Foreword

This booklet is part of a complete service manual. Read the fore‐

word in the service manual.

WARNING!
Always read the booklet Safety before proceeding.

VOE21A1002167

1
Content
00 DESCRIPTION, COMPLETE MACHINE
000 General
Foreword ..................................................................................................... 7

03 SPECIFICATIONS
030 General
VOLVO standard tightening torques ........................................................... 8
Tensile strength class 8.8 Metric coarse and fine threads ........................ 8
Tensile strength class 10.9 Metric coarse and fine threads ...................... 8
UNC threads, coarse pitch ........................................................................ 8
Engine, specifications ................................................................................. 9
Cylinder head, specifications ...................................................................... 9
Cylinder head bolts ................................................................................... 9
Cylinder head gasket .............................................................................. 10
Cylinder block, specifications .................................................................... 10
Pistons, specifications .............................................................................. 10
Piston ...................................................................................................... 10
Piston rings ............................................................................................. 10
Cylinder liner, specifications ..................................................................... 10
Camshaft, specifications ........................................................................... 11
Crankshaft, specifications ......................................................................... 11
................................................................................................................. 12
Connecting rods, specifications ................................................................ 12
Big-end bearings ..................................................................................... 12
Speed sensor, specifications .................................................................... 12
Valve mechanism, tightening torques ....................................................... 12
Rocker arm holder, tightening torque ..................................................... 12
Lock nut, tightening torque ..................................................................... 12
Cylinder head, tightening torques ............................................................. 13
Valve mechanism, specifications .............................................................. 13
Oil trap, tightening torque ......................................................................... 13
Timing gear casing, tightening torques ..................................................... 14
Cylinder block, tightening torques ............................................................. 14
Screw plugs ............................................................................................ 14
Flywheel, tightening torques ..................................................................... 15
Belt pulley/vibration damper, tightening torques ....................................... 15
................................................................................................................. 15
Oil sump, tightening torque ....................................................................... 16
Fuel system, tightening torques ................................................................ 16
Oil pump, tightening torques ..................................................................... 16
Oil cooler, tightening torques .................................................................... 16
Injectors, tightening torques ...................................................................... 17
Exhaust manifold, tightening torques ........................................................ 17
Turbocharger, tightening torques .............................................................. 17
Charge-air pipe, tightening torque ............................................................ 17
Coolant thermostat housing, tightening torques ....................................... 17
Crankshaft, tightening torques .................................................................. 17
Speed sensor, tightening torque ............................................................... 18

21 ENGINE
210 General, common info about 211 - 218
Engine, mounting in work stand ................................................................ 19
Turbocharger, removing ......................................................................... 19
Mounting in work stand ........................................................................... 20
Engine, dismantling .................................................................................. 21
Cable harness, removing ........................................................................ 22
Loosen V-belts alt. flat belt ..................................................................... 23
Coolant pump and thermostat housing, removing .................................. 28

3
 Oil sump, removing ................................................................................. 29
Flywheel, removing ................................................................................. 30
Pistons and connecting rods ................................................................... 33
Crankshaft, removing .............................................................................. 34
Camshaft and valve tappets, removing .................................................. 35
Power take-off housing, removing .......................................................... 36
Pressure control valve, removing ........................................................... 36
Camshaft bushings, removing ................................................................ 37
................................................................................................................. 37
Cylinder liner, removing .......................................................................... 37
Engine, assembling .................................................................................. 39
Assembling ............................................................................................. 39
Timing gear casing, changing crankshaft seal ........................................ 39
Pressure control valve, installing ............................................................ 40
Cylinder liner, installing ........................................................................... 40
Camshaft, installing ................................................................................ 41
Crankshaft, installing .............................................................................. 44
Pistons and connecting rods, installing ................................................... 46
Timing gear casing, installing ................................................................. 47
Front cover with oil pump, installing ........................................................ 48
Power take-off housing, installing ........................................................... 52
Flywheel, installing .................................................................................. 52
Oil cooler and oil filter, installing ............................................................. 54
Determining thickness of cylinder head gasket ...................................... 54
Pistons' height above engine block ......................................................... 54
Cylinder head, installing .......................................................................... 55
Valve adjustment .................................................................................... 56
Pumps, installing ..................................................................................... 57
Exhaust pipe, inlet manifold, and valve cover, installing ......................... 57
Oil trap, installing .................................................................................... 58
Coolant pump and thermostat housing, installing ................................... 58
Crankshaft sensor, installing ................................................................... 59
Fuel pump, installing ............................................................................... 60
Belts, installing ........................................................................................ 60
Injectors and fuel lines, installing ............................................................ 61
Starter motor ........................................................................................... 63
Cable rail with cable harness, installing .................................................. 64
Engine, removing from work stand ........................................................... 65
Removing from work stand ..................................................................... 65
Turbocharger, installing .......................................................................... 66
211 Cylinder head
Cylinder head, reconditioning ................................................................... 67
Valve seat, changing .............................................................................. 69
Valve seat, grinding ................................................................................ 70
Valves, grinding ...................................................................................... 71
Rocker arm bridge, dismantling .............................................................. 71
Valves, installing ..................................................................................... 71
212 Cylinder block with crankcase ventilation
Cylinder block, checking and measuring wear ......................................... 74
Cylinder block, checking ......................................................................... 74
213 Cylinder liner; piston
Piston with connecting rod, checking ........................................................ 75
Dismantling connecting rod and piston ................................................... 75
Connecting rods, checking ..................................................................... 77
Assembling connecting rod and piston ................................................... 78
Cylinder liner, checking and measuring wear ........................................... 78
214 Valve mechanism
Valves, adjusting ....................................................................................... 80
Installing and adjusting IEGR-unit ......................................................... 82

4
215 Engine transmission; camshaft
Camshaft, checking wear ......................................................................... 84
Camshaft outside diameter and bearing hole diameter measure‐
ment ....................................................................................................... 84
216 Crank shaft; connecting rod; vibration damper; fly wheel
Crankshaft, checking ................................................................................ 85
Main bearings ......................................................................................... 85
Main bearing cups .................................................................................. 85
Thrust bearing ......................................................................................... 85
Big-end bearing ...................................................................................... 86
Starter ring gear, replacing ....................................................................... 87

22 LUBRICATING SYSTEM
221 Oil pump; line
Oil pump removed, reconditioning ............................................................ 88
223 Oil cooler
Oil cooler (removed), reconditioning ......................................................... 90
Changing ................................................................................................ 90
Leakage check ........................................................................................ 91

5
GENERAL

00 DESCRIPTION, COMPLETE
MACHINE

000 General
Foreword

This service manuals contains specifications, descriptions, repair

instructions, drawing, and diagrams for engine D7E, equipped to
fulfill governing legislation according to stage 3/stage IIIA for
exhaust emissions.

Instructions are based on method studies conducted on D7E‐

LAE3. There may be some deviations, depending on the machine
type for which the engines are adapted. Since illustrations in the
service literature are re-used for different engine versions, some
details may differ from the version in question. However, the
essential information is always correct.

The instructions are valid on the condition that the engine has
been removed from the machine or that it is exposed in the
machine. The instructions for necessary work to expose the
engine is available in the service manual for each machine type.

The instructions are based on the use of special tools and gen‐
erally available standard tools.

Information about engine power, engine speeds, optional equip‐

ment, etc., see service manual for each machine type.

WARNING!
This warning symbol means risk of fatalities or personal injury if
the instructions are not followed.

Also read through and follow the instructions in Section "Safety"

in the service manual for each machine type.

For reference number of each manual, see the current publica‐

tions catalogue and SSI (Service Support Information).

All lifting devices such as slings, straps, ratchet blocks, etc. must
comply with the governing national regulations for lifting devices.

The operation numbers refer to "Time Guide".

Volvo Construction Equipment will not accept any responsibility

if other tools or work methods other than those described in this
publication are used.

The information and data given in this manual are valid at the time
of publication.

Volvo Construction Equipment reserves the right to modify spec‐

ifications and equipment without prior notice.

7
 03 SPECIFICATIONS

030 General
VOLVO standard tightening torques

The tightening torques in the following tables refer to bolted joints

with tensile strength as indicated. The tables should be regarded
as a general guideline for tightening of bolted joints where nothing
else is specified.

NOTE! For flange bolt of type U6FS, values should be increased

by 10%. Bolts and nuts should be clean and lubricated with oil.

Tensile strength class 8.8 Metric coarse and fine threads

Thread Nm kpm lbf ft

M6 10 ±2 1.0 ±0.2 7.4 ±3.5
M8 24 ±5 2.4 ±0.5 18 ±3.5
M 10 48 ±10 4.8 ±1.0 35 ±7.4
M 12 85 ±18 8.5 ±1.8 63 ±13.0
M 14 140 ±25 14.0 ±2.5 103 ±18.0
M 16 220 ±45 22.0 ±4.5 160 ±33.0
M 20 430 ±85 43.0 ±8.5 320 ±63.0
M 24 740 ±150 74.0 ±15.0 550 ±110.0

Tensile strength class 10.9 Metric coarse and fine threads

Thread Nm kpm lbf ft

M6 12 ±2 1.2 ±0.2 9 ±1.5
M8 30 ±5 3.0 ±0.5 22 ±3.5
M 10 60 ±10 6.0 ±1.0 44 ±7.5
M 12 105 ±20 10.5 ±2.0 78 ±14.5
M 14 175 ±30 17.5 ±3.0 130 ±22
M 16 275 ±45 27.5 ±4.5 204 ±33
M 20 540 ±90 54.0 ±9.0 400 ±66
M 24 805 ±160 80.5 ±16.0 594 ±118

