD750/760VE
2. Undo the belt tensioner and lock it with a drift (1).
3. Remove:
- the belt from the coolant pump (1)
- alternator/fuel pump, incl fixture
- coolant housing complete, with circulation
pump and thermostat.
28
Group 21 Disassembly, complete engine
Installing fixture
Special tools:
Engine fixture ............................................. 888 00050
Assembly stand .......................................... 998 6485
Protective plugs (kit) ..................................... 885 510
1. Remove:
(- exhaust pipe)
(- air cleaner)
(- charge air pipe)
Remove pressure pipe (2) and return pipe (1) from
the turbocharger. Fit protective plugs (885 510) to
the turbocharger connections.
2. Remove the turbocharger, complete with exhaust

manifold.
NOTE: Use lubricant on the exhaust manifold nuts.
3. Fit protective plugs (1) in connections for the re-

turn pipe and delivery pipe.
29
4. Fit engine fixture 888 00050 (1) on the engine and

torque to 25 Nm.
NOTE: Use enclosed bolts. They are stronger than

standard bolts.
Attach the engine to the rotatable assembly
stand 998 6485.
30
Disassembly, complete engine
Cylinder head, removal
1. Remove the exhaust manifold (if not already

done).
Remove the valve cover

2. Undo the cabling from the protective cover (1) and
then remove the protective cover.
Undo the crankcase ventilation hoses.
NOTE: Clean between the valve cover and inlet pipe.
Remove the valve cover (2).
Remove the Common Rail unit

3. Remove the fuel delivery pipes, use specia
tool 888 000 70.
Undo the fuel hose connections.
Remove the connector from the rail pressure sen-
sor (1).
Remove the connector from the “M-plug” (2).
Remove the Common rail unit (3).
NOTE: Plug all connections to exclude dirt.
Remove the injector connection cables, fixing

clamps and injectors (4). Us the lever 999 8511,
to remove the injectors.
NOTE: Be careful not to damage the glowplugs.
31
Remove the two sections of the IEGR unit

4. Remov the bolts (1) from the IEGR-unit (2) for cyl-
inders 4-6, in the direction of the arrow.
Remove the IEGR unit for cylinders 1-3 (in the
same way), including the small oil pipe (3).
5. Remove:
- glowplug
- cable, from temperature sensor
- temperature sensor (650/660)
- plug (1)
- solenoid valve (22 mm thin open wrench)
Remove the inlet pipe

6. Remove:
- any heat shield
- pressure sensor cable, from inlet pipe
- hose and pipe to charge air cooler
- the air connection, on the inlet pipe (1)
- inlet pipe bolts
Lift off the inlet pipe (2).
32
Remove the rocker arm bridges with rocker arms

7. Mark the rocker arm bridges (1).
Remove the rocker arm bridges (torx E14) with
rocker arms, and then remove the pushrods.
8. Remove the cylinder head bolts, use Torx socket

E14 for 650/660 and E18 for 750/760.
9. Connect straps to the lifting eyes and lift cylinder

head to remove it.
33
Oil cooler, oil filter and oil filter housing,

removal (650/660)
750/760: See method, page 109
10. Remove retaining bolts (7 pcs) and remove the oil

cooler.
NOTE: The oil cooler flanges are sensitive to shocks.
11. Remove retaining bolts (8 pcs) and remove oil fil-

ter and oil cooler housing.
12. Remove the coolant housing (1) with connecting

pipe (2).
34
13. Remove the starter motor.
14. Remove:
- the cable from the control valve’s “M-plug” (1)
- feed pipe (2)
- return line (3)
- feed line, from fuel filter (4)
Fuel pump, removal

15. Undo bolts (1) alternately and remove the fuel
pump (2).
NOTE: Turn the crankshaft (tool 999 8681), until fuel
flows from the pump which is not being removed. The
fuel pump that is to be removed is not under load.
16. Remove the roller lifter from the fuel pump.

Use tool 999 1821.
35
17. Pull the dipstick out.
18. Turn the engine 180 degrees. Remove the oil pan.
NOTE: The oil pan is installed using liquid gasket and

can therefore be difficult to remove. Tap in a gasket
scraper of use the lever 999 8511.
19. Remove the oil suction pipe.
20. Remove the belt pulley and oscillation damper.
Use torx tool E20 and counterhold 999 8681.
36
21. Remove oil pump/front casing.
22. Remove the engine speed sensor from the

flywheel housing.
Turn the engine 90°.
Remove the plastic plugs between every other
bolt that lock the flywheel bolts.
Remove the bolts on the flywheel.
Use tool 999 8681 as counterhold.
23. Secure lifting eyes M12 and strap. Use three lift-
ing eyes (1), to balance the lift.
Lift the flywheel away.
WARNING! Be carefull when removing the fly-
wheel (the flywheel is heavy).
24. Remove the flywheel casing.

Use torx tools E20 and E14.
37
25. Remove timing gear casing.
Pistons, connecting rods, removal

26. Check/mark the conrod caps and undo the bolts.
Remove caps with bearing halves.
Keep track of bearing halves.
27. Remove Pistons, complete with connecting rod.

Measure the cylinders before undoing the main
bearings.
IMPORTANT! Replace the bearing cap on the

conrod to avoid damaging the split surface,
which is very sensitive.
NOTE: Check and note the markings on pistons and

conrods with regard to the crankshaft symbol.
38
28. Turn the engine 90°.

0
80
70
90
10
20
Set the dial gauge to 98 mm, or 101/108 mm.
60 30
50 40
29. Check that the liner is free from cracks or other

damage. Measure cylinder ID.
Measure at three depths (longitudonal- trans-
verse).
TAD650VE:
Diameter ...................................... 101 +0.02 mm
Wear limit ........................................... 101.1 mm
TAD660VE:
Diameter ........................................ 98 +0.02 mm
Wear limit ............................................. 98.1 mm
TAD750/760VE:
Diameter ...................................... 108 +0.02 mm
Wear limit ........................................... 108.1 mm
Crankshaft
30. Turn the engine so that the crankshaft faces up.
Check that the camshaft’s and the crankshaft’s
drives are marked.
31. Check that the main bearing caps are marked

(otherwise mark them). Remove the fixing bolts
and remove the bearing caps and shell halves.
Use torque multiplier 885 633 if necessary, to-

gether with counterhold 885 648.
39
32. Remove thrust washers (1) at main bearing num-

ber 2.
33. Lift the crankshaft out of the engine block.
NOTE: The crankshaft is heavy (about 75 kg). Use a

soft lifting strop to lift it out.
34. Remove the bearing shells and thrust bearings on

main bearing no. 2.
NOTE: Mark main bearing halves if they are to be re-

used.
35. Press out piston cooling nozzle.
40
36. Remove the camshaft.
NOTE: Remove the camshaft carefully, taking care

not to damage the bearings.
37. Remove valve lifters and mark them if they are to

be reused.
660 and 750/760 engines only:

38. Remove cylinder liner.
NOTE: Mark the liners if they are to be re-used.
660:
Use plate 999 0144 together with cylinder liner
puller 999 6645 with support legs
999 6394/999 6395.
750/760:
Use plate 999 8675 together with cylinder liner
puller 999 6645 with support legs
999 6394/999 6395.
41
Assembly, complete engine Group 21
Assembly, complete engine
Cylinder liner, installtion

(660 and 750/760 only)
1. Make sure that cylinder liner (2) and cylinder liner
seat in the engineblock are clean and add a thin
film of oil.
2. Tap in the liner using tool (1) 999 8675 for 750/760
and tool 999 0144 for 660, or use the cylinder
head and tool (3,4) 9996645 as illustrated.
NOTE: Measurement of the cylinder liner position and

cylinder liner must be done before installation, accord-
ing to chapter “checking and measurement”.
3. Turn the nut and press the liner down. Check that
the cylinderliner collar meets the base.
Fit the press tool, to hold the liner in place when
inserting the piston later on:
TAD660VE: ........................................ 8882 0027
TAD750/760VE: ................................. 8880 0129
Piston cooling nozzles

4. Check that the oil channels are not clogged.
Secure piston cooling nozzles in the correct posi-
tions in the engine block. Push in the piston cool-
ing nozzles as far as they go.
42
Group 21 Assembly, complete engine
Camshaft
5. Fit valve lifters, lightly oiled.
6. Insert the camshaft.

NOTE: Fit the camshaft, taking care not to damage
the bearings.
7. Fit the bearing shells in the engine block and oil

the bearings.
8. Mark the crankshaft as needed (to facilitate refit-

ting).
43
9. Mark the camshaft as needed and place it in the

right position.
Crankshaft, assembly
10. Insert the crankshaft. The marks must be lined
up. Use a ruler to check that the marks are lined
up through the crankshaft and camshaft centers.
11. Insert the thrust bearing halves without pins.
NOTE: The thrust washer wearing surface (with two

grooves) must point towards the crankshaft.
12. Secure the half thrust washers with pins on the

thrust bearing caps (using a bit of grease on the
pin).
The thrust washers’ bearing races must be aimed
towards the crankshaft.
44
13. Fit the bearing shells in the bearing caps and oil
them.
14. Install the mainbearing caps, according to mark-

ings.
NOTE: The main bearing caps are marked 1-7.

Bearing cap 1 closest to the flywheel.
15. Make sure that the thrust washers on the cap fits
against the washers in the block.
16. Tighten the main bearing cap screws as shown

below.
TAD650VE, TAD660VE:
Initial torque: ............................................ 50 Nm
1st torque angle ............................................. 90°
2nd torque angle ............................................ 90°
TAD750VE, TAD760VE:
1st torque angle ............................................. 60°
2nd torque angle ............................................ 60°
NOTE: The bolts may be used 3 times if you can show

how many times they have been stretched. (Mark them
with a punch for each subsequent stretching.)
45
17 Place dial indicator (3) with magnet base (2).

