Workshop Manual

Group 21-26

TAD1140-2VE
TAD1150-2VE
TAD1170-2VE
 Table of Content

General Information
00-0 General ............................................................................................. 3

Specifications
03-2 Specifications, Engine .................................................................... 9
03-21 Engine ....................................................................................... 26
03-22 Lubrication System ................................................................. 33
03-23 Fuel System .............................................................................. 34
03-25 Inlet and Exhaust System ....................................................... 36
03-26 Cooling System ........................................................................ 36
03-3 Specifications, Electrical .............................................................. 37
Electrical System ............................................................................... 37

Safety and Other Instructions

05-1 Safety Instructions ........................................................................ 38

Special tools
08-2 Special Service Tools ................................................................... 42

Chemical Products
18-0 General ........................................................................................... 48

General
20-0 Engine Information, General ........................................................ 49
Test and Adjustments ....................................................................... 49

Engine
21-0 Engine Complete, General ........................................................... 55
Fitting the Fixture ............................................................................... 55
Engine Disassembly .......................................................................... 57
Engine Assembly ............................................................................... 67
21-1 Cylinder Head ................................................................................ 76
21-3 Cylinder Liner, Pistons ............................................................... 104
21-4 Valve Mechanism ........................................................................ 106
21-5 Timing Gears and Shaft .............................................................. 134
21-6 Crank Mechanism ....................................................................... 161

Lubricating and Oil System

22-0 Lubricating and Oil System, General ........................................ 174
22-1 Oil pump and Line ....................................................................... 177
22-2 Oil filter ........................................................................................ 182
22-3 Oil cooler ..................................................................................... 191

Fuel System
23-0 Fuel System, General ................................................................. 196
23-3 Fuel Feed Pump and Filter ......................................................... 200
23-7 Injectors and Delivery Pipes ...................................................... 212
23-8 Control System, ECM, Data Sets ............................................... 224

Inlet and Exhaust System

25-0 Inlet and Exhaust System, General ........................................... 226
25-1 Inlet and Exhaust Manifolds ...................................................... 227
25-4 Emission Control, Catalytic Converter ..................................... 237

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 25-5 Turbo and supercharger ............................................................ 245
25-6 Air Cleaner, Throttle Housing .................................................... 253
25-8 Emission After-Treatment .......................................................... 255

Cooling System
26-0 Cooling System, General ........................................................... 274
26-2 Coolant Pump, Thermostat ........................................................ 280

Alternator, Charge Regulator

32-1 Alternator ..................................................................................... 288

Starting System
33-1 Starter Motor ............................................................................... 294
Index ......................................................................................................... 299
References to Service Bulletins ............................................................ 301

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00-0 General
About this Workshop manual
General information Certified engines
This Service Manual contains technical data, When carrying out service and repair on
descriptions and maintenance and repair instructions emission-certified engines, it is important to be
for standard model Volvo Penta products. A list of aware of the following:
these products may be found in the section
Specifications. Certification means that an engine type has been
inspected and approved by the relevant authority.
The product designation and the serial number and The engine manufacturer guarantees that all engines
specification is indicated on the engine decal or type of the same type are manufactured to correspond to
plate. This information must be included in all the certified engine.
correspondence regarding the product. This places special demands on service and repair
work, namely:
The service manual is produced primarily for the use
of Volvo Penta workshops and their qualified • Maintenance and service intervals
personnel. It is assumed that any person using the recommended by Volvo Penta must be
Service Manual has a fundamental knowledge of the complied with.
product and is able to carry out mechanical and • Only spare parts approved by Volvo Penta may
electrical work to trade standard. be used.
Volvo Penta continually develops its products; we • Service on injection pumps, pump settings and
therefore reserve the right to make changes. All injectors must always be carried out by an
information in this manual is based on product data authorized Volvo Penta workshop.
which was available up to the date on which the
• The engine must not be converted or modified,
manual was printed. New working methods and
except with accessories and service kits which
significant changes introduced to the product after
Volvo Penta has approved for the engine.
this date are communicated in the form of Service
bulletins. • No changes to the exhaust pipe and engine air
inlet duct installations may be made.
Spare Parts
• No warranty seals (where present on the
Spare parts for the electrical and fuel systems are product) may be broken by unauthorized
subject to various national safety standards. Volvo persons.
Penta Original Spare Parts meet these standards. No
damage of any kind caused by the use of spare parts The general instructions in the Operator's Manual
not approved by Volvo Penta will be compensated by concerning operation, service and maintenance
any warranty undertaking. 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 Each product comprises a large number of interacting
based on a workshop scenario where the product is systems and components. A deviation from the
mounted in a workholding fixture. Maintenance work technical specification may dramatically increase the
is often carried out in situ, in which case - if nothing environmental impact of an otherwise reliable
else is indicated - using the same working methods system. It is therefore critical that the stated wear
as the workshop. tolerances be adhered to, that systems which can be
adjusted be correctly set up and that only Volvo Penta
Warning symbols that occur in the service manual. Original Parts are used. The intervals in the care and
For significance, refer to Safety Information. maintenance schedule must be followed.
Some systems, e.g. fuel systems, often require
DANGER! special expertise and test equipment. A number of
components are factory-sealed, for among other
WARNING! things environmental reasons. Warranty-sealed
components may not be worked on without
CAUTION! authorization to perform such work.
IMPORTANT!, NOTE! Remember that most chemical products, incorrectly
are by no means comprehensive since not everything used, are harmful to the environment. Volvo Penta
can be foreseen as service work is carried out in the recommends the use of biodegradable degreasers
most varied of circumstances. We call attention to whenever components are cleaned, unless otherwise
risks that may occur due to incorrect handling during specified in the Service Manual. When working
work in a well-equipped workshop using working outdoors, take especial care to ensure that oils and
methods and tools tried and tested by us. wash residues etc. are correctly properly for
destruction.
The service manual describes work operations
carried out with the aid of Volvo Penta Special Tools,
where such have been developed. Volvo Penta Tightening torque
Special Tools are designed to ensure the safest and Tightening torques for vital fasteners that must be
most rational working methods possible. It is applied using a torque wrench are indicated in the
therefore the responsibility of anyone using tools or Service Manual, chapter Tightening torques and in
working methods other than those we recommend to the Manual's work descriptions. All torque indications
ensure that no risk of personal injury or mechanical apply to clean threads, bolt heads and mating faces.
damage is present, or that malfunction can result. Indicated torque data apply to lightly-oiled or dry
threads. If lubricants, locking fluids or sealants are
In some cases, special safety regulations and user
required for fasteners, the correct type will be
instructions may be in force for the tools and
indicated in the job description.
chemicals mentioned in the Service Manual. These
rules must always be observed, so there are no
special instructions about this in the workshop
Torque, angle tightening
manual. When torque/angle tightening, the fastener is
tightened to a specified torque, and tightening then
By following these basic recommendations and using continues through a pre-determined angle.
common sense it is possible to avoid most of the risks
involved in the work. A clean workplace and a clean Example: For 90° angle tightening, the fastener is
product will eliminate many risks of personal injury turned an additional 1/4 turn in one sequence, after
and malfunction. 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 Anaerobic agents.

These agents cure in the absence of air. These
Removed lock nuts may not be re-used; they must be preparations are used when two solid components,
replaced by new ones, as locking properties are e.g. two cast components, are fitted together without
impaired or lost with re-use. a gasket. Common uses are also to lock and seal
In the case of lock nuts with plastic inserts, the plugs, stud threads, taps, oil pressure monitors etc.
tightening torque indicated must be reduced if the nut
has the same nut height as a standard, all-metal Hardened anaerobic preparations are vitreous and
hexagonal nut. for this reason, the preparations are colored to make
Reduce the torque by 25% for bolt sizes of 8 mm or them visible. Hardened anaerobic preparations are
larger. highly resistant to solvents, and old compound
In the case of lock nuts with plastic inserts with a high cannot be removed. On re-assembly, it is important
nut-height (where the all-metal thread is as high as a to carefully degrease and wipe dry components first,
standard hexagonal nut), the indicated torque before applying new sealant in accordance with the
applies. instructions.

Strength Classes Safety regulations for fluorocarbon

Nuts and bolts are grouped into different strength rubber
classes. Their classification is shown by a marking on Fluorocarbon rubber is a common material in seal
the bolt head. Markings of a higher number indicate rings for shafts, and in O-rings, for example.
stronger material. For example, a bolt marked 10-9 is
stronger than one marked 8-8. When fluorocarbon rubber is exposed to high
temperatures (above 300°C/572°F), hydrofluoric acid
For this reason, it is important that when bolted joints can form. This is highly corrosive. Contact with the
are removed they are returned to their original skin can result in severe chemical burns. Splashes in
locations on re-assembly. When replacing bolts, your eyes can result in corrosive wounds. If you
check the applicable Spare parts catalog to ensure breathe in the fumes, your lungs can be permanently
the correct bolt is used. damaged.

Sealing compounds etc. WARNING!

To ensure service work is correctly carried out, it is Seals must never be cut with a torch, or be burnt
important that the correct type of sealants and locking afterwards in an uncontrolled manner. Risk for
fluids are used on joints where such are required. poisonous gases.

In each service manual section concerned, the WARNING!

sealants used in product manufacture are indicated. Always use chloroprene rubber gloves (gloves for
The same sealants, or sealants with equivalent chemicals handling) and goggles. Handle the
properties, must be used for maintenance work. removed seal in the same way as corrosive acid. All
A service technician should have a basic knowledge residue, including ash, can be highly corrosive. Never
of how sealing compounds are handled, and are able use compressed air to blow clean.
to assess the condition of existing seals. Put the remains in a plastic container, seal it and
apply a warning label. Wash the gloves under running
Make sure that mating surfaces are dry and free from water before removing them.
oil, grease, paint and anti-corrosion agent before
applying sealant or locking fluid. Always follow the The following seals are most probably made from
manufacturer's instructions regarding applicable fluorocarbon rubber:
temperatures, hardening times and such.
Seal rings for the crankshaft, camshaft, idler shafts.
Two basic types of compound are used:
O-rings, regardless of where they are installed. O-
RTV preparations (Room Temperature rings for cylinder liner sealing are almost always
Vulcanizing). made of fluorocarbon rubber.
Used most often together with gaskets, e.g. sealing
gasket joints, or are brushed on gaskets. RTV Please note that seals which have not been
sealants are completely visible when the part has exposed to high temperature can be handled
been removed. Old RTV sealant must be removed normally.
before the component is sealed again. Use
denatured alcohol.

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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 which is
fastened by a 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.
When this symbol is used on a series of bolts it is
expected that the service technician tighten the bolts
in a logical sequence.

NOTICE! If an arrow with the text “x3” is pointing at

P0015699 only one item, e.g. a bolt, it still applies to the other
1 Focus two alike items (the two other bolts) highlighted in the
(blue) illustration.

2 Fastenings
(red)
3 Body
(light grey) P0015627

4 Background This symbol gives a positioning number to an object,

(white) e.g. 2, which is also mentioned in the supplied text
information.

P0015628

The symbol in the top left shows part no. of the

positioned special tool, e.g. 9991801.
The lower symbol is used when something needs to
be replaced by a new part / kit.
The symbol on the right side is used when a part
needs to be discarded.

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 00-0 General

Movement Tools

P0015622

Movement arrows are used to show which direction a P0015629

component is to be moved / rotated.

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

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.

Measurements

P0015631

A drill in a specified size, duck tape and stripes may

also be shown as symbols.

P0022436

The symbols are used to show different types of

measurements.
Clearance is shown in this feeler gauge symbol.
This dial indicator symbol shows a MIN value.

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00-0 General

Chemicals Units

P0015695
P0015696

Symbols can also describe when and how a chemical

Units are mentioned in the illustration when a specific
product is to be used.
value (e.g. pressure, weight or resistance etc.) is
expected.
Cleanliness
Important

P0015624

The scraper symbol suggests that a contact surface P0015005

needs to be scraped from sealant etc.
The cloth symbol suggests that the mechanic should The eye symbol is used when something needs close
clean the contact surface thoroughly or be prepared inspection or must be performed in a certain way.
for some oil spill or similar. The symbol to the right is used when several
mechanics are needed.

Sealant
Safety

P0015698

P0015697
The tube symbol shows how thick layer of sealant to
applicate. These symbols are used when a certain safety related
The clock symbol is used when something needs to equipment is needed.
be done within or after a certain time.

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 03-2 Specifications, Engine

03-2 Specifications, Engine

Tightening torques
General Tightening Torques Nm (lbf. ft) Angle tightening
M6 standard bolt 10 ±1.5 (7.4 ±1) –
M8 standard bolt 24 ±4 (17.7 ±3) –
M10 standard bolt 48 ±8 (35.4 ±61) –
M12 standard bolt 85 ±15 (62.7 ±11) –
M14 standard bolt 140 ±25 (103.3 ±18) –
M16 standard bolt 220 ±35 (162 ±26) –

NOTICE! Inspect bolts that will be re-installed.

Damaged bolts with e.g. shear marks under the
heads, must be scrapped.

Special Tightening Torques

Group 21: Engine
Front Engine Mounting, cylinder block 275 ±45 (203 ±33) –
Front Engine Mounting, forward engine mount 150 ±30 (111 ±22) –

Main Bearing Caps:

Step 1 150 ±20 (111 ±15) –
Step 2 – 120°±5°

Conrod caps (tightened diagonally):

Step 1 20 ±3 (15 ±2) –
Step 2 35 ±3 (26 ±2) –
Step 3 – 90°±5°

Stiffening plate / stiffening frame (cylinder block) 48 ±8 (35.4 ±6) –

NOTICE! Tighten the screws in sequence, from
the center outwards.

Lifting eye, front

Step 1 30 ±3 (22.1 ±2) –
Step 2 – 80°±5°

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03-2 Specifications, Engine

Standard valve mechanism Tightening

torque
1 Adjustment, exhaust 38 Nm (28.0 lbf.
ft.)
2 Preload, injector 52 Nm (38.4 lbf.
ft.)
3 Adjustment, inlet 38 Nm (28.0 lbf.
ft.)

P0020122

VCB mechanism Tightening

torque
1 Adjustment, exhaust yoke 38 Nm (28.0 lbf.
ft.)
2 Preload, injector 52 Nm (38.4 lbf.
ft.)
3 Adjustment, inlet 38 Nm (28.0 lbf.
ft.)

P0020123

iEGR mechanism Tightening

torque
1 Adjustment, EGR rocker 25 Nm (18.4 lbf.
ft.)
2 Drain nipple 10 Nm (7.4 lbf.
ft.)
3 Adjustment, exhaust 38 Nm (28.0 lbf.
ft.)
4 Preload, injector 52 Nm (38.4 lbf.
ft.)
5 Adjustment, inlet 38 Nm (28.0 lbf.
ft.)
P0024574

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 03-2 Specifications, Engine

Group 22: Lubrication System

Nm (lbf. ft) Angle tightening
Oil Sump 24 ±4 (17.7 ±3) –
NOTICE! Tighten the screws in sequence, from
the center outwards.
Drain plug, oil sump 60 ±5 (44.3 ±4) –
Bracket, lubrication oil pump / main bearing cap 24 ±4 (17.7 ±3) –
Oil strainer, attachment bolts 24 ±4 (17.7 ±3) –
Oil cooler, attachment bolts (tighten the bolts
diagonally)
Step 1 35 ±5 (26 ±5) –
Step 2 35 ±5 (26 ±5) –

Group 23: Fuel System

Feed pump – intermediate housing / power 24 ±4 (17.7 ±3) –
steering pump
Intermediate housing / power steering pump – 30 ±6 (22.1 ±4) –
flywheel housing

Yoke, unit injector:

With new copper sleeve
First tightening:
Step 1 20 +5/0 (14.8 +4/0) –
Step 2 – 180°±5°

Note: Loosen the fixing yoke bolt before the

second tightening.
Second tightening:
Step 1 20 +5/0 (14.8 +4/0) –
Step 2 – 60°±5°

With re-used copper sleeve

Step 1 20 +5/0 (14.8 +4/0) –
Step 2 – 60°±5°

Locking nut for adjuster screw, unit injector:

Step 1 Tighten until contact –
Step 2 – 45°±5°

Hollow screw M16 40 ±4 (29.5 ±3) –

Hollow screw M4 35 ±4 (25.8 ±3) –
Riser, cylinder head front (M16) 50 ±4 (36.9 ±3) –

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03-2 Specifications, Engine

Piston Cooling Nozzles

Nm (lbf. ft) Angle tightening
Attachment bolt 24 ±4 (17.7 ±3) –

IMPORTANT! Faulty piston cooling will cause the pistons to

seize.
If piston cooling nozzle damage or deformation is
suspected, the nozzle must be replaced (also applies to new
nozzles).
Always check that the piston cooling nozzles are correctly
seated in the cylinder block holes concerned, that their
attachment plates are flat against the block and that the
nozzles are aimed at the notches in the pistons.
If the piston cooling nozzle is not correctly installed, the
engine will immediately seize when loaded.

P0008064

Group 25: Inlet and Exhaust System

Nm (lbf. ft) Angle tightening
Turbo 48 ±8 (35.4 ±6)(1) –
1) Note: Tighten the bolts diagonally. Finally tighten the first bolt again to the same torque.

Control valve, e-EGR:

Step 1 25 Nm (18.4 lbf. ft.)
Step 2 53 Nm (39.1 lbf. ft.)
Step 3 Loosen the bolts ≈ −90°
Step 4 25 Nm (18.4 lbf. ft.)
Step 5 53 Nm (39.1 lbf. ft.)

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 03-2 Specifications, Engine

P0020780

1 Under pressure sensor, air filter. Clamp. 8 e-EGR control valve

2 Camshaft position sensor Apply paste for fixture, part no. 1161929.
Tightening torque: 8 Nm (5.9 lbf. ft.) Install bolts with spacers.
3 Pre-NOx sensor (TAD1170-72VE) Tighten the e-EGR control valve in the following
Tightening torque: 50 Nm (36.9 lbf. ft.) steps:
4 Air throttle (TAD1150-52VE, TAD1170-72VE)
1 25 Nm (18.4 lbf. ft.)
5 Coolant level sensor. Plug model.
6 Wastegate valve 2 53 Nm (39.1 lbf. ft.)
7 Coolant temperature sensor 3 Loosen the bolts ≈ −90°
Tightening torque: 22 Nm (16.2 lbf. ft.)
4 25 Nm (18.4 lbf. ft.)
5 53 Nm (39.1 lbf. ft.)
9 Oil pressure sensor
Tightening torque: 25 Nm (18.4 lbf. ft.)

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03-2 Specifications, Engine

P0020781

10 Crankcase pressure sensor 13 Auxiliary stop

Tightening torque: 25 Nm (18.4 lbf. ft.) 14 Fuses
11 Air inlet pressure/intake manifold temperature 15 Oil level/temperature sensor (M40 nut)
sensor Tightening torque: 80 Nm (59 lbf. ft.)
Tightening torque: 8 Nm (5.9 lbf. ft.) 16 Water in fuel switch
12 Flywheel position sensor Tightening torque: 2 Nm (1.5 lbf. ft.)
Tightening torque: 8 Nm (5.9 lbf. ft.) 17 Fuel pressure sensor
Tightening torque: 25 Nm (18.4 lbf. ft.)

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 03-2 Specifications, Engine

Tightening Schedules
Cylinder head
23
13 25 9 21 6 18 1 15 3 19 7 23

14
P0012814 10 4 2 5 8 12
26 22 16 17 20 24

Tightening torques: Nm (lbf.ft) Angle tightening

Stage 1 60 ±10 (44.3 ±7) –
Step 2 (check tightening) 60 ±10 (44.3 ±7) –
Stage 3 – 120°±5°
Stage 4 – 90°±5°

Core plug, cylinder head 60 ±10 (44.3 ±7) –

Locking nut, valve adjustment:
Stage 1 Tighten until contact –
Stage 2 – 60°±5°

Valve Cover
9 10
12 11 1 7 8
13

16
6
15 14 2 3 4 5
P0004253

Nm (lbf.ft) Angle tightening

Tightening torques 24 ±4 (17.7 ±3) –

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03-2 Specifications, Engine

Timing gear plate

Apply silicone to the back of the cylinder head and Tighten the bolts in numerical order.
cylinder block.

Nm (lbf.ft) Angle tightening

Tightening torques 24 ±4 (17.7 ±3) –

NOTICE! Apply a bead of sealant (part # 1161231) with

a diameter of approx. 2 mm (0.079").

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 03-2 Specifications, Engine

Transmission
4 5 1

3 7
3
4
8
1 6
2
3
5
2 4
6
3 1

5 6

2 4

1
5

Nm (lbf.ft) Angle tightening

1. Crankshaft gear 24 ±4 (17.7 ±3) –

2. Intermediate gear, double

Apply locking fluid 1161053 to the bolts and tighten
in the numerical order illustrated.
Stage 1 35 ±4 (25.8 ±3) –
Stage 2 – 60°±5°

3. Intermediate gear, adjustable

Tighten the bolts in the numerical order illustrated.
Stage 1 35 ±4 (25.8 ±3) –
Stage 2 – 120°±5°

4. Camshaft gear / vibration damper

Tighten the bolts in the numerical order illustrated.
Stage 1 45 ±4 (33.2 ±3) –
Stage 2 – 90°±5°

5. Drive, power steering pump / fuel feed pump 100 ±10 (73.8 ±7) –

6. Drive gear, PTO (power take-off) 200 +50 (147.5 +36.9) –

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03-2 Specifications, Engine

Flywheel Housing

35 6 Nm

P0002437
165 10 Nm

NOTICE! Apply a bead of sealant (part # 1161231) with

a diameter of approx. 2 mm (0.079"); see illustration.

Tightening torques: Nm (lbf.ft) Angle tightening

M12 110 ±5 (81.1 ±4) –
M14 165 ±10 (121.7 ±7) –

Timing gear cover, upper

4

2 5

1
3

Nm (lbf.ft) Angle tightening

Tightening torques 24 ±4 (17.7 ±3) –

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 03-2 Specifications, Engine

Flywheel

NOTICE! Make sure that the flange is clean and dry.

Tightening torques: Nm (lbf.ft) Angle tightening

Stage 1 60 ±5 (44.3 ±4) –
Stage 2 – 120°±10°

Cover, front crankshaft seal

NOTICE! Apply a bead of sealant (part # 1161231)*

with a diameter of approx. 2 mm (0.079"); see
illustration.
* Sealant 1161231 (cartridge 0.31 l), or 1161277 (tube 20 g).

Tightening torques: Nm (lbf.ft) Angle tightening

Stage Tighten all bolts by hand (start with bolts 2
1: and 7)
Stage 2 Tighten bolts 2 and 7 24 ±4 (17.7 ±3) –
Stage 3 Tighten all bolts 1–8 24 ±4 (17.7 ±3) –

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03-2 Specifications, Engine

Vibration Damper (crankshaft)

12
10 1

8 3

6 5

4 7

2 9
P0002978 11

NOTICE! Apply a bead of sealant (part # 1161231) with

a diameter of approx. 2 mm (0.079"); see illustration.

Tightening torques: Nm (lbf.ft) Angle tightening

Stage 1 45 ±5 (33.2 ±3) –
Stage 2 – 90°±5°

NOTICE! Tighten the bolts in the numerical order

illustrated.
NOTICE! The vibration damper's 8.8 bolts may NOT be
re-used.

Lubrication oil cooler, cover

3, 6 8 10 12 1, 14 16 18 20 22

24
4

7 9 11 13
5 15 25
P0004254 2, 17 19 21 23

Nm (lbf.ft) Angle tightening

Tightening torques 24 ±4 (17.7 ±3) –

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 03-2 Specifications, Engine

Housing, safety valve

Nm (lbf.ft) Angle tightening

Tightening torques 48 ±8 (35.4 ±6) –

Valve housing, lubrication system

Nm (lbf.ft) Angle tightening

Tightening torques 25 ±5 (18.4 ±4) –

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03-2 Specifications, Engine

Bearing caps, camshaft/rocker arm shaft

If the rocker arm shaft has been loosened or removed,
only the bolts that retain the shaft need be tightened
according to sequence on re-assembly.

Nm (lbf.ft) Angle tightening

Stage Tighten bolts 1–7 25 ±3 (18.4 ±2) –
1:
Stage Tighten bolts 9, 11, 13 90 ±5 (66.4 ±4) –
2: Start with bolt 11.
NOTICE! Tighten the bolts in stages to ensure
that the rocker arm shaft bottoms against the
bearing housing without bending the shaft.
Stage Tighten bolts 8, 10, 12, 14 60 ±5 (44.3 ±4) –
3:
Stage Undo bolts 9, 11, 13 – –
4:
Stage Tighten bolts 9, 11, 13 60 ±5 (44.3 ±4) –
5:
Stage Tighten bolts 1–7 – 90°±5°
6:
Stage Tighten bolts 8-14 – 100°±5°
7:

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 03-2 Specifications, Engine

Intake manifold

P0002679

NOTICE! Apply a bead of sealant (part # 1161231) with

a diameter of approx. 2 mm (0.079"); see illustration.
13 11 1 9 7 5 3

14 12 2 10 8 6 4
P0002979

Tightening torques: Nm (lbf.ft) Angle tightening

Tighten bolts 1 through 14 in numerical order 24 ±4 (17.7 ±3) –
Plug, (M10) 20 ±3 (14.8 ±2) –
Sensor, charge air pressure / charge air temperature 12 ±2 (8.9 ±1.5) –

Exhaust manifold
7 1 9 3 11 5

2 8 4 10 4 12
P0008554

Tightening torques: Nm (lbf.ft) Angle tightening

Stage Tighten bolts (in numerical order) until they 5 ±1.5 (3.7 ±1.1) –
1: touch
Stage 2 Tighten bolts 7–12 in the sequence 7–8–9– 10 ±1.5 (7.4 ±1.1) –
10–11–12
Stage 3 Tighten bolts 1 through 12 in numerical 48 ±8 (35.4 ±6) –
order

47705020 03-2018 © AB VOLVO PENTA 23

03-2 Specifications, Engine

Engine harness

1. Rubber clamp 3. Rubber clamp (when oil level 4. Holder (part # 8131393)*
2. Strap monitor not fitted) 5. Strap (part # 983472)*

* IMPORTANT! Use only Volvo Penta original tension straps and holders under the valve cover for clamping the wiring to the unit injectors.
These parts are specially designed to resist oil and high temperatures.