UNC threads, coarse pitch

Thread Nm kpm lbf ft

1/4" 9 ±2 0.9 ±0.2 6.6 ±1.5
5/16" 18 ±4 1.8 ±0.4 13 ±3.0
3/8" 33 ±8 3.3 ±0.8 24 ±5.9
7/16" 54 ±14 5.4 ±1.4 40 ±10
1/2" 80 ±20 8.0 ±2.0 59 ±15
9/16" 120 ±30 12.0 ±3.0 89 ±22
5/8" 170 ±40 17.0 ±4.0 130 ±30

8
 Thread Nm kpm lbf ft
3/4" 300 ±70 30.0 ±7.0 220 ±52
7/8" 485 ±115 48.5 ±11.5 360 ±85
1" 725 ±175 72.5 ±17.5 530 ±130

Engine, specifications

Model Used in Output Torque

D7E EBE3 Excavator EC240B 125 kW (168 hp) at 1800 870 Nm (642 lb ft) at 1350 rpm
rpm
D7E EAE3 Excavator EC290B 145 kW (195 hp) at 1800 961 Nm (709 lb ft) at 1350 rpm
rpm
D7E GCE3 Motor grader G930 150 kW (201 hp) at 2100 954 Nm (704 lbf ft) at 1550 rpm
rpm
D7E GBE3 Motor grader G940 165 kW (221 hp) at 2100 1049 Nm (774 lbf ft) at 1550 rpm
rpm
D7E GAE3 Motor grader G946, 180 kW (241 hp) at 2100 1100 Nm (811 lbf ft) at 1550 rpm
G960 rpm
D7E LBE3 Loader L110F 169 kW (227 hp) at 1700 1059 Nm (781 lbf ft) at 1400 rpm
rpm
D7E LAE3 Loader L120F 179 kW (240 hp) at 1700 1059 Nm (781 lbf ft) at 1500 rpm
rpm

Type Four-stroke diesel

Combustion system Direct injection
Number of cylinders 6
Cylinder bore 108 +0.02 mm (4.251+0.0008 in)
Stroke 130 mm (5.118 in)
Displacement 7.150 dm3 (litres) (436 in3)
No. of valves 12
Direction of rotation Facing flywheel, counter-clockwise
Compression ratio 18:1
Ignition sequence 1-5-3-6-2-4

Cylinder head, specifications

Type 6 cyl.
Length 849.5 mm (33.4 in)
Width 256 ±0.2 mm (10 in)
Height 110 mm (4.33 in)

Cylinder head bolts

Quantity/cylinder head 26
Thread dimension M15
Length 134 resp. 170 mm (5.27 resp. 6.69 in)

9
 Cylinder head gasket

Marking Intended for piston height

1 hole 0.28–0.53 mm (0.011–0.0208 in)
2 holes 0.54–0.63 mm (0.0209–0.0251 in)
3 holes 0.64–0.75 mm (0.0252–0.029 in)

Cylinder block, specifications

Cylinder diameter (liner) 108 +0.02 mm (4.251+0.0008 in)

Stroke 130 mm (5.118 in)
Cylinder liner's seat, depth 8.92 +0.03 mm (0.3512 +0.0011 in)
Liner position, height above engine block 0.03 – 0.08 mm (0.0012 – 0.0031 in)
Oil cooling nozzle 2-hole

Pistons, specifications

Piston

Height above cylinder block face 0.28–0.75 mm (0.0110-0.0295 in)

Diameter between upper and lower compression ring 107.660 mm (4.2386 in)
Number of ring grooves 3
Marking Symbol facing the flywheel
Piston pin, diameter 42.0 –0.006 mm (1.65 –0.00024 in)

Piston rings

Compression rings
Quantity 2
Piston ring clearance in grooves:
upper compression ring Trapezius-shaped profile
lower compression ring 0.09–0.13 mm (0.0035-0.0051 in)
Piston ring gap:
upper compression ring 0.3–0.55 mm (0.012–0.022 in)
lower compression ring 1.5–2.0 mm (0.059–0.079 in)
Oil scraper ring
Quantity 1
Piston ring clearance in grooves 0.03–0.075 mm (0.0011-0.0029 in)
Piston ring gap 0.3–0.6 mm (0.012–0.024 in)

Cylinder liner, specifications

Type Wet, replaceable

Cylinder bore 108 +0.02 mm (4.25 +0.0008 in)
Cylinder liner's collar height 9.0 –0.02 mm (0.354 –0.0008 in)
Cylinder liner's contact depth 8.92 +0.03 mm (0.351 +0.0012 in)

10
Sealing surface, height above block face 0.03–0.08 mm (0.0011–0.0031 in)
Number of seal rings per cylinder liner 2

Camshaft, specifications

Camshaft
Drive Gear
Bearing position, standard 64.2 ±0,2 (2.53 ±0.008)
Radial clearance 0.050–0.124 mm (0.0020– 0.0048 in)
End float 0.1–0.5 mm (0.0039– 0.0197 in)
Max. gear flank clearance camshaft gear –crankshaft gear 0.031–0.095 mm (0.0012– 0.0037 in)

Bearing bushings
Quantity 7
Bearing bushings, inside diameter 65 +0.054 mm (2.559 ±0.0021 in)
Wear limit 65.08 mm (2.562 in)
Position of the bearing bushing nearest to the flywheel 2 +0.5 mm (0.08 ±0.0020 in) from the engine
block's outer edge

Crankshaft, specifications

General
Length 973.2 mm (38.31 in)
End float 0.1–0.3 mm (0.004–0.012 in)
Radial clearance 0.03–0.092 mm (0.0012–0.0036 in)
Max. "throw" 0.1 mm (0.004 in)

Main bearing journals

Diameter, standard 85.00 –0.02 mm (3.346 –0.0008 in)
1st undersize 0.25 mm 0.25 mm (0.010 in)
2nd undersize 0.50 mm (limit for undersize) 84.50 –0.02 mm (3.327 –0.0008 in)
Max. out-of-round 0.01 mm (0.0004 in)
Max. taper 0.01 mm (0.0004 in)
Width, standard 38.00 +0.06 mm (1.496 +0.0024 in)
Each oversize 0.40 mm (0.016 in)
Limit for oversize 38.46 mm (1.514 in)
Hardness, bearing position 53 ±3 HCR

Main bearings
Type Replaceable
Inside diameter 85.030–85.066 mm (3.3476–3.3490 in)
Thickness, standard 2.727–2.735 mm (0.1074–0.1077 in)
1st oversize 0.25 mm 2.852–2.860 mm (0.1123–0.1126 in)
2nd oversize 0.50 mm 2.977–2.985 mm (0.1172–0.1175 in)

11
Thrust washer (thrust bearing)
Thickness, standard 2.9 +0.05 mm (0.11 +0.0019 in)
Oversize 0.2 mm (0.008 in)

Connecting rod bearing pins

Diameter, standard 68.00 –0.02 mm (2.677 –0.0008 in)
1st undersize 0.25 mm 0.25 mm (0.010 in)
2nd undersize 0.50 mm 67.50 –0.02 mm (2.657 –0.0008 in)
Max. out-of-round 0.01 mm (0.0004 in)
Max. taper 0.01 mm (0.0004 in)

Connecting rods, specifications

Marking of connecting rod and bearing cap respectively Digit code

Small-end bushing, inside diameter 42.04–42.05 mm (1.6551–1.6555 in)
Wear limit 0.034–0.056 mm (0.0013–0.0022 in)
Piston pin, diameter 42.0 –0.006 mm (1.65 –0.00024 in)
Big-end bearing in rod, inside diameter with installed bearing 72.5 +0.02 mm (2.85 +0.0008 in)
shells
Max. clearance crankshaft – connecting rod 0.036–0.095 mm (0.0014–0.0037 in)
Piston pin parallelity Measurement "a" max. 0.05 mm (0.0002 in)
over a distance of x = 100 mm (3.94 in)
Piston pin straightness Permissible tolerance "A" to "B": 0.05 mm
(0.0002 in) over a distance of x = 100 mm (3.94
in)

Big-end bearings

Inside diameter 68.03–68.07 mm (2.6783–2.6799 in)

1st oversize 0.25 mm (0.010 in) 67.78–67.82 mm (2.6685–2.6701 in)
2nd oversize 0.50 mm (0.020 in) 67.53–67.57 mm (2.6587–2.6602 in)

Speed sensor, specifications

Speed sensor
Crankshaft, clearance sensor — sensor ring gear 0.6 ±0.1 mm (0.024 ±0.004 in)

Valve mechanism, tightening torques

Rocker arm holder, tightening torque

Rocker arm holder, tightening torque 30 Nm (22 lbf ft)

Lock nut, tightening torque

Lock nut, tightening torque 20 ±2 Nm (15 lbf ft)

12
 Cylinder head, tightening torques

Valve cover, bolts 13 Nm (9.6 lbf ft)

Attaching bolts
Step 1 50 Nm (37 lbf ft)
Step 2 130 Nm (96 lbf ft)
Step 3 90°

Valve mechanism, specifications

Valves
Valve head diameter:
inlet 48 ±0.1 mm (1.89 ±0.004 in)
exhaust 42 ±0.1 mm (1.65 ±0.004 in)
Valve stem, diameter:
inlet 8.98 – 0.05 mm (0.353 –0.002 in)
exhaust 8.96 – 0.05 mm (0.352 –0.002 in)
Valve clearance, cold engine, value when adjusting:
inlet 90°
exhaust 150°
Clearance between control valve piston and rocker arm 144°
Measurement between valve disc and cylinder head's face:
inlet 0.99 ±0.1 mm (0.039 ±0.0039 in)
exhaust 1.0 +0.15 –0.1 mm (0.039 +0.0059 –0.0039 in )
Valve head edge, thickness:
inlet 2.62 mm (0.103 in)
exhaust 2.30 mm (0.091 in)

Valve guides
Max. clearance valve stem - guide, wear tolerance:
Inlet 0.045 — 0.075 mm (0.002 — 0.003 in)
Outlet 0.065 — 0.105 mm (0.0025 — 0.004 in)

