Oil cooler replacement

DService BulletinVolvo Trucks North AmericaGreensboro, NC USA

Date Group No. Page

10.2007 223 122 1(35)

TrucksThis Service Bulletin replaces SB 223-114, “Oil Cooler,Service,” (6.2007), publication no. PV776-20180432.

Oil CoolerReplacement

D16F

Oil Cooler, Replacement

W2005772

This information covers procedures for servicing the oil cooler on the Volvo D16F engine.

Contents• “Special Tools” page 2

• “Oil Cooler, Replacement” page 3

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

PV776-20124003 USA27772.ihval

DVolvo Trucks North America Date Group No. Page

Service Bulletin 10.2007 223 122 2(35)

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

W0001795

W0002266

9996049Coolant Drain Hose

85108575Turbocharger Lifting Tool

W2004191

DBT2V700Coolant Extractor



2231-03-02-01Oil Cooler, Replacement

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: DBT2V700, 9996049,85108575

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.

3

W2004191

Connect the coolant extractor to the drain fitting at thebottom of the radiator and drain the coolant.

Note: An alternate method is to connect the drain hoseto the drain fitting and drain the coolant into a suitablecontainer.

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.



5

W2004720

Disconnect the air temperature sensor connectorfrom the sensor. Cut the tie strap and disengage thelock tab. Remove the clamp securing the harness tothe main fresh air pipe.

6

W2004719

Loosen the air compressor fresh air pipe couplinghose clamp at the main fresh air pipe. Separate thehose from the pipe.

7

W2006005

Loosen the clamps securing the main fresh air pipe to theair cleaner and to the turbocharger inlet elbow. Removethe main fresh air pipe.



8

W2003861

Disconnect the air restriction gauge harness connectorand remove the clamps securing the wiring harnessto the air filter housing.

9

W2003858

Remove the fasteners securing the air filter housing tothe cab and remove the housing.

10

W2006040

Remove the charge air inlet pipe from between theturbocharger and the charge air cooler.

Note: Disconnect the Discharge Recirculation Valve(DRV) air line. Loosen the clamp and disconnect therecirculation hose from the inlet elbow.

11Remove the turbocharger inlet elbow.



12

W2005620

Cut the tie straps securing the turbocharger actuator andspeed sensor wiring harnesses. Disconnect and removethe connectors mounted in bracket at the oil filter housing.

13

W2005621

Disconnect the coolant supply and return lines from theturbocharger actuator.



14

W2005622

Disconnect the coolant line from the top of theturbocharger.

15

W2005623

Disconnect the turbocharger coolant line from the oilcooler cover.



16

W2005624

Disconnect the oil supply line from the bottom of theturbocharger.

17

W2005628

Remove the fasteners securing the oil drain pipe to thebottom of the turbocharger and spacer block. Removethe spacer block. Separate the gasket and O-ring fromthe spacer block and discard.



18

W2006108

Loosen the diffuser-to-turbocharger clamp and slide thediffuser away from the turbocharger.

19

W2005042

Remove the plug at the top of the turbocharger and installthe turbocharger lifting tool.

85108575



20

W2005011

Support the weight of the turbocharger using a mobilefloor crane such as OTC 16-1815 or equivalent. Removethe turbocharger mounting nuts and spacers.

21

W2005629

With the aid of an assistant, lower the turbochargeraway from the exhaust manifold studs and remove itfrom the engine.

22Place the turbocharger on a suitable support. Plug theturbocharger oil lines and outlet openings to preventcontamination. Install covers on the intake and exhaustopenings of the turbocharger to prevent foreign materialfrom entering.



23

W2005657

Remove the aftertreatment fuel line clamp at thebottom of the diffuser.

24

W2005656

Remove the fuel line from the aftertreatment fuel injector.

25

W2005655

Remove the supply and return coolant lines from theaftertreatment fuel injector.



26Remove the diffuser-to-exhaust pipe clamp and move thediffuser away from the EGR cooler for easier accessto cooler connections.

27

W2005686

Remove the fasteners securing the upper portion of theEGR hot pipe shield and remove the shield.

28

W2005687

Remove the fasteners securing the lower portion of theEGR hot pipe shield and remove the shield.



29

W2005642

Loosen the EGR hot pipe V-clamps. Free the EGR hotpipe clamps from the flanges at the EGR valve and atthe EGR cooler.

30

W2005641

Remove the EGR hot pipe from between the EGR valveand the EGR cooler. Remove and discard the gaskets.

31

W2005646

Remove the fasteners and clamps securing the coolantpipe to the oil cooler cover and the EGR cooler.



32

W2005647

Remove the clamps securing the coolant hose to theEGR cooler and thermostat housing and slide the hoserearward. Remove the clamps securing the EGR coolerhose to the EGR pipe and slide the hose forward.

33Remove the static fill pipe from the EGR cooler.

34

W2005645

Disconnect the EGR cooler straps by removing the topbolts and pulling straps back to allow clearance.



