Volvo d12 Workshop Manual Less Specifications Abby

VOLVO
TSI
Volvo Trucks North America, Inc.

Greensboro, NC USA
This TSI Service Bulletin replaces TSI Service Bulletin

2 1 5 -0 0 1 , Camshaft, D12, D12A, D12B (11.2001),
publication no. P V 776-TS P 160576.
Date
Group
No.
8.2003
2 15
001
Supp.
Page
1(21)
Camshaft
D12, D12A, D12B
Camshaft
Fig. 1: VOLVO D12B Engine

This inform ation covers procedures fo r cam shaft repair on VOLVO D12, D12A, and
D12B engines.
Contents
Special Tools page 2
C am shaft Timing, C hecking page 12
C am shaft Timing, C heck and A djust page 18
Camshaft, R eplacem ent page 3
P V 7 7 6 -T S P 1 9 3 3 4 4
USA13899

TSI
Date
Group
No.
Page
8.2003
215
001
2(21)
Tools
Special Tools
The following special tools are used to replace or repair components. The tools can be
ordered from Volvo. Please use the specified p a rt num ber when ordering.
9996956
9998255
9998264
Flywheel Turning Tool
Rocker Arm Bridge Lifting Tool
Camshaft Removal Tool
J-44457
9996950
Camshaft Bearing Cap Removal Tool
Flywheel Stop Tool

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Date
Group
No.
Page
8.2003
215
001
3(21)
Service Procedures
2154-03-02-01
Camshaft, Replacement
(W ith EPG o r V EB )
You m ust read and understand the precautions and
guidelines in Service Information, Group 20, "General
Safety Practices, Engine" before performing this
procedure. If you are not properly trained and certified
in this procedure, ask your supervisor for training
before you perform it.
A CAUTION
O bserve the greatest possible cleanliness when
w orking on the cylinder head. Dirt particles in the
fuel and oil channels can cause the unit injectors to
malfunction, and can cause the VEB (if equipped)
to fail.
Special tools: 9996956, 9998255, 9998264,

9998270, J-44457
Removal
1
A WARNING
Use a hoist or get assistance when lifting com ponents
that weigh 23 kg (50 lb.) or more. Make sure all lifting
devices such as chains, hooks, or slings are in good
condition and are of the correct capacity. Make sure
hooks are positioned correctly. Always use a spreader
bar when necessary. The lifting hooks MUST NOT be
side loaded. Failure to follow these w arnings may
result in personal injury.
Remove the valve cover (valve cover should be removed
from the exhaust side of the engine).
N ote: On WIA, bring the valve cover towards the radiator
to remove. On WG, it is necessary to remove the engine
cover (doghouse).
N ote: Be careful that the stud bolts do not loosen.
Otherwise, the unit injector w iring harness can be
damaged.
2
D isconnect the connector fo r the electrical w ires on
the upper timing gear cover. Remove the clamp and
the cover.

TSI
Date
Group
No.
Page
8.2003
215
001
4(21)
3
Remove the upper tim ing gear cover
\\
&
T2006672
Remove the inspection cover from underneath the

flywheel housing and install turning tool 9996956.
9996956
5
Turn the flywheel around until the piston in cylinder
num ber 1 is in the Top Dead Center position ( 0 ) on the
flywheel and the cam shaft marking (TDC) is opposite the
marking on the bearing cap.

TSI
Date
Group
No.
Page
8.2003
215
001
5(21)
7
If the engine is equipped with VEB, remove the control
valve and pipe. Plug the ports and place it in a plastic bag
to avoid it being subjected to d irt and contam ination. To
facilitate removal, remove the valve cover stud bolt.
N ote: Failure to remove the control valve before removing
the rocker arm shaft assem bly may result in dam age to
the control valve and/or the pipe.

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Date
Group
No.
Page
8.2003
215
001
6(21)
T2006777
Fig. 4: Removing the rocker arm shaft assem bly bolts
8255
Loosen the rocker arm shaft bolts gradually to avoid

bending the arm shaft assembly. Remove the bolts, install
tool 9998255 and lift off the rocker arm shaft assem bly
N ote: On engines equipped w ith VEB, w rap a rubber

band around each exhaust rocker lever and slave piston.
This is to prevent the VEB slave pistons from falling out of
their rocker arm bore.
9998255
W2000937
Fig. 5: Removing the rocker arm shaft assembly
9
Remove the cam sensor w heel from the cam shaft
drive gear.
T2007096
Fig. 6: Cam sensor wheel

TSI
Date
Group
No.
Page
8.2003
215
001
7(21)
10
Install cam shaft counterhold tool 9998270 on the rear of
the camshaft. Loosen and remove the cam shaft drive
gear center bolt and the cam gear.
9998270
Fig. 7: Tool 9998270 installed
11
Remove the cam shaft cap bolts. M ark the caps for the
respective bearing housings, and remove.
N ote: To facilitate the removal of the cam shaft bearing
caps, use tool J-44457.
N ote: Failure to match the correct cam shaft cap with the
respective bearing housing will cause engine damage.
j -4 4 4 5 7
12
Carefully lift off the cam shaft using tool 9998264.
9998264
Fig. 8: Lifting the cam shaft
13
Remove the bearing shells from the bearing housings.
14
Inspect the bearings and housings for damage.
N ote: W hen replacing the cam shaft on the D12 engine,
rem em ber that the bearing shells are available in different
sizes. Refer to Group 20, Specifications.

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Date
Group
No.
Page
8.2003
215
001
8(21)
Installation
15
Position the cam shaft bearing housings on the cylinder
head by observing the factory m arks 1-7 .
N ote: Check that the mating surface is clean under the
bearing housings and that the guide pins are in good
condition. If installing a new cylinder head, also use the
bearing housings supplied with the cylinder head.
16
Fig. 9: Bearing shell halves

Coat the bearing shell halves with clean engine oil and
install them in the bearing housings. C arefully lower
the cam shaft into place.
N ote: Make sure that bearing shells of the correct size are
installed and correctly positioned in the bearing housing.
Fig. 10: Installing the cam shaft
17
Coat the bearing shell halves with clean engine oil and
install them in the cam shaft caps. Install the caps on their
respective bearing housings. Hand-tighten the bolts.

TSI
Date
Group
No.
Page
8.2003
215
001
9(21)
18
Install the cam shaft drive gear. Use tool 9998270 to lock
the cam shaft into place. Torque-tighten to
645 25 Nm (475 18 ft-lb).
N ote: Do NOT install the bolts for the rocker arm shaft.
645 25 Nm
(475 18 ft-lb)
9998270
T2007148
Fig. 11: Installing the cam shaft drive gear
19
A djust the cam shaft timing; refer to C am shaft Timing,
Check and A d ju st page 18.
20
A pply clean engine oil to the valve bridges and cam shaft
lobes. Using tool 9998255, lift the rocker arm shaft
assem bly into place. Make sure that the valve bridges
and the rocker arm s are correctly positioned in relation to
each other.
9998255
Fig. 12: Installing the rocker arm bridge
21
Hand-tighten the rocker arm shaft with the bolts until it
bottom s against the bearing housings.
N ote: Tighten the rocker arm shaft bolts gradually so that
no distortions occur on the shaft. Do NOT torque.

TSI
Date
Group
8.2003
215 001
No.
Page
10(21)
22
T2006777
Fig. 13: Tightening rocker arm shaft and cam shaft

together
1
bo
l31
31313131
TI
Tighten the rocker arm shaft to g e th e r with the camshaft,

using the 5-step sequence and torques shown:
D12, D12A, D12B:
1
00
6
m
00
1
to
oc
6
Of
El il 3 il il
2]
3]
5]
6\
7|l
4
5
W hen reinstalling a rocker arm shaft that has been

loosened o r removed, torque only the bolts that hold the
rocker arm shaft.
II il
3 il E)
II 3
1 3 E) 7
*-
OC
1
bf
4I
2
3
15 5 Nm (11 4 ft-lb);
+90 5
45 Nm (33 ft-lb)
15 5 Nm (11 4 ft-lb);
+90 5
45 Nm (33 ft-lb);
loosen to 0 Nm (0 ft-lb)
15 5 Nm (11 4 ft-lb);
+90 5
W2003520
Fig. 14: Bearing caps and cam shaft/rocker shaft,

tightening sequence
23
N ote: (E n g in e s w ith V E B :) Reinstall the VEB control
valve R econnect sliding valve and pipe into the rocker
arm shaft as a unit. A pply Loctite to threads and torque
tighten the bolts to 33 4 Nm (24 3 ft-lb).
33 4 Nm
(24 3 ft-lb)
24
Install the cam sensor wheel and mounting bolts. Turn
the cam sensor w heel clockwise (as viewed from the
front o f the engine) against the m ounting bolts; torque
bolts to 25 Nm (19 ft-lb).
25 Nm
(19 ft-lb)

TSI
Date
Group
No.
8.2003
215
001
Page
11(21)
25
Clean the contact surfaces for the upper tim ing gear
cover. Install a new rubber seal.
26
Apply an even bead of sealant around the tim ing gear
cover. Install the cover.
/ j \ CAUTION
Do not allow sealant to harden before installing the
cover. The bolts must be torque-tightened within
20 minutes.
27
Install the alignm ent tool J -4 1 2 7 2 on the forward
right-hand valve cover stud using an existing valve cover
nut. To attach the left-hand side, thread the bolt (supplied
with the tool) into the hole in the cylinder head. The top
of the cover must be flush with the top of the cylinder
head. Otherwise, oil leaks may result.
J-4 1 2 7 2
Fig. 15: Installing alignm ent tool J -4 1 2 7 2

1
2
Upper gear cover

Alignment tool
Valve cover nut
Bolt supplied with J-41272
28
Draw the cover down evenly until the cylinder head and
cover are aligned. Tighten cover mounting bolts in the
proper sequence and torque to 33 3 Nm (24 3 ft-lb).
33 3 Nm
(24 3 ft-lb)

TSI
Date
Group
8.2003
215 001
No.
Page
12(21)
29
Rotate the cam shaft until the cam sensor wheel tooth
aligns with the cam sensor. Verify that the air gap
is between 0.3 - 0.7 mm (0.012 - 0.028 in.). Adjust if
needed by removing or adding shim s between the
sensor and the cover. Relocate the tim ing cover, before
the sealant hardens, if necessary to aid in obtaining
the proper air gap.
N ote: Make sure the air gap is between 0.3 - 0.7
mm (0.011 - 0.028 in.).
0.3 - 0.7 mm
( 0 .0 1 2 - 0.028 in.)
30
C onnect the electrical cable to the cam sensor on
the cover.
31
After installing the camshaft, adjust the valves and unit
injectors; refer to Service Information, Group 21.
2154-06-03-01
Camshaft Timing, Checking
(See also C am shaft Timing, C heck and A djust page 18.)
You must read and understand the precautions and
N ote: Before using the cam gear tim ing tool J-42773,
always make sure that the pointer is straight. To check
the straightness (refer to numbers in accompanying
illustration):
W0002186
Hold the tool with the pointer horizontal (1).
Place a straight edge 90 degrees to the pointer

along its entire length (2).
If light can be seen between the straight edge

and the pointer, bend the pointer and recheck for
straightness (3).

TSI
Date
Group
8.2003
215 001
No.
Page
13(21)
Use the portion of the pointer that is fastened to the

tool shaft as a reference surface since this part is
protected from being bent (4).
Special tools: 9996956, J-41272, J-42773

1
Steam clean around the valve cover and the upper

front cover.
2
Disconnect the negative battery lead.
3
VN m o d e l o n ly
Drain coolant and then remove the top right fan ring
support and the top radiator neck from the therm ostat
housing.
A ll o th e r m o d e ls
Remove the fan ring support bracket, remove the fan belt
and then remove the fan, the fan hub and bracket as
one assembly. Relocate in the fan shroud area while
making sure not to damage the radiator.
4
Remove the intake pipe that spans from the air filter to
the turbo and then cover the turbo.
5
Remove the valve cover.
6
Remove the VEB and cam sensor harness connections
to the upper front cover.
7
Disconnect the internal w iring harness to the VEB
control solenoid.
8
Remove the upper front cover.
9
Slightly loosen the cam sensor wheel and note the
position of the wheel in relation to its mounting bolts, i.e.
clockwise against the mounting bolts, in the center, or
counter-clockw ise against the mounting bolts.
10
Remove the cam sensor wheel.
11
Remove the inspection cover on the flywheel housing.
Install the engine turning tool 9996956.
9996956

TSI
Date
Group
No.
8.2003
215
001
Page
14(21)
12
Install cam shaft alignm ent tool J -4 2 7 7 3 by inserting the
guide pin into the hole under the cam shaft drive gear.
Rotate the tool to position the lever against the drive gear
teeth to ensure that the tool is positioned correctly. Rotate
engine in the direction of rotation until the 2 dots on the
cam shaft gear are equally spaced on both sides o f the
cam shaft alignm ent tool.
J -4 2 7 7 3
T2012262
Fig. 16: Installing cam shaft alignm ent tool
13
A ssure that the 0 m ark aligns with the flywheel pointer.
D irection of
R otation
W2004266
Fig. 17: Flywheel direction of rotation
14
R e -a sse m b le
Install the cam sensor wheel and mounting
bolts. Turn the cam sensor wheel clockwise (as
viewed from the front of the engine) against
the mounting bolts; torque bolts to 25 Nm
(19 ft-lb).
25 Nm
(19 ft-lb)
15
Clean all sealant from the upper front cover.
16
A pply a bead of silicone sealant around the upper cover
along with a new rubber gasket.
17
Position the upper front cover and install the mounting
bolts; hand tighten only.

TSI
Date
Group
No.
8.2003
215
001
Page
15(21)
18
Install the front cover positioning tool, J -4 1 27 2. Tighten
bolts to align front cover. Torque the cover mounting
bolts to 33 4 Nm (24 3 ft-lb). Verify that the cover
is flush with the head.
N ote: Tighten positioning tool, J-41272 until upper front
cover is flush with cylinder head on both sides.
J -4 1 2 7 2
33 4 Nm
(24 3 ft-lb)
19
Remove tool, J-41272.
N ote: Rem ove any sealant that gets on the cam sensor
w heel to prevent any sensor signal faults.
20
Rotate the cam shaft until the cam sensor wheel tooth
aligns with the cam sensor. Verify that the air gap
is between 0.3 - 0.7 mm (0.012 - 0.028 in.). A djust if
needed by removing or adding shim s between the
sensor and the cover. Relocate the tim ing cover, before
the sealant hardens, if necessary to aid in obtaining
the proper air gap.
21
Remove the engine turning tool and reinstall the cover.
T2006672
22
Install the VEB solenoid harness and torque nuts to 1.4
Nm (1 ft-lb). Fasten all clips. Connect the external
harness to the front cover.
1.4 Nm
(1 ft-lb)
23
Clean the valve cover and gasket contact surface.

TSI
Date
Group
8.2003
215 001
No.
Page
16(21)
24
Install the valve cover and torque-tighten the bolts to
specifications using the proper sequence (see Fig. 18:
Valve cover tightening sequence, page 16).
T2007003
Fig. 18: Valve cover tightening sequence
N o te : Tighten the valve cover nuts according to the

proper sequence and torque. This is to prevent the valve
cover from cracking and also to keep the studs in the
cylinder head from loosening. If any of the valve cover
stud bolts loosened from the cylinder head when the nuts
were rem oved, the cable harness for the unit injectors
should be checked. There is a risk that the cable holder
on the stud bolt may have followed with the rotation of the
bolt and possibly dam aged the cable harness.
E n g in e S e ria l N u m b e r
T o rq u e
Below 25748
20 2 Nm (15 1 ft-lb)
Above 25748
30 3 Nm (22 2 ft-lb)
25
Install the intake piping.
26
R eassem ble depending on the model.
27
C onnect negative battery cable.
/ j \ WARNING
Always w ear safety glasses when working around
batteries. Failure to do so could result in serious
personal injury
28
Steam clean the engine, around the valve cover, timing
cover, and transm ission bellhousing.
29
C heck for any active fault codes and clear any inactive
fault codes.

TSI
Date
Group
No.
8.2003
215
001
Page
17(21)
30
Run the engine until the coolant reaches operating
tem perature. Allow to idle for approxim ately 10 minutes
for cylinder balancing. For cylinder balancing to take
place, the following conditions m ust be satisfied:
Idling speed must be below 650 RPM.
Fuel requirem ent m ust be below a specific rating.
Idling adjustm ent function must not be active.
Constant engine speed mode (PTO) not active.
Cruise control mode not active.
A ccelerator pedal in idling position (0%).
Coolant tem perature m ust be above 50 0 C (122 0 F).
Vehicle must be at a standstill (vehicle speed sensor

value of 0).
No fault codes present.
31
Check for leaks.

TSI
Date
Group
8.2003
215 001
No.
Page
18(21)
2154-06-03-02
Camshaft Timing, Check and Adjust
Safety Practices, Engine" before perform ing this
/ j \ CAUTION
Failure to properly set the cam shaft tim ing to the
crankshaft may result in loss o f perform ance, poor fuel
economy, or in extreme cases, engine damage.
Special tools: 9996956, J-41272, J-42773

1
Install the cam shaft alignm ent tool J -4 2 7 7 3 by inserting
the guide pin into the hole under the cam shaft drive
gear. R otate the tool to position the lever against the
drive gear teeth to ensure correct positioning o f the
cam shaft alignm ent tool.
J-4 2 7 7 3
2
Position the cam shaft using the flywheel turning tool
9996956.
N o te : The cam shaft setting m ust be exactly as illustrated
in the figure. It is im portant that the cam shaft gear
m arking is positioned precisely on both sides o f the tool in
a line extending from the center o f the camshaft.
9996956

TSI
Date
Group
8.2003
215 001
No.
Page
19(21)
3
Using flywheel turning tool 9996956, turn the flywheel
opposite to the direction o f engine rotation (A)
approxim ately 1 5 BTDC. Then turn the flyw heel in
direction of engine rotation (B) until the 0 m ark on the
flywheel lines up exactly with the pointer on the flywheel
housing w ithout passing the 0 mark.
/ j \ CAUTION
If the flywheel is turned past 0 TDC, repeat the above
step, completely. Do not ju st back up the flywheel.
Turning the flywheel in the opposite direction of
normal rotation will result in an incorrect setting due to
im proper gear train lash.
Fig. 19: Rotating the flyw heel to 0 TDC

A
Opposite direction of engine rotation
Direction of engine rotation
4
Clean all sealant from the front o f the head.
5
Install the adjustable idler gear assembly.
N ote: The bolts are the single-use stretch type and
should not be reused. Pipe sealant should be used on
the center bolt.

TSI
Date
Group
8.2003
215 001
No.
Page
20(21)
Insert two 0.10 mm (0.004 in.) feeler gauges on the load

sides of the (A and B) gear.
T2008255
7
Torque the bolts to an initial torque of 5 3 Nm (11
2 ft-lb).
N ote: An additional 120 5 is required after the correct
backlash is confirmed.
15 3 Nm
(11 2 ft-lb)
8
Check that both feeler gauges have the same
resistance when inserting them and pulling them
out. The correct backlash is 0.05 - 0.17 mm
(0.002 - 0.007 in.).

TSI
Date
Group
No.
8.2003
215
001
Page
21(21)
9
Tighten the bolts an additional 120 5 per the torque
sequence shown.
W2002245
10
R e-check cam shaft timing; refer to C am shaft Timing,
C hecking page 12. For inform ation on valve adjustm ent
and injector installation, also refer to Service Information,
Group 21.
VOLVO
V o Ivo Trucks North America, inc.

Greensboro, NC USA

21 5 -0 0 2 , C am shaft Wear, D12, D12A, D12B, D12C
(11.2001), publication no. PV776-TS P 160575.
Date
Group
No.
3.2004
_
Z lO
UUZ
Supp.
Page
1(2)
Camshaft Wear, Check

D12, D12A, D12B, D12C
Camshaft Wear
W2004342
Fig. 1: Cam shaft

This inform ation covers procedures for checking cam shaft w e a r in VOLVO D12, D12A,
D12B, and D12C engines.
Contents
P V 77 6 -T S P 1 9 7 4 4 2
Camshaft, W ear Check page 2
USA14441
V o Ivo Trucks North America, inc.
Date
Group
No.
tsi
3.2004
215
002
Page
2(2)
General
Camshaft, Wear Check
Surface irregularities may appear on VOLVO engine
cam shaft lobes in normal operation. This does not
mean that the cam shaft must be replaced. These marks
do not adversely affect the engine's perform ance nor
the durability of the engine or any of its components.
Fig. 2: Cam shafts with acceptable wear, page 2 provides
examples of cam shaft lobes exhibiting this condition.
These cam shafts may be reused.
Fig. 3: Cam shafts with unacceptable wear, page 2
provides examples o f lobes exhibiting unacceptable w ear
and deterioration. These cam shafts and the rocker arms
corresponding to the w orn lobes must be replaced.
Note: If there is any measurable wear, such as shown in
Fig. 3: Cam shafts with unacceptable wear, page 2, the
cam shaft should be replaced.
W2002219
Fig. 2: Cam shafts with acceptable w ear
W2002221
Fig. 3: Camshafts with unacceptable w ear
VOLVO

Greensboro, NC USA

21 1 -0 0 8 , C ylinder Head, D12C (11.01), publication no.
PV776-TSP160569.
Date
8.2003
Gioup
211
No.
008
Supp.
Page
1(32)
Cylinder Head
Replacement
D12C
VN
Cylinder Head Replacement
W2003244
Fig. 1: VOLVO D12C Engine

This inform ation covers procedures for replacing the cylinder head o f VOLVO D12C
engines in VN vehicles.
Contents
C ylinder Head, Removal page 4
C ylinder Head, Installation page 13
Note: Information is subject to change w ithout notice.

Illustrations are used for reference only, and may differ slightly from the actual engine
version. However, key com ponents addressed in this information are represented as
accurately as possible.
P V 7 7 6 -T S P 1 9 4 3 4 4
USA14005

TSI
Date
Group
No.
Page
8.2003
211
008
2(32)
Tools
Special Tools
For special tools ordering instructions, refer to Tools Information, group 08.
9996049
9996956
9996966
Drain Hose
Cylinder Liner Press Tool
9998249
9998251
9998255
Unit Injector Protective Sleeve
Cylinder Head Sealing Plug
Rocker Arm Bridge Lifting Tool

TSI
Date
Group
No.
Page
8.2003
211
008
3(32)
9998602-6/2
PT-2900
J-44514-25
Upper Front Cover Alignment Tool
Chip Vacuum Tool
Camshaft Alignment Tool Kit
J-42885
J -45242
J-44457
Injector Bore Cleaning Tool
Lifting Bracket
Camshaft Bearing Cap Puller

TSI
Date
Group
8.2003
211 008______________ 4(32)
No.
Page
Service Procedures
2111-01-01-01
Cylinder Head, Removal
(W ith VEB o r EPG)

guidelines in S ervice Information, group 20, "General
N ote: The exhaust manifold may remain in place when

removing the cylinder head.
Special tools: 9996966, 9998249, 9998251,

9998255, 9998264, 9998511
1
Drain coolant into approved container using drain hose
9996049 or coolant extractor DBT2V700.
9996049, DBT2V700
2
Disconnect batteries; re fe rto S ervice Information,
Group 33.
3
Disconnect the B+ cable and switch w ires from the
preheater. Remove any harness restraints as needed
from the preheater element.
4
C onnect a 5/16 drain hose onto the drain nipple at the fuel
filter. Open the drain; also open the bleed nipple at the
front o f the head. Drain fuel into appropriate container.

TSI
Date
Group
No.
Page
8.2003
211
008
5(32)
W2003422
6
Remove the 2 bolts mounting the boost pressure sensor
to the intake manifold. Remove the sensor.
7
Remove the driver side upper fan ring support bracket.
8
D isconnect the upper charge air cooler hose.
9
D isconnect the intake air sensor.
10
D isconnect the intake air hose from the air com pressor
and remove the intake air pipe between the turbocharger
and air filter housing.
11
Remove the air cleaner housing.
12
D isconnect the air discharge pipe from the air
compressor. U nbolt the air discharge pipe and the wiring
harness brackets from the cylinder head.
13
Remove the heat shield at the turbocharger.

TSI
Date
Group
No.
Page
8.2003
211
008
6(32)
14
Disconnect the oil supply line.
15
Disconnect the oil return line.
16
Remove the clam p bolt fastening the EPG housing to
the turbocharger.
T2009066
17
Remove the charge air pipe between the turbo and
the charge air cooler.

TSI
Date
Group
No.
Page
8.2003
21 1
008
7(32)
18
Remove the turbo mounting nuts and lift out turbo.
19
Remove the passenger side upper fan ring support bolt.
20
Disconnect the static fill hose at the expansion tank and
move the hose and pipe to the side.
21
Disconnect the top radiator hose and remove the top
radiator hose neck from the cylinder head.
22
Disconnect the heater return tube from the therm ostat
housing.
23
Remove the air bleed pipe between cylinder head and
expansion tank.
24
Disconnect the coolant hose between the air com pressor
and the cylinder head.
25
Remove the valve cover retaining nuts and lift off the
valve cover.
26
Remove the VCB control valve and pipe (if equipped)
and place valve in a clean plastic bag to prevent it
from being contam inated.

TSI
Date
Group
No.
Page
8.2003
211
008
8(32)
28
Disconnect the injector w iring harness at the rear of the
cylinder head at the pass-through connector and pull the
harness through and lay over to the side.
29
Loosen the bolts to the rocker arm shaft uniform ly over
the com plete assem bly to avoid distorting the shaft.
Remove the bolts and install lifting tool 9998255.
Carefully lift off the rocker arm bridge assembly.
Note: On engines installed with VEB, hold the pistons in
the rocker arm s with rubber bands so that the pistons do
not drop out w hen the rocker arm bridge is lifted up.
Pistons and rocker arm s are classed together.
9998255

TSI
Date
Group
No.
Page
8.2003
211
008
9(32)
31
Using lever tool 9998511, remove unit injectors one at
a time.
9998511
32
Install protective sleeve 9998249 on the unit injectors
as they are removed.
Note: Keep the unit injectors in the order in w hich they
w ere removed, so that each injector can be returned to its
corresponding cylinder.
9998249
33
Put protective plug 9998251 in the cylinder head at
each injector bore and secure using the unit injectors
retainer yoke.
9998251
T2008847
34
Remove the crankcase ventilation tube to the upper front
cover bolts. Move the tube to the side.
35
Remove cam shaft position sensor harness and sensor
from upper front cover.
36
Remove the upper front cover (9 mounting bolts).
Note: The fan ring m ust be pushed forward for added
clearance w hen lifting out the upper cover.

TSI
Date
Group
8.2003
211 008
No.
Page
10(32)
37
Remove the cam drive gear and vibration dam per (6
bolts). Remove the outer cam shaft cap bolts.
38
Using tool J-4 4 4 5 7 , remove the upper cam shaft bearing
caps.
Note: Using a felt tip pen, m ark each cam shaft cap and
its respective bearing housing so that each cap will be
reinstalled to the same housing.
J-4 4 4 5 7
39
Using lifting tool 9998264, carefully lift off the camshaft.
9998264
40
Remove the 38 cylinder head bolts.
41
Remove the #4 lower cam shaft cap, then install lifting
bracket J -4 1 5 0 3 onto the cylinder head. Carefully lift
off the cylinder head. W hile lifting the cylinder head,
verify that the coolant pipe behind the air com pressor
disconnects from the cylinder head.
J-4 1 5 0 3
W0002015

TSI_______________________________________________________
Date
Group
No.
8.2003
211
008________ 11 (32)
Page
42
Remove the cylinder head gasket.
44
Remove the coolant line from the com pressor to the
engine oil cooler cover.
45
Disconnect the oil supply line from the compressor.
46
Remove the air com pressor mounting bolts and lift the
com pressor from the engine.
47
Remove the coolant pipe from the w ater pump to the
head (2 bolts) that is located behind the air compressor.
Note: The air com pressor and coolant pipe are removed
to aid in reinstalling the cylinder head.
Note: Place a rag over the opening to prevent debris
from falling into the cooling system passages.

TSI
Date
Group
No.
8.2003
211
GG8
Page
12(32)
W2003987
49
Remove the cable harness box interm ediate cover
50
Loosen mounting bolts and pull cable harness box
away from cylinder block.
Note: The harness box may need to be secured against
the frame rail to be kept out of the way.
W2003988
51
R em ove the intake manifold from the cylinder head (if
not previously removed).

TSI
Date
Group
No.
8.2003
211
008
Page
13(32)
2111-02-01-01
Cylinder Head, Installation
(With VEB or EPG)

/ j \ CAUTION
All new and exchange D12C cylinder heads supplied
from Volvo have the sam e part num ber and are
installed with a plug in the oil channel to the VEB
system 's control valve. W hen replacing the cylinder
head on engines installed with VEB, the plug must be
removed before installing the control valve.
Failure to remove the oil supply plug on a D12 with
Volvo Engine Brake (VEB) exchange cylinder head
will cause cam shaft seizure. Severe engine damage
will result. Engines with Exhaust Pressure Governor
(EPG) only, the plug must remain in place.
Special tools: 9998624, 9998601, 9998264,

9998602, 9998255, 9996956, 9996966,
9998628
1
Clean the gasket and O-ring surfaces of the cylinder
block and head. Make sure all bolt holes in the cylinder
head and block are free of oil or debris.

TSI
Date
Group
8.2003
211 DGB
No.
Page
14(32)
2
If debris or carbon is in the cylinder head bolt holes, clean
the top of the hole above the thread by using a 17 mm
drill bit. Turn it m anually into the hole.
3
If required, clean the cylinder head bolt hole threads with
a M16 x 2 thread tap.
Note: Remove residue from bolt holes using chip
vacuum tool PT-2900.
PT-2900
C2002611
4
Using injector bore cleaning kit J -4 2 8 8 5 , clean the
injector copper sleeves; refer to Service Information,
Group 23.
J-4 2 8 8 5
5
Clean the contact surfaces on the cylinder head and
block to prepare for the alignm ent blocks.
Note: Remove any paint or silicone on all mating
surfaces of the alignm ent blocks.

TSI
Date
Group
No.
8.2003
21 1
008
Page
15(32)
6
Install alignm ent blocks 9998624 on the head at cylinders
3 and 6.
CAUTION
Before installing the alignm ent blocks, check the
flatness o f the surface. If the tools are not flush with the
cylinder head and block, the head will not be installed
correctly, with the risk of serious engine damage.
9998624
W2003999
7
Remove all cylinder liner hold-down tools 9996966.
8
Carefully place new cylinder head gasket on the engine
block and a new rubber seal on the interm ediate
gear plate.
Note: Make sure the contact surfaces are clean before
gasket and seal installation.
9
Using lifting tool J-4 1 5 0 3 , lift the cylinder head and
position it onto the cylinder block, letting the alignm ent
blocks position the cylinder head.
Note: Push the cylinder head so that the alignment
blocks are in contact with the alignm ent surface on
the cylinder block.
J-4 1 5 0 3
10
C heck that the rubber seal on the interm ediate plate is
positioned correctly after the cylinder head is in place.

TSI
Date
Group
No.
8.2003
211
GG8
Page
16(32)
12
Tighten upper bolt of front alignm ent block 9998601 to
properly align front of head.
13
Place a 0.10 mm (0.004 in.) feeler gauge between side
alignm ent block and cylinder block to check that the
cylinder head is positioned correctly. The feeler gauge
should n o t be able to fit between tool and cylinder block
Note: A gap o f 0 - 0.10 mm is acceptable.
W2003424
14
Remove cylinder head lifting fixture J-41503.

TSI
13 36 35 9 28 27 6 22 21 1 15 16 3 23 24 7 31 32 11
Date
Group
8.2003
211 008
No.
Page
17(32)
15
Lubricate cylinder head bolts with clean engine oil.
Install the cylinder bolts and torque-tighten using the
sequence illustrated (see Fig. 2: C ylinder head tightening
sequence, page 17) and the following steps:
1 60 10 Nm (44 7 ft-lb).
2 Check tighten 60 10 Nm (44 7 ft-lb).
3 Turn bolt 90 5 . Make diagonal m ark across bolt
head w /fe lt-tip pen after turning or use angle gauge.
14 38 37 10 30 29 4 18 17 2 19 20 5 25 26 8 33 34 12
T2007004
Fig. 2: C ylinder head tightening sequence
4 Repeat check in step 13 before the final torque is

applied to the cylinder head bolts. If a gap greater than
0.10 mm exists, loosen the bolts and reposition the
cylinder head.
5 Turn additional 90 5 . Make another diagonal mark
across bolt head with felt-tip pen after turning.
Note: Marking diagonal lines across the bolt heads will
help to identify which bolts have been torqued.
Note: O -rings may be included in cylinder head gasket
kits fo r D12 engines. However, these O -rings may be cut
by the cylinder head during installation of the cylinder
head bolts. Therefore, these O -rings are no longer
recom m ended for use w hen installing cylinder head bolts
into the cylinder head.
16
Remove alignm ent blocks 9998624 and 9998601.
17
Clean the cam shaft and inspect for w ear or dam age (See
service literature "Cam shaft Inspection).
18
Install num ber 4 lower cam shaft bearing support to
the cylinder head and carefully tap into place with
a nonm arring hammer.
T2008859

TSI
Date
8.2003
Group
211
No.
ooa
Page
18(32)
20
Using lifting tool 9998264, carefully lower the cam shaft
(w ithout gear attached) into position.
21
Install the bearings into their corresponding upper
cam shaft bearing caps.
22
Install all 7 upper cam shaft bearing caps to their
respective positions. Gently tap into place using a
nonm arring hammer.
Note: Each upper and lower bearing cap assem bly is a
matched pair and m ust be assem bled accordingly. The
upper and lower bearing caps are numbered 1 to 7 to
identify the position on the cylinder head where they are
to be installed, and also to prevent mixing of the upper
and lower housing assemblies.
23
Install outer cam shaft bearing cap bolts and studs.
Hand-tighten only.
24
Using a rag to protect the camshaft, hand-turn the
cam shaft to make sure that it rotates freely. It should
not bind. Axial play should be no more than 0.35 mm
(0.014 in.).
25
R em ove flywheel inspection cover.

TSI
Date
Group
8.2003
211 GG8
No.
Page
19(32)
26
Install flyw heel turning tool 9996956 and rotate engine
to 0 TDC.
Note: Make sure TDC m ark on cam shaft is between
the two hash m arks on front cam bearing cap before
gear is installed.
27
Install cam shaft gear onto camshaft.
28
Using alignm ent kit J-4 4 5 1 4 , install cam shaft alignm ent
collar (A) to front o f gear. Install cam shaft alignm ent tool
(B) to verify that cam shaft is aligned at TDC.
J44514
W2004023

TSI
Date
Group
8.2003
211 008
No.
Page
20(32)
29
Set up a dial indicator on the adjustable idler gear.
30
Use a pry bar or long screw driver to hold the interm ediate
idler gear in place. Measure the gearlash between the
interm ediate-to-adjustable idler gears by rocking the
adjustable idler gear back and forth. Acceptable gear
backlash is 0.05 - 0.17 mm (0.002 - 0.007 in.).
31
Set up a dial indicator on the cam shaft gear; use a pry
bar or long screw driver to hold the adjustable idler
gear in place.
W2003491

TSI
Date
Group
No.
8.2003
211
008
Page
21(32)
32
Measure the gearlash between the cam shaft gear and
adjustable idler gear by rocking the cam shaft gear back
and forth. A cceptable gear backlash is 0.05 - 0.17
mm (0.002 - 0.007 in.).
Note: If either backlash is out of specification, the
adjustable idler gear must be adjusted; refer to Service
Information, Group 21.
33
Remove the cam shaft alignm ent collar and flywheel
turning tool 9996956.
34
Install cam shaft dam per (A) and cam sensor tooth
wheel (B).
W2004024
35
Install spacer and new bolts. Using proper sequence,
torque-tighten bolts to 35 3 Nm (26 2 ft-lb), then
turn additional 90 5 .
Note: C am shaft gear retaining bolts are one-tim e
use only.
35 3 Nm
(26 2 ft-lb);
then 90 5

TSI
Date
Group
No.
8.2003
21 1
008
Page
22(32)
36
Remove protective plugs 9998251 from each injector
bore. Install new O-rings on the injectors. Lubricate the
seals with clean engine oil.
9998251
37
Install each injector, centering it between the valve
springs. Torque-tighten unit injector locator yoke screw
as follows:
If using new copper sleeve:

1
2
3
4
5
Tighten to 20 5 Nm (15 4 ft-lb).

Turn bolt 180 5 .
Loosen to 0 Nm.
Tighten 20 5 Nm (15 4 ft-lb).
Turn bolt 60 5 .
If using old copper sleeve:

1
2
Tighten to 20 5 Nm (15 4 ft-lb).

Turn bolt 60 5 .
Fig. 3: Unit injector retaining bolt
38
Install the injector electrical w ires and route w ires to the
outside of the valve cover studs.

TSI
Date
Group
No.
8.2003
211
GG8
Page
23(32)
39
/ l \ CAUTION
DO NOT OVERTIGHTEN. Hold w ires w hile tightening.
If the screws break, the unit injector must be replaced.
C onnect the unit injector electrical w ires to the injectors.
Using tool 9999708, torque-tighten the nut to 1.4 Nm
(12 in-lb).
1.4 Nm
(12 in-lb)
Fig. 4: Unit injector cable connections
40
Lubricate valve bridges and install on intake and
exhaust guides.
41
Using lifting tool 9998255, install the rocker shaft.
Note: The bolt holes must be free of oil or debris.
9998255
42
Loosely install the rocker shaft mounting bolts.
T2006777

TSI
Date
Group
8.2003
211 008
No.
Page
24(32)
43
Tighten the rocker arm shaft mounting bolts, a little at a
time, over the entire rocker arm shaft to avoid bending
the shaft and to make sure that it is positioned correctly
in the cam shaft brackets. W hen all bolts are hand
tight, torque-tighten using proper sequence (see Fig.
5: Bearing caps and cam shaft/rocker shaft, tightening
sequence, D12C, page 24) and the following steps:
1
2
3
4
15 5 Nm (11
60 5 Nm (44
15 5 Nm (11
60 5 Nm (44
0 Nm (0 ft- lb)
5 15 5 Nm (11
4
4
4
4
ft-lb); +90 5
ft-lb)
ft-lb); +120 5
ft-lb); loosen to
4 ft-lb); +120 5
Fig. 5: Bearing caps and cam shaft/rocker shaft,

tightening sequence, D12C
44
If needed, verify cam shaft timing. Check cam shaft
settings with cold engine and no. 1 intake valve = 0.
Intake valve for cylinder 1 for flywheel position 6 after
TDC must be open 1.6 0.3 mm (0.063 0.001 in.).
W hen checking, timing gears m ust be turned ONLY in the
correct direction (clockwise from the front) to eliminate
any backlash. For more inform ation, refer to Service
Information, Group 21.
45
A djust the injector and valve clearance according to
specifications. Shim s are used to adjust the exhaust
valve clearance on engines equipped with VEB; refer
to Service Information, Group 21.

TSI
Date
Group
8.2003
211 008
46
Install the VEB control
pipe with new O-rings;
mounting bolts to 20 i
connection nut to 1.5 i
No.
valve (if equipped)

connect the wires.
3 Nm (15 i 2 ft-lb)
0.5 Nm (1.5 i 0.4
Page
25(32)
and oil supply

Torque-tighten
and electrical
ft-lb).
20 i 3 Nm (15 i 2 ft-lb),
1.5 i 0.5 Nm (1 i 0.4 ft-lb)
47
Install the valve cover studs.
T2008813
48
Clean sealing surface of upper front cover. Using
pressurized air, blow off any debris.

TSI
Date
Group
8.2003
211 008
No.
Page
26(32)
49
Install gasket between upper and lower front covers.
Note: To prevent leaks, sealant must be placed at
front corners of upper cover and at indentation along
side of cover.
50
A pply a 2 mm bead of sealant to the upper front cover
w here it contacts the cylinder head. Make sure that the
sealant com pletely surrounds the bolt holes.
Note: Cover should be torque-tightened within 20
m inutes after applying sealant.
51
Install the upper front cover. Hand-tighten bolts, only.

TSI
Date
Group
8.2003
211 008
No.
Page
27(32)
53
Torque-tighten upper front cover bolts as follows, using
the sequence illustrated:
M8:
24 4 Nm (18 3 ft-lb)
M10: 48 8 Nm (36 6 ft-lb)
54
Remove upper front cover alignm ent tool 9998602-6/2.
55
Install cam shaft sensor to upper front cover.
Note: The distance between sensor and sensor tooth
wheel should be 0.3 - 1.0 mm (0.012 - 0.039 in.).
56
Install w iring harness and clam ps to upper front cover.
57
Install the valve cover on the engine. Using pattern
illustrated, torque-tighten to 20 2 Nm (15 2 ft-lb).
T2012845

TSI
Date
Group
No.
8.2003
21 1
GGB
Page
28(32)
58
Install coolant tube from w ater pump to cylinder head.
Note: Use new O-rings and gasket.
59
Install air com pressor with new mounting O-ring.
Torque-tighten mounting bolts to 85 15 Nm (63
11 ft-lb).
85 15 Nm
(63 11 ft-lb)
60
Install oil supply line to air compressor.
61
C onnect air com pressor coolant hoses to cylinder head
and oil cooler cover. Tighten hose clamps.
W2004011
62
C onnect air lines to the air com pressor and install line
supports to cylinder head.
63
Clean the intake manifold and install new sealant.
64
Install intake manifold. Using cross-over pattern,
torque-tighten bolts to 24 4 Nm (18 3 ft-lb).
24 4 Nm
(18 3 ft-lb)
65
Install the cable box to the cylinder block.
Note: Do not install the cover at this time.

TSI
Date
Group
No.
8.2003
211
GG8
Page
29(32)
ee
Install the fuel line at the front of the head.
W2003422
67
Install the intake manifold pressure/tem perature sensor.
68
Install the cable box interm ediate cover.
69
Install the cable box outer cover.
70
Install the bracket between the preheater and the fan ring;
connect the upper charge air cooler pipe.
71
Loosen the alternator and pull down to install the front
intake bolt. Torque-tighten to specifications.
72
Reposition and tighten the alternator bolts.
73
Fit new O-ring seal on the coolant tem perature sensor
and install in cylinder head.
74
Install the transm ission oil cooler w ater hose at the
back of the cylinder head.
75
Install the fuel line at the rear o f the cylinder head using
new copper washers.
76
Connect the preheater B+ and switch wires. Install wire
restraints.
77
Connect the AC line support to the intake manifold.

TSI
Date
Group
8.2003
211 008
No.
Page
30(32)
78
Install the heater pipe at the therm ostat housing using
new O-ring.
79
Using a new gasket, lift turbo into position and tighten
mounting nuts.
80
W2003865

TSI
Date
Group
No.
8.2003
211
GGB
Page
31(32)
82
Install the turbo oil supply line to the turbocharger.
83
Install the charge air pipe to the turbo.
84
Install the upper radiator coolant neck and connect the
fan ring to the coolant neck.
85
C onnect the upper radiator coolant hose and static
fill pipe.
86
Install the breather pipe to the upper front cover.
87
Install the oil fille r pipe to the upper front cover.
88
Install the coolant in the engine.
89
Install the air filte r housing and piping.
90
C onnect batteries; re fe rto Service Information, group 33.
91
Prime the fuel system.

TSI
Date
Group
No.
8.2003
21 1
008
92
C rank the engine. Check for leaks and any wires or
hoses that require service.
93
Road te st the truck and recheck for leaks.
Page
32(32)
Service Manual
Trucks
Group
260600
Cooling System
D12, D12A, D12B, D12C
PV776-TSP142854
VOLVO
Foreword
The descriptions and service procedures contained in this manual are based on de
signs and m ethods studies carried out up to A ugust 2000.
The products are under continuous development. Vehicles and com ponents produced
after the above date may therefore have different specifications and repair methods.
When this is believed to have a significant bearing on this manual, supplem entary ser
vice bulletins will be issued to cover the changes.
The new edition o f this manual will update the changes.
In service procedures where the title incorporates an operation number, this is a refer
ence to an S.R .T (Standard Repair Time).
Service procedures which do not include an operation num ber in the title are for gen
eral inform ation and no reference is made to an S.R.T.
The following levels of observations, cautions and w arnings are used in this Service
D ocum entation:
N ote: Indicates a procedure, practice, or condition that must be followed in order to
have the vehicle or com ponent function in the m anner intended.
C aution: Indicates an unsafe practice w here damage to the product could occur.
W arning: Indicates an unsafe practice w here personal injury or severe damage to the
product could occur.
Danger: Indicates an unsafe practice w here serious personal injury or death could oc
cur.

Greensboro, NC USA
Order number: PV776-TSP142854
2000 Volvo Trucks North America, Inc., Greensboro, NC USA
All rights reserved. No part of this publication may be reproduced, stored in

retrieval system, or transmitted in any forms by any means, electronic, me
chanical, photocopying, recording or otherwise, without the prior written
permission of Volvo Trucks North America, Inc..
Contents
General ................................................................................................................... 3
Tools ........................................................................................................................ 5
Special Tools
...................................................................................................... 5
Special E quipm ent ............................................................................................. 9

Design and Function ...................................................................................... 11
Cooling System ................................................................................................... 11
Charge A ir C ooler ............................................................................................ 11
Cooling System, Flow ..................................................................................... 12
T herm ostat
....................................................................................................... 14
T herm ostat Housing

D12C
....................................................................................... 15
................................................................................................................ 15
R adiator ............................................................................................................. 16
AC, W G
........................................................................................................... 16
VN/VHD ........................................................................................................... 16
Coolant Mixture ............................................................................................. 17
Expansion Tank ............................................................................................... 19
Draining Points
.................................................................................................. 20
Coolant Pump .....................................................................................................20

Coolant Filter ......................................................................................................21
W interfront ...........................................................................................................22
Viscous Fan ........................................................................................................ 23
Control Device ................................................................................................. 24
Troubleshooting
................................................................................................. 25
Cooling System Troubleshooting ................................................................... 25

Speed Check ......................................................................................................27
Fan Disengaged
..............................................................................................27
Fan Engaged ....................................................................................................27

Service Procedures
.......................................................................................... 29
Radiator, R eplacem ent .....................................................................................29

Removal ........................................................................................................... 30
Installation
........................................................................................................ 34
Radiator, Checking
.......................................................................................... 38
R adiator Surge Tank, R eplacem ent ........................................................... 38

Cooling System Leak Test, Checking
Coolant Pump, R eplacem ent
Coolant Pump, Overhaul
(U nit Removed)
..........................................................41
.........................................................................43
................................................................................48
............................................................................................... 48
Therm ostat, R eplacem ent ............................................................................. 55

D12, D12A, D12B .......................................................................................... 55
Therm ostat, R eplacem ent ............................................................................. 59
D12C
................................................................................................................ 59
Therm ostat, Checking
......................................................................................61
Viscous Fan, Replacem ent ..............................................................................61

Fan Belt Tensioner, R eplacem ent
.................................................................63
Cooling Fan Drive Belt, R eplacem ent ..........................................................65

Fan Belt Tensioner, Overhaul .........................................................................65
Viscous Fan, Checking .....................................................................................68
Charge A ir Cooler, R eplacem ent ..................................................................69
Removal ........................................................................................................... 70
Installation
........................................................................................................ 71
Coolant Temperature Gauge, Checking
72
1
Radiator, Cleaning ........................................................................................... 73

(Unit Removed)
............................................................................................... 73
Charge A ir Cooler, Cleaning
.......................................................................... 74
System Check .....................................................................................................77

Cooling System, Servicing
..............................................................................77
Feedback
Operation Numbers
G roup 2
General
General
W2003244
This inform ation covers the Cooling System for the D12,
D12A, D12B, and D12C engines.
Group 2
Tools
Tools
Special Tools
The following special tools are required to w ork on the cooling system of the D12
engine. The tools are available from the Parts D epartm ent of Volvo Trucks North A m er
ica, Inc.
Please specify the com plete part num ber when ordering.
9994090
Puller for Coolant Pump Seal
9996049
Drain Hose for coolant
9996222
Air Powered Hydraulic Pump
9992071
Drift for Overhauling Coolant Pump
W0001743
9992671
9994034
Hydraulic Cylinder
Hollow Drift for Overhauling

Coolant Pump
Group 2
Tools
9996626

Coolant Pump
W0001748
9996315
Spindle for Overhauling Coolant

Pump
9996383

Coolant Pump
W0001763
9996662
Pressure Gauge
9996671
Filter Wrench for Coolant Filter
W0001766
9996441
Expansion Tank Cap-VN
Group 2
Tools
W0001761
W0001754
9996883
Adapter for Overhauling Coolant
9998113
9998244
Sleeve for Overhauling Coolant
Pump
W0001755
9996884
W0001764
Pump
W0001762
9998012

Coolant Pump
W0001760
9998291
Drift for Installing Thermostat Seal

ing Ring on the D12 A & B engine
9998511
W0001757
9998039
W0001802
ing Ring on the D12 A & B engine
Group 2
Tools
J-44 3 9 2
Belt Tensioner Release Tool (Kent

Moore)
9998541
Tool for Pressing Impeller onto

Coolant Pump Shaft
W0001929
J-44772
9998619

ing Ring on the D12C engine
Thermostat Housing Install Tool
Group 2
Tools
Special Equipment
Like the special tools, the following are also available from the Parts D epartm ent of
Volvo Trucks North Am erica, Inc.
Please specify the complete part num ber when ordering.
T2007271
1159794
Torque wrench 10-100 Nm

(7-74 ft-lb)
9985011
9999708
H ydrom eter for antifreeze

Torque wrench 0-17.5 Nm
(0-13 ft-lb)
9999795
Tachometer
10
Group 2
Design and Function
Design and Function

Cooling System
Charge Air Cooler
Charge A ir C ooler S ystem s are essential today to meet
em issions regulations. However, they also improve
power density, lower fuel consumption, and reduce ther
mal stresses on the engine by cooling the turbocharged
air before it enters the engine. The turbocharged air is
heated up to 200 C (400 F) or even higher as it enters
the charge cooler, and is cooled to around 40 C (100
F) when it leaves for the engine.
A ccum ulation of bugs and d irt in the finned areas of a
C harge A ir C ooler are known problems. If there is a
build up of any debris like road film, bugs, etc. in ju s t a
section of a charge air cooler, that section overheats and
torsional (twisting) stresses develop in the charge air
cooler core. The fin passage cleanliness may not be as
critical in an over-the-highway vehicle, but in construc
tion, logging and mining equipment, it can be.
W2000730
Fig. 1: C harge air cooler
B efore performing the actual leak test, make sure the

pressure regulator is functioning properly; see Cooling
System, Flow page 12.
11
Group 2
Design and Function
Cooling System, Flow

54
W2003323
Fig. 2: Cooling system
Therm ostat housing
R adiator
Expansion tank
Level sensor
Pressure cap
C oolant filter
12
Coolant pump
H eater return
H eater supply
10
R adiator drain valve
11
S hut-off valve coolant pump
Group 2
Design and Function
Coolant Circulation in Engine

The coolant is forced through the system by a geardriven pump. The coolant enters the cylinder block
through a pipe and first passes the area where the oil
cooler is installed. The coolant is then distributed
through galleries in the cylinder block and cylinder head
to reach the cylinder liners and other parts o f the engine
before leaving the cylinder head through the therm ostat
housing. The illustration shows the engine during the
w arm -up period. The therm ostat is closed and the
coolant is flowing back to the coolant pump.
13
Group 2
Design and Function
Thermostat
The engine is equipped with a therm ostat. The therm o
stat housing incorporates a sensor for coolant
tem perature. D uring engine w arm -up, the therm ostat is
closed, (see Fig. 4: Therm ostat closed , page 14) and
coolant flows from the cylinder head through the outer
section of the therm ostat back to the coolant pump.
W2003283
Fig. 4: Therm ostat closed

W hen the engine has reached operating tem perature
and the therm ostat is open (see Fig. 5: T herm ostat open,
page 14) , the outlet to the coolant pump is gradually
closed. The coolant now passes through the inner sec
tion of the therm ostat housing and then to the radiator.
W2003284
Fig. 5: Therm ostat open
14
Group 2
Design and Function
Thermostat Housing
D12C
The therm ostat housing has been integrated into the
cylinder head.
The therm ostat (1) is located at the right front side of the
cylinder head and its seal ring (2) is accessible once the
connection housing (3) and therm ostat have been re
moved (see illustration, Fig. 6: Therm ostat Housing,
D12C, page 15).
T2012790
Fig. 6: Therm ostat Housing, D12C
15
Design and Function
Group 2
Radiator
AC, WG
There are two (2) sizes of radiators furnished for use
with the D12 engines in different applications:
Vehicle
Type
Radiator
Area
System
Capacity
A utocar
84 dm 2 (1300 in2)
43 (52 qts)
WG
67 dm 2 (1032 in2)
50 (52 qts)
W2003214
Fig. 7: Radiator, AC, WG
VN/VHD
Do to the unique design o f the radiator, do not attem pt to
replace any o f the com ponents on the VN/VH D radiator,
including tanks, seals or core.
Specialized tooling is needed to perform quality repairs
w hen crim ping the tanks and seals to the core. There
fore, you should:
have the radiator repaired by an authorized radiator

service center; or
replace the com plete unit
Vehicle
Type
Radiator
Area
System
Capacity
VN
124 n2
39
VHD
849 n2
39
W2003376
Fig. 8: Radiator, VN
W2003472
Fig. 9: Radiator, VHD (with unique mounting bracket)
16
Group 2
Design and Function
Coolant Mixture
Always mix w ater and antifreeze to the correct concen
tration before filling the cooling system.
Freeze Protection
down to:
Am ount
concentrated
antifreeze,
WG
A m ount
concentrated
antifreeze,
WI and AC
Percent
age of
antifreeze
in mixture
-2 5 c
(- i 3 f )
17 liters
20 liters
40%
-3 0 C
(-22F)
20 liters
23 liters
46%
-38 C
(-36F)
21 liters
25 liters
50%
-46C
(-51F)
26 liters
30 liters
60%
The recom m ended mixture is 50% antifreeze/coolant in

the water.
Note: Mixing concentrated coolants o f a different type
can result in a loss of anti-corrosion properties with dam
age to the engine as a result.
A t the factory, the cooling system is norm ally filled with a
mixture o f tap w ater and concentrated coolant which
gives protection down to m inim um -29 C (-20 F). If the
vehicle is destined for clim ates colder than this, the anti
freeze level of the coolant should be adjusted; see
approxim ate values in the following table.
/ j \ CAUTION
60% antifreeze in the mixture gives optim um freeze
protection. Increasing the antifreeze content beyond
that will only decrease the freeze protection.
/ j \ CAUTION
Never use a mixture w eaker than 40% antifreeze to
60% water. Ignoring this increases the risk o f corro
sion in the cooling system and cylinder liner pitting
leading to damage of the engine.
For more detailed inform ation on Coolants, refer to:
TSI
184-001
Coolant Requirements, Volvo Engines

IMPACT
Function Group 184

Information Type: Service and M ainte
nance
Coolant Requirem ents
17
Group 2
Flushing Cooling System

The cooling system should always be cleaned when the
coolant is replaced.
Coolant is toxic; risk of poisoning. Do not drink

coolant. Use proper hand protection when handling.
Keep coolant out o f reach of children and animals.
Failure to follow these precautions can cause serious
illness or death.
Note: Always dispose of coolant according to Federal or
local regulations. Take all used coolant to a recycling or
waste collection center.
18
Design and Function
Group 2
Design and Function
Expansion Tank
The expansion tank includes a pressure valve and a
coolant level sensor. The tank material is clear and has
maximum (MAX) and minimum (MIN) m arkings to allow
visual fluid level checks.
Fig. 10: Expansion tank for WG and AC
Fig. 11: Expansion tank for VHD
Fig. 12: Expansion tank for VN
19
Group 2
Design and Function
Draining Points
To drain the cooling system, all drain points should be
opened. In addition, the expansion tank cap should be
removed w hile the system is draining.
Draining points:
Radiator
C ylinder block
Oil cooler, transm ission (when installed)
C oolant pump
Note: In som e locations the draining point consists of a

quick-connect valve (1) covered with a rubber cap; see
Fig. 13: Q uick-connect drain valve in bottom o f radiator,
page 20. In this case use tool 9996049 fo r draining. This
is a quick-connect hose needed for draining.
W2003367
Fig. 13: Q uick-connect drain valve in bottom of radiator
Coolant Pump
The coolant pump is mounted to the timing gear plate
and is driven by the timing gears. The coolant pump in
cludes a one-piece carbon/ceram ic seal and a double
ball bearing for the pump shaft. The pump is equipped
with a shut-off valve (1) which prevents coolant from
draining out when changing the coolant filter; see Fig.
14: C oolant pump, page 20. To close the valve, the han
dle is turned to the horizontal position.
Note: The shut-off valve must always be in the open po
sition. That is, the handle should point vertically, except
when replacing the lines.
Fig. 14: C oolant pump
20
Group 2
Design and Function
Coolant Filter
A coolant filter is mounted to the coolant pump. On D12
engines and an adapter is mounted to the pump with
lines to a rem ote-m ounted coolant filter situated on the
right side o f the engine.
Coolant filters used with standard coolant include an anti
corrosive agent, SCA (Supplem ental Coolant Additive),
w hich is added to the standard coolant during filtration.
Coolant filters used with Extended Life Coolant, ELC,
are blanks and do not contain any SCA.
Note: The valve m ust always be in the open position, i.e.
the handle should point vertically, except when changing
the filter.
For more detailed inform ation on coolants, refer to

TSI
184-001
Coolant Requirements, Volvo Engines

IMPACT
Function Group 184

Information Type: Service and M ainte
nance
Coolant Requirem ents
21
Group 2
Winterfront
Volvo Trucks North Am erica, Inc. does not recom mend
the use of winterfronts, shutters or any other shield in
front of the grille or radiator package under norm al cir
cumstances. These devices, if not used properly, can
cause higher exhaust tem peratures, power loss, exces
sive fan usage and a reduction in fuel economy.
Today's electronically controlled engines are designed to
operate in tem peratures w ithout a winterfront. Volvo
Trucks North Am erica, Inc. does not recom mend the use
of a w interfront while the vehicle is being driven. If a w in
terfront is used, it must conform to these specifications:
Note: Please see your local Volvo Truck Dealer for Volvo
recom mended winterfronts. If there is engine or related
damage that can be followed back to an im properly used
winterfront, the warranty is no longer valid for those parts.
V H D -Failure to remove the w interfront when tem pera
tures go above 1 5 F (-25 C.) could cause severe
damage to engine, charge-air-cooler and/or loss of fuel
economy. The grille cover should be able to let airflow
through to the charge-air-cooler at a uniform rate over
the entire area. This means that a single, small opening
in the w interfront is not acceptable. A ir passage must be
distributed evenly across the grille and no more than
85% can be covered.
V N -W interfronts are properly used for overnight parking
in the w inter or very cold tem peratures (b e lo w -5 F[-20
C]). In these cases, coolant and inlet manifold tem pera
tures must be carefully monitored and controlled.
22
Design and Function
Group 2
Design and Function
Viscous Fan
The Viscous fan consists of a fan section and a drive
section connected by a visco-static clutch. The clutch
consists of a drive plate (6) which is mounted in a hous
ing (7); see Fig. 17: Fan, cross-section, page 23.
On each side of the drive plate (6) is an air gap. When
the fan is engaged, these gaps are filled with fluid. With
the fan in operation, the flow o f fluid in the fan hub takes
place in two different ways. The tem perature around the
bim etallic plate (2) determ ines which path the fluid takes
and thereby the degree to which the fan is engaged.
The control device regulates the am ount of fluid reaching
the drive cham ber to meet the cooling requirements. The
more fluid in the drive chamber, the less slip, thus re
sulting in higher fan speed. The fluid circulates between
the storage and drive chambers. W hen the engine and
fan stop, the fluid runs out into the drive chamber, which
is why the fan is generally engaged during the first min
utes after starting the engine.
T2006863
Fig. 15: Cooling fan
A. D isengagem ent
The valve (1) closes and fluid is pumped out into the
storage cham ber (5).
B. E ngagem ent
The valve (1) opens and fluid can enter the drive cham
ber (8).
T2007216
Fig. 16: Sensor, bim etallic plate
T2007217
Fig. 17: Fan, cross-section

Fan, cross se ctio n sh o w s valve disengaged (B)
and engaged (A)
1
Valve
Bimetallic plate
Control pin
Valve lever
Fluid storage chamber
Drive plate
Housing
Drive chamber
23
Group 2
Design and Function
Control Device
The fan rotates at reduced speed. The bim etallic plate
(1) presses against the control pin (2) moving it towards
the valve lever (3).
2
T2007218
Fig. 18: Control valve closed

1
Bimetallic plate
Control pin
Valve lever
The fan is fully engaged. The bim etallic plate flexes out
w ards due to the tem perature increase in the am bient air.
For function check, see "Viscous Fan, Checking page
68.
T2007219
Fig. 19: Control valve open
24
Group 2
Troubleshooting
Troubleshooting
Cooling System Troubleshooting
Coolant Temperature Too High
Excessively high coolant tem perature can be due to:
Blocked radiator (low airflow)
Blocked cooling system
Contam inated coolant
Low coolant level
Broken fan belt
Faulty tem perature gauge
Poor grounding between engine and chassis
Faulty therm ostat
Faulty tem perature-controlled cooling fan
Leaking cylinder head gasket, lower liner seals
Leaking coolant hoses
Coolant Temperature Too Low
Faulty therm ostat
Faulty tem perature gauge
Loss of Coolant
External Leaks
Leaks in hoses or connections
Leaks in radiator and/or expansion tank
Leaks in cab heater
Leaks in coolant pump
C ylinder head gasket leakage
Internal LeaksEngine
Leak at injector copper sleeve
Defective liner seals
Liners pitted or cracked
Crack(s) in cylinder head
Crack(s) in cylinder block

25
Group 2
Coolant Leaks Through Overflow
Faulty pressure cap/relief valve
Engine running too hot
Expansion tank installed incorrectly
C ylinder block cracked
Liners pitted or cracked
Coolant losses, warm engine switched off
Coolant losses after having switched o ff a warm engine

are generally due to heavy load operation and subse
quent stopping w ithout allowing the engine first to run at
idling speed to cool down, or a faulty pressure cap valve.
Temperature Gauge, Checking

Remove the tem perature sensor from the therm ostat
housing and reconnect the electric connector. C onnect a
ground between the tem perature sensor and the cylinder
block. Subm erse the tem perature sensor in heated water.
Using a therm om eter, read off the tem perature. Compare
this reading with the reading o f the tem perature gauge.
Air Flow-through, Checking

Should higher than norm al coolant tem peratures be ob
served, the passage o f air through the charge air cooler,
A/C condenser and radiator must always be checked and
cleaned if necessary. Any obstruction must be removed.
In cases of more serious blockage, the radiator/charge
air cooler and A/C condenser must be removed entirely
and thoroughly cleaned, especially if the pollutant is oil
based.
If the fins of the radiator have been bent by flying stones
etc., straighten them with a fin comb.
Check that the rubber seals between the fan shroud and
the radiator, and in some cases between the radiator
and the front shroud, have not loosened or for any other
reason are not providing a good seal.
Polluted Coolant
If the coolant is polluted it could mean that there is an in
ternal leak (oil) or that the cooling system is clogged
(deposits). Check for leaks.
A clogged system is usually a result o f not changing the
coolant according to the specific change intervals or us
ing the wrong mixture of coolant and water, or that
polluted w ater has been used.
26
Troubleshooting
Group 2
Troubleshooting
Speed Check
/ f \ DANGER
Keep coolant out of reach of children and animals.
illness or death.
/ t\ danger
Keep your hand, clothing, and the measuring instru
ment at a safe distance from the blades of the fan
when checking RPM. Contact may cause personal in
jury or death.
1
Run the engine at idling speed for ap
proximately 5 minutes. Air temperature
in front of the fan must not exceed 30
C (85 F). The silicone fluid, which
drains into the drive chamber when
the engine is switched off, is now
pumped back to the storage chamber.
1
Increase engine speed to maximum
RPM and measure fan speed with spe
cial tool 9999795. Fan speed should
be less than half engine speed when
the fan is fully disengaged.
9999795
/ j \ WARNING
HOT ENGINE! Keep yourself and your test equipment
clear of all moving parts or hot engine parts and/or
fluids. A hot engine and/or fluids can cause burns or
can permanently damage test equipment.
Fan Engaged
Air temperature around the sensor should be approxi
mately 85 C (185 F) for the fan to be fully engaged.
/ j \ WARNING
Always wear appropriate eye protection to prevent the
risk of eye injury due to contact with engine debris or
fluids.
Fan Disengaged
W2003339
Fig. 21: Measuring fan speed
W2003338
1
Run the engine at maximum output
RPM and measure the fan speed and
fan drive pulley speed using tool
9999795. Fan speed must not be less
than 90% o f pulley speed when the
fan is fully engaged.
9999795
Fig. 20: Using hand-held tachometer
27
28
Group 2
Service Procedures
Service Procedures
2611-03-02-01
Radiator, Replacement
/ l \ DANGER
Before working on a vehicle, set the parking brakes,
place the transm ission in neutral, and block the
wheels. Failure to do so can result in unexpected
vehicle movem ent and can cause serious personal in
ju ry or death.
/ j \ WARNING
HOT ENGINE! Keep yourself and your test equipm ent
can perm anently dam age test equipment.
/ j \ WARNING
Never remove the cap on the expansion tank while
the engine is still hot. W ait until the coolant tem pera
ture is below 50 C (120 F). Scalding steam and fluid
under pressure may escape and cause serious per
sonal injuries.
/ j \ WARNING
Fig. 22: Lifting radiator and charge air cooler assembly

Note: WG, AC
The radiator and charge air cooler are removed and
installed as an assembly. Use of a lifting strap during re
moval and installation will help to prevent dam age to the
radiator/charge air cooler assembly.
Do not w ork near the fan with the engine running. The
engine fan can engage at any tim e w ithout warning.
Anyone near the fan when it turns on could be se ri
ously injured. Before turning on the ignition, be sure
that no one is near the fan.
/ j \ WARNING
Always w ear appropriate eye protection to prevent the
fluids.
29
Group 2
Service Procedures
Removal
1
(VHD only) For removal of the
grille in a VHD model truck refer
to procedure:
TSI
8 2 0 -5 0 0
Hood, V H D
Im pact
Function Group
82
Information Type:
Repair
Hood, VHD
T25 Torx bit