Valve springs
Inlet/exhaust
Length, unloaded 64.7 mm (2.55 in)
Diameter, thread 4.5 mm (0.18 in)

Rocker arm
Hole diameter inlet, exhaust 21.02 +0.033 (0.828 +0.0013 in)
Tapp 21.02 –0.021 (0.828 –0.0008 in)

Oil trap, tightening torque

Attaching bolts 20 ±2 Nm (14.7 ±1.5 lbf ft)

13
 Timing gear casing, tightening torques

IMPORTANT! Regarding bolted joints which are not listed here,

see “Volvo standard tightening torques”

Retaining bolts:
M8*55 20 ±2 Nm (15 lbf ft)
M8*35 30 ±3 Nm (22 lbf ft)
M16*6 70 ±5 Nm (52 lbf ft)

Cylinder block, tightening torques

IMPORTANT! Regarding bolted joints which are not listed here,

see “Volvo standard tightening torques”

Starter motor 60 Nm (45 lbf ft)

Screw plugs

Fig.1

Plug 4 35 Nm (25 lbf ft)

Plug 6 95 Nm (70 lbf ft)
Plug 7 75 Nm (55 lbf ft)
Plug 8 35 Nm (25 lbf ft)
Plug 13 35 Nm (25 lbf ft)
Plug 17 9 Nm (6 lbf ft)
Plug 21 9 Nm (6 lbf ft)
Plug 24 10 Nm (7 lbf ft)

14
 Flywheel, tightening torques

IMPORTANT! Regarding bolted joints which are not listed here,

see “Volvo standard tightening torques”

Step 1, bolts 30–45 mm 30 –10 Nm (22 –7 lbf ft)

Step 1, bolts 50–85 mm 30 +10 Nm (22 +7 lbf ft)
Step 2, bolts 30–85 mm 60°
Step 3, bolts 30 mm 30°
Step 3, bolts 35–85 mm 60°
Flywheel housing, M12 bolts, Torx By hand
Preliminary tightening 99 Nm (73 lbf ft)
Final tightening
Flywheel housing, M16 bolts, Torx 99 Nm (73 lbf ft)
Preliminary tightening 243 Nm (180 lbf ft)
Final tightening
Cover plate 9 Nm (7 lbf ft)

Belt pulley/vibration damper, tightening torques

IMPORTANT! Regarding bolted joints which are not listed here,

see “Volvo standard tightening torques”

Belt pulley and inner oscillation damper

Step 1 30 Nm (22 lbf ft)
Step 2 60°
Step 3 60°
Belt tensioner, lock bolt 30 ±3 Nm (22 ±2 lbf ft)

Outer oscillation damper

Attaching bolts 70 Nm (52 lbf ft)

15
 Oil sump, tightening torque

IMPORTANT! Regarding bolted joints which are not listed here,

see “Volvo standard tightening torques”

Oil sump 30 Nm (22 lbf ft)

Oil suction pipe 22 ±2 Nm (16 lbf ft)
Ladder frame 1 30 Nm (22 lbf ft)
2 30 Nm (22 lbf ft)
3 22 Nm (16 lbf ft)
2 1 3 1 1 1 2

3 2 1 3 1 1 1 2

V1027486

Fuel system, tightening torques

IMPORTANT! Regarding bolted joints which are not listed here,

see “Volvo standard tightening torques”

Fuel rail
Fuel rail, attaching bolts 30 Nm (22 lbf ft)
Electrical cables, attaching bolts 1.4 ±0.1 Nm (1.03 lbf ft)
Fuel delivery line (between fuel rail and injector) 25 Nm (18.4 lbf ft)
Injector, yoke 16 ±5 Nm (12 ±4 lbf ft)
Fuel control valve (FCV) 30 Nm (22 lbf ft)
Return line to control valve 39 Nm (28.8 lbf ft)
Fuel feed filter, attaching bolts 30 Nm (22 lbf ft)
Feed line to control valve (from fuel filter) 49 Nm (39.1 lbf ft)
Feed pipe (on control valve) 34 Nm (25.1 lbf ft)
High-pressure pump, attaching bolts
Step 1: 10 Nm (7.4 lbf ft)
Step 2: 50 Nm (36.9 lbf ft)
Safety valve (PRV), fuel rail 100 Nm (73.8 lbf ft)
High-pressure sensor, fuel rail 70 Nm (51.6 lbf ft)

Oil pump, tightening torques

Oil pump's cover, attaching bolts 9 Nm (6.6 lbf ft)

Cover, attaching bolts 21 Nm (15.5 lbf ft)
Oil suction pipe, attaching bolts 21 ±2 Nm (15.5 ±1.5 lbf ft)

Oil cooler, tightening torques

Oil cooler housing, attaching bolts

Step 1 3 Nm (2.2 lbf ft)

16
Step 2 30 Nm (22 lbf ft)
Oil filter bracket 30 Nm (22 lbf ft)
Flange screws
Step 1 80 Nm (59 lbf ft)
Step 2 160 Nm (118 lbf ft)
Screw plugs 80 Nm (59 lbf ft)
Oil pressure switch 30 ±5 Nm (22 ±3.7 lbf ft)

Injectors, tightening torques

Bolt injector retainer:

Step 1 Tighten by hand
Step 2 16 +5 Nm (12 +4 lbf ft)
Nuts, delivery pipes 25 Nm (18 lbf ft)
Electrical connection, injector 1.5 Nm (1.1 lbf ft)

Exhaust manifold, tightening torques

Attaching nuts 25 Nm (18.4 lbf ft)

Turbocharger, tightening torques

Stud bolt 40 ±4 Nm (30 ±3 lbf ft)

Nut 10 ±1 Nm (7.4 ±0.7 lbf ft)
Oil pressure pipe, attaching bolts 39 Nm (29 lbf ft)
Return pipe, attaching bolts 20 Nm (15 lbf ft)

Charge-air pipe, tightening torque

Charge air pipe 11 Nm (8 lbf ft)

Preheating coil 30 Nm (22 lbf ft)

Coolant thermostat housing, tightening torques

Thermostat casing 30 Nm (22 lbf ft)

Thermostat housing 30 Nm (22 lbf ft)
Coolant pump 30 Nm (22 lbf ft)

Crankshaft, tightening torques

Main bearing caps

Initial tightening torque 50 Nm (37 lbf ft)
1st tightening angle 60°
2nd tightening angle 60°

17
Big-end bearing caps
Initial tightening torque 30 Nm (22 lbf ft)
1st tightening angle 60°
2nd tightening angle 60°

Speed sensor, tightening torque

IMPORTANT! Regarding bolted joints which are not listed here,

see “Volvo standard tightening torques”

Speed sensor
Crankshaft sensor, holder 20 Nm (15 lbf ft)

18
 ENGINE WITH MOUNTING
AND EQUIPMENT

21 ENGINE

210 General, common info about 211 -

218
Engine, mounting in work stand

Op. no.210-081

Tools:
88800050 Fixture
9986485 Support
9998547 Lifting tool

Turbocharger, removing
1 Disconnect the delivery and return pipes from the tur‐
bocharger. Install protective plugs in the turbocharger's con‐
nections.

Fig.2
1 Return pipe
2 Delivery pipe
2 Remove the attaching nuts and remove the turbocharger.

Fig.3

19
 3 Install protective plugs in the connections for the return pipe,
delivery pipe, and the manifold.

Fig.4
1 Protective plugs
Mounting in work stand
4 Install the engine fixture the engine.
IMPORTANT! Use the supplied bolts. They have higher
strength than standard bolts.

Fig.5
1 88800050 Fixture

5 Lift the engine into place and bolt down the engine fixture in
the support.
Engine weight: approx. 700 kg (1545 lbs).

V1010650

Fig.6
1 9998547 Lifting tool

20
 Engine, dismantling

Op. no.210-077

Tools:
11668409 Pliers
9998681 Rotation tool
9998674 Adapter
9996400 Impact puller
9998695 Installation tool
9993717 Quick nut
9993713 Puller bolt
9993722 Support
9998675 Puller plate

Socket or spanner Torx E10

Socket Torx E12
Socket Torx E18
Socket Torx E20
Lifting eyes M12
Lifting sling
Thread tap M8 with handle
Drift 20 mm

Check that the engine is drained of oil.

1 Remove the oil trap for the crankcase ventilation.

Fig.7
1 Oil trap

21
 Cable harness, removing
2 Loosen the cable harness' clamping.
Unplug the connector for the E-ECU.
Unplug the connectors for the fuel control valve, oil pressure
sensor, fuel feed pressure sensor, and the fuel pressure
sensor in the fuel rail.
Unplug the electrical connections for the injectors.

Fig.8 Cable harness connections

1 Connector E-ECU
2 Fuel control valve
3 Injectors
4 Fuel feed pressure sensor
5 Oil pressure sensor
6 Fuel pressure sensor
3 Unplug the connectors for coolant temperature sensor,
boost pressure sensor, solenoid valve for I-EGR, and the
engine rpm sensor.

Fig.9 Cable harness connections

1 Boost pressure sensor
2 Coolant temperature sensor
3 Solenoid valve
4 Speed sensor for camshaft

22
 Loosen V-belts alt. flat belt
4 Loosen the belt tensioner for the fuel feed pump. Remove
the belt.

Fig.10 Loader and motor grader version

1 Belt adjustment
2 Fuel feed pump's bracket
3 Water pump
5 Loosen the V-belt for the AC-compressor. Remove the belt.
Loosen the belt tensioner for the flat belt with a wrench.
Remove the belt.

3
2
1 V1054006

Fig.11 Excavator version

1 Water pump
2 Flat belt
3 Belt tensioner
4 V-rib belt
5 AC Compressor
6 Alternator

23
 6 Loosen the clamps from the feed pump to the fuel control
valve. Loosen the fuel feed pump and complete filter hous‐
ing. Loosen the banjo connection to the fuel control valve.
Lift away the fuel feed pump and complete filter housing as
a unit. Plug all open connections.
7 Remove the lubrication oil filter. Install protective plugs.

