Volvo EPA2007 D13F Reference Manual Download Page 112

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106 ENGINE COMPONENT AND LOCATION

EGR Cooler Inlet Pipe

W2033358

1. EGR Valve

4. EGR Cooler

2. Cooler Inlet Pipe

5. Electrical Connector

3. Clamps

6. Oil Supply Line

The cooler inlet pipe conducts the exhaust from the EGR valve to the EGR cooler.
The cooler lowers the exhaust stream temperature before it reenters the combustion
chamber.

Summary of Contents for EPA2007 D13F

Page 1: ... EPA2007 D13F Engine Volvo Group North America Inc 2009 Printed in U S A EPA2007 D13F Engine Quick Reference Guide Quick Reference Guide PV776 QRG07 D13F November 2009 EPA2007 D13F Engine Quick reference Guide PV776 QRG07 D13F v v v ...

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Page 3: ... Gasket and Seal Reuse 50 Engine Lubricants and Sealants 52 Engine Fault Codes 53 Conversion Chart 59 Engine Dimensions 65 Cylinder Head 65 Cylinder Head Bolts 65 Cylinder Block 65 Cylinder Liner 65 Piston 65 Piston Rings 66 Valve Mechanism 67 Rocker Arms 67 Valve Guides 68 Valve Springs 68 Engine Timing Gear 69 Camshaft 70 Camshaft Bearings 71 Crank Mechanism Main Bearing Journals 71 Thrust Washe...

Page 4: ...Cooler 107 EGR Venturi System 107 EGR Cooler Outlet Pipe 107 EGR Mixer 107 Inlet Air Heater 108 EGR Diagnostics 108 Air Intake System 109 Variable Geometry Turbocharger 109 Cooling System 110 Coolant Pump 110 Thermostat 111 Engine Cooling Fan 111 Engine Managment System 112 Engine Electronic Control Unit EECU 112 Exhaust Aftertreatment System 113 Exhaust Gas Recirculation 113 Particulate Matter 11...

Page 5: ... Fuel Filter Replacement 139 Water Separating Pre Filter Replacement 139 Full Flow Main Filter Replacement 140 Cooling System Maintenance 140 Coolant Drain Outlets 140 Coolant Filter 141 Exhaust Aftertreatment System Maintenance 143 Diesel Particulate Filter 143 Compact Unit 143 Vertical Back of Cab Unit 147 Aftertreatment Fuel Injector AFI 152 Drive Belt Replacement and Tensioning 158 General Inf...

Page 6: ...ulate Matter 170 Differential Pressure Sensors 170 Discharge Recirculation Valve DRV 170 Electronic Unit Injector EUI 171 Engine Electronic Control Unit EECU 171 Exhaust Aftertreatment System EATS 171 Exhaust Gas Recirculation EGR 171 Hydrocarbons HC 171 Idler Gear 171 Idler Tensioner 172 Oxides of Nitrogen NOx 172 Passive Regeneration 172 Poly V Belt 172 Regeneration 172 Roller Follower 172 Soot ...

Page 7: ...ing definitions indicate the use of these advisory labels as they appear throughout the manual DANGER Danger indicates an unsafe practice that could result in death or serious personal injury Serious personal injury is considered to be permanent injury from which full recovery is NOT expected resulting in a change in life style WARNING Warning indicates an unsafe practice that could result in pers...

Page 8: ...f a special tool s designed for a specific purpose These special tools must be used in the manner described whenever specified in the instructions DANGER 1 Before starting a vehicle always be seated in the driver s seat place the transmission in neutral apply the parking brakes and push in the clutch pedal Failure to follow these instructions could produce unexpected vehicle movement which can res...

Page 9: ...eath Always use jackstands of adequate capacity to support the weight of the vehicle CAUTION Before towing the vehicle place the transmission in neutral and lift the rear wheels off the ground or disconnect the driveline to avoid damage to the transmission during towing Volvo Trucks Inc cannot anticipate every possible occurrence that may involve a potential hazard Accidents can be avoided by reco...

Page 10: ...e 2007 EPA regulations The Holset VGT features fixed vanes with a sliding nozzle ring The nozzle position is infinitely variable between open and closed This design reacts quickly to exhaust pressure and controls inlet pressure more precisely Reliability is enhanced by having fewer moving parts Its actuator and bearing housing are water cooled and engine oil lubricated for greater durability A wid...

Page 11: ...e forward or axle back vehicles by virtue of optional oil pans The engine fan is mounted high or low depending on vehicle configuration The unit injector incorporates the pump valve and injector Its internal solenoids permit fast precise control of fuel delivery into the cylinder The unit injectors are encased by the valve cover and not exposed to the heat of exhaust system components Fuel passes ...

Page 12: ...engine conforms and other pertinent information required by emissions regulations Valve lash settings for inlet exhaust and engine brake NOx NMHC NOx and particulate matter emissions Exhaust emission control systems A statement concerning the limitation on the fuel to be used in the engine also appears Code letters under Exhaust Emission Control Systems represent basic engine systems that impact e...

Page 13: ...iles 12 000 KM 45 Days or 150 Hours B Service Industry norm or customer specific 30 000 Miles 48 000 KM or 500 Hours 15 000 Miles 24 000 KM 90 days or 300 Hours 3 Axle Alignment Annually minimum Gear Oil Change 250 000 Miles 402 000 KM or 2 years 40 000 Miles 64 000 KM 1 year or 1200 Hours Engine Components Fuel Filter Water Separator Every Oil Change Air Filter At Maintenance Indicator or 12 Mont...

Page 14: ...0 Hours 8 000 Miles 12 000 KM or 150 Hours B Inspection 30 000 Miles 48 000 KM or 500 Hours 15 000 Miles 24 000 KM or 300 Hours C Inspection 60 000 Miles 96 000 KM or 1000 Hours 30 000 Miles 48 000 KM or 600 Hours D Inspection 120 000 Miles 200 000 KM or 2000 Hours 60 000 Miles 96 000 KM or 1200 Hours Genuine Volvo Filters are strongly recommended Certain chassis vocations may require more frequen...

Page 15: ...on for proper alignment 5 Connecting rod caps MUST BE mated to their respective connecting rods due to the fractured manufacturing process used Also the rod caps can be installed only one way because of the difference in spacing between screw holes at each side of the cap 6 DO NOT use the lifting eye on the flywheel housing when tilting the engine transmission assembly to an angle greater than 15 ...

Page 16: ...033586 In addition to the engine information plate on the cylinder head cover the engine is also identified by the engine serial number stamped into the cylinder block This serial number is located on the block left side at the front just below the inlet manifold ...

Page 17: ...der and piston type Wet Sleeve one piece steel piston Electronic control Electronic management system Emission controls Cooled EGR Diesel Particulate Filter DPF Peak power ratings 335 485 hp Peak torque ratings 1830 2237 Nm 1350 1650 ft lb Low idling 10 rps 600 rpm Fast idling 35 8 rps 2150 rpm Maximum full load revolutions 31 7 rps 1900 rpm Weight production engine without vehicle details product...

Page 18: ...335 hp 1400 1700 1830 Nm 1350 ft lb 1100 D13F375 280 kW 375 hp 1400 1700 1966 Nm 1450 ft lb 1100 D13F405 302 kW 405 hp 1500 1700 1966 Nm 1450 ft lb 1100 D13F425 317 kW 425 hp 1500 1600 2102 Nm 1550 ft lb 1100 D13F435 324 kW 435 hp 1400 1800 2237 Nm 1650 ft lb 1100 D13F485 362 kW 485 hp 1600 1900 2237 Nm 1650 ft lb 1100 ...

Page 19: ...valves per cylinder unit injectors cast iron valve guides and oil seals steel valve seats valve alignment 12 degrees from perpendicular copper injector sleeves integral fuel passages and thermostat housing guide slots for installation on block Valve cover Plastic 20 spring tension screws Cylinder liner Wet Sleeve replaceable with EDPM rubber and Viton seals Cylinder head Valve springs Double sprin...

Page 20: ...an pump pressure tube strainer and pressure relief valve Main bearing caps Nodular iron machined with block No 7 mounts oil pump numbered for reassembly sleeve guides for screws thrust washers at No 4 main bearing journal Exhaust manifold Three piece six port Pistons One piece steel three ring grooves Piston rings Compression Two one trapezoidal cross section one rectangular cross section Piston r...