24 47705020 03-2018 © AB VOLVO PENTA

 03-2 Specifications, Engine

Engine, General
Type designation TAD1140-TAD1142VE
TAD1150-TAD1152VE
TAD1170-TAD1172VE
No. of cylinders 6
Weight, dry 1072 kg (2363 lbs)
Stroke 152 mm (5.98”)
Displacement 10.84 l (2.86 US gals)
Bore 123 mm (4.84”)
Firing order 1-5-3-6-2-4
Direction of rotation (seen from front) Counter-clockwise
Low idle 600 rpm
Wide open throttle range
TAD1170-TAD1172VE 2250 rpm
Rating 4 -
Rating 5 -
Number of valves per cylinder 4
Compression ratio 17.0:1
Compression stroke pressure, starter motor cranking 40 kPa (5.8 lbf. ft.)

47705020 03-2018 © AB VOLVO PENTA 25

03-2 Specifications, Engine

Engine
Group 21: Engine
Cylinder head
Type 6 cylinders
Height, min. 135 mm (5.31")
Max. flatness error (base plane) 0.4 mm (0.0157")

Cylinder Head Bolts

May be re-used 5 times
Thread size M16 x 2

Cylinder liner / cylinder

Type Wet, replaceable
Bore 123 +0.03 mm (4.84 +0.00118")
Liner collar height above block plane 0.14-0.21 mm (0.0055-0.0083")
Depth from block plane to liner collar 11 +0.04/-0.01 mm (0.43 +0.00157/-0.00039")
No. of O-rings in upper / lower liner seal 3 pcs

Pistons
Type / material Monosteel S103
Number of ring grooves 3 pcs
Front marking Arrow points forward
Height above engine block plane 0.15-0.65 mm (0.0059-0.0256")

Piston rings
Quantity 3 pcs
Upper compression ring, type Full keystone
Upper compression ring, height 3.5 mm (0.138") (nominal value)
Upper compression ring, marking Top
Upper compression ring, gap (new ring), max 0.3-0.45 mm (0.0118-0.0177")
2nd compression ring, type Taper face
2nd compression ring, height 2.5 -0.005/-0.03 mm (0.098 -0.0002/-0.00118")
2nd compression ring, marking Top
Oil ring, height 3.5 -0.01/-0.03 mm (0.138 -0.00039/-0.00118")

Crankshaft
Type of hardening Induction hardened
Length 1066 mm (42.0")
End float(1) 0.07-0.31 mm (0.0028-0.0122")
Ovality of main and big-end bearings, max 0.01 mm (0.0004")
Taper on main and big end bearings, max 0.01 mm (0.0004")
Center main bearing runout, max 0.15 mm (0.00591")

1. Measurements apply to lubricated components.

26 47705020 03-2018 © AB VOLVO PENTA

 03-2 Specifications, Engine

P0005849

Main bearing journals

Diameter, standard 108 mm (4.25")
Undersize:
0.25 mm (0.0098") 107.85-107.87 mm (4.2460-4.2468")
0.50 mm (0.0197") 107.73-107.75 mm (4.2413-4.2421")
0.75 mm (0.0295") 107.60-107.62 mm (4.2362-4.2370")
1.00 mm (0.0394") 107.48-107.50 mm (4.2315-4.2323")
1.25 mm (0.0492") 107.35-107.37 mm (4.2264-4.2272")
Surface finish, main bearing journal Ra 0.25 (0.0098")
Surface finish, radius Ra 0.4 (0.0157")
Width thrust bearing journal (A) standard 42 mm (1.654")
Oversize:
0.2 mm (0.0079"), thrust bearing 0.1 mm (0.0039") 42.17-42.22 mm (1.6602-1.6622")
0.4 mm (0.0157"), thrust bearing 0.2 mm (0.0079") 42.37-42.42 mm (1.6681-1.6701")
0.6 mm (0.0236"), thrust bearing 0.3 mm (0.0118") 42.57-42.62 mm (1.6760-1.6779")
Fillet radius (R) 4.5 mm (0.177")

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03-2 Specifications, Engine

R
C D

B
p0005210

Thrust washers (thrust bearings)

Width (B) standard 3.2 mm (0.1260")
Oversize:
0.1 mm (0.0039") 3.2-3.3 mm (0.1260-0.1299")
0.2 mm (0.0079") 3.3-3.4 mm (0.1299-0.1.339")
0.3 mm (0.0118") 3.4-3.5 mm (0.1339-0.1.378")

Main bearing shells

External diameter (C) 113 mm (4.45")
Thickness (D) standard 2.5 mm (0.098")
Oversize:
0.25 mm (0.0098") 2.6-2.7 mm (0.102-0.106")
0.50 mm (0.0197") 2.7-2.8 mm (0.106-0.110")
0.75 mm (0.0295") 2.8-2.9 mm (0.110-0.114")
1.00 mm (0.0394") 2.9-3.0 mm (0.114-0.118")
1.25 mm (0.0492") 3.1-3.2 mm (0.122-0.126")
Main bearing, radial clearance, max 0.11 mm (0.0043")

28 47705020 03-2018 © AB VOLVO PENTA

 03-2 Specifications, Engine

C A
B

p0005211

Big-end bearing journals

Diameter 88 mm (3.46")
Undersize:
0.25 mm (0.0098") 87.85-87.87 (3.4587-3.4594")
0.50 mm (0.0197") 87.73-87.75 (3.4539-3.4547")
0.75 mm (0.0295") 87.60-87.62 (3.4488-3.4496")
1.00 mm (0.0394") 87.48-87.50 (3.4441-3.4449")
1.25 mm (0.0492") 87.35-87.37 (3.4390-3.4398")
Surface finish, big end bearing Ra 0.25 (0.0098")
Surface finish, radius Ra 0.4 (0.0157")
Width (A) 54 mm (2.13")
Fillet radius (R) 4.5 mm (0.177")

Big-end journal shells

External diameter (C) 91 mm (3.58")
Thickness (D) standard 2.4 mm (0.0945")
Oversize:
0.25 mm (0.0098") 2.5-2.6 mm (0.0984-0.1024")
0.50 mm (0.0197") 2.6-2.7 mm (0.1024-0.1063")
0.75 mm (0.0295") 2.7-2.8 mm (0.1063-0.1102")
1.00 mm (0.0394") 2.8-2.9 mm (0.1102-0.1142")
1.25 mm (0.0492") 3.0-3.1 mm (0.1181-0.1220")
Connecting rod big end, diameter (D) 90.83 mm (3.5760")

Connecting rod
Length, center-center (E) 225 mm (8.86")
Piston pin bush internal diameter (G) 54 mm (2.13")
Big end bearings, radial clearance, max 0.03 mm ()

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03-2 Specifications, Engine

Marking
FRONT on the connecting rod faces forwards.
The connecting rods and caps are marked in pairs with
a serial number (see illustration).

P0020566

Valves
Valve head diameter:
Inlet 40 mm (1.57")
Exhaust 38 mm (1.50")
Max play, valve stem - valve guide:
Inlet 0.5 mm (0.0197")
Exhaust 0.5 mm (0.0197")
Valve guide, diameter:
Inlet 8 mm (0.315")
Exhaust 8 mm (0.315")
Valve guide, height above spring plane:
Inlet 24.5 ±0.5 mm (0.964 ±0.0197")
Exhaust 16.5 ±0.5 mm (0.650 ±0.0197")
Valve springs, uncompressed length:
Outer valve springs 73-74 mm (2.87-2.91")
Inner valve springs 70-71 mm (2.76-2.80")

Valve clearance
Standard mechanism
Cold engine, setting value:
Inlet 0.2 mm ± 0.05 (0.0079")
Exhaust 0.8 mm ± 0.05 (0.0315")
VCB mechanism
Cold engine, setting value:
Inlet 0.2 mm ± 0.05 (0.0079”)
Exhaust 1.6 mm ± 0.05 (0.0315”)
iEGR mechanism
Cold engine, setting value:
Inlet 0.2 mm ± 0.05 (0.0079”)
Exhaust 0.8 mm ± 0.05 (0.0315")

30 47705020 03-2018 © AB VOLVO PENTA

 03-2 Specifications, Engine

Valve seats
Outer diameter (A):
Inlet, standard 42 mm (1.65")
Exhaust, standard 40 mm (1.57")
Inlet, oversize 42.1 mm (1.657")
Exhaust, oversize 40.1 mm (1.579")
Height (B):
Inlet 7.3 mm (0.287")
Exhaust 6.4 mm (0.252")

B
A

P0020572

Valve seat angle (A):

Inlet 29.5°
Exhaust 29.5°
Seat angle in cylinder head (B):
Inlet 30°
Exhaust 30°

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03-2 Specifications, Engine

Valve seat position

Diameter (C):
Inlet 42 mm (1.65")
Exhaust 40 mm (1.57")
Depth (D):
Inlet 11.5 mm (0.453")
Exhaust 9.9 mm (0.390")
Seat base radius (R):
Inlet, max. 0.8 mm (0.0315")
Exhaust, max. 0.8 mm (0.0315")

Camshaft
Camshaft setting check(1) cold engine and valve clearance
= 0.
Inlet valve for cylinder 1 must be open at flywheel position
6 after TDC 1.7 ±0.4 mm (0.067 ±0.0157")
Propulsion type Gear wheel
Number of bearings 7 pcs
Diameter, bearing journals, standard 69.97-70.00 mm (2.7547-2.7559")
Diameter, bearing journals, undersize dimension:
0.25 mm (0.0098") 69.72-69.78 mm (2.7449-2.7472")
0.50 mm (0.0197") 69.47-69.53 mm (2.7350-2.7374")
0.75 mm (0.0295") 69.22-69.28 mm (2.7252-2.7276")
Valve lift:
Inlet 13.1 mm (0.5157")
Exhaust 12 mm (0.4724")
Permissible wear, full cam profile 0.1 mm (0.0039")
Unit injector, stroke 13 mm (0.5118")
Max end float 0.24 mm (0.0094")
Max permissible ovality (with new bearings) 0.05 mm (0.0020")
Bearing, max permissible wear on diameter 0.05 mm (0.0020")
1) During this check, the timing gear must be turned in the correct direction (clockwise seen from the front) to take up all gear
lash.

Camshaft Bearings
Camshaft bearing thickness, standard 1.92 mm (0.0756")
Oversize:
0.25 mm (0.0098") 2.04 mm (0.0803")
0.50 mm (0.0197") 2.17 mm (0.0854")
0.75 mm (0.0295") 2.29 mm (0.0902")

32 47705020 03-2018 © AB VOLVO PENTA

 03-2 Specifications, Engine

Timing gears

Gear wheel:
1 Drive gear, camshaft
2 Engine PTO (accessory)
3 Intermediate gear, double drive, outer
Intermediate gear, double drive, inner
4 Drive gear, crankshaft
5 Drive gear, lubrication oil pump
6 Drive gear, steering servo and fuel feed pump
7 Intermediate gear, power steering pump
8 Drive gear, air compressor
9 Intermediate gear, adjustable

P0020594

Gear Lash 0.05-0.17 mm (0.0020-0.0067")

Idler wheel stub shaft, diameter 100 mm (3.94")
Idler wheel bush, diameter 100 mm (3.94")
Radial clearance for intermediate gear, max 0.05 mm (0.0020")

Lubrication System
Oil pressure limits

X Engine speed (rpm)

Y Oil pressure (kPa)

A Warning level
B Alarm level
P0020595

Oil volume incl. oil filter, no engine incline 37 l (9.8 US gals)

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03-2 Specifications, Engine

Fuel System

Fuel specification
Fuel must comply with national and international standards for commercially supplied fuels, such
as:
EN 590 (with nationally adapted environmental and cold weather requirements)
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulfur content: According to current legislation in the country concerned.

Low sulfur content fuel (urban diesel in Sweden and city diesel in Finland) may entail a power loss of up to 5% and an
increase in fuel consumption of around 2–3 %.

Fuel pressure limits

X Engine speed (rpm)

Y Fuel pressure (kPa)

A Warning level
P0020596

Type of fuel system Unit injector

Overflow valve, opening pressure 400-550 kPa (58.0-79.8 psi)

34 47705020 03-2018 © AB VOLVO PENTA

 03-2 Specifications, Engine

Pre-load 3–4 flats

(0.75 ±0,1 mm / 0.0295 ±0.0039")
Adjust the unit injector rocker arm to zero
clearance against the camshaft. Then tighten the
adjuster screw a further 3-4 flats (180°-240°).

Location of unit injector trim code(1)

P0020652

1. Note: The trim code specifies individual unit injector tolerances

for the engine control unit. In the example illustrated the trim code is
27547C9M3.

47705020 03-2018 © AB VOLVO PENTA 35

03-2 Specifications, Engine

Inlet and Exhaust System

Charge air pressure limits

X Engine speed (rpm)

Y Absolute pressure, charge air cooler (kPa)

A Warning level
B Alarm level

P0020651

Turbo
Type Holset CTT HX40
End float, turbine shaft 0.127 mm (0.0050")
Radial clearance, compressor disc 0.508 mm (0.0200")

Exhaust temperature, max 492 ºC (917.6 ºF).

Cooling System
Type Overpressure (sealed system)

Coolant type: Volvo Penta Coolant VCS

Color Yellow
Contains Ethylene glycol and anti-corrosion additives
Mix with Water (according to ASTM D4985)
Mixing proportions (conc coolant/water)(1) 40/60, freezing point -24 °C (-11.2 °F)

Coolant volume:
Engine only 17 liters (4.5 US gals)
Including radiator and hoses 21 liters (5.5 US gals)

Filler cap pressure valve opens at 75 / 100 kPa

Check the opening pressure at the filler cap.

Thermostat:
Opens at 82 ºC (179.6 ºF)
Fully open at 92 ºC (197.6 ºF)

1. Volvo Penta recommends ready mix coolant (Ready Mixed).

36 47705020 03-2018 © AB VOLVO PENTA

 03-3 Specifications, Electrical

03-3 Specifications, Electrical

Electrical System
System voltage 24 V (6.7 bhp)
Alternator , make Bosch
Alternator, max voltage / current 110 V / 150 A
Starter motor, output:
Standard 5.5 kW (6.7 bhp)
Start / Stop 7 kW (6.7 bhp)
Cranking speed with starter motor engaged 100 rpm

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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, 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.

This symbol is used to inform that added information needs to be read. And where to find needed information.

This symbol is used where VODIA computer is needed,. either for fault tracing, testing or for programming.

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

38 47705020 03-2018 © AB VOLVO PENTA

 05-1 Safety Instructions

Immobilize the engine by turning off the power Avoid opening the coolant filling cap when the
! supply to the engine at the main switch ! engine is hot. Steam or hot coolant can spray
(switches) and lock it (them) in the off position out and system pressure will be lost. Open the
before starting work. Post a warning notice at filler cap slowly, and release the pressure in the
the main circuit breaker. 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 Hot oil can cause burns. Avoid skin contact with
! out with the engine stopped. However, some ! hot oil. Ensure that the lubrication system is not
work, such as adjustments, will require the under pressure before any work is begun.
engine to be running. Approaching an engine Never start or operate the engine with the oil
which is running is a safety risk. Bear in mind filler cap removed, because of the risk of oil
that loose clothing or long hair can fasten in ejection.
rotating parts and cause serious personal
injury.

Be aware of hot surfaces (exhaust pipes, Never start the engine without installing the air
! turbos, charge air pipes, starting heaters etc.) ! filter. The rotating compressor turbine in the
and hot fluids in pipes and hoses on an engine turbocharger can cause severe injury. Foreign
that is running or has just stopped. objects entering the intake ducts can also cause
If work is done adjacent to a running engine, a mechanical damage. Install all protective
careless movement or a dropped tool may in the covers before the engine is started.
worst case lead to personal injury.

Ensure that the warning symbols or information Only start the engine in a well-ventilated space.
! decals on the product are always clearly visible. ! When running in a confined space, exhaust
Replace decals which have been damaged or fumes and crankcase gases must be led away
painted over. from the engine bay or workshop area.

Avoid getting oil on your skin! Protracted or The majority of chemicals e.g. engine and
! repeated exposure to oil can cause skin to ! transmission oils, glycol, gasoline, and diesel
become dry. Irritation, dryness, eczema and oil, together with chemicals for workshop use
other skin problems may then result. From a such as degreasing agents, paints and
health standpoint, used oil is more dangerous solvents, are injurious to health. Carefully read
than new. Use protective gloves and avoid oil- the instructions on the product packaging!
soaked clothes and rags. Wash regularly, Always follow a product's safety directions, e.g.
especially before eating. Use suitable barrier use of protective mask, glasses, gloves etc.
creams to counteract drying out of the skin and Ensure that other personnel are not exposed to
to aid dirt removal. 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 Clutch adjustments must be carried out with the
! at the main switch(es) before carrying out work ! engine stopped.
on the electrical system.

47705020 03-2018 © AB VOLVO PENTA 39

05-1 Safety Instructions

Always use protective glasses or goggles when Never start the engine with the valve cover
! carrying out work where a risk of splinters, ! removed. There is a risk of personal injury.
grinding sparks, splashes from acid or other
chemicals is present. Your eyes are extremely
sensitive; injury may cause blindness!

Never use start gas or similar products as a Stop the engine before working on the cooling
! starting aid. They may cause an explosion in the ! system.
inlet manifold. Danger of personal injury. 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 Make sure that oil, fuel-soaked rags, and used
! flammable. Do not allow open flames or sparks ! fuel and oil filters are stored in a safe manner.
in their vicinity. Gasoline, some thinners, and Rags soaked in oil can spontaneously ignite
hydrogen gas from batteries are extremely under certain circumstances. Used fuel and oil
flammable and explosive when mixed with air in filters are environmentally hazardous waste
the correct proportions. No Smoking! Ensure and must be handed to an approved waste
that the work area is well ventilated and take the management facility for destruction, as must
necessary safety precautions before welding or any used lubrication oil, contaminated fuel,
grinding work is begun. Always ensure that paint residue, solvents, degreasers and wash
there are fire extinguishers close at hand in the residue.
work area.

Batteries must never be exposed to open Never work alone when removing heavy
! flames or electric sparks. Never smoke in the ! components, even when using lifting devices
vicinity of the batteries; they generate hydrogen such as locking tackle lifts. When using a lifting
gas when charged, which is explosive when device, two people are usually required to do
mixed with air. This gas is easily ignited and the work - one to take care of the lifting device
highly explosive. A spark, which can be caused and the other to ensure that components are
by incorrect battery connection, is sufficient to lifted clear and not damaged during the lifting
cause a battery to explode and cause damage. operations.

Do not touch the connections during start

attempts. Sparking hazard! Do not lean over
batteries.

Never transpose the positive (+) and negative The existing lugs on the engine should be used
! (-) battery posts when installing batteries. Such ! for lifting. Always check that the lifting
a transposition can result in serious damage to equipment used is in good condition and has the
electrical equipment. Refer to the wiring load capacity to lift the engine (engine weight
diagram. including gearbox or extra equipment). For safe
Always use protective goggles when charging handling and to avoid damaging components
and handling the batteries. Battery electrolyte fitted to the top of the engine, the engine must
contains sulfuric acid which is highly corrosive. be lifted with a correctly adjusted lifting boom.
Should the battery electrolyte come into contact All chains or wires must run parallel to each
with unprotected skin, wash it off immediately other and as perpendicular to the engine as
using soap and copious amounts of water. If you possible. If other equipment attached to the
get battery acid in your eyes, flush at once with engine has altered its center of gravity, special
copious amounts of water and seek medical lifting devices may be needed to obtain the
assistance immediately. correct balance for safe handling. Never
perform any work on an engine that is only
suspended from the lifting equipment.

40 47705020 03-2018 © AB VOLVO PENTA

 05-1 Safety Instructions

The components in the electrical and fuel Exercise extreme caution when leak-detecting
! systems on Volvo Penta products are designed ! on the fuel system and testing the fuel injector
and manufactured to minimize the risk of fire nozzles. Use eye protection. The jet from a fuel
and explosion. The engine must not be run in nozzle has very high pressure and great
areas where there are explosive materials. 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 Never use a high-pressure washer for cleaning
! recommended by Volvo Penta. Refer to the ! the engine.
Operator's Manual for the product in question. Pay attention to the following when using a high-
Use of fuels that are of a lower grade may pressure washer on components other than the
damage the engine, the injection pump and the actual engine: Never direct the water jet at
injectors. On a diesel engine, low grade fuel can seals, rubber hoses or electrical components.
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.

Fuel delivery pipes must not be bent or When working on the engine; perform leakage
! straightened under any circumstances. Cracks ! and function test as necessary.
may occur. Damaged pipes must be replaced.

47705020 03-2018 © AB VOLVO PENTA 41

08-2 Special Service Tools

08-2 Special Service Tools

The following special tools are used when working on
the engine. The tools may be ordered from AB Volvo
Penta by specifying the number indicated.

P0004343
P0006764
P0006823

885810 Fixture 885811 Timing tool 885822 Magnetic pen

p0013445
P0002930 P0002784

885633 Torque multiplier 885648 Counterhold 1158957 Pliers

P0004344 P0001872 P0006782

1159794 Torque wrench 3849613 Pressure testing kit 9809726 Pneumatic hydraulic
pump

P0006792 P0006761

9809729 Hydraulic cylinder 9986173 Puller 9986485 Stand

42 47705020 03-2018 © AB VOLVO PENTA

 08-2 Special Service Tools

P0001875 P0006269 P0006765

9989876 Dial indicator 9990006 Puller 9990013 Slide hammer

p00006766
P0006768

9990107 Connection washer 9990113 Drift 9990114 Puller

P0011608 P0006769 P0006770

9990117 Cone 9990118 Cone 9990123 Pressure testing kit

P0004314 P0006774

9990124 Nipple 9990156 Adapter 9990157 Press tool

P0006776 P0006777 P0006795

9990160 Fixture 9990164 Fixture 9990174 Drift

P0006786
P0006793 P0002789

9990176 Press tool 9990185 Lifting tool 9990192 Puller

47705020 03-2018 © AB VOLVO PENTA 43

08-2 Special Service Tools

P0004328
P0006780
P0006791

9990210 Valve spring 9992000 Handle 9992479 Holder for dial

compressor indicator

P0006794 P0006781

9992670 Hand pump 9992873 Nipple 9996049 Draining hose

p0004329
P0006788
p0006802

9996159 Adapter 9996239 Lifting tool 9996394 Support

P0004331

p0004330 P0002947

9996395 Support 9996398 Manometer 9996400 Slide hammer

p0006800 P0004332 P0006804

9996441 Cover, with 9996645 Puller 9996662 Pressure testing kit

connecting nipple

P0010359
p0006801

9996666 Nipple 9996966 Press tool 9998246 Drift

44 47705020 03-2018 © AB VOLVO PENTA

 08-2 Special Service Tools

P0006805 P0006806 P0006808

9998249 Protective sleeve 9998250 Sealing ring 9998251 Protection plug

P0006813 P0004349

9998264 Lifting tool 9998267 Guide sleeve 9998339 Manometer

P0006816 P0004580 P0001859

9998487 Sleeve 9998493 Hose 9998511 Lever

P0006814 P00068115

9998580 Protective sleeve 9998599 Cleaning kit 9998601 Fixture

10
0

20
0
20

P0010358 P0001878 P0001881

9998674 Adapter 9999179 Extractor oil filter 9999683 Dial indicator (short
probe)

P0001879 P0012166

9999696 Magnetic stand 88800011 Drift 88800014 Rotation tool

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08-2 Special Service Tools

P0010364
P0006767

88800021 Drift 88800022 Mounting tool 88800031 Measuring tool

P0006789

P0002793 p0006796

88800062 Drift 88800083 Piston ring pliers 88800147 Drift

P0006809

88800151 Drift 88800513 Drift 88800218 Extractor plate

P0012151 P00013450

88800318 Piston ring 88800387 Puller 88890105 Refractometer

compressor

88800460 Sleeve 88820016 Alignment tool

46 47705020 03-2018 © AB VOLVO PENTA

 08-2 Special Service Tools

9998599 Cleaning kit

Cleaning kit for unit injector. Contains:

• 959239 Screw M10

• 9808570 Brush, white
• 9998580 Sleeve with holder and O-ring
• 276948 O-ring set
• 9808634 Brush kit, contains:
- Storage box
- Holder
- Holder
- Handle
- 9808614 Brush, yellow 10 pcs
- 9808617 Wire brush, narrow
- 9808618 Wire brush, coarse

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18-0 General

18-0 General
Chemical products

P0001869 P0016363

828250 Grease 85145750 Thread locking 1161231 Sealant

P0001870

1161277 Glue 1161771 Sealant 1161929 Lubricant

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 20-0 Engine Information, General

20-0 Engine Information, General

Test and Adjustments

Cooling System, Pressure Testing
WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.

