Service Manual

Buses
Section 2 (20–27)
Engine DH10A,
245, 285, 345, 350, 360

TP 16031/1
 Contents

Group 20: General Group 23: Fuel system

Variant description DH10A .............................. 2 Detailed list of contents .................................... 88
Performance ...................................................... 3 Injection pump .................................................. 91
Specifications ................................................... 4 Injection timer .................................................. 92
Wear tolerances ................................................ 15 Injectors ............................................................ 94
Tightening torques ............................................ 16
Special tools ..................................................... 17 Group 25: Inlet and exhaust systems
Removing and installing engine ....................... 25 Detailed list of contents .................................... 110
Servicing the engine: Air cleaner ........................................................ 111
– Replacing fuel filters ................................... 31 Intercooler, pressure-drop indicator ................. 112
– Topping-up oil ............................................. 32 Starting pre-heater ............................................ 113
– Replacing oil filters ..................................... 33 Turbocompressor .............................................. 115
– Replacing coolant filter ............................... 33 Exhaust pressure governor ............................... 125
– Condition test, compression test.................. 34
– Charge pressure ........................................... 35 Group 26: Cooling system
– Fuel feed pressure........................................ 37 Detailed list of contents .................................... 127
– Oil pressure ................................................. 38 Main thermostat ................................................ 130
– Pressure-testing cooling system .................. 38 Coolant pump ................................................... 131
– Valve tappets, valve timing ......................... 38 Intercooler ........................................................ 135
– Valve adjustment ......................................... 39 Cooling fan ....................................................... 137
High coolant temperature ................................. 141
Group 21: Engine Fan drive ........................................................... 143
Detailed list of contents .................................... 40
Cylinder head ................................................... 41 Group 27: Engine controls
Cylinder liners, pistons, connecting rods ......... 51 Detailed list of contents .................................... 145
Cylinder block, crank mechanism .................... 58 Description EDC .............................................. 146
EDC-components in electrical
Group 22: Lubricating system distributor unit .............................................. 148
Detailed list of contents .................................... 79 Fault diagnosis .................................................. 150
Oil pump ........................................................... 83 Troubleshooting ................................................ 155
Oil cooler .......................................................... 87

Order number: TP 16031/1

1
 Engine DH10A

Variants
Common characteristics: The DH10A-series is largely been changed but still build on the re-entry model, that
based on the earlier THD104 engine. Characteristics: is, a more favourable air rotation and thereby a more
Horizontal design, turbocompressor feed, 9.6 liter dis- complete combustion. The injection system is electron-
placement. Single circuit coolant-intercooler, separated ically controlled (EDC). Injection pressure has been
from the ordinary coolant system. Lube system with raised as a result of changes in the injection pump.
two full-flow filters and piston cooling from oil sprayed Other nozzles also contribute to better combustion, re-
onto the pistons from underneath. Piston peaks have sulting in lower emissions and lower fuel consumption.

Basic engine Type Specific characteristics and areas of use Bus type

DH10A 245 180 kW. B10B, L, B10M

Low emissions for city buses. Wastegate and water-cooled turbo for 1996–
flatter torque curve.
DH10A 285 210 kW. Low emissions engine for city buses, e.g., articulated buses, B10B, L, B10M
bogie buses. Wastegate and water-cooled turbo for flatter torque 1996–
curve.
DH10A 345 250 kW. B10M 1996–
Engine for Japan. Low Nox-value as per Japanese requirements.
Altered a. Otherwise similar to 360.
DH10A 350 260 kW. B10M 1996–
Engine for Taiwan and other countries. Altered a and no injection
timer. Otherwise similar to 360.

DH10A 360 265 kW.

High-output engine for tourist coaches and long-distance buses. B10M, B10B
Large number produced. Injection pump has a timer that is electroni- 1996–
cally controlled. Saves fuel at high power output.

Net output has been measured in accordance with ISO 1585 and SAE J 1349. Smoke requirements met according to ECE/
EEC and the Swedish regulations. DH10A fulfils smoke requirements as per 91/542/EEC, Level B (Euro 2) (EC96).

2
Performance

kW Output Effekt Leistung Puissance Potentia kW Output Effekt Leistung Puissance Potentia

220 280
285 EC96
360 EC96
200 260
350 TW95
345 J96
180 245 EC96 240

160 220

140 200

120 180

100 160

80 140

60 120

1000 1200 1400 1600 1800 2000 2200 2400rpm 1000 1200 1400 1600 1800 2000 2200 2400rpm

Nm Torque Vridmoment Drehmoment Couple Par motor Nm Torque Vridmoment Drehmoment Couple Par motor

1200 1600
360 EC96
1000 285 EC96 1400 350 TW95
800 245 EC96 1200 345 J96

1000 1200 1400 1600 1800 2000 2200 2400rpm 1000 1200 1400 1600 1800 2000 2200 2400rpm

DH10A 245, 285 DH10A 345, 350, 360

3
 Specifications
General
ENGINE DH10A
Type designation ............................ 245 285 345 350 360
Net output* kW/hp ......................... 180/245 210/285 254/345 255/350 265/360
at speed r/s / r/min ...................... 33/2000 33/2000 33/2000 33/2000 34.2/2050
Max. torque Nm/kpm
at 20 r/s (1200 r/min) .................. 1050/107 1200/122 1440/146 1500/153 1500/153
* Net as per ISO 1585.

Number of cylinders ..................................................... 6

Bore .............................................................................. 120.65 mm
Stroke ............................................................................ 140 mm
Displacement ................................................................ 9.6 dm3 (9.6 liter)

DH10A DH10A
245, 285 345, 350, 360
Compression ratio 20:1 18:1
Firing sequence ............................................................. 1-5-3-6-2-4
Direction of rotation (B10M frontal view,
B10B rear view, engine installed in bus) ................ Clockwise

Low idle ........................................................................ 8.8±0.8 r/s 8.8±0.8 r/s

(530±50 r/min) (530±50 r/min)

High idle ....................................................................... 36.6±0.8 r/s 36.6±0.8 r/s

(2200±50 r/min) (2200±50 r/min)

De-regulating speed begins at ...................................... 34.8 r/s 38.8±0.8 r/s

(2085 r/min) (2330±50 r/min)

Weight, engine with flywheel, flywheel housing and

starter motor, approx ............................................... 960–980 kg
Maximum length x width x height ............................... 1460 x 1375 x 590 mm

4
Engine block Piston rings
Compression rings
Cylinder head Number .................................... 2
Type ...................................... 1 per cylinder Piston-ring clearance in groove,
Height, new ........................... 114.85–115.15 mm upper compression ring ...... 0.13 mm
after machining min. 114.65 mm lower compression ring ...... 0.09 mm
Piston-ring gap in ring
Groove for cylinder liner, opening 1st ring ...................... 0.50 mm
width ..................................... 3.4±0.05 mm 2nd ring .................... 0.70 mm
depth ..................................... 3.0±0.3 mm
Oil scraper ring
Number .................................... 1
Cylinder head bolts Piston-ring clearance in ring
Number/cylinder head .......... 4 opening ................................ 0.4 mm
Dimension thread .................. 3/4"–10 UNC Piston-ring clearance in groove 0.05 mm
Length ................................... 200 mm
Gudgeon pins
Cylinder block Clearance, gudgeon pin –
Height, upper block face – connecting-rod bushing ....... 0.03 mm
crankshaft centre (A) min. 438.8 mm Gudgeon pin diameter stnd. ..... 51.998–52.000 mm
Height, lower block face – Gudgeon pin hole diameter
crankshaft centre (B) ........ 120 mm in piston ............................... 52.005–52.013 mm
Length ................................... 990 mm

Valve Mechanism
Valves
Disc diameter
Inlet ..................................... 50 mm
Exhaust ............................... 46 mm

Cylinder liners Stem diameter

Type ...................................... Wet, replaceable Inlet ..................................... min. 10.91 mm
Height, total .......................... 287 mm Exhaust ............................... min. 10.90 mm
Step edge height above
block face .......................... 0.14–0.20 mm Max. permitted wear ................ 0.07 mm

0,14 - 0,20 mm
0.14–0.20 mm Valve seat angle/valve edge
Inlet ..................................... 29.5°/min. 2.4 mm
Exhaust ............................... 44.5°/min. 1.7 mm

Seat angle in cylinder head

Inlet ..................................... 30°
Exhaust ............................... 45°

Cylinder liner (pistons and piston rings) should be re-

placed with 0.40–0.45 mm wear or if oil consumption
is abnormally high.
INLET EXHAUST
Pistons
Height, above block face ...... max. 0.70 mm
No. of ring grooves ............... 3
Piston clearance, fully
cast piston ......................... 0.12–0.15 mm
Front marking ....................... arrow faces forwards

5
Valve clearance, cold engine Depth (meas. D)
Inlet ...................................... 0.40 mm Inlet ...................................... 8.8–8.9 mm
Exhaust ................................ 0.70 mm Exhaust ................................ 11.8–11.9 mm

Recess bottom radius (meas. R)

Inlet ...................................... 0.5–0.8 mm
Exhaust ................................ 0.5–0.8 mm

Meas. between valve disc

and cylinder head face should
INLET
be min.
Inlet ...................................... 0.05–0.50 mm
EXHAUST
Exhaust ................................ 1.2–1.7 mm
Adjust the valves as follows:
The valve seat may be ground
When no. 1 cyl. piston is at T.D.C. after compression, so far that the distance from the
adjust valves 1, 2, 4, 5, 8 and 9. valve disc (new valve) to the
When no. 6 cyl. piston is at T.D.C. after compression, cylinder head face is max.:
adjust valves 3, 6, 7, 10, 11 and 12. Inlet ...................................... 1.5 mm
Exhaust ................................ 2.5 mm
If the distance is greater, replace the seats.

Valve guides
Inside diameter
Valve seat inserts
Inlet ...................................... 11.02–11.04 mm
Outer diameter (meas. A) standard
Exhaust ................................ 11.02–11.04 mm
Inlet ...................................... 54 mm
Exhaust ................................ 49 mm
Height above cylinder head
spring face
Oversize
Inlet ...................................... 20 mm
Inlet ...................................... 54.2 mm
Exhaust ................................ 21 mm
Exhaust ................................ 49.2 mm
Max. permitted clearance between
Height (meas. B)
valve stem and valve guide
Inlet ...................................... 6.8 mm
Inlet ...................................... 0.15 mm
Exhaust ................................ 9.5 mm
Exhaust ................................ 0.25 mm

Valve springs
Outer valve spring
Length, off-load ........................ 61 mm
With 300–390 N
(30–39 kp) load ......................... 49.6 mm
Recess for valve seat inserts Inner valve spring
Diameter (meas. C), standard Length, off-load ........................ 53 mm
Inlet ...................................... 54.00–54.03 mm With 80–170 N
Exhaust ................................ 49.00–49.025 mm (8–17 kp) load ........................... 42.6 mm

Diameter (meas. C), oversize

Inlet ...................................... 54.20–54.23 mm
Exhaust ................................ 49.20–49.225 mm

6
Camshaft Timing gears
Drive ......................................... Gear Number of teeth:
No. of bearings ......................... 7 crankshaft gear (1) ................... 30
intermediate gear (2) ............... 53
Bearing journal diameters, min. injection pump drive gear (4) .. 60
Front bearing journal ........... 68.94 mm servo pump drive gear (8) ....... 19
2nd ....................................... 66.56 mm camshaft gear (3) ..................... 60
3rd ........................................ 64.17 mm compressor drive gear (5) ........ 26
4th ........................................ 63.39 mm intermediate gear for oil pump
5th ........................................ 60.99 mm and coolant pump (6) ............... 48
6th ........................................ 60.21 mm drive gear for oil pump and
7th ........................................ 56.24 mm coolant pump (7) ..................... 21

End float, max. ......................... 0.18 mm Backlash, max. .............................. 0.17 mm

Radial clearance (same for all Bearing sleeve, intermediate gear,
bearings) max. ...................... 0.079 mm diam., max. .............................. 92.106 mm
Bushing, intermediate gear,
Max. permitted out-of-round diam., max. .............................. 92.158 mm
(new bearings) ..................... 0.05 mm Radial clearance for intermediate
gear max. ................................. 0.082 mm
Bearings, max. permitted wear . 0.05 mm Axial clearance for intermediate
gear max. ................................. 0.15 mm
Lift height min., Camshaft
Inlet ...................................... 8.4 mm
Exhaust ................................ 9.0 mm

Valve tappets, max. permitted

radial clearance .................... 0.08 mm

Checking camshaft setting (cold

engine and valve clearance = 0)
At 10° flywheel A.T.D.C. no. 1
cyl. inlet valve should open ...... 4.2–4.8 mm

Max. valve lift:

inlet ...................................... 13.3 mm
exhaust ................................. 14.3 mm

Min. valve lift:

inlet ...................................... 13.0 mm
exhaust ................................. 14.0 mm

Camshaft bearings
1. Crankshaft gear
Bearing bores 2. Intermediate gear
Front bearing ....................... 69.050–69.075 mm 3. Camshaft gear
2nd ....................................... 66.675–66.700 mm 4. Injection pump drive gear
5. Compressor drive gear
3rd ........................................ 64.287–64.312 mm 6. Intermediate gear for oil pump/coolant pump
4th ........................................ 63.500–63.525 mm 7. Drive gear for oil pump/coolant pump
5th ........................................ 61.112–61.137 mm 8. Servo pump drive gear
6th ........................................ 60.325–60.350 mm
7th ........................................ 56.350–56.375 mm
Wear max. ........................... 0.050 mm

7
Crank Mechanism Oversizes
0.2 mm
(axial bearing 0.1 mm) .. 46.175–46.225 mm
Crankshaft 0.4 mm
Length ....................................... 1154 mm (axial bearing 0.2 mm) .. 46.375–46.425 mm
Crankshaft, end float, max. ....... 0.4 mm 0.6 mm
Main bearings, radial (axial bearing 0.3 mm) .. 46.575–46.625 mm
clearance, max. ......................... 0.14 mm Fillet radius (R) ...................... 3.75–4.00 mm
The crankshaft is nitrocarburised or induction-hard-
ened. NOTE: A nitrocaburised crankshaft may be
ground max. to 2nd undersize. With deeper grinding
Thrust washers (axial bearing)
the crankshaft must be re-nitrocarburised. Thickness (B), standard ............... 2.312–2.362 mm
oversize 0.1 mm ...... 2.412–2.462 mm
0.2 mm ...... 2.512–2.562 mm
Main bearing journals 0.3 mm ...... 2.612–2.662 mm
Diameter (Ø) for machining 0.4 mm ...... 2.712–2.762 mm
standard ............................. 99.978–100.000 mm
undersize 0.25 mm ........... 99.724–99.746 mm
0.50 mm ........... 99.470–99.494 mm
Main bearing shells
0.75 mm ........... 99.216–99.238 mm Diameter, bearing shell seat
1.00 mm ........... 98.962–98.984 mm in block ............................ 104.978–105.003 mm
1.25 mm ........... 98.708–98.730 mm Thickness (D),
Main bearing journals standard ........................... 2.447 mm
out-of-round (new) ............ max. 0.006 mm undersize 0.25 mm .......... 2.574 mm
wear out-of-round .............. max. 0.08 mm 0.50 mm .......... 2.701 mm
taper ................................... max. 0.05 mm 0.75 mm .......... 2.828 mm
1.00 mm .......... 2.955 mm
Width axial journal pin (A) 1.25 mm .......... 3.082 mm
standard ............................ 45.975–46.025 mm

8
Big-end bearing journals connecting-rod bushing
Diameter (Ø) for machining internal diameter (G) ........... 52.022–52.028 mm
standard ............................... 86.003–86.025 mm
undersize 0.25 mm ............. 85.753–85.775 mm Axial clearance, crankshaft –
0.50 mm ............. 85.503–85.525 mm connecting rod, max. ........... 0.35 mm
0.75 mm ............. 85.253–85.275 mm Connecting-rod bearings, radial
1.00 mm ............. 85.003–85.025 mm clearance, max. .................... 0.12 mm
1.25 mm ............. 84.753–84.775 mm Max. weight deviation for
Axial bearing surface width (A) 53.90–54.00 mm connecting rods within
Fillet radius (R) ........................ 3.75–4.00 mm same engine ......................... 50 g
Big-end bearing journals
Straightness max. deviation on
out-of-round (new) .............. max. 0.004 mm
100 mm measuring length ... 0.05 mm
slitage orundhet ............. max. 0.08 mm
Torsion, max. deviation on
konicitet ............. max. 0.05 mm
100 mm measuring length ... 0.1 mm

Connecting-rod bearing shells Flywheel, installed

Thickness (C),
Max. permitted axial throw
standard ............................... 2.413 mm
(manual gearbox) measuring
undersize 0.25 mm ............. 2.540 mm
radius 150 mm ..................... 0.16 mm
0.50 mm ............. 2.667 mm
Ring gear on flywheel .............. 156 teeth
0.75 mm ............. 2.794 mm
1.00 mm ............. 2.921 mm
1.25 mm ............. 3.048 mm Flywheel casing, installed
Max. permitted axial throw for
contact surface against clutch
Connecting rods
casing .................................... 0.13 mm
Length, centre crankpin seat –
Max. permitted radial throw for
centre gudgeon pin seat: ........... 277 mm
guide diameter towards clutch
casing ................................... 0.19 mm
Diameter:
connecting-rod bushing ....... 57.300–57.346 mm

9
 15773-13

Lubricating system Reducer valve

Oil change quantity, with Spring length
oil filter ................................ approx. 40 litres Off-loaded ........................... 61 mm
Oil pressure, operating speed ... 300–500 kPa Loaded with
(3–5 bar) 83–86 N (8.3–8.6 kp) .......... 33 mm
Oil pressure, idling (low idle) ... min. 60 kPa Loaded with
(0.6 bar) 64–67 N (6.4–6.7 kp) .......... 39 mm
Oil quality ................................. Volvo Drain
Specification alt.
API Service CD, CE
or CCMC -D4, D5
By-pass valve (oil cooler)
Spring length
Viscosity acc. to diagram below. Off-loaded ........................... 69 mm
-30 -20 -10 0 10 20 30 40 C
Loaded with
17.9 N (1.79 kp) .................. 32 mm
-22 -4 14 32 50 68 86 104 F Loaded with
-15°C SAE 15W/40 14.0 N (1.4 kp) .................... 40 mm
-25°C SAE 10W/30

SAE 5W/30 1
-10°C SAE 20W/30
Relief valve (direct oil filter)
0°C SAE 30
Spring length
+10°C SAE 40
Off-loaded ........................... 69 mm
-30 -20 -10 0 10 20 30 40 C
Loaded with
-22 -4 14 32 50 68 86 104 F 16.9–18.9 N (1.69–1.89 kp) 32 mm
Loaded with
The temperatures refer to stable ambient temperatures.
1)
Refers to synthetic or semi-synthetic oil. 13–14 N (1.3–1.4 kp) .......... 40 mm
NOTE! Only SAE 5W/30 may be used.

Lube oil pump Oil filters

Type .......................................... Gear-driven Direct oil filters
Number of teeth ........................ 11 Number ................................ 2
Axial play, gear wheel .............. 0.02–0.08 mm Volvo P/N ............................ 466634-3
Backlash ................................... 0.15–0.35 mm
Diameter, Tightening torque
bushing for pump shaft ........ 18.050–18.068 mm (oiled sealing ring) .................... 25 Nm
bearing sleeve intermediate
gear ...................................... 92.084–92.106 mm
bushing for intermediate
gear ...................................... 92.141–92.176 mm
Drive gear-bracket, distance ..... 1–1.5 mm

10
Fuel system
Type .............................................................................. EDC (Electronic Diesel Control)
Injection pump direction of rotation, seen from
clutch side ................................................................ Clockwise
Injection sequence ........................................................ 1-5-3-6-2-4

Fuel
Quality must fulfil minimum current legislation as well as national and international standards EN 590, SS-EN 590,
DIN EN 590, ASTMD 975 No. 1-D, No. 2-D, JIS KK 2204.

Injection pump
Volvo P/N ..................................................................... 425 758
Pump type ..................................................................... PE 6 P 120 A320 RS 8033
Governor type ............................................................... RE 30
Injection pump direction of rotation ............................. Clockwise
Injection sequence ........................................................ 1-5-3-6-2-4
Injection pump basic setting on engine:
DH10A 345 .................................................................. 5.5±0.5° B.T.D.C.
DH10A 245, 285, 360 .................................................. 7.0±0.5° B.T.D.C.
DH10A 350 .................................................................. 9.0±0.5° B.T.D.C.

Performance check
Bus stationary
• Engine switched off
• Start key (feed selector switch) in drive position

Accelerator pedal in idle position:

Reference voltage (U ref) ............................................. 4.5–5.0 V
Control rod travel ......................................................... 0.27–0.60 V
(6.0–1.2% of U ref)
Accelertor pedal in full throttle position (incl. kickdown):
Accelrator pedal sensor ................................................ 62–70% of U ref
Turbo pressure (voltage) ............................................... 1.30–1.50 V

11
Speed 1200 r/min 2000 r/min
over- over- control over- over- control
press. press. rod travel press. press. rod travel
kPa volt volt kPa volt volt
DH245 125 3.60 2.40 135 3.76 2.74
DH285 135 3.76 2.55 150 3.99 3.05
DH360 115 3.44 2.87 195 4.71 3.18
D 245 125 3.60 2.36 135 3.76 2.71
DH350 106 3.31 2.87 196 4.75 3.18
DH345 – Values not known when manual went to print.

Measuring during driving

• Fully loaded bus
• Accelerator pedal in full throttle position

Injection timer, only DH10A 345 and 360

Drive ............................................................................. Gear
No. of bearings ............................................................. 2
Bore, bearings ............................................................... 67.05–67.08 mm
The injection timer alters the pump basic timing (µ) with engine at operating temp. (above 55°C), see page 97.

Feed pump
Designation ................................................................... FP/KG 24 P 307
Feed pressure (depending on speed and load) .............. 100–400 kPa (1–4 bar)

Injectors DH10A 245, 285

Nozzle stand ................................................................. KBEL 117 P 73
Nozzle (Volvo P/N) ...................................................... DLLA 150 P555 (425694)
Number marking (complete injector) ........................... 555
Opening pressure .......................................................... 25 +0.8
–0
MPa
Adjusting pressure (new spring) ................................... +0.8
26 –0 MPa
No. of holes x bore. ...................................................... 6 x 0.236 mm

Injectors DH10A 345, 350, 360

Nozzle stand ................................................................. KBEL 117 P 73
Nozzle (Volvo P/N) ...................................................... DLLA 152 P571 (8194095)
Number marking (complete injector) ........................... 571
Opening pressure .......................................................... 25 +0.8
–0
Adjusting pressure (new spring) ................................... 26 +0.8
–0
No. of holes x bore. ...................................................... 6 x 0.236 mm

Fuel filters
Number ......................................................................... 2
Volvo P/N ..................................................................... 466 987

12
Inlet and exhaust systems Measuring during driving
Accelerator pedal in full throttle position and
engine at max. load: See Performance Check
Turbocompressor
For engine DH10 245, 285
Designation ................................ HX 40 W – 8594 Z Starter pre-heater
Cooling ...................................... Water-cooled Output ........................................ 3500 W
Lubricating system .................... Pressure-
lubrication
Wastegate opening pressure ...... 155 kPa engine Pressure-drop indicator
speed 4.04 volts Red indication at mm VP .......... 580–720
at 2000 r/min
With control rod travel on
wastegate ................................... 1±0.3 mm Exhaust-pressure governor
(setting) Control pressure with warm-up
Check value ............................... 0.4–1.5 mm and exhaust pressure braking . 750 kPa
Axial clearance, rotor ................ 0.04–0.09 mm

Cooling system
Type ........................................... Overpressure closed
Pressure valve opens at .............. approx. 50 kPa
(0.5 kp/cm2)

Coolant
Anti-freeze
Type ........................................... C
Consists of ................................. Glycol with
rustproofing
Colour ........................................ Blue-green
Volvo art no. 1 kg ...................... 1128700-9
5 kg ...................... 1129701-7
235 kg .................. 1129702-5

Radial clearance at compressor

wheel .......................................... 0.33–0.50 mm

For engine DH10A 345, 350, 360

Designation ................................ GT 4288 N
Lubricating system .................... Pressure-lubrication
Maximum speed (all) ................. approx. 1400–1800 r/s
(81 000–108 000
r/min)

Measuring with bus stationary

Accelerator pedal in idle position:
Reference voltage ...................... 4.5–5.0 V
Control rod travel ...................... 0.3–0.6 V
Turbo pressure (voltage) ............ 1.30–1.50 V

Accelerator pedal in full throttle position:

Reference value ......................... 62–70% of U ref

13
Thermostats

Engine circuit (1)

Type .......................................... Piston thermostat
Number ..................................... 2
Marking .................................... 82
Opening temperature ................ 82±2°C
Fully open at ............................. 95±2°C

Heating distributor thermostat (2) Fans B10M

Marking .................................... 60
Opening temperature ................ 58–62°C Hydraulic-driven cooling fan
Fully open at ............................. approx. 77°C Pump, type/designation ............ Vickers PVE 19 R
Fan motor, type/designation ..... Volvo Flygmotor
F11-19
Fan speed
at engine speed 1000 r/min
Coolant pump and coolant temperature
under 90°C ....................... approx. 700 r/min
Impeller press-in depth above 94°C ...................... approx. 2000 r/min
Filter, part no. ........................... 4823936
Drive belts ................................ HC 50 1150 Lw x 2
P/N 966846

Fans B10B
Temperature-controlled cooling fan
Type ............................... Bimetal plate/
coolant coupling

Fan speed at engine speed

38.3 r/s (2300 r/min),
Type .......................................... Gear-driven pump under +37°C ............. min. 7 r/s (420 r/min)
with two pump above +63°C ............. min. 35.7 r/s (2100 r/min)
gears
Temperatures refer to temp. round bimetal plate.