Bend with a lever (1) and check the axial clear-
ance of the crankshaft.
Clearance allowed: 0.1-0.3 mm.
Piston and connecting rod, assembling

18. Fit one of the snap clips in the groove in the piston.
IMPORTANT! The snap ring gap should be

turned towards the piston crown.
19. Fit the connecting rod in the piston with guide pins
(1) turned towards the side with the flywheel sym-
bol on the piston or per previous installation.
Press in the piston pin.
Check that the connecting rod can be pushed
sideways on the piston pin.
NOTE: Only 750/760 have guide pins.
46
Pistons and connecting rods, installation

20. Fit the bearing shells on the connecting rods and
oil them.
21. Install the piston rings. Position the piston ring

gaps at 120° offset.
22. Use piston ring compressor and fit pistons with

connecting rods from the cylinder head side. The
flywheel symbol should be turned toward the fly-
wheel side.
650: Piston ring compressor xxx xxxx

660: Piston ring compressor 999 0145
750/760: Piston ring compressor 999 8687
23. Oil big end bearing journals on the crankshaft.

Press theconnecting rod against the bearing jour-
nal and fit bearing caps per marking.
Fit new bolts and tighten them.
Initial torque: ........................................... 30 Nm
1st torque angle: ............................................ 60°
2nd torque angle: ........................................... 30°
NOTE: Check that the crankshaft can turn freely.
47
Timing gear casing, installation

24. Remove remnants of gasket from the timing gear
casing and engine block.
25. Apply gasket compound (1161 231 or 1161 277 –
you can also use 840 879) on timing gear casing
sealing surface.
1161 231 = Large tube
1161 277 = Small tube
840 879 = Flange seal
NOTE: Excess gasket compound must not be pulled

away. It must be cut off.
26. Fit timing gear casing without tightening the bolts.

Place the casing aligned with the oil pan sealing
surface.
Tighten the bolts to: ................................. 21 Nm
27. Check position on the wear groove (1) on the

crankshaft.
28. Oil and fit the crankshaft seal to the crankshaft

with the felt sideside out. Fit the guide (inner part
of assembly tool 11 668 401, for 650/660).
48
29. Fit any washers (1), press sleeve (2), the bearing
(3) and nut (4). Use the number of washers
needed so that the new crankshaft seal does not
end up in the same position as the old.
30. Turn the nut until it stops. Check that the seal is
positioned correctly.
Front casing with oil pump, refitting

31. Turn the engine in assembly stand so that the
front gable faces up.
32. Clean the casing and engine block from gasket
residue, and remove the crankshaft seal from the
casing.
33. Lightly oil the oil pump rotors.
34. Place the gasket on the engine block. Align it

against the guide sleeves.
35. Fit the casing with the oil pump. Make sure that
the oil pump drive fits against the crankshaft.
Note! Will fit in one position only.
Refit the bolts without tightening them.
49
36. Fit the casing to the oil pan sealing surface.

Tighten the screws and cut off excess gasket.
Tightening torque: ..................................... 21 Nm
37. Check position of the wear groove (1) on the

crankshaft.
38. Oil and fit the crankshaft seal (1) with the feltside
out on the crank shaft. Fit the guide (2) (inner part
of assembly tool (11 668 400) for 650/660.
50
41. Fit the guide sleeve (2) and any guide pins (1) to
the crankshaft.
Oil suction pipe/oil pan

42. Install the oil suction pipe with a new gasket.
43. Tighten the oil suction pipe onto the oil pump
housing.
Tighten to ................................................ 30 Nm.
44. Cut off excess gasket from front the casing/oil

pump.
Fill the oil pan sealing surface joints with silicone
(item no: 1161231 large tube or 1161277 small
tube).
45. Place the new gasket correctly on the engine

block.
NOTE: The gasket consists of 4 parts.
51
46. Fill depressions in the gasket with silicone

(item no 1161231).
47. Fit the oil pan.

Tighten to ........................................... 21 ±2 Nm.
48. Lift the flywheel into position and tighten the

bolts by hand.
WARNING! The flywheel is heavy
49. Fit the flywheel casing. Check that the guide

sleeves are in the right position.
Tighten the bolts as below:
M12 bolts: ....................................... 99 ±10 Nm.
M16 bolts: ..................................... 243 ±25 Nm.
(Use torx tools E14 and E20.)
Hold the flywheel using cranking tool 999 8681.
Tighten the bolts per specification below:
1st torque angle:
bolts M10x1x45 ........................................... 60°
2nd torque angle:
bolts M10x1x45 ........................................... 60°
(Use protractor: 885 12)
NOTE: The bolts may be re-used max 5 times. Fit

plastic plugs, that lock the flywheel bolts.
52
50. Fit the cover plate on the flywheel casing.

Install the camshaft sensor.
51. Fit the belt pulley and the vibration damper.

Tighten the bolts as shown below.
NOTE: Counterhold with turning tool 999 8681.
Initial torque: ...................................... 40-50 Nm

1st torque angle: .......................................... 60°
2nd torque angle: ......................................... 60°
Use protractor: 885 11
NOTE: Use torx tool E 20 (885 509).
NOTE: The bolts may be used 5 times.
Determining cylinder head gasket

thickness
52. Cylinder head gaskets are marked (1) with one,
two or three holes in one corner. The gaskets
shall be used with different piston heights above
the engine block top side.
The piston height above the engine block shall
be measured at two points on all pistons.
Cylinder head gasket

53. Determine cylinder head gasket.
Place spacing washers (3) and gauge (1) 999
8678 on the sealing surface on the engine block,
and set the dial indicator (2) to “0”.
53
54. Place the dial indicator on the piston at the mea-

surement points.
Read and note the value on the dial indicator at
the pistons highest position, top dead center.
NOTE: All pistons should be measured at TDC and in

the direction of the piston pin.
NOTE: Pay attention to the measurement points,

since the piston surface is spherical.
55. Compare the highest noted value with the table

below. Decide on the most suitable cylinder head
gasket.
Piston height: Marks on cylinder
head gasket:
TAD650/660
0.33-0.55 mm 1 hole
0.56-0.65 mm 2 holes
0.66-0.76 mm 3 holes
TAD750/760
0.28-0.53 mm 1 hole
0.54-0.63 mm 2 holes
0.64-0.75 mm 3 holes
56. Place the cylinder head gasket with numeralsup-

wards and marking holes toward the flywheel.
NOTE! The sealing surfaces on the cylinder head

and the engine block plane must be clean and free
from oil. Pay attention to the guide sleeves (1).
54
Cylinder head with valve guides

57. Lift the cylinder head into place. Pay attention to
the guidesleeves.
NOTE: The cylinder head screws may be used up to 5

times if you can show how many times they have
been used. (Mark them with a punch for each subse-
quent stretching.)
58. Fit the push rods (1).
59. Oil the cylinder head bolts (1) (M12) and let them
drip off. Fit rocker arm holders with the bolts as
marked. Fit them against the push rods and the
valves and tighten the M10 bolts.
Tightening torque: 21 Nm.
60. Lightly oil the rest of the cylinder head bolts and
fit them. Tighten them in three steps, pay atten-
tion to the order.
Initial torque: 30 Nm.
2nd torque: 80 Nm.
Final torque: 90°.
55
61. Adjust the valve clearances, see “Valve clear-

ance, checking/adjustment” in the chapter on
Component repair.
Remove the cranking tool.
Install the glowplugs.
Injectors and fuel lines, refitting

62. Install a new O-ring (1) and a new copper seal
(2), on the injector.
63. Install the injector.

NOTE: Ensure that the cylinder head is clean.
64. Install the injector holder (loosely).
56
65. Connect the cables (1, 2), to the injectors.
66. Install new fuel delivery pipes (tool 888 00070)

and tighten in two stages:
1. Tighten to ............................................... 5 Nm
2. Tighten to ............................................. 25 Nm
Tighten the injector holder.

Tighten to: ............................................. 16+5 Nm
Exhaust manifold, inlet pipe and valve

cover, installation
67. Fit the manifold (1) with new gaskets. The gas-
ket flange shall point towards the cylinder head.
Use high temperature paste (1161 035) on the
studs and tighten the nuts.
68. Fit air intake pipe (2) with new gaskets and
tighten the bolts.
Install three pre-heater and any ground wire (1).
57
69. Install a new gasket on the valve cover.

NOTE: Make sure the tab (1) on the gasket aligns
properly.
Install the valve cover and tighten the bolts.

Oil trap, refitting

70. Fit a new gasket (1) in the oil trap groove.
71. Fit the oil trap connection to the oil pipe (1).
72. Screw (1) the oil trap to the valve cover.
58
Oil filter housing and oil cooler,

installation (650/660)
750/760: See method, page 109
73. Fit the coolant housing (1) with the connecting
pipe (2).
74. Lubricate the O-ring on the connecting pipe with

soap water (650/660). Fit filter in oil cooler hous-
ing with new gasket. Refit the bolts and tighten
them.
Note! Two bolts with different lengths.
75. Fit the oil cooler and tighten the bolts.

76. Install new O-rings (2 pcs) and apply sealant, to

the circulation pump’s coolant output channel.
59
77. Install the coolant housing. The M8 bolts are

torqued to 21 +2 Nm.
78. Fit the alternator bracket.

Tightening torque: 48 Nm
79. Fit the fuel pump.

Tightening torque: 24 Nm
Fit the fuel lines between the fuel pump and the
fuel filter.
80. Fit the idler pulley complete with bearing block.

Tightening torque: 50 ±8 Nm
60
81. Fit the alternator.

Tightening torque: 50 ±8 Nm
Engine, removal from engine fixture

82. Connect lifting device (1) 999 8547 to the
engine’s lifting eyes.
83. Remove the bolts from the engine fixture (1).

Remove the bolts between assembly stand and
engine fixture (1) 8880 0050 and lift the engine
away.
Remove the engine fixture (1).
Starter motor and turbo unit, refitting

84. Fit the starter motor.
61
85. Remove protection plugs (1) from return pipe and

delivery pipe connections.
86. Install the turbocharger and oil return pipe/oil

pressure pipe, use new gaskets/seals.
Tighten the turbo nuts to: .................... 25 ±2 Nm
Install a new fuel filter, oil filter and air filter.