Page 21: ... geometry type Holset exhaust driven fixed vanes sliding ring nozzle infinitely variable volume oil and water cooled Valve lifters Roller followers Valve seat inserts Pressed in head replaceable Vibration damper Internal fluid filled ring Coolant pump Centrifugal rotor impeller belt driven ...

Page 22: ...olant Temperature front right side of cylinder head 22 3 N m 16 2 lb ft Crankcase Position Engine Speed 10 1 N m 7 1 lb ft Crankcase Pressure block front of air compressor 30 5 N m 22 4 lb ft Fuel Pressure fuel filter housing 25 3 N m 18 5 2 lb ft Oil Level Temperature inside sump standard torque Oil Pressure block front of air compressor 30 5 N m 22 4 lb ft Turbocharger Wheel Speed 8 5 N m 75 lb ...

Page 23: ...ghtened bolts angle tightened bolts or yield limit tightened bolts Grade 8 8 Should not be reused Grade 10 9 Can be reused Grade 12 9 Can be reused Note Check bolts before reusing Bolts showing damage for example cut marks on the underside or distortion of the flats should be discarded General Tightening Torques Intermediate front engine mounting brackets accessories brackets Step 1 105 15 Nm 77 5...

Page 24: ...540 90 Nm 398 66 ft lb Cushion to frame 200 30 Nm 148 24 ft lb Crankshaft main bearing cap Step 1 150 20 Nm 111 15 ft lb Step 2 angle tightening 120 5 degrees Connecting rod cap Step 1 20 3 Nm 15 2 ft lb Step 2 60 3 Nm 44 2 ft lb Step 3 angle tightening 90 5 degrees Piston cooling nozzle 24 4 Nm 18 3 ft lb Engine block plugs 50 5 Nm 37 7 ft lb ...

Page 25: ...merical order 40 5 Nm 30 4 ft lb Step 2 Tighten the bolts 1 24 in numerical order angle tightening 90 5 degrees Note These bolts should not be reused T2022337 Note Apply sealant outside the groove as illustrated maximum 20 minutes before mounting Thickness of sealant bead 2 mm 0 079 inch ...

Page 26: ...20 SPECIFICATIONS Timing Gear Gasket W2005945 Do not reuse mounting plate screws Do NOT apply sealant to new coated screws Timing gear plate tighten in sequence shown 28 4 Nm 21 3 ft lb ...

Page 27: ...ustable Step 1 35 4 Nm 26 3 ft lb Step 2 angle tightening 120 5 degrees Note Tighten following the order shown in the illustration 4 Drive gear camshaft includes vibration damper Step 1 45 5 Nm 33 4 ft lb Step 2 angle tightening 90 5 degrees Note Tighten following the order shown in the illustration 5 Idler gear 140 10 Nm 103 7 ft lb 6 Drive gear power steering pump 100 10 Nm 74 7 ft lb 7 Drive ge...

Page 28: ...M14 M10 M8 bolts 24 4 Nm 18 3 ft lb Step 2 Tighten all bolts in numerical order to the following torque M14 bolts 1 7 140 20 Nm 103 15 ft lb M10 bolts 8 11 48 8 Nm 36 6 ft lb M8 bolts 12 22 24 4 Nm 18 3 ft lb Note Apply sealant in a 2 mm 0 079 inch thick bead as illustrated ...

Page 29: ...th bolts 1 and 2 and install alignment tool Step 2 Tighten the bolts in the numerical order shown 24 4 Nm 18 3 ft lb Note Apply sealant in a 2 mm 0 079 inch thick bead maximum 20 minutes before mounting and carefully tighten the contact surfaces shown in the enlarged parts of the illustration ...

Page 30: ...ghtening 120 10 degrees Note Make sure the flange is dry and clean Tighten the bolts in the numerical order as shown Mark the head of each screw after installation Discard screws with four marks when removed and replace with newscrews Do not lubricate new screws that are coated ...

Page 31: ...96 Step 1 Position the cover with bolts 1and 2 and tighten to contact Step 2 Tighten the bolts in numerical order 1 8 as shown 24 4 Nm 18 3 ft lb Note Apply sealant in a 2 mm 0 079 inch thick bead as illustrated and tighten bolts in numerical order ...

Page 32: ...t Step 2 Verify in the same order 275 45 Nm 203 33 lb ft Front Engine Support Mounting Bracket W2032698 Sequence Torque Angle Tighten Step 1 Screw No 1 80 15 Nm 59 11 lb ft Step 2 Screw No 2 3 and 4 105 15 Nm 77 11 lb ft 60 5 Step 3 Screw No 1 105 15 Nm 77 11 lb ft 60 5 Step 4 Screw No 5 Standard screw torque ...

Page 33: ...TIONS 27 Crankshaft Vibration Damper T2022730 Step 1 35 5 Nm 26 4 ft lb Step 2 90 10 Nm 66 7 ft lb Note Tighten the bolts in the numerical order 1 2 3 4 5 6 1 The vibration damper 8 8 bolts should not be reused ...

Page 34: ...Cylinder Head T2022734 Step 1 100 5 Nm 74 4 ft lb Step 2 angle tightening 120 5 degrees Step 3 angle tightening 90 5 degrees Note The cylinder head must be mounted according to instructions see Cylinder Head Replacement ...

Page 35: ...SPECIFICATIONS 29 Bearing Cap Camshaft Rocker Arm Shaft T2022796 ...

Page 36: ...n the order 4 3 5 2 6 1 7 60 5 Nm 44 4 ft lb Note The bolts must be tightened in stages to ensure that the rocker arm shaft is seated without bending Step 3 Angle tighten marked bolts of bearing caps 1 to 7 90 5 degrees Step 4 Tighten the marked bolts of bearing caps 1 to 6 25 3 Nm 19 2 ft lb Step 5 Angle tighten the bolts of bearing caps 1 to 6 120 5 degrees Step 6 Loosen the marked bolts of bear...

Page 37: ... inlet exhaust 38 4 Nm 28 3 ft lb or angle tighten after contact 60 5 degrees Locknut Valve Adjustment Screw Volvo Engine Brake T2022966 Locknut valve adjustment screw exhaust VEB 38 4 Nm 28 3 ft lb or angle tighten after contact 30 1 5 0 degrees Note Hold the valve bridge while tightening ...

Page 38: ...32 SPECIFICATIONS Locknut Volvo Engine Brake Rocker Arm W2005946 Locknut Volvo Engine Brake rocker arm 52 4 Nm 38 3 ft lb or angle tighten after contact 45 5 degrees ...

Page 39: ...SPECIFICATIONS 33 Camshaft bearing Cap T2022951 Camshaft bearing cap spring tab Volvo Engine Brake only 25 3 Nm 18 2 ft lb ...

Page 40: ...nment pins and bushings in the head before assembling the valve cover Note Tighten the bolts in the numerical order shown 24 4 Nm 18 3 ft lb Oil pump pickup tube 24 4 Nm 18 3 ft lb Oil filter housing 24 4 Nm 18 3 ft lb Oil filter 25 5 0 Nm 18 5 3 5 0 ft lb ...

Page 41: ...lb Install the oil pan bolts A and B and tighten 24 4 Nm 18 3 ft lb Tighten the bolts from the middle and outwards in order 1 4 as shown 24 4 Nm 18 3 ft lb Finish by checking the torque for bolts A and B 24 4 Nm 18 3 ft lb Drain plug oil pan steel and plastic 60 10 Nm 44 7 ft lb ...

Page 42: ...Attaching Screws 150 20 Nm 111 15 lb ft Step 2 Angle tighten 120 5 Connecting Rod Bearing Caps Discard screws with four marks when removed and substitute new screws Tighten screws in a cross pattern Step 1 Attaching Screws 20 3 Nm 15 2 lb ft Step 2 60 3 Nm 44 2 lb ft Step 3 Angle tighten 90 5 Oil Pan Drain Plug 60 10 Nm 44 7 lb ft Oil Pump Attaching Screws 24 4 Nm 18 3 lb ft Nozzle Attaching Screw...

Page 43: ...he cover to the engine block and install bolt A into the oval hole Press the cover against the water pump housing using an assembly tool 88800022 and install bolt B Check that the cover is positioned correctly Install bolts C and D and tighten 24 4 Nm 18 3 ft lb Tighten the cover bolts from the middle and outwards in order 1 4 as shown 24 4 Nm 18 3 ft lb Finish by checking the torque for bolts C a...

