242833 Volvo.Penta Piston

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Capping Kit 1 Start By:
Drain the engine coolant. Refer to Operations and Maintenance Manual, "Coolant (Commercial Heavy Duty - Change" for the correct procedure.
Remove the coolant tank. Refer to Disassembly and Assembly, "Coolant Tank - Remove and Install (DEF Injector Coolant Tank, Open CEM)" for the correct procedure.
Ensure that all adjustments and repairs that are carried out to the Diesel Emission Fluid (DEF) system are performed by authorized personnel that have the correct training.Before beginning ANY work on the DEF system, refer to Operation and Maintenance Manual, "General Hazard" for safety information.
Care must be taken to ensure that Diesel Emission Fluid (DEF) for the system are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Ensure that the purge process for the DEF system is completed before turning the battery disconnect switch to the OFF position. Refer to the Operation and Maintenance Manual, "Battery Disconnect Switch" for further information.
Illustration 1 g06465400
Remove flexible exhaust pipe (1). Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.
Disconnect exhaust temperature sensors (2). Refer to Disassembly and assembly, "Temperature Sensor - Remove and Install (Combined SCR, DOC, and DPF Temperature Sensor)" for the correct procedure.
Disconnect harness assembly (5) from Diesel Exhaust Fluid (DEF) injector (3). Use Tooling (A) to cap the harness assembly and the DEF injector.
Remove Diesel Exhaust Fluid (DEF) line (4) and DEF injector (3). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.
Remove the soot antenna. Refer to Disassembly and assembly, "Soot Antenna - Remove and Install" for the correct procedure.
Use Tooling (A) to cap DEF injector (3).
Use Tooling (A) to plug DEF line (4).
Illustration 2 g06465405
Remove the Original Equipment Manufacture (OEM) exhaust tube assembly (6) from Clean Emissions Module (CEM) (7). Refer to the OEM for the correct procedure.
Attach a suitable lifting device to the assembly of CEM (7).
Remove bolts (8) and bolts (9) from CEM (7). Use the suitable lifting device to remove the CEM from bracket (10).Installation Procedure
Ensure that all components are clean and free from wear and damage. Replace any components that are worn or damaged. If necessary, replace the CEM as an assembly. The assembly of the CEM will be supplied with mounting brackets. The orientation of the CEM to the brackets will be preset. The clamps retaining the CEM to the bracket should not be loosened or removed.
Illustration 3 g06465405
Attach a suitable lifting device to the assembly of CEM (7).
Use the suitable lifting device to install CEM (7) to bracket (10).
Install bolts (8) and bolts (9) to CEM (7). Tighten the bolts to a torque of 44 N m (32 lb ft).
Remove the suitable lifting device from CEM (7).
Install the OEM exhaust tube assembly (6) to CEM (7). Refer to the OEM for the correct procedure.
Install the soot antenna. Refer to Disassembly and assembly, "Soot Antenna - Remove and Install" for the correct procedure.
Illustration 4 g06465400
Install Diesel Exhaust Fluid (DEF) line (4) and DEF injector (3). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.
Connect exhaust temperature sensors (2). Refer to Disassembly and assembly, "Temperature Sensor - Remove and Install (Combined SCR, DOC, and DPF Temperature Sensor)" for the correct procedure.
Connect harness assembly (5) to DEF injector (3).
Install flexible exhaust pipe (1). Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.
Turn the battery disconnect switch to the ON position.End By:
Install the coolant tank. Refer to Disassembly and Assembly, "Coolant Tank - Remove and Install (DEF Injector Coolant Tank, Open CEM)" for the correct procedure.
Fill the engine coolant. Refer to Operations and Maintenance Manual, "Coolant (Commercial Heavy Duty - Change" for the correct procedure.
If a new clean emissions module assembly is installed, use the electronic service tool to perform the "DPF Replacement Reset". Refer to Troubleshooting, "Service Tool Features" for more information.