Fill with engine oil.
After installation:
- Fill with coolant, purge the system.
- Fill with fuel, purge the system.
- Connect all electrical connections.
Check that there are no leaks anywhere.
62
Group 21 Checking and measuring
Checking and measuring
Engine block
Special tools:
Puller for cylinder liner with support ........................... 999 6645, 999 6395
Assembly tool for camshaft bearing .......................... 999 8695
Extractor plate, for cylinder liner ................................ 999 8675
Standard handle ........................................................ 999 2000
1. Remove the screw plugs. Check that the oil chan-

nels are free.
2. Clean the engine block and check that it is not

damaged.
Does not apply to 650 engine

3. Measure with a depth micrometer (1) or use a digi-
tal vernier gauge, the distance between the liner
collar seat to the sealing surface in the engine
block. Measure in several places on each cylinder.
Max depth (660): ........................ 4.38 +0.03 mm
Max depth (750/760): .................. 8.92 +0.03 mm
NOTE: The liner collar height or seat cannot be re-ma-

chined. Replace cylinder liner and engine block when
needed.
63
Checking and measuring Group 21
4. Check the liner collar and measure (with microme-

ter) the liner height, at several places around the
perimeter.
NOTE: Min. collar height, 660: ............. 4.5 -0.02 mm
750/760: .................................................. 9 -0.02 mm
64
Crankshaft, measuring
Main bearing
1. Place the crankshaft in a suitable stand.
2. Diagram for measuring main bearing journals at

the points “1” and “2” in the planes “a” and “b”.
Journal diameter, 650/660: ........ 84.00 -0.02 mm
Journal diameter, 750/760: ........ 85.00 -0.02 mm
Undersize
0.25 mm (650/660): ................... 83.75 -0.02 mm
0.25 mm (750/760): ................... 84.75 -0.02 mm
Wear limit:
Main bearing journal ovality .................. 0.01 mm
Main bearing journal taper ..................... 0.01 mm
Main bearing shells

3. Fit bearing shells in main bearing caps and install
the bearings on the engine.
65
4. Measure main bearing diameter at the points “1”

and “2” in the planes “a” and “b.”
Inner diameter (650/660) Ø ..... 84.03 +0.042 mm
Inner diameter (750/760) Ø ..... 85.03 +0.042 mm
Oversize:
0.25 mm (650/660) ................. 83.78 +0.042 mm
0.25 mm (750/760) ................. 84.78 +0.042 mm
Thrust bearing
Set the (inner) dial gauge to
660/660: ...................................................... 32.2 mm
750/760: ......................................................... 38 mm
5. Measure width of thrust bearing journal.

Journal width (650/660) ............... 32.2 +0.04 mm
Journal width (750/760) .................. 38 +0.04 mm
Oversize ............................................... 0.40 mm
6. Measure the width of the thrust bearing journal
and note as “a”.
Example:
Dimension a = 32.22 mm
7. Fit the half thrust washers on the main bearing

cap. Measure and note the width, dimension “b”.
8. Determine axial clearance.

Example:
Dimension “a” (see previous page) = 32.22 mm
Dimension “b” = 32.10 mm
“a” - “b” = axial clearance = 0.12 mm
Axial clearance allowed = 0.10-0.30 mm
66
9. Measure the big end journals.

Big end journal diameter:
650/660 ................................... 62.994 -0.02 mm
750/760: ......................................... 68 -0.02 mm
Undersize
0.25 mm(650/660) ................... 62.744 -0.02 mm
0.25 mm (750/760): ................. 67.744 -0.02 mm
Wear limit:
Big end journal ovality .......................... 0.01 mm
Big end journal taper ............................. 0.01 mm

10. Check that the crankshaft is straight, Use dial
indicator.
Max throw for middle bearing .................. 0.1 mm
67
Connecting rod, measuring

Connecting rod bushing
80
90
0
10
1. Set dial gauge to (650/660) ...................... 38 mm
70 20
Set dial gauge on (750/760) ..................... 42 mm

60 30
50 40
2. Measure the connecting rod bushing at the points

“1” and “2” in the planes “a” and “b.”
b
Internal diameter of bushing:
650/660 .................................... 38.02 +0.01 mm
750/760 .................................... 42.04 +0.01 mm
Wear limit: ............................................ 0.08 mm

1 2 a
3. If the bushing is outside the wear limit, replace

complete connecting rod.
Big end bearing

4. Make sure that bearing caps fit the connecting rod
so that the number markings are turned towards
each other and identical.
NOTE: Make sure the guide pins are fitted (750/760).
5. Fit the big end bearing cap.

Torque the screws as specified:
68
6. Set dial gauge on (650/660) .................. 66.5 mm

Set dial gauge on (750/760) .................. 72.5 mm
b
7. Measure the big end bearing diameter at the
points “1” and “2” in the planes “a” and “b.”
Big end bearing diameter
1 2 a (650/660) ................................... 66.6 +0.02 mm.
Big end bearing diameter
(750/760) ................................... 72.6 +0.02 mm.
NOTE: If the values measured deviate only slightly,

additional measurements should be performed when
new bearing shells have been installed.
8. Remove the big end bearing cap and fit new bear-
ing shells.
Fit the big end bearing cap.
Torque the screws as specified.

80
90
0
10
70 20
9. Measure the bearing shells at the points “1” and

60 30
50 40
“2” in the planes “a” and “b.”
Big end bearing caps:

Inner diameter Ø (650/660) ... 63.026 +0.039 mm
Inner diameter Ø(750/760) .... 68.026 +0.039 mm
Oversize:
0.25 mm (650/660) ................. 62.724 +0.02 mm
0.25 mm (750/760) ................... 67.78 +0.02 mm
Wear limit:
Radial clearance for big end
bearings ....................................... 0.03-0.09 mm
NOTE: If the readings do not exceed bearing-

tolerances by more than 0.015 mm, the rod can con-
tinue to be used. If the limit value is exceeded, re-
place the connecting rod.
69
If you suspect that a connecting rods is bent

or out of position, check the connecting rods
on the connecting rod tester
NOTE: Check connecting rods without bearing shells.
10. Use a piston pin for measuring the connecting rod

a straightness.
x Tolerance permitted a = 0.05 mm across a dis-
tance (x) of 100 mm.
11. Use a piston pin to measure the connecting rod

twist.
Tolerance permitted a = 0.05 mm across a dis-
tance (x) of 100 mm.
70
Piston
Special tools:
Piston ring tool: .......................................... 8880 0083
Gauge, checking “keystone”: ..................... 8882 0026
1. Remove locking ring. Remove the piston pin.

2. Remove the piston rings with piston ring pliers
8880 0083.
NOTE: Clean and check the piston and piston ring

grooves.
3. Check the piston ring gap (See figure). During the

measurement, the ring will be pushed down below
the lower turning position using a piston. Mea-
sure the ring gap using a feeler gauge.
Max wear limit :
Upper compression ring .......................... 0.8 mm
Lower compression ring .......................... 2.5 mm
Oil ring .................................................. 1.15 mm
4. Clean and check the piston and the ring shaped

grooves in the piston.
Piston ring order and position

5. Install the oil scraper ring.
6. Fit the tapered compression ring with the text
“Top” towards the combustion chamber.
7. Fit the conical compression ring with the text
“Top” towards the combustion chamber.
71
8. Check that the offset between the ring gaps is 120°.
NOTE: The joint on the oil scraper ring inner spring

should be offset 180° relative to the ring gap.
9. Check the upper compression ring “keystone”.

Use gauge 8882 0026, to check if the upper ring
groove is worn.
Upper compression ring ... “keystone” ring (conical

compression ring)
10. Measure the piston ring clearance with a feeler

gauge.
Wear limit:
Lower compression ring ........................ 0.17 mm

Oil scraper ring ..................................... 0.10 mm
11 Check if the piston pin is worn.

Piston pin diameter (650/660) .......... 38 -0.006 mm
Piston pin diameter (750/760) .......... 42 -0.006 mm
72
Assemble connecting rod to piston
1. Place a snap ring in the right position and fit it.
2. Fit the piston to the connecting rod. The flywheel

symbol on the piston and the guide pins (1) on the
conrod (750/760), are most often on the same
side. Check during disassembly.
3. Place the second snap ring in the right position
and fit it.
73
Camshaft
Special tools:
Dial gauge ................................................... 998 9876
Assembly tool for camshaft bearing ............ 999 8695
Camshafts and valve lifters, inspection

Check, using a steel ruler (1), that valve lifter contact
surface facing the camshaft is convex or flat. If the
surface is concave, change the valve lifter.
If the valve lifter is worn across the lift surface, the
lifter should be discarded. “The ditch” shows that the
lifter has not been turning.
A dark line on the outside of the valve lifter shows
that the surface is not worn, on the other hand. The
condition of the valve lifters determines whether it is
necessary to check for camshaft wear.
Check that the lifting surfaces on the camshaft and

valve lifters do not have large pitting damage. Pitting
damage can occur for various reasons. The damage is
caused when small pieces of metal loosen from the
hardened surface. Lifters and camshafts with minor pit-
ting damage can be used. Pitting damage seldom be-
comes worse.
Check that the camshaft’s bearing surfaces and cam
curves are not abnormally worn.
Replace camshaft in case of major damage and wear.
NOTE: When replacing camshaft, all valve lifters

should be replaced too.
74
Guidlines for replacement

In normal conditions, un-evenness may occur on the
camshaft lobes in the engine. This does not mean that
the camshaft has to be changed. These marks do not
have any negative influence on either engine perfor-
mance or durability of the engine and its components.
Examples of acceptable wear and un acceptable wear
are shown below.
Acceptable wear Unacceptable wear

The camshaft does not need to be changed. NOTE: Camshaft with associated rocker arms must be
replaced.
75
Camshaft bearing, Checking
1. Set “the inner” dial gauge:

650/660 ................................................... 63 mm
750/760 ................................................... 65 mm
2. Measure the bearing bushings at the points 1 and

2 in the planes “a” and “b” (see diagram).
Inner diameter (650/660) .............. 63 +0.054 mm
Wear limit (650/660) ........................... 63 08 mm
b
a
Inner diameter (750/760) .............. 65 +0.054 mm
1 2
Wear limit (750/760) ........................... 65.08 mm
Camshaft bearing, Checking
Camshaft bearings, replacing

1. Remove the bearings. They can be pulled out in
either direction.
Use tool:
650/660: ............................................ 11 668 402
750/760: ............................................... 999 8695
76
1. Guide sleeve
2. Bearing bushing
3. Press sleeve
2. Position a new bearing.
NOTE: The oil holes must line up with the oil channels
in the bearing seats.
NOTE: The widest bearing, 27 mm, belongs at the fly-

wheel end.
32 ++0,2
0,5
3. Fit the bearing.

