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REVISION INDEX ................................................................................................................................... Index Page 1General............................................................................................................................................................................. 2Section 1 Cores New to Exchange Program ......................................................................................................... 3Section 2 Complete Engines (Function Group 2102) ......................................................................................... 4Section 3 Basic Long Block Engines (Function Group 2102) .......................................................................... 6Section 4 Short Block Engines (Function Group 2105) ...................................................................................16Section 5 Cylinder Heads (Function Group 2111) .............................................................................................17Section 6 Injector Rocker Arm (Function Groups 2145 & 2371) ...................................................................24Section 7 Crankshafts (Function Group 2161) ...................................................................................................25Section 8 Injection Pumps / Unit Injector (Function Group 2361) .................................................................26Section 9 Injectors (Function Group 2371 & 2374) .........................................................................................27Section 10 Turbo Chargers (Function Group 2551) ..........................................................................................28Section 11 Water Pumps / Coolant Pump / Bearing Housing (Function Group 2621) ............................33Section 12 Thermostat / Viscous Fans (Function Group 2631) .....................................................................35Section 13 Control Units (Function Group 2841) ..............................................................................................36Section 14 Alternators (Function Group 3211) ...................................................................................................37Section 15 Starter Motors (Function Group 3311) ............................................................................................38Section 16 Clutch Kits (Function Group 4111) ..................................................................................................39Section 17 Clutch Cylinder / Actuator / Slave Cylinder (Function Group 4139) ........................................40Section 18 Pressure Plates (Function Group 4112) .........................................................................................41Section 19 Clutch Discs / Driven Plates (Function Group 4117) ..................................................................42Section 20 Transmissions / Gear Boxes (Function Groups 4311, 4312) ....................................................43Section 21 Air Compressors (Function Group 5611) .......................................................................................47Section 22 Brake Chamber / Cylinders (Function Group 5641) ....................................................................48Section 23 Steering Gears (Function Group 6422) ..........................................................................................49Section 24 Steering Pumps / Servo Pumps (Function Group 6453)............................................................50Section 25 Instrument Clusters (Function Group 3811) ..................................................................................51Section 26 Connecting Rods (Function Group 2164) .....................................................................................52Section 27 Loaded Cylinder Kit (Function Group 2131 / 2139) ................................................................55-1Section 28 Loaded Overhaul Kit (Function Group 2131 / 2139) ..............................................................55-2Section 29 EGR Valves – Volvo D12 Series Engines (Function Group 2548) ...........................................56Section 30 EGR Cooler (Function Group 2932) ...............................................................................................58Section 31 Diesel Oxidation Catalyst (Function Group 2587) ........................................................................67Section 32 DPF Filters (Function Group 2587) .................................................................................................68Section 33 DEF Pump (Function Group 2581) ..................................................................................................75Section 34 Driving Devices (Function Group 2159) ..........................................................................................79Section 35 Radiators (Function Group 2611) .....................................................................................................80Section 36 Actuators (Function Group 2559) ....................................................................................................81Section 37 Radios (Function Group 3981) .........................................................................................................82Section 38 Oil Pumps – Volvo D12 Series Engines (Function Group 2211) ..............................................83Section 39 Flywheels (Function Group 2166) ....................................................................................................84
Core Manual Table of ContentsThis guide includes exchange and core number cross over listings and is designed to ensure that returned cores meet acceptance requirements for condition, packaging and cleaning. Additionally, information is included to assist in identifying core markings. Refer to the Parts Operations Manual, Chapter 11, for complete policies and procedures for Volvo Reman cores.
To view a specific section, click on any of the blue links below. To Return to Table of Contents, click on the Volvo Reman Logo on any page or click on the link at bottom of page.
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Revisions
PAGE NUMBER PRODUCT REV. DATE
Page 84 Flywheels 08 / 17
Page 2 General 07 / 17
Page 84 Flywheels 06 / 17
Page 23 Cylinder Heads 01 / 17
Page 27 Injectors 01 / 17
Page 46 through 46-1 Transmissions 01 / 17
Pages 77 EGR Coolers 12 / 16
Pages 76 through 77 EGR Coolers 08 / 16
Page 57 EGR Valves 07 / 16
Page 2-1 General 06 / 16
Pages 77-78 DEF Pump 04 / 16
Page 20 Slab Type Cylinder Heads 04 / 16
Pages 55-1 through 55-2 Loaded Cylinder Kit & Loaded Cylinder Overhaul Kit 01 / 16
Page 27 Injectors 11 / 15
Page 1 Table of Contents 10 / 15
Page 52 through 55 Connecting Rods 10 / 15
Page 1 Table of Contents 10 / 15
Page 55-1 Loaded Cylinder Kit 10 / 15
Page 55-2 Loaded Cylinder Overhaul Kit 10 / 15
Page 56 EGR Valves – Volvo D12 Series Engines 10 / 15
Page 58 EGR Cooler 10 / 15
Page 67 Diesel Oxidation Catalyst 10 / 15
Page 68 through 74 DPF Filters 10 / 15
Page 75 DEF Pump 10 / 15
Page 79 Driving Devices 10 / 15
Page 80 Radiators 10 / 15
Page 81 Actuators 10 / 15
Page 82 Radios 10 / 15
Page 83 Oil Pumps – Volvo D12 Series Engines 10 / 15
Page 1 Table of Contents 07 / 15
Page 46-1 Range Housing Kit 07 / 15
Page 1 Table of Contents 11 / 14
Page 84 Loaded Cylinder Kit / Loaded Overhaul Kit 11 / 14
Page 2 through 2-2 General 11 / 14
Page 1 Table of Contents 07 / 14
Page 2 through 2-5 General 07 / 14
Page 3 New Exchange Cores 07 / 14
Page 32 Turbo Chargers 07 / 14
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Revisions
PAGE NUMBER PRODUCT REV. DATE
Page 33 Water Pumps / Coolant Pump / Bearing Housing 07 / 14
Page 40 Clutch Cylinder / Actuator / Slave Cylinder 07 / 14
Page 68 DPF Filters 07 / 14
Page 83 Oil Pumps – Volvo D12 Series Engines 07 / 14
Page 7 Short Block Engines 03 / 14
Pages 3 & 4 Complete Engines 03 / 14
Page 51 Radios 03 / 14
Page 50 Acutators 03 / 14
Page 49 Radiators 03 / 14
Pages 37 through 43 DPF Filters 03 / 14
Page 27 Steering Pumps / Servo Pumps 03 / 14
Page 8-6 Slab Type Cylinder Heads 03 / 14
Page 1 Table of Contents 03 / 14
Page 23-3 Transmission / Gear Boxes 12 / 13
Page 13-4 Turbo Chargers 09 / 13
Pages 5, 6-8 Basic Long Block Engines 09 / 13
Page 23-3 Transmissions / Gear Boxes 08 / 13
Page 23-1 through 23-3 Transmissions / Gear Boxes 05 / 13
Page 48 Driving Device 09 / 12
Page 44-47 DEF Pump 02 / 12
Page 23 through 23-2 Transmissions / Gear Boxes 02 / 12
Page 35-7 through 35-8 EGR Coolers 02 / 12
Page 3 through 4 Engines 01 / 12
Page 5 through 6-8 Basic Long Block Engines 01 / 12
Page 35-1 through 35-4 EGR Coolers 12 / 11
Page 13 through 13-4 Turbo Chargers 08 / 11
Page 8-3 Cylinder Heads 05 / 11
Page 8 through 8-3 Cylinder Heads 01 / 11
Page 36 Diesel Oxidation 09 / 10
Page 37 DPF Filters 09 / 10
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General
This manual has been compiled in an attempt to provide guidelines for branches, subsidiaries and distributors in evaluating credit for returned cores. The text and pictures represent general conditions since not every situation can be covered with the array of parts and components involved in the Remanufacturing Program. Use common sense and good judgment in core evaluation.
