Volvo EPA2007 D13F Reference Manual
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Volvo EPA2007 D13F Reference Manual

Volvo EPA2007 D13F Reference Manual

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Quick
Reference
Guide
EPA2007 D13F Engine
PV776-QRG07-D13F
© Volvo Group North America, Inc. 2009
November 2009
Printed in U.S.A.
v
Quick
Reference
Guide
EPA2007 D13F Engine
PV776-QRG07-D13F
November 2009

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  • Page 1 Quick Quick Reference Reference Guide Guide EPA2007 D13F Engine EPA2007 D13F Engine PV776-QRG07-D13F © Volvo Group North America, Inc. 2009 PV776-QRG07-D13F November 2009 Printed in U.S.A. November 2009...

  • Page 3: Table Of Contents

    Contents GENERAL INFORMATION ..................1 Specifications .........................1 Safety Information .....................1 Service Procedures and Tool Usage................2 About the Volvo D13F Engine...................4 D13F Engine Model Identification ................6 Service At a Glance ....................7 Service Precautions Summary ...................9 Engine Serial Number Identification ...............10 SPECIFICATIONS......................11 Engine Specification ....................11 Tightening Torques and Patterns..................16...
  • Page 4 Oil Flow Control and Filtration ................91 Crankcase Ventilation ....................93 Fuel System......................95 Fuel Filtration ......................97 Unit Injectors ......................98 Volvo Engine Brake ....................101 Exhaust Gas Recirculation System ................104 EGR Valve ......................105 EGR Valve Function ....................105 EGR Cooler Inlet Pipe ...................106 EGR Cooler......................107 EGR Venturi System ....................107...
  • Page 5 Valve and Unit Injector Adjustment ................159 General Information....................160 Inlet Valve Adjustment ..................161 Unit Injector Adjustment ..................162 Exhaust Valve Adjustment (WITHOUT Volvo Engine Brake) ......163 Exhaust Valve Adjustment (WITH Volvo Engine Brake) ........164 Continuation of Adjustments .................167 Operational Check ....................168 Glossary ........................169...
  • Page 6 Active Regeneration....................169 Aftertreatment Fuel Injector (AFI) ................169 Ash .........................169 Atmospheric Pressure Sensor ................169 Carbon Monoxide (CO) ..................169 Catalyst ........................169 Combustion Air Temperature and Humidity Sensor ..........169 Compressor Discharge Temperature Sensor ............170 Cooled Exhaust Gas Recirculation (CEGR) ............170 Cordierite .......................170 Diesel Particulate Matter..................170 Differential Pressure Sensors .................170 Discharge Recirculation Valve (DRV)..............170 Electronic Unit Injector (EUI) ................171...

  • Page 7: General Information 1

    GENERAL INFORMATION 1 Specifications Safety Information Advisory Labels Cautionary signal words (Danger-Warning-Caution) may appear in various locations throughout this manual. Information accented by one of these signal words must be observed to minimize the risk of personal injury to service personnel, or the possibility of improper service methods which may damage the vehicle or cause it to be unsafe.

  • Page 8: Service Procedures And Tool Usage

    2 GENERAL INFORMATION Service Procedures and Tool Usage Anyone using a service procedure or tool not recommended in this manual must first satisfy himself thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects. Individuals deviating in any manner from the instructions provided assume all risks of consequential personal injury or damage to equipment involved.
  • Page 9 Before towing the vehicle, place the transmission in neutral and lift the rear wheels off the ground, or disconnect the driveline to avoid damage to the transmission during towing. Volvo Trucks, Inc. cannot anticipate every possible occurrence that may involve a potential hazard. Accidents can be avoided by recognizing potentially hazardous situations and taking necessary precautions.

  • Page 10: About The Volvo D13F Engine

    Recirculation (EGR) system, a Exhaust Aftertreatment System which includes a Diesel Particulate Filter (DPF) and the Holset Variable Geometry Turbocharger (VGT). The Volvo Engine Brake is optional. The engine conforms to year 2007 Environmental Protection Agency (EPA) requirements. The D13F EGR system features reduced restriction plus enhanced efficiency and reliability.
  • Page 11 Unique colors and the appearance of the valve cover, filters and logo labels distinguish the D13F from other engines in the Volvo line. Preventive maintenance is important to get the most from the Volvo D13F engine and to ensure many years of reliable, trouble-free operation.

  • Page 12: D13F Engine Model Identification

    6 GENERAL INFORMATION D13F Engine Model Identification Engine Information Plate W2033292 The engine information plate is located on the top of the cylinder head (valve) cover. This plate includes information in English and French concerning the following items. • Engine family, model and serial number •...

  • Page 13: Service At A Glance

    GENERAL INFORMATION 7 Service At a Glance Operating Conditions Highway Vocational Miles / KM / Months / Hours (whichever comes first) BASIC SERVICE Engine oil and Filter Change 30,000 Miles / 48,000 15,000 Miles / 24,000 EO – O premium Plus or VDS-4 KM or 500 Hours 90 days or 300 hours Chassis Lubrication...
  • Page 14 60,000 Miles / 96,000 KM KM or 2000 Hours or 1200 Hours Genuine Volvo Filters are strongly recommended. *Certain chassis vocations may require more frequent service intervals. Alter the maintenance programs to meet your needs, but never exceed Volvo recommended intervals.

  • Page 15: Service Precautions Summary

    GENERAL INFORMATION 9 Service Precautions Summary Following is a summary list of the DO and Don’t issues applying to D13F engine service: 1 DO NOT machine the cylinder head for clean-up since this will change injector depth, thereby affecting emission. It will also upset the ability to correctly adjust timing gear backlash.

  • Page 16: Engine Serial Number Identification

    10 GENERAL INFORMATION Engine Serial Number Identification W2033586 In addition to the engine information plate on the cylinder head cover, the engine is also identified by the engine serial number stamped into the cylinder block. This serial number is located on the block left side at the front just below the inlet manifold.

  • Page 17: Specifications 11

    SPECIFICATIONS 11 Engine Specification Weights and Dimensions Item Specification Engine type In-line direct injection diesel Number of cylinders Displacement 13 L Swept volume 12.78 L Cylinder bore and stroke 131 x 158 mm (5.16 x 6.22 inches) Emissions level EPA 07 (2.5g NOx; 0.1g Pt) maximum Fuel system Electronic unit injector Valve actuation...
  • Page 18 12 SPECIFICATIONS Engine Performance Specification Horsepower Torque Engine @RPM @RPM (Maximum) Designation D13F335 250 kW 1400 – 1700 1830 Nm 1100 (335 hp) (1350 ft-lb) D13F375 280 kW 1400 – 1700 1966 Nm 1100 (375 hp) (1450 ft-lb) D13F405 302 kW 1500 –...
  • Page 19 SPECIFICATIONS 13 Component Features and Materials Item Description Air compressor Flange mounted, oil lubricated, water cooled Camshaft Induction hardened, gear driven Coolant conditioner Spin-on type, disposable Connecting rods Forged steel, cracked cap design Crankshaft Drop forged steel, induction hardened, seven main bearings Cylinder block In-line six cylinder, nodular iron, machined with bearing caps, stiffener...
  • Page 20 14 SPECIFICATIONS Component Features and Materials Item Description Fuel injection Six individually programmed unit injectors: EECU controlled; common fuel gallery in head; constant supply pressure; over-pressure return Fuel supply pump Gear type pump integral with power steering pump; idler gear driven Lubrication system Crankshaft gear driven oil pump;...
  • Page 21 SPECIFICATIONS 15 Component Features and Materials Item Description Turbocharger Variable geometry type: Holset; exhaust driven; fixed vanes; sliding ring nozzle; infinitely variable volume; oil and water cooled Valve lifters Roller followers Valve seat inserts Pressed in head; replaceable Vibration damper Internal fluid-filled ring Coolant pump Centrifugal rotor impeller;...

