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Intake and Exhaust Systems, Fault Tracing
Intake and Exhaust Systems, Fault Tracing
Intake and Exhaust Systems, Fault Tracing
W2004441
This information covers fault tracing components of the intake and exhaust systems of
the Volvo D12D engine.
Contents
General Guide to Fault Tracing page 2
Intake and Exhaust System, Fault Tracing page 3
Intake and Exhaust System, Fault Tracing page 5
You must read and understand the precautions and guidelines in Service
Information.1, "General Safety Practices, Engine" before performing any procedure. If
you are not properly trained and certified in a procedure, ask your supervisor for
training before you perform it.
1
IMPACT or ID DVD: Info type General Information group 200
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 3(22)
Does the air filer restriction gauge indicate a restriction of the air filter?
Action:
Action:
Action:
Action:
Action:
Measured values in VCADS ___ kPa ___ kPa ___ kPa ___ kPa ___ kPa
Pro ___ (psi) ___ (psi) ___ (psi) ___ (psi) ___ (psi)
Voltage measurement ___ Volts ___ Volts ___ Volts ___ Volts ___ Volts
Intake manifold pressure sensor values are correct?
Is the intake manifold pressure the same in VCADS as the pressure gauge?
Action:
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 4(22)
Action:
Is the exhaust system free from damage or modifications that can restrict exhaust gases?
Action:
Action:
Action:
Notes:
1
IMPACT or ID DVD: Info type Specification group 25 or Service literature binder set, Specifications group 200
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 5(22)
2
Attach test plate 9990225 to the turbo making sure that
feet on tool are properly secured to turbo. Tighten
mounting nuts and jam nuts. Do not overtighten
mounting nuts. Ensure that safety valve is attached
to plate.
CAUTION
Make sure safety pressure valve is installed in the
test plate or damage to the turbo seals could occur if
more than 1.1 bar (16 psi) is applied. The safety valve
relief pressure is 1.1 bar (16 psi).
9990225
W2004444
3
Unscrew the reduction valve counter-clockwise on
pressure gauge 9996662. Open the cut-off valve and
connect shop air hose and check that the gauge
is set at 0.
9996662
4
Connect pressure gauge/regulator 9996662 to test
plate 9990225.
9996662, 9990225
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 6(22)
5
Slowly increase pressure on the pressure gauge to
approximately 1 bar (14.5 psi). Shop air line must remain
connected for this test.
If no air pressure is displayed on the pressure gauge after
the reduction valve is turned clockwise, this indicates a
leak in the system. See step 6 for possible leak points.
CAUTION
Do not pressurize the system more than 1 bar
(14.5 psi).
CAUTION
Before the pressure gauge hose is removed, unscrew
the reduction valve to avoid damage to gauge.
T2006950
6
Check the following for leaks:
Note:
8
Check that there is no oil in the charge air pipe or
the charge air cooler.
Note: If there is 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 thoroughly cleaned
internally before the engine is started. If oil is found, see
Turbocharger, Checking page 15
9
VN Install sealing washer 9998289 and seal on the
charge air cooler (lower right side).
VHD Use kit 85107488. Attach hose (3) and plug (2)
and tighten hose clamps (1) supplied with kit (connected
to right (hot) side).
W2004454
VHD
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 8(22)
10
Remove the charge air hose (VN) or the elbow and hose
(VHD) from the left side of the charge air cooler (cool
side). Install connection washer 9998288 along with
seal to charge air cooler.
9998288
W2004455
VN
11
Before check is made, check pressure gauge/regulator
9996662. Connect shop air hose to tool 9996662. Open
the shut off valve and set gage to 100 kPa (1 bar)
9996662
T2006950
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 9(22)
12
Close the shut off valve. For the pressure gauge regulator
to be considered reliable, the pressure reading must not
drop during a period of 2 minutes.
T2006951
13
Connect pressure gauge 9996662 to connection
washer 9998288.
9996662, 9998288
14
Turn the reduction valve and set the pressure to 100 kPa
(14.5 psi). Close the shut off valve. For the charge air
cooler to be pressure-approved, the pressure reading
must drop no more than 20 kPa (3 psi) during a period of
one minute.
Note: Spray soapy water on tool connections to verify
that there are no leaks.
T2006977
15
After completing the checks, remove the test equipment
and reinstall the charge air pipes, hoses and fresh
air pipe.
CAUTION
Be sure that the sealing rings are undamaged and
correctly positioned.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 10(22)
2
Check that there is no oil in the charge air pipes.
Note: If there is 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 thoroughly cleaned
internally before the engine is started.
2
Check the charge air cooler, the engine radiator and the
air conditioning system condenser. Check for external
blockage. (Winter-front, insects, leaves, etc.)
2
IMPACT or ID DVD: Info type Diagnostics group 2547
3
IMPACT or ID DVD: Info type Repair group 2651
4
IMPACT or ID DVD: Info type Repair group 2651
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 11(22)
2
Remove the pressure sensor from the intake manifold.
3
Connect tool 9998538 (A) to sensor and tighten hose
clamp.
W2004215
4
Attach pressure gauge 9996662 to test hose 9998538.
5
Turn the reduction valve counter-clockwise on pressure
gauge 9996662. Open the shut off valve and connect
shop air hose and check that the gauge is set at 0.
