Workshop Manual B

Technical Data 2(0)

31, 32, 41, 42, 43,

44, 300-Series
 Group 20 Technical data
Marine engines
MD31A • TMD31B, D, L-A
TAMD31B, D, S.O.L.A.S, L-A, M-A, P-A, S-A
AD31B, D, L-A, P-A • KAD32P
TMD41B, D, L-A
TAMD41B, D, S.O.L.A.S, L-A, M-A, P-A, H-A, H-B
D41B, D, L-A • AD41B, D, L-A, P-A
TAMD42AWJ, BWJ, WJ
KAMD42A, B, P • KAD42A, B, P
KAMD43P • KAD43P
KAMD44P-A, P-B, P-C • KAD44P-A, P-B, P-C
KAMD300-A • KAD300-A

Contents
Safety information .................................................................................. 2
Introduction .......................................................................................... 2
Important ............................................................................................. 2
General information ............................................................................. 5
About the workshop manual ............................................................... 5
Spare parts .......................................................................................... 5
Certified engines ................................................................................. 5
Technical data ....................................................................................... 6
General information ............................................................................. 6
Short block .......................................................................................... 7
Reciprocating components ................................................................. 9
Valve mechanism ............................................................................. 11
Lubrication system ............................................................................ 15
Fuel system ....................................................................................... 15
Turbocharging system ...................................................................... 20
Cooling system ................................................................................. 22
Electrical system .............................................................................. 22
Wear tolerances ................................................................................ 23
Tightening torque ............................................................................... 24
 Safety information

Introduction
This workshop manual contains technical data, de- Make sure that the warning or information labels
scriptions and repair instructions for the Volvo Penta on the product are always clearly visible. Re-
products or product versions noted in the table of con- place labels which have been damaged or
tents. Make sure that you use the correct workshop painted over.
literature.
Read the available safety information, General infor- Never start an engine without the air filter in
mation and Repair instructions in the workshop place. The rotating compressor turbine in the
manual before you start to do any service work. turbocharger can cause severe injury. Foreign
bodies in the inlet pipe can also cause severe
Important mechanical damage.

The following special warning signs are used in the

workshop manual and on the product. Never use start spray or similar products as a
starting aid. Explosions could occur in the inlet
WARNING! Warns for the risk of personal injury,
manifold. Danger 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 Avoid opening the coolant filling cap when the
which could cause damage or malfunctions to engine is hot. Steam or hot coolant can spray
product or property. out at the same time as the pressure which has
built up is lost. Open the filler cap slowly, and
NOTE! Is used to call attention to important informa- release the pressure in the cooling system if the
tion, to facilitate work processes or operation. filling cap or tap has to be opened, or if a plug or
coolant hose has to be removed when the en-
To give you a perspective on the risks which always
gine is hot. Steam or hot coolant can stream out
need to be observed and precautions which always
in an unexpected direction.
have to be taken, we have noted them below.

Hot oil can cause burns. Avoid skin contact with

Make it impossible to start the engine by cutting
hot oil. Make sure that the oil system is de-
system current with the main switch(es) and
pressurized before doing any work on it. Never
lock it (them) in the off position before starting
start or run the engine with the oil filler cap re-
service work. Fix a warning sign by the
moved, because of the risk of oil spillage.
helmsman’s seat.

Stop the engine and close the sea cocks before

All service work should normally be done on a
doing any work on the cooling system.
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. Only start the engine in a well- ventilated area.
Remember that loose clothes, long hair etc. can When operated in a confined space, exhaust
catch on rotating components and cause severe fumes and crankcase gases must be ventilated
injury. from the engine bay or workshop area.
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. Be careful Always use goggles when doing any work where
with hot surfaces (exhaust pipes, turbos, charge there is any risk of splinters, grinding sparks,
air pipes, starting heaters etc.) and hot fluids in acid splash or other chemicals. Your eyes are
pipes and hoses on an engine which is running extremely sensitive, injury could cause blind-
or which has just stopped. Re- install all guards ness!
which have been removed during service work,
before re- starting the engine.

2
 Safety information

Avoid skin contact with oil! Long- term or re- Batteries must never be exposed to open
peated skin contact with oil can make your skin flames or electric sparks. Do not smoke close
dry out. The consequence is irritation, dry skin, to the batteries. The batteries generate hydro-
eczema and other skin disorders. gen gas when charged, which forms an explo-
Used oil is more hazardous to health than new sive gas when mixed with air. This gas is very
oil. Use protective gloves and avoid oil- soaked flammable and highly explosive. A spark, which
clothes and rags. Wash regularly, especially be- can be formed if the batteries are wrongly con-
fore meals. Use special skin cream to avoid dry- nected, is enough to make a battery explode
ing and facilitate skin cleaning. and cause damage. Do not move the connec-
tions when you attempt to start the engine (risk
of arcing), and do not stand and lean over one of
Most chemicals intended for the product (e.g. the batteries.
engine and transmission oils, glycol, petrol
(gasoline) and diesel oil) or chemicals for work-
shop use (e.g. degreasers, paints and solvents) Never mix up the battery positive and negative
are hazardous. Read the instruction on the poles when the batteries are installed. If the bat-
packages carefully! Always observe the safety teries are wrongly connected, this can cause se-
advice (e.g. use of breathing protection, vere damage to the electrical equipment. Please
goggles, gloves etc.). Make sure that other per- check the wiring diagram!
sonnel are not inadvertently exposed to hazard-
ous substances, such as via the air they Always use goggles when charging and handling
breathe. Ensure good ventilation. Handle used batteries. Battery electrolyte contains highly cor-
and surplus chemicals in the prescribed manner. rosive sulfuric acid. If this comes into contact
with your skin, wash at once with soap and a lot
Be very careful when searching for leaks in the of water. If you get battery acid in your eyes,
fuel system and testing fuel injectors. Use flush at once with a generous amount of water,
goggles. The jet which comes from a fuel injec- and get medical assistance at once.
tor has very high pressure and considerable
penetration ability. Fuel can force its way deep Stop the engine and cut the system current with
into body tissue and cause severe injury. Risk the main switch(es) before doing any work on
of blood poisoning (septicemia). the electrical system.

All fuels, and many chemicals, are flammable. The clutch must be adjusted with the engine
Make sure that open flames or sparks can not shut off.
set them alight. Petrol (gasoline), some thinners
and hydrogen gas from batteries are extremely
flammable and explosive when mixed with air in The existing lugs on the engine/reversing gear
the correct ratio. Do not smoke! Provide good should be used for lifting. Always check that the
ventilation and take the necessary precautions lifting devices are in good condition and that
before you start welding or grinding in the vicin- they have the correct capacity for the lift (the
ity. Always have a fire extinguisher easily avail- weight of the engine plus the reversing gear and
able near the workplace. extra equipment if installed).
The engine should be lifted with a customized or
adjustable lifting boom for safe handling and to
Make sure that oil and fuel soaked rags, and avoid damaging components on top of the en-
used fuel and oil filters are stored in a safe gine. All chains or cables should be parallel to
place. Oil soaked rags can self- ignite in certain each other and should be as square as possible
circumstances. Used fuel and oil filters are pol- to the top of the engine.
luting waste and must be handed to an approved If other equipment connected to the engine has
waste management facility for destruction, to- altered its centre of gravity, special lifting de-
gether with used lubrication oil, contaminated vises may be needed to obtain the correct bal-
fuel, paint residue, solvents, degreasers and ance and safe handling.
wash residue. Never do any work on an engine which just
hangs from a lifting devise.