35

W2005658

Pull the EGR cooler outward and back to free the coolantpipe from the oil cooler cover. Remove the EGR cooler.

36Remove EGR pipe coupling hose and replace withnew hose.

37

W2005659

Remove the O-ring at each end of the EGR coolercoolant pipe and discard.

38Remove the bottom strap nuts and spacers, then removestraps.



39

W2005661

Disconnect the coolant conditioner hose from theoil cooler cover.

40

W2005662

Remove all oil cooler cover bolts except the one at thetop center of the cover.

41

W2005668

Support the cover and remove the top center bolt.Remove the oil cooler cover.

Note: Tap the cover with a soft mallet to loosen thecover if necessary.



42

W2005664

Remove the oil cooler cover gasket from the cylinderblock.

43

W2005667

Remove the bolts securing the oil cooler to the cylinderblock and remove the cooler.

44

W2005663

Remove the oil cooler sealing rings.

45Clean the sealing surfaces of the oil cooler, coolercover and cylinder block.



Installation1Install new oil cooler sealing rings in the cylinder block.

2

W2005667

Install the oil cooler and tighten the bolts to 27 ± 4Nm (20 ± 3 ft-lb).

27 ± 4 Nm(20 ± 3 ft-lb)

3

W2005666

Install two alignment pins one on each side of the oilcooler cover opening. Install a new oil cooler cover gasketon the alignment pins.



4

W2005665

Install the oil cooler cover over the alignment pins andagainst the gasket.

5

W2005662

Install the top center bolt and all remaining bolts. Tightenthe bolts in steps to 24 ± 3 Nm (18 ± 2 ft-lb), evenlyaround the cover.

24 ± 3 Nm(18 ± 2 ft-lb)

6

W2005661

Install the coolant conditioner hose with new seals to theoil cooler cover. Tighten the fitting to secure.



7Position straps on bottom mounts, install the spacersand nuts.

8

W2005659

Install a new O-ring at each end of the EGR coolercoolant pipe and lubricate with coolant. Install the coolantpipe into the EGR cooler.

9

W2005660

Position the EGR cooler onto the cooler brackets. Slidethe cooler forward to engage the coolant pipe with theoil cooler cover.



10

W2005645

Position the straps over the EGR cooler, install the strapbolts and hand tighten.

11Tighten the nuts at the bottom of the cooler straps to 24± 3 Nm (18 ± 2 ft-lb).

24 ± 3 Nm(18 ± 2 ft-lb)

12Tighten the EGR strap bolts to 12 ± 2 Nm (106 ± 18 in-lb).

12 ± 2 Nm(116 ± 18 in-lb)

13

W2005648

Connect the EGR cooler coolant hose, position theclamps and tighten to secure. Connect the EGR coolerhose to the EGR pipe, position the clamps and tightento secure.



14

W2005646

Install the coolant pipe clamps and fasteners and tightento secure.

15Install the static fill pipe to the EGR cooler. Tighten to 10± 2 Nm (89 ± 18 in-lb).

10 ± 2 Nm(89 ± 18 in-lb)

16

W2006187

Install new gaskets onto the EGR valve end of the hotpipe and into the inlet flange of the EGR cooler. Ensurethe gaskets lay flat against the flange surfaces with thebead of the gasket facing toward the hot pipe.

Note: Gaskets are one-time use only. Do not reusegaskets.

17Inspect the V-band clamps and T-bolt threads for wearor damage. If they are OK, lubricate the V-inserts ofthe clamps.

Note: The V-band clamps can be reused if no wear ordamage is visible.



18

W2005641

Hook the upper V-band clamp over the EGR valveflange. Place the lower V-band clamp over the bellowson the hot pipe.

19Lubricate the flange on the EGR cooler inlet and theflange on the EGR hot pipe with fresh engine oil.Lubrication aids in V-band clamp installation.

20Position the EGR hot pipe between the EGR valve andthe EGR cooler. Make sure the flange engages properly.While holding the hot pipe in position, slide the upperV-clamp over the flange and tighten until snug. Slidethe floating flange into the groove of the EGR coolerflange. Slide the lower V-band clamp over the flangeof the EGR cooler and tighten the clamp until enoughpressure prevents the floating flange from falling out ofthe EGR cooler flange.

21

W2006163

1 EGR Pipe Floating Flange2 EGR Cooler Flange3 EGR Pipe4 Flange Assembled Correctly5 Flange Assembled Incorrectly

Visually inspect the floating flange through the gap inthe V-band clamp to make sure it is properly seated inthe EGR cooler flange. The floating flange must beconcentric with the EGR cooler flange.

Note: If the floating flange is not properly seated in theEGR cooler flange, the gasket will not be compressedand the seal will leak.



22

W2006164

1 EGR Pipe Clamp Position

Position the V-band clamps as shown so that the T-boltsclear both heat shields. Apply anti-seize compound to thethreads of the T-bolts. Tighten to 20 ± 4 Nm (15 ± 3 ft-lb).

