2379-03!02!02 sleeve, injector, replacement (one)

2379-03-02-02 Sleeve, Injector, Replacement (One)

You must read and understand the precautions and guidelines in Service Information, group 20, “General SafetyPractices, Engine” before performing this procedure. If you are not properly trained and certified in this procedure, askyour supervisor for training before you perform it.

Special tools: 9996956, 9998249, 9998250, 9998251, 9998252, 9998253, 85112740, 88800014, 88800196, 88880010,88800281, 88800282, 88800283, 88800285, 88800288, 88800289, J42885, PT2900, DBT2V700

Sleeve Identification

Note: There are two types of injector sleeves used in Volvo engines, conical and flat copper. The conical sleeves aremade of stainless steel. A washer is used with the flat copper sleeves. You must determine which type of sleeve is inthe engine to know the proper tools to use for the replacement procedure.

Chassis ID Path237/Repair/VN, ENG-VE16, EM-USA10/Sleeve, Injector, Replacement (One)

Model IdentityVN 130141719

Publish date Operation No.Friday, March 4, 2011 2379-03-02-02

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COPYRIGHT © Copyright Volvo Parts CorporationThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

IMPACT 3.0 Monday, March 11, 2013

Flat Copper Sleeve with Washer (previous design)

Conical Stainless Steel Sleeve (new design)

CautionConical and copper sleeves should not be mixed in the same engine. The same type of sleeve must be used in

all six cylinders. Mixing sleeves can result in damage to the engine.

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For information on how to replace a copper sleeve, see . For information on how toCopper Sleeve Replacementreplace a conical sleeve, see .Conical Sleeve Replacement

Copper Sleeve Replacement

1Apply the parking brake and place the shift lever in neutral.

2

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

3Drain the coolant from the radiator and engine using the coolant extractor.

Note: An alternate method is to connect the drain hose to the drain fitting and drain the coolant.

Special tools: , , DBT2V700 9990649 85112740

4Clean around the fuel supply line fitting on the filter housing. Loosen the fuel line at the filter housing to allow fuel to

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drain from the cylinder head. Allow the fuel to drain into a suitable container.

5Remove the valve cover. Refer to Group 211 for procedure.

Note: Rotate the valve cover as needed, to clear the camshaft gear and damper.

Note: Dependent upon chassis, engine cover may need to be removed for clearance to remove valve cover.

6Thoroughly clean around the unit injectors that are to be removed. Remove the unit injector(s). Refer to Group 237 forprocedure.

7

Install the protective sleeve over the unit injector to prevent damage.

Special tools: 9998249

8

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If the injector sleeve is not being removed immediately, install the protective plug into the unit injector bore of thecylinder head to protect it from debris.


9

Install two sealing rings to prevent dirt from entering the fuel gallery when the injector sleeve is removed.

Note: Two sealing rings are required to cover the fuel gallery.


10

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Install the flywheel turning tool. Turn the flywheel until the piston is at its lowest position in the cylinder. Confirm thepiston is at the lowest position in the cylinder by using a 40 cm (16 inch) piece of straight stiff wire in the injector hole ofthe cylinder.

Note: This is to ensure that the injector sleeve tapping tool does not damage the piston due to tool length.

Note: Ensure the turning tool is well greased before attempting to turn the flywheel.

Note: If it is necessary to replace other injector sleeves, continue the procedure on pairs of companion cylinders (1 and6, 2 and 5, 3 and 4). It is necessary to rotate the crankshaft and place each pair of companion cylinders at the lowestposition in the cylinder.

Special tools: , 88800014 9996956

11

8.5 mm Forming Tap, 88800281Insert the forming tap into the tap handle until it stops. Make sure a flat on the tap is aligned with the upper set screw.Tighten upper set screw first, then tighten lower set screw. Completely coat the forming tap with fresh, extremepressure NLGI #2 grease or equivalent.

Note: Forming taps require extreme pressure grease due to the cold working process used to form threads.

CautionIf the injector sleeve is not completely tapped through to the opening of the tip, an end piece of the tip can

break off and fall into the cylinder during removal. These types of failures are not covered by warranty.

Special tools: , 88800281 9998252

12

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A. 8.5 mm Forming Tap, 88800281B. Tap Handle, 9998252C. Sleeve Hold Down, 88800285

Note: Use a spare fastener to tighten the injector hold down on the sleeve hold down (special tool number 88800285).Do not use the hold down screw from the engine because it is a limited use screw.

