Service Information

Document Title: Function Group: Information Type: Date:

Engine, assembling 210 Service Information 11/12/2017
Profile:
D7E

Engine, assembling
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D7E

Op nbr 210-078

Total procedure time (hr): 9.50

Tools:
885812 Timing tool
9992000 Handle
9992682 Sealing plug
9998672 Installation tool
9998678 Measuring tool
9998681 Rotation tool
88800316 Piston ring compressor
9998695 Installation tool
11668406 Installation tool

Socket or spanner Torx E10

Socket Torx E12

Socket Torx E18

Socket Torx E20

Lifting eyes M10

Lifting sling

Thread tap M8 with handle

Dial test indicator with magnetic base

Dial test indicator with angled base

Dial indicator for inside measurement (crankshaft)

Depth gauge
Piston ring pliers

Feeler gauge

Screw micrometer

Connecting rod testing device

Drift 20 mm

Steel ruler

Torque wrench, open end

Valve spring compressor

11713514 Sealing compound

Assembling
Timing gear casing, changing crankshaft seal

1. Tap out the crankshaft seal with a drift.

Figure 1

2. Lube the new crankshaft seal with oil and install it.

Figure 2
 1. 9992000 Handle
2. 9998672 Installation tool

Pressure control valve, installing

3. Clean the seat for the pressure control valve.

Check that the valve peg can be pushed in.
Apply locking fluid on the valve's sealing surface.

Figure 3

4. Install the valve.

Figure 4

5. Drive in the valve until it bottoms out, use a drift 20 mm (0.8 in).

Figure 5

Cylinder liner, installing

6. Make sure that the cylinder liner position and sealing surface are clean.

7. Install new O-rings.

Figure 6

1. O-rings

8. Lube the engine block and cylinder liner in the indicated area, marked with an x in the figure.

Figure 7

9. Install the cylinder liners in the engine block. Drive them down as far as possible.

NOTICE
Do not use sealing compound.

Figure 8
 10. Measure the cylinder liner's protrusion over the sealing face.
Place the measuring tool with adjustments and dial indicator on the engine block. Reset the dial indicator.
NOTE!
Place the adjustments on the block, not on the liner's edge.

Reset the dial indicator against the engine block's gasket face. Place the dial indicator against the cylinder liner's top
edge. Measure in three places on the cylinder liner.
Replace the cylinder liner if it's outside the tolerance. See Cylinder block, specifications

Figure 9

1. 9998678 Measuring tool

2. Dial indicator
3. Adjustments

Replace camshaft if there is major damage or wear. See Camshaft, specifications

All valve tappets should also be replaced when replacing the camshaft.
Camshaft, installing

11. Check that the contact surface against the camshaft on the valve tappets is convex or flat. If the surface is concave,
replace the valve tappets.
If the valve tappet is worn across the contact surface, the tappet must be discarded. The "ditch" shows that the tappet
has not been rotating. A dark line outermost on the contact surface however, indicates that the surface is not worn
down.
It is the condition of the valve tappets that determines whether a check of the camshaft wear is necessary.
Check that the contact surface against the camshaft on the valve tappets is convex or flat. If the surface is concave,
replace the valve tappets.
Check that the contact surfaces on the camshaft and the valve tappets do not have severe pitting damage. Pitting
damage may arise for varying reasons. The damage is caused by small bits of metal loosening from the hardened
surface. Tappets and camshaft with minor pitting damage may be used. Damage such as pitting usually does not get
any worse.
Check that the camshaft bearing races and cam profiles are not abnormally worn. The cams may, for example, be worn
obliquely in an axial direction. This can, if the damage is light, be adjusted by honing.
 Figure 10

1. Steel ruler

12. Lightly lubricate the valve tappets with oil and install them

Figure 11

13. Change the bearing bushings if they are worn.

NOTE!
The wider bushing, 27 mm (1.0 in), shall be installed on the flywheel side.

The lubrication hole slightly displaced from centre.

NOTE!
The lubrication holes must line up with the oil channels in the bearing positions.

Figure 12
Position of bearing bushings
Figure 13

1. Lubricating oil holes

14. Press in the bushings to correct position.

Figure 14

1. 9998695 Installation tool

Figure 15

1. Guide sleeve
2. Bearing bushing
3. Press sleeve

15. Install the camshaft.Weight approx. 25 kg (55 lbs).

NOTE!
 Take care not to damage the bearing bushings.

Check that the camshaft can rotate freely.

Figure 16

Crankshaft, installing

16. Install the piston cooling nozzles. Press them in as far as possible.

Figure 17

17. Install the bearing shells in the cylinder block and lubricate them with oil.
NOTE!
Make sure that the anti-rotation lug is installed correctly in the slot.

