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Cooling System - Groups 00

1. W2002062 Fig 129 Remove expansion tank from radiator Remove the five bolts fastening the 12 mm socket expansion tank to the radiator Discon screwdriver nect the hose from expansion tank to the radiator top tank Lift off the ex pansion tank and set aside W2002125 2 Fig 131 Remove charge air cooler Remove the remaining bolts fastening 13 mm socket the charge air cooler to the radiator 12 mm wrench and set the charge air cooler aside 4 Remove the one bolt holding the over 12 mm socket flow tube to the radiator assembly 5 W2002124 Fig 130 Remove support brackets Remove the four bolts holding the two 12 mm socket lower air conditioning condenser sup port brackets to the radiator assembly W2002126 Fig 132 Remove head screws from shroud Remove the eight torx head screws T 30 torx bit fastening the shroud to the radiator and set the shroud aside 70 Group 2 Installation 1 Install the overflow hose and bracket the top radiator hose and the bleed hose to the radiator Position the shroud into place install eight torx head screws and hand tighten 7 mm socket screwdriver W2002126 Fig 133 Position the shroud into place install head screws T 30 torx bi
2. W2003472 Fig 9 Radiator VHD with unique mounting bracket 16 Group 2 Coolant Mixture Always mix water and antifreeze to the correct concen tration before filling the cooling system The recommended mixture is 50 antifreeze coolant in the water Note Mixing concentrated coolants of a different type can result in a loss of anti corrosion properties with dam age to the engine as a result At the factory the cooling system is normally filled with a mixture of tap water and concentrated coolant which gives protection down to minimum 29 C 20 F If the vehicle is destined for climates colder than this the anti freeze level of the coolant should be adjusted see approximate values in the following table 60 antifreeze in the mixture gives optimum freeze protection Increasing the antifreeze content beyond that will only decrease the freeze protection Never use a mixture weaker than 40 antifreeze to 60 water Ignoring this increases the risk of corro sion in the cooling system and cylinder liner pitting leading to damage of the engine For more detailed information on Coolants refer to TSI 184 001 Coolant Requirements Volvo Engines IMPACT Function Group 184 Information Type Service and Mainte nance Coolant Requirements Freeze Protection Design and Function down to Amount Amount Percent concentrated concentrated age of antifreeze antifreeze anti
3. Note If the impeller is damaged it must be replaced Note If the pump housing or rear cover is to be replaced transfer pipe fittings to the replacement unit etc 12007117 51 Group 2 Assembly 1 8012 72007111 Fig 84 Installing bearing to shaft sleeve Install the new bearing 3 to the shaft sleeve 2 and using hollow drift 9998012 carefully press down on the inner race of the bearing until it lies up against the flange of the shaft sleeve see Fig 83 Exploded view of coolant pump page 51 Note Install the bearing with the side at which the outer and inner races are level facing the flange of the shaft sleeve The shaft 1 and the shaft sleeve 2 are supplied as a single spare part unit see Fig 83 Exploded view of coolant pump page 51 52 9998012 Service Procedures 72007112 Fig 85 Installing bearing and shaft into pump Place the pump housing 5 in a press 9996383 Using hollow drift 9996383 carefully press in the bearing and shaft until the bearing bottoms out in the pump hous ing see Fig 83 Exploded view of coolant pump page 51 Note Press on the outer race of the bearing and check to make sure that the shaft does not hit the press table 12007119 Fig 86 Press drive gear onto shaft Screw the shorter threaded section of 9996315 spindle 9996315 into the shaft sleeve 2 see Fig 83 Exploded view of coolant pump page 51 Group 2 4 Pla
4. Never remove the cap on the expansion tank while the engine is still hot Wait until the coolant tempera ture is below 50 C 120 F Scalding steam and fluid under pressure may escape and cause serious per sonal injuries Do not work near the fan with the engine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be seri ously injured Before turning on the ignition be sure that no one is near the fan Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids 1 Remove the temperature sensor from the thermostat housing and connect the electric cable 2 Connect a ground between the tem perature sensor and the cylinder block 3 Submerse the temperature sensor in heated water 4 Using a thermometer measure the temperature Compare this reading with the temperature gauge reading Group 2 2611 11 04 01 Radiator Cleaning Unit Removed AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Never remove the cap on the expa
5. cap DUI A WO PY Coolant filter W2003323 Fig 2 Cooling system 10 11 Coolant pump Heater return Heater supply Radiator drain valve Shut off valve coolant pump Group 2 Coolant Circulation in Engine The coolant is forced through the system by a gear driven pump The coolant enters the cylinder block through a pipe and first passes the area where the oil cooler is installed The coolant is then distributed through galleries in the cylinder block and cylinder head to reach the cylinder liners and other parts of the engine before leaving the cylinder head through the thermostat housing The illustration shows the engine during the warm up period The thermostat is closed and the coolant is flowing back to the coolant pump Design and Function 12007265 Fig 3 Coolant circulation Group 2 Design and Function Thermostat The engine is equipped with a thermostat The thermo stat housing incorporates a sensor for coolant temperature During engine warm up the thermostat is closed see Fig 4 Thermostat closed page 14 and coolant flows from the cylinder head through the outer section of the thermostat back to the coolant pump W2003283 Fig 4 Thermostat closed When the engine has reached operating temperature and the thermostat is open see Fig 5 Thermostat open page 14 t
6. conditioner line clamp Fig 43 Tie removal Install the bolt supporting the air con 12mm wrench Cut the four ties holding the rubber ditioner line clamp Torque the line 24 4 Nm shrouding away from the radiator clamp bolt to 24 4 Nm 18 3 ft lb 18 3 ft lb 36 W2002075 Fig 46 Install head screws Position the side shroud into place in T25 torx bit stall two torx head screws and hand tighten 11 W2002058 Fig 47 Add coolant Add the drained coolant Maximum fill rate of 9 5 liter per minute 2 5 gallons per minute For more detailed infor mation on Coolants refer to TSI 184 001 Coolant Require ments Volvo Engines IMPACT Function Group 184 Information Type Ser vice and Maintenance Coolant Require ments Service Procedures 12 s gal W2002077 Fig 48 Install grille Install grille and torque the 14 Torx T25 Torx bit head screws to 5 Nm 44 in lb 8mm wrench 5 Nm 44 in lb 13 Co WL IM W2002104 Fig 49 Cap replacement 1 Fill cap 2 Pressure cap do not remove Start engine and check for leaks Run the engine to operating temperature After the engine has reached operat ing temperature move the heater controls to
7. coolant pump 9 Remove the drain hose from the lower coolant pipe 10 W2003330 Fig 66 Lower radiator pipe location Remove the bolts holding the lower coolant pipe to the pump Note Leave the pipe attached to the lower radiator hose 45 Group 2 11 Remove the coolant filter hoses 12 W2003332 Fig 67 Removing coolant pump Remove the bolts and lift off the coolant pump 13 Remove the adapter for the remote coolant filter from the bottom of the coolant pump Installation 1 Clean all sealing surfaces 46 Service Procedures W2003331 Fig 68 Installing coolant pump Install the new coolant pump using new seals Tighten the bolts to 48 8 Nm 35 6 ft lb 48 8 Nm 35 6 ft lb W2003330 Fig 69 Pipe from radiator to coolant pump Install the pipe from the radiator to the coolant pump using a new sealing ring Service Procedures T2007246 Fig 70 Heater hose connection Connect the heater hose to the coolant pump and tighten the hose clamp 5 Reinstall the coolant filter 6 Connect the remote mounted coolant filter hoses to the adapter and tighten the hose clamps Fig 71 Install sealing ring Install a new sealing ring to the pipe from the expansion tank and bolt the pipe to the coolant pump 8 Coat the sealing ring with soapy water to make installing the pipe into the coolant pump easier AN SS ac A a
8. expansion tank while the engine is still hot Wait until the coolant tempera ture is below 50 C 120 F Scalding steam and fluid under pressure may escape and cause serious per sonal injuries Lift the fan into position Install and tighten the nuts Make sure that the drive belt runs properly in the pulleys Remove the lever 3 Install the bolts for the fan ring AP WARNING Do not work near the fan with the engine running The 4 engine fan can engage at any time without warning Install the charge air hose using new Anyone near the fan when it turns on could be seri seals ously injured Before turning on the ignition be sure that no one is near the fan Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids 63 Group 2 Removal W2003336 Fig 114 Loosening fan belt tension 1 Apply special tool J 44392 to the belt J 44392 tensioner to loosen and remove the belt 72007223 Fig 115 Removing the belt tensioner Remove the protective cover Remove the bolt and the belt tensioner 64 Service Procedures Installation 1 12007224 Fig 116 Installing the belt tensioner Install the belt tensioner making sure that the stud in the tensioner fits cor rectly into the hole in the timing gear cover 2 Tighten the bolt to 24 4 Nm 18 3 24 4 Nm ft lb and install the cover 18 3 ft lb 3 Check that the f
