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Workshop Manual


Group 21-26General Information00-0 General 3Certified enginesWhen carrying out service and repair on emis- sion-certified engines, it is important to be aware of the following:IMPORTANT!Introduction! WARNING!Our mutual responsibilityTightening torquesTorque, angle tighteningLock nutsStrength classesSealing compounds etc.RTV preparations (Room Temperature Vulcaniz- ing).Anaerobic agents.Safety regulations for fluorocarbon rubberWARNING!WARNING!Please note that seals which have not been exposed to high temperature can be handled nor- mally.Illustration colorsPositionMovementToolsTools (continuence)ChemicalsCleanlinessSealantUnitsImportantSafetyFanIMPORTANT!03-2 Specifications, EngineGeneral Tightening TorquesSpecial Tightening Torques Group 21: EngineGroup 22: Lubrication SystemGroup 23: Fuel SystemGroup 25: Inlet and Exhaust SystemLocation of SensorsGroup 26: Cooling SystemEngine, GeneralTechnical Data Engine bodyValve mechanismEngine TransmissionCrank MechanismLubrication SystemFuel SystemInlet and Exhaust SystemCooling System03-3 Specifications, ElectricalSteering System05-1 Safety InstructionsSafety Information08-2 Special Service Tools9996398 Manometer 1678297 Spacer 9991801 Standard handle9988539 Compression meter 9990006 Puller 9990013 Slide hammer9990124 Nipple 9990166 Mounting tool 9990185 Lifting tool9990192 Puller 9992000 Handle 9993590 Rotation tool9996666 Nipple 9998007 Adapter 9998248 Adapter9998249 Protective sleeve 9998251 Protection plug 9998339 Manometer9986173 Puller 9998599 Cleaning kit 9999179 Extractor oil filter9998250 Sealing ring 88800387 Puller 9998493 Hose88800196 Drift 88890102 Nipple 88890104 Pump9992955 Plate 88800031 Measuring tool 9998598 Sleeve9998264 Lifting tool 885810 Fixture 9998601 Fixture9998531 Piston ring compres- sor88800127 Drift 88800147 Drift 9992670 Hand pump88800058 Stand 9990174 Drift 9998246 Drift9990210 Valve spring com- pressor9998267 Guide sleeve 9992269 Drift 9990263 Nipple88890105 Refractometer 88800460 Sleeve885510 Plugs 885633 Torque multiplier 1159794 Torque wrench885648 Counterhold 885812 Timing tool 885822 Magnetic pen9998511 Lever 9999696 Magnetic stand 9989876 Dial indicator9999683 Dial indicator (short probe)885811 Timing tool 1158957 PliersSymptoms and possible causesCommon Interference CausesCompression TestFuel Feed Pressure, CheckCooling System, Pressure TestingCharge Pressure, TroubleshootingCharge Air Cooler, External CleaningCharge Air Pipe, Leakage CheckTurbocharger, InspectionSensors, AdjustmentThermostat, Function Check21-0 Engine Complete, GeneralExposing the EngineFitting the FixtureEngine DisassemblyEngine Assembly21-1 Cylinder HeadCylinder Head, RemovalCylinder Head, Installation21-3 Cylinder Liner, PistonsCylinder Liner and Pistons, InspectionConnecting Rod, CheckConnecting Rod Bushing, Check up21-4 Valve MechanismValves and Unit Injectors, AdjustmentStandard valve mechanismValve mechanism equipped with VCB (Volvo Compression Brake)Valve mechanism equipped with Internal EGR (Exhaust Gas Recirculation)Valve Guides, InspectionValve Guides, ReplacingValves, RemovalValves, InstallationValve Seats and Valve, GrindingValve Seat, ChangeValve Stem Sealings, Replace21-5 Timing Gears and ShaftCamshaft, Wear CheckCamshaft Bearing Housing, ReplaceFlywheel, IndicationGear Ring, Fywheel: ReplaceSensors, Adjustment21-6 Crank MechanismCrankshaft Seal, Change (front)Crankshaft Seal, Change (rear)Crankshaft, InspectionMain bearing, Change22-1 Oil pump and LineLubrication Oil Pump, Change22-2 Oil filterOil Pressure Sensor, CheckOil Filter Bracket, ChangeSafety Valve, Oil Pressure, ReplaceBypass Valve, Oil Filter Bypass, Replace22-3 Oil coolerOil Cooler, ReplaceThermostat Oil Cooler, Change23-0 Fuel System, GeneralFuel system, bleedingDraining, Fuel Duct in Cylinder Head23-3 Fuel Feed Pump and FilterFuel Feed Pressure, CheckFuel filter housing, changeFuel Feed Pump, Change23-7 Injectors and Delivery PipesUnit Injector, ReplaceSleeve for unit injector, replace23-8 Control System, ECM, Data SetsControl Unit, Replace25-0 Inlet and Exhaust System, GeneralCharge Air Pipe, Leakage Check25-1 Inlet and Exhaust ManifoldsIntake Manifold, Change25-4 Emission Control, Catalytic ConverterControl valve e-EGR, changeEGR mixing chamber, change25-5 Turbo and superchargerTurbocharger, InspectionTurbo, Change25-6 Air Cleaner, Throttle HousingAir throttle, change25-8 Emission After-TreatmentRepair instructionsElectrically Heated AdBlue/DEF Hose, ChangeAdBlue/DEF Tank, ChangeAdBlue/DEF Tank, ChangeAdBlue/DEF Tank, CleaningAdBlue/DEF Tank, CleaningExhaust Temperature Sensor, ChangeDosing unit, changeAdBlue/DEF-Pump Filter, ChangeAdBlue/DEF-Pump Filter, ChangePressure Sensor, ChangePump Unit, ChangePump Unit, ChangeCombined Tank Unit, AdBlue/DEF Tank, ChangeCombined Tank Unit, AdBlue/DEF Tank, ChangeTemperature Sensor, ChangeChecking for diesel or oil in the AdBlue/DEF solutionChecking urea concentration in the fluid26-0 Cooling System, GeneralDraining the Cooling SystemCooling System, CleaningCoolant Level, Checking and Topping UpCooling System, Pressure Testing26-2 Coolant Pump, ThermostatCoolant Pump, ChangeThermostat, ChangeThermostat, ChangeDrive BeltsBelt Tensioner, ChangeThermostat, Function CheckCoolant Filter, Change26-3 Fan, Fan ShroudBelt Protector32-1 AlternatorAlternator Belt, ChangeBelt Tensioner, ChangeReferences to Service Bulletins

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