Figure 18
 1. Bearing shell

18. Install the bearing shells in the bearing caps and lubricate them with oil.
NOTE!
Make sure that the anti-rotation lug is installed correctly in the slot.

Figure 19

19. Wipe clean the bearing cap together with thrust bearing and thrust washers with pin. Install the thrust washers and
measure the width.

Figure 20

20. Determine axial run-out. Crankshaft pin's width, see Crankshaft, checking, minus the measured width of the bearing cap
and thrust washers give clearance in question.
Permitted axial run-out, see Crankshaft, specifications.

21. Lift the crankshaft into position. Make sure that the marking in relation to the camshaft gear will be correctly
positioned.
Crankshaft weight: approx. 75 kg (165 lbs).

Figure 21
 1. Marking (Camshaft marking may be hidden)

22. Lubricate the thrust washer halves without pin with oil and install them. Insert them into position under the crankshaft.
Turn the surfaces with the oil grooves toward the crankshaft's axial bearing surfaces.

Figure 22

23. Attach the other thrust washers onto the bearing cap with a little grease. Turn the washers so that the surfaces with oil
grooves are facing toward the thrust bearing surfaces on the crankshaft

Figure 23

24. Lubricate the bearing caps with oil and install them according to the marking. No. 1 nearest to the flywheel end.
Make sure that the thrust washers on the cap fit correctly against the washers in the block.

Figure 24
 25. Torque-tighten the bearing caps
Tightening torques, see Crankshaft, tightening torques

NOTICE
The bolts should be changed after the engine is dismantled for the third time.

Figure 25

26. Install the dial indicator with magnetic base. Pry with a pry bar and check the crankshaft run-out.
Permitted axial run-out, see Crankshaft, specifications.

Figure 26

1. Pinch-bar
2. Magnetic base
3. Dial indicator

Pistons and connecting rods, installing

27. Install the bearing shells in the connecting rods and lubricate them with oil.
 Figure 27

28. Use piston ring compressor and install the pistons with connecting rods from the cylinder head side. The flywheel
symbol shall face the flywheel side.

Figure 28

1. 88800316 Piston ring compressor

Figure 29
Flywheel symbol

29. Lubricate the big-end bearing journals on the crankshaft with oil. Push the connecting rod against the bearing journal
and install the caps according to markings.
Install new bolts and tighten them down.
Tightening torques, see Crankshaft, tightening torques

Figure 30
Timing gear casing, installing

30. Remove any gasket remnants from the timing gear casing and the cylinder block.

31. Use sealant Volvo 11713514 on the timing gear casing's sealing face.

Figure 31
Sealing face

32. Lightly oil the crankshaft oil seal.

33. Install the timing gear casing without tightening down the bolts. Position the casing aligned with the sealing surface on
the oil sump.

Figure 32

34. Tighten the bolts (except the two bolts where the rotation tool is to be secured).
Tightening torque: see Timing gear casing, tightening torques .

35. Check that the crankshaft can rotate freely.

Front cover with oil pump, installing

36. Install the rotation tool.

 Figure 33

1. 9998681 Rotation tool

37. Turn the engine in the adjustable stand so that the front end comes upward.

38. Clean the cover and the cylinder block from any gasket remnants.

39. Overhaul the oil pump according to Oil pump removed, reconditioning.

40. Lightly oil the oil pump rotors.

Figure 34

41. Secure the gasket on the housing with a little grease.

Figure 35

42. Place the oil pump's drive against the crankshaft.

NOTE!
The drive only fits in one position.
 Figure 36

43. Install the housing with the oil pump without tightening down the bolts. Fit the housing against the oil sump's sealing
face.

Figure 37

44. Tighten the bolts.

Tightening torque: see Oil pump, tightening torques .

45. Check the position of the wear groove on the crankshaft.

Figure 38
 1. Wear groove

46. Install the guide (inner part of 11668406 Installation tool). Lubricate the crankshaft seal with oil and install it with the
felt side facing out.

Figure 39

1. Crankshaft oil seal

2. Guide

47. Install any spacer washers, press sleeve, the bearing and the nut. Use the number of washers required to prevent the
new crankshaft oil seal from ending up in the same position as the old one.

Figure 40

1. Washers
2. Press sleeve
3. Bearing
4. Nut

48. Screw the nut until stop. Check that the seal ends up in the correct position.

49. Install the ring gear and the V-belt pulley and align the guide sleeve and the guide pin.
 Figure 41

1. Guide sleeve
2. Guide pin

50. Tighten the bolts (Torx E20), counterhold with the rotation tool on the flywheel side.
Tightening torque: see Belt pulley/vibration damper, tightening torques.

Figure 42

1. Torx E20
2. V-belt pulley
3. Toothed wheel

51. Check that the oscillation dampers are free from external damage.
Install inner vibration damper and the spacer. Make sure that the bolt holes align with the holes in the belt pulley.

