VOLVO CONSTRUCTION EQUIPMENT

SERVICE BULLETIN
Language Code Group Product No. Version Date Page
GB 212 GRD/ WLO 13 K 7 2014-11-28 1/16
Applies to models
G930, G940, G946, G960, L110E, L110F, L120E, L120F, L60E, L60F, L70E, L70F, L90E, L90F
Supersedes SB 212 GRD / WLO 13 K Version 6 dated 2014-11-04. Changes are marked with lines in the margin.
ONLY FOR DISTRIBUTORS / DEALERS

D6/D7 Exhaust gas leakage into the cooling

system
NOTE!
Please pay attention to the safety instructions in the Operator's
and Service Manuals concerned.
This Service Bulletin is to be considered as technical information
only and is not subject to any reimbursement programs outside
normal warranty.

Cause
The cooling system may become over pressurized due to
combustion gases leaking into the coolant passages of the engine
block. When this occurs bubbles can be found in the expansion
tank and coolant may leak out.
This can happen because some of the cylinder liner locations, in
the cylinder block, have been machined a little deeper than the
specification allows for.
NOTE!
Refer to Fig. 2.
Fig.1 Cylinder liner sealing surface
NOTE!
There are other reasons for exhaust gases in coolant, such as
low torque of cylinder head bolts, failed head gasket or cylinder
head. It is important to check other reasons of failure before
checking the liner height.

Volvo Construction Equipment

Feedback mail: sb@volvo.com
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Fig.2
Limit between cylinder liner sealing surface &
cylinder block surface (A).
NOTE: Specification A:
D6; Min. 0.07 mm (0.0028 in) / Max. 0.12 mm
(0.0047 in)
D7; Min. 0.03 mm (0.0011 in) / Max. 0.08 mm
(0.0031 in)
Action
1 An inspection program, with high frequency measurement,
has been introduced in the cylinder block production line in
order to provide strict quality control measurement process.
NOTE!
The D6 and D7 engine serial break number for these
improvements is 10588594.
2 As an additional inspection program, 100% measurements
of 4 points on all cylinders has been introduced in the block
production line.
NOTE!
The engine serial number breaks for additional improvements
are:
1) D6: 10873803
2) D7: 10837245
3 The assembly torque process of cylinder head bolts has
been updated in production. In order to improve the
capability of the cylinder head bolts, the spindle speed is
reduced and also a pause time is introduced in each
sequence of the torque processes which is being operated
by the robot.
NOTE!
The engine serial break numbers for the introduction of this
improved cylinder head torque process are:
1) D7: 11635181
2) D6: 11722178
In case of a field failure:
- Contact regional technical support via Techline when you have
this issue on the machine produced before and after this
improvement.
- First, check and record the torque of cylinder head bolts before
removing cylinder head by following the work instruction.
- Check the cylinder head gasket if there is any defect, such as
crack or wearing.
- If torque of bolts and head gasket does not show any problem,
check the distance between the cylinder liner sealing surface and
cylinder block surface by following the work instruction.
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Part information

Model / Serial Number Part name Part number

L60E, L70E, L90E
Cylinder Block D6D
Engine serial number –01060658
L60E, L70E, L90E
Engine serial number 01060659– Cylinder Block D6D VOE21960405
01099383
L60E, L70E, L90E
Cylinder Block D6D
Engine serial number 01099384–
L60F, L70F, L90F Cylinder Block D6E VOE21679572
L110E/L120E Cylinder Block D7D VOE20544667
G930/G940G946/G960
Cylinder Block D7E VOE20851922
L110E/L110F/L120E/L120F
G930 Engine D7E VOE12736433
G940 Engine D7E VOE12736434
G946/G960 Engine D7E VOE12735836
L60E Engine D6D VOE11172410
L60F Engine D6E VOE11411086
L70E Engine D6D VOE11172409
L70F Engine D6E VOE11411087
L90E Engine D6D VOE11172408
L90F Engine D6E VOE11411088
L110E Engine D7D VOE11173900
L110E/L110F Engine D7E VOE11410961
L120E Engine D7D VOE11172407
L120E/L120F Engine D7E VOE11410957
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Work instructions, checking torque of cylinder head bolts

1 Mark position of screws before loosening cylinder head
bolts.
2 Measure the loosening torque of each bolt. Do not
completely remove head bolt while checking.
NOTE!
For D6E engine, start checking from torque 80 Nm (59 lbf ft)
and increase by 5 Nm (3.7 lbf ft). For D7E engine, start
checking from torque 130 Nm (96 lbf ft) and increase by 5
Nm (3.7 lbf ft).

Fig.3 3 Record the loosening torque value in below table.