Drive-belt driven cooling fan

Fan drive reduction ................... 1:1.22
Belt type/size (4 belts included
in this drive) .......................... HC 12.5 x 1550
P/N 9515805

14
Hydraulic-driven cooling fan Wear tolerances
(rear-mounted) Cylinder head
Pump, type/designation ............ Vickers PVE 19 R
Height, min. .............................. 114.65 mm
Fan motor, type/designation ..... Volvo Flygmotor
Max. pressure at leakage check 150 kPa
F11-19
(1.5 kp/cm2)
Fan speed
at engine speed 1000 r/min
and coolant temperature Cylinder liners
under 90°C ....................... approx. 700 r/min A cylinder liner (pistons and piston rings) should be re-
above 94°C ...................... approx. 2000 r/min newed at 0.40–0.45 mm wear or if oil consumption is
Filter, P/N ................................. 4823936 abnormally high.
Drive belts
late prod. .............................. SPB 2380 Lw Crankshaft
P/N 9518424 Max. permitted out-of-round on
main bearing and big-end
Fan speed Engine speed bearing journals ................... 0.08 mm
Max. permitted taper on main
bearing and big-end bearing
journals ................................ 0.05 mm
Max. crankshaft end float ......... 0.40 mm
Max. radial clearance ................ 0.14 mm

Connecting rods
Straightness, max. deviation on
100 mm length measured .... 0.05 mm
Torsion, max. deviation on
100 mm length measured .... 0.1 mm
End float, max. ......................... 0.35 mm
Radial clearance, max. .............. 0.12 mm
Coolant temperature °C
Valves
Max. permitted clearance between
valve stem and valve guide
Fan B10L Inlet ...................................... 0.15 mm
Fan drive, hydraulic Exhaust ................................ 0.25 mm
Pump type/designation ............. AFGP 31.5 L Valve disc edge should be min.
Volvo P/N ................................. 3118711 Inlet ...................................... 1.9 mm
Fan motor/designation .............. Sauer Sundstrand Exhaust ................................ 1.4 mm
551/1/00888/ETC The valve stem insert may be ground down so
Volvo P/N ................................. 9519828 that distance from the valve disc (new valve)
Thermostat valve ...................... Sauer Sundstrand to cylinder head face is max.
553/1/09648/093 Inlet ...................................... 2.5 mm*
Volvo P/N ................................. 9519829 Utlopp .................................. 1.5 mm
Closes at .................................... 93°C * With greater distance than above, renew inserts.

Fan speed Camshaft

Engine speed 1000 r/min. and coolant temperature: End play, max. .......................... 0.18 mm
Under 80°C ............................... approx. 300 r/min Radial clearance, max. .............. 0.08 mm
Above 93°C .............................. approx. 1500 r/min Max. permitted out-of-round
(with new bearings) ............. 0.05 mm
Bearings, max. permitted wear . 0.05 mm
Valve tappets, max. permitted
radial clearance .................... 0.08 mm

Flywheel, installed
Max. permitted axial throw (manual gearbox)
measuring radius 150 mm ........ 0.16 mm

15
 Tightening torques
Groups 20–21 Nm kpm Group 22 Nm kpm
Cylinder heads (see note 1) Bracket, oil pump ..................... 40±4 4.0±0.4
Main bearings ........................... 340±25 34.0±2.5 Intermediate gear, oil pump ...... 17±2 1.7±0.2
Big-end bearings ....................... (see note 2) Sump ......................................... 18±2 1.8±0.2
Intermediate gear bearings........
+10
60 –5
+1.0
6.0 –0.5 Sump cover ............................... 24±2 2.4±0.2
+5 +0.5 Drain plug, sump ...................... 60±15 6.0±1.5
Flywheel ................................... 185 –10 18.5 –0.1
Pulley, crankshaft ..................... 60±6 6.0±0.6 Groups 23–25
Flywheel casing ........................ 140±15 14.0±1.5
Pressure valve stand,
Drive gear, injection pump
injection pump ..................... 85±5 8.5±0.5
drive with 6 bolts ................. 33±4 3.3±0.4
Nut for retainer, injectors.......... 45±5 4.5±0.5
Drive gear, camshaft ................. 60±5 6.0±0.5
Clamp bolt, injection pump
Cleansing plugs, cylinder block 60±10 6.0±1
M11 ..................................... 90±5 9.0±0.5
cylinder head . 20±5 2.0±0.5 M12 ..................................... 114±10 11.4±1.0
Centre bolt, crankshaft .............. 560±30 56.0±3 Laminate screw, injection pump
Centre bolt, M10 ..................................... 62±5 6.2±0.5
+50 +5.0
with torque converter........... 140 –20 14.0 –2.0 Retaining bolt, injection pump . 40±4 4.0±0.4
Vibration damper flange ........... 60±6 6.0±0.6 Drive, injeciton timer ................ 33±4 3.3±0.4
Front sealing ring ...................... 60±6 6.0±0.6 Turbocompressor thrust
Timing gear casing ................... 40±4 4.0±0.4 bearings ............................... 4.5 0.45
Timing gear cover ..................... 50±5 5.0±0.5 Turbocompressor wheel ........... 17.0 1.7
Engine mounts .......................... 80 8.0 Turbocompressor turbine
Bearing brackets, rocker housing ................................ 13.6 1.4
arm shaft .............................. 40±4 4.0±0.4 Turbocompressor housing ........ 5.7 0.6
Thrust washer, camshaft ........... 40±4 4.0±0.4 Exhaust-pressure governor ....... 10–11 1.0–1.1
Axial journalling,camshaft ....... 40±4 4.0±0.4 Intercooler bearers .................... 20±2 2.0±0.2

Notes:
1 Tightening sequence for cylinder head bolts 2 Tightening sequence for connecting-rod bearings
Clean the contact face for the cylinder head bolts prior to fitting Tighten the connecting-rod bearings in 3 stages.
the bolts. Dip the bolts entirely (incl. bolt heads) in rustproofing 1st stage 40 Nm (4 kpm).
art. no. 1161346-0. The bolts should be drip-free before fitting. 2nd stage 75 Nm (7.5 kpm).
Tighten the cylinder head bolts evenly and unhurriedly accord- Final stage (angle tightening) 90°.
ing to the following stages and torques:

4-stage tightening and torques.

1st stage 50 Nm (5 kpm).
2nd stage 200 Nm (20 kpm).
3rd stage 370 Nm (37 kpm).
Final stage (angle tightening) 90°.

2 4

3 1

16
 Special Tools

1084 1801 1819 1866 2000

2013 2089 2267 2268

2269 2337 2479 2529 2654

(999)- Description, use 2267 Drift, pressing in bearings, injection pump

1084 Drift, pressing out valve guide drive
1801 Standard handle 2268 Drift, pressing out/in bearing coolant pump

1819 Extractor, support bearings flywheel 2269 Counterhold, fitting bearings coolant pump
and fan motor
1866 Drift, pressing out bushing exhaust brake
2337 Lever
2000 Standard handle
2479 Holder, dial indicator
2013 Drift, pressing out/in gudgeon pin
2529 Socket, pressing out/in connecting rod
2089 Puller plate, cylinder liner
2654 Puller, oil pump drive gear

17
 2658 2659 2665 2666 2671 2677

2679 2807 4706

2800

6049 6065 6066 6068 6088

(999)- Description, use 2807 Centering tool, coolant pump

2658 Puller, crankshaft drive gear 4706 Stop tool, flywheel
2659 Press tool, pressing in crankshaft drive gear 6049 Hose, draining coolant, pressure-testing
2665 Press tool, bearings flywheel system
2666 Press tool (holders), measuring cylinder liner 6065 Pressure gauge 2.5 bar, fuel feed pressure,
height charge pressure
2671 Hydraulic cylinder 18 tonnes 6066 Connection nipple (used together with 6065)

2677 Drift, pressing out/in bushing, rocker arm 6068 Drift, exhaust-pressure governor

2679 Puller, camshaft and injection pump drive gear 6088 Drift, crankshaft rear seal

2800 Test bench (pressure tester gauge)

18
 6222 6239 6394 6395

6398 6413 6419 6441 6579 6591

6600 6603 6625 6626 6640 6643

(999)- Description, use 6579 Lever

6222 Hydraulic pump, air-driven for hydraulic 6591 Connection nipple, checking charge pressure
cylinder 6600 Hydraulic cylinder 10 tonnes
6239 Lift chain 6603 Adapter, used with 6600
6394 Spacer, pressing out cylinder liners 6625 Spindle, pressing on polygon hub
6395 Spacer, pressing out cylinder liners 6626 Hollow drift, fitting polygon hub
6398 Pressure gauge 16 bar, checking oil pressure 6640 Hollow drift, used with 8011
6413 Extension, puller, polygon hub 6643 Extractor, injectors
6419 Extractor, steel ring, injectors
6441 Test cap, with nipple, pressure-testing cooling
system

19
 6645 6647 6656 6662 6664

6666 6669 6670 6671 6672

6685 6781 6796 6815 6816

(999)- Description, use 6670 Filter tool 80 mm, fuel filter

6645 Puller yoke, cylinder liners 6671 Oil filter tool
6647 Reaming tool, copper sleeves 6672 Filter tool 108 mm, oil filter
6656 Centering tool, oil pump 6685 Clamp, pressure testing cylinder head
6662 Pressure gauge, cylinder head, cooling 6781 Hollow drift, fitting seal thermostat housing
system 6796 Hollow drift, pulling off polygon hub
6664 Piston-ring compressor, fitting pistons 6815 Connection washer, pressure testing inter-
6666 Union, checking oil pressure cooler
6669 Drift, pressing in valve guide, inlet valve 6816 Sealing washer, pressure testing intercooler

20
 6831 6848 6849 6850 6858

6859 6899 6931 8009 8010

8011 8012 8014 8039 8068* 8074

(999)- Description, use 8010 Extractor, crankshaft rear seal

6831 Pressure-drop gauge, low-pressure indicator 8011 Extractor, seal injection pump drive
6848 Measuring tool, setting injection angle 8012 Press tool, fitting seal injection pump
6849 Drift, pressing out/in bushing, oil pump 8014 Hollow drift, fitting seal polygon hub
6850 Reamer, oil pump 8039 Drift, seal coolant pump
6858 Drift, pressing out shaft, coolant pump 8068* Crank tool, flywheel (formerly 6220)
6859 Counterhold, coolant pump bearings 8074 Nipple, pressure-testing oil cooler
6899 Test box, for troubleshooting
* Fit 2 bolts, P/N 955514.
6931 Adapter, for Troubleshooting (EDC)
8009 Adapter, compression test

21
 8075

8079 8113 8134 8140

8180

8190 8419 8449 8487

9314

9511 9551 9696 9708

(999)- Description, use 8419 Pin spanner, for cleansing plugs

8075 Cover washer, pressure-testing oil cooler, 8449 Drift, pressing in valve guides
used with 2800 8487 Tool, for oil filter
8079 Extractor, for camshaft 9314 Nipple, checking wastegate
8113 Drift, bearing, coolant pump 9511 Expander, turning cylinder liners when
8134 Threading tool, copper sleeves, injectors milling liner seat
8140 Extractor, copper sleeves, injectors 9551 Milling tool, cylinder liner seat
8180 Adapter, checking charge pressure (EDC) 9696 Magnetic stand, for dial indicator
8190 Measuring instrument, for injection timing 9708 Torque gauge

22
 9711
998 5423
998 5468

998 6187
998 7600
998 7057

998 8539

998 8460 981 2546 951 0060

(999)- Description, use (981)- Description, use

9711 Torque multiplier, 4x 2546 Cleansing tool, cleaning copper sleeve seats

(951)- Description, use

(998)- 0060 Multimeter
5423 Piston ring rod
5468 Valve spring tester
6187 Puller, fan motor electric-driven cooling fan Special tool, EDC, for testing injection pump on
7057 Tool, for basic setting injection pump test bench, refer to Testing, injection pump, on
page 102.
7600 Adapter, assembling turbocompressor
8460 Speed gauge, for measuring fan speed
Tool for flange discs
8539 Compression guage pump coupling (made by own workshop)
Spanner Decapitat-
15 mm ed sleeve

Hard
annealed

40 mm

23
 5654

8993

8994

999 9954

(998)- Description, use (999)-

5654 Engine carrier trolley 9954 Component jack, for radiator assembly
8993 Lift table
8994 Engine fixture

24
Removing and installing engine Weight, engine with gearbox approx.
1300 kg
Draining coolant
Warning!
Special tool: Handling heavy components as those men-
(999) 6049 Drain hose tioned above, requires experience in stacking and
lifting. Work involving this must never be done by
inexperienced personnel. Always make sure the lift
tools can cope with the work in hand and are in
good condition.
Make sure the lift fixture slots securely into the en-
gine lift points and that the guide edges fix against
the lift forks or lift table.
Always switch off the main switch and disconnect
the battery cables before removing electrical con-
nections.
6049
The number and location of the drain points vary with
bus type. Drain points common to all types are the radi-
ator and two drain points on the engine. Coolant must
be handled with the same care and caution as for
other fluids dangerous to health.

25
Topping-up coolant
Recommended for the cooling system (and heating On buses with roof-mounted air conditioning system,
system) is a mixture of 50% anti-freeze and 50% wa- where the coolant is above the level of the expansion
ter. tank, the coolant has to be pumped up by starting the
Never use coolant with less than 40% anti-freeze. This circulation pump.
also applies to topping-up. The anti-freeze protects the Top-up gradually via the expansion tank until the sys-
cooling system from corrosion and damage from tem is full. Check the coolant level after having run the
freezing. engine warm.
Volvo coolant is recommended even when the coolant
does not require anti-freeze. It provides very good pro- NOTE! For the B10M (late prod. or older that has been
tection against corossion. altered afterwards) where the vent line from the radi-
ator goes down into the bottom of the expansion tank,
we recommend topping-up from the evacuation con-
nection in the bottom of the radiator. This is a good
way of getting rid of any air pockets in the cooling sys-
tem.

Draining oil
There are three plugs for draining the oil: One under-
neath the sump; one next to the oil pocket on the in-
spection panel; and one on the underside of the oil tank.

Tightening torque for drain plugs:

60±15 Nm (6.0±1.5 kpm).
Instructions on topping-up oil, refer to page 32.

26
Removing and installing engine
Special tools:
(998) 8993 Lift table
8994 Engine fixture

1. Drain the oil and coolant. Switch off the power 4. Release the steering servo pump.
with the battery main switch.
Release the fan prop shaft.

5. Detach/disconnect necessary cables, hoses and

pipes. Release gearbox attachments, if any.
2. Release the propeller shaft.

6. Run the engine carrier trolley in underneath. See

3. Remove the clutch servo. support points overleaf.

8994

8993

27
 Observe due care with regard to the fuel pipes!
The location of the delivery pipes between the in-
jection pump and the injectors require the engine to
be angled slightly so that the pipes do not catch on
the frame member.

Note in connection with lifting out engine…

Tightening torque for the following bolting:
Fan prop shaft 48±5 Nm (4.8±0.5 kpm)
Propeller shaft 54 Nm (5.4 kpm)
Engine mounts 80 Nm (8 kpm)

7. Detach the engine mounts from the frame member Bear in mind that rubber parts age and are affected by
and lift out the engine together with the gearbox. climatic conditions. If necessary, replace them. Check
the engine mounts and replace if necessary.
Top-up oil and coolant.

28
Removing and installing rear
engine
To observe when removing/installing the engine
Special tool:
(998) 5654 Engine carrier trolley Fuel system
Open the fuel pipe joint at the gearbox.

Drain the coolant and engine oil (see pages 25 and 26).
The engine is suitably lifted out together with the gear- Bolting
box. To remove and install, run the engine carrier trol- Engine mounts 80 Nm (8 kpm)
ley in underneath the engine and adjust the supports, Propeller shaft 54 Nm (5.4 kpm)
see next page.
Always turn off the power with the battery main Inlet and exhaust systems
switch. Disconnect the inlet hose from the turbocompressor.
Disconnect the exhaust at the flex hose between the tur-
bocompressor (exhaust brake/EPG) and the silencer
Release the bracket from both the
frame member and the engine mount hook.
pads.

The steering servo pump is detached from

the engine and hung up in a suitable place.

Detach the bracket from the frame

member. Detach the engine rear mount
pad.

Observe due care with regard to the fuel

system delivery pipes! After the engine
has been disconnected from its mounts,
pipes, electric cables, etc., draw the
engine-gearbox out sideways so that the
delivery pipes are free from the frame
member.

Remove the intercooler pipes under the engine

to make room for the engine carrier trolley.
Disconnect the coolant pipe hose. Otherwise,
the coolant pipes can remain in place.

29
Adjust in the supports on the lift unit as shown in the
pictures below.

30
Servicing the engine
The VOLVO warranty for exchange engines (factory
new or overhauled) applies on the following condi-
tions:

1. Fuel filters, oil filters 5. Air cleaner

Both the engine’s fuel filters and both the oil filters Thoroughly clean the air cleaner housing and con-
must be changed at the same time. nections. Install a new filter and check the filter
housing and hose connections for leakage.
2. Cooling system
It must be possible to make use of the cooling sys- 6. Instruments and connections
tem’s entire capacity. The radiator must be well- Make sure oil pressure and coolant pressure
cleaned both inside and outside, or new. Change gauges show correct pressures.
coolant filters, if such are fitted.

3. Hoses
Use new hoses for both the cooling and heating Other measures
systems and new hoses for the oil pipes. Components such as the alternator, starter motor, air
compressor and steering servo pump must not be faulty
4. Drive belts and preferably recently inspected.
Use new drive belts for the fan prop shaft, altern-
ator drive, etc.

Replacing fuel filters

Special tool:
(999) 6670 Filter removal tool

The fuel gauge pressure decides when the filter should

be changed, see also under “Service and maintenance”.
Replace both filters at the same time.

1. Clean the outside of the filter bracket to prevent

dirt getting in when fitting the new filter.

2. Unscrew and discard the filters. Use tool 6670 if

the filters cannot be unscrewed by hand.
6670 3. Screw on the new fuel filters. First by hand to
when the seal makes contact with the filter bracket
and then manually tighten a half turn more.

4. If there is a relief valve mounted on the injection

pump then normally there is no need to bleed the
fuel system. Instead manually pump about 15
strokes with the hand primer and then start the en-
gine.

31
 Topping-up oil
Top-up via the oil tank filler tube.
The oil level is checked with the oil tank level tube.
Thisshould be done with the engine idling or immedi-
ately after stopping the engine.
The level should be between the Max. and Min. levels
on the oil tank level tube.
The oil level must never go below the Min. mark!

Oil quality
According to VOLVO DRAIN SPECIFICATION
(VDS, VDS2) or API CD, CE OR CCMC -D4, D5.

Viscosity, see graph below.

The temperatures refer to stable air temperatures.

-30 -20 -10 0 10 20 30 40 C

-22 -4 14 32 50 68 86 104 F

-15°C SAE 15W/40

-25°C SAE 10W/30

Concerns semi-synthetic or full-synthetic engine oil.
SAE 5W/30 1 NOTE! Only SAE 5W/30 may be used.
-10°C SAE 20W/30

0°C SAE 30

+10°C SAE 40

-30 -20 -10 0 10 20 30 40 C

-22 -4 14 32 50 68 86 104 F

32
 Replacing oil filters

Special tools:
(999) 6672 Filter removal tool
(Alternative tool:
(999) 8487 Filter removal tool)

1. Remove the plate underneath the engine

2. Replace both oil filters when changing the engine

6672 oil

3. The filters cannot be cleaned – renewal the only

service measure permitted.

4. Fit the oil filters according to the instructions on

the filter cannister.

(The alternative filter removal tool can be used if work-

ing area is confined.)

Replacing coolant filter

Special tool:
(999) 6671 Filter removal tool

1. Remove the plate underneath the engine.

Remove the filter with tool 6671.

2. Fit the new filter according to the instructions on

the filter cannister.
Refit the plate underneath the engine.

33
Condition test

A compression test is a simple and reliable way of The cooling system is checked for leakage by
finding out the condition of the engine. The test pressure-testing the coolant remaining in the sys-
shows whether or not cylinders and valves are leak- tem. This means that all the following compo-
ing. nents in the system are check for leakage: radi-
Low compression pressure on all cylinders indicate ator, connections, hoses, coolant pump, heating
worn cylinder liners and/or piston rings. Should a system, etc. See chapter Cooling system.
particular cylinder have a lower pressure, this may
be due to leaking valves, broken piston rings or
damaged cylinder head gasket. Camshaft wear can be checked by measuring the
camshaft lift (valve lift) without having to remove
the camshaft from the engine.
Low charge pressure and fuel system malfunc-
tion can cause the following symptoms: low start
torque, and smoky exhaust gases. The timing gears and camshaft can be checked
by measuring the valve timing. If the valve stroke
deviates from that specified, there is risk of the
Low oil pressure may indicate worn crankshaft exhaust valve striking its piston.
bearings. However, it would be best first to check
the lubricating system valves.

Compression test

Special tools:
(999) 8009 Adapter
9691 Compression gauge
9691

1. Run the engine warm.

2. Stop the engine and let the mechanical stop control

remain pulled out.

3. Remove all the injectors.

8009
4. Fit adaptor 8009. Use the injector retainer to hold
the adaptor in position.
No.
Kompression in bar 5. Connect compression gauge 9691 to the adapter.
Compression value in bar
Pression en bar Dat. - - - - - - - -
10 15 20 25 30 35 40 6. Read-off the compression gauge at normal starter
motor speed (3.7 r/s). Pressure should be:
Zyl.

1
2 DH10A 245, 285 ....................... 3.6 MPa (36 kp/cm2)
3 DH10A 345, 350, 360 ............... 3.2 MPa (32 kp/cm2)
4
5
6
7
Best. Nr. 5 1341 250 00
8 DBGM MADE IN GERMANY

MOTOMETER 7250 Leonberg

34
Charge pressure
Mechanical testing (pressure gauge)

Special tools:
(999) 6065 Pressure gauge
6666 Nipple

At too low charge pressure:

Check:
6065
– for compressor wheel damage
– that the compressor wheel rotates easily
– that the axial/radial clearance feels normal
– that the compressor wheel does not scrape against
the compressor housing when pressed axially
6591 – that the wastegate opens, see Specifications
– Fuel filter, fuel feed pressure
– EDC-sensor, charge pressure
– Control rod travel, injection pump, see Fuel sys-
tem, testing injection pump.

The pressure gauge connection hose should be long

enough to enable gauge read-off from the driver seat.
The measuring socket for the charge pressure is located
on the intercooler.
Drive uphill on full engine load and throttle. Read-off
the charge pressure when engine speed passes 2200
r/min. Repeat this several times and compare the read-
ings with the specified charge pressure.
It is important for proper results that full load is main-
tained long enough for the pressure to stabilize itself.

