Volvo Diesel Engine Parts Operation

25-1 Inlet and Exhaust Manifolds

Intake Manifold, Change

TAD550GE, TAD551GE, TAD750GE, TAD751GE

Removal

NOTICE! Turn off the main switch before any work is carried out.

1 Undo the crankcase ventilation hoses. 

Remove the oil trap.

2 Remove the hose (1) between the inlet manifold and the charge air cooler.

Remove the electrical connection (2) from the pre-heater relay.

Remove the connector (3) from the preheater element.

Remove the electrical connection (4) from the charge air pressure sensor.

3 Disconnect the cable from the pre-heater.

4 Remove the charge air pipe with pre-heater element.

5 Remove the protective cover.

6 Undo the connector (1).

Remove the charge air temperature sensor (2).

7 Remove the harness from the protective cover.

Remove the protective cover.

Remove the valve cover.

8 Remove the inlet manifold.

Installation

9 NOTICE! Clean the sealing surfaces.

NOTICE! Use new seals.

10 Install the inlet manifold.

Tightening torque: 11 Nm (8.1 lbf. ft.)

Tightening sequence: Diagonal

11 Install a new valve cover gasket.

12 Install the valve cover.

Tightening torque: 13 Nm (9.6 lbf. ft.)

Tightening sequence: Diagonal

Install the protective cover. Attach the harness to the protective cover.

13 Transfer the charge air temperature sensor (2) to the new inlet manifold. Connect the harness terminal (1).

14 Install the protective cover.

Tightening torque: 4.5 Nm (3.3 lbf. ft.)

15 Install the charge air pipe with pre-heater element.

Tightening torque: 30 Nm (22.1 lbf. ft.)

16 Install the hose (1) between the inlet manifold and the charge air cooler. Install the electrical connection (2) to the preheater relay.

Fit the connector (3) to the preheater element. Install the electrical connection (4) to the charge

air temperature sensor.

17 Fit the pre-heater cable.

18 Install the oil trap. Install the crank case ventilation hoses.

19 Turn the main switch on. Start the Volvo engine and check for leaks.

Intake Manifold, Change

TAD752GE, TAD753GE, TAD754GE

Removal

NOTICE! The main switch must be in the off position before work is begun.

1 Remove the hose between the inlet manifold and the charge air cooler.

2 Remove the e-EGR cooler; refer to Cooler e-EGR, change page 159.

3 Remove the e-EGR actuator; refer to Actuator e-EGR, change page 169.

4 Remove the preheater; refer to Pre-heating, Change page 184.

5 Remove the starter motor power supply cable.

6 Remove the charge air temperature sensor.

7 Remove the inlet manifold.

Installation

NOTICE! Clean the sealing surfaces.

NOTICE! Use new seals.

8 Install the inlet manifold.

Tightening torque: 30 Nm (22.1 lbf.ft.)

Tightening sequence: Diagonal

9 Move the charge air temperature sensor over to the new inlet manifold.

Tightening torque: 7.5 Nm (5.5 lbf.ft.)

10 Install the starter motor power supply cable.

11 Remove the preheater; refer to Pre-heating, Change page 184.

12 Remove the e-EGR actuator; refer to Actuator e-EGR, change page 169.

13 Remove the e-EGR cooler; refer to Cooler e-EGR, change page 159.

14 Install the hose between the inlet manifold and charge air cooler.

15 Turn the main switch on.

16 Start the engine and check for leaks.

Exhaust Manifold, Change

TAD550GE, TAD551GE, TAD750GE, TAD751GE

Removal

1 Remove the turbocharger according to Turbo, Change page 174.

2 Remove the heat shield, if fitted. Remove the exhaust manifold with gaskets.

3 Change the studs.

Installation

4 NOTICE! Clean the sealing surfaces.

NOTICE! Use new sealings.

NOTICE! Use new bolts.

5 Change the studs.

Install the gaskets.

6 Install washers, spacer sleeves and nuts.

7 Tightening torque: 25 Nm (18.4 lbf. ft.)

Tightening sequence: Diagonal

8 Install the heat shield, where fitted.

9 Install the turbocharger according to Turbo, Change page 174.

Exhaust Manifold, Change

TAD752GE, TAD753GE, TAD754GE

Removal

1 Remove the turbocharger according to Turbo, Change page 174

2 Remove the heat shield.

3 Remove the exhaust pipe, EGR.

NOTICE! Use new seals when dismantling the exhaust pipe, EGR.

4 Undo and remove manifold sections (1) and (2) from the exhaust manifold intermediate section.

5 Remove the exhaust manifold gasket.

6 Remove the sprung sealing ring (1) and laminated ring gasket (2) from the intermediate section.

7 Remove the exhaust manifold (intermediate section) with gasket.

8 Remove the laminated ring gaskets from manifold sections (1) and (2).

Installation

NOTICE! Clean the sealing surfaces.

NOTICE! Use new seals.

NOTICE! Use new bolts.

9 Place the gasket on the sealing surface, install the exhaust manifold and tighten a few turns.

10 Install the sprung sealing ring (1) and the laminated ring gasket (2).

11 Slide on the laminated rings staggered at 180°.

12 Place the gasket on the sealing surface.

13 Insert manifold sections (1) and (2) into the exhaust manifold intermediate section and tighten a few turns.

14 Tightening sequence: Diagonal

Tightening torque:

1 Step 1: 15 Nm (11.1 lbf.ft.)

2 Step 2: 45 Nm (33.2 lbf.ft.)

15 Install the exhaust, EGR.

16 Tightening torque: 20 Nm (14.8 lbf.ft.)

17 Install the heat shield.

18 Install the turbocharger according to Turbo, Change page 174