3
Safety information

Never work alone when heavy components are Fuel delivery pipes must not be bent or straight-
to be dismantled, even when safe lifting devises ened under any circumstances. Damaged pipes
such as lockable blocks & tackle are used. must be replaced.
Even when lifting devises are used, two people
are needed in most cases. One who operates
the lifting devise and other who makes sure that Remember the following when washing with a
components move freely and are not damaged high pressure washer: Never aim the water jet at
during lifting. seals, rubber hoses or electrical components.
When you work aboard a boat, always make Never use a high pressure washer for engine
sure that there is enough space for disassembly cleaning.
where you are working, with no risk for personal
or material damage.
Only use the fuels recommended by Volvo
Penta. Please refer to the instruction book. The
Components in the electrical and fuel systems use of fuel of inferior quality can damage the en-
on Volvo Penta products have been designed to gine. In a diesel engine, poor fuel can cause the
minimize the risks of explosion and fire. The en- regulation rod to bind and the engine will over-
gine must not be operated in environments with rev, entailing a strong risk of personal injury and
adjacent explosive media. machinery damage. Poor fuel can also lead to
higher maintenance costs.

© 2001 AB VOLVO PENTA

We reserve the right to make design changes
and amendments without prior notice.
Printed on environmentally compatible paper.

4
 General information
About the workshop manual Certified engines
This workshop manual contains technical data for the When service or repairs are done to an emission certi-
standard versions of engines in the 31, 32, 41, 42, 43, fied engine, it is important to be aware of the
44 and 300 series. following:
The Workshop Manual, Technical Data, 31, 32, 41, Certification means that an engine type has been
42, 43, 44 and 300 series, contains all the references checked and approved by the relevant authority. The
from the workshop manuals containing references for engine manufacturer guarantees that all engines made
the 31, 32, 41, 42, 43, 44 and 300 series. of the same type are equivalent to the certified en-
The workshop manual has been primarily prepared for gine.
Volvo Penta service workshops and their qualified per- This makes special demands on service and repair
sonnel. This assumes that people who use the work, as follows:
Manual have basic knowledge of marine drive sys-
tems and can do the tasks of a mechanical or electri- ● Maintenance and service intervals recommended
cal nature associated with the trade. by Volvo Penta must be complied with.
Volvo Penta constantly improves its products, so we ● Only Volvo Penta original spares may be used.
reserve the right to make modifications without prior ● Service to injection pumps, pump settings and in-
notification. All information in this manual is based on jectors must always be done by an authorized
product data which was available up to the date on Volvo Penta workshop.
which the manual was printed. Any material changes
● The engine must not be converted or modified, ex-
introduced into the product or service methods after
cept for the accessories and service kits which
this date are notified by means of Service Bulletins.
Volvo Penta has approved for the engine.

Spare parts
● No installation changes to the exhaust pipe and
engine air inlet ducts may be done.
Spare parts for electrical and fuel systems are subject ● No seals may be broken by unauthorized personnel.
to various national safety requirements such as the
US Coast Guard Safety Regulations. Volvo Penta The general advice in the instruction book about op-
Original Spares comply with these requirements. eration, care and maintenance apply.

No damage whatever, occasioned by use of non- origi- IMPORTANT! Delayed or inferior care/mainte-
nal Volvo Penta spares for the product, will be com- nance, and the use of non- original spares,
pensated by the warranty offered by Volvo Penta. mean that AB Volvo Penta can no longer be re-
sponsible for guaranteeing that the engine com-
plies with the certified version.
Damage, injury and/or costs which arise from
this will not be compensated by Volvo Penta.

5
 Technical data

General information
No. of cylinders
31/32 series ....................................................................... 4
41/42/43/44/300 series ...................................................... 6
Bore ...................................................................................... 92.015 mm (3.622")
Stroke ................................................................................... 90 mm (3.543")
Swept volume, total
31/32 series ....................................................................... 2.39 liter (2.5 US quart)
41/42/43/44/300 series ...................................................... 3.59 liter (3.7 US quart)
Compression ratio
MD31 ................................................................................. 18:1
31 (not MD31)/32/41/42P/43 series .................................. 17.5:1
42A,B series ...................................................................... 17.8:1
44/300 series ..................................................................... 16.9:1
Cylinder pressure at starter motor speed 4 r/s (240 rpm) ... 2.5 MPa (25 kp/cm 2 )

Weight, engine without drive or reversing gear*,

MD31 ................................................................................. app. 315 kg (694.4 lb)
TMD31 ............................................................................... app. 342 kg (753.9 lb)
TMD41, D41 ...................................................................... app. 435 kg (959.0 lb)
TAMD31, AD31 ................................................................. app. 351 kg (773.8 lb)
TAMD41, AD41 ................................................................. app. 444 kg (978.8 lb)
KAD32 ............................................................................... app. 380 kg (837.7 lb)
KA(M)D42/43/44/300 ......................................................... app. 477 kg (1051.6 lb)
* When lifting with the reversing gear, add the following weights for:
MS4 = 45 kg (99.2 lb)
HS1A = 58 kg (127.8 lb)
PRM 302 = 85 kg (187.3 lb)
PRM 402 = 93 kg (205.0 lb)
MS25 = 18 kg (39.6 lb)
HS25 = 25 kg (55.1 lb)
HS45 = 47 kg (103.6 lb)
HS63 = 57 kg (125.7 lb)
HS63V = 75 kg (165.4 lb)

Injection sequence*
31/32 series ....................................................................... 1–3–4–2
41/42/43/44/300 series ...................................................... 1–5–3–6–2–4
Direction of rotation (seen from front) .................................. Clockwise
Max. permissible rearwards inclination in operation ........... 15°
Max. forwards inclination in operation ................................. 5°
Max. sideways inclination, constant .................................... 20°
* Cylinder number 4 or 6 closest to the flywheel

6
 Technical data

Short block
Cylinder liner
Type ...................................................................................... Wet, replaceable
Cylinder diameter (no overbores) ......................................... 92.015 mm (3.622630")
Liner collar thickness ........................................................... 9.00–9.03 mm (0.35433-0.355511")
Depth from block plane to liner seat (A) .............................. 8.92–8.94 mm (0.35118-0.351967")
Cylinder liner height above block plane (B) ......................... 0.06–0.11 mm (0.00236-0.004330")
Max. height difference between adjacent liners. ................. 0.02 mm (0.00079-0.000787")

Engine block
Height above upper block plane -
crankcase centerline, (C) ..................................................... 268.95 mm (10.588561")

Cylinder head
Height .................................................................................... 86.9–87.1 mm (3.42125–3.429127")

