Volvo Penta Group 21-26 TAD570VE TAD571VE TAD572VE TAD870VE TAD871VE TAD872VE TAD873VE Shop Manual

Workshop Manual Group 21-26

I 2(0)

TAD570VE, TAD571VE, TAD572VE, TAD870VE, TAD871VE, TAD872VE, TAD873VE

Content General Information 00-0 General ................................................................................................ 2

Specifications 03-2 Specifications, Engine ....................................................................... 8 03-22 Lubrication System ........................................................................ 30

Safety and Other Instructions 05-1 Safety Instructions ........................................................................... 31

Special tools 08-2 Special Service Tools ....................................................................... 35

Engine 21-1 Cylinder Head .................................................................................... 37 21-4 Valve Mechanism .............................................................................. 51 21-5 Timing Gears and Shaft ................................................................... 59 21-6 Crank Mechanism ............................................................................. 63

Lubricating and Oil System 22-2 Oil filter .............................................................................................. 73 22-3 Oil cooler ........................................................................................... 82

Fuel System 23-0 Fuel System, General ....................................................................... 85 23-3 Fuel Feed Pump and Filter ............................................................... 86 23-7 Injectors and Delivery Pipes .......................................................... 112 23-9 Miscellaneous ................................................................................. 131

Inlet and Exhaust System 25-4 Emission Control, Catalytic Converter ......................................... 134 25-5 Turbo and supercharger ................................................................ 145 25-8 Emission After-Treatment .............................................................. 158

Cooling System 26-0 Cooling System, General ............................................................... 193 26-1 Radiator, Heat Exchanger .............................................................. 197 26-2 Coolant Pump, Thermostat ............................................................ 203

Alternator, Charge Regulator 32-1 Alternator ......................................................................................... 221

Starting System 33-1 Starter Motor ................................................................................... 227 Alphabetical index .................................................................................. 231 References to Service Bulletins ............................................................ 233

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00-0 General About this Workshop manual General information

Certified engines

This Service Manual contains technical data, descriptions and maintenance and repair instructions for standard model Volvo Penta products. A list of these products may be found in the section Specifications.

When carrying out service and repair on emission-certified engines, it is important to be aware of the following:

The product designation and the serial number and specification is indicated on the engine decal or type plate. This information must be included in all correspondence regarding the product.

The service manual is produced primarily for the use of Volvo Penta workshops and their qualified personnel. It is assumed that any person using the Service Manual has a fundamental knowledge of the product and is able to carry out mechanical and electrical work to trade standard.

Volvo Penta continually develops its products; we therefore reserve the right to make changes. All information in this manual is based on product data which was available up to the date on which the manual was printed. New working methods and significant changes introduced to the product after this date are communicated in the form of Service bulletins.

Spare Parts Spare parts for the electrical and fuel systems are subject to various national safety standards. Volvo Penta Original Spare Parts meet these standards. No damage of any kind caused by the use of spare parts not approved by Volvo Penta will be compensated by any warranty undertaking.

Certification means that an engine type has been inspected and approved by the relevant authority.

The engine manufacturer guarantees that all engines of the same type are manufactured to correspond to the certified engine.

This places special demands on service and repair work, namely: •

Maintenance and service intervals recommended by Volvo Penta must be complied with.

•

Only spare parts approved by Volvo Penta may be used.

•

Service on injection pumps, pump settings and injectors must always be carried out by an authorized Volvo Penta workshop.

•

The engine must not be converted or modified, except with accessories and service kits which Volvo Penta has approved for the engine.

•

No changes to the exhaust pipe and engine air inlet duct installations may be made.

•

No warranty seals (where present on the product) may be broken by unauthorized persons.

The general instructions in the Operator's Manual concerning operation, service and maintenance apply.

IMPORTANT! Neglected or poorly-performed care/service and the use of spare parts not approved by Volvo Penta, will mean that AB Volvo Penta no longer guarantees that the engine conforms to the certified model.

Volvo Penta accepts no responsibility for damage or costs arising as a result of failure to follow the above mentioned standards.

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00-0 General

Repair instructions Introduction

Our mutual responsibility

The working methods described in this manual are based on a workshop scenario where the product is mounted in a holding fixture. Maintenance work is often carried out on site, in which case – if nothing else is indicated – using the same working methods as the workshop.

Each product comprises a large number of interacting systems and components. A deviation from the technical specification may dramatically increase the environmental impact of an otherwise reliable system. It is therefore critical that the stated wear tolerances be adhered to, that systems which can be adjusted be correctly set up and that only Volvo Penta Original Parts are used. The intervals in the care and maintenance schedule must be followed.

Some systems, e.g. fuel systems, often require special expertise and test equipment. A number of components are factory-sealed, for among other things environmental reasons. Warranty-sealed components may not be worked on without authorization to perform such work.

Warning symbols that occur in the service manual.

For significance, refer to Safety Information .

! ! !

DANGER! WARNING! CAUTION!

IMPORTANT!, NOTICE! are by no means comprehensive since not everything can be foreseen as service work is carried out in the most varied of circumstances. We call attention to risks that may occur due to incorrect handling during work in a well-equipped workshop using working methods and tools tried and tested by us.

The service manual describes work operations carried out with the aid of Volvo Penta Special Tools, where such have been developed. Volvo Penta Special Tools are designed to ensure the safest and most rational working methods possible. It is therefore the responsibility of anyone using tools or working methods other than those we recommend to ensure that no risk of personal injury or mechanical damage is present, or that malfunction can result.

In some cases, special safety regulations and user instructions may be in force for the tools and chemicals mentioned in the Service Manual. These regulations must always be followed, and no special instructions regarding this are to be found in the Service Manual.

By taking these basic precautions and using common sense it will be possible to guard against most elements of risk. A clean workplace and a clean product will eliminate many risks of personal injury and malfunction.

Remember that most chemical products, incorrectly used, are harmful to the environment. Volvo Penta recommends the use of biodegradable degreasers whenever components are cleaned, unless otherwise specified in the Service Manual. When working outdoors, take especial care to ensure that oils and wash residues etc. are correctly properly for destruction.

Tightening torques Tightening torques for vital fasteners that must be applied using a torque wrench are indicated in the Service Manual, chapter Tightening torques and in the Manual's work descriptions. All torque indications apply to clean threads, bolt heads and mating faces.

Indicated torque data apply to lightly-oiled or dry threads. If lubricants, locking fluids or sealants are required for fasteners, the correct type will be noted in the job description.

Torque, angle tightening When torque/angle tightening, the fastener is tightened to a specified torque, and tightening then continues through a pre-determined angle.

Example: For 90° angle tightening, the fastener is turned a further 1/4 turn in one sequence, after the specified tightening torque has been achieved.

Above all, when working on fuel systems, hydraulic systems, lubrication systems, turbochargers, inlet systems, bearings and seals, it is of the utmost importance that dirt and foreign objects are kept away, as malfunctions or shortened service intervals may otherwise result.

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00-0 General

Lock nuts Removed locknuts may not be re-used; they must be replaced by new ones, as locking properties are impaired or lost with re-use.

In the case of lock nuts with plastic inserts the tightening torque indicated must be reduced if the nut has the same nut height as a standard, all-metal hexagonal nut.

Reduce the torque by 25% for bolt sizes of 8 mm or larger.

In the case of lock nuts with plastic inserts with a high nut-height (where the all-metal thread is as high as a standard hexagonal nut), the indicated torque applies.

Strength classes Nuts and bolts are subdivided into different strength classes. The classification is shown by a marking on the bolt head. Markings of a higher number indicate stronger material. For example, a bolt marked 10-9 is stronger than one marked 8-8.

For this reason, it is important that when bolts are removed they are returned to their original locations on re-assembly. When replacing bolts check the applicable Spare parts catalogue to ensure the correct bolt is used.

Sealing compounds etc.

To ensure service work is correctly carried out it is important that the correct type of sealants and locking fluids are used on joints where such are required.

In each service manual section concerned, the sealants used in product manufacture are indicated. The same sealants, or sealants with equivalent properties, must be used for maintenance work.

Make sure that mating surfaces are dry and free from oil, grease, paint and anti-corrosion agent before applying sealant or locking fluid. Always follow the manufacturer's instructions regarding applicable temperatures, hardening times and such.

Two basic types of compound are used: RTV preparations (Room Temperature Vulcanizing).

Used most often together with gaskets, e.g. sealing gasket joints, or are brushed on gaskets. RTV sealants are completely visible when the part has been removed. Old RTV sealant must be removed before the component is sealed again. Use denatured alcohol.

4

Anaerobic agents.

These agents cure (harden) in the absence of air.

These preparations are used when two solid components, e.g. two cast components, are fitted together without a gasket. Common uses are also to lock and seal plugs, stud threads, taps, oil pressure monitors etc.

Hardened anaerobic preparations are glassy and for this reason, the preparations are colored to make them visible. Hardened anaerobic preparations are highly resistant to solvents, and old compound cannot be removed. On re-assembly, it is important to carefully degrease and wipe dry components first, before applying new sealant in accordance with the instructions.

Safety regulations for fluorocarbon rubber Fluorocarbon rubber is a common material in sealing rings for shafts, and in O-rings, for example.

When fluorocarbon rubber is exposed to high temperatures (above 300°C/572°F), hydrofluoric acid can form. This is highly corrosive. Contact with the skin can result in severe chemical burns. Splashes in your eyes can result in chemical wounds. If you breathe in the fumes, your lungs can be permanently damaged.

WARNING! Seals must never be cut with a torch, or be burnt afterwards in an uncontrolled manner. Risk for poisonous gases.

WARNING! Always use chloroprene rubber gloves (gloves for chemicals handling) and goggles. Handle the removed seal in the same way as corrosive acid. All residue, including ash, can be highly corrosive. Never use compressed air to blow clean.

Put the remains in a plastic container, seal it and apply a warning label. Wash the gloves under running water before removing them.

The following seals are most probably made from fluorocarbon rubber: Seal rings for the crankshaft, camshaft, idler shafts.

O-rings, regardless of where they are installed. Orings for cylinder liner sealing are almost always made of fluorocarbon rubber.

Please note that seals which have not been exposed to high temperature can be handled normally.

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00-0 General

Illustrations A lot of illustrations contains standardized symbols and colors. Please refer to the following information to reduce misunderstandings when working on an engine / transmission using this Workshop Manual.

Illustration colors

Position

Most illustrations have a focused component (blue) which is fastened by a (red) bolt or such on a (light grey) engine / transmission body.

P0015623

Focus arrows pointing at object. Sometimes it contains number of items, e.g. three bolts.

P0015699

1 Focus (blue)

NOTICE! If an arrow with the text “x3” is pointing at only one item, e.g. a bolt, it still applies to the other two alike items (the two other bolts) highlighted in the illustration.

2 Fastenings (red) 3 Body (light grey) 4 Background (white)

P0015627

This symbol gives a positioning number to an object, e.g. 2, which is also mentioned in the supplied text information.

P0015628

The symbol to the left shows part no. of the positioned special tool, e.g. 9991801.

The symbol on the right side is used when something needs to be replaced by a new part / kit.

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00-0 General

Movement

Tools (continuence)

P0015622

Movement arrows are used to show which direction a component is to be moved / rotated.

P0015625

Symbol is used in a corner of the illustration to show how many degrees the object shall be turned and at which direction.

P0015630

A symbol of a tool in a corner of the illustration is shown when the tool is recommended to use, e.g. a knife or a crowbar.

P0015626

Symbol is used to show how many revolutions the object shall be turned and at which direction.

Tools

P0015631

A drill in a specified size, duck tape and stripes may also be shown as symbols.

P0015629

One of the following symbols is used when describing the recommended type of screwdriver.

6

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00-0 General

Chemicals

Units

P0015695

Symbols can also describe when and how a chemical product is to be used.

Cleanliness P0015696

Units are mentioned in the illustration when a specific value (e.g. pressure, weight or resistance etc.) is expected.

Important P0015624

The scraper symbol suggests that a contact surface needs to be scraped from sealant etc.

The cloth symbol suggests that the mechanic should clean the contact surface thoroughly or be prepared for some oil spill or similar.

Sealant P0015005

The eye symbol is used when something needs close inspection or must be performed in a certain way.

The symbol to the right is used when several mechanics are needed.

P0015698

Safety

The tube symbol shows how thick layer of sealant to applicate.

The clock symbol is used when something needs to be done within or after a certain time.

P0015697

These symbols are used when a certain safety related equipment is needed.

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03-2 Specifications, Engine

03-2 Specifications, Engine General Tightening Torques General Tightening Torques M6 standard bolt

10 ± 1.5 Nm (7.4 ± 1.1 lbf ft)

M8 standard bolt

24 ± 4 Nm (17.7 ± 2.95 lbf ft)

M10 standard bolt

48 ± 8 Nm (35.4 ± 5.9 lbf ft)

M12 standard bolt

85 ± 15 Nm (62.7 ± 11.1 lbf ft)

M14 standard bolt

140 ± 25 Nm (103.3 ± 18.4 lbf ft)

M16 standard bolt

220 ± 35 Nm (162.3 ± 25.8 lbf ft)

IMPORTANT! Check bolts which are to be re-installed. Damaged bolts, e.g. with shear marks under heads must be scrapped.

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03-2 Specifications, Engine

Special Tightening Torques Group 21: Engine TAD8xxxVE

Main Bearing Caps NOTICE! Use new bolts.

NOTICE! Tighten the bolts in sequence, as illustrated.

Step 1: 60 Nm (44.2 lbf. ft.)

Step 2 (angle tightening): 90° Step 3 (angle tightening): 90°

P0021522

TAD5xxxVE

P0021523

Conrod caps NOTICE! Use new bolts.

Step 1: 75 Nm (55.3 lbf. ft.)

Step 2 (angle tightening): 90°

P0021524

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03-2 Specifications, Engine

TAD8xxxVE

Frame reinforcement Tightening torque: 24 Nm (17.7 lbf. ft.)

Step 1: Tighten the bolts in sequence, as illustrated.

Step 2: Tighten the remaining bolts:

P0021525

TAD5xxxVE

P0021526

Timing gears 1 2

3 4 5 6 7

Drive gear, camshaft 32 Nm (23.6 lbf. ft.)

Idler wheel (hexagon socket head screw) 24 Nm (17.7 lbf. ft.)

Idler wheel 24 Nm (17.7 lbf. ft.)

Idler wheel (dual) 63 Nm (46.5 lbf. ft.)

Drive gear, air compressor 225 Nm (166.0 lbf ft) Idler wheel, adjustable 63 Nm (46.5 lbf. ft.)

Drive gear, fuel feed pump 59 Nm (43.5 lbf. ft.)

P0021527

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03-2 Specifications, Engine

Flywheel and timing cover

P0021528 P0021530

NOTICE! Apply an approximately 2 mm (0.079”) thick string of silicon (product no. 1161231) as illustrated in figure on left, max. 20 minutes before installation.

NOTICE! Tighten the bolts in sequence, as illustrated.

Tightening torque Bolts 1-9 85 Nm (62.7 lbf. ft.)

Bolts 10-12 48 Nm (35.4 lbf. ft.)

Bolt 13, 14: 85 Nm (62.7 lbf. ft.)

Flywheel NOTICE! Tighten the bolts in sequence, as illustrated.

Tightening torque: 190 Nm (140.1 lbf. ft.)

P0021529

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03-2 Specifications, Engine

Vibration damper, crankshaft NOTICE! Tighten the bolts in sequence, as illustrated.

Tightening torque: 110 Nm (81.1 lbf. ft.)

P0021531

Cover, crankshaft seal

P0021533 P0021532

NOTICE! Apply an approximately 2 mm (0.079”) thick string of silicon (product no. 1161231) as illustrated in figure on left, max. 20 minutes before installation.

Tightening torque Step 1: Fasten the cover with bolts 2 and 7.

Tighten until contact is established.

Step 2: Tighten bolts 2 and 7.

24 Nm (17.7 lbf. ft.)

Step 3: Tighten the bolts in sequence 1, 3–6, 8 as illustrated.

24 Nm (17.7 lbf. ft.)

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03-2 Specifications, Engine

Cylinder head TAD8xxxVE

P0021534

NOTICE! Attach the cylinder head as per section Installation in 21-1, Cylinder Head, Change.

