Service Bulletin

Volvo Trucks North America, Inc.

Greensboro, NC USA Trucks
Date Group No. Page

12.2005 253 42 1(25)

Exhaust Pressure Governor

D16D
Exhaust Pressure Governor

W2004977

This information covers the proper procedures for replacement and overhaul of the
Exhaust Pressure Governor (EPG) on the Volvo D16D engine.

Contents
• “Special Tools” page 2
• “Exhaust Pressure Governor, Replacement” page 3
• “Exhaust Pressure Governor, Replacement” page 13
• “Exhaust Pressure Governor, Overhaul” page 21

Note: Information is subject to change without notice.

Illustrations are used for reference only, and may differ slightly from the actual engine
version. However, key components addressed in this information are represented as
accurately as possible.

PV776-20 038626 USA18509

Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 2(25)

Service Procedures
Special Tools
For special tools ordering instructions, refer to Tools
Information, group 08.

9992610 9998225 9998246

Drift Drift Valve Spring Tool
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 3(25)

Exhaust Pressure Governor, Replacement

See also:

• “Exhaust Pressure Governor” page 1

You must read and understand the precautions and

guidelines in Service Information, group 20, "General
Safety Practices, Engine" before performing this
procedure. If you are not properly trained and certified
in this procedure, ask your supervisor for training
before you perform it.

Removal
1
Apply the parking brake and place the shift lever
in neutral.

2
Dependent upon chassis, remove the splash guard and
the fender extender as an assembly, if required.

W2005189

1-Fender extender 4-Splash guard bolt

bolts (2) [rear, at (1) [lower, to frame]
bracket]
2-Fender extender 5-Splash guard
bolts (2) [at brace] bolts (2) [upper
brace]
3-Fender extender
brace at hood
release (1) [bolt
and nut]
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 4(25)

3
Begin removing the air filter housing by disconnecting the
air filter restriction gauge wiring harness.

W2003860

4
Remove the wiring harness clamps (3) and tie straps
(upper portion of housing). Secure the harness away
from the air filter housing.

W2003861

5
Loosen the fresh air pipe to air compressor hose clamp
and reposition out of the way.

W2004719
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 5(25)

6
Unplug the air temperature sensor wiring harness
connector. First, remove the lock tab, then separate the
connector from the sensor.

W2004720

7
Loosen the clamp from the main fresh air pipe to the
turbocharger. Pull the pipe away from the turbocharger
and air compressor fresh air pipe.

W2004721

8
Remove the two upper bolts at the top of the air filter
housing.

W2003858

9
Lift the air filter housing (with fresh air pipe attached)
away from the cab.

W2003859
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 6(25)

10
Disconnect the air supply line from the exhaust governor
end cover fitting.

W2005173

Exhaust pipe removed for clarify

11
Loosen the clamp and remove the exhaust pipe from the
Exhaust Pressure Governor (EPG) housing.

W2003870

12
Remove the exhaust clamp from the EPG to the
turbocharger.

W2005174
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 7(25)

13
Separate the EPG housing from the exhaust pipe and
turbocharger; lift and remove from the engine.

Installation
1
Lower the EPG housing into position between the
exhaust pipe and the turbocharger.

W2005174

2
Position the EPG housing against the turbocharger
and install the exhaust clamp connecting the EPG to
the turbocharger.

Note: A pry bar may need to be used to lift the EPG

housing to match the height of the turbocharger.

W2005175
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 8(25)

3
Loosely install the clamp which secures the EPG to
the exhaust pipe.

W2003870

4
Align the mark on the turbine housing outlet with the
reinforcing web on the EPG housing.

W2005228

5
Tighten the clamps attaching the exhaust pipe and the
turbocharger to the EPG housing.

W2005012
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 9(25)

6
Connect the air supply line to the fitting located on the
end cover.

W2005173

Exhaust pipe removed for clarity

7
Position the air filter housing (with fresh air pipe attached)
against the cab.

W2003859

8
Install the two bolts at the top of the air filter housing.

W2003858
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 10(25)