Mark position of screws
4 Retighten the bolt with corect torque without angle 90°. D6E:
30 Nm(1st) + 80 Nm(2nd), D7E: 50 Nm(1st) + 130 Nm(2nd).
5 Mark and note the new position achieved. Calculate loss
angle and record it.
- If the new angle position is located after the earlier
angle position in direction of rotation (1 in Fig.4), e.g.
loss angle = rotation angle tightening (90°) + α
- If the new angle position is located before the earlier
angle position in direction of rotation (2 in Fig.4), e.g.
loss angle = rotating angle tightening (90°) - α

Fig.4
Loss angle calculation
1 New position after earlier position
2 New position before earlier position

Screw Loosening torque Angle position (α) Loss angle

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
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Screw Loosening torque Angle position (α) Loss angle

17
18
19
20
21
22
23
24
25
26
6 If the torque values are out of allowed specification (loss
angle is permitted to max 60% (54°)), re-torque the head bolt
with correct torque with angle and take a picture to see how
much it varies to previous position.
NOTE!
When tightening the bolts, follow the tightening order to
Fig.5 prevent any damage to cylinder head.
Cylinder head bolts tightening order

Torque specification

D6 D7
Step 1 30 Nm (22 lbf ft) 50 Nm (37 lbf ft)
Step 2 80 Nm (59 lbf ft) 130 Nm (96 lbf ft)
Step 3 90° 90°
7 If the loss angle is out of allowed value, remove cylinder
head and replace the cylinder head gasket with new one.
8 Re-assemble the cylinder head with correct torque.
NOTE!
Cylinder head bolts can be used max. 3 times with written
proof; otherwise renew every time they are loosened.
9 Monitor the machine whether symptom, as described under
“Cause”, appears again or not.
NOTE!
If the torque of cylinder head bolts meets the specification,
visibly check the cylinder head gasket for any crack or
Fig.6
damage.
Checking the position of bolts NOTE!
If both the torque of cylinder head bolts and the head gasket
do not show any problem, measure the liner height by
following the instruction.
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Work instructions, measuring

1) Remove the cylinder head and clean the measuring surface
thoroughly.
2) Place the shim (2) and measuring beam (1), P/N 9998678 on
the sealing surface of the cylinder block.
- Insert a dial gauge (3) into the measuring beam and hold it with
a knurled nut. (Refer to Fig. 3).
3) Place the stylus of dial gauge onto the cylinder block sealing
Fig.7 surface with pre-tension (arrow).
1 Measuring beam - Adjust the dial gauge to "0". (Refer to Fig. 4)
2 Shim
4) Move the measuring beam onto the shim so that the stylus is
3 Dial gauge
now located on the sealing surface for the cylinder liner (arrow).
NOTE! - Make a measurement on at least 4 other points for each cylinder
Dial gauge reference ; MITUTOYO, No.2046S (not liner location, as well as all six cylinder locations.
available from Volvo). Use any equivalent type of dial - Fill in the table below.
gauge (10mm/ 0.01mm (0.393 in/0.000393 in)) that
can be fixed with 9998678 Measurement Cyl.1 Cyl.2 Cyl.3 Cyl.4 Cyl.5 Cyl.6
Average
Pos.1
Pos.2
Pos.3
Pos.4
Pos.5
Pos.6
Pos.7
Pos.8
NOTE!
Fig.8 Stylus on the cylinder block sealing surface Specification:
D6; Min. 0.07 mm (0.0028 in) / Max. 0.12 mm (0.0047 in)
D7; Min. 0.03 mm (0.0011 in) / Max. 0.08 mm (0.0031 in)
(Refer to Fig. 2)
5) Attach the completed table to the Techline call and contact
regional technical support.

Fig.9 Stylus on the cylinder liner sealing surface

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Work instructions, milling and adjusting

Milling cylinder liner seat and adjusting cylinder liner height.
If the previously described measuring method has shown that the
cylinder liner height is outside the tolerance limits, we recommend
the following repair actions:
This is done by milling the cylinder liner seat in the engine block
together with the use of a spacer ring.