9. is required to give the fan its properties Note The fan should be stored upright or to a maximum angle of 45 If the angle is higher or if lying flat on the ground the silicone fluid will drain out of the fan Service Procedures 2651 03 04 01 Charge Air Cooler Replace ment Radiator Removed AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Never remove the cap on the expansion tank while the engine is still hot Wait until the coolant tempera ture is below 50 C 120 F Scalding steam and fluid under pressure may escape and cause serious per sonal injuries Do not work near the fan with the engine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be seri ously injured Before turning on the ignition be sure that no one is near the fan Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids 69 Group 2 Service Procedures Removal 3
10. is still hot Wait until the coolant tempera ture is below 50 C 120 F Scalding steam and fluid under pressure may escape and cause serious per sonal injuries Group 2 Do not work near the fan with the engine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be seri ously injured Before turning on the ignition be sure that no one is near the fan Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids 12007117 Fig 76 Exploded view of coolant pump Note Reference is made in the text to component posi tions as shown in picture 1 Shaft Shaft sleeve Ball Bearing Gear Pump Housing Oil Sealing Ring Coolant Sealing Ring Impeller o 0 nN DO a hb WwW PD O ring a o Rear Cover 11 Coolant Filter Special tools 9992071 9992671 9994034 9994090 9996222 9996315 9996383 Service Procedures 9996626 9996883 9996884 9998012 9998039 9998113 9996671 Disassembly 1 Remove the coolant filter 11 using filter wrench 9996671 Remove the rear cover 10 see Fig 76 Exploded view of coolant pump page 49 9996671 72007116 Fig 77 Attaching tools to coolant pump Screw adapter 9996883 into the shaft 9996883 sleeve 2 of the coolant pump and 9996884 thread drift 9996884 onto hydraulic 9992671 cylinder 9992671 see Fig 76 Ex ploded view of coolan
11. not work near the fan with the engine running The After the engine has reached operat engine fan can engage at any time without warning ing temperature move the heater Anyone near the fan when it turns on could be seri controls to warm and run the engine ously injured Before turning on the ignition be sure an additional 10 minutes that no one is near the fan 8 Shut off engine and recheck coolant AP ag WARNING Note To pressure test the system Always wear appropriate eye protection to prevent the see Cooling System Leak Test risk of eye injury due to contact with engine debris or Checking page 41 fluids 41 Group 2 Service Procedures To be carried out in the vehicle 2 Note Before using pressure gauge 9996662 check its operation Do this by attaching it to an air supply and setting the pressure to 100 kPa 14 psi with the regula tor valve AN DANGER Check that the pressure on the gauge never exceeds 100 kPa 14 psi Excessive pressure may cause air supply to burst which can cause personal injury or death Procedure Special tools 9996049 9996662 Fig 57 Remove fill cap AN E 1 Check the hoses and connections of the cooling system for leaks and to make sure they are in good working condition W2003473 Fig 58 Remove fill cap VHD Model Remove the fill cap and install 9996662 pressure regulator gauge and cap as J 42397 sembly Note Make sure the cooling system is full
12. of coolant before performing this test 42 Group 2 Service Procedures 3 2621 03 02 01 Coolant Pump Replacement AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death 72007258 AP WARNING Fig 59 Increase pressure to 40 kPa 6 psi HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Using the knob of the reduction valve slowly increase pressure to 40 kPa 6 psi Maintain this pressure for approx imately 5 minutes Look over the entire engine radiator and coolant hoses for any leaks and then perform a leakage check on the radiator hoses connec AN WARNING tions and the coolant pump Never remove the cap on the expansion tank while the engine is still hot Wait until the coolant tempera 4 ture is below 50 C 120 F Scalding steam and fluid under pressure may escape and cause serious per sonal injuries Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids Special tools 9996049 T2007257 Fig 60 Increase pressure to 100 kPa 14 psi Slowly increase the pressure to 100 kPa 14 psi and check that the va
13. upper radiator hose elbow Remove the upper radiator hose con necting pipe from the thermostat housing 8 Remove all of the coolant air oil lines from the air compressor 12007250 Fig 95 Rotate the air compressor Remove the air compressor attaching bolts and rotate the compressor out far enough to allow clearance to remove the thermostat housing 56 Service Procedures 10 Remove retaining bolts holding C shaped cooling pipe attached to rear of thermostat housing 11 12007235 Fig 96 Removing the housing Remove the bolts and the thermostat housing 12 12007236 Fig 97 Removing the thermostat Remove the thermostat from the ther mostat housing Group 2 13 12007238 Fig 98 Removing the sealing ring Remove the sealing ring from the ther mostat housing by tapping with a drift until it tips over and can be removed 14 Clean the sealing surfaces of the ther mostat housing and the sealing surfaces of the cylinder head and pipe connections 15 T2007243 Fig 99 Installing a new sealing ring Install a new sealing ring to drift 9998291 9998291 Note The sealing ring must be in stalled with the broad metal plate facing the ledge on the drift Service Procedures 16 E 72007242 Fig 100 Installing a new sealing ring Using drift 9998291 carefully tap the 9998291 sealing ring in until it bottoms out in the housin
14. when it turns on could be seri ously injured Before turning on the ignition be sure that no one is near the fan Group 2 Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids Removal 1 W2002059 Fig 50 Draining the coolant system Open the drain on the bottom of the radiator and drain into a suitable container Drain coolant below the ex pansion tank level AN DANGER Risk of poisoning Coolant is toxic Do not drink coolant Use proper eye and hand protection when handling Keep coolant out of reach of children Per sonal injury or death could result Remove the four expansion tank hoses Service Procedures W2002060 Fig 51 Remove expansion tank hoses 12 mm socket 6 in extension overfill tube fill line air bleed hose to thermostat housing hose from expansion tank to radi ator top tank Unplug the wire harness to the low coolant sensor 39 W2002062 Fig 52 Remove mounting bolts W2002061 Fig 53 Lift the expansion tank Remove the expansion tank mounting 12 mm socket bolts two in the front three in the rear Lift away the expansion tank 40 Service Procedures Installation W2002062 Fig 54 Install mounting bolts 12 mm socket 24 4 Nm 18 3 ft lb Position the expansion tank into place and install the five mounting bolts Torque to 24 4 Nm 18 3 ft lb W20
15. 02060 Fig 55 Connect expansion tank hoses Connect the four expansion tank 7 mm socket hoses screwdriver e overfill tube e fill line e air bleed hose to thermostat housing e hose from expansion tank to radi ator top tank Connect the wire harness to the low coolant sensor Group 2 Service Procedures 6 2619 06 02 01 Cooling System Leak Test Checking AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death v W2002058 Fig 56 Add coolant AP WARNING Install the drained coolant Maximum HOT ENGINE Keep yourself and your test equipment fill rate of 9 5 l min 2 5 gpm clear of all moving parts or hot engine parts and or Note For current coolant require fluids A hot engine and or fluids can cause burns or can permanently damage test equipment ments Service 184 001 Bulletin Coolant Require ments Volvo Engines AS WARNING IMPACT Function group 184 Never remove the cap on the expansion tank while Information type the engine is still hot Wait until the coolant tempera Maintenance ture is below 50 C 120 F Scalding steam and fluid Coolant Require under pressure may escape and cause serious per ments sonal injuries 7 AP WARNING Start engine and check for leaks Run the engine to operating temperature Do
16. 99 9708 999 9795 12007271 1159794 Torque wrench 10 100 Nm 9999795 Tachometer 7 74 ft lb 9985011 Hydrometer for antifreeze 9999708 Torque wrench 0 17 5 Nm 0 13 ft lb 10 Group 2 Design and Function Design and Function Cooling System Charge Air Cooler Charge Air Cooler Systems are essential today to meet emissions regulations However they also improve power density lower fuel consumption and reduce ther mal stresses on the engine by cooling the turbocharged air before it enters the engine The turbocharged air is heated up to 200 C 400 F or even higher as it enters the charge cooler and is cooled to around 40 C 100 F when it leaves for the engine Accumulation of bugs and dirt in the finned areas of a Charge Air Cooler are known problems If there is a build up of any debris like road film bugs etc in just a section of a charge air cooler that section overheats and torsional twisting stresses develop in the charge air cooler core The fin passage cleanliness may not be as 2000730 critical in an over the highway vehicle but in construc Fig 1 Charge air cooler tion logging and mining equipment it can be Before performing the actual leak test make sure the pressure regulator is functioning properly see Cooling System Flow page 12 Group 2 Cooling System Flow Design and Function 1 Thermostat housing Radiator Expansion tank Level sensor Pressure
