Aftertreatment Fuel Injector (AFI) Air Purge System, Kit Installation

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1 Volvo Trucks North America Greensboro, NC USA This service bulletin replaces bulletin (PV ), dated DService Bulletin Trucks Date Group No. Page (13) AFI Air Purge System Kit Installation D13F Aftertreatment Fuel Injector (AFI) Air Purge System, Kit Installation This information covers installation of the aftertreatment fuel injector air purge kit (part number ) on a vehicle equipped with a Volvo D13F engine. For VHD and VNM vehicles only, it is also necessary to order heat shield kit Contents Aftertreatment Fuel Injector Air Purge Kit, New Installation page 2 Note: Information is subject to change without notice. Illustrations are used for reference only, and may differ slightly from the actual engine version. However, key components addressed in this information are represented as accurately as possible. PV USA34627.ihval

2 Service Procedures Service Bulletin (13) Aftertreatment Fuel Injector Air Purge Kit, New Installation You must read and understand the precautions and guidelines in Service Information, group 20, "General Safety Practices, Engine" before performing this procedure. If you are not properly trained and certified in this procedure, ask your supervisor for training before you perform it. Installation 1 Apply the parking brake and place the shift lever in neutral. 2 Remove all cables from ground (negative) battery terminals to prevent personal injury from electrical shock. W

3 Service Bulletin (13) 3 W Use the coolant extractor to remove the coolant from the engine. An alternate method is to drain the coolant into a suitable container using the drain hose. 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. DBT2V700, C Remove the air filter housing and fresh air pipe. 5 Remove inner splash guard as an assembly. Note: Some models may be equipped with fender extenders, attached to the inner splash guard. Remove these as an assembly. 6 Drain the air system. 7 Remove the passenger seat from the cab. 8 Remove the engine cover from the cab.

Service Bulletin 3.2009 258 33 4(13) 9 Disconnect the coolant hard pipe at the rear of the engine at the coupler.

4 Service Bulletin (13) 9 Disconnect the coolant hard pipe at the rear of the engine at the coupler. 10 Disconnect any sensors, cable ties, P-clamps or harness bolts blocking access to the hot side fuel line. 11 Disconnect the aftertreatment injector fuel supply line. Collect any residual fuel that may be in the fuel line in a suitable container. W Remove the hot side fuel line from the engine. 13 On some D13F engines, it may be necessary to remove the cold side fuel line. 14 Remove and discard the aftertreatment fuel injector mounting bolts and spacers. Remove the injector from the diffuser pipe (which attaches to the turbocharger outlet). Note: The coolant lines and coolant do not need to be removed for AFI cleaning. 15 Cover the hole in the diffuser pipe to prevent dirt and cleaning solution from entering the exhaust system. 16 Remove and discard the high-temperature gasket and steel plate gasket from the bottom of the injector.

17 Service Bulletin 3.2009 258 33 5(13) Turn the AFI body to allow the injector tip to be sprayed with carburetor cleaning solution. Brush the injector tip with a stiff bristled nylon "tooth" brush.

Other cleaners, such as brake cleaner products, do not work and may contain chlorine, which could damage the catalyst if they enter the exhaust system.

5 17 Service Bulletin (13) Turn the AFI body to allow the injector tip to be sprayed with carburetor cleaning solution. Brush the injector tip with a stiff bristled nylon "tooth" brush. Repeat two or three times. CAUTION Only high quality carburetor cleaner should be used to clean the injector. Other cleaners, such as brake cleaner products, do not work and may contain chlorine, which could damage the catalyst if they enter the exhaust system. CAUTION Only use a nylon brush to clean the injector tip. Do not use a brass or steel brush. Damage to the injector tip may result. W Inspect the injector tip. Use a mirror if a clear view of the tip is not possible. W Position the injector onto the diffuser pipe (which attaches to the turbocharger outlet) and hand start the bolts.

6 Service Bulletin (13) 20 Using the flow test tool (tool number ) and Tech Tool, test the AFI flow as follows: A. In Guided Diagnostics, go to the Symptoms tab and select "Exhaust Aftertreatment/Service regeneration failure." B. Under the Fault Code and Symptom Analysis tab, select "Exhaust Aftertreatment, Symptom diagnostics." C. Under the Diagnostic Analysis tab, select "Service regeneration failure." D. Under the Diagnostic tab, select "Aftertreatment fuel system check." E. Select "Aftertreatment Fuel Injector check." F. Select "Aftertreatment Fuel Injector Flow check." CAUTION If the Aftertreatment Fuel Injector does not pass the Aftertreatment Fuel Injector Flow check, replace the AFI with a new AFI. 21 Loosen the bolts and remove the injector from the diffuser pipe. Install a new high-temperature gasket and steel plate gasket onto the bottom of the aftertreatment fuel injector. 22 Apply high-temperature nickel-graphite anti-seize compound to the new injector mounting bolt threads and insert the bolts into the spacers. Position the injector onto the diffuser pipe (which attaches to the turbocharger outlet) and hand start the bolts with spacers. 23 Secure the injector mounting bolts. Tighten the bolts to 14 ± 0.5 Nm (125 ± 4.5 in-lb). 14 ± 0.5 Nm (125 ± 4.5 in-lb) 24 On some D13F engines, it may be necessary to install a new cold side fuel line (part number ). Use P-clamps to secure the fuel line. 25 Install the one-way check valve (part number ) on the air line hard pipe (part number ). 26 Position the air line hard pipe on the engine. 27 Position the new fuel line (part number ) on the engine.