Pistons, natural induction engines

Material ................................................................................. Aluminum alloy, with cast iron seat for first ring.
Height, total. ......................................................................... 101.60 mm (3.999992")
Height from gudgeon pin centre to piston crown ................. 66.55–66.60 mm (2.61810–2.622042")
Piston clearance ................................................................... 0.10–0.14 mm (0.00394–0.005511")
Piston installed in engine, height above engine block plane 0.425–0.725 mm (0.01673–0.028543")
Front marking ....................................................................... Arrow towards front

Pistons, turbocharged engines

Material ................................................................................. Aluminum alloy, with cast iron seat for first ring.
Height, total. ......................................................................... 101.65 mm (4.001960")
Height from gudgeon pin centre to piston crown
41H- B ................................................................................ 66.50–66.55 mm (2.58267–2.620073")
other ................................................................................... 66.60–66.65 mm (2.62204–2.624010")
Piston clearance, max ......................................................... 0.12 mm (0.004724")
Piston installed in engine, height above engine block plane 0.475–0.775 mm (0.01870–0.030511")
Front marking ....................................................................... Arrow towards front
Combustion chamber, diameter:
31/32/41/42P/43/44/300 .................................................... 40 mm (1.5748")
42A/42B ............................................................................. 43 mm (1.69291")
Combustion chamber, depth:
31/32/41/42P/43 ................................................................ 19.5 mm (0.767715")
42A/42B ............................................................................. 19 mm (0.74803")
44/300 ................................................................................ 20 mm (0.7874")

7
Technical data

Piston rings

Piston ring clearance in groove, axial

Lower compression ring
31/32/41A,B,D,H- A,L,M,P/42/43/44/300 ......................... 0.052–0.116 mm (0.002047–0.004566")
41H- B ................................................................................ 0.070–0.102 mm (0.002755–0.004015")
Oil scraper ring:
31/32/41/42/43 ................................................................... 0.040–0.075 mm (0.001574–0.002952")
41H- B/44/300 ................................................................... 0.040–0.072 mm (0.001574–0.002834")
Piston ring gap in cylinder liner
Upper compression ring
31A,B,D/41A,B,D .............................................................. 0.40–0.65 mm (0.015748–0.025590")
31L,M,P,S- A/32/41H- A,L,M,P/42/43 .............................. 0.40–0.60 mm (0.015748–0.023622")
41H- B/44/300 ................................................................... 0.25–0.54 mm (0.009842–0.021259")
Lower compression ring
31/32/41A,B,D,H- A,L,M,P/42/43/44/300 ......................... 0.25–0.59 mm (0.009842–0.023228")
41H- B ................................................................................ 0.60–0.89 mm (0.023622–0.035039")
Oil scraper ring:
31/32/41A,B,D,H- A,L,M,P/42/43 ..................................... 0.25–0.40 mm (0.009842–0.015748")
41H- B/44/300 ................................................................... 0.25–0.67 mm (0.009842–0.026377")

Gudgeon pins
Clearance, gudgeon pin - small end bushing
31/32/41/42/43 ................................................................... 0.014–0.032 mm (0.000551–0.001259")
44/300 ................................................................................ 0.024–0.032 mm (0.000944–0.001259")
Clearance, gudgeon pin - small end hole
31/32/41/42/43 ................................................................... 0.008–0.018 mm (0.000314–0.000708")
44/300 ................................................................................ 0.009–0.019 mm (0.000354–0.000748")
Gudgeon pin diameter
31/32/41/42/43 ................................................................... 34.990–35.004 mm (1.377556–1.378107")
44/300 ................................................................................ 34.990–34.994 mm (1.377556–1.377713")
Small end bushing, internal diameter .................................. 35.018–35.022 mm (1.378658–1.378816")
Gudgeon pin hole diameter in piston
MD31 ................................................................................. 35.000–35.006 mm (1.37795–1.378186")
31/32/41/42/43 ................................................................... 35.002–35.008 mm (1.378028–1.378264")
44/300 ................................................................................ 35.003–35.009 mm (1.378068–1.378304")

8
 Technical data

Reciprocating components
Crankshaft
Crankshaft, end float ............................................................ 0.100–0.310 mm (0.012204")

Main bearing journals

Diameter (Ø)
Standard ............................................................................ 69.987–70.000 mm (2.755388–2.7559")
Underdim. 0.25 mm (0.009842") ...................................... 69.737–69.750 mm (2.745545–2.746057")
0.50 mm (0.019685") ...................................... 69.487–69.500 mm (2.735703–2.736215")
0.75 mm (0.029527") ...................................... 69.237–69.250 mm (2.725860–2.726372")
Main bearing clearance ........................................................ 0.040–0.090 mm (0.001574–0.003543")
Fillet radius (R) ..................................................................... 3.9 mm (0.153543")

Main bearing shells

Thickness (A)
Standard ............................................................................ 2.970–2.979 mm (0.116928–0.117283")
Overdim. 0.25 mm (0.009842") ......................................... 3.095–3.104 mm (0.121850–0.122204")
0.50 mm (0.019685") ......................................... 3.220–3.229 mm (0.126771–0.127125")
0.75 mm (0.029527") ......................................... 3.343–3.354 mm (0.013503–0.132046")

9
Technical data

Big end journals

Diameter (Ø)
Standard ............................................................................ 56.487–56.500 mm (2.223893–2.224405")
Underdim. 0.25 mm (0.009842") ...................................... 56.237–56.250 mm (2.214050–2.214562")
0.50 mm (0.019685") ...................................... 55.987–56.000 mm (2.204208–2.20472")
0.75 mm (0.029527") ...................................... 55.737–55.750 mm (2.194365–2.194877")
Big end bearing clearance .................................................... 0.034–0.078 mm (0.001338–0.003070")
Fillet radius (R) ..................................................................... 3.9 mm (0.153543")

Big end journal shells

Thickness (B)
Standard ............................................................................ 1.724–1.733 mm (0.067873–0.068228")
Overdim. 0.25 mm (0.009842") ......................................... 1.849–1.858 mm (0.072795–0.073149")
0.50 mm (0.019685") ......................................... 1.974–1.983 mm (0.077716–0.078070")
0.75 mm (0.029527") ......................................... 2.099–2.108 mm (0.082637–0.082991")

Con rods
End float at crankshaft ......................................................... 0.15–0.30 mm (0.005905–0.011811")
Diameter, gudgeon bushing seat (C) ................................... 39.000–39.030 mm (1.53543–1.536611")
bearing shell seat (D) ........................................................... 60.000–60.013 mm (2.3622–2.362711")
Gudgeon pin bushing ............................................................ See heading: Gudgeon pins

10
 Technical data

Valve mechanism
Camshaft
Drive ...................................................................................... Gearwheel
No of bearings
31/32 series ....................................................................... 5
41/42/43/44/300 series ...................................................... 7
Diameter, bearing journal: .................................................... 52.970–53.000 mm (2.085428–2.08661")
Bearing journal, max. out of round ....................................... 0.010 mm (0.003937")
Camshaft straightness, max. runout ................................... 0.08 mm (0.003149")
End float ............................................................................... 0.04–0.12 mm (0.001574–0.004724")
Radial clearance ................................................................... 0.025–0.074 mm (0.000984–0.002913")
Camshaft lift (cam height),
inlet .................................................................................... 6.773 mm (0.266653")
exhaust .............................................................................. 6.975 mm (0.274605")
Tolerance on lift height ......................................................... ±0.05 mm (0.001968") .