  • Page 22: Tightening Torques And Patterns

    16 SPECIFICATIONS Tightening Torques and Patterns Sensors and Wiring Harness CAUTION Overtorquing a sensor or sensor mounting screw can result in sensor breakage or thread damage Sensors Air Pressure / Temperature, Inlet 3.3 N.m (29 lb-in) Manifold Camshaft Position 8 ± 2 N.m (6 ± 1 lb-ft) Coolant Level (surge tank) Plug-in Coolant Temperature (front, right side of...
  • Page 23 SPECIFICATIONS 17 General Tightening Torques M6 standard bolt 8.8 10 ± 1.5 Nm (7.4 ± 1 ft-lb) (89 ± 13 in-lb) M8 standard bolt 8.8 24 ± 4 Nm (18 ± 3 ft-lb) M10 standard bolt 8.8 48 ± 8 Nm (35 ± 6 ft-lb) M12 standard bolt 8.8 85 ±...
  • Page 24 18 SPECIFICATIONS General Tightening Torques Rear engine mounting Bracket to flywheel housing 300 ± 45 Nm (221 ± 33 ft-lb) Bracket to engine cushion 540 ± 90 Nm (398 ± 66 ft-lb) Cushion to frame 200 ± 30 Nm (148 ± 24 ft-lb) Crankshaft main bearing cap Step 1 150 ±...
  • Page 25 SPECIFICATIONS 19 Engine Stiffening Frame T2022728 Step 1: Tighten the bolts 1-24 in numerical order ....40 ± 5 Nm (30 ± 4 ft-lb) Step 2: Tighten the bolts 1-24 in numerical order (angle tightening) ..90 ± 5 degrees Note: These bolts should not be reused. T2022337 Note: Apply sealant outside the groove as illustrated, maximum 20 minutes before mounting.
  • Page 26 20 SPECIFICATIONS Timing Gear Gasket W2005945 Do not reuse mounting plate screws. Do NOT apply sealant to new, coated screws. Timing gear plate, tighten in sequence shown 28 ± 4 Nm (21 ± 3 ft-lb)
  • Page 27 SPECIFICATIONS 21 Timing Gears W2006478 1. Drive gear, crankshaft............24 ± 4 Nm (18 ± 3 ft-lb) 2. Double idler gear: Step 1 ..................25 ± 3 Nm (19 ± 2 ft-lb) Step 2 (angle tightening)................ 110 ± 5 degrees Note: Tighten following the order shown in the illustration. 3.
  • Page 28 22 SPECIFICATIONS Flywheel Housing W2032456 T2025683 Step 1: Tighten all M14, M10, M8 bolts ........24 ± 4 Nm (18 ± 3 ft-lb) Step 2: Tighten all bolts in numerical order to the following torque: M14 bolts (1–7) ..............140 ± 20 Nm (103 ± 15 ft-lb) M10 bolts (8–11)...............48 ±...
  • Page 29 SPECIFICATIONS 23 Timing Gear Cover T2023649 W2032454 Step 1: Position the cover in place with bolts 1 and 2 and install alignment tool. Step 2: Tighten the bolts in the numerical order shown...24 ± 4 Nm (18 ± 3 ft-lb) Note: Apply sealant in a 2 mm (0.079 inch) thick bead, maximum 20 minutes before mounting, and carefully tighten the contact surfaces shown in the enlarged parts of the illustration.
  • Page 30 24 SPECIFICATIONS Flywheel T2022729 Step 1 ..................60 ± 5 Nm (44 ± 4 ft-lb) Step 2 (angle tightening)..............120 ± 10 degrees Note: Make sure the flange is dry and clean. Tighten the bolts in the numerical order as shown. Mark the head of each screw after installation. Discard screws with four marks when removed and replace with newscrews.
  • Page 31 SPECIFICATIONS 25 Cover, Crankshaft Sseal W2032696 Step 1. Position the cover with bolts 1and 2 and tighten to contact Step 2: Tighten the bolts in numerical order 1–8 as shown..24 ± 4 Nm (18 ± 3 ft-lb) Note: Apply sealant in a 2 mm (0.079 inch) thick bead as illustrated and tighten bolts in numerical order.
  • Page 32 26 SPECIFICATIONS Front Engine Support W2032697 Step 1. Tighten in order: 1, 2, 3, 4, 5 and 6. 275 ±45 Nm (203 ± 33 lb-ft) Step 2. Verify in the same order. 275 ±45 Nm (203 ± 33 lb-ft) Front Engine Support Mounting Bracket W2032698 Torque Sequence...
  • Page 33 SPECIFICATIONS 27 Crankshaft Vibration Damper T2022730 Step 1 ..................35 ± 5 Nm (26 ± 4 ft-lb) Step 2 ..................90 ± 10 Nm (66 ± 7 ft-lb) Note: Tighten the bolts in the numerical order 1, 2 ,3, 4, 5, 6, 1. The vibration damper 8.8 bolts should not be reused.
  • Page 34 28 SPECIFICATIONS Cylinder Head T2022734 Step 1 ..................100 ± 5 Nm (74 ± 4 ft-lb) Step 2 (angle tightening)................ 120 ± 5 degrees Step 3 (angle tightening)................90 ± 5 degrees Note: The cylinder head must be mounted according to instructions, see Cylinder Head, Replacement.
  • Page 35 SPECIFICATIONS 29 Bearing Cap, Camshaft/Rocker Arm Shaft T2022796...
  • Page 36 Step 8: Angle tighten the bolts of bearing caps 1 to 6 and the bolt of bearing cap 7 ......................120 ± 5 degrees Note: When only the rocker arm has been loosened, step 1 and step 3 are not required. Volvo Engine Brake control valve ..........24 ± 4 Nm (18 ± 3 ft-lb)
  • Page 37 Locknut, valve adjustment screw (inlet/exhaust) .....38 ± 4 Nm (28 ± 3 ft-lb) or, angle tighten after contact..............60 ± 5 degrees Locknut, Valve Adjustment Screw (Volvo Engine Brake) T2022966 Locknut, valve adjustment screw (exhaust, VEB)....38 ± 4 Nm (28 ± 3 ft-lb) or, angle tighten after contact.............30 +1.5 -0 degrees...
  • Page 38 32 SPECIFICATIONS Locknut, Volvo Engine Brake Rocker Arm W2005946 Locknut, Volvo Engine Brake rocker arm ........52 ± 4 Nm (38 ± 3 ft-lb) or, angle tighten after contact..............45 ± 5 degrees...
  • Page 39 SPECIFICATIONS 33 Camshaft bearing Cap T2022951 Camshaft bearing cap spring tab (Volvo Engine Brake only) ......... 25 ± 3 Nm (18 ± 2 ft-lb)
  • Page 40 34 SPECIFICATIONS Valve Cover W2032521 Install two alignment pins and bushings in the head before assembling the valve cover. Note: Tighten the bolts in the numerical order shown, .24 ± 4 Nm (18 ± 3 ft-lb) Oil pump, pickup tube ..............24 ± 4 Nm (18 ± 3 ft-lb) Oil filter housing ...............24 ±...
  • Page 41 SPECIFICATIONS 35 Oil Pan T2023838 Oil pan (steel and plastic) ............24 ± 4 Nm (18 ± 3 ft-lb) Install the oil pan bolts A and B, and tighten......24 ± 4 Nm (18 ± 3 ft-lb) Tighten the bolts from the middle and outwards in order 1–4 as shown..24 ± 4 Nm (18 ±...
  • Page 42 36 SPECIFICATIONS Additional Bottom Of Engine Components Lube Valve Housing Attaching Screws (4) Hand start all, then tighten to 48 ± 8 Nm (35 ± 6 lb-ft) Crankshaft Bearing Caps Discard screws with four marks when removed and substitute new screws. Step 1.
  • Page 43 SPECIFICATIONS 37 Oil cooler, retaining bolts T2022733 Step 1 ..................5 ± 1 Nm (44 ± 9 in-lb) Step 2 ..................27 ± 4 Nm (20 ± 3 ft-lb) Note: Tighten the bolts diagonally and finish by tightening the first bolt again. Oil cooler cover T2023837 Position the cover to the engine block and install bolt (A) into the oval hole.
  • Page 44 38 SPECIFICATIONS Retainer, Unit Injector T2022208 Retainer, unit injector: This tightening method is for a unit injector with a sealing washer. First tightening: Step 1 .................20 +5/-0 Nm (15 +4/-0 ft-lb) Step 2. Angle tightening ................ 180 ± 5 degrees Loosen until the torque is 10–15 Nm (7–11 ft-lb).
  • Page 45 SPECIFICATIONS 39 Locknut, Unit Injector Adjusting Screw T2022967 Locknut, unit injector adjusting screw........52 ± 4 Nm (38 ± 3 ft-lb) or, angle tighten after contact..............45 ± 5 degrees...
  • Page 46 40 SPECIFICATIONS Low Pressure Fuel Circuit Fuel line fittings: Filter Housing Attaching Screws, M8 x 1.25 24 ± 4 N.m (18 ± 3 lb-ft) 1....................18 ± 3 Nm (13 ± 2 ft-lb) 2.....................28 ± 4 Nm (20.5 ± 3 ft-lb) 3.
  • Page 47 SPECIFICATIONS 41 Additional Left-Side Engine Components Alternator Mounting Bracket Attaching Screws, 48 ± 8 Nm (35 ± 6 lb-ft) Pad Mount Attaching Screws, M12 85 ± 15 Nm (63 ± 11 lb-ft) Attaching Screws, Tension Idler Roller 48 ± 8 Nm (35 ± 6 lb-ft) Pulley Nuts 101 ±...
  • Page 48 42 SPECIFICATIONS Aftertreatment Fuel Supply Line W2005926 1. Aftertreatment Fuel Injector, fuel 15 ± 0.5 Nm (135 ± 5 in-lb) supply line 2. Mounting Bolts 14 Nm (125 in-lb) 3. Two-Way Check Valve 15 Nm (135 in-lb) 4. Air Line 27 Nm (235 in-lb)
  • Page 49 SPECIFICATIONS 43 Intake manifold W2032557 Tighten the bolts diagonally from the 24 ± 4 Nm (18 ± 3 ft-lb) center outward.
  • Page 50 44 SPECIFICATIONS Exhaust Manifold W2032457 Use anti-seize compound on contact surface of nuts, bolts and screws when reassembled exhaust system components Step 1. All screws 5 ± 1.5 Nm (3.5 ± 1 lb-ft) Step 2. Tighten bolts 1, 4, 5, 8, 9, 12 in 5 ±...
  • Page 51 SPECIFICATIONS 45 Coolant Pump W2005979 Coolant pump (Note: Tighten in sequence 24 ± 4 Nm (18 ± 3 ft-lb) twice) Coolant pump pulley 24 ± 4 Nm (18 ± 3 ft-lb) Coolant pump housing 48 ± 8 Nm (35 ± 6 ft-lb) Front and side cover, thermostat housing 24 ±...
  • Page 52 46 SPECIFICATIONS Tighten Torques front of Engine Starter motor mounting nuts Delco 85 ± 15 Nm (63 ± 11 ft-lb) Melco 60 ± 6 Nm (44 ± 5 ft-lb) Starter cables (Bat+, E-) Delco 26 ± 1.5 Nm (19 ± 1 ft-lb) Melco 25 ±...