Table 1. The following spacer ring thicknesses are available from Volvo Parts.
Engine Spacer ring, part number Thickness “S” Make sure the spacer ring is fitted according to
figure
VOE21663836 2.335 — 1 Up
2.350 mm
VOE21663837 2.315 — 2
2.325 mm
D6 VOE21663838 2.290 — 3
2.300 mm

Fig.10

VOE21663839 1.975 — 1 Up
1.985 mm
VOE21663840 2.015 — 2
D7
2.025 mm

Fig.11
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Table 2. Required tools

Tools D6 Tool number D6 Tools D7 Tool number D7
Support 9993722 Support 9993722
Support 9993722 Support 9993722
Puller plate 9990144 Puller plate 9998675
Milling tool 110V 88890113 Milling tool 110V 88890113
Milling tool 220V 9812524 Milling tool 220V 9812524
Press tool 88800129 Press tool 88800129
Press tool 88800129 Press tool 88800129
Puller bolt 9993713 Puller bolt 9993713
Quick-nut 9993717 Quick-nut 9993717
Pliers 11668409 Pliers 11668409
Measuring tool 9998678 Measuring tool 9998678
Puller plate 9990144 Rotation tool 9998681
Piston ring compressor 88800317 Piston ring compressor 88800316
Support 9986485 Support 9986485
Fixture 88800050 Fixture 88800050
Protractor 885812 Protractor 885812
Lifting tool 9998547 Lifting tool 9998547
Lifting eyes M12 — Lifting eyes M12 —
Lifting sling — Lifting sling —

Milling cylinder liner seat and adjusting cylinder liner height.

1 Remove the engine from the machine according to
instructions in the service manual.
2 Remove the turbocharger and its oil pipes, and set up the
engine in a work stand according to 210, Engine, installing in
work stand (in service manual).
3 Remove the valve cover and the hose for the crankcase
ventilation, the fuel delivery pipes, fuel control valve, high-
pressure pumps, fuel rail (pressure distribution pipe), injectors,
IEGR-unit, rocker arm bridges, and the cylinder head. Follow
the instructions in 210, Engine, dismantling (in service
manual).
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4 Install tool 88800129 Press tool, 2 pcs. Tighten the attaching

bolts with 40 Nm (29.5 lbf ft). Measure the liner height, the
distance between the block face and liner (not the flame edge)
to decide if, and how much, the liner position needs to be
reworked. Measure in eight places, evenly spaced across the
liner edge's circular periphery. Note the values and calculate
an average value.
D6 — Wear limit: 0.07 — 0.12 mm. In our example the average
value is: 0.075 mm.
D7 — Wear limit: 0.03 — 0.08 mm. In our example the average
value is: 0.03 mm.
5 Repeat the measurement on the remaining cylinder liners to
determine which cylinder liner positions need to be reworked.
6 Depending on which liner position needs to be milled, remove
the roller lifters, cable harnesses, belts, charge-air pipe,
Fig.12 coolant pump, oil sump, flywheel, timing gear casing, and the
1 88800129 Press tool, 2 pcs. starter motor.
2 9998678 Measuring tool
NOTE!
Pay attention to what parts are needed when assembling, e.g.,
new seals, seal rings, pressure pipes for injectors, etc.
7 Remove the piston and connecting rod for the cylinder where
the liner position is to be reworked. Also remove the pistons
and connecting rods for the adjoining cylinders, otherwise
there will not be enough room for the milling tool. See 210,
Engine, dismantling (in service manual).
8 Mark the cylinder liner's position in relation to the block.
Remove the cylinder liner. See 210, Engine, dismantling (in
service manual).
NOTE!
Adjoining liners must also be removed to make room for the
milling tool.
NOTE!
If liner damage is suspected, the above measurement must be
repeated with the new liner in place.
9 Clean the liner position thoroughly. Clean the block face from
remains of paint and other debris that may give incorrect
measuring results.
10 A lot of metal shavings are produced when reworking the liner
position, and these will cause major damage if they fall down
into the engine. Place protection made of, e.g., foam rubber,
see Fig.13, up high in the block in the holes for the cylinder
liners. Tape the block face thoroughly to prevent metal
shavings from falling down into the other cylinders as well as
oil and water channels.
NOTE!
Tape placed where the milling tool is located affects the
measuring result. Therefore, plug these channels with foam
Fig.13 rubber or similar, or tape tight against the tool.
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11 Measure the distance (depth) between the block face and the
shelf in the liner position. Measure in eight places evenly
spaced across the periphery. Note the values and calculate
an average value. In our example the average value is 4.44
mm for D6 and 9.01 mm for D7.
12 Cylinder liner's height over block face should be (new
measurement after reworking and installing adjusting shim,
specifications):
D6 – 0.09 — 0.14 mm. Choose 0.14 mm.
D7 – 0.050 — 0.10 mm. Choose 0.10 mm.
— Cylinder liner's height (measured): 0.075 mm for D6 and
0.030 mm for D7.
— Difference: 0.065 mm for D6 and 0.070 mm for D7.
— Adjusting shims are available in three thicknesses for D6
Fig.14 and two thicknesses for D7:
1 Depth micrometer or similar calibrated tool. D6 – 2.290 — 2.300 mm, 2.315 — 2.325 mm, and 2.335 —
2.350 mm. Choose 2.290 mm.
D7 – 1.975 mm and 1.985 mm. Choose 1.975 mm.
— Liner position's depth: 4.44–0.065=4.375 mm for D6 and
9.01–0.07= 8.94 mm for D7.
— Reworked measurement: 4.375+2.290=6.665 mm for D6
and 8.94+1.975=10.91 mm for D7.
13 Choose a cutting tool of suitable size and check that it is not
damaged.
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14 Hold up the lock device and install the cutting tool. The toothed
edge should face the electromagnet (solenoid) and the
centering roller on the side of the spindle which is marked R.

