The document provides information on testing the compression of an engine and describes the steps to test compression on an engine:
1. Prepare the engine by draining fuel, removing hoses and the valve cover.
2. Remove the unit injectors and install adapters in their place.
3. Connect a compression gauge and crank the engine to obtain a compression reading from each cylinder.
4. Reinstall the unit injectors and valve cover after testing is complete. Adjust valves as needed.
The compression test is used to check for issues like low compression from worn parts or a leaking head gasket between cylinders. Proper procedure and safety steps are outlined to correctly perform the test.
Volvo A40D Articulated Dump Truck Service Repair Manual Instant Download.pdftepu22753653
The document provides information on testing the compression of an engine, specifically an Volvo D12 engine. It includes a list of required tools and steps to complete a compression test. The steps involve draining fuel from the cylinder head, removing components like the valve cover and unit injectors. Adapters are installed and the compression gauge is used to test pressure on each cylinder. The procedure also includes assembling the engine components back together after testing. Compression readings are used to identify potential issues like leaks or worn parts that may require an engine overhaul.
Volvo A40D Articulated Dump Truck Service Repair Manual Instant Download.pdfdai20nao
The document provides information on testing the compression of an engine and identifying engine components. It describes removing components like the valve cover and unit injectors to access the cylinders. The procedure involves installing adapters in the cylinders and using a compression gauge to test pressure in each cylinder. Low or uneven pressure between cylinders could indicate issues like worn parts that require an engine overhaul. The document also provides information on engine identification plates and labels to ensure correct parts are installed.
Volvo A40D Articulated Dump Truck Service Repair Manual Instant Download.pdflunrizan628
The document provides information on testing the compression of an engine, specifically an Volvo D12 engine. It includes a list of required tools and steps to complete a compression test. The steps involve draining fuel from the cylinder head, removing components like the valve cover and unit injectors. Adapters are installed and the compression gauge is used to test pressure on each cylinder. The procedure also includes assembling components back onto the engine. Compression pressures are compared between cylinders and to specifications to identify any issues.
Volvo A40D Articulated Dump Truck Service Repair Manual Instant Download.pdfrou774513po
This document provides instructions for performing a compression test on an engine. It describes draining fuel from the cylinder head, removing hoses and the valve cover. The electrical connections for the unit injectors and control valve are disconnected. The control valve, pipe, and rocker arm bridge are removed. The unit injectors are then carefully extracted using specialized tools. Adapters are installed in the injector ports before performing the compression test.
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The document provides information on testing the compression of an engine and identifying engine components. It describes removing components like the valve cover and unit injectors to access the cylinders. The procedure involves installing adapters in the cylinders and using a compression gauge to test pressure in each cylinder. Low or uneven pressure between cylinders could indicate issues like worn parts that require an engine overhaul. The document also provides images and references to other service documents for adjusting valves and bleeding fuel.
Volvo A40D Articulated Dump Truck Service Repair Manual Instant Download.pdff8iosedkdm3e
The document provides information on testing the compression of engine D12, including:
1) Tools and steps to prepare the engine, such as draining fuel and removing components like the valve cover and unit injectors.
2) Instructions to install adapters in place of the unit injectors and connect a compression gauge.
3) Details on cranking the engine with the starter motor to obtain compression readings from each cylinder, which should be around 30 bar for a new engine.
Volvo A40D Articulated Dump Truck Service Repair Manual Instant Download.pdfmanchao854
This document provides instructions for performing a compression test on an engine. It describes dismantling steps including draining fuel from the cylinder head, removing hoses and the valve cover. The unit injectors and rocker arm bridge are then removed. Adapters are installed in the injector ports to allow connection of a pressure gauge for testing compression on each cylinder. Tools and estimated time for reassembly steps are also listed.
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The document provides information on testing the compression of an engine, specifically an Volvo D12 engine. It includes a list of required tools and steps to complete a compression test. The steps involve draining fuel from the cylinder head, removing components like the valve cover and unit injectors. Adapters are installed and the compression gauge is used to test pressure on each cylinder. The procedure also includes assembling components back onto the engine.
