257-003

Service Bulletin Details

Public Details for: 257-003

Summary to be provided on a future date.


- 9999 -

Models from 9999
9999 VOLVO VN 
Field Service Bulletin
Trucks
Volvo Trucks North America
Greensboro, NC USA
Date
10.15
Group
No.
Release
257 003 01
Page
1(30)
Crankcase Ventilation Tube Heater
Installation
D11, D13, D16
FSB 257-003, Crankcase Ventiation Tube Heater
Installation
(October 2015)
For customer operating vehicles in extreme cold temperatures, Volvo Trucks has developed a
device that will prevent the crankcase ventilation (CCV) tube from building up ice and freezing
over which could lead to engine damage. The kit (part number 22578454) is available from
the PDC and consists of two components:
•
•
Heater Cable 12 volt
Vent Heater Jumper
Procedure
You must read and understand the precautions and guidelines in Service Information,
Function Group 2, Engine Safety Practices before performing this procedure. If you are not
properly trained and certified in this procedure, ask your supervisor for training before you
perform it.
1 Secure the vehicle for service by parking it on a flat level surface, applying the parking
brake, chocking the rear wheels, and placing the transmission in neutral or park.
2 Disconnect all cables from the negative (ground) battery terminals to prevent personal
injury from electrical shock and prevent damage to electrical components
Service personnel: Please circulate, read and initial
Service
Manager
Warranty
Administrator
PV729-FSB257-003_V
Workshop
Foreman
Service Technicians
USA73146
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
D11 Engines
1 Remove the secondary fuel filter and discard the filter.
W2106368
A. Filter Wrench
Page
2(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
2 Remove the bracket bolt at the bottom of the CCV pipe.
W2106365
Page
3(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
3 Loosen the hose clamp at the top of the CCV pipe.
W2106369
Page
4(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
4 Remove the CCV pipe.
W2106370
5 Measure and mark the CCV pipe for drilling. Install the grommet on the heating element.
The end of the heating element should extend 25.4 mm (1 in) below the end of the pipe.
W2106371
Mark the pipe at the grommet area
A. 25.4 mm (1 in)
B. 267 mm (10.5 in)
1. Heating Element
2. Grommet
Page
5(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
6 Center punch the CCV pipe.
W2106372
7 Drill a 6 mm (0.25 in) pilot hole.
W2106373
Page
6(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
8 Drill a 16 mm (0.625 in) hole. De-burr the hole.
W2106374
Page
7(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
9 Install the CCV heater element in the pipe. Secure the heating element to the pipe. The
radius of the heater element cable must not be less than 25 mm (0.98 in).
CAUTION
Do not bend the heater cable excessively. Damage to the cable may result.
Note: The end of the heating element should extend 25.4 mm (1 in) below the end of the
pipe.
W2106375
1. Heating Element
2. Grommet
W2106447
X must be greater than 25 mm (0.98 in)
Page
8(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
10 Install the CCV pipe. Tighten the bracket bolt at the bottom of the CCV pipe to 24 ±4 Nm
(18 ±3 ft-lb) and tighten the hose clamp to 4 ±0.6 Nm (35 ±5 in-lb).
11 Install a new secondary fuel filter.
W2106448
Page
9(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
D13 Engines with Molded Rubber CCV Pipe
1 Measure and mark the CCV pipe for cutting. The end of the heating element should extend
25.4 mm (1 in) below the end of the pipe.
W2106453
Mark the pipe at the grommet area
A. 25.4 mm (1 in)
B. 267 mm (10.5 in)
1. Heating Element
Page
10(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
2 Cut a 16 mm (0.6 in) horizontal slice in the pipe.
W2106454
A. 16 mm (0.6 in)
Page
11(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
3 Install the CCV heater element in the pipe. Secure the heating element to the pipe. The
radius of the heater element cable must not be less than 25 mm (0.98 in).
CAUTION
Do not bend the heater cable excessively. Damage to the cable may result.
