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Workshop Ma
Group
TAD1640-42GE, TAD1641-43
TAD1640-42VE-B, TAD165
TAD1651VE, TAD1660-6
TWD1643GE, TWD1652
Content
General Information
00-0 General ...........................
Specifications
03-2 Specifications, Engine ..
03-21 Engine ..........................
03-22 Lubrication System .....
03-23 Fuel System .................
03-25 Inlet and Exhaust Syste
03-26 Cooling System ...........
03-3 Specifications, Electrica
Safety and Other Instructio

05-1 Safety Instructions ........
Special tools
08-2 Special Service Tools ...
General
20-0 Engine Information, Gen
Troubleshooting ....................
Test and Adjustments ...........
Engine
21-0 Engine Complete, Gener
Exposing the Engine .............
Fitting the Fixture ..................
Engine Disassembly .............
Engine Assembly ..................
26-5 Charge Air Cooler with C
Alternator, Charge Regula

32-1 Alternator .......................
Starting System
33-1 Starter Motor .................
Alphabetical index ................
References to Service Bulleti
00-0 General
Ab
General information Ce
This Service Manual contains technical data, descrip- Wh
tions and maintenance and repair instructions for sio
standard model Volvo Penta products. A list of these of t
products may be found in the section Specifica-
tions. Cer
insp
The product designation and the serial number and The
specification is indicated on the engine decal or type of th
plate. This information must be included in all corre- the
spondence regarding the product. This
wor
The service manual is produced primarily for the use
of Volvo Penta workshops and their qualified person- •
nel. It is assumed that any person using the Service
Manual has a fundamental knowledge of the product •
and is able to carry out mechanical and electrical
work to trade standard.
•
Volvo Penta continually develops its products; we
therefore reserve the right to make changes. All infor-
mation in this manual is based on product data which
was available up to the date on which the manual was •
printed. New working methods and significant
changes introduced to the product after this date are
communicated in the form of Service bulletins. •
Spare Parts
•
Spare parts for the electrical and fuel systems are
subject to various national safety standards. Volvo
00-0 General
Repa
Introduction Our m
The working methods described in this manual are Each p
based on a workshop scenario where the product is system
mounted in a holding fixture. Maintenance work is nical sp
often carried out on site, in which case – if nothing environ
else is indicated – using the same working methods tem. It
as the workshop. ances
adjuste
Warning symbols that occur in the service manual. Origina
For significance, refer to Safety Information . mainte
! DANGER! Some
cial exp
! WARNING! ponent
environ
! CAUTION!
nents m
perform
IMPORTANT!, NOTICE!
are by no means comprehensive since not everything Remem
can be foreseen as service work is carried out in the used, a
most varied of circumstances. We call attention to recomm
risks that may occur due to incorrect handling during whene
work in a well-equipped workshop using working specifie
methods and tools tried and tested by us. doors,
residue
The service manual describes work operations car-
ried out with the aid of Volvo Penta Special Tools,
where such have been developed. Volvo Penta Spe-
Tight
cial Tools are designed to ensure the safest and most Tighten
rational working methods possible. It is therefore the applied
responsibility of anyone using tools or working meth- Service
ods other than those we recommend to ensure that the Ma
no risk of personal injury or mechanical damage is apply t
present, or that malfunction can result. Indicat
Lock nuts Ana
The
Removed locknuts may not be re-used; they must be The
replaced by new ones, as locking properties are nen
impaired or lost with re-use. with
In the case of lock nuts with plastic inserts the tight- sea
ening torque indicated must be reduced if the nut has etc.
the same nut height as a standard, all-metal hexag-
onal nut. Har
Reduce the torque by 25% for bolt sizes of 8 mm or this
larger. them
In the case of lock nuts with plastic inserts with a high high
nut-height (where the all-metal thread is as high as a not
standard hexagonal nut), the indicated torque care
applies. befo
inst
Strength classes
Saf
Nuts and bolts are subdivided into different strength
classes. The classification is shown by a marking on rub
the bolt head. Markings of a higher number indicate Fluo
stronger material. For example, a bolt marked 10-9 is ring
stronger than one marked 8-8.
Wh
For this reason, it is important that when bolts are pera
removed they are returned to their original locations can
on re-assembly. When replacing bolts check the skin
applicable Spare parts catalogue to ensure the cor- you
rect bolt is used. brea
dam
Sealing compounds etc.
To ensure service work is correctly carried out it is
important that the correct type of sealants and locking Sea
fluids are used on joints where such are required. afte
pois
In each service manual section concerned the seal-
00-0 General
Illust
A lot of illustrations contains standardized symbols and colors. Plea
misunderstandings when working on an engine / transmission usin
Illustration colors Positio

Most illustrations have a focused component (blue)
which is fastened by a (red) bolt or such on a (light
grey) engine / transmission body.
P0015623
Focus a
tains nu
NOTICE
only one
two alike
P0015699
illustrati
1 Focus
(blue)
2 Fastenings
(red)
3 Body
(light grey)
4 Background
P0015627
(white)
This sym
e.g. 2, w
Movement Too
P0015622
Movement arrows are used to show which direction a

component is to be moved / rotated.
P0015625
Symbol is used in a corner of the illustration to show

how many degrees the object shall be turned and at
P00156
which direction.
A sy
show
knife
00-0 General
Chemicals Units
P0015695
Symbols can also describe when and how a chemical

product is to be used.
Cleanliness
P0015696
Units ar
value (e
expecte
Impor
P0015624
The scraper symbol suggests that a contact surface

needs to be scraped from sealant etc.
The cloth symbol suggests that the mechanic should
03-2 Specifications, Engine
Engine designation TAD1640GE TA
Power, Prime/Stand-by Refer to the sales li
Torque, Prime/Stand-by Refer to the sales li
No. of cylinders 6 6
Bore, mm (inch) 144 (5.67) 14
Stroke, mm (inch) 165 (6.50) 16
Cylinder volume, liter (inch 3) 16,12 (983.9) 16
Weight dry, kg (lbs) 1440 (3175) 14
Weight wet, kg (lbs) 1510 (3329) 15
Firing order 1-5-3-6-2-4 1-5
Compression ratio 17,5:1 16
Low idle, rpm 900 90
High idle, rpm 1500/1800 15
Engine designation TWD1652GE, TW

TWD1653GE TW
TW
Power, Prime/Stand-by Refer to the sales li
Torque, Prime/Stand-by Refer to the sales li
No. of cylindersl 6 6
Bore, mm (inch) 144 (5.67) 14
Stroke, mm (inch) 165 (6.50) 16
Cylinder volume, liter (inch 3) 16,12 (983.9) 16
Weight dry, kg (lbs) 1700 (3748) 17
Engine designation TAD1641VE
Power, Prime/Stand-by Refer to the sales literature

Torque, Prime/Stand-by Refer to the sales literature
No. of cylinders 6
Bore, mm (inch) 144 (5.67)
Stroke, mm (inch) 165 (6.50)
Cylinder volume, liter (inch 3) 16,12 (983.9)
Weight dry, kg (ibs) 1480 (3263)
Weight wet, kg (ibs) 1550 (3417)
Firing order 1-5-3-6-2-4
Compression ratio 17,5:1
Low idle, rpm 600
High idle, rpm 1800
Engine designation TAD1640-43VE-B, TAD16