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The document provides information on testing the compression of an engine, specifically an Volvo D12 engine. It includes a list of required tools and steps to complete a compression test. The steps involve draining fuel from the cylinder head, removing components like the valve cover and unit injectors. Adapters are installed and the compression gauge is used to test pressure on each cylinder. The procedure also includes assembling the engine components back together after testing. Compression readings are used to identify potential issues like leaks or worn parts that may require an engine overhaul.
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The document provides information on testing the compression of an engine and identifying engine components. It describes removing components like the valve cover and unit injectors to access the cylinders. The procedure involves installing adapters in the cylinders and using a compression gauge to test pressure in each cylinder. Low or uneven pressure between cylinders could indicate issues like worn parts that require an engine overhaul. The document also provides information on engine identification plates and labels to ensure correct parts are installed.
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The document provides information on testing the compression of an engine, specifically an Volvo D12 engine. It includes a list of required tools and steps to complete a compression test. The steps involve draining fuel from the cylinder head, removing components like the valve cover and unit injectors. Adapters are installed and the compression gauge is used to test pressure on each cylinder. The procedure also includes assembling components back onto the engine. Compression pressures are compared between cylinders and to specifications to identify any issues.
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This document provides instructions for performing a compression test on an engine. It describes draining fuel from the cylinder head, removing hoses and the valve cover. The electrical connections for the unit injectors and control valve are disconnected. The control valve, pipe, and rocker arm bridge are removed. The unit injectors are then carefully extracted using specialized tools. Adapters are installed in the injector ports before performing the compression test.
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The document provides information on testing the compression of an engine and identifying engine components. It describes removing components like the valve cover and unit injectors to access the cylinders. The procedure involves installing adapters in the cylinders and using a compression gauge to test pressure in each cylinder. Low or uneven pressure between cylinders could indicate issues like worn parts that require an engine overhaul. The document also provides images and references to other service documents for adjusting valves and bleeding fuel.
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The document provides information on testing the compression of engine D12, including:
1) Tools and steps to prepare the engine, such as draining fuel and removing components like the valve cover and unit injectors.
2) Instructions to install adapters in place of the unit injectors and connect a compression gauge.
3) Details on cranking the engine with the starter motor to obtain compression readings from each cylinder, which should be around 30 bar for a new engine.
Volvo A40D Articulated Dump Truck Service Repair Manual Instant Download.pdfmanchao854
This document provides instructions for performing a compression test on an engine. It describes dismantling steps including draining fuel from the cylinder head, removing hoses and the valve cover. The unit injectors and rocker arm bridge are then removed. Adapters are installed in the injector ports to allow connection of a pressure gauge for testing compression on each cylinder. Tools and estimated time for reassembly steps are also listed.
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The document provides information on testing the compression of an engine, specifically an Volvo D12 engine. It includes a list of required tools and steps to complete a compression test. The steps involve draining fuel from the cylinder head, removing components like the valve cover and unit injectors. Adapters are installed and the compression gauge is used to test pressure on each cylinder. The procedure also includes assembling components back onto the engine.
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The document provides information on testing the compression of an engine and identifying engine components. It describes removing components like the valve cover and unit injectors to access the cylinders. The procedure involves installing adapters in the cylinders and using a compression gauge to test pressure in each cylinder. Low or uneven pressure between cylinders could indicate issues like worn parts that require an engine overhaul. The document also provides identification information for the engine, including plates listing serial numbers and assembly plants.
Volvo A40D Articulated Dump Truck Service Repair Manual Instant Download.pdffijsekkkdmdm3e
The document provides information on testing the compression of engine D12, including:
1) Tools and steps to prepare the engine, such as draining fuel and removing components like the valve cover and unit injectors.
2) Instructions to install adapters in place of the unit injectors and connect a compression gauge.
3) Details on cranking the engine with the starter motor to obtain compression readings from each cylinder and what normal readings should be.