Alternative 1:

Tools:
9996441 Cover, with connecting nipple
9996662 Pressure testing kit
1 Check that all hoses and clamps are undamaged.
2 Check that the tap on the reducing valve is
screwed out.
3 Replace the filler cap on the expansion tank with
9996441 Cover, with connecting nipple.
Connect the pressure test device to the nipple on
the cover.

P0010196

4 Connect the pressure test device to the

compressed air system and open tap (B). Adjust
the reducing valve (A) so that the manometer
shows a pressure of 70 kPa (10.2 PSI). Close the
cock (B).
The pressure may not drop within two minutes for
the cooling system to be considered free from
leaks.

NOTICE! Repeat the pressure test if there is any

doubt about whether the cooling system leaks or
not.
5 Shut off the compressed air after pressure
testing.
P0006859
Release excess pressure in the system by
unscrewing the valve on the reducing valve and
opening tap (B).
6 Remove the pressure testing device.
7 Check the coolant level in the expansion tank.
Install the regular filler cap.
Start the engine and check that no leaks are
present.

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20-0 Engine Information, General

8 Start the engine. Check that no leakage occurs.

Alternative 2:

Tools:
9996049 Draining hose
9996662 Pressure testing kit
1 Check that all hoses and clamps are undamaged
and intact.
2 Check the coolant level in the expansion tank.
3 Connect 9996662 Pressure testing kit to
9996049 Draining hose and close the cock.
Connect the hose to the engine drain valve (1).
Open the cock and adjust the pressure to 70 kPa
(0.7 bar) with the adjuster knob. Then close the
tap.
4 For the cooling system to be considered free from
leaks, pressure may not drop during a two-
minute test period.
1 5 Open the cock and increase the pressure until the
filler cap opens (must correspond to opening
pressure according to 03-26, Technical Data).
Reduce the pressure to 50 kPa (0.5 bar) and then
increase to 70 kPa (0.7 bar) and check that
pressure is maintained.

P0010197
6 Remove the compressed air connection. Open
the control valve so that the pressure drops and
shut the cock when coolant runs into the drain
hose.
Remove the drain hose from the engine. Then
remove the drain hose from the test equipment
and empty the coolant from the hose.
Re-install the rubber plug in the engine drain
valve.
7 Check the coolant level in the expansion tank.
8 Start the engine. Check that no leakage occurs.

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 20-0 Engine Information, General

Alternative 3:

Tools:
3849613 Pressure testing kit
1 Check that all hoses and clamps are undamaged
and intact.
2 Check the coolant level in the expansion tank.
3 Replace the filler cap on the expansion tank with
a suitable cover from 3849613 Pressure testing
kit.
4 Connect the pump and pump up a pressure of 70
kPa (0.7 bar).
5 For the cooling system to be considered free from
leaks, pressure may not drop during a two-
minute test period.
6 Release the excess pressure and remove the
pressure testing unit.
7 Check the coolant level in the expansion tank. Fit
P0010195
the regular filler cap.
8 Start the engine. Check that no leakage occurs.

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20-0 Engine Information, General

Cylinder Head, Pressure Testing

Tools:
9990123 Pressure testing kit
9996239 Lifting tool
9986485 Stand
9990160 Fixture
9990107 Connection washer
9990164 Fixture

Checking the pressure test unit

Check pressure testing device 9990123 Pressure
testing kit before it is taken into service:
1 Connect the pressure testing device to the
compressed air mains.
2 Set the pressure gauge to 100 kPa (14.5 PSI)
using the reducing valve. The knob can be locked
with a retainer ring moved axially.

P0006858

3 Close the shut-off valve. The pressure on the

pressure gauge must not fall for 2 minutes, for the
device to be regarded as reliable.
4 Unscrew the knob on the reducing valve and
open the tap.

P0007006

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 20-0 Engine Information, General

Pressure Testing
Cylinder head removed.

For all lifts of the cylinder head use 2 lifting chains, tool
9996239 Lifting tool; refer to 21-1, Cylinder Head,
Removal.
1 Wash the cylinder head in a washing bath.
2 Fit the cylinder head to an assembly stand, tool
9986485 Stand with the aid of 9990160 Fixture
and 4 bolts, M8 x 25.
3 Clean the mating surfaces on the cylinder head.
4 Fit seal plates, tool 9990164 Fixture to the
cylinder head using the cylinder head bolts and
M18 nuts (14 pcs. required).
5 Fit connection washer, tool 9990107 Connection
washer onto the thermostat housing seat. Secure
the washer with a G-clamp; see illustration.
P0007007 Leave the side cover in place.
6 Leave the temperature sensor in place.
Plug any coolant connections for the compressor.
7 Connect the pressure gauge hose to connection
washer, tool 9990107 Connection washer.
8 Remove the cylinder head including fixture from
the assembly stand.
Remove the fixture.
9 Put the cylinder head in a water bath, +70 °C
(+158 °F).
10 Connect air to the pressure testing unit.
Open the shut-off valve.
11 Adjust the reducing valve knob so that pressure
gauge shows a pressure of 50 kPa (7.25 psi).
Maintain the pressure for 1 minute.
12 Raise the pressure to 150 kPa (21.76 PSI). Lock
P0007008 the reducing valve knob with the retainer ring.
Close the shut-off valve.
13 After 1 to 2 minutes, check whether the pressure
has dropped, or if bubbles of air can be seen in
the water bath.
If bubbles are visible, check seal plates and
inspect the cylinder head for any cracks.
14 Unscrew the knob on the reducing valve to relieve
the pressure in the cylinder head, and open the
tap.
15 Take the cylinder head out of the water bath.
Attach the fixture.
Secure the cylinder head in the assembly stand.

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20-0 Engine Information, General

16 Blow the cylinder head dry. Be extra thorough

with the fuel channels.

IMPORTANT!
Make sure no dirt gets into the fuel channels, as
this may cause damage to the unit injectors.
17 Remove all the sealing washers and any plugs
installed for the pressure testing.
18 Remove the cylinder head including fixture from
the assembly stand.
Remove the fixture.

P0006858

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 21-0 Engine Complete, General

21-0 Engine Complete, General

Fitting the Fixture

Engine Fixture, Installation
IMPORTANT!
Turn off the main switch before any work is carried out.

IMPORTANT!
Working with the fuel system requests special
cleanliness.

NOTICE! Be prepared to gather up fluid.

P0020666

1 Remove the fuel lines (1) from the cooling loop.

Plug all fuel unions.
2 Remove the engine control unit (2) with cooling
loop; refer to Control Unit, Replace, page 224.
3 Disconnect the harness from the starter motor
and sensor (the rear harness). Remove the
holder (3) for the relay and stop button.
4 Undo the fuel unions (4) to the feed pump; refer
to Fuel Feed Pump, Change, page 209.

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21-0 Engine Complete, General

Remove the servo pipe from the power steering

pump.
5 Remove the fuel filter housing (5); refer to Fuel
filter housing, change, page 205.
Remove the fuel hose and the engine block
attachment.
6 Remove the separator/crankcase ventilation (6).

P0009967

7 Remove the compressor (7) according to

Compressor, Change.
8 Remove the oil line to the separator turbine.

P0020667

9 Fit 88800146 Fixture and 88800345 Adapter

10 Install the engine with the fixture on the assembly
stand.

P0020668

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 21-0 Engine Complete, General

Engine Disassembly
Lube Oil Pump, Removal
1 Remove the oil pump; refer to Lubrication Oil
Pump, Change, page 177.

P0010153

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21-0 Engine Complete, General

Pistons, Removal
Tools:
885822 Magnetic pen
1 Remove the carbon uppermost in the cylinder
bore.
Make sure the press tool cannot touch the pistons
when the pistons are removed.
9996966

P0010048

2 Remove the piston cooling nozzles with the aid of

885822 Magnetic pen.

P0010126

3 Check that the connecting rods are marked; mark

the position if more than one is removed from the
engine.

P0010127

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 21-0 Engine Complete, General

4 Undo the connecting rod bolts a couple of turns.

Tap the bolt heads so that the bearing cap is freed
from the connecting rod.

1
P0010128

5 Remove the bolts entirely. Hold the connecting

rod in place and lift the bearing cap away at the
same time. Take care of the bearing cup if it does
not stay in place in the cap.

P0010129

6 Press out the piston with the connecting rod and

catch it under the engine. Make sure it does not
fall out and become damaged.
The connecting rod separation plane surface is
very sensitive and must not be exposed to impact
or knocks.

P0010130

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21-0 Engine Complete, General

7 Replace the bearing cap on the connecting rod

immediately to protect the separation plane
surfaces.
8 Remove the remaining pistons the same way.

P0010131

9 Remove one retainer ring for the piston pin and

press the pin out.

P0010132

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 21-0 Engine Complete, General

10 Inspect the connecting rod; refer to Connecting

Rod, Check, page 105.

P0010133

Cylinder Liners, Removal

Tools:
9996394 Support
9996395 Support
9996645 Puller
88800218 Extractor plate
1 Turn the engine so that the crankshaft is at the
bottom.
2 Remove the press tool holding the liner to be
removed.

P0010134

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21-0 Engine Complete, General

3 Assemble 88800218 Extractor plate together with

9996645 Puller and 9996394 Support.

P0021024

4 Insert the tools in the liner to be removed. Make

sure the plate ends up directly under the liner.
Screw down on the nut so that the liner is drawn
up.
Pull the cylinder liner out of the block.

P0010136

5 If the liner does not come free when it has

reached the puller, release the nut sufficiently to
allow installation of spacer 9996395 Support.
Continue to pull the liner up until it is free.
Lift out the liner with the tool and then remove the
9996395 tool from the liner. Remove the remaining liners
in the same way.
Inspect the liners; refer to Cylinder Liner and
Pistons, Inspection, page 104.

P0010137

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 21-0 Engine Complete, General

6 Remove the liner O-rings from the engine block.

Check the O-ring grooves for corrosion or any
other damage.

P0010138

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21-0 Engine Complete, General

Crankshaft, Removal
Tools:
9990114 Puller
9990013 Slide hammer
1 Remove the crankshaft belt pulleys; refer to 26-2,
Drive belts, 32-1, Alternator Belt, Replace.
2 Remove the crankshaft seal holder.

P0010156

3 Remove the main bearing cap bolts.

Use 9990114 Puller together with 9990013 Slide
hammer to rock the main bearing caps loose.
Keep the main bearing halves safe.
4 Remove the front engine mounts if they were not
removed earlier.
Attach a suitable lifting strap to the front and rear
end of the crankshaft according to the following
steps.

P0010165

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 21-0 Engine Complete, General

5 Crank the crankshaft so that the timing mark ends

up exactly as illustrated. The crankshaft can only
be removed in this position.
Insert a bolt in the top hole in the timing gear.

P0010167

6 In the same manner, insert a bolt into the other

end of the shaft and attach the lifting strap.

P0010168

7 Lift the crankshaft and make sure that the

connecting rods and main bearing cups do not
come out with the crankshaft.

P0010169

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21-0 Engine Complete, General

8 Remove the thrust washers.

Remove the main bearing cups and wipe the
bearing seats dry. Fit new bearings.
Make sure the tabs fit into the notch in the bearing
seat and that the oil holes correspond to each
other.
Oil the bearings with engine oil.

P0010170

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 21-0 Engine Complete, General

Engine Assembly
Crankshaft, Installation
Tools:
885811 Timing tool
885633 Torque multiplier
885648 Counterhold
9999696 Magnetic stand
9989876 Dial indicator
9998511 Lever
1 Inspect the crankshaft; refer to Crankshaft,
Inspection, page 169.
2 Check that the crankshaft is clean, that all bearing
surfaces are fault free and that the oil channels
are open. Install the crankshaft gear with a new
O-ring. Suspend the crankshaft in a lifting strap;
refer to Crankshaft, Removal, page 64.
Lubricate all bearing surfaces with engine oil.
3 Lower the crankshaft carefully into position. Align
the gearwheel markings with each other.

IMPORTANT!
Make sure that no connecting rod ends up in the
wrong position. The connecting rod separation
planes are very sensitive.

P0010167

4 When the crankshaft has been lowered onto the

main bearings, check that they are still correctly
positioned.
Install the thrust washers so that the locator tabs
end up in the intended notches.

P0010171

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21-0 Engine Complete, General

5 Wipe the main bearing caps dry and install new

bearings. Lubricate the bearing surfaces with
engine oil.
Install the thrust washers on the center main
bearing cap (fit the locator tab into the notch). The
center cap has a groove that must fit against a
locator tab in the engine block.

P0010172

6 Install the cap according to the marking. Use the

bolts to guide the caps straight. Tighten the bolts
so that the caps are pulled down onto the engine
block.
Check that the crankshaft can be rotated.
Torque and angle tighten the main bearing cap
bolts using 885811 Timing tool, 885633 Torque
multiplier and 885648 Counterhold according to
03-2, Special Tightening Torques.
Check once more that the crankshaft can be
rotated

P0010173

7 Check crankshaft end float with the aid of

9999696 Magnetic stand and 9989876 Dial
indicator.
Use 9998511 Lever move the crankshaft back
and forth. Read off the value on the dial indicator
and compare to Group 21: Engine, page 26.
8 Install new bearings in the connecting rods and
big end bearing caps and install all connecting
rods; refer to Pistons, Removal, page 58.
Check that it is still possible to rotate the
crankshaft
9 Install the piston cooling nozzles if they were
removed.

P0010174

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 21-0 Engine Complete, General

10 Remove the front crankshaft seal from the cover.

Clean the cover and engine block where the
cover is to be installed.
Apply sealant to the cover; refer to 03-2, Special
Tightening Torques.
Install the cover and tighten the bolts in
sequence; refer to 03-2, Special Tightening
Torques.
11 Install a new crankshaft seal and belt pulley; refer
to Crankshaft Seal, Change (front), page 161.
P0005229

4 5

6
3

2 7

1 8
P0005230

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21-0 Engine Complete, General

Cylinder Liner, Installation

Tools:
9989876 Dial indicator
9990157 Press tool
9992479 Holder for dial indicator
9996966 Press tool
9998511 Lever
88800083 Piston ring pliers
88800218 Extractor plate
88800318 Piston ring compressor
1 Inspect the engine block liner seat for damage. If
the liner seat is damaged it must be repaired.

P0010139

2 Install the liner without O-rings and press the liner

down using two 9996966 Press tool.

P0010134

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 21-0 Engine Complete, General

3 Fit 9989876 Dial indicator onto 9992479 Holder

for dial indicator.
Place the holder with dial gauge across the
cylinder liner.
Zero the dial indicator with a couple of millimeters'
pre-load to the engine block plane.
4 Measure the height between the liner and the
cylinder block plane. Measure the height of the
liner in two places, diagonal to each other.
Calculate the average of the two measurements.
For correct liner height above the block plane,
refer to specifications in 03-21, Engine body. If
the liner height is outside specified tolerances,
the liner seat must be repaired (milled).
Always measure the highest point on the liner
sealing surface. Mark the liner's position with a
felt pen in order to re-install it in the exact same
position.

5 Remove 9996966 Press tool and pull out the liner.

Lay out the cylinder liners in the same sequence
that they were installed, together with any
adjusting spacers.
Clean the O-ring grooves in the engine block.

P0010140

Lubrication and location of O-rings

6 NOTICE! The purple seal ring must seat in the
lowest groove

Lubricate new O-rings and insert them in the

grooves in the engine block; black uppermost,
then purple in the lower groove. Use the oil
supplied.
Install the O-ring on the cylinder liner.
Oil the lower part of the cylinder liner with the
lubricating oil supplied.

P0006966

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21-0 Engine Complete, General

Without spacers
7 IMPORTANT!
Do not put sealing compound around the entire
liner; leave a 2 mm (0.08") gap.

When the cylinder liner is fitted without spacers,

an even bead of about 0.8 mm (0.03") of sealing
compound must be applied to the underside of
the cylinder liner collar.

With spacers
8 IMPORTANT!
Sealant must not be used between the spacers
and the cylinder liner collar.

If the liner is installed with spacers, apply the

sealant bead to the cylinder block liner seat.

NOTICE! After applying 1161231 Sealant, the

liner must be installed within 5 minutes.

P0006918

9 If the cylinder head cannot be installed and

torqued within 5 minutes, the liner must be held
to the engine block with two 9990157 Press tool.
Install one of the cylinder head bolts (A). Place
88800218 Extractor plate (D) above the cylinder
liner together with an appropriate spacer (C) and
press the cylinder liner down using
9998511 Lever (B).

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 21-0 Engine Complete, General

10 Lubricate the piston pin, piston bush and the

piston bearing seat with engine oil.
Install the connecting rod in the piston with the
mark 'FRONT' on the connecting rod and the
arrow on the piston facing the same direction.
Press in the piston pin. Install the retainer rings.

NOTICE! It must be possible to press the piston

pin in without much force. If resistance is too
great, the piston may need to be heated. The
connecting rod should turn freely on the piston
pin.

P0006921

11 Install the piston rings. Use 88800083 Piston ring

pliers.
The piston ring gaps must be staggered evenly in
relation to each other. The gap in the oil control
ring must be diametrically opposite the gap in the
spring underneath.

NOTICE! Both the upper piston rings are marked

with letters or dots. The markings must face
upward. The oil control ring is symmetrical and
can face either way.
P0006968

12 Lubricate the piston and piston rings with engine

oil.
Check that the piston ring openings are
staggered 120° in relation to each other.

NOTICE! Connecting rods must be installed in

their original positions. The arrow on the piston
and the “FRONT” marking on the connecting rod
must face forwards. Use 88800318 Piston ring
compressor.

P0006923

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21-0 Engine Complete, General

Pistons, Installation
Tools:
88800318 Piston ring compressor
9996966 Press tool
1 Rotate the crankshaft so that the big end journal
for the piston to be installed ends up as low as
possible.
Remove the two press tools for the liner where
the piston is to be installed.
2 Lubricate the bearing shells and bearing journals
with engine oil.
3 Lift the piston into place with 88800318 Piston
ring compressor and the connecting rod (big end
bearing lubricated). Make sure the piston is facing
the right direction (so that the connecting rod is in
the right position on the crankshaft).
Tap down the piston with a hammer shaft.
Remove the piston ring clamp when the piston is
below it.
Re-install 9996966 Press tool for the cylinder
liner.
Press down the piston so that the connecting rod
touches the crankshaft.
Install the big end bearing cap and align it
precisely with the crankshaft (big end bearing
P0010146
oiled). Install the bolts.
Torque the bolts and check that the crankshaft
can be rotated.
4 Install the remaining pistons the same way.
5 Clean the piston cooling nozzles and check that
they are not damaged. Install the nozzles using
new bolts.
Check that the nozzles are aimed directly at the
piston oil cooling hole.

P0010126

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 21-0 Engine Complete, General

Lube Oil Pump, Installation

1 Install the oil pump, reinforcing plate, pipe and
suction strainer; refer to Lubrication Oil Pump,
Change, page 177.

P0010153

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21-1 Cylinder Head

21-1 Cylinder Head

Cylinder Head, Removal
Tools:
885822 Magnetic pen
9990006 Puller
9990013 Slide hammer
9990185 Lifting tool
9996239 Lifting tool
9996400 Slide hammer
9996966 Press tool
9998249 Protective sleeve
9998251 Protection plug
9998264 Lifting tool
9998674 Adapter
88800014 Rotation tool

IMPORTANT!
Working with the fuel system requests special
cleanliness.

IMPORTANT!
Clean thoroughly before removal.

IMPORTANT!
Install safety plugs in open connections.
1 Switch off main power.
2 Drain the coolant according to Coolant,
Change, page 279.
3 Remove the turbocharger according to Turbo,
Change, page 245.
4 Drain the fuel duct according to Draining, Fuel
Duct in Cylinder Head, page 198.
5 1 Remove the clamp on the charge air pipe
on the charge air cooler.
2 Remove the e-EGR mixing chamber; refer
to EGR mixing chamber,
change, page 242.
3 Remove the e-EGR pipe from the mixing
chamber; refer to Control valve e-EGR,
change, page 237.

P0020987

6 Unscrew the electrical connection from the pre-

heater element.
Remove the pre-heater element from the inlet
manifold.

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 21-1 Cylinder Head

7 Undo / remove:
- Cable ties.
1 Hose union for the PWM valve.
2 Crankcase pressure sensor electrical
connector
3 Crankcase ventilation connection from the
valve cover.
4 Charge air pressure sensor from the inlet
manifold.
5 The pipe (closed crankcase ventilation)
6 Pre-heater element relay.

P0020988

8 Remove the bolts to the harness channel conduit

below the inlet manifold.
Remove the center section of the harness
channel.

P0020989

9 Undo / remove:
1 The pressure drop indicator connector.
2 The flywheel sensor connector.
3 The air cleaner with attachment plate.

P0020990

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21-1 Cylinder Head

10 Remove the coolant connections to the

compressor.

P0020991

11 Drain the fuel duct according to Draining, Fuel

Duct in Cylinder Head, page 198.
12 Remove the IN/OUT fuel connections on the
cylinder head.

P0020996

13 Remove the inlet manifold.

14 Undo / remove:
1 The EGR valve harness terminal.
2 Coolant pipe, expansion tank.
3 Hose union, engine heater (option).
4 Hose union, expansion tank.
5 Connection pipe
6 Thermostat cover and thermostat; refer to
Thermostat, Change, page 283.
7 Lifting eye

P0020992

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 21-1 Cylinder Head

15 Undo / remove:
1 Oil pipe and return pipe; refer to Control
valve e-EGR, change, page 237.
2 Exhaust manifold; refer to Exhaust
Manifold, Change, page 227.
3 Harness terminal and camshaft sensor.

P0020993

16 Remove the valve cover; refer to Valve cover,

change, page 101.
17 Disconnect the injector connectors.
Cut off cable ties and remove the cable harness
from the cable holder.
Remove the cable holders.
Remove the center piece for lubrication of the
rocker arm bridge, together with the delivery pipe.

NOTICE! Make sure the seal under the center

piece does not fall into the timing gear cover.

P0020994

18 Remove the harness bush and carefully pull the

harness out through the cylinder head.

P0020995

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21-1 Cylinder Head

19 Crank the engine in its direction of rotation.

Use 88800014 Rotation tool.

P0020125

20 Crank the engine to camshaft TDC and check that

the mark on the flywheel is at zero.

P0020997

21 Remove the upper timing gear cover.

P0020998

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 21-1 Cylinder Head

22 Remove the upper timing gear casing and

remove the rubber seals.

P0012728

23 Remove the camshaft gear and vibration damper

bolts.
Remove the vibration damper.

IMPORTANT!
Make sure the vibration damper is protected from
impact and shocks.

Remove the camshaft gear.

P0012729

24 Remove the rocker bridge bolts alternately to

avoid uneven load.

P0020999

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21-1 Cylinder Head

25 NOTICE! Make sure the pistons in the exhaust

rocker arms and the adjuster screw ball do not fall
out when the rocker arm bridge is lifted.

Install 9990185 Lifting tool and adjust the rocker

arm holders. This is done to keep the rocker arms
for each cylinder together. Use the higher
holders.
Lift the rocker arm bridge away.

P0004965

26 Mark and then remove the valve yokes.

6
5

4
3

P0010035 2

27 Remove the camshaft cap bolts.

Check that the caps are marked.

P0010038

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 21-1 Cylinder Head

28 Use 9996400 Slide hammer and

9998674 Adapter to rock the caps loose.

999 6400

999 8674

P0010039

29 Use 9998264 Lifting tool to lift the camshaft.

CAUTION!
999 8264 Cutting hazard! Protect your hands!

Remove the unit injector bolts.

P0010040
P0010040

30 Rock a unit injector loose using 9990006 Puller

9990013 and 9990013 Slide hammer.
Check that the seal washer (steel washer) comes
out with the injector. If it is still in the copper
sleeve, remove it using 885822 Magnetic pen.

9990006 NOTICE! The seal washer must always be

replaced when installing an injector.

P0001370

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21-1 Cylinder Head

31 Insert the injector into 9998249 Protective

sleeve.

999 8249

P0010041

32 Insert 9998251 Protection plug into the cylinder

head.
999 8251
Remove the remaining injectors the same way.

P0010042

33 Crank the engine and remove the two bolts (1)

through the timing gear wheel.
Remove the bolts (2) holding the intermediate
plate against the cylinder head.
Remove the three upper bolts (3) from the timing
gear hub.

P0006893

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 21-1 Cylinder Head

34 Remove the cylinder head bolts.

P0010046

35 Wipe away engine oil that has collected in cavities

underneath the camshaft to prevent oil from
running down into the coolant duct when the
cylinder head is lifted away.
36 Fit two 9996239 Lifting tool to the cylinder head
and lift it away.
999 6239 NOTICE! Because of the timing gear sealant, it
may be necessary to carefully prise the cylinder
head free.

Lower the cylinder head onto a clean surface.

IMPORTANT!
The sealing surface must not be damaged.