Figure 43
 1. Spacer
2. Vibration damper

52. Install outer vibration damper and the washer. Tighten down the bolts.
Tightening torque: see Belt pulley/vibration damper, tightening torques .

Figure 44

53. Install the ladder frame.

Figure 45
Ladder frame
NOTE!
Allen head bolts are placed in the corners.

Tighten the bolts.

Tightening torque: see Oil sump, tightening torque.

54. Install a new gasket on the oil suction pipe's connection to the front cover.
 Figure 46

1. Gasket

Install the oil suction pipe with bracket.

Tightening torque: see Oil sump, tightening torque.

55. Install the oil filler pipe.

Figure 47

1. Oil suction pipe

2. Mounting
3. Oil filler pipe

56. Fill the joints between the covers and the oil sump with sealant.

Figure 48

57. Use sealant Volvo 11713514 on the engine block.

 58. Install the oil sump and tighten down the bolts.
Tightening torque: see Oil sump, tightening torque.

Figure 49

59. Install the level sensor's clamps.

Power take-off housing, installing

60. Install the power take-off housing. Apply locking fluid and tighten down the bolts (sockets Torx E10 and E12).

61. Install the oil pipe.

Figure 50

1. Attaching bolts
2. Oil pipe

Flywheel, installing

62. Rotate the engine in the work stand so that the flywheel side faces up.

63. Check that the guide sleeves are in place.

 Figure 51

1. Guide sleeve

64. Lift the flywheel housing Weight: approx 35 kg (77 lbs)..

Install and tighten the bolts by hand.
Pre-tighten the bolts 2, 3, 4, 5 as shown.
Tighten final torque on bolts 1, 6.
Tighten final torque on bolts 2, 3, 4, 5.
Tightening torque, seese Flywheel, tightening torques.

Figure 52

65. Lift the flywheel housing into place.Weight: approx 35 kg (77 lbs).
 Figure 53

1. Lifting eyes M10

66. Install the bolts and tighten them. Use the rotation tool as counterhold.
NOTE!
Use new bolts.

Tightening torque:see Flywheel, tightening torques

Figure 54

1. 9998681 Rotation tool

67. Install the cover washer.

Figure 55
Oil cooler and oil filter, installing

68. Remove protective plugs and masking tape. Install the oil cooler with a new gasket. Install the bolts and tighten them.
Tightening torque: see Oil cooler, tightening torques.

Figure 56

69. Install a new oil filter.

Cylinder head gaskets are marked with one, two, or three holes in one of the corners. The gaskets shall be used for different
piston heights above the cylinder block's face.

Figure 57

1. Marking of cylinder head gasket

Determining thickness of cylinder head gasket

Pistons' height above engine block

70. Install the rotation tool on the engine, 9998681 Rotation tool.

71. Install the measuring tool with spacer washers and dial indicator on the engine block. Reset the dial indicator to zero.
NOTE!
Place the spacer washers on the block, not on the liner edge.
 Figure 58

1. 9998678 Measuring tool

2. Dial indicator
3. Spacer washers

72. Rotate the crankshaft with the rotation tool to find the piston's highest position. Measure at two points diagonally on
the piston's upper edge straight above the piston pin. Read off the height on the indicator.

Figure 59
Measuring points

73. Repeat the same measurement on all pistons. Note the highest value and use cylinder head gasket according to
Cylinder head, specifications.

Figure 60
Cylinder head, installing

74. Place the cylinder head gasket on the cylinder block with the digits upward. Place the guide sleeves in the holes.

Figure 61

1. Guide sleeves

75. Lift the cylinder head into position. Pay attention to the guide sleeves.
Cylinder head weight: approx. 65 kg (143 lbs)

Figure 62

76. Oil the bolts lightly and install them. Tighten them in three steps, note the sequence.
NOTE!
The same bolts may be used max. 3 times.

Tightening torque: Cylinder head, tightening torques.

Use protractor 885812 Timing tool

Figure 63
Torque-tightening, sequence

77. Install the push rods.

 Figure 64
Push rods

78. Install the rocker arm holders according to marking. Line them up with the push rods and valves, and tighten the bolts.
Tightening torque: see Valve mechanism, tightening torques.

Figure 65

Valve adjustment

79. Adjust the valve clearance, see Valves, adjusting.

Pumps, installing

80. Install the roller tappets. Make sure that the correct tappet is installed in the correct place according to markings on the
unit pumps.
Make sure that the guide on the tappet ends up in the groove in the material.
 Figure 66

1. Guide

81. Install new O-rings on the pumps.

Install the pumps. Install the bolts but do not tighten at this time.