Cores are the lifeline of the remanufacturing business. It is important that cores be evaluated properly to insure that you have made a profit on the full transaction, and that they be packaged in a manner that will eliminate shipping damage.
Cores purposely assembled out of scrap and / or old style parts will not be accepted as core returns. Cores must be complete. To receive full credit, they must include all of the material included in the remanufactured part. Credit will be reduced for damaged and missing components.
The remanufactured exchange program is a one-for-one exchange of like part numbers. Branches, Subsidiaries and Distributors purchasing remanufactured basic engines or components from another Branch, Subsidiary or Distributor must make sure that there has not already been a core returned against that component. It is important that each shipment of returned cores include the correct forms properly filled out to identify the components. Over-returns (cores returned in excess of purchases) may be purchased at an outright price at the request of the customer, or “Like” cores will be returned freight collect. You will be notified of over-returns. Over-returns will become the property of Volvo Trucks if disposition of this material is not ascertained within 30 days. Disposition of material rejected for scrap or over-returns must be indicated on the core return paper work. Core returns can be submitted and tracked through CMS.
Hazardous materials of any kind are not returnable under any circumstances. Volvo Trucks shall be indemnified and held harmless for any and all hazardous materials shipped by a dealer. In the event such a shipment should occur the dealer making the shipment shall incur all costs associated with the disposal of the hazardous material. Disposal will be handled in accordance with EPA regulations.
Volvo Trucks reserves the right to make final decisions on all returned cores and credit allowances.
EFFECTIVE IMMEDIATELY
These instructions supersede all previous instructions and must be adhered to.It is very important that you follow all core policies and procedures outlined in this section. Failure to comply with these policies will result in no credit or a reduction in credit.
Shipping Instructions:All cores must be fully assembled and they should be packaged in the original shipping box. Core credit will be denied on any core damaged by improper handling and / or packaging. One Pallet = One Shipment no. (Each pallet must include a unique CMS shipment no./delivery note as well as a clearly visible case label)The proper core return paperwork must be included with each shipment of cores. Delay in receiving these forms will result in a delay of the credit process.
Core Returns SHIP TO address:
Volvo Group Trucks C Dock – Core Hub 13403 Volvo Way Hagerstown, MD 21742 US Freight Policy:• The total BOL (Bill of Lading) may consist of 1 or more CMS Shipments.• Each Bill of Lading weighing 1000 pounds or more, combined, must be shipped using YRC Freight collect. There is no limit
to the number of returns that you are permitted to ship, as long as each return meets the 1000 pound weight requirement.• Returns weighing less than 1000 pounds, combined, may be shipped using the freight carrier of your choice and must be
shipped at dealers cost (pre-paid).
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General
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PACKAGING POLICY: Separation of product will shorten the time involved in receiving your core credits. Prepare the shipment, as you would like to receive it. These requirements are to insure that your return is processed in an expedient manner and that you receive the full value of your return. This is not intended to be all-inclusive and items that are not referenced should be approached with common sense and the realization that remanufacturing wants to produce a quality product at a reasonable price.• All pallets/containers CANNOT exceed 42” length x 48” width x 37” height.• All pallets/containers used must be on a two-way skid that can be accessed by forks from both sides.• Each pallet or container CANNOT exceed 1,200 LBS with the exception of major unit pallets.• The common L size Volvo emballage stacked 4 sides high fits within this limit. • Each pallet requires a case label that is clearly visible on the outside and the delivery note placed in a packing slip sleeve.• These restrictions will be enforced for all brake, mixed container and legacy cylinder head returns.• Shipments received after October 31, 2014 not meeting these requirements will be returned unprocessed at
the dealer’s expense.“One Pallet = One CMS Return Document (“CMS Shipment #”) Policy:• Each pallet must include a CMS shipment no./delivery note specific to the contents of the pallet/carton.PREPARING THE CORE SHIPMENT:When preparing items for shipment and placing them into a shipping container, remember to place heavy items on the bottom and place lighter items on top. Cores damaged from improper packing could result in debit.• Major Unit components (engines, transmissions, carriers) must be claimed on a separate CMS shipment number.
Engines, Carriers, Transmissions should be returned on a metal stand, if applicable, or on a two way skid, shrink wrapped and safely secured. o One Pallet = One CMS Return Document (“CMS Shipment number”) Each pallet must include a CMS shipment number/delivery note specific to its contents. o Cores must be drained free of all fluids to prevent hazardous and costly spills in transit. Any damages related to spills due to improperly drained engines will be the shipping dealer’s responsibility. o Improperly drained engines will result in a reduced core credit (see core credit deductions).
• Cylinder Heads must be claimed on a separate CMS shipment number. o One Pallet = One CMS Return Document (“CMS Shipment number”) Each pallet must include a CMS shipment number/delivery note specific to its contents. o Legacy Cylinder Heads - may be returned in VEMB (emballage) not to exceed 4 layers high or stacked on a pallet, maximum of 24, securely strapped and stretch wrapped. o Slab type Cylinder Heads – return in original wooden (coffin) box, or on a two way skid, shrink wrapped and safely secured.
• Mixed Cartons must contain the required paperwork (Delivery note & Case Labels). o Paperwork attached to each carton should be for the components inside that carton only. o One Pallet = One CMS Return Document (“CMS Shipment number”) Each pallet must include a CMS shipment number/delivery note specific to its contents. o Carton style containers must be securely closed to prevent pilferage or damage. Items should never be shipped lying loose in a container with the opening unsecured. Secure carton lid using banding or stretch wrap. o Please no nails or screws. o It is preferred parts be kept segregated by part type when consolidating into shipping container (package oil pumps with oil pumps, etc.) Use good judgment and common sense. o Arrange items to minimize movement within the packaging utilized. Whenever possible, place largest/heaviest cores on the bottom and smaller/lighter cores on top. o Mixed Cartons may not contain major units, cylinder heads or brake shoes.
• Brake Shoe guidelines. o One Pallet = One CMS Return Document (“CMS Shipment number”) Each pallet must include a CMS shipment number/delivery note specific to its contents. o Brake Shoe Packing: Pallets of brake shoes must be packed securely to ensure safety. Brake shoe pallets CANNOT exceed 1200 LBS. o Using L type Emballage is preferred, but never more than 4 layers high. o Brake shoes stacked (nested) on an open pallet (48x48) and secured with stretch wrap is acceptable, but should not be more than 4 layers high. o Cardboard (Gaylord) packaging or original brake shoe packaging is also acceptable, but completed skid must be secured with stretch wrap.
