KC-2020

IMPACT 4.07.82
11/30/2020
25051-2 Smoke Test for Leak Detection
You must read and understand the precautions and guidelines in Service Information, Function Group 20, "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.
HD PowerSmokeTM Kit
Description
Item
QTY
1 PowerSmokeTM Machine
1
2 PowerSmokeTM Seal (with pass through
2
3
smoke tube)
Safety Chain
2
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.82
4
5
6
7
8
Retention Hoop
Block-Off Plug
Quick Connect Adaptors
High Intensity Halogen Inspection Light
“Y” Tube
11/30/2020
1
1
2
1
1
1
Park the vehicle on a flat and level surface.
2
Apply the parking brake.
3
Place the transmission in neutral or park.
4
Install the wheel chocks on the rear wheels.
5
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.82
11/30/2020
Disconnect the cable from the battery’s negative terminal.
6
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.82
11/30/2020
Open the hood.
7
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.82
11/30/2020
Remove the air intake tube.
8
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.82
11/30/2020
Install the block off plug (5) onto the air seal pas through smoke tube as shown.
9
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.82
11/30/2020
Attach the air seal (2) safety chain (3) to the charge air piping.
10
Insert the air seal into the lower air boot at the engine turbo.
Note: Ensure the clamp on the lower air boot connected to the engine turbo is tight enough to properly seat the air seal.
11
Using an air compressor, Inflate the air seal until the lower boot is properly sealed off.
Note: The air seal is equipped with an air supply tube and a pass through smoke tube. Use the air supply tube to
inflate the seal.
12
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.82
11/30/2020
Attach the high intensity flashlight leads to the battery terminals.
13
Attach the air supply hose to the back of the HD PowerSmokeTM tool (1) and plug the tool into a power supply using
the supplied A/C power cord.
Note: Ensure the polarity is correct or the tool will not operate.
14
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
9 / 37
IMPACT 4.07.82
11/30/2020
Remove the Exhaust Gas Recirculation (EGR) temperature sensor from the crossover pipe.
15
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.82
11/30/2020
Install the adapter (6) in the EGR temperature sensor port, and hand tighten the adapter to ensure no leaks are
permitted.
16
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.82
11/30/2020
Attach the HD PowerSmokeTM vapor supply hose (1) to the adapter (6).
17
Activate the PowerSmoke tool. Turn the flow control on. With machine set to 5 PSI, supply vapor to the intake and
EGR system to purge system of any fresh air. When vapor is emitted from the connector on the air seal, the system is
purged of all fresh air. Install the block off plug onto the air seal at this time.
18
While increasing the pressure as needed, check the intake and EGR system for visible leaks using high intensity
flashlight. If no leaks are found within 8 minutes, the system is considered to be leak free.
Note: DO NOT exceed 18 psi during this operation.
19
For the remainder of testing, the air seal will be left in the lower air boot.
Note: This begins the exhaust side portion of the leak detection testing.
20
Deactivate the HD PowerSmokeTM tool at this time.
21
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
12 / 37
IMPACT 4.07.82
11/30/2020
Remove the vapor supply hose (1) from EGR temperature sensor port adapter (6).
22
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
13 / 37
IMPACT 4.07.82
11/30/2020
Remove the adapter (6) from the EGR temperature sensor port.
23
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.82
11/30/2020
Install the EGR temperature sensor into the port as shown. Tighten the sensor to 45 ± 4.5 Nm (33 ± 3.3 ft-lb).
24
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.82
11/30/2020
Remove the T1 temperature sensor from the Diesel Particulate Filter (DPF).
25
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.82
11/30/2020
Install the adapter (6) in the T1 port. Hand tighten the adapter to ensure no leaks are permitted.
26
Connect the HD PowerSmokeTM vapor hose (1) to the adapter (6) at the T1 sensor port.
27
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.82
11/30/2020
Activate the HD PowerSmokeTM tool. Starting at 5 psi, gradually increase the test pressure as needed or up to 10 psi
for accurate leak detection. Allow the tool to operate for 8 minutes. If vapor is visible with the high intensity flashlight
from the exhaust pipe at the muffler, a cracked DPF is suspected.
28
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.82
11/30/2020
Remove the vapor supply hose from the T1 sensor port.
29
Install the block off plug (5) onto the second air seal pass through smoke tube.
30
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.82
11/30/2020
Install the exhaust stack retention hoop (8) onto the air seal safety chain.
31
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
20 / 37
IMPACT 4.07.82
11/30/2020
Install the air seal in the exhaust pipe.
32
Using an air compressor, inflate the air seal inside exhaust pipe until the air seal is properly seated.
33
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.82
11/30/2020
Remove the T3 temperature sensor at the DPF outlet.
34
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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IMPACT 4.07.82
11/30/2020
Install the adapter (6) at the T3 port in the DPF outlet. Hand tighten the adapter to ensure no leaks are permitted.
35
Attach the “Y” hose to the adapters at the T1 and T3 ports on the DPF.
36
Connect the HD PowerSmokeTM vapor hose to the “Y” adapter as shown.
37
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
23 / 37
IMPACT 4.07.82
11/30/2020
Activate the HD PowerSmokeTM tool Starting at 5 psi, gradually increase test pressure as needed or up to 10 psi for
accurate leak detection. Block the Selective Catalyst Reduction (SCR) drain if necessary. Using the high intensity
flashlight, check the exhaust system for leakage. If no leaks are found after 8 minutes, system is considered to be leak
free.
Note: It is considered normal for vapor to be visible from SCR drain during testing.
38
Deactivate the HD PowerSmokeTM tool.
39
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
24 / 37
IMPACT 4.07.82
11/30/2020
Remove the “Y” hose from the T1 and T3 ports on the DPF. Remove the HD PowerSmokeTM vapor hose from the “Y”
adapter as shown.
40
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
25 / 37
IMPACT 4.07.82
11/30/2020
Remove the adapter (6) from the T3 port.
41
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
26 / 37
IMPACT 4.07.82
11/30/2020
Remove the adapter (6) from the T1 port.
42
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
27 / 37
IMPACT 4.07.82
11/30/2020
Install the T3 temperature sensor into the port as shown. Tighten the sensor to 45 ± 4.5 Nm (33 ± 3.3 ft-lb).
43
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
28 / 37
IMPACT 4.07.82
11/30/2020
Install the T1 temperature sensor into the port as shown. Tighten the sensor to 45 ± 4.5 Nm (33 ± 3.3 ft-lb).
44
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
29 / 37
IMPACT 4.07.82
11/30/2020
Deflate and remove the air seal from the exhaust pipe.
45
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
30 / 37
IMPACT 4.07.82
11/30/2020
Deflate and remove the air seal from the lower air boot at the engine turbo.
46
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
31 / 37
IMPACT 4.07.82
11/30/2020
Remove the safety chain from the charge air piping.
47
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
32 / 37
IMPACT 4.07.82
11/30/2020
Install the intermediate air intake tube.
48
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
33 / 37
IMPACT 4.07.82
11/30/2020
Tighten the air compressor inlet hose clamp to 3.9 ± 0.5 Nm (35 ± 5 in-lb).
49
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
34 / 37
IMPACT 4.07.82
11/30/2020
Tighten the intermediate air pipe clamps to 9 ± 1 Nm (80 ± 9 in-lb).
50
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
35 / 37
IMPACT 4.07.82
11/30/2020
Connect the cable to the battery’s negative terminal.
51
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
36 / 37
IMPACT 4.07.82
11/30/2020
Close the hood.
52
Remove the wheel chocks from the rear wheels.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
37 / 37