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IMPACT 4,07.110 01.03.2021 Vineermacpuxarop waccn Ty 2119/Repair//Sleeve, injector, steel, replace. one Mopens Vinorrudpuxarop VN 148490636 Alara ny6nixayan Vinoetacpuxarop/onepauyis 26.01.2019 2114542 21145-2 Sleeve, injector, steel, replace one DER [testers ay alter signty trom the actual vehicle being serviced. However, key |components addressed in this information are represented as accurately as possible. a [All threaded fasteners that do not have a tightening torque specification in the information are tightened to a standard torque. Standard torques are available in the following specification.» |Standard tightening torques Risk of material damage. A steel brush, rotating steel brush and similar tools can damage or block the injector tip. A damaged injector can reduce engine power and result in incorrect exhaust values. + [Clean the unit injectors carefully. Use only a soft cloth soaked in paraffin or similar Risk of serious personal injury. Using the wrong technique when rotating the crankshaft can cause serious personal injury > JUse the recommended engine barring techniques for manually rotating the crankshaft. Do not Iotate the engine by pulling or prying the fan. Risk of material damage. Risk of impurities being introduced into the fuel system. [> JEnsure conditions of maximum cleanliness when carrying out any work on the fuel system, ‘Copyright this documentaton belongs tthe Valo Group. No reproduction, copying, change, amendment or otha similar lspasal's ented without prir writen consent ay ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 1195 IMPACT 4,07.110 01.03.2021 Risk of skin injury. High fuel pressure. > ]The injection system may be pressurised. When working on the injection system, remove the first part cautiously Risk of material damage. Risk of impurities being introduced into the fuel system. [> ]Seal off all apertures in the fuel system using the protection kil. Do not remove these protective lelements unti itis time to reconnect. Risk of burn injuries. ‘The coolant may be hot + JAllow the engine to cool before starting work. Do not remove the cover for the coolant tank lbefore the coolant has had time to cool down. | JRemove the coolant tank cap carefully. Use the appropriate protective equipment. Risk of material damage. ‘The engine may be hot. [> JMake the adjustment on a cold engine. Risk of skin injury. Grease, oil and chemical substances can cause skin and eye injuries. Oils and grease can cause acne and eczema. A used lubricant is more harmful than an unused lubricant. [> ]Protective equipment such as gloves and eye protection must be used when working with lgrease, oils and chemical substances. Service Information Advisory. Ifyou are not property trained and certified in this procedure, ask your supervisor for training before you perform it JYou must read and understand the precautions and guidelines in Service Information, Function |Group 2, "General Safety Practices, Engine" before performing this procedure. oom STITT Sag Sa ST as tt per writin const by the Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 2195 IMPACT 4,07.110 Special tools 36112740 88800387 38800460 38800513, (38800550 38840317 38890187 9996049 9998250 9998251 85109250 9998249 1 Park the vehicle on a level surface. l2 Apply the parking brake. [8 _|Place the gear lever in neutral [4 install the wheel chocks, [5 [Disconnect the cable from the negative terminal 01.03.2021 ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by pve aneck bop aeyare va MoM 08 ee ‘he Volo Group nna womer Burs vameen, OFpaTATe mane na 0, 00 cocromE NeNaToK 3195 01.03.2021 COOLANT EXTRACTORINJECTOR DRANHOSE = ——=«&; 9996049 on - ‘ IMPACT 4,07.110 01.03.2021 g g é 3 5 3 clover cman bgt oho Goi. Nop, nye pwoesenansneck wtbopuaiyn arya Wa MOM 88 9D IMPACT 4,07.110 01.03.2021 [11 [Remove te ar due | e 3 2 z g 3 8 IMPACT 4,07.110 01.03.2021 {13 [Remove the air fiter housing, | 14 [Disconnect the connector. 