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Group 21-26
General Information
00-0 General 3
Certified engines
When carrying out service and repair on emis- sion-certified engines, it is important to be aware of the following:
IMPORTANT!
Introduction
! WARNING!
Our mutual responsibility
Tightening torques
Torque, angle tightening
Lock nuts
Strength classes
Sealing compounds etc.
RTV preparations (Room Temperature Vulcaniz- ing).
Anaerobic agents.
Safety regulations for fluorocarbon rubber
WARNING!
WARNING!
Please note that seals which have not been exposed to high temperature can be handled nor- mally.
Illustration colors
Position
Movement
Tools
Tools (continuence)
Chemicals
Cleanliness
Sealant
Units
Important
Safety
Fan
IMPORTANT!
03-2 Specifications, Engine
General Tightening Torques
Special Tightening Torques Group 21: Engine
Group 22: Lubrication System
Group 23: Fuel System
Group 25: Inlet and Exhaust System
Location of Sensors
Group 26: Cooling System
Engine, General
Technical Data Engine body
Valve mechanism
Engine Transmission
Crank Mechanism
Lubrication System
Fuel System
Inlet and Exhaust System
Cooling System
03-3 Specifications, Electrical
Steering System
05-1 Safety Instructions
Safety Information
08-2 Special Service Tools
9996398 Manometer 1678297 Spacer 9991801 Standard handle
9988539 Compression meter 9990006 Puller 9990013 Slide hammer
9990124 Nipple 9990166 Mounting tool 9990185 Lifting tool
9990192 Puller 9992000 Handle 9993590 Rotation tool
9996666 Nipple 9998007 Adapter 9998248 Adapter
9998249 Protective sleeve 9998251 Protection plug 9998339 Manometer
9986173 Puller 9998599 Cleaning kit 9999179 Extractor oil filter
9998250 Sealing ring 88800387 Puller 9998493 Hose
88800196 Drift 88890102 Nipple 88890104 Pump
9992955 Plate 88800031 Measuring tool 9998598 Sleeve
9998264 Lifting tool 885810 Fixture 9998601 Fixture
9998531 Piston ring compres- sor
88800127 Drift 88800147 Drift 9992670 Hand pump
88800058 Stand 9990174 Drift 9998246 Drift
9990210 Valve spring com- pressor
9998267 Guide sleeve 9992269 Drift 9990263 Nipple
88890105 Refractometer 88800460 Sleeve
885510 Plugs 885633 Torque multiplier 1159794 Torque wrench
885648 Counterhold 885812 Timing tool 885822 Magnetic pen
9998511 Lever 9999696 Magnetic stand 9989876 Dial indicator
9999683 Dial indicator (short probe)
885811 Timing tool 1158957 Pliers
Symptoms and possible causes
Common Interference Causes
Compression Test
Fuel Feed Pressure, Check
Cooling System, Pressure Testing
Charge Pressure, Troubleshooting
Charge Air Cooler, External Cleaning
Charge Air Pipe, Leakage Check
Turbocharger, Inspection
Sensors, Adjustment
Thermostat, Function Check
21-0 Engine Complete, General
Exposing the Engine
Fitting the Fixture
Engine Disassembly
Engine Assembly
21-1 Cylinder Head
Cylinder Head, Removal
Cylinder Head, Installation
21-3 Cylinder Liner, Pistons
Cylinder Liner and Pistons, Inspection
Connecting Rod, Check
Connecting Rod Bushing, Check up
21-4 Valve Mechanism
Valves and Unit Injectors, Adjustment
Standard valve mechanism
Valve mechanism equipped with VCB (Volvo Compression Brake)
Valve mechanism equipped with Internal EGR (Exhaust Gas Recirculation)
Valve Guides, Inspection
Valve Guides, Replacing
Valves, Removal
Valves, Installation
Valve Seats and Valve, Grinding
Valve Seat, Change
Valve Stem Sealings, Replace
21-5 Timing Gears and Shaft
Camshaft, Wear Check
Camshaft Bearing Housing, Replace
Flywheel, Indication
Gear Ring, Fywheel: Replace
Sensors, Adjustment
21-6 Crank Mechanism
Crankshaft Seal, Change (front)
Crankshaft Seal, Change (rear)
Crankshaft, Inspection
Main bearing, Change
22-1 Oil pump and Line
Lubrication Oil Pump, Change
22-2 Oil filter
Oil Pressure Sensor, Check
Oil Filter Bracket, Change
Safety Valve, Oil Pressure, Replace
