Volvo Engine >> INJECTOR SLEEVE INSTALLATION PROCEDURE FOR VOLVO TD 45

Volvo Engine >> INJECTOR SLEEVE INSTALLATION PROCEDURE FOR VOLVO TD 45

Injector Sleeve Installation Procedure On
Volvo D45, TD45, D45B & TB45B Engines

The AERA Technical Committee offers the following procedure for installing Injector Sleeves On Volvo D45, TD45, D45B & TB45B engines. Volvo offers the following procedure to correctly install these injector sleeves.

1) With the old injector sleeve removed from the cylinder head, make sure that the sealing area in the cylinder head is free of rust and carbon deposits.
2) Check that the pressing drift, SVO6420 runs freely in the new injector sleeve and the steel ring. Polish off any burrs to avoid any difficulties when the pressing drift is removed.
3) Position the steel ring and the copper sleeve on the pressing drift and measure the clearance between the steel ring and the copper sleeve. Clearance should be .020-.040".
4) Oil the upper sealing ring for the copper sleeve and push it down into the cylinder head.
5) Position the lower sealing ring on the copper sleeve. Apply a thin coat of anti-corrosion fluid on the outside of the copper sleeve.
6) Position the steel ring and insert pressing drift down through the steel ring and the copper sleeve.
7) Check that the pressing tool, SVO6422 is positioned parallel to the cylinder head correctly according to the information below.
D45 & TD45 Figures 1-4
D45B & TD45B Figures 5-6
8) Press down the steel ring by tightening the pressing tool spindle to a torque of 50 ft/lbs.
9) Slacken the spindle and remove pressing tool & pressing drift.
10) Insert pressing drift, SVO6402 through the steel ring against the copper sleeve. Check that the drift moves freely in the sleeve. Position pressing tool, SVO6422 according to figures listed above.
11) Press down the copper sleeve by tightening the spindle of the pressing to a torque of 43 ft/lbs. This operation is done in two stages, first with the SVO6420 and then the SVO6402 in order to obtain the correct pressing force on the copper sleeve. This will also obtain correct clearance between the steel ring and the copper sleeve, which is .004-.018".
12) Remove the tools and check clearance which should be .004-.018". This is done using tool E1013 as shown if Figure 7.
13) Apply a thin coat of anti-corrosion fluid on the injector and inside of the copper sleeve and install the injector. Fit the yoke and the nut and tighten to 37 ft/lbs.

The AERA Technical Committee

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