15 [Remove the ties. ‘Copyright to this documentaton belongs tthe Valo Group. No reproduction, copying, change, amendment or eter inl dspsal "Yelvo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 8/95 led without pr ritan consent by 17 [Remove the clamp, IMPACT 4,07.110 01.03.2021 Remove the pipe. IMPACT 4,07.110 01.03.2021 Tm UU — f20 fat Loosen the screws. [22 Remove the vaive cover. INote tis possible, when removing a valve cover screw, that the crush sleeve is drawn out ith it If this happens along the rear, lower edge of the cover, take care to prevent the Chpyart tis dechmentaton belongs tothe Veo Grup. Noreproducto, copying charge, amendment rather sml eee end witb eorwrtn consent by ‘he Volo Group omaman secs opuar aya um reexoanl rt woxe arm OEP mn 1, Wo CREO Nea 12195 IMPACT 4,07.110 01.03.2021 |sleeve from falling into the gear train as this could result in engine damage. [23 |Clean around the fuel line connection [24 Position a container under the component. Risk of skin injury. High fuel pressure. > |The injection system may be pressurised. When working on the injection system, remove the frst part cautiously [25 Remove the fuel line. [26 [Drain the fuel. [27 install the fuel line when the fuel is finished draining. ‘Copyright to this documentaton belongs tthe Valo Group. No reproduction, copying, change, amendment or eter inl dspsal ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 13195 ied witout rr wtan consent by IMPACT 4,07.110 01.03.2021 [28 [Disconnect the connectors. [2a [Remove the cap nuts. [30 JRemove the pressure pipe. ‘Copyright to this docamentaton belongs tthe Vaio Group. No reproduction, copying, change, amendment or ether inl dspsal "Yelvo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 14195 led without pr writen consent by IMPACT 4,07.110 01.03.2021 [31 Perform this procedure when the condition below is met. |conditions. [¢ [IF not previously removed. + [Disconnect the connector. Ccheyri fo this documentaton belongs tthe Vaio Group. No reproduction, copying change, amendment or otha similar lspasal' ented without prir write consent ay ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 15/95 IMPACT 4,07.110 01.03.2021 [32 [Clean around the sensor. [a3 JRemove the sensor. Risk of material damage. ‘Component damage could occur if debris enters. > [Cover openings to prevent debris from entering, [34 Cover or plug openings immediately. ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 16/95 IMPACT 4,07.110 01.03.2021 [35 [Remove the screw. = Note [The pipe is removed at a later stage along with the rocker arm shaft ‘Copyright to this documentaton belongs tthe Valo Group. No reproduction, copying, change, amendment or eter inl dspsal ‘he Volo Group ied witout rr wtan consent by pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 17195 IMPACT 4,07.110 01.03.2021 lLoosen the adjustment screws. i Loosen the screws. d ks his docureraton belongs othe Valo Group. Ne reproduction, copying, endmart or eer aiardlaposal aie aha rnn consent hy the Voh pwoesenaaneck ntbopuaxyn arvana va WoMBNT e8 repova'a IMPACT 4,07.110 01.03.2021 Tightening torque Rocker arm shaft, screw 1. [Remove screws: 1-3-5-7-9-11 6 pes 2 [Remove screws: 13-2-12-4 10-6-8 7 pes INote lLoosen gradually in the sequence indicated, [38 Remove the screws. ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 19/95 IMPACT 4,07.110 01.03.2021 [29 install the tool (A). Required material LIFTING TOOL 85109250 ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 20/95 IMPACT 4,07.110 01.03.2021 [40 JRemove the rocker arm shaft [41 JRemove the pipe. Note Discard the pipe, [Do not reuse. ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 21195 IMPACT 4,07.110 01.03.2021 la Remove the bridges. Note INote the position. 13 [This step contains 2 alternatives, [Select one of the valid alternatives below. print lat te Tpvmetoman anech 01.03.2021 IMPACT 4,07.110 + |Clean around the injectors thoroughly. + JRemove the screw. > |Install the tools. 