Page 44: ...tightening method is for a unit injector with a sealing washer First tightening Step 1 20 5 0 Nm 15 4 0 ft lb Step 2 Angle tightening 180 5 degrees Loosen until the torque is 10 15 Nm 7 11 ft lb Second tightening Step 1 20 5 0 Nm 15 4 0 ft lb Step 2 Angle tightening 90 5 degrees ...

Page 45: ...SPECIFICATIONS 39 Locknut Unit Injector Adjusting Screw T2022967 Locknut unit injector adjusting screw 52 4 Nm 38 3 ft lb or angle tighten after contact 45 5 degrees ...

Page 46: ...sure Fuel Circuit Fuel line fittings Filter Housing Attaching Screws M8 x 1 25 24 4 N m 18 3 lb ft 1 18 3 Nm 13 2 ft lb 2 28 4 Nm 20 5 3 ft lb 3 30 4 Nm 22 3 ft lb 4 35 5 Nm 26 4 ft lb 5 40 5 Nm 29 5 4 ft lb 6 48 5 Nm 35 4 ft lb ...

Page 47: ...t Manifold 20 3 Nm 15 2 lb ft Air Compressor Brake System Gear Attaching Nut 200 50 0 Nm 147 37 0 lb ft Compressor Attaching Nuts 85 15 Nm 63 11 lb ft Grease Connector 25 4 Nm 18 3 lb ft Attaching Studs 25 4 Nm 18 3 lb ft Fuel Pump Attaching Screws to Power Steering Pumps 8 2 0 Nm 6 1 0 lb ft Banjo Bolts 40 5 Nm 30 4 lb ft Power Steering Pump Gear Attaching Nuts 100 10 Nm 74 7 lb ft Attaching Scre...

Page 48: ...TIONS Aftertreatment Fuel Supply Line W2005926 1 Aftertreatment Fuel Injector fuel supply line 15 0 5 Nm 135 5 in lb 2 Mounting Bolts 14 Nm 125 in lb 3 Two Way Check Valve 15 Nm 135 in lb 4 Air Line 27 Nm 235 in lb ...

Page 49: ...SPECIFICATIONS 43 Intake manifold W2032557 Tighten the bolts diagonally from the center outward 24 4 Nm 18 3 ft lb ...

Page 50: ...s when reassembled exhaust system components Step 1 All screws 5 1 5 Nm 3 5 1 lb ft Step 2 Tighten bolts 1 4 5 8 9 12 in order 5 1 5 Nm 7 5 1 ft lb Step 3 Tighten bolts 3 2 7 6 11 10 1 4 5 8 9 12 in order 48 8 Nm 35 6 ft lb Cooling Duct Cover W2032839 Tighten screws in the order indicated to 24 4 Nm 18 3 lb ft ...

Page 51: ...Coolant pump pulley 24 4 Nm 18 3 ft lb Coolant pump housing 48 8 Nm 35 6 ft lb Front and side cover thermostat housing 24 4 Nm 18 3 ft lb Tensioner 48 8 Nm 35 6 ft lb Drive belt idler 24 4 Nm 18 3 ft lb Fan hub 15mm hex wrench size nut 48 8 Nm 35 6 ft lb Viscous fan drive Drive to hub 24 4 Nm 18 3 ft lb ...

Page 52: ... 5 7 5 Nm 48 5 5 ft lb Pulley nut 101 5 6 5 Nm 75 5 ft lb Battery terminal 6 5 0 25 Nm 57 5 2 5 in lb Ground terminal 6 2 0 5 Nm 55 5 in lb I R terminals 2 3 0 5 Nm 20 5 in lb AC refrigerant compressor mounting bolts 24 4 Nm 18 3 ft lb Wiring harness conduit to block 24 3 Nm 18 2 ft lb Wiring harness conduit cover 3 5 0 5 Nm 31 4 4 in lb Cable channel cover 3 5 0 5 Nm 31 4 4 in lb Air Compressor A...

Page 53: ... CAUTION Repeated tightening of fasteners and threaded components reduces their capacity to function adequately The following table describes the various items and the limits of their reusability Failue to conform to these limits may result in severe component damage Fastener Reuse Fssteners Example Reusable Limit Reusable Recommendation Highly loaded screws Phosphating plus oil Cylinder Head Inje...

Page 54: ...crews ZIB Property class 8 8 No limit No limit if no cracks corrosion or damage to the flat surface Fastener Reuse Fssteners Example Reusable Limit Reusable Recommendation V nipple with taper threads With locking fluid pre applied Do not reuse Before fitting the new nipple clean the hole with a nipple tap and apply Loctite 270 on the nipple thread or use a new coated nipple Taper plus or nipples W...

Page 55: ...se When re using bolts the bolt head and threads must be lubricated with clean engine oil Do not lubricate new bolts as they are already lubricated CYLINDER HEAD BOLTS CAMSHAFT and ROCKER SHAFT BOLTS FLYWHEEL BOLTS MAIN BEARING BOLTS CONNECTING ROD BOLTS CAUTION Do not re use timing gear mounting plate bolts Do not re use timing gear mounting bolts Do not re use piston spray nozzle bolts ...

Page 56: ...d oil pan timing gear cover No limit if no damage and no leaks Remove old silicone from the T joints Clean the surface Apply fresh silicone Rubber Gaskets standard O rings and sealing rings No limit if no damage and no leaks Bonded seals steel rubber gasket Nipples hollow screws and oil filter housing No limit if no damage and no leaks Valve seals Valve stems No limit if no damage and no leaks Dis...

Page 57: ...ming Gear Plate and Cylinder Block Flywheel Housing and Timing Gear Plate Front Cover and Cylinder Block Timing Gear Cover and Gear Plate Dow Corning LDC 7091 Silicone can substitute Dow Corning 832 Do not reuse Remove the old RTV1 sealant Clean the Surface Apply fresh RTV1 sealant IMPORTANT Remove the old silicone from the T joints and apply fresh ...

Page 58: ...l filter seal Clean engine oil Holding metal parts in place Petroleum jelly Valve stems and guides Clean engine oil Engine front cover flywheel housing timing gear cover 3092340 sealant Engine parts fasteners and washers Clean engine oil Exhaust manifold studs High temperature 1161929 anti seize Oil cooler assembly O ring Clean engine oil O rings coolant EPDM Clean coolant or Dow Corning 55 O ring...

Page 59: ...r in fuel sensor PID97 Oil Level PID98 Oil Pressure PID100 Boost Pressure PID102 Turbo speed PID103 Boost Temperature PID105 Ambient Pressure PID108 Coolant Temperature PID110 Coolant Level PID111 Crankcase Pressure Crankhouse Pressure PID153 ECU battery potential PID158 Ambient Air Temperature PID171 Exhaust Gas Temperature PID173 Oil Temperature PID175 Transmission Oil Temperature PID177 Immobil...

Page 60: ...es Description Fault Code Total Vehicle Distance PID245 Time data failure PID251 Date data failure PID252 Relative Air Humidity PID354 Compressor Discharge Temperature PID404 EGR Diff Pressure PID411 EGR Temperature After Cooler PID412 ...

Page 61: ... Valve SID18 CAM Speed sensor SID21 Crank Speed sensor SID22 Variable Geometry Turbocharger Actuator 1 SID27 Cooling Fan control SID33 Starter Output SID39 Preheat sense 1 SID70 Preheat sense 2 SID71 EGR Valve 1 LISK SID146 Buffered IVS SID230 CAN1 J1939 communication link SID231 5 V supply SID232 Programme memory SID240 Calibration memory EEPROM SID253 Controller 1 SID254 ...

Page 62: ... compensation PPID272 Soot level PPID326 After treatment injection shut off valve PPID328 After treatment fuel injector PPID329 Discharge Recirculator Valve Solenoid PPID330 Engine fan thermal switch PPID333 Ash Level in the Diesel Particle filter PPID337 Exhaust gas temperature sensor 2 PPID387 Exhaust gas temperature sensor 3 PPID436 After treatment injector fuel pressure PPID437 ...

Page 63: ...ion of dosing activity PSID42 Incorrect EGR flow PSID43 Deactivation of EGR PSID44 High NOx Root cause unknown PSID45 NOx monitoring failure PSID46 Particulate trap regeneration PSID47 Boost Air system PSID98 ATI system PSID108 VIN check 1 PSID161 VIN check 2 PSID162 CAN1 J1939 communication time out PSID201 CAN1 J1939 communication time out PDIS202 CAN2 J1939 communication link PSID232 ...

