DService BulletinVolvo Trucks North AmericaGreensboro, NC USA

Date Group No. Page

3.2009 258 33 1(13)

TrucksThis service bulletin replaces bulletin 258–33(PV776–20189612), dated 2.2009.

AFI Air Purge SystemKit Installation

D13F

Aftertreatment Fuel Injector (AFI) Air PurgeSystem, Kit InstallationThis information covers installation of the aftertreatment fuel injector air purge kit (partnumber 85116274) on a vehicle equipped with a Volvo D13F engine. For VHD and VNMvehicles only, it is also necessary to order heat shield kit 85116296.

Contents• “Aftertreatment Fuel Injector Air Purge Kit, New Installation” page 2

Note: Information is subject to change without notice.Illustrations are used for reference only, and may differ slightly from the actual engineversion. However, key components addressed in this information are represented asaccurately as possible.

PV776-88911752 USA34627.ihval

DVolvo Trucks North America Date Group No. Page

Service Bulletin 3.2009 258 33 2(13)

Service Procedures2589-02-02-01

Aftertreatment Fuel Injector Air Purge Kit, New Installation

You must read and understand the precautions andguidelines in Service Information, group 20, "GeneralSafety Practices, Engine" before performing thisprocedure. If you are not properly trained and certifiedin this procedure, ask your supervisor for trainingbefore you perform it.

Installation1Apply the parking brake and place the shift leverin neutral.

2

W2003815

Remove all cables from ground (negative) batteryterminals to prevent personal injury from electrical shock.

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Service Bulletin 3.2009 258 33 3(13)

3

W2004191

C2000268

Use the coolant extractor to remove the coolant from theengine. An alternate method is to drain the coolant into asuitable container using the drain hose.

DANGER

Coolant is toxic; risk of poisoning. Do not drinkcoolant. Use proper hand protection when handling.Keep coolant out of reach of children and animals.Failure to follow these precautions can cause seriousillness or death.

DBT2V700, 9996049

4Remove the air filter housing and fresh air pipe.

5Remove inner splash guard as an assembly.

Note: Some models may be equipped with fenderextenders, attached to the inner splash guard. Removethese as an assembly.

6Drain the air system.

7Remove the passenger seat from the cab.

8Remove the engine cover from the cab.

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Service Bulletin 3.2009 258 33 4(13)

9Disconnect the coolant hard pipe at the rear of theengine at the coupler.

10Disconnect any sensors, cable ties, P-clamps or harnessbolts blocking access to the hot side fuel line.

11

W2005656

Disconnect the aftertreatment injector fuel supply line.Collect any residual fuel that may be in the fuel linein a suitable container.

12Remove the hot side fuel line from the engine.

13On some D13F engines, it may be necessary to removethe cold side fuel line.

14Remove and discard the aftertreatment fuel injectormounting bolts and spacers. Remove the injector from thediffuser pipe (which attaches to the turbocharger outlet).

Note: The coolant lines and coolant do not need to beremoved for AFI cleaning.

15Cover the hole in the diffuser pipe to prevent dirt andcleaning solution from entering the exhaust system.

16Remove and discard the high-temperature gasket andsteel plate gasket from the bottom of the injector.

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Service Bulletin 3.2009 258 33 5(13)

17

W2006496

Turn the AFI body to allow the injector tip to be sprayedwith carburetor cleaning solution. Brush the injector tipwith a stiff bristled nylon "tooth" brush. Repeat two orthree times.

CAUTION

Only high quality carburetor cleaner should be usedto clean the injector. Other cleaners, such as brakecleaner products, do not work and may containchlorine, which could damage the catalyst if they enterthe exhaust system.

CAUTION

Only use a nylon brush to clean the injector tip.Do not use a brass or steel brush. Damage to theinjector tip may result.

18

W2006436

Inspect the injector tip. Use a mirror if a clear view ofthe tip is not possible.

19Position the injector onto the diffuser pipe (which attachesto the turbocharger outlet) and hand start the bolts.

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Service Bulletin 3.2009 258 33 6(13)

20Using the flow test tool (tool number 88890112) and TechTool, test the AFI flow as follows:

A. In Guided Diagnostics , go to the Symptomstab and select "Exhaust Aftertreatment/Serviceregeneration failure."B. Under the Fault Code and Symptom Analysis tab,select "Exhaust Aftertreatment, Symptom diagnostics."C. Under the Diagnostic Analysis tab, select "Serviceregeneration failure."D. Under the Diagnostic tab, select "Aftertreatment fuelsystem check."E. Select "Aftertreatment Fuel Injector check."F. Select "Aftertreatment Fuel Injector Flow check."

CAUTION

If the Aftertreatment Fuel Injector does not pass theAftertreatment Fuel Injector Flow check, replacethe AFI with a new AFI.

21Loosen the bolts and remove the injector from the diffuserpipe. Install a new high-temperature gasket and steelplate gasket onto the bottom of the aftertreatmentfuel injector.

22Apply high-temperature nickel-graphite anti-seizecompound to the new injector mounting bolt threads andinsert the bolts into the spacers. Position the injector ontothe diffuser pipe (which attaches to the turbochargeroutlet) and hand start the bolts with spacers.

23Secure the injector mounting bolts. Tighten the bolts to14 ± 0.5 Nm (125 ± 4.5 in-lb).

14 ± 0.5 Nm (125 ± 4.5 in-lb)

24On some D13F engines, it may be necessary to install anew cold side fuel line (part number 21014980). UseP-clamps to secure the fuel line.

25Install the one-way check valve (part number 21249090)on the air line hard pipe (part number 21242682).

