Service Information

Document Title: Function Group: Information Type: Date:

Unit injector, replacing 237 Service Information 06/09/2017
Profile:
A25E 4x4 Volvo

Unit injector, replacing

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Valid for serial numbers

Model Production site Serial number start Serial number stop
A25E 4x4 Volvo

Op nbr 237-012

Total procedure time (hr): NaN

Tools:
9990006 Puller
88800352 Lifting tool
9990262 Adapter
9996400 Impact puller
88800550 Brush set
11668024 Rotation tool
88820016 Setting tool
88880003 Bracket

This operation also includes the tools and times needed for required parts of the following actions:
Service positions
Fuel system, bleeding
Valves, adjusting or
Valves, adjusting
Removing

1. Place the machine in service position, see Service positions.

2. Lower the front grill and pump up the engine hood.

3. Drain the fuel from the cylinder head by loosening the hose from the secondary filter head. Open the connection
by the return line on the cylinder head and use a blow-nozzle to get all the fuel out.
NOTE!
Collect the excess fuel.

4. Secure the expansion tank with a strap, and then loosen the bracket for the expansion tank.
 Figure 1

5. Remove the valve cover.

6. Remove the control valve (IEGR-valve).

Figure 2

7. Loosen the bolts for the rocker arm shaft, evenly distributed across the rocker arm shaft to avoid shear stresses.
Remove the bolts.
Lift away the rocker arm shaft with tool 9990185 and 88880003 Bracket.
Rocker arm shaft's weight: : approx. 30 kg (66 lbs)
 Figure 3

1. 9990185

8. Remove the valve yokes.

Figure 4

9. Clean very thoroughly around the unit injector. Remove the electric connection. Remove the bolt for the
attachment caliper. Remove the injector together with the attachment caliper.
 Figure 5

1. 9996400
2. 9990262
3. 9990006

10. Inspect the copper sleeve and change as needed, see Injector sleeves, replacing.

11. Fit the protective sleeve that is included in the kit 9998599. Clean the copper sleeve with the brush/brushes.

Figure 6

1. Extension
 2. Brush
3. Protective sleeve

Installing

12. Fit new o-rings on the unit injector. Fit the unit injector together with the attachment caliper.
Tightening torque, see Fuel system, tightening torques.

13. Note the code for tolerance classification on the electric connection for the new unit injector. This code shall be
used for parameter programming with tool VCADS Pro.

Figure 7

1. Code

14. Lift the rocker arm shaft into place with 9990185 and 88880003 Bracket. Make sure that the guide pins fit in the
support bearing for the camshaft. Tighten the attaching bolts, see Rocker arm shaft, tightening torques.
 Figure 8

15. Install the control valve (IEGR-valve).

Figure 9

16. Adjust clearance of the valves and unit injectors, see .

Valves, adjusting or
Valves, adjusting

17. Install the valve cover. Tighten the bolts according to the tightening diagram.
See Valve cover, tightening torques

18. Install the bracket for the expansion tank and install the expansion tank.

19. Pump down the engine hood and raise the front grill.
20. Bleed the fuel system, see Fuel filter housing, description.

21. Perform parameter programming according to VCADS Pro operation number 17030-2.