Volvo Penta TAD940GE Workshop Manual

Brand: Volvo Penta

Model: TAD940GE

Category: Engine

Type: Workshop Manual

This manual is also suitable for

Workshop Manual

Group 20 Technical Data

TAD940GE, TAD941GE

TAD940VE, TAD941VE, TAD942VE, TAD943VE

TAD950VE, TAD951VE, TAD952VE

1(0)

Technical data

Industrial Engines

TAD940GE, TAD941GE

TAD940VE, TAD941VE, TAD942VE, TAD943VE

TAD950VE, TAD951VE, TAD952VE

Contents

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

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

Technical data ...................................................... 6

General ............................................................... 6

Engine ................................................................ 8

Valve mechanism ............................................... 10

Timing gear ......................................................... 14

Reciprocating components .................................. 16

Lubrication and oil systems................................. 19

Fuel system ........................................................ 22

Inlet and exhaust system .................................... 23

Cooling system ................................................... 24

Engine control system ........................................ 25

Tightening torque ................................................ 27

References to Service Bulletins .......................... 36

Group 20

Safety information

This workshop manual contains technical data, de-

scriptions and repair instructions for the Volvo Penta

products or product versions noted in the table of con-

tents. Make sure that you use the correct workshop

literature.

Important

The following special warning signs are used in the

workshop manual and on the product.

WARNING! Warns for the risk of personal injury,

major damage to product or property, or serious

malfunctions if the instruction is ignored.

IMPORTANT! Is used to call attention to things

which could cause damage or malfunctions to

product or property.

NOTE! Is used to call attention to important informa-

tion, to facilitate work processes or operation.

To give you a perspective on the risks which always

need to be observed and precautions which always

have to be taken, we have noted them below.

Make it impossible to start the engine by cutting

system current with the main switch(es) and

lock it (them) in the off position before starting

service work. Fix a warning sign by the control

station.

All service work should normally be done on a

stationary engine. Some work, such as adjust-

ments, need the engine to be running, however.

Going close to a running engine is a safety risk.

Remember that loose clothes, long hair etc. can

catch on rotating components and cause severe

injury.

If work is done adjacent to a running engine, a

careless movement or a dropped tool can lead

to personal injury in the worst case. Take care

to avoid contact with hot surfaces (exhaust

pipes, turbocharger, charge air pipe, starter

heater etc.) and hot fluids in pipes and hoses in

an engine which is running or has just been

stopped. Reinstall all protective parts removed

during service operations before starting the en-

gine.

Read the available safety information, ”General in-

formation” and ”Repair instructions” in the work-

shop manual before you start to do any service

work.

Check that the warning or information labels on

the product are always clearly visible. Replace

labels which have been damaged or painted

over.

Never start the engine without installing the air

cleaner (ACL) filter. The rotating compressor tur-

bine in the turbocharger can cause severe inju-

ry. Foreign objects entering the intake ducts can

also cause mechanical damage.

Never use start spray or similar products as a

starting aid. They may cause an explosion in

the inlet manifold. Danger of personal injury.

Only start the engine in a well- ventilated area.

When operated in a confined space, exhaust

fumes and crankcase gases must be ventilated

from the engine bay or workshop area.

Avoid opening the coolant filling cap when the

engine 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-

ful if a tap, plug or coolant hose has to be re-

moved from a hot engine. It is difficult to antici-

pate in which direction steam or hot coolant can

spray out.

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.

Never start or operate the engine with the oil fill-

er cap removed, otherwise oil could be ejected.

General instructionsGroup 20

Stop the engine before carrying out operations

on the engine cooling system.

Always use protective glasses or goggles when

carrying out work where there is a risk of splin-

ters, grinding sparks, acid splashes or where

other chemicals are used. Your eyes are ex-

tremely sensitive, injury could cause blindness!

Avoid getting oil on your skin! Repeated expo-

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

from a health aspect. Use protective gloves and

avoid oil soaked clothes and shop rags. Wash

regularly, especially before eating. There are

special skin creams which counteract drying out

of the skin and make it easier to clean off dirt

after work is completed.

Most chemicals intended for the product (e.g.

engine and transmission oils, glycol, petrol (gas-

oline) and diesel oil) or chemicals for workshop

use (e.g. degreasers, paints and solvents) are

hazardous. Read the instructions on the product

packaging with care! Always follow the safety

precautions for the product (for example use of

protective mask, glasses, gloves etc.). Make

sure that other personnel are not exposed to

hazardous chemicals, for example in the air. En-

sure good ventilation in the work place. Follow

the instructions provided when disposing of

used or leftover chemicals.

