Service Bulletin

AB Volvo Penta Group Number Version

SE-405 08 Gteborg 21-1 21 1
Sweden

New copper sleeves for the unit injectors

Marine Diesel D16 ,TAD1640GE, TAD1641GE, TAD1641VE, TAD1642GE, TAD1642VE, TAD1643VE,
TAD1650VE, TWD1643GE
Binder: E Date: 07-2008 Page: 1(3)

A new design of copper sleeve (3) for the unit injectors

has been introduced for the above-mentioned engines
from and including engine number x016021776.(1)
Types 1 and 2
Copper sleeves of earlier design.(2)
Sleeves with one groove have only been produced
for engine manufacture not as spare parts.
Type 3
Copper sleeve in new design.

Copper sleeve for unit injector, replace

The method corresponds to that indicated in the appli-
cable Workshop manual with the following exceptions:

Special tools:
88800196 Expansion tool for copper sleeve for unit
injector.
NOTE! The tool only fits the new design
copper sleeve.

Always use the new design copper sleeve (with two

grooves at the upper edge) when replacing.

NOTICE! When it is necessary to replace one cop-

per sleeve, all six copper sleeves must be replaced
with the new design.

Note: The steel gasket delivered with the new copper

sleeve must be used when installing the unit injec-
tor.

1. The first digit (x) in the engine number indicates the place of man-
ufacture (factory) and may be a 1 or a 2.
2. This design is still used on D12 engines.
Page Group Number Version AB Volvo Penta
Service Bulletin
2(3) 21-1 21 1

1 Lubricate the O-ring on the copper sleeve with

soapy water.
NOTICE! Always use a new O-ring.
2 Put the copper sleeve on tool 88800196.
The steel gasket must not be used when installing
the copper sleeve.
88800196 Lubricate the tool spindle and grease between the
nut and the tool.
3 Carefully press the copper sleeve down so that the
expansion tool locates against the area for the unit
injector (edge) in the cylinder head. Check that the
copper sleeve bottoms in the cylinder head. Install
the unit injector yoke and tighten to 80 Nm (59
lbf.ft).
4 Spread the copper sleeve by turning the nut at the
P0005846 same time as the spindle is kept still, until the
expansion tool has been completely pulled through.
NOTICE! After fitting new copper sleeve, follow
instructions for torquing of unit injector yoke in Unit
injectors, installation.

Unit injector, installation

The method corresponds to that indicated in the appli-
cable Workshop manual with the following exceptions:
1 Fit new sealing rings to the unit injector. Lubricate
the rings with diesel oil.
2 Check that the upper edge of the copper sleeve is
smooth (1), and if it has one groove (2) or two
grooves (3).
If the copper sleeve has two grooves, check that the
old steel gasket is not still in place at the bottom of
the sleeve.
The gasket can be extracted with the aid of a mag-
net.
3 If the copper sleeve has a smooth upper edge (1)
or one groove (2) a steel gasket must never be
used when installing the unit injector.
If the copper sleeve has two grooves (3) a steel
gasket must always be used.
Always use a new steel gasket.
Place the gasket on the tip of the nozzle. The gasket
is held in place by its serrations.
4 Install the unit injector and fixing yoke. Center the
injector so that it does not touch the valve springs.
Tighten the unit injector as follows.
AB Volvo Penta Group Number Version Page
Service Bulletin
21-1 21 1 3(3)

Copper sleeve of type 3 (new or re-used):

NOTICE! Always use a new steel gasket beneath the
unit injector.

Fixing yoke, injector

First tightening
Stage 1: 20 +5/0 Nm (14.8 +4/0 lbf.ft).
Stage 2: Angle tighten 180 5.
Note: Undo the bolt for the unit injector fixing yoke
before the second tightening.
Second tightening
Stage 1: 20 +5/0 Nm (14.8 +4/0 lbf.ft).
Stage 2: Angle tighten 90 5.

Re-used copper sleeves of types 1 and 2:

NOTICE! The steel gasket must never be used under
the unit injector.

Fixing yoke, injector

Stage 1: 20 +5/0 Nm (14.8 +4/0 lbf.ft).
Stage 2: Angle tighten 60 5.

P0007276