  • Page 53: Engine Component Torque Specifications (Critical Fasteners)

    SPECIFICATIONS 47 Engine Component Torque Specifications (Critical Fasteners) Note: All components are to be clean and free from foreign material or corrosion. Assemblies are to be made using suitable tools and procedures so that no permanent damage will occur as a result of the assembly. Threads, washers, under head of screws and washer face of nuts should be lubricated with clean engine oil unless otherwise specified.
  • Page 54 48 SPECIFICATIONS Fastener Reuse (cont’d.) Fssteners Example Reusable Reusable Recommendation Limit Tur- Stainless steel studs 5 times If turbocharger or the exhaust and flange locknuts bocharger manifold is replaced, also replace (Spiralock) the studs and nuts. Prevailing torque Piston 5 times feature screws cooling (Dri-Loc Plastic...
  • Page 55 SPECIFICATIONS 49 W2005481 Bolt Head Punch Marks CAUTION Bolts for the following components may be reused four times only. The heads of these bolts must be marked with a punch (A) after each use. When re-using bolts, the bolt head and threads must be lubricated with clean engine oil.Do not lubricate new bolts as they are already lubricated.

  • Page 56: Gasket And Seal Reuse

    50 SPECIFICATIONS Gasket and Seal Reuse Gasket and Seal Reuse Example Reuse Recom- Components Reusable Limit mendations Gaskets (steel) Cylinder head Do not reuse Discard the old gasket and substitute new if the head is removed. Do not reuse Gaskets (hot) Exhaust manifold, Discard the turbocharger, EGR...
  • Page 57 SPECIFICATIONS 51 Gasket and Seal Reuse Components Example Reusable Limit Reuse Recom- mendations Do not reuse Sealant agent (One Sealing between: Remove the old component RTV1) Timing Gear Plate RTV1 sealant. and Cylinder Block Clean the Surface. Flywheel Housing Apply fresh RTV1 and Timing Gear sealant.

  • Page 58: Engine Lubricants And Sealants

    52 SPECIFICATIONS Engine Lubricants and Sealants Use only the following recommended sealing compounds and lubricants. Note: All genuine cylinder head gaskets are pre-coated and do not require any type of sealing compound. When installing new gaskets, clean and degrease gasket sealing surfaces to avoid leaks.

  • Page 59: Engine Fault Codes

    SPECIFICATIONS 53 Engine Fault Codes Description Fault Code Fan speed PID26 Preheat Relay PID45 Particulate Trap Differential Pressure PID81 Vehicle Speed PID84 Cruise control status PID85 Pedal message PID91 PID94 Fuel pressure PID97 Water in fuel sensor Oil Level PID98 Oil Pressure PID100 Boost Pressure...
  • Page 60 54 SPECIFICATIONS Engine Fault Codes Description Fault Code Total Vehicle Distance PID245 Time data failure PID251 Date data failure PID252 Relative Air Humidity PID354 Compressor Discharge Temperature PID404 EGR Diff Pressure PID411 PID412 EGR Temperature After Cooler...
  • Page 61 SPECIFICATIONS 55 Engine Fault Codes Description Fault Code Injector 1 SID1 Injector 2 SID2 SID3 Injector 3 Injector 4 SID4 Injector 5 SID5 SID6 Injector 6 Water-in-fuel Valve SID18 CAM Speed sensor SID21 Crank Speed sensor SID22 Variable Geometry Turbocharger SID27 Actuator #1 Cooling Fan control...
  • Page 62 56 SPECIFICATIONS Engine Fault Codes PPID PPID35 EGR Mass Flow ECU Temperature PPID55 VGT SRA Temperature PPID89 PPID122 NOx sensor gas outlet PPID270 Air temperature for humidity PPID272 compensation Soot level PPID326 After treatment injection shut-off valve PPID328 PPID329 After treatment fuel injector PPID330 Discharge Recirculator Valve Solenoid Engine fan thermal switch...
  • Page 63 SPECIFICATIONS 57 Engine Fault Codes Description Fault Code PSID Aftertreatment System Conditioning PSID25 Insufficient reagent quality PSID40 Too low reagent consumption PSID41 PSID42 Interruption of dosing activity PSID43 Incorrect EGR flow PSID44 Deactivation of EGR High NOx - Root cause unknown PSID45 NOx monitoring failure PSID46...
  • Page 64 58 SPECIFICATIONS FMI Table Failure Mode Description Indicator DATA VALID BUT ABOVE NORMAL OPERATING RANGE – MOST SEVERE LEVEL DATA VALID BUT BELOW NORMAL OPERATING RANGE – MOST SEVERE LEVEL DATA ERRATIC, INTERMITTENT OR INCORRECT VOLTAGE ABOVE NORMAL, OR SHORTED TO HIGH SOURCE VOLTAGE BELOW NORMAL, OR SHORTED TO LOW SOURCE...

