DService BulletinVolvo Trucks North AmericaGreensboro, NC USA

Date Group No. Page

10.2007 262 03 1(9)

TrucksThis Service Bulletin replaces SB 262-43, “Thermostat,D16F” dated (2.2007), publication no. PV776–20176582.

ThermostatReplacement

D16F

Thermostat, Replacement

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This information covers the replacement of the thermostat on the Volvo D16F engine.

Contents• “Special Tools” page 2• “Thermostat, Replacement” page 3

Note: Information is subject to change without notice.Illustrations are used for reference only and may differ slightly from the actualvehicle being serviced. However, key components addressed in this information arerepresented as accurately as possible.

PV776-20125608 USA27969.ihval

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Service Bulletin 10.2007 262 03 2(9)

Special ToolsFor special tools ordering instructions, refer to ToolsInformation, group 08.

W2004191

9996049Coolant Drain Hose

DBT2V700Coolant Extraction Tool

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Service Bulletin 10.2007 262 03 3(9)

2627-03-02-02Thermostat, Replacement

Excluded: Test

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

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Remove all cables from ground (negative) batteryterminals to prevent personal injury from electrical shock.

3

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Connect 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.

WARNING

Coolant can be very hot and under pressure. Use carewhen opening the drain fitting to avoid hot coolantcontacting your skin. Failure to do so can resultin burns or scalding.

DBT2V700, 9996049

4Loosen the clamp and remove the upper radiator hosefrom the radiator and suction out any remaining coolant.

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Service Bulletin 10.2007 262 03 4(9)

5Loosen the clamp and remove the upper radiator hosefrom the thermostat housing.

6

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Remove the EGR cooler coolant pipe bolt and clamplocated at the front of the engine next to the thermostathousing and loosen hose clamp at the opposite endof pipe.

7

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Remove all the fasteners (clamps and bolts) that securethe bracket to the EGR cooler coolant hard pipe atthe front of the engine.

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Service Bulletin 10.2007 262 03 5(9)

8

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Slide the EGR cooler coolant pipe forward to free the pipefrom the cylinder head bore and at the same time, fromthe EGR cooler coolant rubber hose.

Note: Inspect EGR cooler coolant rubber hose. Replacehose only if damaged or deteriorated.

9

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Replace the O-ring on the EGR cooler coolant pipe at thecylinder head end. Use a suitable pick for removal.

10

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Remove the thermostat housing mounting bolts. Then,remove the thermostat housing.

Note: Thermostat housing removal may require aslight tap with a rubber mallet to free it from the front ofthe cylinder head.

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Service Bulletin 10.2007 262 03 6(9)

11

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Using hand pressure, remove the thermostat from thefront of the cylinder head.

12Clean all the sealing surfaces and pipe connections.

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Service Bulletin 10.2007 262 03 7(9)

Installation1

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Lubricate the seal on the thermostat with soapy water orfresh antifreeze. Install the thermostat into the cylinderhead.

2Put a thin layer of silicone on a new thermostat housinggasket. Position the gasket on the cylinder head.

Note: Make sure that the gasket to the cylinder head iscorrectly positioned. Use a new gasket.

3

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Install the thermostat housing, making sure that thehousing gasket stays in position. Thread the thermostathousing bolts so they hold the thermostat housing inplace. Torque-tighten the thermostat housing bolts to 24± 4 Nm (18 ± 3 ft-lb).

24 ± 4 Nm(18 ± 3 ft-lb)

4Install the EGR cooler coolant hose and slide it rearwardto the original hose position. Secure the hose to thecooler with the original clamp tightened securely.

Note: Inspect EGR cooler coolant rubber hose. Replacehose only if damaged or deteriorated.

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Service Bulletin 10.2007 262 03 8(9)

5

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With a new O-ring seal positioned on the EGR coolercoolant hard pipe, install the pipe into the front of thecylinder head bore next to the thermostat housing. Atthe same time, install the EGR cooler end of the pipeinto the rubber hose of the EGR cooler. Reposition thehose clamp back in the original position on the EGRcoolant pipe and tighten clamp securely. Install the EGRcoolant pipe clamp at the front of the engine and tightenthe coolant pipe bolt to the specified torque.

6

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Reposition the EGR cooler coolant hard pipe bracketback to its original position and install the bracketbolts. Reposition the coolant pipe bracket clamp backto its original position and tighten the clamp bolt.Torque-tighten the bracket bolts to specification.

7Install the upper radiator hose to the thermostat housingand to the radiator. Position the clamps and tightento secure.

8Fill the engine cooling system with the recommendedcoolant using the coolant extractor.

DBT2V700

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Service Bulletin 10.2007 262 03 9(9)

9

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Install all previously removed cables to the ground(negative) battery terminals.

10Start the engine, check for leaks and proper operation.After shutdown, replenish fluids as necessary.