23/95 IMPACT 4,07.110 01.03.2021 A PULLER 9990006 B SLIDE_HAMMER 9990013 + ]Free the injector from the cylinder head, + [Remove the tools. + JRemove the yoke. Ccheyri fo this documentaton belongs tthe Vaio Group. No reproduction, copying change, amendment or otha similar lspasal' ented without prir write consent ay ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 24195 IMPACT 4,07.110 01.03.2021 + Remove the injector. INote INote the location. [Service hint [Rotate the injector away from the common rail pipe and over the top of the valves. IMPACT 4,07.110 01.03.2021 + install the sleeve. Required material PROTECTING_SLEEVE 9998249 IMPACT 4,07.110 01.03.2021 install the plug (A), only if the sleeve will not be replaced immediately. Required material ‘SEALING PLUG 9998251 lAlternative 2 / 2 [Clean around the injector thoroughly. [Remove the screw. choy fo this documentaton belongs tthe Valo Group. No reproduction, copying, change, mandment er other inl dspsal ‘he Volo Group ied witout pre wt consent oy pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 27198 IMPACT 4,07.110 01.03.2021 8 _ | SLIDE HAMMER 2990013 + JRemove the injector. ea INote {= Note the location. + install the sleeve. Required material PROTECTING_SLEEVE 9998249 Install the plugs (A), only ifthe sleeve will not be replaced immediately. Required material ‘SEALING PLUG 9998251 consent by his documertaton belongs othe Volo Group Norepreducon, copying, change, amendment rota smi dsposal sented witout pr wit ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 29195 cheyrant IMPACT 4,07.110 01.03.2021 Risk of material damage. Risk of impurities being introduced into the fuel system. [Ensure conditions of maximum cleanliness when carrying out any work on the fuel system. [44 Clean around the sleeves thoroughly. [45 _ [install the sealing rings (A). Required material ‘SEALING_RING 9998260 2 pes ‘Copyright to this documentaton belongs tthe Valo Group. No reproduction, copying, change, amendment or eter inl dspsal ied witout rr wtan consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 30/95 IMPACT 4,07.110 01.03.2021 [46 [Remove the nut. Required material SLEEVE 88800460 PULLER 88800387 Note io Ifthe tool is being used for the first time remove the nut, [47 [Assemble the tools. Note [Lubricate the threads. Note Hand tighten. ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 31/95 IMPACT 4,07.110 01.03.2021 Yen all (me é tl [48 [install the tool (A). Required material SLEEVE 88800460 PULLER 88800387 [49 [Press down the puller to the bottom of the sleeve. ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 32/95 IMPACT 4,07.110 01.03.2021 [50 Tighten the screw (A). Note i [The screw must be tightened sufficiently to hold the puller in place, use moderate force, ‘Copyright to this documentaton belongs tthe Valo Group. No reproduction, copying, change, amendment or eter inl dspsal ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 33/95 ied witout rr wtan consent by IMPACT 4,07.110 01.03.2021 [51 install a counterhold on the screw (A). a Note lonly tighten the nut using a hand tool [52 [Tighten the nut (B) so that the sleeve releases from the cylinder head. ‘Copyright to this documentaton belongs tthe Valo Group. No reproduction, copying, change, amendment or eter inl dspsal ‘he Volo Group ied witout rr wtan consent by pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 34/95 IMPACT 4,07.110 01.03.2021 [53 JRemove the tool (A) and the sleeve. [54 Remove the sleeve from the tool. ‘Copyright to this documentaton belongs tthe Valo Group. No reproduction, copying, change, amendment or eter inl dspsal ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 35/95 ied witout rr wtan consent by IMPACT 4,07.110 01.03.2021 [55 _ [install the sleeve (A). [56 _ Jinstall the retainer (8). [57 [Clean the cylinder head with the brush (C). Required material TOOL KIT 88800550 ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 36/95 IMPACT 4,07.110 01.03.2021 A SLEEVE 9998580 HEXAGON SOCKET SCREW 994825 c BRUSH 9808618 [58 [Clean the cylinder head with the brush (F).. ‘Copyright this documentaton belongs tthe ValvoGzoup. No reproduction, copying, change, amendment or othe similar lsposal's entila wthotpriarwrtlen conse ‘he Volo Group Towne aneck wntbopacyn aeryare va MoM 88 peor nyBrusagee Won Ents Men, OFpArie ane nT, Mo CoerOMN Nex 37/95 Y IMPACT 4,07.110 01.03.2021 SLEEVE 9998580 HEXAGON SOCKET SCREW 994825 HANDLE 9808616 RETAINER 9808613 RETAINER 9808615 =] m) oO) o) ey] > BRUSH 9808614 [59 [Clean the cylinder head with the brush (C), ‘Copyright this documentaton belongs tthe ValvoGzoup. No reproduction, copying, change, amendment or othe similar lsposal's entila wthotpriarwrtlen conse ‘he Volo Group Towne aneck wntbopacyn aeryare va MoM 88 peor nyBrusagee Won Ents Men, OFpArie ane nT, Mo CoerOMN Nex 38/95 Y IMPACT 4,07.110 01.03.2021 A SLEEVE 9998580 HEXAGON SOCKET SCREW 994825 c BRUSH 9808617 [60 [Check the drive screw. [Tech data Check dimension, drive screw (A) 7.9 £0.03 mm Length, drive screw, assembly tool 46 40.2 mm Note [Discard the drive screw ifit is not in spec. ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group Towne aneck wntbopacyn aeryare va MoM 88 peor nyBrusagee Won Ents Men, OFpArie ane nT, Mo CoerOMN Nex 39/95 IMPACT 4,07.110 [61 |Apply clean engine oil to the threads of the tool. [62 Apply graphite paste onto the swaging bit [63 Jinstalthe O-ring i [Note lUse a new part [64 Apply clean engine oil to the O-ing 01.03.2021 ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 40/95 IMPACT 4,07.110 01.03.2021 [65 Apply activation agent Loctite 7649. Note ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 41195 IMPACT 4,07.110 01.03.2021 les [Apply sealant 5689330083 Loctite 510. Tech data Sealant, bead thickness =25mm Required material ‘SEALING COMPOUND, 1161059 ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pve aneck bop aeyare va MoM 08 ee nna womer Burs vameen, OFpaTATe mane na 0, 00 cocromE NeNaToK 42195 IMPACT 4,07.110 01.03.2021 oO [67 install the sleeve into the injector bore. Required material MANDREL 88800513 [Service hint [Ensure that the injector sleeve seats on the bottom of the tool (A), ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 43/95 IMPACT 4,07.110 01.03.2021 [68 install the tool and sleeve. [69 install the injector yoke. [70 Torque tighten the screw. Tightening torque Yoke, assembly tool ‘80 Nm ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 44195 IMPACT 4,07.110 01.03.2021 [71 [Tighten the nut (1) to draw the drive screw through the sleeve. Note [The nut must only be tightened with a hand tool [72 _ Loosen the nut (3) back through the sleeve until loose. ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group Towne aneck wntbopacyn aeryare va MoM 88 peor nyBrusagee Won Ents Men, OFpArie ane nT, Mo CoerOMN Nex 45/95 IMPACT 4,07.110 01.03.2021 [73 Remove the yoke. [74 Remove the tools. [75 Remove the sealing rings (A). [76 [install the plug (A), only if the injector will not be install immediately Required material SEALING PLUG 9998251 ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 46/95 IMPACT 4,07.110 01.03.2021 [77 |This step contains 2 alternatives, [Select one of the valid alternatives below, lalternative 1/2 [Remove the plug (A), if installed. Ccheyrigt this documentaton belongs tthe Valo Group. No reproduction, copying change, amendment or otha similar lspasal' entlad without pir write consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 47195 IMPACT 4,07.110 01.03.2021 > install the sieeve (A). + [Install the retainer (B) [Clean the conical sleeve using the handle (C) and the brushes (D). Required material TOOL KIT 28800550 INote [The sleeve must be cleaned thoroughly, choy fo this documentaton belongs tthe Valo Group. No reproduction, copying, change, mandment er other inl dspsal ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 48/95 ied witout rr wt consent by IMPACT 4,07.110 01.03.2021 SLEEVE 9998580 HEXAGON SOCKET SCREW 994825 HANDLE 9808616 oO) oe) ay] > KIT 88880056 + Remove the tools. + |Note the injector trim code and cylinder number to facilitate programming. Required material BARCODE SCANNER 88890187 Ccheyri fo this documentaton belongs tthe Vaio Group. No reproduction, copying change, amendment or otha similar lspasal' ented without prir write consent ay ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 49/95 IMPACT 4,07.110 01.03.2021 t [pstaine ora hoya tis Hocertaton belongs 1 te oho Grup. No reproduce, copying, change, amendment abe sme dposl ented witout er wrt consentby ‘heave Group Mvaegoa nec nopuayen anya va owt 68 Nepean Eon wx Eh OMENEA, CEPAHTE outa a 1, wo Cocrome nex 50/95 IMPACT 4,07.110 01.03.2021 INote lUse anew part (iJ INote install an O-ring in the upper groove only. + [Clean the injector. + Apply a thin layer of clean engine oil. choy fo this documentaton belongs tthe Valo Group. No reproduction, copying, change, mandment orate inl dlspsal ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 51/95 itd witout por rita consent by IMPACT 4,07.110 01.03.2021 install the injector and yoke, > [Centre the injector between the valve springs. Note Install the screw, INote lUse a new part choy this Hocumentaton belongs tthe Valo Group. No reproduction, copying change, amendment or oar similar lspasal's entilad without err write consent ay ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 52/95 IMPACT 4,07.110 01.03.2021 ‘orque tighten the screw. Tightening torque Injector, yoke, screw 4 20° Nm 2 (18086 3, [Loosen the screw = 150° 4 25% Nm 5. 