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Service Information
Document Title: Function Group: Information Type: Date:
Engine, assembling 210 Service information 18/11/2008
Profile:
D7E
Engine, assembling
Op nbr 210-078
885812 Timing tool
9992000 Handle
9992682 Sealing plug
9998678 Measuring tool
9998681 Rotation tool
9998687 Installation tool
9998695 Installation tool
11668406 Installation tool
88820043 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
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Valve spring compressor
11713514 Sealing compound
Pressure control valve, installing
1. 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.
Figure 1
2. Install the valve.
Figure 2
3. Drive in the valve until it bottoms out, use a drift 20 mm (0.8 in).
Figure 3
Cylinder liner, installing
4. Make sure that the cylinder liner position and sealing surface are clean.
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5. Install new O-rings.
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
8. 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.
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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
Replace camshaft if there is major damage or wear. See Kamaxel, specifikation
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.
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Figure 8
1. Steel ruler
10. Lightly lubricate the valve tappets with oil and install them
Figure 9
11. Change the bearing bushings if they are worn.
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.
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Figure 10
Position of bearing bushings
Figure 11
1. Lubricating oil holes
12. Press in the bushings to correct position.
Figure 12
1. 9998695Installation tool
Figure 13
1. Guide sleeve
2. Bearing bushing
3. Press sleeve
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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).
NOTE Take care not to damage the bearing bushings.
Check that the camshaft can rotate freely.
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.
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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
.
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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
1. Marking (Camshaft marking may be hidden)
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.
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Figure 22
23. Torque-tighten the bearing caps
Tightening torques, see Vevaxel, åtdragningsmoment
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
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1. Pinch-bar
2. Magnetic base
3. Dial gauge
Pistons and connecting rods, installing
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
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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
Timing gear casing, installing
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
30. Lightly oil the crankshaft oil seal.
31. Install the timing gear casing without tightening down the bolts. Position the casing aligned with the sealing
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surface on the oil sump.
Figure 30
32. Tighten the bolts (except the two bolts where the rotation tool is to be secured).
Tightening torque: see Transmissionskåpa, åtdragningsmoment
.
Rear crankshaft seal
33. Check the position of the wear groove on the crankshaft.
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.
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Figure 32
1. Crankshaft oil seal
2. Guide, 88820043Installation tool
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.
37. Check that the crankshaft can rotate freely.
Front cover with oil pump, installing
38. Install the rotation tool.
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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.
41. Overhaul the oil pump according to Främre kåpa, oljepump
.
42. Lightly oil the oil pump rotors.
Figure 35
43. Secure the gasket on the housing with a little grease.
Figure 36
44. Place the oil pump's drive against the crankshaft.
NOTE The drive only fits in one position.
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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
46. Tighten the bolts.
Tightening torque: see Oljepump, åtdragningsmoment
.
47. Check the position of the wear groove on the crankshaft.
Figure 39
1. Wear groove
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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
1. Crankshaft oil seal
2. Guide
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.
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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.
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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
55. Install the ladder frame.
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Figure 46
Ladder frame
NOTE Allen head bolts are placed in the corners.
Tighten the bolts.
Tightening torque: see Oljetråg, åtdragningsmoment
.
56. Install a new gasket on the oil suction pipe's connection to the front cover.
Figure 47
1. Gasket
Install the oil suction pipe with bracket.
Tightening torque: see Oljetråg, åtdragningsmoment
.
57. Install the oil filler pipe.
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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.
60. 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 Oljetråg, åtdragningsmoment
.
Figure 49
61. Install the level sensor's clamps.
Power take-off housing, installing
62. Install the power take-off housing. Apply locking fluid and tighten down the bolts (sockets Torx E10 and E12).
63. Install the oil pipe.
Figure 50
1. Attaching bolts
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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
1. Lifting eyes M10
66. Install the bolts and tighten them. Use the rotation tool as counterhold.
NOTE Use new bolts.
Tightening torque: see Svänghjul, åtdragningsmoment
Figure 52
1. 9998681Rotation tool
67. Install the cover washer.
NOTE NOTE! Some versions do not have this washer.