Volvo A40D Articulated Dump Truck Service Repair Manual Instant Download.pdfqiuqiaoxi0
The document provides information on testing the compression of an engine and identifying engine components. It describes removing components like the valve cover and unit injectors to access the cylinders. The procedure involves installing adapters in the cylinders and using a compression gauge to test pressure in each cylinder. Low or uneven pressure between cylinders could indicate issues like worn parts that require an engine overhaul. The document also provides images and references to other service documents for adjusting valves and bleeding fuel.
Volvo A40D Articulated Dump Truck Service Repair Manual Instant Download.pdfnie7140zhuang
The document provides information on testing the compression of an engine and identifying engine components. It describes removing components like the valve cover and unit injectors to access the cylinders. The procedure involves installing adapters in the cylinders and using a compression gauge to test pressure in each cylinder. Low or uneven pressure between cylinders could indicate issues like worn parts that require an engine overhaul. The document also provides images and references to other service documents for adjusting valves and bleeding fuel.
Volvo A40D Articulated Dump Truck Service Repair Manual Instant Download.pdffapanhe306271
The document provides information on testing the compression of an engine, specifically an Volvo D12 engine. It includes a list of required tools and steps to complete a compression test. The steps involve draining fuel from the cylinder head, removing components like the valve cover and unit injectors. Adapters are installed and the compression gauge is used to test pressure on each cylinder. The procedure also includes assembling components back onto the engine. Compression pressures are compared between cylinders and to specifications to identify any issues.
Volvo T450D Articulated Dump Truck Service Repair Manual Instant Download.pdftepu22753653
The document provides information on performing a compression test on an engine. It includes instructions to disconnect electrical connections, drain fuel lines, remove the valve cover and unit injectors. Adapters are installed in place of the injectors to connect a compression gauge. The procedure involves testing cylinder compression one at a time and comparing values to identify any low cylinders that could indicate issues like worn rings or valves. Tools required are listed.
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The document provides instructions for testing cylinder compression on an engine using a VCADS Pro computer. It describes connecting the computer and performing the 21006-3 Cylinder compression test program. The test measures the compression pressure in each cylinder to check for leaks. The summary also notes that the document gives instructions for servicing electronic engine components before removing the ECU.
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The document provides information on performing a compression test on an engine. It includes instructions to disconnect electrical connections, drain fuel lines, remove the valve cover and unit injectors. Adapters are installed in place of the injectors to connect a compression gauge. The procedure involves testing each cylinder individually by cranking the engine and noting the compression pressure reading. Low pressure in one cylinder compared to others could indicate issues like worn rings or valves. The test helps identify any cylinders that may need repair.
This document provides service information for compression testing engines, including the necessary tools, safety precautions, and step-by-step instructions. It describes removing the fuel lines and injectors from the engine to access the cylinders. The adapter and pressure gauge are then installed on cylinder 1 to perform the compression test while the safety stop is engaged. Similar steps are followed to test each additional cylinder individually.
This document provides service information for compression testing engines, including the necessary tools, safety precautions, and step-by-step instructions. It describes removing the fuel lines and injectors from the engine cylinder being tested and installing an adapter and pressure gauge to perform the test. Precautions are outlined such as capping injectors and fuel lines.
This document provides service information for compression testing engines, including the necessary tools, safety precautions, and step-by-step instructions. It describes removing the fuel lines and injectors from the engine cylinders to be tested and installing an adapter and pressure gauge to perform the tests. Precautions are outlined such as capping injectors and fuel lines.
This document provides service information for compression testing engines, including the necessary tools, safety precautions, and step-by-step instructions. It describes removing the fuel lines and injectors from the engine to access the cylinders. The adapter and pressure gauge are then installed on cylinder 1 to perform the compression test while the safety stop is engaged. Similar steps are followed to test each additional cylinder individually.
This document provides service information for compression testing engines, including the necessary tools, safety precautions, and step-by-step instructions. It describes removing the fuel lines and injectors from the engine cylinder being tested and installing an adapter and pressure gauge to perform the test. Precautions are outlined such as capping injectors and fuel lines.
This document provides service information for compression testing engines, including the necessary tools, safety precautions, and step-by-step instructions. It describes removing the fuel lines and injectors from the engine cylinder being tested and installing an adapter and pressure gauge to perform the test. Precautions are outlined such as capping injectors and fuel lines.
