General

Type desingation ..... TD163ES

Max. output1

TD163ES at 31.7 r/s (1900 r/min) ..... 368 kW (500 hp)

Max. torque at 18.3 r/s (1100 r/min)

TD163ES..... 2160 Nm (220 kgf m)

Number of cylinders ..... 6

Bore ..... 144 mm

Stroke ..... 165 mm

Displacement ..... 16.123 dm³

Compression ratio

TD163ES..... 17.5:1

Firing sequence ..... 1-5-3-6-2-4

Low idle..... 8.8 r/s (530 r/min)

Adjustable idle ..... 8.0-13.3 r/s (480-800 r/min)

High idle

TD163ES..... 33.7±0.83 r/s (2050±50

r/min)

Max. full load seed ..... 31.7 r/s (1900 r/min)

Weight, engine with flywheel, flywheel casing and starter motor (dry) 1250 kg
.....

Max. length ..... 1667 mm

Max. width ..... 1058 mm

Max. height..... 1332 mm

1 Net output acc. to ISO 1585. Smoke requirements met acc. to ECE Reg. 24 Federal Register
and the Swedish regulations.
Engine

Cylinder head

Type ..... One cylinder head/cylinder

Length ..... 285 mm

Width ..... 235 mm

Height ..... min 134.6 mm

Cylinder head bolts

Number/cylinder head ..... 6

Thread size ..... M16 mm

Length..... 210 mm

Cylinder block

Length ..... 1168 mm

Height, upper block face - crankshaft centre (A) ..... min 480 mm

Height, lower block face - crankshaft centre (B)..... min 120 mm

Cylinder liner

Type ..... Wet, replaceable

Height, total ..... 314.8 mm

Sealing surface height above block face ..... 0.060–0.105 mm

Number of sealing rings, cylinder liner..... 5

Piston

Height, total ..... 163.5 mm

Gudgeon pin - piston upper edge ..... 110.5 mm

Upper ring groove - piston upper edge ..... 16.2 mm

Height under cylinder block face ..... min 0.7 mm

Diameter, combustion chamber ..... 80.0 mm

Depth, piston ball ..... 28.8 mm

Number of ring grooves ..... 3

Front marking ..... Arrow pointing forwards

Piston rings

Compression rings

Number ..... 2

Piston ring clearance in groove

upper compression ring ..... max 0.115–0.157 mm

lower compression ring ..... max 0.07–0.102 mm

Piston ring gap measured in ring opening

upper ring ..... max 0.65 mm

lower ring..... max 0.45 mm

Oil scraper ring

Number ..... 1

Width, incl. spring ..... 4.975 mm

Height ..... 4.984 mm

Piston ring clearance in groove ..... max 0.072 mm

Piston ring gap measured in ring opening..... max 0.65 mm

Gudgeon pins

Gudgeon pin diameter ..... min 59.998 mm

Gudgeon pin bore in piston ..... max 60.011 mm

Connecting rod bushing bore ..... max 60.026 mm

Valve mechanism

Valves

Disc diameter

Inlet ..... 47±0.1 mm

Exhaust ..... 45±0.1 mm

Stem diameter

Inlet ..... 9.485–9.500 mm

 Exhaust ..... 9.472–9.487 mm

Valve seat angle

Inlet ..... 29.5°

Exhaust ..... 44.5°

Valve disc edge, min.

Inlet ..... 1.40 mm

Exhaust ..... 1.40 mm

Seat angle in cylinder head

Inlet ..... 30°

Exhaust..... 45°

Valve clearance, cold engine

Inlet ..... 0.30 mm

Exhaust ..... 0.60 mm

The valves on the TD163ES can be adjusted according to the two-position method. Valve pairs can
also be adjusted in two stages.

First adjust the valve calipers, then the rocker arm clearance.

When 1st cylinder piston is at T.D.C. after compression, adjust valves 1, 2, 4, 5, 8 and 9.

