Service Bulletin Volvo Trucks North America D … Engine Manuals/D13/Timing...Service Bulletin Volvo Trucks North America Greensboro, ... Volvo Trucks North America D ... ask your

DService BulletinVolvo Trucks North AmericaGreensboro, NC USA

Date Group No. Page

2.2007 215 46 1(25)

Trucks

Timing Gear CoverReplacement

D13F

Timing Gear Cover, Replacement

W2005779

This information covers replacement of the timing gear cover on a Volvo D13F engine.

Contents• “Special Tools” page 2• “Timing Gear Cover, Replacement” page 3

Note: Information is subject to change without notice.Illustrations are used for reference only and can differ slightly from the actual vehiclebeing serviced. However, key components addressed in this information arerepresented as accurately as possible.

PV776-20177361 USA23019.ihval

DVolvo Trucks North America Date Group No. Page

Service Bulletin 2.2007 215 46 2(25)

ToolsSpecial ToolsFor special tool ordering instructions, see tool informationin group 08.

W2006190

85111422A/BTiming Cover Clamp Tools

T0012612

W0002268

88800014Flywheel Turning Tool

88800031Sensor Depth Gauge



Service Procedures2151-03-02-02

Timing Gear Cover, Replacement

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 training beforeyou perform the procedure.

Special tools: 85111422A, 85111422B,88800014, 88800031

Removal1Apply the parking brake and place the shift leverin neutral.

2Remove 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.

4Remove engine cover.

5

W2003861

Disconnect and remove the air filter restriction gaugewiring harness from air filter housing.



6

W2004720

Unplug the air temperature sensor wiring harnessconnector. Remove the lock tab and separate theconnector from the sensor. Remove the clamp fromthe main fresh air pipe.

7

W2004719

Loosen the air compressor fresh air hose clamp atthe main fresh air pipe.



8

W2006005

Loosen the clamps and remove the main fresh air pipeclamp from the air compressor fresh air hose, the air filterhousing and the turbocharger air inlet elbow.

9

W2003858

Remove the fasteners and lift the air filter housingaway from the cab.

10

W2005960

Loosen the V-clamps and remove the EGR crossoverpipe.

11Loosen the clamp and mounting brackets to allow aircompressor fresh air pipe to be removed.



12

W2006122

Remove the fasteners which secure crankcase ventilationtube and bracket to valve cover and intake manifold.Relocate the tube away from the manifold.

13Remove the hydrocarbon (aftertreatment fuel) injectorharness clips at the valve cover.

14

T2022732

Remove the spring-loaded bolts from the valve cover.

15Lift and remove the valve cover.



16

W2005952

Remove the exhaust pipe from between the diffuser pipeand the Diesel Particulate Filter (DPF) muffler inlet pipe.Lift the pipe over the diffuser and out from under the cab.

17

W2005951

Remove the fuel line from the hydrocarbon (aftertreatmentfuel) injector.

18Remove the fasteners securing the hydrocarbon injectorfuel line to the EGR valve heat shield.



19

W2005642

Loosen the high temperature V-clamps at the EGR hotpipe by removing the nuts from the T-bolts. Free theclamps from the EGR hot pipe flanges.

20

W2005641

Remove the EGR hot pipe from between the EGRvalve and the EGR cooler.



21

W2005685

Remove the fasteners securing the EGR valve heat shieldand remove the shield.

22

W2005689

Disconnect the wiring harness connector from theEGR valve.



23

W2005954

Loosen, but do not remove, the EGR valve mounting bolts.

Note: Loosening the EGR valve provides clearance forremoving the oil return line.

24

W2005955

Remove the EGR valve oil return line.

Note: P-clamp fasteners may need to be removed tofree oil line.

Note: Oil supply line will remain attached.



25

W2005104

Disconnect the camshaft position sensor harnessconnector, remove the bolt and pull out the sensor.

26

W2006132

Remove all straps, P-clamps and other retainers used torestrain harnesses, oil lines and coolant tubes to therear of the engine. This will allow support bracket at therear of the engine to be removed.

