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Group 21-26
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5(0)ContentGeneral InformationCertified enginesIntroductionOur mutual responsibilityTightening torquesTorque, angle tighteningLock nutsStrength classesSealing compounds etc.Safety regulations for fluorocarbon rubberWARNING!WARNING!Illustration colorsPositionMovementToolsTools (continuence)ChemicalsCleanlinessSealantUnitsImportantSafetyGeneral Tightening TorquesSpecial Tightening TorquesGroup 22: Lubrication SystemGroup 23: Fuel SystemGroup 25: Inlet and Exhaust SystemGroup 26: Cooling SystemTechnical Data Engine bodyValve mechanismEngine TransmissionCrank MechanismLubrication SystemTechnical DataFuel SystemTechnical DataInlet and Exhaust SystemTechnical DataCooling SystemTechnical Data03-3 Specifications, ElectricalSensorCharge air pressure sensorCamshaft sensorFlywheel sensorPressure drop indicatorCharge air temperature sensorCoolant temperature sensor Engine oil temperature sensor05-1 Safety InstructionsSafety InformationA compilation of safety precautions that must be taken and risks which must be paid attention to is presented in the following pages.08-2 Special Service Tools885810 Fixture 9809726 Pneumatic hydraulic pump9809729 Hydraulic cylinder9986173 Puller 9986179 Puller 9990006 Puller9990118 Cone 9990123 Pressure testing kit 9990124 Nipple9990125 Nipple 9990143 Fixture 9990156 Adapter9990157 Press tool 9990158 Piston ring com- pressor9990160 Fixture9990164 Fixture 9990165 Guide sleeve 9990166 Mounting tool9990174 Drift 9990176 Press tool 9990185 Lifting tool9990192 Puller 9990210 Valve spring com- pressor9991801 Standard handle9992000 Handle 9992269 Drift 9992479 Holder for dial indi- cator9992670 Hand pump 9992873 Nipple 9993590 Rotation tool9996394 Support 9996395 Support 9996398 Manometer9996400 Slide hammer 9996441 Cover, with connect-9996645 Puller9996662 Pressure testing kit 9996666 Nipple 9996845 Screw clamp9996963 Plate 9998246 Drift 9998248 Adapter9998249 Protective sleeve 9998250 Sealing ring 9998251 Protection plug9998487 Sleeve 9998494 Hose 9998502 Hose9998511 Lever 9998517 Adjustment tool 9998599 Cleaning kit88800003 Fixture 88800021 Drift 88800064 Drift88800196 Drift 88800123 Plate 88800127 Drift88800147 Drift 88800151 Drift 88800191 Extractor88890105 Refractometer885531 Pressure testing kit 885633 Torque multiplier 885648 Counterhold885811 Timing tool 885812 Timing tool 1159794 Torque wrench9986485 Stand 9988539 Compression meter 9989876 Dial indicator9999683 Dial indicator (short probe)88800083 Piston ring pliers 88890102 Nipple 88890104 Pump31 4 5 2Placement of Instrument Socket(s)Location of SensorsElectrical ComponentsAdBlue/DEF tank heatingSchematic connection stand-by AdBlue/DEF heating system using an independent heater system Hotstart CSM 10302 for a standby heating system or similar.IMPORTANT!Symptoms and possible causesFunctional DisturbancesCloggingSuitable actions External cleaning:Internal cleaning:Further checksCharge Pressure, TroubleshootingCharge Air Pressure, CheckPressure drop indicator, checkExhaust system, inspectionCharge air cooler, checksInlet manifold, checksCharge air pipes, checksCharge Air Cooler, External CleaningIMPORTANT!Test and AdjustmentsCompression