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General
IMPORTANT REMINDERS
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Canadian Dual-Dealers ONLY• Only shipments from your Volvo dealer code may be on a single BOL.
• Multiple truck brands on the same BOL is a violation of US Customs law.
• You will need to schedule a pickup and receive a YRC Pro number for your Volvo shipments.
Canadian Dealers returning any engine core. When calling YRC to schedule your pick-up. Be prepared to provide YRC with necessary engine data for EPA documents required to clear customs. Dealer name, dealer code, address, and phone number; CMS Shipment #, and the following information from the engine label (data plate):
• Engine part number
• Engine build date
• Engine serial number
• Engine family name
*In case of a missing or unreadable engine data label, dealer will first acquire a replacement engine data label, before creating the core return.
Refer to FIELD SERVICE BULLETIN 210-001, Engine Data Label (Oct 2013)
IMPORTANT REMINDERS• If the shipment size and or weight require the use of a pallet, be sure that material-handling equipment can be used. Pallets
should not have cracked or broken boards prior to shipment.• Items shipped on pallets must be securely strapped / stretch wrapped to the pallet to prevent shifting and movement during
transit.• Cores MUST be complete and assembled to be applicable for the maximum credit allowance.• A reduction in credit allowance will be made for cores returned with damaged or missing components.
o Excess rusty or dirty cores are subject to a deduction.• All cores are subject to an External Visual Inspection. Any discrepancies will be verified by a second inspector.• HAZARDOUS MATERIALS:
o Hazardous materials of any kind are not returnable under any circumstances. Mack Trucks shall be indemnified and held harmless for any and all hazardous materials shipped by a dealer. In the event such a shipment should occur, the dealer making the shipment shall incur all costs associated with the disposal of the hazardous material. Disposal will be handled in accordance with EPA regulations.
Core Return Process:1. Check your Open Eligibility in CMS. • Log in with user name and password. • If you do not know your password please call the dealer help desk at 1-877-278-6586.2. Create a CMS shipment.3. Contact Yellow Roadway Consolidated (YRC) to schedule a pickup. Dealers in US and Canada call YRC at 888-610-8249
4. Click on “ready for pick” up in CMS • Click on “get tracking no” • Select shipping terms from drop-down menu • Input YRC provided Pro. no./shipping ref. • Click “send”
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Canadian Dealers
• Print 2 copies of each Delivery Note. (1-in/on each pallet, 1-attached to BOL)
• The Delivey Note will also serve as Customs invoice and MUST be complete.
• Ensure that the following information is complete for EACH core listed on EVERY Delivery Note: • Country of Origin “orig”
• Core value “ext.value”• If any cores are missing either “orig” or “ext.value” on the Delivery Note, contact Volvo
Core Return Dealer Support at 1-800-573-6225, select prompt #2 for assistance.
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5. Prepare your shipment for pick up • Print documents Bill of Lading – provide to YRC driver Case Labels – affix label to outside of the pallet Delivery Note - Each pallet must include a CMS shipment no./delivery note specific to its contents which may be placed, either inside or placed in a packing slip sleeve attached to outside of container
General
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6. Once shipment has been inspected by the Core Hub, if the shipment has exceptions a notification email will be sent to your email address indicating that the inspection is complete and ready for your review and confirmation. • A shipment that has no exceptions will not require action by dealer and will be completed without notification.7. Review and confirm the shipment inspection results within 48 hours. • Disputes can be made during this time in CMS and sent for review. • If you would like the core returned to you, select RETURN TO DEALER and provide the preferred carrier, account number and the amount of insurance if desired. • If CMS receives no response within 48 hours, the shipment will be confirmed on behalf of the dealer.8. CMS shipment is marked complete.9. CMS shipment is processed for crediting.10. Core credits are issued for all eligible cores with matching core groups.
Inspection Guidelines: • All returned cores must be completely assembled. Disassembled cores are unacceptable and will be subject to a 50% deduction. You may request a core to be returned to you within 48 hours of receiving email notification of completed inspection. Volvo Trucks will not be responsible for return freight charges. • All cores must be qualifying units that are included within the Exchange System. Non-qualifying cores will be rejected, if you wish to have them returned to you freight collect you may request a core to be returned to you within 48 hours of receiving email notification of completed inspection. Volvo Trucks will not be responsible for return freight charges. • All core returns must be free from outside damage (fire, water, collision, or due to shipping or rough handling). Damaged cores will be rejected, if you wish to have them returned, you may request a core return within 48 hours of receiving email notification of the completed inspection. Volvo Trucks will not be responsible for return freight charges. • The Core Hub will attach photos to CMS inspection results for all Major Units (engines, transmissions, carriers) with deductions from missing or damaged parts. Photos of all other cores that have been re-identified or that have deductions may be available by request.
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A TYPICAL CORE RETURN may consist of 1 pallet or multiple pallets. Each pallet is referred to as a CMS shipment.
Example Core Return:1- Mixed Carton (CMS shipment no 51308 = Delivery Note + Case Label)1- Pallet of Cylinder Heads (CMS shipment no 51311 = Delivery Note + Case Label)1- Major Unit (Engine) (CMS shipment no 51309 = Delivery Note + Case Label)1- Pallet of Brake Shoes (CMS shipment no 51310 = Delivery Note + Case Label)
• All four CMS shipments are picked up by carrier as a single RETURN and transported to the Core Hub on 1- Bill Of Lading (BOL)
• combined into a single “Return” (BOL), means weight is combined to satisfy the freight policy
• palletized separately
• each created as its own CMS shipment
• each has its own “Delivery Note” & “Case Label”
• delivery note may be placed, either inside or placed in a packing slip sleeve attached to outside of container.
• carriers should be palletized separately
• multiple legacy Cylinder heads may be packaged in emballage as safety standards permit
General
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General
Cores that are not covered within this manual:Any cores returned to the Core Hub, that are not covered within this manual will, at the discretion of Volvo Trucks, be received by the Core Hub and “accepted” “as removed”.
Damages to returned Cores that are not covered within this manual:Assessed damages to Cores that are not covered within this manual, and that render the core unusable, will, at the discretion of Volvo Trucks, be received by the Core Hub and “scraped” with appropriate deductions assessed.
IMPORTANT REMINDER • All core returns must be free from outside damage (fire, water, collision, or due to shipping or rough handling). Damaged cores will be rejected, if you wish to have them returned, you may request a core return within 48 hours of receiving email notification of the completed inspection. Volvo Trucks will not be responsible for return freight charges.
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Section 1 Cores New to Exchange Program
New Exchange Cores
NEW EXCHANGE CORES
Cores that are new to the VOLVO REMAN exchange program, (parts that have a core charge but are not yet available as “REMAN”), will be accepted with full credit if the core meets the following criteria:
CORE INSTRUCTIONS
• The Core must be complete and assembled.
• The Core is in suitable condition for Remanufacture.
• The Core is not damaged by non-operational causes such as rust, rough handling or fire.