Page 64: ...O HIGH SOURCE 4 VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE 5 CURRENT BELOW NORMAL OR OPEN CIRCUIT 6 CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT 7 MECHANICAL SYSTEM NOT RESPONDING OR OUT OD ADJUSTMENT 8 ABNORMAL FREQUENCY OR PULSE WIDTH OR PERIOD 9 ABNORMAL UPDATE RATE 10 ABNORMAL RATE OF CHANGE 11 ROOT CAUSE NOT KNOWN 12 BAD INTELLIGENT DEVICE OR COMPONENT 13 OUT OF CALIBRATION 14 SPECIAL INSTRUCT...

Page 65: ...to Centimeters cm 30 48 Feet ft to Meters m 0 3048 Yards yd to Centimeters cm 91 44 Yards yd to Meters m 0 9144 Miles to Kilometers km 1 609 Millimeters mm to Inches in 0 03937 Centimeters cm to Inches in 0 3937 Centimeters cm to Feet ft 0 0328 Centimeters cm to Yards yd 0 0109 Meters m to Feet ft 3 281 Meters m to Yards yd 1 094 Kilometers km to Miles 0 6214 ...

Page 66: ...ubic Inches cu in to Liters L 0 01639 Quarts qt to Liters L 0 9464 Gallons gal to Liters L 3 7854 Cubic Yards cu yd to Cubic Meters cu m 0 7646 Cubic Centimeters cu cm to Cubic Inches cu in 0 06102 Liters L to Cubic Inches cu in 61 024 Liters L to Quarts qt 1 0567 Liters L to Gallons gal 0 2642 Cubic Meters cu m to Cubic Yards cu yd 1 308 ...

Page 67: ...t sq ft to Square Meters sq m 0 0929 Square Yards sq yd to Square Meters sq m 0 8361 Square Miles sq miles to Square Kilometers sq km 2 590 Square Millimeters sq mm to Square Inches sq in 0 00155 Square Centimeters sq cm to Square Inches sq in 0 155 Square Centimeters sq cm to Square Feet sq ft 0 001076 Square Meters sq m to Square Feet sq ft 10 76 Square Meters sq m to Square Yards sq yd 1 196 Sq...

Page 68: ...z 0 035 Kilograms kg to Pounds lb 2 205 Kilograms kg to Short Tons US tons 0 001102 Kilograms kg to Metric Tons t 0 001 Metric Tons t to Pounds lb 2205 Metric Tons t to Short Tons US tons 1 1023 Metric Tons t to Kilograms kg 1000 Force Calculation Ounces Force ozf to Newtons N 0 2780 Pounds Force lbf to Newtons N 4 448 Pounds Force lbf to Kilograms Force kgf 0 456 Kilograms Force kgf to Pounds For...

Page 69: ...ter kgfm 0 10197 Kilograms Force per Meter kgfm to Pound Feet lb ft 7 223 Kilograms Force per Meter kgfm to Newton Meters N m 9 807 Radiator Specific Heat Dissipation Calculations to British Thermal Unit per Hour BTU hr to Kilowatt per Degree Celsius kW C 0 000293 Kilowatt per Degree Celsius kW C to British Thermal Unit per Hour BTU hr 3414 43 Temperature Calculations Degrees Fahrenheit F to Degre...

Page 70: ... Bar bar 0 06895 Kilopascals kPa to Atmospheres atm 0 00987 Kilopascals kPa to Inches of Mercury in Hg 0 29612 Kilopascals kPa to Inches of Water in H2O 4 01445 Kilopascals kPa to Pounds per Square Inch psi 0 145 Fuel Performance Calculations Miles per Gallon mile gal to Kilometers per Liter km L 0 4251 Kilometers per Liter km L to Miles per Gallon mile gal 2 352 Velocity Calculations Miles per Ho...

Page 71: ... Block Length 1052 mm 41 42 inches Height upper block face crankshaft center 422 mm 16 61 inches Height lower block face crankshaft center 120 mm 4 72 inches Cylinder Liner Type Wet replaceable Height of sealing surface above block face 0 15 0 21 mm 0 006 0 008 inch Number of sealing rings per cylinder liner 1 3 Piston Number of ring grooves 3 Front marking Arrow pointing forwards ...

Page 72: ...g to left of gap Piston ring clearance in groove Upper compression ring Trapezium profile Lower compression ring 0 09 0 14 mm 0 0035 0 0055 inch Oil Scraper Ring Quantity 1 Labelling Up color marking to left of gap Piston ring clearance in groove 0 05 0 10 mm 0 0019 0 0039 inch ...

Page 73: ...xhaust 1 5 mm 0 059 inch Valve lash clearance cold engine adjustment value Inlet 0 2 mm 0 008 inch Exhaust 0 8 mm 0 031 inch Exhaust Volvo Engine Brake 1 0 mm 0 394 inch Valve lash clearance cold engine check value Inlet 0 15 0 25 mm 0 006 0 009 inch Exhaust 0 75 0 85 mm 0 029 0 033 inch Exhaust Volvo Engine Brake 0 95 1 05 mm 0 037 0 041 inch Rocker Arms Rocker arm bearing clearance 0 08 mm 0 003...

Page 74: ...ust 8 mm 0 315 inch Height above cylinder head spring surface Inlet Exhaust 24 5 0 2 mm 0 965 0 008 inch Valve Springs Inlet valve spring Length unloaded 73 8 mm 2 91 inches Exhaust outer valve spring Length unloaded 73 8 mm 2 91 inches Exhaust inner valve spring Length unloaded 70 5 mm 2 78 inches ...

Page 75: ...pump 29 6 Drive gear power steering pump 36 7 Drive gear air compressor 48 8 Drive gear lubricating oil pump 31 9 Engine power take off optional 50 Idler gear to camshaft gear backlash adjustable 0 05 0 15 mm 0 002 0 006 inch Oil pump backlash 0 05 0 40 mm 0 002 0 016 inch Idler gear axle to bushing clearance 0 05 mm 0 002 inch maximum All other drive and idler gear backlash 0 05 0 17 mm 0 002 0 0...

Page 76: ...s Gear Number of bearings 7 Standard bearing journal diameter 69 97 70 00 mm 2 754 2 760 inch Undersize bearing journal diameters 0 25 mm 0 010 inch 69 72 69 78 mm 2 746 2 747 inches 0 50 mm 0 020 inch 69 47 69 53 mm 2 735 2 737 inches 0 75 mm 0 030 inch 69 22 69 28 mm 2 725 2 728 inches Valve lift at zero play Inlet Exhaust Volvo Engine Brake 13 1 mm 0 520 inch 12 5 mm 0 490 inch Permitted wear e...

Page 77: ...0 50 mm 0 020 inch 107 50 mm 4 2323 inches 0 75 mm 0 030 inch 107 25 mm 4 2224 inches 1 00 mm 0 040 inch 107 00 mm 4 2126 inches 1 25 mm 0 050 inch 106 75 mm 4 2027 inches Surface finish main bearing journal Ra 0 25 Surface finish radius Ra 0 4 Width axial bearing pin A standard 47 0 mm 1 850 inches Oversize 0 2 mm 0 008 inch axial bearing 0 1 mm 0 004 inch 47 2 mm 1 858 inches 0 4 mm 0 016 inch a...

Page 78: ...8 mm 0 137 inch 0 4 mm 0 016 inch 3 58 mm 0 141 inch Main Bearings Standard thickness D 2 48 mm 0 098 inch Oversize 0 25 mm 0 010 inch 2 61 mm 0 103 inch 0 50 mm 0 020 inch 2 74 mm 0 108 inch 0 75 mm 0 030 inch 2 86 mm 0 112 inch 1 00 mm 0 040 inch 2 98 mm 0 117 inch 1 25 mm 0 050 inch 3 11 mm 0 122 inch Main bearing maximum permitted diametrical wear value 0 05 0 12 mm 0 002 0 005 inch ...

Page 79: ...8 75 mm 3 888 inches 0 50 mm 0 020 inch 98 50 mm 3 878 inches 0 75 mm 0 030 inch 98 25 mm 3 868 inches 1 00 mm 0 040 inch 98 00 mm 3 858 inches 1 25 mm 0 050 inch 97 75 mm 3 848 inches Surface finish bearing journal Ra 0 25 Surface finish radius Ra 0 4 Width A 57 0 mm 2 244 inches Recess radius R 4 0 mm 0 157 inch ...

