Professional Documents
Culture Documents
Engine, Assembling: Service Information
Engine, Assembling: Service Information
Engine, Assembling: Service Information
Service Information
Profile:
D7E
Engine, assembling
Op nbr 210-078
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 2 of 43
Figure 1
Figure 2
3. Drive in the valve until it bottoms out, use a drift 20 mm (0.8 in).
Figure 3
4. Make sure that the cylinder liner position and sealing surface are clean.
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 3 of 43
Figure 4
1. O-rings
6. Lube the engine block and cylinder liner in the indicated area, marked with an x in the figure.
Figure 5
7. Install the cylinder liners in the engine block. Drive them down as far as possible.
Caution!
Do not use sealing compound.
Figure 6
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 4 of 43
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 Cylinderblock, specifikation
Figure 7
1. 9998678Measuring tool
2. Dial gauge
3. Adjustments
Camshaft, installing
All valve tappets should also be replaced when replacing the camshaft.
9. 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 surface. Tappets and camshaft with minor pitting damage 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.
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 5 of 43
Figure 8
1. Steel ruler
10. Lightly lubricate the valve tappets with oil and install them
Figure 9
The wider bushing, 27 mm (1.0 in), shall be installed on the flywheel side.
NOTE
The lubrication hole slightly displaced from centre.
NOTE The lubrication holes must line up with the oil channels in the bearing positions.
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 6 of 43
Figure 10
Position of bearing bushings
Figure 11
Figure 12
1. 9998695Installation tool
Figure 13
1. Guide sleeve
2. Bearing bushing
3. Press sleeve
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 7 of 43
13. 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).
Figure 14
Crankshaft, installing
14. Blow clean the holes for the piston cooling nozzles
Install the nozzles. Press them in as far as possible.
Figure 15
15. Install the bearing shells in the cylinder block and lubricate them with oil.
NOTE Make sure that the anti-rotation lug is installed correctly in the slot.
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 8 of 43
Figure 16
1. Bearing shell
16. Install the bearing shells in the bearing caps and lubricate them with oil.
NOTE Make sure that the anti-rotation lug is installed correctly in the slot.
Figure 17
17. Wipe clean the bearing cap together with thrust bearing and thrust washers with pin. Install the thrust washers
and measure the width.
Figure 18
18. Determine axial run-out. Crankshaft pin's width, see Vevaxel, kontroll
, minus the measured width of the bearing cap and thrust washers give clearance in question.
Permitted axial run-out, see Vevaxel, specifikation
.
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 9 of 43
19. 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).
Figure 19
20. 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.
Figure 20
21. 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
Figure 21
22. Lubricate the bearing caps with oil and install them according 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.
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 10 of 43
Figure 22
Caution!
The bolts should be changed after the engine is dismantled for the third time.
Figure 23
24. Install the dial indicator with magnetic base. Pry with a pry bar and check the crankshaft run-out.
Permitted axial run-out, see Vevaxel, specifikation
.
Figure 24
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 11 of 43
1. Pinch-bar
2. Magnetic base
3. Dial gauge
25. Install the bearing shells in the connecting rods and lubricate them with oil.
Figure 25
26. Use piston ring compressor and install the pistons with connecting rods from the cylinder head side. The
flywheel symbol shall face the flywheel side.
Figure 26
1. 9998687Installation tool
Figure 27
Flywheel symbol
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 12 of 43
27. 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 Vevaxel, åtdragningsmoment
Figure 28
28. Remove any gasket remnants from the timing gear casing and the cylinder block.
29. Apply sealant Volvo 11713514 on the timing gear casing's sealing face.
Figure 29
Applying sealant
31. Install the timing gear casing without tightening down the bolts. Position the casing aligned with the sealing
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 13 of 43
Figure 30
32. Tighten the bolts (except the two bolts where the rotation tool is to be secured).
Tightening torque: see Transmissionskåpa, åtdragningsmoment
.
Figure 31
1. Wear groove
34. Install the guide (inner part of 88820043Installation tool Installation tool). Lubricate the crankshaft seal with oil
and install it with the felt side facing out on the guide.
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 14 of 43
Figure 32
35. 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.
Figure 33
1. Washers
2. Press sleeve
3. Bearing
4. Nut
36. Screw the nut until stop. Check that the seal ends up in the correct position.
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 15 of 43
Figure 34
1. 9998681Rotation tool
39. Turn the engine in the adjustable stand so that the front end comes upward.
40. Clean the cover and the cylinder block from any gasket remnants.
Figure 35
Figure 36
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 16 of 43
Figure 37
45. Install the housing with the oil pump without tightening down the bolts. Fit the housing against the oil sump's
sealing face.
Figure 38
Figure 39
1. Wear groove
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 17 of 43
48. Install the guide (inner part of 11668406Installation tool). Lubricate the crankshaft seal with oil and install it
with the felt side facing out.
Figure 40
49. 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.
Figure 41
1. Washers
2. Press sleeve
3. Bearing
4. Nut
50. Screw the nut until stop. Check that the seal ends up in the correct position.
51. Install the ring gear and the V-belt pulley and align the guide sleeve and the guide pin.
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 18 of 43
Figure 42
1. Guide sleeve
2. Guide pin
52. Tighten the bolts (Torx E20), counterhold with the rotation tool on the flywheel side.
Tightening torque: see Remskiva/svängningsdämpare, åtdragningsmoment
.
Figure 43
1. Torx E20
2. V-belt pulley
3. Toothed wheel
53. 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.
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 19 of 43
Figure 44
1. Spacer
2. Vibration damper
54. Install outer vibration damper and the washer. Tighten down the bolts.
Tightening torque: see Remskiva/svängningsdämpare, åtdragningsmoment
.