Use tool:
650/660: ............................................ 11 668 402
750/760: ............................................... 999 8695
77
Cylinder Head
Special tools:
Valve spring compressor ............................. 998 5468
Depth vernier gauge .................................... 998 5471
1. Remove valve collet, valve disc, valve spring and

valve with valve spring compressor 998 5468.
2. Remove valve stem seal.
3. Clean the cylinder head and check for damage.
4. Move the valve down a bit so it is not seated.
5. Measure the valve clearance between valve stem

and guide.
Wear limit:
Intake valve .......................................... 0.10 mm
Exhaust valve ...................................... 0.13 mm
NOTE: Measure using a new valve.
78
6. Check the valves and measure them.

A – Valve stem diameter, ∅, standard:
Inlet valve (650/660) ................... 7.98 -0.015 mm
Inlet valve (750/760) ................... 8.98 -0.015 mm
Exhaust valve (650/660) ............... 7.96 -0.05 mm
Exhaust valve (750/760) ............... 8.96 -0.05 mm
B. – Valve disc edge:
Inlet valve, min ....................................... 1.8 mm
Exhaust valve, min ................................. 1.1 mm
C. – Valve head diameter:
Inlet valve (650/660) ..................... 47.7 ±0.1 mm
Inlet valve (750/760) ..................... 48.0 ±0.1 mm
Exhaust valve (650/660) ............... 35.9 ±0.1 mm
Exhaust valve (750/760) ............... 42.0 ±0.1 mm
7. Check valve seat rings and the valve seat.

Valve seat width:
Inlet valve (650/660) ............................... 2.7 mm
Inlet valve 750/760) ................................ 2.8 mm
Exhaust valve (650/660) ......................... 2.1 mm
Exhaust valve (750/760) ......................... 2.2 mm
8. Measure distance between valve disc edge center

and cylinder head plane, use depth vernier gauge
998 5471:
Intake valve/exhaust valve .............. Min 1.4 mm
(If the value exceeds the minimum value, see
method “Valve seat, replace”.)
9. Measure length of valve spring with the spring un-

loaded, Use depth vernier gauge.
Length, unloaded:
650/660 ........................................... 59 ±1.9 mm
750/760 ...................................... 64.70 ±1.3 mm
79
10. Correct valve seat angle in the cylinder head us-

ing the milling tool.
Valve seat angle:
Inlet ............................................................... 30°
Exhaust ......................................................... 45°
The valve’s seat angle
Inlet ...................................................... 29.5 mm
Exhaust ................................................ 44.5 mm
NOTE: Measure the valve depth in the cylinder head

one more time after the valve seat and the valves
have been machined, see Workshop Manual, Techni-
cal data.
11. Fit valve stem seal (1).

The figure shows 650/660.
12. Fit valves, valve springs and spring washers.
NOTE: Oil the stems of the valves.

Press the valves in carefully with a slight rotating
movement. Otherwise the seal edges can be dam-
aged. 750/760 (O-rings).
13. Use valve spring compressor, 998 5468, for the

valve springs.
Fit valve collet.
80
Valve seat, replace
Cylinder head, removed
1. Valve seat should be replaced when the dimension

between valve disc and the cylinder head plane ex-
ceeds the value shown in specification or when
fully acceptable straightness is not achieved.
Max. 1.4 mm.
2. Grind the disc on an old valve and weld it to the

valve seat. Use a MAG weld or a conventional arc
welder (with stainless welding electrode).
IMPORTANT! Carefully cover other cylinder
head surfaces so that any weld splatter will not
stick.
3. Place a suitable socket above the valve/valve-

guide and tap the valve seat out with care.
NOTE: Be careful not to damage the cylinder head.
4. Clean the seat position with care and check the

cylinder head for cracks.
5. Measure the diameter of the valve seat bed. Inves-

tigate whether a standard dimension seat or a
greater dimension should be used. Perform any
machining of valve seat position. Please refer to
“Technical Data”.
6. Cool the seat in dry ice to between -60 °C and -70 °C

and heat the cylinder head by hosing it with hot water
or some other way. Press in the valve seat with a
drift.
NOTE: Turn the seat with the seat angle towards the
tool.
81
Valve seats, grinding
NOTE: As spare parts, the valve seats are fully ma-

chined and should not need additional grinding.
Min 1.8 mm
1. Before grinding, check the valve guides and re-
30° place them if the wear limits have been exceeded.
29.5°
2. Grind the valve seat so you don’t remove material
needlessly, but just enough so the valve seat has
the correct form and the valve disc good contact
surface.
Inlet valve
3. The valve seat is ground so that the dimension be-

Min 1.1 mm tween the cylinder head plane and valve disc sur-
45° face, is as specified.
4. Check the valve seat angle check with a valve

seat gauge once the seat contact surface first has
been coated with a thin layer of marking dye.
44.5°
Exhaust valve Valves, grinding
Valve sealing angles, See “Technical data”.

NOTE! As spare parts, the valves are fully machined
A and should not need additional grinding.
1. Grind the sealing surface as little as possible. But

enough to remove all damage.
2. Check the dimension (A) on valve disc edge. If the
dimension is less than the wear tolerance per
specification, the valve should be replaced. See
“Technical Data”.
Always change a valve with a bent valve stem.
3. Check valve sealing with marker dye.

If it leaks, grind the valve seat some more, but not
on the valve. Repeat the check.
If the result of the grinding is acceptable, the valve
and seat can be “lapped” together, with a fine grind-
ing paste.
82
Rocker arm bridge
Rocker bridge, Disassembly/checking/

assembling
1. Disassemble rocker arm and rocker bridge.
2. Check for wear and replace when needed:

1. Shaft pivots
2. Adjustment screw
3. Rocker arm contact surface
4. Diameter
3. Check that the oil channels are free.
4. Assemble rocker arm and rocker bridge. Fit snap

rings.
83
Component repair Group 21
Component repair
Group 21 Engine
Flywheel ring gear, replacing
Heat the new the flywheel ring gear to

max 210 °C
1. Use oven or gas weld.
If you use an oven, start by placing the new the
flywheel ring gear in the oven.
If you use gas weld, heat the flywheel ring gear
just before you fit it.
Drill a hole between two gear teeth

2. Use a 10 mm drill.
Drill a 9 mm deep hole.
IMPORTANT! Do not drill into the flywheel, you

risk imbalance.
Remove the flywheel ring gear

3. Grip the flywheel in a vise with soft jaws.
Lever off the ring gear with a screwdriver.

If necessary, split the ring gear at the drilled hole.
Clean the contact surface on the flywheel.
84
Group 21 Component repair
Fit the new the flywheel ring gear

4. Check the temperature.
Place the ring gear in position, so that it bottoms

on the flywheel flange.
If necessary, tap the gear down into place.

Use a brass drift.
Let the ring gear cool down.
85
Valve clearances, adjusting (TAD660/760VE)

Special tools:
Cranking tool, crankshaft .............................. 885 530
Protractor (1/2): ............................................. 885 812
NOTE: Normal valve clearance is set when the engine is cold or when it has cooled for at least one half hour.
Oil temperature < 80 °C.
IMPORTANT! Clean the valve cover with cold
degreaser, and blow it clean with compressed air.
It is especially important to clean the area be-
tween the inlet manifold and the valve housing.

1. Loosen the wiring from the protective plate (1) and
remove the protective plate.
Loosen the crankcase ventilation hoses.

