NHTSA ID Number: 10126603
Manufacturer Communication Number: FSB 237-60
TSB/Document Date: 2017-12-22
Summary
Unit Injector and Sleeve, Replacement (Conical)
Service Bulletin
Trucks
Volvo
Trucks North
America
Greensboro, NC USA
Date
Group
No.
Release
Page
3.2013
237
60
01
1(28)
Unit Injector and Sleeve, Replacement
(Conical)
D11, D13, D16
Unit Injector and Sleeve, Replacement (Conical)
CAUTION
This bulletin describes important tools and procedure for injector and injector sleeve
replacement. These tools and procedure replace all existing tools and procedures for
conical sleeve replacement. If the procedure in this bulletin is not followed exactly, damage
to the engine may result.
Failure to follow the procedure in this bulletin exactly may result in warranty claim denial.
Contents
•
•
“Sleeve Identification”, page 2
“Conical Unit Injector and Sleeve Replacement”, page 4
Note: Information is subject to change without notice.
Illustrations are used for reference only, and may differ slightly from the actual engine
version. However, key components addressed in this information are represented as
accurately as possible.
USA53202
PV776-89055236
English
Volvo Trucks North America
Service Bulletin
Date
3.2013
Group
No.
Release
237
60
01
Page
2(28)
Service Procedures
2379-03-02-01
Unit Injector and Sleeve, Replacement (Conical)
You must read and understand the precautions and guidelines in Service Information, Function Group 20, “Engine
Safety Practices” before performing this procedure. If you
are not properly trained and certified in this procedure, ask
your supervisor for training before you perform it.
Special tools: 9990006, 9990013, 9990649,
9998252, 9998253, 85112740, 88800014,
88800283, 88800285, 88800288, 88800289,
88880010, 88880056, J42885, PT2900,
DBT2V700
Sleeve Identification
Note: There are two types of injector sleeves used in Volvo engines, conical and flat copper. The conical sleeves
are made of stainless steel. A washer is used with the flat
copper sleeves. You must determine which type of
sleeve is in the engine to know the proper tools to use
for the replacement procedure.
W2056876
A. Flat Injector
B. Conical Injector
Volvo Trucks North America
Service Bulletin
Date
3.2013
Group
No.
Release
237
60
01
Page
3(28)
CAUTION
Conical and copper sleeves should not be mixed in the
same engine. The same type of sleeve must be used in all
six cylinders. Mixing sleeves can result in damage to the
engine.
W204
Note: Whenever a new conical injector is installed, a new injector sleeve must also be installed.
Volvo Trucks North America
Service Bulletin
Date
3.2013
Group
No.
Release
237
60
01
Page
4(28)
Conical Unit Injector and Sleeve Replacement
1
Apply the parking brake and place the shift lever in neutral.
2
Disconnect all cables from the negative (ground) battery terminals to prevent personal injury from electrical shock and
prevent damage to electrical components.
W2003815
3
Drain the coolant from the radiator and engine using the coolant extractor.
Note: An alternate method is to connect the drain hose to the
drain fitting and drain the coolant.
DBT2V700, 9990649 , 85112740
4
Clean around the fuel supply line fitting on the filter housing.
Loosen the fuel line at the filter housing to allow fuel to drain
from the cylinder head. Allow the fuel to drain into a suitable
container.
5
Remove the valve cover from the engine. Refer to Group 211
for service procedure.
Note: Rotate the valve cover as needed, to clear the camshaft gear and damper.
Note: Dependent upon chassis, engine cover may need to
be removed for clearance to remove valve cover.
6
Remove the rocker arm shaft. Refer to Function Group 214
for service procedures.
CAUTION
The order of the rocker arm assembly must be maintained.
Make certain the sets of four are kept together. Make certain the rocker arms are identified so they can be returned
to their original positions on the shaft. Failure to heed this
caution may result in severe engine damage.
Volvo Trucks North America
Service Bulletin
Date
3.2013
Group
No.
Release
237
60
01
Page
5(28)
7
Make sure the alignment sleeves remain in position on each
bearing cap.
W2005514
1 Camshaft Bearing Cap
2 Camshaft
3 Alignment Sleeve
8
Mark the valve bridges so they can be installed in the same
location during reassembly. Remove the valve bridges.
Note: Mark the location of the injectors for reinstallation. Injectors must be installed in the same cylinder as they were
removed.
9
Thoroughly clean around the injectors that are to be removed. Remove the injector hold down bolt.
Volvo Trucks North America
Service Bulletin
Date
3.2013
Group
No.