TAD1670-72VE
Power, Prime/Stand-by Refer to the sales literature
Torque, Prime/Stand-by Refer to the sales literature
No. of cylinders 6
Bore, mm (inch) 144 (5.67)
Stroke, mm (inch) 165 (6.50)
Cylinder volume, liter (inch 3) 16,12 (983.9)
Weight wet, kg (ibs) 1440 (3175)
Firing order 1-5-3-6-2-4
Compression ratio 16 8:1
Spe
Gro
Front engine mounting, engine block
Front engine mounting
Rear engine mounting, flywheel housing
Main bearing caps

stage 1
stage 2
Big end bearing cap

stage 1
stage 2
stage 3
Stif
Flywh
P0007088
IMPORTANT!
Make sure the flange is clean and dry.
NOTICE! Tighten the bolts in sequence, as illustrated.
stage 1 60
stage 2 12
Flywh
Vib
P0007089
NOTICE! The 8.8 bolts on the oscillation damper may not

be re-used.
Cov
Valve
P0007092
NOTICE! Tighten the bolts in sequence, as illustrated. 25
Cylind
Bea
Sha
P0007094
IMPORTANT!
Tighten the bolts in stages to ensure that the rocker arm
shaft lowers without being bent.
Bearin
Shaft,
20160
1 1 2 3 4 5 6 7 6
15 ± 3 Nm 60 ± 5 Nm
2 7
100 ± 10 Nm 8 9 10 11 12 13
120º ± 5º
1 2 3 4 5 6 7
3 8
90º ± 5º 100º ± 5º
4 9
8 9 10 11 12 13
100 ± 10 Nm 50 ± 5 Nm
5 10
14 15 16 17 18 19
50 ± 5 Nm 120º ± 5º
P0008581
IMPORTANT! If t
Ti ht th b lt i t t th t th k rem
stage 9: Tighten bolts 8 through 13
stage 10: Angle tighten bolts 8 through 13
Tim
P0007096
NOTICE! Apply 2 mm (0.08") silicone (part nos. 1161231

and 1161277) to the back of the engine block as illustrated.
Bolts 1–27
Bolt 28
Trans
5 1
3 7
4
8
1
2 6
3
5
6
4
2
3 1
5 6
2 4
P0007099
1 Drive gear, crankshaft

stage 1 60
stage 2 12
2 Intermediate gear, bull drive, outer

Ti ht th b lt i ill t t d
Valv
Bolt,
Adju
Adju
Adju
Pre-
Adju
P0016365
Valv
Adju
Adju
Pre-
Adju
Grou
Oil Su
P0007100
NOTICE! Tighten the bolts in sequence, as illustrated. 24
Oil pu
stage 1 35
stage 2 (not 17 and 18) 90
Oil co
Oil
7
6
1 2
3 4
P0007023
1 Safety valve, lubricating oil pump

2 Reducing valve
3 Control valve, piston cooling
4 Opening valve, piston cooling
5 Overflow valve, oil cooler
6 Overflow valve, bypass filter
7 Overflow valve, full flow filter
Grou
Feed pump – steering servo pump 25
Fixing yoke, unit injector (new or re-used copper sleeve type 3)

IMPORTANT!
Always use a new steel gasket beneath the unit injector.
First tightening
stage 1 20
stage 2 18
NOTICE! Loosen the fixing yoke bolt before doing the second tigh
Second tightening
stage 1 20
stage 2 90
Fixing yoke, unit injector (re-used copper sleeve, types 1 or 2)

Gro
Inta
12 8 2 4 6 10
P0007102 11 7 1 3 5 9
Stage 1: Tighten the bolts 1-12 until contact

Stage 2: Tighten the bolts 1-12
NOTICE! Apply a 2 mm (approx 0.08") bead of sealing com-

pound 1161231-4, as illustrated.
Plug, M10
Pressure/temperature sensor, charge air
Exh
P0007103
Turbo
TWD1643GE, TWD1652GE, TWD1653GE, Other e
TWD1663GE, TWD1672GE, TWD1673GE
P0018895
P0018887
Turbo – exhaust manifold

Stage 1: Tighten nuts in the sequence illustrated
Stage 2: Tighten nuts in the sequence illustrated
Gro
Tigh
P0020409
Eng
Tech
Engin
Cylind
Length 11
Height, upper block plane - crankcase centerline 45
Height lower block plane - crankcase centerline 12
Crankcase pressure, normal value, irrespective of engine
speed ma
Cylind
Type 6c
Length 11
Width 43
Height 13
Max. out-of-planeness (bottom plane) (1)
0.0
1) per 100 mm (3.937") measured length
Cylind
Number of bolts 38
Dimension, thread M1
Pist
Type
Height above engine block plane
Diameter, combustion chamber
Depth, piston bowl:
TAD1640GE, TAD1641-43VE, TAD1650VE,
TAD1660-62VE, TAD1640-43VE-B, TAD1670-72VE,
TAD1650VE-B, TAD1651VE
TAD1641-42GE, TAD1650-51GE, TWD1643GE,
TWD1652GE, TWD1653GE, TWD1663GE,
TWD1672-73GE
No. of ring grooves
Front marking
Piston pin diameter
Pist
Compression Rings
Quantity
Piston ring clearance in groove:
upper compression ring
lower compression ring

Piston ring gap, measured at ring opening:
upper compression ring
lower compression ring

Oil ring
Valve
Valves
Valve head, diameter:
Inlet 49
Exhaust 46
Valve stem, diameter:
Inlet 10
Exhaust 10
P0007076
Se
Valve seat angle (A): 20
Inlet 19
Exhaust 44
Se
Seat angle in cylinder head (B): 20
Valv
P0007077
Outer diameter (A)

Standard:
Inlet
Exhaust
Oversize dimension:
Inlet
Exhaust
Height (B):
Inlet
Exhaust
Valv
P0007078
Diameter (C) standard:

I l t
Valve
Length:
Inlet 83
Exhaust 83
Inner diameter:
Inlet 10
Exhaust 10
Height above cylinder head spring plane:
Inlet 24
Exhaust 24
Clearance, valve stem guide(1) :
Inlet 0
Wear tolerance m
Exhaust 0
Wear tolerance m
1) The dimensions are calculated for the measurement method described
Rocke
Bearing clearance ma
Clearance rocker arm roller ma
Valve
Inlet
Uncompressed length 67
With 522 N (117.35 lbf) load 57
With 1205 N (270 9 lbf) load 43
En
Tim
P0006837
No. of teeth:
1 Drive gear, camshaft
2 Intermediate gear, adjustable
3 Intermediate gear, bull drive outer
Intermediate gear, bull drive, inner
Cams
Check camshaft setting, cold engine and valve clear-
ance =0.
At a flywheel position of 6° after TDC, the inlet valve must
be open 1.4 ± 0.3 mm (0.055 ± 0.012"). During this check,
the timing gear must be turned clockwise, seen from the
front, to take up all gear lash.
Drive ge
No. of bearings 7
NOTICE! Only check values; not for machining.
Diameter, bearing journals, standard 69
Diameter, bearing journals, undersize dimension:
0.25 mm (0.00984") 69
0.50 mm (0.01968") 69
0.75 mm (0.02953") 69
Max. end float 0.3
Max permissible ovality (with new bearings) 0.0
Bearing, max. permissible wear on diameter 0.0
Valve lift:
inlet 13
exhaust 14
Permitted wear between base circle and max lift ma
Unit injector, stroke 18
Cams
Camshaft bearing thickness, standard 1.9
Oversize dimension:
Cra
Cra
Length
Crankshaft end float(1)
Ovality of main and big end bearings
Taper on main and big end bearings
Runout on center bearing
1) Dimensions refer to oiled components.
Mai
C D
A
Ø
P0007079
R
Thrus
Width (B) standard 3.1
Oversize dimension:
0.1 mm (0.00394") 3.2
0.2 mm (0.00787") 3.3
0.3 mm (0.0118") 3.4
0.4 mm (0.016") 3.5
Main b
Outer diameter (C) 12
Thickness (D) standard 2.5
Oversize dimension:
0.25 mm (0.00984") 2.6
0.50 mm (0.0197”) 2.7
0.75 mm (0.0295") 2.8
1.00 mm (0.0394") 3.0
1.25 mm (0.0492") 3.1
Radial clearance, main bearings 0.0
Big en
Surface finish, big end bearing journal
Surface finish, radius
Width (A)
Fillet radius (R)
Big
Outer diameter (B)
Thickness (C) standard
Oversize dimension:
0.25 mm (0.00984")
0.50 mm (0.0197”)
0.75 mm (0.0295")
1.00 mm (0.0394")
1.25 mm (0.0492")
Diameter, bearing shell seat (D)
Con
Length, center - center (E)
Piston pin bush internal diameter (G)
End float, connecting rod - crankshaft (1)
Big end bearing, radial clearance (1):
Straightness, max. deviation on 100 mm (3.937") measured
length
Twist, max. deviation on 100 mm (3.937") measured length
1) Dimensions refer to oiled components.
Flywh
Runout, measured radius 150 mm (5.905") ma
No. of teeth on starter gear ring 15
Sensor grooves in flywheel 54
Flywh
Runout for mating face against clutch bellhousing. ma
Runout for alignment against clutch bellhousing. ma
Lub
Tech
Oil
Oil change volume, incl. filter:
TAD1650VE (optional for TAD1660-62VE, TAD1640–
43VE-B, TAD1670-72VE) 53
Other engines 48
Oil Pre
Operating speed (above 1,100 rpm) 30
Low idle mi
Oil tem
Oil
P0006839
A: Bypass valve, oil cooler