2. Remove bolts (1) from the IEGR unit (2) for cylin-
ders 4-6. Undo the IEGR unit in the direction of
the arrow (make sure the small oil pipe (3) is not
lost).
Install the replacement bolts (M8x75) in the holes

for the IEGR unit, on the rocker arm holders. (in-
stead of the IEGR unit).
3. Rotate the crankshaft (1) so that cylinder 1 valves

overlap.
Use cranking tool 885 530 (1).
86
Overlapping
4. Overlapping means that the exhaust valve start-
ing to close and the inlet valve is starting to open.
It must not be possible to rotate any of the push
rods by hand for the cylinder in question at this
point.
Mark the position on the vibration damper

5. 1, 3, 5, 7, 9 and 11 are exhaust valves
2, 4, 6, 8, 10 and 12 are inlet valves
Set the valve clearance

6. Set the valve clearance for the cylinder in ques-
tion, according to the black marks in the figure.
Undo the locking screw (2) locknut, on the rocker

arm.
Fit protractor 885 812 (1), on the adjustment

screw (2).
Turn the adjuster screw (2) to zero clearance, be-

tween rocker arm and valve.
Zero the protractor.
Turn the adjuster screw (2) counter-clockwise

90° for the inlet valve and 150° counter-clock-
wise for the exhaust valve.
Hold the adjuster screw still (2) and tighten the

locknut.
Tighten to: ................................................ 30 Nm
87
7. Turn the crankshaft round another turn until the

valves for cylinder 6 overlap. Set the valve clear-
ance for each cylinder as in the black marks in
the figure.
NOTE: When all valves have been adjusted, do not
crank the engine. Continue at once by installing the
IEGR valve and adjusting it.
Installing and adjusting the IEGR unit

8. Change the O-rings on the oil pipe between the
two IEGR sections. Lubricate the O-rings with en-
gine oil.
Remove the replacement bolts from the IEGR unit

mounting hole. Install the two parts of the IEGR
unit (incl oil pipe, between the two sections).
With overlapping valves for cylinder 6, set the

IEGR opening piston for cylinders 1, 3 and 5.
Undo the adjustment screw (2) locknut on the

IEGR unit. Fit protractor 885 812 (1) to the ad-
juster screw.
Turn the adjuster screw (2) to zero clearance be-
tween the IEGR opening piston and the exhaust
rocker arm. Zero the protractor. Turn the adjusting
screw (2) counter-clockwise 144°.
Hold the adjuster screw still and tighten the locknut.
Tighten to: ................................................ 20 Nm
Turn the engine another turn, until the valves on

cylinder 1 overlap. Set the IEGR opening piston
for cylinders 2, 4 and 6.
9. Install the gasket (use a new one if necessary) on

the valve cover.
NOTE: Make sure the tab (1) on the gasket aligns
properly.
Install the valve cover.
Connect the crankcase ventilation hoses.
Install the protective plate for the wiring and then

attach the wiring to the plate.
Warm up the engine. Check for leakage.
88
Cylinder head, removal/installation (Internal EGR)

Drain the coolant.

Clean the valve cover and cylinder head with cold
degreaser and blow clean with compressed air.
Special tools:
Key ...................................................... 888 000 70 NOTE! Make sure the cold degreaser does not enter
Lever ......................................................... 999 8511 the rail pressure sensor connector.
Gauge rod ................................................... 999 8678
Dial indicator ............................................... 998 9876
Protractor (1/2) .............................................. 885 812
Removal
1. Remove:
(- exhaust pipe)
(- air cleaner)
(- charge air pipe)
- turbo oil return pipe
- turbo oil pressure pipe, from the engine block
- exhaust manifold, complete with turbocharger

2. Loosen the wiring from the protective plate (1) and
remove the protective plate.
Loosen the crankcase ventilation hoses.

3. Remove the fuel delivery pipes, use special
tool 888 000 70.
Undo the fuel hose connections.
Remove the connector from the rail pressure sen-
sor (1).
Remove the connector from the “M-plug” (2).
Remove the Common rail unit (3).
NOTE: Plug all connections to exclude dirt.
Remove the injector connection cables, fixing

clamps and injectors (4). Us the lever 999 8511,
to remove the injectors. Be careful not to damage
the glowplugs.
89

4. Remove the bolts (1) from the IEGR-unit (2) for
cylinders 4-6, in the direction of the arrow.
5. Remove:
- glowplug (use tool 888 200 25)
- cable, from temperature sensor
- temperature sensor (650/660)
- plug (1)
- solenoid valve (22 mm thin open wrench)
Remove the inlet pipe

6. Remove:
- pressure sensor cable, from inlet pipe
- hose and pipe to charge air cooler
- air connection, on inlet pipe (1)
- inlet pipe bolts
Lift the inlet pipe away (2).
90
Remove the rocker arm bridges with rocker arms

7. Mark the rocker arm bridges (1).
Remove the rocker arm bridges (torx E14) with
rocker arms, and then remove the pushrods.
8. Remove:
- drive belt
- fuel feed pump
- alternator, with bracket
9. Remove:
- fan with fan bearing
Remove the coolant pump housing

10. Undo the fuel line clamps.
Remove the coolant pump housing (1).
91
11. Remove the cylinder head bolts.

650/660: ............................................... Torx E14
750/760: ............................................... Torx E18
Fit a lifting eye in the front edge of the cylinder

head.
Connect a lifting strop and lift off the cylinder head.
Installation
Clean the sealing surfaces on the cylinder head
and engine block thoroughly.
Determining cylinder head gasket thickness

12. Cylinder head gaskets are marked (1) with one,
two or three holes in one corner. The gaskets
shall be used with different piston heights above
the engine block top side.
The piston height above the engine block shall be
measured at two points on each cylinder.
Cylinder head gasket

13. Determine cylinder head gasket.
Place spacing washers (3) and gauge (1) 999 8678
on the sealing surface on the engine block, and
set the dial indicator (2) to “0”.
92
14. Place the dial indicator on the piston at the mea-

surement points.
Read and note the value on the dial indicator at
the pistons highest position, top dead center.
NOTE: All pistons should be measured at TDC and in

the direction of the piston pin.
NOTE: Pay attention to the measurement points,

since the piston surface is spherical.
15. Compare the highest noted value with the table

below. Decide on the most suitable cylinder head
gasket.
Piston height: Marks on cylinder
head gasket:
TAD650/660
0.33-0.55 mm 1 hole
0.56-0.65 mm 2 holes
0.66-0.76 mm 3 holes
TAD750/760
0.28-0.53 mm 1 hole
0.54-0.63 mm 2 holes
0.64-0.75 mm 3 holes
16. Place the cylinder head gasket with the marking

upwards and the marking hole(s) toward the fly-
wheel.
NOTE: The sealing surfaces on the cylinder head and

the engine block plane must be clean and free from
oil. Pay attention to the guide sleeves (1).
93
17. Lift the cylinder head into place. Pay attention to

the guidesleeves.
Oil the cylinder head bolts, let them drip off and
tighten them lightly.
NOTE: The cylinder head bolts may be used up to 5

times if you can show how many times they have
been used. (Mark them with a punch for each subse-
quent stretching.)
Cylinder head, tightening

18. Note the tightening sequence, as illustrated.
Tighten the bolts in three stages:
1st stage: ................................................. 50 Nm
2nd stage: .............................................. 130 Nm
3rd stage, angle tighten: ................................ 90°
Coolant pump housing, installation

19. Fit the coolant pump housing (1), with new seals.
Connect the fuel line clamps.
NOTE: The sealing surfaces for the coolant pump
housing must be cleaned properly.
20. Install:
- the alternator, with bracket
- the fuel feed pump
- the fan bearing
- the fan
- the drive belt
94
Install the rocker arm bridges with rocker arms

21. Install the pushrods.
Install the rocker arm bridges (1) with rocker

arms, according to the marks.
Install the replacement bolts (M8x75) in the hole
for the IEGR unit, on the rocker are holder.
(instead of the IEGR unit).
Install the inlet pipe

22. Lift the inlet pipe (2) into position, use new gaskets.
Install:
- the inlet pipe bolts, tighten to: ............... 13 Nm
- the air connection, on the inlet pipe (1)
- the hose and pipe to the charge air cooler
- the heat shield
- the pressure sensor cable, to the inlet pipe
23. Rotate the crankshaft (1) so that cylinder 1 valves

overlap*.
Use cranking tool 885 530 (1).
*Overlapping
Overlapping means that the exhaust valve is on
its way to open and the inlet valve is on its way to
close. It must not be possible to rotate any of the
push rods by hand for the cylinder in question at
this point.
95
Mark the position on the vibration damper

24. 1, 3, 5, 7, 9 and 11 are exhaust valves
2, 4, 6, 8, 10 and 12 are inlet valves
Valve clearance, adjusting (750/760)

25. Adjust the valve clearance for each cylinder, ac-
cording to the black markings illustrated.
26. Undo the locknut for adjustment screw (2) on the

rocker arm.
Fit the protractor 885 812 (1), to the adjuster

screw (2). Turn the adjustment screw (2) until zero
clearance is obtained between the rocker arm and
the valve.
Zero the protractor. Turn the adjustment screw (2)

counter-clockwise 90° for the inlet valve and
counter-clockwise 150° for the exhaust valve.
Hold the adjuster screw still (2) and tighten the

locknut. Tighten to: ................................... 30 Nm
27. Turn the crankshaft round another turn until the

valves for cylinder 6 overlap. Set the valve clear-
ance for each cylinder as in the black marks in
the figure.
NOTE: When all valves have been adjusted, do not
crank the engine. Continue at once by installing the
IEGR valve and adjusting it.
96
Install the two parts of the IEGR unit

28. Remove the replacement bolts from the IEGR unit
installation holes.
Install the IEGR unit (1), for cylinders 1-3 (incl the
small oil pipe (2) with new O-rings.
Install the IEGR unit (3) for cylinders 4-6, carefully
connect the small oil pipe (2).
IEGR unit, adjustment

29. With overlapping valves for cylinder 6, set the
IEGR opening piston for cylinders 1, 3 and 5.
Loosen the adjuster screw (2) lock screw on the
IEGR unit. Fit the protractor (1) to the adjuster
screw.
Turn the adjuster screw (2) to zero clearance be-

tween the IEGR opening piston and the exhaust
rocker arm. Zero the protractor. Turn the adjuster
screw (2) counter-clockwise 144°.
Hold the adjuster screw still and tighten the lock
nut. Torque to: .......................................... 20 Nm
Turn the engine another turn, until the valves on

cylinder 1 overlap. Set the IEGR opening piston
for cylinders 2, 4 and 6.
30. Install:
- the solenoid valve (22 mm, thin open wrench)
- the plug (1)
- the temperature sensor (650/660)
- the cable to the temperature sensor
- the glowplugs
97
31. Install a new O-ring (1) and a new copper seal

(2), on the injector.
32. Install:
- the injectors
- injector clamps (loosely)
33. Connect the cables (1, 2), to the injectors.