P0010047

37 Remove the cylinder head gasket.

Fit 9996966 Press tool to keep the liners in place.
Make sure the press tools are not able to damage
the pistons if these must be removed.
9996966

P0010048

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21-1 Cylinder Head

Cylinder Head, Installation

Tools:
885810 Fixture
9990156 Adapter
9996400 Slide hammer
9996966 Press tool
9998264 Lifting tool
9998251 Protection plug
9998601 Fixture
9999683 Dial indicator (short probe)
9999696 Magnetic stand
88800014 Rotation tool
1 Clean the cylinder head carefully both internally
and externally before fitting.

NOTICE! Dirt particles may cause the unit

injectors to fail. Clean the unit injector copper
sleeves. Refer to Sleeve for unit injector,
replace, page 216.

Install the protective plugs immediately after

cleaning.
Clean the cylinder head and the engine block
sealing surfaces and cut away excess sealant.
2 Remove 9996966 Press tool holding the cylinder
liners in place.

9996966

P0010048

3 Immerse the cylinder head bolts fully in

rustproofing agent.
Place the bolts on a net to let the excess drip off.

P0006938

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 21-1 Cylinder Head

4 Apply a 2 mm (0.787") bead of sealant to the back

of the cylinder head.

NOTICE! The cylinder head bolts must be

torqued within 20 minutes of sealant application.

P0006939

5 Fit a new cylinder head gasket.

6 Lower the cylinder head until it rests on the

cylinder head gasket.
Maintain a distance to the transmission plate of
5-10 mm (0.197-0.394"). Locating pins make sure
the cylinder head aligns with the engine block.
Slide the cylinder head toward the transmission
plate.

P0006940

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21-1 Cylinder Head

7 Screw a bolt in the upper intermediate gear hub

(1) into the cylinder head in order to pull the
cylinder head towards the timing gear plate.
Screw in five M8 screws in the transmission plate
(2).
Torque the bolts (1) and (2) as specified in
Tightening Schedules, page 15.
Undo all bolts (1) and (2) about one turn.

NOTICE! The cylinder head is now in the correct

position for fastening and must not be moved. If
the cylinder head is moved, the bolts must once
again be torqued and loosened as above.

P0006941

8 Install the cylinder head bolts and torque

according to the specifications in Tightening
Schedules, page 15.
Use a torque multiplier for angle tightening.

9 Torque the five M8 bolts in the transmission plate

(2) according to the specifications in Tightening
Schedules, page 15.
Crank the engine so that the two M8 bolts (1) can
be installed through the upper intermediate gear.
Tighten according to the specifications in
Tightening Schedules, page 15.
Install the remaining two M10 bolts (3) into the
upper intermediate gear, without tightening.

P0006893

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 21-1 Cylinder Head

10 Clean the surface of sealant as illustrated.

NOTICE! Cut away the sealant.

P0006942

Camshaft, Installation
11 Inspect the camshaft for wear. Refer to Camshaft,
Wear Check, page 155.
12 Clean the surfaces on the bearing blocks and
cylinder head.
Install the camshaft bearing brackets as marked
on the cylinder head and make sure they abut the
cylinder head. # 7 by the timing gear.
Place the bearing shells in the bearing blocks and
lubricate the bearing shells with engine oil.
13 Crank the engine using 88800014 Rotation tool
so that the flywheel is set exactly to zero
according to the marking on the flywheel housing.

P0020125

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21-1 Cylinder Head

14 Check that the cam bearings are fault free and

correctly installed in the caps.
Use 9998264 Lifting tool to lift the camshaft into
999 8264 position.
CAUTION!
Cutting hazard! Protect your hands!

P0010040
P0010040

15 Rotate the camshaft so that the guide hole faces

straight up.
Install the caps according to the markings.
Install M10X80 bolts instead of the rocker arm
bridge.
Tighten the bearing caps according to Tightening
Schedules, page 15
Check that the camshaft can be rotated.

P0010052

16 The camshaft TDC mark must be centered

between the marks on the bearing block.

P0020997

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 21-1 Cylinder Head

17 IMPORTANT!
Tighten the bolts in stages to ensure that the
rocker arm shaft bottoms against the bearing
housing without bending the shaft.

NOTICE! Use a suitable spacer on the rocker arm

side.

Oil the bearing shells and install thrust bearing

caps on the respective bearing blocks. Use a
suitable spacer on the rocker arm side.
- Torque bolts 1-7 according to step 1 in
Tightening Schedules, page 15.
- Torque bolts 9, 11 and 13 according to step
2 in Tightening Schedules, page 15.
P0021000

18 Install the camshaft drive without the vibration

damper; use nuts for spacers.
Place the gear so that the reference hole in the
timing gear plate is between the gear markings.
If necessary, remove the bolts on the upper
intermediate gear.
Temporarily tighten two bolts with low torque,
max 10 Nm (7.38 lbf. ft.).

P0010053

Flank Clearance, Checking

9999683 19 IMPORTANT!
It is important to check gear lash in order to
prevent serious engine problems.

Use 9999696 Magnetic stand and 9999683 Dial

9999696 indicator (short probe) to check gear lash.
Hold the intermediate gear secure and turn the
camshaft gear back and forth to check that gear
lash is within specified limits; refer to Group 21:
Engine, page 26.
If gear lash is correct, tighten the intermediate
gear bolts according to step 2 in Tightening
Schedules, page 15.
Remove the bolts and spacers from the camshaft
gear. Install the inlet manifold and tighten
according to the specifications in Tightening
P0010055
Schedules, page 15.

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21-1 Cylinder Head

Flank Clearance, Adjustment

20 Loosen the bolts (1) in the upper intermediate
gear.
Check that the upper bolts are not tightened.

P0006946

21 Place a 0.1 mm (0.00394") feeler gauge on the

pressure side.
Turn the camshaft gear against the feeler gauge.
Torque the upper intermediate gear according to
step 1 in Tightening Schedules, page 15.
Remove the feeler gauge.

P0006947

22 Check the clearance as follows:

- Fix the adjuster wheel.
- Place a dial indicator on the camshaft drive,
as illustrated.
- Turn the gear back and forth and compare
the result with gear lash specifications; refer
to Group 21: Engine, page 26

If gear lash is correct, torque the upper

intermediate gear (1) bolts according to step 2 in
Tightening Schedules, page 15.

Remove the bolts and spacers from the camshaft

gear. Fit the vibration damper and torque
according to specifications in Tightening
Schedules, page 15.

P0006948

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 21-1 Cylinder Head

23 Apply a 2 mm (0.08") bead of 1161231 Sealant to

the upper timing gear cover contact surface, as
illustrated.

P0013011

24 Fit new rubber seals and install the upper timing

gear casing.

P0006949

25 Only fit the bolts (1) and tighten by hand.

NOTICE! The holes are oblong to allow the cover

to be pressed down against the rubber seal.

P0006950

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21-1 Cylinder Head

26 Press the cover down using 885810 Fixture and

88510 9998601 Fixture so that the cylinder head and the
upper timing gear cover sealing surfaces are
aligned.
Fit the remaining bolts (2). Tighten according to
the specifications in Tightening
Schedules, page 15.

NOTICE! The timing gear casing must be

installed and torqued within 20 minutes of sealant
application.

P0012751

9998601
P0012752

27 Install the camshaft sensor and adjust it

according to Sensors, Adjustment, page 159

Unit injector, Installation

28 NOTICE! Install one injector at a time.

Remove 9998251 Protection plug with

9990156 Adapter and 9996400 Slide hammer.
Fit new seal rings to the unit injectors. Lubricate
the rings with diesel oil.
Install the injector and fixing yoke. Center the
injector so that it does not touch the valve springs.
Tighten according to Tightening torques, page 9.

P0006890

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 21-1 Cylinder Head

29 Reinstall the valve yokes in their original

positions.

NOTICE! Make sure that the yokes are directly

above the valve stems.

Lubricate valve yokes and camshaft.

Remove the temporary bolts and spacers on the
camshaft cap.

P0006953

30 Install the rocker arm bridge using a hoist. Make

sure that the guide pins fit into the rocker arm
shaft.
Guide all rocker arms so that they end up in the
correct positions. Make sure that the exhaust
rocker arm pistons and the adjuster screw balls
are in place.

Remove the lifting tool from the rocker arm

bridge. Install the rocker arm shaft bolts.
Check that the valve yokes are positioned
P0004965
correctly on the valve stem. Tighten the bolts
alternately so that the rocker arm shaft is not bent.
Make sure the shaft locates on the bearing cap
guide sleeves.

Torque the bolts alternately along the rocker arm

shaft as specified in Tightening
Schedules, page 15.

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21-1 Cylinder Head

31 Slide new O-rings over the oil supply pipe to the

rocker arm bridge.
Insert the pipe in the center piece and install the
center piece and pipe.
Check that the O-rings on the pipe and the ring
under the center piece are correctly aligned.

P0006883

32 Adjust the valves and unit injectors; refer to

Valves and Unit Injectors,
Adjustment, page 106.
33 Fit the cable holders.
Pull the cable harness through the cylinder head
to the unit injectors and connect them. Fasten the
harness in the cable holder using oil and heat-
resistant cable ties.
Bolt the center piece in place.

P0020994

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 21-1 Cylinder Head

34 Bolt the harness bush place.

P0020995

35 Install the valve cover: Refer to Valve cover,

change, page 101.
36 Install the exhaust manifold (1); refer to Exhaust
Manifold, Change, page 227.
Install the oil pipe and return pipe (2); refer to
Control valve e-EGR, change, page 237.

P0021013

37 Install:
1 Connection pipe
2 Hose union, expansion tank.
3 Hose union, engine heater (option).
4 The EGR valve harness terminal.
5 Thermostat cover and thermostat; refer to
Thermostat, Change, page 283.
6 Coolant pipe, expansion tank.
7 Lifting eye.

P0021012

38 Install the inlet manifold; refer to Intake Manifold,

Change, page 230.

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21-1 Cylinder Head

39 Install the IN/OUT fuel connections on the

cylinder head.

P0020996

40 Install the coolant connections to the compressor.

P0020991

41 Install the bolts to the harness channel conduit

below the inlet manifold.
Install the center section of the harness channel.

P0020989

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 21-1 Cylinder Head

42 Install:
1 Hose union for the PWM valve.
2 Crankcase pressure sensor electrical
connector
3 Crankcase ventilation connection from the
valve cover.
4 Charge air pressure sensor from the inlet
manifold.
5 The pipe (closed crankcase ventilation)
6 Pre-heater element relay.
• Cable ties.
P0021009

43 Install:
1 The air cleaner with attachment plate.
2 The flywheel sensor connector.
3 The pressure drop indicator connector.

P0021010

44 Install the electrical connection to the pre-heater

element.
Install the pre-heater element from the inlet
manifold.
45 Install the e-EGR mixing chamber (1); refer to
EGR mixing chamber, change, page 242.
Install the e-EGR pipe (2) from the mixing
chamber; refer to Control valve e-EGR,
change, page 237.
Fit the clamp on the charge air pipe (3) on the
charge air cooler.

P0021011

46 Install the turbocharger according to Turbo,

Change, page 245.
47 Check engine oil level; fill as necessary.

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21-1 Cylinder Head

48 Fill with coolant according to Coolant Level,

Checking and Topping Up, page 275.
49 Start the engine and check for leaks; let the
engine run until it reaches normal working
temperature.
Let it run an additional 5-10 minutes at idle.

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 21-1 Cylinder Head

Valve cover, change

Removal
1 Remove the crankcase ventilation connection
from the valve cover.
Disconnect the crankcase pressure sensor.

P0020178

2 Remove the valve cover with gasket.

P0020179

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21-1 Cylinder Head

Installation
3 1 Remove the gasket.
2 Clean along the gasket groove.
3 Check whether the valve cover gasket
needs to be changed. Clean the gasket.
4 Clean the sealing surfaces.
5 Fit the gasket.

P0020180

4 Clean the sealing surfaces.

NOTICE! Remove any sealant from the joint

between the cylinder head and the upper timing
gear cover.

P0020181

5 NOTICE! The components must be installed

within the specified time after the application of
sealant.

Apply an even, 2 mm bead of sealant along the

mating surface between the upper timing gear
cover and the cylinder head.

The valve cover must be installed within 20

minutes of sealant application.

P0020182

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 21-1 Cylinder Head

6 Install the cover, tighten the bolts in sequence

and torque them.

P0020183

7 Tighten the bolts in sequence, as illustrated:

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

P0020184

8 Install the crankcase ventilation connection on

the valve cover.
Connect the crankcase pressure sensor electrical
connector.

P0020178

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21-3 Cylinder Liner, Pistons

21-3 Cylinder Liner, Pistons

Cylinder Liner and Pistons,
Inspection
Clean the cylinder liners carefully before
inspection and measurement.

IMPORTANT!
Cylinder liners and pistons are classed together. This
means that cylinders and liners must not be mixed.

The piston and cylinder liner sets are only available as

a single, complete unit.

Cylinder Liner
Measurement of cylinder liner wear can be done with
the liner installed in the cylinder block.

NOTICE! The cylinder liners must be taken out of the

engine block, to do a careful crack check.

1 Measure the cylinder liners with a cylinder

indicator. In order to obtain the greatest possible
accuracy in the wear measurement, the cylinder
liner must first be set up with a gauge ring or
micrometer. Use the original diameter of the
cylinder liner as the base value.
2 Measure the cylinder liner at top and bottom dead
centers, and at several places vertically.
P0006962
At each measurement location, measurement
must be lengthwise and crosswise in relation to
the engine.
3 If wear is greater than 0.45–0.50 mm, a new
complete lining kit must be used (piston, liner,
piston rings, piston pin and seals).
Oil consumption also affects when cylinder liners
must be changed.
4 Remove the cylinder liner and do a crack check.
Be specially careful when checking the liner
collars.
The Magnaflux method may be used for this
check.

Pistons
5 Check for worn piston ring grooves, damaged
retainer ring grooves, cracks and other damage
to the pistons.
If the piston has deep scratches on its skirt, the
piston (liner kit) must be scrapped. The same
applies if the piston has one or more cracks in the
piston pin hole or in the bottom of the combustion
chamber.
Crack tests must be done using the chalk powder
method.

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 21-3 Cylinder Liner, Pistons

Connecting Rod, Check

Important consideration when removing/installing
fracture-split connecting rods.

Installing a NEW connecting rod:

Carefully fix the connecting rod in a vise with soft jaw
pads.

Undo the connecting rod bolts a few turns and carefully

tap the bearing cap with a plastic faced hammer until
it loosens.

The split line can be difficult to find when the

connecting rod is assembled.

When the cap is separated from the connecting rod, it

may occur that a chip is missing or comes loose. This
does not affect the function of the connecting rod
adversely.

Handle the connecting rod and bearing cap carefully.

If any strike marks occur on the split line, this may
affect strength after torquing.

IMPORTANT!
If the connecting rod or bearing cap are damaged,
change the connecting rod.

Connecting Rod Bushing, Check up

1 Check the connecting rods for cracking,
straightness and twist before any piston pin bush
replacement. Scrap the connecting rod if it is
cracked, bent or twisted.
When the piston pin bush is changed, the bush
must be machined (trapezoid piston pin end).
When the clearance is correct, an oiled piston pin
should slowly slide through the bush under its
own weight.

3 IMPORTANT!
2 Regarding max. allowed straightness and twist
deviations, refer to Group 21: Engine, page 26.

P0006994 P0006995

2 Use a new piston pin and measure the

straightness of the connecting rod, using a fixture.
3 Measure connecting rod twist.

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21-4 Valve Mechanism

21-4 Valve Mechanism

Valves and Unit Injectors,
Adjustment
There are two types of valve mechanisms:
- Standard valve mechanism, page 107.
- Valve mechanism equipped with VCB (Volvo
Compression Brake), page 110.

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 21-4 Valve Mechanism

Standard valve mechanism

Tools:
88800014 Rotation tool
1 Remove the valve cover; refer to Valve cover,
change, page 101.
2 Timing marks
The camshaft has marks (1–6 for the respective
cylinders) for adjusting inlet and exhaust valves
and the unit injectors.

NOTICE! It is important that the line marked on

the camshaft is centered between the marks on
the bearing cap when adjustment is carried out.

P0020124

Valves and Unit Injectors, Adjustment

3 Crank the engine in the direction of rotation to the
next camshaft marking. Use 88800014 Rotation
tool.

P0020125

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21-4 Valve Mechanism

4 Adjust valves and injectors for each cylinder

together.

P0020126

5 NOTICE! Adjust the screw on the inlet valve and

exhaust valve until the feeler gauge can be
moved with a degree of resistance.
6 Adjust inlet valve clearance between the rocker
arm and the valve yoke to 0.2 mm (0.0079") with
the aid of a feeler gauge.
Tighten according to the specifications in 03-2,
Special Tightening Torques.
Check the valve clearance. Mark the rocker arm
once the valve is adjusted.
Adjust the clearance for the exhaust valve and
unit injector.

P0020127

7 Check the valve clearance for the exhaust valves

with the aid of a feeler gauge. Adjust as
necessary. The clearance must be 0.8 mm
(0.0315”).
Tighten the locking nut.

P0020128

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 21-4 Valve Mechanism

8 Adjust the unit injector preload by loosening the

adjuster screw until a clearance is obtained on the
injector.
Adjust the screw until the clearance disappears
(by feel until the roller can no longer be rotated).
Tighten the adjuster screw a further 240° (4 flats).
9 Tighten the adjuster screw locking nut as per
specifications in 03-2, Special Tightening
Torques.

P0020129

10 Adjust the remaining valves and unit injectors as

described above.
11 Remove 88800014 Rotation tool from the gear
ring.
Install the valve cover according to Valve cover,
change, page 101.

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21-4 Valve Mechanism

Valve mechanism equipped with

VCB (Volvo Compression Brake)
Tools:
88800014 Rotation tool
1 Remove the valve cover.
2 Timing marks

NOTICE! Marks 1–6 apply to inlet valve and unit

injector adjustments.
The marks V1-V6 apply to exhaust valve
adjustment.

It is important that the line marked on the

camshaft is centered between the marks on the
bearing cap when adjustment is carried out.

P0020168

Valves and Unit Injectors, Adjustment

3 Crank the engine in the direction of rotation to the
next camshaft marking. Use 88800014 Rotation
tool.

P0020125

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 21-4 Valve Mechanism

4 In this case, camshaft position indicates

adjustment of: 1 = Inlet and injector rocker arm,
cylinder 1.

Adjust the inlet valves and injectors for for each

cylinder together.

P0020169

5 Adjust inlet valve clearance between the valve

yoke and the rocker arm thrust sleeve valve yoke
to 0.2 mm (0.0079") with the aid of a feeler gauge.
Refer to the Valve mechanism section in Group
21: Engine, page 26.

Tighten according to the specifications in 03-2,

Special Tightening Torques.

Check the valve clearance. Mark the rocker arm

once the valve is adjusted.

P0020170

6 Adjust the unit injector preload by loosening the

adjuster screw until a clearance is obtained on the
injector.
Adjust the screw until the clearance disappears
(by feel until the roller can no longer be rotated).
Tighten the adjuster screw a further 240° (4 flats).

Tighten the adjuster screw locking nut as per

specifications in 03-2, Special Tightening
Torques.

P0020171

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21-4 Valve Mechanism

7 Crank the engine to the next camshaft marking

for adjusting the exhaust valves.

In this case, camshaft position indicates

adjustment of: V3 = Inlet and VCB rocker arm,
cylinder 3.

P0020172

8 Press down on the rocker arm as illustrated.

NOTICE! If the rocker arm gives, pull on its piston

spring while the rocker arm is pressed down so
that it makes contact with the valve spindle.

NOTICE! Use a strong metal wire or hooked

screwdriver to pull on the spring.

P0020173

9 NOTICE! Only perform if the rocker arm gives.

NOTICE! Use a strong metal wire or hooked

screwdriver to pull on the spring.

P0020174

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 21-4 Valve Mechanism

10 Check the valve clearance for the exhaust valves

with the aid of a feeler gauge.
The clearance must be 1.6 mm (0.063”).

P0020175

11 IMPORTANT!
Make sure no loose parts fall into the camshaft
drive.

NOTICE! Use a wrench on the yoke as a

counterhold during removal.

If the shims must be replaced, undo the screw on

the yoke while holding the yoke fast with a wrench
so that the valves are not bent.

P0020176

12 Calculate the thickness of the new spacer.

Based on the measured value, calculate how
thick the new spacers must be.

A maximum of two spacers may be used.

If two spacers are used, they must have more or
less the same thickness.

NOTICE! Spacers are available with thicknesses

in 0.05 mm increments. The thickness is stamped
on the spacer.

P0020177

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21-4 Valve Mechanism

13 Insert the spacer and tighten the locking nut as

per specifications in 03-2, Special Tightening
Torques.

P0020176

14 Follow the same procedure on the remaining

valves and unit injectors.
15 Remove 88800014 Rotation tool from the gear
ring.
16 Install the valve cover according to Valve cover,
change, page 101.

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 21-4 Valve Mechanism

Valve mechanism equipped with

Internal EGR (Exhaust Gas
Recirculation)
Tools:
88800014 Rotation tool
88820016 Alignment tool
1 Remove the valve cover
2 Timing marks

IMPORTANT!
Marks 1–6 apply to inlet valve, unit injector,
exhaust valve and IEGR double rocker arm
adjustments.

IMPORTANT!
Keep the camshaft position 1-6 for the
appropriate setting mark when
88820016 Alignment tool use as described.

NOTICE! It is important that the line marked on

the camshaft is centered between the marks on
the bearing cap when adjustment is carried out.
P0024597

Valves and Unit Injectors, Adjustment

3 Crank the engine in the direction of rotation to the
next camshaft marking.
Use 88800014 Rotation tool.

P0020125

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21-4 Valve Mechanism

4 In this case camshaft position indicates

adjustment of:
1 = Inlet and injector rocker arm, cylinder 1
1 = Exhaust and double rocker arm IEGR with
88820016 Alignment tool.

Adjust the inlet valves, injectors, exhaust valves

and IEGR double rocker arm for each cylinder at
the same time.
5 NOTICE! Adjust the screw on the inlet valve and
exhaust valve until the feeler gauge can be
moved with a degree of resistance.

P0020169

6 Adjust inlet valve clearance between the rocker

arm and the valve yoke to 0.2 mm (0.0079") with
the aid of a feeler gauge.
Tighten according to the specifications in
Tightening torques, page 9.
Check the valve clearance. Mark the rocker arm
once the valve is adjusted.
Adjust the clearance for the exhaust valve and
unit injector.

P0024598

7 Adjust the unit injector preload by loosening the

adjuster screw until a clearance is obtained on the
injector.
Adjust the screw until the clearance disappears
(by feel until the roller can no longer be rotated).
Tighten the adjuster screw a further 240° (4 flats).
Tighten the adjuster screw locking nut as per
specification in Tightening torques, page 9.

P0024599

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 21-4 Valve Mechanism

8 Check the valve clearance for the exhaust valves

with the aid of a feeler gauge. Adjust when the
standard is not met. The clearance must be 0.8
mm (0.0315").
Tighten the adjuster screw locking nut as per
specifications in Tightening torques, page 9.

P0024600

9 Check IEGR according to: Checking the IEGR

(double rocker arm), page 120.

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21-4 Valve Mechanism

Adjusting the IEGR (double rocker

arm)
Tools:
88820016 Alignment tool

88820016 Alignment tool

1 For adjustment.
2 For checking.

P0024601

NOTICE! The exhaust valve must be correctly

adjusted.

1 Keep the camshaft in the same position as for

adjusting the valve clearance.
2 Open the drain nipple a half turn.

P0024602

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 21-4 Valve Mechanism

3 1 Undo the locknut and retain the piston with

an Allen key.
2 Insert 88820016 Alignment tool between
double rocker arm’s mating surface and
camshaft base circle.

P0024603

4 NOTICE! Zero clearance means that

88820016 Alignment tool slides stiffly between
the double rocker arm and the camshaft.

Turn the piston with the Allen key to give zero

clearance between the double rocker arm,
88820016 Alignment tool and the camshaft.

P0024604

5 Tighten the locknut at the same time as the piston

is retained in its correct position.
Check clearance, refer to Checking the IEGR
(double rocker arm), page 120.
Tighten the piston locking nut as per
specifications in Tightening torques, page 9.

P0024605

6 Tighten the drain nipple as per specifications in

Tightening torques, page 9.

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21-4 Valve Mechanism

Checking the IEGR (double rocker

arm)
Tools:
88820016 Alignment tool

88820016 Alignment tool

1 For adjustment.
2 For checking.

P0024601

NOTICE! The exhaust valve must be correctly

adjusted.

1 Keep the camshaft in the same position as for

adjusting the valve clearance.
2 Correct clearance for double rocker arm
(between rocker arm mating surface and
camshaft base circle) measured using
88820016 Alignment tool:
- GO side passes.
- STOP side does not pass.
3 Open the drain nipple a half turn.

P0024602

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 21-4 Valve Mechanism

4 Insert the GO side of the 88820016 Alignment

tool between double rocker arm’s mating surface
and camshaft base circle.
88820016 Alignment tool must be able to pass
between; If it cannot, iEGR lift is too great.

P0024606

5 Insert the STOP side of the 88820016 Alignment

tool between double rocker arm’s mating surface
and camshaft base circle.
88820016 Alignment tool must not be able to
pass between; If it can, iEGR lift is too small.

P0024607

6 If clearance is incorrect, refer to Adjusting the

IEGR (double rocker arm), page 118.
7 Tighten the drain nipple as per specifications in
Tightening torques, page 9.