Figure 45
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 20 of 43
Figure 46
Ladder frame
56. Install a new gasket on the oil suction pipe's connection to the front cover.
Figure 47
1. Gasket
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 21 of 43
58. Fill the joints between the covers and the oil sump with sealant.
Figure 48
59. Apply a thin layer of sealant Volvo 11713514 on the engine block.
Figure 49
62. Install the power take-off housing. Apply locking fluid and tighten down the bolts (sockets Torx E10 and E12).
Figure 50
1. Attaching bolts
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 22 of 43
2. Oil pipe
Flywheel, installing
64. Rotate the engine in the work stand so that the flywheel side faces up.
65. Lift the flywheel housing into place. Weight: approx 35 kg (77 lbs).
Figure 51
66. Install the bolts and tighten them. Use the rotation tool as counterhold.
Figure 52
1. 9998681Rotation tool
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 23 of 43
Figure 53
Figure 54
1. Guide sleeve
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 24 of 43
Figure 55
70. Remove protective plugs and masking tape. Install the oil cooler with a new gasket. Install the bolts and
tighten them.
Tightening torque: see Oljekylare, åtdragningsmoment
.
Figure 56
Cylinder head gaskets are marked with one, two, or three holes in one of the corners. The gaskets shall be
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 25 of 43
used for different piston heights above the cylinder block's face.
Figure 57
NOTE Place the spacer washers on the block, not on the liner edge.
Figure 58
1. 9998678Measuring tool
2. Dial gauge
3. Spacer washers
74. 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.
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 26 of 43
Figure 59
Measuring points
75. Repeat the same measurement on all pistons. Note the highest value and use cylinder head gasket according
to Cylinderhuvud, specifikation
.
Figure 60
76. Place the cylinder head gasket on the cylinder block with the digits upward. Place the guide sleeves in the
holes.
Figure 61
1. Guide sleeves
77. Lift the cylinder head into position. Pay attention to the guide sleeves.
Cylinder head weight: approx. 65 kg (143 lbs)
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 27 of 43
Figure 62
78. Oil the bolts lightly and install them. Tighten them in three steps, note the sequence.
Figure 63
Torque-tightening, sequence
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 28 of 43
Figure 64
Push rods
80. Install the rocker arm holders according to marking. Line them up with the push rods and valves, and tighten
the bolts.
Tightening torque: see Ventilmekanism, åtdragningsmoment
.
Figure 65
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 29 of 43
Valve adjustment
Pumps, installing
Figure 66
1. Guide
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 30 of 43
Figure 67
84. Install the fuel control valve. Install the bolts but do not tighten at this time.
Tighten the nuts for the fuel pipes and the bolts for the pumps.
Tightening torque: see Bränslesystem, åtdragningsmoment
.
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 31 of 43
Figure 68
1. Exhaust pipe
87. Install the charge-air pipe with new gaskets and tighten the bolts.
Tightening torque: see Laddluftrör, åtdragningsmoment
.
Figure 69
The protective moulding's profile is not symmetrical. The protective moulding shall be installed
NOTE
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 Cylinderhuvud, åtdragningsmoment
.
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 32 of 43
Figure 70
1. Protective moulding
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 33 of 43
Figure 71
1. Oil trap
Figure 72
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 34 of 43
Figure 73
Figure 74
1. 1 Coolant pump
2. Intermediate housing
3. Thermostat housing
94. Tighten all bolts for the coolant pump and the thermostat housing.
Tightening torque: see Kylvätsketermostathus, åtdragningsmoment
.
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 35 of 43
Figure 75
Checking clearance
96. Install the fuel pump with lines and filter bracket. Tighten the bolts loosely.
Install a new filter.
Figure 76
1. Fuel filter
2. Fuel feed pump
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 36 of 43
Belts, installing
97. Install the V-belt on the belt pulleys. Tension the belt by moving the fuel pump. At correct tension it should be
possible 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 Remskiva/svängningsdämpare, åtdragningsmoment
.
Tighten the bolts for the filter housing.
Tightening torque: see Bränslesystem, åtdragningsmoment
Figure 77
Loader and motor grader version
1. Belt adjustment
2. Fuel feed pump's bracket
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 37 of 43
3. Water pump
98. 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. 10 mm (0.4 in) in the middle between the
belt pulleys.
Figure 78
Excavator version
1. Water pump
2. Flat belt
3. Belt tensioner
4. V-rib belt
5. AC Compressor
6. Alternator
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 38 of 43
Figure 79
1. Injectors
2. Retainer
100. Install the fuel rail and tighten the bolts loosely.
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 39 of 43
Figure 80
1. Fuel rail
101. Install new fuel pipes between injectors and the fuel rail.
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 40 of 43
Figure 81
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 41 of 43
Figure 82
105. Remove the rotation tool and reinstall the cover. Use a new O-ring.
Tightening torque: see Transmissionskåpa, åtdragningsmoment
.
Figure 83
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 42 of 43
1. Cover
Starter motor
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.
Figure 84
1. Connector E-ECU
2. Fuel control valve
3. Injectors
4. Fuel feed pressure sensor
5. Oil pressure sensor
6. Fuel pressure sensor
108. Plug in the connectors for coolant temperature sensor, boost pressure sensor, solenoid valve for I-EGR, and
the rpm sensor.
Clamp the cable harness.
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008
Prosis - Print Page 43 of 43
Figure 85
http://localhost/Prosis/Pages/Print.aspx?PrintType=4&ObjectID=245891&infotype=1,2,5... 11/18/2008