1. Tighten to ............................................... 5 Nm
2. Tighten to ............................................. 25 Nm

Tighten to: ............................................. 16+5 Nm
98
Install the Common Rail unit

35. Install the Common Rail unit (3).
Connect the socket to the “M-plug” (2).
Connect the socket to the rail pressure sensor (1).
Connect the fuel hose.
Install new fuel delivery pipes.
Tighten the delivery pipe nuts (tool 888 00070) in
two stages:
1. Tighten to ............................................... 5 Nm
2. Tighten to ............................................. 25 Nm
Valve cover, install

36. Install the valve cover (2), with a new gasket.
Connect the crankcase ventilation hoses.
Fit the cable protection plate (1) and then fit the
cables to the plate.
37. Install the exhaust manifold, complete with turbo-

charger. Use new gaskets.
Tighten to: ........................................... 25 ±2 Nm
Install the turbo pressure oil pipe to the engine

block. Use new gaskets. Tighten to: ........ 39 Nm
Install the turbo return oil pipe. Use new gaskets.

Tighten to: ................................................ 20 Nm
(Install the charge air pipe, air cleaner and ex-

haust pipe.)
Fill up with coolant.

Warm the engine up.
Check for leakage.
99
Crankshaft seal, replacing (complete engine)

Special tools:
Standard handle, drifts ................................ 999 2000
Fitting tool, rear (650/660) ........................ 11 668 401
Fitting tool, front (650/660) ....................... 11 668 400
Fitting tool, rear (750/760) ........................ 11 668 406
Fitting tool, front (750/760 .......................... 88820043
Tool 999 0192
Slide hammer .............................................. 999 6400
Cranking tool ............................................... 999 8681
Crankshaft seal, rear, replacing

1. Remove the flywheel, use the extractor bolts if

necessary.
NOTE: The flywheel is heavy.
Remove the crankshaft seal from the timing gear

casing using tool 999 0192 and slide hammer
999 6400. (Alternatively tool 999 5919.)

crankshaft.
100
3. Fit the guide (inner part of assembly tool).

Oil and install the crankshaft seal on the crank-
shaft with the felt side outwards.
Use assembly tool:
650/660 ............................................. 11 668 401
750/760 ............................................. 11 668 406

(3) and nut (4).
Use the number of washers needed so that the
new crankshaft seal does not end up in the same
position as the old.

positioned correctly. Remove the tool.
Lift the flywheel into position and tighten the bolts
by hand.
WARNING! The flywheel is heavy.
Hold the flywheel using turning tool 999 8681.
Tighten the bolts per specification below:
1st torque angle:
bolts M10x1x45 ........................................... 60°
2nd torque angle:
bolts M10x1x45 ........................................... 60°
NOTE: The bolts may be used 5 times.
Fit the plastic plugs that lock the flywheel

screws.
101
Crankshaft seal, front (front casing), replacing

1. Remove the belt pulley use cranking tool 999

8681 as counterhold and remove the oscillation
damper (socket 885 509).
Remove the old seal, use slide hammer 999 64
00 and tool 999 0192. (Alternatively tool 999
5919).
WARNING! The oscillation damper is heavy and

shall not be exposed to impact or shock.

crankshaft.
3. Fit the guide (2) (inner part of assembly tool).

Oil and fit the crankshaft seal (1) with the feltside
out on the crank shaft.
Use assembly tool:

650/660 ............................................. 11 668 400
750/760 ............................................... 88820043
102


Fit the guide sleeve (2) and any guide pins (1) to
the crankshaft.
Fit the belt pulley and the oscillation damper.
Use cranking tool 999 8681 as a counterhold.
Tighten the bolts as below:
Initial torque: ...................................... 40-50 Nm
1st torque angle: .......................................... 60°
2nd torque angle: ......................................... 60°
NOTE: Use torx tool E 20 (885 509). The bolts may

be used 5 times.
103
Group 22 Lubrication System
Oil pan/oil suction pipe, remove/install

Removal
1. Remove the oil pan.
NOTE: The oil pan is installed using liquid gasket and

can therefore be difficult to remove. Use lever 999 8511
(or tap in a gasket scraper or similar (to split the seal-
ant)).
2. Remove three bolts (1) and remove the oil suction

pipe (2).
M8 x 25 mm (1)
M8 x 15 mm (2)
Installation
3. Install the oil suction pipe (2), with a new gasket.
Tighten the oil suction pipe bolts (1).

Tighten to: ................................................ 30 Nm
104
4. Cut off the excess front cover/oil pump gasket.
Fill the oil pan sealing surface joints with silicon

(part no: 1161231 large tube or 1161277 small
tube).
5. Place the new gasket on the engine block.

NOTE: The gasket consists of 4 parts.
6. Fill depressions in the gasket with silicone (part

no. 1161231).
7. Install the oil pan.

Tighten to: ................................................ 30 Nm
105
Oil pump, disassembly
1. Tap out the crankshaft seal using a drift.
2. To clean the front the casing:

remove the oil pump and the pressure regulating
valve.
3. Press the compression spring down and remove

the stop washer.
Remove the spring and the valve for checking.
Also check the valve seat in the casing.
NOTE: Be careful. The valve spring force is very

large. A high quality spring compressor is required.
4. Remove drive kit and check that no abnormal

wear has occurred.
When needed, replace oil pump.
Torque the screws to ............................... 8-9 Nm
WARNING!
Make sure that correct oil pump is used for the
respective engine. The pumps for the 420 and
620 engines are different. See “Spare parts
catalog”.
Installation
5. Fit pressure regulating valve and spring.
6. Press the compression spring down and fit the

spring’s stop washer.
NOTE: Make sure that the spring’s stop washer is se-

cure. Lubricate with a thin layer of oil before refitting.
Regarding refitting the seal ring, see section “Crank-

shaft seal, front (front casing), replacing”.
The crankshaft seal should be placed after refit-

ting the front casing.
106
Oil cooler (TAD650/660VE)
Special tools:
Pressure-testing device .............................. 999 6662
G-clamp, 2 pcs ........................................... 999 6845
Sealing pieces, 1 pc
Oil cooler, check (replace)

1. Remove the oil cooler.
Oil cooler, leakage check
NOTE: The oil cooler element should be as dry as

possible inside during the check, since residual
water may have a sealing effect on any cracks.
Water may not leak into the oil cooler element
during the check.
NOTE: Avoid starting or stopping the fan system or
allowing air to enter or leave the room, since the
air pressure in the room can change and be mis-
interpreted as leakage.
NOTE: During the test, the oil cooler element should
have ambient temperature. The oil cooler element
must not be repaired.
2. Use a piece of rubber or gasket material,

35 x 35 mm with a 22 mm hole in the center.
Fit clamp (2), 999 6845 (with rubber original, 3)to-
gether with the sealing piece (1) with a hole to
one of the cooling element’s oil connections as
illustrated. Make sure that it seals properly.
107
3. Turn the second clamp 999 6845 (1) the other way
to seal the second oil connection.
4. Connect pressure gauge 999 6662.

5. Immerse the oil cooler element in a tub of water.
6. Set the air pressure to 100 kPa (1.0 kp/cm²).
Check for air bubbles from the element. Let the
pressure stay on for one minute. The pressure
must not drop.
Increase the pressure to 500 kPa (5.0 kp/cm²).
Let the pressure stay on for one minute. The pres-
sure must not drop.
NOTE: If the pressure drops during this check, there
is a leak. Replace the oil cooler element.
NOTE: If there are bubbles from the water connec-
tions, there is an internal leak. Replace the oil
cooler element.
7. Move clamp 999 6845 (1), to one of the water

connections. Fit a screw clamp to the second
connection and pressure test as above.
8. Make sure that the oil side of the cooler is free
from water before reinstalling.
9. Install the oil cooler with new gaskets.

Tighten to: ................................................ 30 Nm
108
Oil cooler (TAD750/760VE)
Special tools:
Pressure-testing device .............................. 999 6662
Clamp, for cooler ......................................... 999 6845
Plug M26 x 1.5 .................................. part no. 942352
Spacer 30 mm ................................ part no. 1678297
Oil cooler, check (replace)

1. Undo the fuel filter bracket.
Remove the oil cooler housing, complete with oil
cooler.
2. Remove the Allen plugs (1).

Then undo the Allen bolts (17 mm), holding the oil
cooler.
3. Remove:
- O-rings
- Allen bolts
109
Check all parts

4. If you suspect a crack, pressure test the oil
cooler (see below) and replace as necessary.
Oil cooler, leakage check
NOTE: The oil cooler element should be as dry as

possible inside during the check, since residual
water may have a sealing effect on any cracks.
Water may not leak into the oil cooler element
during the check.
NOTE: Avoid starting or stopping the fan system or
allowing air to enter or leave the room, since the
air pressure in the room can change and be misin-
terpreted as leakage.
NOTE: During the test, the oil cooler element should
have ambient temperature. The oil cooler element
must not be repaired.
5. Fit clamp 999 6685 (2), on the cooler core (3)

as in the illustration. Make sure that it seals prop-
erly.
Install plug 942352 (1) on the other connection
(use a suitable aluminum washer or copper
washer).
6. Connect to the pressure testing equipment (1).

Immerse the oil cooler element in a tub of water.
Set the air pressure to 100 kPa (1.0 kp/cm²).
Check for air bubbles from
the element.
Increase the pressure to 500 kPa (5.0 kp/cm²).
Maintain pressure for approx. 1 minute. The pres-
sure must not drop.
NOTE: If the pressure drops during the test, there is a
leak, replace the oil cooler core.
110
Installation
7. Fit new aluminum washers (1), on the Allen bolts.
NOTE: To prevent damage to the aluminum washer,
wrap the Allen bolt threads with protective tape.
Remove the protective tape.
8. Fit new O-rings (1), on the Allen bolts.