This document provides service information for compression testing engines, including the necessary tools, safety precautions, and step-by-step instructions. It describes removing the fuel lines and injectors from the engine cylinders to be tested and installing an adapter and pressure gauge to perform the tests. Precautions are outlined such as capping injectors and fuel lines.
This document provides service information for compression testing engines, including the necessary tools, safety precautions, and step-by-step instructions. It describes removing the fuel lines and injectors from the engine cylinders to be tested and installing an adapter and pressure gauge to perform the tests. Precautions are outlined such as capping injectors and fuel lines.
This document provides service information for compression testing engines, including the necessary tools, safety precautions, and step-by-step instructions. It describes removing the fuel lines and injectors from the engine cylinders to be tested and installing an adapter and pressure gauge to perform the tests. Precautions are outlined such as capping injectors and fuel lines.
This document provides service information for compression testing engines, including the necessary tools, safety precautions, and step-by-step instructions. It describes removing the fuel lines and injectors from the engine cylinders to be tested and installing an adapter and pressure gauge to perform the tests. Precautions are outlined such as capping injectors and fuel lines.
This document provides service information about engines, including:
1. It describes engine models D10 and D9, listing their specifications and components.
2. It shows the locations of various engine sensors and identifies them by number.
3. It explains how to identify engines by their identification plates and provides the assembly plant codes.
4. It provides instructions for changing an engine's pre-programmed or non-programmed electronic control unit (ECU). The process involves using diagnostic software to save or program parameters.
Volvo L150F Wheel Loader Service Repair Manual Instant Download.pdffijsekkkdmdm3e
This document provides instructions for removing an engine from a machine. It outlines 18 steps including draining fluids, disconnecting hoses and electrical connections, and removing components attached to the engine like the filter housing. Safety precautions are noted, and references to other documents are provided for additional details on tasks like draining fluids and removing parts. Tools needed include lifting equipment and various fastener removal tools.
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The document provides instructions for removing an engine from a machine. It describes draining the coolant and oil first. Various hoses, belts, and electrical connections are then disconnected from both sides of the engine. The partition wall and other components are removed to access the engine mounts. Lifting devices are attached to the engine and the mounts are unbolted to lift the engine out after securing the transmission. The process is described over 16 steps with diagrams to illustrate key points.
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This document provides instructions for changing a non-programmed E-ECU (engine control unit) on an engine with MID 128. The steps include: placing the machine in service position 1, connecting the VCADS Pro programming tool, turning off voltage, removing covers, disconnecting connectors and hoses from the old ECU, replacing the ECU, reconnecting connectors and hoses, and finishing installation. Connectors are unplugged, cable clamps removed, cooling coil disconnected, old ECU replaced with new one, then cooling coil, connectors and clamps are reinstalled.
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The document provides information on testing the compression of an engine, specifically an Volvo D12 engine. It includes a list of required tools and steps to complete a compression test. The steps involve draining fuel from the cylinder head, removing components like the valve cover and unit injectors. Adapters are installed and the compression gauge is used to test pressure on each cylinder. The procedure also includes assembling components back onto the engine. Compression pressures are compared between cylinders and to specifications to identify any issues.
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Volvo A35D Articulated Dump Truck Service Repair Manual Instant Download.pdf
1. Service Information
Document Title: Function Group: Information Type: Date:
Engine control unit D12, E–
ECU, description of
function
200 Service Information 2014/8/22
Profile:
ART, A35D [GB]
Engine control unit D12, E–ECU, description of function
Control unit sensors
The unit injectors in the D12 engine are controlled entirely electronically regarding amount of injected fuel and injection
timing. The system is called EMS (Engine Management System).
The following is a brief summary of the parts on the engine. There are a number of other parts that affect the system, for
example, the throttle pedal sensor.
The central part of the system, the control unit, A, is positioned on the left side of the engine. All cable connectors for the
sensors of the engine are of the DIN standard and are connected in a so called cable terminal, B.
