Workshop and repair manual

VOLVO

ENGINE

TAD 1640 & 1641 & 1642 GE

TAD 1641 & 1642 VE

7746012 – 7746022 - 7746032

33525071901_0_1
09/2004
Engine body, general overhaul

17. Remove the upper transmission gear casing and

remove the rubber seals.

18. Remove the middle piece for lubrication of the

rocker bridge, together with the delivery pipe.

19. Remove the cover lid in the flywheel casing and

attach turning tool 9993590.

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 Engine body, general overhaul

20. Turn the engine to TDC on the camshaft, check

that the mark on the flywheel is at “0.”

21. Remove the camshaft drive together with the vi-

bration damper.

NOTE: The vibration damper is very sensitive to

shocks.

22. Remove the rocker bridge screws alternately to

avoid uneven load.

23. Lift the rocker bridge using lifting tool 9990185.

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Engine body, general overhaul

24. Mark and remove the valve calipers.

25. Clean around the unit injectors and unscrew the

screws for the injector retainers.
Remove the unit injectors, one at a time.

26. Pull up the injector using puller 9990006 and slide

hammer 9990013.

27. Place protection plugs 9998251 in the cylinder

head immediately after removal.
Mark the unit injectors and place protective
sleeve 9998249 on the injector.
NOTE: Check that the tools are clean.

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 Engine body, general overhaul

28. Remove the camshaft cap using tools 9990192

and 9996400.

29. Lift the camshaft carefully using tool 9998264.

30. Remove bearing blocks by carefully tapping them

with a plastic hammer.
Remove the bearing blocks with the lower bearing
halves and put them in the right order together
with their respective camshaft bearing caps, upper
bearing halves and screws.
NOTE: The camshaft bearing blocks are held by guide
pins marked 1-7.

31. Turn the engine so that the two screws (1) can be
reached through the transmission wheel.

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Engine body, general overhaul

32. Place a rag in front of the drive to prevent screws

from falling into the transmission housing.
Remove the two screws (1).
NOTE: When the engine is turned, the rag must be
removed.

33. Remove the remaining five screws (2).

Remove the three upper screws (3) from the trans-
mission wheel hub.

34. Remove the cylinder head screws.

Use two lifting chains 9996239 to carefully lift the
cylinder head away. (Alternatively, lifting eyes and
lifting straps can be used.)
NOTE: Place washers between the cylinder head and
lifting chains to protect the cylinder head sealing surfa-
ce.

35. Remove the cylinder head gasket and clean con-

tact surface on the cylinder block thoroughly.
NOTE: Secure all cylinder liners using tool 9990157.

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