27Remove support bracket fasteners and remove the rearsupport bracket.

28Remove the fasteners securing the vibration damper tothe camshaft gear. Leave camshaft gear in place.



29

W2006133

Remove the timing gear cover fasteners and removethe cover.

30Clean all gasket sealing surfaces. All surfaces must becompletely free of any grease or oil.

Installation1

W2006134

Install the timing gear cover seals and gaskets.



2

W2005102

Apply sealant in the bottom corners where the timinggear plate and the flywheel housing meet. Also applysealant to the top of the timing gear plate (in the corner)next to the cylinder head.

3

W2005137

Apply sealant to the mating surfaces of the timing gearcover.

4

W2006133

Position the timing gear cover, install the fastenersmarked 1 and 2.



5

W2006191

Install the timing cover clamp tools so that the timinggear cover surface is flush with the seal surface onthe cylinder head.

85111422A, 85111422B

6

W2006133

Torque the timing gear cover fasteners to 24 ± 4 Nm (18± 3 ft-lb) in the sequence shown.

24 ± 4 Nm(18 ± 3 ft-lb)

7Remove the timing cover clamp tools.



8

W0002368

Remove the plug from the flywheel housing and installthe flywheel turning tool.

88800014

9

W2006135

Install vibration damper and gear clamp plate with newfasteners if the reusability limit has been exceeded (referto Specifications, Tightening Torques and Patterns).Torque-tighten damper mounting screws in two steps inthe sequence shown.

Step 1 — 45 ± 5 Nm (33 ± 4 ft-lb)Step 2 — 90 ± 5 degrees

Note: Bolts and screws that have limited reusability mustbe marked with a punch each time they are installed inservice. Bolts and screws with four punch marks whenremoved have been tightened five times and must bediscarded and replaced with new.

CAUTION

Do not reuse timing gear mounting plate bolts.

45 ± 5 Nm(33 ± 4 ft-lb)90 ± 5 degrees

10Position the rear support bracket onto the rear of engineand install support bracket fasteners to secure.



11

W2006132

Install all tie straps, P-clamps and other retainers usedto restrain harnesses, oil lines and coolant tubes tothe rear of the engine.

12

W2005068

Check for proper camshaft position sensor clearanceusing the sensor depth gauge to determine if shims arerequired for sensor depth. The camshaft position sensorclearance specification is 0.3–1.0 mm (0.011–0.039 inch).

1 Rotate the engine until a tooth of the camshaft toothedwheel is aligned with the sensor bore.

2 Insert the depth gauge into the sensor bore untilthe outer part of the gauge is fully seated againstthe timing gear cover.

3 Loosen the thumb screw of the gauge and push theinner part of the gauge in until it contacts a toothof the toothed wheel.

4 Tighten the thumb screw to secure the inner part ofthe gauge.

5 Carefully remove the gauge from the camshaft sensorbore and observe the location of steps between theinner and outer portions of the gauge:

• Both steps below the surface of the gauge = noshims required.

• One step below the surface of the gauge = oneshim required.

• Both steps above the surface of the gauge = twoshims required.

88800031



13

W2005104

Install the camshaft position sensor with appropriateshim(s), new O-ring, secure with bolt and plug in harnessconnector.

Note: The camshaft position sensor shim part number is20556179.

14

W2005693

With the EGR valve near the exhaust manifold ports,remove mounting bolts then slip a new metal gasketbetween the valve and the exhaust manifold. Start newbolts to hold the EGR valve and gasket in place.

15

W2005955

Install EGR valve oil line and torque-tighten tospecification.



16Torque-tighten the EGR valve mounting bolts tospecification.

17

W2005689

Connect the wiring harness connector to the EGR valve.

18

W2005685

Place the EGR heat shield in position over the EGR valve.Install the fasteners to secure the shield to the cylinderblock and to the studs on the valve mounting bolt heads.Tighten the fasteners to specification.