Fig.12
1 Fuel filter
2 Fuel feed pump
8 Remove the drain plug and drain the coolant.
Remove the attaching bolts and remove the oil cooler.
Remove gasket remains from the sealing surfaces. Install
protective plugs.

Fig.13
1 Oil cooler
2 Drain plug
9 Remove the attaching nuts and remove the exhaust pipe.
10 Remove the preheating coil.

V1010503
Fig.14
1 Exhaust pipe

24
 11 Remove the valve cover and the seal against the inlet man‐
ifold.

Fig.15 Valve cover

12 Remove the attaching bolts and lift away the charge air pipe.

Fig.16
1 Charge air pipe
13 Remove all high-pressure pipes from the injectors.

NOTE! The delivery (pressure) lines may not be reused.

Cover the injector's and the rail's openings.

Fig.17
1 Fuel delivery line

25
 14 Remove the return pipe and the pipes from the high-pres‐
sure pumps.

NOTE! The pressure lines may not be reused. Cover the

high-pressure pumps' openings.
15 Remove the fuel control valve.
Store the valve in a dust-free location, e.g., in a plastic bag.

Fig.18
1 Fuel return pipe
2 High-pressure pumps
3 Control pressure valve

WARNING!
Work carefully when removing due to the spring force.

16 Rotate the crankshaft so that the high-pressure pumps'

spring force is unloaded.
Carefully loosen the high-pressure pumps' crosswise.
Remove the high-pressure fuel pumps.
Store the pumps in a dust-free location, e.g., in a plastic bag.
17 Remove the common rail (pressure distribution pipe).

Fig.19
1 Common rail

26
 18 Remove the holders for the injectors, and remove the injec‐
tors.

NOTE! Make sure that the copper washer on the injectors'

lower part also comes out.

Mark up the position of the injectors.

Store the injectors in a dust-free location, e.g., in a plastic
bag.

Fig.20
1 Injectors
2 Retainer
19 Loosen the bolts and lift away the IEGR-unit.
Pull apart the IEGR-unit and retain the small oil pipe.

Fig.21
1 IEGR-unit
2 Attaching bolts

Fig.22 IEGR-unit
1 Oil pipe

27
 20 Mark up the rocker arm bridges and remove them together
with the rocker arms.
Mark up and remove the push rods.

Fig.23
1 Attaching bolt
Coolant pump and thermostat housing, removing
21 Remove the bolts and remove the thermostat housing.
Remove the bolts and remove the intermediate housing.
Remove the bolts and remove the coolant pump.

Fig.24
1 Coolant pump
2 Intermediate housing
3 Thermostat housing
22 Loosen the bolts for the cylinder head. Use socket Torx E18.

Fig.25

28
 23 Connect lifting slings to lifting eyes, and lift away the cylinder
head. Remove the guide sleeves.
Cylinder head weight: approx. 65 kg (143 lbs)
24 Overhaul the cylinder head according to Cylinder head,
reconditioning page 67

Fig.26
25 Remove the roller lifters with 11668409 Pliers.

Fig.27
1 11668409 Pliers
2 Roller tappet
Oil sump, removing
26 Remove the oil dipstick.
Turn the engine in the work stand so that the oil sump faces
up.
Loosen the clamps for the oil level/-temp. sensor.
Remove the bolts and remove the oil sump.

NOTE! The oil sump is glued to the engine block. Be careful

when removing to avoid damaging the sump.

Remove the suction oil pipe.

Fig.28
1 Oil level/-temp. sensor
2 Oil sump

29
 Flywheel, removing
27 Turn the engine in the adjustable stand so that the flywheel
comes upward.
Install tool 9998681 Rotation tool.

Fig.29
28 Install lifting eyes M12 and lifting sling.
Loosen the bolts and remove the flywheel housing.
Weight: approx. 35 kg (77 lbs).

Fig.30
1 Lifting eyes M12
29 Remove the cover washer.
NOTE! Some versions do not have this washer.

Fig.31

30
 30 Remove the bolts for the flywheel. Use 9998681 Rotation
tool as counterhold.

Fig.32
1 9998681 Rotation tool

31 Install lifting eyes M12 and lifting sling.

Lift away the flywheel.
Flywheel weight: approx. 55 kg (120 lbs).

Fig.33
1 Lifting eyes M12
32 Rotate the engine to horizontal position. Make sure that
9998681 Rotation tool does not rotate. Remove the attach‐
ing bolts and remove the outer vibration damper together
with the spacer and the inner vibration damper.
Weight: approx. 20 kg (44 lbs).

Fig.34
33 Remove the attaching bolts and lift away the V-belt pulley
and the ring gear.

Fig.35
1 Torx E20
2 Toothed wheel
3 V-belt pulley

31
 34 Remove the attaching bolts and remove the cover with com‐
plete oil pump.

Fig.36
1 Oil pump
35 Remove the attaching bolts and remove the timing gear cas‐
ing.

Fig.37 Timing gear casing

36 Tap out the crankshaft seal on the timing gear casing with a
suitable drift.

Fig.38

32
 Pistons and connecting rods
37 Remove the ladder frame.

Fig.39
1 Ladder frame
38 Mark the connecting rods' caps. Remove the cap with bear‐
ing half.

NOTE! Be careful so that the surface between connecting

rod and cap is not damaged.

Fig.40
39 Press out the piston with connecting rod. Continue with the
next piston. etc.
Retain the bearing halves.

V1022057

Fig.41

33
 Crankshaft, removing
40 Check that the camshaft and the crankshaft gears are
marked.

Fig.42
1 Marking
41 Check that the main bearings' caps are marked. Remove the
attaching bolts and remove the caps together with bearing
halves.

Fig.43
42 Remove the thrust washers by main bearing number 2 (the
thrust bearing journal).
Main bearing number 1 is nearest to the flywheel.

Fig.44
1 Thrust washers
43 Connect a lifting sling to the crankshaft and lift it away.
Crankshaft weight: approx. 75 kg (165 lbs).

Fig.45

34
 44 Remove all bearing shells and thrust washers at main bear‐
ing 2. Mark the washers if they are to be used again.

Fig.46
1 Bearing shell
2 Thrust washers
45 Press out the piston cooling nozzles from underneath with a
drift 4 mm (0.16 in).

NOTE! Work carefully so that the nozzle is not damaged.

Fig.47
Camshaft and valve tappets, removing
46 Make sure that the cylinders are turned to face down.
Pull out the camshaft.Weight approx. 25 kg (55 lbs).

NOTE! Work carefully so that the bushings are not dam‐

aged.

Fig.48 Camshaft
47 Remove the valve tappets. Mark them if they are to be used
again.

Fig.49

35
 Power take-off housing, removing
48 Remove the oil pipe's connection from the engine block.
Remove the attaching bolts (socket Torx E10 and E12) and
remove the power take-off housing with the oil pipe.

Fig.50
1 Attaching bolts
2 Oil pipe
Pressure control valve, removing
49 Thread the hole in the pressure control valve with an M8
thread tap.

Fig.51
50 Pull out the pressure control valve with impact hammer
9996400 Impact puller and 9998674 Adapter.

Fig.52

36
 Camshaft bushings, removing
51 Remove the camshaft's bearing bushings with
9998695 Installation tool if these are to be replaced. Bush‐
ings can be pulled out both ways.

Fig.53
1 9998695 Installation tool

V1002028

Fig.54
1 Press sleeve
2 Guide sleeve

Cylinder liner, removing

52 Turn the engine in the adjustable stand so that the cylinder
liners come upward.

37
 53 Install the tools according to the figure. Fit puller plate below
the lower edge of the cylinder liner.
Press out the liner by turning the nut until the liner comes
loose.
Remove the tools and lift out the cylinder liner. Mark up the
cylinder liners if they are to be used again.
Repeat the procedure for all liners.

V1010546

Fig.55
1 9993722 Support
2 9993713 Puller bolt
3 9998675 Puller plate
4 9993717 Quick nut

38
 Engine, assembling

Op. no.210-078

Tools:
885812 Timing tool
9992000 Handle
9992682 Sealing plug
9998672 Installation tool
9998678 Measuring tool
9998681 Rotation tool
9998687 Installation tool
9998695 Installation tool
11668406 Installation tool

Socket or spanner Torx E10

Socket Torx E12
Socket Torx E18
Socket Torx E20
Lifting eyes M10
Lifting sling
Thread tap M8 with handle
Dial test indicator with magnetic base
Dial test indicator with angled base
Dial indicator for inside measurement (crankshaft)
Depth gauge
Piston ring pliers
Feeler gauge
Screw micrometer
Connecting rod testing device
Drift 20 mm
Steel ruler
Torque wrench, open end
Valve spring compressor
11713514 Sealing compound

Assembling

Timing gear casing, changing crankshaft seal

1 Lube the new crankshaft seal with oil and install it.

Fig.56
1 9992000 Handle
2 9998672 Installation tool

39
 Pressure control valve, installing
2 Clean the seat for the pressure control valve.
Check that the valve peg can be pushed in.
Apply locking fluid on the valve's sealing surface.

Fig.57
3 Install the valve.

Fig.58
4 Drive in the valve until it bottoms out, use a drift 20 mm (0.8
in).

Fig.59
Cylinder liner, installing
5 Make sure that the cylinder liner position and sealing surface
are clean.
6 Install new O-rings.

Fig.60
1 O-rings

40
 7 Lube the engine block and cylinder liner in the indicated
area, marked with an x in the figure.

Fig.61
8 Install the cylinder liners in the engine block. Drive them
down as far as possible.
IMPORTANT! Do not use sealing compound.

Fig.62
9 Measure the cylinder liner's protrusion over the sealing face.
First, clean the measuring surface thoroughly.
Place the measuring tool with adjustments and dial indicator
on the engine block. Reset the dial indicator.