8 mm wrench
Fig. 23: VN radiator
W2002077
Fig. 25: VN model- screw fasteners

(VN only)
Remove the 14 Torx screws fas
tening the grille to the hood, and
set the grille aside.
Fig. 24: VHD radiator

Im portant: Do not attempt to replace any of the compo
nents on the V N/VH D radiator, including tanks, seals, or
core.
Specialized tooling is needed to perform quality repairs
when crimping the tanks and seals to the core. There
fore, you should:
30
have the radiator repaired by an authorized radiator

service center; or
replace the complete unit.
G roup 2
Service Procedures
W2002059
Fig. 26: Drain the cooling system
W2002063
Fig. 27: Disconnect radiator hoses
/ l \ DANGER
Risk of poisoning. Coolant is toxic. Do not drink
coolant. Use proper eye and hand protection when
handling. Keep coolant out of reach from children.
Personal injury or death could result.
Drain the cooling system. Open the
drain on the bottom of the radiator and
drain into a suitable container.
N ote: On most older models, use tool
9996049 to drain radiator or engine.
W2002060
Fig. 28: Disconnect w ires/hoses for coolant sensor

D isconnect the hoses to the radiator
and the charge air cooler assembly:
Top radiator hose
Bottom radiator hose
Fill hose from the w ater pump to

the expansion tank
Top charge air cooler hose
Bottom charge air cooler hose
W ires for the low coolant sensor
10 mm socket
7 mm socket
31
Group 2
Service Procedures
W2002065
Fig. 29: Remove radiator mounts

Remove the four bolts fastening the
lower radiator mounts.
13 mm socket
W2002075
Fig. 31: Remove head screws

5
Remove the two torx head screws fastening the side shroud to the radiator.
T25 torx bit
W2002066
Fig. 32: Remove radiator fastener

Remove the one bolt that fastens the
air conditioning lines to the radiator.
W2002078
Fig. 30: Remove bolts for support bracket

Remove the two upper bolts that fasten the air conditioning condenser
upper support bracket to the charge
air cooler assembly.
Note: These bolts also m ount the up
per CAC to the radiator.
Remove the lower two bolts that fasten
the condenser itself to its lower sup
port brackets.
32
12 mm wrench
12 mm socket
13 mm wrench
12 mm wrench
Group 2
Service Procedures
W2002072
Fig. 34: Plastic tie placem ent

Using plastic ties, tie the rubber part of
the fan ring back away from the fan
shroud.
33
Group 2______________________________________________________________________________________ Service Procedures
Installation
11
W2002069
Fig. 36: R adiator removal

Fasten an acceptable lifting device to
the top of the radiator in the holes that
are provided. Lift out the radiator and
the charge air cooler assembly.
OEM 4129
/ \ CAUTION
Be careful not to dam age the radiator assem bly when
removing. Damage to the radiator and/or engine could
result in severe dam age to the engine.
W2002069
Fig. 37: Lowering radiator

Position the radiator into the truck.
Note: Be very careful when lowering
the radiator into the truck. W atch for
any hoses or w ires that m ight interfere
or be damaged. Make sure the fan
does not dam age the radiator core as
sembly.
2
Remove the lifting device from the ra
diator.
34
Group 2
S ervice Procedures
Fig. 40: Install expansion tank hoses
W2002105
Fig. 38: Install the radiator mounts

Install the upper radiator mounts and
nuts. Torque to 48 8 Nm (36 6 ftlb).
15 mm socket
48 8 Nm
(18 3 ft-lb)
Fig. 41: C onnect top hose clamps

Install all coolant hoses on the top side
of the radiator. C onnect the following:
charge air cooler hose
low coolant sensor harness
Torque the hose clamps as follows:
Fig. 39: Install the supports and ties

Install the lower radiator supports and
nuts. Torque to 24 4 Nm (18 3 ftlb).
13 mm socket
24 4 Nm
(18 3 ft-lb)
top radiator hose 5.5 0.8 Nm

(50 8 in-lb).
fill hose clam p 4 0.6 Nm (35 5
in-lb).
small bleed hose clam p 2.3 0.3
Nm (20 3 nibble)
charge air cooler hose clam p to
10 1.5 Nm (90 3 in-lb).
7 mm socket
10mm socket
screw driver
5.5 0.8 Nm
(50 8 in-lb)
4 0.6 Nm
(35 5 in-lb)
2.3 0.3 Nm
(20 3 in-lb)
10 1.5 Nm
(90 3 in-lb)
35
Group 2
Service Procedures
Fig. 42: Connect bottom hose clam ps

Install the bottom radiator hose and
the lower charge air cooler hose.
Torque the hose clam ps as follows:
bottom radiator hose clam p 5.5

0.8 Nm (50 8 in-lb).
lower charge air cooler hose
clam p 10 1.5 Nm (90 13 in-lb).
7 mm socket
10 mm socket
torque wrench
5.5 0.8 Nm
(50 8 in-lb)
10 1.5 Nm
(90 13 in-lb)
Fig. 44: Install mounting brackets
Position the condenser onto the lower
mounting brackets. Install the condenser m ounting bolts and torque to
24 4 Nm (18 3 ft-lb).
Torque the lower condenser m ounting
bracket bolts (previously hand tight) to
24 4 Nm (18 3 ft-lb).
12 mm socket
24 4 Nm
(18 3 ft-lb)
24 4 Nm
(18 3 ft-lb)
W2002066
Fig. 45: Install air conditioner line clamp

Fig. 43: Tie removal
Cut the four ties holding the rubber
shrouding away from the radiator.
36
Install the bolt supporting the air conditioner line clamp. Torque the line
clamp bolt to 24 4 Nm (18 3 ft-lb).
12mm w rench
24 4 Nm
(18 3 ft-lb)
Group 2
Service Procedures
12
10
W2002077
Fig. 48: Install grille

Install grille and torque the 14 Torx
head screws to 5 Nm (44 in-lb).
T25 Torx bit

8mm wrench
5 Nm
(44 in-lb)
13
W2002075
Fig. 46: Install head screws

Position the side shroud into place, install two torx head screws and hand
tighten.
T25 torx bit
11
W2002104
Fig. 49: Cap replacem ent

1
2
W2002058
Fig. 47: Add coolant

Add the drained coolant. Maximum fill
rate of 9.5 liter per m inute (2.5 gallons
per minute). For more detailed infor
mation on Coolants, refer to;
TSI
184-001
Coolant Require
ments, Volvo Engines
IMPACT
Function Group 184

Information Type: Ser
vice and M aintenance
C oolant R equire
m ents
Fill cap
Pressure cap (do not remove)
S tart engine and check for leaks. Run

the engine to operating tem perature.
A fter the engine has reached operat
ing tem perature, move the heater
controls to warm and run the engine
an additional 10 minutes.
14
Shut off engine and re-check coolant
level.
Note: To pressure test the system,
see Cooling System Leak Test,
C hecking page 41.
37
Group 2
Service Procedures
2611-06-02-01
Radiator, Checking
/ | \ DANGER
Before w orking on a vehicle, set the parking brakes,
vehicle m ovem ent and can cause serious personal in
ju ry or death.
/ \ WARNING
clear o f all moving parts or hot engine parts and/or
2
Check the radiator to make sure that
its external sections are not blocked by
insects or other foreign objects which
can obstruct airflow. If obstructions are
found, use a mild detergent and w ater
to clean them off. If the fins of the pipe
system have been bent (by flying
stones, etc.), straighten them out.
3
Make sure that the sealing moldings
between the fan shroud and the radia
to r are not loose or for any reason are
not providing a good seal. Check the
condition of the recirculation shield.
Also make sure it is properly installed.
2612-03-02-01
Radiator Surge Tank, Replace
ment
/ j \ WARNING
sonal injuries.
/ f \ DANGER
ju ry or death.
/ j \ WARNING
Anyone near the fan when it turns on could be seri
/ j \ WARNING
Always w ear eye protection w hen working around bat
teries to prevent the risk of injury due to contact with
sulfuric acid or an explosion.
(Checking CAC and Radiator Air Flow

Through)
1
If coolant tem peratures are higher
than normal, check the passage o f air
through the charge air cooler, A/C
condenser and radiator. Clean if nec
essary.
38
/ j \ WARNING
HOT ENGINE! Keep yourself and your te st equipm ent
can perm anently damage test equipment.
/ j \ WARNING
sonal injuries.
/ j \ WARNING
Do not w o rk near the fan with the engine running. The
Anyone near the fan w hen it turns on could be seri
Group 2
Service Procedures
/ j \ WARNING
Always w e ar appropriate eye protection to prevent the
fluids.
Removal
1
W2002060
Fig. 51: Remove expansion tank hoses

Remove the four expansion tank
hoses:
W2002059
Fig. 50: Draining the coolant system

Open the drain on the bottom of the
radiator and drain into a suitable
container. Drain coolant below the ex
pansion tank level.
12 mm socket
6 in. extension
overfill tube
fill line
air bleed hose (to therm ostat
housing)
hose from expansion tank to radi

ator top tank
Unplug the w ire harness to the low
coolant sensor.
/ j \ DANGER
Risk of poisoning. C oolant is toxic. Do not drink
coolant. Use proper eye and hand protection when
handling. Keep coolant out of reach of children. Per
sonal injury or death could result.
39
Group 2
Service Procedures
Installation
W2002062
W2002062
Fig. 52: Remove m ounting bolts
Fig. 54: Install m ounting bolts

Position the expansion tank into place
and install the five m ounting bolts.
Torque to 24 4 Nm (18 3 ft-lb).
12 mm socket
24 4 Nm
(18 3 ft-lb)
W2002060
Fig. 55: C onnect expansion tank hoses
W2002061
Fig. 53: Lift the expansion tank

Remove the expansion tank mounting
bolts (two in the front, three in the
rear). Lift away the expansion tank.
40
12 mm socket
C onnect the four expansion tank

hoses:
overfill tube
fill line
air bleed hose (to therm ostat
housing)
hose from expansion tank to radi

ator top tank
C onnect the w ire harness to the low
coolant sensor.
7 mm socket
screw driver
Group 2
Service Procedures
2619-06-02-01
Cooling System Leak Test,
Checking
/ | \ DANGER
ju ry or death.
W2002058
Fig. 56: Add coolant

Install the drained coolant. Maximum
fill rate o f 9.5 l/min (2.5 gpm).
Note: For current coolant require
ments;
Service
Bulletin
IMPACT
/ j \ WARNING
can perm anently dam age test equipm ent.
184-001
Coolant Require
ments, Volvo Engines
Function group 184
Information type:
M aintenance
C oolant R equire
m ents
7
S tart engine and check fo r leaks. Run
the engine to operating tem perature.
A fter the engine has reached operat
ing tem perature, move the heater
controls to warm and run the engine
an additional 1 0 minutes.
8
Shut off engine and recheck coolant
level.
Note: To pressure test the system,
see Cooling System Leak Test,
C hecking page 41.
/ j \ WARNING
sonal injuries.
/ j \ WARNING
/ j \ WARNING
fluids.
41
Group 2
Service Procedures
To be carried out in the vehicle
N ote: Before using pressure gauge 9996662, check its

operation. Do this by attaching it to an air supply and
setting the pressure to 100 kPa (14 psi) with the regula
tor valve.
/ f \
DANGER
Check that the pressure on the gauge never exceeds

100 kPa (14 psi). Excessive pressure may cause air
supply to burst which can cause personal injury or
death.
Procedure
Special tools: 9996049, 9996662
W2001430
Fig. 57: Remove fill cap -V N Model
1
Check the hoses and connections of
the cooling system for leaks and to
make sure they are in good w orking
condition.
W2003473
Fig. 58: Remove fill cap -V H D Model

Remove the fill cap and install
pressure regulator, gauge and cap assembly.
N ote: Make sure the cooling system
is full o f coolant before performing this
test.
42
9996662
J-4 2 3 9 7
G roup 2
Service Procedures
2621-03-02-01
Coolant Pump, Replacement
/ f \ DANGER
w heels. Failure to do so can result in unexpected
ju ry or death.
T2007258
Fig. 59: Increase pressure to 40 kPa (6 psi)

Using the knob of the reduction valve,
slow ly increase pressure to 40 kPa (6
psi). Maintain this pressure for approx
imately 5 minutes. Look over the entire
engine, radiator, and coolant hoses for
any leaks.and then perform a leakage
check on the radiator, hoses, connec
tions, and the coolant pump.
/ j \ WARNING
/ j \ WARNING
sonal injuries.
/ j \ WARNING
fluids.
Special tools: 9996049

T2007257
Fig. 60: Increase pressure to 100 kPa (14 psi)

Slowly increase the pressure to 100
kPa (14 psi) and check that the valve
opens. At this pressure, the air flow
should be continuous. End this test af
ter approxim ately 10 seconds.
5
Slowly release the pressure from the
cooling system . Remove the cap as
sem bly and replace the fill cap.
43
Group 2
Service Procedures
Removal
3
Remove the elbow outlet from the tur
bocharger.
W2003328
Fig. 63: Removing coolant pipes

Remove the pipe between the coolant
pump and the cover over the oil cooler.
W2003324
Fig. 61: Draining the coolant

Attach hose 9996049 to lower coolant
pipe and drain the coolant into a suit
able container.
9996049
5
Remove the pipe between the pump
and the therm ostat housing.
Note: If the coolant is not reusable,

dispose of used coolant in a proper
and responsible m anner according to
EPA and local environm ental regula
tions
W2003334
Fig. 62: Charge air cooler piping

Remove charge air cooler pipe and
mounting brackets.
44
Group 2
S ervice Procedures
T2007246
Fig. 65: Heater hose location
W2003329
Fig. 64: Bolt location

Remove the bolt beside the therm ostat
housing holding the pipe between
coolant pump and the expansion tank.
7
Remove the bolt from the coolant
pump and pull the pipe out o f the
pump.
Remove the heater hose from the

coolant pump.
9
Remove the drain hose from the lower
coolant pipe.
10
Note: The bolt beside the therm ostat

housing runs through a bracket on the
pipe. W ith the air com pressor in posi
tion, the pipe cannot be removed.
W2003330
Fig. 66: Lower radiator pipe location

Remove the bolts holding the lower
coolant pipe to the pump.
Note: Leave the pipe attached to the
lower radiator hose.
45
Group 2
Service Procedures
11
Remove the coolant filter hoses.
12
W2003331
Fig. 68: Installing coolant pump

W2003332
Fig. 67: Removing coolant pump
Install the new coolant pump using

new seals. Tighten the bolts to 48 8
Nm (35 6 ft-lb).
48 8 Nm
(35 6 ft-lb)
Remove the bolts and lift off the

coolant pump.
3
13
Remove the adapter for the remote
coolant filter from the bottom o f the
coolant pump.
Installation
1
Clean all sealing surfaces.
W2003330
Fig. 69: Pipe from radiator to coolant pump

Install the pipe from the radiator to the
coolant pump using a new sealing ring.
46
Group 2
S ervice Procedures
Fig. 71: Install sealing ring
T2007246
Install a new sealing ring to the pipe

from the expansion tank and bolt the
pipe to the coolant pump.
Fig. 70: H eater hose connection

Connect the heater hose to the coolant
pump and tighten the hose clamp.
8
C oat the sealing ring with soapy w ater
to make installing the pipe into the
coolant pump easier.
5
Reinstall the coolant filter.
9
6
Connect the rem ote-m ounted coolant
filter hoses to the adapter and tighten
the hose clamps.
W2003329
Fig. 72: Bolt location

Install the bolt holding the pipe beside
the therm ostat housing.
47
Group 2
Service Procedures
10
14
Fig. 75: C oolant filter

Install a new coolant filter on the
coolant pump.
W2003328
Fig. 73: Installing coolant pipe

Using new sealing rings, install the
pipe between the coolant pump and
the therm ostat housing and the pipe
between the coolant pump and the oil
cooler cover.
15
Fill the system with coolant.
16
S ta rt the engine and check the cooling
system fo r leaks.
2621-04-04-01
11
Coat the sealing rings with soapy w a
ter.
(Unit Removed)
/ f \ DANGER
12

ju ry o r death.
/ | \ WARNING
W2003334

Fig. 74: Charge air cooler piping

Reinstall the charge air cooler pipe
and mounting brackets.
13
Reinstall the elbow outlet on the tur
bocharger.
48
/ | \ WARNING
ture is below 50 C (1 2 0 F). Scalding steam and fluid
sonal injuries.
Group 2
Service Procedures
9996626, 9996883, 9996884, 9998012,

9998039, 9998113, 9996671
/ j \ WARNING
Anyone near the fan when it turns on could be se ri
/ j \ WARNING
Disassembly
1
Remove the coolant filter (11), using
filter w rench 9996671. Remove the
rear cover (10); see Fig. 76: Exploded
view of coolant pump, page 49.
9996671

fluids.
T2007116
Fig. 77: Attaching tools to coolant pump

Screw adapter 9996883 into the shaft
sleeve (2) of the coolant pump and
thread drift 9996884 onto hydraulic
cylinder 9992671; see Fig. 76: Ex
ploded view of coolant pump, page 49.
T2007117
9996883
9996884
9992671
Fig. 76: Exploded view of coolant pump

Note: Reference is made in the text to com ponent posi
tions as shown in picture.
1
Shaft
Shaft sleeve
Ball Bearing
Gear
Pump Housing
Oil Sealing Ring
Coolant Sealing Ring
Impeller
O-ring
10
Rear Cover
11
Coolant Filter
Special tools: 9992071, 9992671, 9994034,

9994090, 9996222, 9996315, 9996383,
2671
T2007118
Fig. 78: Removing the shaft

A ssem ble the hydraulic cylinder and
the adapter. U sing hydraulic pump
9996222, press out the shaft (1) the
im peller (8) and the seal (7); see Fig.
76: Exploded view of coolant pump,
page 49.
9996883
9996222
9992671
49
Group 2
Service Procedures
W2003285
Fig. 79: Coolant seal, removal

If parts of the coolant seal do not
come out with the shaft when pressing
this out, use puller 9994090 to remove
the rest of the sealing ring.
9994090
T2007109
Fig. 81: Removing shaft sleeve, drive gear and bearing

5
Place the pump housing in a press.

Using 9994034, carefully press out the
shaft sleeve (2) together with the drive
gear (4) and bearing (3); see Fig. 76:
Exploded view of coolant pum p, page
49.
T2007108
Fig. 80: Removing the oil sealing ring

Remove the seal (6) using tool
9994090; see Fig. 76: Exploded view
of coolant pum p, page 49.
50
9994090
9994034
G roup 2
Service Procedures
Cleaning and Inspection
T2007117
Fig. 83: Exploded view of coolant pump

Fig. 82: Removing the shaft sleeve from drive gear
Using 9992071 and 9996383, press
the shaft sleeve (2) out of the drive
gear (4); see Fig. 76: Exploded view of
coolant pump, page 49.
9992071
9996383
1
C lean all parts which are to be reused.
2
The seals and bearing m ust always be
changed. Check the fit o f the bearing
races to the pump housing and shaft
sleeve.
Note: If the im peller is dam aged, it
must be replaced.
Note: If the pump housing or rear
cover is to be replaced, transfer pipe
fittings to the replacem ent unit, etc.
51
Group 2
Service Procedures
Assembly
T2007112
Fig. 85: Installing bearing and shaft into pump
T2007111
Fig. 84: Installing bearing to shaft sleeve

Install the new bearing (3) to the shaft
sleeve (2) and, using hollow drift
9998012, carefully press down on the
inner race of the bearing until it lies up
against the flange o f the shaft sleeve;
see Fig. 83: Exploded view o f coolant
pump, page 51.
Note: Install the bearing with the side
at which the outer and inner races are
level facing the flange of the shaft
sleeve. The shaft (1) and the shaft
sleeve (2) are supplied as a single
spare part unit; see Fig. 83: Exploded
view o f coolant pump, page 51.
9998012
Place the pump housing (5) in a press.

Using hollow d rift 9996383, carefully
press in the bearing and shaft until the
bearing bottom s out in the pump hous
ing; see Fig. 83: Exploded view of
9996383
Note: Press on the outer race o f the

bearing and check to make sure that
the shaft does not hit the press table.
T2007119
Fig. 86: Press drive gear onto shaft

Screw the shorter threaded section o f
spindle 9996315 into the shaft sleeve
(2); see Fig. 83: Exploded view of
52
9996315
Group 2
4
Place the drive gear (4), hollow drift
9996626 and hydraulic cylinder
9992671 on the spindle and install the
nut; see Fig. 83: Exploded view of
5
Using hydraulic pump 9996222, carefully press the drive gear down until it
bottoms out against the bearing.
Service Procedures
9
9996266
9992671
9996222
6
Remove the tools
T2012620
Fig. 88: Installing the oil seal

Install the oil seal (6) with the sealing
lip against the drive gear; see Fig. 83:
Exploded view of coolant pump, page
51.
T2012619
Fig. 87: Using tool 9996315

Insert the spindle 9996315 through the
hole of sleeve 9998244 and screw the
long threaded end o f the spindle into
the shaft until it bottoms out against
the shaft. Tighten the nut by hand.
9996315
9998244
10
Using drift 9998113, carefully press
the seal into position until it is level
with the edge o f the pump housing.
9998113
Note: Do not press in the drift until it

hits the pump housing.
11
Note: Make sure that the spindle

9996315 is threaded in until it bottoms
out against the shaft before tightening
the nut.
8
Install the pump in a press so that the
spindles nut rests flat against the sur
face of the press.
T201262T m
Fig. 89: C oolant seal, applying Loc-Tite
TM
Apply Loc-Tite locking fluid to the

coolant seals contact surface (A)
against the housing.
53
G roup 2
S ervice Procedures
12
14
Press the im peller approxim ately 10
mm (1/2 in.) on to the shaft.
15
T2007262
Fig. 90: Installing the coolant seal

Carefully press in the coolant seal using the drift 9998039.
W2003286
9998039
Fig. 92: Pressing on the im peller
N ote: To prevent dam age due to ex

cessive pressing force, pressure
should be removed when the seal
flanges out against the housing.
Install the tool 9998541 on the im peller

and carefully press it down until the
tool rests against the pump housing.
16
Remove the spindle 9996315 from the
shaft sleeve.
13
17
Install the rear cover using a new Oring in the pump housing.
N ote: Turn the drive gear and check
that it rotates easily. Bearing noise or
axial play is not perm itted.
18
Install a new coolant filter. Coat the fil
te r gasket with a light film of grease
and hand tighten only.
T2007115
Fig. 91: Installing new im peller

Place the pump with the spindle nut
resting on a flat surface.
54
9998541
9996315
G roup 2
Service Procedures
2627-03-02-01
Thermostat, Replacement
D12, D12A, D12B
/ t\ danger
ju ry or death.
/ j \ WARNING
/ j \ WARNING
Never remove the cap on the expansion ta n k while
sonal injuries.
/ j \ WARNING
T2007264
Fig. 9 3 : Rem oving hoses from therm ostat housing

R em ove the expansion ta n k hose and
the connector for the tem perature sen
sor from the therm ostat housing.
4
R em ove the fan ring stay bolt holding
the upper radiator cooling pipe.
5
R em ove the bolt from the therm ostat
housing and tim ing gear cover which
hold the pipe to the cab heat ex
changer.
6
Loosen the cooling coil nut from the
air compressor. Remove the bolt hold
ing the cooling coil bracket to the
tim ing gear cover and push the coil to
one side.
/ j \ WARNING
fluids.
Special tools: 9996049 , 9998291

1
Using drain hose 9996049, drain the
coolant into suitable container.
2
R em ove the pipe between the air
cleaner housing and the turbo
compressor.
55
Group 2
Service Procedures
10
Remove retaining bolts holding "C"
shaped cooling pipe attached to rear
o f therm ostat housing.
11
T2007234
Fig. 94: Removing the upper radiator hose elbow

Remove the upper radiator hose con
necting pipe from the therm ostat
housing.
T2007235
Fig. 96: Removing the housing

8
Remove all of the coolant/air/oil lines
from the air compressor.
Remove the bolts and the therm ostat

housing.
12
T2007236
Fig. 97: Removing the therm ostat
T2007250
Fig. 95: Rotate the air com pressor

Remove the air com pressor attaching
bolts and rotate the com pressor out far
enough to allow clearance to remove
the therm ostat housing.
56
Remove the therm ostat from the ther

mostat housing.
Group 2
Service Procedures
13
16
T2007238
Fig. 98: Removing the sealing ring

Remove the sealing ring from the ther
m ostat housing by tapping with a drift
until it tips over and can be removed.
Fig. 100: Installing a new sealing ring

U sing drift 9998291, carefully tap the
sealing ring in until it bottoms out in
the housing.
14
Clean the sealing surfaces of the ther
m ostat housing and the sealing
surfaces o f the cylinder head and pipe
connections.
9998291
17
15
8291
Fig. 101: New therm ostat and seal

Install a new therm ostat and a new
seal into the housing.
Fig. 99: Installing a new sealing ring
Install a new sealing ring to drift
9998291.
Note: The sealing ring m ust be in
stalled w ith the broad metal plate
facing the ledge on the drift.
9998291
18
Rem ove the bolts holding the spacer
between the coolant pum p and the
therm ostat housing. Install a new seal
ing ring to the spacer and coat it with
grease.
57
Group 2
Service Procedures
19
23
Install the pipe between the radiator
and the therm ostat housing. Use a
new sealing ring.
24
Attach the cab heater pipe to the th e r
m ostat housing. Install a new sealing
ring.
25
Attach the fan ring stay.
26
T2007235
Fig. 102: Reattaching the therm ostat housing

Install and attach the therm ostat hous
ing to the cylinder head.
20
Push the pipe from the coolant pump
into the therm ostat housing entry and
install the bolts holding the pipe.
21
T2007264
Fig. 104: Reattaching the hoses to therm ostat housing

Plug in the tem perature sensor con
nector and attach the expansion tank
hose.
27
Fill with coolant and carry out a leak
age check.
T2007240
Fig. 103: New air com pressor seal

Install a new seal between the air
com pressor and the tim ing gear plate.
Attach the air compressor.
22
Reinstall all o f the coolant/air/oil lines
to the air compressor.
58
Group 2
Service Procedures
2627-03-02-01
Thermostat, Replacement
2
Remove the two bolts for the exhaust
collector pipe located next to the ther
m ostat housing.
D12C
/ f \
3
Remove the therm ostat housing from
the engine.
DANGER

ju ry or death.
4
Remove piston therm ostat from the
cylinder head.
/ j \ WARNING
/ j \ WARNING
sonal injuries.
W2003428
Fig. 105: Remove the sealing ring

Remove the sealing ring from the
cylinder head, tapping the sealing ring
with a drift so that it is lifted up and
can be removed.
/ j \ WARNING
D o not w ork near the fan with the engine running. The
Anyone near the fan w hen it turns on could be seri
6
Clean all the sealing surfaces and pipe
connections.
/ j \ WARNING
risk o f eye injury due to contact with engine debris or
fluids.
Special tools: 9996049, 9998619, 9998511

Other special equipment: 945408, 946173,
949873, 955894
1
Drain o ff the coolant with drain hose
9996049.
9996049
59
Group 2
Service Procedures
11
Install the therm ostat housing and
tighten the bolts by hand.
Note: Make sure that the gasket to the

cylinder head is correctly positioned.
Use a new gasket.
12
W2003427
Fig. 106: Checking that the sealing ring is correctly posi

tioned
Place a new sealing ring on drift
9998619.
9998619
Note: The ring should be turned with

the w ide plate edge facing the shoul
der of the drift.
W2003539
8
Install the therm ostat housing and
tighten the bolts by hand.
Fig. 108: Tighten the therm ostat housing bolts in the se

quence shown
Tighten the therm ostat housings bolts
in the sequence shown in the illustra
tion (1 -2 -3 ). Tighten to a torque as
per the specifications for standard
bolts.
Note: R em em ber to remove the te n

sioning bolt (M8x20).
13
Install the bolts between the exhaust
manifold and the therm ostat housing
until they push against the seal.
Tighten to the specified torque.
14
C onnect the rem aining coolant line.
W2003482
Fig. 107: T herm ostat housing remove tool

Press drift J-4 4 4 7 2 into the cylinder
head until the drift reaches the bottom
o f the cylinder head.
J-44772
15
Fill with approved coolant.
16
Start the engine.
10
Install the new piston therm ostat.
Lubricate the seal on the piston ther
m ostat with soapy water.
60
Run the engine until it is at operating

tem perature. Then run at 1800 rpm
and check for leaks.
Group 2
Service Procedures
2627-06-05-01
Thermostat, Checking
WARNING
fluids.
A function check must be carried o ut before in
stalling a new therm ostat.
Note: Check to be sure that the therm ostat closes fully.
This can be done by holding it up to the light to check
that there is no visible gap at the opening point. If the
therm ostat does not close properly, replace it.
T2007255
Fig. 110: Checking the therm ostat

Now warm the w ater to 100 C (212
F). A fter at least 30 seconds at boiling
point, check that the therm ostat has
opened at least 7 mm (9/32 in). If the
therm ostat has not opened, it must be
replaced. A good therm ostat starts to
close at 95 C (203 F) and is fully
closed at approxim ately 85 C (185
F).
T2007256
Fig. 109: Checking the therm ostat

W arm up w ater in a receptacle to 75
C (167 F) and immerse the therm o
stat in the w ater as illustrated.
Use a piece of wire attached to the
therm ostat.
2
A fter at least 30 seconds, check that
the therm ostat is still closed.
2631-03-02-01
Viscous Fan, Replacement
/ f \ DANGER
ju ry or death.
/ j \ WARNING
/ j \ WARNING
sonal injuries.
61
Group 2
Service Procedures
/ l \ WARNING
Do not work near the fan with the engine running. The
engine fan can engage at any time without warning.
/ l \ WARNING
1
Remove the charge air hose between
the charge air cooler and inlet pipe, or
where applicable, between the charge
air cooler and starting heater.
2
Remove the bolts holding the fan ring.

fluids.
(Includes removal and installation o f fan blade.)
Note: Before replacing the fan, carry out a function
check. See "Viscous Fan, Checking page 68.
Removal
W2003337
Fig. 112: Removing the fan

Using the Belt Tensioner Release Tool,
J-44392, loosen the drive belt. Re
move the fan nuts and lower the fan
carefully into the fan shroud.
Note: Some engines may have the
belt tensioner mounted on the other
side, compared to shown picture
4
Remove the studs from the fan hub
and carefully lift the fan out. Stand the
fan vertically to avoid leakage of fluid.
T2007261
Fig. 111: Proper storage of fan

The temperature controlled fan is filled with a precise
amount of silicone fluid; this determines its functional
properties. When out of the vehicle, the temperature
controlled fan must always be stood vertically. If placed
horizontally, leakage will occur and the fan will lose its
properties. Before replacing a fan, always make sure
that the new fan has not leaked fluid. If fluid has leaked
out, special instruments are required to check both en
gagement temperature and fan speed.
Special tools: J-44392

62
J -44392
G roup 2
Service Procedures
Installation
1
Place the new fan in the fan shroud.
Install the studs.
2634-03-02-01
Fan Belt Tensioner, Replace
ment
/ f \ DANGER
place the transmission in neutral, and block the
vehicle movement and can cause serious personal in
jury or death.
/ j \ WARNING
/ j \ WARNING
Fig. 113: Installing the fan
Lift the fan into position. Install and
tighten the nuts. Make sure that the
drive belt runs properly in the pulleys.
Remove the lever.
3
Install the bolts for the fan ring.
4
Install the charge air hose using new
seals.

the engine is still hot. Wait until the coolant tempera
sonal injuries.
/ j \ WARNING
/ j \ WARNING
fluids.
63
Group 2
Service Procedures
Installation
Removal
W2003336
Fig. 114: Loosening fan belt tension

1
Apply special tool J-44392, to the belt
tensioner to loosen and remove the
belt.
T2007224
Fig. 116: Installing the belt tensioner

J-4 4 3 9 2
Install the belt tensioner, making sure
that the stud in the tensioner fits cor
rectly into the hole in the timing gear
cover.
2
2
Tighten the bolt to 24 4 Nm (18 3
ft-lb) and install the cover.
3
Check that the fan belt is not damaged
and does not need to be changed be
fore installing it into the correct
grooves of the pulleys.
4
Remove the lever from the belt ten
sioner.
T2007223
Fig. 115: Removing the belt tensioner

Remove the protective cover. Remove
the bolt and the belt tensioner.
64
24 4 Nm
(18 3 ft-lb)
Group 2
Service Procedures
2634-03-02-04
Cooling Fan Drive Belt, Re
placement
4
Install the fan and bolts. Remove the
breaker bar from the belt tensioner.
2634-04-02-01
Fan Belt Tensioner, Overhaul
/ | \ DANGER
jury or death.
/ j \ WARNING
T2007253
Fig. 117: Removing the fan assembly

Remove the nuts holding the fan to the
pulley. Lift off the fan and lower it into
the fan shroud.

/ j \ WARNING

sonal injuries.
/ j \ WARNING
T2007222
Fig. 118: Loosening fan belt tension
Apply a breaker bar to the belt tensioner to loosen and remove the belt.
/ j \ WARNING
3
Install the new belt making sure that it
runs properly in the pulley grooves.

fluids.
65
Group 2
Service Procedures
Removal
T2008291
T2008723
Fig. 119: Remove belt tensioner
Fig. 121: Remove protective cover

Use a 1/2 in. drive ratchet to move the
belt tensioner to a position that will allow the fan belt to be removed from its
pulleys.
1/2 in. drive

ratchet
/ l \ WARNING
Remove the
pulley. Make
cover with a
carefully pry
protective cover from the

a hole in the protective
screwdriver or punch and
the cover off the pulley.
N ote: Make sure you do not damage

the pulley if it will be reused

fluids.
T2008724
Fig. 122: Remove center bolt

Remove the center bolt and lift off the
pulley and bearing.
T2008345
Fig. 120: Remove protective cap

Remove the protective cap from the
belt tensioner. Remove the bolt and lift
off the belt tensioner from the timing
cover.
Overhaul
3
Place the tensioner in a vice.
66
Group 2
Service Procedures
T2008724
Fig. 125: Install the pulley on the belt tensioner

Install the pulley on the belt tensioner
and tighten the center bolt. Check that
the pulley rotates easily.
10
T2008725
Fig. 123: Remove the belt tensioner

Remove the belt tensioner from the
vice. Place sleeve 9996626 under the
pulley and tap out the bearing using
drift 9994113.
9994113
9996626
7
Clean and inspect the parts.
8
T2008727
Fig. 126: Install a new protective cover

Install a new protective cover using
drift 9996383 and counter-hold
9998404. Check that the pulley rotates
easily.
9996383
9998404
Note: It is important that the counter

hold is used, otherwise there is a risk
that the bearing will not seat properly
in the pulley.
T2008726
Fig. 124: Sleeve placement in pulley

Place sleeve 9996626 under the pulley
and press on the bearing using drift
9992413. Make sure that the bearing
bottoms in the pulley.
9992413
9996626
67
Group 2
Service Procedures
2631-06-02-01
Viscous Fan, Checking
Installation
11
/?\ d a n g e r
jury or death.
Fig. 127: Install the belt tensioner

Install the belt tensioner, make sure
that the mounting bolt on the tensioner
correctly enters the hole in the timing
gear cover. Torque the mounting bolt
to 24 4 Nm (18 3 ft-lb). Install the
protective cap.
24 4 Nm
(18 3 ft-lb)
/f\ DANGER
Never work under or around a vehicle unless it is sup
ported on jack stands of adequate rating. Failure to
use adequate jack stands can result in the vehicle
falling, which can cause serious injury or death to
anyone under the vehicle.
12
/ j \ WARNING
/ t \ WARNING
Fig. 128: Adjust the belt tensioner
Use a 1/2 in. drive ratchet to move the
belt tensioner to a position that will al
low the fan belt to be installed on its
pulleys.
13
Check the fan belt, if cracks or chafing
marks are present, replace the fan
belt. Check that the belt is correctly
positioned in the grooves on the pul
leys. Remove the lever from the belt
tensioner and check fan belt tension
with Kent-Moore tool J -2 3 6 0 0 -B .
1/2 in. drive

ratchet

sonal injuries.
/ t \ WARNING
J -2 3 6 0 0 -B
/ K WARNING
Always wear eye protection when working around bat
teries to prevent the risk of injury due to contact with
sulfuric acid or an explosion.
68
Group 2
If any of the following characteristics are observed, it is

possible that the fan could be faulty. However, be sure to
go through the check list below:
1
The fan does not engage, i.e. low fan speed despite
high engine load. This will result in high coolant
temperature and thereby a drop in engine output.
2651-03-04-01
Charge Air Cooler, Replace
ment
(R adiator Rem oved)
/f\ DANGER
The fan does not disengage despite low engine load.
Check the following before m easuring fan speed:
That the radiators are not blocked by insects or

leaves etc.
Coolant level is between MIN and MAX.
Fan drive belt is not loose or cracked.
The radiator is not blocked by insects or leaves etc.
The coolant temperature gauge sensor is function

ing properly.
The cooling system is not blocked.
The fan is clean and undamaged.
Fluid has not leaked out of the fan hub.
Service Procedures
The bimetallic spring/plate of the fan is not damaged

or blocked.
Note: Operational disturbances concerning the fan can

also be due to wear in the control mechanism.
Note: If the thermostat in the cooling system is faulty,
this will also result in faulty fan operation.
Note: The fan drive or clutch is an exchange unit and
cannot be repaired since special instruments are re
quired for adjustment and checking of the engagement
temperature and speed.
Note: If fluid has leaked out of the fan drive or clutch, no
attempt must be made to refill with silicone fluid since a
precise amount of fluid is required to give the fan its
properties.

jury or death.
/ j \ WARNING
/ j \ WARNING
sonal injuries.
/ j \ WARNING
A
Note: The fan should be stored upright or to a maximum
angle of 45. If the angle is higher or if lying flat on the
ground, the silicone fluid will drain out of the fan.
WARNING

fluids.
69
Group 2______________________________________________________________________________________ Service Procedures
Removal
W2002062
Fig. 129: Remove expansion tank from radiator

Remove the five bolts fastening the
expansion tank to the radiator. Discon
nect the hose from expansion tank to
the radiator top tank. Lift off the ex
pansion tank and set aside.
12 mm socket
screwdriver
Fig. 131: Remove charge air cooler

Remove the remaining bolts fastening
the charge air cooler to the radiator,
and set the charge air cooler aside.
4
Remove the one bolt holding the over
flow tube to the radiator assembly.
013101310131013101310131
13 mm socket
12 mm wrench
12 mm socket
Fig. 130: Remove support brackets

Remove the four bolts holding the two
lower air conditioning condenser sup
port brackets to the radiator assembly.
12 mm socket
W2002126
Fig. 132: Remove head screws from shroud

Remove the eight torx head screws
fastening the shroud to the radiator,
and set the shroud aside.
70
T 30 torx bit
Group 2
Service Procedures
Installation
1
Install the overflow hose and bracket,
the top radiator hose and the bleed
hose to the radiator.
7 mm socket
screwdriver
Fig. 134: Install mounting bolts
W2002126
Fig. 133: Position the shroud into place, install head

screws
Position the shroud into place, install
eight torx head screws and hand
tighten.
Position the charge air cooler onto the

radiator. Install the four mounting bolts
leaving the upper two hand tight.
Torque the lower bolts to 24 4 Nm
(18 3 ft-lb).
13
12
24
(18
mm socket
mm wrench
4 Nm
3 ft-lb)
T 30 torx bit
4
Fig. 135: Install expansion tank bolts

Position the expansion tank into place
and install the five mounting bolts.
Torque to 24 4 Nm (18 3 ft-lb).
12mm socket
24 4 Nm
(18 3 ft-lb)
71
Group 2
Service Procedures
/ ? \ WARNING
sonal injuries.
!?!?!?!?!?E?!?!?!
/ t \ WARNING
W2002102
Fig. 136: Install support brackets

Position the air conditioning condenser
mounting brackets. Install the four
mounting bolts hand tight.
12 mm socket
3821 -06-02-01
Coolant Temperature Gauge,
Checking
/ ? \ DANGER
jury or death.
/ T \ WARNING
72
WARNING

fluids.
1
Remove the temperature sensor from
the thermostat housing and connect
the electric cable.
2
Connect a ground between the tem
perature sensor and the cylinder block.
3
Submerse the temperature sensor in
heated water.
4
Using a thermometer, measure the
temperature. Compare this reading
with the temperature gauge reading.
Group 2
Service Procedures
2611-11-04-01
Radiator, Cleaning
(Unit Removed)
/ t\ danger
jury or death.
/ j \ WARNING
/ j \ WARNING
sonal injuries.
/ j \ WARNING
/ j \ WARNING
fluids.
If you see or suspect that the cell packages of the

charge air cooler or radiator cell packages are dirty,
these components should be cleaned. Depending on the
installation, it may be necessary to completely remove
the components from the vehicle; see Radiator, Re
placement page 29.
Note: Regardless o f cleaning method, extrem e cau
tion should be observed so as not to dam age the
radiator fins.
External Cleaning
1
Separate the radiator and the charge
air cooler if they have been removed
from the vehicle as a single unit. This
ensures proper cleaning of each com
ponent.
2
Cover the inlet and outlet pipes to pre
vent degreasing agents or dirt to enter.
3
Clean the radiator with compressed air
if it is clogged with dust.
Note: Air pressure should not exceed
210 kPa (30 psi) for the radiator and
should not exceed 170 kPa (25 psi) for
the condenser.
4
When rinsing, start with the back of
the radiator and then turn it around
and rinse from the front. Use hot water
and make sure that the cells get clean.
5
Gummed up dirt can be removed by
using CALCLEAN cleaners, either in
regular or heavy-duty strength. These
cleaners can be sprayed on the cores
using a hand pump sprayer and rinsed
off. They will not harm the core materi
als.
6
In case a degreasing agent is used,
be sure to thoroughly clean plastic and
rubber parts if these get covered with
degreasing agent.
73
Group 2
S ervice Procedures
2651-11-02-01
Charge Air Cooler, Cleaning
/ j \ DANGER
jury or death.
W2003373
Fig. 137: Correct positioning of high pressure car wash.

A high pressure car wash with a max
working pressure of 100 -1 2 0 bar
(1 4 50-175 0 psi) may be used, but
with extreme caution. Make sure that
the nozzle is held perpendicular to cell
package at all times and that it is
moved from side to side. The nozzle
should always be positioned at a dis
tance of 8 -1 2 inches from the cell
package.
Note: Using a high pressure car
wash will necessitate the removal of
the radiator(s) from the vehicle in
order to correctly clean the radiator
w ith o ut the risk of dam aging the
fins with the high pressure.
8
Rinse the radiator starting with the
back and then turn it around and rinse
from the front.
/ j \ WARNING
/ j \ WARNING
sonal injuries.
/ j \ WARNING
/ j \ WARNING
fluids.
1
Remove the grille
2
Tilt the hood. Support the hood to al
low removal of the safety cables.
74
G roup 2
Service Procedures
W2000460
Fig. 138: Loosening charge air cooler clamps.
W2003523
Fig. 140: Removing A/C condenser mounting bolts on

VN model
Loosen the charge air cooler clamps

on the side of the charge air cooler.
W2003524
Fig. 141: Removing A/C condenser mounting bolts on

VHD model
Fig. 139: Unfasten A/C lines
Unfasten the A/C lines from the right
side of the radiator.
After removing the A/C condenser line

clamps and the A/C condenser mount
ing bolts, the condenser can be laid
aside.
Note: All A/C lines on the VN/VH D are
locted on the left side of the cooling
package. When removing the A/C condensor line clamps make sure not to
lossen the A/C lines.
6
Remove the clamps from the charge
air cooler hoses on both sides. Re
move the left side radiator shield.
75
Group 2
Service Procedures
7
Remove the charge air cooler.
11
Install the radiator recirculation shields
on the top, bottom and both sides of
the radiator. These shields will help
reduce the contaminations that get be
tween the components.
Note: VN/NVHD model trucks are

equipped with air deflectors mounted
on the sides of the radiator.
W2000462
Fig. 142: Direction of air pressure

Clean dirt and debris from the cores
by using air pressure. This should be
done from the backside of the core.
The use of a radiator fin comb will also
loosen dirt and debris fron the fins.
Note: The air pressure should not ex
ceed 30 psi (210kPa) for charge air
cooler core.
Note: The air pressure should not
exceed 25 psi(170 kPa) for the con
denser.
9
Hard to remove gummed up dirt can
be removed by using Calgon cleaners
CALCLEAN, either in regular or heavy
duty strengths. These cleaners can be
sprayed on the cores using a hand
pump sprayer, rinsed off and will not
harm the core materials.
10
Reassemble the charge air cooler and
condenser. Remember to install the
isolators and teflon pads on the
charge air cooler.
76
Group 2
System Check
System Check
2619-09-02-01
Cooling System, Servicing
Draining and Flushing

1
(Flush includes draining and re-filling coolant)
/ j \ DANGER
jury or death.
/ j \ DANGER
Keep coolant out of reach of children and animals.
illness or death.
/ j \ WARNING
fluids.
Note: Should the cooling system have substantial rust
and sludge deposits, the following cleaning method is
recommended:
W2000751
Draining the coolant
Drain the cooling system into suitable

container. Open all drain points. In ad
dition, remove the expansion tank cap
before draining the system.
Draining points:
Radiator
Cylinder block
Oil cooler, transmission

(when installed)
Water pump (remove water

filter and leave drain valve
open)
2
Drain the cooling and heating systems
and flush them with a good commer
cial cooling system cleaner (flush).
Follow the instructions provided on the
cleaner (flush) packaging.
77
Group 2
3
Drain the cooling and heating systems
and flush through with clean water. For
quick, efficient draining, remove the
lower and upper radiator hoses and
the drain valves. Do not forget to drain
the heater element and the engine
heater.
4
Run the engine for 1 0-1 5 minutes at
normal working temperature and then
repeat the flushing procedure.
5
The heating system must be flushed
separately with hoses disconnected to
ensure removal of any impurities left in
the system. Also remove the expan
sion tank cap. For effective cleaning,
flush the expansion tank from below
with the cap removed.
6
When the system is entirely free from
impurities, it is ready to be refilled with
new coolant, seetable page 17
7
If the system is cleaned on a regular
basis (for example, when the concen
trated coolant is drained or filled) or
when the system is relatively free from
deposits, a smaller amount of cleaner
additive or simply flushing with clean
water may be sufficient.
Note: Chemicals for cleaning the cool
ing system are not marketed by Volvo
Trucks North America and must be ob
tained elsewhere. Dispose of all
cleaner's and coolant fluids according
to local and state regulations.
78
System Check
Filling
8
The cooling system is filled through
the expansion tank. The engine must
be switched off and the heater controls
set at WARM.
9
Fill with coolant to the maximum level
on the expansion tank. The cooling
system will vent itself automatically.
10
Place shift lever in neutral and apply
parking brake.
11
After running the engine warm and
then allowing it to cool, check the
coolant level again.
Feedback
One o f our objectives is that w orkshop personnel should have access to correct and
appropriate service m anuals w here it concerns fault tracing, repairs and m aintenance
o f Volvo trucks.
In order to maintain the high standards o f o ur literature, your opinions and experience
when using this m anual would be greatly appreciated.
If you have any com m ents or suggestions, m ake a copy o f this page, w rite down your
com m ents and send them to us, either via telefax o r mailing directly to the address
listed below.
To
From
Volvo Trucks North A m erica, Inc.
.........
Dept. 516 S ervice Publications......................................................... .........

7825 National S ervice Road
.........
P.O. Box 26115......................................................................................... .........

Greensboro, NC 27402-6115
.........
USA
.........
Fax (336) 393-3170................................................................................. .........
C om m ents/proposals
Concerns S ervice Manual:
Operation Numbers
2611-03-02-01
Radiator, R e p la c e m e n t................................................................................................................ 29
2611-06-02-01
Radiator, C h e c k in g ........................................................................................................................ 38
2611-11-04-01
Radiator, C le a n in g ........................................................................................................................ 73
2612-03-02-01
Radiator Surge Tank, Replacement
2619-06-02-01
Cooling System Leak Test, C h eckin g ........................................................................................ 41
2619-09-02-01
Cooling System, S ervicing ............................................................................................................ 77
........................................................................................ 38
.................................................................................................... 43
2621-03-02-01
Coolant Pump, Replacement
2621-04-04-01
2627-03-02-01
Thermostat, R e p la c e m e n t......................................................................................................55, 59
............................................................................................................ 48
2627-06-05-01
Thermostat, C h e c k in g ....................................................................................................................61
2631-03-02-01
Viscous Fan, R e p la c e m e n t........................................................................................................61
2631-06-02-01
Viscous Fan, C h e c k in g ................................................................................................................68
2634-03-02-01
Fan Belt Tensioner, R e p la c e m e n t............................................................................................ 63
2634-03-02-04
Cooling Fan Drive Belt, Replacement
2634-04-02-01
Fan Belt Tensioner, O v e r h a u l.................................................................................................... 65
.................................................................................... 65
2651-03-04-01
Charge Air Cooler, R ep lacem en t................................................................................................ 69
2651-11-02-01
Charge Air Cooler, C le a n in g ........................................................................................................ 74
3821-06-02-01
Coolant Temperature Gauge, C h eckin g .................................................................................... 72
VOLVO
Volvo Trucks N orth A m e ric a , Inc.
P O . Box 261 15, G re e n s b o ro , N C 2 7 4 0 2 -6 1 1 5
V olvo Trucks C a n a d a , Ltd.

64 9 0 V ip o n d Drive, M ississauga, O n ta rio L 5 T 1W 8
h ttp ://w w w .v o lv o tru c k s .v o lv o .c o m
PV776-TSP142854 (1000) 8,2000 Volvo Trucks North America, Inc., 2000
VOLVO
TSI

Greensboro, NC USA

2 1 6 -0 0 3 , Rear C rankshaft Seal, D12, D12A, D12B,
D 12C (11.2001), publication no. P V776-TS P 160567.
Date
Group
No.
8.2003
216
003
Supp.
Page
1(4)
Rear Crankshaft Seal

D12, D12A, D12B, D12C
Rear Crankshaft Seal
VOLVO D12C Engine
This inform ation covers service procedures for replacing rear crankshaft seals on
VOLVO D12, D12A, D12B, and D12C engines.
Contents
C rankshaft Seal, R eplacem ent (R ear) page 3
P V 7 7 6 -T S P 1 92460
USA13823

TSI
Date
Group
No.
8.2003
216
003
Tools
Special Tools
ordered from Volvo; please use the specified p a rt num ber when ordering.
9992000
9998238
9996950
Handle
Drift
Stop Tool for Flywheel
Page
2(4)

TSI
Date
Group
No.
8.2003
216
003
Page
3(4)
Service Procedures
2167-03-03-01
Crankshaft Seal, Replacement (Rear)
(In vehicle transm ission, clutch, and flywheel
rem oved)
Safety Practices, E ngine" before performing this
Special tools: 9992000, 9998238

1
Rotate the sealing ring outward using a drift and hammer.
As the seal rotates outw ard, remove the old sealing ring
with the help o f a hook.
Removing old sealing ring
T2006662
Clean sealing ring seat

TSI
Date
8.2003
Group
216
No.
003
Page
4(4)
3
A pply clean engine oil to the edge o f the new sealing
ring and fit seal on drift 9998238. C arefully tap seal into
the flywheel housing using handle 9992000 and drift
9998238 until the drift evenly contacts the crankshaft.
N ote: Position D rift 9998238 so that it does not interfere
with the alignm ent dowel during installation.
9992000, 9998238
W2004278
Installing sealing ring
VOLVO
TSI

Greensboro, NC USA
This TSI Service Bulletin and others in Groups 21 and

33 replace TSI Service Manual 2 1 0 -6 0 0 , Basic Engine,
D12, D12A, D12B, D12C (8.2000), publication no.
P V 776-TS P 142853.
Date
Group
No.
11.2001
210
004
Supp.
Page
1(18)
Cylinder Compression
D12, D12A, D12B, D12C
Cylinder Compression
W2003244

This inform ation covers the procedure for checking cylinder com pression on VOLVO
D12 engines.
Contents
C ylinder Com pression, C hecking page 3
P V 7 7 6 -T S P 1 6 0 5 8 5
USA10311
Page 2
Tools
Special Tools
ordered from Volvo; please use the specified part num ber when ordering.
3949521
9808570
9808616
VEB Shim Kit
Brush
Handle
9988539
Compression gauge
9996956
Cranking tool
9998248
Adapter
9998249
Protection cap
9998255
9998511
Elevation tool
Lever
9998580
9999693
J-44621
Seal tool
Graphic Card (used with 9988539)
Compression Gauge Adapter Set

TSI
2103-06-02-01
Cylinder Compression, Check
ing
(W ith EPG or VEB)
/ f \ DANGER
ju ry or death.
Date
Group
No.
Page
11.2001
210
004
3(18)
Note:
engine, install all six adapters (9998248) at the same
time. This elim inates the need to remove and reinstall
the rocker arm bridge between each cylinder test. It is
also unnecessary to remove and adjust the unit injector
between each cylinder test.
Note:
their surrounding areas are clean.
Special tools: 9808570, 9808616, 9988539,

9996956, 9998248, 9998249, 9998255,
9998511, 9998580, 9998583, 9999696
1
/ j \ WARNING
/ f \ DANGER
Do not service any part of the fuel system while
smoking or in the presence of flames, sparks, or hot
surfaces. Failure to follow these precautions can result
in fire, which can cause serious injury or death.
WARNING
FIOT ENGINE! Keep yourself and your test equipm ent
Fuel leaked or spilled onto hot surfaces or electrical

com ponents can cause a fire. Clean up fuel spills im
mediately.
Clean around the drain plug in the fuel
filter bracket. C onnect a pipe to the
plug and direct the other end of the
pipe to a suitable container. Open the
plug and let the fuel in the cylinder
head drain into the container.
WARNING
Note: A diagnostic test can identify possible variations
between cylinders; refer to VCAD S Pro tool.

Note:
or the studs may loosen from the
cylinder head and damage the electri
cal installation and the valve cover.
Page 4
T2008818
D isconnect the electrical connections

from the unit injectors.
T2008813
Remove the valve cover stud located

in front of the VEB control valve.
T2008812
D isconnect the electrical connections

from the unit injectors and from the
VEB control valve. C arefully pull the
electrical installation out of the cylinder
head.
Remove the bolts from the VEB con

trol valve and then remove the valve.
Also remove the pipe between the
control valve and the rocker arm shaft.
5
Clean around the VEB control valve.
Note: Save the valve in a place free

from dust. Place a cover over the
cylinder head oil hole.
T2008814

TSI
Date
Group
112001 210
No.
Page
004
5(18)
11
Clean around the unit injectors.
12
C 2001720
Loosen the bolts in the rocker arm

shaft support uniform ly along the en
tire shaft, so that it is not strained and
risk being warped.
9
T20 12 93 2
Remove the unit injector with lever

9998511.
9998511
13
C 2001721
Remove the bolts, attach lifting tool

9998255, and raise the entire rocker
arm assembly.
Note: In engines equipped with the
VEB engine brake, fasten the rocker
pistons with a rubber band or another
suitable device to prevent the pistons
from dropping w hen the rocker arm
assem bly is lifted.
Rocker pistons are classified in pack
ages (2, 3, or 4 points are stam ped on
the rocker arm s and pistons) and
should be kept as an assembly.
10
Remove the bolts fastening the levers
o f all unit injectors.
9998255
C 2000 42 5
Install dust covers 9998249 on the unit

injector to protect them from dirt or
possible damage.
14
Use the same procedure to remove
the other unit injectors, one at a time.
Note:
support so they can easily be rein
stalled in th e ir original cylinders.
9998249
Page 6
15
T2014131
Clean the copper sleeves in the unit

injectors using tools 9808616,
9808570, and 9998580.
9808616
9808570
9998580
C2001726
Lubricate the valve bridges and

cam shaft lobes with engine oil. Using
lifting tool 9998255, install the rocker
arm bridge.
9998255
/ \ CAUTION
18
W hile cleaning the copper sleeves for the unit injec
tors, never use spatulas, steel brushes, or any other
steel objects. Do not clean the injector nozzles, as
this can dam age them or obstruct the nozzle holes,
which can reduce engine power or bind piston rings.
16
-----------------------------------------
C2000411
Install the 6 com pression test adapters

9998248 in the cylinder head.
9998248
W2003520
Fig. 2: Bearing caps and cam shaft/rocker shaft, tighten

ing sequence
/ \ CAUTION
DO NOT leave unit injector tubes opened. If not in
stalling 9998248 adapters, install 9998251 protective
plugs to protect tubes from contam inants.

TSI
Date
Group
11.2001
210 004
No.
Page
7(18)
19
Gradually tighten the bolts so that the
rocker arm shaft does not bend or
w arp (also check that the guide pins /E
correctly In the cam shaft supports).
Tighten the shaft until It lies against
the cam shaft lobes, then torquetlghten using the proper bolt sequence
(see Fig. 2: Bearing caps and
cam shaft/rocker shaft, tightening se
quence, page 7) and the following
5-step process:
D12C:
2
3
15 5 Nm
(11 4 ft-lb);
+90 5
60 5 Nm
(44 4 ft-lb)
15 5 Nm
(11 4 ft-lb);
+120 5
60 5 Nm
(44 4 ft-lb);
loosen to 0 Nm
(0 ft-lb)
15 5 Nm
(11 4 ft-lb);
+120 5
T 20 0 8 9 5 8
In VEB engines, Install the control

valve.
20
D12, D12A,
D12B:
2
3
15 5 Nm
(11 4 ft-lb);
+90 5
45 Nm
(33 ft-lb)
15 5 Nm
(11 4 ft-lb);
+90 5
45 Nm (33 ft-lb);
loosen to 0 Nm
(0 ft-lb)
15 5 Nm
(11 4 ft-lb);
+90 5
9996956'
Install Cfywheel turning tool 9996956.
21
Turn the engine to the next m arking on
the cam shaft for the valve adjustment.
9996956
Page 8
22
24
Turn the engine to the next marking on
the cam shaft for the exhaust valve ad
justm ent.
25
T 20 09 07 5
Loosen the screw in the valve bridge

until the bridge stops contacting the
valve stems. Put pressure on the valve
bridge and hand-tighten the screw to 0
lash. Turn an additional 60 and
torque-tighten the retaining nut to 38
4 Nm (28 3 ft-lb).
38 4 Nm
(28 3 ft-lb)
T 20 09 07 3
To adjust the valve bridge, use the

same procedure described for the in
take valve, but do not tighten the nut.
23
26
-rt f
W 200 21 65
Checking intake valve play with tool 9998248 in

stalled
Check the intake valve play and adjust

if the play is not w ithin specifications:
Intake valves: 0.20 0.05 mm

(0.008 0.002 in.)
Note: M ark each valve with a felt

m arker pen as you adjust them so as
to know w hich valves are already ad
justed.
Using a cotter pin removal tool or sim i

lar instrum ent, com press the coil
spring of the rocker piston.

TSI
27
Note: Be sure there is no oil on the

rocker arm preventing the piston from
reaching the end of its stroke. This
can act as a hydraulic w edge and pre
vent correct adjustment.
Group
No.
Page
112001
210
004
9(18)
28
W2003734
T2009009
W hile com pressing the coil spring,

press down /Emly on the exhaust
rocker arm. This will force out any oil
and properly seat the power piston to
its innerm ost position in the rocker
arm.
Date
Checking exhaust valve play with tool 9998248 in

stalled
Insert a feeler gauge, with the speci/6 d measure, between the valve
bridge and the rocker piston end. Turn
the piston to prevent it from tilting.
Acceptable valve clearance (play)
E xhaust
0.5 0 0 .0 5 m m (0 .0 1 9 6
0 .0 0 1 9 in.)
E x h a u s t w ith
1 .60 0.05 m m (0 .0 6 3 0.0 0 2
VEB
in.)
Note: If there is play: try with different

feeler gauges until the play disap
pears. That makes it possible to /B d
out which shim measure will be used
in step 2 9 . If unable to insert the feeler
gauge, try a thinner gauge until one
/ B or until there is no longer any play.
Page 10
32
29
T2009008
C alculate the thickness for the new

shims using "A-B" (below). A m axi
mum of two shim s may be used. (If
two shims are needed, select the
shims so they are both about the
same thickness.)
C2000183
Remove flywheel turning tool 9996956.
33
A - B = shims required
A = M e a su re d play
/ j \ CAUTION
B = S p e c ifie d play to le ra n c e
Before running the engine with the starter motor, re

move the voltage supply fuse for the engine ECU (fuse
43) to prevent the engine from starting accidentally.
Note:
intervals of 0.05 mm (0.002 in). Sizes
range from 2.0 2.4 mm (0.08
0.094 in.), and from 3.2 3.95 mm
(0.126 0.156 in.). The thickness is
stam ped on the shims.
30
Carefully clean the shims and valve
bridge. Install the shims and tighten
the adjustm ent screw lock nut to 38
4 Nm (28 3 ft-lb).
Note:
screw does not move out of position
when tightening the nut.
31
Use the sam e procedure to check the
play of the other valves.
C onnect a contact switch to the starter

motor or ask another person to help
you run the engine with the contact
switch.
38 4 Nm
(28 3 ft-lb)

TSI
Date
Group
11.2001
210 004
No.
Page
11(18)
37
34
^9988539
u
C 20 00 41 2
Fig. 3: Connecting the com pression tester to adapter

Using adapter 9998248, connect compression tester 9988539 to cylinder
num ber 1 and perform the test. Note
that com pression gauge adapter J44621 must be installed on 9998248
before connecting it to the com pres
sion tester.
Run the engine with the starter m otor
until the com pression gauge needle
stops (com pression maximum value).
W rite down the maximum value for the
cylinder compression.
9988539
9998248
C 2001721
Remove the com plete rocker arm shaft

using lifting tool 9998255.
9998255
38
Note: Do not run the starter m otor for

more than 15 seconds in tim e intervals
of 60 seconds.
35
Repeat the test for all cylinders.
Note:
than 20% below the maximum
cylinder. Make necessary repairs, if re
quired, before reassembly. Refer to
Service Information, Group 21.
Reassembly
C 2000411
Remove adapters 9998248 from all

cylinders.
39
36
Remove the bolts and remove the
VEB control valve.
C 20 00 18 3
Reinstall flywheel turning tool

9996956.
Page 12
4O
43
C2001726
Lubricate the valve bridges and

cam shaft lobes with engine oil. Using
lifting tool 9998255, install the rocker
arm assembly.
T2008956
Install new O -rings in the unit injectors.

(For D12C, choose the two thickest violet rings in the O-ring set.) Lubricate
the O-rings with clean engine oil.
Install the unit injector and align it be
tween the valve springs. Torque-tighten
the lock nut to 52 4 Nm (38 3 ft-lb).
52 4 Nm
(38 3 ft-lb)
41
Use the sam e procedure to install the
other unit injectors.
42
C onnect the wire to the unit injector
term inal. Torque-tighten the nut to 1.4
Nm (1.0 ft-lb).
1.4 Nm
(1.0 ft-lb)
/ j \ CAUTION
Do not over-tighten. Over-tightened nuts may perm a
nently dam age the unit injector.
9998255

TSI
D12C:
44
Date
Group
11.2001
210 004
2
3
D12, D12A,
D12B:
2
3
5
W 20 0 3 5 2 0
Fig. 4: Bearing caps and cam shaft/rocker shaft, tighten

ing sequence
warp (also check that the guide pins /E
correctly in the cam shaft supports).
Tighten the shaft until it lies against
the cam shaft lobes, then torquetighten using the following 5-step
torque sequence (see also Fig. 4:
Bearing caps and cam shaft/rocker
shaft, tightening sequence, page 13):
No.
15 5 Nm
(11 4 ft-lb);
+90 5
60 5 Nm
(44 4 ft-lb)
15 5 Nm
(11 4 ft-lb);
+120 5
60 5 Nm
(44 4 ft-lb);
loosen to 0 Nm
(0 ft-lb)
15 5 Nm
(11 4 ft-lb);
+120 5
15 5 Nm
(11 4 ft-lb);
+90 5
45 Nm
(33 ft-lb)
15 5 Nm
(11 4 ft-lb);
+90 5
45 Nm (33 ft-lb);
loosen to 0 Nm
(0 ft-lb)
15 5 Nm
(11 4 ft-lb);
+90 5
45
Remove the rubber bands holding the
VEB rocker pistons.
Page
13(18)
Page 14
47
46
T2009070
Thoroughly clean the VEB control

valve pipe. Lubricate the rocker arm
shaft hole. Using a 1/2inch extension
and a socket, connect the pipe to the
socket and install a new sealing ring
on the other end of the pipe. Connect
the pipe to the rocker shaft and check
that the seal ring is properly posi
tioned.
T2008958
Install a sealing ring to the pipe and

install the VEB control valve.
Note: Check that the cylinder head oil
channel cover has been removed.
Note:
the VEB control valve and the engine
cylinder head. Check that the ring is
properly positioned before tightening
the bolts for the VEB control valve.

TSI
48
Date
Group
11.2001
210 004
No.
51
To set the play to zero in the valve
bridge, loosen the bolt until valve
bridge stops contacting the valve
stems. Then, hand-tighten the bolt un
til it contacts the support. Turn the bolt
an additional 60 and torque-tighten
the bolt nut to 38 4 Nm (28 3 ft-lb).
Page
15(18)
38 4 Nm
(28 3 ft-lb)
52
T 20 08 96 0
Connect the electrical installation for

the VEB solenoid valve to the control
valve and carefully tighten the term i
nals so that the valve is not damaged.
T20 08 96 8
Adjust the correct intake valve play:
Intake valves: 0.15 - 0.25 mm

(0.006 - 0.010 in.)
49
Note:
m arker pen as you adjust them so as
to know which valves are already ad
justed.
53
T 20 08 95 9
Install the stud in front o f the VEB con

trol valve.
Note: Use loctite to lock the thread.
T 20 08 84 5
50
Turn the engine until the next marking
on the cam shaft for the valve adjust
ment.
Adjust the rocker arm for the unit inje cto r until the play in the cam shaft is
zero. Turn the adjusting bolt 3 or 4
flats and then torque-tighten to 52 4
Nm (38 3 ft-lb).
52 4 Nm
(38 3 ft-lb)
Page 16
54
Use the same procedure to adjust the
other unit injectors.
58
55
Turn the engine until the next marking
on the cam shaft for the exhaust valve
adjustment.
56
T 20 09 00 9
W hile com pressing the coil spring,

press down /Emly on the exhaust
rocker arm. This will force out any oil
and properly seat the power piston to
its innerm ost position in the rocker
arm.
Note: Be sure there is no oil on the
rocker arm preventing the piston from
reaching the end of its stroke. This
can act as a hydraulic w edge and pre
vent correct adjustment.
T 20 09 07 3
To adjust the valve bridge, use the

same procedure described for the in
take valve, but do not tighten the nut.
57
irf f-
W 2 00 21 65
Using a cotter pin removal tool or sim i

lar instrum ent, com press the coil
spring of the rocker piston.