Exercise extreme care when leak detecting on

the fuel system and testing the fuel injector noz-

zles. Use eye protection. The jet from a fuel in-

jector is under very high pressure, and has con-

siderable penetration ability; fuel can force its

way deep into body tissues and cause serious

damage. Danger of blood poisoning (septice-

mia).

WARNING! The delivery pipes must under no

circumstances be bent. Damaged pipes must be

replaced.

All fuels, and many chemicals, are flammable.

Do not allow naked flame or sparks in the vicini-

ty. Certain thinners and hydrogen from batteries

can be extremely flammable and explosive

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.

Make sure that oil and fuel soaked rags, and

used fuel and oil filters are stored in a safe

place. Rags soaked in oil can spontaneously ig-

nite under certain circumstances. Used fuel and

oil filters are polluting waste and must be hand-

ed to an approved waste management facility

for destruction, together with used lubrication oil,

contaminated fuel, paint residue, solvents, de-

greasers and wash residue.

Batteries must never be exposed to open

flames or electric sparks. Do not smoke close

to the batteries. The batteries generate hydro-

gen gas when charged, which forms an explo-

sive gas when mixed with air. This gas is easily

ignited and highly volatile. A spark, which can

be formed if the batteries are wrongly connect-

ed, is enough to make a battery explode and

cause damage. Do not shift the connections

when attempting to start the engine (spark risk)

and do not lean over any of the batteries.

Never mix up the battery positive and negative

poles when the batteries are installed. Incorrect

installation can result in serious damage to the

electrical equipment. Refer to the wiring dia-

gram.

Always use protective goggles when charging

and handling the batteries. Battery electrolyte

contains sulfuric acid, which is highly corrosive.

Should the battery electrolyte come into contact

with unprotected skin wash off immediately us-

ing plenty of water and soap. If you get battery

acid in your eyes, flush it off at once with a gen-

erous amount of water, and get medical assis-

tance at once.

General instructions

Group 20

Turn the engine off and turn off the power at the

main switch(es) before carrying out work on the

electrical system.

The clutch must be adjusted with the engine

shut off.

The existing lugs on the engine should be used

for lifting. Always check that the lifting devises

are in good condition and that they have the cor-

rect capacity for the lift (the weight of the engine

plus the reversing gear and extra equipment).

The engine should be lifted with a customized or

adjustable lifting boom for safe handling and to

avoid damaging components on top of the en-

gine. All chains or cables must be parallel to

each other and should be as square as possible

to the top of the engine.

If other equipment connected to the engine has

altered its center of gravity, special lifting devis-

es may be needed to obtain the correct balance

and safe handling.

Never do any work on an engine which just

hangs from a liftingdevise.

Never work alone when heavy components are

to be dismantled, even when safe lifting devises

such as lockable blocks & tackle are used.

When using a lifting devise, two people are usu-

ally 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 operations.

Always make sure that there is enough space

for disassembly where you are working, with no

risk for personal or material damage.

WARNING! Components in the electrical and

fuel systems on Volvo Penta products have

been designed to minimize the risks of explo-

sion and fire. The engine must not be operated

in environments with adjacent explosive media.

Only use the fuels recommended by Volvo Pen-

ta. Refer to the Instruction Book. Use of fuels

that are of a lower quality can damage the en-

gine. In a diesel engine, poor fuel can cause the

control rod to bind and the engine will over- rev,

entailing a strong risk of personal injury and ma-

chinery damage. Poor fuel can also lead to

higher maintenance costs.

Remember the following when washing with a

high pressure washer: Never aim the water jet at

air filters, seals, rubber hoses or electrical com-

ponents. Never use a high pressure washer for

engine cleaning.

The injectors can leak fuel when the engine is

stationary, if the tank is higher than the engine

and the fuel pressure is positive.

Group 20

General information

Certified engines

The manufacturer certifies that both new engines and

those in use, which are certified for national or region-

al legislation, comply with the environmental require-

ments. Each product must correspond with the unit

used for certification. The following requirements for

service and spare parts must be complied with, for

Volvo Penta as a manufacturer to be responsible for

ensuring that engines in use comply with the stipulat-

ed environmental requirements:

Maintenance and service intervals recommended

by Volvo Penta must be complied with.

