\Pistons and Liners Replace

Volvo Trucks North America
Greensboro, NC USA
D
Service Bulletin
Trucks
Date
Group
No.
Page
4.2007
213
43
1(11)
Pistons and Liners, Replace
D13F
Pistons and Liners, Replace
T2022501
Contents
•
“Cylinder Liners and Pistons, Replacement (All)” page 2
Note: Information is subject to change without notice.
Illustrations are used for reference only and may differ slightly from the actual
vehicle being serviced. However, key components addressed in this information are
represented as accurately as possible.
PV776-20179775
USA25631.ihval
Volvo Trucks North America
Service Bulletin
D
Date
Group
No.
Page
4.2007
213
43
2(11)
2131-03-03-01
Cylinder Liners and Pistons, Replacement (All)
Cylinder heads and oil pan removed
You must read and understand the precautions and
guidelines in Service Information, group 20, "General
Safety Practices, Engine" before performing this
procedure. If you are not properly trained and certified
in this procedure, ask your supervisor for training
before you perform it.
The cylinder liner O-rings are made of fluorocarbon rubber.
When fluorine-rubber is exposed to high temperatures (above 300 C/
572 F) hydrofluoric acid can be generated. Hydrofluoric acid is extremely
corrosive!
•
•
•
Contact with skin can result in serious corrosion injuries.
Splash in the eyes can result in corrosion sores.
Inhalation of vapors can damage the respiratory tract.
WARNING
Take great care when working on engines which can have been exposed to high
temperatures, resulting for example from overheating, cutting or fire.
Under no circumstances are cylinder liner O-rings to be burnt off when dismantling
or destroyed by burning under uncontrolled conditions.
•
•
•
•
•
Always use neoprene gloves (gloves approved for handling chemicals) and
protective goggles.
Handle removed O-rings in the same way as corrosive acids.
Never blow clean using compressed air.
All remnants, including ashes, can be highly corrosive.
Place all remnants in plastic containers, to which warning text is attached.
Before taking the gloves off, they must be washed under running water.
Special tools: 9989876, 9990158, 9996394,
9996395, 9996599, 9996606, 9996645,
85109123, PT-6400-C, 9998511, 9992479,
8880014
Remove
1
Remove the pipe and strainer from the reinforcing frame.
Remove the pressure pipe from the pump.
Remove the reinforcement frame.
Volvo Trucks North America
Service Bulletin
D
Date
Group
No.
Page
4.2007
213
43
3(11)
2
Remove the plug from the flywheel housing and install tool
88800014. Turn the crankshaft until it is possible to get at
the screws on the connecting rod which is to be removed.
88800014
T2022378
3
Remove the piston cooling jet.
T2022286
4
Remove main bearing cap and bearing shells.
5
Remove the piston with the connecting rod.
T2022287
D
Volvo Trucks North America
Service Bulletin
Date
Group
No.
Page
4.2007
213
43
4(11)
6
Pull the cylinder liner out of the block.
PT-6400-C
W2005255
7
Remove the cylinder liner’s sealing rings.
T2019854
Volvo Trucks North America
Service Bulletin
D
Date
Group
No.
Page
4.2007
213
43
5(11)
8
Remove the snap ring from the piston and push out the
piston pin. Remove the piston from the connecting rod.
T2022501
9
Clean the sealing surfaces on the cylinder block and the
groove for the sealing rings. Do not use scrapers or other
tools which can damage the sealing surfaces.
D
Volvo Trucks North America
Service Bulletin
Date
Group
No.
Page
4.2007
213
43
6(11)
Installation
10
Check the cylinder block’s liner seat for damage. If it
is necessary to mill the liner shelf, see service bulletin
“Cylinder liner seat, milling (first)”1.
Install the cylinder liner, without the sealing ring. Fix the
cylinder liner with two clamping tools.
85109123
11
Mount dial gauge 9989876 in dial indicator holder
9992479. Place the holder with the dial gauge across
the cylinder liner.
Zero the dial gauge with a couple of millimeters’ preload
against the cylinder block’s surface.
