Flywheel housing replacement

DService BulletinVolvo Trucks North AmericaGreensboro, NC USA

Date Group No. Page

12.2007 212 30 1(46)

Trucks

Flywheel Housing, ReplacementD16F

Flywheel Housing, Replacement

W2005773

This information covers replacement of the flywheel housing on the Volvo D16F engine.

Contents• “Special Tools” page 2

• “Flywheel Housing, Replacement” page 3

Note: Information is subject to change without notice.Illustrations are used for reference only and may differ slightly from the actualvehicle being serviced. However, key components addressed in this information arerepresented as accurately as possible.

PV776-20115882 USA27033.ihval

DVolvo Trucks North America Date Group No. Page

Service Bulletin 12.2007 212 30 2(46)

ToolsSpecial Tools

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

W0001793 C0000972 W0001798

9992000Standard Handle for Drifts (18 x 200)

9994030Slide Hammer

9998238Rear Seal Install Drift

T0011241 W0001240 T0013033

9990181-1 & 2Engine Supports

9996201Tie Rod Separating Tool

88800031Sensor Depth Gauge

W2005150 W2005151

85109033ATiming Cover Clamp Tool (Straight)

85109033BTiming Cover Clamp Tool (Angled)



Service Procedures2125-03-03-01

Flywheel Housing, ReplacementFlywheel and air filter housing removed and coolant drained

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: 9992000, 9994030,9998238, 9990181-1, 9990181-2, 9996201,85109033A, 85109033B, 88800031

Removal1Remove inner splash guard as an assembly.

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

2

W8003859

Remove the fasteners securing the center dash trim andremove the trim. Then, remove the fasteners securingouter section of the engine cover from inside the cab(includes attached waste basket). Remove cover andplace in a secure location.



3

W2003873

Using a hydraulic jack, lift the front axle until the frontwheels are off the ground. Position jackstands of asuitable size and capacity under the front axle to supportthe weight of the vehicle.

4

W2006077

If required, remove the rock guard from underneath theradiator to allow access for oil pan removal.

5

W2004875

Vehicles equipped with the sump located behind thefront steering axle require removal of the tie rod from theleft-side steering knuckle using the tie rod separating tool.Disconnecting the tie rod provides adequate clearance foroil pan removal.

9996201



6

W2004680

Disconnect the breather tube from the side of the valvecover.

7

W2004679

Remove the engine wiring harness support bracket fromthe front of the valve cover.

8

T2020552

Remove the spring-loaded attaching bolts from thevalve cover.

9Lift and remove the valve cover.



10

W2005686

Remove the fasteners and bolts securing the upper EGRhot pipe shield and remove the shield.

11

W2005687

Remove the bolts securing the lower EGR hot pipe shieldand remove the shield.



12

W2005685

Remove the nuts and bolts securing the EGR valve heatshield and remove the shield.

13

W2005642

Loosen both high temperature V-clamps from the EGRhot pipe by removing the nuts from the T-bolts. Free theclamps from the EGR hot pipe flange.

14

W2005641

Remove the EGR hot pipe from between the EGRvalve and the EGR cooler.



15

W2005688

Remove the high temperature gaskets from the EGRvalve end of the hot pipe and the EGR cooler end ofthe hot pipe. Discard the gaskets.

16

W2005689

Remove the electrical connector from the EGR valve.

17

W2005692

Loosen both the inlet and the return oil line fittings onthe valve.



18

W2005690

Remove the inlet oil line from the EGR valve.

19

W2005693

Remove all the EGR valve mounting bolts and removethe valve from the exhaust manifold. Discard themounting bolts.

20

W2005694

Remove the return oil line from the bottom of the EGRvalve.



21

W2005696

Remove the metal gasket from the EGR valve.

22Remove the battery cable and transmission cooler lineclamps from under the bell housing.

23Disconnect the block heater harness and the main air linefrom the air compressor.

24

W2004714

Remove the starter motor wiring harness and markthe wires for reassembly. Remove the nuts securingthe starter motor to the flywheel housing and removethe starter.

25Disconnect the coolant and oil supply lines from theair compressor.

26Remove the cable ties securing the harnesses to the aircompressor, then remove the mounting nuts securing theair compressor to the front of the flywheel housing andremove the air compressor.



