Service Information Document Title: Engine, assembling
Function Group: 210
Information Type: Service Information
Date: 11/12/2017
Profile: D7E
Engine, assembling Showing Selected Profile Valid for serial numbers Model
Production site
Serial number start
D7E Op nbr nbr 210210-078 078 Total procedure time (hr): 9.50 Tools: 885812 88581 2 Timing tool 9992000 99920 00 Handl Handle e 9992682 99926 82 Sealin Sealing g plug 9998672 99986 72 Insta Installation llation tool 9998678 99986 78 Meas Measuring uring tool 9998681 99986 81 Rotat Rotation ion tool 88800316 88800 316 Piston ring compressor compressor 9998695 99986 95 Insta Installation llation tool 11668406 11668 406 Instal Installation lation 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
Serial number stop
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. Tap out out the the crankshaft crankshaft seal with with a drift.
Figure Figure 1
2. Lube the the new cranksh crankshaft aft seal seal with oil and and install install it.
Figure Figure 2
1. 2.
9992000 Handle 9998672 Installation tool
Pressure control valve, installing 3. Clean the seat seat for the the pressure pressure control control valve. valve. Check that the valve peg can be pushed in. Apply locking fluid on the valve's sealing surface.
Figure Figure 3
4. Inst Install all the the val valve ve..
Figure Figure 4
5. Drive in the valve until until it bottoms bottoms out, use use a drift 20 mm (0.8 in). in).
Figure Figure 5
Cylinder liner, installing
6. Make sure that the cylinder liner position and sealing surface are clean. 7. Install new O-rings.
Figure 6
1.
O-rings
8. Lube the engine block and cylinder liner in the indicated area, marked with an x in the figure.
Figure 7
9. Install the cylinder liners in the engine block. Drive them down as far as possible.
NOTICE Do not use sealing compound.
Figure 8
10. Measure the cylinder liner's protrusion over the sealing face. 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 Cylinder block, specifications
Figure 9
1. 2. 3.
9998678 Measuring tool Dial indicator Adjustments
Replace camshaft if there is major damage or wear. See Camshaft, specifications All valve tappets should also be replaced when replacing the camshaft.
Camshaft, installing 11. 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 surface against the camshaft on the valve tappets is convex or flat. If the surface is concave, replace the valve tappets. 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.
Figure 10
1.
Steel ruler
12. Lightly lubricate the valve tappets with oil and install them
Figure 11
13. 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 channels in the bearing positions.
Figure 12 Position of bearing bushings
Figure 13
1.
Lubricating oil holes 14. Press in the bushings to correct position.
Figure 14
1.
9998695 Installation tool
Figure 15
1. 2. 3.
Guide sleeve Bearing bushing Press sleeve 15. 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 16
Crankshaft, installing 16. Install the piston cooling nozzles. Press them in as far as possible.
Figure 17
17. 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.
Figure 18
1.
Bearing shell
18. 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 19
19. Wipe clean the bearing cap together with thrust bearing and thrust washers with pin. Install the thrust washers and measure the width.
Figure 20
20. Determine axial run-out. Crankshaft pin's width, see Crankshaft, checking, minus the measured width of the bearing cap and thrust washers give clearance in question. Permitted axial run-out, see Crankshaft, specifications. 21. 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 21
1.
Marking (Camshaft marking may be hidden)
22. 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 22
23. 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 23
24. 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.
Figure 24
25. Torque-tighten the bearing caps Tightening torques, see Crankshaft, tightening torques
NOTICE The bolts should be changed after the engine is dismantled for the third time.
Figure 25
26. 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.
Figure 26
1. 2. 3.
Pinch-bar Magnetic base Dial indicator
Pistons and connecting rods, installing 27. Install the bearing shells in the connecting rods and lubricate them with oil.
Figure 27
28. 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 28
1.
88800316 Piston ring compressor
Figure 29 Flywheel symbol
29. 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
Figure 30
Timing gear casing, installing 30. Remove any gasket remnants from the timing gear casing and the cylinder block. 31. Use sealant Volvo 11713514 on the timing gear casing's sealing face.