A clogged air filter or blocked air inlet will result in

pressure drop at the compressor inlet. This lowers
the charge pressure and reduces engine power. Be-
fore checking the charge pressure, check the pres-
sure-drop indicator in the inlet hose from the air
cleaner. If its window is full red, it is time to re-
place the air cleaner filter insert.

After testing fit and tighten up the screw plug for the
measuring socket. Make sure it is properly tightened as
there is always a risk that an insufficiently tightened
plug slackens during driving. If the plug drops off, the
charge pressure will drop and notably lower the power
output, Ther is also risk of dirt getting into the engine,
particularly in connection with much idling and engine
braking.

35
Charge pressure
Electrical testing (multimeter)

Special tools:
(999) 6899 Test box
6931 Adapter
8180 Adapter
(951) 0060 Multimeter
The charge pressure is checked in two stages; on the
engine switched off and on it when driving. The volt-
age measured corresponds to a kPa measuring value.

8180
Connect-up as in figure.
Test box
Measure between the measuring points on the test box
6899.
As alternative, measuring can be done directly in the
6899 nine-pin test socket.

EDC
6931 control unit
1. Measuring on engine switched off
Nine pin Measuring with the engine switched off ensures that
test socket the charge pressure sensor gives a measuring value that
agrees with the “should” value (see Specifications),
providing the charge pressure sensor is functioning
properly, and that gives us a reference voltage which
corresponds to the voltage measured between the
charge pressure sensor and the control unit.
The measuring is done as follows with the engine off
and the start key (feed selector switch) in Drive posi-
tion:
Measuring on text box (6899)
– measuring points 1–4, reference voltage
– measuring points 3–4, charge pressure (voltage)
Nine pin test socket Compare with the “should” values in the specifications
for the respective engine.

Correction of measured values

In order to be able to compare the measured volt value
for max. charge pressure with the value given in the
specifications for the respective engine, the value may
Measured have to be corrected because the reference value can
5
Unorm = volts, x vary. We call the new value the Unorm value (Unorm).
charge pressure Measured If the measuring is done at an ambient temperature oth-
reference er than +20°C, the measured value must be corrected
voltage (see table on next page).
The corrected voltage is then compared to the charge
If the meassuring is done at a temperature other
pressure voltage given in the Specifications.
than +20°C, adjust the Unorm according to the
table on the following page.
2. Measuring on engine during driving
The engine should be max. loaded during driving in or-
der to come up to max. turbo pressure (see instructions,
page 35).
Measuring is done in the same way and between the
same pins as above.

36
 With low charge pressure, check:
(V) – for any damage to the turbocompressor
4.5
– fuel filters, fuel feed pressure
– charge pressure sensor
4.0 v
– control rod travel, injection pump (see Testing in-
4.0 jection pump).
3.75

3.5
Example
3.5 At 0°C ambient temperature, the turbo pressure voltage
3.25 should be 3.7 V.
– Go to 3.7 V on the vertical axis on the diagram.
3.0
3.0
– Follow it horizontally to where it intersects the
2.75 vertical line for the ambient temperature (0°C).
– The corrected voltage is read-off on the respective
2.5 curve in the diagram. In our example 3.5 V, which
2.5 corresponds to the voltage at 20°C.

- 20 - 10 +- 0 + 10 + 20 + 30 + 40
2 3 (C)

Fuel feed pressure

Special tools:
(999) 6065 Pressure gauge
6065 6066 Nipple
6066 968179 Banjo screw

Note: Before using the banjo screw, make sure it has

been decapitated to a length of 26 mm, otherwise it will
break the end of the thread insert in the pump connec-
tion.
Before measuring the feed pressure, run the engine at
high idle and then drop it to low idle when reading-off.
Read-off the pressure within one minute.
The fuel feed pressure must be min. 100 kPa (1.0 kp/
cm2).
A low feed pressure will have a negative effect on the
engine’s top output. In the event of complaints about
poor output, it would be well to check the feed pressure
under load (the same procedure as when checking the
charge pressure). Low fuel feed pressure can be caused
by a contaminated fuel filter, a faulty relief valve or
feed pump failure.

37
 Oil pressure
6398 Special tools:
(999) 6398 Pressure gauge
6666 Nipple

At normal engine operating speed and temperature, the

oil pressure should be 300–50 kPa (3.0–5.0 kp/cm2).
If the oil pressure is below 60 kPa (0.6 kp/cm2) with a
6666 warm engine and at low idle, this does not mean any-
thing is amiss as long as the pressure does not go below
approx. 300 kPa (3.0 kp/cm2) at operating speed.
If the oil pressure is low and a faulty reducer valve is
suspected, it should be removed and checked.

Pressure-testing cooling system

6662
Special tools:
6441 (999) 6441 Test cap with nipple
6662 Pressure tester

Check the coolant hoses for ageing (hardness),

cracks, separation, blisters, scuffing, etc. Replace a
damaged or badly worn hose before checking for
leakage. If necessary, top-up with coolant before
pressure testing.

Connect the pressure tester together with test cap and

fit the cap temporarily in position. Pressure test at 70
kPa (0.7 kp/cm2).
When the pressure stabilizes, check all the components
in the system – radiator, connections, hoses, coolant
pump, heating system, etc. If the pressure gauge shows
a drop in pressure, this indicates leakage, which must
be remedied!

Valve tappets, valve timing

Special tool:
(999) 8068 Crank tool

1. Fit crank tool 8068.

2. Let an assistant rotate the flywheel.

3. Set valve clearance to 0 mm before measuring + a

half turn more on the adjuster screw. Pre-set the
dial indicator to 15 mm.
8068

38
 4. Measure valve lift as follows:

When the valves “change”

direction (open/close) Measure valve lift
on cylinder no. on cylinder no.
1 .................................................... 6
5 .................................................... 2
3 .................................................... 4
6 .................................................... 1
2 .................................................... 5
4 .................................................... 3

5. Check the valve time for no. 1 cylinder (see table

below).
6. Adjust the valves to correct clearance, see below.

Camshaft lift A Valve lift B

Min. camshaft lift in mm (A) Min. valve lift in mm

(new camshaft) 0 mm valve clearance (B)

inlet exhaust inlet exhaust

8.4 9.0 13.0 14.0

Checking camshaft adjustment

Valve lift must be within the stated tolerance in order
to be able to check the camshaft adjustment.
Checking camshaft adjustment (cold engine and
valve clearance = 0).
With flywheel position at 10° A.T.D.C. the no. 1 cyl-
inder inlet valve should open 4. 2 – 4.8 mm.

Adjusting valves
Special tool: (999) 8068 Crank tool
Valve clearance should be adjusted with a cold engine.
Pull out the manual stop control!

Adjusting
1. Fit crank tool 8068.
2. Crank the flywheel in its direction of rotation until
no.1 cyl. piston is at top dead centre position after
the compression stroke (0° on the flywheel).
Adjust valves: 1, 2, 4, 5, 8, 9
Again crank the flywheel in its direction of rota-
tion (one turn) until no. 6 cyl. piston is at top dead
centre position after the compression stroke (0– on
8068 the flywheel).
Adjust valves: 3, 6, 7, 10, 11, 12

Replace valve cover gaskets if necessary.

Valve clearance: ❍ Inlet: 0.40 mm

● Exhaust: 0.70 mm

39
 Group 21

Engine
Contents

Cylinder head
– Description .......................................................................................... 41
– Removing, cleaning ............................................................................. 42
– Pressure-testing ................................................................................... 43
– Valve guides ........................................................................................ 44
– Valves, valve seats .............................................................................. 45
– Valve springs ....................................................................................... 47
– Rocker arm mechanism ....................................................................... 47
– Face-grinding cylinder head ................................................................ 48
– Copper sleeve for injectors .................................................................. 49
– Installing cylinder head ....................................................................... 50

Cylinder liners, pistons, connecting rods

– Description .......................................................................................... 51
– Pistons, piston rings ............................................................................. 52
– Gudgeon pins, connecting rods ........................................................... 53
– Cylinder liners ..................................................................................... 54
– Installing cylinder liners and pistons ................................................... 55

Cylinder block, crank mechanism

– Description .......................................................................................... 59
– Cylinder liner seats, machining ........................................................... 61
– Cylinder block, face-milling ................................................................ 63
– Front sealing ring, crankshaft .............................................................. 64
– Timing gears ........................................................................................ 65
– Drive mechanism, injection pump ....................................................... 69
– Replacing camshaft ............................................................................. 73
– Crankshaft ........................................................................................... 75
– Aligning, machining ........................................................................ 76
– Flywheel .......................................................................................... 76
– Replacing ring gear ......................................................................... 77
– Replacing support bearings, replacing crankshaft rear seal ............ 78

40
Cylinder head

The cylinders have separate cylinder heads, which are

interchangeable and bolted to the cylinder block by
four 3/4" bolts per cylinder head.
Having separate cylinder heads is not only technically
advantageous with regard to sealing between cylinder
head and cylinder block, it also makes servicing easier.

Sealing against the cylinder block consists of a special

groove in the cylinder head face, a steel gasket and a
stepped edge on the cylinder liner collar. Sealing on the
coolant side is provided by O-rings.

The inlet duct in the cylinder head has a defined and

accurately calculated shape that results in “whirled” air
in the piston combustion chamber. Far out on the inlet
valve the cylinder head has a notch that lowers the rota-
tion speed at the beginning of the valve opening move-
ment.

41
 The valve mechanism for each cylinder head consists
of:
– an inlet valve and an outlet valve
– valve guides
– double valve springs with washers and valve locks
– rocker arms with adjusting screws
– rocker arm shaft with bearing brackets
– push rods and valve tappets

The material in the outlet valves is nimonic.The inlet

valves contain nickel and chromium. Valve guides and
valve seats are replaceable.

Cylinder head, removing/cleaning

Special tools:
(998) 5468 Valve spring clamp
(999) 6239 Lift chain
6643 Extractor

1. Drain the coolant.

2. Remove…
6239 – rocker arm cover
– delivery pipes
– injectors, rocker arm bracket and push rods.

If necessary, use extractor 6643 to remove the injec-

tors.

Some alterations have been made to the cylinder head,

compare with the THD 104-engine, particularly with
regard to optimating inlet air flow.

New features
1. Valve seats and valves on the inlet side have been
moved down one millimetre.
2. The inlet valve has a rounded disc edge and small-
er stem diameter, below the valve guide.
3. The inlet valve spring face has been moved down
one millimetre.
4. The exhaust valve inside has been bevelled to im-
prove exhaust flow.
5. New type of cast plug, of cast iron. Use lock fluid
when fitting plugs of this kind. (Die tool 999
8419.)

42
 Cleaning
Disassemble the cylinder head. Clean all the parts and
the cylinder block contact surface.
Rust and carbon deposits, etc., must be removed from
the bolt holes and threads in the cylinder block and cyl-
inder head.
Paint and dirt must be removed from cylinder head sur-
faces in contact with bolt heads otherwise there is risk
of leakage and damage to seals and gaskets.
Threads and under bolt heads must be free from nicks,
5468
etc. Renew damaged bolts.

Cylinder heads, pressure-testing

Special tools:
6662 (999) 6579 Lever (or corresponding)
6662 Pressure gauge
6686 Clamp
8077 Cover washer

Before pressure-testing
Reducer valve A. Connect up pressure tester 6662 to the work-
The tap can be locked
by pushing it in the shop air supply. Adjust pressure to 100 kPa
direction of the arrow. (1.0 kp/cm2) with the reducer valve tap.
B. Close the shut-off tap. No pressure is allowed
to drop during two minutes while reading-off
the pressure gauge.
C. Screw out the reducer valve tap.

Pressure-testing
1. Connect up the equipment. Lower the cylinder
head into water with temperature approx. 70°C.
6662

2. Connect up pressurized air to the pressure tester.

Open the shut-off tap.

3. Pull out the reducer valve tap lock ring. Screw in

the tap until pressure reaches 50 kPa (0.5 kp/cm2).
Hold this pressure for one minute.

Increase pressure to 150 kPa (1.5 kp/cm2). Push in

the lock ring to lock the tap. Close the tap.
8077
After 1–2 minutes check to see if the pressure has
dropped or if air bubbles have formed in the water.
Replace the cylinder head if leaking or damaged.

43
 Valve guides
Special tools:
(999) 1084 Drift
6668 Drift
6669 Drift
9696 Magnetic stand
(998) 9876 Dial indicator

Valves
Max. permitted clearance between valve stem
and valve guide:
– inlet valve ................................................ 0.15 mm
– exhaust valve ........................................... 0.25 mm

Replacing
1. Press out the old valve guides with drift 1084.

2. Oil the outside of the new valve guides before in-

stalling them.

3. Installation tools automatically give correct height

above spring face.
Inlet, drift 8449
Exhaust, drift 6669

4. If necessary, ream the guides with a standard

reamer.

1084

8449

6669

Pressing out Exhaust Inlet

44
Valves, valve seats

Grinding valves

Both inlet and exhaust valves should have a contact

Before grinding, check the valve guides for wear.
surface that is 1/2° smaller than the valve seat contact
Replace worn guides and ream.
surface. The smaller contact surface gives better seal-
ing with a newly ground valve. The surface difference
disappears after a time to get a larger surface for heat
Machine the valves if the sealing surfaces are damaged.
transmission.
Grind the valve sealing surface as little as possible, just
enough to clean the valve.

Inlet valve Exhaust valve

Replace the valves if the valve disc edge is less than:

– inlet valve .................................................. 2.4 mm
– exhaust valve ............................................. 1.7 mm
Replace a valve if the stem is bent.

Valve seats
Grind the valve seat with a grinding machine. Use the The valve seat should be renewed when the distance A,
self-centerer that is fitted in the valve guide. Do not measured with a new valve, exceeds:
grind off too much material. It is essential that the con- Exhaust 2.5 mm
tact angle is correct and that the surface is even. Inlet 1.5 mm
Valve seats are available in standard size and oversize.
The outer diameter on an oversize is 0.2 mm greater
than that on a standard size. They are used when grind-
ing valve seat recesses.
Usually valve seat damage is quite insignificant. This
means that normally it is not necessary to reduce seat
width when grinding. Otherwise the grinding is limited
to the measurements that apply to max. distance from
the top side of the valve disc to the cylinder head con-
tact face.

45
 Weld In connection with removal: grind the valve disc on an
old valve so that it can be pressed down into the valve
seat.
Then weld according to the illustration.
Tap out the valve seat.
Use carbon dioxide snow to cool the seat down to
–70°C and –80°C when refitting. Then use a suitable
tool to press the valve seat into position.

New valve seats

The distance between the valve disc and cylinder head
is adjusted by grinding the valve seats. Grind new
valve seats so that the distance is the same as on new
engines.
Do not grind existing valve seats so that the distance
exceeds the max. measurement, see Specifications.
Otherwise the seats must be replaced.

Inlet 0.5–0.50 mm
Exhaust 1.2–1.7 mm
with new valve.

Checking after machining

Place the valve without springs in the cylinder head.
Pour water over the valve discs. Press the valve against
its seat and blow with pressurized air from underneath
with pressurized air. But not so hard that the valve lifts
from its seat.
If the valve leaks, air bubbles will come up round the
valve disc.If this happens, re-grind, clean the seat and
re-check.

46
Valve springs

Outer valve spring

Length unloaded ................................. 61 mm
With load of 300–390 N (30–39 kp) .. 49.6 mm

Inner valve spring

Length unloaded ................................. 53 mm
With load of 80–170 N (8–17 kp) ...... 42.6 mm

Rocker arm mechanism

Special tools:
(999) 2677 Drift
2267 Drift

Replacing bushings
1. Press out the old bushing with drift 2677 and coun-
terhold 2267.

2. Oil and press in the new bushing.

Make sure the oil hole coincides with the oil drill-
ing in the rocker arm.

3. After pressing in, ream to 25.02–25.04 mm.

Checking
Check:
– rocker arm shaft/bushing wear
– that the adjusting screws are not deformed or
worn on the surface against the push rods
– the threads on the adjusting screws and lock
nut
– that the lock nut is not damaged
– that the contact face against the valve stems is
not worn or damaged in any way. Minor wear
can be remedied by grinding to a smooth fin-
ish.

47
 2677
2677

2267

Note the oil holes!

Face-grinding cylinder head

If leakage is discovered or if there is a trace of a blown
head gasket, there is no reason to check for unevenness.
The head must be machined or renewed anyway.
A rough check can be made with the help of a straight-
steel edge. A slit of light between the straight edge and
cylinder head indicates that the cylinder head should be
machined.
Cylinder head unevenness must not exceed 0.01 mm
within a distance of 100 mm and 0.02 mm across the
entire width.
A more exact method must be used when checking cyl-
inder head unevenness since the tolerances are very
small.

After machining, the distance A from valve disc top face to the Machining
cylinder head face should be. It is most important that the contact face for the cylin-
der liners is even. Max. surface finish (roughness) is
Min. Inlet 0.05–0.5 mm
Exhaust 1.2–1.7 mm 0.006 mm.
The overall height of the cylinder head after machining
If additional cylinder head machining is required, the valve
seats must be ground down to enable the valves to sink down. must be minimum 114.65 mm.
There is no need to alter the depth of the groove for the
cylinder head seal, providing machining stays within
permitted limits.

48
Copper sleeve for injectors

Special tools:
(999) 6419 Extractor 8134 Threading tool
6647 Reaming tool 8140 Extractor

8134
Steel ring 6419

Sealing ring

1. Make threads in the copper sleeve tap.

NOTE: If threading is done with the cylinder head in the
engine, the thread die must be greased to prevent thread fil-
ings from falling down into the cylinder. 2. Pull out the steel ring.

Sealing ring

8140

3. Pull out the copper sleeve. 4. Smear a new rubber seal with soapy solution and fit it in
the cylinder head.

Spindle
Nut

6647
Copper
sleeve

Clearance
min. 0.5 mm

Steel ring Expander

5. Fit the injector steel ring on tool 6647 and a new copper 6. Smear the copper sleeve with a soapy solution and fit the
sleeve. Screw in the expander. sleeve in the cylinder head. Hold the stem on tool 6647
Check that the clearance between the copper sleeve and steady while tightening up the large nut. Continue until the
the steel ring is at least 0.5 mm. stem loosens and the expander can be drawn through the
copper sleeve.

49
 Installing the cylinder head

Special tools:
(998) 9876 Dial indicator
(999) 2479 Stand
2666 Press tool (two)
2666 6239 Lift chain
2479

Clean the cylinder block face, if this has not been done
already. The cylinder block contact surface against the
gasket must be shiny before installing the head.

1. Check the cylinder liner height.

2. Before fitting the bolts, immerse them in rust-

proofing, P/N 1161346-0, after which place them
on a net to drip dry. The bolts must be drip-free
before being fitted.

3. Fit a new gasket, new cylinder head sealing rings

0,14 - 0,20 mm and O-rings for the inlet channel.

4. Lift the cylinder head into position. Use lift chain

6239 if necessary to guide the head into position.
Fit the cylinder head bolts.

5. Tighten the bolts in the correct sequence, see in-

structions below under “Tightening-cylinder head
bolts”.
Cylinder liner Cylinder block
6. Fit and tighten up the bolts for the inlet and ex-
haust manifolds. Use lock washers to lock the ex-
haust manifold bolts.

7. Fit the delivery pipes and by-pass fuel pipes to-

gether with ties, washers and brackets.

8. Fit the push rods, rocker arm mechanism and in-

jectors.
Tightening torque for rocker arm bracket: 40±4
Nm (4±0.4 kpm).

9. Adjust the valves, see instructions.

Tightening – cylinder head bolts

Tighten the bolts in stages and in the sequence illustrat-
2 4 ed here. Tighten evenly; uneven tightening impairs the
bolting and has a negative effect on the sealing.

1st stage: 50 Nm (5.0 kpm)

2nd stage: 200 Nm (20.0 kpm)
3 1 3rd stage; 370 Nm (37.0 kpm)
4th stage: Angle tightening 90°, (that is, a 1/4 turn).

90˚

50
 Cylinder liner, piston, connecting rod

Piston ring set

Upper O-ring
Installed dry
Gudgeon pin and
lock rings

Lower O-rings
Lubricant packed
with gasket set

Marked
FRONT
Cylinder liner Piston

Connect- Tightened in
ing rod stages (see
specifications)

The engines have wet, replaceable cylinder liners. Precisely at the end of the compression stroke the air
Characteristic of this type of liner is its immediate con- will find itself in the area for this surface and be rapidly
tact with the coolant. This ensures good cooling. compressed and pressed down into the scored section
in the lower part of the combustion chamber. The width
The connecting rods have angle-cut connecting-rod of the surface contributes essentially to rapid air rota-
seats to enable them to be taken up through the cylinder tion. The tapered projection in the middle of the piston
liners together with the piston. keeps the air from the middle of the piston and presses
instead the air out from the middle, thereby contribut-
Like the pistons, the cylinder liners are grouped per ing to more effective air rotation. Not only is air rota-
class. This means that pistons are fitted in cylinder tion improved, the fuel dispersion is better.
liners of the same class. Pistons and cylinder liners are
supplied as spare parts only as a single unit.

The engine has pistons with so-called “re-entry” type

combustion chambers. These pistons have a large area
between the piston outer edge and the combustion
chamber.

Difference between re-entry type piston and

the early prod. type piston (dash line).

51
 Piston/piston rings

Special tool:
(998) 5423 Piston ring pliers

NOTE!
To prevent damage to the piston cooling nozzles,
they must first be removed before removing piston
and connecting rod.

1. Remove the piston and connecting rod.

2. Measure the piston ring clearance.

0.13 mm
3. Remove the piston rings. Clean the piston and pis-
0.09 mm ton ring groove.
0.05 mm
Checking piston rings
Check all surfaces for wear. Dark spots indicate
poor contact. Where this is the case, replace the pis-
ton rings.
Replace the piston rings if there is notable wear or
out-of-round, which would make it difficult to fit
the rings in their original positions.
Heavy oil consumption could also be a reason for
replacing piston rings.

4. Measure the piston ring gap.

0.50 mm

0.40 mm
Checking pistons
0.50 mm Check for cracks, broken-off sections between the
piston ring grooves and also for groove wear. Pis-
tons with seizure marks on the jackets must be
scrapped.
The piston should also be renewed if there is one or
several cracks in the gudgeon pin seat or in the bot-
tom of the combustion chamber.
Piston renewal also means replacing the gudgeon
pin, piston rings and cylinder liners as a complete
unit.

5. Use piston ring pliers when fitting the piston rings.

52
 Gudgeon pin, connecting rod
1801
Special tools:
(999) 1801 Standard handle
2013 Drift
2013 2529 Drift

Disassembling
1. Remove the gudgeon pin lock rings.

2. Press out the gudgeon pin from the piston using

drift 2013 and standard handle 1801.

3. Press the bushing out of the connecting rod using

drift 2529.

Checking connecting rods and gudgeon pins

Look for cracks. Check straightness and for warp.
1801 In both cases max. permitted deviation is 0.01 mm
on a measured length of 100 mm. Use the measur-
ing fixture when measuring.
Cracked, bent or warped connecting rods must be
renewed.
2529 In cold condition, the gudgeon pin grip in the pis-
ton should be max. 0.004 mm.

It is most important that the lube hole is positioned op-

posite the lube drilling in the connecting rod. To ensure
correct alignment, line-up mark the bushing with the
connecting rod, as shown here, before pressing in the
bushing.

53
 4. The tools used for removing the old bushing can
1801 also be used for pressing in the new one. Make
sure the bushing is fitted correctly.

5. Ream the bushing to correct fit. An oiled gudgeon

2529 pin should glide under its own weight through
the bushing at a temperature of 17–20°C.

Assembling
1. Fit one of the gudgeon pin lock rings. Oil the
gudgeon pin and bushing.
NOTE! Apply light pressure when pressing in the
gudgeon pin. Do not try to knock it in.

2. Fit the other gudgeon pin lock ring.

Front. Faces engine thermo-

stat housing when installing in
engine.

Cylinder liner

Checking
Measure the cylinder liners with a cylinder indica-
tor. Max. wear 0.40–0.45 mm.

Measure cylinder liner wear with a cylinder indicator.

To get max. accurate wear, first gauge the cylinder in-
dicator with a gauge ring or micrometer.
Use the cylinder liner original diameter as reference
value.