Page 80: ...40 inch 1 39 mm 0 054 inch 1 25 mm 0 050 inch 1 14 mm 0 044 inch Connecting Rod Wear Value End play connecting rod at crankshaft journal1 0 35 mm 0 0138 inch maximum Big end bearing diametrical play 0 1 mm 0 004 inch 1 The measurements refer to lubricated components Marking The FRONT marking on the connecting rod faces forward T2019085 The connecting rod and cap are marked as a pair with a three d...

Page 81: ...dial runout of guide against clutch housing 0 26 mm 0 010 inch maximum Crankshaft T2012873 Wear value Crankshaft axial clearance1 0 4 mm 0 016 inch maximum Machining value Main bearing and connecting rod bearing journal out of round 0 006 mm 0 0002 inch maximum Main bearing and connecting rod bearing journal taper 0 02 mm 0 0008 inch maximum Runout of middle bearing 0 15 mm 0 006 inch maximum 1 Th...

Page 82: ...One piece cast iron Integral thermostat housing Separate chambers for exhaust and inlet at each cylinder make this a crossflow design The fuel channel drilled from front to rear connects with grooves machined around each injector opening A plug at the rear of the cylinder head seals this channel ...

Page 83: ...luding inlet injection and exhaust There are four cams per cylinder in the optional configuration VGT exhaust brake plus Volvo Engine Brake with the addition of a brake cam at each cylinder The rocker arms are positioned on the shaft front to back in the order of inlet injector exhaust and brake if so equipped Both the inlet and exhaust rocker arms each drive the valve pairs via a pinless yoke bri...

Page 84: ...s induction hardened Timing marks for valve and injector adjustment are located on the flange forward of the No 1 camshaft journal These marks are for adjusting valve clearance They do not apply to camshaft timing Camshaft thrust washers are integral on the No 7 journal bearing Smooth rotation is ensured by means of a vibration damper on the camshaft gear Teeth on the damper interact with the cams...

Page 85: ...tor adjustment Volvo Engine Brake includes its own electronic control governed by driver s choice through a switch near the steering wheel This control mounts on the cylinder head between the No 3 and No 4 cylinder rocker arms The wiring harness includes additional wire leads for Volvo Engine Brake ...

Page 86: ...opens into a cast in channel that supplies oil to the timing gears The piston cooling channel is covered by the timing gear cover Main bearing caps are made of nodular cast iron machined together with the cylinder block Cast alignment slots in the block and tabs on the caps ensure proper alignment at installation Each cap is marked with its location beginning with No 1 at the front Cap Nos 4 and 7...

Page 87: ...e to side at assembly Fore and aft the head is aligned by contact with the timing gear plate CAUTION The head is aligned with the timing gear plate by screws passed through the plate into the head and tightened securely It is extremely important to remove these screws before attempting to remove the cylinder head from the block Failure to heed this caution may result in severe damage to the timing...

Page 88: ...ws and washers at the side guide the head into side to side alignment as it is laid on the gasket and block Screws passed through the timing gear plate into the head pull the head into alignment fore and aft Small stamped bosses on the gasket hold the head clear of the seals and allow it to glide accurately into position against the plate during installation Tightening the head bolts flattens the ...

Page 89: ...is sealed against the block with three elastomer rings The upper end is sealed with a ring of EPDM elastomer situated directly under the sleeve collar This design cools the upper section of the sleeve better because the area of coolant circulation is larger The lower seals are fitted in grooves in the cylinder block The bottom seal is of a different material and fluorescent violet in color to dist...

Page 90: ...pts a molded elastomer gasket for a seal The steel pan is sealed with a gasket on the oil pan flange Twenty two spring loaded screws clamp the pan to the block The oil pan includes an oil level temperature sensor with connector The filler tube and dipstick mounting ports are also components of the oil pan Note Oil pans with the sump at the front or at the rear are available to accommodate axle for...

Page 91: ...t for the lube pump Thrust washers to control axial movement straddle the central journal cap No 4 The remaining caps Nos 1 3 5 and 6 are numbered to facilitate correct assembly A Teflon seal bearing directly on the crankshaft flange is used at the front of the crankshaft The front seal has an outer felt ring which serves as a dust cover At the rear of the crankshaft is another seal that bears dir...

Page 92: ...ith one piece Monosteel steel pistons The bearing caps are attached with four M12 capscrews spaced to prevent misalignment The rods and caps are made by a fracture process that requires a cap be assembled with its original rod Never attempt to use mismatched rods and caps The piston is fitted with three rings In the top groove is a compression ring with a keystone cross section In the second groov...

Page 93: ...2 Control Valve Oil flow for the piston cooling system is controlled by two valves The opening valve supplies oil and the control valve balances the oil flow to the piston cooling channel The piston cooling nozzle is aligned so that the oil jet hits the underside of the piston crown ...

Page 94: ...ise levels The power steering fuel pump gear the air compressor gear and the PTO gear are not timing gears The pump and compressor gears fasten to their respective components The pump gear is driven by the auxiliary idler gear The compressor gear is driven by the double idler gear The double idler drives the adjustable idler and the gear used to drive the power take off if so equipped This is part...

Page 95: ...ri 5 Alternator Pad Mount 10 Differential Pressure Sensors Depending on the vehicle the fan location may be high or low on the fan bracket Two poly V belts drive the front engine accessories The outer primary belt 10 or 12 ribs drives the coolant pump and fan hub from a pulley on the crankshaft flange nested in the vibration damper The inner secondary belt six ribs driven by the crankshaft vibrati...

Page 96: ... the cylinder head and rocker shaft duct valve rocker and camshaft and back to the oil pan The system includes crankcase ventilation Two full flow filters and a by pass filter maintain clean lubricant A sensor in the oil pan monitors fluid level There is an oil cooler immersed in engine coolant inside the coolant duct cover Oil Pump W2033324 A strainer and pickup tube lead the lubricant into the p...

Page 97: ...ng 7 Full Flow Filter 8 Main Lubrication Gallery 9 CCV Separator 10 Exhaust brake Oil Control Valve 11 Air Compressor 12 Turbocharger 13 By Pass Filter 14 Piston Cooling Nozzles 15 EGR Valve 16 Reducing Valve 17 Safety Valve 18 Oil Cooler Thermostat Valve 19 Over Flow Valve Full Flow Filter 20 Opening Valve Piston Cooling 21 Control Valve Piston Cooling ...

Page 98: ...alve Piston Cooling Control Valve Piston Cooling The reducing valve maintains constant system oil pressure The safety valve prevents excessive pressure during periods of high viscosity The oil cooler thermostat valve prevents oil from entering the cooler until it warms to the set point The overflow valve allows oil to by pass the filter if it becomes clogged The opening valve prevents oil from mov...

Page 99: ...ENGINE COMPONENT AND LOCATION 93 Crankcase Ventilation W2033326 1 Seal Ring 5 Separator Housing 2 Separator Inlet Hose 6 Housing Seal 3 Separator Vent Tube 7 Pressure Regulator 4 Vent Tube Bracket ...

Page 100: ...to the oil pan The remainder escapes to the atmosphere A turbine in the CCV separator driven by a small stream of oil striking its fins spins at high speed The mixture of gases and oily mist trapped in the valve cover and the timing gear cover drains onto the top of the center of the turbine and runs down onto several discs rotating with the turbine Separation occurs as the mixture flung outward b...

Page 101: ...ENGINE COMPONENT AND LOCATION 95 Fuel System W2033327 ...

Page 102: ...ank Breather 25 AFI Shut Off Valve 26 Line to AFI 27 Deaeration Valve The fuel pump attaches with the power steering pump to the flywheel housing at the rear left side It turns on the same shaft as the power steering pump The common drive gear meshes with the auxiliary idler driven by the crankshaft gear At 600 rpm the pump delivers a minimum 100 kPa 14 5 psi and at 1200 rpm 300 kPa 43 5 psi At 40...

Page 103: ...r primary filter also separates water from the fuel Water collects in a cup on the bottom of the pre filter There is a sensor to keep track of the water and signal the EECU Note The collected water can be dumped only while the engine is not running the key is in the ON position and the parking brake is set A check valve prevents fuel from draining back to the fuel tank when the engine is shut down...

Page 104: ...ivery because of the two solenoids The solenoids pump and nozzle are in a single body in close proximity to each other The injector is set in a pressurized fuel gallery where the fuel temperature is constant Uniform fuel temperature means uniform quantity in each injection which means uniform power output from each cylinder The fuel pump pressurizes the gallery so that fuel rushes into each inject...

Page 105: ...n its way toward the camshaft base circle The fuel valve is open allowing fuel to flow into the unit injector from the lower fuel gallery Fuel flows into the cylinder head and the unit injector pump cylinder Filling continues until the pump plunger reaches its upper position Spill phase B The spill phase begins when the camshaft lobe forces the rocker arm to push the pump plunger down The fuel can...