When 6th cylinder piston is at T.D.C. after compression, adjust valves 3, 6, 7, 10, 11 and 12.
A= Inlet

B= Exhaust

Valve seats

Outer diameter (meas. A)

Standard

Inlet ..... 50.070 mm

Exhaust ..... 48.062 mm

Oversize

Inlet ..... 50.270 mm

Exhaust ..... 48.262 mm

Height (meas. B)

Inlet ..... 7.55 mm

Exhaust ..... 12.4 mm

Valve seat location

Diameter (meas. C)

Standard

Inlet ..... 50.012 mm

Exhaust ..... 48.012 mm

Oversize

Inlet ..... 50.212 mm

Exhaust ..... 48.212 mm

Depth (meas. D)

Inlet ..... 9.5 mm

Exhaust ..... 14.05 mm

Seat bottom radius (meas. R)

Inlet ..... 0.66 mm

Exhaust ..... 0.65 mm

Measurement between valve disc and cylinder head face

Inlet (0.0-0.4 mm) ..... 0.2 mm

Exhaust (0.0-0.4 mm)..... 0.2 mm

Valve guides

Length

Inlet ..... 87 mm

Exhaust ..... 76 mm

Inner diameter

Inlet ..... 9.525-9.540 mm

Exhaust ..... 9.525-9.540 mm

Height above cylinder head spring face

Inlet ..... 23.5±0.35 mm

Exhaust ..... 25.0±0.35 mm

Clearance, valve stem - guide

Inlet ..... 0.040 mm

Utlopp ..... 0.052 mm

Rocker arms

Bearing clearance ..... 0.041 mm

Tappets

Shaft - bushing ..... 0.036 mm

Shaft - shank..... 0.026 mm

Valve springs

Valve spring, exhaust

Outer valve spring

Length, unladen ..... 68.1 mm

With load of 598 N (61 kgf) ..... 49.5 mm

With load of 1022 N (104 kgf) ..... 36.3 mm

Rigid length ..... max 33.5 mm

Inner valve spring

Length, unladen ..... 63.7 mm

With load of 275 N (28 kgf) ..... 45.0 mm

With load of 468 N (48 kgf) ..... 31.8 mm

Rigid length ..... max 28.8 mm

Valve spring, inlet

Length, unladen ..... 61.3 mm

With load of 304 N (31 kgf) ..... 48.0 mm

With load of 624 N (63.5 kgf) ..... 34.0 mm

 Rigid length..... max 31.5 mm

Camshaft

Drive ..... Gear

Number of bearings ..... 7

Diameter, bearing pins, min.

1st bearing pin ..... 68.946-68.965

mm

2nd - 7th bearing pins ..... 68.940-68.965

mm

Axial clearance ..... 0.115 mm

Radial clearance

1st ..... 0.074 mm

2nd - 7th..... 0.078 mm

Check of camshaft setting (cold engine and valve clearance =0).

Inlet valve for no.1 cylinder must with flywheel position 10° A.T.D.C. have opened
2.55 mm.

Valve lift, max

Inlet ..... 14.0 mm

 Exhaust ..... 13.2 mm

Camshaft bearings

Diameter, camshaft bearings

1 st bearing ..... 69.030±0.030 mm

2nd - 7th bearings..... 65.030±0.030 mm

Injection timing adjuster

Drive ..... Gear

Number of bearings ..... 2

Diameter, bearing pin

Front bearing ..... 69.996–70.015 mm

Rear bearing ..... 66.996–67.015 mm

Axial clearance ..... 0.115 mm

Radial clearance

Front bearing ..... 0.075 mm

Rear bearing ..... 0.075 mm

Diameter, bearings

Front bearing .....

70.062 +0,048/–0,013mm

Rear bearing.....
70.062 +0,048/–0,013mm

Timing gears
Backlash ..... max 0.115 mm

Axle journal for intermediate gear, diameter ..... max 99.88–100.00 mm

Bushing for intermediate gear, diameter ..... max 100.026–100.062 mm

Radial clearance for intermediate gear ..... max 0.054 mm

Axial clearance for intermediate gear ..... max 0.100 mm

Number of teeth, timing gears

1. Drive gear, crankshaft ..... 37

2. Intermediate gear, lube oil pump ..... 58

3. Drive gear, lube oil pump ..... 25

4. Drive gear, fan ..... 86

5. Drive gear, coolant pump ..... 25

6. Intermediate gear, right ..... 86

7. Intermediate gear, upper ..... 85

8. Drive gear, camshaft ..... 74

9. Drive gear, servo pump ..... 22

10. Drive gear, injection pump ..... 74

11. Intermediate gear, left ..... 86

12. Drive gear, air compressor ..... 33

13. Drive gear, fan ..... 29

Crank mechanism
Crankshaft

Length ..... 1323 mm

Crankshaft axial clearance ..... max 0.190 mm

Main bearing, radial clearance ..... max 0.120 mm

The crankshaft is nitrocarburized.

