Volvo Penta / Perkins Diesel Marine Engines Workshop Service Repair Manual This workshop manual contains technical data, de- scriptions and repair instructions for the standard versions of engine units TAMD61A, TAMD62A, TAMD63L-A, TAMD63P-A, TAMD71A, TAMD71B, TAMD72A, TAMD72P-A, TAMD72WJ-A. Marine engines TAMD61A • TAMD62A • TAMD63L-A • TAMD63P-A TAMD71A • TAMD71B • TAMD72A • TAMD72P-A TAMD72WJ-A Contents General instructions ............................................ 2 Special tools ........................................................ 9 Other special equipment ..................................... 12 Design and function Engine,generally................................................. 13 Designdifferences,engineversions................... 14 Identification signs .............................................. 15 Locationoftypeapprovalplates......................... 15 Component description ....................................... 24 Repair instructions General ............................................................... 30 Engine jig attachment ......................................... 31 Condition test, engine ......................................... 32 Compression test ................................................ 32 Cylinder head, renovation ................................... 32 Cylinder head, removal ....................................... 32 Cylinder head, stripping/assembly ....................... 34 Cylinder head, leakage test ................................. 35 Cylinder head, inspection .................................... 37 Valve guides, inspection ..................................... 38 Valve guides, replacement .................................. 38 Cylinder head, planing ......................................... 39 Cylinder head, milling the seal groove ................. 39 Valve seat, replacement ..................................... 42 Valve seat, grinding ............................................ 43 Valves, grinding .................................................. 44 Rocker mechanism, renovation ........................... 44 Checking the valve springs ................................. 46 Cylinder head, assembly ..................................... 46 Copper injector sleeve, replacement ................... 48 Cleaning seat for copper sleeve .......................... 49 Copper sleeve, assembly .................................... 50 Valves, adjustment ............................................. 52 Cylinder block, renovation .................................. 53 Piston and con rod, removal ............................... 53 Piston and con rod, inspection ............................ 54 Piston removal, gudgeon pin boss replacement ........................................................ 54 Piston, assembly ................................................ 55 Piston ring inspection and fit ............................... 56 Piston ring assembly .......................................... 56 Cylinder liner, inspection and measurement ........ 57 Cylinder liner, disassembly ................................. 57 Cylinderliner,honing........................................... 58 Cylinderlinerposition,renovation........................ 59 Cylinder liner, assembly ...................................... 60 Piston assembly ................................................. 61 Timing gears, disassembly ................................. 62 Timing gears, assembly ...................................... 65 Sealant application, timing gear lid ...................... 66 Seal ring, polygon hub, replacement ................... 66 Polygon hub, assembly ....................................... 67 Camshaft, wear check ........................................ 67 Camshaft, disassembly ...................................... 68 Inspection of valve lifters and camshaft .............. 69 Camshaft, measurement ..................................... 70 Camshaft bearing, replacement ........................... 70 Camshaft, assembly ........................................... 71 Crankcase, disassembly ..................................... 71 Inspection, crankshaft and bearings .................... 72 Crankshaft, renovation ........................................ 74 Cylinder block, inspection ................................... 75 Cylinder block, planing ........................................ 75 Crankshaft, assembly ......................................... 76 Big end bearings, replacement ............................ 77 Main bearings, replacement ................................ 78 Flywheel, replacement ........................................ 80 Gear ring, replacement ........................................ 81 Flywheel, indication ............................................. 82 Flywheel housing, indication ............................... 82 Crankshaft seal, rear, replacement ...................... 83 Flange seal, flywheel housing, replacement ........................................................ 83