Camshaft bearings
Bearing, diameter: ................................................................ 53.025–53.044 mm (2.087594–2.088342")

Valves
Valve head diameter, inlet
31/32/41/42/43 series ........................................................ 39.0 mm (1.53543")
44/300 series ..................................................................... 32.8 mm (1.291336")
Valve head diameter, exhaust
31/32/41/42/43 series ........................................................ 37 mm (1.45669")
44/300 series ..................................................................... 29.9 mm (1.177163")
Valve stem diameter, inlet
31/32/41/42/43 series ........................................................ 7.955–7.970 mm (0.313188–0.313778")
44/300 series ..................................................................... 5.955–5.970 mm (0.234448–0.235038")
Valve stem diameter, exhaust
31/32/41/42/43 series ........................................................ 7.925–7.940 mm (0.312007–0.312597")
44/300 series ..................................................................... 5.925–5.940 mm (0.233267–0.233857")
Valve seat angle (F), inlet
31/32/41/42/43 series ........................................................ 29.7°
44/300 series ..................................................................... 29.5°
Valve seat angle (F), exhaust
31/32/41/42/43 series ........................................................ 44.7°
44/300 series ..................................................................... 44.5°

11
Technical data

Valve seat angle in cylinder head (C), inlet ......................... 30°

Valve seat angle in cylinder head (C), exhaust ................... 45°
Valve seat width in cylinder head (D), inlet
31/32/41/42/43 series ........................................................ 1.5–3.0 mm (0.059055–0.11811")
44/300 series ..................................................................... 1.4–2.5 mm (0.055118–0.098425")
Valve seat width in cylinder head (D), inlet
31/32/41/42/43 series ........................................................ 1.4–2.9 mm (0.055118–0.114173")
44/300 series ..................................................................... 1.2–2.2 mm (0.047244–0.086614")
Valve height in seat (E), inlet
31/32/41/42P/43 series ..................................................... 0.05–0.45 mm (0.001968–0.017716")
42A/B series ...................................................................... 0.25–0.65 mm (0.009842–0.025590")
44/300 series ..................................................................... 1.00–1.40 mm (0.03937–0.055118")
Valve height in seat (E), exhaust
31/32/41/42P/43 series ..................................................... 0.05–0.45 mm (0.001968–0.017716")
42A/B series ...................................................................... 0.25–0.65 mm (0.009842–0.025590")
44/300 series ..................................................................... 0.90–1.30 mm (0.035433–0.051181")
Valve clearance, (engine cold or at operating temperature),
Inlet .................................................................................... 0.40 mm (0.015748")
Exhaust ............................................................................. 0.40 mm (0.015748")

NOTE! On the 42A/B series, the valve head is just proud of the plane of the cylinder head.

Valve location and cylinder numbering

31/32 series (❍ Inlet, ● Exhaust)

41/42/43 series (❍ Inlet, ● Exhaust)

44/300 series (❍ Inlet, ● Exhaust)

12
 Technical data

Valve seats
Outer diameter (A), standard, inlet:
31/32/41/42/43 series ........................................................ 40.564–40.580 mm (1.597004–1.597634")
44/300 series ..................................................................... 34.065–34.080 mm (1.341139–1.341729")
Outer diameter (A), standard, exhaust:
31/32/41/42/43 series ........................................................ 38.064–38.080 mm (1.498579–1.499209")
44/300 series ..................................................................... 31.065–31.080 mm (1.223029–1.223619")

Outer diameter (A), oversize, inlet:

31/32/41/42/43 series ........................................................ 40.764–40.780 mm (1.604878–1.605508")
44/300 series ..................................................................... 34.200–34.225 mm (1.346454–1.347438")
Outer diameter (A), oversize, exhaust:
31/32/41/42/43 series ........................................................ 38.264–38.280 mm (1.506453–1.507083")
44/300 series ..................................................................... 31.265–31.280 mm (1.230903–1.231493")

Height (B), inlet

31/32/41/42/43 series ........................................................ 7.50–7.55 mm (0.295275–0.297243")
44/300 series ..................................................................... 6.07–6.15 mm (0.238975–0.242125")
Height (B), exhaust
31/32/41/42/43 series ........................................................ 7.50–7.55 mm (0.295275–0.297243")
44/300 series ..................................................................... 6.17–6.25 mm (0.242912–0.246062")

Valve seat beds

Diameter (C), standard, inlet
31/32/41/42/43 series ........................................................ 40.500–40.525 mm (1.594485–1.595469")
44/300 series ..................................................................... 34.000–34.025 mm (1.33858–1.339564")
Diameter (C), standard, exhaust
31/32/41/42/43 series ........................................................ 38.000–38.025 mm (1.49606–1.497044")
44/300 series ..................................................................... 31.000–31.025 mm (1.22047–1.221454")

Diameter (C), oversize, inlet

31/32/41/42/43 series ........................................................ 40.764–40.780 mm (1.604878–1.605508")
44/300 series ..................................................................... 34.200–34.225 mm (1.346454–1.347438")
Diameter (C), oversize, exhaust
31/32/41/42/43 series ........................................................ 38.264–38.280 mm (1.506453–1.507083")
44/300 series ..................................................................... 31.200–31.225 mm (1.228344–1.229328")

Depth (D), inlet

31/32/41/42P/43 series ..................................................... 8.9–9.1 mm (0.350393–0.358267")
42A/42B series .................................................................. 8.2–8.4 mm (0.322834–0.330708")
44/300 series ..................................................................... 8.9–9.1 mm (0.350393–0.358267")
Depth (D), exhaust
31/32/41/42P/43 series ..................................................... 9.4–9.6 mm (0.370078–0.377952")
42A/42B ............................................................................. 8.7–8.9 mm (0.342519–0.350393")
44/300 series ..................................................................... 8.9–9.1 mm (0.350393–0.358267")

Seat base radius (R)

31/32/41/42/43 series ........................................................ 0.4–0.5 mm (0.015748–0.019685")
44/300 series ..................................................................... 0.4–0.6 mm (0.015748–0.023622")

13
Technical data

Valve guides
Length
31/32/41/42/43 series ........................................................ 59 mm (2.32283")
44/300 series ..................................................................... 51 mm (2.00787")
Inner diameter (installed)
31/32/41/42/43 series ........................................................ 8.000–8.015 mm (0.31496–0.315550")
44/300 series ..................................................................... 6.000–6.015 mm (0.23622–0.236810")
Inner diameter (spare part)
31/32/41/42/43 series ........................................................ 8.000–8.022 mm (0.31496–0.315826")
44/300 series ..................................................................... 6.000–6.022 mm (0.23622–0.237086")
Height above cylinder head spring plane,
31/32/41/42/43 series ........................................................ 17.5–18.5 mm (0.688975–0.728345")
Height below cylinder head spring plane,
44/300 series ..................................................................... 0.1–0.6 mm (0.003937–0.023622")
Clearance, valve stem - guide:
Inlet .................................................................................... 0.030–0.060 mm (0.001181–0.002362")
Exhaust ............................................................................. 0.060–0.090 mm (0.002362–0.003543")