Only Volvo Penta Original Spare Parts intended

for the certified engine version may be used

Service related to injection pumps and injectors

must always be done by an authorized Volvo Pen-

ta workshop.

The engine must not be converted or modified in

any way, except for the accessories and service

kits which Volvo Penta has approved for the en-

gine.

Installation changes to the exhaust pipe and the

engine bay air inlet ducts (ventilation ducts) must

not be done without further discussion, since this

could affect exhaust emissions.

No seals may be broken by unauthorized person-

nel.

The general advice in the instruction book about oper-

ation, care and maintenance applies.

IMPORTANT! When spare parts are needed,

use only Volvo Penta Original Spares.

Use of non-original spareparts means that AB

Volvo Penta can no longer be responsible for

guaranteeing that the engine complies with the

certified version.

Any damage, injury and/or costs which arise due

to the use of non-original Volvo Penta spares for

the product in question will not be compensated

by Volvo Penta.

About the workshop manual

This workshop manual contains technical data for the

TAD940GE, TAD941GE, TAD940VE, TAD941VE,

TAD942VE, TAD943VE, TAD950VE, TAD951VE and

TAD952VE engines.

The Workshop Manual, Technical Data, contains all

the references from the workshop manuals to repair

instructions for the TAD940GE, TAD941GE,

TAD940VE, TAD941VE, TAD942VE, TAD943VE,

TAD950VE, TAD951VE and TAD952VE series.

The Workshop Manual is produced primarily for the

use of Volvo Penta workshops and service techni-

cians. For this reason the manual presupposes a cer-

tain basic knowledge and that the user can carry out

the mechanical/electrical work described to a general

standard of engineering competence.

Volvo Penta constantly improves its products, so we

reserve the right to make modifications without prior

notification. All information in this manual is based on

product data which was available up to the date on

which the manual was printed. Any material changes

introduced into the product or service methods after

this date are notified by means of Service Bulletins.

Spare parts

Spare parts for electrical and fuel systems are subject

to various national safety requirements. Volvo Penta

Original Spares comply with these requirements. No

damage whatever, occasioned by use of non-original

Volvo Penta spares for the product, will be compen-

sated by the warranty offered by Volvo Penta.

Group 20

Type designation TAD940VE TAD941VE TAD942VE TAD943VE

Power See Sales Guide Industrial Diesel Power

Torque See Sales Guide Industrial Diesel Power

Compression ratio 20.2:1 20.2:1 20.2:1 20.2:1

Low idle (rpm) 600 600 600 600

High idle (rpm) 2250 2250 2250 2250

No. of valves 24 24 24 24

No. of cylinders 6 6 6 6

Cylinder bore (mm) 120 120 120 120

Stroke (mm) 138 138 138 138

Swept volume (dm

) 9.36 9.36 9.36 9.36

Weight, dry (kg) 1015 1015 1015 1015

Weight, wet (kg) 1065 1065 1065 1065

Injection sequence 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4

Technical data

General

Type designation TAD940GE TAD941GE

Power, Prime/Stand-by See Sales Guide Generating Set Engines

Torque, Prime/Stand-by See Sales Guide Generating Set Engines

Compression ratio 20,2:1 17,4:1

Low idle (rpm) 600-1200 600-1200

High idle (rpm) 1500-1620/1800-1920 1500-1620/1800-1920

No. of valves 24 24

No. of cylinders 6 6

Cylinder bore (mm) 120 120

Stroke (mm) 138 138

Swept volume (dm

) 9.36 9.36

Weight, dry (kg) 1015 1015

Weight, wet (kg) 1065 1065

Injection sequence 1-5-3-6-2-4 1-5-3-6-2-4

(1 mm = 0.03937 inch)

Technical data

Group 20

Type designation TAD950VE TAD951VE TAD952VE

Power Please refer to the sales literature

Torque Please refer to the sales literature

Compression ratio 20.2:1 20.2:1 20.2:1

Low idle (rpm) 600 600 600

High idle (rpm) 2250 2250 2250

No. of valves 24 24 24

No. of cylinders 6 6 6

Cylinder bore, mm (inch) 120 (4.72) 120 (4.72) 120 (4.72)

Stroke, mm (inch) 138 (5.43) 138 (5.43) 138 (5.43)