Position tap holder and sleeve hold down in the unit injector bore. Position the injector hold down over the sleeve holddown and tighten a spare fastener to 80 ± 5 Nm (60 ± 4 ft-lb). Apply moderate downward force to get the tap startedwhile turning the tap handle clockwise. Continue turning in the same direction, , until the injectorwithout reversingsleeve is tapped all the way through. The shoulder of the tap handle bottoms on the injector sleeve. Ensure that the tapis completely through the injector sleeve.

CautionIf threads are not cut completely through the tip of the injector sleeve, the tip can break off and fall into the

cylinder. This can result in damage to the cylinder, piston, valves or turbocharger. These types of failures arenot covered by warranty.

Special tools: , , 9998252 88800281 88800285

13Remove screw from the injector hold down. Remove the injector hold down, sleeve hold down, tap and tapping tool.

14

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Install the 8.5 mm extractor bolt into the end of the extractor tool. Adjust the bolt until it extends approximately 25 mm(1 inch) beyond the end of the tool (dimension A).

Special tools: , 88800282 9998253

15Tighten the set screw of the extractor tool to secure the bolt. Make sure that the set screw is seated against the flat partof the extractor bolt.

16

Caution

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Make sure the extractor bolt is threaded completely into the injector sleeve before attempting to remove it or thetip of the sleeve may break off as it is removed. This broken sleeve tip can seriously damage the piston, valves

or turbocharger. These types of failures are not covered by warranty.

Lubricate the threads of the forcing screw on the puller. Lubricate under the face of the nut. Place the extractor toolwith the bolt into the injector bore. Make sure the nut on the spindle is backed off so that the threaded end can becompletely installed through the injector sleeve tip. Hand tighten until the bolt bottoms out in the sleeve.


17

While holding the top of the tool stationary, turn the large nut clockwise to extract the injector sleeve.

Note: When the injector sleeve is removed, make sure that the extractor bolt is extended at least one thread beyondthe injector sleeve. If not, make sure that no part of the injector sleeve has broken off and fallen into the cylinder.

CautionDo not use air tools to remove injector sleeves, or damage to the injector bore can result.


18

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Remove the two sealing rings from the fuel passage. Using the chip vacuum, remove any remaining debris from theinjector bore.

Special tools: , 9998250 PT2900

19Install the injector bore sealing tool to protect the fuel passage area and prevent debris from entering. Use a sparefastener to secure the tool in the cylinder head.

Special tools: J-42885-25

20

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Using the cleaning kit, clean the injector sleeve seat of the cylinder head.

Note: The injector bore sealing tool must be used to prevent dirt from entering the fuel passage.

Special tools: , , , , J42885-1 J42885-2 J42885-3 J42885-4 J-42885-25

21

Using the brush, clean the cylinder head injector bore walls for the injector sleeve.

Note: The injector bore sealing tool must be used to prevent debris from entering the fuel passage.

Special tools: , J42885-6 J42885-25

22

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Using the brush, clean the injector sleeve opening in the cylinder head.


Note: When replacing the injector sleeves, it is important to check that the sleeve bore in the cylinder head is free fromany carbon deposits or other residue (i.e., pieces of O-ring, etc.) before installing a new injector sleeve. Repeatcleaning if necessary.

Special tools: , J42885-5 J-42885-25

23

WarningDo not attempt to blow away debris using compressed air. Doing so can result in eye injury.

Using the chip vacuum, remove all debris from the injector sleeve bore.

Special tools: PT2900

24Remove the injector bore sealing tool from the cylinder head. Using the chip vacuum, remove any remaining debris.

Special tools: , PT2900 J-42885-25

25Ensure the piston is at the lowest position in the cylinder. If not, use the flywheel turning tool to place the piston at itslowest position.

Note: This is to ensure that the sleeve installation tool does not damage the piston due to tool length.

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Special tools: , 88800014 9996956

26

Copper Injector SleeveBefore installing a copper sleeve, inspect it to ensure that it is the correct part. The correct sleeve is identified by twoconcentric circular grooves machined into the top surface.

27

Note: Always use the new O-ring included in the sleeve kit.

Lubricate a new injector sleeve O-ring with clean coolant or soapy water. Install the O-ring on the injector sleeve andlubricate again with clean coolant or soapy water.

28

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X = 7.8 ± 0.1 mm

CautionFailure to use the proper bit can result in the bit breaking off into the cylinder head. These types of failures are

not covered by warranty.

