NHTSA ID Number: 10252308
Manufacturer Communication Number: CBR-2139 202403
TSB/Document Date: 2024-04-02
Summary
CBR: Vehicles built with an 11 liter engine may experience a complaint of excessive fuel in the oil. It is possible that the source of the fuel is the rear fuel galley plug in the cylinder head.
Preview Solution CBR-2139-5
11 Liter Engines - Fuel In Oil
Published September 2022 - Revised March 2024
Valid for all vehicles built with a 11L engine
Vehicles built with an 11 liter engine may experience a complaint of excessive fuel
in the oil. It is possible that the source of the fuel is the rear fuel galley plug in the
cylinder head.
The presence of fuel in the oil may be accompanied by report of hard start, which
would indicate a loss of pressure in the fuel system when the engine is not running.
The location of the plug can be seen in the image below:
Diagnose
1. Remove the valve cover.
; Live UI
2. Add approporiate UV reactive dye to the secondary fuel filter by removing, then
reinstalling the filter.
3. Use the hand primer to pressurize the system.
4. Check the fuel plug location shown in the pictures above and below for evidence
of fuel leakage.
; Live UI
Repair
1. Ensure engine is on TDC (Cam and Crank) before major disassembly.
2. Drain fuel galley.
3. Follow Impact ID/Operation 2154-03-02-01 Camshaft, Replacement and STOP at
step 84.
• DO NOT REMOVE the camshaft or camshaft bearing caps.
4. With the rocker shaft, upper timing cover, and cam gear removed, remove the
fasteners for the adjustable idler gear and slide the gear toward the rear of the truck.
• NOTE: Timing gear plate fasteners will not allow for complete removal of
adjustable idler gear.
5. Remove the leaking fuel galley plug.
6. Verify the fuel galley plug threads in the cylinder head are clean and free from
damage.
7. Install a NEW fuel galley plug and torque to 40 Nm +/- 3 Nm.
; Live UI
8. Using the hand primer, prime fuel system and verify there are no fuel leaks around
the newly installed plug.
9. Slide the adjustable idler back into original position and loosely install the 5
fasteners.
• NOTE: Use new fasteners.
10. Reassemble using Impact ID/Operation 2154-03-02-01 Camshaft, Replacement
starting at step 102.
• NOTE: Gear train backlash WILL have to be adjusted, follow
Impact ID/Operation 2154-05-03-02.
11. If not done already, change engine oil and filters.
12. Start the engine and verify proper operation and no leaks are observed.
13. Release the unit.
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IMPACT 4.07.174
3/29/2024
21522-2 Camshaft, Replacement
Illustrations may differ slightly from the actual vehicle being serviced. However, key
components addressed in this information are represented as accurately as possible.
Colors used in illustrations are for highlighting purposes only and do not correspond to the
actual colors of the vehicle.
All threaded fasteners that do not have a tightening torque specification in the information are
tightened to a standard torque. Standard torques are available in the following specification.➠
Standard Tightening Torques
WARNING
Risk of serious personal injury.
Using the wrong technique when rotating the crankshaft can cause serious personal injury.
▶
Use the recommended engine barring techniques for manually rotating the crankshaft. Do not
rotate the engine by pulling or prying the fan.
CAUTION
Risk of material damage.
Risk of impurities being introduced into the fuel system.
▶
Ensure conditions of maximum cleanliness when carrying out any work on the fuel system.
CAUTION
Risk of skin injury.
High fuel pressure.
▶
The injection system may be pressurised. When working on the injection system, remove the
first part cautiously
WARNING
Risk of burn injuries.
The coolant may be hot.
▶
The cooling system is under pressure and can reach a temperature sufficient to cause burns.
Allow the coolant temperature to reach a safe level before starting the work.
▶
Remove the coolant tank cap carefully. Use appropriate protective equipment.
CAUTION
Risk of material damage.
The engine may be hot.
▶
Make the adjustment on a cold engine.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.174
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CAUTION
Service Information Advisory.