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21-4 Valve Mechanism

Valve Guides, Inspection

Tools:
9989876 Dial indicator
9999696 Magnetic stand

Cylinder head removed

Refer to removal in 21-1, Cylinder Head, Change.
1 Remove the valve stem seals from the valve
guides.
2
IMPORTANT!
The cylinder head must not be put down so its
entire weight rests on the valve guides (see
illustration).
Put the cylinder head on the bench with the valve
discs facing upwards.
3 Place a new valve in the valve guide with the
valve stem end in the same plane as the edge of
the guide. Use a suitable counterhold under the
valve stem.
4 Place tool 9989876 Dial indicator and tool
999 9696
9999696 Magnetic stand, so that the dial indicator
tip is touching the valve disc edge.
998 9876 Move the valve sideways, in the direction of the
exhaust or inlet duct. Read off the value on the
dial gauge.
5 Check all valve guides.
If the measurement values exceed the values
noted in the specifications, the valve guide must
be changed; refer to Group 21: Engine, page 26.
p0005207

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 21-4 Valve Mechanism

Valve Guides, Replacing

Cylinder head removed.

NOTICE! If the valve seats must also be changed, this

must be done before the valve guides are removed.

CAUTION!
Risk of eye injury. Eye protection required.

Option 1

Tools:
9809726 Pneumatic hydraulic pump
9809729 Hydraulic cylinder
9990176 Press tool
9996159 Adapter
88800147 Drift
88800062 Drift

Optional tools

Tools:
9992670 Hand pump

Note: 9992670 is alternative to 9809726.

Removal
999 2670 980 9729 1 Install tool 9990176 Press tool into the cylinder
980 9726 head retaining bolt holes.

NOTICE! Put washers between the nuts and the

cylinder head plane.
999 0176 2 Tighten the nuts of the tool.
999 6159 3 Install tool 9996159 Adapter in the hydraulic
888 00147 cylinder.
4 Fit tool 9809729 Hydraulic cylinder into tool
9990176 Press tool and press out the valve guide
using tool 88800147 Drift
and9809726 Pneumatic hydraulic pump ,
alternatively 9992670 Hand pump.
5 Press the other valve guides out in the same way.

p0003637

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21-4 Valve Mechanism

Installation
6 Heat the cylinder head with hot water while
cooling the valve guides with e.g. carbon dioxide
snow.
Lubricate the cylinder head valve guides with
engine oil.

IMPORTANT!
Wear protective goggles when pressing.

999 2670 980 9729 7 Press in the valve guide for the inlet valve using
980 9726 tool 88800062 Drift. Press in the exhaust valve
guide using the same tool.
8 Press until the tool bottoms against the cylinder
head plane.
9 Remove the tool from the cylinder head.
999 0176
IMPORTANT!
After the valve guides have been changed, the cylinder
head must be cleaned carefully to prevent dirt particles
from getting into the fuel and oil ducts. Contamination
may cause failure or malfunction of the unit injectors.
999 6159
Option 2
888 00062
p0011273

Tools:
9992000 Handle
88800147 Drift
88800062 Drift

NOTICE! If the valve seats must also be changed, this

must be done before the valve guides are removed.

CAUTION!
Risk of eye injury. Eye protection required.

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 21-4 Valve Mechanism

Removal
NOTICE! Take out the valve guides from beneath the
cylinder head.

1 Tap out the valve guides with tool 88800147 Drift

together with 9992000 Handle.
2 Tap the other valve guides out in the same way.

Installation
3 Heat the cylinder head with hot water while
cooling the valve guides with e.g. carbon dioxide
snow.
Lubricate the cylinder head valve guides with
engine oil.
CAUTION!
Risk of eye injury. Eye protection required.
4 Tap in the valve guide for the inlet valve using tool
88800062 Drift. Tap in the exhaust valve guide
using the same tool.
5 Tap until the tool bottoms against the cylinder
999 2000 head plane.
6 Repeat the procedure for the remaining valve
guides.

IMPORTANT!
After the valve guides have been changed, the cylinder
head must be cleaned carefully to prevent dirt particles
from getting into the fuel and oil ducts. Contamination
may cause failure or malfunction of the unit injectors.

P0011274 888 00062

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Valves, Removal

Work is made easier if the cylinder head is fixed in an

equipment stand using tool 9990160 Fixture. Use 4
pcs. bolts M8 x 25.

NOTICE! It is important that the greatest possible

cleanliness is observed during work on the cylinder
head. Dirt particles in the fuel ducts can cause failure
or malfunction of the unit injectors.

Alternative 1

Tools:
9809726 Pneumatic hydraulic pump
9809729 Hydraulic cylinder
P0006996 9990160 Fixture
9990174 Drift
9992670 Hand pump
9996159 Adapter
9998246 Drift

Note: 9992670 Hand pump is alternative to

9809726 Pneumatic hydraulic pump .

Alternative 2

Tools:
9990210 Valve spring compressor

Alternative 1
1 Fit tool 9809729 Hydraulic cylinder into tool
9990176 Press tool.
2 Install tool 9996159 Adapter and tool
9998246 Drift (inlet) or tool 9990174 Drift (outlet)
on the hydraulic cylinder. Place the tool in the
holes for the cylinder head retaining bolts.
Tighten the tool nuts.
3 Connect tool 9809726 Pneumatic hydraulic pump
(alternatively 9992670 Hand pump).
4 Press the valve spring washer down and remove
the collets.

NOTICE! Check that the tool does not damage

the unit injector electrical connector, if the injector
is left in place.

NOTICE! Put the valves and springs in a marked

stand, to facilitate putting components back in the
same places in the cylinder head.
5 Remove the remaining valves in the same way as
above, using the press tool.
6 Remove the oil seals from the valve guides.

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 21-4 Valve Mechanism

Alternative 2

Tools:
9990210 Valve spring compressor
1 Lay the cylinder head on a flat, clean surface.
Make sure the cylinder head is not damaged
when the valves are to be removed.
2 Fit tool 9990210 Valve spring compressor in the
unit injector hole. Fix the tool in the bolt hole for
the unit injector yoke, M10 x 30.
3 Place the moving part of the tool over the valve
spring to be removed. Screw down the “wing nut”
on the tool until the valve washer has been
pressed down so far that the collets can be
removed.

NOTICE! Put the valves and springs in a marked

P0006997
stand, to facilitate putting components back in the
same places in the cylinder head.
4 Remove the remaining valves in the same way as
above.
5 Remove the oil seals from the valve guides.

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Valves, Installation
Alternative 1

Tools:
9809726 Pneumatic hydraulic pump
88800011 Drift
9990174 Drift
9990176 Press tool
9990210 Valve spring compressor
9992670 Hand pump
9996159 Adapter
9998246 Drift

Note: 9992670 Hand pump is alternative to

9809726 Pneumatic hydraulic pump .

Alternative 2

Tools:
9990210 Valve spring compressor

Alternative 1
1 Oil the valve stems and install the valves.
Oil the oil seals.
2 Install tool 88800011 Drift on the valve stem and
press the new oil seals down over the valve
guides.

NOTICE! Check that the oil seals are pressed

down properly.
3 Install the valve caliper guide pins.
Install the springs and valve spring washers.
Carefully press down the valve spring washer and
install the collets. Use tool 9990176 Press tool
together with 9809726 Pneumatic hydraulic
pump , 9996159 Adapter and 9998246 Drift (inlet)
or 9990174 Drift (outlet), in the same way as for
Valves, Removal.

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 21-4 Valve Mechanism

Alternative 2

Tools:
9990210 Valve spring compressor
1 Alternatively, tool 9990210 Valve spring
compressor may be used instead of the hydraulic
cylinder, in the same way as for Valves, Removal.

P0006997

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21-4 Valve Mechanism

Valve Seat, Change

Cylinder head and valves removed.

Tools:
9989876 Dial indicator
9992479 Holder for dial indicator
1 The valve seats must be changed if a satisfactory
seal cannot be obtained or when the distance (A)
exceeds the value stated in the specification;
refer to Group 21: Engine, page 26.

P0007000

2 Grind the head off an old valve and weld it onto

the valve seat. Use a MAG welder, or a
conventional arc welder (with a stainless welding
electrode).

IMPORTANT!
Carefully cover the other surfaces on the cylinder head
to prevent any weld spatter from fastening.
P0007001

P0007002

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 21-4 Valve Mechanism

3 Place a suitable socket over the valve/valve guide

and carefully tap the valve seat out.

IMPORTANT!
Be careful not to damage the cylinder head.
CAUTION!
Risk of eye injury. Eye protection required.
4 Clean the seat bed carefully and check the
cylinder head for cracks.
5 Measure the diameter of the valve seat bed in the
cylinder head. Determine whether a standard or
oversize dimension valve seat must be used.
Carry out any necessary machining to the valve
P0007003 seat bed; refer to Group 21: Engine, page 26.

6 Cool the seat in carbon dioxide snow between –

60 °C (–76 °F) and –70 °C (–94 °F) and heat the
cylinder head by flushing with hot water, or by
some other method.
Install the new valve seat using a drift.

NOTICE! Align the seat with the seat angle facing

the tool. Check sealing against the valve.

P0007004

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Valve Stem Sealings, Replace

Tools:
9990210 Valve spring compressor
88800014 Rotation tool
88800011 Drift
88800151 Drift
1 Switch off all electrical power to the engine at the
main switch.

Removal
2 Remove the unit injectors; refer to the Removal
section in Injector, Change, page 212.

NOTICE! The pistons must be at top dead center

when the valves are removed. This is to prevent
the valves from falling into the cylinder. Use
88800014 Rotation tool.

Compress the valve springs for # 1 cylinder. Use

9990210 Valve spring compressor.
3 Remove the valve washers, valve springs and
collets.
4 Remove the old valve stem seals.

Installation
5 Lubricate the valve stem with engine oil.
Fit 88800011 Drift to the valve stem.
Thread the new seal on and put it over the
mandrel.

P0021043

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 21-4 Valve Mechanism

6 Slide 88800151 Drift over the valve stem and tap

the seal down carefully with a plastic mallet.
88800151

P0011236

7 Install the valve springs, valve spring washers

and collets.
Carefully tap with a plastic mallet to make sure
the collets end up in the right position.
8 Transfer the valve spring compressor to cylinder
# 6 and repeat the above procedure.
Then crank the engine so that cylinders 3 and 4
are at TDC.
Repeat the procedure. Then continue with
cylinders 2 and 5.
9 Install the unit injectors; refer to the Installation
section in Injector, Change, page 212.
10 Adjust valves and unit injectors; refer to Valves
and Unit Injectors, Adjustment, page 106
11 Bleed the fuel system; refer to Fuel system,
bleeding, page 196.
Perform a leakage and function check.

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21-5 Timing Gears and Shaft

21-5 Timing Gears and Shaft

Timing Gear, Removal
Tools:
9998267 Guide sleeve
9998511 Lever
88800014 Rotation tool
1 Undo / remove:
1 The pressure drop indicator connector.
2 The flywheel sensor connector.
3 The air cleaner with attachment plate.

P0020990

2 Remove the oil sump; refer to Lubrication Oil

Pump, Change, page 177.

P0010454

3 Remove the starter motor; refer to Starter Motor,

Change, page 294.

P0020000

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 21-5 Timing Gears and Shaft

4 Remove the bolts on the starter motor side.

P0021033

5 Remove the fuel pump with drive unit; refer to

Fuel Feed Pump, Change, page 209.

P0021034

6 Remove the timing gear cover's two caps.

Alternatively, remove the air compressor.

P0010158

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21-5 Timing Gears and Shaft

7 Remove the bolts on the fuel pump side.

P0021035

8 Remove the valve cover according to Valve

cover, change, page 101.
9 Crank the engine to camshaft TDC and check that
the mark on the flywheel is at zero. Use
88800014 Rotation tool.

P0020997

10 Disconnect the injector connectors.

Cut off cable ties and remove the cable harness
from the cable holder.
Remove the cable holders.

P0021036

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 21-5 Timing Gears and Shaft

11 Remove the harness bush and carefully pull the

harness out through the cylinder head.

P0020995

12 Remove the upper timing gear cover.

P0021037

13 Remove the upper timing gear casing and

remove the rubber seals.

P0012728

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21-5 Timing Gears and Shaft

14 Remove the vibration damper.

IMPORTANT!
Make sure the vibration damper is protected from
impact and shocks.

Bolt on the crankshaft gear using spacers.

P0021038

15 Remove the flywheel bolts.

Lift the flywheel away using suitable lifting eyes.

P0010159

16 Remove the old crankshaft seal; refer to

Crankshaft Seal, Change (rear), page 165.
17 Remove the remaining timing gear cover bolts.
Install lifting eyes and connect the lifting tool.

P0010162

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 21-5 Timing Gears and Shaft

18 Use 9998511 Lever to release the cover from the

intermediate plate.

P0010163

19 Lift away the cover.

Check which gears need replacing.
The large gear (double drive) may not be split but
must always be replaced whole.
If the oil pump gear needs replacing, remove the
oil pump; refer to Lubrication Oil Pump,
Change, page 177.
1 Drive gear, camshaft gear
2 Upper intermediate gear, adjustable
3 Intermediate gear, Double gear
4 Intermediate gear, power steering pump
and fuel pump
5 Drive gear, crankshaft gear
6 Drive gear, lubrication oil pump
7 Take-off: Drive gear, power steering pump
and fuel pump
8 Accessories: Drive gear, air compressor
P0021039 9 Accessories: Drive gear, power take-off
(auxiliary equipment)

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21-5 Timing Gears and Shaft

20 Check that the crankshaft gear marking

corresponds to the double gear.

P0010180

21 Check that the camshaft gear marking

corresponds to the timing gear plate hole.

P0010181

22 Remove the lower intermediate gear.

Remove the double gear (Allen bolts at center).
Remove the upper intermediate gear.

P0010182

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 21-5 Timing Gears and Shaft

23 NOTICE! Before the timing gear plate is

removed, two pcs 9998267 Guide sleeve must be
installed on the engine block (tighten to 60 Nm
(44 lbf.ft)). This is to make sure the plate is
replaced in exactly the same position.

It is now possible to remove the timing gear plate.

Remove all bolts.
Using a pry bar, carefully prise the plate free (held
in place by sealant), but do not prise such that the
9998267 guide sleeves are dislodged or damaged.

P0010184

24 Remove the two bolts retaining the crankshaft

gear.
Remove the crankshaft gear using a suitable
puller.
Place a larger washer beneath the puller bolt to
protect its thread from damage.
Clean the plate thoroughly on both sides.
Clean the engine block and cylinder head sealing
surfaces, but do not remove the plate guide
sleeves.

P0010185

25 Remove the camshaft gear.

P0021040

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21-5 Timing Gears and Shaft

26 Remove the upper chain guide.

P0021041

27 Clean the timing gear plate, the crankshaft

contact surface and the cylinder head front.

NOTICE! Only remove the timing gear plate if

absolutely necessary.

P0021042

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 21-5 Timing Gears and Shaft

Timing Gear, Installation

Tools:
885810 Fixture
9998601 Fixture

Timing gear plate, installation

1 NOTICE! The timing gear plate must be installed
within 20 minutes of applying the sealant.

Apply a 2 mm (0.08") bead of sealant on the

engine block and the cylinder head, as illustrated.

P0021050

2 Align the plate with the guide sleeves.

Install all the bolts and tighten them in the
following order:

P0021051

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21-5 Timing Gears and Shaft

3 Lubricate the gear contact surface.

P0021049

4 Install a new O-ring on the crankshaft and

lubricate it. Lubricate the inside of the gearwheel
with the same lubricant.
Fit the gearwheel locator pin into the crankshaft
hole and make sure the oil pump gear meshes
with the crankshaft gear.
Install the bolts and tighten them alternately so
that the gearwheel is not skewed.
Torque according to the specifications in
Tightening Schedules, page 15.

P0010187

5 Clean the upper intermediate gear hub.

Check the oil holes are open.
Fit the washer onto the guide sleeve.
Check that the bolt holes align.

P0010186

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 21-5 Timing Gears and Shaft

6 Fit the hub onto the engine by aligning the guide

sleeve.
Lubricate the thrust bearing with engine oil.

P0010189

7 Check that the bearing is fault free. Lubricate the

bearing with engine oil.
Install the intermediate gear such that the bearing
is located outermost.
Check that the plate lubricating hole is open.
Lubricate the rear of the plate.

P0010190

8 Fit the plate onto the centering guide and install

the bolts. Tighten the bolts until contact.
Check that the gearwheel rotates easily.

P0010191

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21-5 Timing Gears and Shaft

9 Make sure that the marking for top dead center

(TDC) on the camshaft is between the markings
on the bearing cap.

P0020997

10 Install the camshaft gear without the vibration

damper.
Align the marking with the hole in the timing gear
plate.
Allow suitable spacers under the bolts to act as a
replacement for the vibration damper.

P0010193

11 Adjust the gear lash according to the sections

Flank Clearance, Checking and Flank Clearance,
Adjustment in the Cylinder Head,
Installation, page 86 chapter.

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 21-5 Timing Gears and Shaft

12 Check the double gear bearing.

Align the marking on the double gear with the
marking on the crankshaft.
Mesh the upper intermediate gears and fit the
locator pin into the center hole.
Turn the hub so the bolt holes align.
Install the bolts and tighten according to the
specifications in Tightening Schedules, page 15.

P0010192

13 Install the lower intermediate gear.

P0010324

14 Apply a 2 mm (0.08") bead of sealant according

to Tightening Schedules, page 15.

NOTICE! Must be torqued within 20 min.

P0005224

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21-5 Timing Gears and Shaft

10 11 15 Lift the cover into place and align the guide

sleeves.
8 9 Install all the bolts and torque according to
Tightening Schedules, page 15.

NOTICE! M14 bolts first as per the chart.

6 7

2 3

4 5

P0005225

16 Inspect the flywheel.

Where necessary, replace the ring gear; refer to
Gear Ring, Fywheel: Replace, page 158.
17 Install a new crankshaft seal; refer to Crankshaft
Seal, Change (rear), page 165
Install the flywheel.
Check the flywheel with regard to distortion; refer
to Flywheel, Indication, page 157

P0010159

18 Install the bolts on the starter motor side.

P0021033

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 21-5 Timing Gears and Shaft

19 Install the bolts on the fuel pump side.

P0021035

20 IMPORTANT!
Make sure the vibration damper is protected from
impact and shocks.

Remove the bolts and spacers from the camshaft

gear.
Install the vibration damper.
For tightening torque, refer to Tightening
Schedules, page 15.

P0021038

21 Apply a 2 mm (0.08") bead of 1161231 Sealant to

the upper timing gear cover contact surface, as
illustrated.

P0013011

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21-5 Timing Gears and Shaft

22 Fit new rubber seals and install the upper timing

gear casing.

P0006949

23 Only fit the bolts (1) and tighten by hand.

NOTICE! The holes are oblong to allow the cover

to be pressed down against the rubber seal.

P0006950

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 21-5 Timing Gears and Shaft

24 Press the cover down using 885810 Fixture and

88510 9998601 Fixture so that the cylinder head and the
upper timing gear cover sealing surfaces are
aligned.
Fit the remaining bolts (2).
Tighten according to the specifications in
Tightening Schedules, page 15.

NOTICE! The timing gear casing must be

installed and torqued within 20 minutes of sealant
application.

P0012751

9998601
P0012752

25 Install the camshaft sensor and adjust it

according to Sensors, Adjustment, page 159

P0010060

26 Check, and where necessary adjust, valves and

unit injectors according to Valves and Unit
Injectors, Adjustment, page 106.

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21-5 Timing Gears and Shaft

27 Fit the cable holders.

Pull the cable harness through the cylinder head
to the unit injectors and connect them.
Fasten the harness in the cable holder using oil
and heat-resistant cable ties.

P0021036

28 Bolt the harness bush place.

P0020995

29 Fit the valve cover; refer to Valve cover,

change, page 101
30 Install the oil sump; refer to Lubrication Oil Pump,
Change, page 177.

P0010454

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 21-5 Timing Gears and Shaft

31 Install the starter motor; refer to Starter Motor,

Change, page 294.

P0020000

32 Install the fuel pump with drive unit; refer to Fuel

Feed Pump, Change, page 209.

P0021034

33 Fit the timing gear cover's two caps.

Alternatively, install the air compressor.

P0010158

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21-5 Timing Gears and Shaft

34 Install:
1 The air cleaner with attachment plate.
2 The flywheel sensor connector.
3 The pressure drop indicator connector.

P0020990

35 Fill with new engine oil.

36 Start the engine and check for leaks; let the
engine run until it reaches normal working
temperature.
Let it run an additional 5-10 minutes at idle.
37 Check engine oil level; fill as necessary.

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 21-5 Timing Gears and Shaft

Camshaft, Wear Check

Rocker bridge removed

Put a steel rule across the camshaft lobes, parallel with

the camshaft axis, to check whether the cam profiles
show signs of wear.

Measure the wear with a feeler gauge or wire gauge.

Alternatively, a digital caliper gauge may be used.

Compare the measured values with those specified in

Group 21: Engine, page 26.

P0007013

Guidlines for replacement

In normal conditions, unevenness may occur on the
surface of engine camshaft lobes. This does not mean
that the camshaft must be changed. These marks do
not have any negative influence on either engine
performance or the durability of the engine and its
components.

Examples of acceptable wear and unacceptable wear

are shown below.

Acceptable wear: Unacceptable wear:

The camshaft need not be changed. IMPORTANT!
The camshaft and associated rocker arms must be
changed.

P0003896 P0003899

P0003898 P0003897

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21-5 Timing Gears and Shaft

Camshaft Bearing Housing,

Replace
The factory-installed bearing housings are machined
together with the cylinder head, and may therefore not
be moved from one cylinder head to another.

Therefore, the first time one or more bearing housings

are replaced, all bearing housings must be replaced so
that the positions of the bearing housings can be
aligned. Bearing housings may then be replaced
individually.

P0007018

The holes for the guide sleeves are oval in the

replacement housings, which allows radial adjustment
of the center bearing housing and axial adjustment of
the front and rear bearing housings.

If a replacement housings are installed, mark them with

their numbers so they can be put back in the same
place as before, if they need to be removed.

P0007019

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 21-5 Timing Gears and Shaft

Flywheel, Indication
Flywheel exposed; refer to Timing Gear, Removal.

Tools:
88800014 Rotation tool
9989876 Dial indicator
9999696 Magnetic stand
1 Install 88800014 Rotation tool in order to rotate
the flywheel.
2 Install 9999696 Magnetic stand and 9989876 Dial
indicator with the measuring tip against the
999 9696 flywheel at a measuring radius of around 150 mm
(5.9”).
Rotate the flywheel at least one revolution and
check the min and max deflections on the dial
indicator. The value should not exceed 0.20
mm (0.0079”).
998 9876
3 If the distortion is greater, and this is not the result
of a damaged surface where the dial indicator is
applied, remove the flywheel and check that there
is no waste material or damage to the contact
flange on the flywheel and crankshaft.
Clean the flanges or change the flywheel if it is
damaged.
P0010194
Torque the bolts; refer to 03-2, Special Tightening
Torques.
4 Check using the dial indicator and magnetic stand
again.
Remove the tool.

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21-5 Timing Gears and Shaft

Gear Ring, Fywheel: Replace

1 Remove the flywheel.
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.

P0020333

4 Heat the new gear ring to 180-200 °C (356–392

°F).
The ring gear must be evenly heated.

P0020334

5 The bevel must face out.

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

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

P0020335

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 21-5 Timing Gears and Shaft

Sensors, Adjustment
Sensor removed.

Tools:
88800031 Measuring tool
1 If the camshaft sensor needs to be adjusted,
rotate the crankshaft so that one tooth on the
camshaft vibration damper is centered in front of
the sensor hole.
2 Remove any shims beneath the sensor.
Clean the tool's contact surface on the engine.
3 Insert 88800031 Measuring tool without
88800031 tightening the lock screw.
press in the tool firmly so that it is in contact with
the cover. Press in the center part of the tool until
it contacts the gearwheel and tighten the lock
screw.
Rove the tool and inspect the center section
position in its sleeve.

P0010198

4 Determine further actions according to the

following:

If the center section of the tool is entirely below

the sleeve's upper edge, no shims are required.

P0010219

If only the center section upper surface is above

the sleeve's top edge, one shim is required.

P0010218

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21-5 Timing Gears and Shaft

If the two center section surfaces are above the

sleeve's top edge, two shims are required.

P0010220

5 Install the sensor with a new seal and any shims.

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 21-6 Crank Mechanism

21-6 Crank Mechanism

Crankshaft Seal, Change (front)
Tools:
9990118 Cone
9990192 Puller
9992000 Handle
9996400 Slide hammer
88800021 Drift
1 Remove the crankshaft pulley and vibration
damper (12 bolts).

2 Drive the seal out with extractor 9990192

together with slide hammer 9996400.
3 Clean the seal seat in the flywheel housing and
the mating surface on the crankshaft.

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21-6 Crank Mechanism

4 Check that the tools are undamaged, to prevent

damage to the seal.

NOTICE! No lubrication. It must be installed

completely dry.

Install cone 9990118 on the tool.

Install the seal on tool 88800021 via 9990118.
Remove tool 9990118.

5 Then install extension 9992000 on 88800021 and

carefully tap the new seal in until the tool bottoms
against the crankshaft.
Remove the tool and check that the seal is
correctly installed.

P0004794

6 Install the vibration damper and pulley. Tighten

according to 03-2, Special Tightening Torques.