NOTE: To prevent damage to the O-rings, wrap the
Allen bolt threads with protective tape.
Remove the protective tape.
9. Placer both the Allen bolts (incl O-ring and

aluminum washer), in the oil cooler housing.
10. Install the oil cooler in the oil cooler housing.
Tighten the Allen bolts in two stages:

Second tightening: .................................. 160 Nm
Fit a new O-ring on the Allen plug and oil it lightly.
Tighten the plug to: ................................... 80 Nm
111
11. Install the oil cooler housing, complete with oil

cooler, use new gaskets.
Tighten to: ................................................ 30 Nm
Install the fuel filter bracket.
112
Group 23 Fuel System
Fuel feed pressure, checking

Special tools:
Banjo nipple ................................................ 999 0124
Pressure gauge ........................................... 999 6398
Nipple ......................................................... 999 6666
IMPORTANT! Clean nipple and hose carefully

before they are connected to the fuel system.
1. Measure the fuel feed pressure before (1) and af-
ter (2) the fuel filter.
Feed pressure:
after pump (before filter): ........... 0.5 MPa/5 bar
after filter:
at 1,500 rpm: ........................... 0.28 MPa/2.8 bar
1 Fuel feed pressure before fuel filter.
2 Fuel feed pressure after fuel filter.
113
Fuel feed pump, removal/installation

Removal
1. Clean the fuel feed pump with cold degreaser and

blow clean with compressed air.
2. Loosen the drive belt, lock the tensioner with a 6

mm drift (1).
3. Remove the drive belt.
4. Remove the fuel inlet pipe.
Loosen the fuel outlet line (1.2), from the fuel feed
pump.
5. Remove the three bolts from the fuel feed pump

and remove the feed pump.
114
Installation
6. Install the fuel feed pump and tighten the three

bolts.
7. Install the fuel lines.

Tighten to: ........................................... 22 ±2 Nm
8. Install the drive belt.
9. Remove the drift, so that the belt is tensioned.
115
Common Rail, rail pressure sensor and

safety valve, removal/installation
Special tools:
Key, pressure pipe ..................................... 888 00 70
Plug (kit) ....................................................... 885 510
Removal
1. Clean the rail, safety valve and rail pressure sen-

sor with cold degreaser and blow clean with com-
pressed air.
NOTE: Make sure the cold degreaser does not enter

the rail pressure sensor connector.
2. Remove the fuel delivery pipe, plug (885 510) the

connections against dirt entry.
3. Loosen the connection (1), for the fuel hose (2).
4. Remove the cable tie (1).

Loosen the connector (2), from the rail pressure
sensor.

5. Undo the bolts (1) and remove the Common rail
unit (2).
116
Rail disassembly
6. Remove the safety valve (1) and rail pressure
sensor (2), from the Common rail unit.
7. Check the safety valve (1) and rail pressure sen-

sor (2), for any damage.
Rail assembly
8. Install a new O-ring on the safety valve.
9. Install the safety valve (1).

Tighten to: .............................................. 100 Nm
Install the rail pressure sensor (2).

Tighten to: ................................................ 70 Nm
117
Installation
Install the Common Rail unit

10. Install bolts (1).
11. Connect connector (2), to the rail pressure sensor.

Fit a cable tie (1).
12. Connect the fuel hose (2) to the rail.

Tighten the connection (1) to: ................... 39 Nm
13. Install new fuel delivery pipes (tool 888 000 70).
Tighten to: ................................................ 25 Nm
118
Control valve, removal/installation
Clean the control valve and fuel connections with cold

degreaser and blow clean with compressed air.
1. Remove:
- feed pipe (2)
- return line from fuel filter (3)
- feed line (4)
2. Remove the control valve.

Check the control valve for damage.
3. Install:
- control valve
- return line (4)
- feed line from fuel filter (3)
- feed pipe (2)
- cable to the control valve “M-plug” (1)
119
Fuel pump, removal/installation
Special tools:
Tool: ........................................................ 999 1821
Cranking tool, flywheel: .............................. 999 8681
1. Clean the rail, safety valve, rail pressure senor

and fuel pumps with cold degreaser and blow
clean with compressed air.
NOTE: Make sure the cold degreaser does not enter

the rail pressure sensor connector.
2. Remove the fuel delivery pipes, plug connections

to prevent dirt entry.
3. Loosen the connection (1), for the fuel hose (2).
4. Remove the cable tie (1).

Loosen the connector (2), from the rail pressure
sensor.

5. Undo the bolts (1) and remove the Common rail
unit (2).
120
6. Remove:
- feed pipe (2)
- return line (3)
- feed line, from fuel filter (4)
Fuel pump, removal

7. Undo bolts (1) alternately and remove the fuel
pump (2).
NOTE: Turn the crankshaft (tool 999 8681), until fuel
flows from the pump which is not being removed. The
fuel pump that is to be removed is not under load.
8. Remove the roller lifter from the fuel pump.

Use tool 999 1821.
Fuel pump, installation

9. Check that there is no damage to the lobe/cam.
121
10. Install the roller lifter. Use tool 9991821.

NOTE: Align the pin (1) in the gap (2).
11. Install a new O-ring on the fuel pump.
12. Install the fuel pump (2).

Screw down the bolts (1), alternately.
Tighten in two stages:

Stage 1: ................................................... 10 Nm
Stage 2: ................................................... 50 Nm
13. If the other pump has been removed:

Crank the engine so that the roller lifter is at it’s
lowest position.
Then screw down bolts (1), alternately.
Tighten in two stages:

Stage 1: ................................................... 10 Nm
Stage 2: ................................................... 50 Nm
122
Injector, removal/installation
Special tools:
Lever: .......................................................... 999 8511
Removal
1. Disconnect the battery.
Remove the three bolts from the protective plate

(1).
Remove the delivery pipe (2) to the injector (Plug

the connection against dirt entry).
Cut off the cable tie (3).
Move the protective plate aside.
2. Remove the cable connector nuts (1), from the in-

jector.
3. Remove:
- fixing clamp bolt (1)
- fixing clamp (2)
123
4. Remove the injector using lever 999 8511. If sev-

eral injectors are to be removed, then mark the
positions.
NOTE: Make sure that leak-off fuel does not leak into
the cylinders. Be careful not to damage the
glowplugs.
Installation
5. Fit new O-ring(s) (1) and new copper seal(s) (2),

to the injector(s).
6. Install the injector(s).

7. Install the injector holder (loosely).
124
8. Connect the cables (1), to the injectors.

1. Tighten to ............................................... 5 Nm
2. Tighten to ............................................. 25 Nm

Tighten to: ............................................. 16+5 Nm
10. Install the protective plate (1).

Tie wrap the cables.
125
Group 25 Inlet and Exhaust System
Exhaust manifold (with turbo), removal/installation
The method consists of removal of the exhaust pipe,

air filter and charge air pipe.
Removal
1. Remove:
- turbo oil return pipe
- turbo oil pressure pipe from the engine block
- exhaust manifold (1) nuts
NOTE: Use lubricant before the exhaust manifold nuts
are removed.
2. Remove:
- exhaust manifold complete with turbocharger
Installation
3. Install the exhaust manifold with turbocharger and
oil return/oil pressure pipes, use new gaskets/
seals on the exhaust manifold and oil return/oil
pressure pipes.
The gasket flange should face the cylinder head.
Tighten the nuts to: ............................. 25 ±2 Nm

NOTE: Use high temperature paste (1161035) on the
studs.
126
Turbocharger, removal/installation
The method consists of removal of the exhaust pipe,

air filter and charge air pipe.
Removal
1. Remove the oil return pipe’s (2) lower clamp (1).
2. Remove the oil return pipe’s (2) upper bolts (1)

and remove the oil return pipe.
3. Undo the oil pipe (2) attachments (1), from the en-
gine block and turbo.
(With high location of the turbo, the oil pipe is re-

moved together with the turbocharger.)
127
4. Remove the nuts (1).

NOTE: Use lubricant before the nuts are removed.
Remove the turbocharger (2), incl. gasket.
Installation
5. Install the turbocharger (2), with a new gasket.

Tighten the nuts (1) to: ............................. 42 Nm
6. Install the oil pressure pipe (2), with a new gasket.

Tighten the bolts (1) to: ............................ 39 Nm
7. Install the oil return pipe with new gaskets.

Tighten the bolts (upper/lower) to: ............. 20 Nm
128
Inlet pipe, removal/installation

Removal
1. Remove bolts (1) and remove the protective plate

for the wiring.
NOTE: First loosen the wiring from the protective plate.
2. Remove all bolts and remove the valve cover (1).
NOTE: Clean thoroughly before removing the valve

cover, especially between the inlet pipe and valve
cover.
3. Loosen the pressure sensor cable (1), from the in-

let pipe.
129
4. Remove the air connection bolts (1) and then re-

move the air connection (2).
5. Remove the inlet pipe bolts.

Lift off the inlet pipe.
Installation
6. Clean the gasket contact surfaces.

Install new gaskets (1).
7. Install the inlet pipe.

Tighten the bolts (from the center) to: ....... 13 Nm
130
8. Install the air connection bolts (1) and then install

the air connection (2).
9. Connect the pressure sensor cable and clamp it

to the inlet pipe.
10. Check the valve cover gasket and replace as nec-

essary.
Install the valve cover.
Tightening torque: ..................................... 13 Nm
11. Install the wiring protection plate with bolts (1).
131
IEGR unit, removal/installation
Removal
1. Remove bolts (1) and remove the protective plate

for the wiring.
NOTE: First loosen the wiring from the protective plate.
2. Remove all bolts and remove the valve cover (1).
NOTE: Clean thoroughly before removing the valve

cover, especially between the inlet pipe and valve
cover.
3. Remove the five bolts (1), from the IEGR bridge.

remove the IEGR bridge (2), pull it to the right
first.
132
4. Remove the bolts (1) from the other IEGR bridge.

Remove the IEGR bridge, with oil pipe (2).
5. Remove the oil pipe (1), from the IEGR bridge.
Installation
6. Fit new O-rings on the oil pipe (1). Reinstall the oil
pipe on the IEGR bridge.
7. Install the IEGR bridge for cylinders 1-3.

133
8. Install the IEGR bridge (2), for cylinders 4-6.

Tighten the bolts (1) to: ............................ 30 Nm
NOTE: Make sure the oil pipe between the IEGR
bridges is in place.
Adjust the valves and IEGR units.