Note: A nitro-carburized crankshaft may be ground down to max. 2nd undersize. If ground more, it
must be re-nitro-carburized.

Main bearing pins

Diameter for machining

standard ..... 117.978-118.000 mm

undersize

0.25 mm..... 117.728-117.750 mm

0.50 mm..... 117.478-117.500 mm

0.75 mm..... 117.228-117.250 mm

Width, axial bearing pin (A)

standard ..... 50.975-51.025 mm

oversize

0.2 mm (axial bearing 0.1 ) ..... 51.175-51.225 mm

0.4 mm (axial bearing 0.2) ..... 51.375-51.425 mm

0.6 mm (axial bearing 0.3) ..... 51.575-51.625 mm

Fillet radius (R)..... 5.255-5.505 mm

Thrust washers (axial bearing)

Width (B)
 standard ..... 3.137–3.213 mm

oversize

0.1 mm..... 3.237–3.313 mm

0.2 mm..... 3.337–3.413 mm

0.3 mm..... 3.437–3.513 mm

Main bearing shells

Type ..... Replaceable

Outer diameter (C) ..... 123.135 mm

Thickness (D)

standard ..... 2.497–2.515 mm

oversize

0.25 mm..... 2.623–2.641 mm

0.50 mm..... 2.747–2.765 mm

0.75 mm..... 2.873–2.891 mm

Connecting rod bearing pin

Diameter (Ø) for machining

standard ..... 99.984–100.000 mm

undersize

0.25 mm..... 99.734–99.750 mm

0.50 mm..... 99.784–99.800 mm

0.75 mm..... 99.234–99.250 mm

Width (A), axial bearing pin ..... 59.945-59.955 mm

Fillet radius (R) (5.25-5.5)..... 5.380 mm

Connecting rod bearing shells

Outer diameter (B) ..... 104.807 mm

Thickness (C)

standard ..... 2.346–2.362 mm

oversize

0.25 mm..... 2.472–2.488 mm

0.50 mm..... 2.596–2.612 mm

0.75 mm..... 2.722–2.738 mm

Diameter, bearing shell bearing seat (D)..... 104.800 mm

Connecting rods

Length, centre - centre (E) ..... 286 mm

Marking

Connecting rod resp. cap ..... 1 to 6

"FRONT" on rod turned ..... Forwards

Diameter, connecting rod bushing bearing seat (F) ..... 65.323 mm

Connecting rod bushing bore (G) ..... 60.026 mm

Axial clearance connecting rod - crankshaft ..... max 0.035 mm

Connecting rod bearing, radial clearance..... max 0.128 mm

Flywheel, installed

Max. permitted axial throw (manual gearbox) measuring radius 150 mm ..... 0.15 mm

Number of teeth on flywheel..... 153

Flywheel casing, installed

Max. permitted axial throw for contact surface against clutch casing ..... 0.20 mm

Max. permitted radial throw for positioning against clutch casing ..... 0.25 mm
Intake and exhaust systems, turbo

Turbocompressor

Designation ..... H3B 098 AR/B 36 S1

Lube system ..... Pressure lubrication

Note: On engines fitted with EDC, boost pressure is checked using instrument 999 6525
(multimeter).
Boost pressure is checked in two stages: with the vehicle stationary and with the vehicle moving.
In conjunction with this check, the control rod travel in the injection pump should also be measured.
Control rod travel is measured in V which corresponds to measurement value in kPa.
For measuring procedure, refer to Service Manual EDC 2(23).

