DService BulletinVolvo Trucks North AmericaGreensboro, NC USA

Date Group No. Page

10.2008 255 56 1(11)

TrucksThis Service Bulletin replaces bulletins 255–56, 255–57and 255–60, dated 3.2007.

Actuator, Variable GeometryTurbocharger, Replacement

D11F, D13B, D13F and D16F Engines

Actuator, Variable Geometry Turbocharger,Replacement

W2006206

This information covers the proper replacement procedure for the turbocharger SmartRemote Actuator (SRA) on the Volvo D11F, D13B, D13F and D16F engines.

Contents• “Special Tools” page 2.

• “Actuator, Variable Geometry Turbocharger, Replacement” page 3.

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

PV776-20168808 USA32115.ihval

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Service Bulletin 10.2008 255 56 2(11)

Special ToolsFor special tools ordering information, refer to Tool Information, group 08.

W0001795

W2004191

9996049Coolant Drain Hose

DBT2V700Coolant Extractor

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Service Bulletin 10.2008 255 56 3(11)

2559-03-02-14Actuator, Variable Geometry Turbocharger, Replacement

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.

Special tools: 9996049, DBT2V700

Removal1Apply 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.

3Using pressure wash equipment, clean the turbochargeractuator while it is still mounted.

Note: Make sure all electrical connections and coolantpipes in the area of the turbocharger actuator aresecurely fastened.

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Service Bulletin 10.2008 255 56 4(11)

4

W2004191

Connect the coolant extractor to the drain fitting at thebottom of the radiator and drain the coolant.

Note: If the coolant extractor is unavailable, connectthe coolant drain hose to the drain fitting and drain thecoolant into an appropriate container.

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

5

W2005620

Disconnect the actuator assembly electrical connector atthe wiring harness. Cut any tie straps as needed.

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Service Bulletin 10.2008 255 56 5(11)

6

W2005699

1 Coolant Return Port2 Coolant Inlet Port

Disconnect the coolant lines from the actuator.

CAUTION

Protect the insides of the actuator assembly and theexposed parts from contamination when removed.Failure to do so can result in component malfunctionor failure.

7

W2005698

1 Alignment Pin2 Actuator Housing3 Gasket4 Screw (4 Required)5 Grease Applicator Tube

Remove the actuator from the turbocharger. Removeand discard the gasket.

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Service Bulletin 10.2008 255 56 6(11)

Installation1

W2005277

Using gloves, manually rotate the turbocharger sectorgear back and forth (counterclockwise and clockwise). Itshould be noted that when the sector gear is at the end oftravel, or at an end stop, it can require significant force toovercome friction then, start it’s motion in the oppositedirection. This is normal and not cause for concern. Applymore force to move the sector gear. Once in motion, thesector gear movement should be smooth, without bindingor sticking until it reaches it’s end of travel (end stop).

2

W2006758

Alignment Hole Inspection, 3mm (0.118 inch) Hole

Rotate the sector gear fully counterclockwise until contactis made with the end stop of the variable geometryinternal mechanism. 1/4 to 3/4 of the 3mm (0.118 inch)reference hole should be visible at the edge of the sectorgear nearest the turbine housing.

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Service Bulletin 10.2008 255 56 7(11)

3

W2005276

For turbochargers manufactured without the small 3mm(0.118 inch) alignment hole, a portion (half) of the 5mm(0.197 inch) alignment hole should be exposed at thecompressor housing side of the sector gear when thesector gear is fully rotated toward the turbine housing.

4

W2005275

Rotate the sector gear fully clockwise. Make sure thatthe alignment pin fits through the sector gear into thealignment hole in the housing. The diameter of thealignment hole is 5mm (0.197 inch).

Note: If the sector gear does not align properly with thealignment hole or does not rotate properly in eitherdirection, replace the turbocharger.

5

W2006760

Lubricate the sector gear teeth using the greaseapplicator tube that comes in the installation kit.

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Service Bulletin 10.2008 255 56 8(11)

6

W2005209

Remove the alignment pin without disturbing the positionof the sector gear. The gear must not be moved fromthis position.

7

W2005620

Connect the actuator electrical wiring harness connectorto the engine wiring harness connector. Install tie strapsas needed to secure the harness.

8

W2003815

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

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Service Bulletin 10.2008 255 56 9(11)

9Connect the VCADS Pro PC to the vehicle diagnosticdata connector and turn the ignition switch ON. Using thedirections in VCADS Pro, command the actuator to theinstall position. Turn OFF the ignition switch when done.

Note: Do not disturb the actuator drive gear after thegear is in the install position. Proper calibration of theactuator drive gear to the turbocharger sector gear mustbe maintained for proper operation.

10

W2005211

Install two new mounting screws diagonally across theactuator. Place a new gasket over the protruding screwsat the back of the actuator.

Note: Always use the new screws and gasket provided inthe actuator installation kit.

11

W2005242

Carefully align the actuator with the turbocharger andinstall it into position. Hold the actuator in place andhand tighten the two screws. Install the two remainingnew screws and hand tighten. Use the following stepsto tighten the screws.

1 Tighten the screws in the pattern shown to 3 Nm(27 in-lb).

2 Tighten the screws in the pattern shown to 11 Nm(97 in-lb).

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Service Bulletin 10.2008 255 56 10(11)

12Connect the VCADS Pro PC to the diagnostic dataconnector and turn ON the ignition switch. Using theon screen directions in VCADS Pro, perform the VGTcalibration procedure. If the actuator is installed correctly,the procedure indicates a successful VGT calibration.If the calibration fails, either the pre-positioning ofthe actuator drive gear is incorrect, the sector gearpositioning is incorrect, the actuator is faulty or theturbocharger sector gear and nozzle ring mechanism isdamaged. Turn OFF the ignition switch when done.

13If the actuator is suspected of being faulty and requiresreplacement, follow the preceding installation stepswith the new actuator.

Note: There are two actuator installation kits available:

• A kit that includes the gasket, screws, alignment pinand gear lubrication grease for an existing actuatorinstallation.

• A kit that includes the actuator, gasket, screws,alignment pin and gear lubrication grease for a newactuator installation.

14

W2005699

1 Coolant Return Port2 Coolant Inlet Port

Connect the coolant lines to the actuator and tightenthe fittings.

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Service Bulletin 10.2008 255 56 11(11)

15

W2004191

Use the coolant extractor to fill the cooling system withthe approved coolant.

DBT2V700

16Start the engine, check for leaks and proper operation.After shutdown, replenish fluids as necessary.