17. M Wy 1738 W2002072 Fig 34 Plastic tie placement Using plastic ties tie the rubber part of the fan ring back away from the fan shroud 10 Service Procedures W2002105 Fig 35 Remove mounting bolts Remove the four upper radiator mounting bolts 15 mm deep socket 33 Group 2 Service Procedures 11 Installation 1 gl N W2002069 Fig 36 Radiator removal Fasten an acceptable lifting device to OEM 4129 the top of the radiator in the holes that w2002069 are provided Lift out the radiator and Fig 37 Lowering radiator the charge air cooler assembly 9 y Position the radiator into the truck Note Be very careful when lowering A CAUTION the radiator into the truck Watch for any hoses or wires that might interfere Be careful not to damage the radiator assembly when or be damaged Make sure the fan removing Damage to the radiator and or engine could does not damage the radiator core as result in severe damage to the engine sembly 2 Remove the lifting device from the ra diator 34 Group 2 Service Procedures 4 W2002060 Fig 40 Install expansion tank hoses W2002105 Fig 38 Install the radiator mounts Install the upper radiator mounts and 15 mm socket nuts Torque to 48 8 Nm 36 6 ft 48 8 Nm lb 18 3 ft lb 4 E W2002063 Fig 41 Connect top hose clamps Install all coolant hoses on the top side 7 mm socket of the radi
18. Radiator Replacement AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Never remove the cap on the expansion tank while the engine is still hot Wait until the coolant tempera ture is below 50 C 120 F Scalding steam and fluid under pressure may escape and cause serious per sonal injuries Do not work near the fan with the engine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be seri ously injured Before turning on the ignition be sure that no one is near the fan Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids W2002101 Fig 22 Lifting radiator and charge air cooler assembly Note WG AC The radiator and charge air cooler are removed and installed as an assembly Use of a lifting strap during re moval and installation will help to prevent damage to the radiator charge air cooler assembly 29 W2003376 Fig 23 VN radiator W2003472 Fig 24 VHD radiator Important Do not attempt to replac
19. S 7 ZS Ae e y Fig 72 Bolt location Install the bolt holding the pipe beside the thermostat housing W2003333 W2003329 47 Group 2 10 W2003328 Fig 73 Installing coolant pipe Using new sealing rings install the pipe between the coolant pump and the thermostat housing and the pipe between the coolant pump and the oil cooler cover 11 Coat the sealing rings with soapy wa ter 12 UH Salt el SE ee DC W2003334 Fig 74 Charge air cooler piping Reinstall the charge air cooler pipe and mounting brackets 13 Reinstall the elbow outlet on the tur bocharger 48 Service Procedures 14 W2003335 Fig 75 Coolant filter Install a new coolant filter on the coolant pump 15 Fill the system with coolant 16 Start the engine and check the cooling system for leaks 2621 04 04 01 Coolant Pump Overhaul Unit Removed AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Never remove the cap on the expansion tank while the engine
20. Service Manual Trucks Group 260 600 Cooling System D12 D12A D12B D12C PV776 TSP142854 VOLVO Foreword The descriptions and service procedures contained in this manual are based on de signs and methods studies carried out up to August 2000 The products are under continuous development Vehicles and components produced after the above date may therefore have different specifications and repair methods When this is believed to have a significant bearing on this manual supplementary ser vice bulletins will be issued to cover the changes The new edition of this manual will update the changes In service procedures where the title incorporates an operation number this is a refer ence to an S R T Standard Repair Time Service procedures which do not include an operation number in the title are for gen eral information and no reference is made to an S R T The following levels of observations cautions and warnings are used in this Service Documentation Note Indicates a procedure practice or condition that must be followed in order to have the vehicle or component function in the manner intended Caution Indicates an unsafe practice where damage to the product could occur Warning Indicates an unsafe practice where personal injury or severe damage to the product could occur Danger Indicates an unsafe practice where serious personal injury or death could oc cur Volvo Trucks North America Inc Greensbor
21. act with sulfuric acid or an explosion Group 2 If any of the following characteristics are observed it is possible that the fan could be faulty However be sure to go through the check list below 1 The fan does not engage i e low fan speed despite high engine load This will result in high coolant temperature and thereby a drop in engine output 2 The fan does not disengage despite low engine load Check the following before measuring fan speed e That the radiators are not blocked by insects or leaves etc e Coolant level is between MIN and MAX e Fan drive belt is not loose or cracked e The radiator is not blocked by insects or leaves etc e The coolant temperature gauge sensor is function ing properly e The cooling system is not blocked e The fan is clean and undamaged e Fluid has not leaked out of the fan hub e The bimetallic spring plate of the fan is not damaged or blocked Note Operational disturbances concerning the fan can also be due to wear in the control mechanism Note If the thermostat in the cooling system is faulty this will also result in faulty fan operation Note The fan drive or clutch is an exchange unit and cannot be repaired since special instruments are re quired for adjustment and checking of the engagement temperature and speed Note If fluid has leaked out of the fan drive or clutch no attempt must be made to refill with silicone fluid since a precise amount of fluid
22. an belt is not damaged and does not need to be changed be fore installing it into the correct grooves of the pulleys 4 Remove the lever from the belt ten sioner Group 2 Service Procedures 2634 03 02 04 4 Cooling Fan Drive Belt Re DEE placement 2634 04 02 01 o Fan Belt Tensioner Overhaul AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death HOT ENGINE Keep yourself and your test equipment l 72007253 clear of all moving parts or hot engine parts and or Fig 117 Removing the fan assembly fluids A hot engine and or fluids can cause burns or Remove the nuts holding the fan to the can permanently damage test equipment pulley Lift off the fan and lower it into the fan shroud Never remove the cap on the expansion tank while the engine is still hot Wait until the coolant tempera ture is below 50 C 120 F Scalding steam and fluid under pressure may escape and cause serious per sonal injuries Do not work near the fan with the engine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be seri ously injured Before turning on the ignition be sure T2007222 Fig 118 Loosening fan belt tension that no one is near the fan Apply a breaker bar to the bel
23. ator Connect the following 10mm socket screwdriver e charge air cooler hose 5 5 0 8 Nm e low coolant sensor harness 50 F 8 in lb Torque the hose clamps as follows 4 0 6 Nm e top radiator hose 5 5 0 8 Nm 35 5 in lb 50 8 in lb 2 3 0 3 Nm Ria e fill hose clamp 4 0 6 Nm 3545 20 3 in lb Fig 39 Install the supports and ties Dy 10 2 o Nim See PP e small bleed hose clamp 2 3 0 3 90 3 in lb Install the lower radiator supports and 13 mm socket Nm 20 3 nibble nuts Torque to 24 4 Nm 18 3 ft 24 4Nm e charge air cooler hose clamp to Ib 18 3 ft lb 10 1 5 Nm 90 3 in lb 35 Group 2 Service Procedures W2002063 Fig 42 Connect bottom hose clamps Install the bottom radiator hose and 7 mm socket the lower charge air cooler hose 10 mm socket Torque the hose clamps as follows torque wrench 5 5 0 8 Nm e bottom radiator hose clamp 5 5 50 8 in lb 0 8 Nm 50 8 in lb 10 1 5 Nm e lower charge air cooler hose 90 13 in lb clamp 10 1 5 Nm 90 13 in lb Position the condenser onto the lower W2002078 Fig 44 Install mounting brackets 12 mm socket mounting brackets Install the con 24 4 Nm denser mounting bolts and torque to 18 3 ft lb 24 4 Nm 18 3 ft lb 24 4 Nm Torque the lower condenser mounting 18 3 ft lb bracket bolts previously hand tight to 24 4 Nm 18 3 ft lb 9 W2002066 Wen02072 Fig 45 Install air
24. ce the drive gear 4 hollow drift 9996626 and hydraulic cylinder 9992671 on the spindle and install the nut see Fig 83 Exploded view of coolant pump page 51 9996266 9992671 5 Using hydraulic pump 9996222 care fully press the drive gear down until it bottoms out against the bearing 9996222 6 Remove the tools 9998244 T2012619 Fig 87 Using tool 9996315 Insert the spindle 9996315 through the 9996315 hole of sleeve 9998244 and screw the 9998244 long threaded end of the spindle into the shaft until it bottoms out against the shaft Tighten the nut by hand Note Make sure that the spindle 9996315 is threaded in until it bottoms out against the shaft before tightening the nut 8 Install the pump in a press so that the spindle s nut rests flat against the sur face of the press Service Procedures 72012620 Fig 88 Installing the oil seal Install the oil seal 6 with the sealing lip against the drive gear see Fig 83 Exploded view of coolant pump page 51 10 Using drift 9998113 carefully press the seal into position until it is level with the edge of the pump housing 9998113 Note Do not press in the drift until it hits the pump housing 11 T201 2621 Fig 89 Coolant seal applying Loc Tite Apply Loc Tite locking fluid to the coolant seal s contact surface A against the housing 53 Group 2 12 72007262 Fig 90 Installing the