Page 106: ...UST be programmed for the cylinder in which it is installed This is done by programming EECU parameters using the VCADS pro or the Premium Tech Tool PTT to set Injector Trim parameters with the trim codes marked on the injectors Note The dimension by which the injector nozzle extends from the head is critical This means that machining the head in any way that changes this nozzle extension is not p...

Page 107: ...ENGINE COMPONENT AND LOCATION 101 Volvo Engine Brake W2033356 1 Tie Wraps 4 Solenoid 2 Electrical Connector 5 Tube Valve to Shaft 3 Attaching Screws ...

Page 108: ... decrease cylinder power output Engine power is reduced assisting the brakes in slowing the vehicle The engine brake rocker arms are equipped with a blade spring which keeps the rollers in contact with the cams Volvo Engine Brake operation depends on all of the following conditions which must exist simultaneously Accelerator pedal released Engine speed above 1100 rpm Clutch pedal released Road spe...

Page 109: ...instrument panel allows the driver to engage or disengage Volvo Engine Brake If the ABS system becomes active it automatically disables Volvo Engine Brake If the oil temperature goes below 55 C 131 F Volvo Engine Brake cannot be activated A warning lamp on the instrument panel flashes if the driver attempts to activate it under this condition A port in the cylinder head allows access to the oil pa...

Page 110: ...trous oxide NOx emission levels increase with combustion temperature The primary function of the Exhaust Gas Recirculation EGR system is to cool exhaust gas and send it back to the combustion chamber to lower the combustion temperature thereby to reduce NOx emissions The mixer where the recirculated exhaust joins the inlet air mounts at the front of the inlet manifold for the conventional chassis ...

Page 111: ...inlet manifold and the mixing chamber are treated to resist corrosion The EGR valve attaches to the rear section of the exhaust manifold for reliable response and turbocharger efficiency This location also protects the EGR cooler from harmful high pressure exhaust pulses that occur during engine braking EGR Valve Function When the EGR valve is open exhaust gas recirculates into the combustion cham...

Page 112: ... 1 EGR Valve 4 EGR Cooler 2 Cooler Inlet Pipe 5 Electrical Connector 3 Clamps 6 Oil Supply Line The cooler inlet pipe conducts the exhaust from the EGR valve to the EGR cooler The cooler lowers the exhaust stream temperature before it reenters the combustion chamber ...

Page 113: ...the exhaust gas from the venturi to the mixer Relatively short the tube passes over the valve cover behind and into the mixer at the front end of the inlet manifold on the conventional chassis engine Relatively much longer on the LCF the tube passes from the venturi around the front of the valve cover and reaches back to the mixer at the rear end of the inlet manifold A temperature sensor monitors...

Page 114: ... when the element is On EGR Diagnostics The EECU commands the EGR valve position and monitors electric current consumed by the EGR valve An abnormally high reading indicates a jammed EGR valve The EECU verifies that its command was sent and that the valve position reflects the command If the valve is jammed or its position doesn t change when commanded the EECU sets fault codes A degraded EGR cool...

Page 115: ...ounted on the pipe between the filter housing and the turbocharger alerts the driver if the filters need replacement prior to the schedule service The brake system air compressor also draws fresh clean air from this same page Variable Geometry Turbocharger W2033362 The engine is equipped with a variable geometry turbocharger The turbine housing has a set of vanes and a sliding nozzle ring that mai...

Page 116: ...t and releases supplemental coolant additives for system protection Coolant Pump W2033363 1 Impeller Housing 3 Coolant Pump Mounting Plate 2 Coolant Pump Seal The back of the coolant water pump with its ducts for distributing coolant is a separate casting attached to the cylinder block A housing containing an impeller shaft seals bearing and pulley attaches to the mounting plate The bearing is a p...

Page 117: ...rop compared to other types The thermostat is mounted on the front of the cylinder head Engine Cooling Fan T2019149 1 Solenoid Valve and Speed Sensor 2 Connector to EECU The cooling fan runs via a viscous or air operated drive through which fan speed is electronically controlled by the EECU With precise EECU control fan speed is continuously adjusted in response to several interrelated influences ...

Page 118: ...ps are programmed in the EECU so that it can translate sensor data into action These maps enable the EECU to receive status information from the sensors and send functional data to the actuators so they can simultaneously assume the proper posture for the safest most efficient operation of the engine in any given instant Due to the EECU self learning capability it is necessary to reset the learned...

Page 119: ... Exhaust Gas Recirculation EGR system is to cool exhaust gas and recirculate exhaust gases back to the combustion chamber to lower the combustion temperature thereby reducing nitrous oxide NOx emissions Reducing the quantity of noxious compounds to an acceptable level beginning in the year 2007 requires altering their chemical composition Directing the flow of exhaust gas through catalytic and par...

Page 120: ...A catalytic filter the diesel oxidation catalyst DOC reduces emissions in diesel exhaust by an average of approximately one third over a system without a DOC Its honeycomb like structure called substrate is coated with an active catalyst The PM is changed to carbon dioxide and water The substrate can be made of a wide range of materials Ceramic cordierite and sintered metal are common Some PM usua...

Page 121: ...stem As with any filter eventually the DOC and the DPF will become clogged Rising back pressure caused by plugging the exhaust system decreases fuel economy and reduces engine efficiency It is necessary to clean these filters from time to time The filters can be regenerated to continue in use The high temperature needed to complete the process exists in the exhaust itself Because some vehicle voca...

Page 122: ...116 ENGINE COMPONENT AND LOCATION Active Regeneration For vehicles that are unable to develop or sustain adequate temperature there is more than one system for supplying sufficient heat W2033245 ...

Page 123: ...aust at this point is hot enough to ignite the fuel which then produces the temperature required to clean the filters If needed the discharge recirculation valve DRV reroutes some of the turbocharger output back through the turbocharger This helps to maintain high exhaust temperature The engine electronic control unit EECU controls the cycle based on information from back pressure sensors in the o...

Page 124: ... property damage Discharge Recirculation Valve The Discharge Recirculation Valve DRV redirects some of the turbocharger output back through the turbocharger This results in elevated exhaust temperature The EECU uses this feature to maintain adequate exhaust temperature in support of active regeneration in the DPF system Ultra Low Sulfur Diesel Fuel A catalyst works better the higher the temperatur...

Page 125: ...ation is in process In Passive Regeneration Mode the engine creates sufficient exhaust temperature to convert the gases and regenerate clean the filters In Active Regeneration Mode exhaust temperature is artificially raised for short periods of time to convert the gases and clean the filters The applicable controller reacts to data from back pressure sensors to start and stop the active regenerati...

Page 126: ...ler for the conventional chassis or a compact unit DPF unit with muffler to accommodate the low cab forward chassis The space saver unit attaches to the outside of the right rail under the cab Either of these connects to the engine exhaust system behind the turbocharger W2033361 1 Vertical Back of Cab Unit 2 Space Saver Compact Unit ...

Page 127: ...ENGINE COMPONENT AND LOCATION 121 COMPONENT PART NUMBER LOCATOR Engine Right Side View W2032499 ...

Page 128: ...R Coolant Outlet Pipe 6 20900934 7 Thermostat Housing 7 20560249 8 Differential Pressure Sensors 8 20930137 9 Venturi 9 21012484 10 Coolant Conditioner 10 20458771 per VIN number 11 Full Flow Oil Filters 11 478736 12 Bypass Oil Filter 12 477556 13 Starter 13 Check per VIN number 14 EGR Cooler 14 85111060 15 EGR Cooler Inlet Pipe 15 20966374 All part numbers are for reference only you should always...

Page 129: ...85116641 Dual Cyl 85116642 4 Power Steering Pump 4 Check per VIN number 5 Low Pressure Fuel Pump 5 85111130 6 DPF Fuel Control Valve 6 20942984 7 Secondary Fuel Filter 7 20972293 7A Primary Fuel Filter 7A 20879806 8 Alternator Pad Mount 8 20487081 9 CCV Separator 9 20499419 Note All part numbers are for reference only you should always refer to truck BOM s before ordering parts ...

Page 130: ...rnator Refrigerant Compressor Belt 4 20762060 5 Alternator Pad Mount 5 Check per VIN number 6 Refrigerant Compressor Pad Mount 6 Check per VIN number 7 Belt Tensioner Fan Drive Water Pump Belt 7 20487079 8 Coolant Pump 8 85116652 9 Venturi 9 21012484 10 Differential Pressure Sensors 10 20930137 Note All part numbers are for reference only you should always refer to truck BOM s before ordering part...