Valve springs
31 series (up to engine number 2203115306)
41 series (up to engine number 2204137475)
Free length ......................................................................... 46.0 mm (1.81102")
Length with 267–312 N loading ......................................... 40.0 mm (1.5748")
Length with 767–852 N loading ......................................... 30.0 mm (1.1811")

31 series (as from engine number 2203115307)

41 series (as from engine number 2204137476)
32/42/43 series
Free length ......................................................................... 44.3 mm (1.744091")
Length with 136–158 N loading ......................................... 40.6 mm (1.598422")
Length with 554–614 N loading ......................................... 29.7 mm (1.169289")

44/300 series
Free length ......................................................................... 41 mm (1.61417")
Length with 166.2–184.2 N loading ................................... 34 mm (1.33858")
Length with 380.5–420.5 N loading ................................... 25 mm (0.98425")

Rocker arm mechanism

Rocker arm bushing, diameter after pressing in
and machining ...................................................................... 22.020–22.041 mm (0.866927–0.867754")

Timing gear
Flank clearance .................................................................... 0.03–0.17 mm (0.001181–0.006692")
Radial clearance for idler wheel ........................................... 0.03–0.09 mm (0.001181–0.003543")
End float for idler wheel ........................................................ 0.03–0.15 mm (0.001181–0.005905")
Shaft stub for idler wheel, diameter ..................................... 54.940–54.970 mm (2.162987–2.164168")
Bushing for idler wheel, diameter ......................................... 55.000–55.030 mm (2.16535–2.166531")
No. of teeth,
crankshaft gear ................................................................. 33 teeth
idler gear ............................................................................ 41 teeth
camshaft gear ................................................................... 66 teeth
injection pump gear ........................................................... 66 teeth
idler gear, oil pump ............................................................ 36 teeth
drive gear, oil pump ........................................................... 39 teeth

14
 Technical data

Lubrication system
Oil grade ............................................................................... VDS–2, ACEA E5, API CH–4
Viscosity ............................................................................... SAE 15W/40
Lube oil pump, type .............................................................. Gearwheel
End float, pump wheel
31 series (up to engine number 2203132044)
32 series (up to engine number 2203204434)
41 series (up to engine number 2204161829)
42 series (up to engine number 2204216479)
43 series (up to engine number 2204306369)
44 series (up to engine number 2204403783) ............... 0,07–0,15 mm (0.002755–0.005905")
End float, pump wheel
31 series (as from engine number 2203132045)
32 series (as from engine number 2203204435)
41 series (as from engine number 2204161830)
42 series (as from engine number 2204216480)
43 series (as from engine number 2204306370)
44 series (as from engine number 2204403784)
300 series (all) ................................................................ 0,03–0,11 mm (0.001181–0.004331")
Gear flank clearance, pump wheel ................................... 0.15–0.35 mm (0.005905–0.013779")
Diameter, idler wheel bearing sleeve ................................ 55.03–55.06 mm (2.166531–2.167712")
Bushing for idler wheel ...................................................... 54.97–55.00 mm (2.164168–2.16535")
Radial clearance for idler wheel ........................................ 0.03–0.09 mm (0.001181–0.003543")
Diameter, bushings in oil pump ........................................ 16.016–16.034 mm (0.630549–0.631258")
Clearance, thrust washer - oil pump drive wheel ............. 0.02–0.08 mm (0.003149")
No. of teeth, oil pump drive wheel .................................... 39
Oil pump idler wheel .......................................................... 36
Reduction valve:
Unloaded length ................................................................. 56.3 mm (2.216531")
with 53–57 N loading ......................................................... 39 mm (1.53543")
with 21.6- 25.5 N loading .................................................. 49 mm (1.92913")
Piston cooling valve:
Unloaded length ................................................................. 56.3 mm (2.216531")
with 53–57 N loading ......................................................... 39 mm (1.53543")
with 21.6- 25.5 N loading .................................................. 49 mm (1.92913")
Safety valve:
Unloaded length ................................................................. 41.8 ±2 mm (1.645664 ±0.0787399")
with 86.3–90.3 N loading ................................................... 30 mm (1.181099")
Oil pressure, hot engine, operating speed
lube oil ............................................................................... 0.41–0.64 MPa (59.7–92.5 psi)
piston cooling oil ............................................................... 0.22–0.30 MPa (31.9–43.5 psi)
Oil volume, max. incl. oil filter, engine inclination 0°.
31/32 series ....................................................................... 9 liter (9.5 US quart)
41/42/43/44/300 series ...................................................... 11 liter (11.6 US quart)
Volume between max - min at 0° engine inclination. .......... 3 liter (3.1 US quart)

Fuel system
Direction of rotation of injection pump, seen from front ...... Anti- clockwise
Injection sequence
31/32 series ....................................................................... 1, 3, 4, 2
41/42/43/44/300 series ...................................................... 1, 5, 3, 6, 2, 4
Injection pump, make ........................................................... Bosch
Regulator, make ................................................................... Bosch
Supply pressure, at low idle
31/32/41/42/43 series (VP part number 860320) ............. 14.7–27.5 kPa (2.13–3.9 psi)
44/300 series (VP part number 3582310) ......................... 30.0–50.0 kPa (4.35–7.2 psi)

Fuel filter
Type designation .................................................................. Bosch

15
Technical data

Injectors
31 (not TAMD31S-A) series, AD41B,TMD41B, TAMD41B, TAMD41D (MD,HD), TAMD41M
Injector holder, make and type ............................................ Bosch KBAL 72 P23
Holder, marked .................................................................. 765
Injector, type ......................................................................... DLLA 140P 196
No. of holes x hole size .................................................... 6 x 0.27 mm (0.010629")
Marked ............................................................................... 196
Opening pressure ................................................................. 26.0–26.8 MPa (3770.9–3887.0 psi)
Setting pressure (new spring) .............................................. 26.8 MPa (3887.0–3887.0 psi)

TAMD42A WJ, KAD42A, KAMD42A

Injector holder, make and type ............................................ Bosch KBAL 72 P23
Holder, marked .................................................................. 861
Injector, type ......................................................................... DSLA 145P 293
No. of holes x hole size .................................................... 5 x 0.27 mm (0.010629")
Marked ............................................................................... 293
Opening pressure ................................................................. 27.0–27.8 MPa (3916.0–4032.0 psi)
Setting pressure (new spring) .............................................. 27.8 MPa (4032.0 psi)

AD41D (PD, MD), TMD41D, TAMD41D (PD), AD41L, TAMD41L, TAMD41H-A

AD41P, TAMD41P, KAD42A (CE), KAMD42A (CE), 42B series
Injector holder, make and type ............................................ Bosch KBAL 72 P23
Holder, marked .................................................................. 684
Injector, type ......................................................................... DLLA 145P 394
No. of holes x hole size .................................................... 5 x 0.27 mm (0.010629")
Marked ............................................................................... 394
Opening pressure ................................................................. 27.0–27.8 MPa (3916.0–4032.0 psi)
Setting pressure (new spring) .............................................. 27.8 MPa (4032.0 psi)