27

W2005380

1-Power SteeringAttaching Bolts

3-FlywheelAttaching Bolt andNut

2-Timing GearPlate to FlywheelAttaching Bolts

Remove the power steering and fuel pump mounting bolts(1). Do not disconnect the hoses from the pumps, insteadallow the pumps to hang from the heavy-duty inlet andoutlet hoses. Next, remove the timing gear plate to theflywheel housing bolts (2). Remove the nuts (3) securingthe rear engine mount to the flywheel housing.

28

W2005428

Remove the frame under-slung crossmember locatedunder the transmission area.

29Place an approved container under the oil pan andremove the oil drain plug.

Note: Use only hand tools when removing or tighteningthe drain plug. Do not use an air ratchet or similar air tool.



30

W2004874

If the vehicle is equipped with a transmission oil cooler,remove the transmission cooler line bracket nuts andseparate the brackets from the oil pan fasteners. Positionthe cooler lines and brackets to the side.

Note: Mark the transmission oil cooler bracket studlocations to aid in reassembly.

31

W2005086

Pull the dipstick partially out of the dipstick tube, thenremove the dipstick tube fastener and tube from the oilpan. Remove and discard the O-ring.

32

W2004884

Remove the oil fill tube fasteners and tube from the oilpan. Remove and discard the tube O-ring.

33

W2004876

Disconnect the oil level/temperature sensor connector.



34

W2005226

Remove the two bolts marked A. Loosen the two boltsmarked B, but do not remove. Remove all other bolts.

35With the aid of an assistant, support the oil pan andremove the two bolts marked B. Carefully lower the panto avoid contact with the oil pickup tube and the oilpump gear.

36Clean the oil pan contact surface on the cylinder block,flywheel housing and front seal cover. All surfaces mustbe completely free of any grease or oil.

37

W2005910

Remove the upper exhaust V-band clamp that connectsthe flex pipe to the inlet module of the Diesel ParticulateFilter (DPF).



38

W2005952

Remove the exhaust pipe from between the diffuser andthe DPF muffler inlet pipe. Lift the pipe over the diffuserand out from under the cab.

39

W2005656

Remove the fuel line from the aftertreatment fuel injector.

40

W2005104

Disconnect the camshaft (engine) position sensorharness connector, remove the bolt and pull out thesensor.



41

W2005377

Harnesses and Tubing (Right Side)

W2005378

Harnesses and Tubing (Left Side)

Remove all tubing such as compressor coolant lines (hardpipes), aftertreatment fuel injector fuel line and electricalharnesses that cross over the rear of the flywheelhousing. Cut tie straps to remove electrical harnesses.

42Position a hydraulic jack under the rear of the flywheelhousing with sufficient capacity to support the rear ofthe engine.



43

W2005365

Remove the large engine mount-to-frame mounting boltsfrom both sides of the rear of the engine.

44Raise the rear of the engine approximately 25.4 mm (1inch) over the rear engine mounts.

45

W2006302

Position the right-side engine support tool 9990181-2onto the right rear corner of the cylinder head and installthe two bolts as indicated. Ensure the support tool footwill contact the upper portion of the frame.

Note: Use appropriate size and length bolts to secure theengine support.

9990181-2



46

W2005362

Position the left-side engine support tool 9990181-1 ontothe left rear corner of the cylinder head and install thethree bolts. Ensure the support tool foot will contact theupper portion of the frame.

Note: Use appropriate size and length bolts to secure theengine support.

9990181-1

47

W2005370

1-Engine SupportTool Pad

2-Left-Side FrameRail

Slowly lower the rear of the engine until both the supporttools rest securely on the frame rail, then remove the jackfrom under the rear of the engine.

48With the engine block supported, remove bothframe-mounted engine mounts located at either side ofthe frame rail of the vehicle.



49

W2005369

Remove the rear engine mounting brackets from theflywheel housing.

50

W2005368

For engines not equipped with rear engine powertake-off, remove the access cover for the PTO opening.

51Remove the screws attaching the timing gear cover tothe cylinder head.



52

T2023198

Remove the upper timing gear cover.

Note: Make sure that the rubber seals do not fall downinto the engine.

53

T2019081

Remove and discard the timing gear cover seals.

54

W2005372

Remove two opposing 14 mm flywheel housing boltsand install alignment dowels at these locations. Dowelsshould be made from 14 mm x 125 mm bolts with theheads removed and slots cut in to allow turning with aflat-blade screwdriver.