Fuel
Tech
Feed p
Feed pressure at:
600 rpm mi
1,200 rpm mi
full load mi
Bypas
Opening pressure 40
Fuel a
Inl
Tec
Tur
TAD1640–1642GE, TAD1641–1643VE, TAD1660-62VE,
TAD1640-43VE-B, TAD1670-72VE, TAD1650VE-B,
TAD1651VE
Manufacturer/type
End float, turbine shaft
TAD1650VE, TAD1650-51GE
Manufacturer/type
TWD1643GE, TWD1652-53GE, TWD1663GE,

TWD1672-73GE
HP Turbo:
Manufacturer/type
LP Turbo:
Manufacturer/type
Inle
Cold engine
Hot engine coolant temperature 75 95 °C (167 203 °F)
Charg
1500 rpm
TAD1640GE 23
TAD1641GE 24
TAD1643VE-B 33
1500 / 1800 rpm

TAD1642GE 26
TWD1643GE, TWD1663GE 46
TAD1650GE 32
TAD1651GE 26
1800 rpm
TAD1640GE 23
TAD1641GE 25
TAD1641VE 19
TAD1642VE 22
TAD1643VE 23
TAD1650VE 20
TAD1643VE-B 33
1900 rpm
TAD1640VE-B, TAD1660VE 17
TAD1641VE-B, TAD1661VE 18
TAD1642VE B TAD1662VE TAD1650VE B
Co
Tec
Gen
Pressure cap opens at 75 k
The
Quantity 1
Opening temperature:
TAD1640–42GE, TAD1641–43VE, TAD1650VE,
TAD1650–51GE, TAD1660–62VE,
TAD1640-43VE-B, TAD1650VE-B, TAD1651VE,
TAD1670-72VE 82 °
TWD1643GE (early mod.), TWD1663GE (early
mod.) 76 °
TWD1643GE (later mod.), TWD1652GE,
TWD1653GE, TWD1663GE (later mod.),
TWD1672-73GE 72 °
Fully open:
TAD1650–51GE, TAD1660–62VE, TAD1640–
43VE-B, TAD1650VE-B, TAD1651VE,
TAD1670-72VE 92 °
mod.) 86 °
TWD1643GE (later mod.), TWD1652GE,
IMPORTANT! IMPORT
Under no circumstances mix VCS (yellow) with Volvo Industria
Penta Coolant (green) or any other coolant. bination
Engines filled with VCS (yellow) will have yellow dec- ted on n
als as external distinguishing features, e.g. the cool-
ant filler cap will be surrounded by a yellow decal.
Refill q
Coolant quantity (engine, radiator and hoses):
TAD1650–51GE, TAD1660–62VE, TAD1640–
43VE-B, TAD1670-72VE, TAD1650VE-B,
TAD1651VE 60 ±2 l
mod.) 95 liter
TWD1643GE (later mod.), TWD1652-53GE,
TWD1663GE (later mod.), TWD1672-73GE 65 liter
03-3 Specifications, Electrical
Sen
Charge air pressure sensor
TAD engines:
Check value
TWD engines:
Check value
Camshaft sensor
Distance to camshaft
Flywheel sensor
Distance to flywheel
Pressure drop indicator

Active
Inactive
Charge air temperature sensor

05-1 Safety Instructions

Safet
This Se
descript
designs
the corr
Read the safety information below and the service manual section
instructions carefully before repair and service work is begun.
!
This symbol is used in the service manual and on the
fact that this is safety information. Always read such
Safety texts in the manual have the following ord
DANGER!
Indicates a hazardous situation which, if not avoided,
injury.
WARNING!
Indicates a hazardous situation which, if not avoided,
personal injury.
CAUTION!
I di t h d it ti hi h if t id d
Immobilize the engine by turning off the power
! supply to the engine at the main switch !
(switches) and lock it (them) in the off position
before starting work. Post a warning notice at
the main circuit breaker.
As a rule, all service operations must be carried

! out with the engine stopped. However, some !
work, such as adjustments, will require the
engine to be running. Approaching an engine
which is running is a safety risk. Bear in mind
that loose clothing or long hair can fasten in
rotating parts and cause serious personal
injury.
Be aware of hot surfaces (exhaust pipes, tur-

! bos, charge air pipes, starting heaters etc.) and !
hot fluids in pipes and hoses on an engine that
is running or has just stopped.
If work is done adjacent to a running engine, a
careless movement or a dropped tool may in the
worst case lead to personal injury.
Ensure that the warning symbols or information

! decals on the product are always clearly visible. !
Replace decals which have been damaged or
painted over.
Avoid getting oil on your skin! Protracted or

! repeated exposure to oil can cause skin to !
become dry. Irritation, dryness, eczema and
other skin problems may then result From a
Always use protective glasses or goggles when N

! carrying out work where a risk of splinters, ! re
grinding sparks, splashes from acid or other
chemicals is present. Your eyes are extremely
sensitive; injury may cause blindness!
Never use start gas or similar products as a S

! starting aid. They may cause an explosion in the ! s
inlet manifold. Danger of personal injury. M
w
te
All fuels, as well as many chemicals, are flam- M

! mable. Do not allow open flames or sparks in ! fu
their vicinity. Gasoline, some thinners, and R
hydrogen gas from batteries are extremely u
flammable and explosive when mixed with air in fi
the correct proportions. No Smoking! Ensure a
that the work area is well ventilated and take the m
necessary safety precautions before welding or a
grinding work is begun. Always ensure that p
there are fire extinguishers close at hand in the re
work area.
Batteries must never be exposed to open N

! flames or electric sparks. Never smoke in the ! p
vicinity of the batteries; they generate hydrogen a
gas when charged, which is explosive when d
mixed with air. This gas is easily ignited and th
highly explosive. A spark, which can be caused a
by incorrect battery connection, is sufficient to li
cause a battery to explode and cause damage. o
Do not touch the connections during start

The components in the electrical and fuel sys-
! tems on Volvo Penta products are designed and !
manufactured to minimize the risk of fire and
explosion. The engine must not be run in areas
where there are explosive materials.
Only use fuels and lubricating oils recom-

! mended by Volvo Penta. Refer to the Operator's !
Manual for the product in question. Use of fuels
that are of a lower grade may damage the
engine, the injection pump and the injectors. On
a diesel engine, low grade fuel can cause the
control rod to bind and the engine to over-rev,
with the risk of engine damage and personal
injury as a result. Low fuel and oil grades may
result in high service, maintenance and repair
costs.
Fuel delivery pipes must not be bent or straight-

! ened under any circumstances. Cracks may
occur. Damaged pipes must be replaced.
08-2 Special Service Tools

The follo
the eng
Penta b
P0006764
P0006782
885810 Fixture 9809726 Pneumatic hydr

pump
For upper timing cover Used with 9809729 or
9992670. Replaces 99962
P0006761 P0006763
9986173 Puller 9986179 Puller

For flywheel bearings For flywheel bearings
P0006771
P0006772
9990125 Nipple 9990143 Fixture

For turbo pressure manometer Up to and including eng
2016010024
P0006774 P0006775
9990157 Press tool 9990158 Piston ring c

pressor
For cylinder liner (7 pcs.
required)
P0006778
P0006777
9990164 Fixture 9990165 Guide sleeve

For pressure testing cylinder For valve spindle seal
head
P0006779 P0006780
9990192 Puller 9990210 Valve spring co

pressor
For rear crankshaft seal, used
with 9996400
P0004328
P0006787
9992000 Handle 9992269 Drift
Standard handle For installation of flywheel

ing
P0006794 P0006781
9992670 Hand pump 9992873 Nipple

Used with 9809729, alternative For pressure checking
to 9809726
p0004329
p0004330
9996394 Support 9996395 Support

P0004331
p0006800
9996400 Slide hammer 9996441 Cover, with c

ing nipple
For cooling system leak
P0004333
P0006804
9996662 Pressure testing kit 9996666 Nipple

P0006806
P0006805
9998249 Protective sleeve 9998250 Sealing ring

For unit injectors (6 pcs. For fuel duct in cylinder he
required) pcs. required)
P0006810
P0006813
9998252 Thread cutting tool 9998264 Lifting tool

