Date Group No. Release Page Greensboro,NCUSA … · J42885,or88880056 2 2 Todetermineiftheinjectorissuitableforreuse,the injectormustbecleaned.Thecapnutseatsurfaceis theonlysurfacewhichrequiresathoroughcleaning

Service BulletinVolvo Trucks North AmericaGreensboro, NC USA Trucks

Date Group No. Release Page

3.2011 237 49 04 1(16)This service bulletin replaces bulletins 237-41,237-47 and 237-49 dated 5.2010.

Injector, Replacement

D11, D13, D16

Injector, Replacement

This information covers replacement procedures for the injectors on the Volvo D11, D13 andD16 engines.

Contents• “Special Tools”, page 2

• “Injector, Replacement (One)”, page 3

Note: Information is subject to change without notice.Illustrations are used as reference only and can differ slightly from the actual engineversion. However, key components addressed in this information are represented asaccurately as possible.

PV776-89008165 USA46934

Volvo Trucks North America Date Group No. Release PageService Bulletin 3.2011 237 49 04 2(16)

ToolsSpecial Tools

For information on ordering special tools, please refer to the special tools information,group 08.

W0001774W2006395

W0001802

9996956D11 Flywheel Turning Tool

J48922Heavy-Duty Injector Puller

9998511Lever

C0000228C0000229 T0012612

9998249Protection Sleeve

9998251Protective Plug

88800014D13 and D16 Flywheel Turning Tool

C0001224C0000249

W0002215

J42885-1Handle

J42885-9Flat Injector Tube Cleaning Brush

J42885-25Fuel Bore Protector

W0001935

W0002416

T2018914

J41989Valve Spring Compressor

J42885Flat Injector Tube Bore Brush Set

9990006Puller

T2018915

9990013Slide Hammer


Service Procedures2374-03-02-01

Injector, Replacement (One)You must read and understand the precautions andguidelines in Service Information, group 20, “GeneralSafety Practices, Engine” before performing thisprocedure. If you are not properly trained and certifiedin this procedure, ask your supervisor for training beforeyou perform it.

Special tools: 9998249, 9998511, 9998251,9996956, J42885, J41989, J48922, 88800014,9990006, 9990013, 88880056

Injector IdentificationNote: There are two types of injectors used in Volvoengines, conical and flat. The conical injector sleevesare made of stainless steel. The flat injector sleeves arecopper and a washer is installed between the injectorand the sleeve. You must determine which type ofinjector is in the engine to know the proper tools to usefor the replacement procedure.

W2056876

A. Flat Injector

B. Conical Injector


W2043908

CAUTION

Conical and copper injectors and sleeves should not bemixed in the same engine. The same type of injector andsleeve must be used in all six cylinders. Mixing sleevescan result in damage to the engine.


Removal1

1Remove the valve cover from the engine. Refer to Group211 for service procedures.

22Remove the rocker arm shaft. Refer to Function Group214 for service procedures.

CAUTION

The order of the rocker arm assembly must bemaintained. Make certain the sets of four are kepttogether. Make certain the rocker arms are identifiedso they can be returned to their original positions onthe shaft. Failure to heed this caution may result insevere engine damage.

3

W2005514

1 Camshaft Bearing Cap

2 Camshaft

3 Alignment Sleeve

3Make sure the alignment sleeves remain in position oneach bearing cap.

44Mark the valve bridges so they can be installed in thesame location during reassembly. Remove the valvebridges.

Note: Mark the location of the injectors for reinstallation.Injectors must be installed in the same cylinder as theywere removed.


5

W2006625

Injector Hold Downs

5Thoroughly clean around the injectors that are to beremoved. Remove the injector hold down bolt. If the holddown has a recess in the yoke, proceed to Removal Step6. If the hold down does NOT have a recess in the yoke,proceed to Removal Step 7.

6

W2005170

6

CAUTION

Do not use excessive force on the injector with theslide hammer. If the injector is stuck in the sleeve, thepuller can be damaged by the slide hammer.