See page 86.
9. Install valve cover (1), with a new gasket.
10. Install the protective plate with bolts (1).

Clamp the wiring to the protective plate.
134
IEGR Solenoid valve, removal/installation

(TAD660/760VE)
1. Remove the plug (1).

TAD660VE: Remove the temperature sensor.
2. Loosen the cable connection (1), to the solenoid

valve (2).
3. Remove the solenoid valve (1), for the IEGR.

Use a 22 mm (thin) open wrench.
135
4. Fit new O-rings (1, 2), to the solenoid valve.

Fit a new plastic seal (3), on the solenoid valve.
5. Install the solenoid valve (1).

Tighten the solenoid valve to: ................... 24 Nm
6. Connect the cable (1), to the solenoid valve (2).
7. Fit the plug (1) with a new copper washer.

Tighten the plug to: ................................... 34 Nm
TAD660VE: Install the temperature sensor.
136
Group 26 Cooling System
Coolant pump, checking/replacing

The method is based on removal of the belt and

drained coolant.
1. Remove coolant pump from the housing.
2. Remove the belt pulley.

3. Check coolant pump and seal with regard to leak-
age, replace coolant pump when needed.
4. Install the belt pulley.

Tighten the bolts to: .............................. 21 Nm
137
5. Reinstall the coolant pump in the housing, with a

new gasket.
Install the drive belt.

Fill with coolant.
Perform a leak check.
138
Thermostat, check
1. Measure dimension “a” on the thermostat.

TAD650/660:
“a”= thermostat starts opening ........ 83°C (T1)
“b”= thermostat fully open .............. 95°C (T2)
TAD750/760:
“a”= thermostat starts opening ........ 87°C (T1)
“b”= thermostat fully open ............. 102°C (T2)
2. Heat thermostat in water.
NOTE: To obtain an exact opening temperature, mea-

sure as close to thermostat as possible without touch-
ing it Stir the water to obtain an even temperature dis-
tribution.
The temperature shall not rise more than 1 °C/min,
otherwise the opening time will be delayed.
3. Measure dimension “b” on the thermostat.

At opening temperature (102 °C):
“a”-“b”= min 8 mm.
139
Drive belts, change

IMPORTANT! Only check or replace the belt when the engine is turned off, reinstall any belt guard.
NOTE: Replace belts which have become oily, worn or damaged in any way.
NOTE: It may be necessary to remove the fan to ac-

cess the belt.
Drive belt, inspection/changing

Inspection should be done after running, when the
belts are hot.
You should be able to depress the alternator belt and
the drive belt about 3-4 mm between the pulleys.
The alternator belts and drive belts have automatic
belt tensioners and do not need to be adjusted.
1. Undo the belt tensioner and lock it with a drift (1).
2. Remove the belt from the coolant pump (1) first.
3. Install the new belt.

Undo the belt tensioner. Check that the belt
runs in the grooves correctly and is correctly
tensioned.
140
Contents
Index
A G
Assembly, complete engine ................................... 42 General information .................................................. 5
C H
Camshaft bearing, checking and measuring ........... 76 High idle, rpm ......................................................... 22
Camshaft, checking and measuring ....................... 74
Camshaft, installation ............................................ 43 I
Checking and measuring ........................................ 63 IEGR solenoid valve, removal/installation ............ 135
Checks and adjustments ........................................ 26 IEGR unit, adjustment ............................................ 97
Common Rail, removal/installation ....................... 116 IEGR unit, removal/installation ............................. 132
Component location, engine ................................... 14 Injector, removal/installation ................................. 123
Component repair ................................................... 84 Injectors and fuel lines, refitting ............................. 56
Compression test ................................................... 26 Inlet pipe, installation ............................................. 95
Connecting rod, measuring ..................................... 68 Inlet pipe, removal ................................................. 90
Coolant pump, checking/replacing ........................ 137 Installing fixture ..................................................... 29
Coolant .................................................................. 23
Cooling System ..................................................... 21 L
Crankcase seal rear, change ................................ 100
Crankshaft seal, front, change ............................. 102 Low idle, rpm .......................................................... 22
Crankshaft, assembly ............................................ 44 Lube oil pressure, check ........................................ 27
Crankshaft, measuring ........................................... 65 Lubrication System .............................................. 104
Crankshaft, removal ............................................... 39 Lubrication ............................................................. 23
Cylinder head gasket, refitting ................................ 53
M
Cylinder head with valve guides, refitting ............... 55
Cylinder head, Checking and measuring ................. 78 Main bearing shells ................................................ 65
Cylinder head, removal ........................................... 31 Manifold ............................................................... 126
Cylinder liner, installation (660/750/ 760) ................ 42 Measuring tolerance deviation, engine block .......... 63
Cylinder numbering ................................................ 13 Measuring tolerance deviation, roller pin and
camshaft ................................................................ 74
D
O
Description of engine ............................................. 12
Disassembly, complete engine ............................... 31 Oil cooler, oil filters and oil cooler housing, removal .. 34
Drive belts, change .............................................. 140 Oil cooler, repair ................................................... 107
Oil filter housing and oil cooler, refitting .................. 59
E Oil suction pipe/oil pan, refitting ............................. 51
Engine block, checking and measuring .................. 63 Oil suction pipe, removal/installation .................... 104
Engine fixture, refitting ........................................... 29 Oil trap, refitting ..................................................... 58
Engine plate placement .......................................... 12
P
Engine plate ........................................................... 12
Engine plate, placement ......................................... 12 Piston and connecting rod, assembling, ................. 73
Engine serial number ............................................. 13 Piston, checking and measuring ............................ 71
Engine, component placement ............................... 14 Pistons and connecting rod, removal ..................... 38
Engine, removal from engine fixture ....................... 61 Pistons and connecting rods, refitting .................... 47
Exhaust manifold, removal/installation ................. 126
Exposing the engine ............................................... 28 R
F Repair Instructions ................................................... 6
Rocker bridge, checking and measuring ................. 83
Flywheel ring gear, replacing .................................. 84
Front casing with oil pump, refitting ........................ 49 S
Front casing, oil pump, repair ............................... 106
Safety information .................................................... 2
Fuel feed pressure, checking ............................... 113
Special Tools ............................................................ 9
Fuel feed pump, removal/installation .................... 114
Fuel pressure, checking ......................................... 27
Fuel pump, removal/installation ............................ 120
Fuel System ........................................................ 113
141
Contents
T
Technical data ........................................................ 22
Thermostat, check ............................................... 139
Tightening torque ................................................... 24
Timing gear casing, installation .............................. 48
Torque order for cylinder head screws .................... 23
Turbocharger, removal/installation ........................ 127
V
Valve clearance, adjusting ..................................... 86
Valve seat, grinding ................................................ 82
Valve seat, replacing .............................................. 81
Valves, grinding ..................................................... 82
142
Report form
Do you have any complaints or other comments about this manual? Please make a
copy of this page, write your comments down and post it to us. The address is at
the bottom of the page. We would prefer you to write in English or Swedish.
From: ............................................................................
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Refers to publication: .............................................................................................................................................
Publication no.: ..................................................................... Issued: ....................................................................
Suggestion/reasons: ..............................................................................................................................................
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Date: ............................................................
Name: ..........................................................
AB Volvo Penta
Global Aftermarket
Dept. CB22000
SE-405 08 Gothenburg
Sweden
7745322 English 03-2013

Volvo TAD750 Workshop Manual

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Workshop Manual I

Group 20-26 4(0)

Special tools .......................................................... 9

Description of engine ........................................... 12 Group 21:

Technical data ...................................................... 22 Group 23:

Introduction If work is done adjacent to a running engine, a

Check that the warning or information labels on

Never use start spray or similar products as a

Only start the engine in a well- ventilated area.

WARNING! The delivery pipes must under no

Remember the following when washing with a

Always check before starting work if there is

© 2013 AB VOLVO PENTA

About this Service Manual Certified Engines

The working methods described in the Service Manual

Torque-angle tightening Sealant

NOTE: Loctite® is a registered trademark of Loctite Corporation,

Safety rules for • Always use gloves made of chloroprene rubber

999 0124 999 0145 (660) 999 0192 999 1821

999 2000 999 6394 1) 999 6395 1) 999 6398

999 6400 999 6645 999 6666 999 6845

Tool Designation – use

888 00050 888 00070 888 00129 999 8676

999 8678 888 20025 888 20026 888 20027

999 8511 999 8681 999 8687 (750/760) 999 8694

Tool Designation – use

Other special equipment

998 5423 998 5468 998 6485 8889 0080

998 8539 998 9876 999 8494

Tool Designation – use

Other special equipment

Tool Designation – use

885 510 Plug, fuel delivery pipe (kit)

The other engine plate is located upon the valve cover.

Engine serial number

Engine, component placement

1. Oil filler cap

1. Inlet, after charge air cooler

1. Speed sensor, camshaft

Summary Fuel control

– solenoid valve, EGR

– MPROP, high pressure fuel pump

Three different cylinder types Fixed or selectable, internal EGR

Cylinder block and crankshaft

1. Fuel tank 8. Fuel pump

1. Radiator 4. Circulation pump

Power Please refer to the sales literature

Torque Please refer to the sales literature

Bore 101 98 108 108

Stroke (mm/inch) 126 126 130 130

Cylinder volume, dm3 6.07 5.70 7.15 7.15

Weight*, app. (kg/lb) 565 565 650 650

Weight*, wet (kg/lb) 585 585 681 681

Firing order 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4

Low idle, rpm 600-800 600-800 600-800 600-800

High idle, rpm 2400 2400 2400 2400

* only engine, excluding cooling system

Oil pressure at rated rpm:

Oil volume, including filter:

Torque sequence for cylinder head bolts

NOTE: Cylinder head bolts can only be re-used five times.

Tightening torque, TAD650/660VE

Tightening torque, TAD750/760VE

Special torques Nm/angle tightening