For removal of copper sleeve For camshaft
P0006816
P0006818
9998487 Sleeve 9998494 Hose

For removal of oil filter For measuring fuel pressu
(red), used with 9990123 a
9990124
P00068115
P0006817
9998601 Fixture 9998629 Lifting tool

For upper timing cover Thread M10, 2 pcs. req
p0006797
P0006767
88800003 Fixture 88800021 Drift

Used with 9986485 (from and For removal of front cra
including engine no. seal
2016010025)
p0006799
P0006819
88800196 Drift 88800123 Plate

For removal of copper sleeve Used with 88800003 (fr
including engine no.
2016010025)
Other
The follo
working
from AB
cated.
P0006821 P0002930
885531 Pressure testing kit 885633 Torque multiplier

Cooling system
P0004342
P0006823
885811 Timing tool 885812 Timing tool

p0013448
P0002793
88800083 Piston ring pliers 88890102 Nipple

20-0 Engine Information, General
20-0 Engine Information, Gener

Place
TAD164
TAD164
TAD164
TAD164
TAD165
TAD166
TAD167
The figu
be locat
P0006848 1 4 5 2 P0006849
Pla
TWD
TWD
The
be lo
4 5
6
Locat
Electrical Components
1 Under pressure sensor, air filter (only TWD engines)
2 Camshaft position sensor
3 Pre-NOx sensor (TAD1670-72VE)
4 Coolant temperature sensor
5 Flywheel position sensor
6 Air inlet pressure/intake manifold temperature sensor
7 Coolant level sensor
8 Aux stop
9 Fuses
10 Crankcase pressure sensor
11 Fuel pressure sensor
12 Oil level/temp sensor
13 Water in fuel switch
14 Oil pressure sensor
AdBl
TWD16
Schematic connection stand-by AdBlue/DEF heating

heater system Hotstart CSM 10302 for a standby he
Tr
A nu
malf
cont
whic
IMP
Rea
nanc
oper
Symptoms and possible causes

The diagnosis button lamp flashes
Please refer to Diagnostic Function
Engine can not be stopped
2, 5
Starter motor does not rotate
1, 2, 3, 4, 5, 6, 7, 24
Starter motor rotates slowly
1, 2
Starter motor rotates normally but engine does not start
8, 9, 10, 11,
Engine starts but stops again
8, 9, 10, 11, 13
Engine does not reach correct operating speed at full throttle
9, 10, 11, 12, 13, 21, 25, 26
Engine runs roughly
10, 11
High fuel consumption
Reason code
1 Discharged batteries
2 Poor contact/open circuit in electrical wiring
3 Main switch turned off
4 Main fuse faulty
5 Faulty ignition lock
6 Faulty main relay
7 Faulty starter motor/-solenoid
8 No fuel:
– fuel cocks closed
– fuel tank empty/wrong tank connected
9 Blocked fuel fine-filter/pre-filter (due to contaminations, or stra
10 Air in the fuel system
11 Water/contamination in fuel
12 Faulty unit injectors
13 In sufficient air supply to the engine:
– blocked air filter
– air leakage between the turbo and the engine's intake man
– dirty compressor part in the turbocharger
– faulty turbo compressor
– poor engine room ventilation
14 Coolant temperature too high
15 Coolant temperature too low
16 Oil level too low
17 Coolant level too low
18 Air in the coolant system
Co
Su
Functional Disturbances Ext
For more detailed information and further fault tracing 1
help, See Operator's Manual, group 30, “MID 128,
PID 110 Engine coolant temperature”. If there is a
malfunction, first check the following items:
• Check that the coolant level is between the
markings on the expansion tank (at approx.
20°C) [68 °F]. If the level in the expansion tank
is too low, top up and start the engine. If the 2
coolant disappears, there is internal or external
leakage.
3
• Check that the coolant is not contaminated. If
the coolant is contaminated, this signifies inter- Int
nal leakage (oil) or that the cooling system has
a blockage (deposits). Blockage in the cooling •
system is caused by one or more of the follow-
ing factors: Fu
1 The coolant has not been changed at the •
specified intervals.
2 Incorrect mixture of coolant and water. •
3 Contaminated water has been used.
Clogging
Is often caused by high coolant temperature, internal •
or external blockage of the cooling system, or a com-
bination of both. If the cooling system is blocked, it
must be cleaned.
Charg
Charg
Tools:
999833
999849
999666
1 Co
to
to
2 Co
be
ma
If t
the
ch
Press
TAD164
TAD164
TAD165
NOTICE
tor is ele
manage
1 Ch
no
2 Re
filt
Cha
TAD
TAD
TAD
1
Inle
1
Cha
1
2
Test
Comp
The fue
remove
Head pa
Tools:
998853
999018
999824
999824
999859
Remo
1 IM
9998248 Ma
is
Re
Re
pro
the
99
2 Fit
to
P0004964 inj
3 Oil
bri
4 Fit
7
9
13 Re
9998248 all
P0004964
Install
14 Mo
Ins
Re
15 Fit
To
av
Ma
po
fie
16 Ins
roc
17 Ad
Un
P0004965 18 Ch
be
19 Re
20 Ve
Co
Too
9996
9996
Che
testi
Test
1
2
P0006858
5
Cylin
Tools:
999012
999623
998648
999016
999010
999016
Check
Check p
ing kit b
1 Co
pre
2 Se
us
wit
P0006858
3 Clo
pre
de
4 Un
op
Pre
Cyli
For a
9996
Rem
1
2
3
4
P0007007
10
16 Blo
wit
IM
Ma
thi
17 Re
ins
18 Re
the
Re
P0006858
Charg
1 Ins
ex
2 Ch
If t
lea
en
are
ca
se
ch
NOTICE
charge
and hos
very car
7
Wast
TWD16
Locali
The was
wastega
Tools:
999012
P0006860
1 Co
ing
pre
Ad
2
P0006862
4
5 Ins
the
Tig
6 Re
it.
7 Re
ac
P0006864
Drive
Inspe
Belts m
still war
be able
between
Both the
matic be
Sens
Sensor
3
88800031
P0010198
P0010219
Therm
Remov
Change
1 Pla
he
03
P0005072
Closed thermostat.
2 If t
pe
3 Ins
Ch
NO
mo
21-0 Engine Complete, Gener
Re
Gro
Cy
Ins
Clea
tion
IMPO
Cylin
mea
The
a sin
Cyl
Mea
the l
NOT
engi
1
21-0 Engine Complete, General
pis
ch
Cr
me
Cylin
(all)
Tools:
998987
999015
999015
999247
999359
999639
999639
999664
999696
999851
888000
Remo
Cylinde
cooling
IMPORT
It is imp
remove
nozzles
1 Re
ho
Tu
bo
2
IMPO
Re-i
dam
P0006912
5
Install
8 Ch
ca
rec
Fit
Lo
9 Fit
99
Pla
ind
Ze
pre
P0006964
10 Me
an
Me
dia
Ca
Fo
sp
pla
co
NO
the
cy
rep
13
P0006917
14
15
17 Lu
an
FRO
NT
P0006920
18 Ins
ma
arr
Pr
NO
pin
gre
co
pin
Ins
20
21
22
P0006923
23
Crank
The cra
Inspect
essary o
The follo
checked
1 Cle
Me
an
sp
2 Ch
the
the
3 Pla
ma
cra
4 Me
on
Fo
nic
IM
Cr
5 Ch
Ma
flu
vio
Ma
Oil p
The
with
Too
9990
9990
9993
Rem
1
P0006884
2
4 Re
ap
be
dir
too
5 Cle
sh
If t
de
6 Ch
wh
NO
ca
P0006971
av
Install
7 Lu
sh
8 Ins
cra
ag
oil
NO
sh
cu
Ma
be
oil
NO
11
12
P0006974
13
14
Big e
Oil pan
remove
Tools:
999359
Remo
1 Fit
wh
1a
be
2 Ma
rod
IM
Be
3 Re
P0006884
ne
NO
led
4 Ch
5 Me
the
rem
Install
6 Fit
be
sh
Fly
Too
9986
9986
9991
9992
1
2
P0006977
3
Flywh
Tools:
999359
999623
1 Re
2 Fit
3 Bo
wit
Re
tur
Lif
4 Cle
sh
5 Cle
fac
6 Ch
ins
Ch
7 Lif
ing
8 To
en
P0006931
too
9 Re
10 Ch
Se
Ins
Ge
Flyw
1
P0006979
P0006980
Flywh
Pressu
Tools:
998987
999359
999969
1 Ins
99
ag
2 Re
ing
3 Se
ob
dia
(0
(5
If t
inv
ne
fla
P0006985
4 Re
the
Cra
Opti
Too
9990
9992
8880
Opti
Too
9990
9990
9992
9996
8880
Rem
1
5
Remo
Tools:
999019
999640
1 Ha
tog
9990192 IM
Inc
da
999 6400
P0006989
Install
Tools:
999200
888000
1 Ch
3
P0004791
4
5 Re
P0004793
6 Ca
ag
7 En
ma
8 Ins
ac
en
Cra
Too
9990
9990
9992
9996
Rem
1
P0006990
Inst
3
5 Pre
bo
co
IM
No
cle
6 Re
P0006993
Conn
Importa
fracture
Install
Carefull
pads.
Undo th
tap the
it loosen
The spl
ing rod
When th
may occ
does no
adverse
Co
1
3 IMPOR
2 Regard
tions, r
P0006994 P0006995
3
Valve
Work is
equipme
pcs. bol
NOTICE
cleanlin
head. D
or malfu
Alterna
Tools:
980972
980972
P0006996 999016
999017
999267
999615
999824
Note: 99
980972