Service Bulletin 3.2009 258 33 7(13) 28 Install the two-way check valve (part number 21226456) on the AFI.

Kinking the lines may result in leakage.

7 Service Bulletin (13) 28 Install the two-way check valve (part number ) on the AFI. 29 Connect the fuel line and air line to the two-way check valve. Hand-tighten the fittings. CAUTION Do not kink the fuel and coolant lines. Kinking the lines may result in leakage. 1 Air Line 2 Fuel Line 3 Coolant Line W Install the air line mounting brackets, P-clamps, screws and nuts to secure the air line. W Bracket and Screw ; P-Clamp , Screw and Nut P-Clamp Bracket and Screw ; P-Clamp , Screw and Nut Air Line Hard Pipe

8 Service Bulletin (13) 31 Use cable ties to secure the air line at the rear of the cylinder head. 32 Install the fuel line mounting bracket, P-clamps. screws and nuts to secure the fuel line. 1 P-Clamp P-Clamp and Nut Bracket , P-Clamp and Screw P-Clamp and Screw Fuel Line Hard Pipe W Connect the fuel line hard pipe to the flexible fuel supply line. 34 Connect any sensors, cable ties, P-clamps or harness bolts removed. 35 Replace the sealing ring on the coolant hard pipe. Connect the hard pipe at the rear of the engine. 36 CAUTION It is mandatory to use a coalescing air dryer filter with the AFI air purge system. If a coalescing filter is not used, damage to components can result. If the air dryer filter is not the coalescing type filter, remove the air dryer filter and install a new coalescing filter.

9 Service Bulletin (13) 37 Install the in-line air filter (part number ) and two 90 swivel fittings (part number ) in the air pressure regulator (part number ). 38 Mount the air pressure regulator to the regulator mounting bracket (part number ). 39 Install the air regulator on the air dryer mounting bracket. Air Lines at Pressure Regulator and Tee Fitting 1. Supply Fitting 2. Delivery Fitting W Cut the discharge recirculation valve air supply line at the frame mounted manifold and install the tee fitting (part number ). 41 Connect flexible air line (part number ) to the tee fitting and the air regulator supply fitting.

10 42 Service Bulletin (13) Connect flexible air line (part number ) to the air regulator delivery fitting and the air line hard pipe on the engine. Chassis Line to Engine Line Connection W Secure the flexible air lines with cable ties. 44 Tighten the two-way check valve on the AFI to specification. Tighten the air and fuel line fittings to specification. Two-way check valve: 15 Nm (135 in-lb), Fuel line: 15 Nm (135 in-lb), Air line: 27 Nm (235 in-lb)

11 45 Service Bulletin (13) For VHD and VNM models only, use two screws to assemble the two heat shields (part numbers and ). Use five nuts to install the heat shields to the underside of the cab floor panel. A. Arrow indicates front of vehicle 1. Bulkhead 2. Cab Floor Panel W Install the air filter housing and fresh air pipe. 47 Fill the cooling system with the recommended coolant using the coolant extractor. DBT2V700 W

12 48 Service Bulletin (13) Install all previously removed cables to the ground (negative) battery terminals. W Start the engine and build air pressure to operating pressure. Check the air and fuel systems for leaks and proper operation. 50 Install the engine cover. 51 Install the passenger seat in the cab. 52 Install the inner splash guard assembly. 53 Use VCADS/Tech Tool to upload the software accessory kit for the AFI upgrade (part number ). Then perform MID128 EECU reprogramming. Note: There is no charge for the EECU download if the accessory kit is uploaded before the MID128 EECU reprogramming. 54 Use VCADS/Tech Tool to reset AFI adaptive factor and clear all codes. 55 To verify proper function of the air purge system, use VCADS/Tech Tool to perform a partial service regeneration. During the service regeneration, monitor the Inlet Temperature and Aftertreatment Catalyst Temperature (using the Diesel Particulate Filter Regeneration operation). When the temperatures reach approximately 260 C (500 F), stop the service regeneration.

13 56 Service Bulletin (13) When the DPF reaches the proper temperature (260 [500 F]), the Aftertreatment Injector Status should indicate 100% duty cycle, and the status should say "Air-Purging." C 57 For additional information concerning the system, or if the system does not seem to be functioning properly, refer to Guided Diagnostics. This information can be accessed in the following manner: A. In Guided Diagnostics, go to the Symptoms tab and select "Exhaust Aftertreatment/Service regeneration failure." B. Under the Fault Code and Symptom Analysis tab, select "Exhaust Aftertreatment, Symptom diagnostics. C. Under the Diagnostic Analysis tab, select "Service regeneration failure." D. Under the Diagnostic tab, select "Aftertreatment fuel system check." E. If asked whether or not the vehicle is equipped with AFI air purge system, Enable AHI air purge, select "Yes." F. Select "Aftertreatment Air Purge System Check." G. Select "AFI Air Purge System, Function check" to test the system. 58 After shutdown, replenish fluids as necessary.

This information covers the proper replacement procedure for the EGR valve on the Volvo D16F engine.

Volvo Trucks North America Greensboro, NC USA EGR Valve, Replacement DService Bulletin Trucks Date Group No. Page 11.2006 254 24 1(17) EGR Valve Replacement D16F W2005772 This information covers the proper