26Position the air line hard pipe on the engine.

27Position the new fuel line (part number 21284463) onthe engine.

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Service Bulletin 3.2009 258 33 7(13)

28Install the two-way check valve (part number 21226456)on the AFI.

29

W2006759

1 Air Line2 Fuel Line3 Coolant Line

Connect the fuel line and air line to the two-way checkvalve. Hand-tighten the fittings.

CAUTION

Do not kink the fuel and coolant lines. Kinking the linesmay result in leakage.

30

W2006797

1 Bracket 965571 and Screw 946471; P-Clamp940374, Screw 946440 and Nut 945408

2 P-Clamp 9403743 Bracket 965556 and Screw 946471; P-Clamp

940374, Screw 946440 and Nut 9454084 Air Line Hard Pipe 21242682

Install the air line mounting brackets, P-clamps, screwsand nuts to secure the air line.

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Service Bulletin 3.2009 258 33 8(13)

31Use cable ties to secure the air line at the rear of thecylinder head.

32

W2006762

1 P-Clamp 9403742 P-Clamp 940374 and Nut 9454083 Bracket 21053482, P-Clamp 940374 and

Screw 9464404 P-Clamp 940374 and Screw 9461735 Fuel Line Hard Pipe 21284463

Install the fuel line mounting bracket, P-clamps. screwsand nuts to secure the fuel line.

33Connect the fuel line hard pipe to the flexible fuelsupply line.

34Connect any sensors, cable ties, P-clamps or harnessbolts removed.

35Replace the sealing ring on the coolant hard pipe.Connect the hard pipe at the rear of the engine.

36

CAUTION

It is mandatory to use a coalescing air dryer filter withthe AFI air purge system. If a coalescing filter is notused, damage to components can result.

If the air dryer filter is not the coalescing type filter, removethe air dryer filter and install a new coalescing filter.

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Service Bulletin 3.2009 258 33 9(13)

37Install the in-line air filter (part number 21266886) andtwo 90 swivel fittings (part number 8397771) in the airpressure regulator (part number 21243502).

38Mount the air pressure regulator to the regulator mountingbracket (part number 21250229).

39

W2006830

Air Lines at Pressure Regulator and Tee Fitting

1. Supply Fitting2. Delivery Fitting

Install the air regulator on the air dryer mounting bracket.

40Cut the discharge recirculation valve air supply line atthe frame mounted manifold and install the tee fitting(part number 8397804).

41Connect flexible air line (part number 21269105) to thetee fitting and the air regulator supply fitting.

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Service Bulletin 3.2009 258 33 10(13)

42

W2006831

Chassis Line to Engine Line Connection

Connect flexible air line (part number 21269105) to the airregulator delivery fitting and the air line hard pipe onthe engine.

43Secure the flexible air lines with cable ties.

44Tighten the two-way check valve on the AFI tospecification. Tighten the air and fuel line fittingsto specification.

Two-way check valve: 15 Nm (135 in-lb), Fuel line: 15 Nm(135 in-lb), Air line: 27 Nm (235 in-lb)

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Service Bulletin 3.2009 258 33 11(13)

45

W8003963

A. Arrow indicates front of vehicle1. Bulkhead2. Cab Floor Panel

For VHD and VNM models only, use two screws toassemble the two heat shields (part numbers 82238149and 82238159). Use five nuts to install the heat shields tothe underside of the cab floor panel.

46Install the air filter housing and fresh air pipe.

47

W2004191

Fill the cooling system with the recommended coolantusing the coolant extractor.

DBT2V700

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Service Bulletin 3.2009 258 33 12(13)

48

W2003815

Install all previously removed cables to the ground(negative) battery terminals.

49Start the engine and build air pressure to operatingpressure. Check the air and fuel systems for leaksand proper operation.

50Install the engine cover.

51Install the passenger seat in the cab.

52Install the inner splash guard assembly.

53Use VCADS/Tech Tool to upload the software accessorykit for the AFI upgrade (part number 85115992). Thenperform MID128 EECU reprogramming.

Note: There is no charge for the EECU downloadif the accessory kit is uploaded before the MID128EECU reprogramming.

54Use VCADS/Tech Tool to reset AFI adaptive factor andclear all codes.

55To verify proper function of the air purge system,use VCADS/Tech Tool to perform a partial serviceregeneration. During the service regeneration, monitorthe Inlet Temperature and Aftertreatment CatalystTemperature (using the Diesel Particulate FilterRegeneration operation). When the temperaturesreach approximately 260 C (500 F), stop the serviceregeneration.

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Service Bulletin 3.2009 258 33 13(13)

56When the DPF reaches the proper temperature (260 C[500 F]), the Aftertreatment Injector Status shouldindicate 100% duty cycle, and the status should say"Air-Purging."

57For additional information concerning the system, or ifthe system does not seem to be functioning properly,refer to Guided Diagnostics . This information can beaccessed in the following manner:

A. In Guided Diagnostics , go to the Symptomstab and select "Exhaust Aftertreatment/Serviceregeneration failure."B. Under the Fault Code and Symptom Analysis tab,select "Exhaust Aftertreatment, Symptom diagnostics.C. Under the Diagnostic Analysis tab, select "Serviceregeneration failure."D. Under the Diagnostic tab, select "Aftertreatment fuelsystem check."E. If asked whether or not the vehicle is equippedwith AFI air purge system, Enable AHI air purge,select "Yes."F. Select "Aftertreatment Air Purge System Check."G. Select "AFI Air Purge System, Function check" totest the system.

58After shutdown, replenish fluids as necessary.