Service Information

Document Title: Function Group: Information Type: Date:

Injectors, description 237 Service Information 3/3/2023
Profile:
G940 Volvo

Injectors, description
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Injection timing and the fuel amount to be injected is determined by the control unit E-ECU, which gives signals to the electro-
magnetically controlled fuel valve in the injector's valve housing. The duration of the injection time determines the amount of
fuel that is injected into the cylinder. The 'common rail' system enables more than one injection during the piston's working
phase, thus giving flexible control of the combustion process.
The injection pressure is determined by the pressure in the rail and can vary between 500 bar to 1400 bar (7252–20305 PSI).
The injector nozzles have six holes and are designed to give a uniform spray pattern, despite the angled injector nozzle.
Figure 1
Figure 2

Software
The function monitors the fuel injectors and informs the operator if there is a system malfunction.

Input signals Conditions for output functions Output functions

Monitoring, Mechanical problem, system error, open circuit or Amber central warning
injectors short-circuiting MA2301-MA2306 (SID1–6) Check — Engine failure
MA2301-2306 See Diagnostics Reduction of engine's
torque
Limitation of engine rpm
to 1100 rpm
Reduces rail pressure with
pressure relief valve (PRV)
 Service Information

Document Title: Function Group: Information Type: Date:

Injectors, replacing 237 Service Information 3/3/2023
Profile:
G940 Volvo

Injectors, replacing
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G930 Volvo
G940 Volvo
G946 Volvo
G960 Volvo

Op nbr 237-002

Total procedure time (hr): 2.50

WARNING
High pressure. Wait 30 seconds after switching off the engine before working on the fuel system.

NOTICE
Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.

NOTICE
Maintain greatest possible cleanliness when working on the fuel system.

NOTE!
Please follow these guidelines when replacing the injectors:

Carefully clean the area around the affected parts.

Blow damp areas dry with compressed air.
Observe the appropriate safety regulations for handling fuels.
Close all connections immediately after opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating fluids in suitable vessels and dispose of according to regulations.

1. Place the machine in the service position. Refer to Service position.

2. Disconnect the cable bracket from the valve cover and carefully fold aside the cable bracket.

3. Disconnect the wiring at each of the injectors.

4. Remove the fuel pipes from the rail to the injectors.

 Figure 1

1. Injectors
2. Fuel delivery pipe
3. Attaching yoke

5. Remove the injectors' attaching yokes and carefully remove the injectors.
NOTE!
Collect the draining fuel and dispose of according to regulations.

Pull the injectors from the engine

NOTE!
Remove residue paint and particles of dirt from the injector before removing it. Carefully clean the area around the
injector.

NOTE!
Ensure the copper sealing washer (at the nozzle end), comes out with the injector.

6. Install new O-rings on the injectors. Lube the O-rings sparingly with oil.

7. Install the new copper washers on the injectors. Install the injectors and attaching yokes. Torque to specification. Refer
to Fuel system, tightening torques.
NOTE!
Before installing the injector, all residue must be cleaned carefully from the bore on the cylinder head.

Do not tighten the clamp screw until after assembling the new injection line on the rail and injector.

8. Reconnect the wiring to each of the new injectors and torque the nuts to specification. Refer to Fuel system, tightening
torques.

9. Install the fuel pipes from the rail to the injectors and torque the fittings to specification. Refer to Fuel system,
tightening torques.
NOTE!
The injection lines must always be renewed after disassembly.

10. Reinstall the cable harness rail to the valve cover and tighten the mounting bolts.
11. Bleed the fuel system. Refer to Fuel system, bleeding.

12. Start the engine and check for leaks.

13. Place the machine back in service.

 Service Information

Document Title: Function Group: Information Type: Date:

High pressure fuel pump, 237 Service Information 3/3/2023
checking
Profile:
G940 Volvo

High pressure fuel pump, checking

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G940 Volvo
G946 Volvo
G960 Volvo

WARNING
High pressure. Wait 30 seconds after switching off the engine before working on the fuel system.

NOTICE
Maintain greatest possible cleanliness when working on the fuel system.

