NHTSA ID Number: 10252317
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.
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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Tightening torque
Camshaft bearing cap, screw
1.
Tightening sequence: 1–7
25 ±3 Nm
(18 ±2 lbf⋅ft)
2.
Tightening sequence: 11,9,13
90 ±5 Nm
(66 ±4 lbf⋅ft)
3.
Tightening sequence: 8,10,12,14
60 ±5 Nm
(44 ±4 lbf⋅ft)
4.
Loosening sequence: 11,9,13
0 Nm
(0 lbf⋅ft)
5.
Tightening sequence: 11,9,13
60 ±5 Nm
(44 ±4 lbf⋅ft)
6.
Tightening sequence: 1–7
90 ±5°
7.
Tightening sequence: 8–14
100 ±5°
Note
Check that the camshaft rotates easily after torque tightening each bearing cap.
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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98
Remove the temporary screws and sleeves.
99
Ensure that the marking (0) is in the correct position.
100 Turn the camshaft until the (TDC) mark aligns with the cap mark.
101 Install the camshaft gear.
102 Install the tool (A).
Required material
KIT
J-44514B
103 Install 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.
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104 Measure the backlash between gears (1) and (2) using the tools.
Tech data
Backlash clearance
0.1 ±0.05 mm
(0.004 ±0.002 in)
Required material
ROCKER INDICATOR
9999683
MAGNETIC STAND
9999696
KIT
J-44514B
Note
Hold the idler gear (1) in place using a suitable tool to correctly check the backlash.
Note
If backlash is out of specification, adjust idler gear (1).
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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105 Check the timing mark.
106 Remove the tools.
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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107 Remove the screws.
108 Remove the tool.
109 Install the gear and sensor wheel.
110 Install the screws.
Note
Use new screws.
111 Torque tighten 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.
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Tightening torque
Gear, screw
1.
Tightening sequence: 1–8
45 ±5 Nm
(33 ±4 lbf⋅ft)
2.
Tightening sequence: 1–8
90 ±5°
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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112 Clean the contact surfaces.
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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113 Install the gasket.
Note
Use a new part.
114 Install the timing gear cover.
Note
The dowels on the timing gear cover act as guides to avoid damaging the sealing strip
during installation.
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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115 Lightly tighten the two timing gear cover screws.
Note
Ensure that the timing gear cover is in contact with the timing gear plate.
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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116 Connect the connector.
117 Install the tools.
Required material
ASSEMBLY TOOL
85109051
2 pcs
118 Press down the timing gear cover with the required force.
Tightening torque
Tool, adjusting screw
27 ±3 Nm
(20 ±2 lbf⋅ft)
Note
Ensure that the timing gear cover aligns with the cylinder head on both sides.
119 Torque tighten the screws.
Tightening torque
Upper timing gear casing, screw
1.
Tightening sequence: 1–2
4 ±1 Nm
(3 ±1 lbf⋅ft)
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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2.
Tightening sequence: 1–5
27 ±3 Nm
(20 ±2 lbf⋅ft)
120 Remove the tools.
121 Install the bracket.
122 Install the clamp.
123 Install the screws.
124 Torque tighten the screws.
Tightening torque
Screw
M8
24 ±4 Nm
(18 ±3 lbf⋅ft)
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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125 Install the pipes.
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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126 Install the clamps.
127 Install the screws.
Tightening torque
Screw
M8
24 ±4 Nm
(18 ±3 lbf⋅ft)
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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128 Lubricate the seals.
Required material
Diesel Engine Oil
Note
Use new parts.
129 Install the pipe.
Note
Use a new part.
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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130 Install the lifting tool.
Required material
LIFTING TOOL
85109250
131 Install the rocker arm shaft.
Note
Take care not to damage the oil pipe.
132 Remove the cable ties.
133 Remove the lifting tool.
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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134 Install the screws.
Note
Note any marks on the screw heads.
Note
Each mark on the screw head indicates the amount of times the screw has been
torqued.
The screws may be torqued for maximum of three times.
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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135 Torque tighten the screws.
Tightening torque
Rocker arm shaft, screw
1.
Tightening sequence: 8-6-10-4-12-2-13
60 ±5 Nm
(44 ±4 lbf⋅ft)
2.
Tightening sequence: 1-3-5-7-9-11
40 ±3 Nm
(30 ±2 lbf⋅ft)
3.
Tightening sequence: 1-3-5-7-9-11
120 ±5°
4.
Loosen the screws: 2-4-6-8-10-12
6 pcs
5.
Tightening sequence: 2-4-6-8-10-12
40 ±3 Nm
(30 ±2 lbf⋅ft)
6.
Tightening sequence: 2-4-6-8-10-12-13
120 ±5°
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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136 Mark the screws.
137 Install the screw.
138 Torque tighten the screw.
Tightening torque
Oil pipe, screw
M8
24 ±4 Nm
(18 ±3 lbf⋅ft)
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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139 Remove the protecting cover and plug.
140 Install the sensor.
Note
No sealant or thread locker should be used.
141 Torque tighten the sensor.
Tightening torque
Pressure sensor, common rail
40 ±5 Nm
(30 ±4 lbf⋅ft)
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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142 Perform this procedure when the condition below is met.
Conditions
●
If not previously installed
▶
Connect 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.
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143 Perform this procedure when the condition below is met.
Conditions
●
If not previously installed.
▶
Remove the plug.
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.
65 / 115
IMPACT 4.07.174
▶
3/29/2024
Install the cranking tool (A).
Required material
CRANKING TOOL
88840317
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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144 Note the camshaft marking.
Note
The marking can be for the adjustment of multiple cylinders.
Note
When checking or adjusting, the mark must be centered between the lines on the
camshaft cap.
145 Adjust the rocker arms according to the chart.
Camshaft marking
CAM 5/PE6
POSITION
Cylinder
INLET 5
INJECTOR
Pump/6PUMP
EXHAUST
Cylinder 6
3/PE2
Cylinder 3
Pump 2
Cylinder 2
6/PE4
Cylinder 6
Pump 4
- 6X better wear protection on critical engine parts than...
- 1.3X better sludge protection than industry standards*
- 3X Stronger against viscosity breakdown than leading full...
- Protection for 10,000 miles between oil changes
- Meets or exceeds the following specifications: API SP/SN...
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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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