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 21-6 Crank Mechanism

Crankshaft Seal, Change (front)

Applies to:

D11 Industrial / Marine SN7011385241 —

Tools:
88800501 Mounting tool
88800502 Puller

Removal
1 Adjust the arms 88800501 Mounting tool and
attach the tool.
Setting diameter: use A. Ø 151 Front seal D11.
1 Forward: Hooks release
Backward: Hooks grip
2 Tension nut
3 Slowly pull out the seal.

P0025163

Installation
Important! The metal side of the seal ring must face
inward.
2 Slide the seal ring onto the tool.
Screw the assembly tool with the seal onto the
crankshaft.
Press the seal in until the cover touches the
bottom. Hold in position for at least 3 seconds.

P0025195

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21-6 Crank Mechanism

3 Reference dimension for a correctly installed

seal.

P0025197

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 21-6 Crank Mechanism

Crankshaft Seal, Change (rear)

Tools:
9990113 Drift
9990117 Cone
9990192 Puller
9992000 Handle
9996400 Slide hammer

Removal
1 Remove the flywheel according to 21-5,
Flywheel, Change.
2 Hammer out the seal using 9990192 Puller
together with 9996400 Slide hammer.
Clean the seal seat in the flywheel housing and
the mating surface on the crankshaft.

P0020200

3 NOTICE! Check for damage on the guide or drift

as they may damage the seal.

Fit the 9990117 Cone to the 9990113 Drift.

P0020201

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21-6 Crank Mechanism

Installation
4 Install the seal on 9990113 Drift, via
9990117 Cone.
Remove 9990117 Cone.

P0020202

5 NOTICE! No lubrication. It must be installed

completely dry.

Fit 9992000 Handle to 9990113 Drift.

P0020203

6 Tap in the new seal until it bottoms against the

crankshaft gear.

P0020204

7 Remove the tool and check that the seal is

correctly installed.
If needed, use two bolts to pull the tool out.
8 Install the flywheel according to: 21-5, Flywheel,
Change.

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 21-6 Crank Mechanism

Crankshaft Seal, Change (rear)

Applies to:

D11 Industrial / Marine SN7011385241 —

Tools:
88800502 Puller
88800561 Mounting tool

Removal
1 Adjust the arms 88800502 Puller and attach the
tool.
Setting diameter: use B. Ø 170 Rear seal D11.
1 Forward: Hooks release
Backward: Hooks grip
2 Tension nut
3 Slowly pull out the seal.

P0025163

Installation
Important! The metal side of the seal ring must face
inward.
2 Slide the seal ring onto the tool.
Screw the assembly tool with the seal onto the
crankshaft.
Press the seal in until the cover touches the
bottom. Hold in position for at least 3 seconds.

P0025193

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21-6 Crank Mechanism

3 Reference dimension for a correctly installed

seal.

P0025172

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 21-6 Crank Mechanism

Crankshaft, Inspection
The crankshaft is induction hardened.

Inspect the crankshaft very carefully to avoid

unnecessary overhaul.
The following applies when the need for overhaul is
checked:
1 Clean the crankshaft carefully.
Measure the bearing journals' out-of-round, wear
and taper. Refer to Group 21: Engine, page 26 for
specifications.
2 Check whether there is any surface damage on
the bearing journals. If there is any damage on
the surface layer, the shaft must be re-ground.
3 Place the shaft pair of V-blocks, under 1st and 7th
main bearing journals. Alternatively, hold the
crankshaft between the two centers.
4 Measure crankshaft axial displacement (throw)
on the 4th main bearing.
For maximum permissible values, refer to Group
21: Engine, page 26.

IMPORTANT!
Crankshaft straightening is not permitted.
5 Check for cracks before and after any grinding.
Magnetic powder testing is used for this test, i.e.
fluorescent powder which is viewed under ultra-
violet light.

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21-6 Crank Mechanism

Main bearing, Change

Oil pan removed

The method describes replacement of main bearings

with the crankshaft in place in the engine

Tools:
9990013 Slide hammer
9990114 Puller
88800014 Rotation tool

Removal
1 Fit tool 88800014 Rotation tool.

P0006884

2 Remove the oil suction pipe and oil pump.

Remove the bracing frame.

P0010124

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 21-6 Crank Mechanism

3 Remove one bearing cap.

P0006970

4 Remove the upper main bearing shell by putting

a pin in the crankshaft oil hole and rolling the
bearing shell out by turning the crankshaft in the
direction of rotation with tool 88800014 Rotation
tool.
5 Clean and check the bearing seat, bearing cap,
shaft journal and bearing shell.
If the bearing has seized, the reason must be
determined before a new bearing is installed.
6 Check that the correct bearing dimension is used
when the bearing shells are changed.

NOTICE! If case of uncertainty, check in Group

21: Engine, page 26 which oversize dimensions
P0006971
are available.

Installation
7 Lubricate the shaft journal and the new bearing
shells with engine oil.
8 Install the upper bearing shell by turning the
crankshaft using tool 88800014 Rotation tool
against the direction of rotation with the pin in the
oil hole.

NOTICE! Check that the pressed-out bearing

shell heel is correctly aligned in the bearing seat
cutout.

Make sure that the upper bearing shells (those to

be located in the engine block) are equipped with
oil holes.

P0006972
NOTICE! Remove the pin when done.

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21-6 Crank Mechanism

9 Fit the main bearing cap together with the lower

bearing shell.

NOTICE! The main bearing caps are asymmetric

and can only be installed in one position. Note the
main bearing cap numbers showing their
locations if several caps are removed
simultaneously.

Torque the caps in two steps as specified; refer

to Group 21: Engine, page 26.
10 Change the other bearing shells, one a time, in
the same way as the first one. Each time a
P0006973
changed is made, check that the crankshaft does
not seize by turning it using tool
88800014 Rotation tool.
11 Check crankshaft end float and replace the thrust
washers if the clearance is too great or if the thrust
washers are damaged.

NOTICE! Measure the end float with a dial gauge.

Thrust bearings are available in a number of
oversize dimensions. Refer to Group 21:
Engine, page 26 for oversize dimensions and
axial play.

The crankshaft thrust bearing is located in the

center main bearing.
12 Use a narrow plastic or wood stick to remove the
thrust bearing washers from the cylinder block
bearing seat.

NOTICE! The thrust washers can only be placed

in one position.

P0006974

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 21-6 Crank Mechanism

13 Check the axial play of the crankshaft when all

main bearing caps have been torqued; refer to
Group 21: Engine, page 26 for specification.
14 Install the bracing frame and torque according to
the tightening chart; refer to Group 21:
Engine, page 26.
15 Install the oil pump and oil suction pipe.
16 Remove tool 88800014 Rotation tool from the
flywheel housing and install the cover.
17 Install the oil pan.
P0006975 Add oil and change the oil filter.
Check the oil pressure.

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22-0 Lubricating and Oil System, General

22-0 Lubricating and Oil System, General

Engine Oil Pressure, Check
Tools:
9992873 Nipple
9996398 Manometer
9998493 Hose

Where incorrect oil pressure sensor readings are

suspected, check the oil pressure with an external
pressure sensor.
There is a plug in the engine block located behind the
control unit.
1 Check the oil pressure with an external pressure
gauge and compare values with the specification
in Administration, page 33.
2 Remove the control unit to get to the plug.
3 Fit 9998493 Hose, 9992873 Nipple and
9996398 Manometer.
4 Start the engine and check the oil pressure.
- If the oil pressure reading shows pressure to
be below the specified minimum, continue
fault tracing by checking the oil filters.
- If the oil pressure reading from an external
pressure sensor shows pressure to be
within limits while the engine's regular
pressure sensor does not, replace the
pressure sensor.
5 Remove the hose, nipple and pressure gauge.
6 Install the plug and bolt on the control unit.

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 22-0 Lubricating and Oil System, General

Oil pressure safety valve, change

Engine oil drained.

Removal
1 Remove the oil filler pipe and the oil dipstick.
Remove the oil level sensor connector.

P0010122

2 Remove the oil sump.

P0010454

3 Unscrew the valve housing cover and remove the

safety valve.

P0021052

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22-0 Lubricating and Oil System, General

Installation
4 Install the new safety valve.
Install and tighten the valve housing cover.
5 Clean the oil sump.
Check the rubber seal.
Cut away excess sealant from the front
crankshaft seal cover.
Cut away excess sealant from the timing gear
plate and the flywheel housing.
Apply new sealant to the joints and install the oil
sump within 20 min.
6 Fit the oil sump.
Tighten the oil sump bolts according to Tightening
torques, page 9.

P0010454

7 Attach the oil dipstick tube to the bracket.

Install the oil filler pipe and the wiring to the oil
level sensor.
Fill with engine oil.
8 Start the engine.
Check the oil pressure and check for leakage.

P0010122

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 22-1 Oil pump and Line

22-1 Oil pump and Line

Lubrication Oil Pump, Change
Engine oil drained.

Removal
1 Remove the oil filler pipe and the oil dipstick.
Remove the oil level sensor connector.

P0010122

2 Remove the oil sump.

P0010454

3 Remove the suction strainer and the pipe to the

pump.

P0021014

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22-1 Oil pump and Line

4 Remove the delivery pipe from the pump.

P0021015

5 Remove the two bolts on either side of the pipe

flange.

P0021016

6 Remove the main bearing cap together with the

oil pump.

P0021017

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 22-1 Oil pump and Line

7 Unbolt the oil pump from the main bearing cap.

P0021018

Installation
8 IMPORTANT!
Clean the contact surface.

Install the oil pump on the main bearing cap.

Check that the tab on the bearing is in the notch
in the bearing seat and that the oil holes
correspond to each other.
Lubricate the bearing shell with engine oil.

P0021019

9 Install the oil pump by meshing the gearwheels

and tightening the main bearing cap.

Tightening torque:
1 150 Nm (110 lbf. ft.)
2 120 °

P0021017

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22-1 Oil pump and Line

10 Fit the pipe flanges.

P0021016

11 Fit the delivery pipe to the oil pump.

P0021020

12 Install the suction strainer and pipe to the oil

pump.

P0021021

13 Clean the oil sump.

Check the rubber seal. Cut away excess sealant
from the front crankshaft seal cover. Cut away
excess sealant from the timing gear plate and the
flywheel housing.
Apply new sealant to the joints and install the oil
sump within 20 min.

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 22-1 Oil pump and Line

14 Fit the oil sump.

Tighten the oil sump bolts according to Tightening
torques, page 9.

P0010454

15 Attach the oil dipstick tube to the bracket.

Install the oil filler pipe and the wiring to the oil
level sensor.
Fill with engine oil.

P0010122

16 Start the engine. Check the oil pressure and

check for leakage.

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22-2 Oil filter

22-2 Oil filter

Oil filter, Change
Tools:
9998487 Sleeve
9999179 Extractor oil filter

Removal
1 Drain the engine oil.
2 Clean around the filter bracket and remove the
2
filters. Use 9998487 Sleeve or 9999179 Extractor
oil filter.

P0004307

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 22-2 Oil filter

Installation
3 Clean the sealing surface for the oil filter seal and
neighboring surfaces on the console.
4 NOTICE! Use recommended oil.

Lightly lubricate the new oil filter's rubber gaskets

(1).
Fill the new the filters with engine oil.
5 Tighten the filters by hand until they touch the
bracket contact surface (2).
Tighten them by hand another 3/4 to one full turn
(3) (or what the filter marking stipulates).

P0019995

6 NOTICE! Use recommended oil.

Re-install the drain plug.

Fill with the requisite quantity of oil; refer to the
service record for the engine type concerned.
7 Start the engine.
Perform a leakage and function check.
8 Switch the engine off and check the oil level after
a few minutes. Top up with oil as necessary.

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22-2 Oil filter

Oil Filter Bracket, Change

Removal
IMPORTANT!
Protect against dirt while work is in progress.

NOTICE! Be prepared to gather up fluid.

1 Disconnect the pressure sensor connector.

Remove the wastegate control hose.
Remove the bracket with the NOx sensor.
Remove the cable ties.

P0020685

2 Clean the oil filter housing and the engine block

mating surfaces.
Remove the oil supply line (1) to the turbocharger.
Unscrew the oil pipe (2).
Pull the pipe out of the EGR control valve.
Remove the oil return pipe.

NOTICE! Plug the oil supply line connection to

the oil filter housing.

P0020686

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 22-2 Oil filter

3 Remove the oil filters.

P0020687

4 Remove the bracket.

Remove the gasket.

P0020688

5 IMPORTANT!
Clean the sealing surfaces.

Remove the oil pipes from the oil cooler cover.

P0020689

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22-2 Oil filter

Installation
6 Install the oil pipes to the oil cooler cover.
7 IMPORTANT!
Sealant may absolutely not be used. The use of
sealant may result in engine breakdown.

Move over the parts for re-use to the new bracket.

P0020690

8 Install the oil filter bracket with a new gasket and

fit the oil pipes into their unions.

P0020688

9 Install a new oil filter and a new bypass filter (1).

Follow the instructions on the filter.

P0020691

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 22-2 Oil filter

10 Fit the oil supply line (1) to the turbo.

Connect the oil pipes the e-EGR control valve.
Connect the oil pipes (2) to the filter bracket and
tighten them.

P0020686

11 Install the bracket with the NOx sensor.

Install the wastegate control hose.
Connect the pressure sensor connector.
Attach new cable ties.
12 Replenish or change the oil.
13 Start the engine;check oil system function and
check for leaks.
14 Switch the engine off and check the oil level.

P0020692

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22-2 Oil filter

Oil filter bracket valves, change

Bypass valve oil filter, replacement
1 Remove the pressure pipe to the turbocharger.
2 Clean the area around the overflow valve.
3 Remove the overflow valve.
4 Clean the valve contact surface in the oil filter
housing.
5 Fit the new the valve with a new seal ring and
tighten the nut.
Tightening torque: 55 Nm (40.6 lbf. ft.)
6 Tighten the turbocharger pressure pipe.
7 Start the engine and check for leaks.

P0021053

Bypass valve, full flow oil filter, replace

1 Clean the area around the overflow valve.
2 Remove the valve and clean the valve seat in the
oil filter bracket.
3 Fit the new the valve with a new seal ring and
tighten the nut.
Tightening torque: 55 Nm (40.6 lbf. ft.)
4 Start the engine and check for leaks.

P0021054

Reduction valve, change

1 Clean the area around the reducing valve.
2 Remove the reducing valve.
3 Clean the valve contact surface in the oil filter
housing.
Check that the old seal is not still in place.
4 Check that the color marking on the new valve
matches the old.
5 Fit the new valve with a new seal ring.
Check that the internal seal does not come loose
when the valve is installed.
Install a new O-ring.
6 Start the engine and check for leaks.

P0021055

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 22-2 Oil filter

Piston cooling valve - opening valve,

replacement
1 Clean around the filter bracket and the piston
cooling valve.
2 Remove the opening valve.
3 Clean the valve seat in the filter bracket.
4 Fit the new valve with a new seal ring.
Tightening torque: 55 Nm (40.6 lbf. ft.)
5 Start the engine and check for leaks.

P0021056

Piston cooling valve - control valve,

replacement
1 Remove the oil filter bracket; refer to Oil Filter
Bracket, Change, page 184.
2 Clean around the filter bracket and the piston
cooling valve.
3 Remove the control valve.
4 Clean the valve seat in the filter bracket.
5 Fit a new valve with a new seal ring.
Tightening torque: 55 Nm (40.6 lbf. ft.)
6 Install the oil filter bracket; refer to Oil Filter
Bracket, Change, page 184.
7 Start the engine and check for leaks.

P0021057

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22-2 Oil filter

Bypass valve, oil cooler

1 Clean the area around the bypass valve.
2 Remove the bypass valve.
3 Clean the valve contact surface in the oil filter
housing.
4 Fit the new valve with a new O-ring.
5 Start the engine and check for leaks.

P0021058

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 22-3 Oil cooler

22-3 Oil cooler

Oil Cooler, Replace
Drain the coolant according to Coolant,
Change, page 279.

Removal
1 Remove the turbocharger charge air pipe.
Remove the heat shield.

P0020043

2 Remove the e-EGR control valve according to

Control valve e-EGR, change, page 237.
3 Remove the turbocharger according to Turbo,
Change, page 245.
4 Remove the radiator hose (1) for the air
compressor (option).
Remove the hose (2) from the engine heater
(option).
5 Remove the exhaust manifold according to
Exhaust Manifold, Change, page 227.

P0020695

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22-3 Oil cooler

6 Remove the oil cooler cover.

7 Remove the oil pipes from the oil cooler cover.

P0020696

8 Remove the oil cooler cover plate.

P0009973

9 Remove the oil cooler.

P0009974

10 Remove the two seal rings.

P0009975

11 Clean all sealing surfaces.

P0009976

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 22-3 Oil cooler

12 Install a new front seal.

P0009977

Installation
13 Install new seal rings on the oil cooler.

P0009975

14 Install the oil cooler.

1 3 Tighten the bolts diagonally and finish off by
tightening the first bolts again.
Tightening torque: 27 Nm (19.9 lbf. ft.)

4 2
P0005238

15 Install the oil cooler plate.

P0009973

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22-3 Oil cooler

16 1 Remove gasket.
2 Clean along the gasket groove.
3 Clean the sealing surfaces.
4 Install a new gasket.

Apply a thin bead of sealant (part # 1161771) in

the groove, max 20 min before the cover is
P0010538 installed.
Press the new seal into the groove.
Make sure the seal's flat surface ends up at the
bottom of the groove.
17 Install the oil pipes.

Install the bolt (1) which will end up behind the

water pump in the cover.
Lift the cover into place.
Fit a bolt (2).

Press the cover forward and fit another bolt.

Install the remaining bolts and tighten them
according to the chart.

P0020697

18 88800022 Mounting tool may make installation

easier

P0020698

Tightening chart
19 Install the cover on the engine block and install
88800022 Mounting tool with bolt A.
A C B Press the cover against the water pump housing.
2 3
Fit bolt B.
Check that the cover is in position.
Install and tighten bolts C and D to standard
torque.
Tighten the cover bolts outwards from the center
4 in the sequence 1–4.
1
D Finish off by checking the torque of bolts C and
p0005239 D.
20 Install the exhaust manifold according to Exhaust
Manifold, Change, page 227.

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 22-3 Oil cooler

21 Install the radiator hose (1) for the air compressor

(option).
Install the hose (2) to the engine heater (option).
22 Install the turbocharger; refer to Turbo,
Change, page 245
23 Install the exhaust pipe e-EGR; refer to Control
valve e-EGR, change, page 237.

P0020695

24 Install the charge air pipe.

Install the heat shield.

P0020043

25 Fill the cooling system, pressure test and check

for leaks. Refer to Cooling System, Pressure
Testing, page 49.
26 Check the engine oil level and top up if necessary.
27 Start the engine. Check that no leakage occurs.

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23-0 Fuel System, General

23-0 Fuel System, General

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

NOTICE! Be prepared to gather up fluid.

1 Free the hand pump from the fuel filter bracket.

P0019904

2 Open the nipple on the front fuel connection.

Connect a drain hose.

P0019905

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 23-0 Fuel System, General

3 Purge the fuel system by pumping with the hand

pump until fuel flows.

P0019889

4 Close the venting nipple and remove the drainage

hose.

P0019905

5 Secure the hand pump.

P0019904

6 Start the engine and allow it to idle for about 10

minutes.
7 Perform a leakage and function check.

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23-0 Fuel System, General

Draining, Fuel Duct in Cylinder Head

IMPORTANT!
Working with the fuel system requests special
cleanliness.

IMPORTANT!
Clean thoroughly before removal.

NOTICE! Be prepared to gather up fluid.

1 Clean the fuel connections.

2 Loosen and fold down the fuel inlet supply line
into a vessel.
Let the fitting remain in the filter.

P0021113

3 Loosen and fold the return line away from the

spacer.

P0021114

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 23-0 Fuel System, General

4 Install a nipple (1), e.g. part. no. 941749. Use a

suitable hose (2).

P0021116

5 IMPORTANT!
Make sure that no dirt gets into the fuel duct.

Let the hoses hang down into a vessel.

Blow out the fuel into the vessel, through the fuel
duct inside the cylinder head (from inlet supply
line).

P0021117

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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.

IMPORTANT!
Clean thoroughly before removal.
CAUTION!
Risk of skin damage.

NOTICE! Be prepared to gather up fluid.

Removal
1 If there is a heater on the water separator,
disconnect the heating element connector.
Disconnect the water separator sensor
connector.

P0019891

2 Undo the drain nipple in the base of the water

separator.
Drain the filter.

NOTICE! Remove the plug on the water

separator housing to allow the fuel to run out more
easily.
3 Reinstall the plug and tighten the drain nipple.

P0019892

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 23-3 Fuel Feed Pump and Filter

4 Remove the pre-filter together with the lower

section of the water separator. Use an oil filter
wrench.

P0019893

5 Remove the lower section of the water separator

and O-ring from the filter.
Keep the filter in a suitable container.

P0019894

6 Clean the lower section of the water separator

and the contact surfaces.
Check that the strainer and drain hole in the lower
section are not clogged.

P0019895

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23-3 Fuel Feed Pump and Filter

Installation
7 Lubricate the O-ring and seal ring with diesel.
Install a new O-ring.
Install the lower part of the water separator.

P0019894

8 Screw the filter onto the filter bracket by hand until

the rubber seal touches the mating surface. Then
tighten a further half turn, no more.

P0019893

9 Connect the connectors (poss. connector for the

heater element).

10 Purge the fuel system according to Fuel system,

bleeding, page 196.
P0019891

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 23-3 Fuel Feed Pump and Filter

Fuel filter, Change

IMPORTANT!
Working with the fuel system requests special
cleanliness.

IMPORTANT!
Clean thoroughly before removal.
CAUTION!
Risk of skin damage.

NOTICE! Be prepared to gather up fluid.

Removal
1 Clean around the fuel filter.
2 Remove the fuel filter with the aid of a suitable
filter puller. Let the fuel drip off into a collection
vessel.
3 Clean around the filter housing sealing surface.

P0019888

Installation
4 NOTICE! Do not fill the new filter with fuel before
installation. There is a risk of system
contamination that may cause malfunction or
damage.

Lubricate the seal with diesel and install the new

fuel filter. Torque the filter according to the
instructions on the filter.

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23-3 Fuel Feed Pump and Filter

5 NOTICE! No nipple need be opened.

Pump the hand pump around 200–300 strokes; a

resistance will be felt in the hand pump when
purging is complete.

P0019889

6 Start and warm up engine.

Perform a leakage and function check.

Fuel Feed Pressure, Check

Tools:
9990124 Nipple
9996666 Nipple
9998339 Manometer
1 Install tool:
1 9998339 Manometer
2 9996666 Nipple
3 9990124 Nipple
2 Check that the fuel feed pressure is according to
specifications: Refer to Administration, page 25.
3 Remove the tool.
Install new fuel line seals.

P0005070

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Fuel filter housing, change

IMPORTANT!
Take great care to keep fuel system unions clean.
Even minimal amounts of dirt can cause engine
breakdown.

Removal
1 Switch off battery power.
2 Thoroughly clean the fuel filter bracket, fuel hoses
and unions, and the area around the bracket.
3 Drain the pre-filter and water separator. Remove
both fuel filters.
Remove the electrical connectors to the pressure
sensor and water sensor.

P0009988

4 Remove the return fuel line from the bracket.

Remove the pump supply line from the bracket.

P0009989

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23-3 Fuel Feed Pump and Filter

5 Remove the inlet line to the bracket. Remove the

pump line from the bracket. Remove the bracket's
rear attachment bolt.
Retain the rubber bushing located behind the
bracket. Remove the supply line banjo bolt.

P0009990

6 Remove the two remaining bracket bolts. Retain

the rubber bushings located behind the bracket.
Lift away the bracket.

P0009989

Installation
7 Move over any parts that are to be reused to the
new bracket.

p0009992

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 23-3 Fuel Feed Pump and Filter

8 Install two retaining bolts and the rubber bushings

to the bracket (the lower one and the front one).

P0009989

9 Install and tighten the supply line banjo bolt with

new seals. Install the rubber bushing and the
bracket's rear bolt.

P0009990

10 Install the upper fuel lines with new seals.

P0009989

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23-3 Fuel Feed Pump and Filter

11 Install new fuel filters and connect the connector.

Vent the fuel system. Start the engine and check
fuel system integrity.

P0009994

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 23-3 Fuel Feed Pump and Filter

Fuel Feed Pump, Change

IMPORTANT!
Working with the fuel system requests special
cleanliness.

IMPORTANT!
Clean thoroughly before removal.

IMPORTANT!
Install safety plugs in open connections.

Removal
1 Close any fuel cocks between the tank and fuel
feed pump, to avoid unnecessary fuel spills.
2 Clean thoroughly around the fuel feed pump and
its connections.
3 NOTICE! Be prepared to gather up fluid.

Remove fuel connections to the fuel feed pump

and allow the fuel to flow out into a suitable
container.

NOTICE! Plug the lines. Mark the suction and

pressure lines.

P0019964

4 Remove the fuel feed pump.

P0019965

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23-3 Fuel Feed Pump and Filter

Installation
5 Lubricate and install a new O-ring.
Check the dog clutch.

P0019966

6 Install the intermediate link.

Rotate the fuel feed pump shaft so that the key
slots into the dog clutch.

