2001 Volvo FM12 (Lorry and Bus) Service & Repair Manual

21002-2 Cylinder compression test Special tools: 9988539, 9990006, 9990185, 9990262, 9996400, 9998248, 9998249, 9998599, 88880056, 88800284 1 Remove the rocker arm shaft, see 21440-1 Rocker arm shaft, removal Group 21. 2 Page 1 of 9

Caution Clean very thoroughly around the unit injectors. Remove the screws to the unit injectors' yoke. Fit puller 9990006 to the injector. Position the puller's fork in the groove in the injector and lock the arm with the screw on the side. Fix the puller by screwing down the screw against the injector's ball socket. Fit slide hammer 9996400 with adapter 9990262 and remove the injector. Note: Check that the steel gasket comes up with the injector and is not left in the copper sleeve. Special tools: 9990006, 9990262, 9996400 3 Fit protective sleeve 9998249 to the removed unit injector. Special tools: 9998249 4 Page 2 of 9

If necessary, fit protective sleeve (C) and clean the unit injector sleeve with brush (A) and extender (B). A = 9808570 for copper sleeve, 88880056 for steel sleeve. B = 9808616 C = 9998580 The tools are available in kit 9998599. Special tools: 9998599 5 Page 3 of 9

Install the six adapters (A) in the cylinder head. A = 9998248 for copper sleeve, 88800284 for steel sleeve. Special tools: 9998248, 88800284 6 Page 4 of 9

Install the rocker arm bridge using lifting tool 9990185. Tighten the bolts evenly along the entire rocker arm bridge to avoid deformation of the rocker arm shaft and to make sure that the guide pins fit properly in the camshaft support bearings. Torque tighten the rocker arm bridge in accordance with the tightening diagram, see Specifications Group 20. Note: Remove the fixing from the exhaust rocker arm pistons. Special tools: 9990185 7 Install the VCB control valve or the adapter on EPG engines. Check that the sealing ring is correctly located before tightening the VCB control valve bolts. Page 5 of 9

8 Check the valve clearances, see 21414-3 Valves and unit injectors, adjustment Group 21. 9 Connect compression gauge (B) to adapter (A) on the first cylinder. Crank the engine with the starter motor until the needle on the compression gauge stops moving (max compression). Repeat for the remaining cylinders. Warning The parking brake must be applied when cranking the engine with the starter motor. Remove the control unit fuse to avoid unintentional starting of the engine and check that the vehicle is not in gear. Note: Do not run the starter motor for longer than 10 seconds at a time at intervals of 60 seconds. Special tools: 9988539 10 Page 6 of 9

Remove the bolts for the VCB control valve or the adapter on EPG engines. Remove the control valve and the pipe between the valve and the rocker arm shaft. 11 Page 7 of 9

Undo the bolts on the rocker arm bridge equally in several stages, to avoid bending the rocker arm shaft. Remove the bolts and carefully lift off the rocker arm bridge using lifting tool 9990185. Special tools: 9990185 12 Remove the adapters 9998248 from all cylinders. 13 Page 8 of 9

The following is applicable to copper sleeve: Fit new O-rings. Fit a new steel gasket. The following is applicable to steel sleeve: Install new O-rings on the unit injector. Fit the unit injector with cap and centre it between the valve springs. Tighten the screw to the torque specified in Specifications Group 20. 14 Fit the rocker arm shaft, see 21442-1 Rocker arm shaft, install Group 21. 15 Bleed the fuel system, refer to 23003-3 Fuel system, bleeding Group 23. 16 Check any fault codes. Page 9 of 9

21002-2 Cylinder compression test Special tools: 9988539, 9990006, 9990185, 9990262, 9996400, 9998248, 9998249, 9998599 1 Remove the Rocker shaft, see 21440-1 Rocker arm shaft, remove . 2 Drain the fuel from the cylinder head fuel channel. 3 Caution Page 1 of 8 2

2001 Volvo FM12 (Lorry and Bus) Service & Repair Manual

You're Reading a Preview

Recently Viewed