Alterna
Tools:
999021
Altern
1 Fit
99
Alte
Too
9990
1
P0006997
5
Valve
Alterna
Tools:
980972
999016
999017
999017
999021
999267
999615
999824
Note: 99
980972

Alterna
Tools:
999021
Altern
IMPORT
1 Blue
2 Brow
Alte
Too
9990
1
P0006997
Valve
Cylinde
Tools:
998987
999247
1 Th
se
ex
ref
P0007000
2 Gr
the
tio
tro
IMPORT
Carefull
to preve
P0007001
3
P0007003
6
Valve
Refer to
Valve
Cylinde
NOTICE
must be
CA
Risk of
Option
Tools:
980972
980972
999017
999615
888000
888001
888001
Optiona
Tools:
999267
Note: 99
Remo
999 2670 980 9729 1 Ins
Inst
6
IMPO
Wea
7
IMPO
After
head
from
may
Opti
Too
9992
8880
8880
8880
Remo
NOTICE
cylinder
1 Ta
tog
2 Ta
Install
3 He
ing
sn
Lu
en
Val
For
Data
NOT
mac
P0007076
P0008416
Inlet valve
Valve
1 Be
gu
era
2 Wh
un
en
sh
3 Gr
be
dis
ref
4 Ch
ga
co
NOTICE
do not n
NOTICE
as poss
age.
Valves
1 Ch
tha
Da
NO
va
2 Ch
an
Val
Too
9990
9990
9993
Rem
1
6
Install
IMPORT
1 Blue
2 Brow
P0021295
7 Lu
Fit
Sli
dre
8 Ins
an
co
ma
9 Tra
ind
en
top
Re
de
9996
9998
9998
9998
9998
8880
8880
1
P0006890
5
7 Us
an
sle
Ins
tor
mu
NO
be
du
8 Cle
P0007010 sle
9 Cle
98
P0007011
10 Cle
999 8580 98
980 8617 11 Re
12 Ch
NO
13
P0003615
1, 2. Older versions of the copper sleeve.

3. New version copper sleeve.
14
88800196
88800196 16 By
dra
sle
Re
P0003618
17 Re
99
18 Ins
tio
19 Pu
ma
20 Ins
an
21 Ins
22 Fil
oc
an
9998250
Ca
Roc
Put a
the c
show
Mea
Alter
Com
Tech
P0007013
Gui
In no
surfa
that
not h
form
pone
Exam
are s
Acceptable wear: Una

The camshaft need not be changed. IMPO
The
chan
Cams
Repla
The fac
togethe
be move
Therefo
are repla
that the
aligned.
vidually
P0007018
The hole
ment ho
center b
front an
If a repla
their nu
place as
P0007019
Tim
Valv
cove
rem
Too
8858
9993
9996
9998
Rem
1
2
3
P0006884
4
6 Re
ho
7 Re
8 Re
9 Re
an
NO
thi
cra
P0006908
10 Re
an
11 Re
NO
an
12 Re
sid
13
14
P0006926
15
16 Ins
17 Ins
bo
Tig
P0006927
18 Ins
be
ge
NO
ha
se
Tig
Sp
P0006929
23
24
P0006944
25
P0006947
28 Re
ing
en
P0006930
29 Ins
ing
blo
30 Ins
se
ne
IM
No
31
32
33
P0006907
34
36 Pre
tur
he
su
Ins
Tig
Tig
NO
led
ap
37 Ins
to
38 Ins
P0007021
999 8601
P0006952
Ex
Exp
TAD
TAD
TAD
TAD
TAD
TAD
TAD
1
P0006865
2 Re
all
Als
co
3 Re
ex
4 Re
P0006866
5 Re
6 Re
ch
Re
bra
7
10
11
12
P0006868 13
Expo
TWD16
TWD16
1 Dr
Sy
Dr
2 Re
Re
(C
P0006865
3 Re
all
Als
co
4 Re
5
6
7
8
P0006867
9
10 Fit
Lif
11 Th
it.
Re
12 Re
13 Re
bra
P0006870
14 Un
pa
Hea
TWD
TWD
The
incre
Re-i
work
Fitti
Engin
Applies
Tools:
999014
1 Re
un
2 Re
tro
Re
3 Re
the
Co
4 Att
P0006873
Engin
Applies
En
Cy
NOT
esse
alwa
Eng
and
Too
9990
9990
9990
9990
9990
9990
9993
9996
9996
9998
9998
9998
9998
1
2
3
4 Co
tur
P0006868
5 Re
P0006876
7
P0006878
P0006879
10
13 Re
ma
14 Th
ind
us
ma
rei
P0006880
15 Re
an
16 Re
ho
P0006881
18
P0006883
19
20 Tu
ch
TDC
C
TD
P0003112
Early model.
22
D9 23
D11
D16
D9 D9
D11 D11 D9
D16 D16 D11
D16
P0006887
24
25 Cle
inj
Re
26 Pu
99
P0006889
27 Ins
ind
Ma
sle
NO
29
30
P0006892
31
P0006893
32
34 Re
Us
to
999 6239 tiv
NO
he
he
P0006895
35 Re
co
NO
99
P0006896
36 Re
37
38
P0006898
39
40
P0006899
42 Re
Ca
loo
NO
an
Lif
P0006901
43 Re
fan
illu
P0006902
45
P0006904
46
P0006905
47
Timin
Tools:
999623
1 Re
ou
2 Att
tw
Re
fly
Pin
IM
Th
P0006907
3 Re
rem
an
4
P0006909
7
Pisto
Tools:
998648
999359
999639
999664
999696
1 Re
en
be
IMPORT
It is imp
remove
nozzles
2 Re
no
3 Tu
99
P0006911
4 Pre
are
ha
Lif
IMPORT
Replace
7
P0006913
Crank
Tools:
999001
999011
1 Re
do
Us
P0006914
2 Lif
NO
(17
Cra
1
3
4
8
Cylin
Tools:
999015
999696
999851
1 Ins
Re
lin
2 Lu
pli
ind
NO
low
P0006916
3
P0006917
Pisto
1 Ins
2 Lu
an
FRO
NT
P0006920
3 Ins
pis
fac
Pr
NO
in;
4 Fit
5
IMPO
Alwa
rings
easi
P0006825
P0006922
6
Pisto
Tools:
999015
999015
1 Oil
be
2 Te
the
3 Us
the
En
the
NO
are
NO
op
too
P0006924
the
4 Re
mu
ve
en
5 Ins
To
Tig
Pis
1
IMPO
Faul
pisto
pect
new
2
IMPO
Che
cylin
pisto
bloc
led,
3
P0006925
4
Timin
1 Ap
en
2 Ins
are
ac
en
NO
be
P0006926
3 NO
ins
Oi
up
qu
4
5
P0006927
6
9 Ins
P0006909
10 Ap
ing
P0006930
12
P0006931
13
14
18 Ins
O-
P0006934
19 Ins
23
P0006900
24
25
P0006899
26
28 Fit
P0006897
29 Ins
Cy
Too
9990
1
P0006896
5
8 Lo
de
Ma
10
cy
blo
9 Sli
pla
10 Pla
fro
NO
en
P0006940
11 Ins
(1)
de
Sc
12 To
cia
Un
NO
po
the
ag
13 Ins
ing
18
P0006942
Cams
Tools:
999359
1 Ins
W
2 Cle
the
3 Ins
on
cy
4 Pla
an
5 Tu
tha
to
P0006943
6
TDC
C
TD
P0003112
P0006885
8 Cle
the
Ins
bra
NO
sid
To
±2
To
±5
P0006945
Fla
Too
8858
9998
1
P0006946
P0006947
6 Ap
up
tra
7 Fit
ge
P0006949
8 On
ho
pre
P0006950
9
10
P0006951
999 8601
P0006952
Unit i
Tools:
999015
999640
999825
NOTICE
1 Re
99
2 Fit
ca
Ins
inj
To
qu
P0006890
3 Re
tio
NO
ab
4 Lu
5 Re
ca
6 Ins
Ma
7
P0006883
Adjus
The cam
cylinder
unit inje
NOTICE
camsha
bearing
P0006954
Early model.
TDC 5
3
En
1
P0006959
4
5
8
10 Fit
11 Fit
rem
po
filt
ac
en
12 Ins
13 Fit
Re
14 Fit
alt
15 Re
rem
P0006868 16 Ins
17 Ins
co
18 Ins
19 Ins
inl
20 Ins
tio
21 Ins
ins
air
22 Ins
ch
23 Ins
ex
21-4 Valve Mechanism
Val
Adj
Iden
Dep
with
tant
acco
Tim
The
ders
injec
P0006954
Early model.
NOT
cam
TDC 5
3 bear
NOTICE
on the e
Check t
Standa
For adju
illustrati
mechan
P0016503
TAD1640-42GE, TAD1641-43VE, TAD1640VE-B, TAD1641VE-B,
TAD1642VE-B, TAD1660-62VE, TAD1670-72VE, TWD1643GE,
TWD1652-53GE, TWD1663GE, TWD1672-73GE.
Valve m
Compre
For adju
marking
anism e
Brake) p
Valv
(Exh
For a
mark
anis
Reci
P0016505
TAD1650GE, TAD1650VE, TAD1651GE TAD1650VE-B,
TAD1651VE.
Stand
TAD164
TAD164
TAD164
TAD166
TAD167
TWD16
TWD16
Tools:
999359
Valves
1 Ad
ind
5 Tu
TDC
3 Us
5
1
2
P0006956
3
Valve
VCB
TAD164
TAD166
TAD167
Valves
1 Re
P0016506
2 Tu
Us
In
me
3
P0016508
P0016509
5 IM
Ad
cy
ma
Ex
ind
P0016507
6 Ad
tha
the
Un
se
be
7
P0006956
8
10 Wh
ad
Ch
the
Th
3.7
Ad
de
P0016513
11 Tig
arm
Tig
NO
rec
Re
rin
Ins
P0016506
Val
Inte
Re
TAD
TAD
TWD
Valv
1
P0016506
TDC 5
3
4 Ad
0.3
Tig
ca
P0016508
5 Ad
ad
inj
Ad
(by
Tig
Tig
to
P0016509
7
P0006956
8
10 Lo
fla
Tig
ca
Re
P0004808
11 Wh
ad
Ch
the
Th
4.0
Ad
de
P0016513
12 Tig
arm
Tig
NO
rec
Re
i
Val
Too
9989
9999
Cyli
Refe
1
4
999 9696
998 9876
5
22-0 Lubricating and Oil System, General
22-0 Lubricating and Oil System