Figure 31 Sealing face 32. Lightly oil the crankshaft oil seal. 33. Install the timing gear casing without tightening down the bolts. Position the casing aligned with the sealing surface on the oil sump.
Figure 32
34. Tighten the bolts (except the two bolts where the rotation tool is to be secured). Tightening torque: see Timing gear casing, tightening torques . 35. Check that the crankshaft can rotate freely.
Front cover with oil pump, installing 36. Install the rotation tool.
Figure 33
1.
9998681 Rotation tool
37. Turn the engine in the adjustable stand so that the front end comes upward. 38. Clean the cover and the cylinder block from any gasket remnants. 39. Overhaul the oil pump according to Oil pump removed, reconditioning. 40. Lightly oil the oil pump rotors.
Figure 34
41. Secure the gasket on the housing with a little grease.
Figure 35
42. Place the oil pump's drive against the crankshaft. NOTE! The drive only fits in one position.
Figure 36
43. Install the housing with the oil pump without tightening down the bolts. Fit the housing against the oil sump's sealing face.
Figure 37
44. Tighten the bolts. Tightening torque: see Oil pump, tightening torques . 45. Check the position of the wear groove on the crankshaft.
Figure 38
1.
Wear groove
46. Install the guide (inner part of 11668406 Installation tool). Lubricate the crankshaft seal with oil and install it with the felt side facing out.
Figure 39
1. 2.
Crankshaft oil seal Guide
47. 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 40
1. 2. 3. 4.
Washers Press sleeve Bearing Nut
48. Screw the nut until stop. Check that the seal ends up in the correct position. 49. Install the ring gear and the V-belt pulley and align the guide sleeve and the guide pin.
Figure 41
1. 2.
Guide sleeve Guide pin
50. Tighten the bolts (Torx E20), counterhold with the rotation tool on the flywheel side. Tightening torque: see Belt pulley/vibration damper, tightening torques .
Figure 42
1. 2. 3.
Torx E20 V-belt pulley Toothed wheel
51. Check that the oscillation dampers are free from external damage. Install inner vibration damper and the spacer. Make sure that the bolt holes align with the holes in the belt pulley.
Figure 43
1. 2.
Spacer Vibration damper
52. Install outer vibration damper and the washer. Tighten down the bolts. Tightening torque: see Belt pulley/vibration damper, tightening torques .
Figure 44
53. Install the ladder frame.
Figure 45 Ladder frame NOTE! Allen head bolts are placed in the corners. Tighten the bolts. Tightening torque: see Oil sump, tightening torque. 54. Install a new gasket on the oil suction pipe's connection to the front cover.
Figure 46
1.
Gasket
Install the oil suction pipe with bracket. Tightening torque: see Oil sump, tightening torque.
55. Install the oil filler pipe.
Figure 47
1. 2. 3.
Oil suction pipe Mounting Oil filler pipe
56. Fill the joints between the covers and the oil sump with sealant.
Figure 48
57. Use sealant Volvo 11713514 on the engine block.
58. Install the oil sump and tighten down the bolts. Tightening torque: see Oil sump, tightening torque.
Figure 49
59. Install the level sensor's clamps.
Power take-off housing, installing 60. Install the power take-off housing. Apply locking fluid and tighten down the bolts (sockets Torx E10 and E12). 61. Install the oil pipe.
Figure 50
1. 2.
Attaching bolts Oil pipe
Flywheel, installing 62. Rotate the engine in the work stand so that the flywheel side faces up. 63. Check that the guide sleeves are in place.
Figure 51
1.
Guide sleeve
64. 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, seese Flywheel, tightening torques .
Figure 52
65. Lift the flywheel housing into place.Weight: approx 35 kg (77 lbs).
Figure 53
1.
Lifting eyes M10
66. Install the bolts and tighten them. Use the rotation tool as counterhold. NOTE! Use new bolts. Tightening torque:see Flywheel, tightening torques
Figure 54
1.