Using calipers, measure the swedging bit to make sure that the proper swedging tool is used. Measurement shouldread 7.8 ± 0.1 mm. Also, verify that the swedging bit has three stages and the length is 108 mm.

Note: Swedging bit can be ordered as a spare part if the bit is worn or broken.


29

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Copper Sleeve Installation Tool, 88800196

CautionBefore installing the sleeve on the installation tool, inspect the tool to ensure that it is the correct tool. For

copper sleeves, the correct tool is identified by a bottom surface that is perfectly flat with no machined circularrecess. Use of a tool with a machined circular recess on the bottom may result in damage to the copper sleeve.

Place the new injector sleeve on the installation tool. Thread the swedging bit completely into the flaring tool until itstops (finger tight). Lubricate the swedging bit and the threads on the tool with fresh, extreme pressure NLGI #2 greaseor equivalent.

Note: Do not place the injector nozzle gasket (flat coated washer) in the copper sleeve, as this will damage theswedging bit.


30Loosen the swedging bit 180° before installing the tool in the cylinder head.

CautionFailure to loosen the swedging bit can result in the bit being twisted or broken.

31Carefully place the sleeve installation tool and new injector sleeve into the unit injector bore of the cylinder head.Carefully move the injector sleeve downward into the injector bore so that the swedging bit is guided into the injector tipbore in the cylinder head. Push downward on the installation tool using hand force to move the injector sleevedownward until it bottoms out on the injector sleeve seat in the bottom of the injector bore. Use the unit injector holddown and a spare fastener to hold the tool in position. To ensure that the copper sleeve is bottomed in the cylinderhead, tighten the unit injector hold down fastener to 80 ± 5 Nm (60 ± 4 ft-lb).

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1.

Note: Remove any oil from the injector hold down bolt holes to avoid hydraulic lock for this step and when the injectoris installed.

32

Installation Tool

Flare the injector sleeve by turning the nut clockwise while holding the spindle until the swedging bit has been pulledcompletely through the injector sleeve.

CautionFailure to hold the spindle can result in a twisted or broken swedging bit.

33Remove sleeve installation tool from the injector bore.

Note: If the unit injector is not being installed immediately, install the protective plug into the injector bore to protect itfrom debris.


34Install the unit injector. Refer to Group 237 for procedure.

35Install the rocker shaft. Refer to Group 214 for procedure.

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36Adjust the valves and unit injectors. Refer to Group 214 for procedure.

37Install the valve cover. Refer to Group 211 for procedure.

38Secure the fuel supply line fitting at the fuel filter housing (loosened earlier to drain fuel from the cylinder head). Cleanany fuel that remains around the fitting.

39

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

40

Use coolant extractor to fill the system with approved coolant per specifications.

Special tools: , DBT2V700 85112740

41

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Prime the fuel system by pumping the hand priming pump on the fuel filter housing until resistance is felt indicating thatthe system is full of fuel.

42Start the engine and run until the engine clears and runs without stumbling. This procedure may need to be repeatedonce or twice to get the fuel system completely free of air.

Note: If the engine does not start on the first attempt, prime the fuel system again, and refer to the previous step.Engine priming may need to occur several times in order to get the engine to start.

43Allow the engine to run at low idle for about 5 minutes. Check for any fuel leaks and correct if necessary.

Note: The engine speed should be increased as any air pockets can be forced into the cylinder head which cannotresult in the engine stopping.

Conical Sleeve Replacement

1Apply the parking brake and place the shift lever in neutral.

2

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

3Drain the coolant from the radiator and engine using the coolant extractor.

Note: An alternate method is to connect the drain hose to the drain fitting and drain the coolant.

Special tools: , , DBT2V700 9990649 85112740

4Clean around the fuel supply line fitting on the filter housing. Loosen the fuel line at the filter housing to allow fuel todrain from the cylinder head. Allow the fuel to drain into a suitable container.

5Remove the valve cover. Refer to Group 211 for procedure.

Note: Rotate the valve cover as needed, to clear the camshaft gear and damper.

Note: Dependent upon chassis, engine cover may need to be removed for clearance to remove valve cover.

6Thoroughly clean around the unit injectors that are to be removed. Remove the unit injector(s). Refer to Group 237 forprocedure.

7

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Install the protective sleeve over the unit injector to prevent damage.


8

If the injector sleeve is not being removed immediately, install the protective plug into the unit injector bore of thecylinder head to protect it from debris.


9

Install two sealing rings to prevent dirt from entering the fuel gallery when the injector sleeve is removed.

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Note: Two sealing rings are required to cover the fuel gallery.