Note. Cylinder lines and pistons are co-classed.This

means that the pistons must be fitted in cylinder liners
of the same classification.
As spare parts, piston and cylinder liner are supplied
only as a complete unit.

54
 Removing
6394
Special tools:
(999) 2089 Puller plate
2479 Holder
6645 6394 Spacer (two)
6395 6395 Spacer (two)
6645 Extractor

1. If the liner is to be refitted, mark the cylinder liner

seating against the cylinder block with a coloured
pen.
2089
2. Pull the cylinder liner up out of the cylinder block.
Mechanical puller
3. Remove the sealing rings from the cylinder block.

4. Thoroughly clean the cylinder liner sealing surfac-

es in the cylinder block. The sealing surfaces must
be entirely free of rust and deposits.
Note: Do not use a scraper tool for this.

Checking the cylinder liner height before fitting the liner.

2666 1. Fit the cylinder liner, but not the sealing rings, in
2479 the cylinder block.

2. Fit tool 2666 (two) to hold the cylinder in position

in the block.

3. Fit a dial indicator on holder 2479. Point the dial

indicator probe at the liner stepped edge and read-
off the liner height above the block face.

4. This measuring should be done at several places

on the liner.
Correct cylinder liner height above the cylinder
block face is 0.14–0.20 mm.
Adjusting cylinder liner height, refer to Machining
cylinder liner height, milling.

Cylinder liners and pistons – installing

0,14 - 0,20 mm
Special tools:
(999) 2000 Standard handle
2666 Press tool
6599 Adapter
6664 Piston ring compressor
8068 Crank tool

1. Fit new sealing rings in the cylinder block.

Note: Lubricate the two bottom rings with the
Cylinder liner Cylinder block grease contained in the packet containing the
rings.
Concerning order and location of the sealing rings,
refer to installation instructions in the packet.

55
 2. Thoroughly clean the cylinder liner collar. Fit a
new O-ring on the cylinder liner.
Note: The O-ring must be dry.

3. Apply an even, max. 0.8 mm, thick bead of seal-

ant round the liner shelf.
Within 20 minutes from the time this is done, the
cylinder liner must be fitted in the cylinder block.

4. Fit the cylinder liner according to the line-up

marking on the cylinder block.

5. Carefully tap the cylinder liner down into the cyl-

inder block using drift 6599 and handle 2000.

2000

6599

Apply load to the the cylinder liner with two tools

2666.
The load must not be taken off the cylinder liner until
2666 the cylinder head is fitted in position.

6. Place tools 6664 on top of the cylinder liner. Oil

the piston. Fit piston and connecting rod in the cyl-
inder liner with the “FRONT” markings pointing
ahead.

7. Check to make sure the connecting-rod bearings

are fitted correctly in the connecting rods and cap.
Oil the connecting-rod bearing journals and shells
with engine oil. Fit the caps according to the line-
2666
up marking.

56
 8. Fit the piston cooling nozzle.

Important…
Follow also the instructions on page 90!

9. Fit installation ring 6664 on the piston. Fit the pis-

ton, along with the connecting rod, in the cylinder.
6664
10. Fit the connecting-rod cap along with bearing as
per line-up marks.

Tightening main bearing bolts

The bolts are tightened in the following stages:
First tightening 40 Nm (4 kpm).
Second tightening 75 Nm (7.5 kpm).
Final tightening (angle tightening) 90°.

Arrow on piston should point towards the front of the engine.

11. Crank the engine with crank tool 8068 and fit the
other pistons.

8068

57
 Cylinder block/crank mechanism

58
 Description
Upper cylinder liner seat

The cylinder block is one-piece cast of special alloy.

Stresses on the cylinder head bolts from combustion
pressure are transmited via reinforced ribbing in the
cylinder block walls directly to the main bearings.
The DH10A engine has a drilling and nozzles for pis-
ton cooling.

Lower cylinder line guide

The camshaft is journalled in seven bearings and is

driven via one of the timing gears from the engine
crankshaft. Its function is to operate the valves via push
rods and rocker arms.
The camshaft bearings range in size starting at the front
and gradually becoming smaller towards the rear. This
arrangement makes it easier to install the bearing bush-
ings in the cylinder block.

4 3 2

1 The following are the engine timing gears:

7 1. Crankshaft gear
2. Intermediate timing gear
8
3. Injection pump drive gear
4. Power steering oil pump drive gear
5. Camshaft gear
6. Space normally occupied by air compressor drive gear
7. Intermediate oil pump gear
8. Oil pump gear

The coolant pump is flange-driven from the oil pump

gear (8). Because the gears are hardended in different
ways, it is important when changing a gear that it is ad-
jacent to one of similar hardness. See further on page
72.
Components gear-driven from the engine have a very
high operational reliability.

59
 Crankshaft
The crankshaft is either nitro-carburized or induction-
hardened (both alternatives exist). It has a new rear 14-
bolt flange against the flywheel (previously 10 bolts).
The crankshaft is single-piece forged in special steel.
The bearing surfaces are nitro-carburized to increase
strength and reduce risk of cracks.
The crankshaft has seven main bearings. Each big-end
bearing is placed between two main bearings. The
counterweights on the crankshaft are there to even out
operating surges so that torque is evenly spread out.
Up front the crankshaft has a polygon hub to which the
vibration damper hub is fixed. The main bearing and
big-end bearings consist of lead-indium plated and
lead-bronze lined steel shells.

Vibration damper
To further its damping qualities, the DH10A engine has
been given a more robust, built-in vibration damper.
The timing gear cover has had its shaped re-designed to
suit the new vibration damper.
The vibration damper consists of a housing containing
a rectangular damper ring, which is surrounded by sili-
cone oil, that acts as a speed buffer between the damper
ring and the housing. Since the housing is fixed to the
crankshaft, the speed buffer has a dampening effect on
crankshaft oscillations. The vibration damper is placed
on the inside of the timing gear cover in the figure.

Sound baffles
The engine timing gear cover and oil sump have been
fitted with sound baffles. These are built up of two
Sound baffle for timing gear casing plastic layers with an intermediate damper layer of
Sound baffles for oil sump plastic/rubber.

Crankshaft movement
Differences compared to THD104

Flywheel
The flyhweel has 14 holes.

Connecting rods
The connecting rods have trapezoidal gudgeon pin
ends.
Sealing strip Sound baffle cover
Pistons
In design the pistons have been adapted to the trap-
ezoidal connecting rods. The shape of the combustion
chamber has been altered, resulting in altered compres-
sion ratio. Altered, too, are the specifications for the
piston rings.

60
 Cylinder liner seats

Checking
Coolant will leak if the cylinder liner seats and /or
the underside of the cylinder liner collars are cor-
roded. The cylinder liner must have a tight fit to
prevent gas leakage.

Machining

Special tools:
(999) 2479 Holder for dial indicator
2666 Press tool (holder) for cylinder liner
9511 Expander tool
9551 Milling tool

Where there is doubt concerning the extent of the

Special milling tool 9551 which is used for major damage damage, use marking colour to check the area in
contact with the cylinder block liner seat.

1. Remove the cylinder liner sealing rings.

2. Lightly apply marking colour underneath the seal

on the cylinder liner collar. Fit the cylinder liner
and rotate it back and forth with expander tool
9511 while pressing down at the same time.

3. Pull out the cylinder liner and check the contact

9511
pattern.

4. Minor defects can be rubbed off with grinding

paste, which is applied to the underside of the cyl-
inder liner collar. Use expander tool 9511 and
press down. Fit the cylinder liner in position and
Checking cylinder liner rotate it back and forth. Clean thoroughly, re-
check and if necessary repeat the grinding.

61
 Use of special milling tool 9551
Before grinding the cylinder liner seat, measure the
cylinder liner height in order to calculate the compen-
sation space for removed material.
2666
2479 1. Use the dial indicator and note the measurement.
Assume, for example, that the seat has sunk a bit
and is 0.12 mm.

2. Remove the cylinder liner. Establish the damage.

As an example of how to estimate this, let us as-
sume that a milling of 0.20 mm would be suitable.

3. Before setting up the milling tool, roughen up the

liner seat with emery paper.

4. Fit the used O-ring at the lower cylinder liner seal

to ensure accurate centering of the milling tool.

5. Remove the small fillet in the bottom of the cylin-

der liner seat, if this has not been done already.
Correct cylinder liner
0,14height
- 0,20 mm
0.14–0.20 mm 6. Use milling tool 9551, which is bolted onto the
cylinder block. Use suitable flat washers under the
bolt heads. Make sure the feed screw does not
press against the tool and that the washer under the
feed screw is clean and greased.

7. Set up the dial indicator as shown in the Fig. Screw

down the feed sleeve to exert light pressure on the
milling head. Zero-set the dial indicator.

62
 9551

Milling cylinder
liner seat

Feed sleeve Milling head

8. Calculate the milling depth.

Example how to calculate shim thickness
and machining depth
9. Use a T-handle and flexible joint to move milling
A. Read-off the cylinder liner height (from the dial in-
dicator, assumed to be 0.12 mm). The cylinder lin-
tool 9551 round. Mill round in smooth even move-
er is thus 0.05 mm too low compared to the recom- ments while turning the feed screw.
mended measurement 0.14–0.20 mm.
B. Damage depth estimated at 0.20 mm. 10. When the estimated depth has been reached, stop
C. Total of the two values: 0.25 mm.
the feed and turn the tool several turns without ap-
plying pressure.
D. An 0.30 mm shim will give a final height of 0.17
mm, if 0.25 mm is milled off.
11. Check the contact surface of the cylinder liner
Shims are available in thickness of 0.20, 0.30 and 0.50 seat.
mm. Note: Place the shim on the cylinder liner, NOT in
Not more than one shim may be fitted under the cylin- the cylinder block.
der liner collar.
An upper O-ring will hold the shim in position on
the underside of the cylinder liner collar.

Cylinder block, face-milling

Checking
Damage round oil and coolant seals on the cylinder
block require repair-milling. The cylinder block
can be milled, provided piston height above the
cylinder block face does not exceed 0.70 mm.
The max. piston height must not be exceeded, oth-
erwise the piston will knock against the cylinder
head or the valves.

63
 Front sealing ring

Special tools:
(999) 2000 Standard handle
2337 Lever
2679 Puller
8014 Hollow drift

1. Remove the thrust ring.

If necessary, use puller 2679.
2679 Tightening torque for thrust ring bolts: 60±6 Nm
(6.9±0.6 kpm).

8014
2000

2337

Removing Fitting

2. Place the sealing ring on the press drift before fit-

ting it.

3. Grease the seal lips.

4. Fit the dust cover.

64
 Timing gears
4 3 2

1 1. Crankshaft gear
2. Intermediate timing gear
7 3. Injection pump drive gear
8 4. Power steering oil pump drive gear
5. Camshaft gear
6. Space normally occupied by air compressor drive gear
7. Intermediate oil pump gear
8. Oil pump gear

Remove:
– rocker arm cover for no. 1 cylinder
– oil sump
– front drive pulley, vibration damper
Replacing/removing timing gears – timing gear cover

Special tools: 2. Removing polygon hub.

(999) 2337 Lever
2658 Puller
2659 Press tool 6603+6413
8068 Crank tool
4706 Stop
6600 Hydraulic cylinder 6222
6222 Hydraulic pump
6796 Hollow drift
6603 Die
6413 Extension
6600
1. Fit crank tool 8068 on the flywheel and crank until
No. 1 cyl. pistion is at top dead centre, compres-
6796
sion stroke (0° on flywheel).
– Lock the crankshaft temporarily with stop 4706.

3. Release the intermediate gear using lever 2337.

Check line-up marking on gear wheels before removal.

65
4. Pull off the crankshaft drive gear with puller 2658. 6 Injection pump drive gear. If necesssary use stand-
ard puller 2679 with hex socket screw 952076-8.

952076-8
2679

2658

5. Camshaft drive gear.

7. Remove the oil pump intermediate gear.

Replacing timing gears

When replacing the compressor and/or the power steer-
ing pump on a factory overhauled engine, it is impor-
tant to check the data plate to make sure which type of
timing gear was installed at the overhaul.

A nitro-carburized gear (“N”) must not mesh with a

hard-tough gear (“HT”), but on the other hand, a case-
hardened gear (“CH”) can be combined with a nitro-
carburized gear (“N”).
Avoid combination “N”/“HT” when replacing timing
gears on earlier engines.
Nitro-carburized gears are easily recognized by their
flat grey to grey-yellow colouring. Moreover they are
marked either with a white spot, or an “N” or “Nitro”
punched into the gear.

66
Timing gears
Checking

Check all clearances when fitting the timing gears.

Axial clearance for all intermediate gears: max. 0.15
mm.
Check the key-way in the crankshaft for damage and
that it sits correctly in the crankshaft groove.

Radial clearance for all intermediate gears: max.

0.082 mm.

Checking
Check the timing gears. Replace worn or damaged
gears. Backlash must not exceed 0.17 mm.

67
Timing gears Pressing on crankshaft hub
Installing (polygon hub)

1. Make sure the crankshaft crosskey is fitted in 1. Smear the crankshaft end with molybdenumndi-
position.Use tool 2659 and fit the crankshaft gear. sulphide grease before pressing on the crankshaft
hub.

6626
2671

8004
2659
6625

6222

2. Make sure the camshaft drive gear guide pin is in 2. Temporarilly lock the crankshaft with stop 4706.
position. Fit the camshaft drive gear. Then the in-
termediate gear. Ensure that the line-up marks on
the intermediate gear, the crankshaft gear and the
camshaft drive gear coincide.

3. Fit the injection pump drive gear.

4706

3. Fit the crankshaft hub centre bolt and washer.

Tighten the centre bolt to 560±30Nm (56±3 kpm).
If torque multiplier 9711 is used, the tightening
torque will be 140 Nm (14 kpm).

4. Tighten the gear wheel bolts to the following

torque:
Nm kpm
Gear, camshaft
(M-thread) ............................................ 60±5 6.0±0.5
Gear, injection pump drive
(M-thread) 6 bolts ................................. 33±4 3.3±0.4
+10 +1.0
Intermediate gear journalling .................... 60 –5 6.0 –0.5
Oil pump intermediate drive gear .............. 22±3 2.2±0.3

68
Sealant for timing gear cover Injection pump drive mechanism
Sealing agent Volvo P/N 1161231-4 is used instead of
a gasket. Replacing seal, output shaft
The sealing areas must be thoroughly cleaned before Special tools:
applying the sealant. Allow the sealing surfaces to dry. (999) 6640, 8011, 8012
Apply an even bead of sealant about 1.5 mm in dia-
meter. Best result is with a 1 mm nozzle hole. The injection pump and the pump coupling must first
be removed (applies only to DH10A, 345, 360) in order
to replace the sealing ring on the injection timer/drive
mechanism.
For the DH10A, 245, 285 and 350 it is enough to re-
move the pump coupling.

Never try to bend or allow the fuel and delivery

pipes to be deformed. This could cause cracks and
result in leakage.

1. Fit drift 6640 in extractor 8011. Turn the drift with

the bottom hole facing the extractor bolt.

6640

Fit the cover and bolts. Tighten the bolts to a torque of

8011
50 Nm (5 kpm), and then the sound baffle.

Note: The injection angle should always be checked/

adjusted after working on the timing gears. 2. Screw the extractor into the seal with the help of a
drift. Press on the extractor at the same time so that
the threads cut into the steel ring.

69
3. Pull out the old seal by screwing down the extrac-
tor. At the same time hold tight the extractor with
the drift.
A

B
NOTE!
Because the drive mechanism does not have a
wedge at the front flange, it is most important that
the clamp bolt is tightened to the correct torque:
Tightening torque Nm kpm
Clamp bolt (A)
M11 .................................... 90±5 9.0±0.5
M12 .................................... 114±10 11.4±1.0
Flange bolt (B)
M10 .................................... 62±5 6.2±0.5
4. Oil the new seal and injection timer shaft.
Seal replacement alternative
5. Fit the sealing ring on the shaft and tap it in until it method DH10A, 345, 360
is flush with the bearing housing.
Use drift 8012. 1. Release the clamp bolt. Remove the bolts and
washers. Take off the front discs first. Remove the
shaft.

2. Tap out the sealing ring using a screwdriver.

6. Fit the flange, pump coupling and injection pump.

See next page under point 3.

7. Set basic timing and check the injection timing.

70
3. Fit a new sealing ring. 5. Fit the bolts and washers as shown in the figure.
Fit the shaft and the rear discs.

6. To torque tighten the bolts properly, a tool like the

one shown here should be made by the workshop.

4. Fit the front discs.

Ring grip
15 mm

Decapitated
sleeve (socket)

40 mm

7. Tightening torques:
Nm kpm
Clamp bolt ......................... 114±10 11.4±1.0
Flange bolt ......................... 62±5 6.2±0.5
NOTE! Torque will be 4% greater if above work-
shop-made tool is used.

Tightening torque
with special tool:
Nm kpm
Clamp bolt ......................... 110 11.0
Flange bolt ......................... 59.7 6.0

8. Check basic timing, see page 97.

71
Injection timer, 3. Remove the drive belts, pulley, vibration damper
removing/installing and timing gear cover.
DH10A, 345, 360 4. Remove the injection timer drive gear bolts and lift
off the gear (with stiff removal, we recommend
Special tools:
use of a standard puller 999 2679 together with in-
(999) 8068 Crank tool
2679 Puller
hex plug socket to pull off the gear).

1. Crank the flywheel in its direction of rotation to

where no. cyl. piston reaches top dead centre after 952076-8
compression stroke (0° on flywheel and both no. 1
cyl. valves closed).

2679

8068

5. Disconnect the delivery oil pipe between the timer

and the cylinder block. (With installation, use new
copper gasket.)
2. Remove the intermediate piece and the flange
bolts. Release the clamp bolt on the front flange 6. Remove the retaining bolts and lift out the timer.
nearest the injection timer and remove the flange.
Do not crank the injection pump or engine.

46
Installing 2. Crank the flywheel until no. 1 cylinder is at top
dead centre, compression stroke.
Note the following…
The sealing surface between the timer and the timing
gear casing must be clean. Fit a new sealing ring on the
timer.
The six bolts on the injection timer gear should be
tightened to a torque of 33±4 Nm.
The flange discs are M10-tightened to a torque of 62±5
Nm.
Before tightening the clamp unit on the flange to the
correct torque 114±10 Nm, check the injection pump
basic setting, see under “Basic setting injection pump
(EDC)”.
8068

3. Line-up mark camshaft gear position with mark-

ing pen.

Replacing camshaft

Special tools:
(999) 2337 Lever
8068 Crank tool
8079 Extractor 4. The guide pin on the camshaft against cylinder
head = no. 1 cyl. piston at top dead centre.
1. Remove…
– rocker arm mechanism for all the cylinder heads 5. Remove the camshaft gear.
– sump
– timing gear cover

2337

73
6. Remove the thrust washer. 9. Remove the valve tappets.
Always check the tappets.

7. Fit extractor 8079.

Crank the camshaft one turn so that the valve tap-
pets are moved aside.

8. Remove the camshaft. Checking

Check cams and bearing races for wear. Cams can
wear at an angle. Slight angle wear can be reme-
died by honing the cams.
With more extensive damage, replace the camshaft.
Use a micrometer and measure the wear on the
bearing races. Max. permitted wear and out-of-
round is 0.05 mm.
Check camshaft straightness with a dial indicator.
Max. permitted warp is 0.04 mm. Otherwise con-
cerning measurements for the camshaft and bear-
ings, refer to “Specifications”.
8079

The camshaft bearings are pressed into their seats and

thereafter bored. Special tools are required for this. The
camshat bearings, therefore, can only be renewed
where there is proper equipment for machining the
bearings.
When pressing in the bearings, check to make sure the
lube holes coincide with the oil drillings in the cylinder
block.
Concerning machining measurements, refer to “Speci-
fications”.

Tightening torqe Nm kpm

Bearing brackets for rocker
arm shaft ........................................... 40±4 4.0±0.4
Timing gear cover ............................. 50±5 5.0±0.5
Sump ................................................. 18±2 1.8±0.2
Sump cover ....................................... 24±2 2.4±0.2
Thrust washer, camshaft ................... 40±4 4.0±0.4
Camshaft gear (M-thread) ................ 60±5 6.0±0.5

74
Crankshaft

Checking
Prior to any machining, check the crankshaft for
cracks. Seizure can cause overheat cracks, which
can only be detected by using special equipment.
The recommended test involves using a magnetic
powder, type MAGNAGLO, which is fluorescent
and is scrutinized under ultraviolet light. For pow-
der type, concentration, current and magnetizing,
follow the instructions of the manufacturer. See
also below the types of cracks that can occur.

Renew crankshaft if…

…fillets have these types of cracks …or the crack is further than 5 mm from the lube drill-
ing. Cracks nearer the lube drilling can be removed by
machining.

…or there are longitudinal cracks within the areas …or when a crack is less than 10 mm outside the area
marked here. marked here.
Individual cracks within 10 mm are acceptable.

75
 Straightening the crankshaft
To assess straightness, the crankshaft must be support-
ed under main bearings 1 and 7 and main bearing 4
checked for out-of-round.

Below 0.2 mm No straightening.

Between 0.2 Careful straightening, not more
and 0.7 mm than necessary.
Above 0.7 mm Replace crankshaft.

Straightening reduces fatigue resistance and should

therefore be avoided. The nitro-carburized bearing sur-
face has a tendency to crack at the fillets between the
bearing races and the webs.

Machining
Damaged bearing surfaces should be lapped. If this is
not enough, replace the crankshaft or machine it. A ni-
tro-carburized crankshaft must be be ground more than
to second undersize, unless the nitro-craburizing treat-
ment is repeated. After treatment, bearing surfaces and
fillets should be lapped to a surface finish of 0.002 mm.
Grinding nicks or sharp edges are not permitted, as
they may cause fracture. The width measurement “A”
for the pilot bearing is particularly important. Refer to
“Specifications”.
After machining, thoroughly clean the crankshaft. Re-
check for cracks, using the magnetic power test method
and de-magnetize. Clean and flush all oil drillings.

NOTE!
It is most important that the fillets are ground to the
right shape and size. They should be between 3.75–
4.00 mm. Use a radial template for the measuring.

Flywheel

Checking
Crank the flyhweel to get max. throw. It must not
exceed 0.15 mm.
If the throw is greater than this, remove the fly-
wheel and check the contact surfaces for dirt or un-
evenness.

Measuring radius 150 mm

76
 Replacing ring gear
1. Punch holes in the ring gear tooth gaps with a
chisel. Crack the ring gear at the punched hole.
Brush clean the contact surface.

2. Polish the ring gear to a shine at several points

round the ring. Evenly blue-anneal heat the pol-
ished sections.

3. Quickly place the heated ring gear on the flywheel

and tap it into position with a soft drift.

Fitting the ring gear

Flywheel casing

Checking
The flywheel contact surface against the clutch cas-
ing should be square to the crankshaft within 0.15
mm.
Its inner edge should be concentric with the fly-
wheel within 0.25 mm.

With excessive dial indicator reading, check the fly-

wheel casing contact against the cylinder block.

77
 Replacing support bearings

Special tools:
(999) 1801 Standard handle
1819 1819 Extractor
2665 Press tool

1. Remove the support bearing using extractor 1819.

2. Tap in the new support bearing into position in the

flyhweel.
2665

1801

Replacing crankshaft rear seal

(Clutch removed)

Special tools:
(999) 2000 Handle
6088 Drift
8010 Extractor
8010
1. Remove the flywheel.

2. Tap out the seal using extractor 8010.

3. Clean the seal seat in the flyhweel casing.

4. Apply gasket sealant (part no. 1161277) to the seal

outer circumference and fit the seal.
2000
5. Fit the flywheel. Tighten the flyhweel, or flange
+0.5
disc bolts, to 185 +5
–10 Nm (18.5 –1.0 kpm).