TAMD31S- A, TAMD41H- B
Injector holder, make and type ............................................ Bosch KBAL 72 P76
Holder, marked .................................................................. 690
Injector, type ......................................................................... DSLA 145P 712
No. of holes x hole size .................................................... 5 x 0.266 mm (0.010472")
Marked ............................................................................... 712
Opening pressure,
first stage .......................................................................... 26.0–27.4 MPa (3770.9–3974.0 psi)
second stage ..................................................................... 39.0–40.8 MPa (5656.4–5917.5 psi)

KAD32P
Injector holder, make and type ............................................ Bosch KBAL 72 P83
Holder, marked .................................................................. 515
Injector, type ......................................................................... DLLA 145P 394
No. of holes x hole size .................................................... 5 x 0.262 mm (0.010314")
Marked ............................................................................... 394
Opening pressure ................................................................. 27.0–28.0 MPa (3916.0–4061.0 psi)
Setting pressure (new spring) .............................................. 28.0 MPa (4061.0 psi)

KAMD42P, KAD42P, KAMD43P, KAD43P

Injector holder, make and type ............................................ Bosch KBAL 72 P23
Holder, marked .................................................................. 684
Injector, type ......................................................................... DLLA 145P 394
No. of holes x hole size .................................................... 5 x 0.27 mm (0.010629")
Marked ............................................................................... 394
Opening pressure ................................................................. 26.5–27.3 MPa (3959.5 psi)
Setting pressure (new spring) .............................................. 27.0–28.0 MPa (4061.0 psi)

16
 Technical data

KAMD44P-A, KAD44P-A
Injector holder, make and type ............................................ Bosch KBAL 75 P77
Holder, marked .................................................................. 689
Injector, type ......................................................................... DSLA 140P 713
No. of holes x hole size .................................................... 5 x 0.298 mm (0.011732")
Marked ............................................................................... 713
Opening pressure,
first stage .......................................................................... 24.0–25.4 MPa (3480.9–3683.9 psi)
second stage ..................................................................... 36.0–37.8 MPa (5221.3–5482.4 psi)

KAMD44P-B, KAD44P-B, KAMD44P-C, KAD44P-C

Injector holder, make and type
cylinder 1 ........................................................................... Bosch KBAL 75 P92
cylinders 2- 6 ..................................................................... Bosch KBAL 75 P77
Holder, marked
cylinder 1 ........................................................................... 632
cylinders 2- 6 ..................................................................... 689
Injector, type ......................................................................... DSLA 140P 713
No. of holes x hole size .................................................... 5 x 0.298 mm (0.011732")
Marked ............................................................................... 713
Opening pressure
first stage .......................................................................... 24.0–25.4 MPa (3480.9–3683.9 psi)
second stage ..................................................................... 36.0–37.8 MPa (5221.3–5482.4 psi)

KAMD300-A, KAD300-A
Injector holder, make and type
cylinder 1 ........................................................................... Bosch KBAL 75 P92
cylinders 2- 6 ..................................................................... Bosch KBAL 75 P77
Holder, marked
cylinder 1 ........................................................................... 526
cylinders 2- 6 ..................................................................... 527
Injector, type ......................................................................... DSLA 140P 1145
No. of holes x hole size .................................................... 5 x 0.308 mm (0.012125")
Marked ............................................................................... 1145
Opening pressure
first stage .......................................................................... 24.0–25.4 MPa (3480.9–3683.9 psi)
second stage ..................................................................... 38.0–39.8 MPa (5511.4–5772.5 psi)

17
Technical data

Data and settings*

* Please refer to Service Bulletins Group 24- 1 for full setting data, including pump marking and injection volumes.

Engine Plunger lift, & Low idle High idle Full load speed
(mm) (r/min) (r/min) (r/min)

MD31A (engine nr. –5093)1,37 (±0,02) 675–725 4000–4100 3500

MD31A (engine nr. 5094–)1,70 (±0,02) 675–725 4000–4100 3500

TMD31B 1,85 (±0,02) 675–725 4100–4200 3900

TMD31B CE) 1,85 (±0,02) 675–725 4100–4200 3900
TMD31D 1,85 (±0,02) 675–725 4250 3900
TMD31L 1,85 (±0,02) 675–725 4150–4250 3900
TAMD31B 1,85 (±0,02) 675–725 4300–4400 3900
TAMD31B (CE) 1,85 (±0,02) 675–725 4300–4400 3900
TAMD31B (MD) 1,85 (±0,02) 675–725 3800–3900 3250
TAMD31D 1,60 (±0,02) 675–725 4350 3900
TAMD31D (MD) 1,85 (±0,02) 675–725 3900 3250
TAMD31L 1,60 (±0,02) 675–725 4250–4350 3900
TAMD31M (MD) 1,85 (±0,02) 675–725 3800–3900 3250
TAMD31P 1,60 (±0,02) 675–725 4250–4350 4100
TAMD31S–A 1,40 (±0,02) 675–725 3400–3500 3000

AD31B 1,85 (±0,02) 675–725 4300–4400 3900

AD31B (CE) 1,85 (±0,02) 675–725 4300–4400 3900
AD31D 1,60 (±0,02) 675–725 4350 3900
AD31XD 1,75 (±0,02) 675–725 4450 4100
AD31L 1,60 (±0,02) 675–725 4250–4350 3900
AD31P 1,60 (±0,02) 675–725 4250–4350 4100

KAD32P 1,55 (±0,02) 675–725 4175–4225 3900

TMD41B 1,70 (±0,02) 625–675 4150–4250 3900

TMD41B (CE) 1,80 (±0,02) 625–675 4150–4250 3900
TMD41D 1,60 (±0,02) 625–675 4350 3900
TMD41L 1,40 (±0,02) 625–675 4250–4350 3900
TAMD41B (PD) 1,80 (±0,02) 625–675 4200–4300 3900
TAMD41B (MD) 1,70 (±0,02) 625–675 3800–3900 3250
TAMD41B (HD) 1,70 (±0,02) 625–675 3200 2500
TAMD41D (PD) 1,60 (±0,02) 625–675 4350 3900
TAMD41D (MD) 1,70 (±0,02) 625–675 3900 3250
TAMD41D (HD) 1,70 (±0,02) 625–675 3200 2500
TAMD41M (MD) 1,70 (±0,02) 625–675 3800–3900 3250
TAMD41L 1,60 (±0,02) 625–675 4000–4100 3600
TAMD41P (LD,PD) 1,60 (±0,02) 625–675 4250–4350 3900
TAMD41H-A (HD) 1,70 (±0,02) 625–675 3300–3400 2700
TAMD41H-B 1,50 (±0,02) 625–675 3300–3400 2700

D41B 1,70 (±0,02) 625–675 4250–4350 3900

D41D 1,60 (±0,02) 625–675 4250–4350 3900
D41L 1,40 (±0,02) 625–675 4250–4350 3900
AD41B 1,80 (±0,02) 625–675 4200–4300 3900
AD41B (LD) 1,80 (±0,02) 625–675 4100–4200 3600
AD41B (CE) 1,80 (±0,02) 625–675 4200–4300 3900
AD41B (MD) 1,80 (±0,02) 625–675 4150 3600
AD41D (PD) 1,60 (±0,02) 625–675 4350 3900
AD41D (MD) 1,60 (±0,02) 625–675 4100 3600
AD41L 1,60 (±0,02) 625–675 4000–4100 3600
AD41P (LD,PD) 1,60 (±0,02) 625–675 4250–4350 3900