Measuring, vehicle stationary

Accelerator pedal at idle position

Reference voltage ..... 4.5-5.6 V

Control rod travel ..... 0.3-0.6 V

Turbo pressure ..... 3.0-3.3 V (corresponds to normal air pressure

 101.3±5 kPa)

Accelerator pedal at full throttle

position

Reference value ..... 62-70%

Measuring, vehicle moving

Accelerator pedal at full throttle and vehicle fully laden.

Boost pressure at engine speed

TD163ES 28.3 r/s (1700 r/min), full load ..... 3.4-3.75 V (115-145 kPa)

Turbo pressure

If the measurement was carried out in an ambient temperature other than +20°C, the turbo pressure
voltage should be adjusted according to the diagram below.

Example

Turbo pressure voltage was measured at 3.7 volts at a temperature of 0°C.

 Find the voltage on the vertical axis of the diagram.

 From here, proceed horizontally to the right until this line intersects the vertical line for 0°C.
 The adjusted voltage is marked by the curved lines.
Starting heater

Starting heater..... 24 V

Pressure drop indicator

The pressure drop indicator 450–550

lamp lights at a vacuum of..... WC

Exhaust pressure governor

Reduced pressure for parking brake circuit ..... 1.5±0.2 bars

Wear tolerances

Cylinder head

Height..... min 134.6 mm

Cylinder liner

Cylinder liners (pistons and piston rings) should be replaced with a wear of 0.45-
0.50 mm or if oil consumption is abnormally high.

Crankshaft

Max. permitted out-of-round on main and connecting rod bearing pins ..... 0.08 mm

Max. permitted taper on main and connecting rod bearing pins ..... 0.05 mm

Max. axial clearance on crankshaft ..... 0.40 mm

Connecting rods

Straightness, max. deviation on a measuring length of 100 mm ..... 0.05 mm

Warp, max. deviation on a measuring length of 100 mm..... 0.1 mm

Valves

Valve stem, max. permitted wear ..... 0.02

mm

Max. permitted clearance between valve stem and valve guide

Inlet ..... 0.30

mm

Exhaust ..... 0.45

mm

Valve disc edge should be min.

Inlet ..... 1.40

mm

Exhaust..... 1.55
mm

Valve seat may be ground down so far that the distance from valve disc (new valve) to
cylinder head face is max

Inlet ..... 1.0 mm

Exhaust..... 1.0 mm

With greater distance, the valve seats must be replaced.

Camshaft

Max. permitted out-of-round (with new bearings) ..... 0.05 mm

Bearings, max. permitted wear ..... 0.05 mm

Lift height, min.

Inlet ..... 7.80 mm

Exhaust ..... 7.35 mm

Tightening torques

Nm Kgf m

Main bearings ..... 440 44.0

Main bearing plates, cylinder block ..... 85±7 8.5±0.7

Connecting rod bearings ..... 240 24.0

Axial journalling, camshaft ..... 24 2.4

Timing gear cover ..... 24 2.4

Gear wheel, camshaft ..... 48 4.8

Gear wheel, injection pump drive ..... 65 6.5

Intermediate gear journalling, for left, right and upper 65 6.5

intermediate gear .....

Axial journalling, injection timing adjuster ..... 24 2.4

Bolts, pump coupling plates ..... 62.5 6.2

Retaining bolts, injection pump ..... 48 4.8

Nut, pump coupling flange ..... 355 35.5

Bearing bracket, rocker arm shaft ..... 65 6.5

Oil sump ..... 24 2.4

Drain plug, oil sump ..... 80 8.0

Bracket, oil pump ..... 48 4.8

Intermediate gear, oil pump ..... 48 4.8

Flywheel ..... 257 25.7

Flywheel casing ..... 140 14.0

Centre bolt, crankshaft ..... 642 64.2

Nut for retainer, injector ..... 50 5.0

Retainer stud, injector ..... 65 6.5

Clamp bolt, injection pump ..... 114 11.4

Hub centre bolt, coolant pump ..... 60 6.0

Valve cover ..... 20±5 2.0±0.5

Engine front mount, cylinder block ..... 200±20 20.0±2.0

Exhaust manifold..... 48±5 4.8±0.5

Centre bolt, fan hub ..... 65±7 6.5±0.7

Vibration damper ..... 48 4.8

Nut, piston cooling nozzle ..... 24±5 2.4±0.5

Stud, piston cooling nozzle ..... 23 2.3

Cleaning plugs, cylinder block (1 3/4") ..... 60 6.0

Cleaning plugs, cylinder block (1/2") ..... 80 8.0

Cleaning plugs, cylinder head (M30) ..... 60 6.0

Cleaning plugs, cylinder head (3/4") ..... 80 8.0

Tighten cylinder head in 4 stages

First tightening ..... 50 5.0

Second tightening ..... 125 12.5

Third tightening ..... 200 20.0

Fourth tightening (angle tightening) ..... 90°

Fifth tightening (angle tightening) 90°

Note: Refer to tightening torque diagram below.