9
Install the main fresh air pipe to the turbocharger. Tighten
the clamps.

W2004721

10
Install the air temperature sensor connector to the sensor.
Insert and secure the connector lock tab.

W2004720

11
Install the fresh air pipe to the air compressor. Tighten
the clamps.

W2004719
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 11(25)

12
Install the wiring harness clamps to the air filter housing.

W2003861

13
Connect the air restriction gauge wiring harness.

W2004249

14
Check all clamp connections at the filter box, turbocharger
and fresh air pipe from the compressor.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 12(25)

15
Install the splash guard and the fender extender as an
assembly, if removed for access.

W2005189

1-Fender extender 4-Splash guard bolt

bolts (2) [rear, at (1) [lower, to frame]
bracket]
2-Fender extender 5-Splash guard
bolts (2) [at brace] bolts (2) [upper
brace]
3-Fender extender
brace at hood
release (1) [bolt
and nut]

16
Start the engine and check for exhaust leaks.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 13(25)

Exhaust Pressure Governor, Replacement

See also:

• “Exhaust Pressure Governor” page 1

• “Exhaust Pressure Governor, Overhaul” page 21

You must read and understand the precautions and

guidelines in Service Information, group 20, "General
Safety Practices, Engine" before performing this
procedure. If you are not properly trained and certified
in this procedure, ask your supervisor for training
before you perform it.

Removal
1
Apply the parking brake and place the shift lever
in neutral.

2
Dependent upon chassis, remove the splash guard and
the fender extender as an assembly, if required.

W2005189

1-Fender extender 4-Splash guard bolt

bolts (2) [rear, at (1) [lower, to frame]
bracket]
2-Fender extender 5-Splash guard
bolts (2) [at brace] bolts (2) [upper
brace]
3-Fender extender
brace at hood
release (1) [bolt
and nut]
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 14(25)

3
Begin removing the air filter housing by disconnecting the
air filter restriction gauge wiring harness.

W2003860

4
Remove the wiring harness clamps (3) and tie straps
(upper portion of housing). Secure the harness away
from the air filter housing.

W2003861

5
Loosen the fresh air pipe to air compressor hose clamp
and reposition out of the way.

W2004719
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 15(25)

6
Unplug the air temperature sensor wiring harness
connector. First, remove the lock tab, then separate the
connector from the sensor.

W2004720

7
Loosen the clamp from the main fresh air pipe to the
turbocharger. Pull the pipe away from the turbocharger
and air compressor fresh air pipe.

W2004721

8
Loosen the two upper bolts at the top of the air filter
housing.

W2003858

9
Lift the air filter housing (with fresh air pipe attached)
away from the cab.

W2003859
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 16(25)

10
Disconnect the air supply line from the exhaust governor
end cover fitting.

W2005173

Exhaust pipe removed for clarity

11
Remove the bolts and lift off the exhaust pressure
governor from the EPG housing.

Note: Exhaust governor can be removed with the EPG

housing and exhaust pipe attached to the engine.

W2005178

Exhaust pipe removed for clarity

Installation
1
Clean the sealing surface of the shutter housing.

W2005179
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 17(25)

2
Install the new exhaust pressure governor and install
and tighten the four bolts.

W2005178

Exhaust pipe removed for clarity

3
Connect the air supply line to the exhaust governor
end cover fitting.

W2005173

Exhaust pipe removed for clarity

4
Position the air filter housing (with fresh air pipe attached)
against the cab.

W2003859
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 18(25)

5
Install the two bolts at the top of the air filter housing.

W2003858

6
Install the main fresh air pipe to the turbocharger. Tighten
the clamps.

W2004721

7
Install the air temperature sensor connector to the sensor.
Insert and secure the connector lock tab.

W2004720

8
Install the fresh air pipe to the air compressor. Tighten
the clamps.

W2004719
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 19(25)

9
Install the wiring harness clamps to the air filter housing.

W2003861

10
Connect the air restriction gauge wiring harness.

W2004249

11
Check all clamp connections at the filter box, turbocharger
and fresh air pipe from the compressor.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 20(25)