  • Page 65: Conversion Chart

    SPECIFICATIONS 59 Conversion Chart Conversion Units Multiply By: Length Calculations 25.40 Inches (in) Millimeters (mm) 25.40 Inches (in) Centimeters (cm) 30.48 Feet (ft) Centimeters (cm) Feet (ft) Meters (m) 0.3048 Yards (yd) Centimeters (cm) 91.44 Yards (yd) Meters (m) 0.9144 Miles Kilometers (km) 1.609...
  • Page 66 60 SPECIFICATIONS Conversion Chart Conversion Units Multiply By: Volume Calculations Cubic Inches (cu-in) Cubic Centimeters 16.387 (cu-cm) 0.01639 Cubic Inches (cu-in) Liters (L) 0.9464 Quarts (qt) Liters (L) 3.7854 Gallons (gal) Liters (L) Cubic Yards (cu-yd) Cubic Meters (cu-m) 0.7646 Cubic Centimeters (cu-cm) Cubic Inches (cu-in) 0.06102...
  • Page 67 SPECIFICATIONS 61 Conversion Chart Conversion Units Multiply By: Area Calculations Square Inches (sq-in) Square Millimeters 645.2 (sq-mm) 6.452 Square Inches (sq-in) Square Centimeters (sq-cm) Square Feet (sq-ft) Square Centimeters 929.0 (sq-cm) Square Feet (sq-ft) Square Meters (sq-m) 0.0929 Square Yards (sq-yd) Square Meters (sq-m) 0.8361 Square Miles (sq-miles)
  • Page 68 62 SPECIFICATIONS CONVERSION CHART Conversion Units Multiply By: Weight Calculations Ounces (oz) Grams (g) 28.5714 Pounds (lb) Kilograms (kg) 0.4536 Pounds (lb) Short Tons (US tons) 0.0005 Pounds (lb) Metric Tons (t) 0.00045 Short Tons (US tons) Pounds (lb) 2000 Short Tons (US tons) Kilograms (kg) 907.18486...
  • Page 69 SPECIFICATIONS 63 CONVERSION CHART Conversion Units Multiply By: Torque Calculation Pound Inches (lb-in) Newton Meters (N?m) 0.11298 Pound Feet (lb-ft) Pound Feet (lb-ft) 1.3558 Pound Feet (lb-ft) Kilograms Force per 0.13825 Meter (kgfm) 8.851 Newton Meters (N.m) Pound Inches (lb-in) Newton Meters (N.m) Pound Feet (lb-ft) 0.7376...
  • Page 70 64 SPECIFICATIONS CONVERSION CHART Conversion Units Multiply By: Pressure Calculations Atmospheres (atm) Bars (bar) 1.01325 Atmospheres (atm) Kilopascals (kPa) 101.325 0.98692 Bars (bar) Atmospheres (atm) Bars (bar) Kilopascals (kPa) Bars (bar) Pounds per Square 14.5037 Inch (psi) Inches of Mercury (in Hg) Kilopascals (kPa) 3.377 0.2491...

  • Page 71: Engine Dimensions

    SPECIFICATIONS 65 Engine Dimensions Cylinder Head Maximum unevenness (bottom face) 0.1 mm (0.004 inch) Cylinder Head Bolts Quantity Thread size Length 200 mm (7.87 inches) Cylinder Block Length 1052 mm (41.42 inches) Height, upper block face — crankshaft 422 mm (16.61 inches) center Height, lower block face —...

  • Page 72: Piston Rings

    66 SPECIFICATIONS Piston Rings T2022726 Quantity Labelling Up (color marking to left of gap) Piston ring clearance in groove Upper compression ring Trapezium profile Lower compression ring 0.09–0.14 mm (0.0035–0.0055 inch) Oil Scraper Ring Quantity Labelling Up (color marking to left of gap) Piston ring clearance in groove 0.05–0.10 mm (0.0019–0.0039 inch)

  • Page 73: Valve Mechanism

    Valve lash (clearance) cold engine, check value Inlet 0.15–0.25 mm (0.006–0.009 inch) Exhaust 0.75–0.85 mm (0.029–0.033 inch) Exhaust, Volvo Engine Brake 0.95–1.05 mm (0.037–0.041 inch) Rocker Arms Rocker arm bearing clearance 0.08 mm (0.003 inch) maximum Rocker arm roller clearance...

  • Page 74: Valve Guides

    68 SPECIFICATIONS Valve Guides Length 83.5 mm (3.287 inches) Inlet/Exhaust Inner diameter 8 mm (0.315 inch) Inlet/Exhaust Height above cylinder head spring surface 24.5 ± 0.2 mm (0.965 ± 0.008 inch) Inlet/Exhaust Valve Springs Inlet valve spring 73.8 mm (2.91 inches) Length unloaded Exhaust outer valve spring 73.8 mm (2.91 inches)

  • Page 75: Engine Timing Gear

    SPECIFICATIONS 69 Engine Timing Gear T2022797 1. Drive gear, crankshaft 2. Idler gear, outer and inner drive Outer: 84, Inner: 56 3. Idler gear, adjustable 4. Drive gear, camshaft 5. Idler gear, power steering pump 6. Drive gear, power steering pump 7.

  • Page 76: Camshaft

    69.47–69.53 mm (2.735–2.737 inches) 0.75 mm (0.030 inch) 69.22–69.28 mm (2.725–2.728 inches) Valve lift at zero play Inlet Exhaust Volvo Engine Brake™ 13.1 mm (0.520 inch) 12.5 mm (0.490 inch) Permitted wear, entire camshaft profile 0.1 mm (0.0039 inch) maximum 18 mm (0.710 inch)

  • Page 77: Camshaft Bearings

    SPECIFICATIONS 71 Camshaft Bearings Camshaft bearing thickness, standard 1.92 mm (0.075 inch) Oversize 0.25 mm (0.010 inch) 2.04 mm (0.080 inch) 0.50 mm (0.020 inch) 2.17 mm (0.085 inch) 0.75 mm (0.030 inch) 2.29 mm (0.090 inch) Crank Mechanism Main Bearing Journals Standard diameter (Ø) 108.0 mm (4.25 inches) Undersize diameter...

  • Page 78: Thrust Washers (Axial Bearing)

    72 SPECIFICATIONS Thrust Washers (Axial Bearing) Standard width (B) 3.18 mm (0.125 inch) Oversize 0.1 mm (0.004 inch) 3.28 mm (0.129 inch) 0.2 mm (0.008 inch) 3.38 mm (0.133 inch) 0.3 mm (0.012 inch) 3.48 mm (0.137 inch) 0.4 mm (0.016 inch) 3.58 mm (0.141 inch) Main Bearings Standard thickness (D)

  • Page 79: Connecting Rod Journals

    SPECIFICATIONS 73 Connecting Rod Journals T2022727 Diameter (Ø) 99.0 mm (3.898 inches) Undersize 0.25 mm (0.010 inch) 98.75 mm (3.888 inches) 0.50 mm (0.020 inch) 98.50 mm (3.878 inches) 0.75 mm (0.030 inch) 98.25 mm (3.868 inches) 1.00 mm (0.040 inch) 98.00 mm (3.858 inches) 1.25 mm (0.050 inch) 97.75 mm (3.848 inches)

  • Page 80: Connecting Rod Bearings

    74 SPECIFICATIONS Connecting Rod Bearings Standard thickness (C) 2.39 mm (0.094 inch) Oversize 0.25 mm (0.010 inch) 2.14 mm (0.084 inch) 0.50 mm (0.020 inch) 1.89 mm (0.074 inch) 0.75 mm (0.030 inch) 1.64 mm (0.064 inch) 1.00 mm (0.040 inch) 1.39 mm (0.054 inch) 1.25 mm (0.050 inch) 1.14 mm (0.044 inch)

  • Page 81: Flywheel, Mounted

    SPECIFICATIONS 75 Flywheel, Mounted Axial runout (manual transmission) 150 mm (5.91 inches) measurement radius Less than 0.21 mm (0.008 inch) Flywheel Housing, Mounted Axial runout of contact surface against 0.2 mm (0.008 inch) maximum clutch housing Radial runout of guide against clutch 0.26 mm (0.010 inch) maximum housing Crankshaft...

  • Page 82: 76 Engine Component And Location

    76 ENGINE COMPONENT AND LOCATION Cylinder Head W2033297 Main features of the cylinder head are: • One-piece cast iron • Integral thermostat housing Separate chambers for exhaust and inlet at each cylinder make this a "crossflow" design. The fuel channel, drilled from front to rear, connects with grooves machined around each injector opening.