55

W2005375

Remove the flywheel housing upper bolts. Note thattwo of the bolts are hidden inside the rear engine powertake-off opening.

56

W2005376

Remove the remaining flywheel housing bolts.

57Remove the flywheel housing using slide hammer9994030 alternately on the left- and right-hand sides.

9994030

58Carefully remove the old sealant from the cylinder blockand the flywheel housing.

59Carefully tap the old crankshaft seal out of the flywheelhousing.

60Carefully clean the contact surface on the block andflywheel housing.

Note: The contact surface should be clean and dry.



Installation1

W2005250

Evenly apply a two mm (0.080 inch) bead of Volvo sealantto the flywheel housing following the pattern shown.Install and tighten the flywheel housing to the cylinderblock within 20 minutes of applying sealant to the housing.

2

W2005373

Position the flywheel housing over the two alignmentbolts that were previously installed into the rear of theblock at housing removal.



3

W2005376

W2005375

Install the flywheel housing mounting bolts. Note the twobolt locations within the rear power take-off opening.Install all bolts snug to ensure a good application ofthe sealant.

4Torque-tighten the flywheel housing bolts to the followingspecifications:

• Tighten all M14 bolts 140 ± 25 Nm (103 ± 18 ft-lb).• Tighten all M10 bolts 48 ± 8 Nm (35 ± 6 ft-lb).• Tighten all M8 bolts 24 ± 4 Nm (18 ± 3 ft-lb).

M14 = 140 ± 25 Nm (103 ± 18 ft-lb)M10 = 48 ± 8 Nm (35 ± 6 ft-lb)M8 = 24 ± 4 Nm (18 ± 3 ft-lb)



5

W2005548

1-EngineCrankshaft Seal

2-CrankshaftInstallation Tool9998238

Apply engine oil to the edge of the new crankshaft sealwhere it butts against the crankshaft. Carefully align thenew seal onto the seal installer 9998238 and handle9992000. Install the seal into the flywheel housing, usinghandle and seal installation tool until the seal installationtool bottoms out against the crankshaft.

9992000, 9998238

6

W2005369

Install both the engine mounting brackets onto the rear ofthe flywheel housing. Torque-tighten the engine mountingbolts to specification of 275 ± 45 Nm (203 ± 33 ft-lb).

275 ± 45 Nm (203 ± 33 ft-lb)

7Install the rear frame-mounted engine supports on bothframe rails. Torque-tighten the engine mounting bolts tospecification of 200 ± 30 Nm (148 ± 22 ft-lb).

200 ± 30 Nm (148 ± 22 ft-lb)



8

W2005368

For engines not equipped with rear engine powertake-off, install the access cover for the PTO opening.

9

T2023204

Position a hydraulic jack under the rear of the flywheelhousing with sufficient capacity to support the rear of theengine. Raise the rear of the engine approximately 25.4mm (1 inch) over the rear engine mounts. This action willremove the engine weight from the support tools.

10

W2006302

Remove the bolts securing the right-hand rear enginesupport tool 9990181-2 and remove the tool.



11

W2005362

Remove the bolts securing the left-hand rear enginesupport tool 9990181-1 and remove the tool.

12

W2005365

Lower the rear of the engine until the rear engine mountsare resting on the frame mounts and install the verticalrear engine support bolts. Hand-tighten the bolts snugusing a socket and handle. Then, remove the jack usedto support the rear of the engine.

13

W2005367

Torque-tighten the vertical rear engine support bolts tospecification of 540 ± 90 Nm (398 ± 66 ft-lb).

540 ± 90 Nm (398 ± 66 ft-lb)



14

W2005380

1-Power SteeringAttaching Bolts

3-FlywheelAttaching Bolt andNut

2-Timing GearPlate to FlywheelAttaching Bolts

Install the power steering and fuel pump mounting bolts(1) to install the pumps which were allowed to hang inplace (at disassembly) from the heavy-duty inlet andoutlet hoses. Next, install the timing gear plate to theflywheel housing bolts (2) and install the nuts (3) securingthe rear engine mount to the flywheel housing.

15Install and secure the air compressor to the left side ofthe engine. Torque the air compressor nuts to 85 ±15 Nm (63 ± 11 ft-lb).

85 ± 15 Nm(63 ± 11 ft-lb)

16Clean the timing gear cover sealing surfaces of the timinggear mounting plate and the flywheel housing.