25. coolant seal Carefully press in the coolant seal us 9998039 ing the drift 9998039 Note To prevent damage due to ex cessive pressing force pressure should be removed when the seal flanges out against the housing 13 72007115 Fig 91 Installing new impeller Place the pump with the spindle nut resting on a flat surface 54 Service Procedures 14 Press the impeller approximately 10 mm 1 2 in on to the shaft 15 W2003286 Fig 92 Pressing on the impeller Install the tool 9998541 on the impeller 9998541 and carefully press it down until the tool rests against the pump housing 16 Remove the spindle 9996315 from the 9996315 shaft sleeve 17 Install the rear cover using a new O ring in the pump housing Note Turn the drive gear and check that it rotates easily Bearing noise or axial play is not permitted 18 Install a new coolant filter Coat the fil ter gasket with a light film of grease and hand tighten only Group 2 Service Procedures 2627 03 02 01 3 Thermostat Replacement D12 D12A D12B AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluid
26. e Faulty temperature controlled cooling fan e Leaking cylinder head gasket lower liner seals e Leaking coolant hoses Coolant Temperature Too Low e Faulty thermostat e Faulty temperature gauge Loss of Coolant External Leaks e Leaks in hoses or connections e Leaks in radiator and or expansion tank e Leaks in cab heater e Leaks in coolant pump e Cylinder head gasket leakage Internal Leaks Engine e Leak at injector copper sleeve e Defective liner seals e Liners pitted or cracked e Cylinder head gasket leakage e Crack s in cylinder head e Crack s in cylinder block Troubleshooting 25 Group 2 Coolant Leaks Through Overflow e Faulty pressure cap relief valve e Engine running too hot e Expansion tank installed incorrectly e Cylinder head gasket leakage e Cylinder block cracked e Liners pitted or cracked e Coolant losses warm engine switched off Coolant losses after having switched off a warm engine are generally due to heavy load operation and subse quent stopping without allowing the engine first to run at idling speed to cool down or a faulty pressure cap valve Temperature Gauge Checking Remove the temperature sensor from the thermostat housing and reconnect the electric connector Connect a ground between the temperature sensor and the cylinder block Submerse the temperature sensor in heated water Using a thermometer read off the temperature Compare this reading with the reading of the
27. e any of the compo nents on the VN VHD radiator including tanks seals or core Specialized tooling is needed to perform quality repairs when crimping the tanks and seals to the core There fore you should e have the radiator repaired by an authorized radiator service center or e replace the complete unit 30 Service Procedures Removal 1 e VHD only For removal of the T25 Torx bit grille in a VHD model truck refer 8 mm wrench to procedure TSI 820 500 Hood VHD Impact Function Group 82 Information Type Repair Hood VHD W2002077 Fig 25 VN model screw fasteners VN only Remove the 14 Torx screws fas tening the grille to the hood and set the grille aside Group 2 Service Procedures W2002059 Fig 26 Drain the cooling system W2002063 Fig 27 Disconnect radiator hoses AN DANGER Risk of poisoning Coolant is toxic Do not drink coolant Use proper eye and hand protection when handling Keep coolant out of reach from children Personal injury or death could result Drain the cooling system Open the drain on the bottom of the radiator and drain into a suitable container Note On most older
28. e cover should be able to let airflow through to the charge air cooler at a uniform rate over the entire area This means that a single small opening in the winterfront is not acceptable Air passage must be distributed evenly across the grille and no more than 85 can be covered VN Winterfronts are properly used for overnight parking in the winter or very cold temperatures below 5 F 20 C In these cases coolant and inlet manifold tempera tures must be carefully monitored and controlled 22 Design and Function Group 2 Viscous Fan The Viscous fan consists of a fan section and a drive section connected by a visco static clutch The clutch consists of a drive plate 6 which is mounted in a hous ing 7 see Fig 17 Fan cross section page 23 On each side of the drive plate 6 is an air gap When the fan is engaged these gaps are filled with fluid With the fan in operation the flow of fluid in the fan hub takes place in two different ways The temperature around the bimetallic plate 2 determines which path the fluid takes and thereby the degree to which the fan is engaged The control device regulates the amount of fluid reaching the drive chamber to meet the cooling requirements The more fluid in the drive chamber the less slip thus re sulting in higher fan speed The fluid circulates between the storage and drive chambers When the engine and fan stop the fluid runs out into the drive chamber which
29. e grooves on the pul leys Remove the lever from the belt tensioner and check fan belt tension with Kent Moore tool J 23600 B 68 Service Procedures 2631 06 02 01 Viscous Fan Checking AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death AN DANGER Never work under or around a vehicle unless it is sup ported on jack stands of adequate rating Failure to use adequate jack stands can result in the vehicle falling which can cause serious injury or death to anyone under the vehicle HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Never remove the cap on the expansion tank while the engine is still hot Wait until the coolant tempera ture is below 50 C 120 F Scalding steam and fluid under pressure may escape and cause serious per sonal injuries Do not work near the fan with the engine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be seri ously injured Before turning on the ignition be sure that no one is near the fan Always wear eye protection when working around bat teries to prevent the risk of injury due to cont
30. ent ic c isiecsisseecsersicisionsteonsessteaseenserees 63 Cooling Fan Drive Belt Replacement eseessesceesereeserereenerees 65 Fan Belt Tensioner Ovelha ion 65 Viscus Fam NS cad 68 Charge Air Cooler Replacement cis icccsscisicisiecscisicisccssmeisicvereseestevaee 69 Removal aia 70 A A 71 Coolant Temperature Gauge Checking oooooccconccconicinancnnoninncnernnnnnns 72 Radiator Cleaning tT ed ool en Cleaning rico iii iii Oe Feedback Group 2 General W2003244 This information covers the Cooling System for the D12 D12A D12B and D12C engines General Group 2 Special Tools Tools The following special tools are required to work on the cooling system of the D12 engine The tools are available from the Parts Department of Volvo Trucks North Amer ica Inc Please specify the complete part number when ordering WO0001739 9992071 Drift for Overhauling Coolant Pump W0001743 9992671 Hydraulic Cylinder W0001744 9994034 Hollow Drift for Overhauling Coolant Pump W0001745 9994090 Puller for Coolant Pump Seal W0001746 9996049 Drain Hose for coolant A CJ TN i W0001747 9996222 Air Powered Hydraulic Pump Group 2 W0001748 9996315 Spindle for Overhauling Coolant Pump W0001763 9996383 Hollow Drift for Overhauling Coolant Pump W0001261 9996441 Expansion Tank Cap VN Tool
31. er and radiator Clean if nec essary 38 Service Procedures 2 Check the radiator to make sure that its external sections are not blocked by insects or other foreign objects which can obstruct airflow If obstructions are found use a mild detergent and water to clean them off If the fins of the pipe system have been bent by flying stones etc straighten them out 3 Make sure that the sealing moldings between the fan shroud and the radia tor are not loose or for any reason are not providing a good seal Check the condition of the recirculation shield Also make sure it is properly installed 2612 03 02 01 Radiator Surge Tank Replace ment AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Never remove the cap on the expansion tank while the engine is still hot Wait until the coolant tempera ture is below 50 C 120 F Scalding steam and fluid under pressure may escape and cause serious per sonal injuries Do not work near the fan with the engine running The engine fan can engage at any time without warning Anyone near the fan