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Figure 53
68. Check that the guide sleeves are in place.
Figure 54
1. Guide sleeve
69. 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 Svänghjul, åtdragningsmoment
.
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Figure 55
Oil cooler and oil filter, installing
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
71. Install a new oil filter.
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
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used for different piston heights above the cylinder block's face.
Figure 57
1. Marking of cylinder head gasket
Pistons' height above engine block
72. Install the rotation tool on the engine, 9998681Rotation tool.
73. First, clean the measuring surface thoroughly.
Install the measuring tool with spacer washers and dial indicator on the engine block. Reset the dial indicator
to zero.
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.
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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
Cylinder head, installing
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)
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Figure 62
78. 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: Cylinderhuvud, åtdragningsmoment
.
Use protractor 885812Timing tool
Figure 63
Torque-tightening, sequence
79. Install the push rods.
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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
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Valve adjustment
81. Adjust the valve clearance, see Ventiler, justering
.
Pumps, installing
82. Install the roller lifters
Make sure that the guide on the lifter ends up in the groove in the engine block.
Figure 66
1. Guide
83. Install new O-rings on the pumps.
Install the pumps. Install the bolts but do not tighten at this time.
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Figure 67
1. Fuel return pipe
2. High-pressure pumps
3. Fuel control valve
84. Install the fuel control valve. Install the bolts but do not tighten at this time.
85. 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 Bränslesystem, åtdragningsmoment
.
Exhaust pipe, inlet manifold, and valve cover, installing
86. 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
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engine and working outward.
Tightening torque: see Avgasgrenrör, åtdragningsmoment
.
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
1. Charge air pipe
88. Install the protective moulding on the valve cover.
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
.
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Figure 70
1. Protective moulding
89. Install the preheating coil.
Tightening torque: see Laddluftrör, åtdragningsmoment
.
Oil trap, installing
90. 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 Oljefälla, åtdragningsmoment
.
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Figure 71
1. Oil trap
Coolant pump and thermostat housing, installing
91. Check that the coolant pump has no noticeable play.
Remove the protective tape. Install the coolant pump with new gasket. Tighten the bolts loosely.
Figure 72
92. Lubricate the O-rings and install the intermediate housing.
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Figure 73
93. Install the thermostat housing, use new gasket.
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
.
Crankshaft sensor, installing
95. 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
.
Lightly press the sensor against the feeler gauge. Tighten the bolts.
Tightening torque: see Speed sensor, tightening torque
Check the clearance.
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Figure 75
Checking clearance
Fuel pump, installing
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
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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
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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
Injectors and fuel lines, installing
99. Install new O-rings and seal rings on the injectors.
Install the injectors together with the holder. Torque-tighten the bolts.
Tightening torque Insprutare, åtdragningsmoment
.
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Figure 79
1. Injectors
2. Retainer
100. Install the fuel rail and tighten the bolts loosely.
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Figure 80
1. Fuel rail
101. Install new fuel pipes between injectors and the fuel rail.
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Figure 81
1. Fuel delivery line
102. Torque-tighten the bolts for the fuel rail.
Tightening torque: see Bränslesystem, åtdragningsmoment
.
103. Torque-tighten the fuel pressure pipes
Tightening torque: see Bränslesystem, åtdragningsmoment
.
104. Install the return fuel line.
Tightening torque: see Bränslesystem, åtdragningsmoment
.
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Figure 82
1. Fuel return pipe
2. High-pressure pumps
3. Fuel control valve
105. Remove the rotation tool and reinstall the cover. Use a new O-ring.
Tightening torque: see Transmissionskåpa, åtdragningsmoment
.
Figure 83
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1. Cover
Starter motor
106. Install the starter motor.
Tightening torque, see Åtdragningsmoment motorkropp
.
Cable rail with cable harness, installing
107. Install the cable harness.
Install the electrical connections for the injectors. Tightening torque, see Bränslesystem, åtdragningsmoment
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.
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Figure 85
1. Boost pressure sensor
2. Coolant temperature sensor
3. Solenoid valve I-EGR
4. Revolution sensor camshaft
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