Tightening torque Step 1: Tighten bolts 1-26 in sequence, as illustrated.

100 Nm (73.8 lbf. ft.)

Step 2: Tighten bolts B1-B6.

29.5 Nm (21.8 lbf. ft.)

Step 3: Angle tighten bolts 1-26 in sequence.

90° (angle tightening) Step 4: Angle tighten bolts 1-26 in sequence.

90° (angle tightening) Step 5: Tighten bolts B1-B6.

29.5 Nm (21.8 lbf. ft.)

Step 6: Tighten bolt (A).

60 Nm (44.3 lbf. ft.)

Stage 7: Tighten bolt (C).

30 Nm (22.1 lbf. ft.)

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03-2 Specifications, Engine

TAD5xxxVE

P0021535

NOTICE! Attach the cylinder head as per section Installation in 21-1, Cylinder Head, Change.

Tightening torque Step 1: Tighten bolts 1-18 in sequence, as illustrated.

100 Nm (73.8 lbf. ft.)

Step 2: Tighten bolts B1-B4.

29.5 Nm (21.8 lbf. ft.)

Step 3: Angle tighten bolts 1-18 in sequence.

90° (angle tightening) Step 4: Angle tighten bolts 1-18 in sequence.

90° (angle tightening) Step 5: Tighten bolts B1-B4.

29.5 Nm (21.8 lbf. ft.)

Step 6: Tighten bolt (A).

60 Nm (44.3 lbf. ft.)

Stage 7: Tighten bolt (C).

30 Nm (22.1 lbf. ft.)

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03-2 Specifications, Engine

Bearing caps, camshaft (camshaft and bearing caps in place)

TAD8xxxVE Tightening torque Step 1: Tighten bolts 1-6 in sequence, as illustrated.

100 Nm (73.8 lbf. ft.)

Step 2: Tighten bolts 7-12.

29.5 Nm (21.8 lbf. ft.)

P0021536

Step 3: Angle tighten bolts 1-6 in sequence.

90° (angle tightening) Step 4: Angle tighten bolts 1-6 in sequence.

90° (angle tightening) Step 5: Tighten bolts 7-12.

29.5 Nm (21.8 lbf. ft.)

TAD5xxxVE Tightening torque Step 1: Tighten bolts 1-4 in sequence, as illustrated.

100 Nm (73.8 lbf. ft.)

Step 2: Tighten bolts 5-8.

29.5 Nm (21.8 lbf. ft.)

P0021537

Step 3: Angle tighten bolts 1-4 in sequence.

90° (angle tightening) Step 4: Angle tighten bolts 1-4 in sequence.

90° (angle tightening) Step 5: Tighten bolts 5-8.

29.5 Nm (21.8 lbf. ft.)

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03-2 Specifications, Engine

TAD5xxxVE

Valve Cover NOTICE! Tighten the bolts in sequence, as illustrated.

Tightening torque: 24 Nm (17.7 lbf. ft.)

P0021539

TAD8xxxVE

P0021538

Valve cover, lower TAD8xxxVE

P0021540

TAD5xxxVE

P0021541

NOTICE! Tighten the bolts in sequence, as illustrated.

Tightening torque: 24 Nm (17.7 lbf. ft.)

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03-2 Specifications, Engine

Group 22: Lubrication System Drain plug, oil sump NOTICE! Tighten the bolts in sequence, as illustrated.

Tightening torque: 24 Nm (17.7 lbf. ft.)

Finish off by checking the tightening torque of bolts 1 and 2.

Drain plug (D), oil sump: Tightening torque: 60 Nm (44.3 lbf. ft.)

P0021542

Oil cooler NOTICE! Tighten the bolts in sequence, as illustrated.

Tightening torque: 48 Nm (35.4 lbf. ft.)

P0021543

Filter cover: Tightening torque: 40 Nm (29.5 lbf. ft.)

Oil cooler: Tightening torque: 12 Nm (8.9 lbf. ft.)

P0021544

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03-2 Specifications, Engine

1 By-pass valve, oil filter Tightening torque: 29.4 Nm (21.7 lbf. ft.)

2 Plug Tightening torque: 24.5 Nm (18.1 lbf. ft.)

3 Plug Tightening torque: 24.5 Nm (18.1 lbf. ft.)

4 By-pass valve, oil cooler Tightening torque: 24.5 Nm (18.1 lbf. ft.)

5 Plug Tightening torque: 24.5 Nm (18.1 lbf. ft.)

6 Plug Tightening torque: 24.5 Nm (18.1 lbf. ft.)

7 Control valve Tightening torque: 39.2 Nm (28.9 lbf. ft.)

P0021545

Oil separator (standard) Oil return pipe, turbo TAD8xxxVE 1 Step 1: Tighten the bolts.

Tightening torque: 12 Nm (8.9 lbf. ft.)

2 Step 2: Tighten the bolts.

Tightening torque: 24 Nm (17.7 lbf. ft.)

TAD5xxxVE 1 Step 1: Tighten the bolts.

Tightening torque: 7 Nm (5.2 lbf. ft.)

P0021546

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2 Step 2: Tighten the bolts.

Tightening torque: 10 Nm (7.4 lbf. ft.)

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03-2 Specifications, Engine

Oil line TAD8xxxVE 1 Step 1: Tighten the bolts.

Tightening torque: 12 Nm (8.9 lbf. ft.)

2 Step 2: Tighten the bolts.

Tightening torque: 24 Nm (17.7 lbf. ft.)

P0021547

TAD5xxxVE Tightening torque: 26 Nm (19.2 lbf. ft.)

P0021548

Piston cooling nozzles Tightening torque: 34 Nm (25.1 lbf. ft.)

P0021549

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03-2 Specifications, Engine

Group 23: Fuel System Fuel Filter Fuel filter cover Tightening torque: 25 Nm (18.4 lbf. ft.)

P0021550

Injector Tightening sequence 1 Connector, injectors, nut Tightening torque: 2.2 Nm (1.6 lbf. ft.)

2 Yoke bracket, injectors (pre-traction) Tightening torque: 5 Nm (3.7 lbf. ft.)

3 Sleeve, injector delivery pipe, injectors Tightening torque: 75 Nm (55.3 lbf. ft.)

4 Yoke bracket, injectors Tightening torque: 57 Nm (42.0 lbf. ft.)

P0021551

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03-2 Specifications, Engine

High-pressure pipe TAD8xxxVE Step 1: Install in sequence (1, 4, 5, 3, 2, 6).

Install the delivery pipes between the common rail and the injector delivery pipes.

Tighten the cap nuts by hand. Check that the clamps are parallel with the bolt holes.

P0019419

Step 2: Install the bolts and tighten.

P0019414

Step 3: Torque tighten the cap nuts.

Tightening torque: 37 Nm (27.3 lbf. ft.)

P0019417

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03-2 Specifications, Engine

Common rail TAD8xxxVE NOTICE! Only perform angle tightening once.

Tightening torque 1 Bolt, common rail unit.

24 Nm (17.7 lbf. ft.)

2 Cap nuts, delivery pipes 37 Nm (27.3 lbf. ft.)

3 Common rail pressure sensor(1) Step 1: 20 Nm (14.8 lbf. ft.)

P0021552

Step 2: 15 ±1° (angle tightening) 4 Pressure limiting valve(2) Step 1: 20 Nm (14.8 lbf. ft.)

Step 2: 45 ±1° (angle tightening) 5 Coil, pressure limiting valve Step 1: 15 Nm (11.1 lbf. ft.)

Step 2: 13 ±0,5° (angle tightening)

P0019361

1. Check the torque 60-180 Nm (44.3-132.8") 2. Check the torque 65-140 Nm (47.9-103.3")

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03-2 Specifications, Engine

Fuel pump High pressure pump, fuel connections: 1 Fuel IN (from main filter) 2 Fuel OUT (To main filter) 3 Fuel supply pre-filter, from the engine control unit cooling coil 4 Fuel OUT to return line 5 Fuel OUT to common rail

P0019287

Gear wheel, high pressure pump, nut: Tightening torque: 65 Nm (47.9 lbf. ft.)

P0019299

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03-2 Specifications, Engine

Group 25: Inlet and Exhaust System Intake manifold TAD8xxxVE A Bolt 1. Tightening sequence: 2-13 Tightening torque: 6 Nm (4.4 lbf. ft.)

B Tightening sequence: 1-18 Tightening torque: 30 Nm (22.1 lbf. ft.)

P0021553

TAD5xxxVE A Bolt 1. Tightening sequence: 2-9 Tightening torque: 6 Nm (4.4 lbf. ft.)

B Tightening sequence: 1-12 Tightening torque: 30 Nm (22.1 lbf. ft.)

P0021554

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03-2 Specifications, Engine

Exhaust Manifold TAD8xxxVE Tightening sequence: 1-18 1 Step 1: Tightening torque: 5-10 Nm (3.7-7.4 lbf. ft.)

2 Step 2: Tightening torque: 40 Nm (29.5 lbf. ft.)

3 Step 3: Tightening torque: 52 Nm (38.4 lbf. ft.)

P0021555

TAD5xxxVE Tightening sequence: 1-12 1 Step 1: Tightening torque: 5-10 Nm (3.7-7.4 lbf. ft.)

2 Step 2: Tightening torque: 40 Nm (29.5 lbf. ft.)

3 Step 3: Tightening torque: 52 Nm (38.4 lbf. ft.)

P0021556

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03-2 Specifications, Engine

Group 26: Cooling System Coolant Pump Step 1: Screw in bolts 1-8 without tightening.

Step 2: Bolt A Tightening torque: 24 Nm (17.7 lbf. ft.)

Step 3: Bolts 1-8 Tightening torque: 48 Nm (35.4 lbf. ft.)

P0019608

Thermostat Tightening sequence: Diagonal Nipple, thermostat housing: Tightening torque: 20 Nm (14.8 lbf. ft.)

P0019525

Fan Adapter, fan: Tightening torque: 150 Nm (110.6 lbf. ft.)

P0019618

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03-2 Specifications, Engine

Belt Tensioner Tightening torque: 60 Nm (44.3 lbf. ft.)

P0021557

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03-2 Specifications, Engine

Group 30: Electrical System

P0019882

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03-2 Specifications, Engine

1

Sensor for coolant temperature Tightening torque: 20 Nm (14.8 lbf. ft.)

2 A Fuel pressure sensor Tightening torque: 24 Nm (18.4 lbf. ft.)

B Oil pressure sensor Tightening torque: 24 Nm (18.4 lbf. ft.)

3 Oil level/temperature sensor Tightening torque: 80 Nm (59.0 lbf. ft.)

4 A Sensor for camshaft position Tightening torque: 8 Nm (5.9 lbf. ft.)

B Flywheel sensor for rpm and position Tightening torque: 8 Nm (5.9 lbf. ft.)

5 NOx sensor, (pre-catalyst).

Tightening torque: 50Nm (36.9 lbf. ft.)

6 Turbine speed sensor Tightening torque: 11 Nm (8.1 lbf. ft.)

7 Sensor for exhaust manifold Tightening torque: Standard 8 Water in fuel sensor Tightening torque: 2 Nm (1.5 lbf. ft.)

9 A Sensor for charge air temperature and charge air pressure Tightening torque: 8 Nm (5.9 lbf. ft.)

B Differential pressure transducer Tightening torque: 20 Nm (14.8 lbf. ft.)

C EGR temperature sensor Tightening torque: 45 Nm (33.2 lbf. ft.)

10 Fuel pressure/temperature sensor (Common rail) Refer to section Group 23: Fuel System in Chapter Special Tightening Torques page 9.

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29

03-2 Specifications, Engine

Engine, General Type designation

TAD570-72VE

TAD870-73VE

No. of cylinders

4

6

Weight, dry

566 kg (1247 lbs)

696 kg (1534 lbs.)

Bore

110 mm (4.33")

110 mm (4.33")

Stroke

135 mm (5.31")

135 mm (5.31")

Displacement

5.1 L (311.2 in3)

7.7 L (469.9 in3)

Number of valves per cylinder

4

4

Direction of rotation (seen from front)

Clockwise

Clockwise

Firing order

1-3-4-2

1-4-2-6-3-5

Compression ratio

17.5:1

17.5:1

Low idle

700 rpm

600 rpm

Lubrication System Group 22: Lubrication System TAD570-72VE

TAD870-73VE

Oil grade

Refer to Technical data (Lubrication system) in the Operator's Manual.

Viscosity

Refer to Technical data (Lubrication system) in the Operator's Manual.

Oil pressure, hot engine, operating rpm

430 kPa (62.4 psi)

425 kPa (61.6 psi)

Oil volume incl. oil filter, no engine incline

16 l (4.3 US gals)

27 l (7.1 US gals)

MIN

10 l (2.5 US gals)

19 l (5.0 US gals)

MAX

14 l (3.6 US gals)

24 l (6.4 US gals)

Oil volume, oil sump

Max oil temperature during operations

30

125 °C (257 °F)

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05-1 Safety Instructions

05-1 Safety Instructions Safety Information This Service Manual contains repair instructions, descriptions and technical data for products or product designs from Volvo Penta. Ensure that you are using the correct service manual.

Read the safety information below and the service manual section About this Workshop manual and Repair instructions carefully before repair and service work is begun.

!

This symbol is used in the service manual and on the product, to call attention to the fact that this is safety information. Always read such information very carefully.

Safety texts in the manual have the following order of priority:

DANGER! Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING! Indicates a hazardous situation which, if not avoided, could result in death or serious personal injury.

CAUTION! Indicates a hazardous situation which, if not avoided, could result in minor or moderate personal injury.

IMPORTANT! Is used to draw your attention to something that may cause minor damage or a minor malfunction to the product or property.

NOTICE! Is used to draw your attention to important information that will facilitate the work or operation in progress.

This symbol is used on certain operations to indicate the following: This operation requires prior theoretical and/or instructor led training before attempting.

Contact your local training organization for further information.

A compilation of safety precautions that must be taken and risks which must be paid attention to is presented in the following pages.

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31

05-1 Safety Instructions

32

!

Immobilize the engine by turning off the power supply to the engine at the main switch (switches) and lock it (them) in the off position before starting work. Post a warning notice at the main circuit breaker.

!

Avoid opening the coolant filling cap when the engine is hot. Steam or hot coolant can spray out and system pressure will be lost. Open the filler cap slowly, and release the pressure in the cooling system if the filler cap or valve has to be opened, or if a plug or coolant hose has to be removed when the engine is hot.

!

As a rule, all service operations must be carried out with the engine stopped. However, some work, such as adjustments, will require the engine to be running. Approaching an engine which is running is a safety risk. Bear in mind that loose clothing or long hair can fasten in rotating parts and cause serious personal injury.

!

Hot oil can cause burns. Avoid skin contact with hot oil. Ensure that the lubrication system is not under pressure before any work is begun.

Never start or operate the engine with the oil filler cap removed, because of the risk of oil ejection.

!

Be aware of hot surfaces (exhaust pipes, turbos, charge air pipes, starting heaters etc.) and hot fluids in pipes and hoses on an engine that is running or has just stopped.

If work is done adjacent to a running engine, a careless movement or a dropped tool may in the worst case lead to personal injury.

!

Never start the engine without installing the air filter. The rotating compressor turbine in the turbocharger can cause severe injury. Foreign objects entering the intake ducts can also cause mechanical damage. Install all protective covers before the engine is started.

!

Ensure that the warning symbols or information decals on the product are always clearly visible.

Replace decals which have been damaged or painted over.

!

Only start the engine in a well-ventilated space.

When running in a confined space, exhaust fumes and crankcase gases must be led away from the engine bay or workshop area.

!

Avoid getting oil on your skin! Protracted or repeated exposure to oil can cause skin to become dry. Irritation, dryness, eczema and other skin problems may then result. From a health standpoint, used oil is more dangerous than new. Use protective gloves and avoid oilsoaked clothes and rags. Wash regularly, especially before eating. Use suitable barrier creams to counteract drying out of the skin and to aid dirt removal.

!