17

T2019475

Clean the sealing surfaces of the timing gear cover andreplace the cover seals.

18

W2005102

Apply Volvo sealant in the bottom corners where thetiming gear plate and the flywheel housing meet. Alsoapply sealant at the top of the timing gear plate in thecorner next to the cylinder head.

19

W2005137

Apply Volvo sealant to the mating surfaces of the timinggear cover.

Note: The cover must be installed within 20 minutes ofapplying sealant.



20

W2005371

Position the timing gear cover on the flywheel housing andtiming gear plate, install the fasteners and loosely tighten.

21

W2005138

Position the timing gear cover alignment tools onto thecylinder head sealing surface as shown.

• Tighten cover alignment tool fasteners so that thetiming gear cover surface is level (flush) with the sealsurface on the cylinder head.

• Tighten the timing gear cover screws to specification.• Remove the timing gear cover alignment tools.

85109033A, 85109033B



22

W2005377

Harnesses and Tubing (Right Side)

W2005378

Harnesses and Tubing (Left Side)

Install all tubing such as compressor coolant lines(hard pipes), aftertreatment fuel injector fuel line andelectrical harnesses that cross over the rear of theflywheel housing. Reattach the tie straps to securethe electrical harnesses.



23

W2005068

Check for proper camshaft position sensor clearanceusing the sensor depth gauge to determine if shimsare required for proper sensor depth. The camshaftposition sensor clearance specification is 0.3–1.0 mm(0.011–0.039 inch).

1 Rotate the engine until a tooth of the camshaft toothedwheel is aligned with the sensor bore.

2 Insert the sensor depth gauge into the sensor boreuntil the outer part of the gauge is fully seated againstthe timing gear cover.

3 Loosen the thumb screw of the depth gauge and pushthe inner part of the gauge in until it contacts thecamshaft gear tooth.

4 Tighten the thumb screw to secure the inner part ofthe depth gauge.

5 Carefully remove the depth gauge from the camshaftsensor bore and observe the location of the stepsbetween the inner and outer portions of the gauge:

• Both steps below the surface of the tool = no shimsrequired.

• One step below the surface of the tool = one shimrequired.

• Both steps above the surface of the tool = two shimsrequired.

88800031

24

W2005104

Install the camshaft position sensor with appropriateshim(s) and new O-ring. Secure the sensor with the boltand plug in the harness connector.

Note: The camshaft position sensor shim part number is20556179.



25

W2005656

Connect the aftertreatment fuel injector fuel line tothe fitting on the injector.

26Reconnect the coolant and oil supply lines to theair compressor.

27

W2006038

Position the exhaust pipe between the diffuser pipeand the DPF muffler inlet pipe and loosely install theV-band clamps. Align the exhaust pipe at the diffuserand torque-tighten the V-band clamp fastener to 7± 2 Nm (62 ± 18 in-lb).

Note: Replace exhaust gaskets at each joint that isseparated.

7 ± 2 Nm(62 ± 18 in-lb)



28

W2005910

Install the upper exhaust V-band clamp that connectsthe flex pipe to the inlet module of the DPF. Position theclamp as shown to prevent the clamp from contactingother components. Torque-tighten the clamp fastener to 7± 2 Nm (62 ± 18 in-lb).

7 ± 2 Nm(62 ± 18 in-lb)

29Clean and inspect the mating surface of the valve covergasket. Replace the gasket if it is damaged or deformed.

30Clean the valve cover contact surface on the cylinderhead and the timing cover. All surfaces should becompletely free of grease and oil.

31

W2005157

Apply a 2 mm (0.079 inch) bead of Volvo sealant to thearea where the timing cover and the cylinder head meet.This parting line is on both sides of the cylinder head.

32Carefully position the valve cover on the cylinder head,making sure that the seal remains properly seated.

Note: The valve cover must be installed within 20minutes of applying sealant to the parting line area.



33

T2020552

Install the spring-loaded attaching bolts in the valve cover.Tighten the attaching bolts to 24 ± 3 Nm (18 ± 2 ft-lb) inthe sequence shown.

Note: The bolt spring provides even tension on thevalve cover gasket.

24 ± 3 Nm(18 ± 2 ft-lb)

34

W2004679

Place the engine electrical wiring harness in positionat the front of the valve cover and install the harnesssupport brackets. Securely tighten the bolts.