  • Page 83: Camshaft And Valve Train

    Both the inlet and exhaust rocker arms each drive the valve pairs via a pinless yoke (bridge). On engines equipped with Volvo Engine Brake, the "brake" rocker arm works in combination with the exhaust rocker arm to precisely control the opening and closing of the exhaust valves for engine braking.
  • Page 84 78 ENGINE COMPONENT AND LOCATION W2033303 1. Exhaust Brake Cam 3. Injector Cam 2. Exhaust Cam 4. Inlet Cam Rollers in the ends of the rocker arms contact the cam shaft. The contacts with the yokes have ball sockets for flexibility. The camshaft is induction-hardened.
  • Page 85 ENGINE COMPONENT AND LOCATION 79 W2033306 Timing marks on the camshaft provide for valve and injector adjustment. Volvo Engine Brake includes its own electronic control governed by driver’s choice through a switch near the steering wheel. This control mounts on the cylinder head between the No.

  • Page 86: Cylinder Block

    80 ENGINE COMPONENT AND LOCATION Cylinder Block W2033309 1. Cylinder Block 2. Block Stiffener Plate The cylinder block is made of cast iron. For increased cylinder block rigidity and noise and vibration reduction, a steel stiffener plate attaches to the bottom. The main and piston lubricating channels are drilled longitudinally through the block.

  • Page 87: Head To Block Alignment

    ENGINE COMPONENT AND LOCATION 81 Head to Block Alignment W2033310 1. Cylinder Head 3. Cylinder Clock 2. Alignment Screws and Washers Three screws and washers installed at the side (two in the block and one in the head) align the head from side to side at assembly. Fore and aft, the head is aligned by contact with the timing gear plate.

  • Page 88: Cylinder Head Gasket

    82 ENGINE COMPONENT AND LOCATION Cylinder Head Gasket T2018766 The cylinder head gasket is made of one piece of sheet steel with vulcanized elastomer seals on oil and coolant conduits. The design of the engine and head gasket requires a unique procedure for installation of the cylinder head.

  • Page 89: Cylinder Liner

    ENGINE COMPONENT AND LOCATION 83 Cylinder Liner W2033311 1. Upper O-Ring – EPDM (Black) 3. Lower Sealing Ring – Viton (Purple) 2. Middle Sealing Rings – EPDM (Black) The cylinder block uses replaceable wet cylinder sleeves. The lower end of each sleeve is sealed against the block with three elastomer rings.

  • Page 90: Oil Pan

    84 ENGINE COMPONENT AND LOCATION Oil Pan W2033312 1. Block Stiffener Plate 2. Oil Pan with Gasket The oil pan is plastic or steel with a threaded plug for draining. The plastic pan has a groove in the mounting flange which accepts a molded elastomer gasket for a seal. The steel pan is sealed with a gasket on the oil pan flange.

  • Page 91: Crankshaft

    ENGINE COMPONENT AND LOCATION 85 Crankshaft W2033313 1. Alignment Tab, Block 3. Thrust Washer 2. Alignment Tab, Cap 4. Upper and Lower Bearings The crankshaft is drop forged steel and induction hardened. It has seven journals with replaceable bearings. Five oversized replacement bearing options are available to accommodate crankshaft regrinding.

  • Page 92: Piston And Connecting Rods

    86 ENGINE COMPONENT AND LOCATION Piston and Connecting Rods W2033314 1. Piston Ring Set 5. Upper and Lower Connecting Rod Bearings 2. Piston 6. Connecting Rod Bearing Cap 3. Wrist Pin 7. Piston Cooling Nozzle 4. Connecting Rod 8. Assembly Matching Marks Connecting rods are forged steel and are used in combination with one-piece Monosteel steel pistons.
  • Page 93 ENGINE COMPONENT AND LOCATION 87 W2033316 1. Piston Cooling Nozzle 3. Opening Valve 2. Control Valve Oil flow for the piston cooling system is controlled by two valves. The opening valve supplies oil and the control valve balances the oil flow to the piston cooling channel.

  • Page 94: Timing Gears

    88 ENGINE COMPONENT AND LOCATION Timing Gears W2033318 1. Crankshaft Gear 6. Power Steering/Fuel Pump Gear 2. Double Idler Gear 7. Air Compressor Gear 3. Adjustable Idler Gear 8. Oil Pump Gear 4. Camshaft Gear and Damper 9. Power Take-Off Gear (Optional) 5.

  • Page 95: Drive Belt

    ENGINE COMPONENT AND LOCATION 89 Drive Belt W2033321 1. EGR Cooler Outlet Pipe 6. Refrigerant Compressor (Pad Mount) 2. Fan Drive 7. Belt Tensioner (Fan Drive/Water Pump Belt) 8. Water Pump 3. EGR Mixer 4. Belt Tensioner (Alternator/Refrigerant 9. Venturi Compressor Belt) 5.

  • Page 96: Lubrication System

    90 ENGINE COMPONENT AND LOCATION Lubrication System A gear-type pump at the rear of the engine, driven by the crankshaft gear, draws lubricant from the oil pan and supplies the system. Oil flows from the pump through the distribution housing to the filters, to a gallery at the right side of the engine serving the crankshaft journals, to a gallery at the left side serving piston lubrication and cooling, to the cylinder head and rocker shaft duct (valve rocker and camshaft) and back to the oil pan.

  • Page 97: Oil Flow Control And Filtration

    ENGINE COMPONENT AND LOCATION 91 Oil Flow Control and Filtration W2033325 1 Strainer 2 Pickup Tube 3 Oil Pump 4 Pressure Pipe 5 Oil Cooler 6 Filter Housing 7 Full-Flow Filter 8 Main Lubrication Gallery CCV Separator 10 Exhaust brake Oil Control Valve 11 Air Compressor 12 Turbocharger 13 By-Pass Filter...
  • Page 98 92 ENGINE COMPONENT AND LOCATION There are three filters, one by-pass and two full-flow, attached to a housing mounted at the lower right side of the engine. Oil flow through the filters and the lubrication system is controlled by six valves, including: •...

  • Page 99: Crankcase Ventilation

    ENGINE COMPONENT AND LOCATION 93 Crankcase Ventilation W2033326 1. Seal Ring 5. Separator Housing 2. Separator Inlet Hose 6. Housing Seal 3. Separator Vent Tube 7. Pressure Regulator 4. Vent Tube Bracket...
  • Page 100 94 ENGINE COMPONENT AND LOCATION Lubricant becomes a mist in many areas of the engine as the result of the motion of the parts (e.g., rocker arms, pistons, crankshaft, camshaft and rocker shaft). The mist rides the drafts of air and other gases that circulate in the open spaces in the engine. To prevent pressure buildup, the open spaces are ducted through a pipe that opens to the atmosphere near the bottom of the engine.

  • Page 101: Fuel System

    ENGINE COMPONENT AND LOCATION 95 Fuel System W2033327...
  • Page 102 96 ENGINE COMPONENT AND LOCATION 1 Fuel Pump 16 Electrical Water Drain Valve 2 Fuel Tank and Inlet Tube 17 Automatic Air Bleed Valve ( closes when filter removed) 3 EECU Cooler 18 Service Port (Pressure Gauge) 4 Fuel Filter Housing 19 Supply Pressure Sensor 5 Fuel Pre-Filter 20 Fuel Heater (Optional)

  • Page 103: Fuel Filtration

    ENGINE COMPONENT AND LOCATION 97 Fuel Filtration Primary and secondary filter elements attach to the underside of the filter valve housing. The housing, located at the front lower left side of the cylinder block, has an integral hand-priming pump for bleeding the system. The 30 micron pre-filter (primary filter) also separates water from the fuel.

  • Page 104: Unit Injectors

    98 ENGINE COMPONENT AND LOCATION Unit Injectors W2033328 1. Injector Yoke 8. Solenoid Coil 2. Copper Sleeve 9. Solenoid Coil 3. O-Ring 10. Injector Valve 4. Fuel Gallery 11. Injector Piston 5. O-Ring 12. Injector Nozzle 6. O-Ring 13. Washer 7.
  • Page 105 ENGINE COMPONENT AND LOCATION 99 There are four phases to the injector cycle of operation. These include: • Fill phase • Spill phase • Injection phase • Pressure drop phase W2033330 1.Pump Plunger 3. Injector Nozzle 2. Fuel Gallery Fill phase (A): During the filling phase, the pump plunger is on its way up, the camshaft lobe is passing its highest point and the rocker arm is on its way toward the camshaft base circle.
  • Page 106 100 ENGINE COMPONENT AND LOCATION W2033335 1. Serial No. 2. Unit Calibration No. Unit injectors are categorized and coded with regard to tolerances. Whenever a unit injector is replaced, the replacement injector MUST be programmed for the cylinder in which it is installed. This is done by programming EECU parameters using the VCADS pro or the Premium Tech Tool (PTT) to set Injector Trim parameters with the trim codes marked on the injectors.