Release
237
60
01
Page
6(28)
10
CAUTION
Do not use excessive force on the injector with the slide
hammer. If the injector is stuck in the sleeve, the puller can
be damaged by the slide hammer.
Install the puller onto the injector. Position the puller fork in
the groove on the injector and lock the arm using the thumb
screw on the side. Secure the puller by screwing down the
screw toward the inner cup of the injector. Install the slide
hammer. Use reasonable force with the slide hammer to pull
the injector free from the cylinder head.
Note: Use care when removing the injector because the injector hold down is not secure and could fall off if not held in
place.
9990006, 9990013
W2005170
11
Install the protective sleeve over the injector to prevent
damage.
9998249
W2005112
Volvo Trucks North America
Service Bulletin
Date
3.2013
Group
No.
Release
237
60
01
Page
7(28)
12
If the injector sleeve is not being removed immediately, install
the protective plug into the injector bore of the cylinder head
to protect it from debris. Using compressed air, clean out the
injector hold down bolt holes.
9998251
W2005172
13
Install the protective sleeve from kit J42885. Use brush
88880056 to clean the injector sleeve.
Note: After cleaning the sleeve, carefully inspect the inside
surface of the sleeve, especially the bottom surface. Any remaining contamination is unacceptable and must be removed. Also, if there is any indication of a discrepancy that
raises concern about suitability of the sleeve for reuse, replace it with a new sleeve.
Note: When reinstalling the existing injector, it is acceptable
to reuse the injector sleeve. When installing a new injector, a
new injector sleeve must also be installed.
J42885, 88880056
14
Install two sealing rings to prevent dirt from entering the fuel
gallery when the injector sleeve is removed.
Note: Two sealing rings are required to cover the fuel gallery.
9998250
W2005171
Volvo Trucks North America
Service Bulletin
Date
3.2013
Group
No.
Release
237
60
01
Page
8(28)
15
Install the flywheel turning tool. Turn the flywheel until the piston is at its lowest position in the cylinder. Confirm the piston
is at the lowest position in the cylinder by using a 40 cm (16
inch) piece of straight stiff wire in the injector hole of the
cylinder.
Note: This is to ensure that the injector sleeve tapping tool
does not damage the piston due to tool length.
Note: Ensure the turning tool is well greased before attempting to turn the flywheel.
Note: If it is necessary to replace other injector sleeves, continue the procedure on pairs of companion cylinders (1 and
6, 2 and 5, 3 and 4). It is necessary to rotate the crankshaft
and place each pair of companion cylinders at the lowest position in the cylinder.
88800014, or 9996956
16
Insert the 8.3 mm forming tap into the tap handle until it
stops. Make sure a flat on the tap is aligned with the upper
set screw. Tighten upper set screw first, then tighten lower
set screw. Completely coat the forming tap with fresh, extreme pressure NLGI #2 grease or equivalent.
Note: Forming taps require extreme pressure grease due to
the cold working process used to form threads.
CAUTION
W2038611
If the injector sleeve is not completely tapped through to
the opening of the tip, an end piece of the tip can break off
and fall into the cylinder during removal. These types of
failures are not covered by warranty.
88800289, 9998252
Volvo Trucks North America
Service Bulletin
Date
3.2013
Group
No.
Release
237
60
01
Page
9(28)
17
Note: Use bolt 8192804 to tighten the injector hold down
yoke on the sleeve hold down (special tool number
88800285). Do not use the hold down screw from the engine because it is a limited use screw.
Position tap holder and sleeve hold down in the injector bore.
Position the injector hold down yoke over the sleeve hold
down and tighten bolt 8192804 to 80 ± 5 Nm (60 ± 4 ft-lb).
Apply moderate downward force to get the tap started while
turning the tap handle clockwise. Continue turning in the
same direction, without reversing, until the injector sleeve is
tapped all the way through. The shoulder of the tap handle
should bottom on the injector sleeve. Ensure that the tap is
completely through the injector sleeve.
CAUTION
T2055473
A. 8.3 mm Forming Tap, 88800289
B. Tap Handle, 9998252
If threads are not cut completely through the tip of the injector sleeve, the tip can break off and fall into the cylinder.
This can result in damage to the cylinder, piston, valves or
turbocharger. These types of failures are not covered by
warranty.
C. Sleeve Hold Down, 88800285
9998252, 88800285, 88800289
18
Remove bolt from the injector hold down yoke. Remove the
injector hold down, sleeve hold down, tap and tapping tool.
19
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TSB/Document ID: FSB 237-60
Replacement Service Bulletin Number:
MFR Communication Date: 2013-03-14
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
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