Install the puller onto the injector. Position the puller forkin the groove on the injector and lock the arm using thethumb screw on the side. Secure the puller by screwingdown the screw toward the inner cup of the injector.Install the slide hammer. Use reasonable force with theslide hammer to pull the injector free from the cylinderhead. If the injector can not be removed with the slidehammer and puller, proceed to Removal Step 12. If theinjector can be removed with the slide hammer and puller,proceed to Removal Step 13.

Note: Use care when removing the injector because theinjector hold down is not secure and could fall off if notheld in place.

9990006, 9990013


7

W2006623

7

CAUTION

Do not use excessive force on the injector with the prybar. If the injector is stuck in the sleeve, the pry bar cancause damage to engine components.

Use reasonable force with a pry bar under the hold downor injector lip to remove the injector. If the injector can notbe removed with the pry bar, proceed to Removal Step 8.If the injector can be removed with the pry bar, proceedto Removal Step 13.


9998511

8

W2006622

8Install valve spring compressor in adjacent cylinderinjector hold down bolt hole.

Note: Cover all oil passage holes in the cylinder headand gear train opening with shop towels.

J41989


99Remove the shop towel from the gear train opening. Usespecial tool to turn the engine until the camshaft is atTDC. Depending on which injector is being removed, turnthe engine from TDC to the appropriate camshaft mark,see table below. Confirm the piston is at the top of thecylinder by using a 40 cm (16 inch) piece of straight stiffwire in the injector hole of the companion cylinder.

D13 Engines with Engine Brake Camshaft Marks

Companion Cylinder Camshaft Mark

1 and 6 TDC

2 and 5 Between 5E6 and 3E2

3 and 4 Between 3E2 and 6E4

D13 Engines without Engine Brake and All D11 andD16 Engines Camshaft Marks

Companion Cylinder Camshaft Mark

1 and 6 V3TDC

2 and 5 V6

3 and 4 V2

88800014, 9996956

1010

WARNING

Use protective goggles or injury to the eyes can occur.

Cover the gear train opening with a shop towel.Compress the intake valve spring and remove keepersand spring. Remove the injector hold down.

1111Position and compress intake valve spring and installkeepers. Tap on the valve stem with a soft-faced malletto make sure keepers are seated properly. Remove thecompressor tool from the cylinder head.


12

W2006624

For clarity, the puller is shown on the cylinder head withthe valve springs removed. If the valve springs were

removed to remove the hold down, it is not necessary toinstall the springs before removing the injector. However,

installing the springs protects the valve stems fromdamage during injector removal.

12Install the puller onto the injector. Position the pullerforks in the grooves on the injector. Secure the puller bysliding the lock collar down over the forks and securewith collar nut to hold the injector. Remove the injector,and hold down if not already removed, from the cylinderhead using hand tools.


CAUTION

If excessive combustion leakage has resulted in thesleeve being stuck-fast to the injector by carbon, theinjector must be replaced. The condition is found whenthe injector is removed and the sleeve comes out withthe injector.

J48922

1313For flat injectors only, remove and discard the injectornozzle gasket (flat washer) from the injector tip or coppersleeve bore.

Note: If an injector nozzle gasket (flat washer) had beenused for the seal joint between the injector copper sleeveand the injector, discard the used gasket immediatelyafter the injector is removed. A used gasket must not bereused. When the injector is removed, this gasket maycome out attached to the injector or it may remain in thebottom of the injector sleeve.

Note: If the nozzle gasket (flat washer) is attached tothe injector, loosen it with gentle prying from a thin flatgasket scrapper blade. If the gasket is in the bottomof the injector sleeve, initially attempt to remove it witha magnet. If this is unsuccessful, use a standard flatblade screwdriver with a long thin shank and narrowwidth blade to loosen the gasket. Locate the blade in therecess between the outside of the gasket and the injectorsleeve. Use the blade to apply force on the outside of thegasket at different locations around the gasket. Continuethis until the gasket separates from the sleeve.