When
Fuel a
! CA
Apply b
tive glov
oil and f
engine o
P0007022
Overv
A By-pa
B Safet
C Redu
D Contr
E Open
22-1 Oil pump and Line
Lub
1
3
4
P0006969
6
9
22-2 Oil filter
22-2 Oil filter

Relie
1 Cle
2 Re
3 Cle
ho
pla
4 Ch
ma
5 Fit
the
va
Tig
Tig
6 Sta
P0007024
Bypa
Repla
1 Re
2 Cle
3 Re
4 Cle
ho
5 Fit
tig
Saf
1
2
3
P0007026
Pis
1
2
3
4
5
22-2 Oil filter
Bypa
1 Cle
2 Re
oil
3 Fit
ac
en
4 Sta
P0007028
Oil Fi
1 Ch
If t
thr
ca
Oil
If yo
rectl
sens
The
refer
Too
9992
9996
9998
1
2
3
5
6
22-2 Oil filter
Engin
chang
Tools:
999848
999917
1 Re
an
nin
Ho
2 Cle
filte
oil
P0007029
3
8
22-2 Oil filter
Relie
1 Ch
ma
NO
red
2 Ch
im
Pre
an
ag
P0007031
Safet
1 Ch
ma
NO
sa
2 Ch
im
Pre
an
ag
P0007031
22-3 Oil cooler
Oil
Rem
1
2
3
4
P0006899
Inst
5
6
22-3 Oil cooler
Oil Co
Tools:
999666
999684
1 Re
Re
2 Cle
ble
Cle
3 Ch
tak
Te
eq
999 6845 4 Ins

are
P0007032
5 Ch
99
tha
By
1
P0007034
23-0 Fuel System, General

Fuel s
TAD164
TAD164
TAD164
TAD164
TAD165
TAD166
TAD167
1 Ch
tha
2 Tw
bra
3 Ve
pu
Air
No
4 Sta
10
5 Pe
P0007042
Fue
TWD
TWD
1
P0004969
Drain
TWD16
TWD16
IMPORT
Make su
and hos
1 Cle
he
2 Re
Re
P0005062
3 Re
(co
Re
NO
filte
4
P0005059
5
23-3 Fuel Feed Pump and Filter

Engin
IMPORT
Do not f
There is
and cau
! W
The fue
cold, to
onto ho
1 Cle
2 Re
filte
Co
3 Cle
4 Lu
ne
ins
5 Ble
ble
Fue
Rem
1
P0004300
Inst
7
Fuel
1 Dis
rat
2 Re
ho
ve
3 Re
fro
4 Cle
wit
ho
5 Ins
ca
Re
6 Lu
Sc
the
Th
7 Co
8 Ble
P0007038 ble
23-7 Injectors and Delivery Pi
Un
Too
9990
9990
9990
9998
9998
The
– 98
– 98
– 99
For a
and
NOT
NOT
code
ice m
the u
Rem
1
2
3
23-7 Injectors and Delivery Pipes
7 Re
9990013 Pla
Pu
loc
the
inje
9990006 Att
the
8 Att
rem
P0001370
9 Ins
tho
98
99
Inst
10
P0005064
11
12 Att
ter
To
to
13 Att
is
Att
14 Ins
15 Lu
wit
P0005066
16 Lift
of
Ch
be
IM
Tig
sh
To
sp
tha
P0004965
17 Cle
led
the
Ins
un
Pu
rin
Sle
Unit
Rep
Too
1159
9986
9996
9998
9998
9998
9998
8880
8880
8880
IMPO
Wor
ness
1
2
4 Th
su
ble
Pre
Re
Ins
Mi
P0019122
5 Pre
sle
Tig
pu
too
P0021200
Pu
Am
If t
ne
Ins
P0021202
7 Alt
Ins
Sc
po
8
P0007010
10
P0007011
11
999 8580
980 8617 12
13
15 Fit
Th
the
the
Oi
NO
sle
88800196
P0003616
88800196 16 Fit
cy
the
Ins
Us
sle
88800196 17
P0003618
18
19
20
21
22
23
9998250
23-8 Control System, ECM, Data Sets
23-8 Control System, ECM, Dat

Engin
NOTICE
warrant
be perfo
trol syst
show de
fault fre
! W
Faulty in
injury to
mation a
refer to
IMPORT
Exchan
fault tra
any circ
1 Cle
ne
2 Dis
ing
3 Re
pip
4 Re
cla
5 Re
the
8
10
11
12
P0007036
13
25-0 Inlet and Exhaust System, General
25-0 Inlet and Exhaust System,