Fig.15
1 Centering roller
2 Lock device
3 Horizontal feed ring
4 Spindle
5 Cutting steel
6 Electromagnet (solenoid)

Fig.16
7 Vertical feed sleeve
8 Lock bolt
9 Scale ring and lock screw (Allen head)

Fig.17
10 Crank
11 Switch
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15 Place the milling tool on the block face so that it is slightly

displaced in relation to the middle of the cylinder.
16 Set the switch in position 1 to activate the electromagnet
(solenoid).
17 Screw the vertical feed sleeve upwards so that the cutting steel
can pass freely over the liner shelf.

Fig.18

18 Press down the lock device and place the centering roller
against the liner seat's wall. Turn the crank clockwise and
press in the steel so that the centering roller has contact with
the wall where the distance to the wall is the longest.
19 Set the switch between position 1 and 2.

Fig.19
Centering roller
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20 Center the tool by turning the crank clockwise at the same time
as the you hold still the horizontal feed ring.
21 The centering roller must be in contact with the liner position's
wall all the time.
If the tool loses contact with the wall:
Turn backwards (counter-clockwise) slightly and repeat the
centering procedure.
22 The tool is centered when it stops moving. Set the switch to
position 1.

Fig.20

23 Move the cutting steel so that it is positioned over the liner shelf
without touching the liner wall.

Fig.21
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24 Turn the crank and the vertical feed sleeve until the cutting tool
comes into contact with the liner shelf.

Fig.22

25 Press down the lock device and move the cutter so that the
point ends up just inside the edge on the liner shelf (inner
diameter).

Fig.23

26 Loosen the Allen head screw and reset the tool to zero by
turning the scale ring. Lock the scale ring by tightening the
Allen head screw.
NOTE!
Use the scale on the scale ring only as an indication of actual
reworking depth. Measure the depth with a measuring tool at
regular intervals in order to not risk exceeding max. reworking
depth. To ensure correct measuring result, remove the milling
tool before each measurement. Measuring must take place
according to step 34, with cylinder liner and adjusting shim in
place.
27 Set the scale ring to max. 0.05 mm for the first reworking to
check that the cutter mills uniformly around the whole cylinder
liner position.

Fig.24
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28 Turn the vertical feed sleeve so that the cutter starts to work
against the liner shelf.
29 Then rework the cylinder with max. 0.15 mm per reworking.

Fig.25

30 Rework the liner shelf by turning the crank clockwise at the

same time as the you hold still the horizontal feed ring.
NOTE!
Turn the crank carefully and let the ring slide a little between
your fingers during reworking. When the cutting tool
approaches the liner shelf's wall, let the ring slide some more
so that you can stop just before the cutting tool reaches the
wall.

Fig.26
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31 Check with a feeler gauge, vertically down between the steel

and the liner wall, so that the cutter horizontally does not pass
by the radius between the liner shelf and the liner wall. This is
to ensure a satisfactory "pocket" for the adjusting shim.
32 Repeat the procedure but stop reworking when at least 0.05
mm remains to desired depth measurement.
33 Loosen the electromagnet (solenoid) by setting the switch in
position 2. Remove the tool.
R A

V1096953

Fig.27
R= 0.3 mm
A= Total liner depth max. 6,745 mm for D6 and
10.91 — 10.94 mm for D7

34 Clean the liner position. Install the adjusting shim and the liner
according to marking. Press down the liner with 88800129
Press tool, 2 pcs. Tightening torque: 40 Nm (29.5 lbf ft). Check
the liner edge's height over the block face. Liner edge's height:
0.09 — 0.14 mm for D6 and 0.050 — 0.10 mm for D7.
35 Repeat the procedure above until correct distance between
liner edge and block face is achieved.
36 Install new seal rings on the cylinder liner.
37 Install the cylinder liner.
38 Assemble the engine according to instructions in 210, Engine,
assembling (in service manual).
39 Remove the engine from the work stand and install the
turbocharger according to 210, Engine, removing from work
stand (in service manual).
40 Install the engine according to instructions in the service
Fig.28 manual.
1 88800129 Press tool, 2 pcs.
2 9998678 Measuring tool