The majority of chemicals e.g. engine and transmission oils, glycol, gasoline, and diesel oil, together with chemicals for workshop use such as degreasing agents, paints and solvents, are injurious to health. Carefully read the instructions on the product packaging! Always follow a product's safety directions, e.g. use of protective mask, glasses, gloves etc. Ensure that other personnel are not exposed to substances that are injurious to health. Ensure good ventilation. Handle used and leftover chemicals in the prescribed manner.

!

Stop the engine and turn off the electrical supply at the main switch(es) before carrying out work on the electrical system.

!

Clutch adjustments must be carried out with the engine stopped.

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05-1 Safety Instructions

!

Always use protective glasses or goggles when carrying out work where a risk of splinters, grinding sparks, splashes from acid or other chemicals is present. Your eyes are extremely sensitive; injury may cause blindness!

!

Never start the engine with the valve cover removed. There is a risk of personal injury.

!

Never use start gas or similar products as a starting aid. They may cause an explosion in the inlet manifold. Danger of personal injury.

!

Stop the engine before working on the cooling system.

Marine engines: Close the sea cock / cooling water inlet valve before work on the cooling system is begun.

!

All fuels, as well as many chemicals, are flammable. Do not allow open flames or sparks in their vicinity. Gasoline, some thinners, and hydrogen gas from batteries are extremely flammable and explosive when mixed with air in the correct proportions. No Smoking! Ensure that the work area is well ventilated and take the necessary safety precautions before welding or grinding work is begun. Always ensure that there are fire extinguishers close at hand in the work area.

!

Make sure that oil, fuel-soaked rags, and used fuel and oil filters are stored in a safe manner.

Rags soaked in oil can spontaneously ignite under certain circumstances. Used fuel and oil filters are environmentally hazardous waste and must be handed to an approved waste management facility for destruction, as must any used lubrication oil, contaminated fuel, paint residue, solvents, degreasers and wash residue.

!

Batteries must never be exposed to open flames or electric sparks. Never smoke in the vicinity of the batteries; they generate hydrogen gas when charged, which is explosive when mixed with air. This gas is easily ignited and highly explosive. A spark, which can be caused by incorrect battery connection, is sufficient to cause a battery to explode and cause damage.

!

Never work alone when removing heavy components, even when using lifting devices such as locking tackle lifts. When using a lifting device, two people are usually required to do the work - one to take care of the lifting device and the other to ensure that components are lifted clear and not damaged during the lifting operations.

!

The existing lugs on the engine should be used for lifting. Always check that the lifting equipment used is in good condition and has the load capacity to lift the engine (engine weight including gearbox or extra equipment). For safe handling and to avoid damaging components fitted to the top of the engine, the engine must be lifted with a correctly adjusted lifting boom. All chains or wires must run parallel to each other and as perpendicular to the engine as possible.

If other equipment attached to the engine has altered its center of gravity, special lifting devices may be needed to obtain the correct balance for safe handling. Never perform any work on an engine that is only suspended from the lifting equipment.

Do not touch the connections during start attempts. Sparking hazard! Do not lean over batteries.

!

Never transpose the positive (+) and negative (-) battery posts when installing batteries. Such a transposition can result in serious damage to electrical equipment. Refer to the wiring diagram.

Always use protective goggles when charging and handling the batteries. Battery electrolyte contains sulfuric acid which is highly corrosive.

Should the battery electrolyte come into contact with unprotected skin, wash it off immediately using soap and copious amounts of water. If you get battery acid in your eyes, flush at once with copious amounts of water and seek medical assistance immediately.

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33

05-1 Safety Instructions

34

!

The components in the electrical and fuel systems on Volvo Penta products are designed and manufactured to minimize the risk of fire and explosion. The engine must not be run in areas where there are explosive materials.

!

Exercise extreme caution when leak-detecting on the fuel system and testing the fuel injector nozzles. Use eye protection. The jet from a fuel nozzle has very high pressure and great penetration power. Fuel can force its way deep into body tissue and cause severe injury. There is a risk of blood poisoning (septicemia).

!

Only use fuels and lubricating oils recommended by Volvo Penta. Refer to the Operator's Manual for the product in question. Use of fuels that are of a lower grade may damage the engine, the injection pump and the injectors. On a diesel engine, low grade fuel can cause the control rod to bind and the engine to over-rev, with the risk of engine damage and personal injury as a result. Low fuel and oil grades may result in high service, maintenance and repair costs.

!

Never use a high-pressure washer for cleaning the engine.

Pay attention to the following when using a highpressure washer on components other than the actual engine: Never direct the water jet at seals, rubber hoses or electrical components.

!

Fuel delivery pipes must not be bent or straightened under any circumstances. Cracks may occur. Damaged pipes must be replaced.

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08-2 Special Service Tools

08-2 Special Service Tools The following special tools are used when working on the engine. The tools can be ordered from AB Volvo Penta by specifying the number indicated.

9986172 Puller Used when removing air compressor drive gear and for gear removal at unit pump replace.

88800014 Rotation tool Used for valve adjustment, BVA assembly, HP pump, air compressor.

88840269 Guide pin Used when removing and installing flywheel. Two guide pins needed.

88840270 Wrench Used for injector replacement, HP pump, common rail, PRV valve.

88840271 Guide pin Used for check valve, high pressure pump.

Used to position the check valve on the fuel pump.

88840272 Sleeve Used when removing PRV valve.

88840274 Guide pin Used for fuel pump installation.

Two pcs needed.

88840406 Mounting tool Used when replacing crankshaft sealings (rear).

88840407 Mounting tool Used when replacing crankshaft sealings (front).

88840282 Extractor Used when removing crankshaft seal (rear and front).

88890105 Refractometer

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35

08-2 Special Service Tools

88840290 Plugs Used when protecting the high pressure system.

36

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21-1 Cylinder Head

21-1 Cylinder Head Upper valve cover, change TAD570VE, TAD571VE, TAD572VE IMPORTANT! Turn off the main switch before any work is carried out.

The procedure in this description assumes that the engine control unit will not be removed but moved to one side with its harness and fuel connection. In connection with control unit replacement, refer to 36-6, Engine Control Unit (ECU), Replace.

1

Undo the cable holder and cable ties.

Remove the control unit retaining bolts.

2

IMPORTANT! Clean thoroughly before removal.

P0019500

Protect the engine control unit by moving it to one side, enclosing it in a plastic bag and tying the bag shut.

P0019501

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21-1 Cylinder Head 3

Remove the crankcase ventilation connection from the valve cover.

4

Remove the valve cover.

P0019502

P0019503

38

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21-1 Cylinder Head

Installation 5

1 Remove gasket.

2 Clean along the gasket groove.

3 Check to see if the valve cover gasket needs to be changed.

Clean the gasket.

4 Clean the sealing surfaces.

5 Fit the gasket.

P0019504

6

Install the cover, tighten the bolts in sequence and torque them.

P0019505

Tighten the bolts in sequence, as illustrated: Tightening torque: 24 Nm (17.7 lbf. ft.)

P0019506

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21-1 Cylinder Head 7

Install the crankcase ventilation connection on the valve cover.

8

Install the control unit.

Fasten it to the harness holder and fit cable ties.

9

Check the connections.

P0019507

P0019508

40

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21-1 Cylinder Head

Upper valve cover, change TAD870VE, TAD871VE, TAD872VE, TAD873VE

Removal 1

Loosen the cable clip.

2

Remove the connection for crankcase ventilation from the valve cover.

3

Remove the valve cover with upper gasket.

P0019482

P0019483

P0019484

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21-1 Cylinder Head

Installation 4

1 Remove gasket.

2 Clean along the gasket groove.

3 Check if the valve cover gasket needs to be changed. Clean the gasket.

4 Clean the sealing surfaces.

5 Install the gasket.

P0019485

5

Install the valve cover and tighten the bolts in sequence and with tightening torque.

P0019486

P0019489

Tighten the bolts in numerical order according to the picture: Tightening torque: 24 Nm (17.7 lbf. ft.)

42

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21-1 Cylinder Head 6

Install the connection for the crankcase ventilation to the valve cover.

7

Install cable and cable clip.

P0019483

P0019482

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21-1 Cylinder Head

Lower valve cover, change TAD570VE, TAD571VE, TAD572VE

Removal IMPORTANT! Turn off the main switch before any work is carried out.

1

Remove the upper valve cover; refer to Upper valve cover, change page 37.

2

Remove the connector from the grommet.

3

Unscrew the wiring from the injectors.

P0019509

P0019510

44

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21-1 Cylinder Head 4

Remove the lower valve cover.

P0019511

Installation 5

1 Remove gasket.

2 Clean along the gasket groove.

3 Check to see if the valve cover gasket needs to be changed.

Clean the gasket.

4 Clean the sealing surfaces.

5 Fit the gasket.

P0019512

6

Install the cover, tighten the bolts in sequence and torque them.

P0019513

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45

21-1 Cylinder Head Tighten the bolts in sequence, as illustrated: Tightening torque: 24 Nm (17.7 lbf. ft.)

P0019514

7

Screw on the injector connectors.

Tightening torque: 2.2 Nm (1.6 lbf. ft.)

8

Connect the connector through the grommet.

9

Install the upper valve cover; refer to Upper valve cover, change page 37.

P0019510

P0019515

46

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21-1 Cylinder Head

Lower valve cover, change TAD870VE, TAD871VE, TAD872VE, TAD873VE

Removal IMPORTANT! Turn off the main switch before any work is carried out.

1

Remove the upper valve cover, see Upper valve cover, change page 37.

2

Remove the stripes and loosen the cable from the cover.

3

Disconnect the connector from the lead-through.

P0019490

P0019491

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21-1 Cylinder Head 4

Unscrew the electrical wiring from the injectors.

5

Remove the lower valve cover.

P0019492

P0019493

Installation 6

1 Remove gasket.

2 Clean along the gasket groove.

3 Check if the valve cover gasket needs to be changed. Clean the gasket.

4 Clean the sealing surfaces.

5 Install the gasket.

P0019494

48

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21-1 Cylinder Head 7

Install the valve cover and tighten the bolts in sequence and with tightening torque.

P0019495

Tighten the bolts in numerical order according to the picture: Tightening torque: 24 Nm (17.7 lbf. ft.)

P0019496

8

Screw the connectors onto the injectors.

Tightening torque: 2.2 Nm (1.6 lbf. ft.)

P0019492

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21-1 Cylinder Head 9

Connect the connector to the lead-through.

10

Clamp the cable harness onto the valve cover with original stripes.

11

Install the upper valve cover, see Upper valve cover, change page 37.

P0019497

P0019498

50

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21-4 Valve Mechanism

21-4 Valve Mechanism Valves, Adjustment Tools: 88800014 Rotation tool IMPORTANT! Clean thoroughly before removal.

NOTICE! Normal valve clearance is set when the engine is cold, or when it has been left to cool for at least a half hour. Oil temperature < 80 °C (176 °F).

Removal 1

Remove the upper valve cover according to: Upper valve cover, change page 37.

2

Remove the plug by the flywheel.

Insert 88800014 Rotation tool.

3

NOTICE! Crank counterclockwise, on the engine flywheel side.

P0019449

Crank the flywheel until the cylinder 1 mark aligns with the mark on the flywheel housing.

The camshaft gear has two markings corresponding to the marking on the flywheel.

P0019450

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51

21-4 Valve Mechanism 4

Check that the gearwheel marking (1) corresponds with the surface of the left side of the cylinder head.

If not, crank the flywheel one more turn.

Marking (1) facing surface of the cylinder head:

• The Inlet valves for cylinders (1), (3) and (5).

• The exhaust valves for cylinders (1), (2) and (4).

P0019451

P0019452

A Inlet valve B Exhaust valve

52

1 2 3

Cylinder 1 Cylinder 2 Cylinder 3

4 5 6

Cylinder 4 Cylinder 5 Cylinder 6

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21-4 Valve Mechanism

Checks and adjustment, inlet valves 5

NOTICE! Cylinder (1) is on the opposite side in relation to the engine flywheel/gearwheel.

Check the valve clearance on the inlet valves for cylinders (1), (3) and (5).

P0019453

Check 6

Check the valve clearance for the inlet valves with the aid of a feeler gauge set.

The clearance must be 0.4 ±0.05 mm.

In the value is not correct, adjust the valve.

P0019454

Adjustment 7

Adjust inlet valve clearance between the rocker arm and the valve yoke to 0.4 ±0.05 mm with the aid of a feeler gauge set.

Loosen the adjuster screw locking nut on the rocker arm. Turn the adjuster screw until the right clearance is achieved.

Feeler gauges should be used when adjusting.

One 0.40 mm, the other 0.45 mm.

Set the clearance so that only the 0.40 mm feeler gauge can be inserted without any great resistance, and only slight resistance should be felt when the feeler gauge is pulled back and forth. It should not be possible to insert the 0.45 mm feeler gauge without resistance.

P0019455

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Counterhold the adjuster screw while tightening the locking nut.

Tightening torque: 33 Nm (24.3 lbf. ft.)

53

21-4 Valve Mechanism

Checks and adjustment, exhaust valves 8

NOTICE! Cylinder (1) is at the opposite side in relation to the engine flywheel/gearwheel.

Check the valve clearance on the exhaust valves for cylinders (1), (2) and (4).

P0019456

Check 9

Check the valve clearance for the exhaust valves with the aid of a feeler gauge set.

The clearance must be 0.5 ±0.05 mm.

In the value is not correct, adjust the valve.

P0019457

Adjustment 10

Adjust exhaust valve clearance between the rocker arm and the valve yoke to 0.5 ±0.05 mm with the aid of a feeler gauge set.

Loosen the adjuster screw locking nut on the rocker arm.

Turn the adjuster screw until the right clearance is achieved.

P0019458

Feeler gauges should be used when adjusting.

One 0.50 mm, the other 0.55 mm.

Set the clearance so that only the 0.50 mm feeler gauge can be inserted without any great resistance, and only slight resistance should be felt when the feeler gauge is pulled back and forth. It should not be possible to insert the 0.55 mm feeler gauge without resistance.

Counterhold the adjuster screw while tightening the locking nut.

Tightening torque: 33 Nm (24.3 lbf. ft.)

54

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21-4 Valve Mechanism 11

NOTICE! Crank counterclockwise, on the engine flywheel side.

Crank the flywheel one turn until the cylinder 1 mark aligns with the mark on the flywheel housing.

P0019450

12

Check that the gearwheel marking corresponds with the surface of the left side of the cylinder head.

If not, crank the flywheel one more turn.

Marking left facing surface of the cylinder head:

• The Inlet valves for cylinders (2), (4) and (6).

• The exhaust valves for cylinders (3), (5) and (6).

P0019459

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55

21-4 Valve Mechanism

Checks and adjustment, inlet valves 13

NOTICE! Cylinder (1) is on the opposite side in relation to the engine flywheel/gearwheel.

Check the valve clearance on the inlet valves for cylinders (2), (4) and (6).

P0019460

Check 14

Check the valve clearance for the inlet valves with the aid of a feeler gauge set.

The clearance must be 0.4 ±0.05 mm.

In the value is not correct, adjust the valve.

P0019461

Adjustment 15

Adjust inlet valve clearance between the rocker arm and the valve yoke to 0.4 ±0.05 mm with the aid of a feeler gauge set.

Loosen the adjuster screw locking nut on the rocker arm.

Turn the adjuster screw until the right clearance is achieved.

P0019462

Feeler gauges should be used when adjusting.

One 0.40 mm, the other 0.45 mm.

Set the clearance so that only the 0.40 mm feeler gauge can be inserted without any great resistance, and only slight resistance should be felt when the feeler gauge is pulled back and forth. It should not be possible to insert the 0.45 mm feeler gauge without resistance.

Counterhold the adjuster screw while tightening the locking nut.

Tightening torque: 33 Nm (24.3 lbf. ft.)

56

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21-4 Valve Mechanism

Checks and adjustment, exhaust valves 16

NOTICE! Cylinder (1) is on the opposite side in relation to the engine flywheel/gearwheel.

Check the valve clearance on the exhaust valves for cylinders (3), (5) and (6).

P0019463

Check 17

Check the valve clearance for the exhaust valves with the aid of a feeler gauge set.

The clearance must be 0.5 ±0.05 mm.

If the value is not correct, adjust the valve.