10Install the flywheel turning tool. Turn the flywheel until the piston is at its lowest position in the cylinder. Confirm thepiston is at the lowest position in the cylinder by using a 40 cm (16 inch) piece of straight stiff wire in the injector hole ofthe cylinder.

Note: This is to ensure that the injector sleeve tapping tool does not damage the piston due to tool length.

Note: Ensure the turning tool is well greased before attempting to turn the flywheel.


Special tools: , 88800014 9996956

11

Insert the 8.3 forming tap into the tap handle until it stops. Make sure a flat on the tap is aligned with the upper setscrew. Tighten upper set screw first, then tighten lower set screw. Completely coat the forming tap with fresh, extremepressure NLGI #2 grease or equivalent.

Note: Forming taps require extreme pressure grease due to the cold working process used to form threads.

CautionIf the injector sleeve is not completely tapped through to the opening of the tip, an end piece of the tip can

break off and fall into the cylinder during removal. These types of failures are not covered by warranty.

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Special tools: , 88800289 9998252

12

A. 8.3 mm Forming Tap, 88800289B. Tap Handle, 9998252C. Sleeve Hold Down, 88800285

Note: Use a spare fastener to tighten the injector hold down on the sleeve hold down (special tool number 88800285).Do not use the hold down screw from the engine because it is a limited use screw.

Position tap holder and sleeve hold down in the unit injector bore. Position the injector hold down over the sleeve holddown and tighten a spare fastener to 80 ± 5 Nm (60 ± 4 ft-lb). Apply moderate downward force to get the tap startedwhile turning the tap handle clockwise. Continue turning in the same direction, without reversing, until the injectorsleeve is tapped all the way through. The shoulder of the tap handle bottoms on the injector sleeve. Ensure that the tapis completely through the injector sleeve.

CautionIf threads are not cut completely through the tip of the injector sleeve, the tip can break off and fall into the

cylinder. This can result in damage to the cylinder, piston, valves or turbocharger. These types of failures arenot covered by warranty.

Special tools: , , 9998252 88800285 88800289

13Remove screw from the injector hold down. Remove the injector hold down, sleeve hold down, tap and tapping tool.

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14

Install the 8.3 mm extractor bolt into the end of the extractor tool. Adjust the bolt until it extends approximately 25 mm(1 inch) beyond the end of the tool (dimension A).

Special tools: , 88800288 9998253

15Tighten the set screw of the extractor tool to secure the bolt. Make sure that the set screw is seated against the flat partof the extractor bolt.

16

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CautionMake sure the extractor bolt is threaded completely into the injector sleeve before attempting to remove it or thetip of the sleeve may break off as it is removed. This broken sleeve tip can seriously damage the piston, valves

or turbocharger. These types of failures are not covered by warranty.

Lubricate the threads of the forcing screw on the puller. Lubricate under the face of the nut. Place the extractor toolwith the bolt into the injector bore. Make sure the nut on the spindle is backed off so that the threaded end can becompletely installed through the injector sleeve tip. Hand tighten until the bolt bottoms out in the sleeve.


17

While holding the top of the tool stationary, turn the large nut clockwise to extract the injector sleeve.

Note: When the injector sleeve is removed, make sure that the extractor bolt is extended at least one thread beyondthe injector sleeve. If not, make sure that no part of the injector sleeve has broken off and fallen into the cylinder.

CautionDo not use air tools to remove injector sleeves, or damage to the injector bore can result.

24 / 33




18

Remove the two sealing rings from the fuel passage. Using the chip vacuum, remove any remaining debris from theinjector bore.

Special tools: , 9998250 PT2900

19Install the injector bore sealing tool to protect the fuel passage area and prevent debris from entering. Use a sparefastener to secure the tool in the cylinder head.

Special tools: J-42885-25

20

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Using the cleaning kit, clean the injector sleeve seat of the cylinder head.

Note: The injector bore sealing tool must be used to prevent dirt from entering the fuel passage.

Special tools: , , , , J42885-1 J42885-2 J42885-3 J42885-4 J-42885-25

21

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Using the brush, clean the cylinder head injector bore walls for the injector sleeve.


Special tools: , J42885-6 J42885-25

22

Using the brush, clean the injector sleeve opening in the cylinder head.


Note: When replacing the injector sleeves, it is important to check that the sleeve bore in the cylinder head is free fromany carbon deposits or other residue (i.e., pieces of O-ring, etc.) before installing a new injector sleeve. Repeatcleaning if necessary.