6088

78
 Group 22

Lubricating System
Contents

– Description .......................................................................................... 80

Oil pump
– Removing, installing ........................................................................... 83
– Servicing .............................................................................................. 85

Oil cooler
– Oil cooler ............................................................................................. 87
– Oil pressure, piston cooling ................................................................. 87

79
 Lubricating system
2. Relief valve,
4. Reducer oil filter
To valve
lube system

3 4 5
2
1 6
0 7

From
reducer valve

From
oil tank

1. Piston cooling valve

2 15773-13

3. By-pass valve

To
oil tank

The system has four control valves:

1. Piston cooling valve
2. Relief valve for oil filters
3. By-pass valve for oil cooler
From To
4. Reducer valve oil cooler oil cooler

80
 3 1

1. The piston cooling valve opens when engine 4. The reducer valve opens at excessive lube oil
speed has just reached above low idle and oil pres- pressure to return the excess oil back to the sump.
sure has increased. The oil is then led by a drilling
to the piston cooling duct in the engine block. Six The engine is lubricated from a pressure-lubricating
nozzles are connected to the piston cooling duct, system. Since the engine lies horizontally, the oil sump
one for each piston, and from these oil is sprayed is of the dry type with separate oil tank.
against the bottom of the pistons.
The oil system delivery pump sucks the oil from the oil
2. The relief valve for the oil filters opens if the fil- tank through a strainer. It then pressurizes the oil out to
ters are clogged. This ensures continued lubrica- the various lube points in the lubricating system.
tion.
Return oil is pumped back to the oil tank by two scav-
3. The by-pass valve opens when the pressure drop enging pumps.
across the oil cooler is too high, e.g., at cold start.
When the valve opens, the oil by-passes the oil
cooler to get more quickly out to the engine lube
points.

4 7

6
General layout, engine oil
A The oil pump is of the gear type and has
3
three pump units. The front unit functions
B as an oil delivery pump and the other two
8 as scavenging pumps. They all pump the
2 10 11 oil back to the oil tank via the oil cooler.
The oil pumps are gear-driven from the
8 9 crankshaft via an intermediate drive gear.

The lubricating oil filters have “spin-on”

type replaceable filter inserts.
1 12
The high capacity of the oil pump places
greater demands for greater lube oil filtra-
tion. It is for this reason that the engines
13
have two full-flow oil filters (direct oil fil-
ters and no by-pass filter). The full-flow
filters are coupled in parallel for best
filtration.Oil pump 81
drive gearScavenging
 The oil pump is of the gear type and has three pump
units. The front unit functions as an oil delivery pump
and the other two as scavenging pumps. They all pump
the oil back to the oil tank via the oil cooler. The oil
pumps are gear-driven from the crankshaft via an inter-
mediate drive gear.

Intermediate Oil delivery

gear pump unit

Oil pump
drive gear

Scavenging
pump unit
Coolant pump
flange

Scavenging
pump unit

2
The lubricating oil filters have “spin-on” type re-
placeable filter inserts.

The high capacity of the oil pump places greater de-

mands for greater lube oil filtration. It is for this reason
that the engines have two full-flow oil filters (direct oil
filters and no by-pass filter). The full-flow filters are
coupled in parallel for best filtration.

82
 The piston-cooling valve is normally closed at low en-
gine speed, this to prevent the oil pressure from drop-
ping at low idle. As engine speed increases, the piston-
cooling valve opens to direct the oil to six calibrated
nozzles, one under each piston.

Piston-cooling nozzles
If piston cooling is cut-off, reduced or wrongly aimed,
the piston will seize after a relatively short period under
load. Oil for the piston cooling does not pass through
the oil filters during pressure feed but from the oil tank
via the oil pump and on to the piston cooling nozzles.

Therefore, the greatest possible cleanliness must be

observed in all work connected with the oil tank, suc-
tion lines and suction strainers, likewise the piston
cooling valves, the nozzles and their ducts.

The piston cooling nozzles must never be straight-

ened or repaired in any other way. If damaged or de-
formed, they must be unreservedly replaced with new
ones. Great care should, therefore, always be taken
when working on pistons, connecting rods, cylinder
liners in piston cooling engines so as not to damage the
nozzles.

Clogged piston cooling nozzles must not be cleaned

and re-used, because of the risk of dirt particles being
left in the system. When servicing after piston seizure,
the oil cooling drillings must be blown clean and all
the piston cooling nozzles replaced.

The nozzles aim the oil jets at a carefully selected area

inside the piston, see arrow.

Oil pump Front main bearing cap

Removing
1. Remove the starter motor, oil filters, coolant
pump, sump.

2. Remove the suction and delivery pipes from the oil

pump, the oil pump rear bracket and housing for
the relief valve.

3. Remove the front main bearing cap together with

the oil pump.

4. Do not separate the oil pump from the main bear-

ing cap.
Should it happen that the oil pump has been sep-
arated from the main bearing cap, adjust the pump
according to the instructions overleaf.
Oil pump

83
Installing

Special tools:
(999) 2807 Centering tool
6656 Centering tool

1. Connect up the pipes. Fit the sump. Tightening torque

Nm kpm
2. Insert centering tool 2807 in the crankcase hole for
the drive gear. Insert centering tool 6656 in the Main bearings ................... 340±25 34.0±2.5
crankcase hole for the return oil. Sump ................................. 18±2 1.8±0.2
Sump cover ....................... 24±2 2.4±0.2
3. Fit and tighten up the sump bolts.

6656
2807

Adjusting

Secure the cap in a vice with aluminium jaws (see Fig. Press the pump to the left. Zero-set the indicator dial.
below). Press the pump to the right. Read-off the dial.
Make sure the pump does not lie against the vice. Press the pump back to half the measured value.
Mount a dial indicator with magnetic foot on the cap Tightening torque: 40±4 Nm (4.0±0.4 kpm).
and position the probe to right angles to the pump.

Press right

84
Servicing oil pump

Special tools:
(999) 2654 Puller
6849 Drift
6850 Reamer

1. Use puller 2654 to remove the oil pump drive gear

from the shaft.

2. Dismantle the oil pump.

Check the pump body for scoring and wear also for 2654
leakage signs between the bracket and the pump
body. The contact surfaces will be black if there is
leakage.

Pressing out/in bushings NOTE! The bushings must be pressed in from the
“outside”, as shown below.

6849
6849

NOTE! The bushings in the middle pump bodies are a

bit narrower and must be centered otherwise they will
block the oil drillings.

85
Reaming bushings

6850

Checking pump gears axial clearance

1. Check the axial clearance for the pump gears. In both cases, place a feeler gauge 1.0–1.5 mm be-
Correct clearance: 0.02–0.08 mm. tween the pump gear and the bracket.

2. There are two ways in which to fit the oil pump

drive gear:
– Heat the gear to approx. 180°C and tap it into
position
or
– Place the gear under the bracket and press in the
shaft.

86
3. Assemble the pump.

4. Draw the pump body halves together with the two

bolts. Check to make sure the gears rotate easily.

NOTE! Fit the main bearing bolts before final assem-

bly.
Tightening torque, oil pump intermediate gear: 22±3
Nm (2.2±0.3 kpm)

Oil cooler

Pressure testing

Special tools:
(999) 2800 Test bench
8074 Nipple
8075 Cover washer

1. Drain the oil and coolant. Remove the oil cooler

from the engine. Change to new O–rings before 2800
mouting the press-testing tools.

2. Fit nipple 8074 and cover washer 8075. Connect

up test bench 2800.

3. Set pressure at 30 kPa (0.3 kp/cm2). Hold this pres-

sure for one minute. No pressure drop is allowed.

4. Set pressure at 400 kPa (4 kp/cm2). Let this pres- 8074

sure remain for one minute. No pressure drop is
allowed.
If pressure drops, the oil cooler must be replaced 8075
since it is not permitted to repair it.

Oil pressure, piston cooling

6398
Special tools:
(999) 6398 Pressure guage
6666 Nipple

Piston cooling oil pressure should be 0.8–1.2 kp/cm2 at

1200–1500 r/min.
If the piston cooling valve does not have a measuring
socket, the valve must be removed from the engine in
order to drill an M10x1 mm hole.Then fit a suitable
plug in the socket after completing the oil pressure 6666
check.

87
 Group 23

Fuel System
Contents

– Description .......................................................................................... 89
– Injection timer ..................................................................................... 92

Injectors
– Replacing, testing ................................................................................ 94
– Cleaning copper sleeves ...................................................................... 95

Injection pump
– Removing, installing ........................................................................... 96
– Basic timing injection pump (EDC) .................................................... 97
– Idling speed ......................................................................................... 99
– Venting fuel system ............................................................................. 100
– Injection timer
Checking......................................................................................... 101
– Testing injection pump ........................................................................ 102
C. Adjuster device ............................................................................... 103
A. Synchronizing................................................................................. 104
D. Speed sensor ................................................................................... 106
B. Checking and setting fuel flows ..................................................... 106
E. Checking oil pump ......................................................................... 107
F. Anti-tamper sealing ........................................................................ 108
– Replacing damper valve holder, injection pump ................................. 109

Note: For more detailed information on the fuel system (EDC), refer to Service Bulletin
2 (23) No. 18. There is also a description of the EDC-system in Service Manual 3 (37)
Electrical System B10B and B12.

88
 Fuel System
Electromagnetic
Feed pump governor

Stop device

Injection pump setting values, chiefly fuel flow and

pre-injection angle, differs for the various engine types.
The reason for this is that these values are adapted to
the properties that the engine has with regard to emis-
sions and power output.

89
The feed pump supplies the injection pump with fuel Pump camshaft
under pressure. Fuel flows through the fuel filters be-
fore reaching the injection pump. Push rod
The pump camshaft pressing down the piston causes
the pump chamber in the feed pump to fill with fluid.
When the cam has passed its highest point and the pis-
ton spring presses back the piston, the pump discharges
the fuel. In other words, fuel pressure is determined by Working
the force of the spring. Inlet
space

The hand primer pump is used to pump up fuel when Suction

space
there is no fuel in the system. Cam lift Outlet

Spring lift
The fuel filters are of the spin-on type and are connect-
ed in parallel.
The filters have a new location compared to their loca-
tion on the THD 104 engine; they are now placed under
the starter motor.
The filter element consists of a spiral-wound paper in-
sert with very large filtration area. The layers of paper
are folded so as to form pockets with openings that face
upwards. The fuel flows axially through the pockets,
and this separates dust particles, water, etc., from the
fuel.

The injectors atomize and distribute the fuel in the en-

gine combustion chamber. Injection is at very high
pressure for maximum possible effective fuel atomiza-
tion.
The push rod and thrust spring press the needle against
the nozzle. Fuel is pressed into the fuel drilling by the
injection pump and the high pressure overcomes the
force acting against the nozzle needle so that it lifts and
fuel is injected. When fuel pressure drops, the nozzle
needle goes down again to shut off the opening.
The force of the spring determines the force acting
Inlet
against the nozzle needle. the thrust spring and thereby
the injector opening pressure is adjusted with the help
of shims.
Return fuel

Fuel
drilling
Push rod and
thrust spring

Nozzle needle

90
Injection pump D10A THD104
Differences
The delivery valves have been replaced by damper
valves in order to maintain a higher pressure at the in-
jectors, without having to raise the injection pump
pressure.
The delivery valve holders (delivery pipe connections)
are now longer and have only one damper valve.
Fuel system venting has been modified to accomodate
the above changes.
After normal venting at the filter bracket, venting is
also required to release the delivery pipes at the injec- Damper ventil Delivery valve
tors.

Injection pump and governor

Engine DH10A has an electronically controlled injec-
tion pump (EDC). Characteristic of the EDC-system is
that it works with an electromagnetic governor mount-
ed on a standard injection pump.

91
The governor adjuster device (1) is placed in the gov- 2B 1
ernor housing end and consists of an electromagnet that
works directly against the injection pump control rod.
The control rod position sensor (2A and 2B) gives the
control unit the opportunity of deciding if current to the 2A
adjuster device should be increased or decreased. The
main speed sensor (3) in the system works against a
toothed gear on the pump camshaft. In addition to the
charge pressure, it is important for the control unit to
know engine speed, otherwise it will not be possible for
the control unit to determine fuel flow.

Injection timer
Engine DH10A, 345 and 360 have an electrically oper- The injection timer angle setting is dependent on three
ated injection timer. Basically this is the mechanical- different factors: speed (r/min), temperature (°C) and
hydraulical timer described in Service Bulletin 2.23.21 load (Q).
11-93 and Service Manual 2 (20–27) Engine THD The information on engine speed and engine load is
101–104. obtrained from the EDC-control unit (9058) and the
The difference is that the centrifugally activated con- temperature from the temperature sensor (756B).
trol valves in the rear flange have been removed and, A special control unit (3104), placed on the electrical
because of this, the infinite timing setting has been re- distributor unit, takes care of the information and con-
placed by a 2-position timer and the maximum timing trols engagement/disengagement of the solenoid valve
angle has been reduced from 6° to 5°. (638) on the injection timer.
Delivery oil flow from the engine is regulated instead
by a solenoid valve (638), mounted on the timer bear-
ing housing.

92
Function
The injection timer alters the a-angle to suit operating The value of a and b can be seen from the following
conditions, see diagram below. When there is no cur- table:
rent in the solenoid valve, the engine a-angle is the
same as the basic setting value (a). When operating DH10A, 345 DH10A, 360
conditions are such that current reaches the solenoid
valve, it opens and the engine lube oil presses the inter- Value a 5,5° 7°
nal torsion piston to compress the pressure return
spring until the piston is against the internal adjuster Value b 10,5° 12°
sleeve. During this movement the piston turns so that
the a-angle increases 5° to maximum a (b).

The above diagrams show the angle setting (a°) in rela- The lower diagrams refer to a cold engine (max 55°)
tion to the engine speed. with engine load (Q) less than 55% resp. more than
The upper diagrams refers to an engine run warm (min. 55%.
55°), with engine load (Q) less than 55%. They show They show that, at low engine load, there is readjust-
that, at low engine load, there is no readjustment from ment at all speeds. At high engine load there is read-
idle up to 800 r/min, irrespective of load, between 1080 justment between 1080 and 1290 r/min, otherwise ad-
and 1290 r/min. At other speeds there is readjustment. justment takes place.

93
 Injectors

Special tool:
(999) 6643 Puller

Replacing
1. Make sure the injector is thoroughly clean before
removing or fitting it. Make sure no paint flakes
stick to the sealing surfaces of the pipe ends.

2. Remove the injector. If necessary use puller 6643.

Installing
6643 3. Clean the copper sleeve according to instructions
next page.

4. Push the injector into position. Fit a new outer

sealing ring with the sealing lip facing the cylinder
head.

5. Fit the retainer and retaining nut. Tighten to a

torque of 50±5 Nm (5±0.5 Nm).

Checking
There are no prescribed intervals for checking the
injectors. They should be removed and checked
when the engine has lost some of its power or if the
exhaust emissions are unacceptable.
Injectors should be checked in an injector tester.
Check results against injector data in “Specifica-
tions”.
Concerning repairs to and maintenance of injec-
tors, refer to the instructions of the Bosch factory.

Testing
To be able to assess injector condition properly, one
must be aware that the different injectors have different
Warning! spray pattern and chatter. Most important is checking
Utmost care must be taken when testing the opening/adjusting pressure and tightness. Spray
injectors. Fuel spray from the injector MUST pattern and chatter are difficult to assess and do not
NOT be allowed to strike unprotected parts of the provide any sure indication of injector condition. All
body. The jet has tremendous force and skin pene- air must be removed from the injector before testing.
tration could lead to blood poisoning. Pump fuel with large pump strokes in order to get max-
imum fuel flow.

94
 Checking/adjusting opening pressure
Connect up a pressure gauge. Slowly push down
the nozzle tester lever until the nozzle opens and
releases fuel. Read-off the opening pressure.
Volvo specifies an adjusting pressure in addition to
the opening pressure. The adjusting pressure refers
to new injectors with new thrust springs. It is high-
er than the opening pressure and provides a certain
margin to allow for thrust spring fatigue.
If the opening pressure obtained when testing does
not comply with the specifications, adjust to the
correct opening pressure with the help of adjusting
Shims
for pressure setting
shims.

Cleaning copper sleeve before

installing injectors Place the installation sleeve
over the copper sleeve.
Special tool:
(981) 2546 Sleeve brush

The copper sleeve seat must be cleaned in order to get

proper sealing between the injector and copper sleeve.

Slide the installation sleeve

over the brush before
fitting the brush in the
machine. Press down the brush
and clean the copper
sleeve.

Slide down the installation

sleeve to compress the
brush.

Spray pattern After the injector has been in use for a short time, this
At a high pumping speed of 4–6 pump strokes per sec- difference diminishes and the contact area increases so
ond, the spray pattern should be uniform and the fuel that the chatter noise should eventually die out.
atomized. The chatter does not have any effect on the injector
when installed in the engine.
Leakage check
Check for fuel leaks between the tip of the nozzle nee-
Servicing nozzle tester
dle and the tapered sealing surface of the nozzle sleeve. If the test fuel has been contaminated by dirt, etc., it
Wipe the nozzle tip dry. Connect up a pressure gauge must be renewed. Also the nozzle tester filter insert
and pump the pressure to approx. 200 kPa below the must be replaced or removed and cleaned in fuel.
injector opening pressure. Keep the pressure constant
for 10 seconds. No fuel should drip from the nozzle tip. When filling with new test fuel, flush the nozzle tester
by pumping the lever, no injector fitted.
Chatter test Check the pressure gauge reading at intervals, using a
Normally only new injectors emit a chatter noise. test gauge. If the pressure gauge shows incorrect read-
The contact area between the nozzle needle and the seat ings, it should be replaced. Minor deviations can be
is narrow as the parts are manufactured with a small corrected by checking against a correction table.
angle difference.

95
Injection pump
Removing/installing

Special tool:
(999) 8068 Crank tool

1. Remove the inspection panel from underneath the 3. Remove the delivery oil pipe from the engine
flywheel casing and fit crank tool 8068. block.

2. Crank the flywheel until no. 1 cyl. piston has just 4. Disconnect the fuel pipes and cables. Plug all open
passed the TDC (compression stroke), (0° on the connections with plastic plugs.
flywheel, mark on pump flange facing up).
5. Release the pump from the pump shelf.

Tightening torques
Injection pump retaining bolts .................................... 40±4 Nm (4,0±0,4 kpm)
Injection pump flange bolts ........................................ 62±5 Nm (6,2±0,5 kpm)

Guide slots To note when installing injection pump

Tightening cable connections

The 7-pin connection for the governor has three guide
slots. The widest slot in the cable unit connection is at
the bottom for correct connect-up to the governor. Con-
nect-up is correct when the cable unit cap nut fits into
Guide slots
the threads in the pump connection.
Pump section Cable unit

7-pin connector

96
 To make sure the cable connection is tight enough, pull
the cable unit axially, see fig, to ensure there is no gap,
which is the case with an improperly tightened coup-
ling. Tighten to take in this gap, if any, and then a fur-
Pump
ther hex side (approx. 60°).
rear NOTE! It is important that all cable connections and
end
joints in the EDC-system are fully plugged in and that
the protection sleeves are pressed fully over insulators
Pull cable unit axially and sensors.
to check for gap

Hex spanner Check that there is engine oil in the bottom section of
grip the injection pump. There should be no oil in the gov-
ernor.

Delivery pipes for EDC-engines

All EDC-engines have pre-pressurized delivery
pipes that tolerate high injection prsssure. This pre-
pressurization is done in the manufacturing pro-
cess, where the pipes are bent and subjected to ap-
prox. 3000 bar pressure in order to get rid of micro-
cracks in the material.
Pull cable unit axially to
check for gap Pre-pressurized pipes must not be bent! This could
cause cracks.
Hex spanner
grip

Turbopressure sensor (3-pin connector)

Basic timing injection pump (EDC)

Special tools:
(998) 7057 Timing tool
8068 Crank tool

1. Remove the inspection panel from underneath the

flywheel casing and fit crank tool 8068.

2. Crank the engine until no. cyl. piston has just

passed TDC, compression stroke (0° on flywheel
and both no. 1 cyl. valves closed). Crank the fly-
wheel back past the degree for the setting.

97
 3. Remove the plug from the pump governor hous-
ing.

4. Fit on position sensor for timing tool 998 7057 in

the governor housing plug hole and earth the tool.

5. Crank the flywheel in the engine direction of rota-

tion. When both the tool diodes light, read-off the
degree on the flywheel. Compare this with what is
given in the Diesel Test Standard or refer to Speci-
fications in this manual.

6. If the timing has to be altered, slacken the clamp

bolt for the pump coupling and tap the pump
flange until the timing is correct.

7. Tighten clamp bolt: M11 ................. 90±5 Nm

M12 ............. 114±10 Nm

8. Check the timing again and adjust if necessary.

98
Low idling speed EDC

Setting, permanent
If the engine is warm (above 45°C), the bus stationary
and the clutch pedal released (parking brake on and
gearbox in neutral on buses with automatic transmis-
sion), idling speed can be set with the help of the break-
ers on the direction indicator stalk.

– Keep the brake pedal depressed. Move the slide

control to “RESUME” and hold it there for min. 4
seconds.

– Still keep the brake pedal depressed and move the

slide control to the neutral position. This should
produce the lowest idle speed (530 r/min).

– By repeatedly depressing “SET+” or “SET–” the

speed can be be altered. Each activation increases/
decreases idle speed by about 10 r/min (within the
adjustable interval). When the desired idling speed
has been reached, activate “RESUME” again for at
least 4 seconds and then move the slide control to
the neutral position.

Setting, temporary

The engine idle speed can be temporarily altered by activating the

rocker switch “SET+” or “SET–”, without depressing the brake
pedal. If the slide control is moved to “RESUME”, the engine will run
at the pre-programmed high idling speed, and if it is moved to
“OFF”, the engine will go down to its lowest set idling speed. These
speed variations are not stored in the control unit. Even with
temporary alteration of the idling speed the clutch pedal must be
released (parking brake on and gearbox in neutral on buses with
automatic transmission).

99
Venting fuel system 3. In the same way slacken each delivery pipe and
use the feed pump hand primer to get fuel free
from air bubbles and then tighten up the pipes
1. Open the vent screw on the fuel filter housing. while the fuel is still flowing out.

2. With the feed pump hand primer pump fuel into 4. Check for leakage and the function.
the fuel system until fuel free from air bubbles
flows out. Then close the vent screw.

100
Injection timer,
checking DH10A, 345, 360
Special tools:
(999) 8060 Crank tool
8190 Measuring instrument

1. Crank the flyhweel to where the 0° mark is oppo-

site the indication pin.

2. Connect up the measuring instrument’s two sen-

sors: one on the injection pump governor housing
and the other on the right-hand side of the flywheel
casing; the upper inner hole (1) is used if the bus
has automatic transmission. The lower outer (2) is
used for a manual gearbox and for the Voith auto-
matic transmission.

3. Check the basic timing for the injection pump by

reading-off the instrument at low idle. Compare
the reading with the value in the diesel test stand-
ard for the engine in question. If necessary, adjust
the basic timing.

4. Increase engine speed to 1200 r/min and check the

timing value on the measuring instrument. The in-
crease engine speed to 1800 r/min and check the
pre-timing value. The pre-timing value should in-
crease 6±1° between 1200 and 1800 r/min. If the
pre-timing does not change between 1200–1800
r/min, overhaul or replace the injection timer.

It is important that the sensor distance to the flywheel/

flex plate is accurately set. This is done by screwing in
the sensor by hand to the flywheel/flex plate and then
by backing the sensor 1.5–2 turns and locking it with
the lock nut.

NOTE! Some flex plates either have a hole or a plate

riveted on that the sensor senses. If the flex plate has a
riveted-on plate, the engine must be cranked round so
that the plate comes opposite the hole where the sensor
should sit. It is then that the sensor distance must be
adjusted otherwise the plate will break up the sensor
when the engine starts.

101
 Testing injection pump, DH10A

Before testing the injection pump, fill the injection pump with engine oil
SAE 20W20 up to the level of the lube oil return outlet.
Concerning adjustment details, refer to the diesel test standard sheet, Serv-
ice Bulletin, Group 23.

Special tools:
(998) 6551 Bracket
7057 Setting tol
7059 Power source, variable 12 V/15 A
– Power sources, fixed voltage 12 V/3 A
alt. on 12 V battery is used
7075 Oscilloscope (needed only for
checking speed sensor)
7085 Test control unit (control unit for
testing pump)
7094 Cable unit
7097 Cable unit
(951) 0060 Voltmeter, accuracy <± mV (Digital)
7085 Test control unit Bosch KDEP 1701 Setting tool

Set the pump up on the test bench and connect up the

test equipment as shown in the Fig.