TSI
Date
Group
11.2001
210 004
No.
59
B0
Insert a feeler gauge, with the speci

fied measure, between the valve
bridge and the rocker piston end. Turn
the piston to prevent it from tilting.
C alculate the thickness for the new

shim s using "A-B" (below). A m axi
mum o f two shim s may be used. (If
tw o shim s are needed, select the
shim s so they are both about the
same thickness.)
Page
17(18)
T2009008
T2008966
Acceptable valve clearance (play)
A - B = shim s required
E xh a u st
A = M e a s u re d play
0.50 0.05 m m (0 .0 1 9 6
0 .0 0 1 9 In.)
E xh a u st w ith
1.60 0.05 m m (0.063 0.002
VEB
In.)
Note: If there is play: try with different

feeler gauges until the play disap
pears. That makes it possible to find
out which shim m easure will be used
in step 6 0 . If unable to insert the feeler
gauge, try a thinner gauge until one
fits or until there is no longer any play.
B = S p e c ifie d play to le ra n c e
Note:
intervals of 0.05 mm (0.002 in). Sizes
range from 2.0 2.4 mm (0.08
0.094 in.), and from 3.2 3.95 mm
(0.126 0.156 in.). The thickness is
stam ped on the shims.
61
Carefully clean the shim s and valve
bridge. Install the shims and tighten
the adjustm ent screw lock nut to 38
4 Nm (28 3 ft-lb).
Note: Make sure that the adjustm ent
screw does not move out of position
when tightening the nut.
62
Use the same procedure to check the
play of the other valves and unit injec
tors.
63
Install the engine ECU fuse.
38 4 Nm
(28 3 ft-lb)
Page 18
64
66
T 20 12 84 5
Install the valve cover and torquetlghten the bolts to 20 2 Nm (15 1

ft-lb) following the sequence shown.
T 20 12 79 7
Connect the hose to the air drain nip

ple on the cylinder head front and
drain the air by pumping fuel with the
manual pump until the fuel com es out
with no air bubbles through the hose.
Tighten the air drain nipple, remove
the hose, and place the protection cap
on the nipple.
Note: Check that the nut (Zfenges and

rubber rings properly /E th e valve
cover holes to avoid dam age to the
valve cover.
65
67
Start the engine and keep It running at
Idling speed for approxim ately 10 min
utes to purge any air remaining In the
fuel system. Check the seals In all fuel
pipe connections.
T 20 12 93 4
Connect a hose to the air bleed nipple

In the fuel /H er bracket. Open the
drain plug and pump fuel with the
manual pump until the fuel comes out
with no air bubbles through the hose.
Tighten the drain plug In the fuel /H er
bracket, remove the hose, and place
the protection cap on the drain plug.
68
Check that the engine reaches the
normal operating tem perature and let
It run for another 5 m inutes at Idling
speed. W hen the Idle speed stabilizes,
the cylinder balancing Is /B ished and
the correct am ount of fuel the unit In
je cto r should Inject In each cylinder Is
de/Eed.
Note:
consum ption components, such as
power take-off, air conditioning, etc., to
allow the cylinder balancing to occur.
Service Manual
Trucks
Group
230600
Fuel System
D12, D12A, D12B, D12C
PV776-TSP142867
VOLVO
Foreword
D ocum entation:
C aution: Indicates an unsafe practice w here damage to the product could occur.
W arning: Indicates an unsafe practice w here personal injury or severe damage to the
cur.

Greensboro, NC USA
Order number: PV776-TSP142867

Contents
General ................................................................................................................... 3
Specifications ...................................................................................................... 5
Fuel System ......................................................................................................... 5
Fuel Supply Pump and Overflow Valve ...................................................... 5
Fuel Supply Pressure ................................................................................... 5
O verflow Valve ............................................................................................... 5
Identifying 450 kPa (65 psi) Fuel System Com ponents
.......................6
Tools ........................................................................................................................ 7
Special Tools
...................................................................................................... 7

Fuel System ...................................................................................................... 11
Fuel Line O-Rings
Unit Injectors
........................................................................................ 12
.................................................................................................. 13
Injector Operational Phases ..................................................................... 14

D12A
............................................................................................................. 18
D12B
............................................................................................................. 18
D12C
............................................................................................................. 18
Fuel Flow ......................................................................................................... 19

D12A
............................................................................................................. 19
D12B
............................................................................................................... 20
D12C
............................................................................................................... 21
Fuel Filter ......................................................................................................... 22

D12C
............................................................................................................... 22
Overflow Valve ................................................................................................. 23

D12C
............................................................................................................... 23
Fuel Feed Pump ..............................................................................................24

Fuel Feed Pump R eplacem ent .................................................................25
Hand P rim er .................................................................................................. 26
Engine Electronic Control Unit (EECU) ....................................................... 26
Troubleshooting
................................................................................................. 27
Fuel System, Fault Tracing ............................................................................. 27

Fault Codes ...................................................................................................... 27
Unit Injector Troubleshooting .......................................................................... 27
Read and Docum ent Fault Codes .............................................................. 27
Troubleshooting Flow Path
........................................................................... 29
Active fault codes ......................................................................................... 29

Inactive fault codes with high counts ...................................................... 29
Unit Injector Mechanical Faults ................................................................... 32
1. Active code or misfiring occur imm ediately after start-up
2. Active code at normal operating tem perature and high idle
3. Active code and misfiring at BASE IDLE ONLY
........... 32
..........32
.................... 33
Locating A ir in the Fuel System .................................................................. 34

Determ ining W hether There is A ir in the Fuel ........................................ 35
Determ ining w hich C ylinder is Introducing A ir into the Fuel ................41
Service Procedures
.......................................................................................... 43
General W ork Practices

Clamping the Fuel Lines
.................................................................................. 43
...............................................................................44
Turning the Engine Over with the S tarter M otor .....................................44

Fuel System Pressure, Checking ..................................................................45
Fuel System, Draining ......................................................................................47
1
Fuel System, Bleeding
.................................................................................... 50
Fuel Feed Pump, R eplacem ent ..................................................................... 52

D12, D12A, D12B .......................................................................................... 52
Fuel Feed Pump, R eplacem ent ..................................................................... 53
D12C
................................................................................................................ 53
Types ............................................................................................................. 54
Removal
Installation
....................................................................................................... 54
.................................................................................................... 55
H and-Prim er Pump, Replacem ent
................................................................56
Fuel Filter, R eplacem ent ............................................................................... 57

Overflow Valve, Checking .............................................................................. 59
D12, D12A, D12B ......................................................................................... 59
Overflow Valve, R eplacem ent .........................................................................60
D12, D12A, D12B ......................................................................................... 60
Overflow Valve, R eplacem ent .........................................................................62
D12C
..................................................................................................................62
Unit Injector, R eplacem ent (O ne) ..................................................................63

Unit Injector, Adjustm ent
................................................................................. 67
Unit Injector C opper Sleeve, R eplacem ent ................................................ 69

Feedback
Operation Numbers
G roup 23 Fuel System, D12, D12A, D12B, D12C__________________
General
General
W2003244
This inform ation covers the fuel system of the Volvo D12 engine and includes engine
versions D12, D12A, D12B, and D12C.
Group 23 Fuel System, D12, D12A, D12B, D12C
Specifications
Specifications
Fuel System
C om ponent
Nm
ft-lb
R etainer bolt
unit injector w / N EW COPPER SLEEVE
First tightening
Step 1
20 5
15 4
First tightening
Step 2
Turn an additional 180 5
Loosen the retainer bolt for the unit injector prior to the second tightening.
Second tightening
Step 1
20 5
Second tightening
Step 2
C om ponent
15 4
Nm
ft-lb
R etainer bolt
unit injector w / OLD COPPER SLEEVE
Step 1
20 5
Step 2
15 4
Fuel Supply Pump and Overflow Valve

Fuel Supply Pressure
Engine num ber ................................................................................................
up to 98799
from 98800
Minimum supply pressure at full load
250 kPa
(36 psi)
350 kPa
(51 psi)
Engine num ber ................................................................................................
up to 98799
from 98800
Opening pressure
300-350 kPa
(44-51 psi)
340-450 kPa
(50-65 psi)
........................................................
Overflow Valve
...........................................................................................
Specifications
Identifying 450 kPa (65 psi) Fuel System Components
W2003117
Fig. 1: Fuel System Com ponents

1
2
350 kPa (51 psi) overflow valve*

New 450 kPa (65 psi) overflow valve can be identified by the groove cut into the hex portion of the valve as
shown above.*
3 350 kPa (51 psi) fuel pump.
4 New 450 kPa (65 psi) fuel pump can be identified by the additional web in the casting as shown above.
(*D12A/B location shown.)
Im portant: W hen changing an overflow valve to the new
450 kPa (65 psi) bar version, the fuel pump m ust also be
changed to the 450 kPa (65 psi) version. However, when
changing a fuel supply pump to the 450 kPa (65 psi) ver
sion, you are not required to change the overflow valve.
W2003394
Fig. 2: O verflow valve location, D12C
Tools
Tools
Special Tools
The following special tools are used to replace o r repair components. The tools can be
ordered from Volvo Parts North A m erica; please use the specified part num ber when
ordering. Tools with part num bers beginning with J are available directly from KentMoore (telephone: 1 -8 0 0 -3 2 8 -6 6 5 7 ).
9996390
Drift indicator extension for setting electronic unit injector
9996534
Gauge for checking fuel feed pressure
9996662
Pressure gauge
9996666
Union for checking fuel feed pressure
9996671
Fuel filter removal tool
9996956
Cranking tool for flywheel
9998249
Protective sleeve for electronic unit injector
9998250
Sealing rings for the fuel gallery (2)
9998251
Sealing plug for cylinder head
9998277
Union for draining fuel system
9812546
Cleaning brush
J-41603
Socket
J-41196
Dial indicator
Tools
W0001802
9998511
Lever tool
W2003530
9998599
Cleaning kit
1
2
3
4
5
6
7
W0001837
J-44515
Fuel vacuum tool
J-42885-25
Injector bore protecting sleeve
W2003529
9808614
9808615
9808613
9808616
J-42885-25
sleeve
9808617
9808618
brush
holder
holder
handle
protecting
brush
brush
Group 23 Fuel System, D12, D12A, D12B, D12C______________________________________________________________Tools
Special Equipment
Like the special tools, the following equipm ent will aid in servicing the D12 engine.
W hen ordering equipm ent, specify the appropriate number.
1159794
Torque wrench, 10 - 100 Nm (7 70 ft-lb)
W0000399
MT302A
SNAP-ON Remote Starter Cable

Switch
10
Design and Function
Design and Function

Fuel System
W2003243
Fig. 3: Fuel system, D12C

The Volvo D12 is an electronic engine designed to meet
todays high environmental standards. Meeting these
standards requires optim um combustion. This demands,
among other things, injecting the exact am ount of fuel
into the com bustion cham ber under very high pressure,
at precisely the correct time, depending on engine
speed, load, tem perature and other conditions.
Because totally m echanical injection system s cannot
meet these demands, the engine is equipped with an
electronically controlled injection system . An engine
electronic control unit (EECU) receives im pulses from
the accelerator pedal and a num ber of sensors on the
engine. The sensors read signals which govern the injec
tion procedure and send these signals to the EECU. The
fuel system has a built-in diagnostic system, which elec
tronically detects and traces any faults in the system.
Each cylinder has four valves. Individual differences
always occur between the cylinders in an internal com
bustion engine. The engine has a cylinder balancing
system, the purpose of which is to even out the am ounts
of fuel between the cylinders. C ylinder balancing takes
place with the engine running at idle speed, providing
certain preconditions have been met.
11
Group 23 Fuel System, D12, D12A, D12B, D12C_______________________________________________ Design and Function
Fuel Line O-Rings
W2002168
Fig. 4: Removing fuel lines
W2002169
Fig. 5: Fuel line O-ring locations

1
2
12
976020
955984
G roup 23 Fuel System, D12, D12A, D12B, D12C
Design and Function
Unit Injectors
The fuel injection system of the D12 engine uses
electronically-governed unit injectors that are electrically
activated and m echanically driven via roller rocker arms
from the cam shaft lobe. They are vertically located In the
center between the four valves In the cylinder head for
each cylinder.
The electronic unit Injector (EUI) com bines an Injection
pump and an Injector. An EUI can operate at considerably higher Injection pressure than a conventional
Injector. The EUI consists of three main com ponents:
P u m p containing a cylinder and piston; this corre

sponds to the pump assem bly In an Injection pump.
In je c to r with nozzle body, nozzle needle and spring.
V alve h o u s in g with an electro-m agnetlcally con

trolled fuel valve.
<
The upper part of the electronic unit Injector, which In

cludes the com pression spring and valve housing, lies
above the cylinder head.
The center part of the electronic unit Injector, w here the
Intake and outlet holes for the fuel are located, lies In the
cylinder head fuel gallery. The electronic unit Injector
takes In fuel directly from the fuel gallery.
T2006848
The lower part of the EUI is located in a copper sleeve

against the bottom of the cylinder head, sim ilar to a
standard injector.
The EECU calculates injection tim ing and the am ount of
fuel to inject into the cylinder and transm its signals to the
electrom agnetically controlled fuel valve in the valve
housing. The length of the injection tim e determ ines the
am ount of fuel injected into the cylinder.
Fig. 6: Electronic unit injector (EUI)
2
3
Pump part
Injector part
Valve housing
13
Design and Function
Injector Operational Phases

Fill Phase
During the filling phase, the pump plunger (2) is on its
way up, the cam shaft lobe is passing its highest point,
and the rocker arm is on its way toward the cam shaft ba
sic circle.
The fuel valve (1) is open, allowing fuel to flow into the
EUI from the lower fuel gallery (4). It flows into the cylin
der head and the EUI pump cylinder. Filling continues
until the pump plunger reaches its upper position.
Fig. 7: Filling phase

1
2
3
4
14
Fuel valve
Pump plunger
Fuel outlet (overflow)
Fuel gallery (inlet and outlet)
Design and Function
Spill Phase
The spill phase begins when the cam shaft turns to the
position at which the cam shaft lobe forces the rocker
arm to push the pump plunger (2) down.
The fuel can now flow through the fuel valve (1), through
the holes in the EUI and out through the fuel gallery (4).
The spill phase continues as long as the fuel valve (1) is
open.
Fig. 8: Spill phase

1
2
3
4
Fuel valve
Pump plunger
15
Design and Function
Injection Phase
The injection phase begins when the fuel valve (1)
closes. The cam shaft lobe and rocker arm continue to
press down the pump plunger (2) and injection occurs as
the route through the fuel valve closes. The injection
phase continues as long as the fuel valve (1) is closed.
T2006815
Fig. 9: Injection phase

1
2
3
4
16
Fuel valve
Pump plunger
Design and Function
Pressure Drop Phase

The injection phase ends when the fuel valve (1) opens
and pressure in the EUI drops below the nozzle opening
pressure. The fuel flows through the open fuel valve (1),
through the electronic unit injector holes and out through
the fuel gallery (4). Note that the fuel valve position
(closed or open) determ ines when the injection phase
begins and ends. The tim e during which the fuel valve is
closed determ ines the am ount of fuel injected at each
pump stroke.
T2006816
Fig. 10: Pressure drop phase

1
2
3
4
Fuel valve
Pump plunger
17
D12A
One unit injector is used for the 345, 385, and 425
horsepower variants. The spray angle has been m odi
fied. These injectors are NOT interchangeable with the
D12 injectors.
D12B
The unit injectors on the D12B have a longer pum p
stroke length than earlier injectors on the D12A. They
are not interchangeable with other engine versions.
The engine electronic control unit (EECU) receives sig
nals both from the engine's own sensors and from the
vehicle control unit. The EECU then controls the unit in
jectors and determ ines the tim ing of the injection as well
as the am ount of fuel to be injected into the cylinders.
W ith the adaptation to the new vehicle electronics, the
throttle position sensor signal on the D12B is now linked
to the engine control unit via the vehicle control unit.
CAUTION
Using incorrect injectors (i.e. D12A injectors in a
D12B engine) can cause engine dam age and/or poor
performance. Injector identification can only be made
using the injector part num ber located on the injector
solenoid valve.
D12C
The D12C has new unit injectors, with 17 mm pump
stroke and higher injection pressure. The injector noz
zles are new, and have a different orifice pattern.
Unlike the D12A and D12B engines, the D12C cylinder
head only has one fuel galley for the unit injectors. This
m eans that only tw o sealing rings are needed for each
unit injector (the D12A and D12B use three rings).
Fuel enters at the rear of the cylinder head and exits out
the front.
18
Design and Function
Design and Function
Fuel Flow
D12A
Fig. 12: Fuel flow, D12A

1
2
3
4
Fuel feed pump

Engine electronic control unit (EECU)
Bleed line
Fuel gallery
5
6
7
8
Electronic unit injector (EUI)

Overflow valve
Fuel tank
Fuel filter
The fuel feed pump (1) is mounted on the tim ing gear
plate and driven through a recess in the pump shaft by
the engine tim ing gears. It picks up fuel from the fuel tank
(7) through the fuel system EECU (2). Return fuel from
the cylinder head is also routed into the fuel feed pump.
A bleed line (3) goes from the fuel feed pump back to
the fuel tank, and is designed to continuously bleed the
system. From the fuel feed pump, fuel first passes
through the filter (8) and then into the cylinder head fuel
gallery (4). The fuel gallery surrounds the part of the EUI
(5) w here the fuel holes are placed. The system overflow
valve (6) is located in the fuel gallery outlet connection.
Leak-off fuel flows from the EUI back to the fuel gallery,
elim inating the need for an external fuel return.
19
Design and Function
D12B
Unlike the D12A, the EECU on th e D12B is fitted with
an external fuel cooling coil.
Fig. 13: D12B, Fuel flow

Supply pump
EECU
Bleed line
4
5
Fuel gallery
Unit injector
The fuel system 's supply pump (1) is attached to the tim
ing gear plate and is driven via a groove in the pump
shaft from the engine's tim ing gears.
The supply pump pulls fuel from the ta n k (7) through the
EECU's cooling coil, which cools the EECU. The return
fuel from the cylinder head is then blended with this fuel
and enters the supply pump. From the supply pump (1),
a bleed line (3) leads back to the fuel tank to provide
continuous venting for the system.
With the bleed line (3) as the only return line to the tank,
the only fuel passing through the EECU's cooling coil is
the am ount consumed by the engine.
From the supply pump (1), the fuel is forced through the
fuel filter (8) and then into the cylinder head fuel gallery
(4). The fuel gallery is designed so that it surrounds that
part o f the unit injectors (5) where the fuel holes are lo
cated.
The system 's overflow valve (6) is located in the fuel
gallery's outlet connection. The overflow valve regulates
the fuel system 's supply pressure. All fuel that exits the
overflow valve (leak-off fuel) is then blended with the fuel
entering the supply pump.
20
Overflow valve
Fuel tank
Fuel filter
Design and Function
D12C
W2003243
Fig. 14: External fuel line installation and fuel flow, D12C.
1
Bypass valve
Fuel passage in cylinder head
The D12C uses a fuel line through the cylinder head.

The bypass valve is also located toward the front o f the
cylinder head.
21
Design and Function
Fuel Filter
The system is equipped with a large fuel filter located on
the left-hand side of the engine. The filter insert consists
of a special corrugated filter paper with a high resistance
to w ater and very good filtering properties. In addition, a
fine-gauge net filter on the fuel suction line in the fuel
tank separates any possible solid impurities before the
fuel is pumped up into the system.
Fig. 15: Fuel filter

1
2
Drain nipple
Bleed nipple
D12C
The D 12C uses a new fuel filter base, with hand pump
mounted directly on the base.
The base has a port for a fuel pressure sensor.
T2012783
Fig. 16: Fuel Filter, D12C
22
Design and Function
Overflow Valve
The overflow valve, located in the outlet from the cylinder
head fuel gallery, regulates the fuel system feed pres
sure. Opening pressure is about 345 kPa (50 psi). The
high feed pressure ensures that the injectors are filled
with fuel.
W2000681
Fig. 17: Overflow Valve Location, D12A/B
D12C
The D12C has a new overflow valve. The valve is inte
grated with the hollow screw in the fuel outlet at the front
of the cylinder head.
T2012784
Fig. 18: Overflow Valve, D12C
W2003527
Fig. 19: Overflow Valve location, D12C
23
Design and Function
Fuel Feed Pump

The capacity of the pump has been adapted to give the
correct pressure and flow to the EUI. Filling the EUIs re
quires relatively high pressure. The flow must be large
enough to even out any fuel tem perature differences in
the cylinder head fuel gallery.
T2006725
Fig. 20: Fuel Feed Pum p
24
Design and Function
Fuel Feed Pump Replacement
Fig. 21: A = Radial Play

W hen replacing a D12 fuel supply pump for any reason,
the accessory drive m ust also be inspected. There
should be no radial or axial play in the accessory drive
shaft. Radial play is m ovem ent parallel (side to side) to
the face of the pulley. Do not confuse with backlash
which is measured by turning the pulley. Axial play is
m ovem ent perpendicular (in and out) to the face of the
pulley. Release the tension on the alternator and fan
belts before checking. This test is done by sim ply at
tem pting to move the accessory drive pulley by hand.
CAUTION
Radial or axial play in the accessory drive shaft may

cause prem ature failure o f the fuel feed pump.
25
Design and Function
Hand Primer
The hand prim er is situated on the fuel filter bracket. It is
used to pump the fuel and bleed the system when the
engine is not running.
Fig. 22: Hand prim er
Engine Electronic Control Unit (EECU)

The electronic control module is the central part of the
injection system. It is located on the left-hand side of the
engine. The EECU receives continuous inform ation from
the accelerator pedal and from several sensors on the
engine. It calculates the am ount and the tim e to inject
fuel into the cylinders. Electrical wiring to the EUI fuel
valves transm its control signals to the injectors.
The EECU uses the flywheel sensor to monitor engine
rotation and engine speed variations during a revolution.
This allows the EECU to ensure that each EUI receives
exactly the correct am ount of fuel. The EECU stores in
form ation when a fault occurs or if som ething in the
system is abnorm al. Occassional faults are also stored
and can be traced at a later stage.
For information about the EECU, EECU sensors, and
their functions, refer to:
Service
Inform ation
2 8 0 -6 0 0
Control Systems, D12
IMPACT
Function Group: 284

Information Type: Design and Function
S ensors
26
Troubleshooting
Troubleshooting
Fuel System, Fault Tracing
C orrect fault diagnosis is essential to accurate engine re
pair. The complex design of the engine (that is, with a
cylinder head that covers all the cylinders, overhead
g e a rw he el-drive n camshaft, and EUI) makes the cylin
der head removal on the D12 a com prehensive w ork
operation. Fault tracing in the fuel system requires thor
ough knowledge on how the system functions, as one
does not have the opportunity as with a conventional fuel
system of seeing and checking directly on the engine.
As the EECU receives all the information electronically
from the different sensors, the EECU must gather all the
inform ation when the engine is started and then check
that the inform ation is correct. This means the D12 en
gine does not start on the first crankshaft revolution, but
requires two revolutions in order for the control unit to set
the correct values. It is im portant that the starter motor
revolutions are not too slow, as slow starter m otor speed
is interpreted by the control unit that the crankshaft does
not rotate and, as a result, the injector fuel valves do not
receive the appropriate signals to release fuel.
The crankshaft must rotate at a minim um of 75 rpm to
ensure that the engine starts. To facilitate fault tracing in
the fuel system, D12 is equipped with a diagnostic sys
tem w hich makes it possible to localize faults in the fuel
system w ithout having to perform extensive dismantling
work.
W ith the fault codes stored in the control unit, it is possi
ble, through the diagnostic system, to quickly establish
w hich fault or faults have occurred.
Fault Codes
It is im portant to delete a fault code from the diagnostic
system after the fault code has been corrected and be
fore the truck leaves the w orkshop. Fault codes
remain in the system until they are removed. They
do not autom atically clear w hen the fault has been
corrected.
Unit Injector Troubleshooting

The following information will aid in troubleshooting of
Electronic Unit Injector (EUI) fault codes.
Read and Document Fault Codes

C onnect the MPSI tool to the vehicle's diagnostic con
nector to determ ine w hether any active or inactive fault
codes are set. Docum ent all set fault codes below:
27
Code #
Occurred counts
Active/Inactive
Troubleshooting
PID
SID
FMI
Description ..................................................................................................................................................................................................
Code #
Occurred counts
Active/Inactive
PID
SID
FMI
Description ..................................................................................................................................................................................................
Code #
Occurred counts
Active/Inactive
PID
SID
FMI
Description ..................................................................................................................................................................................................
Code #
Occurred counts
Active/Inactive
PID
SID
FMI
Description ..................................................................................................................................................................................................
28
Troubleshooting
Troubleshooting Flow Path

Active fault codes
Troubleshoot the active fault codes first.
Inactive fault codes with high counts

If inactive fault codes are recorded, follow the trou
bleshooting path for that same active code. This should
be done; however, only when there is a driver com plaint
in conjunction with the inactive fault code.
29
30
Troubleshooting
Troubleshooting
31
Troubleshooting
Unit Injector Mechanical Faults

Note: A m echanical fault indicates low perform ance of
that cylinder, not just the injector.
Determ ine the correct troubleshooting flow path.
Fault codes: 31, 32, 33, 34, 35, 36.
1. Active code or misfiring occur immediately after start-up

Cause
C orrective action
Incorrect valve or injector adjustm ent
Check the valve and injector adjustm ent as required.
Injector problem
Perform cylinder balancing or manual com pression test

before replacing the injector; refer to appropriate ser
vice literature or diagnostics checklists for information.
Base engine problem
Visual inspection of the cam shaft and high crankcase

pressure. Perform cylinder balancing or manual com
pression test before replacing the injector for piston
and valve condition. Repair as required.
2. Active code at normal operating temperature and high idle

Cause
C orrective action
Incorrect valve or injector adjustm ent
Check the valve and injector adjustm ent as required.
Poor quality fuel or excessive fuel additives
Test with auxiliary fuel and retest.
Aeration
Check for fuel restriction, air or com pression intro

duced into the fuel system and repair as required.
Injector problem
Perform cylinder balancing test or manual com pres

sion test. If w ithin specifications, replace injector.
Base engine problem
Visual inspection of cam shaft and high crankcase

pressure. Perform cylinder balancing or manual com
pression test before replacing injector for piston and
valve condition. Repair as required.
32
Troubleshooting
3. Active code and misfiring at BASE IDLE ONLY

Cause
Incorrect cam shaft to crankshaft static tim ing
C orrective action
Refer to C am shaft Tim ing procedure, Group 21.
If the answer to any o f the following is yes, static tim ing may be the cause o f the fault.
Have previous repairs been made to the engine that required removing the cam shaft?
Can you clear the fault code, unplug the cam shaft sensor, start the engine, and the fault code does not return?
Can you clear the fault code, start the engine, set the idle above the base idle, and the fault code does not return?
33
Locating Air in the Fuel System

A ir in the fuel being supplied to the engine can cause a
num ber of problems including hard starting, poor perfor
mance, and excessive smoke. A ir can enter the fuel
system at several points:
suction side fuel supply lines

pick-up in the fuel tank
prim ary fuel filter
copper sleeve to injector seat
injector tip
fuel supply pump seals
Locating the point o f entry can be troublesom e and time

consuming. A kit has been developed to aid in this
process. The kit (J-4 2 7 5 3) consists of:
34
two fuel line sight glass assemblies

two transparent hose assemblies
a clamp
a washer
a hollow screw
copper gaskets
O-rings
Troubleshooting
Troubleshooting
Determining Whether There is Air

in the Fuel
/ | \ DANGER
ju ry or death.
/ ? \ danger
in fire, w hich can cause serious injury or death.
/ j \ WARNING
/ j \ CAUTION
A fter using the fuel aeration test kit, thoroughly drain
all remaining fuel from the te st hoses, then install
plugs, end caps and washers. This will prevent
accidental spillage w hich could result in fuel contam i
nation.
35
Fig. 23: D12, D12A Fuel System Diagram with Fuel Line Kit Installed
1
2
3
4
5
36
3/8 in. I.D. Transparent Suction Hose/Alternate Fuel Supply

Sight Glass Hose Assembly (S)
3/16 in. I.D. Transparent Hose
Sight Glass Hose Assembly (R)
Vent Line Port Washer (949873)
Troubleshooting
Troubleshooting
Fig. 24: D12B Fuel System Diagram with Fuel Line Kit Installed
1
2
3
4

37
Fig. 25: D12C Fuel System Diagram with Fuel Line Kit Installed
1
2
3
4
38

Troubleshooting
N ote: The numbers w ithin parentheses in the following

steps correspond to the accom panying figures:
D12, D12A
See Fig. 23: D12, D12A Fuel System

Diagram with Fuel Line Kit Installed,
page 37
D12B
See Fig. 24: D12B Fuel System Dia

gram with Fuel Line Kit Installed, page
38
D12C
See Fig. 25: D12C Fuel System Dia

39
1
C onnect the 3/16 in. I.D. transparent
hose (3 ) to the bleed nipple located at
the rear o f the cylinder head and se
cure onto the bleed nipple with the
clamp provided in the fuel line kit.
R oute the line back to the fuel tank
and secure to prevent it from moving
out of the tank. Open the bleed nipple
1 1/2 turns and pump the hand primer
pump until the transparent hose is free
o f air. If the fuel system can be bled
free of air continue to step 3.
2
If air continues to exist in the fuel,
check the following:
that there is ample fuel in both

tanks.
connections from the fuel ta n k to
the fuel supply pump for suction
leaks.
fuel/w ater separator for restric
tions, suction side leaks or an
incorrect micron element.
that the hand prim er pump is ca
pable of pumping fuel.
the fuel supply pump seal for fail
ure.
3
Close the fuel bleed nipple and start
the engine.
Note: It may be necessary to continue
to pump the hand prim er during crank
ing to start the engine. If the engine
does not start then the fuel system is
m ost likely filling with air during crank
ing; skip to step 5.
Troubleshooting
4
O nce the engine starts, open the fuel
bleed nipple, located at the rear of the
cylinder head, 1 1/2 turns with the
transparent hose connected. Monitor
for air in the fuel for 3 to 5 minutes. If
air is present continue to step 5, if not
then there is a possibility that air is en
tering the fuel system only under
loaded conditions. If it is suspected
that air is entering under loaded condi
tions continue to step 5. If not, stop
here, no further testing is required.
5
If the engine would not start in step 3,
continues aeration during cranking, or
if air is noted in the transparent hose
while the engine is running then install
the following hoses and sight glasses
to determ ine w here the air is entering
the fuel system.
6
Install sight glass hose assembly (2)
between the outlet port of the fuel sup
ply pump and the fuel filter.
7
R em ove the fuel supply (suction) line
from the fuel supply pump and install
the alternate transparent fuel supply
line (1) and route back to the fuel tank.
8
Remove the two fuel lines at the over
flow valve and install sight glass
assem bly (4) onto the overflow valve
using hollow screw (941686) from the
kit, and route the line to the fuel tank.
9
Rem ove the transparent hose (3) from
the bleed nipple at the rear o f the
cylinder head to the fuel tank and
close the bleed nipple. Secure all
three lines to prevent them from mov
ing out o f the fuel inside the tank.
Note: For engines equipped with the
small line located between the fuel
supply pump and the top o f the engine
electronic control unit (EECU), this line
must be disconnected from the fuel
supply pump and the port from which
the line was removed (5) must be
plugged using two copper gaskets and
w asher (949873) supplied in the fuel
line kit.
39
10
Using the hand prim er pump attem pt
to purge all air from the fuel system
and start the engine.
Note: Purging tim e may vary.
11
R epeat the conditions in w hich aera
tion was previously noted or test under
loaded conditions, i.e. dyno test.
12
M onitor the two sight glasses and
transparent hose for aeration allowing
3 to 5 minutes for the sight glasses to
clear.
Note: Shining a flashlight into the
backside of the sight glass will im
prove visibility.
13
If no air is noted in either sight glass
and air was noted in previous steps,
the air entry is m ost likely in the suc
tion lines between the fuel supply
pump and the fuel ta nk including the
prim ary fuel filter, copper washers, Orings and pick-up inside o f the fuel
tanks.
14
If air is noted in sight glass (2) be
tween the fuel supply pump and fuel
filter, and the alternate fuel supply is
supplying the fuel supply pump with a
good flow of air free fuel, the problem
is most likely in the fuel pump seals.
Note: The fuel in sight glass (2) is un
der pressure. This com presses the air
bubbles and they will appear to be
small.
40
Troubleshooting
15
If air is noted in the sight glass (4), at
the rear o f the cylinder head, but not
in sight glass (2) at the outlet of the
fuel supply pump (with no engine
load), the problem is most likely within
the cylinder head, i.e. copper sleeve to
injector seat or injector tip leakage.
See Determ ining which C ylinder is
Introducing A ir into the Fuel page 41.
Note: Sight glass (4) will show small
bubbles due to the turbulence created
by the opening and closing of the
overflow valve. To determ ine w hether
norm al or abnorm al aeration is occur
ring, use the transparent hose (3) at
the bleed nipple at the rear of the
cylinder head. Open the bleed nipple 1
1/2 turns and m onitor for air. If the line
is clear then the aeration in the sight
glass (4) is normal. If the transparent
hose indicates aeration then the aera
tion in sight glass (4) is abnormal.
16
If air is noted only under loaded condi
tions, remove all six injectors and
inspect the copper sleeve to the injec
to r seat for signs of leakage.
Determining which Cylinder is In

troducing Air into the Fuel
Troubleshooting
N ote: The numbers w ithin parentheses in the following

steps correspond to the accom panying figures:
D12, D12A
See Fig. 23: D12, D12A Fuel System

Diagram with Fuel Line Kit Installed,
page 37
D12B
See Fig. 24: D12B Fuel System Dia

38
D12C
See Fig. 25: D12C Fuel System Dia

39
/ | \ DANGER
jury or death.
/ ? \ DANGER
WARNING

CAUTION
A fter using the fuel aeration test kit, thoroughly drain
all remaining fuel from the te st hoses, then install
plugs, end caps and washers. This will prevent
accidental spillage w hich could result in fuel contam i
nation.
1
Disconnect the tw o fuel lines from the
overflow valve at the rear o f the cylin
der head and install the sight glass (4)
and line assem bly onto the overflow
valve using hollow screw (941686),
from the kit, and route into the fuel
tank. Tie down the line to prevent it
from moving out of the tank.
2
Remove the fuel supply line from the
fuel supply pump and install the alter
nate fuel supply line onto the feed
pump. Route the line back to the fuel
tank. Tie down the line to prevent it
from moving out of the fuel level inside
the tank.
Note: For engines equipped with the
small line located between the fuel
supply pump and the top o f the engine
electronic control unit (EECU), this line
must be disconnected from the fuel
supply pump. The port from w hich the
line was removed (5) m ust be plugged
using tw o copper gaskets and w asher
(949873) supplied in the fuel line kit.
3
S tart the engine and allow 3 minutes
for the sight glass to clear. Take note
o f the air present in the fuel sight
glass (4).
4
Stop the engine and remove the valve
cover.
41
Troubleshooting
7
R estart the engine and m onitor the
sight glass (4) in the rear o f the cylin
der head. If the air that was noted in
step 3 is gone then the problem is
m ost likely in the num ber 1 cylinder
(injector tip or injector to copper sleeve
seat). Remove the num ber 1 injector
and inspect the injector to the copper
sleeve seat. If the seat appears to be
OK, replace the injector and perform
the test again.
R otate the engine by hand until the

rocker arm for the intake valve for num
ber 1 cylinder is on the base circle of
the cam, (in other words, in position to
be adjusted). Turn the adjusting screw
down (clockwise) until all clearance
has been removed then turn it down
an additional 1/4 turn (90). Install the
valve cover and secure with 4 nuts.
/ \ CAUTION
Do not turn the adjusting screw down more than 1/4
turn (90) after all clearance has been removed. En
gine dam age will result.
6
Using the hand prim er pump, purge all
air from the fuel system.
8
If the air that was noted in step 3 is
not gone, stop the engine, remove the
valve cover, back out (counterclock
wise) the adjusting screw for the
intake valve at the num ber 1 cylinder
1/2 round (180), and repeat the pro
cedure (starting with step 5) on the
num ber 2 cylinder.
9
C ontinue the procedure until the cylin
der that is introducing air into the fuel
system has been determ ined.
10
W hen the cylinder that is introducing
air into the fuel system has been lo
cated, remove that injector and inspect
the injector to copper sleeve seat. If
the seat appears to be O.K., replace
the injector and perform the test again.
If the seat and injector O-rings show
signs of com bustion leakage, clean
the injector and replace the injector
copper sleeve. Reinstall the injector
with new O-rings and adjust all valves
and injectors.
/ l \ CAUTION
Run the engine only at idle speed with no load for this
test. High engine speed or load could cause engine
damage.
42
11
S ta rt the engine and m onitor the sight
glass for air. If no air is present then
stop. If air is present then test again
as required.
Service P rocedures
Service Procedures
General Work Practices
Never remove the EECU connectors or any other

electrical w ires from the sensors while the engine is
running. The ignition key m ust be in the OFF posi
tion and the engine stopped.
Never turn the battery m aster switch OFF or discon

nect the battery cables while the engine is running.
W hen performing electric welding w o rk on the truck,

the EECU connectors must be disconnected from
the EECU.
/ t\ danger
ju ry or death.
/ | \ DANGER
The D12 engine uses high voltage (up to 90 V) to the
electronic unit injectors. Do not come in contact with
the injector term inals while the engine is running as
there could be as much as 90V going to the electronic
injectors. Contact may result in electrical shock. Per
sonal injury or death can occur.
/ j \ CAUTION
Extreme cleanliness must be observed when working
on the fuel system and the Volvo Engine Brake
(V E B ). Always clean the engine before beginning re
pairs. To prevent dirt from entering the fuel system,
install protective plugs w henever connections are re
moved. Store com ponents in sealed plastic bags
(when feasible) until they are to be reinstalled. The
same procedures apply for VEB components. The oil
channels for the VEB control system should also be
plugged. D irt in the fuel system and in the VEB sys
tem can affect engine operation.
Note: A fter removing or replacing any EUI, or after ad
justing preload, start the engine and allow it to reach
norm al operation tem perature. Then let the engine idle
for an additional five minutes. This will enable the ECM
(through the cylinder-balancing system ) to set the
correct am ount of fuel for delivery to the EUI. No power
consuming com ponents, for example, a PTO should be
engaged. The exhaust pressure governor must not be
activated. (Remove wire 636K from the solenoid valve
and apply the parking brake to ensure that the truck can
not move.) W hen the engine runs evenly at idle speed,
the cylinder-balancing function has been carried out.
Note: Before disconnecting the connectors, the key

switch must be turned to the OFF position.
W hen oven-drying spray-paint work, any ECUs must

be removed from the truck. The m aximum allowable
drying tem perature, with the control unit in the vehi
cle, is 8 0 C (176F).
Use only batteries for auxiliary starting. Using a

starting unit can induce peak voltages that can dam
age the electronic components.
W hen charging batteries with a rapid charger, bat

tery cables m ust be disconnected. (Normal trickle
charging does not require this procedure.)
If a connector is removed, make sure it is reinstalled

correctly and is not covered with oil or other fluids
which can result in a poor connection.
For m aintenance intervals, refer to:
S ervice
Bulletin
175-001
Oil and Filter Change Intervals
IMPACT
Function Group 175

Information Type: Maintenance
Engine M aintenance
Note: If the engine is turned over with the starter motor

(for example, when adjusting the valves) the fuse for the
engine control system (B6) must first be removed and
the ignition key must be in the OFF position in order to
elim inate any risk o f the engine starting unintentionally.
Also check that the gear lever is in neutral and the park
ing brake is applied.
43
Clamping the Fuel Lines
Service Procedures
Turning the Engine Over with the

Starter Motor
1
/ \ DANGER
ju ry or death.
A pply the parking brake, block the
wheels, and place the gear lever in
neutral. Make sure that the ignition key
is in the OFF position.
Fig. 27: Fuel line routing and securing
To avoid dam age and operational disturbances in the

fuel system, the fuel lines should be rerouted and se
cured with plastic cable ties.
Note: Always check the fuel lines for cuts, abrasions,
chafing or leakage. Diesel fuel that comes in contact
with a hot surface can start a fire.
Note: Refer to Service Bulletin, Group 23, for oil-cooler
therm ostat plate leak repair.
Note: Refer to Service Bulletin, Group 23, for accessory
drive pulley information.
Note: Refer to Service Bulletin, Group 23, for fuel line
information.
W3000459
Fig. 28: EECU power supply relay, D12A/B
Fig. 29: R3 relay location (TEC Panel), D12C

For D12/A/B only, disconnect the
EECU power supply relay (1); for
D12C (and later versions of D12B),
disconnect the R3 relay (located in the
TEC panel).
44
Service Procedures
2309-06-02-03
Fuel System Pressure, Check
ing
Note: Before beginning this service procedure, please

review General W ork Practices page 43.
/ j \ DANGER
ju ry or death.
/ f \
W3000458
Fig. 30: Remote starter switch and wiring
DANGER
Do not service any part o f the fuel system while

sm oking or in the presence of flames, sparks, or hot
Connect a switch between the battery

positive (+) and the positive (+) con
nection on the sta rte r solenoid.
/ T \ WARNING
4
Do not run the sta rte r fo r m ore than
15 seconds at any one time. However,
if the starter is run for 15 seconds or
longer, w ait at least one minute before
reusing the sta rte r motor.

/ j \ WARNING
Fuel, oil, or coolant leaked/spilled onto hot surfaces or
electrical com ponents can cause a fire. Clean up
spills immediately.
/ T \ WARNING
Do not w ork near the fan with the engine running or
the ignition in the ON position. The engine fan can en
gage at any time w ithout warning. Anyone near the
fan when it turns on could be seriously injured.
Special tools: 9996666, 9998496, J-39200
45
Service Procedures
2
J 39200
999 8496
/ f \
DANGER
When operating a vehicle on streets and highways,

during a data collection procedure, it is mandatory to
have a second person drive while a technician col
lects the data.
Monitor fuel pressure under full load,
i.e, Dyno test or road test with load.
3
Compare measurements with specifi
cations found in "Fuel Supply Pump
and Overflow Valve page 5.
Fig. 31: Bleed nipple, D12A/B

I 'Q O n n
Q Q Q Q /IQ K
Q Q Q RRRR
W2003513
Fig. 32: Bleed nipple, D12C

Remove the bleed nipple at the rear of
the head on the D12A/B, or at the
front of the head on the D12C; install
adapter 9996666 and pressure trans
ducer 9998496.
Connect the transducer to multimeter
J-39200.
Note: The pressure transducer mea
surement scale is in kPa.
46
9996666
9998496
J -3 9 2 0 0
Note: If measurements are found to

be within specifications, no further
testing is required. However, if mea
surements do not meet specifications,
refer to the Diagnostics Checklist B,
"Fuel System.
2309-11-03-01
Fuel System, Draining
Service Procedures

review General Work Practices page 43.
/ j \ DANGER
jury or death.
/ f \ DANGER
WARNING
Fig. 33: Draining the fuel system (D12A/B bleed nipple

location shown)
Carefully clean around the cylinder
head bleed nipple and the fuel filter
bracket drain union located on the
right side of the filter housing.
WARNING
electrical components can cause a fire. Clean up
spills immediately.
2
Connect a 7.9 mm (5/16 in.) drain
hose and open the fuel filter bracket
drain union. Remove the bleed nipple
from the cylinder head.
/ j \ WARNING
Make sure that gauge pressure never exceeds 50 kPa
(7.25 psi). Excessive pressure may cause personal in
jury.
Note: Before using, check the function of pressure
gauge 6662 by attaching it to an air supply and setting
the pressure to 50 kPa (7.25 psi) with the regulator valve.
Special tools: 9996662, 9998277
47
Service Procedures
Fig. 34: Tool installation, D12A/B

Check the pressure gauge assembly
1
Reduction valve
Air supply shut-off
M ake sure the reduction valve knob is

com pletely open (rotate counterclock
wise). Open the shut-off tap. C onnect
pressure gauge 9996662 assem bly to
the shop air supply.
Fig. 35: Tool installation, D12C

When the fuel has com pletely drained
out of the cylinder head, install union
9998277 into the bleed nipple hole.
48
9998277
9996662
Service Procedures
T2006717
Fig. 36: Pressure gauge assem bly connected to union

D12A/B
Fig. 38: Draining the rem ainder of the fuel, D12A/B
Fig. 37: Pressure gauge assem bly connected to union

D12C
Blow the rem aining fuel out of the

cylinder head by carefully increasing
the pressure with the knob on the
pressure gauge reduction valve. DO
NOT EXCEED 50 kPa (7.25 psi).
Check that the pressure gauge indicato r is at "0 (zero) and connect the
gauge to union 9998277.
7
W hen all fuel has been drained:
W2003512
9998277
Remove the pressure gauge as

sembly, union and the drain hose.
Reinstall the bleed nipple and the

protective cap onto the cylinder
head. Do not replace the nipple,
as the original nipple is fitted to
the seating in the cylinder head. A
new nipple can result in leakage.
Tighten the drain union on the

fuel filter bracket and install the
protective cap.
49
2309-05-03-01
Service Procedures

review General Work Practices page 43.
/ f \ DANGER
jury or death.
/ f \ DANGER
T2006713
Fig. 39: Cylinder head bleed nipple, D12A/B location
WARNING
W2003394
Fig. 40: Cylinder head bleed nipple, D12C location
WARNING
spills immediately.
T2006712
Fig. 41: Fuel filter bleed nipple

Clean around the bleed nipples on the
fuel filter housing and cylinder head.
50
Service Procedures
T2006711
Fig. 43: Bleeding the cylinder head, D12A/B

Connect a transparent plastic hose to
the fuel filter housing bleed nipple.
Open the bleed nipple and pump the
hand prim er until clean fuel runs out of
the hose. Tighten the bleed nipple
w hile fuel is still running out.
3
Remove the hose and install the pro
tection plug on the bleed nipple.
W2003510
Fig. 44: Bleeding the cylinder head, D12C

Move the hose over to the cylinderhead bleed nipple and bleed the
system in the sam e way as with the
fuel filter housing.
5
Apply parking brake and place gear
lever into neutral.
6
S ta rt the engine and allow it to run at
fast idle, or with the PTO engaged, for
about five minutes to remove air from
the system. Check for leaks.
51
2331-03-02-01
Fuel Feed Pump, Replacement
Service Procedures
D12, D12A, D12B

review "General W ork Practices page 43.
/ j \ DANGER
ju ry or death.
/ t\ danger
/ l \ WARNING
/ f \
T2006724
Fig. 45: Rem oving fuel line

Rem ove the plastic straps securing
the fuel line on the ECM and cylinder
block. Rem ove the lines at the unions
from the fuel feed pump, as indicated
by arrows in figure Fig. 46: Rem oving
fuel pump, page 52.
WARNING

gage at any tim e w ithout w arning. Anyone near the
/ f \
WARNING

spills immediately.
T2006723
Fig. 46: Removing fuel pump

1
Clean the area around the fuel feed
pump area and remove the bleed line.
Rem ove the bolts indicated by arrows

in figure Fig. 4 6 : R em oving fuel
pump, page 52 and lift out the fuelfeed pump.
4
Clean the contact surface on the tim
ing gear plate.
52
Service Procedures
9
S tart the engine. A llow it to run at fast
idle, or with the PTO engaged, for
the system. Check for leaks.
2331 -03-02-01
Fuel Feed Pump, Replacement
D12C
N ote: Before beginning this service procedure, please
/ T \ DANGER
Check to make sure that the fuel-feed
pump drive engages in the drive slot.
Install a new gasket and tighten the
fuel-feed pump mounting bolts.
6
Connect the fuel lines and the bleed
line. Use new sealing washers. Secure
the fuel lines with plastic tie straps.

jury or death.
/ l \ DANGER
/ i \ WARNING
/ l \ WARNING
spills immediately.
Bleed the fuel system at the fuel filter
as shown in illustration, Fig. 48:
Bleeding fuel system, page 53. See
also Fuel System, Bleeding page 50.
8
Apply parking brake and place gear
lever into neutral.
/ l \ WARNING
gage at any tim e w ithout warning. Anyone near the
fan w hen it turns on could be seriously injured.
53
S ervice Procedures
Types
/ j \ CAUTION
There are tw o types of feed pump on the D12C engine:

1
W hen replacing feed pump Type 1, great care must

be taken with the long drive shaft. Any dam age to the
drive shaft can dam age the feed pump; if it is installed
on the engine, serious engine dam age can result.
Removal
i
drive shaft).
1
2
Seal
Shaft journal
W2003384
C ut the plastic clam ps for the cabling

and remove the bracket under the al
ternator.
2
C arefully clean round the feed pump
and the fuel connections.
W2003385
Fig. 50: Feed pump, type 2 (newer version, available

with one or tw o drive heads; available on newer and re
placem ent engines).
Feed pumps as spare parts are available in both ver
sions.
Note: Both types of feed pumps are interchangeable, i.e.
feed pump type 1 can be replaced with feed pump type
2 and vice versa.
3
Remove all fuel pipes from the feed
pump.
4
Remove the hold-down bolts for the
feed pump. Carefully pull the drive
shaft from the drive exhaust and re
move the pump from the engine.
5
Clean the sealing surface on tim ing
gears plate. Check that the gasket for
the feed pump is in good condition. If
necessary, replace with new gasket.
54
Service Procedures
Installation
W2003386
Fig. 51: Feed Pump Type 1

1
2
Seal
Shaft journal
T2014660
Fig. 53: M 8 -b o lt with sealant

(Feed Pum p Type 1 only:) C heck that
the seal (1) is in good condition and
correctly positioned. Also check that
the shaft journal (2) is lubricated with
graphite grease.
Install the seal on the feed pump and

install the feed pump on the engine.
/ \ CAUTION
(Feed Pump Type 2:) Observe great care with the

feed pum ps drive shaft. Damage to the feed pum ps
drive shaft can perm anently dam age the engine.
Note. The M 8 -b o lt should
stalled with sealant to seal
leakage. Do not install the
w ithout sealant o r leakage
be rein
any oil
old bolt
can occur.
4
C heck the seals on the fuel lines. The
sealing washers for the return line
should always be replaced. R eplace
other seals if necessary.
Install the fuel lines on the feed pump.
W2003387
Fig. 52: Feed pump drive shaft groove

C heck that the feed pum ps drive in
stalls in the groove on the feed pum ps
drive shaft.
The groove in the shaft shows which
position the feed pum ps shaft journal
should have when installing ( applies
to both type 1 and 2).
55
S ervice Procedures
2331-03-02-02
Hand-Primer Pump, Replace
ment

/ t\ danger
ju ry or death.
W2003388
Vent the fuel system.
6
Start the engine and run it at high revs
(approx. 800 - 1000 rpm ) for approx.
10 min. to evacuate any rem aining air
in the fuel system.
7
Conduct leakage check.
8
Check that no fault codes exist.
800 - 1000
rpm
approx. 10
min
/ f \ DANGER
WARNING
/ j \ WARNING
spills immediately.
1
Open the fuel ta n k cap to release any
pressure in the fuel tank.
2
Clean around the hand-prim er fuel fit
tings.
56
Service Procedures
2334-03-02-01
Fuel Filter, Replacement
Prerequisite:
C ontainer for fuel under filter.

review General W ork P ractices page 43.
/ i\
DANGER

ju ry or death.
T2006720
Fig. 54: Removing hand-prim er pump

Remove the hand-prim er pump fuel
lines at the unions.
4
Remove the hand-prim er pump m ount
ing bolts.
5
Install the new hand-prim er pump us
ing new sealing washers.
6
R econnect the m ounting bolts and fuel
lines.
7
Bleed the fuel system (see Fuel Sys
tem, Bleeding page 50).
8
A pply parking brake and place the
gear lever into neutral.
/ | \ DANGER
Do not service any part o f the fuel system while
sm oking or in the presence o f flames, sparks, or hot
/ j \ WARNING
HOT ENG INE! Keep yourself and your test equipm ent
/ j \ WARNING
spills immediately.

9
S tart the engine. Allow it to run at fast
the system and check for leaks.
1
Clean the area around the fuel filter
area.
57
S ervice Procedures
W2003389
Remove the fuel filter.
3
Clean the sealing surface, making
sure that there is no residual gasket.
4
Install the new fuel filter, following the
instructions on the filter.
/ j \ CAUTION
Do not fill the new fuel filter with fuel before installing.
Doing so may allow foreign objects to get into the fuel,
and can cause the injectors to malfuction.
W2003388
Bleed (vent) the fuel system at the fuel

filter. C onnect a transparent plastic
hose to the bleed nipple. Open the
bleed nipple and pum p the hand
prim er until clean fuel runs out of the
hose. Tighten the bleed nipple while
fuel is still running out (see "Fuel Sys
tem, B leeding page 50).
6
Remove the hose and reinstall the
protection plug on the bleed nipple.
7
Apply parking brake and shift lever
into neutral.
8
Start the engine. A llow it to run at fast
about 10 m inutes to evacuate any
residual air in the fuel system.
58
2339-06-02-02
Overflow Valve, Checking
Service Procedures
1
J 39200
999 8 496
D12, D12A, D12B

review "General Work Practices page 43.
/ ? \ DANGER
jury or death.
Fig. 55: Bleed nipple, D12A/B
/ ? \ DANGER
I 'Q O n n
QQQ 4 Q R
QQQ R RR R

/ f \ WARNING
W2003513
Fig. 56: Bleed nipple, D12C
/ l \ WARNING
spills immediately.
Special tools: 9996666, 9998496, J-39200
Remove the bleed nipple at the rear of

the head, install adapter 9996666 and
pressure transducer 9998496. Con
nect the transducer to the multimeter
J-39200.
J -392 00
Note: The pressure transducer mea

surement scale is in kPa.
2
Slowly pump the hand pump while
monitoring the fuel pressure. The
pressure should rise to a point deter
mined by the opening of the overflow
valve then drop quickly. Recheck sev
eral times to get an accurate reading.
59
S ervice P rocedures
3
The opening pressure should corre
spond to specifications found in Fuel
Supply Pump and Overflow Valve
page 5.
2339-03-02-02
Overflow Valve, Replacement
Note: If the overflow valve opens at a

pressure that is less than that given in
the specification, low fuel pressure will
result. The valve m ust be replaced.

4
Replace the valve if necessary.
D12, D12A, D12B
/ f \ DANGER
ju ry or death.
/ | \ DANGER
/ j \ WARNING
/ j \ WARNING
spills immediately.
60
Service Procedures
Overflow valve
Carefully clean the area around the
overflow valve area.
Draining fuel
Drain the fuel by connecting a hose to
the fuel filter housing drain nipple. Re
move the protection plug and open the
bleed nipple on the cylinder head.
Route the fuel from the fuel filter hous
ing into a suitable container.
Removing fuel lines

Remove the fuel line from the overflow
valve.
61
Service Procedures
4
Remove the overflow valve.
2339-03-02-02
Overflow Valve, Replacement
5
Clean the contact surface on the cylin
der head and install a new overflow
valve. Use a new sealing washer.
D12C
6
Reconnect the fuel line. Use new seal
ing washer.
7
Bleed the fuel system.
8
A pply parking brake and place the
gear lever into neutral.
9
S tart the engine and allow it to run at
fast idle, or with the PTO engaged, for
about ten minutes to remove air from
the system.
10
Perform leak and operation checks.

/ f \ DANGER
ju ry or death.
/ | \ DANGER
/ j \ WARNING
/ j \ WARNING
spills immediately.
1
Remove the overflow valve from the
intake pipe.
2
Clean the sealing surfaces.
62
G roup 23 Fuel System, D12, D12A, D12B, D12C
Service Procedures
2371-03-02-02
Unit Injector, Replacement
(One)
Not Included:
Unit Injector, A djustm ent page 67

/ t\ danger
W2003390
Install a new overflow valve with new

copper w ashers and tighten the over
flow valve to 55 5 Nm (40 4 ft-lb).

ju ry or death.
/ t\ danger
/ j \ WARNING
/ j \ WARNING
spills immediately.
Special tools: 9998249, 9998511, 9998599,

J-44515
63
Service Procedures
Drain the fuel out o f the system to pre

vent fuel running down into the cylinder
when a unit injector is dismantled.
T2009070
Prerequisites:
Valve cover removed.
Control valve removed.
Pipe removed between control

valve and rocker arm shaft.
T2008956
Remove the injector hold-down bolt.
5
Clean very carefully round the unit in
je cto r to be changed.
T2008812
Release the rocker arm bridge as per

the specifications.
64
Service Procedures
W2003392
Remove the electrical cables from the

unit injector and the bolt for the unit in
je cto rs attachm ent yoke.
Remove the unit injector with tool
9998511.
9998511
W2003393
Fig. 58: Cleaning the copper sleeve

Install cleaning sleeve 9998580 in the
injector well and carefully clean the
copper sleeve.
9998580
9998251
Leave cleaning sleeve 9998580 on the

cylinder head until the dirt is removed
from the injector well.
Note: If the unit injector is not installed

immediately, install the protective plug
9998251 in the cylinder head.
10
C heck the sealing rings on the unit in
jector. Install the unit injector and
centre it between the valve springs.
Tighten with a torque as per the speci
fications.
W0001837
Fig. 57: Vacuum pump J-44515

Remove fuel from the top of the piston
using vacuum pump J-44515.
8
Install protective sleeve J -4 2 8 8 5 -2 5
on the unit injector.
J-44515
J -4 2 8 8 5 -2 5
65
11
Connect the electric cables to the injector.
Service Procedures
14
1.4 0.1 Nm
(3.5 0.88 in
lb)
Note: Tighten the nuts with a torque of

1.4 0.1 Nm (3.5 0.88 in-lb).
/ \ CAUTION
Do not overtorque. This will break the stud.
12----------------------------------------------------------------Install the rocker arm bridge and
tighten with a torque as per the speci
fications.
13
T2008812
Install the control valve.
15
Connect the cables on the solenoid
valve.
1.4 0.1 Nm
(3.5 0.88 in
lb)
Note: Tighten the nuts with a torque of

1.4 0.1 Nm (3.5 0.88 in-lb).
CAUTION
Do not overtorque. This will break the stud.
T2009070
Install the pipe between the rocker

arm shaft and control valve.
66
16-----------------------------------------------------------------Adjust the valves.
17
Install the valve cover and tighten ac
cording to the tightening schedule in
the specifications.
Service Procedures
2371-05-02-01
Unit Injector, Adjustment
18
(Adjusting pre-load)
/ j \ DANGER
ju ry or death.
W2003388
Vent the fuel system at the fuel filter.
/ j \ DANGER
19
WARNING
W2003394
Vent the fuel system on the cylinder

head.
20
S ta rt the engine and run for approx.
10 minutes to evacuate any residual
air in the fuel system.
21
C heck that the engine has reached
norm al w orking tem perature and then
run for another 5 minutes.
22
C heck to make sure the fuel system is
operating properly. C heck for leaks.
67
/ ? \ WARNING
spills immediately.
Service Procedures
2
Loosen the adjustment screw and ad
just the unit injector rocker arm to zero
clearance against the camshaft.
Tighten the adjustment screw one full
turn and then loosen again. Then re
turn the rocker arm to zero clearance.
WARNING
Do not work near the fan with the engine running or

gage at any time without warning. Anyone near the
CAUTION
Observe the greatest possible cleanliness when work

ing on the cylinder head. Dirt particles in the fuel and
oil channels can cause the unit injectors to malfunc
tion, and can cause the VEB (if equipped) to fail.
T2008845
Preload the unit injector by screwing

down the adjustment screw 3 -4 flats,
(1 8 0 - 2 4 0 ). Torque-tighten the lock
nut according to the specifications.
Unit Injector, Adjusting Pre-load

1
T2006935
Check that the camshaft line marking

for adjusting the intake valves and unit
injector are opposite the marking on
the bearing cap, tolerance 2 mm (al
ternatively between the marks).
Check, via the number marking on the
camshaft on which cylinder unit injec
tor pre-loading is to be adjusted.
Im portant: If tool 6956 is used to
crank the flywheel, make sure that the
tool is removed if the engine is to be
turned over with the starter motor.
68
3 -4 flats
(1 8 0 - 2 4 0 )
2379-03-02-02
Unit Injector Copper Sleeve,
Replacement
Service Procedures

/ f \ DANGER
T2006777

ju ry or death.
Rem ove the rocker arm bridge bolts.

N ote: Loosen the bolts in three equal
stages to avoid bending the rocker
arm shaft.
/ t \ DANGER
/ \ CAUTION

/ j \ WARNING
/ l \ WARNING
spills immediately.
Failure to remove the control valve before removing

the rocker arm bridge may result in dam age to the
control valve and/or the pipe.
If the engine is equipped with a VEB
(Volvo Engine Brake), remove the con
trol valve and the pipe. Plug the ports
and place the valve in a plastic bag to
prevent it from being subjected to dirt
and contam ination. To facilitate re
moval, remove the valve cover stud
bolt.
Note: On engines equipped with a
VEB (Volvo Engine Brake), secure the
rocker arm plungers with rubber bands
so that the plungers do not fall out of
the rocker arms.
/ l \ WARNING
gage at any tim e w ithout warning. Anyone near the
fan w hen it turns on could be seriously injured.
Removal
1
Connect a drain hose 9996049 to the
engine coolant drain nipple and drain
the coolant into a suitable container.
9996049
T2006776
Lift the rocker arm bridge using lifting

tool 9998255.
9998255
69
5
Drain the fuel from the cylinder head.
Refer to the procedure,"Fuel System
Draining, the service manual 210
600, Basic Engine D12.
Service Procedures
6
C arefully clean around the electronic
unit injector (EUI) to be removed.
T2006708
Remove the EUI and check that no dirt

enters the injector w ell in the cylinder
head. Install a dust cover on the EUI,
and install protective plug 9998249 in
the injector well in the cylinder head.
9998249
T2006709
Disconnect the electrical w ires from

the EUI.
CAUTION
Pay close attention to the w ire term inals. If one

breaks, remove the broken pieces. Failure to do so
may result in pieces falling into the cylinder, which can
cause com ponent dam age.
T2007050
Remove the valve bridges at the cop

per sleeve that is to be changed, and
make note o f location fo r reassembly.
10
Make sure that the piston correspond
ing to the copper sleeve being
removed is in the down position.
70
Service Procedures
13
11
W2003433
Using the Allen wrench, loosen the

Allen set-screw on the extractor tool
9992853.
9998253
T2007157
(This step is for D12C only) Check

w hether the copper sleeve has an 8
mm or 9 mm hole in the tip. Install the
8 mm tap in tool 9998252 and try
threading the copper sleeve. If it turns
too easily, replace the 8 mm tap with
the 9 mm tap and continue with the
procedure.
12
Using tool 9998252 turn tap approxim ately 1/4 of a turn, then back off at
least a full turn to remove shavings.
Turn forward again until you feel ten
sion, then repeat this step. Continue
until the tap has passed through the
bottom of the copper sleeve.
9998252
14
A djust the bolt in the end of the tool
until the bolt extends approxim ately 22
mm (0.875 in.) beyond the end of the
tool(A).
9998252
15
Tighten the Allen set-screw and make
sure that the screw is seated against
the flat part of the extractor bolt.
Note: A pply grease to the tap to pre

vent shavings from falling down into
the cylinder.
71
16
Service Procedures
18
W2003434
Install the extractor tool into the cop

per sleeve and hand tighten until it
bottoms out in the sleeve.
Hand turn the retaining nut clockwise

(1) until it is firm ly seated against the
bottom of the extracting cup.
19
17
W2003435
Back off the retaining nut (1) and turn

the extractor bolt (2) so that the
threaded end passes com pletely
through the copper sleeve tip.
Note: If the threaded end does not
pass com pletely through the copper
sleeve, the tip of the sleeve may break
off as it is removed.
72
Do not use air tools to remove the copper sleeve. Use

of air tools can dam age engine components.
Using a wrench, turn the retaining nut
(1) clockwise until the copper sleeve is
removed.
20
Service Procedures
22
Pieces of the copper sleeve that fall into the cylinder

can seriously dam age the piston and/or turbocharger.
T2006821
Install the 2 sealing clam ps 9998250

in the cylinder head fuel gallery.
W hen the sleeve is removed, the

extractor tool should be extended be
yond the cooper sleeve at least 3 mm
(0.125 in); see (1). If it is not, check to
make sure that a piece of the cooper
sleeve has not broken off and fallen
into the cylinder.
9998250
23
Cleaning the Copper Sleeve Bore

21
W ear safety glasses w hile using cleaning brushes or

com pressed air. Failure to do so could cause eye in
ju ry from flying debris.
W2003537
Fig. 59: Cleaning kit J-42885

W hen replacing the injector copper
sleeves in the cylinder h ead, it is im
portant that the sleeve bore in the
head is free from any carbon deposits
and any other residue (i.e. pieces of
the O-ring, etc.) before installing the
new sleeve. Use the cleaning kit J42885 in the following steps.
J-42885
Use the "7/16 in. diam eter brush in

side bore (C). Move the brush up and
down w hile turning it at the same time.
J-42885
73
Service Procedures
Installation
24
W2003528
Place the injector bore sleeve protector into injector bore. Assemble the
Roloc brush (2), the holder (3), and
the extension (4). Install the assembly
into a drill and clean the sleeve seal
(B); see illustration page 73.
25
Install the 1.5 in. diameter brush into
the drill and clean bore (A); see illus
tration page 73.
26
Use the chip vacuum PT-2900 to remove all debris from the copper sleeve
bore.
J-42885
J-42885
PT-2900
2
9998254
27
Inspect the copper sleeve bore for any
remaining debris. Pay close attention
to the O-ring area of the bore for any
remaining pieces of the O-ring that
may require scraping with a pocket
knife to remove. Reclean if needed.
28
Remove the 2 sealing clamps
9998250 from the cylinder head fuel
gallery, and remove any remaining de
bris using chip vacuum PT-2900.
Lubricate the new sealing ring with en

gine oil and install it on the new
copper sleeve.
Lubricate the sealing ring again with
engine oil.
9998250
PT-2900
Install the copper sleeve on the flaring

tool 9998254, and lubricate the flaring
pin 9808000 with engine oil. Thread
the flaring tool 9998000 to the flaring
tool 9998254 until it bottoms. Then,
loosen the flaring pin approximately
180.
Note: Failure to loosen the flaring tool
1 8 0 can result in the pin being twisted
or broken.
3
Check that the piston is not at TD.C.
(if the piston is at T.D.C., the flywheel
must be turned). Carefully tap down
the copper sleeve until it bottoms out
against the sleeve seal in the cylinder
head.
4
Install and tighten the retainer for the
electronic unit injector.
74
9998254
9808000
Service Procedures
T2006707
T2007089
Flare the copper sleeve. Do this by

turning the nut while counterholding
the spindle until the flaring pin,
9998254 has been completely pulled
through the copper sleeve.
9998254
Note: Failure to counterhold the spin

dle will result in a twisted or broken
flaring pin.
6
Remove the flaring tool 9998254 and
pin 9808000.
Install the new sealing rings on the

electronic unit injector (EUI). Lubricate
the sealing rings with grease and in
stall the electronic unit injector.
/ j \ CAUTION
Remove all oil from the injector retainer bolt holes to
prevent a hydraulic lock that may result in damage to
the cylinder head.
9998254
9808000
Tighten the electronic unit injector.
New Copper Sleeve:

9
Tighten retainer bolt to a torque of 20
5 Nm (15 4 ft-lb).
20 5 Nm
(15 4 ft-lb)
75
10
Service Procedures
16
5.
11
Loosen the retainer bolt for the unit in
jector prior to the second tightening.
12
Tighten bolt to a torque of 20 5 Nm
(15 4 ft-lb).
13
Turn the retainer bolt an additional
60 5.
20 5 Nm
(15 4 ft-lb)
6 0 5
Note: Be careful not to pinch the EUI

wiring cable harness when installing
the valve cover.
Old Copper Sleeve:

14
Tighten the retainer bolt to a torque of
20 5 Nm (15 4 ft-lb).
20 5 Nm
(15 4 ft-lb)
Note: If the injector is not to be in

stalled at once, install a protective plug
in the cylinder head.
15
Turn the retainer bolt an additional
60 5 .
76
Connect the electronic unit injector

(EUI) electrical wires and tighten the
nut to a torque of 1.4 Nm (1 ft-lb).
The EUI electrical wires should be
routed to the outside of the valve
cover bolts.
Pay close attention to the cable hold
ers. If one breaks, remove the broken
pieces to prevent clogging or damage
to any components.
60 5
Note: Hold the wires while tightening.

