Impact PDF

IMPACT 4.07.
11 10/05/2019
Imprimido por:Manuel Silva
Servicio
ID de chasis Ruta
E 857123 2232/Repair//Oil cooler insert, replace
Modelo Identidad
FM (4) 136878518
Fecha de publicación ID/Operación

9/03/2016 22327-3
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
La información contenida aquí está actualizada en el momento de su distribución original pero puede ser cambiada. Se avisa al lector de que las copias impresas no son
controladas.
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IMPACT 4.07.11 10/05/2019
22327-3 Oil cooler insert, replace

Illustrations may differ slightly from the actual vehicle being serviced. However, key
components addressed in this information are represented as accurately as possible.
CAUTION
Risk of skin injury.
Grease, oil and chemical substances can cause skin and eye injuries. Oils and grease can cause
acne and eczema. A used lubricant is more harmful than an unused lubricant.
▶ Protective equipment such as gloves and eye protection must be used when working with
grease, oils and chemical substances.
CAUTION
Risk of material damage.
The turbocharger can be damaged if foreign particles enter the charge air system. Particles as small
as 1 mm can cause damage.
▶ Observe maximum cleanliness when working on the charge air system. Cover or plug openings
immediately.
Special tools
21181433 88800022 88800443 88840328 88890148
1 Loosen the hose clamp.(1).
2 Loosen the hose clamps (2).
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3 Remove the pipe.
4 Remove the clamp (A).
5 Move aside the exhaust pipe.
6 Remove the screw.
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7 Remove the pipe.
8 Remove the hose.
9 Remove the clamp.
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10 Remove the exhaust brake.
11 Remove the screws.

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12 Remove the pipes.
13 Remove the V-clamp.
15 Bend aside the charge air pipe.
Note
Blank off the holes.
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16 Remove the hose.
17 Remove the screw.
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19 Remove the pipe.
20 Remove the gasket.
Note
Blank off the holes.
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22 Remove the heat shield.
24 Remove the pipe.
25 Remove the seal.

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27 Remove the nuts and spacers.
28 Remove the turbocharger.
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30 Remove the screws and sleeves.
31 Remove the exhaust manifold.
32 Remove the gaskets.
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34 Remove the pipes.
35 Remove the seal.
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36 Remove the clamps.
37 Remove the hose.
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39 Remove the pipe.
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41 Remove the pipe.
42 Remove the seal.
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Note
There may be residual coolant in the engine.
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46 Remove the pipe.
47 Remove the pipe along with the cover.
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48 Remove the pipe.
49 Remove the seals.
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50 Remove the pipe.
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52 Remove the seal.
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55 Remove the cover.
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57 Remove the oil cooler.
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59 Carefully clean contact surfaces and surrounding engine components.
60 Install the seals.
Note
Use new parts.
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61 Install the oil cooler.
62 Install the screws.
63 Torque tighten the screws.
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Tightening torque
Oil cooler, screw 1. Tightening sequence: 1-2-3-4
5 ±1 Nm
2. Tightening sequence: 1-2-3-4-1
27 ±4 Nm
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Required material
TORQUE WRENCH 88890148
64 Install the cover.
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66 Clean the contact surfaces.
67 Install the seal.
Note
Use a new part.
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Note
Use new parts.
69 Lubricate the seals.
70 Install the pipe.
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Note
Use new parts.
72 Lubricate the seals.
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75 Install the gasket.
Note
Use a new part.
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76 Install the pipe along with the cover.
Note
Take care not to damage the gasket or the seals.
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78 Install the tool.
Required material
ASSEMBLY TOOL 88800022
79 Use the tool to press the assembly against the coolant pump seal.
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Note
Hand tighten the screws.
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Tightening torque
Cylinder block, cover, screw Tightening sequence: 1-27
24 ±4 Nm
Required material

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83 Remove the tool.
Note
Use new parts.
DANGER
Risk of material damage, serious personal injury or death.
Connections that are not tightened in accordance with specified tightening torques may cause
leakage.
▶ Tighten connections according to service information.
Tightening torque
Oil cooler, inlet pipe, screw 24 ±4 Nm
Required material
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Note
Use new parts.
DANGER
leakage.
Tightening torque
Oil cooler, outlet pipe, screw 24 ±4 Nm
Required material
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Note
Use a new part.
89 Lubricate the seal.
91 Install the screw.
Note
Always use a new screw with thread-lock.
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Note
Use a new part.
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96 Install the clamps along with the pipe.
97 Tighten the clamps.
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Note
Use a new seal.
102 Install the pipes.
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Note
Ensure that the threads of the cylinder block are cleaned.
104 Check the flanges between the manifold parts for exhaust leaks.
105 If an exhaust leakage can be found.
106 Replace the gasket kit ➠ Gasket kit, exhaust manifold, replace .
107 Apply a thin layer of assembly compound.
Note
Use a recommended assembly compound.
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108 Install the manifold.
109 Install the sleeves and screws.
Note
Tighten the screws until there is a gap corresponding to the thickness of the gaskets.
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110 Install the gaskets.
Note
Use new parts.
111 Align the gaskets.
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112 Install the sleeves and screws.
Note
Check that the sleeves locate on the machined surfaces of the manifold.
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Tightening torque
Exhaust manifold, screw 1. Tightening sequence: 1-12
10 Nm
2. Tightening sequence: 1-12
30 ±4 Nm
52 ±4 Nm
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Required material
Note
Use a new part.
116 Install the turbocharger.
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117 Install the spacers and nuts.
118 A special tool (extension bar/adapter) must be used for torque tightening due to the limited
space. Different sized nuts or screws are used so different tools with different spanner ring
sizes are required. Two lengths are also required.
Note
Ensure that the wrench and tool remain aligned during the tightening.
Note
The torque wrench setting given in the specifications must be adapted to suit the
increased length of the wrench and tool combination.
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119 The example shows a 450 mm (0.45 m) long torque wrench, two tools, B1, 185 mm and B2,
134 mm long, and a required assembly torque, T, of 48 +-8 Nm. The calculation based on
these examples gives torque settings, C, of 34 Nm for B1 and 37 Nm for B2. This lower setting
results in a tolerance of +- 6 Nm.
Note
Entering these and similar calculation results in the graph provides the settings for any
torque wrench between 250 and 700 mm long.
120 The C value can be calculated using the equation or read off in the graph.
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121 This step contains 3 alternatives.