DESCRIPTION DEDUCTION VALUE
Disassembled Core / Incomplete Core Scrap / 100%Condition unsuitable for Remanufacture Scrap / 100%Damaged by non-operational causes such as rust, rough handling or fire Scrap / 100%
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Section 2 Complete Engines (Function Group 2102)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• Oil and water must be drained.
• Protective plugs must be transferred from Exchange Component to core.
• EGR unit must be protected during shipping by using the EGR bracket supplied on the replacement Exchange engine.
• The unit must be complete and assembled.
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
Volvo Direct Ship Product (VDSP) Complete Engines are not stocked in a PDC; they are shipped directly from the manufacturing facility. VDSP Complete Engines are shipped without a starter motor, alternator, steering pump or EGR Valve. VDSP Engines must be returned as the part number ordered.
Complete Engines
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Section 2 Complete Engines (Function Group 2102)
Return PackagingThe core should be returned on the same engine stand as the Exchange Component was deliveredon, with the plastic sheeting. Ensure ID tag is right side up. Units equipped with an EGR bracket mustbe returned with this bracket in place to ensure no damage to the EGR.
Cleaning ChargesThe returned core must be clean from grime and oil. If the procedure is not followed, a cleaningcharge will be applied to your account.
MARKINGS
New Engines(Example) TD120A 302 30040TD120A = Engine Model302 = Last three digits of engine production number30040 = Engine serial number
Remanufactured EnginesThe marking is placed in the same position as on new models, but has changed its appearance. Theengine is still identified by the last three digits in the production number however. There may also be asign with an Exchange part number, if so, this number should be used as identification.
DESCRIPTIONDEDUCTION VALUE
Engine Crankshaft (Broken) $1,200Engine Head(s) - Missing or Damaged $1,000Engine - Cores w / out Engine Brake in exchange for core w / Engine Brake $500Engine Cylinder Block - Cracked or Broken. No deduction for cracked D12 engine blocks only. $2,000Engine Cylinder Block - Thrown Rod (Includes Block and Crank Deduction) $3,200Engine - Complete Engines (Built up past 3 / 4 Engine) $300Engine - Disassembled Cores 50% of Core ValueEngine - Improperly Drained of Oil and / or Antifreeze $300Engine - Excessively Soiled or Rusty Cores Minimum $50Engine - Damaged Cores Beyond Repair ScrapEngine - Failure to Return Core on Steel Engine Stand $750Engine Stand - Missing Steel Engine Stand Parts Each $40Engine - All Other Missing or Damaged Items Dealer Net
Complete Engines
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Section 3 Basic Long Block Engines (Function Group 2102)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• The block must have no visible cracks. Cracks are acceptable on D12 engine blocks only.
• It must be possible to turn the engine over manually or with the help of the starter motor.
• Oil and water must be drained.
• Protective plugs must be transferred from Exchange Component to core.
• The unit must be complete and assembled.
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
This assembly does not contain:
• Starter motor
• Alternator
• Turbo
• Water pump
• Injection system
• Oil filter
• Oil filter holder
• Flywheel
• Pulleys
• Induction manifold
• Exhaust manifold
Basic Long Block Engines
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Return PackagingThe core should be returned on the same engine stand as the Exchange Component was delivered onwith the plastic sheeting. Ensure unit ID tag is right side up. Failure to package the unit properly willresult in a $750 deduction from your account.
Cleaning ChargesThe returned core must be clean from grime and oil. If the procedure is not followed, a cleaningcharge will be applied to your account.
MARKINGS
New Engines(Example) TD120A 302 30040
TD120A = Engine Model302 = Last three digits of engine production number30040 = Engine serial number
Remanufactured EnginesThe marking is placed in the same position as on new models, but has changed its appearance. Theengine is still identified by the last three digits in the production number however. There may also be asign with an Exchange part number, if so this number should be used as identification.
Basic Long Block Engines
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D11 Engines
D12 Engines
Basic Long Block Engines
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D13 Engines
D16 Engines
Basic Long Block Engines
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Engine Component Identification
Upper Timing Cover
Valve Cover
Drive Device
Lower Timing Cover
Flywheel Housing
Block
Rear of Crankshaft
Head
Basic Long Block Engines
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Block
Upper Timing Cover
Drive Device
Lower Timing Cover
Oil Pan
Flywheel Housing
Oil Cooler Cover
Lower Timing Cover
Upper Timing Cover
Flywheel Housing
Engine Component Identification
Basic Long Block Engines
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Camshaft Tower
Camshaft CamshaftGear
Rocker Arms Exhaust Injector
Intake
Rocker Arms Shaft
Engine Component Identification
Basic Long Block Engines
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HOLE IN BLOCK
CRACKED BLOCK
THROWN ROD
Basic Long Block Engines
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CRACKED PAN RAIL
ATTEMPTED PAN RAIL REPAIR
Basic Long Block Engines
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Core Deductions
DESCRIPTION DEDUCTIONVALUE
Engine Crankshaft (Broken) $1,200
Engine Head(s) - Missing or Damaged $1,000
Engine - Cores w / out Engine Brake in exchange for core w / Dynatard $500
Engine Cylinder Block - Cracked or Broken. No deduction for cracked D12 engine blocks only. $2,000
Engine Cylinder Block - Thrown Rod (Includes Block and Crank Deduction) $3,200
Engine - Complete Engines (Built up past 3 / 4 Engine) $300
Engine - Disassembled Cores 50% of Core Value
Engine - Improperly Drained of Oil and / or Antifreeze $300
Engine - Excessively Soiled or Rusty Cores Minimum $50
Engine - Damaged Cores Beyond Repair Scrap
Engine - Failure to Return Core on Steel Engine Stand $750
Engine Stand - Missing Steel Engine Stand Parts Each $40
Engine - All Other Missing or Damaged Items Dealer Net
Basic Long Block Engines
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CORE INSTRUCTIONS
The returned core must meet the following requirements:
• The block must have no visible cracks or holes.
• The unit must be complete and assembled.
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
Return PackagingPack the return short block with the marking turned to face upwards so that it is clearly visible when unpacking. The core should be returned on the same engine stand as the Exchange Component was delivered on. Ensure unit ID tag is right side up. Failure to package the unit properly will result in a $750 charge deduction from your account.
Cleaning ChargesThe returned core must be clean from grime and oil. If the procedure is not followed, a cleaning charge will be applied to your account.