32. freeze WG WI and AC in mixture 25 C 17 liters 20 liters 40 13 F 30 C 20 liters 23 liters 46 22 F 38 C 21 liters 25 liters 50 36 F 46 C 26 liters 30 liters 60 51 F Group 2 Flushing Cooling System The cooling system should always be cleaned when the coolant is replaced AN DANGER Coolant is toxic risk of poisoning Do not drink coolant Use proper hand protection when handling Keep coolant out of reach of children and animals Failure to follow these precautions can cause serious illness or death Note Always dispose of coolant according to Federal or local regulations Take all used coolant to a recycling or waste collection center 18 Design and Function Group 2 Expansion Tank The expansion tank includes a pressure valve and a coolant level sensor The tank material is clear and has maximum MAX and minimum MIN markings to allow visual fluid level checks Design and Function W2000749 Fig 10 Expansion tank for WG and AC W2003514 Fig 11 Expansion tank for VHD W2003515 Fig 12 Expansion tank for VN Group 2 Draining Points To drain the cooling system all drain points should be opened In addition the expansion tank cap should be removed while the system is draining Draining points Radiator Cylinder block Oil cooler transmission when installed Coolant pump Note In some locations the draining point co
33. g 17 72007237 Fig 101 New thermostat and seal Install a new thermostat and a new seal into the housing 18 Remove the bolts holding the spacer between the coolant pump and the thermostat housing Install a new seal ing ring to the spacer and coat it with grease 57 Group 2 19 12007235 Fig 102 Reattaching the thermostat housing Install and attach the thermostat hous ing to the cylinder head 20 Push the pipe from the coolant pump into the thermostat housing entry and install the bolts holding the pipe 21 12007240 Fig 103 New air compressor seal Install a new seal between the air compressor and the timing gear plate Attach the air compressor 22 Reinstall all of the coolant air oil lines to the air compressor 58 Service Procedures 23 Install the pipe between the radiator and the thermostat housing Use a new sealing ring 24 Attach the cab heater pipe to the ther mostat housing Install a new sealing ring 25 Attach the fan ring stay 26 12007264 Fig 104 Reattaching the hoses to thermostat housing Plug in the temperature sensor con nector and attach the expansion tank hose 27 Fill with coolant and carry out a leak age check Group 2 2627 03 02 01 Thermostat Replacement D12C AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so ca
34. hat the new fan has not leaked fluid If fluid has leaked out special instruments are required to check both en gagement temperature and fan speed Special tools J 44392 62 Service Procedures 1 Remove the charge air hose between the charge air cooler and inlet pipe or where applicable between the charge air cooler and starting heater 2 Remove the bolts holding the fan ring W2003337 Fig 112 Removing the fan Using the Belt Tensioner Release Tool J 44392 J 44392 loosen the drive belt Re move the fan nuts and lower the fan carefully into the fan shroud Note Some engines may have the belt tensioner mounted on the other side compared to shown picture 4 Remove the studs from the fan hub and carefully lift the fan out Stand the fan vertically to avoid leakage of fluid Group 2 Service Procedures Installation 2634 03 02 01 1 Fan Belt Tensioner Replace Place the new fan in the fan shroud Install the studs ment 2 AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Fig 113 Installing the fan Never remove the cap on the
35. he cleaner flush packaging 77 Group 2 3 Drain the cooling and heating systems and flush through with clean water For quick efficient draining remove the lower and upper radiator hoses and the drain valves Do not forget to drain the heater element and the engine heater 4 Run the engine for 10 15 minutes at normal working temperature and then repeat the flushing procedure 5 The heating system must be flushed separately with hoses disconnected to ensure removal of any impurities left in the system Also remove the expan sion tank cap For effective cleaning flush the expansion tank from below with the cap removed 6 When the system is entirely free from impurities it is ready to be refilled with new coolant seetable page 17 7 If the system is cleaned on a regular basis for example when the concen trated coolant is drained or filled or when the system is relatively free from deposits a smaller amount of cleaner additive or simply flushing with clean water may be sufficient Note Chemicals for cleaning the cool ing system are not marketed by Volvo Trucks North America and must be ob tained elsewhere Dispose of all cleaner s and coolant fluids according to local and state regulations 78 System Check Filling 8 The cooling system is filled through the expansion tank The engine must be switched off and the heater controls set at WARM 9 Fill with coolant to the maximum level o
36. he outlet to the coolant pump is gradually closed The coolant now passes through the inner sec tion of the thermostat housing and then to the radiator W2003284 Fig 5 Thermostat open 14 Group 2 Design and Function Thermostat Housing D12C The thermostat housing has been integrated into the cylinder head The thermostat 1 is located at the right front side of the cylinder head and its seal ring 2 is accessible once the connection housing 3 and thermostat have been re moved see illustration Fig 6 Thermostat Housing D12C page 15 T2012790 Fig 6 Thermostat Housing D12C Group 2 Design and Function Radiator AC WG There are two 2 sizes of radiators furnished for use with the D12 engines in different applications Vehicle Radiator System Type Area Capacity Autocar 84 dm 1300 in 43 52 ats WG 67 dm 1032 in 50 52 gts Fig 7 Radiator AC WG VN VHD Do to the unique design of the radiator do not attempt to replace any of the components on the VN VHD radiator including tanks seals or core Specialized tooling is needed to perform quality repairs when crimping the tanks and seals to the core There fore you should e have the radiator repaired by an authorized radiator service center or e replace the complete unit Vehicle Radiator System Type Area Capacity ne VN 124 n 39 Fig 8 Radiator VN VHD 849 n 39
37. instru ment at a safe distance from the blades of the fan when checking RPM Contact may cause personal in jury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids Fan Disengaged 2003338 W Fig 20 Using hand held tachometer Troubleshooting 1 Run the engine at idling speed for ap proximately 5 minutes Air temperature in front of the fan must not exceed 30 C 85 F The silicone fluid which drains into the drive chamber when the engine is switched off is now pumped back to the storage chamber 1 Increase engine speed to maximum RPM and measure fan speed with spe cial tool 9999795 Fan speed should be less than half engine speed when the fan is fully disengaged 9999795 Fan Engaged Air temperature around the sensor should be approxi mately 85 C 185 F for the fan to be fully engaged W2003339 Fig 21 Measuring fan speed 1 Run the engine at maximum output RPM and measure the fan speed and fan drive pulley speed using tool 9999795 Fan speed must not be less than 90 of pulley speed when the fan is fully engaged 9999795 27 28 Group 2 Service Procedures Service Procedures 2611 03 02 01
38. is why the fan is generally engaged during the first min utes after starting the engine A Disengagement The valve 1 closes and fluid is pumped out into the storage chamber 5 B Engagement The valve 1 opens and fluid can enter the drive cham ber 8 Design and Function 12006863 Fig 15 Cooling fan 12007217 Fig 17 Fan cross section Fan cross section shows valve disengaged B and engaged A 1 Valve Bimetallic plate Control pin Valve lever Fluid storage chamber Drive plate Housing oN O a A WO PD Drive chamber 23 Group 2 Design and Function Control Device The fan rotates at reduced speed The bimetallic plate 1 presses against the control pin 2 moving it towards the valve lever 3 72007218 Fig 18 Control valve closed 1 Bimetallic plate 2 Control pin 3 Valve lever The fan is fully engaged The bimetallic plate flexes out wards due to the temperature increase in the ambient air For function check see Viscous Fan Checking page 68 T2007219 Fig 19 Control valve open 24 Group 2 Troubleshooting Cooling System Troubleshooting Coolant Temperature Too High Excessively high coolant temperature can be due to e Blocked radiator low airflow e Blocked cooling system e Contaminated coolant e Low coolant level e Broken fan belt e Faulty temperature gauge e Poor grounding between engine and chassis e Faulty thermostat
39. lve opens At this pressure the air flow should be continuous End this test af ter approximately 10 seconds 5 Slowly release the pressure from the cooling system Remove the cap as sembly and replace the fill cap 43 Group 2 Service Procedures Removal 3 Remove the elbow outlet from the tur 1 bocharger W2003328 Fig 63 Removing coolant pipes W2003324 Remove the pipe between the coolant Fig 61 Draining the coolant pump and the cover over the oil cooler Attach hose 9996049 to lower coolant 9996049 pipe and drain the coolant into a suit 5 able container Remove the pipe between the pump and the thermostat housing Note If the coolant is not reusable dispose of used coolant in a proper and responsible manner according to EPA and local environmental regula tions ES LAA M W2003334 Fig 62 Charge air cooler piping Remove charge air cooler pipe and mounting brackets 44 Group 2 Fig 64 Bolt location Remove the bolt beside the thermostat housing holding the pipe between coolant pump and the expansion tank 7 Remove the bolt from the coolant pump and pull the pipe out of the pump Note The bolt beside the thermostat housing runs through a bracket on the pipe With the air compressor in posi tion the pipe cannot be removed Service Procedures 12007246 Fig 65 Heater hose location W2003329 Remove the heater hose from the