Page 131: ...number 4 Boost pressure Sensor 4 20524936 5 Coolant Temperature at front edge cylinder of head 5 20513340 6 Charge Air Pressure Temperature 6 20524936 7 Camshaft Position 7 20513343 8 Flywheel Position Speed 8 20513343 9 Oil Pressure 9 20898038 10 Crankshaft Pressure 10 20796744 Note All part numbers are for reference only you should always refer to truck BOM s before ordering parts ...

Page 132: ...126 ENGINE COMPONENT AND LOCATION ENGINE DISASSEMBLED VIEW AND PART NUMBERS Upper Engine Components W2032469 ...

Page 133: ...623 5A Camshaft Bearing Rear 5A 20999613 6 Camshaft 6 Check per VIN number 7 Cylinder Head 7 21042138 8 Cylinder Head Gasket Install Kit 8 21409435 9 Camshaft Vibration Dapner 9 20888623 10 Camshaft Gear 10 20891469 11 Camshaft Vibration Damper Bolts 11 8192804 12 Spacer 12 20878608 13 Volvo Engine Brake 13 Check per VIN number 14 Valve Caliper Intake 14 Check per VIN number Note All part numbers ...

Page 134: ...128 ENGINE COMPONENT AND LOCATION Rear Engine Components W2032470 ...

Page 135: ...2364 7 Engine Block 7 NSS 8 Cylinder Head Kit 8 21042138 9 Silicone Sealant 9 1661231 10 Crankshaft Gear 10 20743004 11 Auxiliary Idler gear 11 21049784 12 Power Steering and Fuel Pump Gear 12 Check per VIN number 13 Double Idler 13 21057068 14 Air Compressor Drive Gear 14 8131848 15 Adjustable Idler 15 20850724 16 Camshaft Gear 16 20891469 17 Hamonic Balancer 17 20888623 Note All part numbers are...

Page 136: ...130 ENGINE COMPONENT AND LOCATION Oil Pan and Stiffing Frame W2032451 ...

Page 137: ...ealing Strip 2 20515881 3 Oil Strainer 3 20824910 4 Suction Pipe 4 20521886 5 Pressure Pipe 5 20501240 6 Pressure Pipe 6 20498189 7 Cover 7 20499612 8 Oil Pump 8 20824906 9 Sealant 9 3092340 Note All part numbers are for reference only you should always refer to truck BOM s before ordering parts ...

Page 138: ...132 ENGINE COMPONENT AND LOCATION Lower Engine Components W2032471 ...

Page 139: ...2 9 Piston 9 20928630 10 Wrist Pin Clip 10 2914531 11 Wrist Pin 11 20928630 12 Wrist Pin Bushing 12 NSS 13 Piston Oil Nozzle 13 3155151 14 Connecting Rod 16 20876840 15 Crankshaft Damper 18 20741749 9651191 16 Front Cover to Block Seal 19 20777233 17 Crankshaft Seal 20 85108423 18 Lower Connecting Rod Bearing 21 20580558 19 Connecting Rod Cap 22 20876840 20 Lower Main Bearing 23 20530916 21 Thrust...

Page 140: ...134 ENGINE COMPONENT AND LOCATION Replacement Kits Engine Replacement Kits W2032452 ...

Page 141: ...er Head Kit 21409435 EGR Cooler Replace Kit 85111060 EGR Valve ReplaceKit 85111067 Injector Sleeve Replace Kit 85115712 Oil Cooler Replace Kit 85111858 Coolant Filter Valve Kit 20566236 Engine Overhaul Kit 85115734 2cyl Air Compressor Kit 85116640 Turbocharger Replace Kit Check per VIN number Filter Kit 85112873 Note All part numbers are for reference only you should always refer to truck BOM s be...

Page 142: ...OLD prior to starting at the beginning of the work day or after the vehicle has sat approximately 2 hours At normal operating temperature engine oil temperature above 80 C 175 F oil level can be checked 15 minutes after shut down For accurate oil level readings the dipstick must be inserted fully into the dipstick tube The level must be close to the FULL line at least between the LOW and FULL line...

Page 143: ...t the engine and check for leaks Run the engine for approximately five minutes then shut it off and recheck the oil level Add oil if necessary Note Use of anything other than genuine Volvo filters may cause damage and void the engine warranty Change filters according to the recommended maintenance schedule Crankcase Ventilation System The crankcase ventilation CCV system separator is not repairabl...

Page 144: ...excessive accumulation in the cup The water separating pre filter is in the suction side of the fuel circuit It is a spin on type with one end of its casing threaded to receive the cup The full flow main filter is on the pressure side of the circuit It is also an easily replaced spin on filter The casing completely encloses the filter element This filter is rated at 3 5 microns W2033375 1 Water Se...

Page 145: ...remove the filter from the mounting bracket and discard it safely 6 Apply a thin film of clean engine oil to the sealing gasket of the new filter 7 Screw the new dry filter in place and tighten an additional 3 4 to 1 turn by hand after the gasket contacts the base 8 Screw the water cup into the filter casing Note There is a new style pre filter with a stepped down diameter at the bottom of the fil...

Page 146: ...lter in place and tighten an additional 3 4 to 1 turn by hand after the gasket contacts the base 6 If necessary replace the water separating pre filter See the preceding instructions 7 Start the engine and run at idle for five minutes to fill the filter with fuel 8 Check for leaks CAUTION Severe engine damage may be caused by attempting to prime the fuel system using an auxiliary pump or by applyi...

Page 147: ...141 Coolant Filter The coolant filter attaches to the back of the coolant pump housing It resembles a spin on oil filter The filter element and casing are replaced as a unit W2033376 1 Shut Off Valve 2 Coolant Filter ...

Page 148: ...below the filter to collect spilled coolant 3 Using filter wrench J 48061 or equivalent unscrew the filter and discard it safely 4 Apply a light film of coolant on the face of the new filter gasket 5 Screw the new filter on the threaded nipple extending from the mounting flange 6 Using the filter wrench tighten the filter one full turn after the gasket contacts the base 7 Open the shut off valve o...

Page 149: ...eratures during use Ensure that the unit has cooled to the touch before handling Failure to heed this warning may result in severe personal injury Removal 1 When the fairing if present braces and steps have been removed to permit access remove the lines and sensors connecting the inlet module to the other modules 2 Disconnect wiring and sensor connectors from the DPF and outlet modules Cut tie str...

Page 150: ...V band clamp that connects the catalyst module to the filter W2033380 5 Position a flat surface jack with a very stable support such as a transmission jack under the base of the DPF 6 Remove the fasteners that secure the DPF lower supporting bracket to the chassis frame bracket This releases the weight of the DPF onto the transmission jack ...

Page 151: ... over the outlet module and connect using the V band clamp tightened to specifications Note Make sure the high temperature gasket remains in place and has not become dislodged 3 Place a new high temperature gasket on top of the DPF module 4 Perform the following steps to align and lift the filter and outlet module assembly into position Align the outlet module flange to the exhaust pipe Align the ...

Page 152: ...ting to specification Note A high temperature anti seizing compound should always be applied to the threads of the sensors plugs and fittings in the exhaust system to avoid component seizure or corrosion 10 Install the lines and sensors connecting the various modules to each other Refer to torque specifications for the V band clamp screws lines and sensors in the SPECIFICATIONS section of this man...

Page 153: ...ult in severe personal injury Removal 1 Remove the heat shield stack harness clamps tie straps and V band clamp at the exhaust elbow 2 Disconnect all harness connectors W2033377 3 Using a suitable lifting device support the assembly Remove the band clamps and mounting bracket from the stanchion 4 Remove the assembly from the chassis and place it in the VBOC DPF support stand 85111327 or equivalent...

Page 154: ...ve the pressure differential tube from the catalytic filter module 7 Remove the V band clamp joining the outlet module to the filter module W2033384 8 With an assistant and a suitable lifting device remove the outlet module from the DPF filter module 9 Remove the V band clamp joining the DPF filter module to the catalytic filter module ...

Page 155: ...evice to install the outlet module onto the DPF filter module Ensure that the differential pressure tube does not become damaged during outlet module installation Note Make sure the high temperature gasket remains in place and has not become dislodged 5 Install the V band clamp to secure the outlet module to the DPF filter module and tighten clamp fasteners to specification All clamps should now b...