14

W2005112

14Using compressed air, clean out the injector hold downbolt holes. Install the protective sleeve over the injectorto prevent damage.

9998249

15

W2005172

15If the injector is not being installed immediately, installthe protective plug into the injector bore of the cylinderhead to protect it from debris.

9998251


Installation1

1Install the protective sleeve, J42885-25, and clean theinjector sleeve with the appropriate brush and extension.For copper sleeves, use bushes in kit J42885. Forstainless steel sleeves, use brushes in kit 88880056.

Note: After cleaning the sleeve, carefully inspect theinside surface of the sleeve, especially the bottomsurface. Any remaining contamination is unacceptableand must be removed. Also, if there is any indication ofa discrepancy that raises concern about suitability of thesleeve for reuse, replace it with a new sleeve.

J42885, or 88880056

22To determine if the injector is suitable for reuse, theinjector must be cleaned. The cap nut seat surface isthe only surface which requires a thorough cleaning.Remove the two O-rings from the injector. Cover thetwo O-ring grooves and the complete area between thegrooves with tape or equivalent to prevent contaminationfrom getting into the injector. Also, cover the electricalconnection opening. Protect the nozzle spray holes fromdamage by covering approximately half of the nozzle tiplength with a piece of 6 mm (0.25 inch) ID hose.

CAUTION

Injectors operate at very high fuel injection pressures,which keep the nozzle tip spray holes clean and freeof carbon. The outer surface of the tip spray holesdoes not need to be cleaned and to prevent spray holedamage MUST NOT be cleaned with a wire wheel.


3

W2006513

Flat Injector Shown

3With the injector surfaces protected as described above,clean the cap nut seat surface of hard carbon depositsby careful use of a wire wheel, confining the wire wheelcontact to the cap nut seat surface only and completingthe cleaning with hand tools. Carefully remove the carbonby applying slight nominal pressure with the wire wheelagainst the cap nut and nozzle for short periods of time.Clean any remaining carbon using hand tools such as ahand scraper or medium grit emery cloth.

CAUTION

The carbon will be very hard and difficult to remove.Variables such as size and condition of the wire wheelmay result in a tendency to force the wheel harderagainst the cap nut. However, it is very important to notuse excessive pressure against the wire wheel to cleanthe cap nut seat surface. The use of excessive forcemust be avoided and can damage the seat surfaceresulting in an injector that cannot be reused.

Note: Using the precautions described in this procedure,a steel wire wheel is allowed to be used to clean thenozzle cap nut seat surface as described, but must nottouch the nozzle tip spray holes under any circumstancesor hole damage will result.

Note: The spray hole damage described here cannotbe seen with a magnifying glass or an eye loop. Amicroscope with a minimum 10x magnification is neededto see this damage.

44After cleaning, inspect the injector nozzle cap nut seatsurface for pitting or related damage. If there is pitting orother damage, the injector can not be reused. If there isno pitting on the seat surface, the injector can be reused.

Note: Pitting on surfaces other than the cap nut seatsurface does not effect the function of the injector and isacceptable.

55Install new O-rings on the injector as follows:

• Upper ring — large diameter, violet

• Lower ring — small diameter, violet

66Lubricate both sealing O-rings with clean engine oil.


77For flat injectors only, preassemble the new injectionnozzle NBR washer to the injector. Three smallprojections (grippers) on the inside diameter of this NBRwasher provide the means to retain the gasket to theinjector on assembly. Using hand force, push the NBRwasher over the injector tip until it becomes fully seatedagainst the bottom of the injector.

Note: Before installing the gasket, inspect it to ensurethat it is the correct part. The correct gasket is identifiedby three small projections on the inside diameter and agray coating over the entire gasket to enhance the abilityto seal.

Note: This gasket must be installed dry. Do not usegrease or any other materials to secure this gasket tothe injector for installation.