Swept volume, dm

(US quart) 9.36 (9.89) 9.36 (9.89) 9.36 (9.89)

Weight, dry, kg (lb) 1015 (2238) 1015 (2238) 1015 (2238)

Weight, wet, kg (lb) 1065 (2348) 1065 (2348) 1065 (2348)

Injection sequence 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4

Group 20

Engine

Engine block

Length .................................................................... 967 mm (38.07")

Height, upper block plane - crankcase centerline ... 379 mm (14.92")

Height lower block plane - crankcase centerline ..... 120 mm (4.72")

Crankcase pressure

normal value, irrespective of engine speed............. max 0.5 kPa (0.07 psi)

Cylinder head

Type ...................................................................... 6-cylinder

Length .................................................................... 996 mm (39.21")

Width .....................................................................410 mm (16.14")

Height .................................................................... 135 mm (5.32")

Max. flatness error (base plane) .............................0.4 mm (0.0158")

Cylinder head screws

No. of screws ......................................................... 26

Dimension, thread .................................................. M16

Length .................................................................... 200 mm (7.874")

Cylinder liner

Type ...................................................................... Wet, replaceable

Height, total. .......................................................... 250 mm (9.8425")

Sealing surface height above block plane .............. 0.15 - 0.20 mm (0.0059 - 0.0079")

No. of seal rings per cylinder liner .......................... 3

Cylinder bore ..........................................................120.00 - 120.02 mm (4,72 - 4,73”)

Piston

Type ...................................................................... aluminium

Height above engine block plane ............................ 0.15 -0.65 mm (0.0059 - 0.0256")

Diameter, combustion chamber

TAD940GE, TAD940-943VE ............................... 77 mm (3.032")

TAD941GE ......................................................... 78,5 mm (3.090")

TAD950-52VE ..................................................... 77,1 mm (3.035")

Depth, piston bowl

TAD940GE, TAD940-943VE ............................... 15 mm (0.590")

TAD941GE ......................................................... 17,3 mm (0.681")

TAD950-952VE ................................................... 14,6 mm (0.575")

No. of ring grooves ................................................. 3

Front marking ......................................................... Arrow towards front

Gudgeon pin diameter ............................................54 mm (2.126")

Technical data

Group 20

Piston rings

Compression rings

Specification:

Quantity .................................................................2

Piston ring clearance in groove

upper compression ring ....................................... 0.12 -0.19 mm (0.0047 - 0.0075")

lower compression ring ....................................... 0.09 -0.13 mm (0.0035 - 0.0051")

Piston ring gap, measured at ring opening:

upper compression ring ....................................... 0.35 -0.55 mm (0.013779 - 0.021653")

lower compression ring ....................................... 1.15 -1.3 mm (0.045275 - 0.051181")

Oil scraper ring:

Quantity .................................................................1

Width, including spring ........................................... 4.3 mm (0.011811")

Piston ring clearance in groove, ............................. 0.05 -0.10 mm (0.001968 - 0.003937")

Piston ring gap, measured at ring opening .............. 0.35 -0.75 mm (0.013779 - 0.029527")

Technical data

Group 20

Valve mechanism

Valves

Valve head, diameter:

Inlet .................................................................... 38 mm (1.49606")

Exhaust

TAD940-941GE, TAD940-943VE ...................... 38 mm (1.49606")

TAD950-952VE ................................................. 36 mm (1.41732")

Valve stem, diameter:

Inlet .................................................................... 8 mm (0.31496")

Exhaust .............................................................. 8 mm (0.31496")

Valve seat angle (A):

Inlet .................................................................... 29.5°

Exhaust .............................................................. 29.5°

Seat angle in cylinder head (B):

Inlet .................................................................... 30°

Exhaust .............................................................. 30°

Dimension between valve head and cylinder head plane:

Inlet .................................................................... min 0.95 mm (0.037401")

Exhaust .............................................................. min 1.25 mm (0.049212")

NOTE! When the valve seats are changed, the valves must be changed at the same time.

Valve clearance, cold engine, setting value:

Inlet .................................................................... 0.2 mm (0.007874")

Exhaust

TAD940-941GE, TAD940-943VE ...................... 0.5 mm (0.019685")

TAD950-952VE ................................................. 0,8 mm (0.031496")

Valve clearance, cold engine, check value:

Inlet .................................................................... 0.15 -0.25 mm (0.005905 - 0.009842")

Exhaust

TAD940-941GE, TAD940-943VE ...................... 0.45 -0.55 mm (0.017716 - 0.021653")

TAD950-952VE ................................................. 0,75 - 0,85 mm (0.029527 - 0.033465")

TAD950-952VE

Clearance, double rocker arm

– base circle on camshaft ......................................using gauge tool

Technical data

Group 20

Valve seats

Outer diameter (A)

Standard:

Inlet ....................................................................