40. models use tool 9996049 to drain radiator or engine W2002060 Fig 28 Disconnect wires hoses for coolant sensor Disconnect the hoses to the radiator 10 mm socket and the charge air cooler assembly 7 mm socket e Top radiator hose e Bottom radiator hose e Fill hose from the water pump to the expansion tank e Top charge air cooler hose e Bottom charge air cooler hose e Wires for the low coolant sensor 31 Group 2 Service Procedures W2002065 Fig 29 Remove radiator mounts Remove the four bolts fastening the 13 mm socket lower radiator mounts W2002075 Fig 31 Remove head screws 5 Remove the two torx head screws fas 125 torx bit tening the side shroud to the radiator 7 W2002066 Fig 32 Remove radiator fastener Remove the one bolt that fastens the 12 mm wrench air conditioning lines to the radiator GEN Fig 30 Remove bolts for support bracket Remove the two upper bolts that fas 12 mm wrench ten the air conditioning condenser 12 mm socket upper support bracket to the charge 13 mm wrench air cooler assembly Note These bolts also mount the up per CAC to the radiator Remove the lower two bolts that fasten the condenser itself to its lower sup port brackets 32 Group 2 SY LESY Sa Le W2002071 Fig 33 Lift out the condenser Lift out the condenser raise across the top of the radiator and let rest on top of the engine valve cover EA Es GU pr A
41. n result in unexpected vehicle movement and can cause serious personal in jury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Never remove the cap on the expansion tank while the engine is still hot Wait until the coolant tempera ture is below 50 C 120 F Scalding steam and fluid under pressure may escape and cause serious per sonal injuries Do not work near the fan with the engine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be seri ously injured Before turning on the ignition be sure that no one is near the fan Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids Special tools 9996049 9998619 9998511 Other special a 945408 946173 949873 95589 1 Drain off the coolant with drain hose 9996049 9996049 Service Procedures 2 Remove the two bolts for the exhaust collector pipe located next to the ther mostat housing 3 Remove the thermostat housing from the engine 4 Remove piston thermostat from the cylinder head W2003428 Fig 105 Remove the sealing ring Remove the sealing ring from the cylinder head tapping the sealing ring with a drift so that it is lifted up and can be removed 6 Clean all
42. n the expansion tank The cooling system will vent itself automatically 10 Place shift lever in neutral and apply parking brake 11 After running the engine warm and then allowing it to cool check the coolant level again Feedback One of our objectives is that workshop personnel should have access to correct and appropriate service manuals where it concerns fault tracing repairs and maintenance of Volvo trucks In order to maintain the high standards of our literature your opinions and experience when using this manual would be greatly appreciated If you have any comments or suggestions make a copy of this page write down your comments and send them to us either via telefax or mailing directly to the address listed below To From Volvo Trucks North America INC 0 ccccccccnnnnnnnnnnnnnnnnnnnnnnnnnnnnr nn nn rn n nr nnnnnnnnnns Dept 516 Service Publications eeeeteetetteteteeteaeeteeeteaeeeeeeeeaeeteaeeseaeeeeeseneeeneeeenes 7825 National Service Road o cnc PO Box 26115 00 aida ctlicedesseeh Panes Greensboro NC 27402 6115 0 iaeeeettteceeeeececsscneeeececccnaaeeeeeceesceceaeeeeeseesnaaeeeeeeeess USA Fax 336 393 3170 Comments proposals 2611 03 02 01 2611 06 02 01 2611 11 04 01 2612 03 02 01 2619 06 02 01 2619 09 02 01 2621 03 02 01 2621 04 04 01 2627 03 02 01 2627 06 05 01 2631 03 02 01 2631 06 02 01 2634 03 02 01 2634 03 02 04 2634 04 02 01 2651 03 04 01 2651 11 02 01 3821 06 02 01 Operati
43. nsion tank while the engine is still hot Wait until the coolant tempera ture is below 50 C 120 F Scalding steam and fluid under pressure may escape and cause serious per sonal injuries Do not work near the fan with the engine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be seri ously injured Before turning on the ignition be sure that no one is near the fan Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids Service Procedures If you see or suspect that the cell packages of the charge air cooler or radiator cell packages are dirty these components should be cleaned Depending on the installation it may be necessary to completely remove the components from the vehicle see Radiator Re placement page 29 Note Regardless of cleaning method extreme cau tion should be observed so as not to damage the radiator fins External Cleaning 1 Separate the radiator and the charge air cooler if they have been removed from the vehicle as a single unit This ensures proper cleaning of each com ponent 2 Cover the inlet and outlet pipes to pre vent degreasing agents or dirt to enter 3 Clean the radiator with compressed air if it is clogged with dust Note Air pressure should not exceed 210 kPa 30 psi for the radiator and should not exceed 170 kPa 25 psi for the conden
44. nsists of a quick connect valve 1 covered with a rubber cap see Fig 13 Quick connect drain valve in bottom of radiator page 20 In this case use tool 9996049 for draining This is a quick connect hose needed for draining Coolant Pump The coolant pump is mounted to the timing gear plate and is driven by the timing gears The coolant pump in cludes a one piece carbon ceramic seal and a double ball bearing for the pump shaft The pump is equipped with a shut off valve 1 which prevents coolant from draining out when changing the coolant filter see Fig 14 Coolant pump page 20 To close the valve the han dle is turned to the horizontal position Note The shut off valve must always be in the open po sition That is the handle should point vertically except when replacing the lines 20 Design and Function W2003367 Fig 13 Quick connect drain valve in bottom of radiator Ly W2003282 Fig 14 Coolant pump Group 2 Coolant Filter A coolant filter is mounted to the coolant pump On D12 engines and an adapter is mounted to the pump with lines to a remote mounted coolant filter situated on the right side of the engine Coolant filters used with standard coolant include an anti corrosive agent SCA Supplemental Coolant Additive which is added to the standard coolant during filtration Coolant filters used with Extended Life Co
45. o NC USA Order number PV776 TSP142854 O 2000 Volvo Trucks North America Inc Greensboro NC USA All rights reserved No part of this publication may be reproduced stored in retrieval system or transmitted in any forms by any means electronic me chanical photocopying recording or otherwise without the prior written permission of Volvo Trucks North America Inc Contents center EE 3 ROESER 5 opera TOO ee 5 special EU A 9 Design and Funcion scr Eeer 11 Coding SIR q RI RR ERRADA E 11 pio es cd Tiro PR AR RD RENO ia 11 Cooling Systemi FION nasa dean ppa Ab a 12 RR GE 14 Thermostat AUS rada 15 E EE 15 HAS iia 16 A A AAA 16 Ce E 16 Cota NES a T7 Expansion TANK ra 19 Een PAME benennen 20 COLA PUII aa 20 A prai 21 PANETONE as 22 SEA a 23 COME DEVICE macia 24 TROUBIESNOO LINA aia a 25 Cooling System Troubleshooting aiii 25 e KEN 27 Fan DISSNGADEO coran 27 Fan ENRICO alii 27 Sorico EE suspira 29 Radiator Replacement is iia 29 O ea 30 al o E 34 Radiator LASER a 38 Radiator Surge Tank Replacement cesceceeesesnereeneeeseeersenerseees 38 Cooling System Leak Test CHECKING seseesnmminsersiotensierstelivessinisieisto 41 Coolant Pump Replacement asrncinnarin iaa 43 codant Pump Overhaul ia 48 UR Ge EE 48 Thermostat REPIACOMEN crias 55 EN E EE eee ene ee eer E ee Sere reer A ae 55 Thermostat Feieren au aa 59 E e PO ncn eon ees 59 wen da 61 VISCDUS Fan Replacomeni ai 61 Fan Belt Tensioner Replacem
46. olant ELC are blanks and do not contain any SCA Note The valve must always be in the open position i e the handle should point vertically except when changing the filter For more detailed information on coolants refer to TSI 184 001 Coolant Requirements Volvo Engines IMPACT Function Group 184 Information Type Service and Mainte nance Coolant Requirements Design and Function 21 Group 2 Winterfront Volvo Trucks North America Inc does not recommend the use of winterfronts shutters or any other shield in front of the grille or radiator package under normal cir cumstances These devices if not used properly can cause higher exhaust temperatures power loss exces sive fan usage and a reduction in fuel economy Today s electronically controlled engines are designed to operate in temperatures without a winterfront Volvo Trucks North America Inc does not recommend the use of a winterfront while the vehicle is being driven If a win terfront is used it must conform to these specifications Note Please see your local Volvo Truck Dealer for Volvo recommended winterfronts If there is engine or related damage that can be followed back to an improperly used winterfront the warranty is no longer valid for those parts VHD Failure to remove the winterfront when tempera tures go above 15 F 25 C could cause severe damage to engine charge air cooler and or loss of fuel economy The grill
