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Volvo Diesel Engine Parts Operation

Oct. 18, 2019


25-1 Inlet and Exhaust Manifolds

 

Intake Manifold, Change

TAD550GE, TAD551GE, TAD750GE, TAD751GE

Removal

NOTICE! Turn off the main switch before any work is carried out.

1 Undo the crankcase ventilation hoses. 


P0015556.png


Remove the oil trap.

 

2 Remove the hose (1) between the inlet manifold and the charge air cooler.


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Remove the electrical connection (2) from the pre-heater relay.

Remove the connector (3) from the preheater element.

Remove the electrical connection (4) from the charge air pressure sensor.

 

3 Disconnect the cable from the pre-heater.


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4 Remove the charge air pipe with pre-heater element.


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5 Remove the protective cover.


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6 Undo the connector (1).

Remove the charge air temperature sensor (2).


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7 Remove the harness from the protective cover.


P0015673.jpg


Remove the protective cover.

Remove the valve cover.

8 Remove the inlet manifold.


P0015674.jpg

 

Installation

9 NOTICE! Clean the sealing surfaces.

NOTICE! Use new seals.


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10 Install the inlet manifold.


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Tightening torque: 11 Nm (8.1 lbf. ft.)

Tightening sequence: Diagonal

11 Install a new valve cover gasket.


P0015677.jpg

 

12 Install the valve cover.

Tightening torque: 13 Nm (9.6 lbf. ft.)

Tightening sequence: Diagonal

Install the protective cover. Attach the harness to the protective cover.


P0015673.jpg


13 Transfer the charge air temperature sensor (2) to the new inlet manifold. Connect the harness terminal (1).


P0015672.jpg

 

14 Install the protective cover.

Tightening torque: 4.5 Nm (3.3 lbf. ft.)

 

P0015671.jpg

 

15 Install the charge air pipe with pre-heater element.


P0015670.jpg


Tightening torque: 30 Nm (22.1 lbf. ft.)

16 Install the hose (1) between the inlet manifold and the charge air cooler. Install the electrical connection (2) to the preheater relay.


P0015668.png


Fit the connector (3) to the preheater element. Install the electrical connection (4) to the charge

air temperature sensor.

 

17 Fit the pre-heater cable.


P0015669.jpg

 

18 Install the oil trap. Install the crank case ventilation hoses.


P0015556.jpg


19 Turn the main switch on. Start the Volvo engine and check for leaks.

 

Intake Manifold, Change

TAD752GE, TAD753GE, TAD754GE

Removal

NOTICE! The main switch must be in the off position before work is begun.

1 Remove the hose between the inlet manifold and the charge air cooler.

2 Remove the e-EGR cooler; refer to Cooler e-EGR, change page 159.

3 Remove the e-EGR actuator; refer to Actuator e-EGR, change page 169.

4 Remove the preheater; refer to Pre-heating, Change page 184.

5 Remove the starter motor power supply cable.


P0015272.png


6 Remove the charge air temperature sensor.

7 Remove the inlet manifold.


P0015273.png

 

Installation

NOTICE! Clean the sealing surfaces.

NOTICE! Use new seals.


P0015233.png


8 Install the inlet manifold.

Tightening torque: 30 Nm (22.1 lbf.ft.)

Tightening sequence: Diagonal


9 Move the charge air temperature sensor over to the new inlet manifold.

Tightening torque: 7.5 Nm (5.5 lbf.ft.)


P0015274.png


10 Install the starter motor power supply cable.

11 Remove the preheater; refer to Pre-heating, Change page 184.

12 Remove the e-EGR actuator; refer to Actuator e-EGR, change page 169.

13 Remove the e-EGR cooler; refer to Cooler e-EGR, change page 159.


P0015272.png


14 Install the hose between the inlet manifold and charge air cooler.

15 Turn the main switch on.

16 Start the engine and check for leaks.

 

Exhaust Manifold, Change

TAD550GE, TAD551GE, TAD750GE, TAD751GE

Removal

1 Remove the turbocharger according to Turbo, Change page 174.

2 Remove the heat shield, if fitted. Remove the exhaust manifold with gaskets.


P0015678.png


3 Change the studs.


P0015679.png


Installation

4 NOTICE! Clean the sealing surfaces.

NOTICE! Use new sealings.

NOTICE! Use new bolts.

5 Change the studs.


P0015680.png


Install the gaskets.

6 Install washers, spacer sleeves and nuts.


P0015681.jpg


7 Tightening torque: 25 Nm (18.4 lbf. ft.)

Tightening sequence: Diagonal


P0015682.jpg


8 Install the heat shield, where fitted.

9 Install the turbocharger according to Turbo, Change page 174.

 

Exhaust Manifold, Change

TAD752GE, TAD753GE, TAD754GE

Removal

1 Remove the turbocharger according to Turbo, Change page 174

2 Remove the heat shield.


P0015261.jpg


3 Remove the exhaust pipe, EGR.


P0015262.jpg

 

NOTICE! Use new seals when dismantling the exhaust pipe, EGR.


P0015263.jpg


4 Undo and remove manifold sections (1) and (2) from the exhaust manifold intermediate section.

5 Remove the exhaust manifold gasket.


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6 Remove the sprung sealing ring (1) and laminated ring gasket (2) from the intermediate section.

7 Remove the exhaust manifold (intermediate section) with gasket.


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8 Remove the laminated ring gaskets from manifold sections (1) and (2).


P0015218.jpg


Installation

NOTICE! Clean the sealing surfaces.

NOTICE! Use new seals.

NOTICE! Use new bolts.

9 Place the gasket on the sealing surface, install the exhaust manifold and tighten a few turns.

10 Install the sprung sealing ring (1) and the laminated ring gasket (2).


P0015266.jpg

 

11 Slide on the laminated rings staggered at 180°.


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12 Place the gasket on the sealing surface.


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13 Insert manifold sections (1) and (2) into the exhaust manifold intermediate section and tighten a few turns.


P0015268.jpg


14 Tightening sequence: Diagonal

Tightening torque:

1 Step 1: 15 Nm (11.1 lbf.ft.)

2 Step 2: 45 Nm (33.2 lbf.ft.)


P0015269.jpg


15 Install the exhaust, EGR.


P0015262.jpg


16 Tightening torque: 20 Nm (14.8 lbf.ft.)

 

17 Install the heat shield.


P0015261.jpg


18 Install the turbocharger according to Turbo, Change page 174

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