TJ21965-5-0-2019

VOLVO CAR
SERVICE AND PARTS BUSINESS
Technical Journal
TITLE:
Oil in cooling system. New cleaning method developed
REF NO:
ISSUING DEPARTMENT:
CAR MARKET:
TJ 21965.5.0
Technical Service
United States and Canada
PARTNER:
ISSUE DATE:
STATUS DATE:
3 US 7510 Volvo Car USA
2019-01-23
2019-02-05
FUNC GROUP:
FUNC DESC:
2600
Cooling system
Page 1 of 8
“Right first time in Time”
Attachment
File Name
T9318EN01.doc
File Size
0.1547 MB
Vehicle Type
Type
Eng
Eng
Desc
Sales
Body
Gear
1XX
2XX
3XX
5XX
Steer
Model Year
1999-9999
2000-9999
2001-9999
2004-9999
Plant
Chassis range
0000000-9999999
0000000-9999999
0000000-9999999
0000000-9999999
Struc Week
Range
199815-0
199943-0
200032-0
200339-0
CSC Customer Symptom Codes
Code
J9
Description
Lubrication and oil system/Oil leakage
VST Operation Number
VST Operation Number
99703-2
Description
DTC Diagnostic Trouble Codes
Rows beginning with * are modified
Note! If using a printed copy of this Technical Journal, first check for the latest online version.
Produced in the USA and available as an electronic document. Hard copy documents are printed in USA on recycled paper containing
a minimum of 50% wastepaper and 10% post-consumer waste.
© 2019 VOLVO CAR USA, LLC
Technical Journal 21965.5.0
Text
*Updated with correct attachment.
DESCRIPTION:
Oil can be found in cooling system for several reasons, e.g:
-- defect engine oil cooler
-- defect radiator (mixing coolant - ATF oil)
-- defect cylinder head gasket
SERVICE:
New cleaning method developed, using a “flush gun”.
See attachment for instruction how to use it.
VSTG OPERATION NUMBER:
99703-2
To view TJ attachment continue to next page. This TJ has one attachment.
Page 2 of 8
2019-02-05
Page 1 of 6
§ Volvo Car Customer Service
TJ Instruction
No. T9318
Date
Nov - 09
Issue 01
Title
Cooling system, flushing
Model
All (see exception in the method)
Model Year
All
Competence
requirement
Volvo Level 1 Technician
Material
Quantity
Part No.
Radiator hoses
See spare parts
catalogue for relevant
Model and engine
Expansion tank and cover
See spare parts
catalogue for relevant
Model and engine
Thermostat/Thermostat kit
See spare parts
catalogue for relevant
Model and engine
Coolant glycol Volume see relevant
engine
Special tools
Quantity
Part No.
Cleaning gun
1
9814122
Radiator hose
1
31319442
Radiator hose
1
30761633
1.
Note! Some variation in the
illustrations may occur, but the
essential information is always correct.
Instruction T9318
Page 2 of 6
2.
General
A new tool 9814122 for flushing the
cooling system has been introduced.
The tool uses water and compressed
air.
After flushing, the thermostat, all
rubber radiator hoses and the
expansion tank with cover must be
replaced.
Note! The thermostat must be
removed from the thermostat housing
and the thermostat housing reinstalled
for flushing to be effective.
These instructions do not apply to
D4164Tx, D4204Tx and
D5244T10/14/16/19 because the
thermostat cannot be removed from
the thermostat housing.
IMG-333178
3.
The hose that is connected to the
thermostat housing during flushing
must reach outside the engine
compartment.
Tip! Use radiator hoses 30776224 and
30761633 as tools. These are suitable
for the different diameters on the
outgoing connector on the thermostat
housings.
IMG-333508
TJ Instruction
T9318
Page 3 of 6
4.
Thermostat removal
Drain the cooling system.
Remove the thermostat, see:
Removal, replacement and installation
2 Engine with mountings and
equipment
26 Cooling system
Thermostat/temperature sensor
coolant, replacement
5.
On most engines the thermostat
housing with thermostat is only
available as a spare part. In these
cases, the thermostat must be
removed from the thermostat housing
The following steps show how to do
this.
6.
Removal of the thermostat
from the thermostat
housing
B4184Sx, B4204Sx
IMG-333181
Instruction T9318
Page 4 of 6
7.
B6324S, B6304T2, Step 1
IMG-333180
8.
B6324S, B6304T2, Step 2
IMG-333533
TJ Instruction
T9318
Page 5 of 6
9.
S80 07-/V70 08-/ C30/S40/V50
B5254Sx/Tx
Remove the thermostat.
Remove the rubber gasket from the
thermostat.
Install the rubber gasket in the
thermostat housing.
Assemble the thermostat housing.
IMG-333314
10.
Other engines not shown in any steps:
See relevant model and engine in
VIDA.
Reinstall the thermostat housing on
the engine.
Instruction T9318
Page 6 of 6
11.
Flushing cooling system
Connect the cleaning gun to hose (1).
Connect the water hose and
compressed air to the cleaning gun.
Connect a long hose (2) to the
thermostat housing, which extends
outside the engine compartment.
Suggestion: radiator hose 30776224
and 30761633.
Use hot water.
Note! When flushing, the first 20 litres
must be flushed out into a container
because the fluid contains coolant that
must not be flushed out into the
drainage network. Flushing can then
occur over a flush plate with oil
separation.
Flush the cooling system for at least
10 minutes if hot water is used.
If hot water is not available, extend the
time to 20 minutes.
IMG-333208
12.
After flushing, the thermostat, all
rubber radiator hoses and the
expansion tank with cover must be
replaced.
For thermostat replacement, see:
Removal, replacement and installation
2 Engine with mountings and
equipment
26 Cooling system
Thermostat/temperature sensor
coolant, replacement
To replace radiator hoses and
expansion tank, see the spare parts
catalogue for the relevant model and
engine.
There is no method to be followed for
the replacement of radiator hoses and
expansion tank.