P0019464

Adjustment 18

Adjust exhaust valve clearance between the rocker arm and the valve yoke to 0.5 ±0.05 mm with the aid of a feeler gauge set.

Loosen the adjuster screw locking nut on the rocker arm.

Turn the adjuster screw until the right clearance is achieved.

P0019465

Feeler gauges should be used when adjusting.

One 0.50 mm, the other 0.55 mm.

Set the clearance so that only the 0.50 mm feeler gauge can be inserted without any great resistance, and only slight resistance should be felt when the feeler gauge is pulled back and forth. It should not be possible to insert the 0.55 mm feeler gauge without resistance.

Counterhold the adjuster screw while tightening the locking nut.

Tightening torque: 33 Nm (24.3 lbf. ft.)

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57

21-4 Valve Mechanism 19

Remove 88800014 Rotation tool from the gear ring.

Install the plug.

20

Insert plug for the flywheel mark.

21

Install the upper valve cover according to: Upper valve cover, change page 37.

P0019449

P0019466

58

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21-5 Timing Gears and Shaft

21-5 Timing Gears and Shaft Flywheel, Change Tools: 9996239 Lifting tool 88840269 Guide pin

CAUTION! Pinch hazard. Keep fingers clear.

Removal 1

Remove the flywheel sensor.

2

Remove two diametrically opposed bolts.

P0020336

P0020337

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21-5 Timing Gears and Shaft 3

Replace with locating pins 88840269 Guide pin.

4

Attach and secure tool 9996239 Lifting tool.

5

Remove the remaining bolts.

P0020338

P0020339

P0020340

60

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21-5 Timing Gears and Shaft 6

Remove the flywheel.

P0020344

Installation 7

Clean the flywheel contact surface on the crankshaft.

Check the crankshaft seal.

8

Check the position of the crankshaft guide pins in relation to the flywheel locating holes.

Install the flywheel.

P0020341

P0020342

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21-5 Timing Gears and Shaft 9

Install the bolts. Screw in the bolts without tightening.

Remove the guide pins and lifting tool.

10

Tighten the bolts in the sequence i as llustrated.

Tightening torque: 190 Nm (140 lbf. ft.)

11

Install the flywheel sensor.

P0020343

P0020345

P0020336

62

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21-6 Crank Mechanism

21-6 Crank Mechanism Gear Ring, Fywheel: Replace 1

Remove the flywheel; refer to Flywheel, Change page 59

2

Drill 1–2 holes between teeth on the ring gear.

Split the ring gear at the drilled hole(s), using a cold chisel; lift the ring gear away from the flywheel.

3

Brush the flywheel contact surface clean with a steel wire brush.

4

Heat the new gear ring to 180-200 °C (356–392 °F).

The ring gear must be evenly heated.

5

The bevel must face out.

Ring gear–flywheel gap: 0-0.2 mm (0-0.008”)

P0020333

P0020334

Put the heated ring gear onto the flywheel and tap it into place with a soft drift and hammer.

P0020335

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21-6 Crank Mechanism

Crankshaft Seal, Change (front) Tools: 88840407 Mounting tool 88840282 Extractor IMPORTANT! Turn off the main switch before any work is carried out.

Because access depends on the type of cooling system installed, different methods are used when replacing the component.

Removal 88840282 Extractor 1 Reversible arms for front and rear seals 2 Hook clamp for rear crankshaft seal replacement 3 Hook clamp for front crankshaft seal replacement 4 Pin 5 Lock screw 6 Pressure plate (for rear crankshaft seal) 1

Remove the fan; refer to Coolant Pump, Change page 203.

2

Remove the drive belt according to Drive Belt, Change page 219.

3

Remove the fan adapter and pulley from the coolant pump.

P0020364

P0019601

64

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21-6 Crank Mechanism 4

Remove the vibration damper and pulley.

5

NOTICE! The tool arms are reversible for use with front or rear seals.

P0020365

NOTICE! The seal is bonded to the shaft and may adhere with moderate to high strength.

NOTICE! Use a hose clamp around the arms to prevent the hook clamps from losing their grip on the seals.

Adjust the arms on 88840282 Extractor and fit the hook clamps around the metal edge of the seal.

Pull out the seal slowly.

P0020366

6

NOTICE! Remove all sealant residue from the crankshaft.

NOTICE! Clean the sealing surfaces.

P0020367

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21-6 Crank Mechanism

Installation 7

NOTICE! Curing will not begin until the seal is pressed up against the sealant.

Run a bead of adhesive/sealant, part no.

21597610 around the circumference of the crankshaft, as illustrated.

Maintain the distance: D5: 60.8 mm (2.39") D8: 54.8 mm (2.16")

P0020368

8

Fit 88840407 Mounting tool onto the crankshaft and screw it in place.

9

IMPORTANT! The seal ring is in two parts and may not be separated.

P0020369

IMPORTANT! The metal side of the seal ring must face out.

Slide the seal ring onto the tool.

P0020370

66

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21-6 Crank Mechanism 10

Fit the tool cover (88840407 Mounting tool) with the screw handle.

Press in the seal until the cover bottoms against the crankshaft seal cover.

11

Remove the tool and check that the seal is correctly installed against the crankshaft seal cover.

Permissible clearance: ±0.15 mm (±0.0059").

P0020371

Remove any sealant residues.

Curing takes 15-30 minutes. Full strength is achieved after 24 hours.

P0020372

12

Fit the vibration damper and the pulley.

P0020365

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21-6 Crank Mechanism 13

Tighten the bolts in sequence, as illustrated.

Tightening torque: 110 Nm (81 lbf. ft.)

14

Install the fan adapter and pulley on the coolant pump Tighten the bolts diagonally.

15

Install the drive belt according to Drive Belt, Change page 219.

16

Install the fan; refer to Coolant Pump, Change page 203.

P0020373

P0019610

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21-6 Crank Mechanism

Crankshaft Seal, Change (rear) Tools: 88840406 Mounting tool 88840282 Extractor 88840282 Extractor 1 Reversible arms for front and rear seals 2 Hook clamp for rear crankshaft seal replacement 3 Hook clamp for front crankshaft seal replacement 4 Pin 5 Lock screw 6 Pressure plate (for rear crankshaft seal)

P0020364

Removal 1

Remove the flywheel according to Flywheel, Change page 59.

2

NOTICE! The tool arms are reversible for use with front or rear seals.

NOTICE! The seal is bonded to the shaft and may adhere with moderate to high strength.

Adjust the arms on 88840282 Extractor and fit the hook clamps around the metal edge of the seal.

Pull out the seal slowly.

P0020374

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21-6 Crank Mechanism 3

IMPORTANT! Remove all sealant residue from the crankshaft.

NOTICE! Clean the seal seat in the flywheel housing and the sealing surface on the crankshaft.

P0020375

Installation 4

NOTICE! Curing will not begin until the seal is pressed up against the sealant.

Run a bead of adhesive/sealant, part no.

21597610 around the circumference of the crankshaft, as illustrated. Maintain the distance 16.2 mm (0.638").

P0020376

5

Check the position of the crankshaft guide pins in relation to the 88840406 Mounting tool.

P0020377

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21-6 Crank Mechanism 6

Fit 88840406 Mounting tool onto the crankshaft and screw it in place.

7

IMPORTANT! The seal ring is in two parts and may not be separated.

P0020378

IMPORTANT! The metal side of the seal ring must face out.

Slide the seal ring onto the tool.

P0020379

8

Fit the tool cover with the screw handle.

Press in the seal until the cover bottoms against the flywheel housing.

P0020380

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21-6 Crank Mechanism 9

Remove the tool and check that the seal is correctly installed against the flywheel housing.

Permissible clearance: ±0.15 mm (±0.0059").

Remove any sealant residues.

Curing takes 15-30 minutes. Full strength is achieved after 24 hours.

P0020381

10

72

Install the flywheel according to: Flywheel, Change page 59.

47705010 05-2015 © AB VOLVO PENTA

22-2 Oil filter

22-2 Oil filter Oil filter, Change IMPORTANT! Risk of material damage. Use only an oil fuel filter approved by the manufacturer.

The wrong type of oil filter can lead to damage to bearings, the crankshaft and connected components as a result of unfiltered oil entering the lubrication system.

A Volvo oil filter constantly cleans dirt, metal particles, carbon, etc. from the oil so that only clean oil reaches lubrication and bearing points.

IMPORTANT! Protect against dirt while working.

NOTICE! Be prepared to gather up fluid.

Removal Engine oil drained.

1

Clean around the filter cover and housing.

Carefully remove the oil filter cover and filter.

2

Remove the O-ring and filter.

Let the oil drip into a collection vessel.

P0019348

P0019349

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22-2 Oil filter

Installation 3

NOTICE! Use recommended oil.

Lubricate the O-ring lightly before installing the filter cover.

P0019350

4

NOTICE! Use recommended oil.

Lubricate around the sealing surface on the new filter's inner component.

P0019351

5

Install a new filter in the filter cover.

Make sure the filter seats properly in the cover.

P0019352

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22-2 Oil filter 6

IMPORTANT! Make sure that the component is clean before installation.

Install the filter cover and filter in the bracket.

Carefully screw in the cover and check that the O-ring does not get twisted.

Lubricate the seal again, as necessary.

Tighten the cover.

Tightening torque: 40 Nm (29.5 lbf. ft.)

P0019353

7

Install the drain plug (D) on the oil sump.

Tightening torque: 60 Nm (44.3 lbf. ft.)

8

NOTICE! Use recommended oil.

P0019354

Fill with the requisite quantity of oil; refer to the service record for the engine type concerned.

P0019355

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Start the engine.

Check that no leakage occurs.

10

Switch the engine off and check the oil level after a few minutes.

Top up with oil as necessary.

75

22-2 Oil filter

Oil Filter Housing, Change Removal NOTICE! Be prepared to gather up fluid.

1

Drain the coolant, according to: Coolant, Change page 195.

2

Remove the fuel filter housing, according to: Fuel filter housing, change page 93.

3

Disconnect the oil pressure sensor connector.

Remove the cable ties.

4

Remove the cable clamps.

Remove the cable ties.

Loosen the harness aside.

P0019821

P0019822

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22-2 Oil filter 5

Unclip the fuel lines from the bracket.

6

Remove the retainer bracket.

7

Remove the hose for outgoing coolant.

Loosen the coolant pipe.

P0019823

P0019824

P0019825

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22-2 Oil filter 8

Remove the oil filter housing.

P0019826

Installation 9

Clean the mating surfaces on the engine block.

10

During reassembly of the existing oil filter; clean the mating surfaces.

P0019827

P0019828

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22-2 Oil filter 11

Use new O-rings.

Lubricate the O-rings.

12

Install the oil filter housing.

13

Tighten the screws in numerical order as shown: Tightening torque: 48 Nm (35.4 lbf. ft.)

P0019829

P0019826

P0019830

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22-2 Oil filter 14

Install the hose for outgoing coolant.

Fasten the flange to the coolant pipe.

15

Install the retainer bracket.

16

Install the fuel lines to the bracket.

P0019825

P0019824

P0019823

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22-2 Oil filter 17

Position the harness.

Install the cable clamps.

Install the cable ties.

18

Connect the oil pressure sensor connector.

Install the cable ties.

19

Install the fuel filter housing, according to: Fuel filter housing, change page 93.

20

Top up with coolant; refer to Coolant Level, Checking and Topping Up page 193.

21

Check that no leakage occurs.

22

Make sure that the oil level is between the MIN and MAX marks.

P0019822

P0019821

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22-3 Oil cooler

22-3 Oil cooler Oil Cooler, Replace Removal NOTICE! Be prepared to gather up fluid.

1

Drain the coolant, according to: Coolant, Change page 195.

2

Unscrew the oil cooler.

NOTICE! Depending which version of oil filler assembly can this affect the removal of the oil cooler. This description has free access to component.

P0019841

3

Remove the oil cooler.

P0019842

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22-3 Oil cooler 4

Remove the O-rings.

P0019843

Installation 5

Clean the contact surfaces on the oil filter housing.

6

Use new O-rings.

Lubricate the O-rings.

P0019844

P0019843

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22-3 Oil cooler 7

Install the oil cooler to the oil filter housing.

8

Tighten the oil cooler.

Tightening torque: 12 Nm (8.9 lbf. ft.)

9

Top up with coolant; refer to Coolant Level, Checking and Topping Up page 193.

10

Check that no leakage occurs.

11

Make sure that the oil level is between the MIN and MAX marks.

P0019845

P0019841

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23-0 Fuel System, General

23-0 Fuel System, General Fuel system, bleeding 1

Check that there is sufficient fuel in the tank, and that any fuel taps are open.

2

Operate the hand pump by pumping it until it offers resistance.

3

Wait 15 seconds.

Repeat the operation as many times as necessary.

4

Start the engine and let it run at high idle for at least 5 minutes before speed is increased.

5

Perform a leakage and function check.

P0019266

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23-3 Fuel Feed Pump and Filter

23-3 Fuel Feed Pump and Filter Fuel Pre-filter, Change IMPORTANT! Working with the fuel system requests special cleanliness. Clean thoroughly before removal.

IMPORTANT! Risk of material damage.

The use of the wrong type of fuel filter may damage the fuel injection circuit. Use only fuel filters approved by the manufacturer.

CAUTION! Risk of skin damage.

NOTICE! Be prepared to gather up fluid.

Removal 1

Clean around the pre-filter and the water separator.

Disconnect the connector. Remove the wire harness:

2

Undo the drain nipple.

Drain the filter.

Tighten the drain nipple.

P0019269

NOTICE! Undo a pipe if necessary.

P0019270

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23-3 Fuel Feed Pump and Filter 3

Remove the pre-filter and seal ring together with the lower section of the water separator. Use an oil filter wrench.

4

Remove the lower section of the water separator and O-ring from the filter.

Keep the filter in a suitable container.

Clean the lower section of the water separator and the contact surfaces.

P0019271

P0019272

Installation 5

NOTICE! Use new component.

Lubricate the O-ring and seal ring with diesel.

Install a new O-ring.

Install the lower part of the water separator.

P0019273

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23-3 Fuel Feed Pump and Filter 6

Install the new pre-filter.

Screw the filter on by hand until it stops.

Tighten the filter until it bottoms, then a further 180-240°.

7

Connect the connector.

Secure the wire harness.

8

Open the fuel tap and purge the fuel pre-filter according to Fuel pre-filter, bleeding page 89.

P0019271

P0019269

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23-3 Fuel Feed Pump and Filter

Fuel pre-filter, bleeding It is only necessary to purge the fuel system following maintenance on the system or if a fault has caused it to run dry.

NOTICE! Be prepared to gather up fluid.

1

Remove the cover.

Lightly undo the nipple (two turns).

2

Position a collection vessel.

Connect a transparent hose.

Operate the hand pump by pumping it until fuel flows without air bubbles.

3

Tighten the nipple while the fuel flows.

Remove the hose.

Tighten the nipple.

P0019267

Tightening torque 3.5 Nm (2.6 lbf. ft.)

4

Install the cap.

P0019268

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23-3 Fuel Feed Pump and Filter

Fuel filter, Change IMPORTANT! Risk of material damage. Use only a fuel filter approved by the manufacturer. The wrong type of fuel filter may damage the fuel injection circuit.

IMPORTANT! Working with the fuel system requests special cleanliness.

IMPORTANT! Protect against dirt while working.

NOTICE! Be prepared to gather up fluid.

Removal 1

Clean around the filter cover and housing.

Carefully remove the filter cover and filter.

2

Remove the O-ring and filter.

Let the fuel drip off into a collection vessel.

P0019259

P0019260

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23-3 Fuel Feed Pump and Filter

Installation 3

NOTICE! Lubricate with diesel.

Lubricate the O-ring before installing the filter cover.

P0019261

4

NOTICE! Lubricate with diesel.

If the filter housing is completely empty, lubricate around the inner section's sealing surface on the new filter.

P0019262

5

Install a new filter in the filter cover.

Make sure the filter seats properly in the cover.

P0019263

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23-3 Fuel Feed Pump and Filter 6

IMPORTANT! Make sure that the component is clean before installation.

Install the filter cover and filter in the bracket.