Note: Ensure the same bolts removed at disassemblyare reinstalled in their respective bracket locations.Damage to the valve cover will result if bolts that are toolong are installed in the wrong locations.

35

W5001572

Connect the air discharge line to the air compressorand install the clamp bracket securing the line to theintake manifold.



36

W2004681

Inspect the crankcase ventilation tube O-ring and replaceif necessary.

37

W2005747

Place the ventilation tube in position at the side of thevalve cover and install the mounting bolts in the tubeflange. Tighten the bolts to 24 ± 3 Nm (18 ± 2 ft-lb). Installthe P-clamp to secure the tube to the intake manifold.

Note: Ensure that the bolts removed at disassembly arereinstalled in the same location. Damage to the valvecover will result if the bolts installed are too long.

24 ± 3 Nm(18 ± 2 ft-lb)

38

W5001571

Place the air compressor fresh air inlet pipe in positionover the valve cover and connect the pipe to the couplinghose at the compressor. Tighten the coupling hose clampand install the clamp brackets to secure the pipe.

39Connect the coolant lines, oil supply line and air governorsignal line to the air compressor.

40Clean and inspect the mating surface of the oil pan seal.Replace the seal if it is damaged or deformed.



41

W2004878

Install the oil pan seal into the groove of the oil pan.Check that the seal locating tabs are properly aligned andseated in the locating holes on the mounting flange.

42

W2006078

Apply a two mm (0.079 inch) bead of Volvo sealant to theseam between the flywheel housing and the timing gearmounting plate and between the timing gear mountingplate and the engine block.

Note: Make sure that the block flange is flush with theflywheel housing to prevent leaking. If not flush, flywheelhousing must be realigned.

43

W2006079

Apply a two mm (0.079 inch) bead of Volvo sealant to theseam between the front seal cover and the engine block.

Note: Make sure that the block flange is flush with thecrankshaft front cover to prevent leaking. If not flush, frontcover must be realigned.



44

W2005226

With assistance, position the oil pan to the engine blockand install the bolts marked B. Install all other bolts,except those marked A, which should be installed last.

Note: Press the oil pan rearward as far as possiblebefore tightening the bolts.

Note: Use care to prevent damage to the oil pickup.

Note: Install transmission oil cooler bracket studs inlocations marked previously.

45

W2005985

Torque-tighten the bolts to 24 ± 4 Nm (18 ± 3 ft-lb)following the numbered sequence.

24 ± 4 Nm(18 ± 3 ft-lb)

46Install the oil drain plug and tighten to specification.

CAUTION

Do not use a copper washer with the hex-head oil drainplug. Always use the steel washer.

Note: Do not use air tools when installing the oildrain plug.



47

W2004876

Reconnect the oil level/temperature sensor connector.

48

W2004884

Install a new O-ring on the oil fill tube and install the tubeto the side of the oil pan. Install the oil fill tube fastenersand tighten to secure.

49

W2005086

Install a new O-ring on the dipstick tube, then install thetube and secure with the fastener. Install the dipstick.



50

W2006077

Install skid plate if removed for access.

51

W2005190

If previously removed, reconnect the tie rod into theleft-side steering knuckle and torque-tighten the locknutto 200 ± 30 Nm (148 ± 22 ft-lb). Insert the cotter pinand lock in place.

200 ± 30 Nm(148 ± 22 ft-lb)

52Position the starter motor into the opening on the rightside of the engine and install the nuts securing the startermotor to the flywheel housing. Torque-tighten the startermotor nuts to specifications.

53Route the battery cables and transmission cooler linesand secure under the flywheel housing.

54Connect the oil cooler lines to the transmission.



55

W2004874

Position the transmission cooler brackets onto the oil panfasteners as marked at disassembly, and then install thecooler line bracket nuts.

Note: Position the transmission oil cooler brackets at studlocations marked at disassembly.

56

W2004714

Install the starter motor wiring harness per the markingson the wires made at disassembly. Tighten the harnessnuts securely.

57

W2004715

Install the frame under-slung crossmember locatedunder the transmission.

58Reconnect the block heater (if equipped) and securethe harness.

59Secure the main air line (hard pipe) to the bracket at theflywheel housing, then connect the flexible air line.



60

W2003873

Using a hydraulic jack, raise the front axle and removethe jack stands from the front axle. Lower the front axleand remove the hydraulic jack.