  • Page 107: Volvo Engine Brake

    ENGINE COMPONENT AND LOCATION 101 Volvo Engine Brake W2033356 1. Tie Wraps 4. Solenoid 2. Electrical Connector 5. Tube — Valve to Shaft 3. Attaching Screws...
  • Page 108 102 ENGINE COMPONENT AND LOCATION The engine can be equipped with a Volvo engine brake system to assist in slowing the vehicle when necessary. The system includes the: • Wiring harness • Camshaft • Oil control valve • Exhaust rocker arms •...
  • Page 109 ENGINE COMPONENT AND LOCATION 103 When the accelerator pedal is released (and the Volvo Engine Brake switch is ON), the solenoid opens allowing some oil to escape through a small port. Reduced spring pressure moves the piston, opens the passage to the rocker shaft and increases the oil pressure.

  • Page 110: Exhaust Gas Recirculation System

    104 ENGINE COMPONENT AND LOCATION Exhaust Gas Recirculation System W2033359 1.EGR Valve 5. Differential Pressure Sensors 2. EGR Cooler Inlet Pipe 6. EGR Cooler Outlet Pipe 3. EGR Cooler 7. EGR Mixer 4. Venturi Nitrous oxide (NOx) emission levels increase with combustion temperature. The primary function of the Exhaust Gas Recirculation (EGR) system is to cool exhaust gas and send it back to the combustion chamber to lower the combustion temperature thereby to reduce NOx emissions.

  • Page 111: Egr Valve

    ENGINE COMPONENT AND LOCATION 105 EGR Valve This engine uses the EGR valve to recirculate exhaust gases. Engine oil operates the EGR valve. The EECU determines the desirable valve opening based on inputs from a number of sensors and commands the EGR valve solenoid to open or close the valve. Corrosion occurs in the inlet manifold if exhaust gas condenses there.

  • Page 112: Egr Cooler Inlet Pipe

    106 ENGINE COMPONENT AND LOCATION EGR Cooler Inlet Pipe W2033358 1. EGR Valve 4. EGR Cooler 2. Cooler Inlet Pipe 5. Electrical Connector 3. Clamps 6. Oil Supply Line The cooler inlet pipe conducts the exhaust from the EGR valve to the EGR cooler. The cooler lowers the exhaust stream temperature before it reenters the combustion chamber.

  • Page 113: Egr Cooler

    ENGINE COMPONENT AND LOCATION 107 EGR Cooler The EGR valve is connected to the EGR cooler by the cooler inlet pipe. Using engine coolant, the EGR cooler lowers the temperature of the gas coming from the EGR valve. The cooler contains a series of vanes that increase cooling efficiency by swirling the hot gas before it enters the mixer.

  • Page 114: Inlet Air Heater

    108 ENGINE COMPONENT AND LOCATION Inlet Air Heater The optional inlet air heater mounts between the mixer and the inlet manifold. It is activated when the operator turns the key to the preheater position and the engine coolant temperature is lower than 10°C (50°F). Operating time is controlled by the EECU.

  • Page 115: Air Intake System

    ENGINE COMPONENT AND LOCATION 109 Air Intake System Fresh air enters the intake above the back of the cab. Plastic duct work leads the air to the filter assembly mounted on the bulkhead under the hood. An impregnated paper filter prevents foreign particles from passing through. The assembly design permits the addition of a second filter if needed in extreme environments.

  • Page 116: Cooling System

    110 ENGINE COMPONENT AND LOCATION Cooling System The cooling system incorporates a belt-driven coolant pump mounted on the front of the engine on the right. It also uses a piston-type thermostat housed in the front of the cylinder head and a fan with viscous or air-operated drive mounted above the crankshaft pulley.

  • Page 117: Thermostat

    ENGINE COMPONENT AND LOCATION 111 Thermostat This is a piston-type, full-flow thermostat with piston, bulb, seal and housing in a single assembly. Coolant flows continuously, either back to the pump, or to the radiator and back to the pump. It has lower pressure drop compared to other types. The thermostat is mounted on the front of the cylinder head.

  • Page 118: Engine Managment System

    112 ENGINE COMPONENT AND LOCATION Engine Managment System Engine Electronic Control Unit (EECU) W2033364 The engine management system module, also known as the Engine Electronic Control Unit (EECU), is located on the left side of the engine just below the inlet manifold. The EECU is cooled by fuel circulating through a plate attached to the cover of the unit.

  • Page 119: Exhaust Aftertreatment System

    ENGINE COMPONENT AND LOCATION 113 Exhaust Aftertreatment System New, stringent standards for exhaust emission control begin with the 2007 model year. The Exhaust Aftertreatment System (EATS) has been developed to act in combination with Ultra Low Sulfur Diesel (ULSD) fuel and the EGR system to reduce noxious emissions to meet the requirement.

  • Page 120: Catalytic Filters

    114 ENGINE COMPONENT AND LOCATION Catalytic Filters W2033360 1. Diesel Oxidation Catalyst 2. Catalyzed Diesel Particulate Filter A catalytic filter (converter) is a porous form (like a sponge) that has been coated with a catalytic material. The flow of exhaust gas must pass through the pores on its way to the atmosphere.

  • Page 121: Diesel Particulate Filter

    ENGINE COMPONENT AND LOCATION 115 Diesel Particulate Filter Basically a trap, a diesel particulate filter (DPF) collects the soot and ash to hold until they can be burned off. A catalyzed DPF also transforms unburned fuel, engine lubricant and carbon monoxide into carbon dioxide and water. Depending on vehicle vocation, the operating temperature of the exhaust may or may not be sufficient to consume the trapped soot and ash.

  • Page 122: Active Regeneration

    116 ENGINE COMPONENT AND LOCATION Active Regeneration For vehicles that are unable to develop or sustain adequate temperature, there is more than one system for supplying sufficient heat. W2033245...
  • Page 123 ENGINE COMPONENT AND LOCATION 117 1 DPF Muffler 2 Temperature Sensor 3 Differential Pressure Sensor 4 Stack Pipe 5 Pipe Clamp 6 Outlet Module 7 Clamp 8 Filter 9 Catalyst 10 Inlet Module 11 Exhaust Pipe 12 Hose Clamp 13 Flex Pipe 14 Aftertreatment Fuel Injector 15 Turbocharger 16 Discharge Recirculation Valve...

  • Page 124: Manual Regeneration

    118 ENGINE COMPONENT AND LOCATION Manual Regeneration A procedure called "Manual Regeneration" can be used to regenerate the filters while they remain in the vehicle. The VCADS service tool or the Premium Tech Tool (PTT) can be used to perform this function. WARNING The exhaust system reaches extremely high temperatures.

  • Page 125: Operational Mode

    ENGINE COMPONENT AND LOCATION 119 Operational Mode The exhaust aftertreatment system (EATS) usually operates in one of five modes. Normal Mode Heat Mode Passive Regeneration Mode Active Regeneration Mode Service Mode In the Normal Mode, the engine is controlled by its regular calibration. However, the filters can be self-cleaning through passive regeneration.

  • Page 126: Dpf System Vehicle Mounting

    120 ENGINE COMPONENT AND LOCATION DPF System Vehicle Mounting The DPF system is either a vertical back-of-cab (VBOC) DPF unit with muffler for the conventional chassis or a compact unit DPF unit with muffler to accommodate the low cab forward chassis. The space saver unit attaches to the outside of the right rail under the cab.

  • Page 127: Component Part Number Locator

    ENGINE COMPONENT AND LOCATION 121 COMPONENT PART NUMBER LOCATOR Engine, Right-Side View W2032499...
  • Page 128 122 ENGINE COMPONENT AND LOCATION Part Number Description 1. EGR Valve 1. 85111067 2. 21082971 2. Aftertreatment Fuel Injector 3. Variable Geometry Turbo 3. Check per VIN number 4. Discharge Recirculation Valve 4. 20940438 5. EGR Mixer 5. 21033737 6. EGR Coolant Outlet Pipe 6.