TAD940-941GE, TAD940-943VE ...................... 40.0 mm (1.5748")

TAD950-952VE ................................................. 42,0 mm (1.6535")

Exhaust

TAD940-941GE, TAD940-943VE ...................... 41.0 mm (1.61417")

TAD950-952VE ................................................. 40,0 mm (1.5748")

Oversize dimension:

Inlet

TAD940-941GE, TAD940-943VE ...................... 40.3 mm (1.586611")

TAD950-952VE ................................................. 42,3 mm (1.665349")

Exhaust

TAD940-941GE, TAD940-943VE ...................... 41.3 mm (1.625981")

TAD950-952VE ................................................. 40,3 mm (1.586609")

Height (B):

Inlet

TAD940-941GE, TAD940-943VE ...................... 7.3 mm (0.287401")

TAD950-952VE ................................................. 7,4 mm (0.291338")

Exhaust

TAD940-941GE, TAD940-943VE ...................... 7.4 mm (0.291338")

TAD950-952VE ................................................. 6,4 mm (0.251968")

Technical data

Group 20

Valve seat bed

Diameter (C) standard:

Inlet

TAD940-941GE, TAD940-943VE ...................... 40.0 mm (1.5748")

TAD950-952VE ................................................. 42,0 mm (1.6535")

Exhaust

TAD940-941GE, TAD940-943VE ...................... 41.0 mm (1.61417")

TAD950-952VE ................................................. 40,0 mm (1.5748")

Diameter (C) oversize dimension:

Inlet

TAD940-941GE, TAD940-943VE ...................... 40.2 mm (1.582674")

TAD950-952VE ................................................ 42,2 mm (1.661412")

Exhaust

TAD940-941GE, TAD940-943VE ...................... 41.2 mm (1.622044")

TAD950-952VE ................................................. 40,2 mm (1.582672")

Depth (D):

Inlet .................................................................... 11.5 mm (0.452755")

Exhaust .............................................................. 11.9 mm (0.468503")

Seat base radius (R):

Inlet .................................................................... max 0.8 mm (0.031496")

Exhaust .............................................................. max 0.8 mm (0.031496")

Technical data

Group 20

Valve guides

Length:

Inlet .................................................................... 83.4 mm (3.283458")

Exhaust .............................................................. 83.4 mm (3.283458")

Inner diameter:

Inlet .................................................................... 8 mm (0.31496")

Exhaust .............................................................. 8 mm (0.31496")

Height above cylinder head spring plane:

Inlet .................................................................... 24.5±0.5 mm (0.964564 ± 0.019685")

Exhaust .............................................................. 16.5±0.5 mm (0.6496043 ± 0.019685")

Clearance, valve stem - guide:1

Inlet .................................................................... max 0.2 mm (0.007874")

Exhaust .............................................................. max 0.2 mm (0.007874")

The dimensions have been calculated for the method of measurement described in the workshop manual (group 21).

Rocker arms

Bearing clearance .................................................. max 0.08 mm

Valve springs

Inlet

Outer valve springs:

Unloaded length .................................................. 73.8 mm (2.905506")

With 590 N (132.6 lbf) loading ............................. 58.4 mm (2.299208")

With 1150 N (258.5 lbf) loading ........................... 45.3 mm

Coilbound length, max ......................................... 39.5 mm (1.555115")

Inner valve spring:

Unloaded length .................................................. 70.5 mm (2.775585")

With 243 N (54.6 lbf) loading ............................... 54.4 mm (2.141728")

With 447 N (100.4 lbf) loading ............................. 41.3 mm (1.625981")

Coilbound length, max ......................................... 36.5 mm (1.437005")

Exhaust

Outer valve springs:

Unloaded length .................................................. 73.8 mm (2.905506")

With 590 N (132.6 lbf) loading ............................. 58.4 mm (2.299208")

With 1150 N (258.5 lbf) loading ........................... 45.3 mm (1.783461")

Coilbound length, max ......................................... 39.5 mm (1.555115")