9085" lalternative 2/2 + JRemove the plug (A), if installed. Chey fo this documentaton belongs tthe Valvo Geoup. No reproduction, consent oy IMPACT 4,07.110 01.03.2021 > install the sieeve (A). + [Install the retainer (B) [Clean the conical sleeve using the handle (C) and the brushes (D). Required material TOOL KIT 28800550 INote [The sleeve must be cleaned thoroughly, choy fo this documentaton belongs tthe Valo Group. No reproduction, copying, change, mandment er other inl dspsal ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 54/95 ied witout rr wt consent by IMPACT 4,07.110 01.03.2021 SLEEVE 9998580 HEXAGON SOCKET SCREW 994825 HANDLE 9808616 oO) oe) ay] > KIT 88880056 + Remove the tools. + |Note the injector trim code and cylinder number to facilitate programming. Required material BARCODE SCANNER 88890187 Ccheyri fo this documentaton belongs tthe Vaio Group. No reproduction, copying change, amendment or otha similar lspasal' ented without prir write consent ay ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 55/95 01.03.2021 IMPACT 4,07.110 I E [rst the O-ring. hoya tis Hocentaton belongs 1 te Veh Grup. No reproduce, coping, change, amendment abe smi dposl ented witout eer wrt consent by ‘heave Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 56 / 95 IMPACT 4,07.110 01.03.2021 INote lUse anew part (iJ INote install an O-ring in the upper groove only. > TApply a thin layer of clean engine oil choy fo this documentaton belongs tthe Valo Group. No reproduction, copying, change, mandment er other inl dspsal ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 87/95 ied witout rr wt consent by IMPACT 4,07.110 01.03.2021 [Position the injector, INote ja [Rotate the injector away from the common rail pipe and over the top of the valves. > Install the yoke. INote js [Tilt the injector toward the common rail pipe, install the yoke. IMPACT 4,07.110 01.03.2021 + ]Seat the injector into the cylinder head. INote [The injector must be centred to connect the pressure lines correctly. > Jinstall the screw. INote lUse a new part, [Torque tighten the screw. Tightening torque Injector, yoke, screw 1 20°° Nm 2 *([18085° 3. [Loosen the screw choy fo this Hocarentaton belongs tothe Varo Group. No reproduction, copying, change, render ofa ilar lspsel eiled wihau pir wie consent ay ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 59/95 01.03.2021 IMPACT 4,07.110 [78 install the bridges. ee the seals. " chow IMPACT 4,07.110 | JNote L |Use new parts, [20 install the pipe. Note lUse a new part ei [a1 install the rocker arm shaft | |Note | [Take care not to damage the oil pipe. ls2 [Remove the lifting toot (A). ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, pyar aneck wntbopmaxyn ayaa na MoM 0 pepo 01.03.2021 IMPACT 4,07.110 01.03.2021 q [23 install the screws. Note INote any marks on the screw heads. Note [Each mark on the screw head indicates the amount of times the screw has been torqued. [The screws may be torqued for a maximum of five times, ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 62/95 IMPACT 4,07.110 01.03.2021 fea [Torque tighten the screws. chy Tightening torque ‘Camshaft bearing cap, screw otis documertaton belongs tthe Vero Gzoup. No reproduction Tightening sequence: 14-15-16-17-18-19-20 40 £3 Nm Repeat the tightening sequence until the rocker arm bridge contacts the bearing housings. Tightening sequence: 8-6-10-4-12-2-13 6025 Nm Tightening sequence: 14-15-16-17-18-19-20 9035" Tightening sequence: 1-3-5-7-9-11 4023 Nm Tightening sequence: 1-3-5-7-9-11 120 5° Loosen the screws: 2-4-6-8-10-12 6 pes bya. Perea ria 2 tea pr writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 63/95 IMPACT 4,07.110 01.03.2021 4023 Nm Tightening