88

CAUTION

Any oil which may have pooled in the bottom of theinjector yoke screw hole must be cleaned from the holeto avoid hydraulic lock when the screw is installed andtightened. Hydraulic lock would result in a lack of clampload and/or a cylinder head cracked at the screw hole.

CAUTION

The new long screw must be used with the 38 mmhigh yoke. If the shorter screw for the 28 mm highyoke is used with the 38 mm yoke, insufficient threadengagement in the cylinder head will result and thecylinder head threads will fail during screw tightening.

CAUTION

Do not mix tall (38mm) and short (28mm) hold downsin the same engine. Use either all tall or all short holddowns. Mixing tall and short hold downs in the sameengine may result in engine damage.

When reusing a hold down screw, clean the screw beforeinstallation. Apply a light coat of oil to the threads on thescrew and to the underside of the screw head. Slip theinjector hold down and screw onto the injector.

99For conical injectors only, use diesel fuel to lubricate theinjector capnut cone.


1010Center the injector between the valve springs and thenpush down on the injector using hand pressure to seat theO-rings. Clamp the injector in position with the injectorhold down by tightening the injector hold down bolt.Tighten the injector hold down bolt using the followingfive step procedure:

1 Tighten 20 +5-0 Nm (15 +4-0 ft-lb).

2 Tighten 180 ±5 degrees angle of tightening.

3 Loosen the hold down bolt until torque is 10 to 15 Nm(7.0 to 11.0 ft-lb), then:

Note: This should be achieved by loosening with anangle of 100-110 degrees. Do not completely loosenthe bolt to prevent components from moving after theprevious seating process.

4 Tighten 20 +5-0 Nm (15 +4-0 ft-lb).

5 Tighten 90 ±5 degrees angle of tightening.

Note:

• For flat injectors only, assembly with a new injectionnozzle gasket always requires that the five (5) stepinjector hold down bolt tightening process be used.

• The injector hold down bolt can be reused only four(4) times. After the initial installation, every additionalapplication of the five step injector hold down bolttightening process requires that a punch mark beapplied to the head of the bolt. After four (4) punchmarks have been accumulated, the bolt cannot bereused again and must be replaced.


11

W2004684

11When replacing injectors, the engine control module(ECM) must be programmed with the new injector’s trimcodes. The code is printed on top of the injector electricalconnector. The programming is performed using VCADSand is necessary to ensure that engine timing andemission levels are correct.

Note: Due to the ECM self learning capability, it isnecessary to reset learned ECM parameters afterservicing some engine related components. This allowsthe ECMU to learn the new components behavior. Afterservicing is complete, perform the “Learned Data Reset”using the PC tool. This is located in the Function Group1 menu.

Note: If reinstalling an injector into the same location,reprogramming is not required.

1212Install the valve bridges onto the same cylinders asmarked at disassembly. Lubricate the valve bridges andcamshaft lobes with engine oil.


1313Install the rocker arm shaft. Refer to Function Group 214for service procedures.

1414Adjust the inlet and exhaust valves and injectors. Referto Function Group 214 for service procedures.

1515Install the valve cover on the cylinder head. Refer toGroup 211 for service procedures.

1616Start the engine and run until the engine clears and runswithout stumbling. This procedure might need to berepeated to get the fuel system completely free of air.

Note: If the engine does not start on the first attempt,prime the fuel system again. Engine priming might needto occur several times in order to get the engine to start.

1717Allow the engine to run at low idle for about 5 minutes.Check for any fuel leaks and correct as necessary.

Note: The engine speed should not be increasedbecause air pockets can be forced into the cylinder headwhich could result in the engine stopping.

Documents

Date Group No. Release Page Greensboro,NCUSA … · J42885,or88880056 2 2 Todetermineiftheinjectorissuitableforreuse,the injectormustbecleaned.Thecapnutseatsurfaceis theonlysurfacewhichrequiresathoroughcleaning