Test Voltage source Before testing

Voltmeter
box Before testing, the voltage from the test control unit
should be checked/calculated as follows:
GN+
BL
1. Connect up the voltmeter. Blue contact to “–” and
red to “+” on the voltmeter.
R+ SB–
R+
Power source Note: After the test, connect up the green contact
Cable unit variable instead of the red one.
7094
R+
2. Connect up power sources for 12 V constant volt-
SB– age.
Cable unit Oscillo- Read-off the working voltage (U/ref) on the volt-
7097 scope meter. Should be 4.99–5.01 V.
Injection pump
BL–
GN+ If the working voltage is not within 4.99–5.10 V
and deviation is not greater than 10%, voltage re-
quired for further testing can still be calculated.
These voltages should then be used instead of the
values given for the U/norm. The diesel test stand-
ard sheet new values we call U/RV/a = calculated
standard value. Use the following formula for the
calculation:

U/norm x 5.00
U/RV/a =
U/ref
Ex. measured working voltage (U/ref) = 4.97 V
For test in question: U/norm = 3.10 V
3.10 x 5.00
U/RV/a = ≈ 3.12V to be used for test
4.97 in question

102
C. Adjuster device
The first to check on the injection pump is the control
rod travel.

Position sensor for control rod travel

(pump speed 0/min)

Test No.

1 Unorm 3.10 V
Control rod travel: 12.95–13.05 mm (Setting value)
12.90–13.10 mm (check value)

2 Unorm 1.70 V
Control rod travel: 5.90–6.40 mm (Setting value)
5.85–6.45 mm (check value)

3 Unorm min V
Control rod travel: 0.5–1.0 mm (Setting value)
0.4–1.1 mm (check value)

1. Fit the fuel feed line and return line to the pump. 5. Check to make sure the dial indicator measuring
Run the pump warm (600 r/min) for 3 minutes. probe has contact with the travelled control rod.
Unorm = 2.5 V. Set the dial indicator to 21 mm.

2. Fit the bracket and dial indicator (Volov P/N 998 6. Reduce the variable voltage to 0 V and read-off the
6551) at the front of the injection pump to measure dial indicator. Compare the measured value with
control rod travel. The Fig. shows an adapted the value given in the diesel standard sheet at C.
bracket. Adjuster device with U/norm = min. 0.4–1.1 mm.
If the control rod travel is not within the tolerance,
adjust by replacing the setting device end pin,
which is available in different sizes.

When calculating the size of the end pin, bear in

mind that there must be a 0.1–0.3 mm gap between
the control rod and the end pin when the control
3. Switch on the power sources with constant 12 V rod is in the non-travel position and the adjuster
voltage to the test control unit. device off-circuit.

4. Switch on the variable power source and slowly 7. Thereafter carry out tests 1 and 2 under C. Adjust-
increase the voltage until you can hear the adjuster er device adjustment as per diesel test standards
device going to its end position. sheet. Tips: Carry out the tests at low pump rota-
Note: The adjuster device may only be in the end tion, e.g., 200 r/min.
position for max. 1 minute, otherwise there is risk Compare the measured values with those given in
of it catching fire. the diesel test standards sheet.

103
A. Synchronizing 3. Open the tap on the test bench injector for no. 1
Fit the bracket and dial indicator on the rear side of the cylinder.
pump to measure the lift from the basic circle on no. 1 Increase the voltage to the adjuster device (control
pump piston. Crank the pump so that no. 1 pump piston rod travel voltage Unorm) to correspond to the val-
is at its bottom position. Zero-set the dial indicator. ue given in the standards sheet.

4. Crank the pump drive coupling in the pump direc-

tion of rotation to when the tap on no. 1 injector
Test sequence: changes to drip form. Read-off the dial indicator.
Crank back the pump and repeat the test. Compare
A. SYNCHRONISATION
the read-off value on the dial indicator with the
Lift from base circle at start value given in the diesel test standard.
➀ of supply 4.05±0.05 mm (initial value)
4.05±0.10 mm (check value)

At control voltage Unorm 2.6±0.1 V

Injection sequence 153624
Rotational direction Clockwise
Supply pressure 2.5–2.7 (360–390) MPa (psi)

➂ Tolerance between cylinders ±0.50

±0.75
° (initial value)
° (check value)

➁ Pulse wheel cam should match

the impact point on cylinder no. 1
Tolerance ±0.20 ° (initial value)
±0.75 ° (check value)

1
Lift from basic circle at start of measuring
1. Set no. 1 pump piston to its bottom position. Zero-
set the dial indicator. Remove the relief valve from
the injection pump. Connect the test bench high-
pressure hose to the pump fuel inlet. Plug the
pump fuel outlet.

2. Start high-pressure feed on the test bench. Check

that the feed pressure is the same as that recom-
mended in the diesel test standards sheet.
Note: The test bench must be disconnected.

If necessary, adjust stroke by fitting/removing

shims under the flange bushing.

If the pump piston stroke is too early, fit thicker

shims. Fit thinner ones if the stroke is delayed.

104
 2
Checking pulse gear cam
Fit special tool 998 7057 on the injection pump and
earth the tool.
7057
Both the diodes should light when no. 1 pump piston is
in stroke position. If both diodes light, carefully crank
the pump and at the same time read-off the protractor
on the test bench. Compare the difference in degrees
between no. 1 stroke position and when both diodes
light with the value permitted in the diesel test stand-
ards.

Adjusting: Set no. 1 piston to stroke position, ad-

just the pump up-down until both the diodes light.

3
Tolerance between pump cylinders
The other 5 pump elements are checked and if neces-
sary adjusted in accordance with engine firing se-
quence 1-5-3-6-2-4.
The dial indicator is used only on no. 1 tappet. The oth-
er pump elements are adjusted with the help of the test
bench protractor. Mark the stroke position for no. 1
pump element on the test bench protractor. Then re-
move the dial indicator.
The pump camshaft is cranked 60° for each pump ele-
ment. Compare the angle deviation with the value pre-
scribed in the diesel test standards (see tolerance be-
tween the cylinders).
If necessary, adjust with shims under the flange bush-
ing.

105
D. Speed sensor
This check is carried out only if there are problems
with speed control or when the sensor/toothed gear has
been removed.

D. SPEED SENSOR (Control rod in stop position)

Pump speed: 60 r/min Positive amplitude 0.8–2.0 V (Setting value)
Positive amplitude 0.6–3.0 V (Control value)

Pump speed 600 r/min Difference in ampl. 1.4 V

– An oscilloscope is required to check the speed sen-

sor.
Contact unit on pump
– Connect the cables with blue and green contacts
from the test equipment to the oscilloscope. Start
the test bench and compare the read-offs with the
values given in the diesel test standards.
With different values, check the speed sensor pins Bosch
3–4 in the contact unit, check value 900–1100 KDEP 1701
ohms and the sensor setting with special tool
Bosch KDEP 1701. The sensor attachment mount-
ing has oval holes to allow for sensor position ad-
justment.

B. Check and setting fuel flows

Run the injection pump up to normal operating temper-
ature.

Note: With continuous driving at altitudes of 2000–

4000 metres above sea level, fuel flow must be reduced
by 10%. At 4000 metres and above 20%. Note that with
altered fuel flow, the engine data programmed into the
control unit when the engine was delivered from the
factory must be accordingly altered.

B. CHECKING AND SETTING FUEL FLOWS

Test Pump Total Control rod voltage Delivery Difference
no. speed strokes flow max.

Pump
setting
values

Pump
check
values

106
Run the tests as specified in the diesel test standards
and check that the flow difference between the pump
elements is as little as possible. The difference must not
exceed “Difference max. cm3”.

Adjust fuel flow and the differences by turning the

pump element flange bushings within the area for ob-
long holes.
Slacken the retaining nuts and turn with Bosch tool
1687 950 525.

E. CHECKING THE VACUUM

Speed r/s (r/min) Requirement

After 10 seconds vacuum must be higher than 40 mbar (0.6 psi) Setting

After 10 seconds vacuum must be higher than 30 mbar (0.45 psi) Check

E. Checking oil pump (vacuum)

Check the oil pump if its function is unsatisfactory (too
much oil collects in governor housing) or when the oil
pump has been removed. It should also be checked
when the entire injection pump has been dismantled.
The oil pump is checked by measuring the vacuum
created by the pump in the governor housing.
The function of the oil pump is to pump back oil that
has leaked into the governor housing.There will always
be a small amount of oil in the housing to ensure oil
pump lubrication.

107
 Checking oil pump, cont…

Fill the governor housing with engine oil up to the hole

(see arrow).

Connect a vacuum guage to the hole in the governor

housing. Remove the plug at the front of the pump
(where the control rod travel is measured).
Start the test bench and run the pump according to the
diesel test standards. Compare the vacuum measured
with that in the standards.

F. Anti-tamper sealing
Anti-tamper seal the pump and the governor with the
two screws on the governor cover.

108
Replacing damper valve holder, Important!
injection pump If the washer has fallen down, in all probability the in-
jection pump is damaged and must be repaired. If the
pump is damaged, the delivery pipes and the injectors
Special tool:
425973 Removal/installation tool will also have to be replaced.

Remember that cleanliness is of utmost importance

when working on the injection system.
1. Thoroughly clean the injection pump and its sur-
rounding area. Blow dry.
2. Slacken the delivery pipes cap nuts at both ends.
Do not remove them. Valve holder
3. Thoroughly clean round the nuts and pipes. Re-
move them.
O-ring
4. Slacken all six valve holders with the special tool
(see below). Do not remove the valve holders.

Pressed-in washer

10. Tighten the new valve holder in two stages with

Special tool 425973 for removing and installing valve holders
the special tool. First to 50 Nm (5 kpm) and then to
on bus type engines 110±5 Nm (11±0.5 kpm).
11. Refit the injection pump pipes and tighten the caps
by hand.
Important:
12. Tighten the nuts at the pump to 25 Nm (2.5 kpm).
Make sure the flange bushing (yoke) does not move Be careful not to deform (twist) the pipes.
under the two nuts. If the flange bushing turns, the in-
jection pump must be removed from the bus and adjust- 13. Vent the fuel system by priming with the hand
ed in a test bench. primer. The system is full when fuel drips from the
delivery pipes at the injector end.
5. Clean very thoroughly round the old valve holders. 14. Tighten the nuts at the injectors to 25 Nm (2.5
6. Dip the new valve holderss (with new O-rings fit- kpm). Be careful not to deform (twist) the pipes.
ted) in straight transmission oil SAE 80W/90. 15. Mark that the valve holders have been replaced by
7. Replace the valve holders, one by one. punching two puch marks on the injection pump
product plate, see Fig. on the previous page.
8. Check that the bottom of the removed valve holder
is in order, that is, the washer has not loosened. 16. Destroy the replaced valve holders, e.g., by sub-
(Compare with a new.) stantially deforming the threads with a heavy ham-
mer.
9. Also check the uncovered upper part of the pump
looks alright.

109
 Group 25

Inlet and Exhaust Systems

Contents

– Description .......................................................................................... 111

– Air cleaner ........................................................................................... 111
– Intercooler ........................................................................................... 112
– Pressure-drop indicator ........................................................................ 112

Starting pre-heater
– Troubleshooting................................................................................... 113
– Replacing heating coil ......................................................................... 114

Turbocompressor
– Description DH10A, 345, 350, 360 ..................................................... 115
– Servicing DH10A, 345, 350, 360 ........................................................ 116
– Description DH10A, 245, 285 ............................................................. 119
– Servicing DH10A, 245, 285 ................................................................ 121
– Wastegate ............................................................................................ 120

Exhaust pressure governor

– Description .......................................................................................... 125
– Servicing .............................................................................................. 126

110
Description
The intake system for the air is entirely separated from
the fuel system. It consists of four main parts:
– air intake with inlet pipe
– air cleaner
– turbocompressor
– inlet manifold with starting pre-heater (including
intercooler on engines with intercooler). The start-
ing pre-heater is optional, so it may not be fitted on
some engines.

Turbo-
Turbo-compressor
compressor
Exhaust
Exhaustpressure
pressure
governor
governor

Air cleaner
Air cleaner

Inlet manifold
Inlet pipe with
withintercooler
intercooler

Air cleaner
The air cleaner is of the dry filter type. Air flows
through it from the outside to the inside.

Filter insert

To Tighten nut hard to ensure that

engine all air going into the engine
goes through the filter insert.

Press-drop
indicator

Air cleaner, single filter insert type The air cleaner may have one or two filter inserts. The
inner insert in the double filter variant does not need to
be replaced as often as the outer one.
Buses fitted with double filter inserts usually also have
a cyclone filter. This is mounted next to the air cleaner
The filter insert should be replaced when the pressure- intake. It swirls the incoming air so that large dust and
drop indicator window shows red or if the filter has dirt particles drop down. When the engine stops, these
been in use for 18 months. fall down through a rubber valve in the bottom of the
cyclone filter sleeve.
For more details, look up the Service Manual “Service The rubber valve should be squeezed now and again
and Maintenance”. just to make sure no dirt has stuck inside.

111
Intercooler
All the DH10A-engines have the single-circuit type in-
tercooler with a separate cooling circuit, radiator and
pump.
The intercooler lowers the temperature of the inlet air
and this has a better effect on engine power. The sys-
tem cools the inlet air down to approx. 60°C. Concern-
ing pressure testing and description of the coolant cir-
cuits, refer to “Cooling system”.

Pressure-drop indicator

Checking
The pressure-drop indicator should show full red at
the Vp vacuum value given in the Specifications. If
the indicator is not faulty, depress the reset button.
If faulty, replace the pressure-drop indicator.
When fitting the pressure-drop indicator, make
sure it is screwed on tight. There must not be any
air leakage on the “clean” side of the air cleaner.

Connection, pressure-
drop indicator

From external air supply

6831

Free air release

The tap must be closed when

connecting up to external air supply.
Open it slowly when checking
pressure drop.

112
Starting pre-heater

Troubleshooting
An indicator lamp lights when the starting pre-heater is
engaged. Should it light during testing, the fault is in
the power supply circuit or in the operating circuit. But
first check the fuses and also relay 312.
If cable failure or short-circuit is suspected, carry out
the following checks:

1. Engage the starting pre-heater and feel with the

hand the inside of the manifold where the retaining
bolts and cable connection are. Slight heat should
be felt after about 50 seconds.

2. Measure the resistance through the heater coil be-

tween the stud where the cable is connected and
the outer retaining bolt at the other end. This resist-
ance should be approx. 0.3 ohm. High resistance
indicates failure. Low resistance points to short-
circuit, in which case the starting pre-heater fuse
has momentarily popped out when the starting pre-
heater engaged.

3. Measure the power consumption with the current

gun aimed at the starting pre-heater cable. This
should be approx. 160 amperes at 24 volts.
No power consumption = cable failure.
High power consumption, or if starting pre-heater
fuse has popped out = short-circuit.

113
Switch off the electric circuits when about to
replace the starting pre-heater!

Intercooler housing

Gasket

Heating coil

Starting pre-heater
housing

Replacing heating coil

Remove the intercooler housing and starting pre-heater
housing as a complete unit. Separate these housings on
the work bench in order to get at the coil.
This procedure makes it easier to align correctly the in-
tercooler assembly with the starting pre-heater housing
gasket.
When installing a new heating coil, it is important to
de-insulate all retaining screws except the earth screw.
The earth screw is insulated on the inside but has good
earth contact on the outside. Current flows through this
screw to engine earthing.
After installing the coil, switch it on and see that it The screws must not be check-tightened after installing the
intercooler housing, as this would mean it would not be
reaches operating temperature. Then allow it to cool and possible to check the heating coil without twisting it and
check-tighten the screws. causing a short-ciruit.

114
Turbocompressor

General
Use is made of the engine exhaust gases to drive the The turbine wheel and compressor wheel are mounted
turbocompressor turbine wheel. on the same shaft. When the compressor wheel rotates,
it sucks air in from the air cleaner, the turbocompressor
compresses it and presses it through the intercooler to
the engine. Concerning the charge pressure, refer to
“Condition test”.
From exhaust manifold The turbocompressor is lubricated and cooled by the
engine oil, on the DH10A, 245, 285, the turbo is also
cooled by coolant. Turbocompressor function is de-
pendent on oil supply. Therefore the engine lubricating
system must be well looked after.
The turbocompressor is adapted to engine type, where
the size of the turbine is of great importance.

From
To exhaust air cleaner
system

Turbocompressor To intercooler

Removing/installing 1. Remove…
– the compressed-air pipe for the exhaust pressure
governor,
– the clamp between the shutter housing and the ex-
4 haust pipe,
3 – the nuts for the diffusor.
5
1 5 2. Lift out the shutter housing.
3. Remove the inlet hose.
1 4. Disconnect the delivery and return oil pipes from
the turbo.
4 5. For DH10A, 245, 285: Disconnect the coolant con-
2
nections (do not disconnect the wastegate and con-
trol rod).
6. Remove the turbocompressor from the exhaust
manifold.
1
115
Installing
Fit new gaskets on the
– exhaust manifold
– delivery oil pipe
– return oil pipe
– coolant connections (DH10A, 245, 285).
Sealant 591247-2

Sealant 591 247-2 between

turbine housing and diffusor

Servicing turbocompressor, DH10A,

345, 350, 360

Special tools:
(998) 7600 Adapter
(999) 9708 Torque wrench

Always line-up mark the position for the turbine hous-

ing (1) and compressor housing (2) before starting the
disassembling.
Remove in the following numerical sequence… 7 Thrust bearing and thrust ring*
➂ Compressor wheel*

➇ Retaining rings
➁ Compressor
housing
and bushings

6 O-ring and splash plate

➄ Retaining ring and end*

➀ Turbine housing

➈ Retaining rings and

bushings

* See instructions on following 4 Bearing housing and heat shield*

page.

116
 NOTE!
L-H thread

➂ ➄

7600

4 7

Circled digits refer to previous page.

Cleaning
Some parts are sensitive to corrosive cleaners. Such
cleaners should therefore be avoided.
Make sure all areas adjacent to wheels and housings are
free from deposits, are clean and smooth.
Let the parts seep in the cleaner until deposits drop off.
Use a plastic scraper or soft brush for cleaning the alu-
minium parts.
Note: A steel brush or metal scraper must never be
used. Steam wash can also be used providing that
shafts and other bearing surfaces are adequately pro-
tected.

Checking
Check all parts for wear. Always replace bearings,
seals, circlip, lock washer with new ones from the re-
pair kit.

Axial clearance, checking

117
 Checking, cont.
A damaged shaft with scored bearing surfaces must not
be refitted. Minor scratches are acceptable.
A damaged turbine or compressor wheel must always
be replaced. Do not try to straighten out a deformed
blade. The housing should be replaced if it has cracks
or has been exposed to overheating.
Very often the best alternative is to replace the entire
compressor (exchange unit) if, e.g., the shaft, housing
or some blades are damaged.

Axial clearance, rotor .................... 0.10–0.16 mm

Radial clearance at
compressor wheel, max. ............ 0.635 mm
new bearings .............................. 0.37–0.56 mm
Throw, at shaft smallest diameter .. max. 0.015 mm
Radial clearance, checking Throw, turbine wheel rear ............. max. 0.16 mm

9708 To note when assembling

– Oil the bearing bushings and piston rings with
straight engine oil.
– Make doubly sure that the piston ring seals
centre correctly against the bearing bushings.
– Tightening torque for thrust bearing three bolts
7600 is 4.5 Nm (0.45 kpm). Torque wrench 999
9708 and adapter 998 7600.
– Tightening torque for compressor wheel lock
nut 17 Nm (1.7 kpm). NOTE! L-H thread.
– Tightening torque for turbine housing bolts
13.6 Nm (1.4 kpm) and compressor housing
bolts 5.7 Nm (0.6 kpm).

Repair kit

1. –
2. Bearing bushing
3. Thrust bearing
4. Lock ring
5. Circlip
6. Screw
7. Screw
8. Lock washer
9. O-ring
10. Piston ring seal

118
Turbocompressor To intercooler
DH10A, 245, 285

From air
cleaner

To exhaust
system

From exhaust
manifold

The turbocompressor on engine DH10A, 245 and 285,

has a wastegate function that limits charge pressure at
high power output. The wastegate-shutter functions as
a by-pass valve for the exhaust turbine. The shutter is
activated by a pressure box that, together with a hose
connection, senses the charge pressure in the compres-
sor housing.
At low charge pressure, the pressure box spring keeps
the shutter closed with a control rod. When the charge
pressure reaches the pressure box opening pressure, the
shutter starts to open to by-pass the exhaust pressure Closed
directly to the exhaust pipe. This offloads the exhaust
turbine and the turbo speed drops.
The above function provides the turbocompressor with
a broader working range and this results in an engine
characteristic that has a wide high torque range and a
limited charge pressure at full power output.
The turbine shaft journalling is lubricated and cooled
by the engine pressure-lubricating system. Since en-
gine DH10A, 245 and 285, is a typical city bus engine,
which often has sound encapsulation, the bearing hous-
ing is moreover cooled by a coolant feed connected to
the engine cooling system. Oil supply is essential to the
function of the turbo compressor. That is why it is
vitally important that the engine lubricating system is
maintained according to instructions and that lube oil
of the right quality and viscosity is used.
Open

119
 3
2

1. Wastegate
2. Pressure box 4
3. Lube oil
4. Coolant

Wastegate, checking opening pressure 2. Remove the hose from the pressure box at the
compressor housing and connect nipple 999 9314
Special tools: to the hose. Connect pressure tester 999 6662 to
(999) 6662 Pressure gauge the nipple. Always check to make sure the pres-
9324 Nipple sure gauge is correctly calibrated.

Opening pressure Control rod opening

155 kPa 1.0±0.3 mm when adjusting
0.5–1.5 mm control value
If you suspect that the charge pressure is incorrect,
check the wastegate opening pressure according to be- 6662
low. First check that the pressure box diaphragm seals
correctly, but replace the pressure box if it leaks. Care-
fully follow the installation instructions supplied with
the exchange kit for the pressure box. A wrongly
mounted pressure box will result in an incorrect open-
ing pressure.
9314

3. With the reducer valve on 6662 carefully let in

pressure to the pressure box and observe the dial
indicator at the same time. Read-off the indicator
exactly when the control rod has opened 1 mm.
Opening pressure must not exceed 155 kPa.
Should the control rod opening deviate 0.5 mm or
more from the specified value (1.0 mm) at correct
opening pressure, adjust according to below.
4. If necessary adjust the control rod length, in-
creased length lowers the opening pressure. The
indicated opening must be maintained within a tol-
erance of ±0.3 mm at specified opening pressure.
1. Place a dial indicator (0–20 mm) with magnetic
holder on the turbocompressor so that the measur- 5. Tighten the lock nut on the control rod, and renew
ing probe is in line with the control rod from the the lock ring at the lever if necessary. Refit the
pressure box. pressure box hose to the nipple on the compressor
housing using a new hose clamp.
120
Turbocompressor, repairs

Important!
Refers to repairs to turbo on DH10A, 245, 285.
The wastegate with pressure box and bracket is not to
be removed from the turbine housing. Nor is the lock
nut on the push rod to be released. But, if it has to be
released, the push rod must be adjusted, in which case
refer to Checking wastegate opening pressure.
If the pressure box has to be replaced, use the repair kit
for this (see Parts Catalogue). The kit contains a service
tool (fixture) and necessary instructions for a correct
mounting of the wastegate.
Always line-up mark the position of the turbine hous-
ing (1) in relation to the compressor housing (2) before
disassembling.

Remove:
– Compressor housing (5).
– Bearing housing (4), compressor wheel (6) and turbine
wheel (7). Avoid damage to the wheel blades.

6 1
5
2

3
4

1. Pressure box wastegate

2. Lock nut
3. Turbine housing
4. Bearing housing complete
5. Compressor housing
6. Lock nut, wheel
7. Turbine shaft/wheel
8. Heat shield

121
– Observe due care when removing the compressor Cleaning
housing/turbine housing not to damage the blades Corossive cleaners can damage certain parts and
on the wheels. should therefore be avoided.
Make sure all surfaces adjacent to the wheels and hous-
ings are free from deposits and are clean and smooth.
Allow the parts to seep in a cleaner until the deposits
drop off.
Use a plastic scraper or soft brush on the aluminium
parts.
Note: A steel brush or metal scraper must never be
used. Steam can be used on condition that shafts and
other bearing surfaces are not damaged.
Blow all parts clean with pressurized air; check par-
– The lock nut on the compressor wheel (6) has a l-h ticularly to make sure that all drillings and slide sur-
thread. faces are free from dirt.