9989876, 9992479
T2019670
1
IMPACT: Group 2139
D
Volvo Trucks North America
Service Bulletin
Date
Group
No.
Page
4.2007
213
43
7(11)
12
Measure the height between the cylinder liner and the
cylinder block surface.
Measure the liner’s height at two different diagonally
opposite positions.
Calculate the average of both the measurements.
For correct liner height above the block surface see
specifications, group 20.
If the height of the liner above the surface of the
block is outside the specified tolerance, the liner seat
on the cylinder block should be milled “Cylinder liner
seat, milling (first)”2.
Note: Always measure at the highest point on the
sealing surface.
Mark the liner’s position on the cylinder block with
a felt tip pen, so that it will be put back in the same
position on assembly.
Repeat the procedure for the remaining cylinder liners.
T2019761
13
Remove the press tool.
Pull the cylinder liner out of the block.
Place cylinder liners in the same sequence that they are
installed, together with their adjustment spacers.
PT-6400-C
W2005255
2
IMPACT: Group 2139
D
Volvo Trucks North America
Service Bulletin
Date
Group
No.
Page
4.2007
213
43
8(11)
14
Install the liner sealing rings to the engine block.
Note: The purple sealing ring is installed furthest down.
T2019854
15
If the liner is installed with a shim, a bead of sealing
compound should be put on the engine block liner seat.
Note: No sealant is to be used between the adjustment
spacer and the cylinder liner’s collar.
Note: Once the sealing compound has been applied, the
liner must be installed within 20 minutes.
If the cylinder head cannot be installed and torque
tightened within 20 minutes, the liner must be fixed in the
engine block with two press tools.
85109123
T2009013
16
Install one of the cylinder head bolts (A). Position
press tool (D) above the cylinder liner together with a
suitable spacer (C) and press the cylinder liner down
using lever (B).
9996599, 9996963, 9998511
T2019950
Volvo Trucks North America
Service Bulletin
D
Date
Group
No.
Page
4.2007
213
43
9(11)
17
Lubricate the piston pin and the piston bushing with
engine oil.
T2022502
18
Install the connecting rod in the piston with the marking
“FRONT” on the connecting rod and the arrow on the
piston facing the same direction.
Push the piston pin in.
Note: The piston pin should go in when pushed without
any great force. If the resistance is too great, the piston
needs to be heated.
The connecting rod should rotate freely on the piston pin.
Install the snap ring.
T2022504
19
Using piston ring pliers, install the piston rings.
Regarding the oil ring, the gap in the spring should be
situated diametrically opposite the ring gap.
Note: All the piston rings (even the oil scraper) are
marked with letters or punch marks. These marks
should face upwards.
20
Lubricate the piston and the piston rings with engine oil.
Check that the piston rings gaps are radically displaced.
The piston ring gaps should be situated with the equal
spacing in relation to one another 60 .
D
Volvo Trucks North America
Service Bulletin
Date
Group
No.
4.2007
213
43
Page
10(11)
21
Use a piston ring compressor, insert the piston with its
connecting rod.
Temporarily remove the press tool when the piston is
installed. Reinstall the press tools when the piston is
in position.
9998531, 85109123
W2006211
22
Lubricate the crankshaft bearing shells and crankshaft
pin with engine oil. Install the connecting rod caps. Check
that they sit correctly in the connecting rod and caps.
Install the connecting rod cap according to the markings
and torque tighten according to specifications, see
group 20.
23
Clean the piston cooling jet and check that it is not
damaged Install the piston cooling jet with new bolts
and O-ring.
Note: Use only new bolts, pre-treated with locking
material.
Torque tighten as specified in “Specifications”, see
group 20.
T2022286
24
Remove cranking tool 88800014 and replace the plug.
88800014
Volvo Trucks North America
Service Bulletin
D
Date
Group
No.
4.2007
213
43
Page
11(11)
25
Install the reinforcement frame and torque tighten
according to Specifications, Group 20.
Install the pressure pipe on the pump and tighten
according to Specifications, Group 20.
Install the pipe and strainer on the reinforcement frame.
Secure the bolts with thread lock and torque tighten
according to Specifications, Group 20.