TestCooling System, Pressure TestingCylinder Head, Pressure TestingCharge Air Pipe, Leakage CheckTurbocharger, InspectionWastegate Valve, AdjustmentDrive Belt and Alternator Belt, InspectionSensors, AdjustmentThermostat, Function Check21-0 Engine Complete, GeneralReplacement of Components Group 21: EngineClean the cylinder liners carefully before inspec- tion and measurement.PistonsCylinder Liner and Pistons, Replace (all)Tools:Cylinder head, oil pan, bracing frame and piston cooling nozzles removed.IMPORTANT!InstallationCrankshaft, InspectionThe crankshaft is induction hardened.IMPORTANT!Main bearing, ChangeOil pan removedTools:InstallationBig end bearing, Change (all)Oil pan, oil suction pipe and bracing frame removed.IMPORTANT!InstallationFlywheel Bearing, ChangeTools:Flywheel, ChangeTools:Gear Ring, Fywheel: ReplaceFlywheel removed.Flywheel, IndicationPressure plate removed.Tools:Crankshaft Seal, Change (front)Option 1 Tools:Option 2 Tools:Removal, alternative 2999 6400InstallationCrankshaft Seal, Change (rear)Tools:IMPORTANT!InstallationConnecting Rod, CheckImportant consideration when removing/installing fracture-split connecting rods.IMPORTANT!Connecting Rod Bushing, Check up3 IMPORTANT!Valves, RemovalAlternative 1Tools:Alternative 2Alternative 2Valves, InstallationAlternative 1 Tools:Alternative 2IMPORTANT!Alternative 2Valve Seat, ChangeCylinder head and valves removed.IMPORTANT!IMPORTANT!Valve Guides, InspectionValve Guides, ReplacingCylinder head removed.Option 1 Tools:Optional tools Tools:999 2670980 9729InstallationCAUTION!RemovalInstallationValve Seats and Valve, GrindingValve seat, grindingValves, grindingValve Stem Sealings, ReplaceTools:InstallationCylinder Head, Pressure TestingSleeve for unit injector, replaceUnit injector removed999 85808880019688800196888001969998250Camshaft, Wear CheckRocker bridge removedAcceptable wear: Unacceptable wear:Camshaft Bearing Housing, ReplaceTiming Gear, ReplaceValve cover, cable harness, upper timing gear cover, camshaft sensor, oil pan, and oil pump removed.WARNING!ExposingExposingHeat ProtectionFitting the FixtureEngine Fixture, InstallationEngine Fixture, InstallationEngine DisassemblyCylinder Head, RemovalTiming Gear, RemovalPistons, RemovalCrankshaft, RemovalCrankshaft, InstallationCylinder Liner, InstallationPiston, Pre-installationPistons, InstallationPiston Cooling Jet, InstallationTiming Gear, InstallationCylinder Head, InstallationCamshaft, InstallationFlank Clearance, AdjustmentUnit injector, InstallationAdjustment MarkingsEngine Assembly21-4 Valve Mechanism5Timing marksStandard valve mechanismValve mechanism equipped with VCB (Volvo Compression Brake)Valve mechanism equipped with Internal EGR (Exhaust Gas Recirculation)Tools:Valve mechanism equipped with VCB (Volvo Compression Brake)Valves and Unit Injectors, AdjustmentValves and Unit Injectors, AdjustmentValve Guides, InspectionTools:Cylinder head removedIMPORTANT!999 969622-0 Lubricating and Oil System, GeneralWhen you work with Chemicals, Fuel and Lubrication Oil, Change! CAUTION!Overview Control Valve22-1 Oil pump and LineLubrication Oil Pump, ChangeOil Pump, Check22-2 Oil filterRelief Valve, ReplaceBypass Valve, Oil Filter Bypass, ReplaceSafety Valve, Oil Pressure, ReplacePiston Cooling Valves, ReplaceBypass