47. on Numbers Radiator Replacement 29 Radiator Checking saeu a a eb A eee ER AA a 38 Radiator Cleaning 73 Radiator Surge Tank Replacement 38 Cooling System Leak Test Checking 2 e 41 Cooling System Servicing 00052 2 eee ee 77 Coolant Pump Replacement 43 Coolant Pump Overhaul e 48 Thermostat Replacement o 55 59 Thermostat Checking e 61 Viscous Fan Replacement 2 00005 eee eee 61 Viscous Fan Checking 68 Fan Belt Tensioner Replacement 2 2 285 63 Cooling Fan Drive Belt Replacement 2 0 65 Fan Belt Tensioner Overhaul 2 2 o 65 Charge Air Cooler Replacement 2 22 20222005 69 Charge Air Cooler Cleaning e 74 Coolant Temperature Gauge Checking 220 72 VOLVO Volvo Trucks North America Inc P O Box 26115 Greensboro NC 27402 6115 Volvo Trucks Canada Ltd 6490 Vipond Drive Mississauga Ontario L5T 1W8 http Avww volvotrucks volvo com PV776 TSP142854 1000 8 2000 O Volvo Trucks North America Inc 2000
48. r line clamps and the A C condenser mount ing bolts the condenser can be laid aside Note All A C lines on the VN VHD are locted on the left side of the cooling package When removing the A C con densor line clamps make sure not to lossen the A C lines 6 Remove the clamps from the charge air cooler hoses on both sides Re move the left side radiator shield 75 Group 2 7 Remove the charge air cooler W2000462 Fig 142 Direction of air pressure Clean dirt and debris from the cores by using air pressure This should be done from the backside of the core The use of a radiator fin comb will also loosen dirt and debris fron the fins Note The air pressure should not ex ceed 30 psi 210kPa for charge air cooler core Note The air pressure should not exceed 25 psi 170 kPa for the con denser 9 Hard to remove gummed up dirt can be removed by using Calgon cleaners CALCLEAN either in regular or heavy duty strengths These cleaners can be sprayed on the cores using a hand pump sprayer rinsed off and will not harm the core materials 10 Reassemble the charge air cooler and condenser Remember to install the isolators and teflon pads on the charge air cooler 76 Service Procedures 11 Install the radiator recirculation shields on the top bottom and both sides of the radiator These shields will help reduce the contaminations that get be tween the components Note VN NVHD model tr
49. rating temperature Then run at 1800 rom and check for leaks Group 2 2627 06 05 01 Thermostat Checking Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids A function check must be carried out before in stalling a new thermostat Note Check to be sure that the thermostat closes fully This can be done by holding it up to the light to check that there is no visible gap at the opening point If the thermostat does not close properly replace it 1 12007256 Fig 109 Checking the thermostat Warm up water in a receptacle to 75 C 167 F and immerse the thermo stat in the water as illustrated Use a piece of wire attached to the thermostat 2 After at least 30 seconds check that the thermostat is still closed Service Procedures 12007255 Fig 110 Checking the thermostat Now warm the water to 100 C 212 F After at least 30 seconds at boiling point check that the thermostat has opened at least 7 mm 9 32 in If the thermostat has not opened it must be replaced A good thermostat starts to close at 95 C 203 F and is fully closed at approximately 85 C 185 F 2631 03 02 01 Viscous Fan Replacement AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle mo
50. s W0001750 9996626 Hollow Drift for Overhauling Coolant Pump W0001751 9996662 Pressure Gauge W0001766 9996671 Filter Wrench for Coolant Filter Group 2 9996883 9996884 9998012 9998039 W0001754 Adapter for Overhauling Coolant Pump CS W0001755 Drift for Overhauling Coolant Pump ER Hollow Drift for Overhauling Coolant Pump GA NNN S ES W0001757 Drift for Overhauling Coolant Pump Tools oi RINE KY SORA AI d o RQ RSS LO Oo d KLX gt W0001761 9998113 Drift for Overhauling Coolant Pump W0001764 9998244 Sleeve for Overhauling Coolant Pump W0001760 9998291 Drift for Installing Thermostat Seal ing Ring on the D12 A amp B engine W0001802 9998511 Drift for Installing Thermostat Seal ing Ring on the D12 A amp B engine Group 2 WO0001765 9998541 Tool for Pressing Impeller onto Coolant Pump Shaft L I W0001806 9998619 Drift for Installing Thermostat Seal ing Ring on the D12C engine C0000353 J 42397 A Expansion Tank Cap VHD J 44392 Belt Tensioner Release Tool Kent Moore J 44772 W0001929 Thermostat Housing Install Tool Tools W2003340 Group 2 Tools Special Equipment Like the special tools the following are also available from the Parts Department of Volvo Trucks North America Inc Please specify the complete part number when ordering 115 9794 998 5011 9
51. s can cause burns or can permanently damage test equipment Remove the expansion tank hose and the connector for the temperature sen sor from the thermostat housing Remove the fan ring stay bolt holding the upper radiator cooling pipe T2007264 Fig 93 Removing hoses from thermostat housing Never remove the cap on the expansion tank while the engine is still hot Wait until the coolant tempera ture is below 50 C 120 F Scalding steam and fluid under pressure may escape and cause serious per 5 sonal injuries Remove the bolt from the thermostat housing and timing gear cover which hold the pipe to the cab heat ex changer AP WARNING Do not work near the fan with the engine running The 6 engine fan can engage at any time without warning Loosen the cooling coil nut from the Anyone near the fan when it turns on could be seri air compressor Remove the bolt hold ously injured Before turning on the ignition be sure ing the cooling coil bracket to the that no one is near the fan timing gear cover and push the coil to one side N WARNING Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids Special tools 9996049 9998291 1 Using drain hose 9996049 drain the coolant into suitable container 2 Remove the pipe between the air cleaner housing and the turbo compressor 55 Group 2 12007234 Fig 94 Removing the
52. ser 4 When rinsing start with the back of the radiator and then turn it around and rinse from the front Use hot water and make sure that the cells get clean 5 Gummed up dirt can be removed by using CALCLEAN cleaners either in regular or heavy duty strength These cleaners can be sprayed on the cores using a hand pump sprayer and rinsed off They will not harm the core materi als 6 In case a degreasing agent is used be sure to thoroughly clean plastic and rubber parts if these get covered with degreasing agent 73 Group 2 Service Procedures 7 2651 11 02 01 Charge Air Cooler Cleaning AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death HOT ENGINE Keep yourself and your test equipment A high pressure car wash with a max clear of all moving parts or hot engine parts and or working pressure of 100 120 bar fluids A hot engine and or fluids can cause burns or 1450 1750 psi may be used but can permanently damage test equipment with extreme caution Make sure that the nozzle is held perpendicular to cell package at all times and that it is moved from side to side The nozzle AP WARNING should always be positioned at a dis tance of 8 12 inches from the cell Never remove the cap on the expansion tank while package the engine is s
53. t Service Procedures W2002125 Fig 134 Install mounting bolts Position the charge air cooler onto the 13 mm socket radiator Install the four mounting bolts 12 mm wrench leaving the upper two hand tight 24 4Nm Torque the lower bolts to 24 4 Nm 18 3 ft lb 18 3 ft lb W2002062 Fig 135 Install expansion tank bolts Position the expansion tank into place 12mm socket and install the five mounting bolts 24 4 Nm Torque to 24 4 Nm 18 3 ft lb 18 3 ft lb 71 Group 2 W2002102 Fig 136 Install support brackets Position the air conditioning condenser 12 mm socket mounting brackets Install the four mounting bolts hand tight 3821 06 02 01 Coolant Temperature Gauge Checking AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment 72 Service Procedures
54. t pump page 49 2671 72007118 Fig 78 Removing the shaft Assemble the hydraulic cylinder and 9996883 the adapter Using hydraulic pump 9996222 9996222 press out the shaft 1 the 9992671 impeller 8 and the seal 7 see Fig 76 Exploded view of coolant pump page 49 49 Group 2 W2003285 Fig 79 Coolant seal removal If parts of the coolant seal do not 9994090 come out with the shaft when pressing this out use puller 9994090 to remove the rest of the sealing ring 12007108 Fig 80 Removing the oil sealing ring Remove the seal 6 using tool 9994090 9994090 see Fig 76 Exploded view of coolant pump page 49 50 Service Procedures T2007109 Fig 81 Removing shaft sleeve drive gear and bearing Place the pump housing in a press 9994034 Using 9994034 carefully press out the shaft sleeve 2 together with the drive gear 4 and bearing 3 see Fig 76 Exploded view of coolant pump page 49 Group 2 72007248 Fig 82 Removing the shaft sleeve from drive gear Using 9992071 and 9996383 press 9992071 the shaft sleeve 2 out of the drive 9996383 gear 4 see Fig 76 Exploded view of coolant pump page 49 Service Procedures Cleaning and Inspection Fig 83 Exploded view of coolant pump 1 Clean all parts which are to be reused 2 The seals and bearing must always be changed Check the fit of the bearing races to the pump housing and shaft sleeve