sequence: 2-4-6-8-10-12-13 120 45° le5 [Mark the screws, la6 install the screw. [7 Torque tighten the screw Tightening torque Oil pipe, screw Me 2424 Nm ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 64/95 IMPACT 4,07.110 01.03.2021 “G Zi (& VAS [88 [Remove the protecting cover and plug, [a9 install the sensor. | JNote INo sealant or thread locker should be used, [20 Torque tighten the sensor. Tightening torque Pressure sensor, common rail 40 25 Nm ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 65/95 IMPACT 4,07.110 01.03.2021 [91 Perform this procedure when the condition below is met. |conditions. fe [ifnot previously installed > [Connect the connector. choy fo this documentaton belongs tthe Valo Group. No reproduction, copying, change, mandment er other inl dspsal ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 66/95 ied witout rr wt consent by IMPACT 4,07.110 01.03.2021 [s2 install the pressure pipe. Note lUse a new part. Note [Do not use lubricant when installing the pipe. Install the pipe on the common rail first. Hand tighten the nuts. [93 fTo avoid damaging the pressure pipe when the nuts are tightened, check that itis correctly positioned, ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 67/95 IMPACT 4,07.110 01.03.2021 [4 Torque tighten the cap nut. Tightening torque Pressure pipe, cap nut 20 +2 Nm ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 68/95 IMPACT 4,07.110 01.03.2021 [95 Torque tighten the cap nut. Tightening torque Pressure pipe, cap nut 20 +2 Nm ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 69/95 IMPACT 4,07.110 [96 [Anglecighten the cap nut Tightening torque Pressure pipe, cap nut (common rail) 30" 01.03.2021 IMPACT 4,07.110 01.03.2021 [97 JAngletighten the cap nut. Tightening torque Pressure pipe, cap nut (injector) 30" [98 [Connect the connectors. ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 71195 IMPACT 4,07.110 01.03.2021 [99 Perform this procedure when the condition below is met, IConditions [¢ [if not previously installed. > [Remove the plug cheyrant his documertaton belongs othe Volo Group Norepreducon, copying, change, amendment rota smi dsposal sented witout pr wit ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 72195 consent oy + install the cranking adapter (A). Required material CRANKING ADAPTER 28840317 IMPACT 4,07.110 01.03.2021 100 Note the camshaft marking Note \camshatt cap. When checking or adjusting, the mark must be centred between the lines on the 1101 [Adjust the rockers according to the chart. ‘he Volo Group Icamshaft marking ‘CAM POSISTION INLET INJECTOR/PUMP] EXHAUST 3, Cylinder 1 _ Cylinder 3 45 Cylinder 4 - Cylinder 5 an Gylinder 2 _ Cylinder 4 cia Oylinder 6 Pump 4 Oylinder 4 3/P2 Cylinder 3 Pump 2 Cylinder 2 Cheyne hs docmentton lng ine Voko Gp. No repost cpyng, change, renamed oe iar depos led witht err rian consent by pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea T4195 IMPACT 4,07.110 01.03.2021 5IP6 | oylinders | Pumpé | _—_Svlindor | | 1102 Rotate the crankshaft to the next timing mark on the camshaft, INote [Rotate the crankshaft in the normal engine rotation direction. |Ask for assistance. ‘Copyright to this documentaton belongs tthe Valo Group. No reproduction, copying, change, amendment or eter inl dspsal ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 75195 ied witout rr wtan consent by IMPACT 4,07.110 01.03.2021 103. [Check the inlet valve rocker arm clearance. Tech data Inlet valve, rocker arm, clearance 0.2 £0.05 mm ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group Towne aneck wntbopacyn aeryare va MoM 88 peor nyBrusagee Won Ents Men, OFpArie ane nT, Mo CoerOMN Nex 76195 IMPACT 4,07.110 01.03.2021 1104 [Perform this procedure when the condition below is met. IConditions Je [ifthe valve clearance is not correct. + JLoosen the nut (A) [Adjust the screw (B) until the feeler blade can be moved but there is some resistance, [Prevent the screw from turning (B), and torque tighten the nut (A). Tightening torque Rocker arm, lock nut 38 44Nm 105 Loosen the nut (A) 106 Adjust the screw (B) until there is zero clearance between the adjustment screw and the injector ball socket, ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea T7195 IMPACT 4,07.110 01.03.2021 10 [Angle tighten the screw (B), Tech data Injector, adjusting screw 240 #20" troupe wtan consent by 2 elua Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 78195 IMPACT 4,07.110 01.03.2021 108 [Prevent the screw (B) from turning and torque tighten the nut (A). Tightening torque Injector, rocker arm, lock nut 52.4 Nm 109. [Check the clearance. Tech data Exhaust valve, rocker arm, clearance (0.8 £0.05 mm_ Note lUse a set of feeler gauges. [ 0 Pero this procedure when the condition below is met. Chpyrart his decumentton belongs othe Veo Grup. Noreproducton, copying charge, amendment rahe sml peal end wine eer wth consent by ‘heVoho Group owgnenananech webopuacy axyarbva a MoMONT ee nepeonwanvo nyErvacgnH Wome Bu MeNE, OBPRDAT WAN 0, 70 COETONNE NEAR 79195 IMPACT 4,07.110 |Conditions 01.03.2021 [° [ifthe valve clearance is not correct, > |Loosen the nut (1) > JAdjust the screw (2) unti the feeler blade can be moved but there is some resistance. Tech data Exhaust valve, rocker arm, clearance 0.80 #0.05 mm + |Prevent the sorew from turning (2) , and torque tighten the nut (A) . Tightening torque Rocker arm, lock nut 38 £4Nm + JAdjust all the other rocker arms in the same way. 111 JRemove the cranking adapter (A). Required material CRANKING ADAPTER 88840317 ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 80/95 IMPACT 4,07.110 01.03.2021 112 [Install the plug. ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 81/95 IMPACT 4,07.110 01.03.2021 Position the screws. [Note Inspect the gasket, replace as needed. [Service hint [Temporarily securing the screws at the rear of the cover in the upmost position will ald jn installation 114 [install the valve cover. ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, IMPACT 4,07.110 01.03.2021 115 [Torque tighten the screws. Tightening torque Valve cover, screw Tightening sequence: 1-20 2424 Nm 116 [Install the pipe. Si Note Inspect the internal sealing ring. ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 83/95 IMPACT 4,07.110 117 [install the pipe. i Note |Check the sealing ring and hose for damage, replace as needed. 01.03.2021 IMPACT 4,07.110 Tightening torque 01.03.2021 \V band clamp screw 10.21 Nm Tightening torque Hose clamp 14,9 22Nm 119 [Install the clamp. 120. [Torque tighten the screws. Tightening torque Screw Ma 24 24 Nm ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, IMPACT 4,07.110 01.03.2021 12 [Connect the connector. 12 install the ties as needed. ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 86/95 IMPACT 4,07.110 01.03.2021 ‘he Volo Group IMPACT 4,07.110 01.03.2021 Tightening torque Screw M10 48 48 Nm 126 [Install the air duct. 127 [Torque tighten the clamps. Tightening torque ‘Air duct clamp 921 Nm ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, jndent or ote similar lspasal's ented without prior writen consent by pwoeaenaanock wtbopwauyen arya Wa MOM 88 po IMPACT 4,07.110 01.03.2021 [= Choyrnt pwoesenaaneck ntbopuaxyn arvana va WoMBNT e8 repova'a IMPACT 4,07.110 01.03.2021 Tightening torque Clamp, screw 3.95 40.6 Nm 1130 Fil the cooling system, | JNote | |Use approved coolant. ‘Copyright to this documentaton belongs tthe Valo Group. No reproduction, copying, change, amendment or eter inl dspsal "Yelvo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 91/95 led without pr ritan consent by IMPACT 4,07.110 01.03.2021 131 [Connect the cable to the negative terminal, ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group pwoesnasneck ntbopuaxyn arya wa MoM 88 repeoaarAnok nySreeayee W Wome Ens HoMeNOKA, OEparite avant 1, WTO CocromN nea 92/95 IMPACT 4,07.110 01.03.2021 Note jon engines with manual hand pump, bleeding of the fuel system is only required when the Gl |whole fuel system has been drained. 1132. [Pump with the hand pump about 200 times. Note [Do not open any connections.| IMPACT 4,07.110 01.03.2021 133 [Lower the bonnet Note [Ensure that the bonnet is latched, 1134. JRemove the wheel chocks. IMPACT 4,07.110 01.03.2021 ‘Copyright this documentaton belongs tthe Vlvo Group. No reproduction, copying, change, amendment or ota similar lspasal's ented without prir writen consent by ‘he Volo Group Towne aneck wntbopacyn aeryare va MoM 88 peor nyBrusagee Won Ents Men, OFpArie ane nT, Mo CoerOMN Nex 95/95