Op nbr 237-030

Total procedure time (hr): 1.00

Tools:
88890080 Pressure checking set

1. Unplug the connector from the fuel control valve.

Figure 1
Connector on fuel control valve
 2. Remove the delivery lines between the high-pressure pumps and the common rail (fuel rail).

Right high-pressure pump

NOTICE
Exceeding the tightening torque can cause damage on the component.

3. To prevent damage to the fuel system, use counterhold tools on the adapters when pressure hoses are connected and
disconnected.
NOTE!
Tightening torque for input pressure pipes in 88890080 Pressure checking set: 17 Nm (12.5 lbf ft).

Fit:

Delivery pipe (10, angle: 50°) on the right high-pressure pump.

Delivery pipe (8, angle: 170°) on the left high-pressure pump.
Adapter and the plug (3) on the connection on the common rail (fuel rail) (2).
Adapter (4) on the connection on the common rail (fuel rail).

Connect:

Delivery hose between the delivery pipe on the right high-pressure pump and the measuring tool (1)
Delivery hose between the adapter (4) on the common rail (fuel rail) and the measuring tool (1)
Rubber hose to the measuring tool's (1) drain nipple
Rubber hose to the delivery pipe (8)

Collect the excess fuel in a suitable container (6).

Figure 2
Checking right high-pressure pump (principle illustration), 88890080Pressure checking set

1. Pressure gauge
2. Common rail (fuel rail)
3. Adapter for connecting plug
4. Adapter for connecting delivery hose
5. Draining nipple
6. Collection container waste fuel
7. Rubber hoses
 8. Delivery pipe (170° between openings)
9. High-pressure pumps
10. Delivery pipe (50° between openings)

4. Plug in the connector to the fuel control valve.

5. Open the drain nipple (5) on the measuring tool. Run the starter motor until fuel free of air flows out of the measuring
tool. Close the drain nipple on the measuring tool.
NOTE!
Collect the excess fuel in a suitable container.

6. Check that there are no leaks on the measuring equipment.

7. Connect the VCADS Pro computer and run the Sensor valve, monitoring program. Refer to VCADS Pro, 28407-3 -
Sensor values, monitoring.

8. Start the engine and check that the pressure is according to fuel system specifications. Refer to Fuel system,
specifications.
If the rail pressure sensor does not show the same value as 88890080, the rail pressure sensor should be changed
before the left high-pressure pump is tested. Refer to Fuel rail pressure sensor, replacing.

9. Release any fuel pressure by opening the drain nipple (5) on the measuring tool.

Left high-pressure pump

NOTICE
Exceeding the tightening torque can cause damage on the component.

To prevent damage to the fuel system, use counterhold tools on the adapters when pressure hoses are connected and
disconnected.

10. NOTE!
Tightening torque for input pressure pipes in 88890080 Pressure checking set: 17 Nm (12.5 lbf ft).

Connect:

Delivery hose between the delivery pipe (8) on the left high-pressure pump and the measuring tool.
Rubber hose to the right high-pressure pump's delivery pipe (10).
 Figure 3
Checking left high-pressure pump (principle illustration), 88890080Pressure checking set

1. Pressure gauge
2. Common rail (fuel rail)
3. Adapter for connecting plug
4. Adapter for connecting delivery hose
5. Draining nipple
6. Collection container waste fuel
7. Rubber hoses
8. Delivery pipe (170° between openings)
9. High-pressure pumps
10. Delivery pipe (50° between openings)

11. Repeat steps 5 – 8.

12. Remove the checking equipment.

If any of the high-pressure pumps delivers a lower fuel pressure than the fuel system specifications indicate then the pump/
pumps should be changed. Refer to Fuel system, specifications and High pressure fuel pump, replacing.

13. Install new delivery pipes between the high-pressure pumps and the common rail (fuel rail). Torque to specification.
Refer to Fuel system, tightening torques.

