DService BulletinVolvo Trucks North AmericaGreensboro, NC USA

Date Group No. Page

2.2007 251 39 1(14)

Trucks

Intake Manifold GasketReplacement

D16F

Intake Manifold Gasket Replacement

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This information covers the proper procedure for replacing the intake manifold gasket onthe Volvo D16F engine.

Contents• “Gaskets, Intake Manifold, Replacement” page 2

Note: Information is subject to change without notice.Illustrations are used for reference only, and may differ slightly from the actual engineversion. However, key components addressed in this information are represented asaccurately as possible.

PV776-20177483 USA23165.ihval

DVolvo Trucks North America Date Group No. Page

Service Bulletin 2.2007 251 39 2(14)

2512-03-02-01Gaskets, Intake Manifold, Replacement

See also:

• “Intake Manifold Gasket Replacement” page 1

You must read and understand the precautions andguidelines in Service Information, group 20, "GeneralSafety Practices, Engine" before performing thisprocedure. If you are not properly trained and certifiedin this procedure, ask your supervisor for trainingbefore you perform it.

Removal1Apply the parking brake and place the shift leverin neutral.

2

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Remove all cables from ground (negative) batteryterminals to prevent personal injury from electrical shock.

3Remove inner splash guard as an assembly.

Note: Some models may be equipped with fenderextenders, attached to the inner splash guard. Removethese as an assembly

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Service Bulletin 2.2007 251 39 3(14)

4

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Remove V-band clamps at the charge air cooler andthe mixing chamber. Remove the hose and pipe as anassembly.

5Loosen the clamp and mounting brackets to allow aircompressor fresh air pipe to be relocated.

6Disconnect the discharge line and mounting bracketsfrom the air compressor and intake manifold. Move thedischarge line out of the way and strap in place.

7Remove the bracket securing the A/C suction hoseto the intake manifold.

8

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Remove crankcase ventilation tube from valve coverand P-clamp at the intake manifold.

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Service Bulletin 2.2007 251 39 4(14)

9

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Remove crankcase ventilation tube from separator.

10

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Disconnect the electrical connector from the charge airboost sensor located on the top of the EGR mixingchamber. Cut the tie strap securing the harness andallow the harness to hang out of the way.

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Service Bulletin 2.2007 251 39 5(14)

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Loosen both hose clamps securing the EGR inlet hose tothe mixing chamber pipe. Slide the hose down to free itfrom the inlet pipe and discard the hose. Remove thebolts from the inlet pipe connection at the mixing chamberand remove the pipe.

Note: EGR inlet gas hose should not be reused.

12

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If equipped, remove all power and ground wire connectorsfrom the inlet air preheater. Mark the wire locations beforeremoval to ensure correct wire installation at reassembly.

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Service Bulletin 2.2007 251 39 6(14)

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If equipped, disconnect the inlet air preheater electricalharness connector from the preheater relay. Also,disconnect the charge air temperature sensor connectorand cut the tie strap securing the harness at theintake manifold.

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Remove the EGR mixer mounting bolts, then remove theEGR mixer and preheater (if equipped) or spacer blockoff the intake manifold.

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Service Bulletin 2.2007 251 39 7(14)

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If equipped, remove the fastener securing the preheaterrelay supporting bracket to the intake manifold. Also,remove the fastener securing the P-clamps for the DRVair line and preheater control harness. This will allowthe preheater relay (with wires and mounting bracketattached) to hang free.

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Remove the P-clamps securing the fuel line and engineharness.

17Remove two top intake manifold mounting bolts andinstall two alignment pins to support the manifold.

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Service Bulletin 2.2007 251 39 8(14)

18

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Remove the remaining intake manifold mounting bolts.Using a plastic mallet, carefully tap the manifold looseand remove.

19

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Using a sharp pick, carefully remove the rubber seal(molded gasket) from the groove in the intake manifold.Also, remove all gasket material from the forwardsealing surface.

20Clean manifold of any dirt, adhesives and inspect forany damage to the sealing surface. Also, inspect thecylinder head and ensure the sealing surface is cleanand undamaged.

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Service Bulletin 2.2007 251 39 9(14)

Installation1Install a new rubber seal (molded gasket) into the grooveof the intake manifold.

2

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Position the intake manifold onto the two previouslyinstalled alignment pins. Start two mounting bolts to holdthe manifold in place, then remove the alignment pins andinstall the remaining manifold bolts.

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Torque-tighten the intake manifold bolts to specification inthe sequence shown.

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Service Bulletin 2.2007 251 39 10(14)

4

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Install the P-clamps securing the fuel line and engineharness.

5

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Install crankcase ventilation tube to separator.

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Service Bulletin 2.2007 251 39 11(14)

6

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Install the fasteners securing crankcase ventilation tubeto valve cover and intake manifold. Torque-tightenfasteners to 24 ± 4 Nm (18 ± 3 ft-lb).

Note: Inspect the crankcase ventilation tube O-ringand replace if necessary.

Note: Ensure that the same bolts that were removedat disassembly are reinstalled in the same location.Damage to the valve cover will result if the bolts installedare too long.

24 ± 4 Nm(18 ± 3 ft-lb)

7

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If equipped, position and secure the preheater relaysupporting bracket to the intake manifold. Also, install thefastener securing the P-clamps for the DRV air line andpreheater control harness.

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Service Bulletin 2.2007 251 39 12(14)

8

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Position the EGR mixing chamber and inlet air preheater(if equipped), or spacer block with new gaskets onto theintake manifold. Next, start the bolts to hold the assemblyto the intake manifold. Tighten all mixing chamberfasteners to specification.

9

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If equipped, connect the inlet air preheater electricalharness connector to the preheater relay. Also, connectthe charge air temperature sensor connector and installthe tie strap securing the harness to the intake manifold.

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Service Bulletin 2.2007 251 39 13(14)

10

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If equipped, install all power and ground wire connectorsto the inlet air preheater at the previously markedlocations.

11Connect the air compressor discharge line and mountingbrackets to the air compressor and intake manifold.

12Position and secure air compressor fresh air inlet pipe.

13Install the bracket securing the A/C suction hose to theintake manifold.

14

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Position and secure charge air cooler outlet hose andpipe assembly located between the charge air cooler andEGR mixing chamber.

Note: Check V-band clamp for galled threads anddeformation. V-band clamps must be lubricated beforeinstallation.

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Service Bulletin 2.2007 251 39 14(14)

15

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Install a new O-ring in the EGR inlet pipe. Then, positionthe pipe onto the mixing chamber of the intake manifoldand install the bolts securing the EGR inlet pipe to themixing chamber. Next, position a new EGR gas inlethose between the inlet pipe and venturi pipe and securewith two clamps.

Note: EGR inlet gas hose should not be reused.

16

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Reconnect the electrical connector to the charge air boostsensor located on the top of the EGR mixing chamber.Connect the tie strap securing the sensor harness.

17Install the inner splash guard assembly.

18

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Install all previously removed cables to the ground(negative) battery terminals.

19Start the engine, check for leaks and proper operation.After shutdown, replenish fluids as necessary.