  • Page 129: Engine, Left-Side View

    ENGINE COMPONENT AND LOCATION 123 Engine, Left-Side View W2032501 Part Number Description 1. EGR Mixer 1. 21033737 2. 20900934 2. EGR Cooler Outlet Pipe 3. Air Compressor 3. Single Cyl. 85116641 Dual Cyl. 85116642 4. Power Steering Pump 4. Check per VIN number 5.

  • Page 130: Engine, Front View

    124 ENGINE COMPONENT AND LOCATION Engine, Front View W2032449 Part Number Description 1. 20900934 1. EGR Cooler Outlet Pipe 2. Fan Drive 2. Check per VIN number 3. 21033737 3. EGR Mixer 4. Belt Tensioner (Alternator/Refrigerant 4. 20762060 Compressor Belt) 5.

  • Page 131: Engine Sensors

    ENGINE COMPONENT AND LOCATION 125 Engine Sensors W2032450 Description Part Number 1. Oil Level/Temperature 1. 21042447 2. Fuel Pressure 2. 20796740 3. Fan Speed (in fan hub) 3. Check per VIN number 4. Boost pressure Sensor 4. 20524936 5. Coolant Temperature (at front edge 5.

  • Page 132: Engine Disassembled View And Part Numbers

    126 ENGINE COMPONENT AND LOCATION ENGINE DISASSEMBLED VIEW AND PART NUMBERS Upper Engine Components W2032469...
  • Page 133 10. 20891469 11. 8192804 11. Camshaft Vibration Damper Bolts 12. Spacer 12. 20878608 13. Volvo Engine Brake 13. Check per VIN number 14. Valve Caliper Intake 14. Check per VIN number Note: All part numbers are for reference only, you should always refer...

  • Page 134: Rear Engine Components

    128 ENGINE COMPONENT AND LOCATION Rear Engine Components W2032470...
  • Page 135 ENGINE COMPONENT AND LOCATION 129 Part Number Description 1. Power Take-Off Cover and Gasket 1. 976068 2. Flywheel Housing 2. Check per VIN number 3. 1543896 3. Crankshaft Seal 4. 20817742 4. Timing Gear Cover Sealing Strip 5. Timing Gear Cover Seals 5.

  • Page 136: Oil Pan And Stiffing Frame

    130 ENGINE COMPONENT AND LOCATION Oil Pan and Stiffing Frame W2032451...
  • Page 137 ENGINE COMPONENT AND LOCATION 131 Part Number Description 1. Oil Pan 1. Check per VIN number 2. 20515881 2. Sealing Strip 3. 20824910 3. Oil Strainer 4. 20521886 4. Suction Pipe 5. Pressure Pipe 5. 20501240 6. Pressure Pipe 6. 20498189 7.

  • Page 138: Lower Engine Components

    132 ENGINE COMPONENT AND LOCATION Lower Engine Components W2032471...
  • Page 139 ENGINE COMPONENT AND LOCATION 133 Part Number Description 1. Upper Cylinder Liner Seal – EPDM 1. 270950 (Black) 2. Cylinder Liner 2. 20928630 3. Middle Cylinder Liner Seal – EPDM 3. 270950 (Black) 4. Lower Cylinder Liner Seal – Viton 4.

  • Page 140: Replacement Kits

    134 ENGINE COMPONENT AND LOCATION Replacement Kits Engine Replacement Kits W2032452...
  • Page 141 ENGINE COMPONENT AND LOCATION 135 Part Number Description Repair Kits, Main and Big-end Bearings 20530916 20586428 CCV Pipe Connection Replace Kit 85111130 Fuel Pump Replace Kit 85116652 Coolant Pump Replace Kit Cylinder Head Kit 21409435 EGR Cooler Replace Kit 85111060 EGR Valve ReplaceKit 85111067 Injector Sleeve Replace Kit...

  • Page 142: 136 Basic Service

    136 BASIC SERVICE Maintenance Oil Level Check W2033374 When checking oil levels, the vehicle must be parked on level ground and the engine at normal operating temperature. Components must be filled to the correct level. DO NOT OVERFILL. The best time to check oil level is while the engine is COLD (prior to starting at the beginning of the work day, or after the vehicle has sat approximately 2 hours).

  • Page 143: Oil And Filter Change Procedure

    7 Start the engine and check for leaks. Run the engine for approximately five minutes, then shut it off and recheck the oil level. Add oil if necessary. Note: Use of anything other than genuine Volvo filters may cause damage and void the engine warranty. Change filters according to the recommended maintenance schedule.

  • Page 144: Fuel Filter Replacement

    138 BASIC SERVICE Fuel Filter Replacement Filter Description Two filters ensure that clean, waterless fuel reaches the electronic unit injectors. One is a full-flow filter, the other is a water separating pre-filter with a transparent cup to collect and drain the water. A water-in-fuel sensor informs the driver of excessive accumulation in the cup.

  • Page 145: Fuel Filter Replacement

    BASIC SERVICE 139 Fuel Filter Replacement Note: Because of ice buildup or fuel waxing which can clog fuel filters, it may be necessary during extremely cold weather to reduce the time or mileage interval between fuel filter changes. Be careful to prevent foreign matter of any kind from entering the filters during service.

  • Page 146: Full-Flow Main Filter Replacement

    140 BASIC SERVICE Full-Flow Main Filter Replacement To replace the full-flow main filter: 1 Make sure the filter casing is thoroughly cleaned. If not already done, wash the area around the filter mounting adapter with a suitable solvent and blow dry with compressed air.

  • Page 147: Coolant Filter

    BASIC SERVICE 141 Coolant Filter The coolant filter attaches to the back of the coolant pump housing. It resembles a spin-on oil filter. The filter element and casing are replaced as a unit. W2033376 1. Shut-Off Valve 2. Coolant Filter...
  • Page 148 142 BASIC SERVICE Note: VCS coolant is used to protect the cooling system. Remove and Replace 1 Close the shut-off valve on the coolant pump housing. Note: In the closed position, the pin on the shut-off valve should be horizontal. 2 Place a suitable container below the filter to collect spilled coolant.

  • Page 149: Exhaust Aftertreatment System Maintenance

    BASIC SERVICE 143 Exhaust Aftertreatment System Maintenance Diesel Particulate Filter The diesel particulate filter should be removed from the system and replaced at the recommended service interval. If the filter is not replaced, it will become clogged and increase exhaust back pressure. As back pressure increases, engine power and economy decline as does the ability of the system to remove undesirable emissions.
  • Page 150 144 BASIC SERVICE W2033379 4.Remove the lower exhaust V-band clamp that connects the DPF outlet module to the exhaust pipe. Also, remove the V-band clamp that connects the catalyst module to the filter. W2033380 5. Position a flat surface jack with a very stable support (such as a transmission jack) under the base of the DPF 6.
  • Page 151 BASIC SERVICE 145 W2033381 7. Lower the DPF unit and roll the transmission jack from the right side of the chassis to remove the lower portion of the DPF. 8. Loosen the nut securing the large V-band clamp between the exhaust outlet module and the filter module 9.
  • Page 152 146 BASIC SERVICE W2033382 6. Install and tighten the V-band clamp that joins the outlet module to the exhaust pipe. W2033381 7. Secure the DPF bracket to the chassis frame bracket and tighten all fasteners to specification. 8. Remove the transmission jack from under the assembly. 9.

  • Page 153: Vertical Back-Of-Cab Unit

    BASIC SERVICE 147 Vertical Back-of-Cab Unit WARNING The components reach high temperatures during use. Ensure that the unit has cooled to the touch before handling. Failure to heed this warning may result in severe personal injury. Removal 1. Remove the heat shield, stack, harness clamps, tie straps and V-band clamp at the exhaust elbow.
  • Page 154 148 BASIC SERVICE W2033378 5. Using a marker, make alignment marks on each of the module sections, above and below each V-band clamp. 6. Remove the pressure differential tube from the catalytic filter module. 7. Remove the V-band clamp joining the outlet module to the filter module. W2033384 8.
  • Page 155 BASIC SERVICE 149 Installation 1. Install a new gasket between the catalytic filter module and the DPF filter module. 2. Align the locator tab located on the bottom of the DPF filter module with the slot located in the top of the catalytic filter module. Install the DPF filter module onto the catalytic filter module and secure the modules together using a V-band clamp tightened to specification.
  • Page 156 150 BASIC SERVICE W2033377 7. Lift the DPF muffler using a suitable lifting device and with assistance, position the muffler next to the frame-mounted stanchion, at the back of the cab. W2033385 8. Align the slot in the muffler bottom with the tab on the stanchion.
  • Page 157 BASIC SERVICE 151 9. Perform the following steps to align the DPF muffler into final position on the muffler stanchion: • Align the muffler inlet with the exhaust elbow. • Align the muffler upper supporting bracket to the stanchion and install the bolts loose.