P0019967

7 Install the fuel pump.

Tightening torque: 8 Nm (5.9 lbf. ft.)

P0019969

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8 IMPORTANT!
Mark the suction and pressure lines.

Install the sealing washers.

Tighten the fuel connections.
Tightening torque: 48 Nm (35.4 lbf. ft.)

P0019968

9 NOTICE! No nipple need be opened.

Pump the hand pump around 200–300 strokes; a

resistance will be felt in the hand pump when
purging is complete.
Repeat purging if the engine is difficult to start.

P0019889

10 Start the engine.

Perform a leakage and function check.

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23-7 Injectors and Delivery Pipes

23-7 Injectors and Delivery Pipes

Injector, Change
Tools:
9990006 Puller
9990013 Slide hammer
9990185 Lifting tool
9998249 Protective sleeve
9998599 Cleaning kit

9998599 Cleaning kit includes:

- 9808570 Brush
- 9808616 Extender
- 9998580 Protective sleeve

For adjusting valves and unit injectors; refer to Valves

and Unit Injectors, Adjustment, page 106.

NOTICE! When reinstalling, use new seals.

NOTICE! When replacing a unit injector, a new injector

code must be programmed into the control unit. Refer
to the applicable ”Service Manual, Group 30, EMS
2.3”. The injector code is stamped on the unit injector.

Removal
1 Remove the valve cover according to Valve
cover, change, page 101.
2 Detach the electric connectors from the unit
injectors.
Cut the cable ties holding the cable harness and
move it to one side.

P0006879

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 23-7 Injectors and Delivery Pipes

3 Remove the fuel supply pipe and the rocker arm

bridge lubrication oil supply union.

P0006883

4 NOTICE! VCB: Make sure the pistons in the

exhaust rocker arms and the adjuster screw ball
do not fall out. Secure the exhaust rocker arm
D9
D11 pistons with cable ties or similar.
D16 D9 Undo the rocker arm bridge bolts incrementally by
D9
D11 D11 D9 equal amounts each time, to avoid bending the
D16 D16 D11 rocker shaft.
D16
Carefully lift away the rocker arm bridge using
9990185 Lifting tool.

P0006887

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23-7 Injectors and Delivery Pipes

5 Mark and remove the valve yokes.

P0006888

6 Empty the fuel channel in the cylinder head; refer

to Draining, Fuel Duct in Cylinder
Head, page 198.
7 Clean around the unit injector for removal.
8 Remove the unit injector yoke bolts.
9990013 Fit 9990006 Puller onto the injector.
9 Put the puller fork in the groove in the injector and
lock the arm with the screw on the side.
Fasten the puller by turning the screw down
against the injector ball seat.
9990006 Attach a 9990013 Slide hammer and remove the
injector.

P0001370

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 23-7 Injectors and Delivery Pipes

10 Mark the injectors and fit 9998249 Protective

sleeve to the injector.
11 Fit 9998251 Protection plug into the unit injector
location in the cylinder head if the new unit
injector is not fitted right away.

P0006890

12 Install 9998580 Protective sleeve and clean

thoroughly using 9808570 Brush and
9808616 Extender from tool kit
9998599 Cleaning kit.

P0005063

Installation
13 Read and note the unit injector trim code and the
cylinder it is installed in to make programming
easier.
14 Fit new seal rings to the unit injectors.
Lubricate the O-rings with diesel.

P0005064

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23-7 Injectors and Delivery Pipes

15 Fit the yoke to the unit injector and center it

between the valve springs.
Torque the bolts according to specifications; refer
to 03-2, Special Tightening Torques.
16 Install the valve yokes.

P0005066

17 Oil the valve yoke and camshaft lobes with engine

oil.
Lift the rocker arm bridge into place with the aid
D9
D11 of 9990185 Lifting tool.
D16 Check that the guide pins are in the correct
D9 D9 positions on the bearing caps.
D11 D11 D9
D16 D16 D11 NOTICE! Remove the exhaust rocker arm piston
D16
restraints.
18 Tighten alternately, to avoid bending the rocker
shaft.
Torque the rocker arm bridge bolts so that the
shaft rests on the bearing brackets. Refer to 03-2,
Special Tightening Torques.
19 Install new seal rings on the oil supply pipe and
union.
P0006887
Put a thin layer of petroleum jelly on the pipe seal
rings and connect the pipe to the union.
20 Fit the union and tighten according to 03-2,
Special Tightening Torques.
21 Adjust valves and unit injectors; refer to Valves
and Unit Injectors, Adjustment, page 106.
22 Connect the wiring to the unit injectors.
23 Check that there is no dirt in the cylinder head oil
channel.
24 Install the valve cover according to Valve cover,
change, page 101.
25 Bleed the fuel system; refer to Fuel system,
bleeding, page 196.

Sleeve for unit injector, replace

Unit injector removed

Tools:
9998251 Protection plug
9998250 Sealing ring
9998580 Protective sleeve
9998599 Cleaning kit
9996049 Draining hose

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 23-7 Injectors and Delivery Pipes

88800513 Drift
9986173 Puller
88800196 Drift
88800387 Puller
88800460 Sleeve

IMPORTANT!Working with the fuel system requests

special cleanliness.
1 Drain the coolant with the aid of 9996049 Draining
hose; refer to 26-0, Draining the Cooling System.
Mark and remove the valve yokes.
2 Remove the protective plug.

P0019120

3 Clean carefully around the sleeve.

Install 2 seal rings to prevent dirt from entering the
fuel ducts when the sleeve is removed.

P0019121

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23-7 Injectors and Delivery Pipes

4 The puller marking (A) should be visible when the

support ring (2) is fitted. If the marking is not
visible it may be difficult to remove the sleeve.
Press the puller (1) down to the sleeve bottom;
see arrow marking.
Install the support ring (2).
- 9998250 Seal ring, 2 pcs (3)
- Expander (4)
- Sleeve (5)
- Nut (6)

P0019122

5 Push the tool down to the bottom of the sleeve.

Tighten the nut (1) sufficiently hard to hold the
puller in place; apply moderate force and use the
tool (2) as a counterhold.

P0019123

6 Alternative 1
Remove the sleeve from 88800387 Puller and fit
88800460 Sleeve.

P0021199

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 23-7 Injectors and Delivery Pipes

7 NOTICE! Tighten the bolt moderately.

Install the sleeve with bolt (1).

Screw down to the end position towards the puller
(2).

P0021200

8 Counterhold the screw puller (2) and screw the

sleeve nut (1) until the sleeve releases.

P0021202

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23-7 Injectors and Delivery Pipes

9 Pull up the puller and sleeve.

A misshapen sleeve can be difficult to remove. If
this is the case, remove the puller and find a new
grip for the expander.
Install the support ring and make a new attempt.

P0021201

10 Alternative 2
Install the puller.
Screw down until the puller lugs meet the support
ring.

P0019124

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 23-7 Injectors and Delivery Pipes

11 Screw until the sleeve releases and the puller and

sleeve can be removed.
A misshapen sleeve can be difficult to remove. If
this is the case, remove the puller and find a new
grip for the expander.
Install the support ring and make a new attempt.

P0019125

12 Use tool 9998599 Cleaning kit and a power drill

before fitting the new sleeve.
Install tool 9998580 Protective sleeve in the
injector hole and secure it with a holder.
IMPORTANT! Tool no. 9998580 Protective
sleeve must be used to prevent dirt from entering
the fuel duct.
13 Clean the cylinder head walls using 9808618.

P0007010

P0007010

14 Clean the sleeve seat using Brush 9808614

together with the handle and holders.

P0007011
P0007011

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23-7 Injectors and Delivery Pipes

15 Clean the cylinder head hole with Brush 9808617.

999 8580 16 Remove tool 9998580 Protective sleeve. Make
980 8617 sure the O-ring is removed.
17 Check that the piston is at BDC.
IMPORTANT! This must be done so that tool no.
9808617, due to its length, does not damage the
piston.

P0007012

P0007012

18 Lubricate the tap with graphite paste 85134750.

P0025230

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 23-7 Injectors and Delivery Pipes

19 1 Fit the sleeve to the expander tool.

Lubricate the O-rings with soapy water.
2 Use the unit injector yoke to steady the tool.
Tightening torque: 80 Nm (59 lbf ft)
3 Run the tap down through the tip of the
sleeve.
20 Remove the expander tool.

P0025231

21 Remove the seal ring, (2 pcs).

22 Install the unit injectors with washer; refer to 23-7,
Unit Injector, Replace.
23 Reinstall the valve yokes according to the
markings.
24 Install the rocker arm bridge. Check play on
valves and unit injectors.
25 Install the valve cover.
26 Fill up with coolant and check that no leakage
occurs.

9998250

P0003619
P0003619

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23-8 Control System, ECM, Data Sets

23-8 Control System, ECM, Data Sets

Control Unit, Replace
NOTICE! Before the control unit is replaced and any
warranty claim made, all checks in the check list must
be performed, to exclude any defect in the engine
control system. If the measurements of the cable
harness show defects, it is highly likely that the control
unit is fault free. Refer to the “Service Manual, EMS 2”.

! WARNING!
Faulty individual control unit settings may result in
injury to persons or damage to the engine. For
information about reprogramming and reading of
software, refer to “Service manual, EMS 2”

IMPORTANT!
Exchange of control units between engines, during
fault tracing or repair, must never be performed under
any circumstances.
1 Clean thoroughly around the control unit fuel
connections.
2 Disconnect power from the engine by
disconnecting the negative battery terminal.
3 Remove the lower part of the crankcase breather
pipe.
4 Remove the upper and lower cable harness
clamps.
5 Remove the control unit cable harness by moving
the connector block retaining clips outwards.
6 Remove the upper and lower fuel connections to
the cooling element; plug the fuel lines.
7 Remove the control unit retaining bolts and
remove the control unit.

P0010470

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 23-8 Control System, ECM, Data Sets

8 Transfer the cooling element to the new control

unit. Make sure that the surface between the
cooling element and the control unit is clean.
9 Install the new control unit.
10 Connect the upper and lower fuel connections to
the cooling element with new sealing washers.
11 Install the harness and clamps.
12 Install the crank case breather lower pipe.
13 Bleed the fuel system. Refer to Fuel system,
bleeding, page 196.
Start the engine and check for error codes. Refer
to the “Service Manual, EMS 2”.

P0010470

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25-0 Inlet and Exhaust System, General

25-0 Inlet and Exhaust System, General

Charge Air Pipe, Leakage Check
1 Inspect the charge air pipes for visible cracks and
external damage.
2 Check that there is no oil in the charge air pipes.
If the pipes are damaged or the union seal rings
leak, the charge pressure will be too low and
engine performance will be affected. If the pipes
are contaminated with oil on the inside, this
indicates oil leakage in the turbocharger turbine
shaft seal. In this case, the turbocharger should
be changed as a unit.

NOTICE! If there is any oil in the charge air pipes and

charge air hoses, the charge air cooler and all pipes
and hoses in the charge air system must be cleaned
very carefully before the engine is started.

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 25-1 Inlet and Exhaust Manifolds

25-1 Inlet and Exhaust Manifolds

Exhaust Manifold, Change
Removal
1 Remove the turbocharger according to Turbo,
Change, page 245.
2 Remove the e-EGR control valve; refer to Control
valve e-EGR, change, page 237.
3 Remove the clamp and undo the pipe connection,
e-EGR.

P0020658

4 Remove the exhaust manifold.

P0020659

Exhaust manifold inspection

5 In case of inspection:
Dismantle the exhaust manifold.
Check that the components have no cracks or
damage.

P0020660

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25-1 Inlet and Exhaust Manifolds

6 Clean the mating surfaces and install the gaskets

as illustrated.

NOTICE! Apply assembly paste (part # 1161929)

around the exhaust manifold insertion surfaces at
the connections.

Assemble the exhaust manifold.

P0020661

Installation
7 Apply assembly paste (part # 1161929) for
fasteners.
8 Place the gaskets on the sealing surface.
Install the exhaust manifold.

P0020662

9 Torque the exhaust manifold in the following

stages:
1 Torque bolts 1, 8, 3, 10, 5, 12
Tightening torque: 12 Nm (8.9 lbf. ft.)
2 Torque bolts 2, 7, 4, 9, 6, 11, 1, 8, 3, 10, 5,
12
Tightening torque: 48 Nm (35.4 lbf. ft.)

P0020663

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 25-1 Inlet and Exhaust Manifolds

10 Check the pipe connection gasket, e-EGR.

P0020664

11 Secularly clamp the pipe connection.

P0020658

12 Install the e-EGR control valve; refer to Control

valve e-EGR, change, page 237.
13 Install the turbocharger according to Turbo,
Change, page 245.
14 Start the engine and perform a function check.

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25-1 Inlet and Exhaust Manifolds

Intake Manifold, Change

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

NOTICE! Be prepared to gather up fluid.

IMPORTANT!
Working with the fuel system requests special
cleanliness.

Removal
1 Loosen, fold away or remove:
1 Connection for crankcase ventilation.
2 Closed crankcase ventilation pipe.
3 Hose connection for PWM valve.
4 Return fuel pipe.

P0021101

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 25-1 Inlet and Exhaust Manifolds

2 Loosen, fold away or remove:

P0021102

- Stripes.

1 Electrical connector for crankcase

pressure sensor.
2 Charge air pipe.
3 Connector for air inlet pressure sensor.
4 Connector to preheat element.
5 Cover for cable duct.

3 Loosen, fold away or remove:

- Stripes.
1 Relay box for preheat element.
2 Air throttle, see Air throttle,
change, page 253.
3 EGR mixing chamber, see EGR mixing
chamber, change, page 242.
4 Preheat element and electrical connection.

P0021103

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25-1 Inlet and Exhaust Manifolds

4 Remove the air filter bracket bolts.

P0021104

5 Remove the intake manifold.

P0021105

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 25-1 Inlet and Exhaust Manifolds

Installation
6 Clean the sealing surfaces on the cylinder head
and intake manifold.

P0021106

7 Apply a 2 mm (0.0787 in) thick bead of sealant

(part no. 1161231) in the groove.

P0021107

8 NOTICE! The planar surface of the sealing shall

be against the bottom of the groove.

Install the new silicone sealing in the groove.

P0021108

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25-1 Inlet and Exhaust Manifolds

9 Install two pieces of 885519 Guide pin on the

cylinder head.
Guide the intake manifold onto the guide pins.

P0021109

10 Tighten the intake manifold.

P0021105

11 Tighten the air filter bracket bolts.

P0021104

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 25-1 Inlet and Exhaust Manifolds

12 Install:
1 Preheat element and electrical connection.
2 Relay box for preheat element.
3 EGR mixing chamber, see EGR mixing
chamber, change, page 242.
4 Air throttle, see Air throttle,
change, page 253.
- Stripes.

P0021110

13 Install:

P0021111

1 Cover for cable duct.

2 Connector to preheat element.
3 Connector for air inlet pressure sensor.
4 Electrical connector for crankcase
pressure sensor.
5 Charge air pipe.

- Stripes.

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25-1 Inlet and Exhaust Manifolds

14 Install:
1 Return fuel pipe.
2 Closed crankcase ventilation pipe.
3 Connection for crankcase ventilation.
4 Hose connection for PWM valve.
- Stripes.

P0021112

15 Turn on the main switch.

16 Start the engine.
Perform a function check.

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 25-4 Emission Control, Catalytic Converter

25-4 Emission Control, Catalytic Converter

Control valve e-EGR, change
Removal
NOTICE! Turn off the main switch before any work is
carried out.

1 Suspend and secure the exhaust elbow and pipe

elbow (1). Alternatively, remove them.
Undo the attachment bolts. Remove the support
bracket (2).

P0021025

2 Disconnect the harness terminal.

Remove the cable ties.

P0019060

3 If necessary, remove the control valve electrical

connection and the cable ties.

P0019061

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25-4 Emission Control, Catalytic Converter

4 NOTICE! Be prepared to gather up fluid.

Unscrew the oil pipe (1).

Pull the pipe out of the EGR control valve.
Remove the oil return pipe (2).

P0021026

5 NOTICE! No gasket replacement; exercise

caution.

Undo the bolts a few turns and carefully tap the

valve with a plastic mallet until it comes loose.
Remove the control valve.

P0021027

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 25-4 Emission Control, Catalytic Converter

Installation
6 NOTICE! Clean the sealing surfaces.

Check that the valve gaskets are undamaged.

P0021028

7 Apply joint sealant, part # 1161929.

Install the bolts and spacers.
Torque the e-EGR control valve as according to
Tightening torques, page 9.

P0021029

8 Connect the oil pipes (1) and (2) to the control

valve.

P0021030

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25-4 Emission Control, Catalytic Converter

9 Connect and tighten the oil pipes.

P0021031

10 Where necessary, connect the control valve

electrical connection and attach new cable ties.

P0019061

11 Connect the harness terminal.

Attach new cable ties.

P0019060

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 25-4 Emission Control, Catalytic Converter

12 Install the support bracket.

P0021032

13 Install the exhaust elbow and pipe elbow (1).

Tighten the attachment bolts (2).
Install the clamps and fasten them.

P0021025

14 Turn the main switch on.

15 Start the engine. Check that no leakage occurs.

NOTICE! If there is exhaust leakage from the

control valve, repeat valve torque tightening
steps 3-5 and carry out follow-up checks.

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25-4 Emission Control, Catalytic Converter

EGR mixing chamber, change

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

NOTICE! Do not attempt to force the pipe into position

by bending, twisting or extending the bellows.

Removal
1 Remove the shutter housing; refer to Air throttle,
change, page 253.
2 Undo the EGR pipe from the EGR mixer.

P0020665

3 Disconnect (1) the electrical connection from the

pre-heater relay.
Disconnect (2) the pre-heater element cable
terminals from the alternator.
Remove the bolts from the EGR mixer.

P0019055

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 25-4 Emission Control, Catalytic Converter

4 Slide the EGR mixer and the pre-heater element

away sideways at the same angle as the EGR
pipe.
Remove the gaskets.

P0019056

Installation
5 NOTICE! Clean the sealing surfaces.
6 Install the gaskets and the pre-heater element.
Slide the EGR mixer sideways back into position
at the same angle as the EGR pipe.

P0019057

7 Install the EGR mixer bolts.

Torque the bolts diagonally in pairs in stages.

Stage 1: 10 Nm (7.4 lbf. ft.)
Stage 2: 24 Nm (17.7 lbf. ft.)

Fit pre-heater element connections (1) and (2).

P0019055

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25-4 Emission Control, Catalytic Converter

8 Bolt the EGR pipe to the EGR mixer.

P0020665

9 Install the shutter housing; refer to Air throttle,

change, page 253.

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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 might have been damaged or
have too much clearance between 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 (muffler) from the
turbocharger and check the turbine disc.
7 Check 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 245.

Removal
1 Drain the coolant according to: Coolant,
Change, page 279.
2 Remove the exhaust pipe connection pipe
between the turbocharger and the aftertreatment
system.

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25-5 Turbo and supercharger

3 Remove the turbocharger charge air pipe.

Remove the heat shield.

P0020043

4 Remove the heat shield brackets.

P0020044

5 1 Remove the inlet pipe from the air filter.

2 Remove the pipe bend from the
turbocharger.
3 Remove the bracket and clamp and lift
away the pipe connection to the exhaust
pipe .

P0020045

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 25-5 Turbo and supercharger

6 Remove the rubber bellows from the air intake

with the connecting hose for crankcase
ventilation.

P0020046

7 Undo and lift up the heat shield.

Remove the NOx sensor, wiring and holder.
Remove the heat shield.

P0020047

8 IMPORTANT!
Clean thoroughly before removal.

Remove the oil return pipe with gasket.

Remove the oil supply line.
Remove the intermediate piece for the NOx
sensor.
Remove the waste gate actuator hose.

P0020048

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25-5 Turbo and supercharger

9 Remove the nuts and spacers from the

turbocharger.
Lift away the turbocharger.
Remove the gasket.

P0020049

Installation
10 Check the sealing surface on the manifold.
11 New turbocharger:
Fit new studs in the turbocharger with the long
thread toward the manifold.

Install a new gasket on the exhaust manifold.

Lift the turbocharger into position.
Install the spacer sleeves and nuts, and fasten
the turbocharger.

P0020050

12 Tightening sequence: Diagonally 1–4

Tightening torque:
Stage 1: 20 Nm (14.8 lbf. ft.)
Stage 2: 48 Nm (35.4 lbf. ft.)

P0020051

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 25-5 Turbo and supercharger

13 NOTICE! Use new seals.

1 Fit oil return pipe.

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

Fill the turbocharger with new, clean engine

oil.
2 Install the oil supply line.
Tightening torque: 26 Nm (19.2 lbf. ft.)

Install the intermediate piece for the NOx

sensor.
Connect the waste gate actuator hose.

P0020052

14 Install the heat shield.

15 Install the NOx sensor, wiring and holder.
Pull down the heat shield and secure it with cable
ties.

P0020053

16 Install the rubber bellows on the air intake with the

connecting hose to the crankcase ventilation.

P0020046

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25-5 Turbo and supercharger

17 1 Bolt on the bracket and clamp the pipe

connection to the exhaust pipe.
2 Fit the pipe bend to the turbo.
3 Attach the inlet pipe to the air filter.

P0020054

18 Install the heat shield brackets.

P0020044

19 Install the heat shield.

Install the charge air pipe.

P0020043

20 Install the exhaust pipe connection pipe between

the turbocharger and the aftertreatment system.
21 Fill with new cooling fluid recommended by Volvo
Penta as per: Coolant Level, Checking and
Topping Up, page 275.

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 25-5 Turbo and supercharger

Turbocharger, bearing clearances

check
Axial clearance- and end float are normally only
checked during overhaul, when you want to measure
the amount of wear in the unit.

Checking the end float

Tools:
9989876 Dial indicator
9999696 Magnetic stand
1 Place the magnetic stand 9999696 Magnetic
stand with dial indicator 9989876 Dial indicator in
a suitable position.
Put the measurement tip on the center of the
shaft.

9989876
P0012191 9999696

2 Press in the exhaust turbine (A) by hand. Zero the

dial gauge.
B
A 3 Press in the compressor turbine (B) by hand.
Read the end float on the dial gauge. Permissible
P0012192
end float: Max. 0.127 mm (0.0050").
Replace / overhaul the turbocharger if the wear
tolerances are exceeded.

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25-5 Turbo and supercharger

Radial clearance, check

Tools:
9999696 Magnetic stand
9999683 Dial indicator (short probe)
1 Attach the 9999683 Dial indicator (short probe) to
the 9999696 Magnetic stand. Position the
measurement tip on the compressor wheel.
9999683 2 Press the compressor wheel down at the same
time as the other end of the shaft (the turbine end)
is moved upwards. Zero the dial indicator.
3 Move the compressor wheel upwards, at the
same time as the other end of the shaft is pressed
down. Read off the radial clearance on the dial
indicator. Then rotate the shaft 90° and repeat the
measurement.

9999696 NOTICE! Ensure that the shaft is not rotated

during measurement.

Permissible radial clearance (compressor

wheel): Max. 0.508 mm (0.0200").
Replace the turbocharger if the wear limits have
been exceeded

P0004364

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 25-6 Air Cleaner, Throttle Housing

25-6 Air Cleaner, Throttle Housing

Air throttle, change
TAD1150VE, TAD1151VE, TAD1152VE,
TAD1170VE, TAD1171VE, TAD1172VE
CAUTION!
Pinch hazard. Keep fingers clear.

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

Removal
1 Remove the hose between the inlet manifold and
the charge air cooler.
2 Remove the electrical connection to the shutter
housing.

P0019046

3 Remove the shutter housing.

P0019047

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25-6 Air Cleaner, Throttle Housing

4 Check that the shutter can be turned easily from

fully open to closed.

Press the shutter to the closed position and

release it. The valve is spring loaded and must
return to its default position (fully open).

NOTICE! Refer to Service handbook, Group 30

Electrical system, EATS for any fault tracing and
other unit measurements.

P0015227

Installation
5 Install the shutter housing and gaskets.
6 Fit the electrical connection to the shutter
housing.
7 Install the hose between the inlet manifold and
charge air cooler.
8 Turn on the main switch.

P0019048

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 25-8 Emission After-Treatment

25-8 Emission After-Treatment

Repair instructions
TAD1170VE, TAD1171VE, TAD1172VE

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 (such as diesel) 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
TAD1170VE, TAD1171VE, TAD1172VE

1 NOTICE! Wait at least 2 minutes after engine

stop so that the automatic drainage function is
depressurized before beginning to remove
components.
2 Remove the hose.
3 Install a new hose.

P0025276

4 Run the Urea pressure build up test.

Check that there are no leaks.

256 47705020 03-2018 © AB VOLVO PENTA

 25-8 Emission After-Treatment

AdBlue/DEF Tank, Change

TAD1170VE, TAD1171VE, TAD1172VE

Tools:
1 NOTICE! Wait at least 2 minutes after engine
stop to give the automatic drainage function time
to complete operations. Make sure the system is
depressurized before beginning to remove
components.
2 Unscrew the hexagonal cover (1).
Remove the drain screw (2) and empty the tank.
3 Remove the tank fittings; refer to Combined Tank
Unit, AdBlue/DEF Tank, Change, page 270.

P0019366

4 Hold the tank securely and remove the bolts.

P0025278

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25-8 Emission After-Treatment

5 Lift the tank module and pull it carefully out of the

locating pins on the bracket.