Section 4 Short Block Engines (Function Group 2105)
DESCRIPTIONDEDUCTIONVALUE
Engine Crankshaft (Broken) $1,200Engine Cylinder Block - Cracked or Broken. $2,000Engine - Disassembled Cores 50% of Core ValueEngine - Improperly Drained of Oil and / or Antifreeze $300Engine - Cores Damaged Beyond Repair ScrapEngine - All Other Missing or Damaged Items Dealer Net
Short Block Engines
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Section 5 - All Cylinder Heads (Function Group 2111)
11L, 12L, 13L and 16L (Slab type)
Any Style Cylinder Head other than Slab Type
Cylinder Heads
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Slab Type Cylinder Head Indentification
D11
D13
D12
D16
Slab Type Cylinder Heads
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Cam Tower
Spring
ValveRotator
Slab Type Cylinder Head Parts Indentification
Slab Type Cylinder Heads
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All cores are subject to visual inspection only. Non-current heads are unacceptable for credit. Full credit will be issued on all VOLVO SLAB CYLINDER HEADS which are completely assembled with the valves, springs, rotators, etc., as well as meeting the minimum dimension for head thickness. Damage resulting in a hole through combustion surface renders cylinder head scrap (see below). All cylinder heads must meet a minimum thickness specification as listed on the below chart to be accepted for credit. All cylinder heads thinner than the below specification will be rejected.*
Example of a SCRAP Volvo Slab Cylinder Head with a crack between the counterbores
Below is a chart listing minimum thicknesses for cylinder head core returns.
*If your cylinder head has been previously remanufactured by VOLVO Reman the minimum thickness requirement will be waived and accepted for full credit.
HeadType
MinimumThickness
D11, D12, D13, D16 5.306”
Slab Type Cylinder Heads
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Two Examples of Acceptable Volvo Slab Cylinder Heads with Minor Deck Damage
Two Examples of a $500 Deduction on Volvo Slab Cylinder Heads with Major Deck Damage
Minor pitting to the deck surface consists of small areas of slight damage
Major pitting to the deck surface consists of excessive damage over large areas
See deduction page (23)
Imprint from a broken valve stem
Slab Type Cylinder Heads
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Example of a SCRAP Volvo Slab Cylinder Head with a hole in the combustion surface
Example of a SCRAP Volvo Slab Cylinder Head with a cracked cam rail
Damage resulting in a hole through combustion surface
renders CYLINDER HEAD scrap. (All heads)
Slab Type Cylinder Heads
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SLAB CYLINDER HEAD 11L, 12L, 13L, 16L DEDUCTIONSSprings – Missing or Damaged (Each) $6Valves – Missing or Damaged (Each) $25Cam Tower (Slab Heads) – Missing / Damaged Tower $200Cracks Between Counterbore & Injector Sleeve ScrapUnder Minimum Head Thickness Dimension (Non-Volvo Reman) ScrapMajor Deck Damage (Slab Heads) $500Hole Through Combustion Surface ScrapCracked Cam Rail (Slab Heads) ScrapDamaged by Non-Operational Causes ScrapDisassembled Core 50%
ALL CYLINDER HEADS OTHER THAN SLAB TYPE (LEGACY)Damaged by Non-operational Causes (Rust, Rough Handling, Fire) ScrapDisassembled Core ScrapBroken Casted Features ScrapMajor Deck Damage ScrapHole Through Combustion Surface ScrapCracks Between Counterbore & Injector Sleeve Scrap
APPROXIMATE WEIGHT
438 lbs. (D11 Shipping weight with box)450 lbs. (D12 and D13 Shipping weight with box)480 lbs. (D16 Shipping weight with box)
Slab Type Cylinder Heads
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Section 6 Injector Rocker Arm (Function Groups 2145 & 2371)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
• Core must have no visible cracks.
Injector Rocker Arm
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Section 7 Crankshafts (Function Group 2161)
NOTE: Rod bearings, main bearings and thrust washers are included.
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• If it has no indications of serious radial cracks.
• It has no permanent discoloration (dark blue in appearance).
• Surface of the rod or main journals cannot be scored due to bearing failure.
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
Crankshafts
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Section 8 Injection Pumps / Unit Injector (Function Group 2361)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• It is complete and assembled.
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
Injection Pumps / Unit Injector
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Section 9 Injectors (Function Group 2371 & 2374)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• The unit must be complete.
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
Injectors
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Section 10 Turbo Chargers (Function Group 2551)
Turbo Chargers
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Complete VGT Turbo: Full Core Credit
Band Clamps
Speed Sensor
Actuator / SRA
Turbo Chargers
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Incomplete VGT Turbo: Missing or damaged Speed Sensor Missing or damaged Actuator / SRA
Missing Speed SensorMissing Actuator / SRA
Missing name plate is acceptable IF unit can be identified as a genuine core.
Turbo Chargers
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Complete Waste Gate Turbo
Waste Gate: deduction if missing
Turbo Chargers
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DESCRIPTION DEDUCTION VALUEMissing Band Clamps $40 eachMissing or damaged Speed Sensor (when applicable) $45Missing or damaged Actuator / SRA (when applicable) $75Missing nameplate and non-branded ScrapMissing or damaged Waste Gate Assembly (when applicable) $75Broken propeller / Broken Shaft No DeductionCracked or Broken Housings Scrap
1. Check for “Volvo” stamped into the housing
2. Check Turbine Opening
11L - has 60mm wheel bore
13L - has a 68mm wheel bore
Use 2 ½” plastic pipe to determine if 13L.
2 ½” plastic pipe will not fit if 11L.
3. Check Blade Count
US07 - has 12 vanes (blades)
US10 - has 11 vanes (blades)
Hint: turn the wheel so that a vane is at 12 o’clock. If there is a vane at 6 o’clock
(directly opposite), then it is an ‘07.
07 / 14
CORE INSTRUCTIONS
The returned core must meet the following guidelines:
• The unit is complete and assembled.
• Like-for-like part numbers or accepted as part of a Core Clearing Group.
• Is a Genuine core, which can be identified by I.D. tag or Logo on compressor housing.
• Core is not damaged by non-operational causes such as rust, welding, torch, grinder, rough handling, or fire.
DEDUCTIONS
Turbo Chargers
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Section 11 Water Pumps / Coolant Pump / Bearing Housing (Function Group 2621)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
• It is complete and assembled with pulleys and drive.
• It shows no visible cracks.
• It must be drained of fluid.
Water Pumps / Coolant Pump / Bearing Housing
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WATER PUMP MARKINGS
TYPE 1
SPECIAL MODELSWITH GEAR DRIVE
WITH V-SHAPED CONNECTION
D12 / D12A / D12B F16, FH16
TYPE 2 F4, FL4, B10R 3 CONNECTIONS INDIFFERENT
DIRECTIONS
Water Pumps / Coolant Pump / Bearing Housing
D SERIES BEARING HOUSING
BEARING HOUSING
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Section 12 Thermostat / Viscous Fans (Function Group 2631)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
Thermostat / Viscous Fans
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Section 13 Control Units (Function Group 2841)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
• It is complete and assembled.
Control Units
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Section 14 Alternators (Function Group 3211)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
• It is complete and assembled.
Alternators
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Section 15 Starter Motors (Function Group 3311)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
• It is complete and assembled.
Starter Motors
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Section 16 Clutch Kits (Function Group 4111)
CORE INSTRUCTIONS
Kit core returns will be credited by individual component. See below for breakdown.
• Unit must be complete.
• The disc centers must not be loose.
• No springs can be missing.
• The clutch disc must have no damage to the splines in the center.
• There must be no cracks in the pressure plate.
• The unit is to be returned in the packaging supplied together with the Exchange Unit.