14. Plug in the connector to the fuel control valve..

15. Start the engine and check that there aren't any leaks.
 Service Information

Document Title: Function Group: Information Type: Date:

Fuel control valve (FCV), 237 Service Information 3/3/2023
checking
Profile:
G940 Volvo

Fuel control valve (FCV), checking

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G930 Volvo
G940 Volvo
G946 Volvo
G960 Volvo

Op nbr 237-038

Total procedure time (hr): 0.70

Tools:
11666052 Pressure gauge
11666027 Adapter
9993720 Nipple
11666037 Hose

WARNING
High pressure. Wait 30 seconds after switching off the engine before working on the fuel system.

NOTICE
Maintain greatest possible cleanliness when working on the fuel system.

Testing conditions

Fuel feed pressure is according to the specifications. Refer to Fuel system, specifications.
Batteries are in good condition and fully charged.

Pressure checking procedures

1. Place the machine in service position. Refer to Service position.

2. Connect 9993720 Nipple, 11666027 Adapter, 11666037 Hose and 11666052 Pressure gauge to the fuel control valve's
outlet connection.
 Figure 1

1. Fuel control valve's outlet connection

3. Connect the VCADS Pro computer and peform the fuel feed pressure test. Refer to VCADS Pro, 23017-3 - Feed
pressure, inspection.
NOTE!
Compare the pressure in the common rail (fuel rail) during the test with Fuel system, specifications.

Checking fuel control valve's output pressure at start

4. Disconnect the cable bracket from the valve cover and carefully move aside the cable bracket, disconnect all electric
connections from the injectors.
NOTE!
Isolate the disconnected cables.

Figure 2
Injector cables, disconnection

1. Cable bracket
2. Electric connections

5. Connect the VCADS Pro computer and perform the fuel feed pressure test. Refer to VCADS Pro, 23017-3 - Feed
pressure, inspection.
NOTE!
Compare the pressure in the common rail (fuel rail) during the test with Fuel system, specifications.
 6. Crank the engine with the starter motor for 15 to 20 seconds, check if the measured values for the fuel control valve's
output pressure matches with Fuel system, specifications.
In case the output pressure is not normal:

If the fuel supply pressure to the fuel control valve has been verified , replace the fuel control valve. Refer to
Fuel control valve (FCV), replacing.
When the engine is running, check the pressure according to the following.

In case the pressure is normal:

Check the common rail's (fuel rail's) pressure relief valve and the high-pressure pumps. Refer to High pressure
fuel pump, checking.

7. Connect the cables to the injectors and install the cable bracket on the valve cover.

Checking fuel control valve's output pressure at low and high idle

8. Connect the VCADS Pro computer and perform the fuel feed pressure test. Refer to VCADS Pro, 23017-3 - Feed
pressure, inspection.
NOTE!
Compare the pressure in the common rail (fuel rail) during the test with Fuel system, specifications.

9. Start the engine. Place the gear selector in position “P”.

10. Check if the measured values for the fuel control valve's output pressure at low and high idle match with Fuel system,
specifications.
If the fuel control valve's output pressure is too high and the pressure in the common rail (fuel rail) is low:

Check the common rail's (fuel rail's) pressure relief valve and the high-pressure pumps. Refer to High pressure
fuel pump, checking.

If the fuel control valve's output pressure is too low or unstable:

Replace the fuel control valve. Refer to Fuel control valve (FCV), replacing.

If the fuel control valve's output pressure is normal and the pressure in the common rail (fuel rail) is low:

Check the high-pressure pumps. Refer to High pressure fuel pump, checking.
Check the pressure relief valve.

11. Place the machine back in service.

 Service Information

Document Title: Function Group: Information Type: Date:

Fuel control valve (FCV), 237 Service Information 3/3/2023
replacing
Profile:
G940 Volvo

Fuel control valve (FCV), replacing

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G930 Volvo
G940 Volvo
G946 Volvo
G960 Volvo

Op nbr 237-033

Total procedure time (hr): 1.25

WARNING
High pressure. Wait 30 seconds after switching off the engine before working on the fuel system.

NOTICE
Maintain greatest possible cleanliness when working on the fuel system.

Removing

1. Place the machine in the service position. Refer to Service position.

2. Unplug the connector from the fuel control valve.

3. Remove the feed pipes.

 Figure 1

1. Fuel control valve

2. Connector
3. Feed pipes
4. Feed lines
5. Return line

4. Disconnect:

The feed line (from the fuel filter) from the fuel control valve.
The return line from the fuel control valve.