Carefully screw in the cover and check that the O-ring does not get twisted. Re-lubricate the seal as necessary.

Tighten the cover to: 25 Nm (18.4 lbf. ft.)

P0019264

92

7

Purge the fuel system according to Fuel system, bleeding page 85.

8

Start and warm up engine. Check that no leakage occurs.

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23-3 Fuel Feed Pump and Filter

Fuel filter housing, change Tools: 88840290 Plugs IMPORTANT! Working with the fuel system requests special cleanliness.

IMPORTANT! Clean thoroughly before removal.

IMPORTANT! Risk of material damage.

Using the wrong type of fuel filter can damage the injector circuit. Use only fuel filters approved by the manufacturer.

WARNING! Hot fluid. Scalding risk.

NOTICE! Be prepared to gather up fluid.

Removal 1

Close the cock on the return line to the tank.

2

Disconnect the pressure relief valve connector.

Disconnect the fuel pressure sensor connector.

Remove the cable ties.

3

NOTICE! Clean the area around the delivery pipe connection on the high pressure pump before starting any work.

P0019657

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23-3 Fuel Feed Pump and Filter 4

Remove fuel connection (1) 'fuel IN' from the fuel feed pump and returnline (2) and let the fuel run into a suitable vessel.

Remove fuel connection (3) 'fuel OUT' to high pressure pump.

Install safety plugs on all fuel connections. Use kit 88840290 Plugs.

P0019658

5

Remove the fuel filter housing.

P0019659

Installation 6

Move the bracket and sensor over to the new fuel filter housing if needed.

7

Install the fuel filter housing.

P0019660

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23-3 Fuel Feed Pump and Filter 8

Install fuel connection 1, 2, and 3.

NOTICE! Different diameter for proper connection.

P0019661

9

Connect the pressure relief valve connector.

Connect the fuel pressure sensor connector.

Install the cable ties.

10

Open the cock on the return line to the tank.

11

Vent the fuel system according to Fuel system, bleeding page 85.

P0019662

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23-3 Fuel Feed Pump and Filter

High Pressure Pump, Change Tools: 9986172 Puller 88800014 Rotation tool 88840270 Wrench 88840274 Guide pin 88840290 Plugs IMPORTANT! Working with the fuel system requests special cleanliness. Clean thoroughly before removal.

IMPORTANT! Install safety plugs in open connections.

CAUTION! Risk of skin damage.

CAUTION! The fuel system may be under pressure.

When working on the fuel system, undo a closed system at the first point with caution.

NOTICE! Turn off the main switch before any work is carried out.

High pressure pump, fuel connections: 1 Fuel IN (from main filter) 2 Fuel OUT (To main filter) 3 Fuel supply from the engine control unit cooling coil 4 Fuel OUT to return line 5 Fuel OUT to common rail

P0019287

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23-3 Fuel Feed Pump and Filter

Removal 1

Undo the diagnostics panel and move it aside.

2

NOTICE! Clean the area around the delivery pipe connection on the high pressure pump before starting work.

P0019274

NOTICE! Be prepared to gather up fluid.

3

Remove fuel connection 'fuel IN' from the main filter and let the fuel run into a suitable vessel.

Install safety plugs on all fuel connections. Use kit 88840290 Plugs.

4

Fit a protective plug over 'fuel IN' on the high pressure pump. Use kit 88840290 Plugs.

Remove the MPROP valve connector.

P0019288

P0019289

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23-3 Fuel Feed Pump and Filter 5

Remove the fuel supply connection (1) from the engine control unit cooling coil.

Undo the fuel supply connection (2) (from the prefilter) to the engine control unit cooling coil.

Install safety plugs on all fuel connections. Use kit 88840290 Plugs.

6

Remove the cable clamps and cable ties.

7

Remove the bolts and carefully move the engine control unit aside and stow it securely.

P0019290

P0019279

P0019280

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23-3 Fuel Feed Pump and Filter 8

Undo connection (1) 'fuel OUT' to the return line.

Undo connection (2) 'Fuel OUT' to the main filter.

Install safety plugs on all fuel connections. Use kit 88840290 Plugs.

9

Remove the holder

10

Remove the control unit mounting bracket.

P0019291

P0019308

P0019282

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23-3 Fuel Feed Pump and Filter 11

Remove the delivery pipe between the high pressure pump and the common rail. Use 88840270 Wrench.

Install safety plugs on all fuel connections. Use kit 88840290 Plugs.

12

NOTICE! Do not hold the pump by the connection pipes.

P0019292

Remove the high pressure pump and its intermediate flange as one unit.

P0019293

13

Remove the O-ring and undo the nut.

P0019294

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23-3 Fuel Feed Pump and Filter 14

Use 9986172 Puller to remove the high pressure pump gearwheel.

15

Remove the intermediate flange and O-ring.

P0019295

P0019296

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23-3 Fuel Feed Pump and Filter

Installation 16

Wash the tapered joint on the shaft and the gearwheel with denatured alcohol. Clean the contact surfaces and sealing surfaces.

Fit a new O-ring (1) on the inside of the flange.

Turn the flange as illustrated and fit the high pressure pump and intermediate flange together.

Tightening torque: 24 Nm (17.7 lbf. ft.)

17

Check that the key is in the keyway.

18

Fit the gearwheel on the shaft, install the washer and the nut.

Tightening torque 65 Nm (47.9 lbf. ft.)

P0019297

P0019298

Fit a new O-ring onto the intermediate flange.

P0019299

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23-3 Fuel Feed Pump and Filter 19

Turn the gearwheel so that the mark on the gearwheel lines up with the punch mark on the intermediate flange.

See illustration.

20

Remove the plug by the flywheel.

Insert 88800014 Rotation tool.

21

Crank the flywheel until the cylinder 1 mark aligns with the mark on the flywheel housing.

P0019300

P0019303

P0019304

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23-3 Fuel Feed Pump and Filter 22

NOTICE! Do not hold the pump by the connection pipes.

Screw 88840274 Guide pin into the flywheel housing.

Make sure the gearwheel mark lines up with the punch mark.

Slide the pump in without turning the gearwheel.

P0019305

23

NOTICE! Use new bolts.

Screw in (1) without tightening.

Remove 88840274 Guide pin.

Screw in (2) without tightening.

Tighten bolts diagonally (1-2).

Tightening torque 24 Nm (17.7 lbf. ft.)

P0019306

24

Remove 88800014 Rotation tool.

Insert both plugs by the flywheel.

P0019303

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23-3 Fuel Feed Pump and Filter 25

NOTICE! Use new component.

Install a new delivery pipe between the high pressure pump and the common rail.

Adjust without tightening. Use 88840270 Wrench.

Tightening torque 37 Nm (27.3 lbf. ft.)

P0019307

26

Install the control unit mounting bracket.

27

Install the holder and the fuel lines.

P0019282

P0019308

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23-3 Fuel Feed Pump and Filter 28

Connect connection (1) 'fuel OUT' to the return line.

Connect connection (2) 'Fuel OUT' to the main filter.

29

Bolt the engine control unit in place.

30

Secure the harness with cable clamps and cable ties.

P0019309

P0019280

P0019279

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23-3 Fuel Feed Pump and Filter 31

Connect the fuel supply connection (1) from the engine control unit cooling coil.

Connect the fuel supply connection (2) (from the pre-filter) to the engine control unit cooling coil.

32

Connect the harness terminal to the MPROP valve, high pressure pump.

33

Connect the fuel connection, 'fuel IN' from the main filter.

34

Purge the fuel system according to Fuel system, bleeding page 85.

35

Turn the main switch on.

Start the engine.

Perform a leakage and function check.

P0019310

P0019311

P0019312

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23-3 Fuel Feed Pump and Filter

MPROP valve, high pressure pump, change Tools: 885812 Timing tool 88840271 Guide pin 88840290 Plugs 88890148 Torque wrench IMPORTANT! Working with the fuel system requests special cleanliness. Clean thoroughly before removal.

IMPORTANT! Install safety plugs in open connections.

CAUTION! Risk of skin damage.

CAUTION! The fuel system may be under pressure.

P0019336

When working on the fuel system, undo a closed system at the first point with caution.

Removal 1

Disconnect the MPROP valve connector, high pressure pump.

P0019275

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23-3 Fuel Feed Pump and Filter 2

IMPORTANT! Make sure no contaminants get into the component.

Mark the position.

Remove the MPROP valve.

Remove the O-ring.

P0019337

3

Install the protective plug. Use kit 88840290 Plugs.

P0019338

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23-3 Fuel Feed Pump and Filter

Installation 4

Insert 88840271 Guide pin.

Tighten by hand.

5

Lubricate a new O-ring (1) and fit it onto the oil cooler housing (2).

P0019339

NOTICE! Use a recommended oil.

P0019340

6

Install the MPROP valve.

Note the positioning.

P0019341

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23-3 Fuel Feed Pump and Filter 7

Press the MPROP valve firmly against the pump when removing the tools and installing the bolts.

Remove 88840271 Guide pin.

Install new screws. Tighten by hand and then tighten.

Tightening torque: 9 Nm (6.6 lbf. ft.)

P0019342

8

Connect the connector to the MPROP valve, high pressure pump.

9

Turn the main switch on.

Start and warm up engine.

Perform a function check.

P0019275

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23-7 Injectors and Delivery Pipes

23-7 Injectors and Delivery Pipes Injector, Change IMPORTANT! Working with the fuel system requests special cleanliness. Clean thoroughly before removal.

IMPORTANT! Install safety plugs in open connections.

CAUTION! Risk of skin damage.

CAUTION! The fuel system may be under pressure.

When working on the fuel system, undo a closed system at the first point with caution.

Tools: 9996400 Slide hammer 9998007 Adapter 88840270 Wrench 88840290 Plugs NOTICE! Turn off the main switch before any work is carried out.

NOTICE! Be prepared to gather up fluid.

Removal 1

Remove the upper valve cover according to Upper valve cover, change page 37.

2

Remove the lower valve cover according to Lower valve cover, change page 44.

3

Remove the hollow screw from the return line on the cylinder head.

4

Remove the injector delivery pipe according to Fuel Injection Pipe, Change page 128.

P0019313

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23-7 Injectors and Delivery Pipes 5

Remove the sleeves 1 -6.

6

Remove the injector delivery pipe with the aid of 9996400 Slide hammer and 9998007 Adapter.

7

Install safety plugs on all fuel connections. Use kit 88840290 Plugs.

P0019314

P0019315

P0019316

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23-7 Injectors and Delivery Pipes 8

Remove the injector yoke bolts.

9

Use a 10 mm drift/screwdriver in the yoke as a lever to prize the injector loose.

10

NOTICE! Mark the injector locations for re-installation.

P0019317

P0019318

Remove the injectors and washers.

Check that no washers remain in any of the injector wells.

Install protective plugs on all fuel unions. Use kit 88840290 Plugs.

P0019319

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23-7 Injectors and Delivery Pipes 11

Plug the hole.

Install protective plugs on all fuel unions. Use kit 88840290 Plugs.

12

Remove the washer and O-ring.

13

Repeat the same procedure on the other injectors.

P0019320

P0019321

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23-7 Injectors and Delivery Pipes

Installation NOTICE! Clean the sealing surfaces.

NOTICE! Use new components.

14

Install a new washer and O-ring.

Fit the washer and the protective plug.

NOTICE! Lightly oil the O-ring.

P0019322

15

Repeat the same procedure on the other injectors.

16

IMPORTANT! Carefully clean away combustion residue from the injector wells before installing the injectors.

Vacuum out dirt particles.

NOTICE! If the injectors are re-used, pay attention to the numbered locations on re-installation.

Install the injectors.

Position injectors so that the installation hole is turned to face the injector delivery pipe inlet channel on the high pressure pump side.

P0019323

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23-7 Injectors and Delivery Pipes 17

NOTICE! When changing an injector, a new injector code must be programmed into the control unit; refer to the appropriate Service Handbook, Group 30: Electrical System. The injector code is stamped on the unit injector.

NOTICE! Cylinder (1) is on the opposite side in relation to the engine flywheel.

In the case of new injectors, take into account the injector numbers and the corresponding cylinders.

P0019324

18

Lubricate the bolts.

Install bolts in the injector yokes.

Preload the bolts.

Tightening torque: 5 Nm (3.7 lbf. ft.)

P0019317

19

NOTICE! Use new components. O-ring and injector delivery pipe.

Lubricate and install the O-ring.

P0019325

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23-7 Injectors and Delivery Pipes 20

Repeat the same procedure on the other injector delivery pipes.

21

Align the injector delivery pipe and press in the pipe with the guide facing up until it fits all the way into its seat.

1 Lubricate the sleeve with Renolin PGK 680.

Install the sleeve.

Tightening torque: 75 Nm (55.3 lbf. ft.)

2 Undo the injector yoke bolts and tighten.

Tightening torque: 57 Nm (42.0 lbf. ft.)

P0019326

22

Check the tightening tightening torque on the sleeves.

Tightening torque: 75 Nm (55.3 lbf. ft.)

23

Tighten the injector yokes bolts.

Tightening torque: 57 Nm (42.0 lbf. ft.)

24

Install the injector delivery pipes according to Fuel Injection Pipe, Change page 128.

P0019314

P0019327

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23-7 Injectors and Delivery Pipes 25

Install the hollow screw from the return line on the cylinder head.

26

Install the the lower valve cover according to: Lower valve cover, change page 44.

27

Install the the upper valve cover according to: Upper valve cover, change page 37.

28

Bleed the fuel system according to: Fuel system, bleeding page 85.

29

Turn the main switch on.

Start the engine.

Perform a leakage and function check.

P0019328

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23-7 Injectors and Delivery Pipes

Common Rail, Change Tools: 88840270 Wrench 88840290 Plugs IMPORTANT! Working with the fuel system requests special cleanliness. Clean thoroughly before removal.

IMPORTANT! Install safety plugs in open connections.

CAUTION! Risk of skin damage.

CAUTION! The fuel system may be under pressure.

When working on the fuel system, undo a closed system at the first point with caution.

Removal 1

Undo the diagnostics panel and move it aside.

2

Disconnect the control valve connector, high pressure pump.

P0019274

P0019275

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23-7 Injectors and Delivery Pipes 3

Disconnect the pressure relief valve connector.

4

Disconnect the common rail pressure sensor.

5

Remove the fuel supply connection (1) from the engine control unit cooling coil.

Undo the fuel supply connection (2) (from the prefilter) to the engine control unit cooling coil.

Install protective plugs on all fuel unions. Use kit 88840290 Plugs.

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P0019276

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23-7 Injectors and Delivery Pipes 6

Remove the cable clamps and cable ties.

7

Remove the bolts and carefully move the engine control unit aside and stow it securely.

8

Remove the holder

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23-7 Injectors and Delivery Pipes 9

Remove the control unit mounting bracket.

10

Remove the delivery pipe between the high pressure pump and the common rail. Use 88840270 Wrench.

Install protective plugs on all fuel unions. Use kit 88840290 Plugs.

11

Remove the delivery pipes according to Fuel Injection Pipe, Change page 128.

12

Remove the common rail unit.

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P0019283

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23-7 Injectors and Delivery Pipes

Installation 13

Install the common rail unit and the bolts.

Tightening torque: 24 Nm (17.7 lbf. ft.)

14

Install the delivery pipe; refer to Fuel Injection Pipe, Change page 128.

15

NOTICE! Use new component.

P0019284

Install a new delivery pipe between the high pressure pump and the common rail.

Adjust without tightening. Use 88840270 Wrench.

Tightening torque 37 Nm (27.3 lbf. ft.)

P0019285

16

Install the control unit mounting bracket.

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23-7 Injectors and Delivery Pipes 17

Install the holder.

18

Bolt the engine control unit in place.

19

Secure the harness with cable clamps and cable ties.

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P0019280

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23-7 Injectors and Delivery Pipes 20

Connect the fuel supply connection (1) from the engine control unit cooling coil.

Connect the fuel supply connection (2) (from the pre-filter) to the engine control unit cooling coil.

21

Connect the connector to the control valve, high pressure pump.

22

Connect the connector to the common rail pressure sensor.

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P0019275

P0019276

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23-7 Injectors and Delivery Pipes 23

Connect the connector to the pressure relief valve.