Checking
Check all parts for wear. Bearings, seals, lock rings and
circlips requiring replacement should be replaced with
the corresponding parts from the repair kit.
A damaged shaft with scoring on the bearing surfaces
must not be re-fitted. Minor scores are acceptable.
If damaged, the turbine and compressor wheels must
always be replaced. Do not attempt to straighten out a
deformed blade. The housing is replaced if it is cracked
or been exposed to overheating.
Very often the better alternative is to replace the entire
compressor (exchange unit) if, e.g., the shaft, housing
or some blades are damaged.

For DH10, 245, 285

Check to make sure the wastegate pressure box is not
– Line-up mark the position of the axial bearing and leaking air.
the oil guide plate. NOTE! Max. test pressure 155 kPa (1.55 kp/cm2).
With leakage, replace the pressure box.

122
Repair kit
3
2
1
6
5
4

1. Lock nut
8 2. Circlip
3. O-ring
10 4. Piston ring seal
5. Oil guide plate
8 9 6. Axial bearing
7. Retaining rings
7 8. Bearing bushings
9. Piston ring seal
10. Screw

Installing – Use straight engine oil and oil the bearing parts
Important! and the piston ring seals.
– Always make sure that the balance mark is in line
on the rotor when assembling the turbo.

– Turn the piston ring seal on the turbine shaft so

that its opening coincides with the oil drain hole
(180° from the oil drain hole).
Fitting the piston ring seal is made easier by rotat-
– Note when fitting the retaining rings (7) that the ing the shaft while carefully pressing the turbine
bevelled side faces the bearing bushing (8). wheel together with the bearing housing.

123
– Line-up the balance mark on the oil guide plate – Align the line-up marks on the bearing housing
with the mark on the axial bearing (6) and the and the turbine housing. Tighten the screws (10) to
mark on the shaft end. 14 Nm.
Oil the O-ring (3) on the oil seal and make sure – Secure the turbine housing and check-measure ra-
that the axial bearing and oil guide plate are placed dial and axial clearance with the help of a dial indi-
correctly. cator.
– Fit the circlip (2), with the bevelled side facing the
bearing bushing. Check to make sure the circlip
properly locates in the groove.

Axial clearance: For DH10A, 245, 285

– Align the compressor wheel balance mark.

Mount the wheel and tighten the lock nut (1) to 17
Nm. Note that the nut has a l-h thread.

Radial clearance: For DH10A, 245, 285

– Align and carefully fit the compressor housing.

Make sure that the circlip locates properly in the
groove.

124
 Exhaust Pressure Governor (EPG)
The engine has been fitted with an exhaust pressure
governor (EPG) the function of which is to provide
cleaner exhaust gases while the engine is warming
up.When the parking brake is on and coolant temper-
ature is below 70°C, the governor shutter closes off the
exhaust gases so that the engine works against a certain
backpressure and this reduces hydrocarbon emissions
and white smoke. The EPG is controlled by pressurized
air via a solenoid valve and a reducer valve.
The EPG also functions as an exhaust brake when the
exhaust brake switch is activated.
Note. The same control pressure is used for the EPG
during warm-up as for exhaust braking, which is max.
750 kPa.

660

+15
D+

”8”
+30

30
”14”

333
4
23 3005
15 3

200
756
318

+15
max. 750 kPa
▲

”8”

125

626 78143-31

Electric and compressed-air circuits for exhaust pressure governor

125
Exhaust pressure governor, servicing

Special tool:
(999) 6068 Drift

Tightening torque
10–11 Nm (1.0–1.1 kpm)

Cover

O-ring

Piston

Sealing ring

Cylinder

Spring

(Evacuation hole)

Bearing housing

Spacer washer

Bushings

Scraper ring

Stopp ring

Piston rod

Shutter housing cover

Shutter

Disassembling Assembling
1. Remove 5. Fix the shutter in a vice.
– cover
– piston 6. Fit on the shutter housing cover.
– spring
7. Fit the bearing housing and piston rod.
2. Remove
– cylinder 8. Fit the cylinder. Make sure the evacuation hole
– bearing housing faces down.
– spacer washer
9. Fit the spacer washer, spring and piston.
3. Remove
– piston rod 10. Fit the cover.
– shutter

4. Replace parts that are damaged and worn.

Use drift 6068 for changing bushings in bearing
housing.

126
 Group 26

Cooling System
Contents

– Description .......................................................................................... 128

– Main thermostat, checking .................................................................. 130
– Pressure valve ...................................................................................... 131

Coolant pump
– Disassembling/assembling .................................................................. 131

Intercooler
– Pressure-testing ................................................................................... 135

Cooling fan
– Description .......................................................................................... 137
– Pressure-testing cooling system .......................................................... 139

High coolant temperature

• Radiator, sealing ............................................................................. 141
• Coolant temperature sensors .......................................................... 142

Fan drive
– Fan drive with drive belts .................................................................... 143
– Hydraulic fan drive .............................................................................. 144

127
Cooling system – description
The function of the cooling system is to cool the en- the engine oil temperature. Two piston type main ther-
gine, and if the bus has a separate hydraulic retarder or emostats regulate the engine coolant temperature. The
retarder built into the gearbox, also the oil for the re- system also has two other thermostats: a heating sys-
tarder or gearbox. The engine gets its cooling from tem thermostat and a thermostat for the retarder (or
coolant pumped round the engine in the coolant drill- gearbox) oil cooler. The thermostats direct the coolant
ings and by the coolant also flowing through the oil flow to the respective circuit to the extent they are in-
cooler, this contributing to engine cooling by lowering fluenced by the coolant temperature.

Layout diagram, cooling system

1. Expansion tank
1 max.
2. Radiator for intercooler 2
min. 3. Radiator for engine circuit and intercooler
19
circuit 1
4. From bus interior radiators
5. From windscreen defroster and possibly
heated lube oil tank
6 6. To windscreen defroster and possibly
18
heated lube oil tank
7 17 7. To bus interior radiators
8
9
8. Thermostat, interior heaters
16 9. Thermostat for regulating fan speed
10. Thermostats, engine
10 11. Pressure retaining valve
4 5 12. Coolant pump, engine circuit and intercoo-
11 14 ler circuit 1
13. Coolant pump, intercooler circuit 2
15 14. Oil cooler, engine
2 3 15. Engine
12 16. Intercooler element 2
17. Intercooler element 1
13 18. Thermostat, intercooler circuit 1
19. Oil cooler in gearbox/retarder

The engine and intercooler circuits are connected up as inter-coupled with a pipe elbow and the thermostat
before. The cooling circuit for the hydraulic retarder housing has only one vent hose.
and the automatic transmission are coupled in series Pos. 9 is the thermostat valve that controls the hydrau-
with the engine cooling circuit. If the bus does not have lic pump and thereby the fan speed. (Hydraulic-driven
an hydraulic retarder or automatic transmission (pos. fan.)
19), their connections on the thermostat housing are

128
Cooling system vent lines, B10M Better use of cooling system heating
To prevent air from getting into the cooling system a capacity
vent line from the radiator lies in the bottom of the ex-
Check valve between intercooler and expansion
pansion tank, that is, below coolant level. This, how- tank
ever, makes for slower venting when filling an empty When the coolant diverts heat from the engine, some of
cooling system from the expansion tank. For this rea- the coolant goes up to the cooling system expansion
son, we recommend filling via the evacuation connec- tank. At the same time a small amount of coolant flows
tion in the bottom of the cooler, using filler unit from the intercooler circuit also up to the expansion
9812271-6. tank. This coolant is much cooler than the coolant that
comes from the remaining part of the engine. From the
NOTE! point of view of heating, this is not a good mixture, par-
The radiator vent line must not be inter-coupled with ticularly at low ambient temperatures. It is estimated
the other vent lines as this could risk air feedback. that up to 5% of the heating capacity is lost. This corre-
sponds to an approx. 3–5°C loss in temperature for the
coolant flowing into the bus heating system. To reduce
these losses and thereby raise the temperature of the
bus heating system, a check valve has been installed in
the vent hose between the LLK-radiator and the expan-
sion tank. The check valve prevents coolant circulation
but does not prevent venting.

Check valve
Pos. Description
1. Nipple
2. Ball (B10B)
3. Nuts
4. Nipple
5. Hose clamps
6. Ball (B10M)

129
Main thermostat
The thermostat housing contains two thermostats for
maintaining temperature in the engine cooling circuit
and one thermostat for the bus interior heating system.
If the bus does not have an hydraulic retarder or auto-
matic transmission with oil cooler, their connections 2
and 3 on the thermostat housing are inter-coupled with
a pipe elbow and the housing has only one vent hose.

The following is the flow in the thermostat housing:

1. From engine
2. To oil cooler in gearbox/retarder
3. From oil cooler in gearbox/retarder
4. To windscreen defroster and (if fitted) heated lube oil
tank
5. To bus interior heating circuit
6. To radiator
7. To coolant pump

Main thermostat, checking

1. Check to make sure the thermostat is fully closed.
To confirm this hold the thermostat up against a
light. No light may shine through where the joints
meet. If it does, this means that the thermostat can-
not be closed and must, therefore, be replaced.

2. Heat the water to 75°C and insert the thermostat.

3. After at least 30 seconds check to see if the ther-

mostat is still closed.

4. Heat the water to boiling point (100°C). After the

water has been on the boil for at least 30 seconds,
check to see if the thermostat has opened at least
7 mm. If the thermostat has not opened, replace it.
6781
Replacing main thermostat sealing
ring

Special tool:
(999) 6781 Drift

Use the special drift, 6781, to locate the sealing ring

properly in relation to the thermostat contact surface.

1. Place the new sealing ring on drift 6781.

2. Carefully tap in the sealing ring until the drift bot-

toms in the thermostat housing.

130
 The pressure valve, which is placed in the tube be-
tween the thermostat housing and the coolant pump,
increases the pressure in the inner circuit when the
main thermostat is closed, especially at low engine
speed. This improves circulation in the heating system
circuits.
The Fig. shows valve opening under load.

Coolant pump

Special tools:
(999) 2268 Drift
2269 Counterhold
6858 Drift
8039 Drift 1. Remove the pump cover and flange.
8113 Drift
6859 Counterhold Press out the shaft enough to loosen the impeller.

6858

2. Press out the shaft.

6858

Cont. next page…

131
3. Tap out the seals. 6. Press a new bearing into the bearing cage.

2268

4. Remove the circlip. 7. Fit the circlip.

Press out the outer bearing and the deflector ring. Tap on the deflector ring.

8113

5. Press the shaft out of the bearing cage. 8. Mark the shaft 37 mm from its end.
Press the shaft in up to the mark.

6858

132
 9. Tap the inner bearing into the bearing housing. 12. Tap down the unit seal.

8039

8039

10. Press in the shaft, bearing and bearing cage. 13. Press the impeller about 10 mm down on the shaft.
First use counterhold 2269 as a counterhold. Then
continue with drift 8113, using the handle as a
counterhold.

2269

11. Carefully press down the seal, past the drain drill- 14. Place counterhold 6859 as a support under the im-
ing. peller and press on the impeller.

8113

6859

133
15. Check the distance. 18. Fit the O-ring and the outer cover.
NOTE! The marks on the intermediate cover and
the outer cover must coincide.

16. Tap the seal into the intermediate cover.

NOTE! With the sealing edge facing down.

17. Fit the O-ring and the intermediate cover. Press on

the intermediate cover and impeller at the same
time. Stop pressing down when the gap between
the pump housing and the cover is 0.5–1.0 mm.

0.5–1.0 mm

134
Intercooler 3. Connect the pressure gauge to the nipple and test
the pressure. It must not drop during one minute. If
it does, replace the intercooler!
Pressure-testing

For single-circuit system

Special tools:
(999) 6662 Pressure gauge
6815 Connection washer
6816 Sealing washer

For two-circuit system

Special tool: 6815
(999) 6662 Pressure gauge

1. Connect the pressure gauge to the compressed-air 6662

system. Set pressure at 50 kPa (0.5 kp/cm2).

2. Fit the cover washer.

4. Increase pressure to 150 kPa (1.5 kp/cm2). Pres-

sure must not drop during one minute. If it does,
replace the intercooler!

6816

135
 Disassembling
Use a standard puller and pull out the intercooler tubu-
lar sleeves.

Assembling
Tighten the screws in two stages in the sequence shown
below.
Stage 1: Tighten the screws until the screw head makes
contact with the block.
Stage 2: Tighten the screws to 20±2 Nm (2±0.2 kpm).

Check-tightening screws difficult to access on the in-

tercooler requires a special tool with P/N 1158239.

136
Cooling fan
Up front the temperature-controlled cooling fan has pin (4) transfers the bi-metal washer movements to a
two temperature-sensitive bi-metal plates that regulate spring-loaded valve (5) in the fan hub.
fan engagement.
A thermostat-controlled fan should always be in
The bi-metal plates start to bend when the cooling air
the vertical position. Placed horizontally could
reaches a temperature of approx. 40°C. The hotter the
cause leakage and impair the efficiency of the fan.
air flowing through, the greater the bending. A control

1. Temperature-sensitive
bi-metal plate
2. Cover
3. Oil scraper
4. Control pin
5. Spring-loaded valve
6. Intermediate plate with
valve arm
7. Drive plate
8. Fan bearings
9. Coupling housing
10. Drive shaft hub

The fan engagement fluid is a silicone oil of high vis- However, because of slip caused by the silicone oil, fan
cosity. At temperatures below approx. 40°C, the spring- speed will never be higher than 95% of the drive shaft
loaded valve (5) is fully closed. Oil can then go through speed.
a return channel from the coupling housing (9) to the When the cooling air temperature drops, the fan speed
space in the cover (2). In this mode, the fan speed is re- decreases, rapidly between 60°C and 50°C, but fan
duced to approx. 1/4 of the drive shaft (10) speed. This speed reduction is slower when the temperature drops
is the lowest stage at which engagement takes place. down towards 37°C.
As the temperature increases, the valve starts to open
and the degree of engagement increases to full engage-
ment at approx. 65°C, at which the spring-loaded valve
is fully open.

Oil
Oil

Closed control valve – Open valve –

reduced fan speed full fan speed

137
 Cooling fan speed B10B
Checking
Expensive testing equipment is required to do a
complete check on the thermostat-regulated cool-
ing fan. One of the reasons for this is that it is diffi-
cult to measure the air temperature round the bi-
metal plates. If the cooling fan does not seem to
work, there is a simple way in which to check the
fan.
Fan speed and drive shaft speed can be measured
with an optical tachometer that works with reflec-
tion tape. A piece of this tape is stuck on a fan blade
and another piece next to the fan drive shaft. Start
the check with a cold engine and an ambient tem-
perature of max. 25°C. Then run the engine to
about 2000 r/min. If fan speed increases at temper-
atures below 25°C, then there is something wrong
with fan control mechanism.
The fan control mechanism is functioning properly
if the degree of engagement is within the gray-
marked sector in the diagram below.
Note, however, that it is fully normal if the fan en-
gages at full speed to begin with. Wait, therefore,
until the fan speed has stabilized before checking.

Engine speed = 2000 r/min

Pulley with fan journalling = 1.05x2000 = 2100 r/min

Warning!
Do not go near the fan when it is rotating.
Engage degree
Viscofan
[%]
100
90
80
70
60
50
40
30
20
10
Air temperature (°C)
0
40 50 60 70 80
138
Pressure-testing cooling system Temporarily connect the pressure tester along with the
Special tools: test cap in place of the pressure cap. Test at a pressure
(999) 6662 Pressure tester of 70 kPa (0.7 kp/cm2).
6049 Hose (with nipple) When pressure has stabilized, check all the compo-
6441 Test cap for expansion tank nents in the system for leakage – radiator, connections,
with thread hoses, coolant pump, heating system, etc. If the pres-
sure gauge indicates pressure drop, then there is leak-
age, which must be remedied without delay.

Stage 1 Stage 2

From compressed-air workshop supply

Check the coolant hoses for ageing (hardness), Level sensor

cracks, etc. Replace damaged or worn hoses before Because of the different types of impurities that can get
checking for leakage. If necessary, top-up before into the expansion tank, the level sensor should be tak-
pressure testing. en out and cleaned at least at the annual service.

Place or hang up the pressure tester gauge above the Coolant

radiator to prevent coolant from getting into it. The mixture in the Volvo coolant should be between
Slowly raise the pressure to above 40 kPa (0.4 kp/cm2) 40% and 60%. Less than 40% will not provide protec-
to build up the pressure in the cooling system. At ap- tion against rust, in some cases it may even increase.
prox. 50 kPa (0.5 kp/cm2), the pressure cap overflow
function should start to release the pressure. If the pres-
sure cap does not work in this way, renew it.
Lower the pressure in the system and disconnect the
pressure tester from the engine drain nipple.

WARNING! Coolant is poisonous.

Mix per cent for 40% 45% 50% 60%

protection against –25°C –30°C –40°C –56°C
frost down to –13°F –23°F –40°F –69°F

139
Radiator, removing/installing

Special tool:
(999) 9954 Component lift

1. Close the taps for the bus heating system.

Drain the coolant.
2. Take off the drive belts and remove the fan.
3. Remove…
– the hoses for the coolant and intercooler
– the engine rear plate on the inside of the air cleaner
– both the edge plates in front of the radiator assem-
bly.
4 Place lift 9954 under the radiator assembly.
5. Remove…
– the upper retaining iron bars
– the outer lower bracket with rubber pads
– the inner lower bracket without rubber pads.
6. Lower as far as possible the radiator assembly with
the lift.
Raise the bus and pull out the radiator assembly.

Installing

1. Place the radiator assembly on lift 9954. 4. Fill with coolant and open the taps in the bus heat-
Raise the bus enough to run the radiator assembly ing system.
in underneath. Start the engine and check for leakage.
2. Lower the bus and raise the lift far enough so that Top-up with coolant if necessary.
the assembly mount brackets can be bolted on. 5. Fit the edge plates and the engine rear plate.
Fit and tighten all the bracket bolts and lower the
lift.
3. Connect up the hoses for the intercooler and cool-
ant.
Install the fan and fit the drive belts.
Adjust the drive belts.

140
 High coolant temperature
Radiator
Check the radiator for clogging and for deformed fins
or for poor coolant flow to the radiator pipes. If neces-
sary clean the radiator.
NOTE! Observe great care not to damage the fins
when cleaning the radiator. Do not use high-pressure
flushing. Pressurized air can be used from the rear side
of the radiator.
A radiator with loose or damaged fins should be re-
placed.
Upper seal
(viewed from left side)

Sealing round radiator

Make sure the gap between the radiator and the body is
properly sealed. Side seals should go all the way down
to the frame flange bottom edge. Defective sealing can
be rectified with rubber stripping or similar.
Also check that the sealing ring between the fan shroud
and the fan ring is in good condition and makes a tight
fit against the fan shroud. If necessary, adjust the lie of
the sealing ring.

Side seals
(viewed from above)

141
 Coolant temperature sensors

2 1, 3

Temp. sensor EDC P/N 1619819 (2-pin) max. test current 1mA
C° Ω
60 615±62
90 255±29
120 119±15

Temp. sensor, temp. gauge P/N 1619819 (2-pin) max. test current 1mA
between pins 1–3 between pins 2–3
C° Ω C° Ω
60 116.6±14.2 0 1634±21
90 45.9±4.5 25 2000±22
100 34.9±3.1

Warning lamp activation is controlled by an electronic circuit in the temp. gauge.

Thus, the temp. sensor does not have this function. Activation temp. is 102± 3°C.

Temp. sensor EDC (4-pin) max. test current 1 mA P/N 3944 168
between pins 1–2 between pins 3–4
C° Ω C° Ω
60 607.5±59 0 1634±21
90 250.6±26.8 25 2000±22
120 116.6±14.0

142
Fan drive with drive belts B10B

Adjusting drive belts

1. Check to make sure that the tension on the fan Check-tighten the drive belt tension twice: Check 1 af-
drive belts is correct: 13–14 mm deflection at 50 N ter 500–1500 km; check 2 after 3000–5000 km.
(5 kp) midway between the pulleys. Check pulleys
inter-level with a straight edge.

Belt tensioner

°
30
°
15
Position of tensioned belts 0°
30° 15°

Gummistav
Rubber rod
Function
Funktion
atpå15°
15°
2. With incorrect relationship between the belt ten-
sioner and pulleys, adjust the belt tensioner posi-
tion.

3. Tension the drive belts as shown in the Fig. Tight-

en the lock bolt and check the belt tensioner posi-
tion again according to pos. 1. The spring-loaded belt tensioner automatically adjusts
to correct belt tension and this makes for quieter belt
transmission, among other things.
As a result of the selected geometry in the tensioner
movement the belts slacken when the engine switches
off and the mass force in the fan draws the belt trans-
mission. This eases up tensions on the other compo-
nents in the fan transmission.
Tension is created by means of the four rubber ele-
ments (rods) mounted between the two square pipes.

Belt tensioning
The tensioner has a scale. Adjust the pre-tension to 15°
on the scale. This corresponds to correct belt tension-
Rotational centre/angle setting ing. Tighten up the lock bolt.

143
Hydraulic fan drive
An alternative to the mechanical fan drive is the hy-
draulic version, which is to be found on both the B10M
and B10B.

Fan drive, B10M

System layout, hydraulic fan drive

11 9
10

3
1 5

6 8

7
1. Pump
2. Fan motor
3. Thermostat valve
4. Control valve 06886
5. Modulator
6. Restrictor
7. Oil tank Delivery line
8. Oil filter By-pass oil line
9. Radiator assembly Suction line
10. Pulley Return line
11. Max. pressure valve
Concerning troubleshooting, servicing the hydraulic pump,
hydraulic motor, refer to Service Manual, Section 2 (26) Hy-
draulic Fan.

144
 Group 27

Engine Controls
Contents

– Description .......................................................................................... 146

– Sensor function, driver area ................................................................. 147
– Sensors on engine ................................................................................ 147

EDC–components in electrical distributor unit

– Relay box ............................................................................................. 148
– Control unit .......................................................................................... 149

Fault diagnosis
– Activating fault diagnosis .................................................................... 150
– Fault codes ........................................................................................... 151

Troubleshooting
– EDC, troubleshooting with multimeter ............................................... 154
– Connecting-up ..................................................................................... 155
– Measurements table ............................................................................. 155
– Remarks ............................................................................................... 158

145
 EDC – Electronic Diesel Control
EDC is an electric system for regulating and monitor- Compared to a conventional fuel system, the advant-
ing the engine fuel injection. ages of the EDC is that it has greater opportunities to
Characteristic of the system is that it works with an control fuel flow. The electromagnetic governor reacts
electromagnetic governor mounted on a standard injec- more rapidly and provides a more precise fuel control
tion pump. On the engine and in the driver area there compared to a mechanical governor.
are a number of sensors that send different signals to This chapter contains a description of the system,
the electronic control unit, which processes incoming check/remedy measures when one or several fault
signals and converts them to signals that go to the elec- codes have been registered and instructions for adjust-
tromagnetic governor on the injection pump. ing the accelerator pedal and the setting of the injection
The EDC-system also has capacity for cruise control pump on the engine.
and, possibly, an adjuster function for low and raised
idling.

1
2

1. Rev/speed control
2. Diagnosis
3 3. Accelerator pedal
4 4. Speed
5 5. Brake pedal
6 6. Clutch pedal
7 7. Exhaust brake
8 8. Turbo pressure (charge pressure)
9. Intercooler temp.
9
10. Coolant temp.
10
11. Speed
11
12. Regulated fuel flow
13. Engine switch off
12
13

146
Function of sensors, driver area
Clutch pedal position breaker
Controlled mechanically by the clutch pedal. When the A speed signal is despatched as information to the con-
clutch pedal is depressed, this position breaker disen- trol unit from the speedometer/tachograph.
gages the cruise control.
Cruise control
Used for three different functions:
• Idle speed, setting.
• Raised idle speed (so-called “constant speed
hold”).
• Cruise control.

The EDC-system has a diagnostic function that indi-

cates a fault via the diagnostic lamp.

Accelerator pedal position sensor

Provides information about accelerator pedal position
(and kick-down for buses with automatic transmis-
sion).
Brake pedal breaker
Disengages the cruise control with braking. Applies
also to activated exhaust brake.

Sensors on engine Coolant temperature sensor 756B

The coolant temperature uses the control unit to deter-
mine the following: start fuel flow, fuel flow at full
load (should the coolant temperature exceed a fixed
value), low idle speed with cold engine, speed limita-
tion during a certain period after starting.