The cable terminal, which is positioned above the control unit, is made of plastic and is in three parts. The inner part nearest
the engine contains all cables and connectors that concern the engine. On the outside of these there is a partition (C) and an
outer cover (D). On the inside of the outer cover there is room for other cable harnesses that belong to the machine.
Figure 1
D12C. Engine sensors (some have dual functions)
1.
2.
Fuel pressure. Positioned on the fuel filter bracket. Senses feed pressure after the filter, SE2301 (PID 94).
Charge air pressure and charge air temperature. Combined sensor positioned on the inlet manifold, SE2507 (PID
2. 3.
4.
5.
6.
7.
8.
105), SE2508 (PID 102).
Camshaft position. Positioned near the top of the cylinder head at the front, SE2703 (SID 21).
Coolant level. Positioned in the expansion tank, SE2603 (PID 111).
Air pressure and air temperature. Combined sensor, positioned on the connecting pipe between the air filter and
the turbocharger, SE2501 (PID 172), SE2502 (PID 107).
Coolant temperature. Positioned in the rear end of the cylinder head, SE2606 (PID 110).
Flywheel position and rotational speed. Positioned in the flywheel housing, SE2701 (SID 22).
Oil pressure and oil temperature. Combined sensor positioned in the lubrication system main duct in the cylinder
block, SE2202 (PID 175), SE2203 (PID 100).
Figure 2
D12D Engine sensors (some have dual functions)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Sensor for coolant level, SE2603
Sensor for coolant temperature, SE2606
Sensor for charge air pressure/temperature, SE2507/SE2508
Tachometer sensor, flywheel, SE2701
Sensor for oil level/temperature, SE2205/SE2202
Sensor for crankcase pressure, SE2509
Sensor for oil pressure, SE2203
Camshaft sensor, engine position, SE2703
Sensor for air pressure/temperature, SE2501/SE2502
Sensor for feed pressure, fuel, SE2301
Sensor for water indicator, SE2302
3. Service Information
Document Title: Function Group: Information Type: Date:
E–ECU D12, Functions 200 Service Information 2014/8/22
Profile:
ART, A35D [GB]
E–ECU D12, Functions
Fuel amounts, unit injectors
Figure 1
Unit injector "Bosch"
Figure 2
Unit injector "Delphi"
Exhaust brake Applies only to machine equipped with engine D12C
4.
Figure 3
Exhaust brake
Exhaust brake Applies only to machine equipped with engine D12D
Figure 4
Exhaust brake
Compression brake Applies only to machine equipped with engine D12C
Figure 5
MA2503 (PPID 122), solenoid valve for compression brake
Temperatures, pressures and rpms
5.
Figure 6
SE2507 (PID !05)/SE2508 (PID 102) Charge air temperature/pressure
Preheating element, preheating
Figure 7
Preheating element
Raised engine speed. The switch is connected to the cab control unit (C–ECU) which sends a message via the data
bus to the engine control unit (E–ECU).
NOTE!
Raised engine speed is optional equipment.
Figure 8
Switch, raised engine speed
6. Service Information
Document Title: Function Group: Information Type: Date:
E–ECU D12D, Input and
Output terminals
200 Service Information 2014/8/22
Profile:
ART, A35D [GB]
E–ECU D12D, Input and Output terminals
INPUTS ECU OUTPUTS
Digital Digital
Detection of preheating
(RE2501, pin 87)
Control, injectors 1–6,
MA2301–2306
Monitor, air filter, pressure,
SE2502
Control, pressure governor,
exhaust brake (EPG1),
PWM2501
Monitor, coolant level, SE2603 Control, pressure governor /
shutter, exhaust brake (EPG2),
MA2502
Preheating induction air,
RE2501
Control, exhaust circulation,
MA2504
[T1]
[T1]Only applies to A35D equipped with engine D12DAAE3 and A40D equipped with engine D12DABE3
INPUTS ECU
Analogue
Sensor, engine oil temperature, SE2202
Sensor, engine oil pressure, SE2203
Sensor, fuel pressure, SE2301
Sensor, ambient air, temperature, SE2501
Sensor, charge-air temperature, SE2507
Sensor, charge-air pressure, SE2508
Sensor, coolant temperature, engine, SE2606
Sensor, engine speed, SE2701
Sensor, camshaft speed, SE2703
Monitor, water in fuel, SE2302
8. Service Information
Document Title: Function Group: Information Type: Date:
Engine D12, description 200 Service Information 2014/8/22
Profile:
ART, A35D [GB]
Engine D12, description
Engine D12, description
Engine D12 is available in two versions, D12C and D12D. See the product plate for the machine regarding which engine
version applies to the machine.