19Install new high temperature gaskets into the EGR valveend of the hot pipe and the inlet of the EGR cooler.Ensure the gaskets lay flat against the flange surfaces.

20Inspect the V-clamps and T-bolt threads for wear ordamage. If they are OK, apply anti-sieze compoundto the T-bolt threads. Lubricate the V-inserts of theclamps with oil.



21

W2005641

Hook the upper V-clamp over the EGR valve flange. Placethe remaining V-clamp over the bellows on the hot pipe.

22Lubricate the flange on the EGR cooler inlet and theflange on the EGR hot pipe with fresh engine oil.Lubrication aids in proper V-clamp installation.

23Position the EGR hot pipe between the EGR valve andthe EGR cooler. Make sure the flanges engage properly.Slide the upper V-clamp over the flange and tighten untilsnug. Slide the lower V-clamp over the flange andtighten the clamp until snug.

24Make sure the hot pipe flange is seated properly in theEGR cooler. The hot pipe flange must be concentricwith the cooler flange.

25Position the V-clamps so that the T-bolts clear both heatshields. Tighten the clamps to specification.

Note: After reaching the specified torque, inspect theV-clamps to make sure that no portion of the clamp has“bottomed out.”



26

W2006038

Position the exhaust pipe between the diffuser pipe andthe DPF muffler inlet pipe and loosely install the V-clamps.

27Adjust the exhaust pipe and diffuser pipe as needed andthen, tighten the V-clamps to specification.

28

W2005951

Install the fuel line to the hydrocarbon injector. Installthe hydrocarbon injector fuel line clamp to the EGRvalve heat shield.



29

W2005157

Apply a 2 mm (0.079 inch) bead of Volvo sealant to thearea where the timing cover and the cylinder head meet.This parting line is on both sides of the cylinder head.Carefully position the valve cover on the cylinder headand make sure that the seal remains properly seated.

30

T2022732

Install the spring-loaded bolts in the valve cover.Torque-tighten the valve cover bolts to 24 ± 4 Nm (18± 3 ft-lb) in the sequence shown.

24 ± 4 Nm(18 ± 3 ft-lb)

31Connect the discharge line and mounting bracketsto the air compressor.

32Install the hydrocarbon injector harness clips to thevalve cover.



33

W2005960

1 Venturi Outlet Pipe2 Crossover Pipe3 Mixer Inlet Pipe

Position the crossover pipe (with new O-rings) betweenthe venturi outlet pipe and the mixer inlet pipe.

34

W2005804

Install a V-clamp at each end of the crossover pipe andtighten the clamps to secure the pipe.

Note: Make sure the O-rings remain in place whilepositioning the pipe.

35Install the air compressor fresh air pipe to the aircompressor. Secure the mounting brackets to thecylinder head.



36

W2006122

Install the fasteners securing crankcase ventilationtube and bracket to valve cover and intake manifold.Torque-tighten fasteners 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 too long ofbolts are installed.

24 ± 4 Nm(18 ± 3 ft-lb)

37

W2003858

Position the air filter housing against the cab and installfasteners to secure.

38

W2006005

Install the main fresh air pipe between the air filterhousing and the turbocharger air inlet elbow. Positionthe clamps and tighten to secure.



39

W2004719

Install the air compressor fresh air hose to the main freshair pipe, position the clamp and tighten to secure.

40

W2004720

Install the air temperature sensor connector to the sensor.Insert and secure the connector lock tab. Install thesensor harness clamp to the main fresh air pipe.



41

W2003861

Connect and secure the air filter restriction gauge wiringharness to air filter housing.

42Install engine cover.

43Install the inner splash guard assembly.

44Install all previously removed cables to the ground(negative) battery terminals.

45Start the engine, check for leaks and proper operation.

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Service Bulletin Volvo Trucks North America D … Engine Manuals/D13/Timing...Service Bulletin Volvo Trucks North America Greensboro, ... Volvo Trucks North America D ... ask your