18
 Technical data

Engine Plunger lift, & Low idle High idle Full load speed
(mm) (r/min) (r/min) (r/min)

TAMD42A WJ 1,82 (+0,02) 625–675 4250–4350 3900

TAMD42B WJ 1,82 (+0,02) 625–675 4250–4350 3900
TAMD42WJ–A 1,50 (+0,02) 625–675 4250–4350 3900

KAMD42A 1,82 (±0,02) 625–675 4350 3900

KAMD42A (CE) 1,70 (±0,02) 625–675 4350 3900
KAMD42B (PD, SLD) 1,82 (±0,02) 625–675 4350 3900
KAMD42B (CE) 1,70 (±0,02) 625–675 4350 3900
KAMD42P 1,50 (±0,02) 625–675 4250–4350 3900
KAD42A 1,82 (±0,02) 625–675 4350 3900
KAD42A (CE) 1,70 (±0,02) 625–675 4350 3900
KAD42B (PD, SLD) 1,82 (±0,02) 625–675 4350 3900
KAD42B (CE) 1,70 (±0,02) 625–675 4350 3900
KAD42P 1,50 (±0,02) 625–675 4250–4350 3900

KAMD43P 1,50 (±0,02) 625–675 4250–4350 3900

KAD43P 1,50 (±0,02) 625–675 4250–4350 3900

KAD44P-A 1,20 (±0,02)* 590–610 – 3700–3900

KAMD44P-A 1,20 (±0,02)** 590–610 – 3700–3900
KAD44P-B 1,00 (±0,01) 600–620 – 3700–3900
KAMD44P-B 1,00 (±0,01) 600–620 – 3700–3900
KAD44P-C 1,00 (±0,01) 600–620 – 3700–3900
KAMD44P-C 1,00 (±0,01) 600–620 – 3700–3900

KAD300–A 1,40±0,01 600–620 – 3700–3900

KAMD300–A 1,40±0,01 600–620 – 3700–3900

PD = pleasure duty, SLD = special light duty, LD = light duty

MD = medium duty, HD = heavy duty, CE = certified engines

* In engines where control unit 874081 or software 874082 has been installed, plunger lift 1.05±0.02 mm must be used.
** In engines where control unit 874040 or software 874140 has been installed, plunger lift 1.05±0.02 mm must be used.

19
Technical data

Turbocharging system
Turbocharger
Make and type
31B,D ................................................................................. KKK K26 2960 GA/6.71
TAMD31M,L,P/AD31L,P/32 .............................................. KKK K26 2960 MXA/6.71 GAAXB
TAMD31L (spare part turbo) ............................................. KKK K26 2960 MXAAA/4.71 GABXB
TAMD31S–A ..................................................................... Garret GT1549S/55 c100/0.35 72
41B .................................................................................... KKK K26 3262 MGA/10.71
TAMD41H- A, TMD31L ..................................................... KKK K26 2660 GGA/6.71 GAAXB
TAMD41H- B ..................................................................... KKK K26 2660 GGA/4.71 GAAXB
42A .................................................................................... KKK K26 3264 MGA/10.71
41D,M,L,P/ 42B(CE)/42WJ/43 .......................................... KKK K26 3264 MGA/8.71
KAD44P- A,P- B,P- C ....................................................... KKK K26 3267 OGAAA/10.71
KAMD44P- A,P- B,P- C .................................................... KKK K26 3267 OGAAA/12.71
KA(M)D300P- A ................................................................. KKK K26 3272 OXAAA/10.72 GZAXB
Lubrication system ............................................................... Pressure lubrication from engine
Max. permissible run out (compressor side) ....................... 0.42 mm
Max. permissible end float ................................................... 0.16 mm

Mechanical supercharger
Make and type ...................................................................... Ogura TX 15F/OSC–MGC

Charge pressure, mechanical supercharger

Charge pressure (measured in engine induction manifold) at 2000 rpm.
NOTE! The charge pressure provided by the supercharger can only be measured at an engine speed where the
compressor is engaged and the turbo is not charging. Do not exceed 2000 rpm.

Charge pressure at 20°C (68.0°F) and 760 mm (29.9212") Hg barometric pressure.

32 series ............................................................................ 70 kPa (10.1 psi)
42/43 series ....................................................................... 70 kPa (10.1 psi)
44/300 series* ................................................................... 80 kPa (11.6 psi)
* Measurement should be done at 1500 rpm and must be done in accordance with the instructions in the workshop manual.
* Induction, exhaust and cooling systems.

20
 Technical data

Charge pressure, turbocharger

Charge pressure (measured at inlet manifold) at 100 % load, full throttle and 20°C (68.0°F) ambient temperature.
If measurements are done at another temperature, the measured charge pressure must be corrected as per the di-
agram. If full power can not be developed, the pressure will be considerably lower.
Charge pressure at different temperatures

A. Measured charge pressure

B. Correction curves
C. Induction air temperature

Example: A pressure of 100 kPa (14.5 psi) which is

registered at 0°C (32.0°F) is equivalent to 92 kPa
(13.3 psi) at +25°C (77.0°F).

Charge pressure

TMD31 TAMD31M TAMD31L TAMD31P

1800 r/min 20 kPa (2.9 psi) 30 kPa (4.3 psi) 30 kPa (4.3 psi) 30 kPa (4.3 psi)
2500 r/min 45 kPa (6.5 psi) 60 kPa (8.7 psi) 80 kPa (11.6 psi) 95 kPa (13.7 psi)
3250 r/min – 95 kPa (13.7 psi) – –
3800 r/min 90 kPa (13.0 psi) – 140 kPa (20.3 psi) 155 kPa (22.4 psi)

TAMD31S-A TMD41 TAMD41H TAMD41M

1800 r/min 100 kPa (14.5 psi) 40 kPa (5.8 psi) 80 kPa (11.6 psi) 30 kPa (4.3 psi)
2500 r/min 110 kPa (16.0 psi) 80 kPa (11.6 psi) 110 kPa (15.9 psi) 80 kPa (11.6 psi)
3000 r/min 110 kPa (16.0 psi) – – –
3250 r/min – – – 120 kPa (17.4 psi)
3800 r/min – 140 kPa (20.3 psi) – –

TAMD41P KAD32P KA(M)D42/43

1800 r/min 30 kPA (4.3 psi) min 150 kPa (21.7 psi) 115 kPa (16.6 psi)
2500 r/min 100 kPA (14.5 psi) min 175 kPA (25.3 psi) 145 kPa (21.0 psi)
3800 r/min 150 kPA (21.7 psi) min 165 kPa (23.9 psi) 175 kPa (25.3 psi)

KA(M)D44P KA(M)D300-A
1500 r/min 130 kPa (18.8 psi) 124 kPa (17.9 psi)
2000 r/min 150 kPa (21.7 psi) 140 kPa (20.3 psi)
2500 r/min 160 kPa (23.2 psi) 148 kPa (21.4 psi)
3000 r/min 165 kPa (23.9 psi) 140 kPa (20.3 psi)
3500 r/min 170 kPa (24.6 psi) 170 kPa (24.6 psi)
3800 r/min 180 kPa (26.1 psi) 176 kPa (25.5 psi)
3900 r/min – 178 kPa (25.8 psi)