9998681 Rotation tool
67. Install the cover washer.
Figure 55
Oil cooler and oil filter, installing 68. 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.
Figure 56
69. Install a new oil filter. Cylinder head gaskets are marked with one, two, or three holes in one of the corners. The gaskets shall be used for different piston heights above the cylinder block's face.
Figure 57
1.
Marking of cylinder head gasket
Determining thickness of cylinder head gasket Pistons' height above engine block 70. Install the rotation tool on the engine, 9998681 Rotation tool. 71. 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. 2. 3.
9998678 Measuring tool Dial indicator Spacer washers
72. 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.
Figure 59 Measuring points 73. Repeat the same measurement on all pistons. Note the highest value and use cylinder head gasket according to Cylinder head, specifications.
Figure 60
Cylinder head, installing 74. 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
75. Lift the cylinder head into position. Pay attention to the guide sleeves. Cylinder head weight: approx. 65 kg (143 lbs)
Figure 62
76. 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. Use protractor 885812 Timing tool
Figure 63 Torque-tightening, sequence 77. Install the push rods.
Figure 64 Push rods 78. 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.
Figure 65
Valve adjustment 79. Adjust the valve clearance, see Valves, adjusting.
Pumps, installing 80. Install the roller tappets. Make sure that the correct tappet is installed in the correct place according to markings on the unit pumps. Make sure that the guide on the tappet ends up in the groove in the material.
Figure 66
1.
Guide
81. Install new O-rings on the pumps. Install the pumps. Install the bolts but do not tighten at this time.
Figure 67
1. 2. 3.
Fuel return pipe High-pressure pumps Fuel control valve
82. Install the fuel control valve. Install the bolts but do not tighten at this time. 83. 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.
Exhaust pipe, inlet manifold, and valve cover, installing 84. Install the exhaust pipe with new gaskets. The gasket flange shall point to the cylinder head. 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 .
Figure 68
1.
Exhaust pipe
85. Install the charge-air pipe with new gaskets and tighten the bolts. Tightening torque: see Charge-air pipe, tightening torque .
Figure 69
1.
Charge air pipe
86. 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.
Figure 70
87. Install the preheating coil. Tightening torque: see Charge-air pipe, tightening torque.
Oil trap, installing 88. 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.
Figure 71
1.
Oil trap
Coolant pump and thermostat housing, installing 89. 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
90. Lubricate the O-rings and install the intermediate housing.
Figure 73
91. Install the thermostat housing, use new gasket.
Figure 74
92. Tighten all bolts for the coolant pump and the thermostat housing. Tightening torque: see Coolant thermostat housing, tightening torques .
Crankshaft sensor, installing 93. 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.
Figure 75 Checking clearance
Fuel pump, installing 94. Install the fuel pump with lines and filter. Tighten the bolts loosely.
Figure 76
1. 2.
Fuel filter Fuel feed pump
95. 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 Belt pulley/vibration damper, tightening torques . Tighten the bolts for the filter housing. Tightening torque: see Fuel system, tightening torques
Figure 77
1. 2. 3.
Belt adjustment Fuel feed pump's bracket Water pump
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.
Figure 78
1. 2.
Injectors Retainer
97. Install the fuel rail and tighten the bolts loosely.
Figure 79
1.
Fuel rail
98. Install new fuel pipes between injectors and the fuel rail.
Figure 80
1.
Fuel del ivery line
99. Torque-tighten the bolts for the fuel rail. Tightening torque: see Fuel system, tightening torques. 100. Torque-tighten the fuel pressure pipes
Tightening torque: see Fuel system, tightening torques. 101. Install the return fuel line. Tightening torque: see Fuel system, tightening torques.
Figure 81
1. 2. 3.
Fuel return pipe High-pressure pumps 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.
Figure 82
1.
Cover
Starter motor 103. Install the starter motor. Tightening torque, see Engine, tighten torques.
