Re/Re blown turbo - Volvo VN

[LGMechanical]

I always enjoy reading building/rebuilding threads so I figured I would post one of my own. Someone might consider it interesting. Although I don't have pictures from start to finish because I didn't think of doing it till after I removed it But I will post a full one next time.

The job is on a Volvo VN day cab. The turbo blew while he was on the road. It came in on the hook. When I seen the oil coming down the muffler stack I knew what was wrong About 10L of oil and a whole lot of shrapnel from the turbo ended up in the intercooler and the pipes so I had to flush that out.

This is the turbo thats going in. Small compared to other engines but is still 30+ PSI. Oh and also in the picture is that tech who mashed up my Matco MT2858 air ratchet if any of you seen that post. Don't mind him.

Here is a shot of the turbo mounted under the exhaust manifold. Loctite must be used on the bolts to prevent loosening. Once it's all together there is no access to these bolts so it must be done right!

This one shows me adjusting the turbo to line up with all the plumbing. Don't worry, I have it set on low torque

 

[LGMechanical]

Here, I am clamping the turbo to the exhaust brake manifold. I'm not a fan of this style of clamps. Also when I removed the manifold, it had to be pushed back in order to seperate it. Pushing flex pipe in is easy, but pulling it back took some effort.

Assembling the intercooler piping takes a bit of time. Lining it up with all the mounts is not always easy. When I first removed this hose a whole lot of oil came pouring out.

Now the turbo is mounted, so it's time to mount the EGR (Exhaust Gas Recirculation) valves that go on top of the turbo. All the clamps and gaskets must be replaced to prevent leaks. Below this picture is a shot of the back EGR valve.

I will post the rest soon!

 

[LGMechanical]

Here is a shot of the 2 valves mounted, lines and wire rail on aswell. Below, the EGR cooler pipes are installed. It's all a very tight fit so it must be held and pressed against the flange while clamping it.

Finally the heat shields are on and the EGR is fully assembled and the job is nearly done. Now to deal with all the plastic.

The air cleaner housing is mounted and below is a the new filter. The old one was full of metal filings. The plastic hose is then installed from the cleaner housing to the turbo. The filter cover goes on and I move on to installing the splash gaurd.

Splash gaurd, hood lock mounted

 

[LGMechanical]

Now all thats left to do is fill it with coolant, run it and check for leaks. It must be ran without the intake hose incase it has some pieces left in the intercooler. After leaving it on high idle for some time, I threw it on. It takes 9 gallons to fill it up. Some trucks need more! (I also replcaed the muffler because it was soaked with oil but I didn't take photos of that)

And it's complete! Just under 8 hours of labour including flushing, cleaning, time spent heating bolts so they don't break and replacing the muffler. Thanks for reading! If you have any questions or comments, post up! Next time I will post a more detailed thread with more pictures of the complete job. Whatever it may be.

 

[kiall1987]

Do you deal with any scannia units over their ?

 

[LGMechanical]

Over here you won't see Scania trucks. They are all over europe. The major of trucks here are the conventional type with a hood. I've done alot of work on cab-overs though. Alot of old Freightliners, old Peterbilts, GMC, Hino, Mitsubishi Fuso, etc.

 

[kiall1987]

Only real american type truck we get is hinos many scannia, daf , mans , merc renault , But very tidy work you've done their do you have the picture off the truck itself?

 

[LGMechanical]

The north american trucks are getting alot worse as they get newer. Tons of problems ranging from electrical to body to power train. I've been hearing good things about the euro trucks though. For instance, the new Frieghtliners come with rack and pinion steering with is a complete joke. I've seen a couple fail, mostly leaks, and guess what? No parts. You have to replace the whole cylinder.

I don't have a picture of the whole truck but it like the one on the left below.

 

[kiall1987]

Mostly we see here are the scannia r420 most common I would say , but like you say they are all over cab although theirs a few bullnose lorrys starting to creep up . What do you use few your technical data ?

Haha scannia with volvo on back

 

[LGMechanical]

We have software for most engine types on the shop laptop. Allowing us to electronically diagnose problems. There is also a whack-load of literature with all the specs and wiring diagrams one can desire. But using your head is the most important thing obviously

 

[Carlitos]

Nice post.
Mostly Scania and Mercedes (the both have factorys here and in Brazil), also Volvo is gaining market.

 

[LGMechanical]

Nice post.
Mostly Scania and Mercedes (the both have factorys here and in Brazil), also Volvo is gaining market.

All the Mercedes engine parts we order come from Brazil

 

[chammyman]

brings back memories, I miss working on trucks sometimes.

Only pics I have of any engine stuff would be off my camera phone and the volvo fh12

this pic was for scale for a friend who didn't think stuff was big on them

a piston out of the same engine, it had a split skirt which is seperate on these engines

 

[LGMechanical]

Yea those suckers get big. Although it gets even bigger if you start getting into heavy equipment. But thats not something I'd want to do. I'm happy working on trucks.

 

[Re-Volv]

Which turbo is that and what year is the truck?

 

[LGMechanical]

Its a 4" Holset. I don't have the P/N handy, sorry. The truck was manufactured in 2004. I wish I had thought of taking a picture of the blown turbo. What a mess. Even after the job was completed, the oil that remained in the exhaust began to leak through the exhaust clamps. It's gotta burn off unless he was to replace all his pipes. Which is unneccesary.

 

[hopper1]

Looks like the D12 engine. There's a local fleet that brings their VNs to our shop so we've been getting familiar with the D12 over the past couple of years. Haven't changed any turbos yet, but we've done quite a few EGR valves (I'd like to meet the guy responsible for placing the nearest electrical connector all the way on the OTHER side of the engine) and EPGs. Changing alternators isn't much fun either due to that damned back bolt.

 

[LGMechanical]

Looks like the D12 engine. There's a local fleet that brings their VNs to our shop so we've been getting familiar with the D12 over the past couple of years. Haven't changed any turbos yet, but we've done quite a few EGR valves (I'd like to meet the guy responsible for placing the nearest electrical connector all the way on the OTHER side of the engine) and EPGs. Changing alternators isn't much fun either due to that damned back bolt.

Haha yes! I never put the back bolt back in afterwards though. We get more Volvos at our shop then the damn dealership! So I have become very good with them.