Inner valve spring:

Unloaded length .................................................. 70.5 mm (2.775585")

With 243 N (54.6 lbf) loading ............................... 54.4 mm (2.141728")

With 447 N (100.4 lbf) loading ............................. 41.3 mm (1.625981")

Coilbound length, max ......................................... 36.5 mm (1.437005")

Technical data

Group 20

Timing gear

Timing gear wheels

No. of teeth:

1. Drive gear, crankshaft .......................................... 54

2. Idler wheel, double, outer ...................................... 72

Idler wheel, double, inner ...................................... 56

3. Idler wheel, adjustable .......................................... 73

4. Drive gear, camshaft ............................................ 84

5. Idler wheel, servo pump ........................................ 37

6. Drive wheel, steering servo and fuel feed pump .... 31

7. Drive wheel, air compressor ................................. 42

8. Drive wheel, lubricating oil pump .......................... 23

Gear backlash

min ..................................................................... 0.05 mm (0.001968")

max .................................................................... 0.17 mm (0.006692")

Shaft stub for idler wheel, diameter ........................ 100 mm (3.937")

Bushing for idler wheel, diameter............................ 100 mm (3.937")

Radial clearance for idler wheel .............................. max 0.05 mm (0.001968")

Technical data

Group 20

Camshaft

Check camshaft setting, cold engine and valve clearance =0.

Inlet valve for cylinder 1 at flywheel position 6 ATDC must be open 1.3±0.3 mm (0.05118±0.0118").

During the check, you must turn the timing gear in the correct direction (clockwise seen

from the front), to take up all gear flank clearance.

Drive ...................................................................... gear wheel

No of bearings ........................................................ 7

Diameter, bearing journals, standard ...................... 69.97 -70.00 mm (22.754718 - .7559")

NOTE! Only check values, not for machining.

Diameter, bearing journals, undersize dimension

0.25 .................................................................... 69.72 -69.78 mm (2.744876 - 2.747238")

0.50 .................................................................... 69.47 -69.53 mm (2.735033 - 2.737396")

0.75 .................................................................... 69.22 -69.28 mm (2.725191 - 2.727553")

Max. end float ........................................................ 0.24 mm (0.009448")

Max permissible ovality (with new bearings) ........... 0.05 mm (0.001968")

Bearing, max. permissible wear on diameter .......... 0.05 mm (0.001968")

Valve lift:

inlet ..................................................................... 13 mm (0.51181")

outlet (EPG) ........................................................ 12 mm (0.47244")

Permissible wear between base circle

and max. lift ....................................................... max 0.1 mm (0.003937")

Unit injector, stroke ................................................13 mm (0.51181")

Camshaft bearings

Camshaft bearing thickness, standard ................... 1.92 mm (0.075590")

Oversize dimension:

0.25 .................................................................... 2.04 mm (0.080314")

0.50 .................................................................... 2.17 mm (0.085432")

0.75 .................................................................... 2.29 mm (0.090157")

Technical data

Group 20

Reciprocating components

Crankshaft

Length .................................................................... 1.066 mm (0.041968")

Crankshaft, end float

.............................................0.10–0.40 mm (0.0039–0.0157")

Ovality of main and big end bearings .....................max 0.01 mm (0.000393")

Taper of main and big end bearings ....................... max 0.02

Runout on center bearing .......................................0.15 mm (0.005905")

Dimensions refer to oiled components.

Main bearing journal

NOTE! Only check values, not for machining.

Diameter (Ø) standard ............................................ 108.0 mm (4.25196")

Undersize dimension:

0.25 mm .............................................................107.85 -107.87 mm (4.246054 - 4.246841")

0.50 mm .............................................................107.73 -107.75 mm (4.241330 - 4.242117")

0.75 mm .............................................................107.60 -107.62 mm (4.236212 - 4.236999")

1.00 mm .............................................................107.48 -107.50 mm (4.231487 - 4.232275")

1.25 mm .............................................................107.35 -107.37 mm (4.226369 - 4.227156")

Surface finish, main bearing journal ....................... Ra 0.25

Surface finish, radius ............................................. Ra 0.4

Width, main bearing journal (A) standard ................ 42 mm (1.65354")

Oversize dimension:

0.2 mm (thrust bearing 0.1) ................................. 42.17 -42.22 mm (1.660232 - 1.662201")