5. Remove the fuel control valve.

Installing

6. Check that the fuel control valve is free from damage.

7. Install the fuel control valve. Only tighten the bolts by hand.

8. Connect the feed line with new gaskets (from the fuel filter) to the fuel control valve. Refer to Fuel system, tightening
torques.

9. Connect the return line to the fuel control valve with new gaskets. Refer to Fuel system, tightening torques.

10. Install the feed pipes with new gaskets. Refer to Fuel system, tightening torques.

NOTICE
The pressure lines may not be bent.

11. Tighten the bolts for the fuel control valve. Refer to Fuel system, tightening torques.

12. Plug in the connector for the fuel control valve.

13. Bleed the fuel system. Refer to Fuel system, bleeding. Check that there are no leaks.

14. Place the machine back in service.

 Service Information

Document Title: Function Group: Information Type: Date:

Pressure relief valve (PRV), 237 Service Information 3/3/2023
inspecting
Profile:
G940 Volvo

Pressure relief valve (PRV), inspecting

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G930 Volvo
G940 Volvo
G946 Volvo
G960 Volvo

Op nbr 237-036

Total procedure time (hr): 0.70

Tools:
11666052 Pressure gauge
11666037 Hose
11666027 Adapter
9993720 Nipple

WARNING
High pressure. Wait 30 seconds after switching off the engine before working on the fuel system.

NOTICE
Maintain greatest possible cleanliness when working on the fuel system.

The pressure relief valve is a mechanical safety device that opens at 1900 (±50) bar. In case of any malfunction in the circuit, the
fuel control valve (FCV) opens fully to open the pressure relief valve and protect the system against excessive pressures.

NOTICE
The pressure relief valve (PRV) is only allowed to remain open for a total time of 300 minutes. After that time the
component must be replaced.

Testing conditions

Fuel feed pressure is according to the specifications. See Fuel system, specifications.
Batteries are in good conditions and fully charged.
Abnormal value for pressure in common rail (fuel rail) measured with VCADS Pro. See Fuel system, specifications.
The pressure relief valve (PRV) has not been open for more than a total of 300 minutes. Check this with VCADS Pro,
17030–3 Parameter programming.
Pressure checking procedures

1. Place the machine in service position, see Safety rules when servicing.

2. Unplug the connector (1) from the fuel control valve.

Figure 1

3. Connect 11666027 Adapter, 11666037 Hose, 9993720 Nipple and 11666052 Pressure gauge to the fuel control valve (1).

Figure 2
Fuel control valve

1. Fuel control valve pressure checking point

4. Connect VCADS Pro computer and start 23017-3, checking fuel feed pressure.

Checking fuel control valve's output pressure at start

NOTE!
This test is used only if there are the engine starting problems.

5. Disconnect the cable bracket (1) from the valve cover and carefully move aside the cable bracket. Disconnect all cables
(2) for the injectors.
NOTE!
Isolate the disconnected cables.
 Figure 3
Injector cables, disconnection

1. Cable bracket
2. Electric connections

6. Crank the engine with the starter motor for 15 to 20 seconds, and check if the measured values for the fuel control
valve's output pressure matches with Fuel system, specifications.

7. Stop the engine.

8. Connect the cables to the injectors and install the cable bracket.

Checking fuel control valve's output pressure at low and high idle
NOTE!
Due to the software function 'engine protection', engine rpm will be restricted after approx. 30 s.

9. Check if the measured values for the fuel control valve's output pressure at low and high idle match with Fuel system,
specifications.

In case the injector control unit's pressure is too low in all situations:

Check or replace fuel control valve, see Fuel control valve (FCV), replacing.

In case the rail pressure is too low at all conditions, and FCU pressure is normal

Check or replace common rail's (fuel rail's) pressure relief valve according to Pressure relief valve (PRV), replacing.