Engine D12 is an straight, six-cylinder, direct injection, diesel engine with at cylinder capacity of 12 litres. It is equipped with
a turbocharger and an intercooler and electronically controlled fuel injection, EMS (Engine Management System). It has an
overhead camshaft and unit injectors instead of injection pump and injectors.
The unit injectors are positioned in the centre above the pistons and are controlled via the camshaft and a control unit (E-
ECU).
The control unit is positioned on the left side of the cylinder block.
Engine D12C
Applies to machine equipped with engine D12C, with serial number according to the table.
Machine Place of manufacture, serial number
BRA ASH PED
A35D – 12999 – 61303 – 71999
A40D – 11999 – 60286
Engine D12D
Applies to machine equipped with engine D12D, with serial number according to the table.
Machine Place of manufacture, serial number
BRA PED
A35D 13001– 72001–
A40D 12001– 70001–
Figure 1
9. Service Information
Document Title: Function Group: Information Type: Date:
Engine, identification 200 Service Information 2014/8/22
Profile:
ART, A35D [GB]
Engine, identification
Identification plate 1
Engine designation, serial number, part number and assembly plant are stamped in one field on the engine block's left rear
edge
Identification plate 2
A decal with the software's ID-number, the engine's serial number and assembly plant is located on the valve cover to
ensure installation of correct ECU on the engine in production. On the back of the ECU, there is a decal indicating its
hardware number.
Assembly plants:
A = Skövde, Sweden
E = Curitiba, Brazil
F = Flen, Sweden
L = Lyon, France
Identification plate 3
The certification decal is located on the valve cover as well as on the left side of the machine's front frame.
Figure 1
Engine identification, D12D
11. Service Information
Document Title: Function Group: Information Type: Date:
Compression test 210 Service Information 2014/8/22
Profile:
ART, A35D [GB]
Compression test
Op nbr 210-002
9990185 Lifting tool
9998248 Adapter
88880003 Bracket
9998248 Adapter
9998248 Adapter
9998248 Adapter
9998248 Adapter
9998248 Adapter
9998665 Adapter
9988539 Pressure gauge
9990006 Puller
9990262 Adapter
9996400 Impact puller
9998599 Cleaning tool
88820003 Setting tool
9993590 Gear wheel
This operation also includes the tools and times needed for required parts of the following actions:
214 Valves, adjusting
233 Fuel system, bleeding
Dismantling
1. Place the machine in service position.
2. Pump up the engine hood.
3. Drain the cylinder head to avoid fuel in the engine oil. Loosen and plug the hose connection in the engine's trailing
edge. Loosen the feed hose and lead it into a container. Since the feed pump will pump out fuel during the test, the
container's volume must be at least5 litres (1.3 US gal).
Figure 1
12. V1022266
4. Open the bleeder nipple on the cylinder head's leading edge and use an air nozzle in the fuel's inlet channel to lead
out the fuel.
NOTE!
Collect the excess fuel in a container.
5. Remove the hose from the oil trap and remove the valve cover.
NOTE!
Do not use a nut runner since the studs bolts may come loose from the cylinder head and damage electrical cables
and valve cover.
Figure 2
V1022264
6. Remove the unit injectors' electrical connections.
7. Remove the IEGR control valve's electrical connections and wipe clean around the control valve.
8. Remove the valve cover's stud bolt located in front of the IEGR control valve.
Figure 3
Stud bolt
9. Remove the bolts for the IEGR control valve. Remove the control valve and the pipe between the valve and the
13. rocker arm shaft.
Figure 4
V1050815
10. Loosen the bolts for the rocker arm bridge equally in sequences, so that the rocker arm shaft is not bent. Remove
the bolts and carefully lift away the rocker arm bridge with 9990185 and 88880003.