9996662
6
Turn the ignition key to ON position but DO NOT
START ENGINE.
5
IMPACT or ID DVD: Info type Diagnostics group 2841
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 12(22)
7
Connect the PC tool to the vehicle diagnostics connector.
Perform the Sensor values checks, engine not running
test. Check the sensor value for intake manifold pressure.
Follow the instructions in VCADS.
8
Increase the pressure on the pressure gauge to 50 kPa
(7 psi).
T2006950
9
Check that the value in VCADS corresponds to the set
value on the pressure gauge.
10
CAUTION
Do not exceed 250 kPa (36 psi) on the sensor. Doing
so can damage the sensor.
11
Optional Check Sensor voltage check at EECU
Connect the breakout box and adapter.
Conditions
9990014, 9998699
12
If the values are incorrect, but the sensor wiring and
connections are correct, replace the sensor.
2
Check whether the EPG shutter has become stuck in the
closed or half-closed position. If it is, replace or overhaul
the EPG according to instructions in Service Information.6.
W2003781
6
IMPACT or ID DVD: Info type Repair group 2538
7
IMPACT or ID DVD: Info type Diagnostics group 2538
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 15(22)
Turbocharger, Checking
1
Check that the turbo unit part number corresponds to that
for the engine variant. Verify using the chassis ID (last 6
digits of VIN) in IMPACT.
The wrong turbo unit for the engine variant can produce
intake manifold pressure that is too low; this will reduce
engine output.
T2019239
2
Remove the intake pipe from the turbocharger.
W2003782
3
Check the turbo inlet, ensure that:
4
Remove the charge air pipe from the turbo and check
for signs of oil in the turbo outlet.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 16(22)
5
Remove the shutter housing from the turbo and check
the turbine wheel.
W2003783
6
Check turbo outlet:
7
If there is damage to turbine wheel or if turbine shaft oil
seal is leaking, the entire turbo must be replaced. Refer
to service information, Turbocharger Replacement. 8
8
IMPACT or ID DVD: Info type Repair group 2551
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 17(22)
2
Check whether the exhaust system has been modified.
Check for bends or damage that can prevent exhaust
gases from flowing freely.
3
Check exhaust system backpressure if suspected to be
a problem; see:
J44403
W2004212
2
Drill a 2 mm (0.08 in.) hole through the test fitting
into the exhaust pipe.
W2004213
3
Connect pressure transducer 9998496 to the test fitting
on tool J44403. Attach transducer to multimeter J39200.
9998496, J39200
W2004214
Backpressure Reading
4
Run the engine under full load conditions.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 19(22)
5
Check maximum exhaust backpressure under full engine
load; refer to Dyno Test (preferred method) page 21 or
Road Test page 21.
6
If backpressure is greater than 15 kPa (2.18 psi or 4.4
in. Hg), check the exhaust piping for damage or other
possible sources of restriction. If no faults are found in
the exhaust piping, replace muffler.
7
Remove test equipment and plug hole in exhaust pipe
with sheet metal screw.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 20(22)
W2004448
2
Install test fitting 85105034 into the test port.
Note: Backpressure measurement is made between the
turbocharger and the internal catalyst of the tuned muffler.
3
Connect transducer 9998496 to test fitting 85105034
and transducer multimeter J39200.
Note: If transducer and multimeter are not available,
use a gauge with minimum 3% accuracy and a range
of up to 10 in. Hg (140 in. H2O).
W2004449
WARNING
HOT COMPONENTS! Keep yourself and your test
equipment clear of all hot exhaust components. Hot
exhaust components can cause serious burns or can
permanently damage test equipment.
Tie test leads away from tuned muffler and any other part
of the exhaust system.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 21(22)
5
Run engine at operating temperature with engine fully
loaded to record a maximum exhaust backpressure.
Test using:
7
With accelerator pedal fully depressed, run engine
at rated speed (1800 rpm) for max hp output under
full load. Note the maximum exhaust backpressure
and compare with specifications (see Backpressure
Reading page 21).
Road Test
8
If a chassis dyno test is unavailable, select a SAFE road
test area.
9
Operate engine until it reaches normal operating
temperature.
10
Drive vehicle up a long hill with maximum gross vehicle
weight. With accelerator pedal fully depressed, run
engine at rated speed (1800 rpm) under full load. Note
the maximum exhaust backpressure and compare with
specifications (see Backpressure Reading page 21).
Backpressure Reading
11
Replace tuned muffler if backpressure is greater than
20 kPa (or 6 in. Hg or 80 in. H2O).
2
Dyno or road test under full load at:
1200 RPM
1400 RPM
1600 RPM
1800 RPM
and compare values with specifications.9
Smoke Check
1
Note: Always check and adhere to applicable federal,
state and local laws or regulations for smoke opacity
requirements.
Check smoke opacity with Kent Moore smoke opacity
meter RM1020. Use operators manual provided with the
meter for proper operation of equipment.
Smoke opacity should be less than 40%. If smoke opacity
is greater than 40%, this may indicate a fault in one of the
components. If no faults are found after performing this
checklist, refer to symptom fault tracing.10
RM1020
W2004452
9
IMPACT or ID DVD: Info type Specs group 25 or service literature binder set Specs group 200.
10
Impact or ID DVD: info type "Diagnostics" Abnormal Smoke Development, group 2000