24

Purge the fuel system according to Fuel system, bleeding page 85.

25

Turn the main switch on.

Start the engine.

Perform a leakage and function check.

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23-7 Injectors and Delivery Pipes

Fuel Injection Pipe, Change TAD870VE, TAD871VE, TAD872VE, TAD873VE Tools: 88840270 Wrench 88840290 Plugs IMPORTANT! Working with the fuel system requests special cleanliness. Clean thoroughly before removal.

IMPORTANT! Install safety plugs in open connections.

CAUTION! Risk of skin damage.

CAUTION! The fuel system may be under pressure.

When working on the fuel system, undo a closed system at the first point with caution.

NOTICE! Turn off the main switch before any work is carried out.

NOTICE! Be prepared to gather up fluid.

Removal 1

Undo the fuel return line connection from the common rail.

Install protective plugs on all fuel unions. Use kit 88840290 Plugs.

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23-7 Injectors and Delivery Pipes 2

Remove the attachment bolts.

3

Remove and discard the delivery pipes in the following order. 1, 2, 5, 3, 4, 6. Use 88840270 Wrench.

P0019414

Install protective plugs on all fuel unions. Use kit 88840290 Plugs.

P0019415

P0019416

Installation 4

NOTICE! Use new component.

Install in the following order. 1, 4, 5, 3, 2, 6.

Install the delivery pipes between the common rail and the injector delivery pipes.

Tighten the union nuts by hand. Check that the clamps are parallel with the bolt holes.

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23-7 Injectors and Delivery Pipes 5

Install the bolts and tighten.

6

Torque the union nuts.

Tightening torque: 37 Nm (27.3 lbf. ft.)

Use 88840270 Wrench.

7

Connect the fuel return line.

8

Purge the fuel system according to Fuel system, bleeding page 85.

9

Turn the main switch on.

Start the engine.

Perform a leakage and function check.

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P0019417

P0019418

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23-9 Miscellaneous

23-9 Miscellaneous Pressure Limiting Valve, Change IMPORTANT! Working with the fuel system requests special cleanliness. Clean thoroughly before removal.

IMPORTANT! Install safety plugs in open connections.

CAUTION! Risk of skin damage.

CAUTION! The fuel system may be under pressure.

When working on the fuel system, undo a closed system at the first point with caution.

Tools: 885812 Timing tool 88840272 Sleeve 88840290 Plugs

Removal 1

Remove the common rail unit according to Common Rail, Change page 120.

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23-9 Miscellaneous 2

Support the common rail in a vise. Use soft jaw pads in the vise.

Remove the nut. Use 88840272 Sleeve.

Remove the solenoid.

3

Clean away any paint residue.

Remove the solenoid valve.

4

Install the protective plug. Use kit 88840290 Plugs.

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23-9 Miscellaneous

Installation 5

NOTICE! Angle tightening may only be performed once.

Install a new O-ring. Use the recommended grease.

1 Install the pressure reducing solenoid valve.

Tightening torque: 20 Nm (14.8 lbf. ft.)

2 45 ±1° (use 885812 Timing tool).

3 Check the torque 65-140 Nm (47.9-103.3 lbf. ft.)

P0019360

6

IMPORTANT! The joint must be tightened correctly.

NOTICE! Observe the installation drawing.

NOTICE! Angle tightening may only be performed once.

1 Install the solenoid.

2 Install the nut. Use 88840272 Sleeve.

3 Align the marks.

4 Torque the nuts.

Tightening torque: 15 Nm (11.1 lbf. ft.)

5 13 ±0.5° Use 885812 Timing tool.

P0019361

6 Check the torque 6-21 Nm (4.4-15.5 lbf. ft.)

7

Install the common rail unit according to Common Rail, Change page 120.

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25-4 Emission Control, Catalytic Converter

25-4 Emission Control, Catalytic Converter Cooler e-EGR, change TAD570VE, TAD571VE, TAD572VE IMPORTANT! Turn off the main switch before any work is carried out.

NOTICE! Be prepared to gather up fluid.

Drain the coolant according to Coolant, Change page 195.

NOTICE! Drain the coolant until the level is below the e-EGR radiator.

Removal 1

Remove the heat shield.

2

Undo and lift up the heat shield.

Unscrew the NOx sensor.

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P0020526

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25-4 Emission Control, Catalytic Converter 3

Remove the coolant pipe outlet.

Remove the heat shield cover.

4

Remove the pipe clamp.

P0020527

1 Move aside the coolant hose.

2 Remove the coolant pipe clamping ring, inlet from the e-EGR cooler.

P0020528

5

Undo the EGR pipe connection.

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25-4 Emission Control, Catalytic Converter 6

Remove the e-EGR and gaskets.

7

Clean the sealing surfaces and inspect the seal ring.

8

Check the radiator core for visible cracks.

For radiator pressure testing, refer to 25-4, Cooler e-EGR, pressure testing.

P0020530

P0020531

NOTICE! If the radiator core is sooty with significant deposits it must be cleaned internally extremely thoroughly; refer to 25-4, Cooler eEGR, pressure testing.

Also check the EGR pipe in connection with cleaning.

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25-4 Emission Control, Catalytic Converter

Installation 9

NOTICE! Clean the sealing surfaces.

10

Install the e-EGR radiator and gaskets. Adjust the coolant pipes; insert the inlet into the e-EGR radiator.

Tightening torque: 48 Nm (35.4 lbf. ft.)

11

Install the pipe and gasket.

Tightening torque: 60 Nm (44.3 lbf. ft.)

12

Fit the pipe clamp.

P0020532

P0020529

1 Slide on the coolant outlet pipe from the eEGR cooler.

2 Slide on the coolant inlet pipe from the eEGR cooler.

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25-4 Emission Control, Catalytic Converter 13

Install the coolant line outlet.

Tightening torque: 26 Nm (19.2 lbf. ft.)

Install the heat shield cover bracket.

P0020527

14

Brush lubricant onto the threads and install the NOx sensor.

Install the heat shield.

Examples of lubricants: Permatex Anti Seize or Bostik Never-Seez.

Tightening torque: 50 Nm (36.9 lbf. ft.)

P0020526

15

Install the heat shield.

16

Fill with coolant; refer to Coolant Level, Checking and Topping Up page 193.

17

Turn the main switch on.

18

Start and warm up engine. Perform a leakage and function check.

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25-4 Emission Control, Catalytic Converter

Cooler e-EGR, change TAD870VE, TAD871VE, TAD872VE, TAD873VE IMPORTANT! Turn off the main switch before any work is carried out.

NOTICE! Be prepared to gather up fluid.

Removal 1

Remove the turbo, see Turbo, Change page 145.

2

Remove the pipe clamps.

Remove coolant hose, inlet and outlet, from cooler e-EGR.

3

Unscrew the EGR pipe connection.

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25-4 Emission Control, Catalytic Converter 4

Remove cooler e-EGR with gaskets.

5

Remove the EGR pipe.

6

Check the cooling element for visible cracks.

For cooling element pressure testing, see 25-4, Cooler e-EGR, pressure testing.

7

If the cooling element is fouled with an indicating dirt covering it must be cleaned thoroughly inside, see Cooler e-EGR, Cleaning page 143.

While cleaning, also check the EGR pipe.

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P0020087

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25-4 Emission Control, Catalytic Converter

Installation 8

NOTICE! Clean the sealing surfaces.

Install the pipe with gasket.

Tightening torque: 60 Nm (44.3 lbf. ft.)

P0020087

9

Install cooler e-EGR with gaskets.

Tightening torque: 48 Nm (35.4 lbf. ft.)

10

Screw on the EGR pipe (1).

Tightening torque: 24 Nm (17.7 lbf. ft.)

P0020088

Screw on the EGR pipe (2).

Tightening torque: 60 Nm (44.3 lbf. ft.)

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25-4 Emission Control, Catalytic Converter 11

Thread on the coolant hoses for inlet and exhaust.

12

Install the turbo, see Turbo, Change page 145.

13

Turn the main switch on.

14

Start and warm up engine. Perform a leakage and function check.

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25-4 Emission Control, Catalytic Converter

Cooler e-EGR, Cleaning Remove cooler e-EGR, according to Cooler e-EGR, change page 134.

Cleaning agent: 1 Degreasing agent (alternatively, use a paraffin fraction as a second choice).

2 Heavy duty alkaline cleaner for coarse industrial cleaning. Supposedly used in bath for degreasing of metal constructions.

Cleaning 1

Clean the e-EGR cooler by first washing through it with degreasing or recommended cleaning agent a couple of times.

2

Soak the radiator for 24 h in a suitable cleaning agent.

3

Steam clean, or rinse hot water through the cooler, in an upright position so that dirt can flow downward.

Repeat with some cleaning agent. Turning cooler on tap and rinse. Make sure the cooler is flushed through thoroughly, until clean water comes out of the cooler.

P0020091

P0020092

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25-4 Emission Control, Catalytic Converter 4

Blow dry air through the e-EGR cooler in an upright position until the cooler is dry.

5

Inspect that the cooling element is clean and free from grime and other contaminants.

6

Install cooler e-EGR, according to Cooler e-EGR, change page 134.

P0020093

P0020094

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25-5 Turbo and supercharger

25-5 Turbo and supercharger Turbocharger, Inspection 1

Check that the turbocharger part number is correct for the engine variant. The wrong turbocharger for the engine variant might not provide enough charge pressure, which would reduce engine power.

2

Check that the turbocharger has the correct compressor housing.

If the wrong compressor housing is installed on the turbocharger, the compressor wheel may be damaged or have excessive clearance between turbine wheel and housing. In both cases, charge air pressure will be too low.

3

Remove the inlet manifold from the turbocharger.

4

Check the turbocharger for damage to the compressor wheel and excessive end float on the turbine shaft.

5

If there is any damage on the compressor wheel or excessive end float on the turbine shaft, the turbocharger must be changed as a unit.

6

Remove the exhaust pipe (silencer) from the turbocharger and check the turbine wheel.

7

Inspect the turbine wheel for damage.

If the turbine wheel is damaged, the turbocharger must be changed as a unit.

Turbo, Change Always identify and correct the cause of turbocharger failure before fitting a new turbocharger. Check and rectify according to: Turbocharger, Inspection page 145.

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1

Drain the coolant according to: Coolant, Change page 195

2

Remove the exhaust pipe connection between the turbocharger and the aftertreatment system.

145

25-5 Turbo and supercharger 3

Remove the turbocharger charge air pipe.

4

Remove the intake pipe.

5

Remove the heat shield.

P0019420

P0019421

P0019422

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25-5 Turbo and supercharger 6

Remove the pipe bend (1) from the turbocharger.

Remove the rubber bellows (2) from the air intake with the connecting hose for crankcase ventilation.

7

Undo and lift up the heat shield.

Unscrew the NOx sensor.

8

NOTICE! Note the clamp position.

P0019424

P0019425

Remove the clamp (1).

Remove the attachment bracket (2).

Lift away the pre-Cat with the connection pipe.

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25-5 Turbo and supercharger 9

Disconnect the exhaust manifold pressure sensor connector.

10

Remove the exhaust pressure sensor unit.

11

Remove the heat shield.

P0019427

P0019428

P0019429

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25-5 Turbo and supercharger 12

Disconnect the turbocharger tachometer sensor (1) connector and the VGT actuator (2).

13

Remove the cable ties and the cable harness from the cable holder.

14

Remove the cable holder brackets.

P0019430

P0019431

P0019436

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25-5 Turbo and supercharger 15

Remove the coolant inlet pipe.

16

Remove the coolant outlet pipe.

17

Remove the oil return pipe with gasket.

P0019432

P0019433

P0019434

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25-5 Turbo and supercharger 18

Remove the oil supply pipe and the clamps.

19

Remove the nuts, bolts and spacers from the turbocharger.

Lift away the turbocharger.

Remove the gasket.

P0019435

P0019437

Installation 20

NOTICE! Use new sealings.

Check the sealing surface on the manifold.

Install a new gasket on the exhaust manifold.

Lift the turbocharger into position.

Install the spacer sleeves, nuts and bolts and fasten the turbocharger.

Tightening torque: Bolt (1): 44 Nm (32.5 lbf. ft.)

Nut (2): 54 Nm (39.8 lbf. ft.)

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25-5 Turbo and supercharger 21

Install the oil return pipe with new seals on the engine block and turbocharger.

Tightening torque: 24 Nm (17.7 lbf. ft.)

22

NOTICE! Use new sealings.

P0019439

Fill the turbocharger with new, clean engine oil.

Then install the oil supply pipe and clamps.

Tightening torque: 26 Nm (19.2 lbf. ft.)

P0019440

23

Install the upper coolant connection (outlet).

Tightening torque: 38 Nm (28.0 lbf. ft.)

P0019433

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25-5 Turbo and supercharger 24

install the coolant inlet pipe.

Tightening torque: 38 Nm (28.0 lbf. ft.)

25

Install the harness holder brackets.

26

Install the harness and secure it with cable ties.

P0019441

P0019436

P0019431

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25-5 Turbo and supercharger 27

Connect the turbocharger tachometer sensor (1) connector and the VGT actuator (2).

28

Install the heat shield.

29

Install the exhaust pressure sensor unit.

P0019430

P0019429

P0019428

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25-5 Turbo and supercharger 30

Connect the connector.

31

Check the sealing surface and gasket.

Lift the pre-Cat and connection pipe into position.

Install the clamp (1).

Install the unit and bracket (2).

32

Brush lubricant onto the threads and install the NOx sensor.

Examples of lubricants: Permatex: Anti seize or Bostik: never seize.

P0019427

P0019442

Tightening torque: 50 Nm (36.9 lbf. ft.)

P0019443

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25-5 Turbo and supercharger 33

Install the pipe bend (1) on the turbocharger.

Tighten the clamp.

Remove the rubber bellows (2) to the air intake with the connecting hose for crankcase ventilation.

34

Install the heat shield.

35

Connect the inlet pipe.

P0019424

P0019422

P0019421

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25-5 Turbo and supercharger 36

Install the charge air pipe.

37

Install the exhaust pipe connection between the turbocharger and the after-treatment system.

38

Fill the fresh water system according to Coolant, Change page 195.

39

Turn the main switch on.

40

Run the engine warm and perform a function check for possible leakage.

P0019420

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25-8 Emission After-Treatment

25-8 Emission After-Treatment Repair instructions NOTICE! Because the illustrations in the maintenance literature are used for different engine variants, certain details may vary compared to the actual model concerned. The essential information in the illustrations is always correct, however.

IMPORTANT! AdBlue/DEF and urea solutions cause corrosion damage. Do not remove AdBlue/DEF hoses, urea hoses or electrical wiring during normal service or when moving a component. Tools that have come into contact with AdBlue/DEF or urea solution must be cleaned.

CAUTION! Gloves must be changed. Take off contaminated clothes.

WARNING! In the case of any contact with eyes or skin the affected area must be thoroughly rinsed with lukewarm water.

If you inhale any fumes, make sure you breathe fresh air.

NOTICE! Always plug AdBlue/DEF and urea hoses in order to avoid dirt in the AdBlue/DEF system, and any crystallization of AdBlue/DEF. NOTICE! Clean the AdBlue/DEF system before any type of work is done to avoid dirt.

IMPORTANT! Fluids other than AdBlue/DEF, and that are not approved by Volvo, will cause a breakdown of the exhaust aftertreatment system.

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25-8 Emission After-Treatment

Electrically Heated AdBlue/DEF Hose, Change 1

Stop the engine.

NOTICE! Wait at least two minutes before removing the AdBlue/DEF hoses so that automatic drainage of the AdBlue/DEF system can proceed and for the AdBlue/DEF system to de-pressurize.

2

Disconnect the battery negative terminal.

3

Remove the cable tie from the AdBlue/DEF hoses and electrical cables and expose the AdBlue/DEF hose.

4

We recommend covering the connector with a plastic bag to avoid spilling AdBlue/DEF.

5

Install the new AdBlue/DEF hose and check that the connections are properly fitted and locked.

6

Connect the heater cable terminals.

7

Attach new cable ties.

P0019364

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25-8 Emission After-Treatment 8

Reconnect the battery negative terminal.