Select one of the valid alternatives below.
Alternative 1 / 3
▶ Ensure that the tool is in the correct position.
Note
Risk for incorrect torque tightening if the tool is not in the correct position.
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▶ Torque tighten the nuts.
Tightening torque
Turbocharger, nut (when using the special tool) 1. Tightening sequence: 1-4
14 ±2 Nm
34 ±6 Nm
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Required material
KEY 21181433
Alternative 2 / 3
Note
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Tightening torque
14 ±2 Nm
37 ±6 Nm
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Required material
WRENCH 88840328
Alternative 3 / 3
Note
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controladas.
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Tightening torque
14 ±2 Nm
37 ±6 Nm
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Required material
WRENCH 88800443
123 Install the O-ring.
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Note
Use a new part.
124 Lubricate the O-ring.
Note
Use a recommended lubricant.
Note
Use a new part.
DANGER
leakage.
Tightening torque
Oil return pipe, screw 1. Screw 1
12 Nm
2. Screw 2
24 ±2.4 Nm
3. Screw 1
24 ±2.4 Nm
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Required material
129 Install the heat shield.
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131 Fill the turbocharger and hose with engine oil.
Note
Use recommended oil.
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Note
Use a new part.
DANGER
leakage.
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controladas.
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Tightening torque
Oil feed hose, screw 1. Tightening sequence: 1-2
10 ±2 Nm
60 ±5°
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Required material
135 Install the hose.
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137 Install the pipes.
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139 Apply assembly compound.
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140 Install the charge air pipe.
141 Install the clamp.
Required material
143 Apply assembly compound to the clamps.
Note
Use a recommended assembly paste.
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144 Install the exhaust brake.
145 Turn the exhaust brake to the correct position.
146 Install the clamp.
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147 Tighten the clamp.
Tightening torque
Turbocharger, clamp 12 ±2 Nm
Required material
148 Install the hose.
149 Torque tighten the nut.
Tightening torque
Pressure pipe, nut 24 ±5 Nm
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151 Torque tighten the nut.
Tightening torque
Pressure pipe, nut 24 ±5 Nm
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153 Install the exhaust pipe.
154 Install the clamp (A).
155 Tighten the clamp.
Tightening torque
Exhaust brake, clamp 20 ±4 Nm
Required material
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Note
Check that the heat shield is correctly located.
157 Tighten the clamps (2).
158 Tighten the clamp (1).
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IMPACT 4.07.

Imprimido por:Manuel Silva

Fecha de publicación ID/Operación

22327-3 Oil cooler insert, replace

21181433 88800022 88800443 88840328 88890148

1 Loosen the hose clamp.(1).

2 Loosen the hose clamps (2).

3 Remove the pipe.

4 Remove the clamp (A).

5 Move aside the exhaust pipe.

6 Remove the screw.

7 Remove the pipe.

8 Remove the hose.

9 Remove the clamp.

10 Remove the exhaust brake.

11 Remove the screws.

12 Remove the pipes.

13 Remove the V-clamp.

14 Remove the screws.

15 Bend aside the charge air pipe.

16 Remove the hose.

17 Remove the screw.

18 Remove the screws.

19 Remove the pipe.

20 Remove the gasket.

21 Remove the screws.

22 Remove the heat shield.

23 Remove the screws.

24 Remove the pipe.

25 Remove the seal.

26 Remove the gasket.

27 Remove the nuts and spacers.

28 Remove the turbocharger.

29 Remove the gasket.

30 Remove the screws and sleeves.

31 Remove the exhaust manifold.

32 Remove the gaskets.

33 Remove the screw.

34 Remove the pipes.

35 Remove the seal.

36 Remove the clamps.

37 Remove the hose.

38 Remove the screw.

39 Remove the pipe.

40 Remove the screw.

41 Remove the pipe.

42 Remove the seal.

43 Remove the screws.

44 Remove the screws.

45 Remove the screws.

46 Remove the pipe.

47 Remove the pipe along with the cover.

48 Remove the pipe.

49 Remove the seals.

50 Remove the pipe.

51 Remove the seals.

52 Remove the seal.

53 Remove the gasket.

54 Remove the screws.

55 Remove the cover.

56 Remove the screws.

57 Remove the oil cooler.

58 Remove the seals.