Bypass Valve, Oil Filter Bypass, Replace
22-3 Oil cooler
Oil Cooler, Replace
Thermostat Oil Cooler, Change
23-0 Fuel System, General
Fuel system, bleeding
Draining, Fuel Duct in Cylinder Head
23-3 Fuel Feed Pump and Filter
Fuel Feed Pressure, Check
Fuel filter housing, change
Fuel Feed Pump, Change
23-7 Injectors and Delivery Pipes
Unit Injector, Replace
Sleeve for unit injector, replace
23-8 Control System, ECM, Data Sets
Control Unit, Replace
25-0 Inlet and Exhaust System, General
Charge Air Pipe, Leakage Check
25-1 Inlet and Exhaust Manifolds
Intake Manifold, Change
25-4 Emission Control, Catalytic Converter
Control valve e-EGR, change
EGR mixing chamber, change
25-5 Turbo and supercharger
Turbocharger, Inspection
Turbo, Change
25-6 Air Cleaner, Throttle Housing
Air throttle, change
25-8 Emission After-Treatment
Repair instructions
Electrically Heated AdBlue/DEF Hose, Change
AdBlue/DEF Tank, Change
AdBlue/DEF Tank, Change
AdBlue/DEF Tank, Cleaning
AdBlue/DEF Tank, Cleaning
Exhaust Temperature Sensor, Change
Dosing unit, change
AdBlue/DEF-Pump Filter, Change
AdBlue/DEF-Pump Filter, Change
Pressure Sensor, Change
Pump Unit, Change
Pump Unit, Change
Combined Tank Unit, AdBlue/DEF Tank, Change
Combined Tank Unit, AdBlue/DEF Tank, Change
Temperature Sensor, Change
Checking for diesel or oil in the AdBlue/DEF solution
Checking urea concentration in the fluid
26-0 Cooling System, General
Draining the Cooling System
Cooling System, Cleaning
Coolant Level, Checking and Topping Up
Cooling System, Pressure Testing
26-2 Coolant Pump, Thermostat
Coolant Pump, Change
Thermostat, Change
Thermostat, Change
Drive Belts
Belt Tensioner, Change
Thermostat, Function Check
Coolant Filter, Change
26-3 Fan, Fan Shroud
Belt Protector
32-1 Alternator
Alternator Belt, Change
Belt Tensioner, Change
References to Service Bulletins
×
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Next >
Workshop Manual
Group 21-26
General Information
00-0 General 3
Certified engines
When carrying out service and repair on emis- sion-certified engines, it is important to be aware of the following:
IMPORTANT!
Introduction
! WARNING!
Our mutual responsibility
Tightening torques
Torque, angle tightening
Lock nuts
Strength classes
Sealing compounds etc.
RTV preparations (Room Temperature Vulcaniz- ing).
Anaerobic agents.
Safety regulations for fluorocarbon rubber
WARNING!
WARNING!
Please note that seals which have not been exposed to high temperature can be handled nor- mally.
Illustration colors
Position
Movement
Tools
Tools (continuence)
Chemicals
Cleanliness
Sealant
Units
Important
Safety
Fan
IMPORTANT!
03-2 Specifications, Engine
General Tightening Torques
Special Tightening Torques Group 21: Engine
Group 22: Lubrication System
Group 23: Fuel System
Group 25: Inlet and Exhaust System
Location of Sensors
Group 26: Cooling System
Engine, General
Technical Data Engine body
Valve mechanism
Engine Transmission
Crank Mechanism
Lubrication System
Fuel System
Inlet and Exhaust System
Cooling System
03-3 Specifications, Electrical
Steering System
05-1 Safety Instructions
Safety Information
08-2 Special Service Tools
9996398 Manometer 1678297 Spacer 9991801 Standard handle
9988539 Compression meter 9990006 Puller 9990013 Slide hammer
9990124 Nipple 9990166 Mounting tool 9990185 Lifting tool
9990192 Puller 9992000 Handle 9993590 Rotation tool
9996666 Nipple 9998007 Adapter 9998248 Adapter
9998249 Protective sleeve 9998251 Protection plug 9998339 Manometer
9986173 Puller 9998599 Cleaning kit 9999179 Extractor oil filter
9998250 Sealing ring 88800387 Puller 9998493 Hose
88800196 Drift 88890102 Nipple 88890104 Pump
9992955 Plate 88800031 Measuring tool 9998598 Sleeve
9998264 Lifting tool 885810 Fixture 9998601 Fixture
9998531 Piston ring compres- sor