Lubricating system

Lubricating system, general

Oil pressure

operating speed ..... 400 kPa

idling speed ..... min 150 kPa

piston cooling ..... 180 kPa

Oil change quantity

without oil filter ..... 40 litres

with oil filter ..... 47 litres

with oil cooler ..... 48 litres

MIN-MAX on dipstick ..... 15 litres

Lube oil pump

Type ..... Gear driven

Number of teeth

drive gear ..... 25

intermediate gear ..... 58

Diameter

bearing sleeve, intermediate gear ..... 99.88–100.00 mm

bushing, intermediate gear ..... 100.026–100.062 mm

Axial clearance

drive gear, pump ..... 0.095 mm

intermediate gear ..... 0.100 mm

Backlash..... 0.115 mm

Oilfilters

Number ..... 3

Full-flow filter ..... 2

By-pass filter..... 1

Lubricating oil valves

A. Safety valve

Spring, length unladen ..... 121.6 mm

With load of 17.8-20.0 N (1.7-2.0 kgf) ..... 59.6 mm

 With load of 21.5 N (2.1 kgf)..... 51.0 mm

B. By-pass valve

Spring, length unladen ..... 91.2 mm

With load of 41.4-47.4 N (4.1-4.7 kgf) ..... 59.6 mm

With load of 56.5 N (5.6 kgf)....... 51.0 mm

C. Overflow valve

Free length ..... 68.8 mm

Rigid length ..... max 30.0 mm

D. Reduction valve

Spring, length unladen ..... 93.0 mm

With load of 96-108 N (9.6-11.0 kgf) ..... 59.6 mm

With load of 128.3 N (12.8 kgf)..... 51.0 mm

E. Piston cooling valve

Spring, length unladen ..... 58.4 mm

With load of 18.6-20.6 N (1.8-2.0 kgf) ..... 40.5 mm

With load of 28.9 N (2.9 kgf) ..... 32.0 mm

Fuel system

Fuel

Standard ..... DIN 51601, CEC-ERF-DI or ASTM-D975-No 2-D

Firing response (cetane number) ..... Min 45

Viscosity at +20°C ..... 2-6 cSt

Min. pour point

summer quality ..... -10°C

winter quality1..... -25°C

Flash point ..... +40°C min

Solid impurities ..... None

Sulphur content ..... 0.3 weight %, max.2

1 Alternative filterability at low temperatures acc. to SIS 155122.

2 For engine oil which meets the special requirements acc. to Volvo Drain Specification, max. 0.7
weight % is permitted.

Injection pump

Pump type ..... PE 6 R 120 RS 1502

Governor type ..... RE 31

Injection pump direction of rotation viewed from front ..... Clockwise

Firing sequence ..... 1-5-3-6-2-4

Basic setting of injection pump on engine.....

12° +1/–0 B.D.T.C.

Injection timing adjuster

The injection timing adjuster gradually alters pump setting between two
speeds.

Between 1000 r/min (16.6 r/s) and 1550 r/min (25.8 r/s), pump setting on 7±1
TD163ES should alter..... °

Feed pump
Designation ..... FP/KG 24P 307

Feed pressure..... 100–150 kPa

Overflow valve

Designation..... 2417413064

Injectors

Designation

nozzle holder ..... KBAL-116 S75

nozzle ..... DLLA 140 S1204

Number marking (complete injector) ..... 562

Opening pressure ..... 23 MPa

Adjustment pressure (new spring) ..... 23.5±0.08 Mpa

Number of holes ..... 7

Fuel filter

Number ..... 2

Part no ..... 466987–5