9

Switch on the ignition and allow the pump to build up pressure in the hoses. Check that no leakage occurs.

10

Perform a function test and delete any fault codes.

P0019365

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25-8 Emission After-Treatment

AdBlue/DEF Tank, Change Tools: 1158957 Pliers

Removal 1

Stop the engine.

NOTICE! Wait until the pump unit has stopped running as it usually performs automatic emptying of the AdBlue/DEF hoses.

2

Disconnect the battery negative terminal.

3

Place a receptacle underneath the tank.

NOTICE! Use approved safety equipment and receptacle.

P0019364

4

Undo the filler cap (1) and remove the drain plug (2).

Empty the AdBlue/DEF from the tank.

P0019366

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25-8 Emission After-Treatment 5

Remove the AdBlue/DEF hoses from the tank fitting and seal the connectors (A) in a plastic bag.

6

Pinch off flow in both coolant hoses (B) using 1158957 Pliers on each hose.

Remove the hoses.

P0019367

1158957

p0013226

p0013222

7

Hold the tank secure and remove the bolts.

P0019368

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25-8 Emission After-Treatment 8

Lift the tank and pull it carefully out of the locating pins on the bracket.

9

Undo the bolts and remove the stainless steel sheet.

10

Remove the bolts to the LT module and undo the hose clamp to the tank fitting.

Carefully lift the tank fitting out of the tank.

P0019369

P0019370

P0019371

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25-8 Emission After-Treatment 11

Remove the bolts.

12

Remove the bolts and hose holder.

13

Carefully prize the tank sides (1) apart and then pull out the tank (2). Be aware that the venting hose is attached.

P0019372

P0019373

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25-8 Emission After-Treatment

Installation 14

Carefully prize the tank sides (1) apart and install the new tank (2).

15

Install the bolts and hose holder.

16

Install the bolts.

P0019375

P0019373

P0019372

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25-8 Emission After-Treatment 17

Insert the tank fitting with the LT module.

18

Install the stainless steel sheet.

19

Suspend the tank module from the locating pins.

P0019376

P0019370

NOTICE! Make sure no hoses or cables get pinched.

P0019377

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25-8 Emission After-Treatment 20

Install the bolts.

21

Install the AdBlue/DEF hoses and coolant hoses.

Check that the connections are properly attached and locked.

22

Remove 1158957 Pliers.

23

Fill with AdBlue/DEF.

24

Top off coolant as necessary.

25

Reconnect the battery negative terminal.

26

Switch on the ignition and allow the pump to build up pressure in the hoses.

Check that no leakage occurs.

27

Perform a function test and delete any fault codes.

P0019368

P0019378

P0019365

IMPORTANT! Fluids other than AdBlue®/DEF, and that are not approved by Volvo, will cause a breakdown of the exhaust aftertreatment system.

NOTICE! Care for equipment and the remaining AdBlue®/DEF solution. p0013225

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167

25-8 Emission After-Treatment

AdBlue/DEF Tank, Cleaning Tools: 1158957 Pliers

CAUTION! Gloves must be changed. Take off contaminated clothes.

1

Stop the engine.

NOTICE! Wait until the pump unit has stopped running as it usually performs automatic emptying of the AdBlue/DEF hoses.

2

Disconnect the battery negative terminal.

3

Place a receptacle underneath the tank.

P0019364

NOTICE! Use approved safety equipment and receptacle.

4

Undo the filler cap (1) and remove the drain plug (2).

Empty the AdBlue/DEF from the tank.

5

Remove the AdBlue/DEF hoses from the tank fitting and seal the connectors (A) in a plastic bag.

6

Pinch off flow in both coolant hoses (B) using 1158957 Pliers on each hose.

Remove the hoses.

P0019366

P0019367

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25-8 Emission After-Treatment

1158957

p0013226

p0013222

7

Hold the tank secure and remove the bolts.

8

Support the tank and pull it carefully out of the locating pins on the bracket.

P0019368

P0019369

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25-8 Emission After-Treatment 9

Remove the bolts to the LT module and undo the hose clamp to the tank fitting.

Carefully lift the tank fitting out of the tank.

10

Flush the AdBlue/DEF line clean using hot water and clean the strainer.

P0019371

NOTICE! Always replace a damaged strainer.

P0019379

11

Remove the filler cap and undo the filler assembly.

P0019380

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25-8 Emission After-Treatment 12

Immerse the filler cap and filler assembly in a water bath for at least 2 minutes.

13

Flush the tank with hot water for at least 10 minutes.

NOTICE! Make sure that the tank is completely drained of water afterwards.

P0019381

14

Install the filler assembly.

P0019382

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25-8 Emission After-Treatment 15

Insert the tank fitting with the LT module.

16

Suspend the tank module from the locating pins.

P0019376

NOTICE! Make sure no hoses or cables get pinched.

P0019377

17

Install the bolts.

P0019368

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25-8 Emission After-Treatment 18

Install the AdBlue/DEF hoses and coolant hoses.

Check that the connections are properly attached and locked.

19

Remove the hose pinchers.

20

Fill with Adblue/DEF.

21

Top off coolant as necessary.

22

Change the AdBlue/DEF-Pump filter, see AdBlue/DEF-Pump Filter, Change page 179.

23

Reconnect the battery negative terminal.

24

Switch on the ignition and allow the pump to build up pressure in the hoses.

Check that no leakage occurs.

25

Perform a function test and delete any fault codes.

P0019378

P0019365

IMPORTANT! Fluids other than AdBlue®/DEF, and that are not approved by Volvo, will cause a breakdown of the exhaust aftertreatment system.

NOTICE! Care for equipment and the remaining AdBlue®/DEF solution. p0013225

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25-8 Emission After-Treatment

Exhaust Temperature Sensor, Change 1

Disconnect the battery negative terminal.

2

Remove the cable tie.

3

Undo the connector.

4

Undo the temperature sensor.

5

Screw in a new temperature sensor.

6

Install the connector. Attach new cable ties.

7

Reconnect the battery negative terminal.

8

Start the engine. Check for leaks; check function.

9

Delete any fault codes.

P0019364

P0019383

P0019365

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25-8 Emission After-Treatment

Dosing unit, change Removal 1

Stop the engine.

NOTICE! Wait at least two minutes before removing the AdBlue/DEF hoses so that automatic drainage of the AdBlue/DEF system can proceed and for the AdBlue/DEF system to de-pressurize.

2

Disconnect the battery negative terminal.

CAUTION! Hot surfaces can cause burns.

P0019364

3

Remove the AdBlue/DEF hoses and seal the connectors in a plastic bag.

P0019384

p0013222

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25-8 Emission After-Treatment 4

Remove the connector.

NOTICE! Make sure the connector does not become contaminated with AdBlue/DEF fluid.

P0019385

5

Remove the bolts.

6

Remove the dosing unit.

P0019386

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25-8 Emission After-Treatment

Installation 7

Clean the contact surface.

8

NOTICE! Grease the bolts with water resistant grease. E.g. 828250 Grease.

9

Install the bolts.

10

Connect the connector.

11

Install the AdBlue/DEF hoses.

P0019387

P0019388

P0019384

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25-8 Emission After-Treatment 12

Reconnect the battery negative terminal.

13

Start the engine. Check for leaks; check function.

14

Delete any fault codes.

P0019365

NOTICE! Care for equipment and the remaining AdBlue®/DEF solution.

p0013225

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25-8 Emission After-Treatment

AdBlue/DEF-Pump Filter, Change 1

Stop the engine.

NOTICE! Wait until the pump unit has stopped running as it usually performs automatic emptying of the AdBlue®/DEF hoses.

2

Disconnect the battery negative terminal.

3

Place a receptacle under the filter cover.

4

Undo the filter cover

P0019364

NOTICE! Use approved safety equipment and receptacle.

P0019389

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25-8 Emission After-Treatment 5

Use the puller (supplied with the filter kit) to pull out the filter by first pressing it into the filter hole until it clicks.

6

Pull out the filter.

7

Install the new filter (1).

Install the rubber gasket (2).

Screw on the filter cover (3).

P0019390

P0019391

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25-8 Emission After-Treatment 8

Tighten the cover.

Tightening torque: 20 (+5) Nm (14.8 +3.68 Ibf. ft.)

9

Reconnect the battery negative terminal.

10

Start the engine. Check for leaks; check function.

11

Delete any fault codes.

P0019392

P0019365

NOTICE! Care for equipment and the remaining AdBlue®/DEF solution.

p0013225

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25-8 Emission After-Treatment

Solenoid Valve, AdBlue/DEF Tank, Change Tools: 1158957 Pliers

Removal 1

Cut power to the engine by disconnecting the negative battery terminal.

2

Clamp 1158957 Pliers (A) on both coolant hoses on either side of the solenoid valves so that coolant does not run out.

P0019364

NOTICE! The hose connections are available in different designs.

A

A p0013271

3

Remove the electrical connection from the solenoid valve.

4

Remove the coolant hoses from the solenoid valve.

5

Remove the solenoid valve retaining bolts.

Remove the solenoid valve.

P0013270

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25-8 Emission After-Treatment

Installation 6

Install the solenoid valve.

Install the solenoid valve retaining bolts.

7

Install the electrical connection.

8

Install the coolant hoses. Secure them with hose clamps.

9

Remove 1158957 Pliers (A) from the coolant hoses.

10

Reconnect the battery negative terminal.

P0013270

A

A p0013271

P0019365

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25-8 Emission After-Treatment

Pump Unit, Change Removal 1

Stop the engine.

NOTICE! Wait until the pump unit has stopped running as it usually performs automatic emptying of the AdBlue/DEF hoses.

2

Disconnect the battery negative terminal.

3

Remove the harness terminal

P0019364

P0019393

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25-8 Emission After-Treatment 4

Remove the AdBlue/DEF hoses and seal the connectors in a plastic bag.

NOTICE! Use approved safety equipment.

P0019394

p0013222

5

Remove the pump unit.

NOTICE! Make sure the electrical connection does not become contaminated with AdBlue/DEF fluid.

P0019395

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25-8 Emission After-Treatment

Installation 6

Install the new pump unit and fasten it with the bolts.

7

Install the AdBlue/DEF hoses.

8

Install a new harness terminal and make sure the connection lock clicks.

P0019395

P0019394

P0019393

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25-8 Emission After-Treatment 9

Reconnect the battery negative terminal.

10

Start the engine. Check for leaks; check function.

11

Delete any fault codes.

P0019365

NOTICE! Care for equipment and the remaining AdBlue®/DEF solution.

p0013225

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25-8 Emission After-Treatment

Combined Tank Unit, AdBlue/DEF Tank, Change Tools: 1158957 Pliers

Removal 1

Stop the engine.

NOTICE! Wait until the pump unit has stopped running as it usually performs automatic emptying of the AdBlue/DEF hoses.

2

Disconnect the battery negative terminal.

P0019364

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25-8 Emission After-Treatment 3

Remove the AdBlue/DEF hoses from the tank fitting and seal the connectors (A) in a plastic bag.

4

Pinch off flow in both coolant hoses (B) using 1158957 Pliers on each hose.

Remove the hoses.

P0019367

1158957

p0013226

p0013222

5

Remove the bolts to the LT module and undo the hose clamp to the tank fitting.

Carefully lift the tank fitting out of the tank.

P0019371

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25-8 Emission After-Treatment

Installation 6

Insert the new tank fitting with the LT module.

7

Install the AdBlue/DEF hoses and coolant hoses.

Check that the connections are properly attached and locked.

8

Remove 1158957 Pliers.

9

Reconnect the battery negative terminal.

10

Switch on the ignition and allow the pump to build up pressure in the hoses.

Check that no leakage occurs.

11

Perform a function test and delete any fault codes.

P0019376

P0019378

P0019365

NOTICE! Care for equipment and the remaining AdBlue®/DEF solution.

p0013225

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25-8 Emission After-Treatment

Checking for diesel or oil in the AdBlue/DEF solution 1 Remove the insertion in the tank inlet for better visibility and access to the fluid.

P0019380

2 Dip the indicating paper in the AdBlue/DEF solution in the tank by halves.

3 Attach the indicating paper to a suitable stick to reach down to the surface.

Evaluation

• If there is diesel or oil in the fluid, the dipped part of the paper will turn dark blue.

• As small amount of diesel as down to 0,5 % can be detected.

• Most of the diesel will stay on the surface of the P0020548

AdBlue/DEF solution, but traces of diesel can be found throughout the entire tank.

• The system is very sensitive for incorrect AdBlue/DEF solution.

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25-8 Emission After-Treatment

Checking urea concentration in the fluid Tools: 88890105 Refractometer NOTICE! Rinse the test equipment carefully with distilled water before use.

1 Remove the insertion in the tank inlet for better visibility and access to the fluid.

2 Draw in a small amount of the liquid from the surface using the pipette.

Use a clean hose as extension to the pipette if tank level is low.

P0019380

3 Apply a drop on the viewer of the instrument (88890105 Refractometer).

Evaluation

• The level must be exactly on the line for correct concentration.

• The system is very sensitive for incorrect urea solution.

• If no level is shown in the instrument it may indicate chemical residue, such as pure water or diesel.

P0020549

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26-0 Cooling System, General

26-0 Cooling System, General Coolant Level, Checking and Topping Up IMPORTANT! Only use coolant recommended by Volvo Penta.

CAUTION! Avoid opening the filler cap for engine coolant system (freshwater cooled engines) when the engine is still hot. Steam or hot coolant can spray out as system pressure is lost.

NOTICE! Use suitable safety equipment when working with the system.

1

NOTICE! Only open the filler cap (1).

Do not open the pressure cap (2).

Check that the coolant level is above the MIN mark on the expansion tank.

Top up with coolant as required, so that the level is between the MIN and MAX marks.

P0019343

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26-0 Cooling System, General

Refill of completely empty system NOTICE! Mix the correct amount of coolant in advance to ensure that the cooling system is completely filled.

Refer to 03-26, Technical Data for the correct coolant volume.

IMPORTANT! Do not start the engine until the system is purged and completely filled.

NOTICE! If a heating unit is connected to the engine cooling system, the heat control valve must be opened and the installation purged during filling.

1

Check that all drain points are closed.

2

NOTICE! Only open the filler cap (1).

Do not open the pressure cap (2).

Check that the coolant level is above the MIN mark on the expansion tank.

P0019343

194

3

Start the engine when the cooling system has been completely filled and purged.

Open any venting taps a short while after starting, to allow trapped air to escape.

4

Run the engine at idle a while.

Increase engine speed to 1600-1700 rpm over three minutes.

Check the coolant level.

5

Start the engine.

Run it until it reaches operating temperature (thermostat open).

Check the coolant level. Adjust the level as required.

6

Carry out a follow-up check of the coolant level after approx 1 hour's operation.

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26-0 Cooling System, General

Coolant, Change CAUTION! Avoid opening the filler cap for engine coolant system (freshwater cooled engines) when the engine is still hot. Steam or hot coolant can spray out as system pressure is lost.

NOTICE! Use suitable safety equipment when working with the system.

NOTICE! Be prepared to gather up fluid.

Tools: 9996049 Draining hose 1

NOTICE! Do not open the pressure cap (2).

Remove the filler cap (1).

P0019343

2

Open all drain points.

NOTICE! There may be other taps or plugs at the lowest points of the coolant system

3

Connect 9996049 Draining hose.

Connect a drainage vessel.

Empty the radiator.

P0019344

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26-0 Cooling System, General 4

Connect 9996049 Draining hose.

Connect a drainage vessel.

Drain the engine block.

Check that all coolant drains out.

5

Remove the tool.

Close any taps.

6

Refill with new, Volvo Penta-recommended cooling fluid.

Refer to 03-26, Technical Data and Coolant Level, Checking and Topping Up page 193.

P0019345

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26-1 Radiator, Heat Exchanger

26-1 Radiator, Heat Exchanger Radiator Assembly, Change Removal IMPORTANT! Turn off the main switch before any work is carried out.

1

Drain the coolant, according to: Coolant, Change page 195.

2

Remove the the turbo pressure pipe (1) for outgoing charge air.

Remove the coolant hose (2), coolant outlet to the radiator.

Remove the hose (3) between the radiator and expansion tank.