Special tools: , J42885-5 J-42885-25

23

WarningDo not attempt to blow away debris using compressed air. Doing so can result in eye injury.

Using the chip vacuum, remove all debris from the injector sleeve bore.

Special tools: PT2900

24

27 / 33



Remove the injector bore sealing tool from the cylinder head. Using the chip vacuum, remove any remaining debris.

Special tools: , PT2900 J-42885-25

25Ensure the piston is at the lowest position in the cylinder. If not, use the flywheel turning tool to place the piston at itslowest position.

Note: This is to ensure that the sleeve installation tool does not damage the piston due to tool length.

Special tools: , 88800014 9996956

26

Before installing a conical sleeve, apply a 2-3 mm bead of Volvo approved sealing compound (part number 1161059)to the bottom of the injector sleeve.

27

Note: Always use the new O-ring included in the sleeve kit.

Lubricate a new injector sleeve O-ring with clean coolant or soapy water. Install the O-ring on the injector sleeve andlubricate again with clean coolant or soapy water.

28

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X = 7.9 ± 0.05 mm

CautionFailure to use the proper bit can result in the bit breaking off into the cylinder head. These types of failures are

not covered by warranty.

Using calipers, measure the swedging bit to make sure that the proper swedging tool is used. Measurement shouldread 7.9 ± 0.05 mm. Also, verify that the swedging bit has four stages and the length is 120 mm.

Note: Swedging bit can be ordered as a spare part if the bit is worn or broken.


29

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Conical Sleeve Installation Tool, 88800283

CautionBefore installing the sleeve on the installation tool, inspect the tool to ensure that it is the correct tool.

Place the new injector sleeve on the installation tool. Thread the swedging bit completely into the flaring tool until itstops (finger tight). Lubricate the swedging bit and the threads on the tool with fresh, extreme pressure NLGI #2 greaseor equivalent.

Note: To ensure that the swedging bit is pulled completely through the sleeve, install at least 8 mm (0.3 in) of spacersunder the nut on the flaring tool.


30Loosen the swedging bit 180° before installing the tool in the cylinder head.

CautionFailure to loosen the swedging bit can result in the bit being twisted or broken.

31Carefully place the sleeve installation tool and new injector sleeve into the unit injector bore of the cylinder head.Carefully move the injector sleeve downward into the injector bore so that the swedging bit is guided into the injector tipbore in the cylinder head. Push downward on the installation tool using hand force to move the injector sleevedownward until it bottoms out on the injector sleeve seat in the bottom of the injector bore. Use the unit injector holddown and a spare fastener to hold the tool in position. To ensure that the sleeve is bottomed in the cylinder head,tighten the unit injector hold down fastener to 80 ± 5 Nm (60 ± 4 ft-lb).

Note: Remove any oil from the injector hold down bolt holes to avoid hydraulic lock for this step and when the injectoris installed.

32

30 / 33



1. Installation Tool

Flare the injector sleeve by turning the nut clockwise while holding the spindle until the swedging bit has been pulledcompletely through the injector sleeve.

CautionFailure to hold the spindle can result in a twisted or broken swedging bit.

33Remove sleeve installation tool from the injector bore.

Note: If the unit injector is not being installed immediately, install the protective plug into the injector bore to protect itfrom debris.


34Install the unit injector. Refer to Group 237 for procedure.

35Install the rocker shaft. Refer to Group 214 for procedure.

36Adjust the valves and unit injectors. Refer to Group 214 for procedure.

37

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Install the valve cover. Refer to Group 211 for procedure.

38Secure the fuel supply line fitting at the fuel filter housing (loosened earlier to drain fuel from the cylinder head). Cleanany fuel that remains around the fitting.

39

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

40

Use coolant extractor to fill the system with approved coolant per specifications.

Special tools: , DBT2V700 85112740

41

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Prime the fuel system by pumping the hand priming pump on the fuel filter housing until resistance is felt indicating thatthe system is full of fuel.

42Start the engine and run until the engine clears and runs without stumbling. This procedure may need to be repeatedonce or twice to get the fuel system completely free of air.

Note: If the engine does not start on the first attempt, prime the fuel system again, and refer to the previous step.Engine priming may need to occur several times in order to get the engine to start.

43Allow the engine to run at low idle for about 5 minutes. Check for any fuel leaks and correct if necessary.

Note: The engine speed should be increased as any air pockets can be forced into the cylinder head which cannotresult in the engine stopping.

33 / 33



2379-03!02!02 sleeve, injector, replacement (one)

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