NOTE! Place the adjustments on the block, not on the liner's

edge.

Reset the dial indicator against the engine block's gasket

face. Place the dial indicator against the cylinder liner's top
edge. Measure in three places on the cylinder liner.
Replace the cylinder liner if it's outside the tolerance. See
V1005553 Cylinder block, specifications page 10
Fig.63
1 9998678 Measuring tool
2 Dial gauge
3 Adjustments
Camshaft, installing
Replace camshaft if there is major damage or wear. See
Camshaft, specifications page 11
All valve tappets should also be replaced when replacing the
camshaft.

41
 10 Check that the contact surface against the camshaft on the
valve tappets is convex or flat. If the surface is concave,
replace the valve tappets.
If the valve tappet is worn across the contact surface, the
tappet must be discarded. The "ditch" shows that the tappet
has not been rotating. A dark line outermost on the contact
surface however, indicates that the surface is not worn
down.
It is the condition of the valve tappets that determines
whether a check of the camshaft wear is necessary.
Check that the contact surfaces on the camshaft and the
valve tappets do not have severe pitting damage. Pitting
damage may arise for varying reasons. The damage is
caused by small bits of metal loosening from the hardened
Fig.64 surface. Tappets and camshaft with minor pitting damage
1 Steel ruler may be used. Damage such as pitting usually does not get
any worse.
Check that the camshaft bearing races and cam profiles are
not abnormally worn. The cams may, for example, be worn
obliquely in an axial direction. This can, if the damage is light,
be adjusted by honing.
11 Lightly lubricate the valve tappets with oil and install them

Fig.65
12 Change the bearing bushings if they are worn.

NOTE! The wider bushing, 27 mm (1.0 in), shall be installed

on the flywheel side.
The lubrication hole slightly displaced from centre.

NOTE! The lubrication holes must line up with the oil chan‐
nels in the bearing positions.

Fig.66 Position of bearing bushings

42
Fig.67
1 Lubricating oil holes
13 Press in the bushings to correct position.

Fig.68
1 9998695 Installation tool

Fig.69
1 Guide sleeve
2 Bearing bushing
3 Press sleeve
14 Make sure that the cylinders face down so that the valve
tappets do not move from their positions.
Install the camshaft.Weight approx. 25 kg (55 lbs).

NOTE! Take care not to damage the bearing bushings.

Check that the camshaft can rotate freely.

Fig.70

43
 Crankshaft, installing
15 Blow clean the holes for the piston cooling nozzles
Install the nozzles. Press them in as far as possible.

Fig.71
16 Install the bearing shells in the cylinder block and lubricate
them with oil.

NOTE! Make sure that the anti-rotation lug is installed cor‐

rectly in the slot.

Fig.72
1 Bearing shell
17 Install the bearing shells in the bearing caps and lubricate
them with oil.

NOTE! Make sure that the anti-rotation lug is installed cor‐

rectly in the slot.

Fig.73
18 Wipe clean the bearing cap together with thrust bearing and
thrust washers with pin. Install the thrust washers and mea‐
sure the width.
19 Determine axial run-out. Crankshaft pin's width, see
Crankshaft, checking page 85, minus the measured width
of the bearing cap and thrust washers give clearance in
question.
Permitted axial run-out, see Crankshaft,
specifications page 11.
Fig.74

44
 20 Lift the crankshaft into position. Make sure that the marking
in relation to the camshaft gear will be correctly positioned.
Crankshaft weight: approx. 75 kg (165 lbs).

Fig.75
1 Marking (Camshaft marking may be hidden)
21 Lubricate the thrust washer halves without pin with oil and
install them. Insert them into position under the crankshaft.
Turn the surfaces with the oil grooves toward the
crankshaft's axial bearing surfaces.

Fig.76
22 Attach the other thrust washers onto the bearing cap with a
little grease. Turn the washers so that the surfaces with oil
grooves are facing toward the thrust bearing surfaces on the
crankshaft

Fig.77
23 Lubricate the bearing caps with oil and install them accord‐
ing to the marking. No. 1 nearest to the flywheel end.
Make sure that the thrust washers on the cap fit correctly
against the washers in the block.

Fig.78

45
 24 Torque-tighten the bearing caps
Tightening torques, see Crankshaft, tightening
torques page 17
IMPORTANT! The bolts should be changed after the engine
is dismantled for the third time.

Fig.79
25 Install the dial indicator with magnetic base. Pry with a pry
bar and check the crankshaft run-out.
Permitted axial run-out, see Crankshaft,
specifications page 11.

Fig.80
1 Pinch-bar
2 Magnetic base
3 Dial gauge
Pistons and connecting rods, installing
26 Install the bearing shells in the connecting rods and lubricate
them with oil.

Fig.81
27 Use piston ring compressor and install the pistons with con‐
necting rods from the cylinder head side. The flywheel sym‐
bol shall face the flywheel side.

Fig.82
1 9998687 Installation tool

46
Fig.83 Flywheel symbol
28 Lubricate the big-end bearing journals on the crankshaft with
oil. Push the connecting rod against the bearing journal and
install the caps according to markings.
Install new bolts and tighten them down.
Tightening torques, see Crankshaft, tightening
torques page 17

Fig.84
Timing gear casing, installing
29 Remove any gasket remnants from the timing gear casing
and the cylinder block.
30 Apply sealant Volvo 11713514 on the timing gear casing's
sealing face.
31 Lightly oil the crankshaft oil seal.

Fig.85 Applying sealant

32 Install the timing gear casing without tightening down the
bolts. Position the casing aligned with the sealing surface on
the oil sump.
33 Tighten the bolts (except the two bolts where the rotation tool
is to be secured).
Tightening torque: see Timing gear casing, tightening
torques page 13 .
34 Check that the crankshaft can rotate freely.

Fig.86

47
 Front cover with oil pump, installing
35 Install the rotation tool.
36 Turn the engine in the adjustable stand so that the front end
comes upward.
37 Clean the cover and the cylinder block from any gasket rem‐
nants.
38 Overhaul the oil pump according to Oil pump removed,
reconditioning page 88.

Fig.87
1 9998681 Rotation tool

39 Lightly oil the oil pump rotors.

Fig.88
40 Secure the gasket on the housing with a little grease.

Fig.89
41 Place the oil pump's drive against the crankshaft.

NOTE! The drive only fits in one position.

Fig.90

48
 42 Install the housing with the oil pump without tightening down
the bolts. Fit the housing against the oil sump's sealing face.
43 Tighten the bolts.
Tightening torque: see Oil pump, tightening
torques page 16 .

Fig.91
44 Check the position of the wear groove on the crankshaft.

V1010602

Fig.92
1 Wear groove
45 Install the guide (inner part of 11668406 Installation tool).
Lubricate the crankshaft seal with oil and install it with the
felt side facing out.

V1010603
Fig.93
1 Crankshaft oil seal
2 Guide

49
 46 Install any spacer washers, press sleeve, the bearing and
the nut. Use the number of washers required to prevent the
new crankshaft oil seal from ending up in the same position
as the old one.
47 Screw the nut until stop. Check that the seal ends up in the
correct position.

V1010597
Fig.94
1 Washers
2 Press sleeve
3 Bearing
4 Nut
48 Install the ring gear and the V-belt pulley and align the guide
sleeve and the guide pin.

Fig.95
1 Guide sleeve
2 Guide pin
49 Tighten the bolts (Torx E20), counterhold with the rotation
tool on the flywheel side.
Tightening torque: see Belt pulley/vibration damper, tight‐
ening torques page 15.

Fig.96
1 Torx E20
2 V-belt pulley
3 Toothed wheel

50
 50 Check that the vibration dampers are free from external
damage. Replace with new in case of damage or leaks.
Install inner vibration damper and the spacer. Make sure that
the bolt holes align with the holes in the belt pulley.

Fig.97
1 Spacer
2 Vibration damper
51 Install outer vibration damper and the washer. Tighten down
the bolts.
Tightening torque: see Belt pulley/vibration damper, tight‐
ening torques page 15 .

Fig.98
52 Install the ladder frame.

NOTE! Allen head bolts are placed in the corners.

Tighten the bolts.

Tightening torque: see Oil sump, tightening
torque page 16.

Fig.99 Ladder frame

53 Install a new gasket on the oil suction pipe's connection to
the front cover.
Install the oil suction pipe with bracket.
Tightening torque: see Oil sump, tightening
torque page 16.
54 Install the oil filler pipe.

Fig.100
1 Gasket

51
 55 Fill the joints between the covers and the oil sump with
sealant.
56 Apply a thin layer of sealant Volvo 11713514 on the engine
block.

Fig.101
57 Install new gasket.
Install the oil sump and tighten the bolts. Tighten the bolts
from the centre and out, alternating from side to side.
Tightening torque: see Oil sump, tightening
torque page 16.
58 Install the level sensor's clamps.

Fig.102
Power take-off housing, installing
59 Install the power take-off housing. Apply locking fluid and
tighten down the bolts (sockets Torx E10 and E12).
60 Install the oil pipe.

Fig.103
1 Attaching bolts
2 Oil pipe
Flywheel, installing
61 Rotate the engine in the work stand so that the flywheel side
faces up.
62 Lift the flywheel housing into place.Weight: approx 35 kg (77
lbs).

Fig.104
1 Lifting eyes M10

52
 63 Install the bolts and tighten them. Use the rotation tool as
counterhold.

NOTE! Use new bolts.

Tightening torque: see Flywheel, tightening

torques page 14

Fig.105
1 9998681 Rotation tool

64 Install the cover washer.

NOTE! NOTE! Some versions do not have this washer.

Fig.106
65 Check that the guide sleeves are in place.