3

Remove the right belt guard.

Remove the right fan protection.

P0019573

P0019574

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197

26-1 Radiator, Heat Exchanger 4

Remove the charge air pipe (1) from the charge air cooler and pipe elbow.

Remove the filler hose (2) between the expansion tank and coolant inlet coolant pipe.

5

Remove the left belt guard.

Remove the left fan protection.

Remove the pipe elbow.

6

Remove the hose between the expansion tank and thermostat housing side cover.

Remove the connector to coolant level sensor, expansion tank.

P0019575

P0019576

P0019577

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26-1 Radiator, Heat Exchanger 7

Loosen the fan ring.

Remove the coolant hose, coolant inlet (from the radiator).

Loosen the upper radiator stay.

8

Connect the radiator to a hoisting device. Loosen the lower bracket.

9

Release the cooler for further work.

Remove the fan ring.

P0019578

P0019579

P0019580

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26-1 Radiator, Heat Exchanger

Installation 10

Thread the fan ring over the fan.

Align the radiator over the frame and upper bracket.

11

Bolt on the radiator at the top and at the bottom bracket.

12

Fit the fan ring.

Install the coolant hose, coolant inlet (from the radiator).

P0019580

P0019581

P0019582

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26-1 Radiator, Heat Exchanger 13

Install the hose between the expansion tank and thermostat housing side cover.

Connect the connector to coolant level sensor, expansion tank.

14

Install the left belt guard.

Fit the left fan protection.

Install the pipe elbow.

15

Install the charge air pipe (1) from the charge air cooler and pipe elbow.

Install the filler hose (2) between the expansion tank and coolant inlet coolant pipe.

P0019577

P0019576

P0019575

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26-1 Radiator, Heat Exchanger 16

Install the right belt guard.

Fit the right fan protection.

17

Install the the turbo pressure pipe (1) for outgoing charge air.

Install the coolant hose (2), coolant outlet to the radiator.

Install the hose (3) between the radiator and expansion tank.

18

Refill with new, Volvo Penta recommended cooling fluid. Refer to 03-26, Technical Data and Coolant Level, Checking and Topping Up page 193.

19

Turn the main switch on.

P0019574

P0019573

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26-2 Coolant Pump, Thermostat

26-2 Coolant Pump, Thermostat Coolant Pump, Change IMPORTANT! Turn off the main switch before any work is carried out.

There are different procedures for access point at replacement of the component dependent on which cooling system that is connected.

Removal NOTICE! Be prepared to gather up fluid.

1

Drain the coolant, according to: Coolant, Change page 195.

2

Remove the radiator hoses and charge air connections.

Remove belt guard and fan guard, see Radiator Assembly, Change page 197.

3

IMPORTANT! Do not allow the visco coupling to lay flat for more than a moment. Oil may run out which will mean that the coupling must be changed.

4

Disconnect the sensor harness from to the engine harness.

Remove the sensor bracket from the engine console.

P0019589

P0019590

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26-2 Coolant Pump, Thermostat 5

NOTICE! Left hand thread.

Unscrew the visco coupling with the fan.

P0019591

6

Remove the hose connection (1) from the coolant pipe. (Warm-circuit fluid from the turbo, cooler eEGR).

Remove the hose (2). (Connection hose to the expansion tank).

7

Remove the the connection pipe for the crankcase ventilation.

Remove the cable ties.

Remove the electrical connection from the preheater element.

P0019592

P0019593

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26-2 Coolant Pump, Thermostat 8

Disconnect the harness terminal.

Remove the cable ties.

Open the cover of the pre-heating relay. Remove the input nut.

Remove the engine attachment.

9

Remove the pre-heating relay.

10

Remove the clamps.

Loosen the harness.

Remove the screws.

Remove the support.

P0019594

P0019595

P0019596

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26-2 Coolant Pump, Thermostat 11

Remove the thermostat housing.

12

Remove the gaskets.

13

Remove the breather pipe from the separator.

P0019597

P0019598

P0019599

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26-2 Coolant Pump, Thermostat 14

Release the belt tensioner and lock it in place with a drift.

Remove the drive belt.

Check the function of the tensioner, the condition of the pulleys and the idler wheel bearings.

15

Remove the fan adapter and the coolant pump pulley.

16

NOTICE! Be prepared to gather up fluid.

P0019600

P0019601

Loosen the drain plug.

Drain the coolant pump.

P0019602

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26-2 Coolant Pump, Thermostat 17

Remove the coolant pump.

Remove the gaskets.

P0019603

Installation 18

NOTICE! Clean the sealing surfaces.

19

NOTICE! Clean the sealing surfaces.

P0019604

NOTICE! When remounting the existing component.

P0019605

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26-2 Coolant Pump, Thermostat 20

Install new gaskets.

21

Install the coolant pump; first guide in the coolant pump "neck" and O-ring.

22

Tighten the screws in numerical order according to the picture.

P0019606

P0019607

Stage 1 Stage 2 Stage 3

Screw in 1-8 without tightening.

Tightening torque, screw (A): 24 Nm (17.7 lb. ft.)

Tightening torque, screw 1-8: 48 Nm (35.4 lb. ft.)

P0019608

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26-2 Coolant Pump, Thermostat 23

NOTICE! When remounting the existing component.

Tighten the plug.

P0019609

24

Install the fan adapter and the coolant pump pulley. Tighten the screws crosswise.

25

Fit the belt.

Release the belt tensioner and the drift.

Check that the belt is properly aligned in the groove and correct on all pulleys.

P0019610

P0019611

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26-2 Coolant Pump, Thermostat 26

Install the breather pipe between the separator and the pipe connection.

27

NOTICE! Clean the sealing surfaces.

28

Install new gaskets.

Lubricate the o-ring.

P0019599

P0019612

P0019613

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26-2 Coolant Pump, Thermostat 29

Install the thermostat housing.

Tighten the screws crosswise.

30

Install the support.

Install the screws. Tighten the screws.

Position the harness.

Install the clamps.

31

Install the pre-heating relay.

P0019597

P0019614

P0019595

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26-2 Coolant Pump, Thermostat 32

Install the engine attachment.

Install the cable to the input nut.

Close the cover to the pre-heating relay.

Fasten with cable ties.

Connect the harness terminal.

33

Fit the the connection pipe for the crankcase ventilation.

Install the electrical connection from the preheater element.

Fasten with cable ties.

34

Install the hose connection (1) to the coolant pipe.

Install the hose (2).

P0019615

P0019616

P0019617

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26-2 Coolant Pump, Thermostat 35

Lift the fan and carefully offer the coupling onto the engine attachment.

NOTICE! Left hand thread.

Rotate the fan slowly clockwise (viewed as illustrated) so that the threads grip. Rotate the fan until the threads bottom and tighten so that the coupling grips the adapter.

Tightening torque: 150 Nm (110.6 lbf. ft.)

P0019618

36

Install the sensor bracket from the engine console.

Connect the sensor harness to the engine harness and secure them with a cable tie.

37

Refit the radiator hoses and charge air connections.

Install belt guard and fan guard, see Radiator Assembly, Change page 197.

38

Fill with coolant; refer to: Coolant, Change page 195.

39

Turn the main switch on.

Start the engine. Check that no leakage occurs.

P0019590

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26-2 Coolant Pump, Thermostat

Thermostat, Change Removal NOTICE! Be prepared to gather up fluid.

1

Drain off coolant sufficient for its level to drop below the thermostat housing, refer to Coolant, Change page 195.

2

Disconnect the hose from the radiator.

3

Remove the connection for the crankcase breather from the valve cover.

P0019521

P0019483

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26-2 Coolant Pump, Thermostat 4

Loosen the hose between the expansion tank and thermostat housing.

5

Remove the thermostat housing cover.

Remove the thermostat.

6

Clean the mating surfaces of the thermostat housing.

P0019522

P0019523

P0019524

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26-2 Coolant Pump, Thermostat

Installation 7

Install a new thermostat.

Install the thermostat housing cover.

Tightening sequence: Diagonal

P0019525

8

Install the hose between the expansion tank and thermostat housing.

9

Connect the hose to the radiator.

P0019522

P0019521

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26-2 Coolant Pump, Thermostat 10

Fit the connection for the crankcase breather to the valve cover.

11

Top up with coolant; refer to Coolant Level, Checking and Topping Up page 193.

12

Check that no leakage occurs.

P0019483

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26-2 Coolant Pump, Thermostat

Drive Belt, Change Right belt guard removed; refer to Belt protector, change page 220.

Removal CAUTION! Pinch hazard. Keep fingers clear.

1

Unfasten the belt tensioner and restrain it with a drift.

2

Remove the belt.

3

Check the function of the tensioner and the condition of the pulleys and the idler pulley bearings.

P0019255

Installation 4

Install the belt.

5

Release the belt tensioner and remove the drift.

6

Check that the belt is correctly aligned on all the pulleys.

7

Install the belt guard; refer to Belt protector, change page 220.

P0019256

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26-2 Coolant Pump, Thermostat

Belt protector, change Right belt guard Removal 1

Remove the belt guard.

Installation 2

Install the belt guard.

P0019257

Left belt guard Removal 1

Remove the belt guard.

Installation 2

Install the belt guard.

P0019258

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32-1 Alternator

32-1 Alternator Alternator, Change Removal NOTICE! Turn off the main switch before any work is carried out.

1

Remove components 1-5; refer to Turbo, Change page 145 1 Remove the turbocharger charge air pipe.

2 Remove the intake pipe.

3 Remove the heat shield.

4 Remove the pipe elbow from the turbocharger.

5 Remove the rubber bellows from the air intake with the connecting hose for crankcase ventilation.

P0019406

2

Remove the right belt guard; refer to Belt protector, change page 220.

3

Remove the drive belt according to Drive Belt, Change page 219.

4

Disconnect the alternator cable terminals.

P0019407

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221

32-1 Alternator 5

Disconnect the connector.

6

Remove the alternator.

P0019408

P0019409

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32-1 Alternator

Installation 7

Install the alternator.

Tighten the two attachment bolts and nuts.

Tightening torque: Upper attachment bolt (1), 48 Nm (35.4 lbf. ft.)

Lower attachment bolt (2), 85 Nm (62.7 lbf. ft.)

P0019410

8

Connect the connector.

9

Install the alternator cable connections.

P0019408

Tightening torque: Negative terminal (1), 10 Nm (7.4 lbf. ft.)

Positive terminal (2), 12 Nm (8.9 lbf. ft.)

P0019411

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32-1 Alternator 10

Install the drive belt according to Drive Belt, Change page 219

11

Install the right belt guard: refer to Belt protector, change page 220.

12

Install components 1-5; refer to Turbo, Change page 145.

1 Install the rubber bellows on the air intake with the connecting hose to the crankcase ventilation.

2 Install the pipe elbow on the turbocharger.

3 Install the heat shield.

4 Install the inlet pipe.

5 Install the charge air pipe.

P0019412

13

224

Turn the main switch on.

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32-1 Alternator

Pulley, alternator, change Removal 1

Remove the drive belt. / Alternator removed.

2

Clean the nut and the alternator shaft.

3

Using a marker pen, mark the position of the nut in relation to the alternator shaft.

4

Undo the nut with a few short bursts from an impact wrench.

Remove the belt pulley.

P0020358

P0020359

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32-1 Alternator

Installation 5

Clean thread locker away from the threads with a brush.

6

Install the pulley and first screw on the nut by hand.

Select the tightening alternative that corresponds to the specified torque: Alternative 1 Use a few short bursts from an impact wrench until the marks are aligned.

Alternative 2 Use a torque limiting socket Alternative 3 (M17) Angle tighten the nut 40 degrees.

Tightening torque: M16: 95 Nm (70 lbf. ft.)

P0020360

M17: 118 Nm (87 lbf. ft.)

7

The markings must be aligned.

8

Install the alternator.

Fit the drive belt.

P0020358

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33-1 Starter Motor

33-1 Starter Motor Starter Motor, Change IMPORTANT! Turn off the main switch before any work is carried out.

Removal 1

Unscrew the nut from starter plus terminal.

Fold aside cable (1) from the main power switch (+), generator cable (2) and cable split / fuse holder (3).

2

Disconnect the connector.

P0020346

P0020347

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33-1 Starter Motor 3

Remove the starter motor.

P0020348

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33-1 Starter Motor

Installation 4

Clean the contact surface on the flywheel housing.

5

Fasten the start motor.

6

Connect the connector.

7

Connect the cables 1-3 to the starter motor.

Tightening torque: 18 Nm (13.3 lbf. ft.)

P0020348

P0020350

Secure the cables with cable ties after performed installation.

P0020349

8

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Turn the main switch on.

229

Alphabetical index A About this Workshop manual..................................... 2 AdBlue/DEF Tank, Change.................................... 161 AdBlue/DEF Tank, Cleaning.................................. 168 AdBlue/DEF-Pump Filter, Change......................... 179 Alternator................................................................ 221 Alternator, Change................................................. 221

I Illustrations................................................................. 5 Injector, Change..................................................... 112 Injectors and Delivery Pipes................................... 112

B Belt protector, change............................................ 220

M Miscellaneous......................................................... 131 MPROP valve, high pressure pump, change......... 108

C Checking for diesel or oil in the AdBlue/DEF solution................................................................... 191 Checking urea concentration in the fluid................ 192 Combined Tank Unit, AdBlue/DEF Tank, Change. 188 Common Rail, Change........................................... 120 Coolant Level, Checking and Topping Up.............. 193 Coolant Pump, Change.......................................... 203 Coolant Pump, Thermostat.................................... 203 Coolant, Change.................................................... 195 Cooler e-EGR, change................................... 134, 139 Cooler e-EGR, Cleaning......................................... 143 Cooling System, General....................................... 193 Crank Mechanism.................................................... 63 Crankshaft Seal, Change (front)............................... 64 Crankshaft Seal, Change (rear)............................... 69 Cylinder Head........................................................... 37 D Dosing unit, change................................................ 175 Drive Belt, Change................................................. 219 E Electrically Heated AdBlue/DEF Hose, Change..... 159 Emission After-Treatment....................................... 158 Emission Control, Catalytic Converter.................... 134 Exhaust Temperature Sensor, Change.................. 174 F Flywheel, Change..................................................... 59 Fuel Feed Pump and Filter....................................... 86 Fuel filter housing, change....................................... 93 Fuel filter, Change.................................................... 90 Fuel Injection Pipe, Change................................... 128 Fuel pre-filter, bleeding............................................. 89 Fuel Pre-filter, Change............................................. 86 Fuel system, bleeding.............................................. 85 Fuel System, General............................................... 85

L Lower valve cover, change................................. 44, 47 Lubrication System................................................... 30

O Oil Cooler, Replace.................................................. 82 Oil filter..................................................................... 73 Oil Filter Housing, Change....................................... 76 Oil filter, Change....................................................... 73 P Pressure Limiting Valve, Change........................... 131 Pulley, alternator, change....................................... 225 Pump Unit, Change................................................ 184 R Radiator Assembly, Change .................................. 197 Radiator, Heat Exchanger...................................... 197 Repair instructions.............................................. 3, 158 S Safety Instructions.................................................... 31 Solenoid Valve, AdBlue/DEF Tank, Change.......... 182 Special Service Tools............................................... 35 Special Tightening Torques........................................ 9 Specifications, Engine ............................................... 8 Starter Motor.......................................................... 227 Starter Motor, Change............................................ 227 T Thermostat, Change............................................... 215 Timing Gears and Shaft........................................... 59 Turbo and supercharger......................................... 145 Turbo, Change....................................................... 145 Turbocharger, Inspection....................................... 145 U Upper valve cover, change................................. 37, 41 V Valve Mechanism..................................................... 51 Valves, Adjustment................................................... 51

G Gear Ring, Fywheel: Replace.................................. 63 General....................................................................... 2 General Tightening Torques....................................... 8 Group 21: Engine....................................................... 9 Group 22: Lubrication System............................ 17, 30 Group 23: Fuel System............................................ 20 Group 25: Inlet and Exhaust System........................ 24 Group 26: Cooling System....................................... 26 Group 30: Electrical System..................................... 28 H High Pressure Pump, Change.................................. 96

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References to Service Bulletins Group No.

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Refers to

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