If the screw gets damaged, the com
plete electronic unit injector must be
replaced.
Note: Applies to engines equipped
with VEB (Volvo Engine Brake).
The VEB control valve should be rein
stalled at this time. Reconnect sliding
valve and pipe into the rocker arm
shaft as a unit. Apply Loctite 242 to
threads and tighten the bolts to a
torque of 33 4 Nm (24 3 ft-lb).
1.4 Nm
(1 ft-lb)
33 4 Nm
(24 3 ft-lb)
17
Service Procedures
19
Install all rocker arm shaft bolts, mak

ing sure they are hand tight before
continuing.
Note: When reinstalling a rocker arm
shaft which has been removed or loos
ened, only the bolts which hold the
rocker arm shaft should be tightened.
lobes with engine oil.
18
T2006776
/ l \ CAUTION
Remove all oil from the rocker arm bridge bolt holes
to prevent a hydraulic lock that may result in damage
to the cylinder head.
Install the rocker arm bridge, using lift
ing tool 9998255.
9998255
77
20
Fig. 60: Bearing caps and camshaft/rocker shaft,

tightening sequence
D12C:
1
2
3
4
5
15 5 Nm (11
60 5 Nm (44
15 5 Nm (11
60 5 Nm (44
0 Nm (0 ft-lb)
15 5 Nm (11
4 ft-lb); +90 5
4 ft-lb)
4 ft-lb); +120 5
4 ft-lb); loosen to
4 ft-lb); +120 5
D12, D12A, D12B:

1
2
3
4
5
15 5 Nm (11 4 ft-lb); +90 5

45 Nm (33 ft-lb)
15 5 Nm (11 4 ft-lb);+90 5
45 Nm (33 ft-lb); loosen to
0 Nm (0 ft-lb)
15 5 Nm (11 4 ft-lb); +90 5

warp. Tighten the shaft until it lies
against the camshaft lobes, then
torque tighten using the 5-step torque
sequence shown.
21
Adjust the valves and the electronic
unit injector (EUI).
78
Service Procedures
Feedback
One o f our objectives is that w orkshop personnel should have access to correct and
appropriate service m anuals w here it concerns fault tracing, repairs and m aintenance
o f Volvo trucks.
In order to maintain the high standards o f o ur literature, your opinions and experience
when using this m anual would be greatly appreciated.
If you have any com m ents or suggestions, m ake a copy o f this page, w rite down your
com m ents and send them to us, either via telefax o r mailing directly to the address
listed below.
To
From
Volvo Trucks North A m erica, Inc.
.........
Dept. 516 S ervice Publications
.........
7825 National S ervice Road
.........
P.O. Box 26115
.........
.........
USA
.........
Fax (336) 393-3170
.........
C om m ents/proposals
Concerns S ervice Manual:
Operation Numbers
2309-05-03-01
2309-06-02-03
Fuel System Pressure, Checking
2309-11-03-01
Fuel System, D raining....................................................................................................................47
2331-03-02-01
Fuel Feed Pump, R e p la c e m e n t..........................................................................................52, 53
2331-03-02-02
Hand-Primer Pump, R e p la c e m e n t............................................................................................ 56
2334-03-02-01
Fuel Filter, Replacement
................................................................................................................ 50
............................................................................................ 45
............................................................................................................ 57
2339-03-02-02 Overflow Valve, R e p la c e m e n t..............................................................................................60, 62

2339-06-02-02
Overflow Valve, C h e c k in g ............................................................................................................ 59
2371-03-02-02
Unit Injector, Replacement (One)
2371-05-02-01
Unit Injector, Adjustment
2379-03-02-02
Unit Injector Copper Sleeve, R e p la c e m e n t............................................................................ 69
............................................................................................ 63
............................................................................................................ 67
VOLVO
Volvo Trucks Canada, Ltd.

PV776-TSP142867 (1000) 08.200 Volvo Trucks North America, Inc., 2000
VOLVO
TSI

Greensboro, NC USA

P V 776-TS P 142853.
Date
Group
No.
11.2001
215
007
Supp.
Page
1(4)
Idler Gear Assembly

D12, D12A, D12B
Idler Gear Assembly

This inform ation covers procedures for overhauling the idler gear assem bly on VOLVO
D12, D12A, and D12B engines.
Contents
Idler G ear Assembly, O verhaul page 3
P V 7 7 6 -T S P 1 6 1 5 6 5
USA10457
Page 2
Tools
Special Tools
ordered from Volvo; please use the specified part number when ordering.
9998244
Hollow Drift

TSI
Date
Group
No.
112001
215
007
Page
3 (4 )
Service Procedures
2153-04-05-01
Idler Gear Assembly, Overhaul
(Unit removed.)
/ j \ WARNING
risk of eye injury due to contact with debris.
Special tools: 9988183, 9992267, 9992584,

9998244
1
Clamp the idler gear assem bly se
curely in a vise.
T 2 0 0 7 1 74
Fig. 3: Removing the shaft and the bearing together
Disassembly
Using tool 9998244, press the shafts
and bearings out of both the idler
gears.
9998244
T 20 07 09 7
T 20 07 07 7
Fig. 2: Removing the snap ring
Fig. 4: Removing the snap ring

Using snap ring pliers 9988183, remove the snap ring at the front of the
idler gears equipped with roller bear
ings.
9988183
Using snap ring pliers 9988183, remove the snap rings on the other side
of the idler gears.
9988183
Page 4
8
Install the snap ring onto the side of
the bearing that faces the timing gear
plate.
T2007141
Fig. 5: Removing the shaft from the bearing

Using puller 9992584 and drift
9992267, press the shafts out o f the
bearings.
9992584
9992267
T2007140
Fig. 7: Installing the shaft and bearing assembly
Assembly
Place the shaft and the bearing lock
w asher into a press.
Using tool 9998244, carefully press

the shaft and the bearing into the idler
gear until the bearing lies up against
the snap ring.
Note: Do not press too hard against

the snap ring.
10
Install the other snap ring and remove
the washer.
T2007094
Fig. 6: Installing a new bearing

Using tool 9992584, press the new
bearing onto the shaft until it bottoms
against the washer.
9992584
9998244
VOLVO

Greensboro, NC USA

2 1 4 -0 1 3 , Valves, D12C (11.2001), publication no.
P V776-TS P 160587.
Date
Group
No.
7.2004
214
020
Supp.
Page
1(9)
Valve and Injector Adjustment with EPG

D12, D12A, D12B, D12C
Valve and Injector Adjustment with EPG
W2003805
This information covers procedures for adjusting valves and injectors on VOLVO D12,
Contents
Valves and Unit Injectors, A djustm ent page 3
N ote: Information is subject to change w ithout notice.

Illustrations are used for reference only and may differ slightly from the actual
vehicle being serviced. However, key com ponents addressed in this inform ation are
represented as accurately as possible.
P V 776 -20 006218
USA15092

Date
TSI_______________________________________________________________________________ 7.2004
Group
214
No.
020
Tools
Special Tools
ordered from Volvo. Please use the specified part num ber when ordering.
C0000220
W0000416
9996956
J41610
Cranking tool
Feeler Gauge Set
Other Special Equipment

Like special tools, the following items can be ordered directly from Volvo. Please refer to
the specific tool num ber when ordering.
' HI I
C2001260
1159794
Torque Wrench
Page
2(9)

TSI
Date
Group
No.
7.2004
214
020
Page
3(9)
Service Procedures
2140-05-03-01
Valves and Unit Injectors, Adjustment
(V alve c o v e r re m o ve d .)

guidelines in Service Information, group 20, "General
Safety Practices" before performing this procedure.
If you are not properly trained and certified in this
procedure, ask your supervisor for training before
you perform it.
N ote: Variant abbreviations are used to identify an engine

equipped with the following components:
EPG
Exhaust Pressure Governor
Special tools: 9996956, J41610

Other special equipment: 1159794

TSI
Date
Group
No.
7.2004
214
020
Page
4(9)
1
Remove the flywheel inspection cover located under
the engine flywheel housing. Install engine turning
tool 9996956.
9996956
2
Turn the engine to the cam shaft marking to adjust the
corresponding valve (for example, no. 5, as shown in
illustration), as indicated below:
Marking 1 - 6: Apply to adjustm ent o f valve bridge

intake valves, exhaust valves, and unit injector.
Example:
Adjustm ents for no. 5 intake clearances, no. 5 injector
preload, and no. 5 exhaust valve clearances w ould be
made in this engine position.
T2006771

TSI
Date
Group
No.
7.2004
214
020
Page
5(9)
Valve and Unit injector, adjustment

3
Loosen lock nut and back off adjusting screw until it no
longer m akes contact with the injector socket.
N ote: A djust injector before adjusting intake and
exhaust valves.
V alve a n d In je c to r S e ttin g s
W2004460
Cam
Position
Injector
Intake
Exhaust
4
A djust the unit injectors adjusting screw to zero
clearance.
5
Tighten the adjusting screw 4 flats or 2 4 0 .
6
Torque-tighten the adjusting screw lock nut to
52 4 Nm (38 3 ft-lb).
N ote: M ark the rocker arm and injector rocker when each
valve has been adjusted.
52 4 Nm
(38 3 ft-lb)

TSI
Date
Group
No.
7.2004
214
020
Page
6(9)
Intake and Exhaust Valve Bridge Adjustm ent

7
T2019496
Valve bridge with guide
W2004467
Valve bridge w ithout guide

N ote: A valve bridge design (w ithout guide pin) is used in
D12 engines. These may be installed in combination
with the current valve bridge design with guide pin. The
procedure for adjusting valves rem ains the same, except
that the valve bridge w ithout guide pin does not need
adjusting. Valve clearances are also unchanged. For
intake valves, the valve bridge w ithout guide pin may
be installed facing either direction. A valve bridge with
guide pin must always be installed as a replacem ent
component.

TSI
Date
Group
No.
7.2004
214
020
Page
7(9)

8
W2004433
/ l \ CAUTION
The valve bridge must be adjusted prior to the valve
clearance adjustm ent that is related to it. Failure to
do this can result in breakage or dam age to the
valve bridge guide.
N ote: The valve bridge adjustm ent can only be made
w hen there is clearance between the valve bridge
and the rockerarm.
A djust the valve bridge clearance:
Loosen the adjusting screw lock nut.

Loosen adjusting screw until it no longer contacts
valve stem.
Press valve bridge downward toward the valve stem.
Tighten adjusting screw until it makes contact, then
turn an additional 1 flat or 6 0 .
Hold adjusting screw in place and torque-tighten nut to
38 3 Nm (28 2 ft-lb).
38 3 Nm
(28 2 ft-lb)
9
R echeck valve clearance after nut is torque-tightened.
10
Rotate the engine to the next cylinder m ark on the
camshaft. A djust unit injector, valve bridges, intake and
exhaust valves on that cylinder.

TSI
Date
Group
No.
7.2004
214
020
Page
8(9)
11
With engine cold (1 4 0 F or less), adjust the valve
clearance for exhaust to 0.5 mm (0.020 in.). Hold
adjusting screw in place and torque-tighten lock nut to 38
3 Nm (28 2 ft-lb).
N ote: Mark each valve rocker lever as you adjust it to
know w hich valves have already been adjusted.
Intake Valves, adjustment

12
With engine cold (1 4 0 F or less), adjust valve clearance
to 0.2 mm (0.008 in.). Hold adjusting screw in place and
torque-tighten lock nut to 38 3 Nm (28 2 ft-lb).
N ote: Mark each valve rocker lever as you adjust it to
38 3 Nm
(28 2 ft-lb)
T2008968

TSI
Date
Group
No.
7.2004
214
020
Page
9(9)
13
Use steps 3 - 1 3 to adjust the injectors and valves.
V a lve C le a ra n ce , C o ld E n g in e S e ttin g V alve
Inlet
0.2 mm (0.00B in.)
Exhaust
0.5 mm (0.020 in.)
V a lve C le a ra n ce , C o ld E n g in e C h e ck V alve
Inlet
0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust
0.45 - 0.55 mm (0.01B - 0.22 in.)
V a lve and In je c to r S e ttin g s

Cam
Position
Injector
Intake
Exhaust
VOLVO

Greensboro, NC USA

21 4-013, Valves, D 12C (11.2001), publication no.
PV776-TS P 160587.
Date
Group
No.
7.2004
214
019
Supp.
Page
1(11)
Valve and Injector Adjustment with VEB

D12, D12A, D12B, D12C
Valve and Injector Adjustment with VEB
W2004459
This inform ation covers procedures for adjusting valves and injectors on VOLVO D12,
Contents
Valves and Unit Injectors, A djustm ent page 3
N ote: Information is subject to change w ithout notice.

Illustrations are used for reference only and may differ slightly from the actual
P V 7 76-20 005870
USA15071

TSI
Date
Group
No.
Page
7.2004
214
019
2(11)
Tools
Special Tools
For special tools ordering instructions, refer to Tool Information, group 08.
W0001924
W0001774
W0000416
3949521
VEB shim kit
9996956
Engine turning tool
J41610
Feeler gauge set

Like special tools, the following items can be ordered directly from Volvo. Please refer to
the specific tool num ber when ordering.
C2001260
1159794
Torque Wrench

TSI
Date
Group
No.
Page
7.2004
214
019
3(11)
Service Procedures
2140-05-03-01
Valves and Unit Injectors, Adjustment
(Valve c o v e r re m o ve d .)

guidelines in Service Information, group 20, "General
in this procedure, ask your supervisor fo r training
N ote: V ariant abbreviations are used to identify an engine
equipped with the following components:
VEB
Volvo Engine Brake
Special tools: 3949521, 9996956, J41610

Other special equipment: 1159794
1
Remove the flywheel inspection cover from the flywheel
housing. Install engine turning tool 9996956.
9996956
2
C a m s h a ft m a rk in g s fo r s e ttin g o f v a lv e s and u n it
in je c to rs :
W2004440
Markings 1 -6 , apply to adjustm ent of intake valves

and unit injector.
Markings V 1 -V 6 , apply to adjustm ent of exhaust

valves only.

TSI
Date
Group
7.2004
214 019
No.
Page
4(11)
Valve and Unit injector, adjustment

3
Loosen lock nut and back off adjusting screw until it no
longer m akes contact with the injector socket.
V alve a n d In je c to r S e ttin g s
Cam
Position
Injector
Intake
Exhaust
V6
3
X
X
V2
6
X
X
V4
W2004460
X
X
V1
4
X
X
V5
1
X
X
V3
4
A djust the unit injectors adjusting screw to zero
clearance.
5
Tighten the adjusting screw 4 flats or 2 4 0 .
6
Torque-tighten the adjusting screw lock nut to
52 4 Nm (38 3 ft-lb).
N ote: Mark the rocker arm and injector rocker when each
valve has been adjusted.
52 4 Nm
(38 3 ft-lb)

TSI
Date
Group
7.2004
214 019
No.
Page
5(11)

7
T2019496
Valve bridge with guide
W2004467
Valve bridge w ithout guide

N ote: A valve bridge design (w ithout guide pin) is used in
D12 engines. These may be installed in combination
with the current valve bridge design with guide pin. The
procedure for adjusting valves rem ains the same, except
that the valve bridge w ithout guide pin does not need
adjusting. Valve clearances are also unchanged. For
intake valves, the valve bridge w ithout guide pin may
be installed facing either direction. A valve bridge with
guide pin must always be installed as a replacem ent
component.

TSI
Date
Group
7.2004
214 019
No.
Page
6(11)
/ j \ CAUTION
The valve bridge m ust be adjusted prior to the valve
clearance adjustm ent that is related to it. Failure to
do this can result in breakage or damage to the
valve bridge guide.
N ote: The valve bridge adjustm ent can only be made
when there is clearance between the valve bridge
and the rockerarm.
A djust the valve bridge clearance:
W2004468
Loosen the adjusting screw lock nut.

Loosen adjusting screw until it no longer contacts
valve stem.
Press valve bridge downward toward the valve stem.
Tighten adjusting screw until it makes contact, then
turn an additional 1 flat or 6 0 .
Hold adjusting screw in place and torque-tighten nut to
38 3 Nm (28 2 ft-lb).
38 3 Nm
(28 2 ft-lb)
9
Recheck valve clearance after nut is torque-tightened.

Date
TSI_______________________________________________________ 7.2004
Group
No.
214 019_________
Page
7(11)
Intake Valves, adjustment

10
W ith engine cold (1 4 0 F or less), adjust valve clearance
to 0.2 mm (0.008 in.). Hold adjusting screw in place and
torque-tighten lock nut to 38 3 Nm (28 2 ft-lb).
N ote: M ark each valve rocker lever as you adjust it to
38 3 Nm
(28 2 ft-lb)
11
Turn the engine to the next cam shaft marking before
adjusting another cylinder.
N ote: Engine tem perature at 1 4 0 F or less.
V alve C le a ra n ce , C o ld E n g in e S e ttin g V alve
Inlet
0.2 mm (0.008 in.)
Exhaust VEB
1.6 mm (0.063 in.)
V alve C le a ra n ce , C o ld E n g in e C h e ck V alve
Inlet
0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust VEB
1.55 - 1.65 mm (0.061 - 0.065 in.)

TSI
Date
Group
7.2004
214 G1S_______ 8 ( i i )
No.
Page
Exhaust valves (VEB), adjustment

12
Turn the engine to the next cam shaft marking (V plus
number) fo r the adjustm ent of exhaust valves.
13
Loosen the adjusting screw until the valve bridge does
not make contact with the valve stem.
V alve and In je c to r S e ttin g s
Cam
Position
Injector
Intake
V6
3
X
X
V2
6
X
X
V4
2
X
X
V1
4
X
X
V5
1
V3
Exhaust
X
X
X
X
14
Tighten the adjusting screw until it makes contact (zero
clearance) against the valve stem. Turn an additional
1 flat or 6 0 . Do not tighten the adjusting screw lock
nut at this point.
N ote: W hen the adjusting screw is screwed down, the
valve bridge m ust be pushed down at the sam e tim e until
it makes contact with the valve stems.
W2004427

TSI
Date
Group
No.
Page
7.2004
214
019
9(11)
15
Push the rocker arm down as

shown. If the rocker arm springs, the rocker arm pistons
spring should be pulled outward while the rocker
arm is pushed down until the piston makes contact
with the VEB housing.
N ote: Use a strong w ire or a bent screw driver to pull out
the spring.
N ote: For correct reading o r measurement, make sure
that the wire or the screw driver has been well cleaned
before they are used. Im purities between the rocker
arm piston and the rocker arm can lead to the piston
seizing and the brake function on the cylinder failing to
work. Make sure that the pistons sliding surface in the
rocker arm is not damaged.
W2004446
W2004447
VEB Plunger Piston with oil trapped

(Incorrect valve lash adjustm ent)
VEB C om pressed Piston in Housing

(Correct valve lash adjustm ent)
16
Measure the clearance between the rocker arm s piston
and the valve bridge. A cceptable clearance is
1.55 - 1.65 mm (0.061 - 0.065 in.).
1.55
- 1.65 mm (0.061 - 0.065 in.)

TSI
Date
Group
No.
7.2004
214
019
Page
10(11)
17
N ote: The exhaust valve rockers do not have adjusting

screws. The exhaust valve clearance is adjusted by
adding and/or removing the correct VEB shims.
N ote: Shim s are available in intervals of 0.05 mm. The
thickness is stam ped on the shim. VEB shim kit is
tool no. 3945921.
If the valve clearance needs to be
adjusted, remove the lock nut w ith o u t m o v in g
th e a d ju s tin g scre w .
N ote: If the shim is wearing on one side, turn it over
and reuse.
N ote: If the adjusting screw turns while removing the lock
nut, repeat steps for Valve Bridge Adjustm ent.
3945921
18
Use the m easured value to calculate the thickness of
the new shims.
If two shim s m ust be used, select
shims of approxim ately the sam e thickness.
N ote: A maximum of two shims can be used.

TSI_______________________________________________________
Date
Group
7.2004
214 019_________ 11(11)
No.
Page
19
Make sure that the shim (s) and the valve bridge have
been properly cleaned. Install shims and torque-tighten
the adjusting screw lock nut to 38 4 Nm (28 3 ft-lb).
N ote: The adjusting screw m ust not be moved on the
valve bridge when the lock nut is tightened.
38 4 Nm (28 3 ft-lb).
20
A fter tightening the adjusting screw, recheck the valve
clearance.
N ote: M ark the rocker arm when the valve has been
adjusted.
21
A fter w ork has been com pleted, start the engine and
check for incorrect valve adjustm ent and leaks.
22
Bring engine to normal operating tem perature. Let engine
idle for approxim ately 5 minutes; the system perform s its
own cylinder balancing in order to attain smooth idling.
N ote: During cylinder balancing, do not use any form of
power-consum ing equipm ent, such as power take-off or
air conditioning.
Service Manual
Trucks
Group
250600
Intake and Exhaust System

D12, D12A, D12B, D12C
PV776-TSP144524
VOLVO
Foreword
ence to an S.R.T. (Standard Repair Time).
D ocum entation:
C a u tio n : Indicates an unsafe practice w here damage to the product could occur.
W a rn in g : Indicates an unsafe practice w here personal injury or severe damage to the
D anger: Indicates an unsafe practice w here serious personal injury or death could oc
cur.

Greensboro, NC USA
O rder num ber: PV776-TSP144524

Contents
G eneral ................................................................................................................... 3
S p e c ific a tio n s ...................................................................................................... 5
Intake and Exhaust System ............................................................................... 5
T o o ls ........................................................................................................................ 7
Special Tools
...................................................................................................... 7

D e sig n and F u n c tio n
........................................................................................ 9
Intake and Exhaust System ............................................................................... 9

Preheater ............................................................................................................... 9
D12C
................................................................................................................ 9
Engines w ithout Preheater ......................................................................... 10

Engine Brake .................................................................................................... 11
D12C
............................................................................................................. 12
Crankcase Ventilation ..................................................................................... 18

D12C
............................................................................................................. 18
Exhaust Pressure G overnor ......................................................................... 19

D12C
............................................................................................................... 21
EPG Control Valve
......................................................................................... 22
D12A
............................................................................................................... 22
D12B
............................................................................................................... 22
A ir Restriction Indicator ................................................................................... 23

Turbocharger ....................................................................................................... 24
D12A
............................................................................................................... 24
Exhaust Manifold ............................................................................................... 25

Tightening Sequence
T ro u b le s h o o tin g
.................................................................................... 26
................................................................................................. 27
A ir Restriction Indicator, Checking

S e rv ic e P ro c e d u re s
................................................................27
.......................................................................................... 29
A ir Filter Element, R eplacem ent
................................................................... 29
Intake Manifold Gasket(s), R eplacem ent .................................................. 30

Removal
......................................................................................................... 31
Installation
...................................................................................................... 31
Turbocharger, R eplacem ent

Removal
........................................................................... 32
......................................................................................................... 32
Installation
...................................................................................................... 33
Exhaust Manifold Gasket(s), R eplacem ent .............................................. 34

(Turbocharger Removed) ...............................................................................34
Exhaust Pressure Governor, R eplacem ent .............................................. 35
Exhaust Pressure Governor, Overhaul
(Unit Removed)
..................................................... 36
............................................................................................. 36
D isassem bly .................................................................................................. 36

A ssem bly ........................................................................................................ 37
Charge A ir C ooler Leak Test, Checking .................................................... 39
S y s te m C h e ck
.....................................................................................................41
Boost Pressure, Checking ...............................................................................41

Exhaust Backpressure, Checking ..................................................................42
Pressure Testing O utlet Location ................................................................42
Backpressure M easuring Techniques
....................................................... 42
F ee d b a ck
O p e ra tio n N u m b e rs
1
G roup 25 Intake and Exhaust System
General
General
This inform ation covers the Intake and Exhaust System for the D12, D12A, D12B, and
D12C engines.
Group 25 Intake and Exhaust System
Specifications
Specifications
Maximum Restriction (Rated speed full load)
6.2 kPa (H 2 O) (25 in.)
Air Cleaner torque

Plastic
9 2 Nm (7 2 ftlbs)
Metal
20 2 Nm (15 2 ft-lbs)
For Specifications, including torques, refer to:

S e rv ic e M an u a ls
2 0 0 -8 9 0 , Specifications, D12C
2 0 0 -8 5 0 , S pecifications, D12B
2 0 0 -8 2 0 , Specifications, D12A
IMPACT
Function Group 25
Info Type: Specifications
Group 25 Intake and Exhaust System________________________________________________________________ Specifications
Tools
Tools
Special Tools
Servicing the VE D12 intake and exhaust system s requires the following special tools.
The tools are available from parts departm ents of Volvo Trucks North America, Inc.
W hen requesting tools, provide the appropriate number, preceded by 999 , for exam
ple, 9992610.
9992610
Drift for overhauling exhaust pressure

governor
9998225
Hollow drift for overhauling exhaust

pressure governor
9996065
G auge for checking boost pressure
9998246
Drift for overhauling exhaust pressure

governor
9996666
Union for checking boost pressure
9996662
Pressure gauge
9998288
Connecting w asher for leakage test of

charge air cooler
9996831
Vacuum gauge for checking pressure

drop indicator
9998289
Sealing w asher for leakage test of

charge air cooler
Tools
Special Equipment
Like the special tools, the following are available from the parts departm ent of Volvo
Trucks North America, Inc.. W hen requesting tools, provide the appropriate part num
ber.
W0001840
1159794
Torque wrench 10-100 Nm (7-7 3 ft-lb)
1159795
Torque wrench 40-340 Nm (30-250 ft-lb)
1159796
Torque wrench 150-800 Nm (110-590 ft-lb)
W0001841
W0001842
Design and Function
Design and Function

Preheater
Selected versions o f the D12 are equipped with a pre
heater. Its purpose is to warm air in the intake manifold
when starting the engine. This heated air eases starting
at very low tem peratures and reduces engine smoking
when starting a cold engine. The following conditions are
required to engage the preheater:
The parking brake must be applied.
The power take-off must not be engaged.
The preheater does not engage at coolant tem peratures

over 1 0 C ( 5 0 F). A t a coolant tem perature of 1 0 C
( 5 0 F), the preheating tim e is 25 seconds. A t coolant
tem peratures below - 1 0 C ( 0 F), the preheating tim e is
55 seconds. Preheating tim e increases linearly between
1 0 C ( 5 0 F) and - 1 0 C ( 0 F).
T2006975
Fig. 1: Preheater
The post-heating tim e is always the sam e as the pre

heating time.
D12C
The D12C is equipped with a new preheater. The func
tion of the starting heater is sim ilar for both vehicle
variants, but the location of the relay differs. The pre
heater on both engine variants is grounded to the engine
block through the intake manifold.
W2003281
Fig. 2: Preheater, D12C
Engines without Preheater

On engines not equipped with a preheater, engine
coolant tem perature determ ines the point at which fuel
injection begins while starting. The crankshaft rotates an
extra num ber of turns to increase cylinder tem perature
before fuel injection begins. This gives more reliable
starting and reduces exhaust em issions during cold
starts down to about - 1 5 C ( 5 F). This means that the
crankshaft may need to rotate about 3 -4 rotations before
fuel injection begins and the engine fires.
An exhaust pressure governor is activated during start
up.
10
Design and Function
Design and Function
Engine Brake
Fig. 3: D12 Engine

1
2
Camshaft
Shutter
Rocker arm
Control valve
Exhaust pressure governor
Shim
The Volvo Engine Brake (VEB) is a combination o f two

brake systems: the exhaust brake and the compression
brake.
E x h a u s t b rake
The exhaust pressure governor uses a shutter mounted
in the exhaust outlet from the turbocharger. This shutter,
connected to the exhaust pressure governor plunger,
can restrict the exhaust gas flow. This creates a braking
effect during the exhaust stroke when the exhaust gases
cannot evacuate freely and create an overpressure be
tween the pistons and the shutter.
C o m p re s s io n b ra ke
During the engine com pression stroke and combustion
(operating) stroke, the controlled opening of the exhaust
valves creates an overpressure in the combustion cham
ber. This, in turn, produces a braking effect on the
crankshaft.
The cam shaft on an engine with a com pression brake
has tw o extra lobes on each exhaust cam profile. The
lifting height of the extra lobes is very low w hen com
pared to the norm al exhaust lobes. To enable the extra
lobes to open the exhaust valves, the exhaust rocker
arm s are arranged in a m anner by which the valve clear
ance can be reduced during the braking sequence.
S h im S h im s are available in thickness invtervals of 0.05
mm (0.0002 in). Sizes range from 2 .0 -2 .4 mm (0.08
0.094 in) and from 3 .2 -3 .9 5 m m (0.126-0.156 in).
Thickness is stam ped on the shims.
11
Design and Function
D12C
The VEB solenoid has been moved to the center of the
rocker shaft. The oil supply is internal, rather than having
the external piping visible.
Control Valve
The control valve is mounted on the cylinder head under
the valve cover, and is connected to the oil system
ahead of the rocker arm shaft. Its purpose is to reduce
the oil pressure to the rocker arms w hile the engine is
operating (com pression brake not activated).
There is always full system oil pressure to the control
valve intake (1) because the intake is connected via a
pipe to the lube oil gallery in the cylinder block. The oil
pressure to the rocker arm shaft can be increased via a
solenoid valve (2) mounted on the control valve, from ap
proximately 100 kPa (14.5 psi) while the engine is
operating, to more than 200 kPa (29 psi) during com
pression braking.
W hile the engine is operating, the oil pressure is reduced
after the control valve by the plunger (3) being held in
balance by the force of a spring (4) and the oil pressure
in the oil cham ber (6) on the opposite side of the plunger.
W hen the solenoid valve is activated, the oil cham ber (6)
is drained and the spring (4) presses the plunger (3) to
its end position. The plunger com pletely opens the oil
outlet (5) to increase oil pressure to the rocker arm shaft.
Fig. 4: Control Valve
1
2
12
Oil inlet
Solenoid valve
Plunger
4
5
Spring
Oil outlet
Oil chamber
Design and Function
Camshaft on Engine with Compression Brake

The cam shaft on an engine with a com pression brake
has an induction lobe (1) and a decom pression lobe (2)
in addition to the normal exhaust lobe (3) on each
cam profile for the exhaust valves.
The induction and decom pression lobe lifting height is
0.8 mm (0.032 in.) above the basic circle, which is equiv
alent to approxim ately 1.1 mm (0.043 in.) at the valve
bridge.
The induction lobe is positioned so that it opens the ex
haust valves at the end o f the intake stroke and holds
them open until the beginning of the com pression stroke.
The decom pression lobe is positioned so that it opens
the exhaust valves at the end of the com pression stroke.
In order for the induction and decom pression lobes to
open the exhaust valves, the valve clearance must be re
duced to zero by the activation of the non-return valve
and plunger located in the rocker arm for the exhaust
valves.
Fig. 5: Cam Shaft Profile

1
Induction lobe
2
3
Decompression lobe
Exhaust lobe
13
Design and Function
Exhaust Rocker Arms

The exhaust rocker arm s on an engine with a com pres
sion brake are larger than those on a conventional
engine.
The rocker arm includes a non-return valve (2) and a
plunger (3) with a pressure limiting valve, the purpose of
which is to regulate the oil flow during com pression brak
ing.
The rocker arm is held in its position against the valve
bridge with the help of a spring tab (1).
W2003502
The valve clearance is greater than that on an engine

w ithout a com pression brake, because the induction and
decom pression lobes must not open the exhaust valves
w hile the engine is in normal operating mode (com pres
sion brake not activated).
Valve adjustm ent is carried out with shim s which are
placed on the valve bridge.
Fig. 6: Rocker arm assembly, side view:

1
2
Spring tab
Non-return valve
Rocker arm plunger
Shims
N ote: A maximum o f two shim s are allowed to obtain

proper valve clearance.
Non-Return Valve
The engine brake has a non-return valve, consisting of a
plunger (1), spring (2) and a ball (3) in the rocker arm.
When oil from the rocker arm shaft enters the valve, the
movem ent of the plunger is determ ined by the spring
force and the oil pressure.
When the oil pressure is low approxim ately 100 kPa
(14.5 psi); the control valve is in its normal engine oper
ating position the plunger (1) will not move out of its
rest position because the oil pressure is not sufficient to
overcom e the spring force. The plunger pin prevents the
ball (3) from entering the seating area, and the oil can
then flow freely through the valve in both directions.
W hen the control valve takes up the position for com
pression braking, the oil pressure increases to the
non-return valve. The spring force in the non-return valve
is such that when the oil pressure exceeds approxi
mately 200 kPa (29 psi), the spring force is overcom e
and the plunger (1) moves so that it no longer influences
the ball (3). The spring (5) presses the ball (3) against
the seat and prevents the oil contained above the
plunger (4) from flowing past the ball (3). This form s high
oil pressure above the plunger (4).
14
T2006834
Fig. 7: Rocker arm assembly, top view:

1
Plunger
2
3
Spring
Ball
Rocker arm plunger
Spring
Design and Function
Rocker Arm Plunger

The purpose o f the rocker arm plunger is to elim inate all
valve clearance during the com pression braking.
Engine Operation
W hen the engine is operating (com pression brake not
activated), there is reduced oil pressure approx. 100
kPa (14.5 psi) via the control valve to the rocker arm
shaft and the rocker arm non-return valve (1) is open. Oil
can flow freely through the non-return valve in both di
rections. A s a result, no oil pressure is built up between
the rocker arm plunger (2) and the rocker arm.
The set valve clearance is great enough to prevent the
cam shaft induction and decom pression lobes from open
ing the exhaust valves.
The valve m echanism operates the same as on an en
gine w ithout a com pression brake; in other words, only
the exhaust lobe opens the exhaust valves.
T2006828
Fig. 8: Rocker Arm Plunger

1
Non-return valve
Rocker arm plunger
Compression Braking
D uring com pression braking, the control valve does not
reduce the oil pressure, so an oil pressure o f at least
200 kPa (29 psi) is delivered to the rocker arm shaft.
The pressure in the rocker arm non-return valve (1) be
com es so great that the plunger in the non-return valve
is moved out o f its rest position, and the ball now func
tions as a non-return valve. Pressure is built up between
the rocker arm plunger (2) and the rocker arm. The
plunger is pressed out and presses the rocker arm roller
against the lobes on the camshaft. In this way, the valve
clearance is elim inated and the lifting height on the in
duction and decom pression lobes is sufficient to open
the exhaust valves.
The rocker arm plunger is fitted with a pressure limiting
valve (3). W hen the oil pressure between the rocker arm
plunger and the rocker arm becom es too great, the pres
sure limiting valve opens and oil can exit through the
hole in the bottom o f the plunger. The opening pressure
of the pressure limiting valve is governed by the force of
the valve spring.
Fig. 9: Rocker Arm Plunger

1
Non-return valve
Rocker arm plunger
Pressure limiting valve
15
Design and Function
Control System
The engine brake is connected to the throttle pedal and
is activated w hen the pedal is com pletely released, ac
cording to the selection made with the engine brake
switch on the instrum ent panel.
The selection made with this switch also regulates en
gine braking activated by the cruise control.
N ote: The engine brake functions as long as the engine
control system has received signals from engine sensors
indicating that the required preconditions for engine
braking have been met. For example, the engine speed
must be greater than 1100 rpm, the vehicle speed must
be greater than 12 km/h (7.5 mph), and the engine tem
perature m ust be above 70 C (160 F).
The switch has three positions:
F ig 10: Switch fo r engine brake
0 No engine brake engaged

1 Exhaust brake, EPG
2 Exhaust brake and com pression brake, VEB
Exhaust Brake
When exhaust braking, the exhaust pressure governor
(EPG) is activated with a control pressure of approxi
mately 750 kPa (110 psi). A t this point, the shutter is
forced out of the EPG and into the shutter housing. This
restricts the flow of exhaust gases out of the cylinders,
as the shutter blocks the outlet from the turbocharger.
Restricting the flow of exhaust gases form s an air cush
ion between the shutter and the piston crowns. During
the exhaust stroke, this air cushion provides a braking
effect on the pistons as the exhaust valves are then
opened.
The higher the engine speed during the exhaust braking,
the greater the braking effect.
Fig. 11: Exhaust pressure governor
16
T2006832
Design and Function
Compression Brake
T he e x h a u s t b ra ke is a lw a ys e n g a g e d in c o n ju n c tio n
w ith th e c o m p re s s io n brake. In the com pression brake
induction phase, the exhaust brake creates an overpres
sure in the exhaust manifold, making the com pression
brake more efficient.
In d u c tio n ph a se
The induction phase begins at the end of the intake
stroke and continues slightly into the com pression stroke.
The piston travels towards its bottom
tion and the cam shaft induction lobe
valves for the tim e required to fill the
overpressure created by the exhaust
haust manifold.
dead center posi

opens the exhaust
cylinder with the
brake in the ex
W hen the induction lobe closes the exhaust valves, the

cylinder has an overpressure at the start of the com pres
sion stroke.
This overpressure considerably increases the com pres
sion during the com pression stroke, w hich in turn
creates a powerful braking effect during the upward
movem ent of the piston.
Fig. 12: C harging phase
D e c o m p re s s io n ph a se
A t the end of the com pression stroke, when the piston is
nearing its top dead center position, the cam shaft
decom pression lobe opens the exhaust valves and re
leases the pressure out of the cylinder.
S hortly before the bottom dead center position, the ex
haust valves are opened by the ordinary exhaust lobe.
D uring the exhaust stroke, the counterpressure is cre
ated in the exhaust manifold which, in turn, has a
braking effect because the exhaust pressure governor
shutter is still restricting the flow of exhaust gases out of
the turbocharger.
Fig. 13: Decom pression phase
17
Design and Function
Crankcase Ventilation
D12C
The D12C has new crankcase ventilation with its outlet
from the upper tim ing gear cover.
The tim ing gear cover is designed with an oil trap to pre
vent oil from escaping through the ventilation tube.
T2012791
Fig. 14: C rankcase Ventilation, D12C
W2003503
Fig. 15: Crankcase Ventilation, D12B and D12C
W2003504
Fig. 16: Crankcase Ventilation, D12A
18
Design and Function

The exhaust pressure governor(EPG ) acts as an exhaust
brake when slowing the vehicle down. It also speeds en
gine w arm -up by applying a load to the engine during
idle and warm-up. Engine load is created by the (EPG)
throttling the flow of exhaust gases, causing the engine
to w o rk against a backpressure. This increases com bus
tion tem perature and shortens the w arm -up period.
On engines w ithout a pre-heater, the (EPG) is activated
before the starter motor is engaged. For engines with a
pre-heater, the (EPG) is activated after pre-heating,
start-up and post-heating have taken place.
The (EPG) is activated by a control pressure of about
200 kPa (29 psi), by a combi relay when it is used during
starting and warm-up. W hen used for engine braking,
the exhaust pressure governor is controlled by a single
tw o-position switch if the engine is equipped with an ex
haust brake only, and by dual tw o-position switches if the
engine is equipped with a Volvo Engine Brake, or VEB
(both exhaust brake and com pression brake).
T2006948
Fig. 17: Exhaust pressure governor (EPG)
Engines with Exhaust Brake Only

Two-position switch (ON/OFF)
W ith the switch in the ON position, the exhaust pressure
governor is activated by a control pressure of approx.
750 kPa (110 psi) subject to the following conditions:
A ccelerator pedal fully up.
Clutch pedal fully up.
Engine speed above 1100 rpm.
Boost pressure below 52 kPa (7.5 psi).
W hen using cruise control and preselected road
speed is exceeded by 7 km/h (4 mph) (disengage
ment at 4 km/h (3 mph) over preselected speed).
Fig. 18: Exhaust brake switch for WX, W G and AC
ABS not activated (continuous control).
Fig. 19: Exhaust brake switch for VN/VHD
19
Design and Function
Engines with VEB

W hen the engine brake ON/O FF switch is in the ON po
sition, the engine brake is activated according to the
position of the engine brake HI/LO switch.
W ith the HI/LO switch in the LO position, only the ex
haust pressure governor is activated and is subject to
the sam e conditions as for engines with an exhaust
brake only.
W ith the HI/LO switch in the HI position, the VEB is
activated (both the exhaust pressure governor and com
pression brake are switched on).
In addition to satisfying exhaust brake prerequisites, the
following conditions must be met:
Coolant tem perature above 70C (158F).
Vehicle speed must be greater than 12 km/h

(7.5 mph).
Engine tem perature must be above 43C (110F).
Fig. 20: Engine brake switches for W G and AC

Dual tw o-position switches:
1
ON/OFF
HI (VEB)/LO (exhaust brake)
For VN/VHD, engine exhaust brake switches are located

on the dash (5); see Fig. 21: Engine brake switches for
VN/VHD, page 20.
W3004361
Fig. 21: Engine brake switches for VN/VHD
20
Left Dash Switches
Driving Light Switches
Pneuam tic Switches
Auxiliary Switches
R ight Dash Switches
Design and Function
D12C
The EPG on the D12C has a new air valve. The valve is
located on the right, rear edge of the engine block and is
controlled by current from the EECU. There are two
on/off valves and two reduction valves in the valve body.
T2012788
Fig. 22: Exhaust Pressure Governor, D12C
21
Design and Function
EPG Control Valve

The exhaust pressure governor is controlled by a valve
that regulates air pressure to the EPG.
The exhaust pressure governor operates using two dif
ferent pressures:
When the exhaust pressure governor is activated

during starting and keeping the engine warm, the
control valve provides a control pressure of approxi
mately 200 kPa (29 psi).
When the exhaust pressure governor is activated for

engine braking, the control valve provides a control
pressure of approxim ately 750 kPa (110 psi).
D12A
The D12A is provided with two solenoid valves, one for
controlling the starting and engine warm ing pressure
and one for controlling the pressure fo r engine braking.
Both solenoid valves are located in a bracket on the
cylinder head.
D12B
The D12B is provided with an EPG control valve that
controls both the starting and engine warm ing pressure,
and the pressure for engine braking. The valve is located
at the lower rear edge on the right-hand side of the cylin
der block.
The EPG c o n tro l va lve on th e D12B re p la c e s th e tw o
s o le n o id v a lve s on th e D 12A to p e rfo rm th e sa m e
fu n c tio n .
22
W2002624
Fig. 23: EPG control valve, D12B
Design and Function
Air Restriction Indicator

There are several types of restriction indicators which
can be mounted in certain locations, such as on the air
cleaner duct o r on/above the instrum ent panel. The air
restriction indicator mounted on the instrum ent panel
perm its continuous m onitoring o f the gauge.
W hen either the flag or piston-type restriction gauge is
mounted directly on the air cleaner, the piston is usually
drawn downward into view as the elem ent loads with dirt.
It locks into full view only after the restriction (caused by
a dirty elem ent) reaches the rated value of the indicator.
Fig. 24: A ir restriction indicator WX, W G , AC(dash

mounted)
Fig. 25: A ir restriction indicator VN, VHD, VNM (located

beneath the air box)
Fig. 26: A ir restriction indicator VN, VHD (located on the

air pipe)
W2000741
Fig. 27: Piston-type air restriction indicator-W G

23
Design and Function
Turbocharger
The turbocharger is driven by the exhaust gases from
the engine passing through the turbine housing on their
way out into the exhaust system.
The flow of exhaust gases causes the turbine wheel in
side the turbine housing to rotate. On the same shaft as
the turbine wheel is a com pressor wheel. The com pres
sor wheel is mounted in a housing which is connected
between the air cleaner and the intake manifold.
W hen the com pressor wheel starts to rotate, air is drawn
in from the air cleaner, com pressed and forced into the
cylinders of the engine but not before it has been
cooled down after passing through the charge air cooler.
T2006949
Fig. 28: Turbocharger
D12A
The turbo used on the D12A engine is NOT interchange
able with turbos on other D12 engine versions.
24
Design and Function
Exhaust Manifold
N ew d e s ig n o f e x h a u s t m a n ifo ld s e c tio n s
W2002222
Fig. 29: Manifold designs
Description
New design P/N
Qty
Old design P/N
Qty
Side section
3964707
1547521
Middle section
3964708
1547520
Complete
3964706
1677205
Im p ro ve d g a s k e t
W2002223
Fig. 30: Gasket
N ote: The gaskets are marked "M ANIFOLD SIDE to aid

in installation.
25
G roup 25 Intake and Exhaust System
Tightening Sequence
Old Style Manifold.
New Style Manifold
26
Design and Function
Troubleshooting
Troubleshooting
Air Restriction Indicator, Checking
Low restriction readings may be difficult to identify. They
can result from a damaged elem ent gasket, ruptured
element, incorrectly installed elem ent or a leak in the en
gine air intake ducts and piping. W hen servicing the air
cleaner, make sure to check for these. A w ater m anom e
te r may also be used to check for service. A m axim um of
25 in. o f w ater (20 in. o f w ater measured at air cleaner
body outlet) is the limit of elem ent service and indicates
a need for replacement.
On turbocharged engines, connect the m anom eter to the
air intake pipe, one to tw o pipe diam eters upstream from
the turbocharger inlet, in a straight section of pipe. Tur
bocharged engines should be under full load long
enough to allow the turbocharger to reach maximum
speed.
N ote: Dust conditions and accum ulated mileage deter
mine the interval for replacing the air cleaner element.
The air cleaner should be inspected every 24,000 km
(15,000 m iles) and replaced as necessary. The air
cleaner elem ent should be replaced at least once a year
regardless of service or restriction indicator readings.
27
28
Service Procedures
Service Procedures
2562-03-02-01
Air Filter Element, Replacement
DANGER

ju ry or death.
W2000940
WARNING

Fig. 31: Removing the endcap,(W G, AC)
CAUTION
W hen removing and installing the intake manifold on

engines equipped with VEB, keep the w ork area as
clean as possible to prevent im purities from entering
the oil system. This also applies to the com pression
brake oil delivery pipe between the cylinder block and
intake manifold.
Remove the endcap by removing the

hardware (depending on the type of
endcap) that attaches the endcap to
the air filter.
N ote: The type of hardware used to
hold the endcap varies, depending on
the style o f air cleaner and air cleaner
assembly.
Removal
1
A pply parking brakes. make sure the

shift lever is in neutral.
W2002051
Fig. 32: Removing the air filter (VN,VHD and VNM )

2
Tilt hood.
Remove the air filter.
29
Service Procedures
W2000746
Fig. 34: Endcap reinstall

W2000941
Fig. 33: Remove the air filter (WG, AC)
Reinstall the endcap and attach, using

the necessary hardware. Tighten to a
torque of 24 2 Nm (18 2 ft-lb).
Rem ove the elem ent from the canister.

If the elem ent is held by a wing nut,
remove the wing nut before removing
the element.
N o te : Refer to the label attached in

side the endcap on som e models.
Installation
6
Clean and inspect the inside of the
housing and endcap.
7
Lubricate the rear seal on the new fil
ter with Vaseline or the like.
8
Install the new filter. Make sure that it
is correctly positioned in the filter
housing.
24 2 Nm
(18 2 ft-lb)
2512-03-02-01
Intake Manifold Gasket(s), Re
placement
/f\ DANGER
jury or death.
/ j \ WARNING
/ j \ CAUTION
W hen removing and installing the intake manifold on
engines equipped with VEB, keep the w o rk area as
clean as possible to prevent im purities from entering
the oil system. This also applies to the com pression
brake oil delivery pipe between the cylinder block and
intake manifold.
30
Service Procedures
W2000733
Fig. 36: Replacing intake manifold gasket
Remove the intake manifold bolts and

carefully tap the manifold loose, using
a plastic-headed mallet.
Removal
1
Remove the plastic ties from the elec

tric cables under the intake manifold.
D isconnect the term inals from the sen
sors for the charge air pressure and
the charge air tem perature on the in
take manifold.
2
Remove the boost pressure gauge
connection from the intake manifold.
3
Remove the bolt for the
the spacer, from the fan
bracket.
Remove the pre-heater,
from the intake manifold
pre-heater, or
shroud
or the spacer,
and set aside.
6
Clean the sealing surfaces of the in
take manifold and the cylinder head.
Install a new gasket.
Installation
1
Install a new seal on the com pression
brake oil duct.
2
Apply a 2 mm (1/16 in.) bead of
sealant to the intake manifold. The
manifold must be installed and tight
ened within 20 m inutes after applying
sealant.
2 mm
(1/16 in.)
N o te : Do not allow the sealant to enter

the oil duct of the com pression brake.
4
Loosen the alternator drive belt and re
move the nut for the gear lever bracket.
Remove the alternator.
31
Service Procedures
W2000734
W2000943
Fig. 38: Turbocharger assembly
A djust the alternator, A/C refrigerant

compressor, drive belt tension if so
equipped.
4
Install the pre-heater (if equipped) or
the spacer, using new gaskets, and
bolt the mounting to the fan shroud.
5
Install the boost air gauge connections
to the intake manifold.
6
Reconnect the term inals to the sen
sors for the boost air pressure and the
boost air tem perature on the intake
manifold. Tie the electrical cables.
2551-03-02-02
Turbocharger, Replacement
/ j \ danger
ju ry or death.
WARNING
32
n/a
2
3

Oil delivery and return pipes
Clamp
Nuts
G eneral G u id e lin e s and P re c a u tio n s

Always determ ine the reasons for replacing a tu r
bocharger before making the repair. C orrect any noted
defects before replacing.
W hen replacing a turbocharger, always thoroughly read
and carefully follow the procedures.
A fter degreasing, wipe the cooler clean and dry it with
com pressed air. Also check the air pipes and charge air
hose. If contam inated with oil, replace the charge air
hose to prevent dam age to the rubber.
The engine oil system and intake system must be kept in
good condition to ensure proper turbocharger operation.
That is, change oil and filters at specified times, use the
correct engine oil and properly care for the air cleaner.
W hen replacing a turbocharger, use com pressed air to
remove any rust or carbon flakes from the exhaust mani
fold. Carbon flakes can dam age the turbine of the new
unit. It is also im portant to clean the intake pipe from the
air filter. Pieces of broken com ponents can remain in the
pipe and cause im m ediate turbocharger failure.
Also, always check to be sure that the injection equip
ment is in good condition.
N o te : Once the turbocharger is installed put oil in oil
supply port to ensure proper turbo lubrication. Once
turbo is sufficently lubricated you can crank the engine.
Removal
1
Remove the air cleaner hose from the
turbocharger.
Service Procedures
2
R em ove the bolts holding the charge
air pipe to the mounting bracket. Pull
the charge air pipe off the tu r
bocharger.
1
Before installing the new turbocharger,
check the engine oil and change the
oil filters, if required. Then, run the en
gine a few minutes before installing
the new turbocharger. W hen running
the engine w ithout a turbocharger, be
sure to plug the oil delivery line. As a
precaution to prevent the oil from en
tering the new turbocharger, a strainer
can be tem porarily installed into the oil
entry point. Then run the engine for at
least a half hour.
3
Rem ove the air line from the exhaust
pressure governor.
4
Rem ove the turbocharger oil delivery
and return pipes. Install a protective
plug into the connection for the oil de
livery pipe on the oil filter bracket.
N ote: After this test, remove the

strainer to prevent strainer blockage
that may occur if the oil system is not
properly maintained.
5
Loosen the clam p between the tu r
bocharger and the shutter housing.
R em ove the shutter housing from the
turbocharger.
2
Before installing a new turbocharger,
pre-lubricate the bearing system. This
will ensure adequate lubrication of the
turbocharger at start-up. Install a new
gasket and install the new tu r
bocharger.
6
Remove the nuts and lift the tu r
bocharger off.
3
Apply sealant to the shutter housing
sealing surface and install the housing
to the turbocharger. Mate the shutter
housing flange with the heel of the tu r
bocharger. Retighten the clamp.
7
Clean the sealing surfaces of the ex
haust manifold, shutter housing and
oil-pipe connections.
Installation
4
C onnect the air line to the exhaust
pressure governor.
5
Install the turbocharger oil delivery
pipe using new seals.
N ote: Be sure to remove the delivery
oil plug if used to run the engine w ith
out the turbocharger.
W2000739
Fig. 39: Turbocharger assembly

7
6
Install the turbocharger oil return pipe
to the cylinder block using a new seal.
Do not attach the oil return pipe to the
turbocharger at this time.
Gasket
Clamp
Air line
10
Oil delivery pipe
11
Oil return pipe
7
Install the charge air pipe into the tu r
bocharger using new sealing rings.
Attach the charge air pipe.
33
Service Procedures
Removal
8
Reconnect the air cleaner hose to the
turbocharger.
1
Rem ove the bolts holding the exhaust
manifold and lift off the manifold.
9
Attach the turbocharger oil return pipe,
using new seals.
2
D isassem ble the exhaust manifold and
remove all sealing rings. Clean the ex
haust manifold and the cylinder head.
10
Apply parking brake and place shift
lever in neutral. S tart the engine and
check for proper operation and leaks.
Installation
2516-03-04-01
Exhaust Manifold Gasket(s),
Replacement
(Turbocharger Removed)
3
Use com pressed air to blow any
carbon out of the manifold. Then as
semble the manifolds.
/ j \ CAUTION
W ear appropriate eye protection.
/f\ DANGER
B efore working on a vehicle, set the parking brakes,
ju ry or death.
/ j \ WARNING
N ote: Three sealing rings must be in

stalled at each side. Install the sealing
ring with the sm allest diam eter in the
middle.
4
Install the exhaust manifold using new
gaskets. Begin by lining up all three
manifold sections onto the cylinder
head, starting with section A.
N ote: Make sure that the sleeves fit
correctly into the milling of the exhaust
manifold and install the gaskets with
the graphite surface facing the cylinder
head.
5
A fter applying anti-sieze to the mani
fold bolts and turbo studs, screw the
bolts in by hand, starting with section
A and then sections B and C.
T2006979
6
Tighten the bolts cross-wise starting
with section A, and then sections B
and C. Torque to 25 Nm (18 ft-lb). See
illustration, page 26
25 Nm
(18 ft-lb)
Fig. 40: Exhaust manifold

N ote: It is easy to get the wrong impression from ex
haust manifold leakage (m ixture of moisture and soot).
This mixture may drip down on the turbo and could eas
ily be mistaken for an oil leak from the turbo.
34
7
Begin the tightening sequence again;
however, raise the torque to 48 8 Nm
(35 6 ft-lb).
48 8 Nm
(35 6 ft-lb)
8
S ta rt the engine and run until it
reaches operating tem perature.
Service Procedures
9
Verify the torque at 48 8 Nm
(35 6 ft-lb).
2538-03-02-01
Exhaust Pressure Governor,
Replacement
T2006940
/ j \ danger
jury or death.
i4 = = 3
Fig. 42: Removing air pressure governor

Remove the bolts and lift off the ex
haust pressure governor.
Installation
3
/ j \ WARNING
Removal
1
T2006941
Fig. 43: Cleaning shutter housing

Clean the sealing surface of the shut
te r housing.
4
Install the new exhaust pressure gov
ernor. Install the air line.
T2006942
Fig. 41: Removing air line

Remove the air line from the exhaust
pressure governor.
5
lever in neutral. S ta rt the engine and
check for proper operation and leaks.
35
2538-04-04-01
Exhaust Pressure Governor,
Overhaul
(Unit Removed)
/ j \ DANGER
ju ry or death.

8
Disassembly
i
Remove the end cover from above the
plunger.
2
Remove the bolts and take out the
plunger.
3
Remove the seals (4, 20 and 19, Fig.
44: Exhaust pressure governor, page
36).
4
Remove the set screw on the plunger
rod.
WARNING
Service Procedures
22

1-Setscrew
11-Valve Collets
2-Bolts
12-Bolts
3-Plunger
13-Cover
4-Seazls
14-Heat shield
5-Plunger Rod
15-Securing flange
6-Spring
16-Nut
7-Spring holder
17-Nut
8-Spring
18-Housing
9-Seal
19-Seals
10-Shutter
20-Seals
21-End cover
Special tools: 999 2610, 999 8225, 999 8246

36
T2006747
Fig. 45: Removing collets

Place the exhaust pressure governor
into a press. Com press the spring
enough to remove the valve collets
N ote: Do not press more than
necessary to remove the collets. C om
pressing the spring fully can dam age
the cover.
6
Remove the plunger rod, spring and
shutter.
7
R em ove the bolts holding the cover,
the heat shield and the securing
flange.
Service Procedures
Fig. 48: Plunger rod installation
Fig. 46: Rem oving spring holder

Carefully tap out the spring holder that
secures the spring and the seal (9,
Fig. 44: Exhaust pressure governor,
page 36).
9
Clean all parts and replace any that
are dam aged or worn.
Put the plunger rod onto drift 9992610

in a press. Using drift 9998225, press
on the spring holder until it bottoms in
the housing. Remove the plunger rod.
Check to make sure that the spring
holder is correctly centered.
3
Install the securing flange, the heat
shield and the cover. Tighten the bolts
to 13 2 Nm (10 2 ft-lb).
9992610
9998225
13 2 Nm
(10 2 ft-lb)
4
Install the shutter, spring and plunger
rod into the housing.
Assembly
5
T2006745
Fig. 47: Assembly

Install the plunger rod into the housing
from behind so as to center the spring
holder. Install a new seal with the
beveled edge facing inside the hous
ing. Install the spring and a new spring
holder.
Fig. 49: D epressing spring

Com press the spring by hand, making
sure that the shutter shaft and plunger
rod fit together and that the plunger
rod fits correctly into the seal. Stop ap
plying pressure if undue resistance is
felt. Install the valve collets.
37
6
Install the set screw into the plunger
rod. A pply sealant to the set screw before installing. Tighten the set screw to
40 5 Nm (30 4 ft-lb).
7
Install a new seal into the plunger rod
and install the plunger. A pply sealant
to the boltsand tighten them to 13 2
Nm (10 2 ft-lb).
8
Install the end cover using new seals.
Make sure that the seal bottoms in the
housing. Install the seal with the flat
side facing the housing. Tighten the
bolts (22) to 24 2 Nm (18 2 ft-lb).
38
Service Procedures
40 5 Nm
(30 4 ft-lb)
13 2 Nm
(10 2 ft-lb)
24 2 Nm
(18 2 ft-lb)
Service Procedures
2651-06-04-01
Charge Air Cooler Leak Test,
Checking
/ j \ WARNING
Make s u re th a t th e g a u g e p re s s u re n e ve r e xce e d s
100 kPa (14.5 psi). F a ilu re to d o s o ca n re s u lt in
p e rs o n a l in ju ry .
If the turobocharger fails on an intercooled engine, it is

essential to check the charge air cooler. W hen consider
able oil loss or the presence o f foreign material (for
example, broken com pressor wheel parts forced into the
charge air cooler) is suspected, take the following m ea
sures:
/ j \ WARNING
C heck the charge air cooler hoses up to the cooler. If

there are traces of oil at the charge air cooler, remove
the cooler and clean it internally, using a low-aroma,
w hite-spirit type degreasing agent.
If turbocharger failure results in a broken com pressor
whell, pressure-test the charge air cooler to see if it has
been dam aged by broken com pessor w heel pieces.
Always w ear appropriate eye protection to prevent

the risk of eye injury due to contact with engine debris
or fluids.
1
S p e c ia l to o ls : 9 9 9 6 6 6 2 , 9 9 9 8 2 8 8 , 9 9 9 8 2 8 9
N ote: Check the function of pressure gauge 9996662

before using it. Attach it to an air supply and set the
pressure to 100 kPa (14.5 psi) with the regulator valve.
/ ? \ danger
ju ry or death.
MD
W2000715
Fig. 50: Pressure gauge
/ j \ WARNING
Shut-Off Valve
Reduction Valve
C onnect the pressure gauge to out

side air source and set the gauge
reading to 100 kPa (14.5 psi) using
the reduction valve. The knob of the
reduction valve is locked by a ring
which is engaged by pulling up on the
ring, and pushing down to release.
/ j \ WARNING
Never disconnect an air system com ponent unless all
system pressure has been depleted. Failure to de
plete system pressure before disconnecting hoses or
com ponents may result in their violent separation and
can cause serious bodily injury.
2
Close the shut-off valve. For the pres
sure gauge to be considered reliable,
the pressure reading must not drop
during a period of tw o minutes.
39
Service Procedures
W2000735
Fig. 51: Removing charge air hoses

Remove the air hoses from the charge
air cooler. Install connecting w asher
9998288, sealing w asher 9998289 and
new O-rings.
9998288
9998289
W2000736
Fig. 52: Connecting pressure gauge

Remove the pressure gauge reduction
valve and check that the gauge read
ing is 0. C onnect the pressure gauge
to the charge air cooler.
5
Open the shut-off valve and set the
pressure gauge to 100 kPa (14.5 psi),
using the reduction valve.
6
C lose the shut-off valve. For the
charge air cooler to be serviceable, the
pressure reading must not drop more
than 50 kPa (7 psi) during 30 seconds.
7
If a leak is found, repeat the test a few
times. Also check pressure gauge
hoses and connections.
40
System Check
System Check
2559-06-02-02
Boost Pressure, Checking
N ote: This operation num ber covers only the installation

and removal of test equipment.
Special tools: 9996065, 9996666

1
-4 F
-20 C
14 F
32 F
-10 C
0 C
50 F
68 F
86 F
10 C
20 C
30 C
104 F
40 C
W2000737
Boost pressure at various temperatures
T2006943
measured boost pressure
B
C
correction curves
intake air temperature
Boost pressure gauge installation
Clean around the plug for the boost

pressure gauge on the intake m ani
fold. Remove the plug and install
union 9996666. Connect pressure
gauge 9996065 to the 9996666 union.
Make sure the pressure gauge hose is
long enough to reach the drivers seat
in the cab.
N ote: Secure the hose so that it does
not contact any moving parts.
2
The m easurem ent should be carried
out:
with a fully loaded vehicle
driving up an incline at full accel

eration (full load)
while engine revs (rpm), slowly
pass the speed specified for boost
pressure.
The specifications state engine speed

and boost pressure at +20C (68F). If
reading at any other tem perature, use
the chart above to correct the resulting
boost pressure.
Example:
A pressure of 80 kPa (12 psi) m ea
sured at 10C (14F) is equivalent to
about 70 kPa (10 psi) +20C (68F).
That is, pressure drops as tem pera
ture rises.
If boost pressure does not reach spec
ified levels, check the following:
properly tightened bolts on intake

and exhaust manifolds
exhaust brake
backpressure in exhaust system
air cleaner elem ent
fuel pressure
N ote: For a reliable result, engine load

must be maintained long enough for
the pressure to stabilize. Boost pres
sure specifications at 28.3 r/s (1700
rpm):
VE D 1 2 -3 7 0 125 -1 7 0 kPa (1 8 -2 4 .7 psi)

VE D 1 2 -4 1 5 145 -1 7 5 kPa ( 2 1 -2 5 .4 psi)
41
System Check
Exhaust Backpressure, Checking

P re ssu re gauge: O f indicating or U-tube type, graded to
24 kPa or 2,440 mm w ater column (3.5 psi) and
equipped with damper.
S teel pipe: A bout 200 mm (8 in.) long and able to con
nect to a union.
U nion: The union must be brazed onto the exhaust pipe
as shown. Then drill a 1.5 - 2.0 mm (0.06 - 0.08 in)
hole through the center of the union and the side of the
exhaust pipe.
Hose: The hose is installed between the pressure gauge
and steel pipe and must be long enough for the gauge to
be read inside the cab.
Measuring equipment
1
Damper
Pressure gauge
3
4
Steel pipe
Union
Pressure Testing Outlet Location

The pressure-testing fitting should be located on as
straight a section of the pipe as possible, tw o-thirds after
and one-third before a bend in the pipe.
The test fitting must not be located on an outer or inner
bend of the exhaust pipe.
Outlet location
Backpressure Measuring Techniques

Using a chassis dynam om eter is the best way to m ea
sure backpressure. If such equipm ent is not available,
the vehicle can be driven up a long hill. The accelerator
pedal must be kept fully floored with the vehicle acceler
ating up the hill until the engine reaches specified rpm.
Note the highest backpressure reading and com pare it
with specifications.
After the test, make sure to block off the union in the ex
haust pipe with a plug, or in some other suitable manner.
42
Feedback
O ne o f o u r o b je c tiv e s is th a t w o rk s h o p p e rs o n n e l s h o u ld have a c c e s s to c o rre c t and
a p p ro p ria te s e rv ic e m a n u a ls w h e re it c o n c e rn s fa u lt tra c in g , re p a irs and m a in te n a n c e
o f V o lvo tru c k s .
In o rd e r to m a in ta in th e h ig h s ta n d a rd s o f o u r lite ra tu re , y o u r o p in io n s and e x p e rie n c e
w h e n u s in g th is m a n u a l w o u ld be g re a tly a p p re c ia te d .
If yo u have any c o m m e n ts o r s u g g e s tio n s , m ake a c o p y o f th is page, w rite d o w n y o u r
c o m m e n ts and se n d th e m to us, e ith e r v ia te le fa x o r m a ilin g d ire c tly to th e a d d re s s
lis te d below.
To
F rom
V o lvo T ru cks N o rth A m e ric a , Inc.
.........
D ept. 516 S e rv ic e P u b lic a tio n s
.........
7825 N a tio n a l S e rv ic e R oad
.........
P.O. B o x 26115
.........
G re e n s b o ro , NC 27402-6115
.........
U SA
.........
Fax (336) 393-3170
.........
C o m m e n ts /p ro p o s a ls
C o n c e rn s S e rv ic e M anual:
Operation Numbers
2512-03-02-01
Intake Manifold Gasket(s), R e p la c e m e n t.................................................................................30
2516-03-04-01
Exhaust Manifold Gasket(s), R e p la c e m e n t............................................................................. 34
2538-03-02-01
Exhaust Pressure Governor, R e p la c e m e n t............................................................................. 35
2538-04-04-01
Exhaust Pressure Governor, O v e r h a u l..................................................................................... 36
2551-03-02-02
Turbocharger, R e p la c e m e n t........................................................................................................ 32
2559-06-02-02
Boost Pressure, C h e c k in g ............................................................................................................ 41
2562-03-02-01
A ir Filter Element, R e p la c e m e n t................................................................................................ 29
2651-06-04-01
Charge A ir C ooler Leak Test, Checking
................................................................................ 39
VOLVO

Service Manual
Trucks
Group
220600
Lubricating and Oil System

D12, D12A, D12B, D12C
PV776-TSP144525
VOLVO
Foreword
D ocum entation:
N o te : Indicates a procedure, practice, or condition that must be followed in order to
cur.