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
Clutch Kits
3919067 CLUTCH KIT KIT CORE NUMBER 851039608112600 Front Disc 8118600 Core
8112601 Rear Disc 8118601 Core
8112602 Exchange Clutch 8118602 Core
3919079 CLUTCH KIT KIT CORE NUMBER 851039618112340 Release Bearing 8118340 Core
8112597 Exchange Clutch 8118597 Core
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Section 17 Clutch Cylinder / Actuator / Slave Cylinder (Function Group 4139)
CORE INSTRUCTIONS
The returned core must meet the following guidelines:
• It must be complete and assembled.
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
Clutch Cylinder / Clutch Actuator
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Section 18 Pressure Plates (Function Group 4112)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• It must be complete and assembled.
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
• There must be no cracks in the plate or housing.
Pressure Plates
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Section 19 Clutch Discs / Driven Plates (Function Group 4117)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• The clutch disc must be complete and assembled.
• The clutch disc must not be cracked.
• The clutch disc must have no damage to the splines in the center.
• The disc center must not be loose.
• No springs can be missing.
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
Clutch Discs / Driven Plates
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Section 20 Transmissions / Gear Boxes (Function Group 4311) Mechanical
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• It must be cleaned, complete and assembled.
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
• The transmission is to be emptied of oil (see below re: Cleaning Charges).
• The core is to be returned in the same packaging material the Exchange Component was delivered.
• The transmission housing must have no visible cracks.
• It must be possible to turn the input shaft by hand with the gear engaged.
Return PackagingThe core should be returned using the same packaging the Exchange Component was delivered in.Ensure unit ID tag is right side up. Failure to package the unit properly may result in a charge debitedto your account.
Cleaning ChargesThe returned core must be clean from grime and oil. If the procedure is not followed, a cleaningcharge will be applied.
Transmissions / Gear Boxes
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Oil Filter Housing and Filter included Top Cover Assembly
with Electronic Control Module included
No Top Cover Assembly with
Electronic Control Module included
No Top Cover Assembly with
Electronic Control Module included
Clutch Control Actuator (CCA) included
Solenoid, Harness and Lines
included
Volvo Reman I-Shift Complete
Volvo Reman I-Shift Basic
Volvo Reman I-Shift Short
Oil Filter Housing and Filter included
Oil Filter Housing and Filter included
No Solenoid, Harness and Lines
included
No Solenoid, Harness and Lines
included
Auto-Mechanical / I-SHIFT
No Range Assembly included
No Clutch Control Actuator (CCA) included
No Clutch Control Actuator (CCA) included
Transmissions / Gear Boxes
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Plastic Bonnet must be installed for core return
on Transmissions to avoid deductions
Top Assembly cover must be installed for core return
on Basic and Short Transmissions to avoid deductions
Plastic bonnet must be installed for core return on Short Transmission to avoid deducations
Transmissions / Gear Boxes
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CORE PART NUMBER GROUPING - CORES WITHIN GROUP ARE INTERCHANGEABLE
Transmissions / Gear Boxes
COMPLETE TRANSMISSIONS
MODEL AT2512C GROUP # AMT 001 8500914485009831
MODEL ATO2512CGROUP # AMT 0028500914585009832
MODEL ATO3112CGROUP # AMT 0038500914785009833
MODEL AT2612DGROUP # AMT 00485009221850098518513180485131807
MODEL ATO2612DGROUP # AMT 005850092228500985285131805 85131808
MODEL ATO3112D STD OR HDGROUP # AMT 00685009223851318068502657985026582
BASIC TRANSMISSIONSMODEL AT2612DGROUP # AMT 0108501943185019437
MODEL ATO2612DGROUP # AMT 0118501943385019439
STAND ALONE850194178501941985019421
SHORT TRANSMISSIONSMODEL AT2612DGROUP # AMT 0168501943285019438
MODEL ATO2612DGROUP # AMT 0178501943485019440
STAND ALONE850194188501942085019422
HD COMPLETE TRANSMISSIONSMODEL AT2612DGROUP # AMT 001 HD8502635185026349
MODEL ATO2612DGROUP # AMT 002 HD8502635285026350
HD BASIC TRANSMISSIONSMODEL AT2612D HDGROUP # AMT 010 HD8502643785026435
MODEL ATO2612D HDGROUP # AMT 011 HD8502643885026436
MODEL ATO3112D STD OR HDGROUP # AMT 012 HD8502643985026755 85019435
HD SHORT TRANSMISSIONSMODEL AT2612D HDGROUP # AMT 016 HD8502644485026442
MODEL ATO2612D HDGROUP # AMT 017 HD8502644585026443
MODEL ATO3112D STD OR HDGROUP # AMT 015 HD850264468502675685019436
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CORE DEDUCTIONS
DESCRIPTIONDEDUCTION VALUE
Return of a “C” Model against a purchase of a “D” Model or Other Returns which are Non like-for-like Model ( AT for an ATO or an ATO for an AT) $1500
Return of a “D” Model against a purchase of a “C” Model (Contact required for proper credit) $0Broken, Cracked or Missing Bell Housing $600Broken, Cracked or Missing Main Case $1000Broken, Cracked or Missing Range Housing ( Complete and Basic only) $1000Broken, Cracked or Missing Top Cover Assembly (TCU) $2500Improperly Drained Transmission $300Failure to Return with shipping covers (Basic and Short only) $50 ea.Excessively Soiled or Rusty Core Minimum $50Disassembled Core ½ Core ChargeFire Damage ScrapAll Other Missing or Damaged Items Dealer NetReturns of Std model for an HD of the same model, except ATO3112D model.(AT2612D for a AT2612D HD or a ATO2612D for a ATO2612D HD) $500
*All Volvo Reman Transmissions must be returned safely on a steady skid or stand. There will be no credit given for the return of a 2512 or 2612 Series Transmission against the purchase of a 3112 series.
Transmissions / Gear Boxes
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(Function Group 4312)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• Kit must be returned with all 4 pieces shown (Ring Gear, Engaging Rings and Synchronizer Ring) in the picture above to receive credit
Range Housing Kit
DESCRIPTION DEDUCTION VALUE1 or more missing parts 100%
Synchronizer RingEngaging Ring (Drum/Hub)
Engaging RingRing Gear
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Section 21 Air Compressors (Function Group 5611)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• It must be complete and assembled.
• The crankshaft is not broken. (It can be turned.)
• The housing has no visible cracks or holes.
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
Air Compressors
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Section 22 Brake Chamber / Cylinders (Function Group 5641)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• It must be complete and assembled.
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
• The housing has no visible cracks or holes.
MARKINGS
TYPE 1 MAXIBRAKE (Membrane in rear
part, thick stainless rod)
MGM-MODEL (Membrane in front part,
thin rod)
DBA (Unic) AP (Unic)
Brake Chamber / Cylinders
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Section 23 Steering Gears (Function Group 6422)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• It must be complete and assembled.
• There must be no visible cracks in the housing.
• Nut on output shaft must be screwed into shaft.
• The core must be returned in the same packaging material as the Exchange Component is delivered.
• Plastic plugs must be transferred.
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
Nut
Steering Gears
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Section 24 Steering Pumps / Servo Pumps (Function Group 6453)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• It must be complete and assembled.