Valve Oil Filter, ChangeOil Filter, CheckOil Pressure Sensor, CheckTools:Engine oil and engine oil filter, changingTools:Relief Valve, CheckSafety Valve, Check22-3 Oil coolerOil Cooler, ReplaceRemovalInstallationOil Cooler, Pressure Testing999 6845Bypass Valve, Oil Cooler, Replace23-0 Fuel System, GeneralFuel system, bleedingFuel system, bleedingDraining, Fuel Duct in Cylinder HeadIMPORTANT!IMPORTANT!23-3 Fuel Feed Pump and FilterEngine Fuel Filter ReplacementIMPORTANT!! WARNING!Fuel Feed Pump, ChangeRemovalInstallationFuel Pre-filter, Change23-7 Injectors and Delivery PipesUnit Injector, ReplaceTools:InstallationSleeve for unit injector, replaceTools:IMPORTANT!6 Alternative 17 Alternative 2IMPORTANT!999 8580IMPORTANT!IMPORTANT!IMPORTANT!888001968880019688800196999825023-8 Control System, ECM, Data SetsEngine Control Unit (ECU), Replace! WARNING!25-0 Inlet and Exhaust System, GeneralCharge Air Pipe, Leakage Check25-2 Exhaust Pipe, SilencerExhaust Pipe (Y-pipe), ReplaceRemovalInstallation25-5 Turbo and superchargerTurbocharger, InspectionTurbo, ChangeRemovalVariants with single turboInstallationVariants with single turboIMPORTANT!Low Pressure Turbo, ChangeRemovalLow Pressure Turbo Variants with twin turboInstallationLow Pressure Turbo Variants with twin turboIMPORTANT!High Pressure Turbo, ChangeRemovalHigh Pressure Turbo Variants with twin turbo22XInstallationHigh Pressure Turbo Variants with twin turboIMPORTANT!1Wastegate Valve, ReplaceRemovalInstallation25-8 Emission After-TreatmentRepair instructionsIMPORTANT!WARNING!Electrically Heated AdBlue/DEF Hose, ChangeAdBlue/DEF Tank, ChangeTools:1158957IMPORTANT!AdBlue/DEF Tank, ChangeTools:1158957InstallationAdBlue/DEF Tank, CleaningCAUTION!AdBlue/DEF Tank, CleaningTools:1158957IMPORTANT!Exhaust Temperature Sensor, ChangeDosing unit, changeRemovalCAUTION!InstallationAdBlue/DEF-Pump Filter, ChangeTools:AdBlue/DEF-Pump Filter, ChangeTightening torque: 20 (+5) Nm (14.8 +3.68 Ibf. ft.)ATools:AInstallationPressure Sensor, ChangeTools:IMPORTANT!BPump Unit, Change1 1IMPORTANT!IMPORTANT!Pump Unit, ChangeRemovalInstallationCombined Tank Unit, AdBlue/DEF Tank, ChangeCombined Tank Unit, AdBlue/DEF Tank, ChangeTools:1158957InstallationTemperature Sensor, ChangeTools:IMPORTANT!BChecking for diesel or oil in the AdBlue/DEF solutionEvaluationChecking urea concentration in the fluidTools:Evaluation26-0 Cooling System, GeneralDraining the Cooling SystemWARNING!Cooling System, CleaningWARNING!Coolant Level, Checking and Topping UpWARNING!Coolant Level, Checking and Topping UpFilling a completely empty systemTWD enginesCooling System, Pressure TestingTools:26-1 Radiator, Heat ExchangerRadiator Assembly, ChangeRemovalInstallation26-2 Coolant Pump, ThermostatCoolant Pump, ChangeRemovalInstallationThermostat, ChangeTools:InstallationDrive Belt, ChangeDrive Belt, ChangeBelt Tensioner, ChangeRemovalInstallationThermostat, Function CheckCoolant Filter, ChangeIMPORTANT!26-5 Charge Air Cooler with ConnectionsLower Charge Air Cooler, Replace6 5 36 5 3Upper Charge Air Cooler, ReplaceRemovalIMPORTANT!Installation32-1 AlternatorAlternator Belt, ChangeRemovalCAUTION!InstallationCAUTION!Alternator Belt, ChangeIMPORTANT!33-1 Starter MotorStarter Motor, ChangeRemovalInstallationReferences to Service Bulletins