Greensboro, NC USA
O rder num ber: PV776-TSP144525

Contents
G eneral ................................................................................................................... 3
S p e c ific a tio n s ...................................................................................................... 5
Torque C hart ....................................................................................................... 5
Tightening Specifications
.............................................................................. 5
T o o ls ........................................................................................................................ 7
Special Tools
...................................................................................................... 7

...................................................................................... 11
............................................................................. 11
General ............................................................................................................ 11
D12, D12A, D12B .......................................................................................... 12
D12C
................................................................................................................ 13
Oil Valves ........................................................................................................... 14

D12, D12A, D12B .......................................................................................... 14
D12C
................................................................................................................ 15
Oil Pump ............................................................................................................ 16

Oil Filter ............................................................................................................. 16
Piston Cooling
.................................................................................................. 16
............................................................................................... 17
Lube System Fuel Contamination, Checking ........................................... 17

Oil C ooler Leak Test, Checking ................................................................... 17
........................................................................................ 19
Oil Pan, Installation .......................................................................................... 19

Lube Oil Pump, R eplacem ent ...................................................................... 19
Removal
Installation
......................................................................................................... 20
......................................................................................................21
Lube System Pressure, Checking .................................................................22

Oil Filter, Replacem ent .....................................................................................23
Piston Cooling Valve, R eplacem ent ............................................................. 24
Piston Cooling Nozzle, R eplacem ent ...........................................................25
Oil Pressure Reduction Valve, R eplacem ent ............................................. 26
Oil C ooler Core, R eplacem ent ...................................................................... 28
Removal
Installation
......................................................................................................... 28
......................................................................................................29
Oil C ooler Bypass Valve, R eplacem ent .................................................... 31

Oil System Passages, Cleaning .................................................................... 31
Oil Filter Nipple, R eplacem ent
...................................................................... 42
Oil Filter Overflow Valve, R eplacem ent ....................................................... 43

F e e d b a ck
G roup 22 Lubricating and Oil System
General
General
This inform ation covers the Lubricating and Oil System for the D12, D12A, D12B, and
D12C engines.
Group 22 Lubricating and Oil System
Specifications
Specifications
Torque Chart
Part
Torque
Oil cooler elem ent bolts
27 4 Nm (20 3 ft-lb)
Oil cooler elem ent cover bolts
33 4 Nm (24 3 ft-lb)
Oil pump interm ediate gear bolts
24 4 Nm (18 3 ft-lb)
Oil pump main bearing bolts
150 20 Nm (111 14 ft-lb)
Oil pump main bearing cap bolts
24 4 Nm (18 3 ft-lb)
Oil strainer bolts
27 4 Nm (20 3 ft-lb)
Delivery pipe union
10 Nm (7.4 ft-lb)
Oil pan bolts
24 4 Nm (18 3 ft-lb)
Piston cooling nozzle bolts
24 4 Nm (18 3 ft-lb)
Oil filter base
40 5 Nm (30 4 ft-lb)
Tightening Specifications
Part
Tighten Until:
Oil filter (full flow)
Seal contacts housing then additional 1/2 - 3/4 turn
Oil filter (bypass)
Seal contacts housing then additional 3/4 -1 turn
Tools
Tools
Special Tools
The following special tools are required fo r w o rk on the VE D12 oil system . Tools are
available from Volvo Trucks N orth A m erica, Inc. parts departm ent. U nless otherwise
noted, all tool num bers are preceded by 99 9 . W hen requesting tools, provide the ap
propriate p a rt number, for example, 9992873.
9992873
Connection union fo r checking lube oil

pressure
9996398
Pressure gauge fo r checking lube oil

pressure
9996662
9996672
Removal tool fo r oil filter
9996845
C-clam p for leak test, oil cooler elem ent
9996956
Pressure gauge fo r leak test, oil cooler

elem ent
Tools
W0001809
J-43051
Reducation valve cap socket
9998691
Oil Filter Nipple installation Kit

1
9809706
9809702
9809703
9809705
9809704
Tools
Special Equipment
Like the special tools, the following are available from the parts departm ent of Volvo
Trucks North Am erica, Inc.. W hen requesting tools, provide the appropriate part num
ber.
W0001840
1159794
Torque wrench 10-100 Nm (7 - 73 ft-lb)
1159795
Torque wrench 40 - 340 Nm (30 - 250 ft-lb)
1159796
Torque wrench 150 - 800 Nm(110 - 590 ft-lb.)
W0001841
W0001842
1Q
Design and Function
Design and Function

General
Reducing valve
Overflow valve
Cooling valve
Overflow valve
Safety valve
Thermostatic valve
The engine has a forced lubrication provided by a gear

pump driven by the crankshaft through an interm ediate
gear. The lubrication system contains two full flow filters
and a by-pass filter. The oil flow is adjusted by six
valves. Three of these are individual valves and they are
identified with color codes to avoid an incorrect installa
tion. This color code may be replaced by a num ber that
represents the valve opening pressure.
A flat oil cooler is assembled under a cast aluminum
cover in the engine block right side.
The lubrication oil pump impels the oil towards the two
full flow filters and the by-pass filter.
The by-pass filter contains a low oil passageway and a
high degree of filtering.
A fte r passing through the full flow filters, the oil moves to
the cylinder block, w here it is distributed through gal
leries to engine points in need of lubrication.
The purpose of the lubrication system is to lubricate the
engines movable parts in order to keep friction and
w earing to a minimum. The oil transports coal and other
residues stuck on the cylinder walls after combustion.
The oil also functions as a sealer, for the cylinder liners
have been projected in such a way that a thin layer of oil
is always kept in its walls. This make it easier for the pis
ton rings to seal the com bustion chamber. The oil also
cool the engine inner and, at the same time, reduces the
sounds produced by the engine.
11
Design and Function
D12, D12A, D12B
T2006823
1
Oil pressure regulator valve
Oil cooler by-pass valve
Oil filter by-pass valve
Piston cooling valve
5
6
By-pass filter
Full-flow filter
Full-flow filter
Oil pipe for engine brake (VEB)
The engine is pressure-lubricated by a gear pump driven

by the engine tim ing gears. The lube oil is cleaned by
two full-flow filters and one bypass filter. The flat-type oil
cooler is mounted under a cast alum inum cover on the
right-hand side of the cylinder block.
The lube oil pump forces the oil to the full-flow filters and
the bypass filter. The bypass filter has a low through flow
and provides a high degree of filtration. The oil is led
from the full-flow filters to the cylinder block where it is
distributed by passages to the lubricating points o f the
engine.
12
The lubricating system incorporates four valves:
Oil pressure regulator valve
Oil cooler bypass valve
Oil filter bypass valve
Piston cooling valve
Design and Function
D12C
Reducing valve
Filter
Overflow valve
Compressor
Cooling valve
Overflow valve
10
11
Turbocompressor
Regulator valve
Safety valve
12
Oil cooler
Thermostatic valve
Filter
13
14
Pulverizer nozzle
Oil pump
The oil pump (14) forces the oil through the coolant
elem ent in the oil cooler (12) to the filter casing that con
tains both the full flow filter (7) and the by-pass filter (8).
The oil goes then to the gallery in the engine block
w here it is distributed through the galleries and all the
engine lubrication points. A gallery that passes through
the engine block and the cylinder head lubricates the
cam shaft and the rocker arm mechanisms. In the VEB

engines, the oil passes through the regulator valve (11)
The com pressor (9) is lubricated through an external
pipe that comes from the filter casing.
The turbocom pressor (10) is lubricated through a pipe
that comes from the bypass filter.
Valve Functions
1
2
The reducing valve regulates engine oil pressure let

ting go the oil excess to the oil sump.
The filter overflow valve (8) opens up if the filters
become clogged, assuring the continuity of the tu r
bocom pressor lubrication.
The piston cooling valve is pressure sensible and
opens up as soon as the rotates exceeds idling
speed pressure.
The oil is conducted to the longitudinal gallery on
the block and pulverized by the pulverizer nozzle
(13), one for each piston, on the piston flange bot
tom side.
5
6
The filter overflow valve (7) opens up if the filters

become clogged, assuring the continuity of the en
gine lubrication.
The safety valve opens up if the pressure in the lu
brication system gets too high.
The oil cooling therm ostatic valve is used to conduct
the oil through the outside of the cooler during the
engine heating, so that the engine gets a faster lu
brication during a cold start and heats faster. This
valve is therm ostatically controlled and it acts as an
oil tem perature sensor.
13
Design and Function
Oil Valves
D12, D12A, D12B
Regulator Valve
Overflow valve for oil filters (bypass)
Bypass valve for oil cooler
Reducing valve
1 R e g u la to r va lv e The regulator valve regulates the

oil pressure. It does this by opening when the lube oil
pressure becom es too high and letting any surplus oil
back to the oil pan.
2 B y p a s s va lv e fo r o il c o o le r The purpose of the
bypass valve is to regulate the oil flow through the oil
cooler. W hen the pressure drop across the oil cooler is
low, for example, im m ediately after starting when oil tem
perature is low, the overflow valve opens and oil is led
past the oil cooler. W hen oil tem perature rises and pres
sure drops across the oil cooler increases, the bypass
valve closes, and oil flows through the oil cooler before
being pressed out into the lubrication system. The by
pass valve is also available with a built-in therm ostat.
W hen the oil tem perature is under 105-115 C (221
239 F), the by pass valve opens and oil is led past the
oil cooler and directly out into the lubrication system.
A t higher oil tem peratures, the therm ostat closes the by
pass valve and the oil passes through the oil cooler
before it is forced out into the lubrication system.
14
3 B y p a ss v a lv e fo r o il filte r If the filters become

blocked, the by pass valve opens guaranteeing lubrica
tion, but with no filtration.
4 P is to n c o o lin g v a lv e The piston cooling valve
opens when the engine speed (rpm) has increased to
slightly over idling speed. Oil flows through the piston
cooling passage to the six piston cooling nozzles which
spray oil against the underside of the pistons.
Design and Function
D12C
6 5
T2012843
1
Safety valve
Oil valve for pistons cooling
Thermostatic valve
Reducing valve
1 S a fe ty valve
The safety valve opens up if the pressure in the lubrica
tion system gets too high, for example, during a cold
start in the winter.
2 T h e rm o s ta tic v a lve
The therm ostatic valve function is to regulate the oil flow
through the oil cooler.
W hen the pressure in the oil cooler is too low, for in
stance, ju st after a start with a low oil tem perature, the
therm ostatic valve opens up and the oil passes through
near to the oil cooler. W hen the oil tem perature increase
and the pressure drop in the oil cooler get higher, the
therm ostatic valve closes and the oil passes through the
cooler before being impelled to the lubrication system.
4 O il va lv e fo r p is to n s c o o lin g
The oil valve for pistons cooling opens up as soon as the
rotates exceeds idling speed.
The oil passes through the piston cooling circulation gal
leries to the six piston cooling oil injectors.
5 O v e rflo w v a lv e fo r o il filte rs (b y p a s s )
The overflow valve opens up if the filters become
clogged, assuring the continuity of the lubrication
process.
6 R e d u c in g va lve
The reducing valve regulates oil pressure, opening up
w hen the pressure exceeds the specified value, letting
go the oil excess to the engine oil sump.
3 O v e rflo w v a lv e fo r o il filte rs (b yp a ss)

The overflow valve opens up if the filters become
clogged, assuring the continuity o f the lubrication
process.
15
Oil Pump
The oil pump is a gear pump set in motion by an inter
mediate gear in the synchronized gearing. The pump is
made up of two gears that are turned in a w ell-sealed
casing. W hen gears turn, the oil is transported between
its teeth and the walls o f the pump casing. W hen the
teeth are geared, the oil is pumped out and inserted in
the lubrication system.
Oil Filter
One o f the purposes of the oil lubrication to clean up im
purities on the engine lubrication points and on the
bearings surface. The oil, then, accum ulates dirt that
needs to be cleaned up before it goes back to the lubri
cation points. The oil is roughly filtered while passing
through the oil manifold filter. In order to get rid of the
dirt particles, the D12C engine lubrication system is
equipped with three filters.
The oil filters are made up o f replaceable filtering ele
ments.
All the oil coming through the pump passes through the
filters before entering the engine.
Piston Cooling
W hen the engine is running, there usually is a buildup of
heat in the piston that, in some cases, needs an extra
cooling. The piston cooling is set in motion when the oil
pressure gets so high that the piston cooling valve in the
cylinder block opens up. The oil is then forced through
the engine block drilled galleries into the injection noz
zles o f piston cooling, one for each piston. The oil is
then pulverized on the bottom of the piston.
16
Design and Function
Troubleshooting
Troubleshooting
Lube System Fuel Contamina
tion, Checking
i
W hen fuel contam ination is suspected
in the lube system, use a highintensity black-light lamp (Kent-Moore
part num ber J 28428 E) along with a
fluorescent additive to locate the point
at which fuel is entering the system.
2231-06-05-01
Oil Cooler Leak Test, Checking
/ f \ DANGER
ju ry or death.
Special tools: 9996662, 9996845

1
Flush the coolant side of the oil cooler
elem ent with water-soluble degreasing
fluid. Wash the oil side of the cooler
elem ent with degreasing solvent.
Pressure gauge and bath
Make sure the reduction valve knob of

pressure gauge 9996662 is fully open
and that the pressure gauge is in the
0 position.
C onnect the pressure gauge needle to
9996845. Lower the oil cooler elem ent
into a bath which contains w ater at 70
C (160 F).
Increase pressure to 250 kPa (35 p si)
using the reduction valve knob. The
test period should last for a t le a s t o n e
m in u te .
A ir bubbles emerging from the oil
cooler elem ent indicate a leak and the
elem ent should be replaced.
9996662
9996845
T2006695
Tools 9996845
Install tools 9996845, making sure

they are properly seated.
9996845
17
18
Service Procedures
Service Procedures
2171-02-02-01
Oil Pan, Installation
2
Fill the engine with the correct am ount
o f oil.
3
C rank the engine with the starter until
oil pressure is recorded on the pres
sure gauge.
4
Apply parking brake. Place the shift
lever in neutral.
5
Start the engine, check operation and
perform a leak test.
2211-03-02-01
Lube Oil Pump, Replacement
Fig. 1: Oil pan, gasket and rail-D12, D12A, D12B, D12C
/ | \ DANGER
ju ry or death.
/ j \ WARNING
/ j \ WARNING
W2003249
Fig. 2: Oil pan, gasket and rail-D12C

Make sure the gasket is correctly positioned. Then position the oil pan and
tighten the bolts to 24 4 Nm (18 3
ft-lb).
N o te : Tighten the bolts in the metal
rail joints first.

fluids.
24 4 Nm
(18 3 ft-lb)
(O il Pan R em oved)
Not Included:
Oil Filter, R eplacem ent page 23
19
S ervice Procedures
Removal
Drain engine oil into suitable container

and remove the oil pan.
N ote: Dispose of oil according to local
and state regulations.
Fig. 5: O-ring and oil strainer

Remove the O-ring and oil strainer
from the oil delivery pipe.
T2006798
Fig. 3: Oil delivery pipe nuts

Remove the oil delivery pipe nut in the
cylinder block, and bolts for the oil
strainer.
Fig. 6: Remove oil pump

Remove the oil pump from the main
bearing cap.
T2006799
Fig. 4: Oil pump bolts

Remove the bolts for the first main
bearing cap. Lift out the oil pump to
gether with the main bearing cap.
T2006698
Fig. 7: Interm ediate gear

Remove the interm ediate gear from
the oil pump housing.
7
Clean the oil strainer. Make sure the
oil strainer mesh is not damaged.
20
Service Procedures
8
Clean and check the bushings and
teeth on the interm ediate gear.
Fig. 10: Installing lube oil pump
Fig. 8: Interm ediate bushing locations

Interm ediate bushings with engine oil.
Insert the interm ediate gear into the
new oil pump. Tighten the bolts to 24
4 Nm (18 3 ft-lb).
24 4 Nm
(18 3 ft-lb)
Installation
Install the lube oil pump, making sure

that the teeth in the interm ediate gear
make contact with the crankshaft drive
gear. Tighten the main bearing bolts to
150 20 Nm (111 14 ft-lb). Then
turn a further 120 5.
150 20 Nm
(111 14 ft-lb)
4
Check the oil delivery pipe for cracks in
the flange w here it contacts the union.
T2006801
Fig. 11: Oil strainer installation
Fig. 9: Mounting oil pump to main bearing cap

Install the new oil pump on the main
bearing cap. Tighten the bolts to 24
4 Nm (18 3 ft-lb).
Place the oil strainer on the oil delivery

pipe and install new O-rings.
24 4 Nm
(18 3 ft-lb)
N ote: R em em ber to install the main

bearing cap bolts before fastening the
pump to the bearing cap.
2
Clean the main bearing shell and lubri
cate it with engine oil.
21
S ervice Procedures
2211-06-02-01
Lube System Pressure, Check
ing
/f\ DANGER
ju ry or death.
T2006798
Fig. 12: Installing oil strainer and delivery pipe

Install the oil strainer and the oil delivery pipe. Tighten the oil strainer to the
oil pump to 27 4 Nm (20 3 ft-lb).
27 4 Nm
(20 3 ft-lb)
/ j \ WARNING
Special tools: 9992873, 9996398

1
parking brake.
2
Lubricating oil pressure is checked by
connecting a pressure gauge and
hose to the oil pressure sender outlet
on the left-hand side of the engine.
T2006701
Fig. 13: Oil pipe union installation
T2006825
Fig. 14: Union tightening torque

Tighten the union in the cylinder block
until it bottoms at about l 0 Nm (7.4 ftlb).
For a previously installed pipe, tighten
the union a further 60 . For a new pipe,
tighten the union a further 180. Make
sure the pipe is installed properly.
22
10 Nm
(7.4 ft-lb)
N ote: The oil pressure sender is

mounted in the cylinder block front
outlet. The rear outlet can be plugged
or an oil tem perature sender may be
installed. On some trucks, a hose is
connected to the front outlet, and the
oil pressure sender is positioned in an
attachm ent on the fram e side.
Service Procedures
4
Rem ove the gauge, hose and union.
Reinstall the oil sender and reconnect
the sender wiring.
2223-03-02-01
Oil Filter, Replacement
/ i \ danger
jury or death.
W2003484
Fig. 15: Pressure gauge and hose installation-D12C
/ j \ WARNING
/ j \ WARNING
fluids.
W2003499
Fig. 16: Pressure gauge and hose installation-D12B

C arefully clean and disconnect the oil
pressure sender w iring and remove the
sender. Install connect union 9992873
into the engine block and then attach
the hose and pressure gauge
9996398. S tart the engine; engine oil
should be at operating tem perature.
Take the oil pressure reading at low
idle speed and at high idle. A t low idle
speed, the oil pressure should be
150 kPa (22 psi) minimum. A t high
idle, it should be 3 0 0 -5 5 0 kPa (4 5 -8 0
psi).
9992873
9996398
23
Service Procedures
2229-03-02-02
Piston Cooling Valve, Replace
ment
/ f \ DANGER
jury o r death.
W2003413
Fig. 17: Replacing oil filters

1
Bypass filter
2
3
Full-flow filter
Full-flow filter
Drain the engine oil into suitable container and clean around the oil filter
housing. Remove the filters, using filter
tool 9996672.
/ T \ WARNING
9996672
1
Clean the filter housing and remove
the cover of the piston cooling valve.
Remove the O -ring.
N ote: Dispose of oil in accordance to

local and state regulations.
2
Moisten the seals of the new filters
with clean engine oil and screw on the
filters by hand until the seals come in
contact with the filter housing. Then
tighten the full-flow filters a fu rth e r
1/2 -3/4 turn. Tighten the bypass filter
3/4-1 turn after making contact with
the filter housing.

1 /2 -3 /4 turn
3/4-1 turn
2
Remove the piston cooling valve and
clean the valve seat in the filter hous
ing. Make sure to remove the old
O-ring from the filter housing.
3
Fill the engine with oil.
4
C rank the engine with the sta rte r until
oil pressure is recorded on the pres
sure gauge.
5
parking brake.
6
Start the engine and check fo r leaks
around the oil filters.
24
T2006676
Fig. 18: Piston cooling valve

Make sure the color marking on the
new piston cooling valve is o ra n g e .
Service Procedures
695 6
T2006702
Fig. 20: Cranking tool
T2006684
Fig. 19: Inserting valve

Insert the new valve in the cover.
Place new O -rings on the valve and
the filter housing.
Remove the inspection cover from the

bottom of the flywheel housing and in
stall cranking tool 9996956.
9996956
2
5
Install the valve in the filter housing
and tighten the cover bolts.
6
A pply parking brake. Place shift lever
in neutral.
7
S tart the engine and perform a leak
test.
2229-03-02-03
Piston Cooling Nozzle, Re
placement
A
Turn the crankshaft until the piston

cooling nozzle to be replaced is easily
accessible.
DANGER

jury or death.
T2006685
Fig. 21: Piston cooling nozzle
3
Remove the piston cooling nozzle.
WARNING

fluids.
(O il Pan R em oved)
N ote: To prevent the piston cooling nozzles from being
damaged, always remove them before removing pistons
and cylinder liners.
25
S ervice Procedures
Fig. 22: Installing new piston cooling nozzle

Install new piston cooling nozzle, using a new bolt. Tighten to 24 4 Nm
(18 3 ft-lb)
24 4 Nm
(18 3 ft-lb)
N o te : The piston cooling nozzle at

tachm ent bolt is coated with a
friction-inducing com pound. Do not
reuse.
N o te : Any piston cooling nozzle sus
pected to be dam aged or deformed
must be replaced (this even applies to
a new nozzle). Always make sure the
piston cooling nozzle fits correctly in
its hole in the cylinder block and that
the attachm ent plate is flush with the
cylinder block.
T2006797
Fig. 23: R em oving oil filter

Drain the engine oil into a suitabel
conatainer and clean around the oil fil
ter housing. Rem ove the front oil filter,
using filter removal tool 9996672 or
equilavent.
9996672
N ote: Dispose of oil in accodance to

local and state regulations.
5
Remove the cranking tool and reinstall
the inspection cover on the flywheel
casing.
2229-03-02-04
Oil Pressure Reduction Valve,
Replacement
T2006675
/ f \ DANGER
jury or death.
/ j \ WARNING

26
Fig. 24: Plug location on engine

C lean around the plug on the cylinder
block. Unfasten the plug and remove
the regulator valve.
3
C lean the regulator valve seat and
make sure to remove the old O-ring.
Service Procedures
T2006676
Fig. 25: Regulator valve

Check that the color marking on the
new regulator valve is bro w n .
5
W3000459
Fig. 27: ECM relay location

Remove the ECM relay from engine
valve cover.
10
Fig. 26: Inserting regulator valve in plug

Insert the regulator valve in the plug.
Place new O -rings on the valve and
plug. Install the plug into the cylinder
block.
6
Install a new oil filter. Moisten the seal
of the new filter with engine oil and
screw on the filter by hand until the
seal is in contact with the filter hous
ing. Then tighten the filter a fu rth e r \
7
8
Place the shift lever in neutral and ap
ply parking brake.
- f
turn
W3000458
Fig. 28: Connections fo r rem ote sta rter cable

C onnect a rem ote sta rte r switch cable
(Snap-On M T302A or equivalent) be
tween the battery (+) and the positive
connection (+) on the sta rte r m otor so
lenoid. C rank the engine with the
sta rte r until oil pressure is recorded by
the pressure gauge.
N o te : Do not run the sta rte r any
longer than 15 seconds at one time.
Allow the sta rte r to cool before re
running the sta rte r motor.
11
Remove rem ote sta rte r cable and re
place the ECM relay after completion.
27
12
S tart the engine and perform an oper
ation and leak check.
S ervice Procedures
2232-03-02-01
Oil Cooler Core, Replacement
/ j \ DANGER
ju ry or death.
/ j \ WARNING
T2006687
Fig. 29: Removing pipes

Remove the pipes between the ther
mostat housing and the coolant pump,
and between the coolant pump and
the oil cooler cover.
(C o o la n t D ra ine d, A ir C o m p re s s o r R em oved.)
3
Remove the therm ostat housing.
Not Included:
Oil C ooler Leak Test, C hecking page 17
N ote: R adiator and cooling system m ust be properly

cleaned and flushed in the event of a suspected oil
cooler failure. Refer to:
S e rv ic e
M anual
IMPACT
2 6 0 -6 0 0
C o o lin g S y s te m , V E D 1 2 - D 1 2 C
Function Group 2619

Information Type: Repair
Cooling S ystem
Removal
1
Remove the turbocharger. Plug turbo
oil lines and outlet openings to prevent
contam ination. Install cover on turbo
intake and exhaust openings to pre
vent foreign material from possibly
becoming lodged in turbine wheels.
28
T2006688
Fig. 30: Inner stud bolts

Remove the turbocharger inner m ount
ing stud from the exhaust manifold.
Service Procedures
Installation
Fig. 31: Oil cooler elem ent cover
T2006691
Fig. 33: Oil cooler O-rings
Remove the oil cooler elem ent cover.
Clean and place new O -rings in the

cylinder block. Install the oil cooler elem ent and tighten the bolts to 27 4
Nm (20 3 ft-lb).
27 4 Nm
(20 3 ft-lb)
T2006692
Fig. 34: Gasket inserted
Fig. 32: Removing oil cooler elem ent

Remove the oil cooler element.
7
Remove the oil cooler elem ent O-rings
and the gasket in the cover. Clean the
contact surfaces o f the cylinder block
and cover.
Insert a new gasket in the cover. Replace and tighten the cover. Tighten
the bolts to 24 4 Nm (18 3 ft-lb).
33 4 Nm
(24 3 ft-lb)
N o te : Tighten the oil cooler cover

bolts evenly and in several steps to
avoid dam aging the oil cooler cover.
8
If a leak test on the oil cooler element
is desired, see Oil C ooler Leak Test,
C hecking page 17.
29
S ervice Procedures
T2006688
Fig. 35: Inner turbo mounting stud

Install the tw o inner stud bolts for the
turbocharger.
T2006694
Fig. 37: Installing pipe

Install the pipe between the therm o
stat housing and the coolant pump.
Use new O-rings.
4
7
Replace the turbocharger. Use a new
mounting gasket.
8
Replace the air compressor. Use a
new mounting gasket.
9
Fill with coolant. Use only a concen
trated coolant that meets or exceeds
ASTM D4985 specifications. The rec
om m ended coolant is monoethylene
glycol (M EG) based or monopropylene
glycol (M PG) based anti-freeze.
Fig. 36: Installing pipe
Install the pipe between the coolant
pump and the oil cooler cover. Re
place the gasket between the cover
and pipe connection. Use new O-rings.
5
Replace the therm ostat housing, using
a new gasket.
10
11
Pre-lube the turbo unit with engine oil.
Add tw o ounces of engine oil through
turbo lube line opening before connect
ing the lube line. This will ensure turbo
has sufficient lubricant at start up.
N ote: It is very im portant to make sure
there is an adequate oil supply to the
turbo before starting the engine.
12
lever in neutral.
30
Service Procedures
13
S tart the engine and perform opera
tion and leak tests.
2239-03-02-02
Oil Cooler Bypass Valve, Re
placement
/ t\
danger

ju ry or death.
T2006682
Fig. 39: Inserting cone and spring

Insert the new cone and spring along
with a new O-ring. Install and tighten
the plug.
/ j \ WARNING
4
lever in neutral.
5
S tart the engine and perform a leak
test.
2209-11-02-01
Oil System Passages, Cleaning
/f\ DANGER
T2006681

ju ry or death.
Fig. 38: Installed Plug

Clean around the oil filter housing and
remove the plug. Remove the cone
and spring.
2
Clean and check the valve seat. If the
valve seat shows signs of corrosion,
replace the oil filter housing.
WARNING
/ j \ WARNING
fluids.
31
1
Drain coolant into suitable container.
Service Procedures
N ote: Dispose of coolant in accor

dance to local and state regualtions.
2
N ote: Before flushing the passage you
myst remove the turbocharger. Refer
to:
S e riv c e
M anual
2 5 0 -6 0 0
In ta k e a n d E x h a u s tS y s te m s , D 1 2 , D 1 2 A ,
D 12B, D 12C
W2002380
IPMPACT
Function Group
Information Type: RepairTurbocharger
Fig. 41: W ater pump discharge pipe

Remove the 3 bolts fastening the w a
ter pump discharge pipe to the oil
cooler cover. Unplug the Volvo Engine
Brake (VEB) tem perature sensor (if
equipped) and remove the pipe.
T2006688
Fig. 40: Turbo moutning studs

Remove the inner 2 turbo mounting
studs.
W2002338
Fig. 42: A ir com pressor diconnect

1) coolant supply hose
2) air compressor discharge line
3) coolant return hose
D isconnect the air com pressor coolant

supply hose (1) from the oil cooler
cover.
6
D isconnect the air com pressor
discharge line (2) from the air com
pressor.
32
7
Disconnect the air com pressor coolant
return hose (3) from the bypass pipe.
Service Procedures
10
T2006694
Fig. 43: Remove bypass pipe

W2002339
Remove the bolts fastening the bypass

pipe and remove pipe.
Fig. 45: Therm ostat housing hoses

Remove the 2 hoses from the therm o
stat housing (the heater hose and the
bleed hose).
11
Remove the lower right front exhaust
manifold bolt.
12
F o r B e n d ix A ir C o m p re s s o rs : Re
move the 4 bolts fastening the outer
cover of the therm ostat housing.
Remove the 3 bolts mounting the ther
mostat housing to the head. Separate
the outer cover from the therm ostat
housing and remove both separately.
T2007234
Fig. 44: Remove radiator hose neck

Disconnect the w iring harness from
the cam sensor and remove the 2
bolts fastening the upper radiator hose
neck to the therm ostat housing. Move
the neck and the upper radiator hose
to the side.
N ote: F o r V o lvo (K n o rr) A ir C o m

p re s s o rs : Remove the com pressor
mounting bolts and rotate the com
pressor for clearance.
33
13
Service Procedures
16
T2006942
Fig. 47: Remove air supply line

Disconnect the Exhaust Pressure Gov
ernor (EPG) air supply line.
W2002343
Fig. 46: Expansion tank pipe

Remove the 2 bolts fastening the w a
ter pump to the expansion tank pipe.
Move the pipe to the side.
17
Remove the clam p fastening the ex
haust pipe to the EPG and remove the
EPG and centering ring.
18
14
Disconnect the w ire to the block
heater (if equipped with block heater).
15
Remove the bolt fastening the trans
mission cooler w ater pipe to the oil
cooler cover and move the pipe to the
side (if equipped with transm ission oil
cooler).
Fig. 48: Remove oil cooler cover

Remove all o f the 27 bolts fastening
the oil cooler cover and remove the
cover.
34
19
Service Procedures
23
6 5
12006690
Fig. 49: Oil cooler elem ent

Remove the 4 bolts fastening the oil
cooler elem ent to the engine block and
remove the element.
20
Remove the turbo oil return line from
the block.
21
D isconnect the lower charge air cooler
pipe and remove.
22
T2012843
Fig. 51: Reducation valves

Remove the oil reduction valves (1)
and (6).
24
Remove the oil pan.
25
Remove the oil pump pick-up and de
livery pipe assembly.
26
T2006685
Fig. 50: Oil filter base removal

filter base to the block, and remove
the base.
Fig. 52: Remove piston cooling jets

Remove all 6 piston cooling jets.
27
Inspect the pistons and liners from the
bottom side fo r dam age due to metal
contam ination.
35
Service Procedures
31
28
Position the catch pan under the en
gine.
29
W2002427
Fig. 54: Oil cooler elem ent oil galleys

Flush out both oil cooler elem ent oil
galleys.
32
W2002426
Fig. 53: Piston cooling oil galley
WARNING
Most solvents are flamm able, stay away from open

flam e and observe extreme caution w hen using these
so as to prevent fire.
WARNING

fluids.
Blow dry all flushed oil galleys with
com pressed air.
33
WARNING
Always w ear eye protection and protective gloves

w hen w orking with solvent. Exposure to eyes and/or
bare skin will cause burns.
Flush out the piston cooling oil galley
using clean solvent and a siphon type
spray gun. Flush from the top side and
also up from the bottom.
N ote: Do not attem pt to remove metal
contam inants using shop air only.
W2002341
Fig. 55: Oil pump cover removal

N ote: C lean solvent m ust also be
used w henever flushing is required.
Remove the rear cover o f the oil pump.
30
Flush out the oil reduction valve galley
from the side and underside of the
block.
34
Flush out the oil pump and inspect the
pump housing and gears fo r damage.
Replace if needed.
36
Service Procedures
39
35
Pre-lube and install the rear cover on
the oil pump. Torque bolts 27 4 Nm
(20 3 ft-lb).
27 4 Nm
(20 3 ft-lb)
36
Flush out all piston cooling jets and in
stall with new bolts. Torque to
24 4 Nm (18 3 ft-lb).
24 4 Nm
(18 3 ft-lb)
N ote: The piston cooling je t attach

ment bolt is coated with a friction
inducing compound. Do not reuse
bolts.
T2006675
Fig. 56: D12, D12A, D12B Engines

37
6 5

fluids.
Flush out and blow dry the oil pipe
pick-up and delivery pipe assembly. In
spect the screen for trapped metal
chips.
38
Install the oil pump pick-up and delivery pipe assem bly with new O-rings.
Torque for delivery pipe to block union
10 Nm (7.4 ft-lb) plus an additional 60
for a used pipe, 180 for a new pipe.
Torque for strainer to oil pump bolts 27
4 Nm (20 3 ft-lb).
T2012843
10 Nm
(7.4 ft-lb) +
60 used or
180 new
27 4 Nm
(20 3 ft-lb)
Fig. 57: D12C Engine

Flush and blow dry the reduction valve
and inspect for dam age or trapped de
bris.
40
Install the oil reduction valve with a
new O-ring on the valve as well as the
cover. Torque the cover to 50 Nm
(37 ft-lb).
50 Nm
(37 ft-lb)
41
Remove oil filters and clean the exte
rior of the filter base.
37
Service Procedures
42
44
Fig. 59: Torquing the mounting bolts
Fig. 58: Remove the piston cooling valves
Attach the oil filter base to the block

with a new gasket. Torque the mounting bolts to 24 4 Nm (18 3 ft-lb).
1) piston cooling valve

2) overflow valve, oil filter
3) overflow valve, oil cooler
Remove the piston cooling valve (1)

and the 2 overflow valves (2)(3). Flush
out and blow dry the filter housing
valve ports and valves.
38
W2002340
W2002342
43
Install the 2 overflow valves (2)(3) and
the piston cooling valve (1). Torque the
bolts to 10 2 Nm (7 1 ft-lb). Torque
plug to 55 5 Nm (41 4 ft-lb).
45
Install new oil filters.
46
Install the oil pan.
10 2 Nm
(7 1 ft-lb)
55 5 Nm
(41 4 ft-lb)
47
Install new engine oil.
24 4 Nm
(18 3 ft-lb)
Service Procedures
48
50
Fig. 62: Elem ent cover gaskets
Install a new oil cooler elem ent with

new seals. Torque bolts to 27 4 Nm
(20 3 ft-lb).
N ote: Once inside the oil cooler ele
ment, metal contam ination cannot be
flushed out. If this happens, replace
the element.
27 4 Nm
(20 3 ft-lb)
Install the cover with a new gasket.

Torque bolts to 24 4 Nm
(18 3 ft-lb).
24 4 Nm
(18 3 ft-lb)
51
C onnect the block heater (if equipped).
52
Install the transm ission w ater cooler
pipe to the cover with a new seal (if
equipped).
49
T2006692

Clean the oil cooler elem ent cover and
mounting gasket surface of the block.
39
Service Procedures
53
56
T2006694
Fig. 64: Installing the bypass pipe

Install the bypass pipe using a new
seal and gasket.
57
Fig. 63: W ater pump installation

Install the w ater pump to the expan
sion tank w ater pipe with a new seal.
Install retaining clam p and bolt assem
bly.
54
Clean all gasket surfaces on the ther
m ostat housing.
55
Install the therm ostat housing with a
new seal. Torque the 4 M6 bolts to
10 1.5 Nm (7.4 1 ft-lb), and the 3
M8 bolts to 24 4 Nm (18 3 ft-lb).
F o r V o lvo (K n o rr) A ir C o m p re s s o r:
re-align the com pressor with mounting
bolts and tighten to 85 15 Nm
(63 1 1 ft-lb).
40
10 1.5 Nm
(7.4 1 ft-lb)
24 4 Nm
(17.7 3 ft-lb)
Knorr:
85 15 Nm
(63 11 ft-lb)
T2007234
Fig. 65: R adiator hose for therm ostat housing

Install the top radiator hose neck to
the therm ostat housing using a new
O-ring. Connect the cam sensor w iring
harness.
Service Procedures
62
T2006693
Fig. 66: Installing the w ater pump

Clean and install the w ater pump to
the oil cooler cover pipe using a new
gasket and seal. C onnect the VEB
tem perature sensor w iring harness.
Torque the 3 mounting bolts to
24 4 Nm (18 3 ft-lb).
24 4 Nm
(18 3 ft-lb)
W2002339
Fig. 68: Hoses to the therm ostat housing

Connect the 2 hoses (heater and
bleed hoses) to the therm ostat hous
ing. Hand-tighten the hose clamps.
63
Install the lower right exhaust manifold
bolt and torque to 47 8 Nm
(35 6 ft-lb).
47 8 Nm
(35 6 ft-lb)
64
Add coolant and inspect fo r leaks.
65
W2002338
Fig. 67: Hoses for the air com pressor

Connect the air com pressor coolant
supply hose (1) to the oil cooler cover.
Hand-tighten the hose clamp.
60
Connect the air com pressor discharge
line (2) to the air compressor.
T2006942
Fig. 69: C onnecting the E P G air line

61
Connect the air com pressor coolant
return hose (3) to the bypass pipe.
Hand-tighten clamp.
Position the centering ring and EPG

against the exhaust pipe. Hand-tighten
the clam p bolt only. Connect the EPG
air line.
41
Service Procedures
4
Use an air gun to blow the dirt out of
the oil filter base threads.
5
Install thread lock 577 on the nipple
threads.
6
Thread the nipple back into the oil fil
te r base by hand until it stops.
7
Thread the nipple installer into the nip
ple.
Fig. 70: Turborcharger mounting studs
Install the turbocharger mounting
studs.
8
Use the nipple installer wrench,
9998691, to hold the outer nut.
67
Install the tu rb o c h a rg e r, see;
S e rivce
M anual
9
Using a torque wrench on the jam nut,
torque the nut to 40 nm 5 (30 4 ftlb). Remove the torque wrench.
2 5 0 -6 0 0
In t a k e a n d E x h a u s t S y s te m s , D 1 2 , D 1 2 A ,
D12B, D 12C
IPMPACT
10
Use a pull bar to loosen the jam nut
with the wrench holding the outer nut.
Function Group
Information Type: Re
pair
Turbocharger
11
Remove the nipple installer from the
filter base.
68
Tighten the EPG to exhaust pipe
clamp. Torque the clam p bolt to
60 10 Nm (44 7 ft-lb).
60 10 Nm
(44 7 ft-lb)
69
S tart the engine, check for proper op
eration, and inspect for leaks.
2229-03-02-06
Oil Filter Nipple, Replacement
1
Remove oil filters.
2
If the oil filter nipples are loose remove
them.
3
Clean the filter base with appropriate
cleaning solution.
42
12
Let the locktite set up for about 5 m in
utes before putting the filter back on.
13
Moisten the o-ring on the oil filte r with
clean engine oil. P ut the filter in place
and torque to 15 nm 5 (10 3 ft-lb).
9998691
Service Procedures
2229-03-02-01
Oil Filter Overflow Valve, Re
placement
4
S tart engine and check for leaks.
i
1
Overflow valve (bypass)
Clean oil filters bracket and remove

valves caps (1).
R em ove valves needles and springs.
2
Clean and check valve seats. If valve
seat is corroded, oil filters bracket
m ust be changed.
C2000646
Fig. 71: Valve needles and springs

Assem ble new valve needles and
springs.
Assem ble and tighten cap. Use a new
seal ring.
43
44
Feedback
O ne o f o u r o b je c tiv e s is th a t w o rk s h o p p e rs o n n e l s h o u ld have a c c e s s to c o rre c t and
a p p ro p ria te s e rv ic e m a n u a ls w h e re it c o n c e rn s fa u lt tra c in g , re p a irs and m a in te n a n c e
o f V o lvo tru c k s .
In o rd e r to m a in ta in th e h ig h s ta n d a rd s o f o u r lite ra tu re , y o u r o p in io n s and e x p e rie n c e
w h e n u s in g th is m a n u a l w o u ld be g re a tly a p p re c ia te d .
If yo u have any c o m m e n ts o r s u g g e s tio n s , m ake a c o p y o f th is page, w rite d o w n y o u r
c o m m e n ts and se n d th e m to us, e ith e r v ia te le fa x o r m a ilin g d ire c tly to th e a d d re s s
lis te d below.
To
F rom
V o lvo T ru cks N o rth A m e ric a , Inc.
.........
D ept. 516 S e rv ic e P u b lic a tio n s
.........
7825 N a tio n a l S e rv ic e R oad
.........
P.O. B o x 26115
.........
G re e n s b o ro , NC 27402-6115
.........
U SA
.........
Fax (336) 393-3170
.........
C o m m e n ts /p ro p o s a ls
C o n c e rn s S e rv ic e M anual:
Operation Numbers
Oil Pan, In s ta lla tio n .......................................
19
Oil System Passages, C le a n in g ................
31
Lube Oil Pump, R e p la c e m e n t...................
19
Lube System Pressure, Checking
22
. . . .
Oil Filter, R e p la c e m e n t...............................
23
Oil Filter Overflow Valve, R eplacem ent . .
43
Piston Cooling Valve, R eplacem ent
. . .
24
Piston Cooling Nozzle, R eplacem ent . . .
25
Oil Pressure Reduction Valve, Replacem ent
26
Oil Filter Nipple, R eplacem ent . . . . . .
42
Oil C ooler Leak Test, Checking
................
17
Oil C ooler Core, R eplacem ent . . . . . .
28
Oil C ooler Bypass Valve, R eplacem ent . .
31
VOLVO

VOLVO
TSI

Greensboro, NC USA

P V 776-TS P 142853.
Date
Group
No.
11.2001
213
004
Supp.
Page
1(5)
Piston to Connecting Rod

D12, D12A, D12B, D12C
Piston to Connecting Rod

This inform ation covers procedures for replacing the piston connecting rod of VOLVO
D12 engines.
Contents
Piston to Connecting Rod, R eplacem ent page 3
P V 776 -T S P 16 1 5 7 1
USA10463
Page 2
Tools
Special Tools
ordered from Volvo; please use the specified part num ber w hen ordering.
9991801
9996966
Clamping tool
9992013
9996956
Flywheel turning tool

TSI
Date
Group
No.
112001
213
004
Page
3 (5 )
Service Procedures
2132-03-05-01
Piston to Connecting Rod, Re
placement
/ \ CAUTION
O bserve the greatest possible cleanliness when w o rk
ing on the cylinder head. D irt particles in the fuel and
oil channels can cause the unit injectors to m alfunc
tion, and can cause the VEB (if equipped) to fail.
Special tools: 9991801, 9992013
Removal
T 20 07 06 6
Fig. 3: Piston rings
1
Remove the snap rings from the old
piston.
If the piston rings are to be removed

and reinstalled, use piston ring pliers.
Installation
1
Install one snap ring into the piston
sleeve.
T 20 0 7 0 7 0
Fig. 2: Removing piston from connecting rod

Remove the piston pin using d rift
9992013 and handle 9991801.
9991801
9992013
3
Remove the connecting rod.
T 20 07 06 9
Fig. 4: Assem bling the piston and the piston skirt

Assem ble the upper and lower sec
tions of the piston so that the stud in
the upper section of the piston mates
with the recess in the bottom section.
Note: Heat the piston skirt to 100 C

(212 F) if necessary for easier a s
sembly.
Page 4
T 20 0 7 0 6 8
Fig. 5: Installing the piston pin
Align the connecting rod with piston so

that the "Front" marking on the con
necting rod and arrow on the piston
are facing in the same direction.
Install the piston pin to hold the piston

halves together.
6
4
T 20 0 7 0 7 0
Fig. 8: Installing piston pin

Press in the piston pin using drift
9992013 and handle 9991801.
Lubricate the piston pin, piston pin
bushings, and connecting-rod bushing
with engine oil.
Note: It should be possible to lightly

press in the piston pin. Do not tap it in.
7
Install the other snap ring to hold the
piston pin.
8
Make sure that the upper and lower
sections of the piston can move easily
relative to each other and that the pis
ton pin moves freely in the connecting
rod bushing.
9
Lubricate the piston and piston rings
with engine oil.
9992013
9991801

TSI
10
Date
Group
No.
112001
213
004
Page
5(5)
15
Make sure that the piston ring gaps

are evenly staggered around the pis
ton.
11
W2003725
Fig. 9: Installing piston and connecting rod

Install the piston and connecting rod
with the arrow and front m arkings fac
ing forward. Use tool (A) to guide the
piston rings into the cylinder liner.
9996966
Note: Temporarily remove cylinder

liner clamping tools 9996966 when us
ing tool piston installation tool. When
the piston is in position, reinstall
clamping tools 9996966 onto the liner.
T2007058
Fig. 10: Measuring the height o f the piston

W ith piston at TDC, m easure the
height o f the piston above the cylinder
block face. The height should be 0.15
- 0.65 mm (0.006 - 0.026 in.).
12
Lubricate the crankshaft bearing shells
and crankshaft pin with engine oil. In
stall the bearing shells and make sure
that they are mounted correctly in the
connecting rod and bearing cap.
Note: It is not necessary to m easure

the piston height if the cylinder block
has not been machined.
13
16
Install the bearing cap according to the

marking and tighten the bolts by hand.
Remove flywheel turning tool 9996956.
9996956
17
14
Make sure clam ping tools 9996966
are in position and carefully rotate the
flywheel with flywheel turning tool
9996956 until the piston reaches bot
tom dead center. Torque tighten the
rod bearing cap bolts to 275 - f Nm
(205 -J1 ft-lb).
0.15 - 0.65
mm
(0.006 - 0.026
in.)
275 - f Nm
(205 -J1 ft-lb)
9996956
9996966
Install and torque-tighten the piston

cooling je t to 24 4 Nm (18 3 ft-lb).
Note:
is not damaged. A dam aged je t must
be replaced. Also make sure that the
je t is directed toward the recess on the
piston.
24 4 Nm
(18 3 ft-lb)
VOLVO
TSI

Greensboro, NC USA
Date
Group
No.
11.2001
215
006
Supp.
Page
1(7)
Timing Gear Cover

D12C
Timing Gear Cover

This inform ation covers procedures for replacing the timing gear cover on VOLVO
D12C engines.
Contents
Tim ing G ear Cover, R eplacem ent page 3
P V 7 7 6 -T S P 1 6 1 5 6 6
USA10458
Page 2
Tools
Special Tools
9996049
9998602-2
9998602-6
9998628
Drain hose
Upper Front Cover Alignment Tools
Press tool

TSI
Date
Group
No.
11.2001
215
006
Page
Service Procedures
2151-03-02-02
Timing Gear Cover, Replace
ment
5
Remove the fuel pump drive pulley
and the fan pulley.
/ j \ DANGER
ju ry or death.
Special tools: 9996049, 9998602, 9998628
Removal
1
Remove the radiator assembly; see
T 20 12 86 2
Remove the alternator and air condi

tioning compressor.
2
Remove the fan ring.
7
Remove the support for the alternator
and air conditioning, w hich is fastened
to the timing gear cover.
3
Remove the fan stud nuts and the fan.
Note: W hen removed from the vehicle,
the therm ostat-controlled fan can be
stored vertically or horizontally with
the front (bimetal strip) downwards,
w ith o ut causing oil to leak internally.
T 20 07 26 0
Remove the fan hub.
9
Remove the fuel pump driveshaft.
22002628
Remove the belts.
10
Remove the fan belt tensioner.
11
Remove the plate on the tim ing gear
cover.
3 ( 7)
Page 4
12
Remove the air pipe connecting the
coil to the air drier.
Installation
i
13
Remove the vent pipe for the timing
gear top cover.
/ j \ WARNING
risk of eye injury due to contact with debris or fluids.
Note: Loosen the com pressor air pipe

to remove the vent pipe.
14
Remove the w ater pipe for the therm o
static valve box, which is fastened to
the tim ing gear cover.
15
Remove the sum p front bolts in the
tim ing gear cover.
16
Clean the engine surface by carefully

removing all sealant residue.
Note:
tools, objects, or dirt fall Inside the oil
pan.
2
Thoroughly clean the timing gear
cover.
/ j \ CAUTION
Do not use an impact w rench to remove the bolts. Do
ing so may loosen the bolts from the cylinder head
and can dam age the electrical w iring and the valve
cover.
17
Remove the cam shaft sensor. Save
the shim s to reuse them w hen in
stalling the sensor.
18
Remove the tim ing gear top cover.
19
Remove the tim ing gear bottom cover.
Note:
cover sealing area while removing the
cover. Doing so may dam age the
cover and cause leakage.
T2009026
Remove the oil Injector nozzle from

the tim ing gear plate and check to
make sure that the oil channel Is not
clogged.
4
Install the oil Injector nozzle and
torque-tlghten the bolt to 33 4 Nm
(24 3 ft-lb).

TSI
Date
Group
No.
112001
215
006
Page
C2002668
A pply an even 2 mm bead of Volvo siiicone (part no. 1161247) to the inside
of the tim ing gear lower cover and in
stall it in place. Torque-tighten the
lower cover bolts to 34 4 Nm (25 3
ft-lb).
T2015004
A pply an even 2 mm bead of Volvo sil

icone on the inside of the timing gear
top cover.
1161247
T2015008
Apply an even 2 mm bead of Volvo sil

icone on the edge between the timing
gear bottom cover and the cylinder
head.
5(7)
Page 6
11
T 20 12 84 5
Fig. 3: Valve cover tightening sequence

Install the valve cover and torquetighten the bolts to 20 2 Nm (15
1.5 ft-lb) and according to the se
quence shown (see Fig. 4: Valve cover
tightening sequence, page 6).
Note:
rubber seals fit the valve cover holes
properly to prevent damage to the
valve cover.
T20 14 15 0
Fig. 2: U pper timing gear cover, tightening sequence

Install the timing gear top cover. Install
the alignm ent tools 9998 6 0 2 -2 and
9 9 9860 2-6 and tighten them by press
ing the timing gear cover down so that
the sealing surfaces between the valve
cover, the cylinder head and the timing
gear cover are lined up. Torque-tighten
the upper cover bolts to 34 4 Nm
(25 3 ft-lb) following the proper tig h t
ening sequence shown.
9998 6 0 2 -2
9 9 9 8 6 0 2 -6
12
Install the oil pan bolts in the timing
gear cover.
13
Note: Install and tighten down the tim

ing gear cover within 20 minutes after
having applied the sealant.
9
After torque-tightening the bolts, w ait a
few minutes for the silicone to harden,
then remove the alignm ent tools.
10
Install the cam shaft sensor. A djust the
sensor clearance.
C 20 02 64 3
Install the plate for the fan belt tensioner in the timing gear cover and
install the fan belt tensioner.
14
Install the hub for the fuel pump drive
shaft.

TSI
15
Date
Group
No.
11.2001
215
006
19
Install the pulleys.
20
Install the belts and adjust the alterna
to r belt.
21
Install the air com pressor coll.
T2007260
Install the fan hub.

16
Install the venting pipe In the timing
gear top cover.
17
Install the support for the alternator
and for the air conditioning com pres
sor In the tim ing gear cover. Install the
alternator In the support.
22
Install the w ater pipe for the therm o
static valve box.
23
Install the fan and fan ring.
24
Install the radiator assembly; refer to
25
Fill up the reservoir with coolant.
18
Install the air conditioning compressor.
C onnect the electrical w iring for the air
conditioning compressor.
26
Start the engine and check for leaks.
Page
7(7)
VOLVO

Greensboro, NC USA

Date
Gru p
N.
11.2001
215
005
S upp.
Page
1(4)
Timing Gear Plate

D12, D12A, D12B, D12C
P V 7 76-T S P 14 2 8 5 3 .
Timing Gear Plate
W2003244

This inform ation covers procedures for servicing the timing gear plate on VOLVO D12,
Contents
Tim ing G ear Plate Sealant, R eplacem ent page 3
P V 7 7 6 -T S P 1 6 1 5 7 0
USA10462
Page 2
Tools
Special Tools
ordered from Volvo; please use the specified part num ber w hen ordering.
9998267
Guide Sleeves

TSI
Date
Group
No.
112001
215
005
Page
3 (4)
Service Procedures
2153-03-05-01
Timing Gear Plate Sealant, Re
placement
(Timing gears, coolant pump, power steering pump,
and air compressor removed)
Install two guide sleeves 9998267 in

the guide holes for the tim ing gear
plate. Remove the bolts (1 -1 8 ) that
hold the plate to the cylinder block.
Carefully tap the plate free.
9998267
/ j \ DANGER
ju ry or death.

1
T2007131
Fig. 4: C ontact surfaces (D12C shown)

Carefully clean the contact surfaces of
the plate and cylinder block, making
sure they are free of oil and/or oil
residue.
Note: Do not remove the guide

sleeves.
8267
T2007064
Fig. 2: Guide sleeves for tim ing gear plate (D12B shown)
T2006740
W2003462
Fig. 3: Guide sleeves for tim ing gear plate (D12C shown)
Fig. 5: Lube oil nozzle
Page 4
/ \ WARNING
17

risk of eye injury due to contact with debris or fluids.
Remove the lube oil nozzle from the
tim ing gear plate and use com pressed
air to clean the lube holes.
4
h
W2003462
Fig. 8: Guide sleeves (D12C shown)

Install the tim ing gear plate on the
cylinder block within 20 minutes of
sealant application. Torque-tighten
bolts to 33 4 Nm (24 3 ft-lb) follow
ing the tightening sequence shown
(1 18).
33 4 Nm
(24 3 ft-lb)
T2007132
Fig. 6: Sealant application (D12B shown)

Apply a 2 mm (0.08 in.) bead of Volvo
silicone on the cylinder block as
shown in accom panying figure.
T2006740
Fig. 9: Lube oil nozzle

Install the lube oil nozzle.
T2006741
Fig. 7: Guide sleeves (D12B shown)
7
Remove the guide sleeves (9998267).
9998267
VOLVO
TSI

Greensboro, NC USA

P V 776-TS P 142853.
Date
Group
No.
11.2001
215
004
Supp.
Page
1(11)
Timing Gears Replacement

D12, D12A, D12B
Timing Gears Replacement
Fig. 1: VOLVO D12B Engine

This inform ation covers procedures for replacem ent of the tim ing gears on VOLVO
D12, D12A, and D12B engines.
Contents
Tim ing Gears, R eplacem ent (All) page 4
P V 7 7 6 -T S P 1 6 0 5 8 3
USA10309
Page 2
Tools
Special Tools
9992584
Hollow Drift
9992658
Crankshaft Drive Gear Puller
9992671
Hydraulic Cylinder, 18-ton capacity
9996160
9996222
Foot Pump
9996315
Pins, used with Yoke 9996358
|c C
Spindle
C1 O il
9996358
9996401
9996413
Timing Gear Yoke
Puller Arms
Adapter
9996600
9996603
9996626
Hydraulic Cylinder, 10-ton capacity
Adapter
Hollow Drift

TSI
Date
Group
No.
Page
215
004
3(11)
9996950
9996956
9996958
Flywheel Blocking Tool
Polygon Flub Puller
9996972
9996973
9998269
Puller
Drift
Gear Wheel Puller
9998270
9999683
9999696
Counterhold
Rocker Dial Indicator
Magnetic Stand
Page 4
Service Procedures
2153-03-03-01
Timing Gears, Replacement
(All)
/ K CAUTION
Never turn the crankshaft or cam shaft when the tim
ing gears have been removed. Otherwise, the pistons
can come into contact with the valves resulting in
dam age to engine components.
(Oil pan and timing gear cover removed)
/ K WARNING
fluids.
Special tools: 9992584, 9992658, 9992671

9996160, 9996222, 9996315, 9996358,
9996401, 9996413, 9996600, 9996603,
9996626, 9996900, 9996950, 9996956,
9996958, 9996965, 9996972, 9996973,
9998270, 9999683, 9999696
Removal of Drive and Idler Gears
1
T2006672
Fig. 3: Cranking tool installed

T2006852
Fig. 2: Tim ing gear arrangem ent

D e scrip tio n (no. o f teeth):
Crankshaft Drive Gear (36)
1
2
Idler Gear, 36 mm (87)
3
4
Coolant Pump Drive Gear (24)

Air Compressor Drive Gear (27)
Camshaft (72)
6
7
Adjustable Idler Gear (58)

Upper Idler Gear (60)
Lower Idler Gear (58)
9
10
Power Steering Pump Drive Gear (22)

Drive Gear Arrangement (Accessory Drive Pul
11
ley and Fuel Feed Pump) (26)

Power Take Off (PTO) Idler Gear, 28 mm (87)
12
Power Take Off (PTO) Drive Gear for Hydraulic
13
Pump (37)
Oil Pump Drive Gear (24)
14
Oil Pump Idler Gear (57)
Remove the inspection cover from beneath the flywheel housing and install
cranking tool 9996956.
9996956
Volvo Trucks North America, Inc

TSI
Date
11 2001
Group
2 l5
No.
Page
004
5(11)
T2007076
W2000936
Fig. 6: Vibration dam pener
Fig. 4: Aligning cam shaft

Rotate the A w h e e l until num ber 1 pis
ton is at TDC and the cam shaft
marking is opposite the marking on
the cap.
T2008984
Fig. 7: Removing polygon hub
6950
T2006666
Remove the vibration dampener. Remove the crankshaft bolt together with
the washer. Secure the puller 9996958
on the polygon hub. Fit adapter
9996603 on hydraulic cylinder
9996600. Screw the hydraulic cylinder
to the puller and pull off the polygon
hub using foot pump 9996222.
Fig. 5: Blocking tool installed

Remove cranking tool 9996956 and install blocking tool 9996950.
9996950
9996956
5
Remove idler gears (see 2, 6 and 11,
Fig. 2: Timing gear arrangem ent, page
4) from the tim ing gear plate.
6
Remove the washers from the upper
and lower idler gear (see 7 and 8 , Fig
2: Timing gear arrangem ent, page 4).
7
Remove the socket head bolts and re
move upper and lower idler gears (see
ment, page 4). Use tw o screwdrivers

to assist in removal.
9996958
9996413
9996600
9996603
Page 6
10
T2007072
T2007096
Fig. 10: Removing the crankshaft drive gear
Fig. 8: Cam sensor wheel
Using cylinder 9996600, pins

9996160, puller arm s 9996401, and
yoke 9996358 connected to pump
9996222, remove the crankshaft drive
gear (see 1 , Fig. 2: Tim ing gear arrangement, page 4).
Remove the cam sensor w heel from

the cam shaft drive gear.
9996160
9996222
9996358
9996401
9996600
11
Remove the retaining bolts in the oil
pump idler gear and remove the idler
gear from the oil pump (see 14 , Fig. 2:
Tim ing gear arrangem ent, page 4).
12
T2007148
Fig. 9: Installing counterhold tool

Attach the cam shaft holding tool
9998270 to the rear cam shaft support.
Remove the cam shaft gear retaining
bolt and remove the cam shaft drive
gear (see 5 , Fig. 2: Tim ing gear ar
rangement, page 4).
9998270
T2007074
Fig. 11: Removing the oil pump drive gear

Install an M 12x20 bolt in the
the oil pump drive gear (see
2: Tim ing gear arrangem ent,
Remove the gear, using tool
and drift 9996973.
shaft for
13 , Fig.
page 4).
9996972
9996972
9996973

TSI
Date
Group
No.
Page
112001
215
004
7(11)
13
Installation of Drive and Idler Gears
Remove the air com pressor drive gear

(see 4 , Fig. 2: Timing gear arrange
ment, page 4).
16
6965
14
Remove the power steering pump
drive gear (see 9 , Fig. 2: Timing gear
arrangem ent, page 4).
6315
15
Install puller 9998269 onto the coolant
9998269
3
gear arrangem ent, page 4). Place a
plug on the shaft as a support and pull
off the gear.
T2007151
T2007080
Fig. 12: Installation of crankshaft drive gear

Install adapter and spindle on the
crankshaft. Install the new crankshaft
9992584
9992671
1
arrangem ent, page 4) on the spindle
9996315. Install drifts 9992584 and
9992671. Install the nut and carefully
press on the drive gear, using pump
9996222.
Note: Make sure that the key rem ains

in position in the keyway. Remove the
tools.
9996315
9996626
Page 8
17
21
180 20
t-
(iAV
[..........................................
rm
UJ
\---i
T o n n7 n7 g
Idler gears
Lubricate the oil pump idler gear (see
24 4 Nm
14
page 4) bearing and install. Torquetighten bolts to 24 4 Nm (18 3
ft-lb).
180
T2007079
Fig. 13: Installation of the oil pump drive gear

Heat the oil pump drive gear (see 13,
Fig. 2: Tim ing gear arrangem ent, page
4) to approxim ately 180C (360F) and
tap it onto the lube oil pump.
22
Lubricate the bearings for idler gears
(see 2 and 11 , Fig. 2: Tim ing gear arrangem ent, page 4). Place them into
position and torque-tighten bolts to 15
3 Nm (11 2 ft-lb). Turn an addi
tional 120 5.
15 3 Nm
(11 2 ft-lb)
120 5
Note: New bolts must be used each

time the idler gear is loosened or re
moved; these bolts are designed for
single use only and cannot be torqued
a second time.
18
Install the air com pressor drive gear
(see 4 , Fig. 2: Tim ing gear arrange
ment, page 4).
19
Install the power steering pump drive
23
Install upper and lower idler gears (see
7 and 8 , Fig. 2: Tim ing gear arrangement, page 4). Torque-tighten the
socket head bolts to 15 3 Nm (11
2 ft-lb). Turn an additional 120 5.
15 3 Nm
(11 2 ft-lb)
120 5
9
rangem ent, page 4).
24
20
A pply assem bly paste to the coolant
pump shaft. Install the spindle into the
shaft. Place the coolant pump drive
3
rangem ent, page 4) onto the spindle
and press the gear on with the help of
the hydraulic cylinder.
Install the w ashers for the idler gears

and torque-tighten to 10 2 Nm (7 1
ft-lb). Turn an additional 60 3.
Note:
time the idler gear is loosened or re
moved; these bolts are designed for
single use only and cannot be torqued
a second time.
10 2 Nm
(7 1 ft-lb)
60 3

TSI
Date
Group
No.
Page
112001
215
004
9(11)
28
T2007155
Fig. 14: Installing polygon hub

A pply assembly paste to the crankshaft. Place the polygon hub, tool
9992671 on 9996315. Install the nut
onto the spindle and use tool 9996222
to press on the polygon hub.
T2007083
9996626
9992671
9996315
9996222
Fig. 16: Torque-tightening the cam shaft drive gear bolt
26
T2007148
Fig. 17: Installing the cam shaft drive gear

Install the cam shaft drive gear. Use
tool 9998270 as a support. Torquetighten to 645 25 Nm (475 18 ft-lb).
T2007125
Fig. 15: Torque-tightening the crankshaft drive gear bolt

Remove the tools. Install the bolt and
w asher and torque-tighten to 645 25
Nm (475 18 ft-lb).
645 25 Nm
(475 18 ft-lb)
27
Remove blocking tool 9996950 from
the Gfywheel housing and install t y wheel turning tool 9996956.
9996950
9996956
645 25 Nm
(475 18 ft-lb)
9998270
Page 10
29
32
Make sure the A w h e e l is at 0 and

that the cam shaft is at TDC (see
marking).
gear
Use a tw o-step process to torquetighten the idler gear bolts:
30
Install the adjustable idler gear (see 6,
Fig. 2: Tim ing gear arrangem ent, page
4).
Note: Hand-tighten the bolts until they
Tighten to 15 3 Nm
(11 2 ft-lb).
Turn bolts an additional 120 5.
15 3 Nm
(11 2 ft-lb)
120 5
Note:
bottom against the bearing shield

(these bolts will be individually re
placed in a later step).
gear are NOT reusable. If they are

loosened or removed, they MUST be
replaced with new bolts.
31
33
T 2 0 0 7 1 58
T 20 0 7 0 8 4
Fig. 19: Idler gear adjustm ent

A djust the idler gear using two feeler
gauges. The correct backlash is 0.05 0.17 mm (0.002 - 0.007 in.). By using
feeler gauges, an equal am ount of
backlash between cam gear and the
nonadjustable upper idler gear can be
obtained.
Fig. 21: Checking the backlash

A fter adjustment, check the backlash
with rocker dial indicator 9999683
mounted on m agnetic base 9999696.
Note:
the same for both gear w heels which
mesh with the adjustable idler gear.
9999683
9999696

TSI
34
Install the cam sensor wheel on the
cam shaft drive gear. Install and
torque-tighten the three bolts to 25 Nm
(19 ft-lb).
25 Nm
(19 ft-lb)
35
Install the vibration dam per and
torque-tighten bolts to 50 5 Nm (37
4 ft-lb).
Note: New bolts should be used.
50 5 Nm
(37 4 ft-lb)
Date
Group
No.
11.2001
215
004
Page
11(H )
VOLVO
TSI

Greensboro, NC USA

21 4 -0 1 1 , Valve Stem Seals, D12, D12A, D12B, D12C
(11.2002), publication no. PV776-TS P 161564.
Date
Group
No.
8.2003
2 14
011
Supp.
Page
1(5)
Valve Stem Seals

D12, D12A, D12B, D12C
Valve Stem Seals
This inform ation covers the proper procedure fo r servicing valve stem seals on the
VOLVO D12, D12A, D12B, D12C engines.
Contents
Valve Stem Seals, Replacem ent page 3
N o te : Information is subject to change w ithout notice.