0.4 mm (thrust bearing 0.2) ................................. 42.37 -42.42 mm (1.668106 - 1.670075")

0.6 mm (thrust bearing 0.3) ................................. 42, 57-42.62 mm (1.65354 - 1.677949")

Fillet radius (R)....................................................... 4.5 mm (0.177165")

Technical data

Group 20

Thrust washers (thrust bearing)

Width (B) standard ................................................. 3.2 mm (0.125984")

Oversize dimension:

0.1 mm ............................................................... 3.2 -3.3 mm (0.125984 - 0.129921")

0.2 mm ............................................................... 3.3 -3.4 mm (0.129921 - 0.133858")

0.3 mm ............................................................... 3.4 -3.5 mm (0.133858 - 0.137795")

Main bearing shells

Outer diameter (C) ................................................. 113 mm (4.44881")

Thickness (D) standard .......................................... 2.5 mm (0.098425")

Oversize dimension:

0.25 mm ............................................................. 2.6 -2.7 mm (0.102362 - 0.106299")

0.50 mm ............................................................. 2.7 -2.8 mm (0.106299 - 0.110236")

0.75 mm ............................................................. 2.8 -2.9 mm (0.110236 - 0.114173")

1.00 mm ............................................................. 2.9 -3.0 mm (0.114173 - 0.11811")

1.25 mm ............................................................. 3.1-3.2 mm (0.122047 - 0.125984")

Radial clearance, main bearings ............................. max 0.11 mm (0.004330")

Big end bearing journal

NOTE! Only check values, not for machining.

Diameter (Ø) .......................................................... 88 mm (3.46456")

Undersize dimension:

0.25 mm ............................................................. 87.85 -87.87 mm (3.458654 - 3.459441")

0.50 mm ............................................................. 87.73 -87.75 mm (3.453930 - .3454717")

0.75 mm .............................................................87.60 -87.62 mm (3.448812 - 3449599")

1.00 mm ............................................................. 87.48 -87.50 mm (3.444087 - 3.444875")

1.25 mm ............................................................. 87.35 -87.37 mm (3.438969 - 3.439756")

Surface finish, big end bearing journal ....................Ra 0.25

Surface finish, radius ............................................. Ra 0.4

Width (A) ................................................................ 54 mm (2.12598")

Fillet radius (R)....................................................... 4.5 mm (0.177165")

Technical data

Group 20

Big end journal shells

Outer diameter (B) ................................................. 93 mm (3.66141")

Thickness (C) standard .......................................... 2.4 mm (0.094488")

Oversize dimension:

0.25 mm ............................................................. 2.5 -2.6 mm (0.098425 - 0.102362")

0.50 mm ............................................................. 2.6 -2.7 mm (0.102362 - 0.106299")

0.75 mm ............................................................. 2.7 -2.8 mm (0.106299 - 0.110236")

1.00 mm ............................................................. 2.8 -2.9 mm (0.110236 - 0.114173")

1.25 mm ............................................................. 3.0 -3.1 mm (0.11811 - 0.122047")

Diameter, bearing shell seat (D) ............................. 92.85 mm (3.655504")

Con rods

Length, center - center (E) ..................................... 225 mm (8.85825")

Small end bushing, internal diameter (G) ................ 54 mm (2.12598")

End float, con rod - crankshaft

: ............................. max 0.35 mm (0.013779")

Big end bearing, radial clearance 1: ....................... max 0.10 mm (0.003937")

Straightness, max. deviation on 100 mm (3.937")

measured length .................................................... 0.06 mm (0.002362")

Twist, max. deviation on 100 mm (3.937")

measured length .................................................... 0.15 mm (0.005905")

Dimensions refer to oiled components.

Marking:

”FRONT” on the con rod faces forwards.

The con rods and caps are marked in pairs, using a three digit serial number (please refer to the illustration).

Flywheel, installed

Runout (manual gearbox), measurement

radius 150 mm (5.9055") . ...................................... max 0.20 mm (0.007874")

No. of teeth on starter gear ring .............................. 153

Sensor grooves in flywheel .................................... 54 pcs.

Flywheel housing, installed

Runout for mating face against bellhousing. ...........max 0.1 mm (0.003937")

Radial runout for alignment against bellhousing. ..... max 0.05 mm (0.001968")

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Volvo Penta TAD940GE Workshop Manual

Brand: Volvo Penta

Model: TAD940GE

Category: Engine

Type: Workshop Manual

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