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
Steering Pumps / Servo Pumps
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Section 25 Instrument Clusters (Function Group 3811)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
1. Core must be returned in original carton with packing material that reman unit was shipped in.
2. Cores are allowed on a strict like-for-like basis.
3. Core is complete and not disassembled.
4. Core is not damaged by non-operational causes such as rust, rough handling or fire.
Instrument Clusters
NEW # REMAN #8510202485102029 8510200685102011 85102022 8510202585102007
85001106850002248500022585000226850002278500022885000232
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Section 26 Connecting Rods (Function Group 2164)
Connecting Rods
11L CONNECTING ROD
D12 CONNECTING ROD
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Connecting Rods
13L CONNECTING ROD
16L CONNECTING ROD
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Connecting Rods
CONNECTING ROD AND CAP mustmatch and seated with the bolts to be acceptable.
Spun and damaged bores renderCONNECTING ROD scrap.
Spun or damaged wrist pin bores render
a connecting rod scrap and therefore
are unacceptable for core credit.
Excessively damaged and burned thrust walls are unacceptable for core credit.
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Connecting Rods
Bent connecting rods are unacceptableand no credit will be given for cores
returned in this condition.
Burned rods from excessive heat andexcessively rusted rods are rendered
scrap and unacceptable for credit.
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Connecting Rods
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• Connecting rod and cap must match and be seated with the bolts to be acceptable. Mismatched rod and cap are unacceptable.
• Core must be free of spun and damaged bores.
• Rods must not be bent or burned.
Returning Connecting Rods
• Extreme care must be taken when packing connecting rod cores for return. Rods which are damaged in shipping due to improper packing are unacceptable.
DEDUCTIONS
• If rod is damaged beyond repair, rod is scrap.
PART # REMAN # CORE # DESCRIPTION21405253 (NEW EXCHANGE) N/A 85019220 11L CONNECTING ROD20412200 85001360 85007360 D12 CONNECTING ROD20876840 (NEW EXCHANGE) N/A 85007362 13L CONNECTING ROD20898595 (NEW EXCHANGE) N/A 85019292 16L CONNECTING ROD21527863 (NEW EXCHANGE) N/A 85019587 16L CONNECTING ROD
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Section 27 Loaded Cylinder Kit (Function Group 2131 / 2139)
Loaded Cylinder Kit
CORE INSTRUCTIONS
Cores must be returned in original packaging to avoid deduction. Proper handling of the crown is necessary to prevent damage to ring grooves. DO NOT RETURN LINER WITH CORE.
In order to ensure the proper credit is given, be sure to distinguish clearly on the core return paperwork whether the credit requested is for a single Loaded Cylinder or for a Loaded Cylinder Overhaul kit. Use of the proper core part number listed below is the best way to ensure the correct credit is given.
(D12D single loaded cylinder pictured)
REMAN PART # CORE PART # DESCRIPTION85125028 85125048 D12C Loaded Cylinder Kit85125029 85125049 D12D Loaded Cylinder Kit85146556 85146557 D11 EPA 07/10 Loaded Cylinder Kit85146622 85146623 D13 EPA 07 Loaded Cylinder Kit85146626 85146627 D13 EPA 10 Loaded Cylinder Kit85146631 85146632 D16 EPA 04/07 Loaded Cylinder Kit85146663 85146664 D16 EPA 10 Loaded Cylinder Kit
LOADED CYLINDER KIT
***Please see Connecting Rods section for further damage criteria
DEDUCTIONS
DESCRIPTION DEDUCTION VALUE PER CYLINDER
BENT, BURNT, SPUN DAMAGED ROD*** $120
RUSTY OR DAMAGED PISTON CROWN $50
FAILURE TO RETURN IN ORIGINAL PACKAGE $50
MISSING / DAMAGED WRIST PIN $5
SPUN/DMG BORES REJECTED
EXCESSIVE RUST REJECTED
MISMATCH CAP & ROD REJECTED
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Section 28 Loaded Cylinder Overhaul Kit (Function Group 2131 / 2139)
Loaded Cylinder Overhaul Kit
CORE INSTRUCTIONS
Cores must be returned in original packaging to avoid deduction. Proper handling of the crown is necessary to prevent damage to ring grooves. DO NOT RETURN LINER WITH CORE.
In order to ensure the proper credit is given, be sure to distinguish clearly on the core return paperwork whether the credit requested is for a single Loaded Cylinder or for a Loaded Cylinder Overhaul kit. Use of the proper core part number listed below is the best way to ensure the correct credit is given.
REMAN PART # CORE PART # DESCRIPTION85125018 85125045 D12C Loaded Cylinder Overhaul Kit85125020 85125046 D12D Loaded Cylinder Overhaul Kit85146672 85146674 D11 EPA 07/10 Loaded Cylinder Overhaul Kit85146679 85146680 D13 EPA 07 Loaded Cylinder Overhaul Kit85146683 85146684 D13 EPA 10 Loaded Cylinder Overhaul Kit85146687 85146688 D16 EPA 04/07 Loaded Cylinder Overhaul Kit85146692 85146693 D16 EPA 10 Loaded Cylinder Overhaul Kit
LOADED CYLINDER OVERHAUL KIT
***Please see Connecting Rods section for further damage criteria
DEDUCTIONS
DESCRIPTION DEDUCTION VALUE PER CYLINDER
BENT, BURNT, SPUN DAMAGED ROD*** $120
RUSTY OR DAMAGED PISTON CROWN $50
FAILURE TO RETURN IN ORIGINAL PACKAGE $50
MISSING / DAMAGED WRIST PIN $5
SPUN/DMG BORES REJECTED
EXCESSIVE RUST REJECTED
MISMATCH CAP & ROD REJECTED
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Section 29 EGR Valves – Volvo D12 Series Engines
ACCEPTABLE
CORE INSTRUCTIONS
Criteria applies to all EGR Valves:
• Unit must be complete.
• Cut or spliced harnesses are acceptable.
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
NOTE: Only the valve assemblies need to be returned. Do not return piping and clamping.
EGR Valve - Volvo D12 Series Engines
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NOT ACCEPTABLE
DO NOT RETURN PIPING AND CLAMPING
EGR Valve - Volvo D12 Series Engines
DEDUCTIONS
DESCRIPTION DEDUCTION VALUE
NON GENUINE $100
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Section 30 EGR Cooler
EGR Coolers
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D-12DUS04
Coolant Bleed Screw Housing
Mounting Tab
Coolant Ports
Exhaust Ports
EGR Coolers
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Protective plugs shipped on Dex Part # 20722340DEX
Housing
EGR Coolers
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Protective plugs shipped on Dex Part # 20801814DEX
Exhaust Port
Coolant Port
Coolant PortCoolant Bleed Screw
Mounting Brackets
Mounting Bolts
Exhaust Port
D-16D US04
EGR Coolers
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D-11, D-13, D-16US07 – US10
Compression Pads
Coolant Ports
Mounting Pin
Exhaust PortsCoolant Bleed Screw Housing
EGR Coolers
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Protective plugs shipped on new and Dex parts
Extra protective plug included on DEX part #s 21480644DEX,
21480645DEX, 21480646DEX
Protective plugs shipped on new and Dex parts
Broken weld on coolant port
EGR Coolers
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Examples of unacceptable cores:
Bent / Damaged Exhaust Port
Bent / Damaged Coolant Port
EGR Coolers
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APPROXIMATE WEIGHT
Note: Weight may vary based on usage.D-11 Shipping weight with box-37lbsD-12 Shipping weight with box-19lbs without housing, 26lbs with housing attachedD-13 Shipping weight with box-40lbsD-16 Shipping weight with box-43lbs
Bent / Damaged Coolant Port
EGR Coolers
Examples of unacceptable cores:
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The returned core must meet the following guidelines:
• Core is not damaged by non-operational causes such as rust, fire, or rough handling.