Fig.107
1 Guide sleeve

53
 66 Lift the flywheel housing Weight: approx 35 kg (77 lbs)..
Install and tighten the bolts by hand.
Pre-tighten the bolts 2, 3, 4, 5 as shown.
Tighten final torque on bolts 1, 6.
Tighten final torque on bolts 2, 3, 4, 5.
Tightening torque, see se Flywheel, tightening
torques page 14.

Fig.108
Oil cooler and oil filter, installing
67 Remove protective plugs and masking tape. Install the oil
cooler with a new gasket. Install the bolts and tighten them.
Tightening torque: see Oil cooler, tightening
torques page 16.
68 Install a new oil filter.

Fig.109
Determining thickness of cylinder head gasket
Cylinder head gaskets are marked with one, two, or three holes
in one of the corners. The gaskets shall be used for different pis‐
ton heights above the cylinder block's face.

Fig.110
1 Marking of cylinder head gasket
Pistons' height above engine block
69 Install the rotation tool on the engine, 9998681 Rotation
tool.

54
 70 First, clean the measuring surface thoroughly.
Install the measuring tool with spacer washers and dial indi‐
cator on the engine block. Reset the dial indicator to zero.

NOTE! Place the spacer washers on the block, not on the

liner edge.

V1005553

Fig.111
1 9998678 Measuring tool
2 Dial gauge
3 Spacer washers
71 Rotate the crankshaft with the rotation tool to find the piston's
highest position. Measure at two points diagonally on the
piston's upper edge straight above the piston pin. Read off
the height on the indicator.

Fig.112 Measuring points

72 Repeat the same measurement on all pistons. Note the
highest value and use cylinder head gasket according to
Cylinder head, specifications page 9.

V1005554

Fig.113
Cylinder head, installing
73 Place the cylinder head gasket on the cylinder block with the
digits upward. Place the guide sleeves in the holes.

Fig.114
1 Guide sleeves

55
 74 Lift the cylinder head into position. Pay attention to the guide
sleeves.
Cylinder head weight: approx. 65 kg (143 lbs)

Fig.115
75 Oil the bolts lightly and install them. Tighten them in three
steps, note the sequence.

NOTE! The same bolts may be used max. 3 times.

Tightening torque: Cylinder head, tightening

torques page 13.
Use protractor 885812 Timing tool

Fig.116 Torque-tightening, sequence

76 Install the push rods.

Fig.117 Push rods

77 Install the rocker arm holders according to marking. Line
them up with the push rods and valves, and tighten the bolts.
Tightening torque: see Valve mechanism, tightening
torques page 12.

Fig.118
Valve adjustment
78 Adjust the valve clearance, see Valves,
adjusting page 80.

56
 Pumps, installing
79 Install the roller lifters
Make sure that the guide on the lifter ends up in the groove
in the engine block.

Fig.119
1 Guide
80 Install new O-rings on the pumps.
Install the pumps. Install the bolts but do not tighten at this
time.
81 Install the fuel control valve. Install the bolts but do not
tighten at this time.
82 Install the high-pressure fuel pipes.

NOTE! Use new fuel pipes and copper washers.

Tighten the nuts for the fuel pipes and the bolts for the
pumps.
Tightening torque: see Fuel system, tightening
torques page 16.

Fig.120
1 Fuel return pipe
2 High-pressure pumps
3 Fuel control valve
Exhaust pipe, inlet manifold, and valve cover, installing
83 Install the exhaust pipe with new gaskets.
Use paste for bolted flanges on the studs' threads. Install
and tighten the nuts, starting from the middle of the engine
and working outward.
Tightening torque: see Exhaust manifold, tightening
torques page 17 .

Fig.121
1 Exhaust pipe

57
 84 Install the charge-air pipe with new gaskets and tighten the
bolts.
Tightening torque: see Charge-air pipe, tightening
torque page 17.

Fig.122
1 Charge air pipe
85 Install the protective moulding on the valve cover.

NOTE! The protective moulding's profile is not symmetrical.

The protective moulding shall be installed with its red-
coloured end forward, in the engine's direction.

Place the gasket for the valve cover on the cylinder head.
Install the valve cover and tighten down the bolts.
Tightening torque: see Cylinder head, tightening
torques page 13.
86 Install the preheating coil.
Tightening torque: see Charge-air pipe, tightening
torque page 17.

Fig.123
1 Protective moulding
Oil trap, installing
87 Install a new gasket in the groove on the oil trap.
Align the oil trap connection with the oil line.
Tighten down the oil trap against the valve cover.
Tightening torque: see Oil trap, tightening torque page 13.

Fig.124
1 Oil trap
Coolant pump and thermostat housing, installing
88 Check that the coolant pump has no noticeable play.
Remove the protective tape. Install the coolant pump with
new gasket. Tighten the bolts loosely.

Fig.125

58
 89 Lubricate the O-rings and install the intermediate housing.

Fig.126
90 Install the thermostat housing, use new gasket.
91 Tighten all bolts for the coolant pump and the thermostat
housing.
Tightening torque: see Coolant thermostat housing, tighten‐
ing torques page 17 .

Fig.127
1 1 Coolant pump
2 Intermediate housing
3 Thermostat housing
Crankshaft sensor, installing
92
Install the crankshaft's speed sensor. Hand-tighten the bolts.
Insert a feeler gauge between the ring gear and the speed
sensor. See Speed sensor, specifications page 12.
Lightly press the sensor against the feeler gauge. Tighten
the bolts.
Tightening torque: see Speed sensor, tightening
torque page 18
Check the clearance.

Fig.128 Checking clearance

59
 Fuel pump, installing
93 Install the fuel pump with lines and filter bracket. Tighten the
bolts loosely.
Install a new filter.

Fig.129
1 Fuel filter
2 Fuel feed pump
Belts, installing
94 Install the V-belt on the belt pulleys. Tension the belt by
moving the fuel pump. At correct tension it should be possi‐
ble to press down the belt approx. 10 mm (0.4 in) in the
middle between the belt pulleys.
Tighten the bolts for the belt tensioner.
Tightening torque: see Belt pulley/vibration damper, tight‐
ening torques page 15.
Tighten the bolts for the filter housing.
Tightening torque: see Fuel system, tightening
torques page 16

Fig.130 Loader and motor grader version

1 Belt adjustment
2 Fuel feed pump's bracket
3 Water pump

60
 95 Tighten up the belt tensioner for the flat belt with a wrench.
Install the belt and release the tensioner.
Install the V-belt for the AC-compressor. Tighten the belt
with the belt tensioner on the AC-compressor. At correct
tension it should be possible to press down the belt approx.
6
10 mm (0.4 in) in the middle between the belt pulleys.

3
2
1 V1054006

Fig.131 Excavator version

1 Water pump
2 Flat belt
3 Belt tensioner
4 V-rib belt
5 AC Compressor
6 Alternator
Injectors and fuel lines, installing
96 Install new O-rings and seal rings on the injectors.
Install the injectors together with the holder. Torque-tighten
the bolts.
Tightening torque Injectors, tightening torques page 17.

Fig.132
1 Injectors
2 Retainer

61
 97 Install the fuel rail and tighten the bolts loosely.

Fig.133
1 Fuel rail
98 Install new fuel pipes between injectors and the fuel rail.
99 Torque-tighten the bolts for the fuel rail.
Tightening torque: see Fuel system, tightening
torques page 16.
100 Torque-tighten the fuel pressure pipes
Tightening torque: see Fuel system, tightening
torques page 16.

Fig.134
1 Fuel delivery line

62
 101 Install the return fuel line.
Tightening torque: see Fuel system, tightening
torques page 16.

Fig.135
1 Fuel return pipe
2 High-pressure pumps
3 Fuel control valve
102 Remove the rotation tool and reinstall the cover. Use a new
O-ring.
Tightening torque: see Timing gear casing, tightening
torques page 13.

Fig.136
1 Cover
Starter motor
103 Install the starter motor.
Tightening torque, see Cylinder block, tightening
torques page 14.

63
 Cable rail with cable harness, installing
104 Install the cable harness.
Install the electrical connections for the injectors. Tightening
torque, see Fuel system, tightening torques page 16
Plug in the connectors for the fuel control valve, oil pressure
sensor, fuel feed pressure sensor, and the fuel pressure
sensor in the fuel rail.
Clamp the cable harness.

Fig.137
1 Connector E-ECU
2 Fuel control valve
3 Injectors
4 Fuel feed pressure sensor
5 Oil pressure sensor
6 Fuel pressure sensor
105 Plug in the connectors for coolant temperature sensor, boost
pressure sensor, solenoid valve for I-EGR, and the rpm sen‐
sor.
Clamp the cable harness.

Fig.138
1 Boost pressure sensor
2 Coolant temperature sensor
3 Solenoid valve I-EGR
4 Revolution sensor camshaft

64
 Engine, removing from work stand

Op. no.210-082

Tools:
9998547 Lifting tool

Removing from work stand

1 Secure the lifting tool on the engine. Lift away the engine
from the support
Set down the engine in the transport stand.
Engine weight: approx. 700 kg (1545 lbs).
2 Install the engine mounts for the transport stand.

V1010650

Fig.139
1 9998547 Lifting tool

3 Remove the engine fixture from the engine.

Fig.140
1 88800050 Fixture

65
 Turbocharger, installing
4 Remove protective plugs in the connections for the return
pipe, delivery pipe, and the manifold.

Fig.141
1 Protective plugs
5 Fit a new gasket.
Install the turbocharger and tighten down the attaching nuts.
Tightening torque: see Turbocharger, tightening
torques page 17.

Fig.142
6 Install the turbocharger's delivery pipes.
Install a new O-ring on the return pipe and install the pipe.
Tightening torque: see Turbocharger, tightening
torques page 17.

Fig.143
1 Return pipe
2 Delivery pipe

66
 211 Cylinder head
Cylinder head, reconditioning

Op. no.211-069

Tools:
2904634 Installation tool

Valve spring compressor

Dial indicator with magnetic stand
Sliding calipers for measuring depths
88830047 installation tool for valve seal
1 Place the cylinder head in a vice.