Page 156: ...Lift the DPF muffler using a suitable lifting device and with assistance position the muffler next to the frame mounted stanchion at the back of the cab W2033385 8 Align the slot in the muffler bottom with the tab on the stanchion ...

Page 157: ... secure the lower V band clamp at the inlet side of the muffler 11 Install the heat shield onto the DPF muffler 12 Secure all fasteners and clamps that connect the DPF muffler to the stanchion Tighten all clamps and muffler fasteners according to specification 13 Disconnect the lifting device and remove the lifting chain from the muffler 14 Reconnect the harness connectors for all temperature and ...

Page 158: ...e the shift lever in neutral 2 Disconnect all cables from ground negative battery terminals to prevent personal injury from electrical shock 3 Remove P clamp screws securing the AFI harness and fuel supply line 4 Connect coolant extraction tool DBT2V700 to the drain fitting at the bottom of the radiator Drain the coolant Note An alternative method is to use drain hose 9996049 to drain coolant into...

Page 159: ...FI is positioned with the higher side of the AFI heat shield facing the turbocharger With the new style diffuser the AFI is positioned with the higher side of the heat shield facing the EGR valve 9 Remove and discard the high temperature gasket and steel plate gasket from the bottom of the injector Installation 1 Install a new high temperature gasket and steel plate gasket onto the bottom of the a...

Page 160: ...he bolts according to specification 4 Reconnect the aftertreatment fuel injector wiring harness connector Secure the injector wiring harness with clips and tie straps W2033386 5 Reconnect the coolant lines to the aftertreatment injector fittings and tighten to specification ...

Page 161: ...tive Factor Reset using VCADS Premium Tech Tool PTT 11 Start the engine check for leaks and proper operation After shutdown replenish fluids as necessary Cleaning 1 Apply the parking brake and place the shift lever in neutral 2 Disconnect all cables from ground negative battery terminals to prevent personal injury from electrical shock 3 Remove P clamp screws securing the AFI harness and fuel supp...

Page 162: ...and discard the high temperature gasket and steel plate gasket from the bottom of the injector 8 Carefully turn the AFI body and spray the injector tip with carburetor cleaning solution Brush the injector tip with a stiff bristled nylon toothbrush Repeat two or three times CAUTION Do NOT kink the fuel and coolant lines when cleaning the injector Kinking the lines may result in leakage CAUTION Only...

Page 163: ...t the bolts into the spacers Position the injector onto the diffuser pipe which attaches to the turbocharger outlet and hand start the bolts with spacers 12 Secure the injector mounting bolts Tighten the bolts according to specification W2005656 13 Connect the aftertreatment fuel injector fuel supply line and tighten to specification 14 Install P clamp bolts to secure the AFI harness and fuel line...

Page 164: ...coolant pump housing This tensioner applies its load counterclockwise The upper tensioner for the alternator and refrigerant compressor if so equipped is mounted on the alternator bracket The tensioner applies its load in a counterclockwise direction Automatically Tensioned System INSTALLATION Swing the tensioner to the fully sprung position and without force using belt tensioner tool J 44392 plac...

Page 165: ...W2033395 1 Rocker Shaft Bearing Cap Attaching Screws 5 Inlet Valve Rocker Arm 2 Exhaust Brake Rocker Arm 6 Plate Spring 3 Exhaust Valve Rocker Arm 7 Plate Spring Attaching Screws 4 Injector Rocker Arm 8 Bearing Cap Attaching Screws 9 Camshaft Bearing Cap ...

Page 166: ... center TDC mark is used for basic camshaft timing The TDC mark must be between the two lines on the front camshaft bearing cap when the flywheel is at 0 top dead center for cylinder No 1 The engine must be cold 60 C 140 F or less before making these adjustments Camshaft markings for setting of valves and unit injectors Without Volvo Engine Brake Markings 1 6 apply to adjustment of inlet valves ex...

Page 167: ... 4 and 1 1 Using the flywheel turning tool 88800014 bar the engine over manually to the appropriate camshaft marking for adjustment of the inlet valves and injector for that cylinder W2033397 2 Using a feeler gauge check the clearance between the rocker arm adjusting screw and the valve yoke bridge of the inlet valves 3 If the clearance is not within specification loosen the locknut and adjust the...

Page 168: ... nut and turn the adjusting screw out counterclockwise to relieve the preload 2 Turn the adjusting screw in clockwise until it firmly contacts the injector Do not compress the spring 3 Turn the adjusting screw in a further 240 four flats on the hex head 4 Hold the adjusting screw to prevent it from turning further and using a torque wrench tighten the jam nut to specification 5 Mark the respective...

Page 169: ... following the same procedure described for adjustment of the inlet valves However the valve clearance specification is different 2 Mark the rocker arm when adjustment is complete 3 Using the flywheel turning tool bar the engine over manually to the appropriate marking for the next cylinder Adjust the inlet valves unit injector and exhaust valves at that cylinder ...

Page 170: ...d to adjust the exhaust valves when the engine is equipped with Volvo Compression Brake VCB Engines equipped with the VCB engine brake have two rocker arms working in combination to control the exhaust valves They are the exhaust rocker arm and the brake rocker arm which are adjusted separately as described in the following procedure ...

Page 171: ...lve yoke bridge Adjusting Exhaust Rocker Arm Clearance a Remove the shim retaining screw and remove the shim s b Determine the thickness of the shim s required to provide the specified clearance c Make sure that the valve yoke and shim s are clean Place the shim s in position on the valve yoke and install the retaining screw Tighten the screw to specification Note Do NOT use more than two shims Sh...

Page 172: ...n the yoke as close as possible to the rocker arm yoke pad Zero the gauge c Tighten the rocker arm adjusting screw B until the dial shows that the yoke has been pushed downward 0 60 0 05 mm 0 024 0 002 inch d Loosen the rocker arm adjusting screw two full turns 720 e Hold the adjusting screw to prevent it from turning further and using a torque wrench tighten the locknut to specification 6 Remove ...

Page 173: ...nt is completed Continuation of Adjustments Continue the procedure by barring the engine to the appropriate timing marks and adjusting the valves and unit injectors at each of the remaining cylinders Follow the steps described above to adjust the inlet and exhaust valves and unit injector at each cylinder For engines equipped with the Volvo compression brake tighten the plate spring attaching scre...

Page 174: ...es occur readjust the valves as needed BEFORE starting the engine 2 Start the engine and bring it up to normal operating temperature 3 Once normal operating temperature is attained let the engine idle for an additional five minutes During this time the electronic engine management system EMS will perform its own cylinder balancing resulting in smooth engine idling Note Do NOT use any form of power...

Page 175: ...culate matter Diesel fuel produces little ash but crankcase lubricant and fuel borne catalysts produce considerable ash Atmospheric Pressure Sensor A sensor incorporated into the EECU that detects atmospheric barometric pressure and relays this value to the EECU This pressure is affected by altitude Carbon Monoxide CO An odorless colorless gas resulting from incomplete combustion of hydrocarbons f...

Page 176: ... Cordierite A ceramic material constructed to be used as a substrate in diesel oxidation catalysts With additional processing it may also be used as a diesel particulate filter Diesel Particulate Matter The complex mixture of extremely fine particles and liquid droplets that are discharged by an operating diesel engine The chemical compositions can be broken down to safer substances Differential P...

Page 177: ...ke operation Exhaust Aftertreatment System EATS Equipment installed to remove the maximum amount of noxious emissions from the exhaust gases after they leave the combustion chamber before they reach the atmosphere This includes exhaust gas recirculation EGR the variable geometry turbocharger VGT the discharge recirculation valve DRV the aftertreatment fuel injector AFI and the diesel particulate f...

Page 178: ...iculate filter by spontaneous burning of soot that collects on it The exhaust temperature remains continuously high enough to incinerate the soot Poly V Belt A multi ribbed belt design incorporated into the accessory drive belt and pulley arrangement at the front of the engine Regeneration Cleaning a diesel particulate filter so as to renew its capacity to function efficiently Roller Follower A ty...

Page 179: ...ts to control flow of exhaust gas and build back pressure in the exhaust system for EGR flow The VGT also performs as an engine brake VGT Wheel Speed A sensor mounted in the turbo bearing housing that detects turbine and compressor wheel speed and relays this data to the EECU Vehicle Electronic Control Unit VECU A microprocessor based controller sometimes referred to as a module mounted in the cab...

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Volvo EPA2007 D13F, Reference Manual

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