88800127 Drift 88800147 Drift 9992670 Hand pump
88800058 Stand 9990174 Drift 9998246 Drift
9990210 Valve spring com- pressor
9998267 Guide sleeve 9992269 Drift 9990263 Nipple
88890105 Refractometer 88800460 Sleeve
885510 Plugs 885633 Torque multiplier 1159794 Torque wrench
885648 Counterhold 885812 Timing tool 885822 Magnetic pen
9998511 Lever 9999696 Magnetic stand 9989876 Dial indicator
9999683 Dial indicator (short probe)
885811 Timing tool 1158957 Pliers
Symptoms and possible causes
Common Interference Causes
Compression Test
Fuel Feed Pressure, Check
Cooling System, Pressure Testing
Charge Pressure, Troubleshooting
Charge Air Cooler, External Cleaning
Charge Air Pipe, Leakage Check
Turbocharger, Inspection
Sensors, Adjustment
Thermostat, Function Check
21-0 Engine Complete, General
Exposing the Engine
Fitting the Fixture
Engine Disassembly
Engine Assembly
21-1 Cylinder Head
Cylinder Head, Removal
Cylinder Head, Installation
21-3 Cylinder Liner, Pistons
Cylinder Liner and Pistons, Inspection
Connecting Rod, Check
Connecting Rod Bushing, Check up
21-4 Valve Mechanism
Valves and Unit Injectors, Adjustment
Standard valve mechanism
Valve mechanism equipped with VCB (Volvo Compression Brake)
Valve mechanism equipped with Internal EGR (Exhaust Gas Recirculation)
Valve Guides, Inspection
Valve Guides, Replacing
Valves, Removal
Valves, Installation
Valve Seats and Valve, Grinding
Valve Seat, Change
Valve Stem Sealings, Replace
21-5 Timing Gears and Shaft
Camshaft, Wear Check
Camshaft Bearing Housing, Replace
Flywheel, Indication
Gear Ring, Fywheel: Replace
Sensors, Adjustment
21-6 Crank Mechanism
Crankshaft Seal, Change (front)
Crankshaft Seal, Change (rear)
Crankshaft, Inspection
Main bearing, Change
22-1 Oil pump and Line
Lubrication Oil Pump, Change
22-2 Oil filter
Oil Pressure Sensor, Check
Oil Filter Bracket, Change
Safety Valve, Oil Pressure, Replace
Bypass Valve, Oil Filter Bypass, Replace
22-3 Oil cooler
Oil Cooler, Replace
Thermostat Oil Cooler, Change
23-0 Fuel System, General
Fuel system, bleeding
Draining, Fuel Duct in Cylinder Head
23-3 Fuel Feed Pump and Filter
Fuel Feed Pressure, Check
Fuel filter housing, change
Fuel Feed Pump, Change
23-7 Injectors and Delivery Pipes
Unit Injector, Replace
Sleeve for unit injector, replace
23-8 Control System, ECM, Data Sets
Control Unit, Replace
25-0 Inlet and Exhaust System, General
Charge Air Pipe, Leakage Check
25-1 Inlet and Exhaust Manifolds
Intake Manifold, Change
25-4 Emission Control, Catalytic Converter
Control valve e-EGR, change
EGR mixing chamber, change
25-5 Turbo and supercharger
Turbocharger, Inspection
Turbo, Change
25-6 Air Cleaner, Throttle Housing
Air throttle, change
25-8 Emission After-Treatment
Repair instructions
Electrically Heated AdBlue/DEF Hose, Change
AdBlue/DEF Tank, Change
AdBlue/DEF Tank, Change
AdBlue/DEF Tank, Cleaning
AdBlue/DEF Tank, Cleaning
Exhaust Temperature Sensor, Change
Dosing unit, change
AdBlue/DEF-Pump Filter, Change
AdBlue/DEF-Pump Filter, Change
Pressure Sensor, Change
Pump Unit, Change
Pump Unit, Change
Combined Tank Unit, AdBlue/DEF Tank, Change
Combined Tank Unit, AdBlue/DEF Tank, Change
Temperature Sensor, Change
Checking for diesel or oil in the AdBlue/DEF solution
Checking urea concentration in the fluid
26-0 Cooling System, General
Draining the Cooling System
Cooling System, Cleaning
Coolant Level, Checking and Topping Up
Cooling System, Pressure Testing
26-2 Coolant Pump, Thermostat
Coolant Pump, Change
Thermostat, Change
Thermostat, Change
Drive Belts
Belt Tensioner, Change
Thermostat, Function Check
Coolant Filter, Change
26-3 Fan, Fan Shroud
Belt Protector
32-1 Alternator
Alternator Belt, Change
Belt Tensioner, Change
References to Service Bulletins
Next >
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