• Compression pads must be returned. *Except D12D* (Deduction if missing from unit or not returned in box with core part) NOTE: Compression pads can be taped securely to cooler.
• No visible exterior damage, bends, or cracks.
• Protective plugs must be transferred from purchase part to core part. (See illustrations for examples of plugs included in shipping.)
• No bent or damaged coolant or exhaust ports.
• No bent or broken mounting pins, brackets or bolts.
DESCRIPTION DEDUCTION VALUEMissing Compression Pads. (except D12D) $25 eachUnacceptable - Bent or Damaged Exhaust Ports. REJECTEDUnacceptable - Bent or Damaged Coolant Ports. REJECTED
Note: Do not return piping or clamping hardware.
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EGR Coolers
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Section 31 Diesel Oxidation Catalyst
Diesel Oxidation Catalyst (DOC)
CORE CRITERIA
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
CORE INSTRUCTIONS
• The core must be returned in the original packaging.
o Place dirty core into plastic bag that is provided for you.
o Insert into smaller box.
o Insert smaller box into larger outer box.
Component Indentification
Diesel Oxidation Catalyst
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CORE CRITERIA
• Core is not damaged by non-operational causes such as rough handling or fire.
CORE INSTRUCTIONS
• The core must be returned in the original packaging. o Core must be returned in bag, inside original box.
Complete DPF & Filters
Section 32 Complete DPF & Filters
DPF FILTER
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Stain on Outlet.Rust stain.No signs of soot on outlet.
Heavy soot on inlet.Soot completely plugs channels.
Oil on Outlet.Staining due to oil passing into filter.Oil is dry.
Section 32 Acceptable Clean and Return DPF Filters
Complete DPF & Filters
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Scrape on Ceramic.Ceramic surface rubbed by hard material in removal / shipping.Channels have plugs intact.
Bent Flanges.Flange has been bent in removal / shipping.
Fingerprint on Outlet.Spot appears to be soot on outlet and would normally be scrap.Spots are fingerprints from handling.
Section 32 Acceptable Clean and Return DPF Filters
Complete DPF & Filters
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Oil on Outlet.Staining due to oil passing thru DPF.Oil is wet.
Section 32 Acceptable Clean and Return DPF Filters
Soot on Inlet.Even coating of soot.
Soot on Inlet.Variations of soot on surface.
Clean on Outlet.No signs of soot on outlet.
Complete DPF & Filters
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Soot on Outlet.Soot showing on outlet indicates filter failure.
Soot on Outlet.Multiple locations of soot passing thru filter.
Ceramic Cracked.Large portion of ceramic cracked.Crack reveals open channels below plugs.
Section 32 Scrap Clean and Return DPF Filters
Complete DPF & Filters
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Ceramic Pushed out of Can.Ceramic is driven out of canning due to extremely highback pressure.
Filter Melted.Ceramic shows signs of abnormally high temperatures.Channels are melted.
Channels are Round.Ceramic channels are not square.Ceramic shows signs of abnormally high temperatures.
Section 32 Scrap Clean and Return DPF Filters
Complete DPF & Filters
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Swirl Pattern on Exhaust and / or Intake Surface.Sign of filter getting too hot and overheating.Soot on exhaust surface.Early stages of a melted filter.
Another Example of a Swirl Pattern on Exhaust and / or Intake Surface.Sign of filter getting too hot and overheating.No sign of soot on exhaust surface.Early stages of a melted filter.
Filter Sent in to Reman for Clean / Return Service.Identified as Scrap at the Reman Center and sent back to dealer.
Section 32 Scrap Clean and Return DPF Filters
Complete DPF & Filters
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Section 33 DEF Pump
DEF Pump
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Mounting Points
Mounting Points
Mounting Points
DEF Pump
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Caps
Caps
DEF Pump
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CORE CRITERIA
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
• Broken fittings are acceptable.
• The core must be returned in the original packaging. o Core must be returned in bag, inside original box.
• Must be returned with all caps and covers.
• DEF pump should be free of any paint marks, writing, or paint.
APPROXIMATE WEIGHT
Note: Weight may vary based on usage.Shipping weight -8.5 lbs
DEF Pump
DESCRIPTION DEDUCTION VALUE
Broken Mounting Points ½ of Core Charge
Improper Packaging ½ of Core Charge
DEDUCTION
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Section 34 Driving Device (Function Group 2159)
CORE CRITERIA
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
• The core must be returned in the original packaging.
DESCRIPTION DEDUCTION VALUE
Missing or Damaged Hub $30.00
Missing or Damaged Gear $30.00
Disassembled Core ½ of Core Charge
NEW PART # REMAN PART # CORE PART # CORE VALUE20838388 85013115 85019115 $150
APPROXIMATE WEIGHT
Note: Weight may vary based on usage.Shipping weight -10.75 lbs.
Driving Device
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Section 35 Radiators (Function Group 2611)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
• Core must be complete and assembled.
• Must not have broken or otherwise damaged tanks or brackets.
• Core is not damaged by physical or chemical effect of any corrosive substances in operating environment.
Radiators
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Section 36 Actuators (Function Group 2559)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• Core is not damaged by non-operational causes such as rust, rough handling, fire, improper removal or improper protection while storing.
• Core must be complete and assembled.
• Casting is not visibly cracked or damaged.
Actuators
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Section 37 Radios (Function Group 3981)
CORE INSTRUCTIONS
The returned core must meet the following requirements:
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
• Core must be complete and assembled.
• Core must be returned in the original shipping box.
Radios
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Section 38 Oil Pumps – Volvo D12 Series Engines (Function Group 2211)
Oil Pumps – Volvo D12 Series Engines
CORE INSTRUCTIONS
Criteria applies to all D Series Oil Pumps:
• Unit must be complete.
• No visable cracks or damage to Housing.
• No visable damage to mating gears.
• Core is not damaged by non-operational causes such as rust, rough handling or fire.
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Section 39 Flywheels (Function Group 2166)
DESCRIPTION DEDUCTION
Core is damaged by non-operational causes such as rust, rought handling or fire Rejected
16L twin mass flywheel is not an acceptable core Rejected
Flywheels
ACCEPTABLE SINGLE MASS FLYWHEEL
UNACCEPTABLE - TWIN MASS FLYWHEEL (16L ONLY)
Single mass flywheel has one group of bolt holes around center.
16L twin mass flywheel has two sets of bolt holes around center of flywheel.