aftermarket injector replacement
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DService BulletinVolvo Trucks North AmericaGreensboro, NC USA
Date Group No. Page
12.2007 258 26 1(8)
TrucksThis Service Bulletin replaces publicationsPV776-20176599, PV776–20177685, andPV776–20177500.
Aftertreatment InjectorReplacement
D11F, D13F, D16F
Aftertreatment Injector, Replace
W2005655
This information covers replacement of the aftertreatment fuel injector used for the DPFsystem on a Volvo D11F, D13F, and D16F engines.
Contents• “Special Tools” page 2• “Injector, Aftertreatment, Replacement” page 3
Note: Information is subject to change without notice.Illustrations are used for reference only, and may differ slightly from the actual engineversion. However, key components addressed in this information are represented asaccurately as possible.
PV776-20131971 USA28540.ihval
DVolvo Trucks North America Date Group No. Page
Service Bulletin 12.2007 258 26 2(8)
ToolsSpecial ToolsFor special tools ordering instructions, refer to ToolsInformation, group 08.
W0001795
W2004191
9996049Coolant Drain Hose
DBT2V700Coolant Extractor
DVolvo Trucks North America Date Group No. Page
Service Bulletin 12.2007 258 26 3(8)
Service Procedures2589-03-02-13
Injector, Aftertreatment, ReplacementSee also:
• “Aftertreatment Injector, Replace” page 1
You must read and understand the precautions andguidelines in Service Information, group 20, "GeneralSafety Practices, Engine" before performing thisprocedure. If you are not properly trained and certifiedin this procedure, ask your supervisor for trainingbefore you perform it.
Special tools: 9996049, DBT2V700
Removal1Apply the parking brake and place the shift leverin neutral.
2
W2003815
Remove all cables from ground (negative) batteryterminals to prevent personal injury from electrical shock.
3Connect coolant extraction tool DBT2V700 to the drainfitting at the bottom of the radiator. Drain the coolant.
Note: An alternative method is to use drain hose9996049 to drain coolant into an approved container.
DBT2V700, 9996049
4Remove inner splash guard as an assembly.
Note: Some models may be equipped with fenderextenders, attached to the inner splash guard. Removethese as an assembly.
DVolvo Trucks North America Date Group No. Page
Service Bulletin 12.2007 258 26 4(8)
5
W2005656
Disconnect the aftertreatment injector fuel supply line.Collect any residual fuel that may be in the fuel linein a suitable container.
6
W2005655
Disconnect both the coolant inlet and outlet lines from theaftertreatment fuel injector fittings.
7Disconnect the aftertreatment fuel injector wiring harnessconnector. Remove all the clips and tie straps to allow theharness to hang free.
DVolvo Trucks North America Date Group No. Page
Service Bulletin 12.2007 258 26 5(8)
8
W2005766
Remove the aftertreatment fuel injector mounting boltsand spacers, and remove the injector from the diffuserpipe (which attaches to the turbocharger outlet).
9
W2005765
Remove and discard the high-temperature gasket andsteel plate gasket from the bottom of the injector.
Installation1Transfer both coolant fittings from the originalaftertreatment injector to the replacement injector.
DVolvo Trucks North America Date Group No. Page
Service Bulletin 12.2007 258 26 6(8)
2
W2005765
Install a new high-temperature gasket and steel plategasket onto the bottom of the aftertreatment fuel injector.
3
W2005766
Apply high-temperature nickel-graphite anti-seizecompound to the injector mounting bolt threads and insertthe bolts into the spacers. Position the injector onto thediffuser pipe (which attaches to the turbocharger outlet)and hand start the bolts with spacers.
4
W2005767
Secure the injector mounting bolts. Torque-tightenthe bolts to specification.
DVolvo Trucks North America Date Group No. Page
Service Bulletin 12.2007 258 26 7(8)
5Reconnect the aftertreatment fuel injector wiring harnessconnector. Secure the injector wiring harness withclips and tie straps.
6
W2005655
Reconnect both coolant lines to the aftertreatment fuelinjector fittings and tighten to secure.
7
W2005656
Connect the aftertreatment injector fuel supply line andtighten to secure. Install the clamp bracket and tightenthe screw.
8Fill the engine cooling system with the recommendedcoolant using the coolant extractor.
DBT2V700
9Install the inner splash guard assembly.
DVolvo Trucks North America Date Group No. Page
Service Bulletin 12.2007 258 26 8(8)
10
W2003815
Install all previously removed cables to the ground(negative) battery terminals.
11Perform Aftertreatment Injector Adaptive Factor Resetwith VCADS/Tech Tool.
12Start the engine, check for leaks and proper operation.After shutdown, replenish fluids as necessary.
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