Extra speed sensor 753B

In addition to the charge pressure, it is important that
the control unit knows the engine speed, otherwise it
cannot determine the fuel flow. The function of the
EDC requires at least one speed signal. For this reason
the speed signals are doubled.
Charge pressure sensor 7066
It is the charge pressure that determines the fuel flow to
the engine at a particular speed.

756B
753B

Intercooler air temp. sensor 7067

The intercooler air temperature uses the control unit in
order to reduce fuel flow with abnormally high inter-
cooling air temperature.

147
 EDC-components in electrical distributor unit

Relay box 3060 Fuse 45 for Fuse 44 for Control unit 9058
normal voltage cruise control
feed stalk

Relay box
Relay box 3060 contains relays for voltage feeding the TR2 circuit is wired to the automatic transmission and
system and three small electronic circuits, which main- parking brake. Its function is to simulate “clutch pedal”
ly contain transistors. Normal voltage feed, from fuse up. It must be possible, namely, to earth pin 27 on the
45, comes in to pins 1 and 9. At input to R1, there is a control unit, even if the hus has automatic transmission
diode that prevents reverse current. Before R1 can and thus does not have a clutch pedal. “+” in the N-
close, TR1 must open, which it does at a (+) via 3063 position is used when the bus is stationary and gives
relay (engine shut-off). This (+) also closes R2. On the (–) on pin 6 when the parking brake is on. “+” above
strength of the power available, R2 distributes the feed 3 km/h is converted by the TR2 circuit to (–) on pin 6
to the two lines going to the control unit. during driving.

Electronic circuit TR3 converts engine speed sensor With no voltage at pins 1 and 9, relay R1 remains in the
(753B) impulses, which vary between –12V and +12 V inactive position and voltage is fed instead from pin 10.
up to pin 15, to a pulse signal from 0–24V, which is fed The TR4-circuit then lights warning lamp EDC+ by
to pin 32 in the control unit. Pin 14 is earthed. giving a (–) at pin 11.

+30 from
coupling box
Relay 3063
“+” “+” above breaks “+”
in N-pos. 3 km/hr when engine
stops

“–” Control unit 9058

when p-brake
is applied

148
Control unit
Control unit 9058 houses the electronics for regulating
fuel flow. The electronic system has two microproces-
sors, a main processor M1, that normally looks after all
engine and vehicle control, and another microprocessor
that takes care of fault diagnostics, communication
with the other control units, that is, ABS/ASR and EST
18. M2 also monitors processor M1and takes over its
functions should M1 break down.

In its original form, the control unit is generally pro-

grammed (part (1) in one of the EE programs) and can-
not be used until it has been programmed with engine
data for some engine variants. For each engine variant
there is a so-called “engine data statement” stored in a
disk. With the help of a PC, the data statement can be
stored in part 2 in the EE program.

Moreover, each control unit is programmed with the

bus data (3), that is, the drive line reduction ratios for
the bus in which the control unit in question is in-
stalled. So-called “customer data” (4), that is, the cruise
control limits and possibly speed limitation are also
programmable.

Voltage feed (+30) from

relay box 3060

Speed signal (24 V

pulse from relay
box 3060)

149
Pin Signals to/from control unit 9058
32 Speed signal from relay box 3060 35 Sensor earth.
2/1 Voltage feed 17/13 Accelerator pedal position from position sensor,
18/12/30/5 Signals from “cruise control” (1125). In series accelerator pedal (7065). In the EDC-system,
between pin 5 and the cruise control stalk there the kick-down breaker for automatic transmis-
is also a pressure breaker (2008) that breaks the sion is housed in the position sensor.
current during braking. 33/34 Intercooler pressure sensor (7066). A 5 V refer-
9 C3-signal from speedometer/tachograph. ence voltage (outsignal) comes in from 33 and a
voltage of 1.3–2.5V is sent to 34, depending on
16 Voltage from activated exhaust brake (breaks
the charge pressure.
cruise control function) and accelerator pedal
function. 11 Voltage from activated brake lights (breaks
cruise control function).
7 PWM (Pulse Wide Modulated) voltage signal to
automatic transmission and ASR-system (Anti- 28 Control rod position signal from control unit.
Slip Regulation) passes on information on the 14 Not used.
throttle position. 20/19 Earth connection.
25 Signal from ASR-system concerning dethrot- 4 Doubled engine shut-off (apart from switching
tling with skidding. off power to adjuster device on governor) is ef-
15 Input and output for diagnostic lamp. fected by a “+” to the solenoid valve (603)
21/3 Outsignal to adjuster device on governor (6064) which, via a compressed-air cylinder (emergen-
for regulating throttle. cy stop) activates the injection pump stop lever.
Breaking “+” to the solenoid valve 603 opens
6/29/10 Control rod position from sensor in governor
the valve.
(6064).
27 Position breaker (2007) on the clutch pedal
31 Speed from sensor in governor (6064).
earths when the clutch pedal is released. (Ap-
26 Intercooler temp. from sensor (7067) in inlet plies only to manual gearbox – for automatic
pipe. transmission, see pin 6 relay box.)
23 Coolant temp. from sensor (756B) in thermostat
housing cover on B10B and in discharge pipe af-
ter engine (to retarder) pn B12.

Fault diagnosis about 3 seconds. Release the diagnostic switch. This

The EDC-system monitors sensors, functions and the should erase all stored fault codes.
governor adjuster device. With fault, the diagnostic
lamp lights, either continuously or with blinks. Fault With failure in the normal voltage feed to the control
coding is based on diagnostic lamp blinks. To get this, unit, the indicator lamp EDC+ for voltage feed comes
depress the diagnostic switch (button). Several faults on and gives a steady light. If there is nothing wrong
can be stored simultaneously in the control unit mem- with the voltage feed, the control unit is doubly protect-
ory. ed against voltage failure and the lamp goes out.
Should the lamp light when driving, the bus can be
driven as usual but. to avoid risk of total voltage break-
Activating fault diagnosis down, which would mean that the engine would stop, it
Turn the start key to the drive position, depress the is recommended that the fault be put right without de-
diagnostic switch. Release it after a few seconds and lay.
count the number of blinks. Note the number. It corre-
sponds to a specific fault code. If two or more faults are
stored, the lamp will show them after each other. The
diagnostic switch must be depressed to start the next
blink sequence. The lamp shows all the blink codes
when it returns to the first one.

How to erase stored fault codes:

Turn the start key to the “0” position. Keep the dia-
gnostic switch depressed and at the same time turn the
start key (feed selector switch) to the drive position. Do
not release the diagnostic switch. Keep it depressed for

150
Fault code/ Probable fault(reaction) Check/action
Diagnosis

2B The control unit is not programmed (engine Program the control unit with the data statement speci-
will not start) fied for the engine, see further page 9.

3HE Brake indication faulty or not checked (cruise Turn the start key to the drive (feed selector switch)
control does not function) position. Depress the brake pedal and keep it depressed
for about 4 seconds. The lamp should then go out. “+”
must not be in the connector TB “5” when the brake
pedal is depressed hard, “+” on the other hand should
be in TC “6”.

4E No main or assist speed signal (engine does Check the resistance in the sensors, see below fault
not start) code 5 B. If there is nothing wrong with the sensors,
check for failure in cables to pins 31 and 32.

5B Main speed signal faulty (reduced engine The sensor is housed inside the injection pump gov-
power) ernor. Sensor resistance between pins 3 and 4 on the
governor 0.8–1.2 Ω.

6HE Assist speed signal faulty The sensor is place on the engine. Correct resistance is
1050±100 Ω between the sensor connection pins.

7B Speedometer/tachograph indicates abnormal- Incorrect values from speedometer/tachograph C3

ly high speed (reduced max. engine speed) signal. Check speedometer/tachograph calibration and
that C3 does not have “+”.

8B No speed signal Measure the voltage between the C3 signal and earth.
At 0 km/h, voltage should be 1.0–1.4 V. Voltage
should increase 0.2–0.3 V for every speed increase of
10 km/h.

9B Intercooler temp. abnormally high (90° C) Check the intercooling. If both fault codes 9 and 11 are
(reduced engine power) indicated, measure the sensor resistance which should
be 220–280 Ω at 90°C, (1mA) between the sensor con-
nection pins.

10B Intercooler temp. abnormally low (reduced Check for failure in the cables and connections.
engine power)

11B Intercooler temp. abnormally high (higher Sensor resistance between the sensor connection pins
than 100° C) should be 100–130 Ω at 120°C (1 mA).

12B Coolant temp. abnormally low Failure to/or in sensor 756 B. Sensor resistance be-
tween sensor connection pins should be 500–800 Ω at
55–65°C.
Check the cooling system thermostat.

13B Collant temp. abnormally high (reduced en- Check the cooling system. Check the temp. sensor re-
gine power) sistance, which should be 220–280 Ω at 90°C (1mA).

14B Charge pressure abnormally low (reduced Check the fuel filters, feed pressure, air cleaner and
engine power) charge pressure. Refer to specifications for respective
engine.
15B –

151
Fault code/ Probable fault(reaction) Check/action
Diagnosis

16B Accelerator pedal indicates abnormally low Check voltage in connector TB“7”. Should be 5V.
voltage (does not react to throttling, remains Voltage in TB“6” should be 0.5V with accelerator ped-
at low idle) al released.

17B Accelerator pedal indicates high voltage Check for earth failure, pin TA“3”.
(does not react to throttling, remains at low Note: With accelerator pedal released, the voltage
idle) range for the accelerator pedal sensor, measured in
“TEST7”, should be 0.5 V and with the accelerator
pedal depressed 2.8–3.5 V. Voltage in connector
TB“7” must not exceed 5 V.

18BE Cruise control faulty Check fuse 44. Measure the voltage (24 V) in TB “5”.
Depress the brake pedal and check that voltage cuts-out
at 2008 (extra brake pressure breaker). Set cruise con-
trol to “RESUME”, measure the voltage (24 V) in TB
“3”, in “SET-”, in TB“2” and in “SET+” and in TB “1”.

19H System fault (communication error) Fault inside control unit. Engine can start and be driven
but with reduced power and lower engine speed.
20–24
BE System fault EDC Fault code 20. Control problem, general
21. Control problem, control rod position
extremely low
22. Control problem, control rod position
extremely high
23. Control problem, internal communica-
tion fault
24. –

Fault codes 20–24 can also be indicated through exter-

nal electromagnetic disturbances. There-
fore, erase the control unit fault memory
and check to see if the fault code returns.
Note: “B” indicates blinking warning lamp
“H” indicates that the warning lamp gives a steady light
“E” indicates that the fault is not stored in the fault memory
This information is obtained without having to depress the
diagnostic switch.

152
Injection pump governor Compressed-air cylinder for
The governor adjuster device (1) is placed in the gov- emergency stop
ernor housing end and consists of an electromagnet that For safety reasons, there is a compressed-air cylinder
works directly against the injection pump control rod. for emergency engine switch-off. It is placed on the in-
(2A) and (2B) function as position sensors for the con- jection pump.
trol rod. They enable the control unit to decide at every
Normally the engine shuts down when the feed voltage
moment if current to the adjuster device has to be in-
to the EDC control unit is broken by turning the start
creased or decreased. (3) is the main speed sensor in the
switch to position “0”. The compressed-air cylinder
system and it works against the toothed gear on the
then turns the governor stop lever to the stop position.
pump camshaft.
The chief function of the compressed-air cylinder is,
nevertheless, to act as an emergency stop in order to
eliminate negative results from involuntary throttling
caused by cable failure between the control unit and the
injection pump. A signal is sent out from the EDC con-
trol unit to cut out voltage to the compressed-air cylin-
der solenoid valve and this activates the compressed-air
cylinder to engage emergency stop.
In some cases there may also be a stop control in the
engine compartment or next to the battery box. This
control must be pushed in before the engine can be re-
started.

Adjusting
The clearance between the stop lever and the stop cyl-
inder push rod, when the stop cylinder is activated,
should be, on the THD103 engine, 0.3–0.6 mm. Ad-
justment is made with the push rod adjuster screw.
Adjustment is made on the engine by adjusting the po-
sition of the stop cylinder with the attachment adjuster
nuts. Remove the push rod from the stop lever. Turn
the top lever to the stop position and pull the stop cyl-
inder push rod out to the end position. Adjust the posi-
tion of the stop cylinder to get a clearance of 1–2 mm
between the push rod and the lever.

153
Accelerator pedal, adjusting
At full throttle or kick-down position, the stop screw Obs!. Vridverktyg 999 6956 finns inte under Special-
for the accelerator pedal should be able to stop pedal verktyg och på sid. 97 nämns 998 8068? Översättarens
movement precisely before the throttle control reaches anm.
the max. throttle stop lug for the position sensor.
For buses with automatic transmission, the stop screw
should be screwed up 1–2 mm from the position where
the throttle control has stopped against the position
sensor stop lug.
Change over from full throttle to kick-down is felt
through more resistance from the accelerator pedal.

Injection pump, adjusting on engine

For adjusting the injection pump on the engine, use ad-
juster tool 998 7057 and crank tool 999 6956. See page
97.

EDC – wiring diagram EDC, troubleshooting with multimeter

See Service Manual, Electrical system for respective Troubleshooting with a multimeter is a complement to
bus model, Section 3 (37) the EDC-system fault codes. In the first place, the sys-
tem’s fault codes should be checked, see page 150, and
Fuse Power Circuit(s)
(protected by fuse) in the second place, troubleshooting can be done with a
“44” 5A EDC-control and warning lamp multimeter. Troubleshooting is done either with the en-
on redundant power supply. gine switched off or with it running.
“45” 15A EDC-system. For troubleshooting with a multimeter, use 60-unit test
“46” 15A Redundant power supply, EDC- box P/N 981 3190 and 35-pin adapter P/N 981 3192.
system. With the test box and adapter it is possible to do a more
No. Component realistic troubleshooting on the signals to and from the
753B Speed sensor control unit in a very simple way.
756B Temp. sensor, coolant
1125 EDC-control (cruise control stalk) Special tools:
1142 Breaker, EDC-diagnosis (may be marked 1131) (999) 5009 Pedal support
2007 Breaker, clutch pedal (951) 0060 Multimeter
2008 Breaker, brake pressure (981) 3190 Test box 60-pin
3060 Relay box (981) 3192 Adapter 35-pin
5020 Warning lamp, redundant power supply
5020B Diagnostic lamp. EDC-diagnosis
6064 Regulator Troubleshooting requires a multimeter with a fault
7065 Sensor, accelerator pedal tolerance of max. 0.4% and 2 decimal display when
7066 Sensor, intercooler temp. measuring voltage between 0–24 V. (Multimeter
7067 Sensor, intercooler temp. (999) 6525 does not meet this accuracy require-
9058 Control unit, EDC ment.)
“COM” Communictions socket
“TEST” Test socket

Test box 60-pin Adpater 35-pin

P/N 981 3190 P/N 981 3192

154
Connecting-up
Switch off the power with the battery main switch.

NOTE! Never pull out or plug in the control unit

cable contact when the power supply (ignition) is
on.
Disconnect the connector to the EDC-control unit and
connect it to the test box.
Connect the other connector to the EDC-control unit.

EDC

2
31 9
981

190
9813

12
X 11
MÄ TBO 10
9 24
8 23
7 22
6 21 36
5 20 35
4 19 34
3 18 33 48
2 17 32 47
1 16 31 46
15 30 45 60
14 29 44 59
28 43 58
13 57
27 42
26 41 56
25 40 55
39 54
38 53
37 52
51
50
49

Measuring voltage (start/feed selector switch in drive position, engine off).

Measuring range D.C. voltage unless stated otherwise

Testbox
Pin+ Pin– Nominal value Component Remarks
1 19 Battery voltage Feed to control unit
2 20 Battery voltage Feed to control unit
1 15 Battery voltage Diagnostic lamp
32 19 19 V Speed sensor, engine 5
33 19 4.6–4.9 V Reference voltage, intercooler pressure 9
34 19 1.3–1.5 V Voltage from intercooler pressure sensor 9
21 19 Battery voltage Adjuster device, injection pump
3 19 Battery voltage Adjuster device, injection pump
4 19 Battery voltage To solenoid valve for engine switch-off
31 35 0V Speed sensor, injection pump 10
17 35 4.6–4.9 V Reference voltage, accelerator pedal
13 19 2.75–3.5 V Depressed accelerator pedal
13 19 0.32–0.5 V Released accelerator pedal
9 19 0.3–1.4 V Speed signal (C3)
27 19 0–1.3 V Clutch pedal released 1 (automatic transmission)
27 19 3–5 V Clutch pedal depressed 1 (automatic transmission)
16 19 0–1 V Exhaust brake, not activated

155
cont. …

Test box
Pin+ Pin– Nominal value Component Remarks
16 19 Battery voltage Exhaust brake, activated
28 35 0.3–0.6 V Control rod travel, accelerator pedal released 2
28 35 2.8–3.5 V Control rod traval, accelerator pedal depressed
7 19 2.1–2.5 V Position signal to automatic transmission 3
and ASR
25 19 2.1–2.5 V Without ASR
25 19 approx. 20 V With ASR 4
11 19 0–1 V Brake pedal released
11 19 Battery voltage Brake pedal depressed
11 19 Battery voltage Retarder control, activated
5 19 0–1 V Brake pedal depressed
5 19 Battery voltage Brake pedal released
5 19 0–1 V EDC-control, held in “OFF” position
5 19 Battery voltage EDC-control, held in “SET+”, “SET–”,
“RESUME” or neutral position
12 19 Battery voltage EDC-control, held in “SET–” position
12 19 0–1 V EDC-control, held in “OFF”, “SET+”,
“RESUME” or neutral position
18 19 Battery voltage EDC-control, held in “SET+” position
18 19 0–1 V EDC-control, held in “OFF”, “SET–”,
“RESUME” or neutral position
30 19 Battery voltage EDC-control, held in “OFF”, “SET–”, “SET+”
30 19 0–1 V EDC-control, held in “OFF”, “SET–”, “SET+”
or neutral position

156
The following measurements are made with the engine started

Pin+ Pin– Nominal value Component Remarks

32 19 9.7 V ~ (300 Hz) Speed sensor, engine low idle 5
32 19 9.4 V ~ (840 Hz) Speed sensor, engine 1650 rpm 5
9 19 1.3–2.5 V ~ (70 Hz) Speed signal, C3 30 km/h 6
9 19 2.2–3.3 V ~ (150 Hz) Speed signal, C3 60 km/h 6
26 35 2.5–3.9 V Intercooler temp. sensor 60°C 7
23 35 0.9–1.85 V Coolant temp. sensor 60°C 8
34 19 2.5–4.0 V* Turbopressure sensor 110–165 kPa 9
25 19 6.9–7.3 V ~ Without ASR low idle
25 19 10–11.5 V ~ Without ASR approx. 1650 rpm
25 19 ca 5.5 V~ With ASR 4
7 19 6.9–7.3 V ~ Signal to Automatic transmission and AST
control unit. Control value low idle 3
7 19 10–11.5 V ~ Signal to Automatic transmission and ASR
control unit. Control value 1650 rpm 3
28 35 2.6–3.05 V* Control rod travel, accelerator pedal in max. position
and engine max. loaded. Measured while driving. 2
31 35 ** Speed sensor, injection pump 10

* Depending on engine variant, see Specifications.

** Measured with oscilloscope.

Measuring resistance, control unit

disconnected
NOTE! Never pull out or plug in the control unit cable
contact when the power supply (ignition) is on.

EDC

31 92
981

190
9813

12
OX 11
MÄTB

6
7
8
9

21
10

22
23

35
24

36
Without ASR With ASR
5 20
4 19 34
3 18 33 48
2 17 32 47
1 16 31 46
15 30 45 60
14 29 44 59

Extract from “Wiring diagram EDC-system”

28 43 58
13 57
27 42
26 41 56
25 40 55
39 54
38 53
37 52
51
50
49

6 29 18–24 ohm Control rod travel sensor, injection pump 2

6 10 18–24 ohm Control rod travel sensor, injection pump 2
31 35 0.9–1.1 ohm Speed sensor, injection pump 10
1 21 0.5–1.2 ohm Adjuster device, injection pump
19 earth ca 0 ohm Control, earth connection
20 earth ca 0 ohm Control, earth connection

157
Remarks

1. If the bus has automatic transmission, the relay 3. Signal to control unit for ABS/ASR and automatic
box earths pin 27 when the transmission is in neu- transmission. It is the socalled “pulse wide modu-
tral and the parking brake on or if speed exceeds 3 lated signal” and indicates the throttle position to
km/h. To simulate a depressed clutch pedal on an the control units for the automatic transmission
automatic transmission, depress the D-button on and ABS/ASR. When measuring with an average-
the gear selector panel or release the parking forming voltmeter on a pulse wide modulated sig-
brake. nal, the voltage increases with greater pulse width
NOTE! The engine must be switched off and the (measuring in the alternating current position).
bus wheels chocked to prevent it from rolling. If there is no ASR, “MR” 1 and “MR” 2 loop to-
gether (see page 157).
2. Control rod travel: the voltage is in proportion to
the position of the control rod travel. In other
words, the position sensor in the injection pump
informs the control unit what voltage it should
give to pin 28. To be able to compare the measured
voltage value for max. control rod travel with the
value given in the specifications for the engine in
question, it is necessary to correct the value with a
view to the fact that the reference voltage can vary
(pins 17 and 35). The new value we call Unorm.

5
Unorm = measured voltage measured
value, control rod X reference
travel voltage
Also check the resistance, see page 157 (control
rod travel sensor, injection pump)

Ex. of pulse
wide modu-
lated signal

A signal at low idle B signal at 1650 rpm

200 Hz 200 Hz
10% pulse wide ratio 40% pulse wide ratio

The pulse wide ratio is estimated as t/T* 100 (%).

158
4. Signal from ABS/ASR (pulse wide modulated) 5. Pulse signals from the engine speed sensor, so-
that indicates if dethrottling is necessary. When called “square” signal (but not a pulse wide modu-
dethrottling is not required, the signal should have lated signal). Frequency increases with increased
a pulse wide ratio of 90% (fixed value). When a speed. Should be measured with an oscilloscope.
power reduction is required, a 10–90% signal is Low idle (550 r/min) 270–300 Hz.
emitted. 10% of this corresponds to low idle.

Ex. of a square signal

6. The speed signal from the tachograph is a so- 7. Sensor of type NTC-resistance. Temperature-
called “square” with varying width on the pusle dependent resistance reduces with increased tem-
interval. Amplitude is approx. 7 V and the pulse perature.
width is 2.5 ms long (varies according to setting on
the dip-switches on the tachograph). At approx. 8. Sensor of type NTC-resistance. Temperature-
100 km/h, the pulse-interval ratio is 1:1, frequency dependent resistance reduces with increased tem-
200 Hz. The pulse width is constant, but it alters perature.
with speed (frequency changes).

159
 9. Turbopressure sensor. To be able to compare the
measured voltage value for max. turbo pressure
with the value given in the specifications for the
engine in question, it is necessary to correct the
value with a view to the fact that the reference
voltage can vary. The new value we call Unorm.
5
Unorm = measured voltage measured
value, control rod X reference
travel voltage

If the measuring is done at a temperature other

than +20°C, then the value must also be corrected
in order to be able to compare it with the voltage
value specified in the specifications. The estimat-
ed Unorm value is corrected as per the following
graph.

Example
The voltage for the turbo pressure Unorm is estimated
at 3.7 V at an ambient temperature of 0°C.
– Go in on the vertical axis in the diagram to 3.7 V.
– Follow the horizontal axis to the right until it inter-
sects the vertical line for 0°C ambient temperature.
– The corrected voltage is read-off on the respective
curve in the diagram. In our example 3.5 V, which
corresponds to the voltage at 20°C.

10. An oscilloscope is required for a complete check At low idle (550 r/min), positive amplitude should
on the injection pump speed sensor. Max. differ- lie between 2.3–11.6 V (50–60 Hz). Average A.C.
ence in positive amplitude 1.4 V. Positive ampli- voltage 2.2–2.4 V (average reading voltmeter).
tude should lie between 10–30 V at 1200 r/min en-
gine speed (injection pump revs 600 r/min).

160
 Volvo Bus Corporation
Göteborg, Sweden

TP 16031/1 English 2500.06.97 Printed in Sweden by Novum Grafiska AB. 97.24296