11 Rumbold advises that each time the air filter is changed
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the turbocharger bearing is checked. This is done by removing the inlet air trunking and using finger and thumb to hold the spindle and detect any play in the bearing. When replacing the trunking check all the joints for security.
12 Volvo's 16-litre engine is
fitted with a coolant filter which should be changed every six months except when it concides with the two-yearly coolant change. The filter is situated at the front nearside of the engine and has a small tap set in the housing. The tap should be turned off (horizontal) before removing the filter with a strap wrench. Smear the seal with a drop of oil before screwing the filter on until the seal butts. Then give a further half to three-quarters of a turn and remember to open the tap again (pointing upwards). Rumbold checks next for play in the kingpin. The Volvo method is to lift the front axle so the wheels are free and apply the park brake. A set square is then placed against the tyre and its position marked. A bar is put through the knave of the wheel and levered upwards. Any play will move the set square away from the vehicle. If on the 22.5in wheels this movement is more than 5.2mm, the kingpin requires attention.
13 There are a couple of checks on the front oil filled hub. First remove the central plastic plug. "If you can see the oil the level is fine, if not add some more," is Rumbold's advice. An SAE 30 oil should be used — not a multigrade. If the level is going down there is probably a leak that needs investigating. The plastic plug can easily be broken by over tightening: it has a torque setting of just 3.5Nm. Spin the wheel and listen for the rumble that comes with worn bearings and also put a bar through the wheel to detect any play. 14 15 Draining the oil requires a 12mm hexkey and should be
done at 15,000km if an oil to API CD or CCMC 1)2 or D3 is used. If the oil conforms to Volvo's VDS specification the changes can be at 30,000km. Whichever specification you choose you will need 47 litres of 15W/40 oil to refill the sump. The drain plug is magnetic and the copper sealing washer need only be replaced when flattened. Retighten the drain plug to 80Nm. There are three filters on the 16 litre engine, two are full flow and one bypass. All the filters are set on the nearside of the engine and should be changed at the same time as the oil. Both full flow filters are identical but the bypass one (at the front) has finer filtration and a different attaching thread. All are removed with a strap wrench and have their seals smeared with oil before fitting. Again the correct procedure is to screw them on until the seals butt and then give an additional half to three-quarters turn.
16 17 Oil changes on the SR2000
gearbox are restricted to once a year with a level check on the other services. A cluster of three plugs are set at the rear offside of the gearbox and are removed with a 12nun hexkey. The level] filler is the uppermost plug and the lower. the drain. Refilling requires 11 litres (12 with an oil cooler) of 80W/90 oil to APIGL-1. When the gearbox oil is changed so should its filter. This is situated at the rear of the casing and is protected with a guard. Changing is done in the Volvo prescribed fashion.
18 To check the clutch adjustment measure the distance
from the cylinder face to the back of the locknut: it should be 40mm. It can be adjusted by removing the clevis pin and rotating the fork before re-tightening the locknut. If there is no adjustment left, a new clutch is required. Next the split cylinder inhibitor's 13mm gap should be checked. To adjust, slacken the pinch bolt and move the arm round the shaft.
19 On the rear axle the oil
should be changed on the annual service and the level checked on the others. The 12mrn hexkey is used to remove the level filler plug from the back of the diff housing (the drain is underneath). Both have tapered threads so no sealing device is required. Ten litres of SAE 80W/140 oil to API-GL-5 will be needed to refill the differential. The rear hubs are grease filled and have telltale holes to warn of a leaking seal.
20 With air suspension, greas
ing on the rear is reduced to one nipple on each brake cross-shaft and the propshaft UJs. To lubricate the clutch cross shaft remove, fill with grease and replace the small cap set halfway up the nearside of the bell-housing. Front road springs have two nipples at the rear and one at the front. Front brake cross-shafts have a single nipple while kingpins have three (two at the top). Other greasing points under the front grille are two on the cab cross-shaft, two on the steering column Ws and one on the slider (grease only when cab is down).
21 There are no wear indica
tors on Volvo's asbestos free brake linings so the remaining thickness must be measured. This is extremely difficult on the rear as the air suspension covers most of the backplates. Volvo allows linings to wear down to 5mm minimum which is about the thickness of the rivets. The brake has an internal self-adjusting mechanism and the shoes are handed and are different top and bottom so a reline is not without its difficulties.
22 Steering ball joints are
spring loaded units that are sealed for life. The way to check for wear is to compress the joint and measure how much it moves. If it's more than 2mm the joint should be replaced. Shackle ends of the springs can be checked with a bar and should not have more than 4.5mm of play. Rumbold gives the underside a final check round and then torques the wheel nuts. These are all right-handed and require 625±75Nm. One final word of warning — make sure the gear lever is in neutral and that it feeds through the hole in the floor when the cab is lowered.