55. t ten sioner to loosen and remove the belt N WARNING 3 Install the new belt making sure that it Always wear appropriate eye protection to prevent the runs properly in the pulley grooves risk of eye injury due to contact with engine debris or fluids 65 Group 2 Removal 1 72008291 Fig 119 Remove belt tensioner Use a 1 2 in drive ratchet to move the 1 2 in drive belt tensioner to a position that will al ratchet low the fan belt to be removed from its pulleys Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids 12008345 Fig 120 Remove protective cap Remove the protective cap from the belt tensioner Remove the bolt and lift off the belt tensioner from the timing cover Overhaul 3 Place the tensioner in a vice 66 Service Procedures 12008723 Fig 121 Remove protective cover Remove the protective cover from the pulley Make a hole in the protective cover with a screwdriver or punch and carefully pry the cover off the pulley Note Make sure you do not damage the pulley if it will be reused 12008724 Fig 122 Remove center bolt Remove the center bolt and lift off the pulley and bearing 72008725 Fig 123 Remove the belt tensioner Remove the belt tensioner from the 9994113 vice Place sleeve 9996626 under the 9996626 pulley and tap out the bearing using drift 9994113 7 Clean and inspec
56. t the parts 2413 6626 12008726 Fig 124 Sleeve placement in pulley Place sleeve 9996626 under the pulley 9992413 and press on the bearing using drift 9996626 9992413 Make sure that the bearing bottoms in the pulley Service Procedures 12008724 Fig 125 Install the pulley on the belt tensioner Install the pulley on the belt tensioner and tighten the center bolt Check that the pulley rotates easily 10 72008727 Fig 126 Install a new protective cover Install a new protective cover using 9996383 drift 9996383 and counter hold 9998404 9998404 Check that the pulley rotates easily Note It is important that the counter hold is used otherwise there is a risk that the bearing will not seat properly in the pulley 67 Group 2 Installation 11 72008346 Fig 127 Install the belt tensioner Install the belt tensioner make sure 24 4Nm that the mounting bolt on the tensioner 18 3 ft lb correctly enters the hole in the timing gear cover Torque the mounting bolt to 24 4 Nm 18 3 ft lb Install the protective cap 12 T2008291 Fig 128 Adjust the belt tensioner Use a 1 2 in drive ratchet to move the 1 2 in drive belt tensioner to a position that will al ratchet low the fan belt to be installed on its pulleys 13 Check the fan belt if cracks or chafing J 23600 B marks are present replace the fan belt Check that the belt is correctly positioned in th
57. temperature gauge Air Flow through Checking Should higher than normal coolant temperatures be ob served the passage of air through the charge air cooler A C condenser and radiator must always be checked and cleaned if necessary Any obstruction must be removed In cases of more serious blockage the radiator charge air cooler and A C condenser must be removed entirely and thoroughly cleaned especially if the pollutant is oil based If the fins of the radiator have been bent by flying stones etc straighten them with a fin comb Check that the rubber seals between the fan shroud and the radiator and in some cases between the radiator and the front shroud have not loosened or for any other reason are not providing a good seal Polluted Coolant If the coolant is polluted it could mean that there is an in ternal leak oil or that the cooling system is clogged deposits Check for leaks A clogged system is usually a result of not changing the coolant according to the specific change intervals or us ing the wrong mixture of coolant and water or that polluted water has been used 26 Troubleshooting Group 2 Speed Check AN DANGER Coolant is toxic risk of poisoning Do not drink coolant Use proper hand protection when handling Keep coolant out of reach of children and animals Failure to follow these precautions can cause serious illness or death AN DANGER Keep your hand clothing and the measuring
58. the sealing surfaces and pipe connections 59 Group 2 7 9998619 1 de NE W2003427 Fig 106 Checking that the sealing ring is correctly posi tioned Place a new sealing ring on drift 9998619 9998619 Note The ring should be turned with the wide plate edge facing the shoul der of the drift 8 Install the thermostat housing and tighten the bolts by hand o W2003482 Fig 107 Thermostat housing remove tool Press drift J 44472 into the cylinder head until the drift reaches the bottom of the cylinder head J 44772 10 Install the new piston thermostat Lubricate the seal on the piston ther mostat with soapy water 60 Service Procedures 11 Install the thermostat housing and tighten the bolts by hand Note Make sure that the gasket to the cylinder head is correctly positioned Use a new gasket BPE Fig 108 Tighten the thermostat housing bolts in the se quence shown W2003539 Tighten the thermostat housing s bolts in the sequence shown in the illustra tion 1 2 3 Tighten to a torque as per the specifications for standard bolts Note Remember to remove the ten sioning bolt M8x20 13 Install the bolts between the exhaust manifold and the thermostat housing until they push against the seal Tighten to the specified torque 14 Connect the remaining coolant line 15 Fill with approved coolant 16 Start the engine Run the engine until it is at ope
59. till hot Wait until the coolant tempera ture is below 50 C 120 F Scalding steam and fluid under pressure may escape and cause serious per sonal injuries 8 Do not work near the fan with the engine running The Rinse the radiator starting with the engine fan can engage at any time without warning back and then turn it around and rinse Anyone near the fan when it turns on could be seri from the front ously injured Before turning on the ignition be sure that no one is near the fan W2003373 Fig 137 Correct positioning of high pressure car wash Note Using a high pressure car wash will necessitate the removal of the radiator s from the vehicle in order to correctly clean the radiator without the risk of damaging the fins with the high pressure Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids 1 Remove the grille 2 Tilt the hood Support the hood to al low removal of the safety cables 74 Service Procedures W2000460 Fig 138 Loosening charge air cooler clamps Loosen the charge air cooler clamps on the side of the charge air cooler W2000461 Fig 139 Unfasten A C lines Unfasten the A C lines from the right side of the radiator W2003523 Fig 140 Removing A C condenser mounting bolts on VN model W2003524 Fig 141 Removing A C condenser mounting bolts on VHD model After removing the A C condense
60. ucks are equipped with air deflectors mounted on the sides of the radiator Group 2 System Check System Check 2619 09 02 01 Cooling System Servicing Flush includes draining and re filling coolant AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death AN DANGER Coolant is toxic risk of poisoning Do not drink coolant Use proper hand protection when handling Keep coolant out of reach of children and animals Failure to follow these precautions can cause serious illness or death Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids Note Should the cooling system have substantial rust and sludge deposits the following cleaning method is recommended Draining and Flushing 1 W2000751 Draining the coolant Drain the cooling system into suitable container Open all drain points In ad dition remove the expansion tank cap before draining the system Draining points e Radiator e Cylinder block e Oil cooler transmission when installed e Water pump remove water filter and leave drain valve open 2 Drain the cooling and heating systems and flush them with a good commer cial cooling system cleaner flush Follow the instructions provided on t
61. vement and can cause serious personal in jury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Never remove the cap on the expansion tank while the engine is still hot Wait until the coolant tempera ture is below 50 C 120 F Scalding steam and fluid under pressure may escape and cause serious per sonal injuries Group 2 Do not work near the fan with the engine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be seri ously injured Before turning on the ignition be sure that no one is near the fan Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids Includes removal and installation of fan blade Note Before replacing the fan carry out a function check See Viscous Fan Checking page 68 Removal SZ ISA A A Ly 12007261 Fig 111 Proper storage of fan The temperature controlled fan is filled with a precise amount of silicone fluid this determines its functional properties When out of the vehicle the temperature controlled fan must always be stood vertically If placed horizontally leakage will occur and the fan will lose its properties Before replacing a fan always make sure t
62. warm and run the engine an additional 10 minutes 14 Shut off engine and re check coolant level Note To pressure test the system see Cooling System Leak Test Checking page 41 37 Group 2 2611 06 02 01 Radiator Checking AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Never remove the cap on the expansion tank while the engine is still hot Wait until the coolant tempera ture is below 50 C 120 F Scalding steam and fluid under pressure may escape and cause serious per sonal injuries Do not work near the fan with the engine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be seri ously injured Before turning on the ignition be sure that no one is near the fan Always wear eye protection when working around bat teries to prevent the risk of injury due to contact with sulfuric acid or an explosion Checking CAC and Radiator Air Flow Through 1 If coolant temperatures are higher than normal check the passage of air through the charge air cooler A C condens

Cooling System - Groups 00

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