NOTE! Note! Use soft jaws so that the cylinder head is not
damaged.
2 Use a valve compressor and compress the valve spring.

Fig.144
3 Remove the lock ring and the thrust washers with a screw‐
driver.
Remove valve collets, holders, valve springs, and valves.

Fig.145
1 Thrust washer
2 Lock ring

67
 4 Remove the valve spindle seals.
5 Clean the cylinder head and check that it is not damaged.

V1010657
Fig.146
1 Valve spindle seal
6 Measure the valve spindle clearance with a dial indicator and
a valve free from defects in the valve guide.

NOTE! The valve head shall not have contact with the valve
seat when measuring. “Open” the valve a few millimetres.

Wear tolerances: see Valve mechanism,

specifications page 13.

Fig.147 .
7 Check the valves.
A Valve spindle diameter standard: see Valve mecha‐
nism, specifications page 13.
B Valve head edge, thickness:
Wear tolerances: see Valve mechanism,
specifications page 13
C Valve head's diameter: see Valve mechanism,
specifications page 13

Fig.148
8 Check the valve seat rings. Wear limit for valve seat width,
see Valve mechanism, specifications page 13.

Fig.149

68
 9 Measure the depth of the valves in the cylinder head (the
distance between the valve head centre and the cylinder
head sealing surface).
Wear tolerances: see Valve mechanism,
specifications page 13

Fig.150
10 Measure the valve spring lengths (unloaded).
Standard lengths: see Valve mechanism,
specifications page 13.

Fig.151
Valve seat, changing
11 The valve seats must be replaced when the measurement
between valve head and cylinder block face exceeds the
value given in the specifications or when good seal is not
obtained.
12 Grind down two edges on the head of a discarded valve.

V1033041

Fig.152 Principle illustration

13 Weld the valve in the valve seat.

NOTE! Work carefully so that the cylinder head is not dam‐

aged.

V1033042

Fig.153 Principle illustration

69
 14 Place a suitable sleeve as protection over the valve/valve
guide. Carefully tap out the valve and the valve seat with a
hammer.

NOTE! Work carefully so that the cylinder head is not dam‐

aged.
15 Thoroughly clean the seat's position and check the cylinder
head for scratches. Scratches are not permitted on the cylin‐
der head.
16 Measure the diameter of the valve seat's position. Check if
seat of standard dimension shall be used. Perform any
required reworking of the valve seat's position.

V1033043

Fig.154

WARNING!
Risk of frostbite! Use protective gloves.

17 Cool the seat in dry ice to a temperature between -60 °C (-76

°F) and -70 °C (-94 °F) . If needed, warm the cylinder head
with a hot-air gun or similar. Press in the valve seat with a
suitable drift.
18 Rework the seat to correct angle and width according to
Valve mechanism, specifications page 13

Valve seat, grinding

NOTE! As spare parts the valve seats are pre-finished and shall
not need any additional grinding.

19 Before grinding the valve seats, check the valve seats, valve
guides and replace them if wear tolerances are exceeded.
20 When grinding valve seats, do not remove too much mate‐
rial, only enough so that the valve seat gets the right shape
and the valve disc good contact surface.
21 The valve seat is ground down so that the measurement
between the cylinder head's plane and the valve plate's head
is according to Valve mechanism, specifications page 13.

Fig.155 Inlet valve Fig.156 Exhaust valve

1 Valve disc, thickness of edge (A) 1 Valve's edge thickness (A)
2 Valve's seat angle (B) 2 Valve's seat angle (B)
3 Valve seat's angle (C) 3 Valve seat's angle (C)

22 The valve seat's angle is checked with a valve seat gauge

after the seat's contact face has been coated with a thin layer
of marking paint.

70
 Valves, grinding
NOTE! As spare parts the valves are pre-finished and shall not
need any additional grinding.

23 The sealing surface shall be ground as little as possible, only

grind enough to remove all damage.
24 Check the measurement (A) on the valve plate's edge. If the
measurement is less than the wear tolerance according to
Valve mechanism, specifications page 13 the valve shall be
changed.

NOTE! Always change a valve with crooked valve spindle.

25 Check the seal of the valves using marking paint.

In case they do not seal tight, repeat grinding of the valve
seat, but not on the valve. Check once again.
When the grinding result is acceptable, then the valve and
seat can be lapped together using a fine lapping paste.

Rocker arm bridge, dismantling

26 Remove the lock washer on the rocker arm bridge. Remove
the rocker arm.
27 Remove the adjusting screws and check the oil channels.
28 Measure the rocker arm's hole, see Valve mechanism,
specifications page 13
29 Measure the rocker arm's pin, see Valve mechanism,
specifications page 13
30 Lubricate the pins lightly. Install the rocker arms.

NOTE! Thrust surface for the valve against the threaded

Fig.157 Rocker arm bridge hole.
1 Rocker arm pin
2 Rocker arm 31 Carefully tap the lock washer on the rocker arm bridge.
3 Oil duct
4 Threaded hole
Valves, installing
32 Install the valves in the valve guides.

71
 33 Install protective sleeves, included in 88830047 on the valve
spindle.
34 Fit the new valve seals over the protective sleeves to the
valve guides.
35 Remove the protective sleeves.

Fig.158
1 Protective sleeve
36 Press the valve seals on the valve guides with
2904634 Installation tool .

Fig.159
1 2904634 Installation tool

37 Install the valve.

Use a valve compressor and compress the valve spring.
Install holders and valve collets.

Fig.160

72
 38 Install the thrust washers and the lock rings.

Fig.161
1 Thrust washer
2 Lock ring

73
 212 Cylinder block with crankcase
ventilation
Cylinder block, checking and measuring wear

Op. no.212-012

Tools:

Depth gauge

Cylinder block, checking

1 Check that the seats for the liner collars and the cylinder
liners' sealing surfaces are free from damage.
2 Use a depth micrometer to check the distance between the
top of the engine block and the liner collars' seat.
Measure in approx. 8 places at each cylinder. Depth shall
be according to Cylinder block, specifications page 10.

NOTE! If depth is greater, the engine block shall be

scrapped.

V1010549
Fig.162
1 Depth gauge

74
 213 Cylinder liner; piston
Piston with connecting rod, checking

Op. no.213-009

Tools:

Piston ring pliers

Feeler gauge
Screw micrometer

Dismantling connecting rod and piston

1 Remove one of the lock rings that hold the piston pin in
place. Press out the piston pin. Remove the connecting rod.
2 Remove the piston rings using a pair of piston ring pliers.
3 Clean and check the piston and piston ring grooves.

V1010550

Fig.163
1 Piston ring pliers
4 Push down one piston ring at a time into the cylinder bore,
below the upper turn-around position, using a piston. Make
sure that the piston ring is positioned horizontally. Check the
piston ring gaps with a feeler gauge.
Wear tolerances: see Pistons, specifications page 10

V1010551
Fig.164
1 Feeler gauge

75
 5 Install the oil scraper ring.
Install the tapered compression ring (2) with the text "top"
facing up.
Install the tapered compression ring (1) with the text "top"
facing up.
Displace the piston rings' gap 120° in relation to each other.

NOTE! The gap of oil scraper ring's inside spring shall be

displaced 180° in relation to the ring gap.

V1010553

Fig.165
1 Compression ring
2 Compression ring
3 Oil scraper ring
6 Measure the piston ring clearance axially with a feeler
gauge.
Wear limits, see Pistons, specifications page 10.

V1010552

Fig.166
7 Check if the piston pin is worn. Piston pin diameter, see
Pistons, specifications page 10.

V1010555

Fig.167
8 Check the piston pin's parallelity, see Connecting rods,
specifications page 12.

Fig.168

76
 9 Check the piston pin's straightness, see Connecting rods,
specifications page 12.

Fig.169
Connecting rods, checking
10 Check the bearing bushing at the connecting rods' piston
end with a dial indicator. Measure at points 1 and 2 and in
planes a and b according to figure. The bushings shall be in
place in the connecting rods.
Inner diameter: see Connecting rods,
specifications page 12.

V1010559
Fig.170
11 Calculate the clearance between bushing and pin.
Permitted clearance, see Connecting rods,
specifications page 12.
Replace bearing bushings when required.
12 Press out the old bushing.
13 Press in the new bearing bushing until flush with the rod.

NOTE! The lubrication hole in the bushing must line up with

the oil channel in the connecting rod.
14 After pressing in, precision-ream the bushing to correct inner
diameter, see Connecting rods, specifications page 12.
Fig.171 V1005509
15 Check that the bearing cap fits the connecting rod and that
the digit marking agrees. Check that the guide studs are in
their locations.
16 Install the bearing caps with new bearing shells. Torque-
tighten the bolts.
Tightening torque: see Crankshaft, tightening
torques page 17.
17 Measure the inside diameter at points 1 and 2 and in planes
"a" and "b" according to the figure.
Inner diameter: see Connecting rods,
specifications page 12.

V1010559
Fig.172

77
 18 Calculate radial run-out between bearing shells and
crankshaft.
Bearing clearance, see Connecting rods,
specifications page 12

Fig.173
Assembling connecting rod and piston
19 NOTE! The ring gaps for the circlips must face the piston
crown.

Place a circlip in correct position and install it.

V1010584
Fig.174
20 Install the piston together with the connecting rod. The fly‐
wheel symbol on the piston and the guide pins on the con‐
necting rod must be located on the same side.
21 Install the other circlip.

V1054010

Fig.175
1 Guide pin

Cylinder liner, checking and measuring wear

Op. no.213-011

1 Check that the liner is free from cracks or other damage.

2 Measure the cylinder liner's inner diameter. Measure at
three different depths as shown, both longitudinally and
across. Measurement, see Cylinder liner,
specifications page 10.