Illustrations are used fo r reference only and may differ slightly from the actual
P V 7 7 6 -T S P 1 92731
USA13849

TSI
Date
Group
No.
8.2003
214
011
Tools
Special Tools
For special tools ordering inform ation, refer to Tool Information, Group 08.
9996950
9996956
9998335
Flywheel blocking tool
Flywheel turning tool
Valve stem seal guide sleeve
9998255
J-41989
Rocker arm shaft lifting tool
Valve spring compressor tool
9998260
9998261
9998263
Press Tool
Valve Guide Drift
Valve Guide Removal Drift
Page
2(5)

TSI
Date
Group
No.
8.2003
214
011
Page
3(5)
Service Procedures
2149-03-02-01
Valve Stem Seals, Replacement
(C y lin d e r head in s ta lle d .)

N ote: Make sure that piston is at TDC for the cylinder

w here the valve stem seals are being replaced. If valve
stem seal replacem ent is attem pted with the piston NOT
at TDC, the valve may fall into the cylinder, and the
cylinder head may have to be removed.
Special tools: 9996950, 9996956, 9998255,

9998335, J-41989
1
Remove the valve cover; refer to Service Information,
Group 21.
2
Remove the flywheel housing inspection cover.
3
Install tool 9996956 and turn the engine to TDC, 0
degrees on the flywheel.
N ote: W hen the flywheel is at TDC, the piston in No. 1
cylinder will be at the top of the cylinder stroke.
9996956
4
Remove flywheel turning tool. Install blocking tool
9996950.
9996950

TSI
Date
Group
No.
8.2003
214
011
Page
4(5)
5
Loosen the rocker arm shaft bolts gradually to avoid
bending the arm shaft assembly. Remove the bolts, install
tool 9998255 and lift off the rocker arm shaft assembly.
9998255
6
Using tool 9998255, remove the rocker arm shaft from the
cylinder head. Remove all valve bridges.
N o te : Valve bridges need to be installed in the same
location from which they w ere removed.
9998255
7
Install tool J-41989 to remove the valve springs on
cylinder No. 1.
W ith the flywheel locking tool still in place, do the valve
seal on No. 6 cylinder, also. Rotate the engine, then move
to cylinders 2 and 5. Then, rotate to cylinders 3 and 4.
J-41989
8
Remove the valve springs and old valve seals.
N o te : E xhaust valves have inner and outer springs
(double springs).
9
Place tool 9998335 on the valve guide and slip the
valve seal over the tool. Push seal until it bottoms
against the valve guide.
N ote: Use tool 9998335 to avoid dam age to the new
seals.
9998335
10
Reinstall the valve springs, making sure that the valve
retainers (keepers) lock correctly. Make sure that inner
springs are on the exhaust valves.

TSI
Date
Group
No.
8.2003
214
G11
Page
5(5)
11
Replace the valve stem seals on cylinder No. 6 in the
same way.
12
Remove blocking tool 9996950. Install flywheel turning
tool 9996956 and rotate the engine 1 2 0 until the next
pair of pistons are located at TDC.
9996950, 9996956
13
Remove flywheel turning tool 9996956. Reinstall
blocking tool 9996950 and replace valve stem seals for
these cylinders. Continue until all stem seals have
been replaced.
9996950, 9996956
14
Remove blocking tool 9996950. Using tool 9998255,
install the rocker arm shaft assembly.
9996950, 9998255
w2002159.tif
15
Adjust the valve bridges, valves, and injectors on all
cylinders; refer to Service Information, Group 21.
16
Install the valve cover.
TSI
Number
030-500
Vehicle Management System

Vectro II From 1 9 9 8
PV776-TSP144528
VOLVO
Foreword
signs and m ethods studies carried out up to June 2001.
W hen this is believed to have a significant bearing on this manual, supplem entary ser
Service procedures w hich do not include an operation num ber in the title are for gen
Documentation:
Note: Indicates a procedure, practice, or condition that must be followed in order to

Caution: Indicates an unsafe practice w here damage to the product could occur.
Warning: Indicates an unsafe practice w here personal injury or severe damage to the
cur.

Greensboro, NC USA
Order number: PV776-144528

permission of Volvo Trucks North America, Inc.
Contents
General ................................................................................................................... 7
Vehicle M anagem ent System ......................................................................... 7
Engine Control System G lossary ................................................................ 8
Specifications .................................................................................................... 10
D escription o f Signals ..................................................................................... 10
EECU (D7C) and Breakout Box Connected in Series Between
EECU and W iring Harness ........................................................................ 10
EECU, D7C, with Breakout Box Connected to W iring Harness Only
13
EECU (D12B and D12C), Breakout Box Connected in Series Be

tween EECU and W iring H arness ............................................................ 16
EECU (D12B and D12C), Breakout Box Connected to W iring
Harness Only .................................................................................................. 19
Pinouts ..................................................................................................................22
....................................................22
Pinouts ..................................................................................................................26
Vehicle Electronic Control Unit(VECU)
..................................................... 26
S chem atic ............................................................................................................28

D12B ...................................................................................................................28
S chem atic ............................................................................................................29
D12C
..................................................................................................................29
S chem atic ............................................................................................................30

D7C
.................................................................................................................. 30
S chem atic ............................................................................................................31

VECU ................................................................................................................ 31
Tools ..................................................................................................................... 33
Special Tools
...................................................................................................... 33
O ther Special E quipm ent ................................................................................35

Vehicle M anagem ent System ......................................................................... 37
Strategy ........................................................................................................... 37
Conventional Control System s .................................................................... 37
Data Link System .......................................................................................... 38
Data Links, Design and Function .............................................................. 39
Diagnostic C onnector .................................................................................... 47
Com m unication Equipm ent .......................................................................... 48
Instrum ent C luster .......................................................................................... 49
Vehicle Electronic Control Unit (VECU) .................................................. 50
Engine Electronic Control Unit .................................................................... 51
ABS Brake System ECU ...............................................................................63
SRS Airbag ECU .............................................................................................64
Transmission ECU .......................................................................................... 65
Breakout Boxes and Harnesses ..................................................................66
VECU O verview
..............................................................................................67
VECU Functions ..............................................................................................68

Sensor Locations ........................................................................................... 73
Control Unit Locations ................................................................................. 77
Fuses and Relays .......................................................................................... 81
Troubleshooting ................................................................................................. 85
Fault Code Troubleshooting ...............................................................................85
M essage and Param eter Descriptions ....................................................... 85
FMI Table .............................................................................................................87
Reading/C learing Fault Codes
88
1
Fault Tracing Strategy
................................................................................... 88
MID 128 EECU ................................................................................................... 92

MID 128 Fault Code Table
............................................................................. 92
MID 128 PID 45 Preheater Status
................................................................96
Fault Codes .................................................................................................... 96

MID 128 PID 45 Preheater Status, Check ................................................ 97
MID 128 PID 49 ABS Control Status ....................................................... 98
Fault Codes ...................................................................................................... 98
MID 128 PID 49 ABS Control Status, Check ............................................99
MID 128 PID 84 Road Speed
.................................................................. 100
Fault Codes ................................................................................................... 100

MID 128 PID 84 Road Speed, Check .................................................... 101
MID 128 PID 85 Cruise Control Status .................................................. 102
Fault Codes ................................................................................................... 102
MID 128 PID 85 Cruise Control Status, Check
MID 128 PID 91 A ccelerator Pedal Position
................................... 103
......................................... 104
Fault Codes ................................................................................................... 104

MID 128 PID 91 A ccelerator Pedal Position, Check ........................... 105
MID 128 PID 94 Fuel Delivery Pressure ............................................... 106
D7C and D12C ............................................................................................. 106
Fault Codes ................................................................................................... 106
MID 128 PID 94 FuelDelivery Pressure, Check
..................................... 107
D7C and D12C ............................................................................................. 107

MID 128 PID 100 Engine Oil Pressure ................................................... 110
Fault Codes .................................................................................................. 110
MID 128 PID 100 Engine Oil Pressure, Check .................................... 111
MID 128 PID 102 Boost Pressure ........................................................... 114
Fault Codes ................................................................................................... 114
MID 128 PID 102 Boost Pressure, Check ............................................ 115
MID 128 PID 105 Boost A ir Temperature
............................................. 118
Fault Codes ................................................................................................... 118

MID 128 PID 105 Boost A ir Temperature, Check ............................... 119
MID 128 PID 107 A ir Filter Differential Pressure ................................. 122
Fault Codes ................................................................................................... 122
MID 128 PID 107 A ir Filter Differential Pressure, Check ................... 124
MID 128 PID 108 A tm ospheric Pressure ............................................... 125
Fault Codes .................................................................................................. 125
MID 128 PID 110 Engine Coolant Temperature
................................... 126
Fault Codes .................................................................................................. 126

MID 128 PID 110 Engine Coolant Temperature, Check .................... 127
MID 128 PID 111 Coolant Level
.............................................................. 129
Fault Codes ................................................................................................... 129

MID 128 PID 111 Coolant Level, Check ................................................ 130
MID 128 PID 158 Battery Voltage ........................................................... 131
Fault Codes ................................................................................................... 131
MID 128 PID 158 Battery Voltage, Check
............................................ 132
MID 128 PID 172 A ir Inlet Temperature ................................................. 133

Fault Codes ................................................................................................... 133
MID 128 PID 172 A ir Inlet Temperature, Check
.................................. 134
MID 128 PID 174 Fuel Temperature ....................................................... 136

D7C and D12C ............................................................................................. 136
Fault Codes
.................................................................................................. 136
MID 128 PID 174 Fuel Temperature, Check .......................................... 137

D7C and D12C ............................................................................................. 137
MID 128 PID 175 Engine Oil Temperature
140
2
Fault Codes
.................................................................................................. 140
MID 128 PID 175 Engine Oil Temperature, Check ............................ 141
MID 128 PID 228 Road Speed Sensor Calibration
Fault Codes
........................... 144
.................................................................................................. 144
MID 128 PID 228 Road Speed Sensor Calibration, Check ............. 145
MID 128 PPID 86 Engine Brake Torque Percent ................................ 146
Fault Codes
.................................................................................................. 146
MID 128 PPID 86 Engine Brake Torque Percent, Check ................. 147
MID 128 PPID 119 High Coolant Temperature ................................... 148
Fault Codes .................................................................................................. 148
MID 128 PPID 119 High Coolant Temperature, Check .................... 149
MID 128 PPID 122 VCB Engine Com pression Brake
....................... 151
D12B and D12C .......................................................................................... 151

Fault Codes .................................................................................................. 151
MID 128 PPID 122 VCB Engine Com pression Brake, Check .......... 152
D12B and D12C .......................................................................................... 152
MID 128 PPID 123 EPG 2 ......................................................................... 153
D12B and D12C .......................................................................................... 153
Fault Codes .................................................................................................. 153
MID 128 PPID 123 EPG 2, Check ........................................................... 154
D12B and D12C .......................................................................................... 154
MID 128 PPID 124 EPG 1 ......................................................................... 155
Fault Codes .................................................................................................. 155
MID 128 PPID 124 EPG 1, Check ........................................................... 156
MID 128 SID 1/2/3/4/5/6 Injector
............................................................ 157
D12B and D12C .......................................................................................... 157

Fault Codes .................................................................................................. 157
MID 128 SID 1/2/3/4/5/6 Injector, Check
................................................ 159
D12B and D12C .......................................................................................... 159

MID 128 SID 17 Fuel S hutoff Valve ......................................................... 161
Fault Codes .................................................................................................. 161
MID 128 SID 17 Fuel S hutoff Valve, Check ........................................... 162
D7C only ....................................................................................................... 162
MID 128 SID 20 Tim ing Sleeve ................................................................. 163
D7C only ....................................................................................................... 163
Fault Codes .................................................................................................. 163
MID 128 SID 20 Tim ing Sleeve, Check .................................................. 165
D7C only ....................................................................................................... 165
MID 128 SID 21 Engine Position Tim ing Sensor .................................. 166
D12B and D12C .......................................................................................... 166
Fault Codes .................................................................................................. 166
MID 128 SID 21 Engine Position Tim ing Sensor, Check .................... 167
D12B and D12C .......................................................................................... 167
MID 128 SID 21 Needle Lift Sensor ........................................................ 168
Fault Codes .................................................................................................. 168
MID 128 SID 21 Needle Lift Sensor, Check .......................................... 169
D7C only ....................................................................................................... 169
MID 128 SID 22 Engine Speed Sensor .................................................. 170
Fault Codes .................................................................................................. 170
MID 128 SID 22 Engine Speed Sensor, Check .................................... 171
MID 128 SID 23 Rack A ctuator ................................................................. 172
D7C only ....................................................................................................... 172
Fault Codes .................................................................................................. 172
MID 128 SID 23 Rack Actuator, Check
174
D7C only ..................................................
174
3
MID 128 SID 24 Rack Position Sensor ................................................... 175

D7C only ....................................................................................................... 175
Fault Codes .................................................................................................. 175
MID 128 SID 24 Rack Position Sensor, Check ..................................... 176
D7C only ....................................................................................................... 176
MID 128 SID 33 Fan Control ...................................................................... 177
Fault Codes .................................................................................................. 177
MID 128 SID 33 Fan Control, Check ....................................................... 178
MID 128 SID 64 R edundant Engine Speed Sensor ............................ 179
D7C only ....................................................................................................... 179
Fault Codes .................................................................................................. 179
MID 128 SID 64 R edundant Engine Speed Sensor, Check .............. 180
D7C only ....................................................................................................... 180
MID 128 SID 70 Preheater Elem ent 1 .................................................... 181
Fault Codes .................................................................................................. 181
MID 128 SID 70 Preheater Elem ent 1, Check ..................................... 182
MID 128 SID 71 Preheater Elem ent 2 ................................................... 183
D12B only ..................................................................................................... 183
Fault Codes .................................................................................................. 183
MID 128 SID 71 Preheater Elem ent 2, Check ...................................... 184
D12B .............................................................................................................. 184
MID 128 SID 230
Idle Validation Switch 1 .............................. 185
Fault Codes .................................................................................................. 185

MID 128 SID 230
Idle Validation Switch 1, Check ................. 186
MID 128 SID 231 SAE J1939 Control Link ............................................. 187
Fault Codes .................................................................................................. 187
MID 128 SID 232
5 Volt DC Supply .......................................... 189
Fault Codes .................................................................................................. 189

MID 128 SID 232
5 Volt DC Supply, Check ............................ 190
MID 128 SID 240
Program M em ory
......................................... 191
Fault Codes .................................................................................................. 191

MID 128 SID 250
SAE J1587/1708 Information Link ........... 192
Fault Codes .................................................................................................. 192

MID 128 SID 253
Data Set M em ory EEPROM
..................... 193
Fault Codes .................................................................................................. 193

MID 128 SID 254
Engine Electronic Control Unit(EECU) ... 194
Fault Codes .................................................................................................. 194

MID 144 VECU ................................................................................................ 196
........................................................................ 196
MID 144 PID 29 Second A ccelerator Pedal Position Sensor .......... 198
Fault Codes .................................................................................................. 198
MID 144 PID 29 Second A ccelerator Pedal Position Sensor, Check
199
.................................................................... 201
Fault Codes ....................................................................................................201

MID 144 PID 84 Road Speed, Check ...................................................... 202
MID 144 PID 91 A ccelerator Pedal Position
.......................................... 204
Fault Codes ....................................................................................................204

MID 144 PID 91 A ccelerator Pedal Position, Check .............................205
MID 144 PID 152 VECU, N um ber of Resets ......................................... 207
Fault Codes ....................................................................................................207
MID 144 PPID 69 Idle Validation Switch ...................................................208
Fault Codes ....................................................................................................208
MID 144 PPID 69 Idle Validation Switch, Check
.................................. 209
MID 144 PPID 70 Pedal Switches, Supply .............................................211

Fault Codes ....................................................................................................211
4
MID 144 PPID 70 Pedal Switches, Supply, Check ............................... 212

MID 144 PPID 71 Cruise Control and Engine Brake, Supply Switch
Fault Codes
215
....................................................................................................215
MID 144 PPID 71 Cruise Control and Engine Brake, Supply

Switch, Check .................................................................................................. 216
MID 144 PPID 72 A ccelerator Pedal, Supply Sensors ......................... 220
Fault Codess
............................................................................................... 220
MID 144 PPID 72 A ccelerator Pedal, Supply Sensors, Check ..........221

MID 144 PPID 73 Second A ccelerator Pedal, Supply Sensors .........223
Fault Codes .................................................................................................. 223
MID 144 PPID 73 Second A ccelerator Pedal, Supply Sensors,
Check ................................................................................................................ 224
MID 144 PPID 75 Range Inhibitor, Solenoid Valve Status .................. 226
Fault Codes .................................................................................................. 226
MID 144 PPID 75 Range Inhibitor, Solenoid Valve Status, Check ... 227
MID 144 SID 230
Idle Validation Switch 1 ..............................................229
Fault Codes .................................................................................................. 229

MID 144 SID 230
Idle Validation Switch 1, Check ................................230
MID 144 SID 231
SAE J1939 Control Link .......................................... 232
Fault Codes .................................................................................................. 232

MID 144 SID 231
SAE J1939 Control Link, Check ............................. 233
MID 144 SID 240
Program M em ory
........................................................ 234
Fault Codes .................................................................................................. 234

MID 144 SID 243 Cruise Control Set Switch ...........................................235
Fault Codes .................................................................................................. 235
MID 144 SID 243 Cruise Control Set Switch, Check ............................. 236
MID 144 SID 250 SAE J1587/1708 Information Link .............................238
Fault Codes .................................................................................................. 238
MID 144 SID 250 SAE J1587/1708 Information Link, Check .............. 239
MID 144 SID
253 Data Set M em ory EEPROM...................................... 240
Fault Codes .................................................................................................. 240

MID 144 PSID 3 Idle Validation Switch 3
..............................................241
Fault Codes .................................................................................................. 241

MID 144 PSID 3 Idle Validation Switch 3,Check .................................... 242
Service Procedures ........................................................................................ 245

Engine ECU, R eplacem ent ......................................................................... 245
Feedback
Operation Numbers
Group 28
General
General
W2002520
This inform ation covers the Vehicle M anagem ent System, which includes VECTRO II
electronics, the vehicle ECU, and other control system s used in the vehicle.
Group 28
General
Engine Control System Glossary

ATA
FMI (Failure Mode Identifier)
Am erican Trucking Association
Num bers and names used to identify how a system or

part failed.
ATDC (After Top Dead Center)
FMI
Description
Data valid but above normal operating range
Data valid but below normal operating range
Data erratic, intermittent, or incorrect
The 180 of crankshaft rotation before the piston reaches

top center (norm al direction of rotation).
Voltage above normal
INFO lamp
Voltage below normal
Light that warns the operator of an active diagnostic fault

code; also referred to as the diagnostic lamp.
C urrent below normal or open circuit
Data link
C urrent above normal or short circuit
Mechanical system not responding properly
The 180 of crankshaft rotation after the piston reaches

top center (norm al direction of rotation).
AC (Alternating Current)
An electrical current that alternates level and direction.
BTDC (Before Top Dead Center)
An electrical connection for com m unication with other

m icroprocessor-based devices (such as powertrain con
trol, trip recorders and m aintenance system s) that are
compatible with the ATA and SAE standard.
A bnorm al frequency, pulse rate or period
Diagnostic fault code

9
These codes indicate an electronic system malfunction,
indicating a problem with the D12 electrical systems.
A bnorm al update
10
A bnorm al rate of change
11
Failure mode not identifiable
12
Defective device or com ponent
13
Uncalibrated device or com ponent
Diagnostic flash code

Codes flashed out in a series via the INFO lamp to indi
cate an active fault code.
DC (Direct Current)
An electrical current that flows in one direction only.
EEPROM (Electrical Erasable Programmable Read

Only Memory)
14/15
The contents of this type of m em ory may be electroni

cally erased and new information programmed into the
device.
Hz (Hertz)
EECU (Engine Electronic Control Unit)
MID
The com puter that controls the power supplied to the en

gine electronics, monitors and governs engine functions.
M essage Identification Description
EUI (Electronic Unit Injector)

An injector pump w hich is m echanically activated and
electronically controlled. It combines m etering and inject
ing in a single unit.
Engine brake disable system

During the tim e ABS (anti-lock braking system ) is active,
the engine brake is disabled.
Reserved for future assignm ent
M easure of frequency in cycles per second.
Open circuit
Condition where an electrical wire or connector is bro
ken, preventing signal or supply voltage from reaching its
intended destination.
Parameter
A program m able value that affects the characteristics or
behavior of the engine and/or vehicle.
Group 28
General
PID
SID
Param eter Identification code.
Subsystem Identification code.
PTO (Power Takeoff)
Signal
Operated with the cruise control switches, this mode per

mits setting a constant engine rpm when the vehicle is
not moving.
A voltage value used to transm it information typically

from a sensor to the EECU.
Supply voltage
PWM (Pulse Width Modulation)

A signal consisting of variable-width pulses at fixed inter
vals to vary; TIME O N versus versus TIME O F F
A constant voltage that supplies electrical power to a

component. It may be generated by the EECU or sup
plied by the vehicle battery.
RAM (Random Access Memory)
Throttle Position Sensor (TPS)
A m em ory that has stored inform ation im m ediately avail

able when addressed.
An electronic sensor that is connected to the accelerator

pedal and sends a Pulse W idth M odulated signal to the
EECU.
Reference voltage
Vehicle Specification Programming (VSP)
A regulated voltage supplied by the EECU to a sensor,
w hich uses it to generate a signal voltage.
Password
VSP consists o f two levels of programming: engine con

figuration (level 1) and custom er param eters (level 2).
Vehicle Speed Sensor (VSS)

A group of seven alphanum eric characters designed to
restrict access to level-2 parameters. The password is
autom atically defaulted to seven empty spaces if cus
tom er has not specified password.
An electrom agnetic device that measures vehicle speed

from the rotation of gear teeth in the drivetrain of the ve
hicle.
SAE
VEB (Volvo Engine Brake)
Society o f Autom otive Engineers.
C onsists of a com pression brake (VCB) and an exhaust

pressure governor (EPG).
Short circuit
A connection of com paratively low resistance, acciden
tally or intentionally made between two points on a
circuit.
Specifications
Group 28
Specifications
Description of Signals
EECU (D7C) and Breakout Box Connected in Series Between EECU
and Wiring Harness
For the measurements below, the following applies:
The EECU connected.
Breakout box J-41132 connected between connec

tor EA or EB and the EECU.
Ignition key in ON position.
Jum per harness J -4 3 2 3 3 connected between con

nector EA or EB and the EECU.
Engine not running.

M easuring voltage.
Fig. 3: EECU voltage check, EB
Fig. 1: EECU with pinouts
Fig. 2: EECU voltage check, EA
B+ = battery voltage
C on n e c
S ignal typ e
M easuring p o in ts
Oil temperature sensor, signal
EA1 - EA5
Ig n itio n key in the ON p o sitio n
tio n
EA1
3.0 V (+20 0C/68 F)

0.4 V (+100 0C /2 1 2 0F)
EA2
Intake manifold temperature sensor,
EA2 - EA5
signal
EA3
Intake manifold pressure sensor, sig
2.6 V (+ 2 0 C/68 F)
1.6 V (+40 C/104 F)
EA3 - EA5
1 .1 V (sea level)
EA4 - EA5
4.8 - 5.15 V
nal
EA4
Supply to sensors (5 V), +
EA5
Signal ground to sensors, -
EA6
Not currently used
EA7
Redundant engine speed sensor, +
EA8
Rack drive PWM, +
EA9
Timing sleeve PWM, +
10
O ther
Group 28
C o n n e c
Specifications
S ignal typ e
EA13 - EA5
3.0 V (+20 C/68 F)
O th e r
tion
EA10
Rack drive PWM, -
EA11
Not currently used
EA12
Not currently used
EA13
Fuel temperature sensor, signal
2.0 V (+40 C/104 F)

EA14
Oil pressure sensor, signal
EA15
Needle lift sensor, +
EA16
Rack position sensor, search coil
EA17
Rack position sensor, common
EA18
Redundant engine speed sensor, -
EA19
Not currently used
EA20
Not currently used
EA21
Timing sleeve PWM, -
EA22
Not currently used
EA23
Not currently used
EA24
Not currently used
EA25
Coolant temperature sensor, signal
EA14 - EA5
0.5 V (for cold engines)
EA25 - EA5
3.0 V (+20 C/68 F)

0.6 V (+85 C/185 F)
EA26
Not currently used
EA27
Fuel pressure sensor, signal
EA28
Needle lift sensor, -
EA29
Rack position sensor, reference coil
EA30
Engine speed sensor (crank), +
EA31
Engine speed sensor (crank), -
EA32
Not currently used
EA33
Not currently used
EA34
Not currently used
EA35
Not currently used
EA36
Not currently used
EB1
EA27-EA5
~ 0.5V (for cold engines)
D12 C
SAE J1939 A Communications link
EB1/EB9
~2-5V
EB2
SAE J1939 B Communications link
EB2/EB9
~0-3V
EB3
Ambient air temperature sensor, sig

nal
EB3 - EB13
2.6 V (+20 C/68 F)

1.2 V (+50 C/122 F)
EB4
Buffered idle validation switch
EB4 - EB9
< 4 V (idle)
> 8 V (off idle)
EB5
Pre-heat sense 1
EB5 - EB9
55 % of B+ (open)
Normally closed with
0 V (closed)
the ignition key in the

ON position.
EB6
Not currently used
11
Group 28
C o n n e c
Specifications
S ignal type
O th e r
Coolant level sensor, signal
EB7 - EB8
80% B+ (open)
0 V (closed)
Applies to WX and
VN. Normally open
tio n
EB7
with the ignition key in

the ON position.
EB8
Signal ground to sensors, -
EB9
EECU ground, -
EB10
EECU ground, -
EB11
EECU B+
EB11 - EB9
B+
EB12
EECU B+
EB12 - EB10
B+
EB13
Ambient air temperature sensor
EB14
Not currently used
EB15
Not currently used
EB16
Not currently used
EB17
Air filter indicator sensor signal
EB18
Not currently used
EB19
Not currently used
EB20
Not currently used
EB21
Fan control (if equipped with on/off

fan)
EB21 - EB9
B+ (fan on)
Normally ON with the
0 V (fan off)
ignition key in the ON

position.
EB22
Not currently used
EB23
Not currently used
EB24
EOL Enable
EB24 - EB9
< 6 V or O/C (EOL Disable)

> 9.6 V (EOL Enable)
EB25
SAE J1587A/J1708A Information link
EB25-EB9
~ 0-5V
EB26
SAE J1587B/J1708B Information link
EB26-EB9
~ 0-5V
EB27
Not currently used
EB28
Not currently used
EB29
Not currently used
EB30
Not currently used
EB31
Pre-heating relay, Coil ground
EB31 - EB9
B+ (pre-heat off)
0 V (pre-heat on)

position.
EB32
Not currently used
EB33
Not currently used
EB34
Fuel shut-off valve
EB34 - EB9
EB35
EPG 1
EB35 - EB9
0 V (valve on)
> 1.0V (valve off)

position.
B+ (EPG off)
Normally OFF with
0 V (EPG on)

ON position.
EB36
12
Not currently used
Group 28
Specifications
EECU, D7C, with Breakout Box Connected to Wiring Harness Only

Breakout box J-41132 connected to connector EA or

EB.
The EECU is not connected.
Ignition key must be in the OFF position.
Measuring resistance.
W2002711
Fig. 5: EECU harness checks, EB
Fig. 4: EECU harness checks, EA
C o n n e c
Signal typ e
Ig n itio n key in th e OFF p o sitio n
EA1 / EA5
1.9 kfi (+20 0C/68 0F)
O ther
tio n
EA1
100 0 (+100 0C/212 0F)

EA2
EA2 / EA5
signal
6.2 kO (+20 0C/68 0F)

2.5 kO (+40 0C/104 0F)
EA3

nal
EA4
Sensor supply to (5 V), +
EA5
Sensors ground , -
EA6
Not currently used
EA7
Redundant engine speed sensor, +
EA7 / EA18
EA8
Rack drive PWM, +
EA8 / EA10
1.5
EA8 / alternate
open circuit
775 - 945 O
ground
EA9
Timing sleeve PWM, +
EA9 / EA21
1.5
EA9 / alternate
ground
open circuit
EA10 / alternate
ground
open circuit (see also EA8)
EA13 / EA5
1.9 kO (+20 0C/68 0F)

800 0 (+4 0 C /1 0 4 F )
EA10
Rack drive PWM, -
EA11
Not currently used
EA12
Not currently used
EA13
EA14
EA15
Needle lift sensor, +
EA15 / EA28
65 - 165 O
EA16
Rack position sensor, search coil
EA16 / EA17
20.0 O
EA17
Rack position sensor, common
EA18
Redundant engine speed sensor, -
EA18 / EA7
775 - 945 O
EA19
Not currently used
13
Group 28
C o n n e c
Specifications
S ignal type
Ig n itio n key in the OFF p o sitio n
EA21 / alternate
open circuit (see also EA9)
O th e r
tio n
EA20
Not currently used
EA21
Timing sleeve PWM, -
ground
EA22
Not currently used
EA23
Not currently used
EA24
Not currently used
EA25
EA25 / EA5
1.9 k i! (+20 C/68 F)

160 i! (+85 C/185 F)
EA26
Not currently used
EA27
Fuel pressure sensor
EA28
Needle lift sensor, -
EA29
Rack position sensor, reference coil
EA29 / EA17
20.0 n
EA30
EA30 / EA31
775 - 945 H
EA31
EA31 / EA30
775 - 945 H
EB3 / EB13
6.2 k i! (+20 C/68 F)
EA32
Not currently used
EA33
Not currently used
EA34
Not currently used
EA35
Not currently used
EA36
Not currently used
EB1
SAE J1939A Communications link
EB2
SAE J1939B Communications link
EB3
D12 C
nal
EB4
EB5
Pre-heat sense 1
EB6
Not currently used
EB7
EB8
Sensor ground
EB9
EECU ground, -
EB10
EECU ground, -
EB11
EECU, B+
EB12
EECU, B+
EB13
Ambient air temperature ground
EB14
Not currently used
EB15
Not currently used
EB16
Not currently used
EB17
EB18
Not currently used
EB19
Not currently used
EB20
Not currently used
EB21
Not currently used
EB22
Not currently used
EB23
Not currently used
EB24
EOL Enable
14
1.7 k i! (+50 C/122 F)
EB5 / EB9
open circuit (open)

< 5 i! (closed)
EB7 / EB8
open circuit (coolant level normal)

<1 i! (coolant level low)
EB24/EB9
open circuit (open)
Applies to W X and VN
G roup 28
C o n n e c
Specifications
S ignal typ e
EB25 / (connection
A in 6 pin diagnos
<1
O th e r
tion
tics connector)
EB25
SAE J1587/J1708 A Information link

EB25 / (connection
<1
F in 9 pin diagnos
tics connector)
EB26
SAE J1587/J1708 B Information link
EB26 / (connection
B in the 6 pin diag
<1
nostics connector)
EB26 / (connection
<1
G in the 9 pin diag

nostics connector)
EB27
Not currently used
EB28
Not currently used
EB29
Not currently used
EB30
Not currently used
EB31
Pre-heating relay, coil ground
EB32
Not currently used
EB33
Not currently used
EB34
Fuel shut-off valve, include
EB35
EPG 1, -
EB36
Not currently used
15
Group 28
Specifications
EECU (D12B and D12C), Breakout Box Connected in Series Between

EECU and Wiring Harness
Breakout box J-41132 connected between connec
tor EA or EB and the EECU.
Jum per harness J43233 connected between con
nector EA or EB and the EECU.
The EECU connected.
Engine not running.
M easuring voltage.
oj
W2002710
W2002712
Fig. 7: EECU voltage check, EB
Fig. 6: EECU voltage check, EA
B+ = battery voltage
C on n e c
S ignal typ e
EA1 / EA5
O ther
tio n
EA1
3.0 V (+20 C/68 F)

0.4 V (+100 C/212F)
EA2
EA2 / EA5
signal
EA3
2.6 V (+20 C/68 F)

1.6 V (+40 C/104 F)
EA3 / EA5
1 .1 V (sea level)
EA4 / EA5
4.8 - 5.15 V
nal
EA4
Sensor supply (5 V), +
EA5
Sensor ground
EA6
Not currently used
EA7
Engine position sensor (cam), +
EA8
Not currently used
EA9
Not currently used
EA10
Not currently used
EA11
Unit injector cylinder 1, -
EA12
Unit injector cylinder 1, 2, 3 (90

Volt), +
EA13
EA14
EA15
Not currently used
16
D12 C
E A 1 4 /E A 5
0.5 V (for cold engines)
Group 28
C o n n e c
Specifications
S ignal typ e
EA25 / EA5
3.0 V (+20 C/68 F)
O th e r
tion
EA16
Not currently used
EA17
Not currently used
EA18
Engine position sensor (cam), -
EA19
Not currently used
EA20
Not currently used
EA21
Not currently used
EA22
EA23
EA24

Volt), +
EA25
0.6 V (+85 C/185 F)

EA26
Not currently used
EA27
EA28
Not currently used
EA29
Not currently used
EA30
EA31
EA32
Not currently used
EA33
VCB, -
D12 C
EA33 / alternate
B+ (VCB off)
Normally OFF with
ground
0 V (VCB on)

ON position.
EA34
EA35
EA36
EB1
SAE J1939 Communications link,
EB1/EB9
~ 2-5V
EB2/EB9
~ 0-3V
EB3 / EB13
2.6 V (+20 C/68 F)
can HI
EB2
SAE J1939 Communications link,

can LOW
EB3

nal
EB4
1.2 V (+50 C/122 F)

EB4 / EB9
< 4 V (inactive)
> 8 V (active)
EB5
Pre-heat sense 1 (if equipped)
EB5 / EB9
55% of B+ (open)
0 V (closed)

ON position.
EB6
Not currently used
EB7
EB7 / EB8
80% B+ (open)
VN and VHD. Nor
0 V (closed)
mally open with the

position.
EB8
Sensor ground
EB9
EECU ground, -
EB10
EECU ground, -
17
Group 28
C o n n e c
Specifications
S ignal type
O th e r
EB11
EECU B+
EB11 / EB9
B+
EB12
EECU B+
EB12 / EB10
B+
EB13
EB14
Not currently used
EB15
Not currently used
EB16
Pre-heat sensor 2 (if equipped)
EB16 / EB9
55 % of B+ (open)
0 V (closed)

ON position.
tio n
EB17
EB18
Not currently used
EB19
Not currently used
EB20
Not currently used
EB21
Engine fan control (if equipped with
EB21 / EB9
on/off fan), -
B+ (fan on/solenoid inactive)
0 V (fan off/solenoid active)

position.
EB22
Not currently used
EB23
Not currently used
EB24
EOL Enable
EB24 / EB9
< 6 V or O/C (EOL disable)

> 9.6 V (EOL Enable)
EB25
SAE J1587/J1708 + Information link
EB26
SAE J1587/J1708 - Information link
EB25/EB9
~ 0-5V
EB27
Not currently used
EB26/EB9
~ 0-5V
EB28
Not currently used
EB29
Not currently used
EB30
Not currently used
EB31
Pre-heating relay coil ground (if
EB31 / EB9
equipped)
B+ (pre-heat off)
Normally OFF with
0 V (pre-heat on)

ON position.
EB32
Not currently used
EB33
Not currently used
EB34
Not currently used
EB35
EPG 1
EB36
EPG 2
EB35 / EB9
EB36 / EB9
B+ (EPG off)
Normally OFF with
0 V (EPG on)

ON position.
B+ (EPG off)
Normally OFF with
0 V (EPG on)

ON position.
18
Group 28
Specifications
EECU (D12B and D12C), Breakout Box Connected to Wiring Harness

Only
Breakout box J-41132 connected to connector EA or

EB.
The EECU not connected.
Measuring resistance.
Fig. 8: EECU harness checks, EA
C o n n e c
tio n
Signal typ e
Ig n itio n key in th e OFF p o sitio n
EA1
EA1 / EA5
1.9 kfi (+20 0C/68 0F)

100 0 (+100 0C/212 0F)
EA2

signal
EA2 / EA5
6.2 kO (+20 0C/68 0F)

2.5 kO (+40 0C/104 0F)
EA3

nal
EA4
Sensor supply (5 V), +
EA5
Sensor ground
EA6
Not currently used
EA7
Engine position sensor (cam), +
EA7 / EA18
775 - 945 O
EA8
Not currently used
EA9
Not currently used
EA10
Not currently used
EA11
EA11 / EA12
1.5 - 2.0 O
EA12

Volt), +
EA13
EA14
EA15
Not currently used
EA16
Not currently used
EA17
Not currently used
EA18
Engine position sensor (cam), -
EA19
Not currently used
EA20
Not currently used
O ther
see EA11, EA22 and EA23
D12 C
see EA7
19
Group 28
C o n n e c
Specifications
S ignal type
O th e r
EA22 / EA12
EA23
EA23 / EA12
EA24
K)
o
EA22
cn
Not currently used
K)
o
EA21
cn
tio n
see EA34, EA35, and EA36
Volt), +
EA25
EA25 / EA5
1.9 k i! (+20 C/68 F)

160 i! (+85 C/185 F)
EA26
Fuel pressure sensor, signal
D12 C
EA27
Not currently used
EA28
Not currently used
EA29
Not currently used
EA30
EA30 / EA31
775 - 945 H
EA31
EA31 / EA30
775 - 945 H
EA32
Not currently used
EA33
VCB, -
EA34
EA34 / EA24
1.5 - 2.0 n
EA35
EA35 / EA24
1.5 - 2.0 n
EA36
EA36 / EA24
1.5 - 2.0 n
EB1
SAE J1939 + Communications link
EB2
SAE J1939 - Communications link
EB3

nal
EB3 / EB13
6.2 k i! (+20 C/68 F)

1.7 k i! (+50 C/122 F)
EB4
EB5
Pre-heat sense 1 (if equipped)
EB5 / EB9
open circuit (open)

< 5.0 i i (closed)
EB6
Not currently used
EB7
EB8
Sensors ground
EB9
EECU ground, -
EB10
EECU ground, -
EB11
EECU B+
EB12
EECU B+
EB13
EB14
Not currently used
EB15
Not currently used
EB16
Pre-heat sensor 2 (if equipped)
EB7 / EB8
open circuit (coolant level normal)

<1 i!; closed (coolant level low)
EB16 / EB9
open circuit (open)

< 5.0
EB17
EB18
Not currently used
EB19
Not currently used
20
i!
(closed)
Applies to WX , VN
and VHD
Group 28
C o n n e c
Specifications
S ignal typ e
EB24/EB9
Open circuit(open)
EB25 / (connection
A in the 6 pin diag
<1
O th e r
tion
EB20
EB21
Not currently used

Engine fan control (if equipped with
on/off fan)
EB22
Not currently used
EB23
Not currently used
EB24
EOL Enable
nostics connector)
EB25
SAE J1587/J1708 A Information link
EB25 / DCA (con
<1
nection F in the 9
pin diagnostics con
nector)
EB26 / (connection
B in the 6 pin diag
<1
nostics connector)
EB26
SAE J1587/J1708 B Information link

EB26 / (connection
<1
G in the 9 pin diag

nostics connector)
EB27
Not currently used
EB28
Not currently used
EB29
Not currently used
EB30
Not currently used
EB31
Preheating relay coil ground (if

equipped)
EB32
Not currently used
EB33
Not currently used
EB34
Not currently used
EB35
EPG 1, -
EB36
EPG 2, -
21
Group 28
Specifications
Pinouts
VOLVO D12B/D12C EECU/EA Connector
Cavity
C olor
Description
GN
BL/W
GR
G N /W
BOO ST & OIL PRESSURE COMMON (+)
BN /W
PRESSURE & TEMP. SENSOR COMMON
OIL TEMPERATURE
BOO ST TEMPERATURE
BOO ST PRESSURE
(-)
6
7
NOT USED
Y
8-10
ENGINE POSITION SENSOR, CAM (+)

NOT USED
11
INJECTOR, CYL 1 (-)
12
CYL 1, CYL 2, CYL 3 INJECTOR CO M

MON, 90 Volt (+)
13
GN
FUEL TEMPERATURE (D12C)
14
BN
OIL PRESSURE
15-17
18
NOT USED
BN /W
19-21
ENGINE POSITION SENSOR, CAM (-)

NOT USED
22
INJECTOR, CYL 2 (-)
23
INJECTOR, CYL 3 (-)
24
CYL 4, CYL 5, CYL 6 INJECTOR CO M
25
Y /W
MON, 90 Volt (+)
26
27
NOT USED
BN
28-29
FUEL PRESSURE (D12C)

NOT USED
30
BL/SB
ENGINE SPEED SENSOR, CRANK (+)
31
BL/R
ENGINE SPEED SENSOR, CRANK (-)
32
NOT USED
33
G N /W
34
INJECTOR, CYL 4 (-)
35
INJECTOR, CYL 5 (-)
36
INJECTOR, CYL 6 (-)
W ire C o lo rs:
22
COOLANT TEMPERATURE
BL
VCB SOLENOID VALVE RETURN
BLUE
RED
BN
BROWN
SB
SOLID BLACK
GN
GREEN
VO
VIO LET
GR
GRAY
WHITE
OR
ORANGE
YELLO W
PINK
W3000945
Group 28
Specifications
VOLVO D12B/D12C EECU/EB Connector

Cavity
Color
Description
DATA LINK J1939 CAN HI
GN
DATA LINK J1939 CAN LO
BL/Y
AMBIENT AIR TEMPERATURE
BUFFERED IDLE VALIDATION
W3000945
SWITCH
5
PREHEAT SENSE 1
NOT USED
BL/SB
COOLANT LEVEL WARNING
GR/W
AIR FILTER, COOL LVL COMMON
GROUND (-)
10
GROUND (-)
11
R/SB
POWER SUPPLY (+)
12
R/SB
POWER SUPPLY (+)
13
V0/W
AMBIENT AIR TEMP COMMON (-)
14-15
NOT USED
16
R/W
PREHEAT SENSE 2
17
BL/R
AIR FILTER INDICATOR
18-20
21
NOT USED
GR/R
22-23
24
COOLING FAN CONTROL (-)

NOT USED
Y/SB
FACTORY PROGRAMMING (NOT

USED)
25
GR
DATA LINK J1708/1587 (+)
26
OR
DATA LINK J1708/1587 (-)
27-30
31
NOT USED
BL/R
32-34
PREHEAT RELAY(Coil Ground)

NOT USED
35
GR/SB
EPG1 CONTROL
36
GR/W
EPG2 CONTROL
W ire C o lo rs:
BL
BLUE
RED
BN
BROWN
SB
SOLID BLACK
GN
GREEN
VO
VIO LET
GR
GRAY
WHITE
OR
ORANGE
YELLO W
PINK
23
G roup 28
Specifications
VOLVO D7C EECU/EA C onnector

Cavity
C olor
GN
BL/W
GR
GN/W
BOOST, OIL & FUEL PRESSURE COMMON (+)
BN/W
PRESSURE & TEM P SENSOR COMMON
OIL TEMPERATURE
BOOST TEMPERATURE
WS000945
BOOST PRESSURE
NOT USED
REDUNDANT ENGINE SPEED SENSOR (+)
Y/R
RACK DRIVE, PWM (+)
Y/SB
TIMING SLEEVE, PWM
10
GN/BN
RACK DRIVE, PWM (-)
11-12
NOT USED
13
GN/BN
14
BN
15
GR/SB
16
BL/R
RACK POSITION SENSOR, SEARCH COIL
17
Y/GR
RACK POSITION SENSOR, COMMON
18
BN/W
REDUNDANT ENGINE SPEED SENSOR (-)
19-20
21
25
FUEL TEMPERATURE
OIL PRESSURE
NEEDLE LIFT SENSOR(+)
NOT USED
OR
22-24
TIMING SLEEVE, PWM (-)

NOT USED
Y/W
26
COOLANT TEMPERATURE
NOT USED
27
BN
28
GR/R
29
Y/W
30
BL/SB
ENGINE SPEED SENSOR, CRANK(+)
31
BL/R
ENGINE SPEED SENSOR, CRANK(-)
32-36
W ire C o lo rs:
24
Description
FUEL PRESSURE
NEEDLE LIFT SENSOR (-)
RACK POSITION SENSOR, REFERENCE COIL
NOT USED
BL
BLUE
RED
BN
BROWN
SB
SOLID BLACK
GN
GREEN
VO
VIO LET
GR
GRAY
WHITE
OR
ORANGE
YELLO W
PINK
Group 28
Specifications
VOLVO D7C EECU/EB Connector

Cavity
Color
Description
GN
DATA LINK J1939 CAN LO
BL/Y
AMBIENT AIR TEMPERATURE
BUFFERED IDLE VALIDATION
W3000945
SWITCH
5
PREHEAT SENSE 1
NOT USED
BL/SB
COOLANT LEVEL WARNING
GR/W
AIR FILTER, COOL LEVEL COM

MON (-)
GROUND (-)
10
GROUND (-)
11
R/SB
POWER SUPPLY (+)
12
R/SB
POWER SUPPLY (+)
13
V0/W
AMBIENT AIR TEMP COMMON (-)
14-16
17
NOT USED
BL/R
18-23
24
AIR FILTER INDICATOR

NOT USED
Y/SB
FACTORY PROGRAMMING (NOT

USED)
25
GR
DATA LINK J1708/1587 (+)
26
OR
DATA LINK J1708/1587 (-)
27-30
31
NOT USED
BL/R
32-33
NOT USED
34
Y/BN
35
GR
36
W ire C o lo rs:
PREHEAT RELAY, CONTROL
FUEL SHUTOFF VALVE CONTROL

EPG1
NOT USED
BL
BLUE
RED
BN
BROWN
SB
SOLID BLACK
GN
GREEN
VO
VIO LET
GR
GRAY
WHITE
OR
ORANGE
YELLO W
PINK
25
Group 28
Specifications
Pinouts
Vehicle Electronic Control Unit(VECU)
Vehicle ECU Connector A-(GREEN)
Cavity
Circuit
564A
CC/PTO SWITCH SET(-) INPUT
563A
CC/PTO SWITCH SET(+) INPUT
562A
CC/PTO SWITCH ON INPUT
Description
NOT USED
567B
SERVICE BRAKE SWITCH INPUT
284-A
12V STARTER CONTROL SOLE

NOID FEED
245
ENGINE PREHEAT CIRCUIT PRO

TECTION FEED
571
CLUTCH SWITCH INPUT
385-A
10
388
INTERMITTENT WIPER INPUT
11
387-C
SWITCH TO WASHER MOTOR
12
0XE
ELECTRONIC GROUND
13
18V
ELECTRONIC ENGINE SWITCHED
PARK CONTROL WIPER MOTOR
BATTERY FEED
14
196 V
15-18
IGNITION SWITCH DR FEED

NOT USED
19
300D
20
629
ENGINE BRAKE MEDIUM FEED
21
628
ENGINE BRAKE LOW FEED
22
MANUAL FAN SWITCH INPUT
NOT USED
23
555
24
682
IDLE VALIDATION INPUT

HIGH REFRIGERANT PRESSURE
SWITCH FEED
25-28
26
NOT USED
29
573
30
565A
PTO SWITCH ON INPUT

CC/PTO SWITCH RESUME INPUT
15
W3002689
Group 28
Specifications
Vehicle ECU C onnector B-(BLUE)

Cavity
Circuit
Description
NOT USED
312A
3-4
TRANSMISSION AREA INHIBITOR

VALVE RETURN
NOT USED
597
ECU COMMON 12V OUTPUT
550
VEHICLE SPEED INPUT
NOT USED
553
THROTTLE POSITION SENSOR IN

PUT
NOT USED
10
552
THROTTLE POSITION SENSOR

SUPPLY
11
581
12-14
PARKING BRAKE SWITCH INPUT

NOT USED
15
583
POWER CONTROL FROM ENGINE

ECU
16
389B
INTERMITTENT WIPER RELAY

COIL RETURN
17
555A
IDLE VALIDATION FROM ENGINE

ECU
18
312C
RANGE INHIBITOR VALVE RETURN
19
558
ECU COMMON +12V OUTPUT
20
551
VEHICLE SPEED RETURN FROM

ECU
21
317B
TRANSMISSION LOW RANGE INDI

CATOR SIGNAL
22
554
THROTTLE POSITION SENSOR RE

TURN
23-26
NOT USED
27
567A
28-30
SERVICE BRAKE SWITCH INPUT

NOT USED
Vehicle ECU C onnector C-(GREEN)

Cavity
Circuit
401-D
DATA LINK J1708 (-)
400-D
DATA LINK J1708 (+)
408-B
DATA LINK J1939 SHIELD
406-B
407-B
DATA LINK J1939 CAN LOW
Description
27
Group 28
Schematic
D12B
28
Specifications
Group 28
Specifications
Schematic
D12C
29
D
-v i
CONN.
NO.
V E H IC L E IN TER FAC E C O N N E C T O R
EA
1
2
3
EB
V E H IC L E IN T E R F A C E C O N N .
EP G C O N T R O L VALVE (PW M )
4
5
6
7
8
9
10
S Y M B O L D E F IN IT IO N
IN JE C T IO N P U M P C O N N .
N E E D L E LIFT S E N S O R
R E D U N D A N TS P E E D SENDER
C R ANK SENDER
C O O L A N T TEM P, S E N S O R
O IL TEM P. /P S I S E N S O R
B O O S T TEM P. /P S I S E N S O R
11
12
./
D E N O T E S TW IS TE D
PAIR
3"
CD
3
0)
D E N O T E S C O N N EC T O R D E N O T E S CAVITY
FU EL T E M P ./P S I S E N S O R
13
14
E N G IN E S T O P S O L E N O ID VALVE
C O O L A N T LEVEL S E N S O R
15
A M B IE N T A IR TEM P. S E N S O R
r
F UEL
TEM P
D E S C R IP T IO N
c/>
Group 28
co
o
FU EL
PRESS
r
B O O S T
T EM P.
BO OST
PRESS.
O IL
TEM P.
O IL
PRESS.
C RANK
SENDER
Specifications
t
AM
REDUNDANT
SP EED
SENDER
:
Group 28
Specifications
Schematic
VECU
31
32
Group 28
Tools
Tools
Special Tools
The following special tools are required for w o rk with the D12 electronic control sys
tem. The 3917916 VOLVO breakout kit, along with its components, is available from
Volvo Truck. W hen requesting tools, provide the appropriate part number. Part num
bers beginning with J are available from Kent-Moore.
See list on next page for information about the tools in the picture.
33
Group 28
Tools
9998534
4pin breakout harness
J-39200
digital multim eter
J-43147
2pin breakout harness
9998482
Guage for inspection of control unit con

nector
J-41132
3 6 -p in breakout box
J-42472
2 -p in breakout harness
J-43233
3 6 -p in jum per
J-38748
34
7 -p in fuel injection pump breakout box
9809687
AC/DC power supply for PC

toll.(optional)
9809678
12 Pin DIN C onnector cable-alternative

program m ing cable for EECU
9809685
Power extension cable used together

w /9808635.
J-43234
Adapter(Kent Moore).
9998551/J43340
60 Pin Breakout Box/Overlay.
Group 28
Tools

The following hardware is used to operate V CAD S Pro. The tools can be ordered from
Volvo quoting the specified part number.
V CAD S Pro tools for diagnostics is for vehicles built from 1998 and later. For diagnos
tics on vehicles built prior to 1998, use Pro-Link 9000 (J-38500) with Volvo Application
C artridge J-38500-2000.
See list on next page fo r inform ation about the tools in the picture.
35
Group 28
Tools
PC tool -package.
Didgipass password generator, model 300 or 500.
Laser printer; HP 1100A (To be purchased from a local supplier. Not supplied by
Volvo.)
9998574
Laser printer labels. Used when printing labels for the engine electronic control
unit (EECU).
9998555
Com m unication interface unit; for connection between the PC tool and the vehi
cle's diagnostic connector.
9812331
Extension Cable; for comm unication, 22 yards (optional)
J-43999
6 Pin Diagnostic adapter; for vehicles prior to 1999
J-43939
9 Pin Diagnostic adapter; for vehicles built from January 1999.
9998496
Pressure Guage
9998489
Oscilloscope interface
9998554
Oscilloscope Cable-BNC connector cable to banana ja ck (optional)
9998553
Oscilloscope Cable-25 pin parallel cable (optional)
9998617
Program m ing Kit (see below)
980 8635
P ro g ra m m in g U nit
9808560
Cable for direct

connection to the Engine ECU
9808561
9808562
9808563
Cable for direct

connection to the Vehicle ECU
Cable for direct
connection to the Intstrum ent C luster
Cable for power supply
Note: There are three ways o f connecting the power cable; 1) To radio power supply, 2) Directly to battery with battery.
3) To cigar lighter.
36
G roup 28
Design and Function
Design and Function

Strategy
The vehicle m anagem ent system is designed to incorpo
rate the entire vehicle system and instantly receive
real-tim e data from key vehicle com ponents.
Vehicle
Production
Uniform interfaces between the control systems.

Standard adaptations to the vehicle's functions.
Stand-alone diagnostics for the vehicle's main elec
tronic components.
Com m unication
Equipm ent
Transmission
Owner
SRS
Brakes
Driver
Engine
Instrum ent Cluster
Expansion capability
Body Builder
Service
Conventional Control Systems

In principle, a conventional control system is constructed
so that one or several of the vehicle's com ponents have
their own control units that receive signals from different
sensors. Each control unit serves its own com ponent and
sends signals to other control units via electrical wires.
An example of this is the engine control unit that re
ceives signals from different sensors on the engine, as
well as from other control units on the vehicle. The ac
celerator pedal position, the clutch pedal position, the
speed signal, engaged power take-off etc., are sent to
the engine electronic control unit (EECU) via w ires from
different sensors and contacts.
The system must have one or more com m unication
ports, to which tools can be connected for programming
as well as for reading inform ation and any fault codes.
In the future, the vehicle's sub-com ponents will require
several specific control units and the vehicle electronics
will therefore become even more complex. In the long
run this will limit the ability of conventional control sys
tem s to fulfill their tasks.
T3008752
37
Group 28
Design and Function
Data Link System

Volvo's vehicle electronics are constructed on the princi
ple that all com m unications between the control units in
the system are accom plished via two data links:
the J1939 Control Data Link

and the J1587/1708 Information Data Link
The vehicle's main com ponents have their own control

units that are connected to one or both links in order to
be able to com m unicate with each other.
Here is how the system w orks on a vehicle equipped
with a Volvo engine: w hen the driver wants to increase
the vehicle's speed, a signal is sent from the accelerator
position sensor to the vehicle electronic control unit
(VECU). The signal is then transferred via the data link
to the engine electronic control unit (EECU).
The EECU com m unicates with its own sensors to verify
that the conditions exist to perm it increased acceleration.
If the conditions are met, it carries out the VEC U 's re
quest.
The EECU com m unicates with the other control units via
the data links, either by requesting or by receiving direct
inform ation that all prerequisites are met in order to be
able to carry out the request.
If an error should occur in any o f the systems, a signal is
sent out on the J1587/1708 information data link, which
makes it possible to read the inform ation, either on the
driver's instrum ent cluster, or via a PC or diagnostic tool
(i.e. Pro-Link, VCADS or VCADS Pro) connected to the
diagnostic connector.
The data link system provides an extrem ely flexible solu
tion with great potential for expansion.
/ j \ CAUTION
No modifications or connections should be made to
wires 406 (yellow), 407 (green) or 408 (shielded).
These wires carry the high-speed com m unications be
tween the electronic system s in the vehicle. Any
modification, connection to, or damage to these

wires can result in the failure of the vehicle's elec
tronic systems.
38
Group 28
Design and Function
Data Links, Design and Function

Data links are one way of transferring information be
tween various components. In conventional systems,
analog signals have mostly been used.
Analog signals mean that different voltage levels repre
sent different values. A simplified example o f analog
signals could be:
1 volt = 1 0 C
2 volts = 2 0 C
3 volts = 3 0 C
Data links use digital comm unication. This means that

the voltage only varies between tw o different values, ei
th e r high or low. By combining these high and low
signals various values can be described.
The diagram shows an oscilloscope image w here the
voltage of the data link is measured. As can be seen
from the diagram, a large part o f the tim e the link is
silent but at tim es a num ber o f fast pulses are sent. A
group o f pulses is called a message.
The enlarged portion of the diagram shows that each
message consists o f a combination of high and low volt
age levels.
The following sections describe w hat type o f information
this m essage contains.
W3003957
39
Group 28
Design and Function
Messages and Information Content

Different voltage levels are represented by the different
numbers in the binary num ber system. The binary num
ber system has only tw o numbers, one and zero.
The ones are norm ally represented by a high voltage
and the zeros by a low voltage.
Each binary num ber is called a bit. This m essage con
sists of four groups of binary numbers. Each group of
eight bits makes up a byte, a decimal num ber from 0
255 with information, as well as a start bit and a stop bit.
The purpose of the start and stop bits is to function as
markers for where that group of data begins and ends.
In the diagram above only the start and stop bits are la
beled. The other information is shaded.
Example
The diagram shows the information content in the four
different parts of the message. The start and stop bits
are shaded since they do not contain any information.
The box in the diagram shows the different binary and
decimal values which com prise the message.
Note: The inform ation is sent over the data link with the
least bit first in the binary numbers. The normal way to
notate binary numbers is shown in the box in the
diagram.
40
10
mi
10
10
rr nn
W3003956
Group 28
Design and Function
W2003293
Message 1 4 4 -0 9 1 -0 0 0 -24 0 in this example, has the following meaning:
A
MID 144 The message comes from the Vehicle ECU.
PID 091 The message states the accelerator pedal position percentage.
Data 000 The accelerator pedal is in the completely released position.