12
Install the splash guard and the fender extender as an
assembly, if removed for access.

W2005189

1-Fender extender 4-Splash guard bolt

bolts (2) [rear, at (1) [lower, to frame]
bracket]
2-Fender extender 5-Splash guard
bolts (2) [at brace] bolts (2) [upper
brace]
3-Fender extender
brace at hood
release (1) [bolt
and nut]

13
Start the engine and check for proper operation and leaks.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 21(25)

Exhaust Pressure Governor, Overhaul

Removed

See also:

• “Exhaust Pressure Governor” page 1

• “Exhaust Pressure Governor, Replacement” page 3

You must read and understand the precautions and

guidelines in Service Information, group 20, "General
Safety Practices, Engine" before performing this
procedure. If you are not properly trained and certified
in this procedure, ask your supervisor for training
before you perform it.

T2006749

Fig. 1: Exhaust Pressure Governor

1-Set Screw 12-Bolts

2-Bolts 13-Cover
3-Plunger 14-Heat Shield
4-Seals 15-Securing Flange
5-Plunger Rod 16-Nut
6-Spring 17-Nut
7-Spring Holder 18-Housing
8-Spring 19-Seals
9-Seal 20-Seals
10-Shutter 21-End Cover
11-Valve Collets 22-End Cover Bolts
23-End Cover Fitting

Special tools: 9992610, 9998225, 9998246

Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 22(25)

Disassembly
1
Remove the end cover from above the plunger.

2
Remove the bolts and take out the plunger.

3
Remove the seals (4, 20 and 19, Fig. 1: Exhaust
Pressure Governor, page 21).

4
Remove the set screw on the plunger rod.

5
Place the exhaust pressure governor into a press.
Compress the spring enough to remove the valve collets.

Note: Do not press more than necessary to remove the

collets. Compressing the spring fully can damage
the cover.

T2006747

Fig. 2: Removing Collets

6
Remove the plunger rod, spring and shutter.

7
Remove the bolts holding the cover, the heat shield
and the securing flange.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 23(25)

8
Carefully tap out the spring holder that secures the spring
and the seal (9, Fig. 1: Exhaust Pressure Governor,
page 21).

T2006744

Fig. 3: Removing Spring Holder

9
Clean all parts and replace any that are damaged or worn.

Assembly
1
Install the plunger rod into the housing from behind so as
to center the spring holder. Install a new seal with the
beveled edge facing inside the housing. Install the spring
and a new spring holder.

T2006745

Fig. 4: Assembly
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 24(25)

2
Put the plunger rod onto drift 9992610 in a press. Using
drift 9998225, press on the spring holder until it bottoms
in the housing. Remove the plunger rod. Check to make
sure that the spring holder is correctly centered.

9992610
, 9998225

T2006746

Fig. 5: Plunger Rod Installation

3
Install the securing flange, the heat shield and the cover.
Tighten the bolts to 13 ± 2 Nm (10 ± 2 ft-lb).

13 ± 2 Nm
(10 ± 2 ft-lb)

4
Install the shutter, spring and plunger rod into the housing.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2005 253 42 25(25)

5
Compress the spring by hand, making sure that the
shutter shaft and plunger rod fit together and that the
plunger rod fits correctly into the seal. Stop applying
pressure if undue resistance is felt. Install the valve
collets.

T2006748

Fig. 6: Depressing Spring

6
Install the set screw into the plunger rod. Apply sealant to
the set screw before installing. Tighten the set screw to
40 ± 5 Nm (30 ± 4 ft-lb).

40 ± 5 Nm
(30 ± 4 ft-lb)

7
Install a new seal into the plunger rod and install the
plunger. Apply sealant to the bolts and tighten them to 13
± 2 Nm (10 ± 2 ft-lb).

13 ± 2 Nm
(10 ± 2 ft-lb)

8
Install the end cover using new seals. Make sure that the
seal bottoms in the housing. Install the seal with the flat
side facing the housing. Tighten the end cover bolts to 24
± 2 Nm (18 ± 2 ft-lb).

24 ± 2 Nm
(18 ± 2 ft-lb)