V1010532

Fig.176

78
 3 Measure the height of the cylinder liner collar. Measure at
eight places around the liner.
Height, see Cylinder liner, specifications page 10.

V1010547
Fig.177

79
 214 Valve mechanism
Valves, adjusting

Op. no.214-012

Tools:
885812 Timing tool
9998681 Rotation tool
1 Install M8x75 mm —10.9 bolts in the holes for the IEGR-unit
on the rocker arm holders.
2 Rotate the engine to where the valves on cylinder 1 overlap
each other Use 9998681 Rotation tool.

Overlapping means that the exhaust valve is about to open and

the inlet valve is about to close. It should not be possible to rotate
any push rods by hand for the cylinder in question in this position.

Fig.178 Overlapping

Fig.179
1, 3, 5, 7, 9 and 11 are exhaust valves
2, 4, 6, 8, 10 are 12 inlet valves
3 Mark the position on the vibration damper.

80
 4 Adjust the valve clearance for each cylinder according to the
black markings in the figure. Procedure for adjusting:
1 Loosen the adjusting screw's lock bolt on the rocker
arm.
2 Install the protractor on the adjusting screw.
3 Turn the adjusting screw until zero clearance is
obtained between rocker arm and valve. Reset the
protractor to zero.
4 Turn the adjusting screw counter-clockwise according
to Valve mechanism, specifications page 13.
Fig.180
5 Hold the adjusting screw and tighten the lock nut at the
same time. Tightening torque: see 210, Engine, tight‐
ening torques

Fig.181
1 885812 Timing tool
2 Adjusting screw
5 Rotate the crankshaft another full turn until the valves for
cylinder 6 overlap. Adjust the valve clearance for each cylin‐
der according to the black markings in the figure.

NOTE! When all valves are adjusted, do not rotate the

engine. Continue directly with installing and adjusting the
6 IEGR-unit.

Fig.182

81
 Installing and adjusting IEGR-unit
6 Change the O-rings on the pipe between the two IEGR-sec‐
tions. Lubricate the O-rings.
7 Remove the replacement bolts from the IEGR-unit's instal‐
lation holes.
8 Install the IEGR-unit.

Fig.183 IEGR-unit
1 Oil pipe
9 With overlapping valves for cylinder 6, adjust IEGR—open‐
ing piston for cylinder 1, 3 and 5. Procedure for adjusting
IEGR-opening piston:
1 Loosen the adjusting screw's lock bolt on the IEGR-
unit.
2 Install the protractor on the adjusting screw.
3 Turn the adjusting screw until zero clearance is
obtained between the IEGR-opening piston and
exhaust rocker arm. Reset the protractor to zero.
4 Turn the adjusting screw counter-clockwise according
to Valve mechanism, specifications page 13.
5 Hold the adjusting screw and tighten the lock nut at the
same time. Tightening torque: see 210, Engine, tight‐
ening torques
10 Rotate the crankshaft another full turn until the valves for
cylinder 1 overlap. Adjust IEGR–opening piston for cylinder
2, 4 and 6.

Fig.184
1 885812 Timing tool
2 Adjusting screw

82
83
 215 Engine transmission; camshaft
Camshaft, checking wear

Op. no.

Tools:

Micrometer
1 Visually inspect cams and journals for wear, renew camshaft
if necessary.

Fig.185
Camshaft outside diameter and bearing hole diameter
measurement
2 Measure the camshaft outside diameter with a micrometer.
The oil clearance shall be calculated by subtracting the mea‐
sured camshaft outside diameter from the camshaft bushing
inside diameter after insertion to the cylinder measured with
a cylinder gauge.
Camshaft outside diameter measurement, see Camshaft,
specifications page 11.

Fig.186
3 Diagram for measuring the journals at the points (1 and 2)
in the levels (a and b).

V1010562
Fig.187

84
 216 Crank shaft; connecting rod;
vibration damper; fly wheel
Crankshaft, checking

Op. no.

Tools:

Sliding calipers
Dial test indicator with magnetic base
Dial test indicator for inside measurements
Screw micrometer

Main bearings
1 Place the crankshaft in v-block or similar.

V1010561
Fig.188
2 Diagram for measuring main bearing pins at points 1 and
2 in the planes a and b.
Bearing pin diameter, undersizes and wear limit, see
Crankshaft, specifications page 11.

V1010562
Fig.189
Main bearing cups
3 Install the bearing shells in the main bearing caps, and install
the main bearing caps in the engine block.
4 Measure the main bearing diameter at points 1 and 2 in the
planes a and b.
Inside diameter and oversizes, see Crankshaft,
specifications page 11.

V1010559
Fig.190
Thrust bearing
5 Set the dial indicator to 38 mm.

85
 6 NOTE! Before reworking the crankshaft, measure the width
of the new thrust bearings. Measure the thrust bearing pin's
width. Use dial indicator for inside measurement. Measure
the width of the crankshaft's thrust bearing pins.

Bearing pin width and oversize, see Crankshaft,

specifications page 11.

V1010563
Fig.191
7 Wipe clean the bearing cap, the thrust bearing and thrust
washers. Install the thrust washers and measure the width
of the cap.
8 Determine the axial clearance. The big-end bearing pin's
width, minus the measured width of the bearing cap and
thrust washers gives the current clearance. Permitted axial
clearance, Crankshaft, specifications page 11.
V1010578
Fig.192
Big-end bearing
9 Measure the big-end bearing pins. Big-end bearing diame‐
ter, undersize and wear limit, see Crankshaft,
specifications page 11.

V1010564

Fig.193
10 Check straightness of the crankshaft. Use dial indicator.
Max. out-of-round on the middle bearing, see Crankshaft,
specifications page 11.

V1010565

Fig.194

86
 Starter ring gear, replacing

Op. no.

Tools:
1 Heat the new starter ring gear to +210 °C. If oven is used,
start work with heating the starter ring gear. If acetylene
torch is used, heat the ring gear just prior to installing.
2 Drill a 10 mm hole between two gear teeth on the old ring
gear. Drill to a depth of 9 mm.
IMPORTANT! Do not drill in the flywheel. Risk of imbalance.

Fig.195
3 Secure the flywheel in a vice with soft jaws. Crack the starter
ring gear by the drilled hole using a cold chisel.

Fig.196
4 Install the starter ring gear. Make sure that it bottoms against
the flywheel flange. If necessary use a drift.
5 Allow the starter ring gear to cool.

Fig.197

87
 22 LUBRICATING SYSTEM

221 Oil pump; line

Oil pump removed, reconditioning

Op. no.463-020

1 Drive out the crankshaft seal using a drift.

2 Clean the front cover.

V1036741

Fig.198
3 Press down the compression spring and remove the stop
washer. Remove the spring and valve peg for checking.
Also check the valve seat in the cover.

NOTE! Be careful, use protective glasses. The valve's spring

force is powerful. A high-quality spring compressor is
required.

V1036743

Fig.199
4 Remove the gear set and check that there is no abnormal
wear. Replace the oil pump if needed.
5 Install the gear set.

NOTE! The outer gear ring shall be turned with the beveled
edge facing down.
6 Install the cover for the gear set. Tightening torque, see 030,
Lubrication and oil system, tightening torques.
7 Install the valve peg and compression spring.

NOTE! Use safety glasses.

V1036742

Fig.200

88
 Press down the compression spring and install the spring's
stop washer.

NOTE! Make sure that the spring's stop washer is ade‐

quately secured. Apply a thin layer of oil before installing.

Wait with installation of the crankshaft seal until the cover is

located on the cylinder block.

89
 223 Oil cooler
Oil cooler (removed), reconditioning

Op. no.421-013

Tools:
9996662 Pressure gauge
9996685 Clamp

Plug M26x1.5 Part no. 942352

Spacer 30 mm (e.g., socket 10 mm)
1 Remove the Allen head plugs (17 mm).

V1038434

Fig.201
2 Remove the two hollow flange bolts (17 mm) that hold the
oil cooler.
3 Check all parts. If you suspect a crack, pressure-test the
cooler according to the following and replace, if needed.

V1038435

Fig.202
Changing
4 Place the oil cooler core in the oil cooler housing.

V1038436

Fig.203

90
 5 Install a new aluminum washer on the hollow flange bolts.
Use thread locking compound on the threads.
6 Tighten the flange bolts according to 030, Lubrication and
oil system, tightening torques
7 Install new O-rings on the Allen head plugs and oil them
lightly. Tighten the Allen head plug according to 030, Lubri‐
cation and oil system, tightening torques
8 Secure the oil cooler with a new gasket.

V1038438

Fig.204
Leakage check
When checking, the oil cooler core shall be as dry as possible on
the inside, since any remaining water may have a sealing effect
on possible cracks. As well, water may not leak into the cooler
core during the check.

During the test, avoid starting or stopping fan systems or letting

air in or out of the room, since this may cause the air pressure in
the room to change and this may be misinterpreted as a leak.

During the test, the oil cooler core must be at the same temper‐
ature as the surroundings. The oil cooler core may not be
repaired.
9 Install 9996685 on the oil cooler core according to fig. Make
1 2 3 sure that it seals tight.
10 Install 942352 on the other connection.

V1038430

Fig.205
1 Plug
2 9996685
3 Spacer

91
 11 Connect the pressure-test equipment.
12 Immerse the oil cooler core in a bowl of water.
13 Set the air pressure to 100 kPa (14.5 PSI) . Check if air bub‐
bles escape from the core.
14 Increase the pressure to 500 kPa (72.5 PSI).
Leave the pressure on for 1 minute.
The pressure may not drop.

NOTE! There is a leak if the pressure drops when checking.

If so, replace the oil cooler core.

1 V1038431

Fig.206 V1038431
1 9996685

92
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To From
Volvo Construction Equipment AB ....................................................................................
Customer Support Division
Dept. CEE ....................................................................................
S-631 85 Eskilstuna
Sweden ....................................................................................
e-mail: servicemanuals@volvo.com

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