000 is a data component, which in this case states how much the accelerator pedal has been
pressed down. The value can vary between 000 for a completely released pedal and 255 for a com
pletely pressed down accelerator pedal.
Check 240 The checksum is used as a check that the message is reasonable.
41
Group 28
Design and Function
Diagnostic Message Description

The Society o f Autom otive Engineers (SAE) and the Am erican Trucking Association
(ATA) have developed a standardized list of diagnostic messages, or fault codes. These
diagnostic m essages are used to com m unicate information about problems detected
by an electronic control unit's (ECU's) self-diagnostic program. In addition to the
industry-standard SAE codes, Volvo has developed a list of diagnostic messages that
are unique to Volvo applications. Generally, diagnostic messages and their descriptions
are listed in the service manual for each respective ECU and in the user manual for di
agnostic tools.
MID
MID is an acronym for M essage Identification Description. MIDs are SAE stan
dardized codes used to identify individual electronic control units.
PID
PID is an acronym for Param eter Identification Description. PIDs are SAE stan
dardized codes used to identify param eters or values.
PPID PPID is an acronym for P roprietary Param eter Identification Description. PPIDs
are Volvo's unique codes used to identify param eters or values.
SID
SID is an acronym for Subsystem Identification Description. SIDs are SAE stan
dardized codes used to identify components.
PSID PSID is an acronym for P roprietary Subsystem Identification Description. PSIDs

are Volvo's unique codes used to identify components.
FMI
42
FMI is an acronym for Failure Mode Identifier. FMIs are SAE standardized codes
used to identify a type of failure.
Group 28
Design and Function
Data Link Communication

General
Com m unication between the different ECUs takes place
via the two data links: the J1939 control data link and
the J1587/1708 inform ation data link.
The diagram shows how the control units, the diagnostic
connector, and the instrum ent cluster are connected in
principle.
The instrument cluster, the engine ECU and the diag

nostic connector are always included in the system.
The system may include other control units, depending
on the vehicle type, engine type and optional equipment.
43
Group 28
Design and Function
SAE J1939 Control Data Link

The system 's control signals are sent via this link.
The J1939 link is very fast, operating at 250,000 bits per
second. This operating speed allows the system to func
tion more effectively and adapt quickly to changing
conditions and vehicle requirements.
The link com plies with SAE standards, and consists of
three twisted wires: a green wire (407), a yellow wire
(406) and in early deisgns a shield wire (408-optional).
The twisted wire set (40 turns per meter) is used to pro
tect the link from electrical interference.
/ j \ CAUTION
No modifications or connections should be made to
wires 406 (yellow), 407 (green) or 408 (shielded).
These wires carry the high-speed com m unications be

tronic systems.
44
G roup 28
Design and Function
Terminating Resistor
W3002905
Terminating resistors are w ired into each end of the

J1939 data link. One is located near the ABS ECU and
the other near the engine ECU. On Volvo engines, the
term inating resistor at the engine ECU end is located in
side the EECU.
If you m easure 120 ohm (+/- 10 ohm) between circuits
406 and 407, then there is only one term inatig resistor.
Check to determ ine which is missing and reconnect it.
Note: W ith Volvo engines, one term inating resistor is

within the engine ECU. The other is poitioned at the end
of the J1939 network, typically at the ABS ECU. The one
within the ECU is not accessible and should not be at
fault.
If you m easure less than 60 ohm, only two term inating
resistors are used in a vehicle. Never install three in one
truck. If more than two term inating resistors exist in the
J1939 circuit, dam age to the ECU electronics can occur
over time. You can easily check to see if you have two
resistors by m easuring the resistance between circuits
406 and 407 with the ignition OFF. The correct resis
tance is 60 .
The purpose of these resistors is to prevent data link
signal reflections. They must remain connected for the
system to function properly.
45
Group 28
Design and Function
SAE J1587/1708 Information Data Link

Information and diagnostic signals are sent via this
link. The link also functions as a backup should the
J1939 control data link fail to function for any reason.
SAE J1708 is a standard that specifies hardware and a
databus speed of 9600 bits per second. SAE J1587 is a
protocol that provides a standard method for exchanging
inform ation between microprocessors.
The J1587 link consists of tw o w ires (400 and 401) that
are twisted around each other approx. 30 turns per me
ter. The tw isted-pair wires are to protect the link against
electrical interference.
/ j \ CAUTION
If a circuit must be added to the electrical system, and
will carry high currents or frequencies, route it in a lo
cation AWAY from wires 400 and 401 to prevent
mutual inductance from interfering with data link func
tions.
/ j \ CAUTION
W ires 400 and 401 MUST NOT be cut or spliced for
any connections. These wires are used for the trans
mission of data for diagnostic m essages and gauges.
M odifying this circuit can cause these functions to fail.
SAE J1922 Data Link

For a short period o f tim e some vehicles w ere produced
which used the J1922 data link. The J1922 data link was
developed as an interim standard until the J1939 control
data link was established. The J1922 link operates on
J1708 defined hardware and is used like a control link
for com m unication between engine, transm ission and
ABS ECUs.
The J1922 link consists of tw o w ires (404 and 405) that
are twisted around each other approx. 30 turns per me
ter. The tw isted-pair wires are to protect the link against
electrical interference.
46
G roup 28
Design and Function
Diagnostic Connector
W8001310
The diagnostic connector is a round Deutsch connector

located in the driver's side kick panel. The diagnostic
connector is connected to the J1587/1708 information
link and gives the system a way to com m unicate with an
external P C or diagnostic tool.
W ith a P C or diagnostic tool connected, fault codes can
be read from all the control units. This is im portant in
fault tracing to carry out basic checks of all the vital
parts of the vehicle's electronics.
Som e program m ing can also be done via the diagnostic
connector.
The standard diagnostic connector is a 6 -p in Deutsch. A
newer 9 -p in Deutsch version has been introduced on
certain vehicle/engine variants. The new 9 -p in connector
connects to both the J1939 and J1587/1708 data links.
47
Group 28
Design and Function
Communication Equipment
W2003295
Pro-Driver Display
Various m anufacturers offer com m unication equipm ent

designed to allow drivers to keep log book records elec
tronically, m aintain com m unication with the home office,
m onitor and record vehicle operations, and many other
functions. Currently these com m unication devices are
connected to the J1587/1708 Information Data Link.
Newer and more sophisticated versions of these devices
may also connect to the J1939 Control Data Link. Note:
No provisions have currently been made to add com m u
nication equipm ent to the J1939 link in afterm arket
adaptations.
/ j \ CAUTION
No m odifications or connections should be made to
w ires 406 (yellow), 407 (green) or 408 (shielded).
These w ires carry the high-speed com m unications be

tronic systems.
Provisions are made for adding afterm arket com m unica

tion devices to the J1587/1708 link via connectors in the
w iring harness.
Some of the com m unication devices currently used in
Volvo trucks include Road Relay, Pro-Driver, Qualcomm
and Highway Master.
48
G roup 28
Design and Function
Instrument Cluster
The instrum ent cluster used on Volvo vehicles uses both

data link signals and hardwired sensors depending on
the vehicle/engine variant and instrum ent configuration.
A graphic display screen is integrated into the instrum ent
cluster to provide additional features and vehicle system
inform ation not available from other gauges. Diagnostic
codes can also be retrieved and displayed. The instru
ment cluster is connected to the J1587/1708 information
data link.
For inform ation about the instrum entation that com m uni
cates via the data link, refer to service manuals in group
38:
Model:
See Publication:
W G /AC/W C/W I from

1994; W X with elec
tronic engines from
5.96
Data Link Instrumentation,

P V 7 7 6 -3 8 1-6 2 0 S M
WX
Kysor Mini-Cluster, PV776TSP108262
VN from 1 .98-2.99
Instrumentation, P V 7 7 6 TSP106805/1
VN from 3.99 ADN

VHD
Instrumentation, P V 7 7 6 TSP139790
49
Group 28
Vehicle Electronic Control Unit (VECU)
The vehicle electronic control unit (VECU) is part of the

integrated vehicle electronics. The VECU is located in the
cab, but its specific mounting location varies by model.
The main function of the VECU is to collect data from
different cab control units and then to pass this data to
other ECUs in the system (prim arily to the engine ECU).
For detailed inform ation about the VECU see V e h ic le
Volvo service publica
tion num ber P V 7 7 6 -3 0 0 -6 1 0 .
E le c t r o n ic C o n t r o l U n it, M ID 1 4 4 ,
The VECU is only used in vehicles equipped with

Volvo engines.
50
Design and Function
Group 28
Design and Function
Engine Electronic Control Unit
W2003294
Irrespective o f engine variant, the engine electronic con

trol unit (EECU) perform s the same basic functions in
the system: control of engine operation. The EECU re
ceives signals from various sensors and the data links.
B ased on these signals and the param eters program m ed
into the EECU, the EECU calculates the proper injection
angle and fuel quantity to satisfy the requested operating
requirements.
Com m unication
Equipm ent
(Expansion
capability)
The EECU is connected to both the J1939 control data

link and the J1587/1708 inform ation data link.
Note: Early production model EECUs may use only the

J1587/1708 data link, or the J1587/1708 and the J1922
data links.
SRS ECU
M ID 2 3 2
For detailed inform ation about EECUs see the service

literature for that particular engine.
Engine ECU
M ID 12 8
Terminating
Resistor
Diagnostic
connector
Vehicle ECU
M ID 144
SAE J1587
/1708
SAE J1939
Transmission ECU
M ID 13 0
Control unit
(Expansion
capability)
ABS ECU
M ID 1 3 6
Terminating
Resistor
51
Group 28
Design and Function
EECU
The EECU is an electronic control unit that monitors cer
tain operational param eters of the Volvo engine from the
SAE J1587 Data Link and appropriate sensors.
W2003076
52
Group 28
Design and Function
ON/OFF Engine Cooling Fan

The EECU receives the input from the engine coolant
tem perature sensor to turn on the cooling fan at 115 C
(202 F). The fan will remain engaged until the engine
coolant drops to 90 C (195 F).
The ON/O FF cooling fan can also be engaged by the
EECU if it receives a signal from the air conditioning sys
tem s APADS module. W hen the A/C system pressure
reaches 20.5 bar (300 psi) the APADS module will send
a signal to the EECU to engage the cooling fan. The on
tim e of the cooling fan is controlled by the APADS m od
ule.
Ifth e EECU does not receive any coolant tem perature
data, the fan is engaged for a m inim um of 30 seconds.
The fan will stay engaged until valid coolant tem perature
data is received and the coolant tem perature drops be
low 90 C (195 F).
Converting Engine Oil Pressure Signal

The EECU takes an analog signal from a pressure trans
ducer and broadcasts the signal on the SAE J1587 data
link.
Engine Information and Warning Lamp-On Dash
Engine Oil Pressure

The EECU will make the A STOP lamp light and the
icon in the display light up if the oil pressure is < 41
3 kPa (6 1.2 psi). Also a warning signal sounds
if the engine is running.
Engine Coolant Level

The EECU will make the A STOP lamp light stay on
(solid) if the low coolant level sensor detects a low
coolant level condition. The low coolant level condi
tion is active only after 5 seconds o f a constant
signal from the low level sensor.
Engine Coolant Temperature

The EECU will make the A STOP lamp light illumi
nate and gauge LED illuminate, plus the icon in the
display if a high coolant tem perature from the en
gine ECU is received.
Engine Oil Temperature

If the Engine oil tem perature becomes too high an
inform ation m essage is shown autom atically with
the text HIGH. A t the same tim e the yellow AIN FO
lamp under the display lights up. The engine may
also derate, if it is set up to do so in the engine
ECU programming. The tem perature which activates
this warning varies for different engines. This
tem perature is set in the engine ECU. For Volvo en
gines, it is 275 F (135 C).
Note: If the engine is running and the stop lamp comes

on you will get a buzzer or warning signal.
53
Group 28
Design and Function
Electronic Unit Injectors

The engine has six unit injectors, one for each cylinder.
Each Electronic Unit Injector , or EUI, is a com bination
of injection pump and injector, but operates at a consid
erably higher pressure than a standard injector.
Each unit injector is m ounted vertically in the cylinder
head at each cylinder, centered between the four valves.
The com pressive force for the unit injector is developed
by a lobe on the overhead camshaft. It is then trans
ferred by a rocker arm to the injector.
The injection angle and the am ount of fuel to be injected
into the cylinder is determ ined by the EECU, which
transm its signals to the electrom agnetically controlled
fuel valve in the unit injector valve housing.
/ j \ DANGER
Make sure to turn the ignition key off before working
on the electronic unit injectors. This elim inates the
possibility of electric shock which may result in per
sonal injury or death.
Electronic unit injector
Calculating Fuel Quantities

The EECU calculates the quantity of fuel to be injected
into a cylinder. This calculation provides the period of
tim e during which the fuel valve is closed (when the fuel
valve is closed, fuel is injected into the cylinder). Factors
that determ ine how much fuel to inject into a cylinder are:
Requested fuel amount
Limitation of fuel amount
Flywheel
There are 54 notches cut into the flywheel; these are
read by the speed sensor for the flywheel. W ith the help
of these notches, the EECU can set the correct injection
angle and calculate the tim e which gives the correct fuel
amount.
The notches are divided into three groups, with 18
notches in each group. There is a flat area between
each group of notches equivalent to 18. A flat area and
18 notches is equivalent to 1 2 0 on the flywheel, or a
third of a full turn. The area between each notch equals
6 on the flywheel.
Flywheel
54
Group 28
Design and Function
Cam Sensor Wheel

The cam sensor wheel has six teeth (one tooth for each
unit injector) evenly spaced at 60 center-to-center, plus
an extra tooth, placed 15 before the tooth that indicates
cylinder num ber 1.
The EECU uses these teeth to determ ine w hich injector
is in line for injection. In other words, each tooth (teeth
1 -6 ) represents the start of a cylinder operating phase
(does not apply to the extra tooth).
Flywheel and Cam Sensor Wheel

The ratio between the flywheel and cam sensor is 2:1.
This means that when the flywheel has rotated two
turns, the cam sensor wheel has rotated one turn or
when the flywheel has rotated 3 0 , the cam sensor
w heel has rotated 15 and so on.
55
Group 28
Design and Function
Injector Operational Phases

The operational phase of the num ber 1 cylinder is given
in the following example. Fuel is injected at 7 before top
dead center (BTDC) (the injection angle may vary be
tw een 1 8 BTDC and 6 after top dead center).
The cam sensor reacts to the extra tooth on the cam
sensor wheel. This informs the control unit that the next
tooth in turn (tooth 1) indicates the num ber 1 cylinder.
T2007100
Locating number 1 cylinder
A
top dead center (TDC)
The cam sensor wheel detects tooth 1 and the flywheel

sensor reaches a flat area on the flywheel at the same
time.
At this point, the piston is on its way upward in the cylin
der and no fuel is injected into the cylinder.
T2007101
Engine speed calculated
A
top dead center (TDC)
The sensor detects the first notch after a flat area on the
flywheel. Using the engine speed calculation, the EECU
can determ ine:
W hen to begin injecting fuel into the num ber 1 cylin

der. This gives selected injection angle (7 BTDC in
the example).
W hen to stop injecting fuel into the num ber 1 cylin

der. This gives the selected fuel amount.
56
Calculating injection angle

A
TDC
7 BTDC (injection begins)
ATDC (injection stops)
Group 28
Design and Function
From the first notch after a flat area, the EECU ad

vances the angle from w hich it is to begin injecting fuel
into the cylinder and on to the angle w here it is to stop
injecting fuel into the cylinder. If the calculated angles do
not agree with the notches on the flywheel, the EECU
m easures the tim e between the last notches to rectify
the angles.
Because the EECU m ust calculate the engine speed
during 120, the engine speed calculation for each cylin
der occurs one step ahead at all times. In other words,
during the operational phase for one cylinder, the EECU
calculates engine speed for the next cylinder and so on.
This procedure is repeated for the next cylinder in the
same m anner as described for the num ber 1 cylinder.
Note: Note that the calculation of the injection angle and

fuel am ount takes place continuously, regardless of the
operational phase o f the cylinders.
Cylinder Balancing
The EECU can provide each cylinder with a different
quantity o f fuel to make the engine run more sm oothly at
idling speeds. A t higher speeds, there are no problems
with smooth running and all cylinders receive the same
am ount o f fuel. If the variation in fuel quantity between
different cylinders is too great during cylinder balancing,
the EUI, which deviates most, triggers a fault code from
31 to 36. This indicates that there m ust be a fault in the
cylinder in question.
For cylinder balancing to take place, the following condi
tions must be satisfied:
Idling speed must be below 650 rpm.

Fuel requirem ent must be below a specific rating.
Idling adjustm ent function m ust not be active.
PTO not active.
Cruise control mode not active.
A ccelerator pedal in idling position.
C oolant tem perature must be above 50 C (122 F).
Vehicle m ust be at a standstill.
No fault codes in existence.
57
Group 28
Other Functions
The EECU guides the EUIs based on the following con
trol functions.
Smoke limitation To prevent injecting too much fuel

into the cylinder, the EECU checks:
Boost pressure
Engine speed
Boost air tem perature
PTO engine speed The engine can be kept at a con

stant rpm level that is at least 100 rpm greater than low
idle and less than high idle.
Cruise control The engine can be set to maintain a
constant speed between 48 km/h (30 mph) and 140
km/h (87 mph). For the cruise control mode to function,
the following conditions must be satisfied:
Cruise control in ON position.
Brake pedal m ust not be depressed.
Clutch pedal must not be depressed.
Speed limitation The EECU can be programmed to

limit the m aximum speed up to 140 km/h (87 mph). A
fault on the sensor signal and/or a faulty cable to the
EECU generates a fault code.
Differentiated speed limitation This mode is avail

able as an option. It limits the speed to various levels
depending on the gear selected. In other words, each
gear has a maximum speed.
58
Design and Function
Group 28
Design and Function
Engine protection To a certain extent, the EECU can

also protect the engine by:
Reducing engine speed at low coolant tem peratures

(cold engine cranking): W hen coolant tem perature is
lower than 50 C (122 F), engine speed is limited
during a specific tim e to 1000 rpm im m ediately after
starting. At -2 0 C (-4 F) and lower, this period is
16 seconds, and above 50 C (122 F) the period is
0 second. This function allows oil pressure to build
up before engine speeds become too high.
Engine speed during cold cranking
Reducing engine output at high coolant tem pera

tures (during engine operation): Should coolant
tem perature exceed 102 C (216 F), the maximum
fuel provision is reduced by a certain percentage of
its original rating and the coolant tem perature w arn
ing lamp lights up. If the coolant tem perature
becomes excessively high, the engine will gradually
reduce power to 50%. W hen coolant tem perature
has dropped below 100 C (212 F), m aximum fuel
provision is perm itted again and the coolant tem per
ature warning lamp goes out.
Engine speed during operation
The safety signal is an optional system that enables the

EECU too switch off the engine. The EECU can be pro
gram m ed to provide three levels of engine protection:
No engine protection (fire engine)
Engine protection
Extended engine protection
59
Group 28
Design and Function
Idle shutdown This function is available as an option.

It switches off the engine after it has run at idling speed
for a specific time. This tim e can be set to between 1
and 40 minutes. The engine will be switched o ff if the fol
lowing conditions are met:
Vehicle speed is 0.
Parking brake is applied.
Engine running at idle speed.

Coolant tem perature is above 45
C (113 F).
Cold starts, idling Idling speed is autom atically

boosted to heat the engine more quickly from a cold start
when coolant tem perature is below a specific level. W hen
this mode is activated, idling speed is boosted to 650
rpm. W hen coolant tem perature has reached 30 C (86
F), idling speed drops steadily to its norm al level which
is reached at a coolant tem perature of 45 C (113 F).
60
Group 28
Design and Function
Starting the engine

Before any fuel can be injected into the cylinders, the
EECU must have had a sufficient am ount of tim e to
carry out the first calculations on injection angles and
fuel quantities. This tim e is equivalent to two engine rev
olutions.
VEB (VOLVO engine brake)

The VEB consists o f an exhaust brake and a com pres
sion brake. The EECU activates the VEB when the
following conditions are satisfied:
A ccelerator pedal at idling position (fuel injection

m ust not occur).
Engine speed must exceed 1200 rpm.
Boost pressure m ust be lower than 152 kPa (22 psi)

(overpressure).
PTO not activated.
Vehicle speed is greater than 3.2 km/h (2 mph).
ABS not activated.
Engine coolant tem perature is greater than 40 2

C (104 5 F).
Engine oil tem perature is greater then 55 C (130

F).
The VEB may be activated when the cruise control is in

use. For this to take place, the following condition must
be satisfied:
Vehicle road speed m ust exceed the set speed of

the cruise control by between 5 and 30 km/h (4 and
20 mph), depending on w hat level has been pro
gram med into the EECU.
61
Group 28
Design and Function
Idle Speed Adjustment

N ote: This service inform ation should be considered
supplem ental to the Engine Control inform ation for base
D12 B and C engine.
The idle speed is adjusted on the V N vehicles at the turn
signal stalk. The idle speed can be adjusted between
500 RPM and 650 RPM.
Prerequisites to adjusting idle speed:
A ccelerator pedal not depressed.

Engine tem perature above 45 C (113 F).
Vehicle is stationary / Parking brake set.
Idle sp e e d a d ju s tm e n t
1
2
3
Cruise control in the ON position.

D epress the brake pedal and continue to hold it dur
ing the entire adjustm ent procedure.
Move the ON/OFF switch to the RESUME position
and hold for four seconds. Release the switch; the
engine speed w ill drop to approxim ately 500 RPM.
The idle speed can be adjusted with the SET
sw itch. Each tim e the SET switch is pressed, the
idle speed will increase approxim ately 10 RPM.
Move the ON/OFF switch to the RESUME position
and the idle speed w ill decrease approxim ately 10
RPM each tim e.
Hold in the SET switch and move the ON/OFF
switch to the RESUME position and hold them in
position for four seconds. Release the switches
Release the brake pedal and the new idle speed is
set. If an error was made during the adjustm ent pro
cedure, the default idle speed will be maintained.
T3014326
62
A-Set
B-Resume, On/Off
G roup 28
Design and Function
ABS Brake System ECU
The ABS ECU continuously m onitors wheel speed and

helps to control braking in exterm e situations. It also
helps prevent w heel spin in vehicles equipped with trac
tion control system s (ATC or TCS).
The ABS ECU is connected to the J1939 control data
link and the J1587/1708 inform ation data link.
Note: Early production model ABS ECUs may be con
nected to the J1587/1708 and J1922 data link or have
no data link connection at all.
For detailed inform ation about ABS system s see the ap
propriate service literature for the type of ABS system
used on the vehicle.
63
Group 28
SRS Airbag ECU
The Supplem ental Restraint System (SRS) ECU senses

frontal collisions with two rapid deceleration sensors.
The SRS ECU will deploy the airbag module in the
steering wheel if a collision of sufficient force and dura
tion is detected.
The SRS ECU is connected to the J1587/1708 inform a
tion data link. For detailed inform ation about the SRS
see S u p p le m e n t a l R e s t r a in t S y s t e m ( S R S ) , V N L , V N M ,
Volvo service publication num ber PV776-TS P 21771/1.
Note: The SRS system is not available on all models.
64
Design and Function
G roup 28
Design and Function
Transmission ECU
The transm ission electronic control unit (ECU) receives

signals directly from switches and sensors and via the
data links. Based on those inputs, the transm ission ECU
controls transm ission operation via solenoid valves and
switches. The transm ission ECU also supplies system
status and diagnostic information.
The transm ission ECU is connected to both the J1939
control data link and the J1587/1708 inform ation data
link.
Note: Early production model transm ission ECUs may

be connected to the J1587/1708 and J1922 data links.
F or detailed inform ation about transm ission ECUs see
the service literature for that particular transm ission.
65
Group 28
Design and Function
Breakout Boxes and Harnesses

The harness adapters are used to gain access to the
EECU, the VECU, the throttle pedal and certain other
sensors on the engine, w hile the circuit is intact. This al
lows the technician and vehicle to take m easurem ents
on functional circuits.
Example:
The 36-pin breakout box allows the technician to
measure resistance and voltage on the EECUs EA con
nector (which covers the engine mounted com ponents)
and the EB connector (which covers the rem aining com
ponents involved).
/ l \ CAUTION
Check that the proper cable and connector location is
observed and used while connectin to the ECU.
Ohterwise, dam age to the ECU or tool will occur.
J-41132
J-41132
W2002710
66
Group 28
Design and Function
VECU Overview
The Vehicle Electronic Control Unit (VECU) receives
inputs and generates output signals for functions associ
ated with cab devices. It also converts inform ation into
digital data to be broadcast over the J1587/1708 Infor
mation Link and the J1939 Control Link.
N ote: The VECU may also be referred to as the Cab
C ontroller on the graphics display o f the VN series dash
and in some Volvo publications.
VECU Programming
Each VECU is program m ed with specific vehicle
perform ance characteristics corresponding to custom erordered options for that particular vehicle. This dataset is
stored in the VECU m em ory, making the VECU unique
to each vehicle.
For this reason, it is not possible to swap a suspected
faulty VECU with one from another vehicle w ithout repro
gram m ing the replacem ent VECU.
R eplacem ent VEC U s are program m ed using the VCADS
Pro tool. Program m ing is based on the particular dataset
that matches the vehicle; datasets are stored in the
Volvo Data Adm inistration (VDA) database. Authorized
technicians can update and/or alter software datasets,
change custom er parameters, and perform campaigns.
For more inform ation about the proper operation o f the
VCADS Pro tool and VECU programming, please refer
to Information on VCADS Pro in Group O. This manual
is also available as a pdf file within VCADS Pro tool lo
cated under Help.
N ote: C ustom er param eter changes are not stored in
the VDA database. Therefore, after a replacem ent VECU
is program m ed for the vehicle, it will have to be cus
tom ized to include those custom er alterations.
67
Group 28
VECU Functions
The following functions are monitored or controlled by
the VECU. Only the functions needed for each specific
vehicle/engine application are wired and programmed
into the VECU.
Accelerator Pedal
The accelerator pedal signals travel first to the VECU
and are transferred to the Engine Electronic Control Unit
(EECU) via the J1939 Control Link.
If there is a fault in the J1939 Control Link, the accelera
to r pedal signal travels to the EECU via the J587/1708
Information Link. The vehicle can also be driven in the
limp hom e mode is there is a fault in both links. In this
situation, the idle validation switch is used to determ ine
when the accelerator pedal is pressed; then, the VECU
sends a buffered idle validation switch signal (via hard
w ire) to the EECU.
Second Accelerator Pedal

If the vehicle is equipped with a second accelerator
pedal, the second accelerator pedal signals travel first to
the VECU and are transferred to the Engine Electronic
Control Unit (EECU) via the J1939 Control Link.
A road speed limit may be programmed into the VECU
to limit vehicle speed when the second accelerator pedal
is being used. Second accelerator pedal road speed limit
can be programmed using the VCADS Pro tool.
Speedometer
The speed signal comes from a sensor on the transm is
sion or as a digital signal, if an electronically-controlled
transm ission (Allison) is used. The VECU then sends the
vehicle speed signal on both the J1939 Control Link and
J1587/1708 Information Link. The signal on the J1939
Control Link is used to control vehicle operation. The
signal on the J1587/1708 Information Link is collected by
the instrum ent cluster and is displayed on the
speedometer.
Cruise Control
The VECU receives signals from the cruise control
switch and sends signals to the EECU via the J1939
Control Link. Cruise control param eters can be pro
grammed with the VCADS Pro too.
68
Design and Function
Group 28
Design and Function
Power Take-Off (PTO)

PTO functions are controlled by the VECU through the
cruise control switch. Basic or optional PTO param eters
can be programmed with the VCADS Pro tool.
Ignition Switch
Ignition switch positions are recognized by the VECU,
w hich transfers the ignition switch position inform ation to
the EECU.
Idle Shut-Down
Tim ed engine shut-off can be controlled by the VECU as
a custom er option. Idle shut-down tim e can be pro
gram med with the VCADS Pro tool.
Engine Brake
The control for the engine brake (including the exhaust
pressure governor [EPG] and com pression brake [VCB],
if installed) are monitored by the VECU. A t the request
o f the ABS ECU, the VECU can de-activate the engine
brake.
Windshield Wipers
W indshield w iper function on the VN and VHD (with
Volvo engine) is controlled by the VECU using signals
received from the w iper switch.
Calibration Number
The calibration num ber (K factor) is a m easurem ent of
Drivetrain Constant Pulses per M ile and is used by the
VECU to determ ine vehicle speed and distance traveled.
The calibration num ber is calculated by multiplying tire
revolutions per mile x rear axle ratio x num ber of
teeth on the transm ission output shaft chopper w heel.
The calibration num ber is programmed into the VECU
using the VCADS Pro tool.
69
Group 28
Optional Engine Speed Limit

Optional engine speed limit is the maximum speed at
which the engine can be operated with the vehicle at
zero road speed and the PTO mode engaged. Optional
engine speed limit param eters can be programmed with
the VCADS Pro tool.
Optional Vehicle Speed Limit

Optional vehicle speed limit allows for an optional switch
to limit vehicle speed. Typically, this switch is operated
on the vehicle by someone other than the driver, such as
a garbage collector who rides on the back o f the vehicle.
Optional vehicle speed limit param eters can be pro
grammed with the VCADS Pro tool.
Note: Basic vehicle speed limit is set by the EECU.
Shut-Down Request
Optional engine shut-down request is made via a remote
mounted switch (the ignition switch is the basic engine
shut-down request). A fter the VECU receives the shut
down request, the request is sent to the EECU via the
J1939 Control Link. Shut-down request is enabled using
the VCADS Pro tool.
Note: The engine shut-down request function should not

be considered or used as an em ergency shut-down.
Torque Limit
Torque limit 1 and 2 are used to limit drive line torque.
Torque limit param eters can be programmed with the
VCADS Pro tool.
Engine Fan Request

The VECU receives the request for engine fan operation
from either a manual switch or a high pressure A/C re
frigerant switch. The VECU then transfers the request to
the EECU via the J1939 Control Link.
Brake/Clutch Status Switches

The VECU recognizes the position o f the brake, clutch,
and parking brake. Various VECU functions (i.e. cruise
control or PTO) operate only w hen these switches are in
the proper position.
70
Design and Function
Group 28
Design and Function
Safety Warnings/Cautions
Always w e a r approved eye protection.
To avoid personal injury and damage to the vehicle,

always refer to and follow the vehicle m anufacturers
W ARNINGS, CAUTIONS, and service procedures.
Unless otherwise directed, turn the ignition switch
OFF before disconnecting or connecting any electri

cal components.
Read and understand the manual provided with the

tool before operating your Pro-Link 9000.
VGHT recom m ends an assistant drive the vehicle

while you use the Pro-Link 9000.
Never leave the vehicle unattended while testing.
71
Group 28
VCADS Pro
From the VCADS Pro Main Menu, VCADS Pro Test, Cal
ibration, Program m ing and Job Cards are started. In
addition, a num ber of settings can be done, i.e. the se
lection of language. Ensure your language is selected
to get the right tests for your country's vehicle variant.
Do one of the following to start an application:
Select the application in the menu Select applica

tion. W hen highlighted press Enter.
Click the program 's function button in the toolbar;

test (1), calibration (2), programming (3) and job
card (4).
Double click the desired program in the function tree.
The following can be performed in the Adm inistrative

functions
Language selection
Selection of screen saver and screen saver delay.
Selection of background image.
Selection of default application.
Update the system. Get a new program version of

VCADS Pro from Volvo via connection to the central
systems.
User administration. Select the user to change the

password for. This function requires authorization
and is not available to all users.
72
General adminstration. Selection of comm unication

method, vehicle/m achine type and activa
tion/deactivation o f the sim ulator is possible.
Design and Function
G roup 28
Design and Function
Sensor Locations
VN/VHD Sensors and Switches
ON OFF
W2003551
Inside cab
1
Throttle position sensor
Microswitch(service brake)
Engine/Exhaust Brake
VECU
Pressure Switch-Parking and Service Brake
ON/OFF Resume Switch
Resume Switch
Diagnostic connector
73
Group 28
D7C
EECU connector EA/EB
EPG solenoid
Boost pressure/tem perature sensor
Oil pressure/tem perature sensor
Engine tim ing (crank) sensor
Needle lift sensor (at injector #1)

C oolant tem perature sensor
Redundant engine speed sensor (1); Fuel pres
sure/tem perature sensor (2); Fuel shut-off valve (3);
7 -p in connector (4), includes rack drive, rack posi
tion sensor, and tim ing sleeve
74
Design and Function
Group 28
Design and Function
D12B
1
2
3
4
5
6
7
Boost pressure/tem perature sensor

Coolant tem perature sensor
Oil pressure/tem perature sensor
Engine tim ing (crank) sensor
EECU connector EA/EB
Engine position (cam ) sensor
1
2
Com pression brake, VCB (under valve cover)

EPG control (PW M box)
75
Group 28
Design and Function
D12C
Several engine sensors send signals to the EECU. They

are:
1
Cam Sensor (timing gears) This sensor deter
76
Coolant Temperature Sensor (cylinder head)
mines which cylinder is in line for injection. It detects

the cam shafts position via a pole wheel bolted to
the cam shaft drive gear.
This sensor monitors coolant tem perature.
Oil Pressure/temperature sensor (cylinder

block) This com bined sensor monitors oil pressure
is a com bined sensor that m onitors both the intake

manifold air pressure and tem perature.
and oil tem perature.

3
Crank Sensor (flywheel housing) This sensor

detects the crank-shaftss position and speed, via
teeth in the flywheel. Detects Engine RPMs.
Fuel Pressure/Temperature Sensor Monitors

the fuel pressure and fuel tem perature
Intake Manifold Pressure (intake manifold) This
Group 28
Design and Function
Control Unit Locations

VN/VHD: Cab and Engine Compartment
The diagram shows the normal location of the different
control units on a VN vehicle equipped with a Volvo en
gine.
Control units may vary slightly in location, depending on
vehicle and com ponent type (variant). The locations are
virtually the sam e on a VHD vehicle.
Vehicle electronic control unit (VECU)
SRS control unit
Instrum ent cluster
ABS control unit; crossm em ber located toward rear

of cab
77
Group 28
Design and Function
WG/AC: Cab and Engine Compartment

The diagram shows the norm al location o f the different
control units on WG and AC vehicles.
vehicle type (variant).
W3003963
A B S control unit, on right side fram e rail
Instrum ent cluster
78
3
4
Vehicle electronic control unit (VECU)

Group 28
Design and Function
WX/WXLL: Cab and Engine Compartment

The diagram shows the normal location of the different
control units on a W X or W XLL vehicle.
W3003961
Vehicle electronic control unit (VECU), location in

W X narrow cab only
Instrum ent cluster
Transmission ECU, under drivers seat
ABS control unit, right side engine tunnel
VECU, W X and W XLL, right side engine tunnel
ABS control unit, location in W X narrow cab only
79
Group 28
Design and Function
WXR: Cab and Engine Compartment

The diagram shows the normal location o f the different
control units on a W XR vehicle.
W3003962
Instrum ent cluster
ABS control unit
80
4
5
Transmission ECU
Vehicle electronic control unit (VECU) on left side
of cab, below center dash panel
Group 28
Design and Function
Fuses and Relays
W8000923
The VN/VHD vehicles have easy access to the TEC

panel. Fuses and relays are easily identified by referring
to the decals inside the TEC covers.
W3004398
81
Group 28
Design and Function
VN
Note: Refer to the decal inside the TEC cover for vehi
cle's exact fuse descriptions and ratings.
Fig. 11: Fuse and Relay Positions (in the top TEC panel, VN)
B1-1 th ro u g h B 1 -6
Ignition Expansion Blocks
B 2 -2 th ro u g h B 2 -4
Battery Expansion Blocks
PR1
Accessory Power Relay
PR2, PR3
Igntion Power Relays
One Accessory an two Ignition Power relays are used to transfer the heavy current load coming from the battery
to the Ignition/Accessory circuits. These relays are located on the TEC tray for easy access and replacement.
82
Group 28
Design and Function
VHD
N ote: Refer to the decal inside the TEC cover for vehi
cles exact fuse descriptions and ratings.
Fig. 12: Fuse and Relay Positions (in the top TEC panel, VHD)
B1-1 th ro u g h B 1 -6
Battery and Ignition Expansion Block
PR1
Accessory Power Relay
PR2, PR3, PR4, R24
Ignition Power Relays
One Accessory and four ignition Power relays are used to transfer the heavy current load coming from the
battery to the Ignition/Accessory circuits. These relays are located on the TEC tray for easy access and re
placement. PR4 is used in the VHD bodybuilder applications
83
84
Group 28
Troubleshooting
Troubleshooting
Fault Code Troubleshooting
Message and Parameter De
scriptions
MID's
(message ID's)
Description
128
EECU (Engine Electronic Control Unit)
232
SRS (Supplem ental Restraint System)
136
ABS (Antilock Braking System
140
Instrum ent C luster C enter Module
234
Instrum ent C luster Left Module
144
VECU (Vehicle Electronic Control Unit)
130
TECU (Transmission Electronic Control Unit)
PID's
(Parameter ID's)
Description
84
Road Speed
91
% A ccelerator Pedal
100
Engine Oil Pressure
102
Boost Pressure
105
A ir Inlet Temperature
110
111
Coolant Level
173
Pyrom eter
175
Engin Oil Temperature
190
Engine Speed
85
Group 28
Troubleshooting
PPID's
(Proprietary Parameter
ID's)
86
Description
69
Buffered idle switch
70
Pedal switches, supply
71
Cruise control and retarder, supply switch
72
A ccelerator pedal and retarder, supply sensors
73
A ccelerator control 2 and prim ary tank, supply sensors
75
Range inhibitor, status solenoid valve
77
Compressor, status solenoid valve
78
Interval wiper, status relay
79
Area inhibitor, status solenoid valve
86
Engine brake torque percent
109
EOG3 drive stage failure
121
MTE (Engine com psressor control output) failure
122
VCB Engine com pression brake
123
EPG2 S tart and W arm hold
124
EPG1 Engine brake
125
EOL Enable failure
195
Proprietary Diagnostic Data Request C lear Count
196
Proprietary Diagnostic Data/Count C lear Response
Group 28
Troubleshooting
FMI Table
SAE Standard
FMI value
SAE Text
0
Data Valid, but above norm al operating range.
Data Valid, but under norm al operating range.
Interm ittent or incorrect data.
A bnorm ally high voltage.
A bnorm ally low voltage.
A bnorm ally low current or open circuit.
A bnorm ally high current or chort circuit.
Mechanical system no repsonse
A bnorm al frequency or Pulse W idth
A bnorm al update rate
10
A bnorm al change rate
11
Failure unkown
12
Bad device
13
Out of calibration
14
Special instruction (see Note)
Note: The special instruction FMI 14 is broadcast when the airbag has stored crash data.
Engine-specific for Injectors

FMI value
Explanation
2
S hort circuit to battery voltage, unit injector high side.
S hort circuit to battery voltage, unit injector low side.
S hort circuit to ground, unit injector high or low side.
Open circuit in the unit injector circuit.
Engine-specific for Injection Pump

FMI value
Explanation
2
S hort circuit to battery voltage, injection pump high side.
S hort circuit to battery voltage, injection pump low side.
S hort circuit to ground, injection pump high or low side.
Open circuit in the unit injection pump circuit.
S hort circuit to ground, injection pump high side.
Injection pump current too high for long period of time.
87
Group 28
Troubleshooting
Reading/Clearing Fault Codes

Fault codes can be read and cleared using the VCADS
Pro tool or the Pro-Link tool with Volvo application car
tridge. See the appropriate service inform ation for details
on reading and clearing fault codes using VCADS Pro or
Pro-Link tools.
On V N -series vehicles, fault codes also can be accessed,
read, and cleared via the instrum ent cluster graphic dis
play. Clearing fault codes is password protected. For
information, see Instrum entation VN, from 3/99 and
VHD, Volvo Service Publication P V 776 -T S P 1 3 9 7 9 0 .
The Data Link Instrum ent cluster used W X -series vehi
cles can access and read a limited num ber of fault
codes. However, it does not have the ability to clear fault
codes. For more information, see Data Link Instrum en
tation, Volvo Service Publication P V 7 7 6 -3 8 1 -6 2 0 S M .
Fault Tracing Strategy

CAUTION
Check that the proper cable and connector location is
observed and used w hile connecting to the ECU. Fail
ure to do so m ay result in perm anent dam age to the
ECU or the tool.
Generally, the fault tracing strategy employed in this sec
tion follows a set sequence in w hich m easurem ents are
taken at specific points in the vehicle wiring. The three
basic elem ents in this strategy are:
C
O
M
PO
NENT
C
O
M
PO
NENT
W
IRING
40
Vehicle Electronic Control Unit (VECU)
The actual com ponent being tested (varies with

each fault code)
W iring between VECU and the com ponent being

tested
The following inform ation describes the three test strate

gies:
M easurem ent at the C om ponent's Connector, to

the V E C U page 90
C heck of C om ponent page 90
C heck of the S ubsystem page 91
88
VEC
U
VECU
Group 28
Troubleshooting
Measurement at the Components Connector, to the VECU

In this procedure, the com ponent Is disconnected and
m easurem ents are made at specific pin locations on the
w iring harness end of the connector. Measurements
usually Involve supply, ground, and signal w ire connec
tions through the w iring harness and VECU.
Breakout boxes or harnesses may be used to assist in
taking m easurements. M easurem ents outside expected
values may indicate faults in the w iring or in the VECU
itself
Check of Component
In this procedure, the com ponent is disconnected and
m easurem ents are made at specific pin locations on the
com ponent w iring harness or directly to the component.
The com ponent is usually a sensor or switch; it is identi
fied at the beginning of each check.
Breakout boxes or harnesses may be used to assist in
taking m easurements. M easurem ents outside expected
values may indicate faults in the com ponent or in the
w iring to the component.
89
Group 28
Troubleshooting
Check of the Subsystem

In this procedure, the VECU is disconnected, a breakout
box is connected between the VECU and w iring harness,
and m easurem ents are made at specific pin locations on
the breakout box. This check is made to measure the
voltage that is present at the VECU with the circuit intact.
M easurem ents outside expected values may indicate
faults in the com ponent, wiring, o r VECU.
Tests Using the VCADS Pro Tool

The VCAD S Pro tool is a W indows95-based PC tool
that is used to program, test, and read inform ation from
the VECU and EECU.
A num ber of real tim e tests can be perform ed by con
necting the VCAD S Pro tool to the vehicles diagnostic
connector. If a test in the VCAD S Pro tool may be of
benefit when troubleshooting a specific fault code, that
test will be referenced in the section titled, A ppropriate
tests in the VCAD S Pro tool.
N ote: Not all tests will apply to all vehicle variants. W hen
starting VCAD S Pro, menu selections for various vehi
cles and engines are entered. Only those tests that
apply will be available fo r selection.
For inform ation about the proper operation of the
VCAD S Pro tool, please refer to VCAD S Pro Service In
form ation in group 0.
W0001632
90
Group 28
Troubleshooting
MID 128 EECU

MID: Message Identification Description.
SID: Subsystem Identification Description.
PID: Param eter Identification Description.
FMI: Failure Mode Identifier.
Error code
Component/Function
FMI
Section
MID 128-PID 45
Preheater Status
3, 4, 5
MID 128 PID 45 Pre

heater Status page 96
MID 128-PID 49
ABS Control Status
MID 128 PID 49 ABS

Control Status page 98
MID 128-PID 84
Road speed
9, 11
MID 128 PID 84 Road

S peed page 100
MID 128-PID 85
Cruise Control Status
MID 128 PID 85

Cruise Control S tatus
page 102
MID 128-PID 91
A ccelerator Pedal Position
9, 11
MID 128 PID 91 A ccel

erator Pedal Position
page 104
MID 128-PID 94
Fuel Delivery Pressure (D7C

and D12C only)
1, 3, 4
MID 128 PID 94 Fuel

Delivery P ressure page
106
MID 128-PID 100
Engine Oil Pressure
1, 3, 4
MID 128 PID 100 En

gine Oil Pressure page
110
MID 12 8-P ID 102
Boost Pressure
3, 4
MID 128 PID 102

Boost Pressure page
114
MID 12 8-P ID 105
Boost A ir Temperature
3, 4
MID 128 PID 105

Boost A ir Tem perature
page 118
MID 12 8-P ID 107
A ir Filter Differential Pressure
0, 3, 4, 5
MID 128 PID 107 A ir

Filter Differential Pres
sure page 122
MID 128-P ID 108
A tm ospheric Pressure
3, 4
MID 128 PID 108 A t

m ospheric P ressure
page 125
MID 128-P ID 110
0, 3 ,4
MID 128 PID 110

Engine Coolant Temper
ature page 126
MID 128-P ID 111
Coolant level
MID 128 PID 111

Coolant Level page 129
MID 128-P ID 158
Battery Voltage
MID 128 PID 158 Bat

tery Voltage page 131
MID 128-P ID 172
A ir Inlet Temperature
3, 4
MID 128 PID 172 A ir

Inlet Tem perature page
133
MID 128-P ID 174
Fuel Temperature (D7C and

D12C only)
3, 4
MID 128 PID 174 Fuel

Tem perature page 136
91
Group 28
Troubleshooting
Error code
Component/Function
FMI
Section
MID 128-P ID 175
Engine Oil Temperature
0, 3, 4
MID 128 PID 175 En

gine Oil Tem perature
page 140
MID 128-P ID 228
Road Speed Sensor C alibra

tion
11
MID 128 PID 228

Road Speed Sensor
C alibration page 144
MID 128-P P ID 86
Engine Brake Torque Percent
MID 128 PPID 86 En

gine Brake Torque
Percent page 146
MID 128-P P ID 119
High Coolant Temperature
MID 128 PPID 119

High Coolant Tempera
tu re page 148
MID 128-P P ID 122
VCB Engine Compression

Brake (D12B adn D12C only)
3, 4, 5
MID 128 PPID 122

VCB Engine C om pres
sion Brake page 151
MID 128-P P ID 123
EPG 2 (D12B adn D12C only)
3, 4, 5
MID 128 PPID 123

EPG 2 page 153
MID 128-P P ID 124
EPG 1
3, 4, 5
MID 128 PPID 124

EPG 1 page 155
MID 128-S ID 1-6
Injector (D12B and D12C only)
2, 3, 4, 5, 7, 11
MID 128 SID

1/2/3/4/5/6 Injector
page 157
MID 128-S ID 17
Fuel S hutoff Valve (D7C only)
3, 4, 5
MID 128 SID 17 Fuel

S hutoff Valve page 161
MID 128-S ID 20
Tim ing Sleeve (D7C only)
2, 3, 4, 5, 6, 7, 8, 11
MID 128 SID 20 Tim

ing S leeve page 163
MID 128-S ID 21
Engine Position Tim ing S en

sor (D12B and D12C)
3, 8
MID 128 SID 21 En

gine Position Timing
S ensor page 166
MID 128-S ID 21
Needle Lift Sensor (D7C only)
MID 128 SID 21 Nee

dle Lift Sensor page
168
MID 128-S ID 22
Engine Speed Sensor
2, 3, 8
MID 128 SID 22 En

gine Speed S ensor
page 170
MID 128-S ID 23
Rack A ctuator (D7C only)
2, 3, 4, 5, 6, 7, 8, 11
MID 128 SID 23 Rack

A ctuator page 172
MID 128-S ID 24
Rack Position Sensor (D7C

only)
2, 13
MID 128 SID 24 Rack

Position Sensor page
175
MID 128-S ID 33
Fan Control
3, 4, 5
MID 128 SID 33 Fan

C ontrol page 177
MID 128-S ID 64
R edundant Engine Speed

Sensor (D7C only)
3, 8
MID 128 SID 64 Re

dundant Engine Speed
S ensor page 179
MID 128-S ID 70
Preheater Elem ent 1
3, 4, 5
MID 128 SID 70 Pre

heater Elem ent 1 page
181
92
Group 28
Troubleshooting
Error code
Component/Function
FMI
Section
MID 12 8-S ID 71
Preheater Elem ent 2 (D12B

only)
3, 4, 5
MID 128 SID 71 Pre

heater Elem ent 2 page
183
MID 128-S ID 230
Idle Validation Switch 1
3, 4
MID 128 SID 230 Idle

Validation Switch 1
page 185
MID 128-S ID 231
SAE J1939 Control Link
2, 9, 11, 12
MID 128 SID 231 SAE

J1939 Control Link
page 187
MID 128-S ID 232
5 Volt DC Supply
3, 4
MID 128 SID 232 5 Volt

DC S upply page 189
MID 128-S ID 240
Program M em ory
2, 12
MID 128 SID 240 Pro

gram M em ory page 191
MID 128-S ID 250
SAE J1587/1708 Information

Link
12
MID 128 SID 250 SAE

J1587/1708 Information
Link page 192
MID 128-S ID 253
2, 12
MID 128 SID 253 Data

Set M em ory EEPR O M
page 193
MID 128-S ID 254
Engine Electronic Control U nit

(EECU)
2, 8, 9, 11, 12, 13
MID 128 SID 254 En

gine Electronic Control
Unit (E E C U ) page 194
93
Group 28_________________________________________________________________________________________ Troubleshooting
94
Group 28
Troubleshooting
MID 128 PID 45 Preheater Status

The preheat relay is provided battery voltage at all tim es through the supply wire. If the
EECU requests preheat operation (based on engine tem perature), the control wire will
be grounded through the EECU. Preheating is standard on the D7C engine with one
preheat relay/element. Preheating is optional on the D12B engine with tw o preheat re
lays/elements.
Fault Codes
FMI 3
Reaction from the EECU:
S hort circuit to battery voltage.
Fault code is set.
Conditions for fault code:
Yellow lamp is requested.
O utput activated.
Noticeable external symptom:
S hort circuit to battery voltage on EB31.
Yellow lamp lights up.
The intake air is warm since the preheating relay is

on all the time.
High current consumption.
Possible cause:
S hort circuit to battery voltage on wire between pre

heating relay and EECU.
S hort circuit in the preheating relay.
FMI 5:
Break
Fault code is set.
The EECU switches o ff the output.
The preheating relay is not activated.
W hite smoke for cold start.
Difficult to start in extreme
cold.
Output switched off.
Open circuit.
Possible cause:
Blown fuse to the supply for preheating relay.
Open circuit in wire between EECU and preheating

relay.
Open circuit in the preheating relay.
Open circuit in supply wire to preheating relay.
FMI 4
Fault code is set.
The EECU switches off the output.
S hort circuit to ground.

O utput switched off.
S hort circuit to ground on EB31.
Possible cause:
The preheating relay is not activated.
S hort circuit to ground on wire between preheating

relay and EECU.
Difficult to start in extreme cold.
95
Group 28
Troubleshooting
MID 128 PID 45 Preheater Sta

tus, Check
Special tools: J-43233, J-39200, J-41132
Check of component
Preheating relay
i
Disconnect the control and supply
w ires to the preheat relay
NOTE!
Check all the particular connectors for loose connec
tions, switch resistance, and oxidation.
For detailed circuit information, refer to VNL, VNM Elec
trical S chem atics, Group 37.
J-39200
Ignition key must be in the OFF posi

tion.
Note: Each relay must be checked in

dependently.
Measurement at the components

connector, to the EECU
1
Note: Check the com ponent to verify
that each of the following values is
correct. Incorrect values can cause
this com ponent to fail.
Measuring
points
Optimal value
Control and sup

ply term inals on
the preheat relay
8.5 0
Check of Subsystem
2
Control of the preheating relay
Disconnect the control wire (D7C:

small blue/red wire; D12B: small solid
black w ire) at the preheat relay
Control wire:
3
J-39200
Ignition key must be in the ON posi

tion.
C onnect breakout box J-41132 in se
ries between connector EB and the
EECU. C onnect ju m p e r harness J43233 in series between connector EA
and the EECU.
Note: Test with Preheat O N can only

Measuring
points
Optimal value
Control wire / al
ternate ground
180 kO
be performed if the EECU requested

preheat.
Supply wire:
4
M easure the voltage at the supply wire
(D7C: small solid black wire; D12B:
small blue/red w ire) using voltm eter J39200.
tion.
Measuring
points
Optimal value
Supply wire / al
ternate ground
B+
96
J-39200
Measuring
points
Optimal value
EB31 / EB9
B+ (preheat off)
EB31 / EB9
0 V (preheat on)
Ground term
EB31 with a
ju m p e r wire
preheat relay
clicks on
J-41132
J-43233
J-39200
Group 28
Troubleshooting
MID 128 PID 49 ABS Control Status

Applies only to vehicles with ABS.
Fault Codes
FMI 9
Status m essage from the ABS control unit is not avail
able (SAE J1587 message).
PID 49 the message is unavailable or is not be

ing updated regularly.
Possible cause:
E rror in the inform ation link (SAE J1587).
E rror from the ABS control unit.
Fault code is set.
97
Group 28
Troubleshooting
MID 128 PID 49 ABS Control

Status, Check
NOTE!
Check all the particular connectors for loose connections
as well as for switch resistance and oxidation.
Also check if the ABS system has any active fault codes.
This fault code could be due to the fact that there is a
fault in the ABS system.
Check of Subsystem
Check of the SAE J1587 Information link
1
tion.
EECU.
2
C onnect ju m p e r harness J-43233 in
series between connector EA and the
EECU.
Measuring
points
Optimal value
EB25 / DCA
(connection A in
diagnostics con
nector)
<1 0
EB26 / DCB
(connection B in
diagnostics con
nector)
<1 0
98
J-41132
J-43233
J-39200
Group 28
Troubleshooting

Fault Codes
FMI 9
Vehicle road speed signal not available (SAE J1587
message).
PID 84 the message is unavailable or is not be

ing updated regularly.
Possible cause:
Fault in speed sensor.
Fault in the inform ation link (SAE J1587).
E rror from the vehicle ECU (VECU).
Fault code is set.
If FMI 11 has also been set, the EECU limits the en

gine speed to approx. 1700 rpm.
If FMI 11 has also been set, the m aximum engine

speed is approx. 1700 rpm.
FMI 11
Vehicle road speed signal not available. (SAE J1939
message).
The vehicle speed signal is not available on the

com m unications link (SAE J1939).
Possible cause:
Fault in speed sensor.

Fault in the com m unications link (SAE J1939).
Fault in VECU.
Fault code is set.
The message is read from the information link (SAE

J1587) instead.
If FMI 9 has also been set, the EECU limits the en

gine speed to approx. 1700 rpm.

If FMI 9 has also been set, the maximum engine
speed is approx. 1700 rpm.
99
Group 28
Troubleshooting
MID 128 PID 84 Road Speed,

Check
NOTE!
Also check the speed sensor and the VECU. This fault
code could be due to the fact that there is a fault in any
of these components.
Check of Subsystem
i
tion.
EECU.
2
EECU.
Measuring
points
Optimal value
EB25 / DCA
(connection A in
diagnostics con
nector)
<1 0
EB26 / DCB
(connection B in
diagnostics con
nector)
<1 0
100
J-41132
J-43233
J-39200
Group 28
Troubleshooting
MID 128 PID 85 Cruise Control Status

Fault Codes
FMI 9
Status m essage from Cruise Control is not available
(SAE J1587 message).
PID 85 the message is unavailable or not being

updated regularly.
Possible cause:
Fault in the VECU.
Fault code is set.
101
Group 28
Troubleshooting
MID 128 PID 85 Cruise Control

Status, Check
NOTE!
Also check the cruise control switch and VECU. This
fault code could be due to the fact that there is a fault in
any of these components.
Check of Subsystem
1
tion.
EECU.
2
EECU.
Measuring
points
Optimal value
EB25 / DCA
(connection A in
diagnostics con
nector)
<1 0
EB26 / DCB
(connection B in
diagnostics con
nector)
<1 0
102
J -4 1 1 3 2
J-43233
J-39200
Group 28
Troubleshooting
MID 128 PID 91 Accelerator Pedal Position

Fault Codes
FMI 9
A ccelerator pedal m essage not available. (SAE J1587
message)
PID 91 m essage is unavailable or not being updated

regularly.
Possible cause:
Fault in the accelerator pedal.
E rror from the VECU.
the Limp home m ode.
If FMI 9 has also been set, the engine will be put in

the Limp home m ode and the buffered idle valida
tion switch is used instead of the accelerator pedal
position sensor.
Fault code is set.
If FMI 11 has also been set, the EECU will switch to

the Limp home m ode.
If FMI 11 has also been set, the engine will be put

in the Limp home m ode and the buffered idle vali
dation switch is used instead of the accelerator
pedal position sensor.
FMI 11
A ccelerator pedal faulty. (SAE J1939 message)
Faults in the accelerator pedal sensor are sent on

the com m unications link (SAE J1939).
The accelerator pedal signal is not available on the

com m unications link (SAE J1939).
Possible cause:
Fault in the accelerator pedal.
Fault in the com m unications link (SAE J1939).
Fault code is set.
A ccelerator pedal signal is retrieved instead from

the inform ation link (SAE J1587).
If FMI 9 has also been set, the EECU will switch to

103
Group 28
Troubleshooting
MID 128 PID 91 Accelerator

Pedal Position, Check
NOTE!
Also check the accelerator pedal and the VECU. This
fault code could be due to the fact that there is a fault in
any of these components.
Check of Subsystem
1
tion.
EECU.
2
EECU.
Measuring
points
Optimal value
EB25 / DCA
(connection A in
diagnostics con
nector)
<1
EB26 / DCB
(connection B in
diagnostics con
nector)
<1
104
J-41132
J-43233
J-39200
Group 28
Troubleshooting
MID 128 PID 94 Fuel Delivery Pressure

D7C and D12C
In addition to the fuel pressure, the sensor also measures the fuel tem perature.
Fault Codes
FMI 1
Pressure too low.
The voltage on EA27 is below the alarm limit.
Possible cause:
Clogged fuel filter.
A ir in fuel system.
Opening pressure too low on overflow valve.
W orn out fuel pump.
M echanical fault in sensor.
S hort circuit to voltage, signal wire.
Fault in sensor.
Fault code is set.
FMI 4
Short circuit to ground.

Fault code is set.
Low power output.
Difficult to start.
Blue smoke.
FMI 3
The voltage on EA27 is under 0.08 V.
Possible cause:
Break, 5 V supply wire.
Break, signal wire.
Break, ground wire.
S hort circuit to ground, 5 V supply wire.
S hort circuit to ground,signal wire.
Fault in sensor
S hort circuit to voltage or perm anent loss of signal.
Fault code is set.
Possible cause:
S hort circuit to voltage, 5 V supply wire
105
Group 28
Troubleshooting
MID 128 PID 94 Fuel Delivery

Pressure, Check
Signal wire:
5
M easure the resistance with ohm m e
te r J-39200.
D7C and D12C

Special tools: J-43233, J-39200, J-41132,
9998534
J-39200

tion.
Measuring
points
Optimal value
2 / alternate
ground
100 kO
NOTE!
Check of component

1
1
Note: An incorrect value (below) can
Disconnect the connector for the fuel

pressure sensor. Install breakout har
ness 9998534 to the sensor connector
only.
also cause the com ponent to fail;

therefore, it is im portant to check the
com ponent if any of the values are in
correct.
9998534
2
2
Disconnect the connector for the fuel
ness 9998534 to the w iring harness
end only.
9998534

tion.
Ground wire:
3
M easure the resistance with ohm m ete r J-39200.

te r J-39200.
J-39200

tion.
Measuring
points
Optimal value
1/ 4
11 kO
1/ 2
40 kO
2 /4
40 kO
1 / alternate
ground
open circuit
Measuring
points
Optimal value
2 / alternate
ground
open circuit
4 / alternate
ground
<1 0
4 / alternate
ground
open circuit
Supply wire:
4
M easure the voltage with voltm eter J39200.
tion.
Measuring
points
Optimal value
1 / alternate
ground
5 V
106
J-39200
J-39200
Group 28
Troubleshooting
Check of Subsystem
Fuel Pressure
1
tion.
ries between connector EA and the
EECU. C onnect ju m p e r harness J43233 in series between connector EB
and the EECU.
Measuring
points
Optimal value
EA27 / EA5
0.5 V (engine
not running)
J-41132
J-43233
J-39200
Note: For fuel pressure/voltage chart,

see page 109.
107
Group 28
Fuel Pressure Sensor, Pres

sure/Voltage Chart
108
Troubleshooting
Group 28
Troubleshooting
MID 128 PID 100 Engine Oil Pressure

In addition to the oil pressure, the sensor also measures the oil tem perature.
Fault Codes
FMI 1
Pressure too low.
Fault in sensor.
Fault code is set.
The EECU stops sending PID 100.
Possible cause:
Fault in overflow valve.
Oil level too low.
Contam inated oil, slow-flowing or too thin.
W orn oil pump.
The oil pressure gauge shows 0.
Fault in sensor.
FMI 4
Short circuit to ground or open circuit.
Fault code is set.
Power reduction in the first stage and shutdown in

2nd stage (if engine protection is chosen in the data
set).
Possible cause:
LED lights up at the oil pressure gauge.
Break, signal wire.
Power reduction (if engine protection is chosen in

the data set).
Engine shut-down if the vehicle speed falls below 5

mph (3 km/h), if engine protection is chosen in the
data set.
S hort circuit to ground, signal wire.

Fault in sensor.
FMI 3
S hort circuit to voltage.
The voltage on EA14 exceeds 4.95 V.
Possible cause:
Fault code is set.

S hort circuit to battery voltage, 5 V supply wire.
S hort circuit to battery voltage or 5 V, signal wire.
109
Group 28
Troubleshooting
MID 128 PID 100 Engine Oil

Pressure, Check
9998534
Signal wire:
5
te r J-39200.
J-39200

tion.
NOTE!

Measuring
points
Optimal value
2 / alternate
ground
100 kO
Check of component
1
Oil pressure sensor

com ponent if any o f the values are in
correct.
1
Disconnect the connector to the oil
ness 9998534 to the sensor harness
end only.
9998534
2
end only.
9998534

te r J-39200.
tion.
Ground wire:
3
J-39200

tion.
Measuring
points
Optimal value
1/ 4
11 kO
1/ 2
40 kO
2 /4
40 kO
Measuring
points
Optimal value
1 / alternate
ground
open circuit
4 / alternate
ground
<1 0
2 / alternate
ground
open circuit
4 / alternate
ground
open circuit
Supply wire:
4
tion.
Measuring
points
Optimal value
1 / alternate
ground
5 V
110
J-39200
J-39200
Group 28
Troubleshooting
Check of Subsystem
Oil pressure
1
tion.
and the EECU.
Measuring
points
Optimal value
EA14 / EA5
0.5 V (engine
not running)
J-41132
J-43233
J-39200
Note: For oil pressure/voltage chart,

see Oil Pressure Sensor, Pres
sure/Voltage C h a rt page 113.
111
Group 28
Oil Pressure Sensor, Pres

sure/Voltage Chart
112
Troubleshooting
Group 28
Troubleshooting
MID 128 PID 102 Boost Pressure

In addition to the boost pressure, the sensor also m easures the boost air tem perature.
Fault Codes
FMI 3
Possible cause:
S hort circuit to battery voltage, 5 V supply wire.
S hort circuit to battery voltage or 5 V,signal wire.
Fault in sensor.
Fault code is set.
Power reduction.
The boost pressure gauge shows 0.
Low power output.
FMI 4
S hort circuit to ground or open circuit.
Possible cause:
Break, signal wire.
Fault in sensor.
Fault code is set.
Power reduction.
Low power output.
113
Group 28
Troubleshooting
MID 128 PID 102 Boost Pres

sure, Check

9998534
NOTE!

tion.
Signal wire:

For detailed circuit information, refer to VN/VHD, Electri
cal S chem atics, Group 37.

Measuring
points
Optimal value
2 / alternate
ground
100 kO
Check of component
1
Boost pressure sensor

com ponent if any o f the values are in
correct.
1
Disconnect the connector to the boost
pressure sensor. Install breakout harness 9998534 to the sensor harness
end only.
2
end only.
9998534

te r J-39200.
tion.
Ground wire:
Measuring
points
Optimal value
1/ 4
11.5 kO
1/ 2
44 kO
2 /4
44 kO
1 / alternate
ground
open circuit
3
J-39200

tion.
Measuring
points
Optimal value
2 / alternate
ground
open circuit
4 / alternate
ground
<1 0
4 / alternate
ground
open circuit
Supply wire:
4
tion.
Measuring
points
Optimal value
1 / alternate
ground
5 V
114
J-39200
J-39200
9998534
J-39200
Group 28
Troubleshooting
Check of Subsystem
Boost pressure
1
tion.
and the EECU.
Measuring
points
Optimal value
EA3 / EA5
1.2 V (sea level,

engine not run
ning)
J-41132
J-43233
J-39200
Note: For boost pressure/voltage

chart, see Boost Pressure Sensor,
Pressure/Voltage C hart page 117.
115
Group 28
Boost Pressure Sensor, Pres

sure/Voltage Chart
116
Troubleshooting
Group 28
Troubleshooting
MID 128 PID 105 Boost Air Temperature

In addition to the boost air tem perature, the sensor also measures the boost pressure.
The boost air tem perature signal can be used to switch on the radiator fan.
Fault Codes
FMI 3
S hort circuit to voltage or open circuit.
The voltage on EA2 exceeds 4.95 V
Possible cause:
S hort circuit to voltage, ground wire.
Break, signal wire.
Break, ground wire.
Fault in sensor.
Fault code is set.
FMI 4
Possible cause:
Fault in sensor.
Fault code is set.
117
Group 28
Troubleshooting
MID 128 PID 105 Boost Air

Temperature, Check
9998534
Signal wire:
5
tion.
NOTE!

Measuring
points
Optimal value
3 / alternate
ground
5.7 kO
Check of component
1
Boost air temperature sensor

correct.
i
air tem perature sensor. Install breakout harness 9998534 to the sensor
harness only.
2
air tem perature sensor. Install break
out harness 9998534 to the w iring
harness end only.
9998534
3
Optimal value
4 / alternate
ground
<1 0
Measuring
points
Optimal value
3 /4
6.2 kO (20 C/68

F)
3 /4
2.5 kO (40
C /104 F)
1 / alternate
ground
open circuit
2 / alternate
ground
open circuit
4 / alternate
ground
open circuit
J-39200

tion.
Measuring
points

te r J-39200.
tion.
Ground wire:
Supply wire:
4
tion.
Measuring
points
Optimal value
1 / alternate
ground
5 V
118
J-39200
J-39200
Note: For boost air tem pera

ture/resistance chart, see Boost A ir
Temperature Sensor, Tempera
ture/R esistance C h a rt page 121.
9998534
J-39200
Group 28
Troubleshooting
Check of Subsystem
Boost air temperature
1
Ignition key must be in the O N posi
tion.
C onnect breakout box J -4 1 132 in se
EECU. C onnect jum per harness J43233 in series between connector EB
and the EECU.
Measuring
points
Optimal value
EA2 / EA5
2.6 V (20 C/68

F)
EA2 / EA5
1.6 V (40 C /104

F)
J-4 1 132
J-43233 J39200
Note: For boost air tem pera

ture/resistance chart, see Boost A ir
Tem perature Sensor, Tempera
119
Group 28
Boost Air Temperature Sensor,

Temperature/Resistance Chart
120
Troubleshooting
Group 28
Troubleshooting
MID 128 PID 107 Air Filter Differential Pressure

(D12B, D12C, D7C Engines)
Ov
1. 1v
FMI 4
3.25v .25
Air Filter
Restriction Normal
7.7v
FMI 0
11.
FMI 5
FMI 3
Fault Codes
FMI 0
Filter restriction is too great.
The pressure drop (filter restriction) is greatest at high
engine speed/load. With current engine software, once
PID 107 is triggered, it rem ains active until the ignition is
turned to the OFF position. A t that time, the fault code is
reset (neither active nor inactive) until the fault condition
recurs.
Possible checks:
MID 128 PID 107 A ir Filter Differential Pressure,

Check page 124.

Filter restriction too great.
Voltage between E B 17-E B 8 exceeds 3.25 0.25 V.
Possible cause:
Clogged air filter.
Fault in sensor.

Fault code is set.

Yellow lamp is illuminated.
Loss of tractive power.
Possible action:
Fig. 13: 7084 - air filter restriction/tem perature sensor;

9070 - EECU.
Check/replace the air filter.

See Service Bulletin, C hecklist A: Turbo Boost
Pressure, publication num ber P V 7 7 6 -2 0 0 -0 4 0 S B .
FMI 3
Voltage between E B 17-E B 8 exceeds 11.1 V.
Possible cause:
S hort circuit to battery voltage, signal wire.
S hort circuit to battery voltage, ground wire.
Fault in sensor.
Fault code is set.

121
Group 28
FMI 4
Voltage between E B 1 7 -E B 8 is under 1 . 1 V
Possible cause:
Short circuit to ground, signal wire.
Fault in sensor.
Fault code is set.
Possible checks:

Check page 124.
FMI 5:
Break
Voltage between E B 1 7 -E B 8 exceeds 7.7 V.
Possible cause:
Break in signal wire.
Fault in sensor.
Fault code is set.
Possible checks:
122

Check page 124.
Troubleshooting
Group 28
Troubleshooting
MID 128 PID 107 Air Filter Dif

ferential Pressure, Check
Special tools: 9998534, J-39200, J-43233, J41132
Check of Component
Note: Faults in the com ponent can be caused by faults
in the w iring harness o f the EECU. Thus, a check o f the
w iring harness should also be made before connecting a
new component.
Air Filter Restriction/Temperature Sensor
NOTE!
Check all the particular connectors for loose connec
tions, switch resistance, and oxidation.
cal Schem atics, Group 37.
Measurement at the Components

Connector, to the EECU
1
1
Disconnect the connector to the air
filter restriction/tem perature sensor. In
stall breakout harness 9998534 to the
sensor harness end only.
2
M easure the resistance with DMM J39200.
J-39200
Ignition key m ust be in the OFF posi

tion.
Note: C heck to verify that each of the

following values is correct. Incorrect
values can also cause this com ponent
to fail. It is im portant to check the
correct.
2
D isconnect the connector to the air
filter restriction/tem perature sensor. In
stall breakout harness 9998534 to the
w iring harness only.
9998534
Measuring
points
Optimal value
1/ 2
330 O (inactive;
norm al position)
1/ 2
2.2 kO (active)
9998534
Check of Subsystem
Air Filter Indicator
Ground wire:
3
M easure the resistance using DMM J39200.
J-39200

and the EECU.

tion.
2
Measuring
points
Optimal value
M easure the voltage with DMM J39200.
2 / alternate
ground
<1 O
Ignition key m ust be in the ON posi

tion.
Signal wire/supply wire:

4
M easure the voltage at the supply wire
using DMM J-39200.
J-39200
Measuring
points
Optimal value
EB8 / EB17
1.35 V (inactive;
normal position)
5.1 V (active)
J-41132
J-43233
J-39200

tion.
Measuring
points
Optimal value
1 / alternate
ground
80% B+
123
Group 28
Troubleshooting
MID 128 PID 108 Atmospheric Pressure

The sensor is located inside the EECU and therefore cannot be checked. The signal is
used to calculate the turbo pressure and to com pensate the fuel when driving at high
altitudes.
Fault Codes
FMI 3
The signal from the internal sensor exceeds 4.95 V.
Possible cause:
Internal fault in the EECU.
The EECU has been exposed to extrem ely high

pressure.
Fault code is set.
Poor response at high altitudes.
FMI 4
The signal from the internal sensor is under 0.08 V.
Possible cause:
The EECU has been exposed to extrem ely low

pressure.
Fault code is set.
Poor response at high altitudes.
124
Group 28
Troubleshooting
MID 128 PID 110 Engine Coolant Temperature

Fault Codes
FMI 0
Tem perature too high.
The coolant tem perature exceeds 102 C/216 F.
Possible cause:
Low coolant level.
Fault in therm ostat.
Clogged radiator (internally/externally).
Clogged intercooler (on the outside).
Poor through-flow in the cooling system.
W orn coolant pump.
Fault in pressure cap, expansion tank.
Fault in sensor.

Fault code is set.
Power reduction in the first stage.
The engine is shut down in the second stage (if en
gine protection is chosen in the data set).

LED lights up at the coolant tem perature gauge.
Low power output.
The engine is shut down (if engine protection is cho
sen in the data set).
Fault code is set.
The coolant tem perature gauge shows 0.
FMI 4
Possible cause:
Fault in sensor.

Fault code is set.