21
Technical data

Cooling system
Type ...................................................................................... Pressurized, sealed
Filler cap valve opens at ...................................................... 75 kPa (10.8 psi)
Fresh water volume, incl. heat exchanger, app.
31/32 series ....................................................................... 13 liter (13.7 US quart)
41/42/43/44/300 series ...................................................... 19 liter (20.0 US quart)

Thermostat
Type ...................................................................................... Wax
Quantity ................................................................................ 2
Starts to open at ................................................................... 79°C–83 °C (174.1–181.4°F)
Fully open at ......................................................................... 92°C–96 °C (197.5–204.8°F)

Electrical system
System voltage .................................................................... 12 V (some models 24 V)
Battery capacity for starter motor:
with 12 V electrical system .............................................. 88–143 Ah
Battery electrolyte specific gravity at +25°C
fully charged battery: ........................................................ 1.28 g/cm3
re-charge battery at ........................................................... 1.24 g/cm3

Alternator
Make ..................................................................................... VALEO
Voltage/max. current density
31A/31B/41A/41B/42A series ........................................... 14 V/50 A
other ................................................................................... 14 V/60 A
optional (SOLAS) .............................................................. 24 V/60 A
Brush length ......................................................................... min. 8 mm (0.31496")

Starter motor
Starter motor power, kW
12 V ................................................................................... 3
24 V ................................................................................... 4

22
 Technical data

Wear tolerances
Cylinder
Cylinder liners (and pistons with piston rings)
should be changed when worn by ........................................ 0.25–0.30 mm (0.009842–0.011811")

Crankshaft
Permissible ovality in main and big end bearings, max. .... 0.006 mm (0.000236")
Permissible taper in main and big end bearings, max. ....... 0.006 mm (0.000236")
Max. crankshaft end float .................................................... 0.40 mm (0.015748")

Valves
Valve stem, max. permissible wear .................................... 0.02 mm (0.000787")
Max. clearance between valve stem and guide
Inlet valve .......................................................................... 0.15 mm (0.005905")
Exhaust valve ................................................................... 0.17 mm (0.006692")
Valve head edge shall be min.: (G)
31/32/41/42/43 series ........................................................ 1.7 mm (0.066929")
44/300 series ..................................................................... 1.2 mm (0.047244")

Valve seats should be changed when distance (E) exceeds

(or on the 42A/B series, is less than)
Inlet
31/32/41/42/43 series ........................................................ 0.65 mm (0.025590")
42 A/B series ..................................................................... 0.05 mm (0.001968")
44/300 series ..................................................................... 1.60 mm (0.062992")
Exhaust
31/32/41/42/43 series ........................................................ 0.65 mm (0.025590")
42A/B series ...................................................................... 0.05 mm (0.001968")
44/300 series ..................................................................... 1.50 mm (0.059055")

Camshaft
Max. permissible wear ......................................................... 0.05 mm (0.001968")
Bearings, max. permissible wear ......................................... 0.05 mm (0.001968")

23
Technical data

Tightening torque
Cylinder head screws ........................................................... See next page
Main bearing screws (early model)
31 series (up to engine number 2203118631)
41 series (up to engine number 2204144595)
42 series (up to engine number 2204203834) .................. 80 Nm (59.0 lbf-ft) + 60° in one movement
Main bearing screws (late model)
31 series (as from engine number 2203118632)
41 series (as from engine number 2204144596)
42 series (as from engine number 2204203835)
32/43/44/300 series ........................................................... 60 Nm (44.2 lbf-ft) +90° in one movement
Con rod nuts ......................................................................... 113 Nm (83.3 lbf-ft)
Flange, front camshaft bearing ............................................ 24 Nm (17.7 lbf-ft)
Gear wheel, camshaft .......................................................... 85 Nm (62.6 lbf-ft)
Gear wheel, pump drive ....................................................... 24 Nm (17.7 lbf-ft)
Shaft stub for idler wheel, gear train .................................... 24 Nm (17.7 lbf-ft)
Pump housing, lube oil pump ............................................... 24 Nm (17.7 lbf-ft)
Bracket, lube oil pump ......................................................... 24 Nm (17.7 lbf-ft)
Idler wheel, lube oil pump ..................................................... 24 Nm (17.7 lbf-ft)
Bearing cap, rocker arm shaft
31/32/41/42/43 series ........................................................ 48 Nm (35.4 lbf-ft)
44/300 series ..................................................................... 24 Nm (17.7 lbf-ft)
Sump .................................................................................... 15 Nm (11.0 lbf-ft)
Drain plug, sump (where appropriate) .................................. 60 Nm (44.2 lbf-ft)
Timing cover ......................................................................... 24 Nm (17.7 lbf-ft)
Valve housing (31/32/41/42/43 series: upper) ..................... 8 Nm (5.9 lbf-ft)
Inspection hatch for valve lifter ........................................... 24 Nm (17.7 lbf-ft)
Hollow screw for adapter / oil filter ....................................... 50 Nm (36.8 lbf-ft)
Hose connection for oil filter ................................................ 50 Nm (36.8 lbf-ft)
Nipple for hose connection to oil filter ................................. 60 Nm (44.2 lbf-ft)
Flywheel ................................................................................ 65 Nm (47.9 lbf-ft) + 60° in one movement
Bell housing .......................................................................... 48 Nm (35.4 lbf-ft)
Vibration damper, fixing screws ........................................... 28 Nm (20.6 lbf-ft)
center screw for hub .......................................................... 180 Nm (132.7 lbf-ft)
Injection pump, delivery valve holder .................................. 40 Nm (29.5 lbf-ft)
Nut, injection pump flange ................................................... 90 Nm (66.3 lbf-ft)
Injectors, nut for stud ........................................................... 24 Nm (17.7 lbf-ft)
Turbocharger, exhaust pipe flange ...................................... 45 Nm (33.1 lbf-ft)

Main bearing screws

Early model

Late model

24
Cylinder head screws
Tighten screws in 5 stages as per schedule:
1:st tightening 30 Nm (22.1 lbf-ft)
2:st tightening 60 Nm (44.2 lbf-ft)
3:rd tightening 100 Nm (73.7 lbf-ft)
4:th tightening 90° in one movement
Final tightening 90° in one movement
NOTE! Inspect the waists of the screws for perma-
nent set, before assembly.

Tightening schedule, 31/32 series

Tightening schedule, 41/42/43/44/300 series

25
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 References to Service Bulletins

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 Report form

Do you have any complaints or other comments about this manual? Please make
a copy of this page, write your comments down and post it to us. The address is at
the bottom of the page. We would prefer you to write in English or Swedish.

From: ............................................................................

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Refers to publication: .............................................................................................................................................

Publication no.: ..................................................................... Issued: ....................................................................

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Date: ...........................................................
Name: .........................................................

AB Volvo Penta
Customer Support
Dept. 42200
SE-405 08 Gothenburg
Sweden
7741716-0 English 09-2001