Charg
1 Ins
ex
2 Ch
If t
lea
en
are
ca
se
ch
NOTICE
charge
and hos
very car
25-2 Exhaust Pipe, Silencer
Exh
TWD
TWD
Rem
1
2
3
4
25-2 Exhaust Pipe, Silencer
7 Ma
Ad
Tig
8 Ins
Re
9 Ins
ted
25-5 Turbo and supercharger
Tur
1
3
4
Tur
Alwa
Remo
TAD164
TAD164
TAD164
TAD164
TAD165
TAD166
TAD167
Variant
1 Re
air
2 Re
fro
3 Re
Ins
TAD
TAD
TAD
TAD
TAD
TAD
TAD
Vari
1
P0006868
4 Co
ag
5 Fil
de
IM
Ma
str
6 Fit
7 Fit
8 Fit
9 Sta
P0006875
Low
Alwa
boch
insta
A pr
rily is
are k
chan
grad
corre
Ther
oil a
to ru
befo
Blow
fold w
coul
It is
filter
plac
char
Re
TWD
TWD
Low
Vari
1
2
3 Re
4 Re
5 Un
the
6 Re
7 Re
tur
blo
8 Re
9 Lif
10 Tra
tur
4
P0007044
8
9
10
High
Always
bocharg
installed
A prereq
rily is th
are kep
changes
grade o
correctly
Therefo
oil and r
to run th
before t
Blow an
fold whe
could da
It is also
filter. De
place an
charger
Re
TWD
TWD
High
Vari
1
2
1
4
3
4
5
6
6 7
3
8 Re
wa
2X
2X
P0003630
9 Se
fre
Lif
P0007045
Insta
2
3
P0007047
The picture shows TWD1643GE, TWD1652-53GE.
8
9 Ins
ne
1 10 Fit
11 Tig
12 Ch
Fit
NO
the
13 Ins
ch
14 Tig
tig
NO
wa
Ad
15 Ins
2 Re
1
Wa
TWD
TWD
Rem
1
P0007049

3 Re
4 Re
5 Lif
P0007050
P0018881
Inst
6
7
8
10
11
25-8 Emission After-Treatment

Repa
TAD166
TAD167
TWD16
NOTICE
literatur
details m
cerned.
always
IMPORT
AdBlue/
age. Do
electrica
a compo
AdBlue/
CA
Gloves
clothes.
WA
In the ca
area mu
If you in
air.
NOTICE
order to
crystalli
Ele
Ho
TAD
TAD
TWD
1
P0019364
3
8 Re
9 Sw
up
oc
10 Pe
co
P0019365
Ad
TAD
TWD
Too
1158
1159
1
4
1158957 5 Cla
co
p0013226
6 Re
lat
7 Ins
8 Ins
To
9 Ins
Ins
tio
13
14
p0013223
IMPO
Fluid
Volv
exha
NOT
15
AdBl
TAD167
TWD16
Tools:
115895
Remo
1 Sto
NO
run
ing
2 Dis
3 Pla
NO
rec
P0019364
4 Un
(2)
Em
5
P0019367
p0013226
p0013222
7
8 Lif
pin
P0019369
9 Un
sh
P0019370
11
P0019372
12
P0019373
13
Install
14 Ca
the
P0019375
15 Ins
P0019373
16 I
17
P0019376
18
P0019370
20 Ins
P0019368
21 Ins
Ch
an
22 Re
23 Fil
24 To
P0019378
25 Re
Ad
TAD
TWD
Glov
cloth
P0013268 1
2
3 Im
wa
4 Un
6
p0013237
7
AdBl
TAD167
TWD16
Tools:
115895
CA
Gloves
clothes.
1 Sto
NO
run
ing
2 Dis
P0019364
3 Pla
NO
rec
5
P0019367
p0013226
p0013222
7
8 Su
loc
P0019369
9 Re
ho
Ca
P0019371
11
P0019380
12
14 Ins
P0019382
15 Ins
P0019376
17
P0019368
18
19
20
21
22
P0019378
23
Exha
Chan
TAD166
TAD167
TWD16
1 Dis
P0019364
2 Re
3 Un
4 Un
5 Sc
6 Ins
Do
TAD
TAD
TWD
Rem
1
P0019364
3
4 Re
NO
be
P0019385
5 Re
6 Re
P0019386
Inst
7
8
P0019387
10
P0019388
12 Re
13 Sta
14 De
P0019365
NOTICE
AdBlue®
p0013225
Ad
TAD
TWD
Too
1159
1
3
4 Ex
ga
Ad
ing
5 Re
Re
6
p0013242
8
AdBl
TAD167
TWD16
1 Sto
NO
run
ing
2 Dis
P0019364
3 Pla
4 Un
NO
rec
5
P0019390
7
8 Tig
Tig
ft.)
P0019392
9 Re
10 Sta
11 De
P0019365
NOTICE
AdBlue®
So
Ch
TAD
TAD
TWD
Too
1158
Rem
1
P0019364
A
Install
6 Ins
Ins
7 Ins
8 Ins
cla
P0013270
9 Re
ho
A
p0013271
10 Re
Pre
TAD
TWD
Too
8889
8889
1
p0013258
2 Cle
Re
p0013259
3 Re
4
p0013262
p0013264
Pump
TAD166
TWD16
1 1
2
2
2 2
p0013266
IMPORT
The dos
ent vers
Before c
corresp
IMPORT
Make su
1
4
5 Re
NO
p0013257
6 Ex
ac
ho
ca
7
p0013232
9
10 Tra
ne
NO
an
11 Ins
the
NO
pro
12 Re
tric
p0013251
13 Ins
ing
loc
14 Ins
ele
D
16
17
18
19
20
p0013223
Pump
TAD167
TWD16
Remo
1 Sto
NO
run
ing
2 Dis
P0019364
3 Re
4
P0019394
p0013222
5
Install
6 Ins
bo
P0019395
7 Ins
9
10
11
P0019365
NOT
AdB
p0013225
Co
Tan
TAD
TWD
1
Comb
Tank
TAD167
TWD16
Tools:
115895
Remo
1 Sto
NO
run
ing
2 Dis
P0019364
3
P0019367
115895
p0013226
p0013222
5
Install
6 Ins
P0019376
7 Ins
Ch
an
8 Re
P0019378
Tem
TAD
TWD
Too
8889
8889
1
p0013258
2 Cle
co
p0013259
3 Re
4
p0013261
7
Chec
AdBl
TAD166
TAD167
TWD16
1 Rem
ibility
P0019380
2 Dip t
in th
3 Attac
reac
Evaluat
• If the
the p
Ch
flui
TAD
TAD
TWD
Too
8889
NOT
tilled
1 R
ib
2 D
fa
U
le
P0019380
3 A
(8
26-0 Cooling System, General

Drain
NOTICE
TAD165
corresp
WA
Do not o
hot, exc
persona
IMPORT
On eng
the eng
coolant
Tools:
999604
NOTICE
1 Re
NO
ex
ato
2
P0006865
Co
NOT
TAD
corre
All c
men
Coo
radia
shou
om
cle
5 Dr
Re
if n
To
in
wit
be
6 Flu
wit
on
nin
he
tyi
7 Sh
pe
Vo
me
low
co
8 Wh
co
9 Re
ing
Co
Up
Coola
Topp
NOTICE
TAD165
1
TAD engines
P0002096
TWD engines
Filling
NOTICE
advance
pletely f
correct
IMPORT
Do not s
complet
1 Ch
2 Op
ca
3 Fil
MI
4 Sta
be
ve
tra
If a
sys
an
TAD engines 5 Sto
the
TWD e
2 1 Op
rad
1
2 Fil
ple
3
4
IMPO
Do n
3 com
P0002098
Co
Too
9996
9996
NOT
TAD
corre
Che
ing k
Hea
1
2
3
4 Co
pre
red
ap
(B
5 Th
the
lea
NO
do
no
6 Sh
ing
P0006859 un
op
7 Re
8 Ch
Ins
9 Sta
oc
26-1 Radiator, Heat Exchange
Ra
TWD
TWD
Rem
1
2
3
4
5
26-1 Radiator, Heat Exchanger
6 Re
7 NO
rel
Lif
NO
P0007058
P0007059
Inst
8
P0007060
10
11
12
26-2 Coolant Pump, Thermostat
26-2 Coolant Pump, Thermosta