If you are not properly trained and certified in this procedure, ask your supervisor for training before
you perform it.
▶
You must read and understand the precautions and guidelines in Service Information, Function
Group 2, "General Safety Practices, Engine" before performing this procedure.
CAUTION
Risk of material damage.
Applying more sealant than a specified volume will lead to oil leakage. Excess sealant can result in
over-compression and damage to the gasket.
▶
The surface must be thoroughly cleaned and free of oil, dirt or grease prior to applying the
sealant.
▶
Oil or grease on the surface will prevent proper bonding of parts.
CAUTION
Risk of material damage.
The turbocharger can be damaged if foreign particles enter the charge air system. Particles as small
as 1 mm can cause damage.
▶
Observe maximum cleanliness when working on the charge air system. Cover or plug openings
immediately.
Special tools
85112740
J-42189
88800420
88840317
9992669
9996049
9996400
9998264
9999683
9999696
85109051
85109250
J-44514B
1
Park the vehicle on a level surface.
2
Apply the parking brake.
3
Place the gear lever in neutral.
4
Install the wheel chocks.
Copyright to this documentation belongs to the Volvo
Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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Disconnect the cable from the negative terminal.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.174
6
3/29/2024
Drain the compressed air tanks.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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7
Unlatch and raise the hood.
8
Perform this procedure when the condition below is met.
Conditions
9
●
If the vehicle is equipped with a removable bumper end cap
▶
Remove the end cap.
Drain the cooling system using either a coolant extractor or a drain hose and pan.
Required material
COOLANT EXTRACTOR/INJECTOR
85112740
9996049
Note
Take the collected coolant to a recycling facility as per local safety regulations.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
6 / 115
IMPACT 4.07.174
10
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Loosen the clamps.
Note
Note the orientations and the positions.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
7 / 115
IMPACT 4.07.174
11
Remove the hose.
12
Remove the cable ties.
3/29/2024
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
8 / 115
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Note
Note the positions.
13
Disconnect the sensor connector.
Note
To avoid damaging the sensor, do not remove from the pipe.
14
Loosen the clamps.
15
Remove the pipe assembly.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
9 / 115
IMPACT 4.07.174
16
3/29/2024
Loosen the clamps.
Note
Note the orientations and the positions.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
10 / 115
IMPACT 4.07.174
17
Remove the air duct.
18
Remove the screws.
3/29/2024
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
11 / 115
IMPACT 4.07.174
19
Remove the air filter housing.
20
Disconnect the connector.
21
Remove the cable tie.
3/29/2024
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
12 / 115
IMPACT 4.07.174
22
Remove the screws.
23
Remove the clamp.
3/29/2024
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
13 / 115
IMPACT 4.07.174
24
3/29/2024
Loosen the clamps.
Note
Note the positions.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
14 / 115
IMPACT 4.07.174
25
3/29/2024
Remove the pipe.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
15 / 115
IMPACT 4.07.174
26
Remove the protecting covers.
27
Remove the screws.
28
Remove the panel.
3/29/2024
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
16 / 115
IMPACT 4.07.174
29
Remove the seat belt.
30
Disconnect the air tube.
3/29/2024
Required material
DISASSEMBLY TOOL
J-42189
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
17 / 115
IMPACT 4.07.174
31
3/29/2024
Disconnect the connector.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
18 / 115
IMPACT 4.07.174
32
3/29/2024
Remove the screws.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
19 / 115
IMPACT 4.07.174
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WARNING
Risk of serious injury.
Heavy component.
▶
33
Exercise caution when moving the component. Assistance is required.
Remove the seat from the cab.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
20 / 115
IMPACT 4.07.174
34
Remove the screw cover.
35
Remove the screws.
36
Remove the grab handle.
3/29/2024
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
21 / 115
IMPACT 4.07.174
37
Remove the nut.
- Advanced protection against the four main causes of engine...
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TSB/Document ID: CBR-2139 202403
Replacement Service Bulletin Number:
MFR Communication Date: 2024-03-01
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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