NOTE!
For engines with VEB: fixate the pistons in the rocker arms with rubber bands or similar so that the pistons do not
fall out.
NOTE!
Pistons and rocker arms are classed as units. Marking (one, two, or three dots) must match.
14. Figure 5
11. NOTE!
Clean very thoroughly around the unit injectors.
Remove the bolts for the unit injectors' attaching yoke. Remove the unit injector with 9996400 Impact
puller9990262 Adapter9990006 Puller.
NOTE!
Place each injector in separate new plastic bags. Mark which cylinder they were installed in. It is important to not
mix up the injectors since they are classed for a certain cylinder.
15. Figure 6
12. Clean the unit injectors' copper sleeves with a brush on an extension.
Figure 7
1.
2.
3.
Extension
Brush
Protective sleeve
13. Check that all adapters have O-rings and seal against the copper sleeve. Install adapters 9998248 in the unit
injectors' place in the cylinder head.
16. Figure 8
14. Tighten down the adapter with the unit injector's attaching yoke. Tightening torque: 40 Nm (30 lbf ft).
Figure 9
V1022271
15. Install the rocker arm bridge with the lifting tool 9990185. Tighten the bolts along the whole rocker arm shaft to
prevent warping and to make sure that the guide pins fit in the camshaft's support bearing. See
.
214 Rocker arm shaft, tightening torques
16. Install the IEGR control valve. Check that the seal ring is placed correctly before the bolts for the IEGR control valve
are tightened.
17. Transfer the rubber bands so that they are located between the adapter and the unit injector's rocker arm. This is
done so that the rocker arm will not rattle.
17. Figure 10
V1022272
18. The condition for reading off correct compression pressure is that the valve clearance is correct. See:
214 Valves, adjusting
19. Connect compression gauge 9988539 to adapter 9998248 on the first cylinder. Run the engine with the starter
motor until the needle on the compression gauge stops (max.compression value). Repeat the procedure for the
other cylinders. On a new engine, the compression pressure is normally approx. 30 bar. Low compression pressure
on all cylinders indicates worn cylinder liners and/or worn piston rings. When comparing the compression pressure
in the different cylinders and you detect any cylinder with lower pressure, this may be due to leaking valves,
cracked piston rings, worn cylinder liner, or leaking cylinder head gasket. In case of this, Engine, overhauling should
be done. Uniformity between the cylinders' compression pressure is the most important and should not exceed
20%.
NOTE!
The parking brake must be applied when cranking the engine with the starter motor.
NOTE!
Do not run the starter motor for longer than 10 seconds at a time, with intervals of 60 seconds.
Figure 11
V1022273
Assembling
20. Remove the compression gauge 9998539 and adapters 9998248.
21. Loosen the bolts for the rocker arm shaft evenly across the entire shaft, so that the rocker arm shaft is not
subjected to transverse loading. Remove the bolts and install lifting tool 9990185 and 88880003. Carefully lift away
the rocker arm shaft.
18. Figure 12
V1039942
22. Install the unit injectors with new O-rings and centre the unit injectors between the valve springs. Install the
attaching yokes. Tightening torque: see 230 Tightening torque, fuel system
Figure 13
23. Lift the rocker arm shaft into place with 9990185. Make sure that the guide pins fit in the support bearing for the
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20. camshaft. Tighten the attaching bolts, see: 214 Rocker arm shaft, tightening torques
24. Wipe clean the cylinder head by the IEGR-valve. Check for any impurities or dirt in the cylinder head's oil channel.
25. Install the IEGR control valve with new O-rings.
26. Install the stud bolt in front of the IEGR-valve.
27. Install the electrical connections for the unit injectors and the control valve.
28. Adjust the valves and the unit injectors, see .
214 Valves, adjusting
29. Install the valve cover. Tighten the bolts according to tightening diagram. Tightening torque, see
200 Engine, tightening torques
30. Install the fuel lines' connections on the cylinder head.
31. Bleed the fuel system, see 233 Fuel system, bleeding