Coola
Remo
! CA
Disconn
the eng
1 Dr
to
2 Re
ab
3 Re
pu
be
Re
4 Re
Pre
ac
the
The
Too
9996
Rem
1
P0004690
4
Install
5 Cle
the
P0005071
6 Ins
P0004691
Dri
TAD
TAD
TAD
TAD
TAD
TAD
TAD
1
3
4
6
7
8
9
10
11
Drive
TWD16
TWD16
1 Sw
the
2 Re
low
P0007073
3
P0006869
6
Belt T
Right b
tector.
Drive b
Change
Remo
1 Un
an
2 Un
the
The
Rem
Cha
1
P0005072
Closed thermostat.
3
Coola
IMPORT
The coo
intervals
significa
engine w
coolant
always
1 Sh
2 Cle
plie
3 Lu
so
Sc
the
4 Op
5 Sta
P0007065
1 Tap open
2 Tap closed
26-5 Charge Air Cooler with C
Low
TWD
TWD
Rem
1
2
3
4
5
6
6 5 3
7
7 2 8
4x
1
4
P0003633
9
26-5 Charge Air Cooler with Connections
10 Re
bra
11 Un
12 Lift
P0007067
Install
13 Ins
un
14 Tig
15 Ins
P0007067
19
20
21
6 5 3
22
7 2
4x
1
4
P0003633
23
24
25
26
P0007068
Uppe
TWD16
TWD16
Remo
1 Re
2 Dr
3 Un
4 Re
bra
ch
P0007070
7
8
9
P0007071
Inst
10
P0007072
11
14 Ins
bra
15 Ch
Fit
air
16 Ins
17 Ins
bra
ch
Tig
18 Ins
19 Ins
20 Ad
Re
Up
21 Ch
32-1 Alternator
Alt
TAD
TAD
TAD
TAD
TAD
TAD
TAD
Left
Coo
Cha
Rem
1
32-1 Alternator
2 De
Pin
Wi
P0004688
Altern
TWD16
TWD16
IMPORT
Always
cracked
1 Sw
the
2
P0007073
32-1 Alternator
3 Fit
Lif
dri
4 Fit
(2)
Pre
alt
5 Ch
rol
reg
6 Pre
do
7 Lif
ins
8 Ins
P0007074 9 Fit
10 Sta
33-1 Starter Motor
Sta
Rem
1
2
3
P0007066
5
33-1 Starter Motor
7 Ins
Tig
P0007075
8 On
Ins
co
9 Ins
10 Ch
Alphabetical index
A E
About this Workshop manual..................................... 3 Electrica
AdBlue/DEF tank heating......................................... 60 Emission
AdBlue/DEF Tank, Change............................ 251, 254 Engine...
AdBlue/DEF Tank, Cleaning.......................... 261, 264 Engine A
AdBlue/DEF-Pump Filter, Change................. 275, 278 Engine b
Adjustment Markings.............................................. 180 Engine C
Alternator................................................................ 329 Engine C
Alternator Belt, Change.................................. 329, 330 Engine D
B Engine F
Belt Tensioner, Change.......................................... 320 Engine F
Big end bearing, Change (all)................................... 90 Engine In
Bypass Valve Oil Filter, Change............................. 202 Engine o
Bypass Valve, Oil Cooler, Replace........................ 209 Engine T
Bypass Valve, Oil Filter Bypass, Replace.............. 200 Exhaust
Exhaust
C Exhaust
Camshaft Bearing Housing, Replace..................... 120 Exposing
Camshaft, Installation............................................. 172 Exposing
Camshaft, Wear Check.......................................... 119
Charge Air Cooler with Connections...................... 323 F
Charge Air Cooler, External Cleaning...................... 65 Fitting th
Charge Air Pipe, Leakage Check..................... 72, 230 Flank Cle
Charge Pressure, Troubleshooting.......................... 64 Flywhee
Checking for diesel or oil in the AdBlue/DEF Flywhee
solution................................................................... 302 Flywhee
Checking urea concentration in the fluid................ 303 Fuel Fee
Combined Tank Unit, AdBlue/DEF Tank, Fuel Fee
Change........................................................... 295, 296 Fuel Pre
Common Interference Causes................................. 63 Fuel Sys
Compression Test.................................................... 66 Fuel syst
Connecting Rod Bushing, Check up...................... 101 Fuel Sys
Connecting Rod, Check......................................... 100 G
O V
Oil cooler................................................................ 207 Valve Gu
Oil Cooler, Pressure Testing.................................. 208 Valve Gu
Oil Cooler, Replace................................................ 207 Valve Me
Oil Filter, Check...................................................... 202 Valve me
Oil Pressure Sensor, Check................................... 203 Valve Se
Oil pump and Line.................................................. 199 Valve Se
Oil Pump, Check.................................................... 199 Valve Ste
Other Equipment...................................................... 54 Valves a
Overview Control Valve.......................................... 198 Valves, I
P Valves, R
Piston Cooling Jet, Installation............................... 161 W
Piston Cooling Valves, Replace............................. 201 Wastega
Piston, Pre-installation............................................ 158 Wastega
Pistons, Installation................................................ 160 When yo
Pistons, Removal................................................... 152 cation O
Placement of Instrument Socket(s).................... 56, 57
Pressure Sensor, Change...................................... 283
Pump Unit, Change........................................ 286, 292
R
Radiator Assembly, Change .................................. 311
Radiator, Heat Exchanger...................................... 311
Relief Valve, Check................................................ 206
Relief Valve, Replace............................................. 200
Repair instructions.............................................. 4, 248
Replacement of Components................................... 79
S
Safety Instructions.................................................... 44
Safety Valve, Check............................................... 206
Safety Valve, Oil Pressure, Replace...................... 201
Sensors, Adjustment................................................ 76
Sleeve for unit injector replace 114 221
References to Servi
Group No. Date
....................................................................................................
....................................................................................................
....................................................................................................
....................................................................................................
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....................................................................................................
....................................................................................................
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Workshop Ma

Safety and Other Instructio

Alternator, Charge Regula

Illustration colors Positio

Movement arrows are used to show which direction a

Symbol is used in a corner of the illustration to show

Symbols can also describe when and how a chemical

The scraper symbol suggests that a contact surface

Engine designation TWD1652GE, TW

Engine designation TAD1641VE

Power, Prime/Stand-by Refer to the sales literature

Engine designation TAD1640-43VE-B, TAD16

Main bearing caps

Big end bearing cap

NOTICE! Tighten the bolts in sequence, as illustrated.

NOTICE! The 8.8 bolts on the oscillation damper may not

NOTICE! Tighten the bolts in sequence, as illustrated. 25

NOTICE! Apply 2 mm (0.08") silicone (part nos. 1161231

1 Drive gear, crankshaft

2 Intermediate gear, bull drive, outer

NOTICE! Tighten the bolts in sequence, as illustrated. 24

1 Safety valve, lubricating oil pump

Fixing yoke, unit injector (new or re-used copper sleeve type 3)

Fixing yoke, unit injector (re-used copper sleeve, types 1 or 2)

Stage 1: Tighten the bolts 1-12 until contact

NOTICE! Apply a 2 mm (approx 0.08") bead of sealing com-

Turbo – exhaust manifold

lower compression ring

upper compression ring

lower compression ring

Outer diameter (A)

Diameter (C) standard:

A: Bypass valve, oil cooler

TWD1643GE, TWD1652-53GE, TWD1663GE,

1500 / 1800 rpm

Pressure drop indicator

Charge air temperature sensor

05-1 Safety Instructions

As a rule, all service operations must be carried

Be aware of hot surfaces (exhaust pipes, tur-

Ensure that the warning symbols or information

Avoid getting oil on your skin! Protracted or

Always use protective glasses or goggles when N

Never use start gas or similar products as a S

All fuels, as well as many chemicals, are flam- M

Batteries must never be exposed to open N

Do not touch the connections during start

Only use fuels and lubricating oils recom-

Fuel delivery pipes must not be bent or straight-

08-2 Special Service Tools

885810 Fixture 9809726 Pneumatic hydr

9986173 Puller 9986179 Puller

9990125 Nipple 9990143 Fixture

9990157 Press tool 9990158 Piston ring c

9990164 Fixture 9990165 Guide sleeve

9990192 Puller 9990210 Valve spring co

9992000 Handle 9992269 Drift

Standard handle For installation of flywheel

9992670 Hand pump 9992873 Nipple

9996394 Support 9996395 Support

9996400 Slide hammer 9996441 Cover, with c

9996662 Pressure testing kit 9996666 Nipple

9998249 Protective sleeve 9998250 Sealing ring