Note: The end of the heating element should extend 25.4 mm (1 in) below the end of the
pipe.
W2106455
A. 25.4 mm (1 in)
1. Heating Element
2. Cable Tie
Page
12(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
W2106447
X must be greater than 25 mm (0.98 in)
Page
13(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
D13 Engines with Plastic CCV Pipe
1 Remove the clamp.
W2106457
Page
14(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
2 Remove the CCV pipe.
W2106458
Page
15(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
3 Measure and mark the CCV pipe for drilling. Install the grommet on the heating element.
The end of the heating element should extend 25.4 mm (1 in) below the end of the pipe.
W2106459
Mark the pipe at the grommet area
A. 25.4 mm (1 in)
B. 267 mm (10.5 in)
1. Heating Element
2. Grommet
Page
16(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
4 Drill a 6 mm (0.25 in) pilot hole.
W2106460
Page
17(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
5 Drill a 16 mm (0.6 in) hole. De-burr the hole.
W2106461
Page
18(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
6 Install the CCV heater element in the pipe. Secure the heating element to the pipe. The
radius of the heater element cable must not be less than 25 mm (0.98 in).
CAUTION
Do not bend the heater cable excessively. Damage to the cable may result.
Note: The end of the heating element should extend 25.4 mm (1 in) below the end of the
pipe.
W2106462
A. 25.4 mm (1 in)
1. Heating Element
2. Grommet
Page
19(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
W2106447
X must be greater than 25 mm (0.98 in)
Page
20(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
7 Install the pipe. Tighten the clamp fastener to 24 ±4 Nm (18 ±3 ft-lb).
W2106463
Page
21(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
D16 Engines
1 Loosen the hose clamp.
W2106464
Page
22(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
2 Remove the clamp
W2106465
Page
23(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
3 Remove the pipe
W2106466
4 Measure and mark the CCV pipe for drilling. Install the grommet on the heating element.
The end of the heating element should extend 25.4 mm (1 in) below the end of the pipe.
W2106371
Mark the pipe at the grommet area
A. 25.4 mm (1 in)
B. 267 mm (10.5 in)
1. Heating Element
2. Grommet
Page
24(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
5 Center punch the CCV pipe.
W2106372
6 Drill a 6 mm (0.25 in) pilot hole.
W2106373
Page
25(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
7 Drill a 16 mm (0.625 in) hole. De-burr the hole.
W2106374
Page
26(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
8 Install the CCV heater element in the pipe. Secure the heating element to the pipe. The
radius of the heater element cable must not be less than 25 mm (0.98 in).
CAUTION
Do not bend the heater cable excessively. Damage to the cable may result.
Note: The end of the heating element should extend 25.4 mm (1 in) below the end of the
pipe.
W2106375
1. Heating Element
2. Grommet
W2106447
X must be greater than 25 mm (0.98 in)
Page
27(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
9 Install the CCV pipe. Tighten the bracket bolt at the bottom of the CCV pipe to 24 ±4 Nm
(18 ±3 ft-lb) and tighten the hose clamp to 4 ±0.6 Nm (35 ±5 in-lb).
Page
28(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
Complete the Installation, All Engines
1 Disconnect the chassis harness from the air dryer. Connect the chassis harness to the
CCV harness. Connect the CCV harness at the air dryer. Route the harness to the engine
interface connector (EI). Install cable ties approximately 305 mm (12 in) apart.
W3106449
1. CCV Harness
2. Chassis Harness
Page
29(30)
Volvo Trucks North America
Field Service Bulletin
Date
10.15
Group
No.
Release
257
003
01
2 Route the CCV heating element harness to the EI connector. Connect the harness to the
CCV heater element. Secure the CCV harness as shown to the EI connector harness.
W3106450
3 Reconnect all previously removed cables to the negative (ground) battery terminals.
4 Prime the fuel system. Start the engine and check for leaks.
Page
30(30)

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