10. Save the labour card and disconnect the VCADS Pro cable. Remove the measuring tools.

11. Plug in the connector for the fuel control valve.

12. Restore the machine to operating condition.

 Service Information

Document Title: Function Group: Information Type: Date:

Pressure relief valve (PRV), 237 Service Information 3/3/2023
replacing
Profile:
G940 Volvo

Pressure relief valve (PRV), replacing

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G946 Volvo
G960 Volvo

Op nbr 237-034

Total procedure time (hr): 0.80

Tools:
88894000 Diagnostics unit
Tech Tool Service Tool

WARNING
High pressure. Wait 30 seconds after switching off the engine before working on the fuel system.

NOTICE
Maintain greatest possible cleanliness when working on the fuel system.

1. Place the machine in service position, see Safety rules when servicing.

2. NOTE!
Collect the excess fuel in a container.

Remove the pressure relief valve. Use socket 18 and extension.

If the machine is equipped with secondary steering:

Remove the oil trap. Remove the pressure relief valve. Use socket 18.
 Figure 1

Figure 2
Machine equipped with secondary steering

1. Motor for secondary steering

2. Oil trap

3. Check that the pressure relief valve is free from damage. Check that the pressure relief valve's threads and the internal
threads on the fuel rail are free from damage. Oil the threads lightly and install the new pressure relief valve. Tightening
torque, see: Fuel system, tightening torques

If the machine is equipped with secondary steering:

Install the pressure relief valve. Install the oil trap.

Figure 3
4. Run Tech Tool operation 17030-3, Parameter programming and reset the parameter GFH, PRV total opened time.

5. Start the engine, and check that there are no leaks.

 Service Information

Document Title: Function Group: Information Type: Date:

Delivery pipe, replacing one 237 Service Information 3/3/2023
Profile:
G940 Volvo

Delivery pipe, replacing one

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G946 Volvo
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Fuel Rail, replacing

Op nbr 237-018

Total procedure time (hr): 0.70

1. Place the machine in the service position. Refer to Service position

2. Thoroughly clean the work area around the fuel system before carrying out any repairs.

NOTICE
Maintain greatest possible cleanliness when working on the fuel system.

3. Disconnect the wiring harness from the sensor on the end of the fuel rail.

4. Disconnect the banjo fitting for the fuel return line.

NOTE!
Collect draining fuel from the line into an appropriate container.

NOTICE
Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.

NOTICE
Plug all opened connections on fuel and oil lines.

5. Disconnect all fuel pipes from the fuel rail to the injectors and high pressure pumps.

NOTICE
Fit protective caps on all injectors and on the injection pump's connections.

6. Loosen the mounting bolts and remove the fuel rail from the engine.

7. Install the new fuel rail assembly onto the engine and torque the mounting bolts to specification.
 8. Check the condition of the fuel pipes and replace if required. Reconnect the fuel pipes to the high pressure pumps and
injectors. Torque the fuel fittings to specification.

9. Reconnect the fuel return line to the rail.

10. Reconnect the wiring harness to the fuel rail sensor.

11. Bleed the fuel system. Refer to Fuel System Bleeding Procedure.

12. Place the machine back into service. Start the engine and check to make sure that there are no leaks.
 Service Information

Document Title: Function Group: Information Type: Date:

Fuel rail pressure sensor, 237 Service Information 3/3/2023
replacing
Profile:
G940 Volvo

Fuel rail pressure sensor, replacing

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Valid for serial numbers

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G930 Volvo
G940 Volvo
G946 Volvo
G960 Volvo

Op nbr 237-035

Total procedure time (hr): 0.30

WARNING
High pressure. Wait 30 seconds after switching off the engine before working on the fuel system.

NOTICE
Maintain greatest possible cleanliness when working on the fuel system.

1. Place the machine in service position, see Service position.

2. Remove the cable tie (2) and unplug the connector (1) from the rail pressure sensor.

Figure 1
3. NOTE!
Collect the excess fuel in a container.

Remove the high-pressure sensor.

4. Check that the threads on the high-pressure sensor and the internal threads in the fuel rail are free from damage. Oil
the threads lightly and install the new sensor. Tightening torque, see: Fuel system, tightening torques.

Figure 2

5. Plug in the connector and install the cable tie.

6. Start the engine, and check that there are no leaks.