61

W2005691

Replace the O-rings on both the inlet and return oil linefittings of the EGR valve. Lubricate the new O-rings withfresh engine oil.

62

W2005697

Clean any carbon deposits from the sealing surface of theEGR ports of the exhaust manifold.



63

W2005695

Position the EGR valve near the exhaust manifoldEGR ports.

64

W2005694

Install the return oil line to the bottom of the EGR valve.Allow the fitting to remain only finger tight at this time.

65With the EGR valve positioned close to the exhaustmanifold ports, slip a new metal gasket between the valveand the manifold. Install two new bolts to the top of theEGR valve to hold the gasket in place.

Note: The EGR mounting bolts are one-time use only.Whenever the EGR valve is removed for service, themounting bolts must be replaced with new.

Note: Apply anti-seize compound to the threads andunder the heads of the fasteners. Anti-seize helps preventfastener oxidation corrosion and reduces friction to helpachieve the intended clamp load on the component whentightening the fasteners to specification.



66

W2005693

Install the other two new EGR valve bolts. Torque-tightenall EGR valve bolts to 62 ± 5 Nm (46 ± 3.5 ft-lb).

Note: The EGR mounting bolts are one-time use only.Whenever the EGR valve is removed for service, themounting bolts must be replaced with new.

Note: Apply anti-seize compound to the threads andunder the heads of the fasteners. Anti-seize helps preventfastener oxidation corrosion and reduces friction to helpachieve the intended clamp load on the component whentightening the fasteners to specification.

62 ± 5 Nm(46 ± 3.5 ft-lb)

67

W2005690

Install the inlet oil line to the EGR valve and tightento specification.

68

W2005692

Tighten the return oil line to specification.



69

W2005689

Inspect the electrical connector for damage. Make surethat the rubber seal is in good condition and in placeon the connector. Install the electrical connector ontothe EGR valve.

70Position the EGR valve heat shield and install nutsand bolts.

71

W2006187

Install new high temperature gaskets onto the EGR valveend of the hot pipe and the inlet of the EGR cooler.Ensure the gasket lays flat against the flange surfaceswith the bead of the gasket facing the hot pipe.

Note: Gaskets are one-time use only. Do not reusegaskets.

72Inspect the V-clamps and T-bolt threads for wear ordamage. If they are OK, lubricate the V-inserts ofthe clamps.



73

W2005641

Hook the upper V-clamp over the EGR valve flange.Place the lower V-clamp over the bellows on the hot pipe.

74Lubricate the flange on the EGR cooler inlet and theflange on the EGR hot pipe with engine oil. Lubricationaids in V-clamp installation.

75Position the EGR hot pipe between the EGR valve andthe EGR cooler. Make sure the flanges engage properly.While holding the hot pipe in position, slide the upperV-clamp over the flange and tighten until snug. Slidethe lower V-clamp over the flange of the EGR coolerand tighten the clamp until snug.

76

W2006163

1 EGR Pipe Floating Flange2 EGR Cooler Flange3 EGR Pipe4 Flange Assembled Correctly5 Flange Assembled Incorrectly

Visually inspect the floating flange through the gap in theV-clamp to make sure it is properly seated in the EGRcooler flange. The floating flange must be concentric withthe EGR cooler flange.

Note: If the floating flange is not properly seated in theEGR cooler flange, the gasket will not be compressedand the seal will leak.



77Position the V-clamps so that the T-bolts clear both heatshields. Apply anti-seize compound to the threads of theT-bolts and torque-tighten to 20 ± 4 Nm (15 ± 3 ft-lb).

Note: After reaching the specified torque, inspect theV-clamps to ensure that no portion of the clamp has“bottomed out.”

20 ± 4 Nm(15 ± 3 ft-lb)

78

W2005687

Position the lower EGR hot pipe heat shield over the hotpipe and secure with bolts. Do not tighten at this time.

79

W2005686

Position the upper EGR hot pipe heat shield and install thefasteners and bolts. Tighten the fasteners to specification.



80

W2005685

Position the EGR heat shield over the EGR valve andsecure using the nuts that attach to the EGR bolts andthe bolt that attaches to the cylinder head. Tighten thefasteners to specification.

81Refill the engine with the specified quality of oil to thefull level on the dipstick.

82

W8003859

Install the outer section of the engine cover (includeswaste basket and center dash trim panel).

83Install the inner splash guard assembly.

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Flywheel housing replacement

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