Figure 67

1. Fuel return pipe

2. High-pressure pumps
3. Fuel control valve

82. Install the fuel control valve. Install the bolts but do not tighten at this time.

83. Install the high-pressure fuel pipes.

NOTE!
Use new fuel pipes and copper washers.

Tighten the nuts for the fuel pipes and the bolts for the pumps.
Tightening torque: see Fuel system, tightening torques.
Exhaust pipe, inlet manifold, and valve cover, installing

84. Install the exhaust pipe with new gaskets. The gasket flange shall point to the cylinder head.
Use paste for bolted flanges on the studs' threads. Install and tighten the nuts, starting from the middle of the engine
and working outward.
Tightening torque: see Exhaust manifold, tightening torques .

Figure 68

1. Exhaust pipe

85. Install the charge-air pipe with new gaskets and tighten the bolts.
Tightening torque: see Charge-air pipe, tightening torque .

Figure 69

1. Charge air pipe

86. Place the gasket for the valve cover on the cylinder head.
Install the valve cover and tighten down the bolts.
Tightening torque: see Cylinder head, tightening torques.
 Figure 70

87. Install the preheating coil.

Tightening torque: see Charge-air pipe, tightening torque.

Oil trap, installing

88. Install a new gasket in the groove on the oil trap.

Align the oil trap connection with the oil line.
Tighten down the oil trap against the valve cover.
Tightening torque: see Oil trap, tightening torque.

Figure 71

1. Oil trap

Coolant pump and thermostat housing, installing

89. Check that the coolant pump has no noticeable play.

Remove the protective tape. Install the coolant pump with new gasket. Tighten the bolts loosely.

Figure 72

90. Lubricate the O-rings and install the intermediate housing.

 Figure 73

91. Install the thermostat housing, use new gasket.

Figure 74

92. Tighten all bolts for the coolant pump and the thermostat housing.
Tightening torque: see Coolant thermostat housing, tightening torques .

Crankshaft sensor, installing

93. Install the crankshaft's speed sensor. Hand-tighten the bolts.

Insert a feeler gauge between the ring gear and the speed sensor. See Speed sensor, specifications.
Lightly press the sensor against the feeler gauge. Tighten the bolts.
Tightening torque: see Speed sensor, tightening torque
Check the clearance.
 Figure 75
Checking clearance

Fuel pump, installing

94. Install the fuel pump with lines and filter. Tighten the bolts loosely.

Figure 76

1. Fuel filter
2. Fuel feed pump

95. Install the V-belt on the belt pulleys. Tension the belt by moving the fuel pump. At correct tension it should be possible
to press down the belt approx. 10 mm (0.4 in) in the middle between the belt pulleys.
Tighten the bolts for the belt tensioner.
Tightening torque: see Belt pulley/vibration damper, tightening torques.
Tighten the bolts for the filter housing.
Tightening torque: see Fuel system, tightening torques
 Figure 77

1. Belt adjustment
2. Fuel feed pump's bracket
3. Water pump

Injectors and fuel lines, installing

96. Install new O-rings and seal rings on the injectors.

Install the injectors together with the holder. Torque-tighten the bolts.
Tightening torque Injectors, tightening torques.

Figure 78
 1. Injectors
2. Retainer

97. Install the fuel rail and tighten the bolts loosely.

Figure 79

1. Fuel rail

98. Install new fuel pipes between injectors and the fuel rail.

Figure 80

1. Fuel delivery line

99. Torque-tighten the bolts for the fuel rail.

Tightening torque: see Fuel system, tightening torques.

100. Torque-tighten the fuel pressure pipes

 Tightening torque: see Fuel system, tightening torques.

101. Install the return fuel line.

Tightening torque: see Fuel system, tightening torques.

Figure 81

1. Fuel return pipe

2. High-pressure pumps
3. Fuel control valve

102. Remove the rotation tool and reinstall the cover. Use a new O-ring.
Tightening torque: see Timing gear casing, tightening torques.

Figure 82

1. Cover

Starter motor

103. Install the starter motor.

Tightening torque, see Engine, tighten torques.
Cable rail with cable harness, installing

104. Install the cable harness.

Install the electrical connections for the injectors. Tightening torque, see Fuel system, tightening torques
Plug in the connectors for the fuel control valve, oil pressure sensor, fuel feed pressure sensor, and the fuel pressure
sensor in the fuel rail.
Clamp the cable harness.

Figure 83

1. Connector E-ECU
2. Fuel control valve
3. Injectors
4. Fuel feed pressure sensor
5. Oil pressure sensor
6. Fuel pressure sensor

105. Plug in the connectors for coolant temperature sensor, boost pressure sensor, solenoid valve for I-EGR, and the rpm
sensor.
Clamp the cable harness.

Figure 84

1. Boost pressure sensor

2. Coolant temperature sensor
3. Solenoid valve I-EGR
4. Revolution sensor camshaft