P0019369

6 Remove the bolts.

P0019370

7 Remove the bolts.

P0019372

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 25-8 Emission After-Treatment

8 Remove the bolts and hose holder.

P0019373

9 Carefully pry the tank sides (1) apart and then pull
out the tank (2). Be aware that the venting hose
is attached.
10 Install the new tank in reverse order.

P0019374

11 Run the Urea pressure build up test.

Check that there are no leaks.

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25-8 Emission After-Treatment

AdBlue/DEF Tank, Cleaning

TAD1170VE, TAD1171VE, TAD1172VE

AdBlue/DEF contamination
If a fluid other than AdBlue/DEF is used in the system, or if the AdBlue/DEF tank is contaminated with other
material, the AdBlue/DEF system must be assessed, cleaned and tested to ensure it is functioning correctly.
This information provides general guidelines for the inspections that must be carried out and the actions that
must be taken if the AdBlue/DEF tank is contaminated.
The technician is expected to be acquainted with the SCR system and be able to judge of components can be
cleaned or must be replaced.

Inspection
Action: Checking for diesel or oil in the AdBlue/DEF solution, page 272.

Cleaning / replacement
If the tank has been contaminated by diesel, biodiesel, oil/grease, solvents or alkaline cleaning agents, the
tank fittings must be replaced and all hoses thoroughly cleaned with warm water.

Contamination < 20% Contamination > 20%

Change Change
• Pump unit • Pump unit
• Dosing unit • Dosing unit
• Tank fittings • Tank fittings
• All filters • AdBlue/DEF tank

Clean • All AdBlue/DEF hoses

• Use hot water to clean the AdBlue/DEF tank and • All filters
all AdBlue/DEF hoses.

NOTICE! Operations with contaminated AdBlue/DEF over extended periods can damage the SCR silencer. High
emissions following a complete cleaning as described above indicate a replacement of the SCR silencer may be
necessary.

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 25-8 Emission After-Treatment

1 Remove the tank module and tank fittings; refer

to steps 1–5 AdBlue/DEF Tank,
Change, page 257.
2 Flush through the tank fitting with warm water.
Replace the tank fitting filter.

P0019379

3 Remove the filler filter.

Place the cover and the unit in warm water for at
least 2 minutes.

P0019380

4 Flush the tank with hot water for at least 10

minutes.
5 Install in reverse order with a new filler filter and
breather filter.

NOTICE! Fit the drain screw.

P0019381

6 Run the Urea pressure build up test.

Check that there are no leaks.

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25-8 Emission After-Treatment

Exhaust Temperature Sensor,

Change
TAD1170VE, TAD1171VE, TAD1172VE
1 Disconnect the battery negative terminal.
2 Remove the cable ties.
3 Disconnect the connector.
4 Disconnect and remove the temperature sensor.
5 Screw in a new temperature sensor.
6 Connect the connector. Attach new cable ties.
7 Reconnect the battery negative terminal.
8 Start the engine. Check operation and inspect for
leaks.
9 Delete any fault codes.
P0019383

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 25-8 Emission After-Treatment

Dosing unit, change

TAD1170VE, TAD1171VE, TAD1172VE

1 NOTICE! Wait at least 2 minutes after engine

stop to give the automatic drainage function time
to complete operations. Make sure the system is
depressurized before beginning to remove
components.
2 Disconnect the connector.

P0025288

3 Remove the hoses.

P0025276

4 Remove the dosing valve.

5 Clean the contact surfaces.
6 Install the dosage valve.
Tightening torque: 8Nm (5.9 Ibf ft)

P0025289

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25-8 Emission After-Treatment

7 Run the Urea pressure build up test.

Check that there are no leaks.

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 25-8 Emission After-Treatment

AdBlue/DEF-Pump Filter, Change

TAD1170VE, TAD1171VE, TAD1172VE

1 NOTICE! Wait at least 2 minutes after engine

stop to give the automatic drainage function time
to complete operations. Make sure the system is
depressurized before beginning to remove
components.
2 Unscrew the filter cover.

P0019389

3 Remove the rubber gasket.

Pull out the filter. Use the puller (supplied with the
filter kit).

P0019390

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25-8 Emission After-Treatment

4 Install as illustrated.
Filter cover:
Tightening torque: 20 Nm (14 Ibf ft).

P0019391

5 Run the Urea pressure build up test.

Check that there are no leaks.

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 25-8 Emission After-Treatment

Solenoid Valve, AdBlue/DEF Tank,

Change
TAD1170VE, TAD1171VE, TAD1172VE

Tools:
1158957 Pliers
1 Pinch off the coolant hoses.
Remove the hoses.

A
p0013271

2 NOTICE! When installing the valve. Check valve

installation direction. Arrow toward tank.

P0025292

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25-8 Emission After-Treatment

Pump Unit, Change

TAD1170VE, TAD1171VE, TAD1172VE

1 NOTICE! Wait at least 2 minutes after engine

stop to give the automatic drainage function time
to complete operations. Make sure the system is
depressurized before beginning to remove
components.
2 Disconnect the connector.

P0025290

3 Remove the hoses.

P0019394

268 47705020 03-2018 © AB VOLVO PENTA

 25-8 Emission After-Treatment

4 Remove the pump.

5 Install the new pump in reverse order.

P0025291

6 Run the Urea pressure build up test.

Check that there are no leaks.

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25-8 Emission After-Treatment

Combined Tank Unit, AdBlue/DEF

Tank, Change
TAD1170VE, TAD1171VE, TAD1172VE

Tools:
1158957 Pliers

1158957 1 NOTICE! Wait at least 2 minutes after engine

stop to give the automatic drainage function time
to complete operations. Make sure the system is
depressurized before beginning to remove
components.

p0013226
P0013226

2 Pinch off the coolant hoses (B).

3 Remove the hoses. Seal the connectors (A) in a
plastic bag.

P0019367

4 Remove the hose clamp.

Lift out the tank fitting.
5 Install the new tank fitting in reverse order.

P0025293

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 25-8 Emission After-Treatment

6 Run the Urea pressure build up test.

Check that there are no leaks.

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25-8 Emission After-Treatment

Checking for diesel or oil in the

AdBlue/DEF solution
TAD1170VE, TAD1171VE, TAD1172VE

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
TAD1170VE, TAD1171VE, TAD1172VE

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

Cooling System, Cleaning
WARNING!
All coolant is hazardous and harmful to the
environment. Do not consume. Coolant is flammable.

Cooling performance is reduced by deposits in the

radiator and cooling galleries. The cooling system
should be cleaned out when the coolant is changed.

IMPORTANT!
Cleaning must not be done if there is any risk of the
cooling system freezing, since the cleaning solution
does not have antifreeze properties.

IMPORTANT!
It is extremely important that the correct concentration
and volume of coolant is added to the system. Mix in a
separate clean vessel before filling the cooling system.
Make sure that the liquids mix.
1 Drain the cooling system. Refer to 26-0, Draining
the Cooling System.
2 Put a hose into the expansion tank filling hole and
flush with clean water, according to specifications
in 03-26, Technical Data, until the water draining
out is completely clear.
3 Should there still be some contamination left after
flushing for a long time, cleaning may be done
with coolant. Otherwise, continue as in stage 8
below.
4 Fill the cooling system with 15-20% mixture of
concentrated coolant. Use only Volvo Penta
recommended concentrated coolant mixed with
clean water.
5 Drain the coolant after 1–2 days of operation.
Remove the filler cap and the lower radiator hose
if necessary to increase emptying speed.
To prevent suspended material from settling back
in the system, emptying should be done rapidly,
within 10 minutes, without the engine having
been at a standstill for a long time.
6 Flush the system immediately and thoroughly
with clean hot water to prevent dirt from settling
on the inner surfaces. Flush until the water
running out is completely clean. Make sure that
any heater controls are set to full heating during
emptying.
7 Should contamination still remain after a long
period of flushing, a clean-out may be done using
Volvo Penta radiator cleaner, followed by
treatment with Volvo Penta neutralizer. Carefully
follow the instructions on the package.
Otherwise, continue as in stage 8 below.
8 When the cooling system is completely free from
contamination, close the drain taps and plugs.

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 26-0 Cooling System, General

9 Refill with new, Volvo Penta-recommended

cooling fluid. Refer to 03-26, Technical Data and
Coolant Level, Checking and Topping
Up, page 275.

Coolant Level, Checking and

Topping Up
Tools:
9996049 Draining hose

IMPORTANT!
Only use Volvo Penta recommended coolant.
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).
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.

P0019914

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26-0 Cooling System, General

Filling a empty cooling 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
quantity.

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 vented during filling.

1 Check that all drain points are closed.

2 Open the filler cap (1). Do not open the pressure
cap (2).
3 Top up with coolant so that the level is between
the MIN and MAX marks.
4 Start the engine when the cooling system has
been completely filled and vented.
Open any venting nipples a short while after
starting, to allow trapped air to escape.
5 Run the engine at idle.
Increase engine speed somewhat after five
minutes. Increase for three minutes.
6 Check the coolant level.
7 Start the engine.
P0019914 Run it until it reaches operating temperature
(thermostat open).
8 Check the coolant level.
Adjust the level as required.

Cooling System, Pressure Testing

Alternative 1
WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.

Tools:
3849613 Pressure testing kit
1 Check that all hoses and clamps are undamaged
and intact.
2 Check the coolant level in the expansion tank.
3 Replace the filler cap on the expansion tank with
a suitable cover from 3849613 Pressure testing
kit.

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 26-0 Cooling System, General

4 Connect the pump and pump up a pressure of 70

kPa (0.7 bar).
5 Pressure must not drop for a two minute test
period, for the cooling system to be regarded as
being free from leakage.
6 Release the excess pressure and remove the
pressure testing unit.
7 Check the coolant level in the expansion tank.
P0010195
Install the regular filler cap.
8 Start the engine and check that no leakage
occurs.

Alternative 2
WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.

Tools:
9996441 Cover, with connecting nipple
9996662 Pressure testing kit
1 Check that all hoses and clamps are undamaged
and intact.
2 Check the coolant level in the expansion tank.
3 Replace the filler cap with 9996441 Cover, with
connecting nipple. Connect 9996662 Pressure
testing kit to the cap. Connect compressed air to
the equipment and open the cock. Adjust the
pressure to 70 kPa (0.7 bar) with the adjuster
knob. Then close the tap.
4 Pressure must not drop for a two minute test
period, for the cooling system to be regarded as
being free from leakage.
5 Release the excess pressure and remove the
pressure testing unit.
6 Check the coolant level in the expansion tank.
Install the regular filler cap.
P0010196
7 Start the engine and check that no leakage
occurs.

Alternative 3
WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.

Tools:
9996662 Pressure testing kit
9996049 Draining hose
1 Check that all hoses and clamps are undamaged
and intact.
2 Check the coolant level in the expansion tank.

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26-0 Cooling System, General

3 Connect 9996662 Pressure testing kit to

9996049 Draining hose and close the cock.
Connect the hose to the engine drain valve (1).
Open the cock and adjust the pressure to 70 kPa
(0.7 bar) with the adjuster knob. Then close the
tap.
4 Pressure must not drop for a two minute test
period, for the cooling system to be regarded as
being free from leakage.
1 5 Open the cock and increase the pressure until the
filler cap opens (must correspond to opening
pressure according to 03-26, Technical Data).
Reduce the pressure to 50 kPa (0.5 bar) and then
increase to 70 kPa (0.7 bar) and check that
pressure is maintained.

P0010197
6 Remove the compressed air connection. Open
the control valve so that the pressure drops and
shut the cock when coolant runs into the drain
hose.
Remove the drain hose from the engine. Then
remove the drain hose from the test equipment
and empty the coolant from the hose.
Re-install the rubber plug in the engine drain
valve.
7 Check the coolant level in the expansion tank.
8 Start the engine and check that no leakage
occurs.

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 26-0 Cooling System, General

Coolant, Change
Tools:
9996049 Draining hose
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.

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

Remove the filler cap (1).

2 Open all drain points.

NOTICE! There may be other taps or plugs at the

lowest points of the coolant system.

P0019914

3 Connect 9996049 Draining hose.

Connect a drainage vessel.
Empty the radiator.

NOTICE! The drain nipples are situated under the

radiator on the right side of the engine block.
4 Remove the tool.
Close any taps.
5 Refill with new, Volvo Penta-recommended
cooling fluid.
Refer to 03-26, Technical Data and Coolant
Level, Checking and Topping Up, page 275.

P0019915

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26-2 Coolant Pump, Thermostat

26-2 Coolant Pump, Thermostat

Coolant Pump, Change
NOTICE! Turn off the main switch before any work is
carried out.

Removal
1 Drain the coolant; refer to Coolant,
Change, page 279.
2 Remove the belt guard.
3 Free the belt tensioner for the coolant pump.
Remove the belt and put it aside.
Remove the coolant pump belt pulley.

P0019960

4 NOTICE! Be prepared to gather up fluid.

Remove the coolant pump.

P0019961

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 26-2 Coolant Pump, Thermostat

Installation
5 Clean the sealing surfaces.

P0019962

6 Install a new coolant pump seal.

Use petroleum jelly to hold the seal in place
during installation.

P0019963

7 Fit the coolant pump with seal. Torque the screws

as specified; refer to 03-2, Special Tightening
Torques.

P0019961

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26-2 Coolant Pump, Thermostat

8 Install the belt pulley.

Free the belt tensioner and fit the belt.

P0019960

9 Install the belt guard.

10 Fill with coolant; refer to Coolant Level, Checking
and Topping Up, page 275.
11 Turn on the main switch.
Start the engine. Check that no leakage occurs.

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 26-2 Coolant Pump, Thermostat

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

1 Disconnect the radiator hose.

P0020014

2 Remove the EGR pipe heat shield bolts.

Slide the plate up a little to unbolt the connection
pipe.

P0020015

3 Remove the thermostat housing connection pipe.

P0020016

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26-2 Coolant Pump, Thermostat

4 Remove the thermostat housing cover.

P0020017

5 Remove the thermostat.

6 Clean the mating surfaces for the thermostat and
the thermostat housing cover.

P0020018

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 26-2 Coolant Pump, Thermostat

Installation
7 Install the new thermostat and a new gasket.

P0020019

8 Install the thermostat housing cover.

P0020017

9 Install the thermostat housing connection pipe.

P0020016

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26-2 Coolant Pump, Thermostat

10 Slide the plate down and tighten the EGR pipe

heat shield bolts.

P0020020

11 Connect the radiator hose.

P0020014

12 Fill with coolant; refer to Coolant Level, Checking

and Topping Up, page 275.
13 Start the engine. Check that no leakage occurs.
14 Pressure test the cooling system; refer to Cooling
System, Pressure Testing, page 276.

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 26-2 Coolant Pump, Thermostat

Thermostat, Function Check

Remove the thermostat, see Thermostat,
Change, page 283.
1 Place the thermostat in a big pot with water and
heat it to the opening temperature as specified in
Administration, page 25.

P0005072

Closed thermostat.

2 If the thermostat does not open at specified

temperature, it should be replaced.
3 Install the thermostat, see Thermostat,
Change, page 283.

NOTICE! Always use a new seal, even if the

thermostat is not replaced.

P0005073

Open thermostat.

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32-1 Alternator

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

Removal
1 Remove the right belt guard.

P0019906

2 Remove the drive belt according to Drive belt,

change, page 292.
3 Undo the alternator body connection (1) (starter
motor).
Undo the alternator body connection (2) (pre-
heater element).

P0019907

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 32-1 Alternator

4 Undo B1+ positive alternator connection (starter

motor).

P0019908

5 Disconnect the connector (1) (multifunction

regulator).
Undo B2+ cable connection (2) (pre-heater
relay).

P0019909

6 Remove the alternator.

P0019910

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32-1 Alternator

Installation
7 Install the insulating bushing.
Install the alternator and tighten the two
attachment bolts and nuts.

P0019911

8 Connect B2+ cable connection (1) (pre-heater

relay).
Attach the connector to the terminal (2).
Secure it to the cable clip using cable ties.

P0019912

9 Connect B1+ positive alternator connection

(starter motor).

P0019908

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 32-1 Alternator

10 Connect the alternator body connection (1) (pre-

heater element).
Connect the alternator body connection (2)
(starter motor).

P0019913

11 Install the drive belt according to Drive belt,

change, page 292.
12 Install the right belt guard

P0019906

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32-1 Alternator

Drive belt, change

CAUTION!
Pinch hazard. Keep fingers clear.

Removal
1 Remove the fan guards and fan ring round the
cooling fan.
2 NOTICE! Fit a 1/2" socket drive to the belt
tensioner (1).

Free the belt tensioner, pass the drive belt round

the fan blades and remove it.
3 Check the function of the tensioner, the condition
of the pulleys and the idler wheel bearings.

P0019870

Installation
4 Pass the new drive belt over the fan.
Free the belt tensioner and fit the belt.
5 Check that the belt is correctly aligned on all the
pulleys.
6 Install the fan guard and fan ring round the cooling
fan.

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 32-1 Alternator

Alternator Belt, Replace

CAUTION!
Pinch hazard. Keep fingers clear.

Removal
1 Remove the fan guards and fan ring round the
cooling fan.
2 NOTICE! Fit a 1/2" socket drive to the belt
tensioner (1).

Free the belt tensioner and lift the water pump

drive belt off.
3 NOTICE! Fit a 1/2" socket drive to the belt
tensioner (2).

Free the belt tensioner and lift the alternator drive

belt off.
4 Check the function of the tensioner and the
condition of the pulleys and the idler pulley
bearings.
P0019871

Installation
5 Pass the new alternator drive belt over the fan.
Free the belt tensioner (2) and fit the belt.
6 Free the belt tensioner (1).
Lift the water pump drive belt back into place.

P0019871

7 Install the fan guard and fan ring round the cooling
fan.

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33-1 Starter Motor

33-1 Starter Motor

Starter Motor, Change
Removal
1 IMPORTANT!
Turn off the main switch before any work is
carried out.
2 Remove the cable from the negative terminal.

P0019364

3 Remove the battery cables from the starter motor.

P0019996

4 Remove the cable ties.

Disconnect and move aside the alternator cables.

P0019997

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 33-1 Starter Motor

5 Disconnect and move aside the cables to the

cable split/fuse holder.

P0019998

6 Disconnect the connector.

P0019999

7 Remove the starter motor.

P0020000

Installation
8 Clean the mating surface on the flywheel
housing.
9 Re-install all wiring and cables to their original
locations.

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33-1 Starter Motor

10 Fit the gasket over the studs.

Install the starter motor with the insulating
bushings. The starter motor must be fully
electrically insulated from the flywheel housing.

Check as necessary using a multimeter between

flange bolts, studs and the starter motor casting.

NOTICE! Other engine electrical systems must

be disconnected when measuring to avoid
incorrect values.
The resistance must be more than: 1 MΩ.

P0020001

11 Connect the connector.

P0020002

12 Connect the respective cables to the cable split/

fuse holder.

P0019998

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 33-1 Starter Motor

13 Connect the alternator cables.

P0020003

14 Tighten using cable ties.

P0020004

15 Fasten the cable shoes – positive cable first,

negative cable last.

P0019996

16 IMPORTANT!
Check that the wiring and cables do not chafe
against the starter motor or engine block.
Check that all wiring and cables are properly
secured.

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33-1 Starter Motor

17 Connect the cable to negative terminal.

18 Turn on the main switch.

P0019365

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Index
A Engine................................................................ 26, 55
About this Workshop manual..................................... 3 Engine Assembly...................................................... 67
AdBlue/DEF Tank, Change.................................... 257 Engine Complete, General....................................... 55
AdBlue/DEF Tank, Cleaning.................................. 260 Engine Disassembly................................................. 57
AdBlue/DEF-Pump Filter, Change......................... 265 Engine Fixture, Installation....................................... 55
Adjusting the IEGR (double rocker arm)................ 118 Engine Information, General.................................... 49
Air Cleaner, Throttle Housing................................. 253 Engine Oil Pressure, Check................................... 174
Air throttle, change................................................. 253 Exhaust Manifold, Change..................................... 227
Alternator................................................................ 288 Exhaust Temperature Sensor, Change.................. 262
Alternator Belt, Replace......................................... 293 F
Alternator, Change................................................. 288 Fitting the Fixture...................................................... 55
C Flywheel, Indication................................................ 157
Camshaft Bearing Housing, Replace..................... 156 Fuel Feed Pressure, Check.................................... 204
Camshaft, Wear Check.......................................... 155 Fuel Feed Pump and Filter..................................... 200
Charge Air Pipe, Leakage Check........................... 226 Fuel Feed Pump, Change...................................... 209
Checking for diesel or oil in the AdBlue/DEF Fuel filter housing, change..................................... 205
solution................................................................... 272 Fuel filter, Change.................................................. 203
Checking the IEGR (double rocker arm)................ 120 Fuel Pre-filter, Change........................................... 200
Checking urea concentration in the fluid................ 273 Fuel System..................................................... 34, 196
Chemical products.................................................... 48 Fuel system, bleeding............................................ 196
Combined Tank Unit, AdBlue/DEF Tank, Change. 270 Fuel System, General............................................. 196
Connecting Rod Bushing, Check up...................... 105 G
Connecting Rod, Check......................................... 105 Gear Ring, Fywheel: Replace................................ 158
Control System, ECM, Data Sets........................... 224 General........................................................... 3, 48, 49
Control Unit, Replace............................................. 224 Group 21: Engine..................................................... 26
Control valve e-EGR, change................................. 237 I
Coolant Level, Checking and Topping Up.............. 275 Illustrations................................................................. 6
Coolant Pump, Change.......................................... 280 Injector, Change..................................................... 212
Coolant Pump, Thermostat.................................... 280 Injectors and Delivery Pipes................................... 212
Coolant, Change.................................................... 279 Inlet and Exhaust Manifolds................................... 227
Cooling System................................................ 36, 274 Inlet and Exhaust System................................. 36, 226
Cooling System, Cleaning...................................... 274 Inlet and Exhaust System, General........................ 226
Cooling System, General....................................... 274 Intake Manifold, Change........................................ 230
Cooling System, Pressure Testing................... 49, 276
Crank Mechanism.................................................. 161 L
Crankshaft Seal, Change (front)..................... 161, 163 Lube Oil Pump, Installation...................................... 75
Crankshaft Seal, Change (rear)..................... 165, 167 Lube Oil Pump, Removal......................................... 57
Crankshaft, Inspection............................................ 169 Lubricating and Oil System, General...................... 174
Crankshaft, Installation............................................. 67 Lubrication Oil Pump, Change............................... 177
Crankshaft, Removal................................................ 64 Lubrication System................................................... 33
Cylinder Head........................................................... 76 M
Cylinder Head, Installation....................................... 86 Main bearing, Change............................................ 170
Cylinder Head, Pressure Testing............................. 52
O
Cylinder Head, Removal.......................................... 76
Oil cooler................................................................ 191
Cylinder Liner and Pistons, Inspection................... 104
Oil Cooler, Replace................................................ 191
Cylinder Liner, Installation........................................ 70
Oil filter................................................................... 182
Cylinder Liner, Pistons........................................... 104
Oil filter bracket valves, change............................. 188
Cylinder Liners, Removal......................................... 61
Oil Filter Bracket, Change...................................... 184
D Oil filter, Change..................................................... 182
Dosing unit, change................................................ 263 Oil pressure safety valve, change.......................... 175
Draining, Fuel Duct in Cylinder Head..................... 198 Oil pump and Line.................................................. 177
Drive belt, change.................................................. 292
P
E Pistons, Installation.................................................. 74
EGR mixing chamber, change............................... 242 Pistons, Removal..................................................... 58
Electrical System...................................................... 37 Pump Unit, Change................................................ 268
Electrically Heated AdBlue/DEF Hose, Change..... 256
R
Emission After-Treatment....................................... 255
Radial clearance, check......................................... 252
Emission Control, Catalytic Converter.................... 237

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Repair instructions.............................................. 4, 255
S
Safety Information.................................................... 38
Safety Instructions.................................................... 38
Sensors, Adjustment.............................................. 159
Sleeve for unit injector, replace.............................. 216
Solenoid Valve, AdBlue/DEF Tank, Change.......... 267
Special Service Tools............................................... 42
Specifications, Electrical........................................... 37
Specifications, Engine ............................................... 9
Starter Motor.......................................................... 294
Starter Motor, Change............................................ 294
T
Test and Adjustments............................................... 49
Thermostat, Change............................................... 283
Thermostat, Function Check.................................. 287
Tightening Schedules............................................... 15
Tightening torques...................................................... 9
Timing Gear, Installation........................................ 143
Timing Gear, Removal........................................... 134
Timing Gears and Shaft......................................... 134
Turbo and supercharger......................................... 245
Turbo, Change....................................................... 245
Turbocharger, bearing clearances check............... 251
Turbocharger, Inspection....................................... 245
V
Valve cover, change............................................... 101
Valve Guides, Inspection........................................ 122
Valve Guides, Replacing........................................ 123
Valve Mechanism................................................... 106
Valve mechanism equipped with Internal EGR
(Exhaust Gas Recirculation)................................... 115
Valve mechanism equipped with VCB (Volvo
Compression Brake)............................................... 110
Valve Seat, Change............................................... 130
Valve Stem Sealings, Replace............................... 132
Valves and Unit Injectors, Adjustment.................... 106
Valves, Installation................................................. 128
Valves, Removal.................................................... 126

300
 References to Service Bulletins

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AB Volvo Penta
Service Communication
Dept. CB22000
SE-405 08 Gothenburg
Sweden
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