Volvo Trucks North America Greensboro, NC USA This service bulletin replaces bulletin 258 33 (PV776 20189612), dated 2.2009. DService Bulletin Trucks Date Group No. Page 3.2009 258 33 1(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 85116274) on a vehicle equipped with a Volvo D13F engine. For VHD and VNM vehicles only, it is also necessary to order heat shield kit 85116296. 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. PV776-88911752 USA34627.ihval
Service Procedures Service Bulletin 3.2009 258 33 2(13) 2589-02-02-01 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. W2003815
Service Bulletin 3.2009 258 33 3(13) 3 W2004191 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, 9996049 C2000268 4 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. 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. W2005656 12 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. 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. W2006496 18 Inspect the injector tip. Use a mirror if a clear view of the tip is not possible. W2006436 19 Position the injector onto the diffuser pipe (which attaches to the turbocharger outlet) and hand start the bolts.
Service Bulletin 3.2009 258 33 6(13) 20 Using the flow test tool (tool number 88890112) 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 21014980). Use P-clamps to secure the fuel line. 25 Install the one-way check valve (part number 21249090) on the air line hard pipe (part number 21242682). 26 Position the air line hard pipe on the engine. 27 Position the new fuel line (part number 21284463) on the engine.
Service Bulletin 3.2009 258 33 7(13) 28 Install the two-way check valve (part number 21226456) 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 W2006759 30 Install the air line mounting brackets, P-clamps, screws and nuts to secure the air line. W2006797 1 Bracket 965571 and Screw 946471; P-Clamp 940374, Screw 946440 and Nut 945408 2 P-Clamp 940374 3 Bracket 965556 and Screw 946471; P-Clamp 940374, Screw 946440 and Nut 945408 4 Air Line Hard Pipe 21242682
Service Bulletin 3.2009 258 33 8(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 940374 2 P-Clamp 940374 and Nut 945408 3 Bracket 21053482, P-Clamp 940374 and Screw 946440 4 P-Clamp 940374 and Screw 946173 5 Fuel Line Hard Pipe 21284463 W2006762 33 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.
Service Bulletin 3.2009 258 33 9(13) 37 Install the in-line air filter (part number 21266886) and two 90 swivel fittings (part number 8397771) in the air pressure regulator (part number 21243502). 38 Mount the air pressure regulator to the regulator mounting bracket (part number 21250229). 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 W2006830 40 Cut the discharge recirculation valve air supply line at the frame mounted manifold and install the tee fitting (part number 8397804). 41 Connect flexible air line (part number 21269105) to the tee fitting and the air regulator supply fitting.
42 Service Bulletin 3.2009 258 33 10(13) Connect flexible air line (part number 21269105) to the air regulator delivery fitting and the air line hard pipe on the engine. Chassis Line to Engine Line Connection W2006831 43 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)
45 Service Bulletin 3.2009 258 33 11(13) For VHD and VNM models only, use two screws to assemble the two heat shields (part numbers 82238149 and 82238159). 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 W8003963 46 Install the air filter housing and fresh air pipe. 47 Fill the cooling system with the recommended coolant using the coolant extractor. DBT2V700 W2004191
48 Service Bulletin 3.2009 258 33 12(13) Install all previously removed cables to the ground (negative) battery terminals. W2003815 49 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 85115992). 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.
56 Service Bulletin 3.2009 258 33 13(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.