Note: After reaching the specified torque, inspect theV-band clamps to make sure that no portion of theclamp has “bottomed out.”

20 ± 4 Nm(15 ± 3 ft-lb)

23

W2005687

Position the lower EGR hot pipe heat shield over the pipeand secure with bolts. Do not tighten at this time.



24

W2005686

Position the upper EGR hot pipe heat shield and installthe fasteners to secure the shield. Tighten all fastenersto specification.

25Position the diffuser to the exhaust pipe and looselyinstall the V-band clamp.

26

W2005655

Install the coolant supply and return lines to theaftertreatment fuel injector.



27

W2005656

Install the fuel line onto the aftertreatment fuel injector.

28

W2005657

Install the aftertreatment fuel injector line clamp andfastener to the bottom of the diffuser.

29Clean the contact surface of the exhaust manifoldand the turbocharger.

30Remove the plugs from the turbocharger oil lines.Remove the covers from the turbocharger intake andexhaust openings.



31

W2005636

Install a new gasket onto the studs of the turbocharger.

32

W2005629

Attach the turbocharger to a mobile floor crane such asOTC 16-1815 or equivalent. With the aid of an assistant,position the turbocharger against the exhaust manifold,aligning the studs with the holes.



33

W2005206

Install the turbocharger flange nuts and spacers andtighten to 135 Nm (100 ft-lb). The nuts should betightened in the sequence shown.

Note: Apply anti-seize compound to the threads andunder the heads or contact surfaces of the fasteners.Anti-seize helps to prevent fastener oxidation corrosionand reduces friction to help achieve the intended clampload on the component when tightening the fastenersto specification.

135 Nm(100 ft-lb)

34Remove the hoist and turbocharger lifting tool. Install theplug in the threaded hole at the top of the turbocharger.

35Clean the contact surface of the turbocharger, spacerblock and drain back pipe.

36

W2005628

Position a new O-ring and gasket on the spacer block andinstall the turbocharger oil drain pipe and spacer block tothe bottom of the turbocharger. Tighten the fasteners to24 ± 4 Nm (18 ± 3 ft-lb).

24 ± 4 Nm(18 ± 3 ft-lb)



37

W2005624

Install the turbocharger oil supply line to the bottom fittingof the turbocharger and tighten the fitting.

38

W2005623

Install the turbocharger coolant line to the fitting on the oilcooler cover and tighten to secure.



39

W2005626

Position the diffuser against the turbocharger and install anew V-band clamp. Align the cast marks on the diffuserwith the mark on the turbocharger and tighten the clampto secure. Tighten the diffuser-to-exhaust pipe clamp.

Note: The diffuser V-band clamp is a one time use clamp.

40

W2005622

Install the coolant line to the top of the turbocharger andtighten the fitting to secure.

Note: This coolant line also connects to the turbochargeractuator.



41

W2005621

Install the turbocharger actuator coolant lines to thefittings and tighten to secure.

42

W2005620

Connect the turbocharger actuator and turbochargerwheel speed sensor wiring harnesses. Make sure theconnectors are oriented with the flat side toward the flatin the bracket. Install the cable clamp on the oil filterhousing. Secure the wiring harness to itself and to theturbocharger oil drain pipe using tie straps.

43Install the inlet elbow to the turbocharger. Do not tighten.

44

W2003858

Position the air filter housing against the cab, install thebolts and tighten to secure.



45

W2006005

Install the main fresh air pipe to the air filter housingand the turbocharger inlet elbow. Tighten the clampsto secure.

46

W2004719

Install the air compressor fresh air coupling hose to themain fresh air pipe, position the clamp and tightento secure.



47

W2004720

Install the air temperature sensor connector to the sensor.Insert the connector lock tab, push in place and securewith a tie strap. Install the clamp and fastener to securethe harness to the main fresh air pipe. Tighten the clampbolt to 8 ± 1.2 Nm (6 ± 1 ft-lb).

8 ± 1.2 Nm(6 ± 1 ft-lb)

48

W2003861

Install the air filter restriction gauge wiring harness to theair filter housing and tighten the clamps to secure.

49

W2004249

Connect the air filter restriction gauge electrical harnessconnector.



50

W2006040

Inspect the O-rings at each end of the charge air inletpipe for damage, replace if needed. Install the chargeair inlet pipe assembly between the turbocharger andcharge air cooler.

Note: Connect the DRV air line. Connect the recirculationhose to the inlet elbow, position the clamp and tightento secure.

51Check the engine oil level and replenish as needed withthe recommended oil.

52

W2004191

Fill the cooling system with the recommended coolantusing the coolant extractor.

DBT2V700

53Install the inner splash guard assembly.

54

W2003815

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



55Start the engine, check for leaks and proper operation.After shutdown, replenish fluids as necessary.

Automotive

Oil cooler replacement