  • Page 158: Aftertreatment Fuel Injector (Afi)

    152 BASIC SERVICE Aftertreatment Fuel Injector (AFI) WARNING When replacing the AFI, check the part number of the injector to ensure that an injector with a proper flow rate for the engine is installed. Installing an injector with the incorrect flow rate may cause dangerously high regeneration temperatures and subsequent DPF damage.
  • Page 159 BASIC SERVICE 153 W2033386 6. Disconnect both the inlet and outlet coolant lines from the aftertreatment fuel injector fittings. 7. Disconnect the aftertreatment fuel injector wiring harness connector. Remove all clips and tie straps to allow the harness to hang free. 8.
  • Page 160 154 BASIC SERVICE W2033387 3. Secure the injector mounting bolts. Tighten the bolts according to specification. 4. Reconnect the aftertreatment fuel injector wiring harness connector. Secure the injector wiring harness with clips and tie straps. W2033386 5. Reconnect the coolant lines to the aftertreatment injector fittings and tighten to specification.
  • Page 161 BASIC SERVICE 155 W2005656 7. Install the P-clamp and screws to secure the AFI harness and fuel supply line to the diffuser. 8. Fill the engine cooling system with the recommended coolant using the coolant extractor. 9. Install all previously removed cables to the ground (negative) battery terminals. 10.
  • Page 162 156 BASIC SERVICE Note: The coolant lines do not have to be disconnected nor coolant drained for AFI cleaning. 5. Remove and discard the aftertreatment fuel injector mounting bolts and spacers, and then remove the injector from the diffuser pipe attached to the turbocharger outlet. 6.
  • Page 163 BASIC SERVICE 157 W2033389 9. Inspect the injector tip to make sure it is thoroughly clean and all soot has been removed. Use a mirror if a clear view of the tip is not possible. 10. Install a new high-temperature gasket and steel plate gasket onto the bottom of the aftertreatment fuel injector.

  • Page 164: Drive Belt Replacement And Tensioning

    158 BASIC SERVICE Drive Belt Replacement and Tensioning General Information The service life of the multi-groove belts is considerably improved over other systems and allows the use of higher horsepower cooling fans. All D13F engines are equipped with multi-groove belt systems. In the dual multi-groove drive belt arrangement, the fan drive and coolant pump are driven directly from the crankshaft pulley by a 10- or 12-rib multi-groove belt.

  • Page 165: Valve And Unit Injector Adjustment

    BASIC SERVICE 159 Valve and Unit Injector Adjustment W2033395 1. Rocker Shaft/Bearing Cap Attaching 5. Inlet Valve Rocker Arm Screws 2. Exhaust Brake Rocker Arm 6. Plate Spring 3. Exhaust Valve Rocker Arm 7. Plate Spring Attaching Screws 4. Injector Rocker Arm 8.

  • Page 166: General Information

    Without Volvo Engine Brake : Markings 1–6 apply to adjustment of inlet valves, exhaust valves and injectors. • With Volvo Engine Brake : Markings 1–6 apply to adjustment of inlet valves and injectors. Markings E1–E6 apply to adjustment of exhaust valves.

  • Page 167: Inlet Valve Adjustment

    BASIC SERVICE 161 Inlet Valve Adjustment WARNING Apply the parking brake before barring the engine over. Remove the EMS power supply fuse to avoid starting the engine unintentionally. Make sure that the transmission is not in gear. With the engine cold, 60°C (140°F) or less, check and adjust the valves and injector as required for each cylinder before moving to the next.

  • Page 168: Unit Injector Adjustment

    162 BASIC SERVICE Unit Injector Adjustment The unit injector adjustment is done with the engine and camshaft in the same position as for the inlet valve adjustment on each cylinder. W2033398 1. Loosen the injector rocker arm adjusting screw jam nut and turn the adjusting screw out (counterclockwise) to relieve the preload.

  • Page 169: Exhaust Valve Adjustment (Without Volvo Engine Brake)

    BASIC SERVICE 163 Exhaust Valve Adjustment (WITHOUT Volvo Engine Brake) W2033399 1. At the current camshaft setting used for the inlet valves, adjust the exhaust valves following the same procedure described for adjustment of the inlet valves. However, the valve clearance specification is different.

  • Page 170: Exhaust Valve Adjustment (With Volvo Engine Brake)

    Note: The numbers on the camshaft preceded by an E are used to adjust the exhaust valves when the engine is equipped with Volvo Compression Brake (VCB).. Engines equipped with the VCB engine brake have two rocker arms working in combination to control the exhaust valves.
  • Page 171 BASIC SERVICE 165 W2033400 1. Loosen the screws holding the plate springs to release the spring tension against the engine brake rocker arms. 2. Using the flywheel turning tool, 88800014, bar the engine over so that the appropriate E number marking is between the lines on the front camshaft bearing cap. W2033401 3.
  • Page 172 166 BASIC SERVICE W2033402 A. Locknut B. Adjusting Screw a. Loosen the locknut A on the brake rocker arm adjusting screw. b. Using the dial indicator with angled extension and base (9989876, 85111493 and 9999696), place the tip of the dial gauge on the yoke as close as possible to the rocker arm yoke pad.

  • Page 173: Continuation Of Adjustments

    For engines equipped with the Volvo compression brake, tighten the plate spring attaching screws to specification after the valve and unit injector adjustments have...

  • Page 174: Operational Check

    168 BASIC SERVICE Operational Check W2033400 After the valve and unit injector adjustments have been completed, check engine operation as follows: 1 Using the flywheel turning tool, bar the engine over manually two complete revolutions to ensure that no piston-to-valve contact occurs. If contact does occur, readjust the valves as needed BEFORE starting the engine.

  • Page 175: Glossary 169

    Glossary 169 GLOSSARY OF TERMS Active Regeneration Cleaning a diesel particulate filter using an auxiliary heating mechanism to achieve optimum temperature for rapidly inducing chemical changes in the particulate matter trapped in the filter. Aftertreatment Fuel Injector (AFI) A device to inject fuel into the exhaust stream between the turbocharger and the diesel particulate filter where it is ignited.

  • Page 176: Compressor Discharge Temperature Sensor

    170 Glossary Compressor Discharge Temperature Sensor Mounted between the turbocharger compressor housing and CAC, detects compressor discharge air temperature and relays this value to the EECU. Cooled Exhaust Gas Recirculation (CEGR) A system whereby a pre-determined amount of exhaust gas is diverted through a heat exchanger where it is cooled and sent to the inlet manifold for reintroduction into the combustion chambers.

  • Page 177: Electronic Unit Injector (Eui)

    Glossary 171 Electronic Unit Injector (EUI) Controlled electronically by the EECU, there is one electronic unit injector for each cylinder of an engine. A unit injector incorporates the pump, the injector nozzle and two solenoids in a single body. Actuated by the camshaft via rocker arms with roller followers, electronic unit injectors offer precise fuel metering using a process called "rate shaping."...

  • Page 178: Idler Tensioner

    172 Glossary Idler Tensioner A belt tensioning device designed to maintain optimum tension under varying engine speeds and load. Oxides of Nitrogen (NOx) High temperatures and pressures of combustion produce oxides of nitrogen (NOx). When combustion temperature exceeds 1372°C (2,500°F), oxygen and nitrogen combine in large quantities to form NOx.

  • Page 179: Soot

    Glossary 173 Soot Carbonaceous particulate matter, black in color, found in diesel exhaust. Soot particles are extremely fine. Captured by the diesel particulate filter, their chemical characteristics are changed by the heat to which they are exposed, turning the soot into ash.

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