FMI 3
Possible cause:
S hort circuit to battery or 5 V voltage, signal wire.
Break, signal wire.
Break, ground wire.
Fault in sensor.
125
Group 28
Troubleshooting
MID 128 PID 110 Engine

Coolant Temperature, Check
Check of component

9998534
NOTE!

1
correct.
Coolant temperature sensor

Disconnect the connector to the
coolant tem perature sensor. Install
breakout harness 9998534 to the sen
sor harness only.
te r J-39200.
tion.
Note: For coolant tem pera

ture/resistance chart, see Coolant
Measuring
points
Optimal value
1/ 2
1.9 kO (20 C/68

F)
1/ 2
160 0 ( 8 5
C /185 F)
1 / alternate
ground
open circuit
2 / alternate
ground
open circuit
2
breakout harness 9998534 to the
wiring harness end only.
9998534
Ground wire:
3
J-39200
Optimal value
2 / alternate
ground
<1 0
1
tion.
and the EECU.
Signal wire:
4
tion.
Measuring
points
Optimal value
1 / alternate
ground
1.4 kO
126
Check of Subsystem
Coolant temperature

tion.
Measuring
points
9998534
J-39200
J-39200
Measuring
points
Optimal value
EA25 / EA5
3.0 V (20 C/68

F)
EA25 / EA5
0.6 V (85 C /185

F)
Note: For coolant tem pera

ture/resistance chart, see Coolant
J-41132
J-43233
J-39200
Group 28_________________________________________________________________________________________ Troubleshooting
Coolant Temperature Sensor, Tem

perature/Resistance Chart
127
Group 28
Troubleshooting
MID 128 PID 111 Coolant Level

The inform ation applies only to the m agnetic coolant level sensor that is mounted in
the bottom of the radiator expansion tank. Some models (WG, AC) are equipped with a
capacitive probe and an electronic coolant level module that converts the capacitive
signal to an output signal that the EECU can understand.
Fault Codes
FMI 1
Level too low.
Coolant level switch closed.
The voltage on EB7 is under 45% o f the battery

voltage.
Possible cause:
Low coolant level.
Fault in sensor.
Fault code is set.
Red lamp is requested.
The EECU reduces the output after 30 seconds and

shuts down the engine if the vehicle speed goes un
der 5 mph or 3 km/h (if engine protection is chosen
in the data set).
128
Red lamp lights up.

The EECU reduces the output after 30 seconds and
shuts down the engine if the vehicle speed goes un
der 5 mph or 3 km/h (if engine protection is chosen
in the data set).
Group 28
Troubleshooting
MID 128 PID 111 Coolant Level,

Check
Special tools: J-43233, J-39200, J-41132, J42472
NOTE!

Check of component
The coolant level sensor
1
coolant level sensor. Install breakout
harness J-42472 to the sensor har
ness end only.
te r J-39200.
tion.
Measuring
points
Optimal value

correct.
1/ 2
open circuit
(coolant level
norm al)
1/ 2
< 1 0 (coolant
level low)
1 / alternate
ground
open circuit
2 / alternate
ground
open circuit
D isconnect the connector to the

coolant level sensor. Install breakout
harness J-42472 to the wiring harness
end only.
J-39200
J-42472
J-42472
Check of Subsystem
Ground wire:
Coolant level
3
J-39200

tion.
and the EECU.

tion.
Measuring
points
Optimal value
1 / alternate
ground
<1 0
Signal wire:
Measuring
points
Optimal value
EB7 / EB8
80% B+ (open,
coolant level nor
mal)
EB7 / EB8
0 V (closed,
coolant level low)
4
J-39200
J-41132
J-43233
J-39200

tion.
Measuring
points
Optimal value
2 / alternate
ground
2.1 kO
129
Group 28
MID 128 PID 158 Battery Voltage

Fault Codes
FMI 3
B attery voltage too high.
The battery voltage exceeds 36 V
Possible cause:
Fault in alternator.
Fast charger connected.
Fault code is set.
130
Troubleshooting
Group 28
Troubleshooting
MID 128 PID 158 Battery Volt

age, Check
NOTE!
Check of Subsystem
EECU supply relay
1
Ignition key must be in the ON position.
C onnect breakout box J-41132 in series between connector EB and the
and the EECU.
Measuring
points
Optimal value
EB9 / EB11
B+
EB10 / EB12
B+
EB9 / EB10
<1 0
EB11 / EB12
<1 0
J-41132
J-43233
J-39200
131
Group 28
Troubleshooting
MID 128 PID 172 Air Inlet Temperature

An ambient air tem perature sensor is mounted in the piping between the air filter and
the turbo inlet. In addition to am bient air tem perature, the sensor also measures air fil
te r restriction. The air filter restriction function is currently not used.
Fault Codes
FMI 3
The voltage on EB3 exceeds 4.95 V.
Possible cause:
Short circuit to voltage, signal wire.
Short circuit to voltage, ground wire.
Break, signal wire.
Break, ground wire.
Fault in sensor.
Fault code is set.
Blue smoke in cold w eather conditions.
FMI 4
The voltage on EB3 is under 0.08 V.
Possible cause:
Fault in sensor.
Fault code is set.
Blue smoke in cold w eather conditions.
132
Group 28
Troubleshooting
MID 128 PID 172 Air Inlet Tem

perature, Check
9998534
NOTE!

1
Check of component
Air temperature sensor
1
Disconnect the connector to the am bi
ent air tem perature sensor. Install
sor harness end only.
9998534
J-39200

te r J-39200.
tion.
Note: For am bient air tem pera

ture/resistance chart, see Am bient A ir

correct.
Measuring
points
Optimal value
3 /4
5.7 kO (20 C/68

F)
2
Disconnect the connector to the am bient air tem perature sensor. Install
w iring harness only.
9998534
Check of Subsystem
Ambient air temperature inlet
1
Ground wire:
3
Measure the resistance with ohm m ete r J-39200.
J-39200

tion.
Measuring
points
Optimal value
4 / alternate
ground
<1 0
Signal wire:
4
tion.
Measuring
points
Optimal value
3 / alternate
ground
6 kO
J-39200

tion.
and the EECU.
Measuring
points
Optimal value
EB3 / EB13
2.6 V (20 C/68

F)
EB3 / EB13
1.2 V (50 0C/122

F)
J-41132
J-43233
J-39200
Note: For am bient air tem pera

ture/resistance chart, see Am bient A ir
133
Group 28
Ambient Air Temperature Sensor,

Temperature/Resistance Chart
134
Troubleshooting
Group 28
Troubleshooting
MID 128 PID 174 Fuel Temperature

D7C and D12C
In addition to the fuel tem perature, the sensor also measures the fuel pressure. The
signal is used for fuel density compensation.
Fault Codes
FMI 3
Possible cause:
Break, signal wire.
Break, ground wire.
Fault in sensor.
Fault code is set.
Incorrect fuel quantity.
FMI 4
Possible cause:
Fault in sensor.
Fault code is set.
Incorrect fuel quantity.
135
Group 28
Troubleshooting
MID 128 PID 174 Fuel Tempera

ture, Check
9998534
Signal wire:
5
tion.
D7C and D12C

Note: Check all the particular connectors for loose con
nections as well as for switch resistance and oxidation.

Measuring
points
Optimal value
3 / alternate
ground
1.4 kO
Check of component
1
Fuel temperature sensor

correct.
1
Disconnect the connector to the fuel
tem perature sensor. Install breakout
harness 9998534 to the sensor con
nector only.
2
harness 9998534 to the w iring har
ness end only.
9998534

tion.
Ground wire:
3
J-39200

tion.
Measuring
points
Optimal value
4 / alternate
ground
<1 0
Supply wire:
4
tion.
Measuring
points
Optimal value
1 / alternate
ground
5 V
136

te r J-39200.
Note: For fuel tem perature/resistance

chart, see Fuel Temperature Sensor,
Temperature/Resistance C h a rt page
139.
J-39200
J-39200
Measuring
points
Optimal value
3 /4
1.9 kO (20 C/68

F)
3 /4
800 0 (40
C /104 F)
1 / alternate
ground
open circuit
3 / alternate
ground
open circuit
4 / alternate
ground
open circuit
9998534
J-39200
Group 28
Troubleshooting
Check of Subsystem
Fuel temperature
1
tion.
EECU. C onnect jum per harness J43233 in series between connector EB
and the EECU.
Measuring
points
Optimal value
EA13 / EA5
3.0 V (20 C/68

F)
EA13 / EA5
2.0 V (40 C /104

F)
J-41132
J-43233
J-39200
Note: For fuel tem perature/resistance

chart, see Fuel Temperature Sensor,
Tem perature/Resistance C h a rt page
139.
137
Group 28
Fuel Temperature Sensor, Tempera

ture/Resistance Chart
138
Troubleshooting
G roup 28
Troubleshooting
MID 128 PID 175 Engine Oil Temperature

In addition to the oil tem perature, the sensor also m easures the oil pressure.
Fault Codes
FMI 0
FMI 4
The oil tem perature exceeds 130 C (266 F).
Possible cause:
The voltage on EA1 is under 0.08 V
Possible cause:
Poor cooling capacity.
Fault in sensor.
Fault in sensor.
Fault code is set.
Fault code is set.

Red lamp lights up.
Power reduction in the first stage (at 130 C (266 F)
and shutdown in 2nd stage (if engine protection is
chosen in the data set).

The oil tem perature gauge shows 0.
FMI 3
Possible cause:
Break, signal wire.
Break, ground wire.
Fault in sensor.

Fault code is set.

139
Group 28
Troubleshooting
MID 128 PID 175 Engine Oil

Temperature, Check
9998534
Signal wire:
5
tion.
NOTE!
cal S chem atics, Group 37.

Measuring
points
Optimal value
3 / alternate
ground
1.44 kO
Check of component
1
Oil temperature sensor

correct.
1
harness 9998534 to the sensor har
ness end only.
2
ness end only.
9998534

te r J-39200.
tion.
Note: For oil tem perature/resistance

chart, see Oil Temperature Sensor,
Temperature/Resistance C h a rt page
143.
Ground wire:
3
J-39200

tion.
Measuring
points
Optimal value
4 / alternate
ground
<1 0
Supply wire:
4
tion.
Measuring
points
Optimal value
1 / alternate
ground
5 V
140
J-39200
J-39200
Measuring
points
Optimal value
3 /4
1.9 kO (20 C/68

F)
3 /4
100 0 (100
C/212 F)
9998534
J-39200
Group 28
Troubleshooting
Check of Subsystem
Oil temperature
1
tion.
and the EECU.
Measuring
points
Optimal value
EA1 / EA5
3.0 V (20 C/68

F)
EA1 / EA5
0.4 V (100
C/212 F)
J-41132
J-43233
J-39200
Note: For oil tem perature/resistance

chart, see Oil Temperature Sensor,
Tem perature/Resistance C h a rt page
143.
141
Group 28
Oil Temperature Sensor, Tempera

ture/Resistance Chart
142
Troubleshooting
Group 28
Troubleshooting
MID 128 PID 228 Road Speed Sensor Calibration

Fault Codes
FMI 11
K factor message not available on the inform ation link
(S A E J158 7).
PID 228 the m essage is not available on the infor

mation link (SAE J1587).
Possible cause:
Fault code is set.
143
Group 28
Troubleshooting

Sensor Calibration, Check
NOTE!
Also check the VECU. This fault code could be due to
the fact that there is a fault in the VECU.
Check of Subsystem
1
EECU. C onnect jum pe r harness J43233 in series between connector EA
and the EECU.
Measuring
points
Optimal value
EB25 / DCA
(connection A in
diagnostics con
nector)
<1 0
EB26 / DCB
(connection B in
diagnostics con
nector)
<1 0
144
J-41132
J-43233
J-39200
Group 28
Troubleshooting
MID 128 PPID 86 Engine Brake Torque Percent

Fault Codes
FMI 9
Engine brake torque inform ation is not available (SAE
J1587 message).
PPID 86 the message is not available on the infor

mation link (SAE J1587).
Possible cause:
Fault code is set.
145
Group 28
Troubleshooting
MID 128 PPID 86 Engine Brake

Torque Percent, Check
NOTE!
For detailed circuit information, refer to VNL, V N M Elec
Also check the VECU. This fault code could be due to
the fact that there is a fault in the VECU.
Check of Subsystem
1
EECU. C onnect jum per harness J43233 in series between connector EA
and the EECU.
Measuring
points
Optimal value
EB25 / DCA
(connection A in
diagnostics
socket)
<1 0
EB26 / DCB
(connection B in
diagnostics
socket)
<1
146
J-41132
J-43233
J-39200
Group 28
Troubleshooting
MID 128 PPID 119 High Coolant Temperature

D12B, D12C, D7C Engines
Fault Codes
FMI 0
The coolant tem perature exceeds 102 C (216 F).
Possible cause:
Low coolant level.
Fault in therm ostat.
Clogged radiator (internally/externally).
Clogged intercooler (on the outside).
Poor through-flow in the cooling system.
W orn coolant pump.
Fault in pressure cap, expansion tank.
Fault in sensor.
Fault code is set.
Power reduction in the first stage.
The engine is shut down in the second stage (if en

gine protection is chosen in the data set).
LED lights up at the coolant tem perature
Low power output.
gauge.
The engine is shut down (if engine protection is cho

sen in the data set).
Possible checks:
MID 128 PPID 119 High Coolant Temperature,

C heck page 149.
147
Group 28
Troubleshooting
MID 128 PPID 119 High Coolant

Temperature, Check
Special tools: 9998534, J-43233, J-39200, J41132
NOTE!
Check of Component
in the w iring harness of the EECU. Thus, a check o f the
w iring harness should also be made before connecting a
new component.
Coolant Temperature Sensor

1


Connector, to the EECU
Note: An incorrect value (below) can also cause the
com ponent to fail; therefore, it is im portant to check the
com ponent if any of the values are incorrect.
1
9998534
Ground wire:

2
M easure the resistance with DMM J39200.
tion.
Note: A coolant tem pera

ture/resistance chart is available; see
System C heck in Service Publication
20 0 -8 7 0 , Fault Codes, Engine Elec
tronic Control U nit, order num ber
P V 7 7 6 -T S P 1 05620/1.
Measuring
points
Optimal value
1/ 2
1.9 kO / 2 0 C
(68 F)
1/ 2
160 0 / 85 C
(185 F)
2
J-39200

tion.
Measuring
points
Optimal value
1 / alternate
ground
open circuit
2 / alternate
ground
<1 O
2 / alternate
ground
open circuit
Signal wire:
3
tion.
Measuring
points
Optimal value
1 / alternate
ground
1.4 kO
148
J-39200
9998534
J-39200
Group 28
Troubleshooting
Check of Subsystem
Coolant Temperature
1
and the EECU.
2
M easure the voltage using DMM J39200.
J-41132
J-43233
J-39200

tion.
Measuring
points
Optimal value
EA25 / EA5
3.0 V / 20 C (68
F)
EA25 / EA5
0.6 V / 85 C (185
F)
149
Group 28
Troubleshooting
MID 128 PPID 122 VCB Engine Compression Brake

D12B and D12C
Fault Codes
FMI 3
Output activated.
Short circuit to battery voltage on EA33.
The output is switched off.
VCB is on all the time.
Low power output.
Black smoke.
Extrem e uneven operation.
Possible cause:
Short circuit to battery voltage between the VCB so

lenoid valve and EECU.
Short circuit in VCB solenoid valve.
FMI 5
Break.
Fault code is set.
The output is switched off.
Open circuit in the VCB circuit.
Possible cause:
Reduced engine brake power because the VCB

cannot be activated.
Open circuit between the VCB solenoid valve and

EECU.
Open circuit in the supply wire to VCB solenoid

valve.
Blown fuse for supply to VCB solenoid valve.
Open circuit in VCB solenoid valve.
Short circuit to ground on EA33.
Fault code is set.
Possible cause:
O utput is switched off.
FMI 4
Short circuit to ground between the VCB solenoid

valve and EECU.
Fault code is set.
150
Reduced engine brake power because the VCB

cannot be activated.
Group 28
Troubleshooting
MID 128 PPID 122 VCB Engine

Compression Brake, Check
Check of component
Compression brake solenoid, VCB
1
NOTE!
Disconnect the tw o w ires at the

com pression brake solenoid. The com
pression brake solenoid is located
under the valve cover.


te r J-39200.


tion.
D12B and D12C

Measuring
points
Optimal value
Solenoid term i
nal A / B
21 0
A / alternate
ground
open circuit
B / alternate
ground
open circuit
1
correct.
J-39200
Check of Subsystem
D isconnect the two wires at the

com pression brake solenoid. The com
pression brake solenoid is located
under the valve cover.
Compression brake, VCB

1
Ground wireVControl wire:

3
J-39200

tion.
Measuring
points
Optimal value
Ground control
wire / alternate
ground
215 kO
J-41132
J-43233
J-39200
Note: Test with VCB O n can be

performed only if the EECU has re
quested VCB operation.
Supply wire:
4
Ignition key m ust be in the ON position.

C onnect breakout box J-41132 in series between connector EA and the
and the EECU.
J-39200
Measuring
points
Optimal value
EA33 / alternate
ground
B+ (VCB off)
EA33 / alternate
ground
0 V (VCB on)
ground term inal

EA33 with a
ju m p e r wire
VCB solenoid
clicks on

tion.
Measuring
points
Optimal value
Supply wire / al
ternate ground
B+
151
Group 28
Troubleshooting
MID 128 PPID 123 EPG 2

D12B and D12C
Fault Codes
FMI 3
Output activated.
Short circuit to battery voltage on EB36.
Possible cause:
Short circuit to battery voltage between solenoid

valve and EECU.
Short circuit in solenoid valve.
Fault code is set.
EPG1, EPG2 and VCB outputs are switched off.
EPG 2 constantly activated.
Low power output.
Black smoke.
FMI 5
Break.
Open circuit in the EPG2 circuit.
Possible cause:
Open circuit between solenoid valve and
EECU.
Open circuit in supply wire to solenoid valve.
Blown fuse for supply to EPG2.

Open circuit in the solenoid valve.
The heat retention does not function.
Blue smoke under cold conditions.
The engine may be difficult to start.
Engine brake does not function.
FMI 4
Fault code is set.
Short circuit to ground on EB36.
The heat retention does not function.
The engine may be difficult to start.
Possible cause:
152
Short circuit to ground between solenoid valve and

EECU.
Fault code is set.
Group 28
Troubleshooting
MID 128 PPID 123 EPG 2,

Check
Check of component
D12B and D12C

9998534
NOTE!
EPG control (PWM box)

Disconnect the connector to the EPG
control box. Install breakout harness
9998534 to the EPG control connector
only.
tion.

Measuring
points
Optimal value
1/ 3
23 0

1 / alternate
ground
open circuit
1
3 / alternate
ground
open circuit

correct.
9998534
J-39200
Check of Subsystem
Exhaust pressure governor 2, EPG 2

control box. Install breakout harness
9998534 to the wiring harness end
only.
9998534
Ground wlreVControl wire:
Ignition key m ust be in the RUN positio n .

and the EECU.
J-41132
J-43233
J-39200
Note: Test with EPG O n can be
3
J-39200

tion.
Measuring
points
Optimal value
3 / alternate
ground
180 kO
Supply wire:
4
Measure the voltage with voltm eter J39200.
J-39200

quested EPG 2 operation.
Measuring
points
Optimal value
EB36 / EB9
B+, EPG 2 off

(Engine running,
parking brake
released, accel
erator pedal
above idle)
EB36 / EB9
0 V, EPG 2 on
(Engine running,
parking brake
on, accelerator
at idle)

tion.
Measuring
points
Optimal value
1 / alternate
ground
B+
153
Group 28
Troubleshooting
MID 128 PPID 124 EPG 1

Fault Codes
FMI 3
Output activated.
Possible cause:

valve and EECU.
Short circuit in solenoid valve.
Fault code is set.
EPG 1 constantly activated.
Low power output.
Black smoke.
FMI 5
Break.
Open circuit in the EPG1 circuit.
Possible cause:
Open circuit between solenoid valve and EECU.
Open circuit in supply wire to solenoid valve.
Blown fuse for supply to EPG1.
Engine may be difficult to start.
Open circuit in the solenoid valve.
Heat retention does not function.
FMI 4
Fault code is set.
Heat retention does not function.
Engine may be difficult to start.
Possible cause:
154

EECU.
Fault code is set.
Group 28
Troubleshooting
MID 128 PPID 124 EPG 1,

Check
9998534
NOTE!

Check of component (D12B only)

EPG control (PWM box)
1
Note: This procedure is for the D12B
engine o n ly The D7C engine uses a
single EPG solenoid; to check the
solenoid used on the D7C, see publi
cation T S I-2 7 0 -6 0 0 -0 7 (11/96).
2
Disconnect the connector to EPG control. Install breakout harness 9998534
to the EPG control connector only.
tion.
1
correct.
Measuring
points
Optimal value
1/ 4
23 0
1 / alternate
ground
open circuit
4 / alternate
ground
open circuit
2
control box (D12B) or the EPG sole
noid (D7C). Install breakout harness
9998534 to the wiring harness end
only.
9998534
J-39200
9998534
Check of Subsystem
Exhaust pressure governor 1, EPG 1
Ground wire/Control wire:
3
J-39200

tion.
Measuring
points
Optimal value
4 / alternate
ground
180 0

and the EECU.
J-41132
J-43233
J-39200
Note: Test with EPG O n can be

quested EPG 1 operation.
Supply wire:
4
J-39200
Measuring
points
Optimal value
EB35 / EB9
B+ (EPG off)
EB35 / EB9
0 V (EPG on)

tion.
Measuring
points
Optimal value
1 / alternate
ground
B+
155
Group 28
Troubleshooting
MID 128 SID 1/2/3/4/5/6 Injector

D12B and D12C
Error Code Information
Error code
Explanation
SID 1
Injector 1
SID 2
Injector 2
SID 3
Injector 3
SID 4
Injector 4
SID 5
Injector 5
SID 6
Injector 6
Fault Codes
FMI 2
S hort circuit to battery voltage, injectors high side.
Injector activated.
Short circuit to battery voltage on pin EA12 or EA24

(each respective injector bank's high side).
Possible cause:
Short circuit to battery voltage in the w iring to the in

jectors' high side.
Fault code is set.
The particular injector bank is switched off.
Low power output.
Uneven operation.
A bnorm al noise.
3 cylinder operation.
FMI 3
S hort circuit to battery voltage or short-circuited injector,
injector low side.
Injector activated.
Short circuit to battery voltage on each respective

injector's low side (EA11, EA22, EA23, EA34, EA35,
EA36).
156
Possible cause:
S hort circuit between high and low side.
S hort circuit to battery voltage in the w iring to the in

jectors' low side.
Fault code is set.
The particular injector or the w hole of the affected

injector bank is switched off.
Low power output.
Uneven operation.
A bnorm al noise.
3 or 5 cylinder operation.
Group 28
FMI 4
S hort circuit to ground, injector low or high side.
Injector activated.
S hort circuit to ground on each respective injector's

low side (EA11, EA22, EA23, EA34, EA35, EA36) or
high side (EA12, EA24).
Possible cause:
S hort circuit to ground in the wiring for each respec

tive injector's low or high side.
Troubleshooting
FMI 7
The mechanical system does not respond in the correct
way
Injector activated.
C ylinder balancing data too high.
Possible cause:
Fault in injector.
Poor compression.
Fault code is set.
Fault code is set.
The particular injector is switched off.
Low power output.
Uneven operation.
Low power output.
A bnorm al noise.
Uneven operation.
Abnorm al noise.
The particular injector bank is switched off.
FMI 5
Open circuit in the injector circuit.
FMI 11
Unidentifiable error.
Injector activated.
Open circuit in the injector circuit.
Possible cause:
Open circuit in the wiring on low or high side. If 3

fault codes have been set (a bank) the open circuit
is on that bank's high side, if there is only one fault
code the open circuit is on the particular injector's
low side.
Injector activated.
Possible cause:
Interm ittent faults.
Fault code is set.
Fault code is set.
The particular injector or the whole injector bank is

switched off.
One or three injectors are switched off.
Low power output.
Uneven operation.
Abnorm al noise.
Low power output.
Uneven operation.
A bnorm al noise.
157
Group 28
MID 128 SID 1/2/3/4/5/6 Injector,

Check
Troubleshooting
Wires
2
C onnect breakout box J-41132 to the

EA connector, w iring harness end only.
D12B and D12C
DO NOT connect 100pt to the EECU.
NOTE!

te r J-39200.


tion.

Measuring
points
Optimal value
EA11 / EA12
1.7 0
EA22 / EA12
1.7 0

EA23 / EA12
1.7 0
EA34 / EA24
1.7 0
1
EA35 / EA24
1.7 0
EA36 / EA24
1.7 0
EA11 / alternate
ground
open circuit
EA22 / alternate
ground
open circuit
EA23 / alternate
ground
open circuit
EA34 / alternate
ground
open circuit
EA35 / alternate
ground
open circuit
EA36 / alternate
ground
open circuit
Note that small resistances are difficult to measure. Use

the value instead as a standard value for the open circuit
in the injector circuits.

correct.
158
J-39200
J-41132
Group 28
Troubleshooting
Check of component
Injectors
1
Disconnect both the connections for
each respective injector.
J-39200
Measure the resistance with ohm m e

te r J-39200 on the injector.
tion.
Measuring
points
Optimal value
High side / low

side
1.5 - 2.0 0
High side / alter

nate ground
open circuit
Low side / alter

nate ground
open circuit
159
Group 28
Troubleshooting
MID 128 SID 17 Fuel Shutoff Valve

D7C only
Fault Codes
FMI 3
Output activated.
Possible cause:
Short circuit to battery voltage on wire between so

lenoid valve and EECU.
Short circuit internally in the solenoid valve.
valve and EECU.
Fault code is set.
The solenoid valve perm anently activated.
FMI 5
Open circuit in the fuel shut-off circuit.
Fault code is set.
Output is switched off.
Open circuit in the fuel shut-off circuit.
Possible cause:
Open circuit between solenoid valve and EECU.
Engine stops or does not start.
Open circuit in supply wire to fuel shut-off valve
No fuel reaches the nozzle.
Open circuit in solenoid valve.
FMI 4
Fault code is set.
Possible cause:
Engine stops or does not start.
No fuel reaches the nozzle.
160
Short circuit to ground on wire between solenoid
Group 28
Troubleshooting
MID 128 SID 17 Fuel Shutoff

Valve, Check
9998534
D7C only
Check of component
Fuel shut-off valve solenoid
1
shut-off valve solenoid. Install breakout
harness 9998534 to the solenoid har
ness end only.
tion.
1
Measuring
points
Optimal value
1/ 2
10.7 0
1 / alternate
ground
open circuit
2 / alternate
ground
open circuit

correct.
2
shut-off valve solenoid. Install breakout
ness end only.
9998534
9998534
J-3 9 2 0 0
Check of Subsystem
Fuel shut-off
3
J-39200

tion.
Measuring
points
Optimal value
2 / alternate
ground
190 kO

tion.
and the EECU.
Measuring
points
Optimal value
EB34 / EB9
0 V
J-41132
J-43233
J-39200
Supply wire:
4
J-39200

tion.
Measuring
points
Optimal value
1 / alternate
ground
B+
161
Group 28
Troubleshooting
MID 128 SID 20 Timing Sleeve

D7C only
Fault Codes
FMI 2
S hort circuit to battery voltage, tim ing sleeve, positive

side.
Short circuit to battery voltage on EA9 (EECU

checks only w hen switching on the ignition).
Possible cause:
Fault code is set.
FMI 3
S hort circuit to battery voltage, tim ing sleeve, ground
side.
Short circuit to battery voltage on EA21 (EECU

checks only w hen switching on the ignition).
Possible cause:
Short circuit between power and ground side.
Short circuit to battery voltage on ground side.
Fault code is set.
The tim ing sleeve cannot be checked.
Output for tim ing sleeve and rack drive are switched
off.
Red lamp lights up.
The engine stops or does not start.
FMI 4
S hort circuit to ground, tim ing sleeve, ground side.
Possible cause:
162
Fault code is set.
Injection angle cannot be checked.
O utput for tim ing sleeve and rack drive are switched
off.
Short circuit to battery voltage on positive side.
S hort circuit to ground, ground side.
Red lamp lights up.
FMI 5
Open circuit in the circuit to tim ing sleeve.
Open circuit between the EECU and the injection

pump.
Possible cause:
Open circuit in the wires between the EECU and the

injection pump.
Fault code is set.
off.
Red lamp lights up.
Group 28
FMI 6
S hort circuit to ground, tim ing sleeve positive side.
S hort circuit to ground on EA9.
Troubleshooting
Fault code is set.
off.
Possible cause:
S hort circuit to ground, positive side.
Noticeable external sym ptom :
Red lamp lights up.
Fault code is set.
FMI 11
off.
Red lamp lights up.
An unidentifiable error has been found.
Fault code is set.
FMI 7
The m echanical system does not respond in the correct

way
off.
Needle lift signal available.
Incorrect tim ing sleeve.
Red lamp lights up.
Possible cause:
Internal fault in the injection pump.
Interference in needle lift signal.
Fault code is set.
off.
Red lamp lights up.
FMI 8
C urrent too high to tim ing sleeve under long period of
time.
Current too high to timing sleeve.
Possible cause:
Internal fault in the injection pump.

163
Group 28
Troubleshooting
MID 128 SID 20 Timing Sleeve,

Check

te r J-39200.
D7C only

tion.
Supply wire:
NOTE!
For detailed circuit information, refer to:
Service
Manuals
Function Group 37
Electrical Schematics, VNL, VNM
Measuring
points
Optimal value
3 / alternate
ground
40 0
J-39200
Check of component
Timing sleeve
IMPACT
Function Group 2841

Information Type: Diagnostic Fault
C odes

the value instead as a standard value for an open in the
tim ing sleeve circuit.

i
correct.
2
Disconnect the connector to the timing
sleeve (7 -p in connector on the rear of
the injection pump). Take m easure
ments on the w iring harness
connector only.
Ground wire:
3
tion.
Measuring
points
Optimal value
4 / alternate
ground
60 kO
164
J-39200
1
Disconnect the connector to the timing
sleeve (7 -p in connector on the rear of
the injection pump). Install breakout
box J-38748 to the pump connector
end only.
te r J-39200.
tion.
Measuring
points
Optimal value
3 /4
1.3 0
3 / alternate
ground
open circuit
4 / alternate
ground
open circuit
J-38748
J-39200
Group 28
Troubleshooting
MID 128 SID 21 Engine Position Timing Sensor

D12B and D12C
The prim ary function of the engine position sensor (cam sensor) is to provide engine
position inform ation to the EECU. As a secondary function, it also provides engine tim
ing (speed) information.
Fault Codes
FMI 3
Engine position signal is not available.
Possible cause:
S hort circuit to voltage, positive wire.
S hort circuit to voltage, negative wire.
S hort circuit to ground, positive wire.
Open circuit in positive wire.
cam sensor wheel).
Faulty sensor.
Damaged cam sensor wheel.
Fault code is set.
The EECU uses the engine tim ing sensor signal in

stead; if this is also incorrect, the engine stops.
Open circuit in negative wire.
An incorrectly installed sensor (incorrect distance to

cam sensor wheel).
Difficult to start at the next start (no sym ptom if the

fault code is set when the engine is running).
Reversed polarity on the sensor.
Faulty sensor.
Damaged cam sensor wheel.
Fault code is set.
The EECU uses engine tim ing sensor signal in

stead; if this is also incorrect, the engine stops.
Difficult to start at the next start (no sym ptom if the

fault code is set when the engine is running).
FMI 8
A bnorm al frequency.
The EECU detects extra pulses on the engine posi

tion signal.
Possible cause:
Electrical interference in the engine position signal.
Poor insulation or faulty wires.

165
Group 28
Troubleshooting
MID 128 SID 21 Engine Position

Timing Sensor, Check
998534
Supply wire:
4
J-39200

tion.
D12B and D12C

NOTE !
Measuring
points
Optimal value
1 / alternate
ground
2 V


Disconnect the connector to the engine position sensor. Install breakout

ness end only.

correct.

te r J-39200.
2
9998534
Ground wire:
3
tion.
Measuring
points
Optimal value
2 / alternate
ground
48 kO
166
Engine position sensor

1
1
Disconnect the connector to the engine position sensor. Install breakout

ness end only.
Check of component
J-39200

tion.
Measuring
points
Optimal value
1/ 2
775 - 945 0
1 / alternate
ground
open circuit
2 / alternate
ground
open circuit
9998534
J-39200
Group 28
Troubleshooting
MID 128 SID 21 Needle Lift Sensor

D7C only
Needle lift sensor. The needle lift sensor is located on first the cylinder.
Fault Codes
FMI 2
Interm ittent loss o f signal or incorrect signal.
Engine speed greater than 450 rpm.
Fuel injection is carried out.
Missing signal.
Possible cause:
Loose connection sensor.
Open circuit in one o f the wires.
S hort circuit to ground on any of the wires.
S hort circuit to battery voltage onany o f the wires.
Lack
Faulty sensor.
of fuel.
No fuel injection in cylinder 1.
Fault code is set.
Tim ing sleeve (injection angle) is controlled w ithout

feedback.
Higher fuel consum ption than normal.
167
Group 28
Troubleshooting
MID 128 SID 21 Needle Lift

Sensor, Check
9998534
Supply wire:
4
J-39200

tion.
D7C only
NOTE!
C heck all the particular connectors for loose connections
Measuring
points
Optimal value
1 / alternate
ground
B+


Disconnect the connector to the needle lift sensor. Install breakout harness
9998534 to the sensor harness end
only.

correct.

te r J-39200.
2
9998534
Measuring
points
Optimal value
2 / alternate
ground
0.5 n
168
Optimal value
1/ 2
1 / alternate
ground
open circuit
2 / alternate
ground
open circuit

tion.
J-39200
Measuring
points
L
O
C
O

tion.
L
O
C
O
Ground wire:
Needle lift sensor

1
1
Disconnect the connector to the needle lift sensor. Install breakout harness
9998534 to the w iring harness end
only.
Check of component
9998534
J-39200
Group 28
Troubleshooting
MID 128 SID 22 Engine Speed Sensor

The prim ary function of the engine tim ing sensor (crank sensor) is to provide engine
tim ing (speed) information to the EECU. As a secondary function, it also provides lim
ited engine position information.
Fault Codes
FMI 2
Interm ittent loss o f signal or incorrect signal.
Fault code is set.
The EECU uses the engine position signal instead.

If this is also incorrect, the engine stops.
Incorrect engine tim ing signal.
Possible cause:
Electrical interference in the engine tim ing signal.
Loose connection.
Poor insulation or faulty wire.

the flywheel).
Faulty sensor.
Damaged teeth on flywheel.
The engine stops if the engine position signal also

disappears.
FMI 8
Fault code is set.

The EECU detects extra pulses on the engine tim

ing signal.
Possible cause:
Electrical interference.

disappears.
An incorrectly installed sensor.
Faulty sensor.
Damaged teeth on flywheel.
FMI 3
Signal is not available.
Possible cause:
Fault code is set.
S hort circuit to voltage, positive wire.
S hort circuit to voltage, negative wire.
S hort circuit to ground, positive wire.

An incorrectly installed sensor.
Faulty sensor.

disappears.
169
Group 28
Troubleshooting
MID 128 SID 22 Engine Speed

Sensor, Check
9998534
Supply wire:
4
tion.
NOTE

Measuring
points
Optimal value
1 / alternate
ground
2 V
Check of component
1
Engine timing sensor

correct.
1
Disconnect the connector to the engine tim ing sensor. Install breakout
ness end only.
2
Disconnect the connector to the engine tim ing sensor. Install breakout
ness end only.
9998534
3
tion.
Measuring
points
Optimal value
2 / alternate
ground
48 kO

te r J-39200.
tion.
Ground wire:
170
J-39200
J-39200
Measuring
points
Optimal value
1/ 2
775 - 945 0
1 / alternate
ground
open circuit
2 / alternate
ground
open circuit
9998534
J-39200
Group 28
Troubleshooting
MID 128 SID 23 Rack Actuator

D7C only
Fault Codes
FMI 2
FMI 4
S hort circuit to battery voltage, rack drive positive side.
Short circuit to ground, rack drive ground side.
S hort circuit to battery voltage on EA8 (EECU

checks only when switching on the ignition).
Possible cause:
S hort circuit to battery voltage, positive side.
Fault code is set.
Possible cause:
FMI 3
S hort circuit to battery voltage, rack drive ground side.
Fuel injection is requested.
S hort circuit to battery voltage on EA10.
Possible cause:
S hort circuit between power and ground side.
S hort circuit to battery voltage, ground side.
S hort circuit to ground, ground side.
Fault code is set.
EECU connection for power and ground sides is

switched off.
S hort circuit to ground on EA10.
Red lamp lights up.
FMI 5
Open circuit in the circuit for rack drive.
Open circuit in the circuit for rack drive.
Possible cause:
Open circuit in w ires between EECU and rack drive.

Open circuit in rack drive.
Fault code is set.

switched off.
Fault code is set.

switched off.
Red lamp lights up.
Red lamp lights up.
171
Group 28
FMI 6
S hort circuit to ground, rack drive positive side.
Possible cause:
Troubleshooting
FMI 8
C urrent too high to rack drive under long period o f time.
Short circuit to ground, positive side.
The current to rack drive is too high for a long pe

riod.
Possible cause:
Fault code is set.
Internal fault in the pump.

switched off.
Fault code is set.

switched off.
Red lamp lights up.
FMI 7
The m echanical system does not respond in the correct

way
Red lamp lights up.
The rack drive does not move as expected.
Possible cause:
FMI 11
Rack drive stuck.
Mechanical fault in the pump.
Fault in rack drive position sensor.
An unidentifiable error has been found.
Fault code is set.
Fault code is set.

switched off.

switched off.
Red lamp lights up.
172
Red lamp lights up.
Group 28
Troubleshooting
MID 128 SID 23 Rack Actuator,

Check
Supply wire:
4
te r J-39200.
J-39200

tion.
D7C only
NOTE
Measuring
points
Optimal value
7 / alternate
ground
40 kO

rack drive.
Check of component
Rack drive
1

1
correct.
Disconnect the connector to the rack

drive (7 -p in connector on the rear of
end only.
J-38748
J-39200

te r J-39200.
tion.
2
ments on the wiring harness
connector only.
Measuring
points
Optimal value
2 / 7
0.7 0
1 / alternate
ground
open circuit
Ground wire:
2 / alternate
ground
open circuit
3
J-39200

tion.
Measuring
points
Optimal value
2 / alternate
ground
60 kO
173
Group 28
MID 128 SID 24 Rack Position Sensor

D7C only
Fault Codes
FMI 2
Incorrect data.
Unreasonable m easurem ent value from rack posi

tion sensor.
Possible cause:
Sensor value outside m easurem ent range.
Open circuit or short circuit in wires.
Internal fault in the pump.
Faulty sensor.
Fault code is set.
Output for rack drive is switched off.
Red lamp lights up.
FMI 13
Sensor values outside calibration values.
Unreasonable m easurem ent value at start-up.
Possible cause:
Uncalibrated sensor.
Faulty sensor.
Fault code is set.
Output for rack drive actuator is switched off.
Red lamp lights up.
The engine does not start.
174
Troubleshooting
Group 28
Troubleshooting
MID 128 SID 24 Rack Position

Sensor, Check
Search wire:
4
te r J-39200.
J-39200

tion.
D7C only
NOTE!
Measuring
points
Optimal value
5 / alternate
ground
5.5 kO

rack position sensor.
Check of component
Rack position sensor
1

1
correct.
J-38748
J-39200

te r J-39200.
tion.
2
D isconnect the connector to the rack
ments on the wiring harness
connector only.
Reference wire:
3

end only.
Measuring
points
Optimal value
5 /6
20 0 (search
coil)
1/ 6
20 0 (reference
coil)
1, 5, 6 / alter
nate ground
open circuit
J-39200

tion.
Measuring
points
Optimal value
1 / alternate
ground
5.5 kO
175
Group 28
Troubleshooting
MID 128 SID 33 Fan Control

Fault Codes
FMI 3
Output activated.
Short circuit to voltage on EB21.
Possible cause:

valve and EECU.
Short circuit in solenoid valve for fan control.
FMI 5
Break.
Open circuit in the circuit for fan control.
Possible cause:
Open circuit in the wiring between solenoid valve

and EECU.
Open circuit in solenoid valve for fan control.
Open circuit in supply wire to solenoid valve for fan

control.
Blown fuse to supply for the fan control's solenoid

valve.
Fault code is set.
Fault code is set.
O utput is switched off.
The fan is in constant operation.
Increased fuel consumption.
The fan is in constant operation.
FMI 4
Possible cause:

EECU.
Fault code is set.
The fan does not come on.
Increased coolant tem perature.
176
Increased fuel consumption.
Group 28
Troubleshooting
MID 128 SID 33 Fan Control,

Check
NOTE!

1
correct.
Check of component
Fan control solenoid valve
1
Disconnect the connector to the fan
control solenoid valve. Install breakout
harness J-43147 to the solenoid valve
harness end only.
J-43147
J-39200

te r J-39200.
tion.
Measuring
points
Optimal value
A/ B
20 O
Check of Subsystem
Fan control
1
2
D isconnect the connector to the fan
control solenoid valve. Install breakout
end only.
J-43147

3
J-39200

tion.
Measuring
points
Optimal value
B / alternate
ground
200 kO

tion.
and the EECU.
Measuring
points
Optimal value
EB21 / EB9
B+ (fan on)
EB21 / EB9
0 V (fan off)
ground term inal

EB21 with a
ju m p e r wire
fan control sole

noid valve
releases fan
J-41132
J-43233
J-39200
Supply wire:
4
J-39200

tion.
Measuring
points
Optimal value
A / alternate
ground
B+
177
Group 28
Troubleshooting
MID 128 SID 64 Redundant Engine Speed Sensor

D7C only
The redundant engine speed sensor is used as a secondary engine tim ing (speed) and
secondary engine position sensor. Prim ary engine tim ing (speed) information is pro
vided by the engine tim ing (crank) sensor. Prim ary engine position inform ation is
provided by the needle lift sensor.
Fault Codes
FMI 3
FMI 8
Engine position signal is not available.
Possible cause:
Short circuit to battery voltage, positive wire.
Short circuit to voltage, negative wire.
Short circuit to ground, positive wire.
The EECU detects extra pulses on the engine posi

tion signal.
Possible cause:
Electrical interference in the engine position signal.
Poor insulation or faulty wires.

pump speed sensor wheel).

pump speed sensor wheel).
Faulty sensor.
Reversed polarity on the sensor.
Faulty sensor.
Damaged pump speed sensor wheel.
Damaged pump speed sensor wheel.
Fault code is set.
178
Fault code is set.
Group 28
Troubleshooting
MID 128 SID 64 Redundant En

gine Speed Sensor, Check
Supply wire:
4
D7C only

tion.
NOTE!

1
Measuring
points
Optimal value
1 / alternate
ground
2 V
J-39200
Check of component
Redundant engine speed sensor
1
Disconnect the connector to the redundant engine speed sensor. Install
breakout harness J-43233 to the sen

correct.
J-43233
J-39200

te r J-39200.
2
D isconnect the connector to the engine position sensor. Install breakout
ness end only.
9998534
Ground wire:
3
tion.
Measuring
points
Optimal value
2 / alternate
ground
48 kO
J-39200

tion.
Measuring
points
Optimal value
1/ 2
775 - 945 0
1 / alternate
ground
open circuit
2 / alternate
ground
open circuit
179
Group 28
Troubleshooting
MID 128 SID 70 Preheater Element 1

Each preheater is equipped with a fuse between the preheating relay and element. The
fuse and elem ent are monitored by a sense wire that determ ines if the circuit is intact.
Fault Codes
FMI 3
Preheating relay not activated.
The voltage on EB5 is greater than 65% B+.
Preheating does not function.
Possible cause:
FMI 5
Preheating relay constantly on.
Fault code is set.
Preheating relay is switched off.
Break.
The voltage on EB5 is greater than 5% B+ and less

than 65% B+.
Possible cause:
Open circuit in elem ent or wires.
Fault code is set.
High inlet tem perature.
O utput for the pre-heating relay is switched off.
Discharged battery.
Preheating relay may be constantly activated.
FMI 4
Preheating requested.
Possible cause:
Preheating relay damaged.
Fault code is set.
Output to pre-heating relay is switched off.
180
Group 28
Troubleshooting
MID 128 SID 70 Preheater Ele

ment 1, Check
NOTE!

1
correct.
2
D isconnect sense wire (small solid red
w ire) at pre-heat relay #1.
Check of Subsystem
Preheating 1, element diagnostics
1
and the EECU.
J 41132
J 43233
J 39200
Note: Test with P reheat O n can be

quested pre-heat.
Measuring
points
Optimal value
EB5 / EB9
B+ (Preheating
on)
EB5 / EB9
0 V (Preheating
off)
Signal wire:
3
J-39200

tion.
Measuring
points
Optimal value
Sense wire / al
ternate ground
1.4 kO
Check of component
Preheating 1, element
1
R em ove the fuse and support (red
plastic part) between the pre-heat re
lay and the pre-heat elem ent terminal.
J-39200

tion.
Measure the resistance with ohm m e
te r J-39200.
Measuring
points
Optimal value
Preheat element
term inal / alter
nate ground
<1 0
181
Group 28
Troubleshooting
MID 128 SID 71 Preheater Element 2

D12B only
Each preheater is equipped with a fuse between the preheating relay and element. The
fuse and elem ent are monitored by a sense wire that determ ines if the circuit is intact.
Fault Codes
FMI 3
Preheating relay not activated.
The voltage on EB16 is greater than 65% B+.
Possible cause:
Preheating relay constantly on.
FMI 5
Break.
The voltage on EB16 is greater than 5% B+ and

less than 65% B+.
Possible cause:
Fault code is set.
The preheating relay is switched off.
Fault code is set.
O utput for preheating relay is switched off.
Preheating relay may be constantly on.
High inlet tem perature.
Discharged battery.
FMI 4
Preheating requested.
Possible cause:
Preheating relay damaged.
Fault code is set.
Output to preheating relay is switched off.
182
Open circuit in elem ent or wires.
Group 28
Troubleshooting
MID 128 SID 71 Preheater Ele

ment 2, Check
Check of component
Preheating 2, element
D12B
Remove the fuse and support (red

plastic part) between pre-heat relay #2
and pre-heat elem ent #2 terminal.
NOTE!

1
correct.

tion.
te r J-39200.
Measuring
points
Optimal value
Preheat elem ent

term inal / alter
nate ground
<1 0
Check of Subsystem
Preheating 2, element diagnostics
1
Signal wire:

and the EECU.
Note: Test with P reheat O n can be
2
D isconnect the sense wire (small
red/white w ire) at pre-heat relay #2.

tion.
J-39200
J-39200
J-41132
J-43233
J-39200

quested pre-heat.
Measuring
points
Optimal value
Measuring
points
Optimal value
EB16 / EB9
B+ (Preheating
on)
Sense wire / al
ternate ground
1.4 kO
EB16 / EB9
0 V (Preheating
off)
183
Group 28
MID 128 SID 230 Idle Validation Switch 1

Fault Codes
FMI 3
A ccelerator pedal released.
The voltage on EB4 exceeds 75% o f B+.
Possible cause:
Short circuit to battery voltage on wire between

EECU and VECU.
Error in accelerator pedal.
Fault code is set.
The "limp home" function does not function.
FMI 4
A ccelerator pedal pressed down > 50 %.
The voltage on EB4 is below 25% o f B+.
Possible cause:
Short circuit to ground on wire between EECU and

VECU.
Open circuit in wire between EECU and VECU.
Error in accelerator pedal.
Fault code is set.
The limp hom e function does not function.
184
Troubleshooting
Group 28
Troubleshooting
MID 128 SID 230 Idle Validation

Switch 1, Check
NOTE!
C heck all the particular connectors for loose connections
Check of Subsystem
1
and the EECU.
Measuring
points
Optimal value
EB4 / EB9
< 4 V (accelera
to r pedal at idle)
EB4 / EB9
> 8 V (accelera
to r pedal o ff idle)
J-41132
J-43233
J-39200
185
Group 28
Troubleshooting
MID 128 SID 231 SAE J1939 Control Link

Fault Codes
FMI 2
Com m unications link (SAE J1939) does not function.
Information is read/sent instead on the information

link (SAE J1587).
Temporary loss o f function on:- Cruise ControlPTO.- Pre-heating- Engine brake- D river position no.
2
No messages are received from the com m unica

tions link (SAE J1939).
Possible cause:
Open circuit in com m unications link (SAE J1939).
Short circuit to voltage on com m unications link (SAE

J1939).
Short circuit to ground on com m unications link (SAE

J1939).
wires in com m unications link (SAE J1939) shortcircuited to each other.
FMI 11
C om m unications link (SAE J1939) does not function

internally in EECU at start-up.
Possible cause:
Fault code is set.

link (SAE J1587).
Internal fault in EECU.
Cruise Control does not function.
PTO does not function.
Preheating relay does not function.
Driver position no. 2 does not function.
Fault code is set.

link (SAE J1587).
FMI 9
Com m unications link (SAE J1939) does not function.
C om m unications link (SAE J1939) does not function.
Possible cause:
W ires in com m unications link (SAE J1939) shortcircuited to each other.
Temporary malfunction in hardware.
Loose connection.
Interm ittent fault in the wiring.
Fault code is set.
186
D river position no. 2 does not function.
Group 28
Troubleshooting
FMI 12
Loss of m essage from the VECU.
The com m unication between EECU and VECU

does not function.
Possible cause:
No contact with VECU.
Fault code is set.

link (SAE J1587).
D river position no. 2 does not function.
187
Group 28
MID 128 SID 232 5 Volt DC Supply

Fault Codes
FMI 3
Possible cause:
Short circuit to battery voltage on the output.
Fault code is set.
Incorrect values on oil pressure sensor and boost

pressure sensor.
fault code on oil pressure sensor and boost pres

sure sensor.
Low power output.
Oil pressure gauge and boost pressure gauge show

0 in the instrument.
FMI 4
Possible cause:
Short circuit in sensor.
Faulty sensor.
Fault code is set.
fault code on oil pressure sensor and boost pres

sure sensor.
Oil pressure gauge and boost pressure gauge show

0 in the instrument.
Low power output.
188
Troubleshooting
Group 28
Troubleshooting
MID 128 SID 232 5 Volt DC Sup

ply, Check
9998534
Supply wire:
4
J-39200
Ignition key m ust be in the O N posi

tion.
NOTE!
Measuring
points
Optimal value
1 / alternate
ground
5 V (oil pres
sure/temperature,
boost air pres
sure/temperature,
fuel tem perature)

1
Check of sub-system

correct.
5 y supply to sensors
1
2
Disconnect the individual connectors
to the fuel tem perature sensor (D7C
only), boost air tem perature/pressure
sensor, coolant tem perature sensor,
and oil tem perature/pressure sensor.
Install breakout harness 9998534 to
the wiring harness end only.
9998534

tion.
and the EECU.
Measuring
points
Optimal value
EA4 / EA5
4.8 - 5.15 V
J-41132
J-43233 J39200
Ground wire:
3
J-39200

tion.
Measuring
points
Optimal value
2 / alternate
ground
< 1 0 (coolant
tem perature)
4 / alternate
ground
<1
(oil pres
sure/temperature,
boost air pres
sure/temperature,
fuel tem perature)
189
Group 28
MID 128 SID 240 Program Memory

Fault Codes
FMI 2
Incorrect checksum in program memory.
Incorrect checksum (EECU calculates only at start

up).
Possible cause:
Error when programming.
Fault code is set.
Red lamp lights up.
FMI 12
Incorrect checksum in program memory.
Incorrect checksum.
Possible cause:
Fault code is set.
190
None.
Troubleshooting
Group 28
Troubleshooting
MID 128 SID 250 SAE J1587/1708 Information Link

Fault Codes
FMI 12
The information link (SAE J1587) does not function

internally in the EECU.
Possible cause:
Fault code is set.
Information from the EECU is not available on the

inform ation link (SAE J1587).
The tachom eter shows 0.
191
Group 28
MID 128 SID 253 Data Set Memory EEPROM

Fault Codes
FMI 2
Incorrect checksum in data set memory.
Checksum error.
Possible cause:
Error when programming.
Fault code is set.
Red lamp lights up.
FMI 12
Incorrect checksum in data set memory.
Checksum error.
Possible cause:
Fault code is set.
Red lamp lights up.
192
Troubleshooting
Group 28
Troubleshooting
MID 128 SID 254 Engine Electronic Control Unit (EECU)

Fault Codes
FMI 2
Incorrect self test in the EECU.
Possible cause:
Fault code is set.
Red lamp lights up.
FMI 8
Possible cause:
Fault code is set.
Red lamp lights up.
FMI 11
Possible cause:
Fault code is set.
Red lamp lights up.
Fault code is set.
Red lamp lights up.
FMI 9
Possible cause:
193
Group 28
FMI 12
Possible cause:
Fault code is set.
Red lamp lights up.
FMI 13
Possible cause:
The EECU restarts.
fault code can be requested, will not autom atically

be shown.
194
The engine falters.
Troubleshooting
Group 28
Troubleshooting
MID 144 VECU

MID: Message Identification Description.
SID: Subsystem Identification Description.
PID: Param eter Identification Description.
FMI: Failure Mode Identifier.
Error code
Component/Function
FMI
Section
MID 144-PID 29
S econdAccelerator Pedal Po
sition
3, 4, 5
MID 144 PID 29 Sec

ond A ccelerator Pedal
Position Sensor page
198
MID 144-PID 84
Road Speed
MID 144 PID 84 Road

S peed page 201
MID 144-PID 91
A ccelerator Pedal Position
9, 11
MID 144 PID 91 A ccel

erator Pedal Position
page 204
MID 144-PID 152
VECU, N um ber of Resests
MID 144 PID 152

VECU, N um ber of Re
sets page 207
MID 144-PPID 69
Idle Validation Switch
9, 11
MID 144 PPID 69 Idle

Validation S w itch page
208
MID 144-PPID 70
Pedal Switches, Supply
1, 3, 4
MID 144 PPID 70

Pedal Switches, S upply
page 211
MID 144-PPID 71
Cruise Control and Engine

Brake, Supply Switch
1, 3, 4
MID 144 PPID 71

Cruise Control and En
gine Brake, Supply
Sw itch page 215
MID 14 4-P P ID 72
A ccelerator Pedal, Supply

Sensors
3, 4
MID 144 PPID 72 A c

celerator Pedal, Supply
S ensors page 220
MID 14 4-P P ID 73
Second A ccelerator Pedal,

S upply Sensors
3, 4
MID 144 PPID 73 Sec

ond A ccelerator Pedal,
Supply S ensors page
223
MID 14 4-P P ID 75
Range Inhibitor, Solenoid

Valve Status
0, 3, 4, 5
MID 144 PPID 75

Range Inhibitor, Sole
noid Valve S tatus page
226
MID 14 4-S ID 230
3, 4
MID 144 SID 230 Idle

Validation Switch 1
page 229
MID 14 4-S ID 231
SAE J1939 Control Link
0, 3 ,4
MID 144 SID 231 SAE

J1939 Control Link
page 232
MID 14 4-S ID 240
Program M em ory
MID 144 SID 240 Pro

gram M em ory page 234
MID 14 4-S ID 243
Crusie Control Set Switch
MID 144 SID 243

Cruise Control Set
Sw itch page 235
195
Group 28
Troubleshooting
Error code
Component/Function
FMI
Section
MID 144-S ID 250
SAE J1587/1708 Information

Link
3, 4
MID 144 SID 250 SAE

J1587/1708 Information
Link page 238
MID 144-S ID 253
3, 4
MID 144 SID 253 Data

Set M em ory EEPR O M
page 240
M ID144-PSID 3
MID 144 PSID 3 Idle

Validation Switch 3
page 241
196
Group 28
Troubleshooting
MID 144 PID 29 Second Accelerator Pedal Position Sensor

Applies only to vehicles with a second accelerator pedal assem bly (such as the WX).
Text Messages
In vehicles equipped with diagnostic display, the fol
lowing m essage(s) will appear:
Instrument Cluster Graphics Display (VN):

Second throttle.
Data Link Instrument Cluster (WG, AC, WX):

The Data Link instrum ent cluster graphics display
used on WG-, AC-, and W X -series vehicles can
display a limited num ber of text messages. For infor
mation, see Data Link Instrum entation, Volvo
Service Publication P V 7 7 6 -3 8 1 -6 2 0 S M .
VCADS Pro Display:

Second throttle position, %
Fault Codes
FMI 3
FMI 4
If the VECU receives a signal from the sensor that

is higher than 4.3 V, the VECU interprets this as a
fault and an fault code is set.

is lower than 0.4 V, the VECU interprets this as a
Possible cause:
Possible cause:
Open circuit in ground wire.
Open circuit in supply wire.
Signal wire short circuited to higher voltage.
Open circuit in signal wire.
Faulty second accelerator position sensor.
Signal wire short-circuited to ground.
Faulty idle validation switch 3.
Faulty second accelerator position sensor.
Reaction from the VECU:
Fault code is set.
Switch resistance and oxidation.
Fault code is set.

The engine does not respond w hen the second ac

celerator pedal is depressed.
The engine does not respond when the second ac

197
Group 28
Troubleshooting
MID 144 PID 29 Second Accel

erator Pedal Position Sensor,
Check
5
C onnect a voltm eter to the breakout
harness pins and measure the voltage.
Other special equipment: J-39200, J-41133,

9998551, J-43340, J-43234
NOTE!
Measuring points
Expected value
Pin A / Pin E
5 .4 2 0 % V
J-39200
Signal wire:
Read off the other fault codes for the VECU.
Check the particular connectors during the fault

tracing for oxidation and switch resistance. For
detailed circuit inform ation, refer to VNL, VNM Elec
6
Turn the ignition key to the OFF posi
tion.
Appropriate Tests in the VCADS

Pro Tool
C onnect an ohm m eter to the breakout

harness pins and m easure the resis
tance.
The following test(s) are useful for closely examining the

com ponent's function:
27104-8
Extra accelerator control, switches and

sensor, test
Measuring points
Expected value
Pin B / Pin E
100 20% k Q
J-39200
Wiring harness

Connector, to the VECU
Note: Faults in the w iring harness to the VECU can
damage the component. Therefore, a check of the com
ponent should also be made if any of the m easurem ent
values deviate from the expected value.
8
To check the w iring harness, see
VNL, VNM Electrical S chem atics,
Group 37.
Check of component
Second accelerator position sensor
1
Disconnect the connector at the second accelerator pedal. Install 5-pin
breakout harness J-41133 to the
J-41133

in the w iring harness of the VECU. A check o f the wiring
harness should also therefore be made before connect
ing a new component.
Ground wire:

breakout harness J-41133 to the sec
ond accelerator pedal harness end
only.
2
tion.
3
tance.
Measuring points
Expected value
Pin E / a lte rn a te
<1 0
g ro u n d
J-39200
2
tion.
3
tance.
Supply wire:
Measuring points
Expected value
Pin A / Pin E
4 20% kQ
Turn the ignition key to the ON posi

tion.
Pin A / Pin B
198
J-4 1 133
4 .5 2 0 % kQ (a c c e le r
a to r pedal a t idle)
J-39200
Group 28
Troubleshooting
Check of Subsystem
Supply wire:
D isconnect the VECU and install

adapter J-43234 between the VECU
and w iring harness connectors PB/PA.
J-43234
6
C onnect a voltm eter to the 6 0 -p in
breakout box and m easure the voltage.
2
C onnect the 6 0 -p in breakout box
9998551 (with overlay J-43340) to the
adapter.
9998551
J-43340
Measuring points
Optim al value
P B 26 / PB 23
5 20% V
Ground wire:
Signal wire:

tion.

tion.
J-39200
C onnect an ohm m eter to the 6 0 -p in

breakout box and measure the resis
tance.
J-39200
C onnect a voltm eter to the 60-pin

Measuring points
Measuring points
Optim al value
P B 23 / A lte rn a te
<1 0
P B 25 / PB 23
J-39200
Expected value
0 .5 20% V (a c c e le ra
to r ped al at idle)
gro u n d
3 .2 20% V (full a c
ce le ra tio n )
Verification
To verify that the fault has been corrected, use the test
in the VCADS Pro tool (see A ppropriate Tests in the
VCADS Pro Tool page 198).
199
Group 28
Troubleshooting

The speed signal comes from a sensor on the transm ission or as a digital signal if an
electronically-controlled transm ission is used (i.e. Allison). Diagnostic settings (level 1.5
param eters) are factory programmed based on the transm ission type used.
Text M essages


Road speed.

VCADS Pro Display:

Road speed
Fault Codes
FMI 5
FMI 6
A bnorm ally low current or open circuit.
A bnorm ally high current or short circuit.
If the VECU registers a current lower than 90 /(A on

any o f the signal wires from the speed sensor the
VECU interprets this as a fault and an fault code is
set.
Possible cause:
Poor contact, sensor connection.
Break, signal wire.
Fault in sensor.
If the VECU registers a current higher than 140 //,A

on any of the signal wires from the speed sensor,
the VECU interprets this as a fault and an fault code
is set.
Possible cause:
Signal wire short-circuited to higher voltage.
Fault in sensor.
No vehicle speed on gauge.
No vehicle speed on gauge.
No PTO.
No PTO.
No cruise control.
No cruise control.
200
Group 28
Troubleshooting
MID 144 PID 84 Road Speed,

Check
Other special equipment: J-39200, 9998551,
J-43340, J-43234
Wiring Harness
5
To check the wiring harness, refer to
Group 37.
NOTE!

detailed circuit information, refer to VNL, VNM Elec

Pro Tool
N/A
Check of Component Vehicle

Speed Sensor
in the w iring harness o f the VECU. A check of the wiring
ing a new com ponent.
1
Disconnect the 2 -p in vehicle speed
sensor connector at the transm ission.
No te st currently available.

dam age the component. Therefore, a check o f the com
1
adapter J-43234 to the wiring harness
connector PB only.
J-43234

tion.
3
C onnect an ohm m eter to the vehicle
speed sensor connector and measure
the resistance.
Measuring
Expected
points
value*
Pin A / Pin B
2 6 5 20% Q
Volvo
3 .4 k 20% 0
F uller
2
C onnect 6 0 -p in breakout box 9998511
(with overlay J-43340) to the adapter.
9998511
J-43340
J-39200
T ra n s m is s io n
3 .1 7 k 20%
A llis o n H T-
74G
N O D IA G
A llis o n A u to
N O S T IC S
m atic
* V a lue m ay v a ry d e p e n d in g on tra n s m is s io n
Signal wire
m anufactu rer.
3
tion.
4
breakout box and measure resistance.
Measuring
Expected
points
value
P B 6 /P B 2 0
265 2 0 % Q
Volvo
3 .4 k 20% O
F uller
J-39200
3 .1 7 k 20%
A llis o n H T-
74G
N O D IA G
A llis o n A u to
N O S T IC S
m atic
* V a lue m ay v a ry d e p e n d in g on tra n s m is s io n
m anufactu rer.
201
Group 28
Troubleshooting
Check of Subsystem
Signal wire
4
/ ? \ danger

tion.

ju ry or death.
1
Disconnect the VECU and install
and w iring harness connector PA/PB.
J-43234
5
breakout box and measure the voltage
while turning the wheel by hand. The
voltage will alternate from positive to
negative and will vary with speed. Volt
m eter function M IN/M AX may be
useful to determ ine value.
J-39200
Note: The transm ission output shaft

m ust be turning.
2
9998551
J-43340
Measuring
Expected
points
minimum
value
P B 6 / PB 20
+0.1 V to -0.1
V olvo
/ | \ DANGER
+0.1 V to -0.1
F uller
Personal injury hazard. Never w o rk under or around a

raised vehicle unless it is securely supported on jack
stands o f adequate rating and the front w heels are
securely chocked. Failure to use adequate ja ck stands
and chock the w heels can result in the vehicle falling,
w hich can cause serious injury or death to anyone un
der or near the vehicle.
Chock the front wheels. Release the
parking brake and jack up one rear
wheel so that it can be turned by hand.
202
+0.1 V to -0.1
A llis o n H T-
7 40
N O D IA G
A llis o n A u to
N O S T IC S
m atic
Verification
No VCADS Pro tool test is currently available to verify
this fault correction.
Group 28
Troubleshooting
MID 144 PID 91 Accelerator Pedal Position
Text Messages

Acc. pedal pos. %

VCADS Pro Display:

A ccelerator pedal position, %
Fault Codes
FMI 3
FMI 4

is higher than 4.3 V, the VECU interprets this as a
Possible cause:
Signal wire short-circuited to higher voltage.
Faulty accelerator position sensor.
Faulty idle validation switch 1.

is lower than 0.4 V, the VECU interprets this as a
Possible cause:
Open circuit in signal wire.
Fault code is set.
fault code is set.
The engine does not respond w hen the accelerator

pedal is depressed.
The engine does not respond when the accelerator

pedal is depressed.
203
Group 28
Troubleshooting
MID 144 PID 91 Accelerator

Pedal Position, Check

9998551, J-41133, J-43340

tion.
NOTE!


Pro Tool
27102-8
A ccelerator pedal, switches and sensor,

test

Supply Wire:
5
C onnect a voltm eter to the connector
and m easure the voltage from pin A to
pin E (5 -p in harness).
Measuring points
Expected value
Pin A / Pin E
5 .4 2 0 % V
J-39200
Signal Wire:
6
tion.
7
Using an ohmmeter, m easure the resistance from pin B to pin E (5 -p in
harness).
Measuring points
Expected value
Pin B / Pin E
100 20% kQ
J-39200
1
Disconnect the connector at the accelerator pedal. Install 5-pin breakout
end only.
J-41133
Wiring harness
8
To check the w iring harness, refer to
Group 37.
Ground wire:
2
Check of component accelerator

pedal position sensor

tion.

3
Using ohm m eter J-39200, measure resistance from pin E (5 -p in harness) to
alternate ground.
J-39200

1
Measuring points
Expected value
<1 O
g ro u n d
204
Disconnect the connector at the accelerator pedal. Install 5 -p in breakout

harness J-41133 to the accelerator
pedal harness only.
J-4 1 133
Group 28
Troubleshooting
Supply Wire:

tion.
5
tion.
3
Using an ohmmeter, m easure the resistance of pin A to pin E, and pin A to
pin B.
J-39200
6
Using a voltm eter at the 60-pin breakout box, m easure the voltage from pin
PB10 to PB22.
Measuring points
Expected value
Pin A / Pin E
4 20% kQ
Measuring points
Expected value
Pin A / Pin B
4.5 2 0 % kQ
P B 10 / PB 22
5 20% V
Signal Wire:
Remove the 5 -p in breakout harness

and reconnect the connector at the ac
celerator pedal.
Check of Subsystem
Ignition key in the ON position.
1
and w iring harness connectors PA/PB.
J-39200
J-43234
Using a voltm eter at the 60-pin breakout box, m easure the voltage from pin
PB8 to PB22.
Measuring points
P B 8 / P B 22
J-39200
Expected value
0 .5 20% V (a c c e le ra
to r a t idle)
2
C onnect 60-pin breakout box 9998551
9998551
J-43340
3 .2 20% V (full a c
ce le ra tio n )
Ground Wire
Verification

tion.
4
Using an ohm m eter at the 60-pin
breakout box, m easure the resistance
between pin PB22 and the alternate
ground.
Measuring points
Expected value
P B 22 / a lte rn a te
<1 Q
J-39200
gro u n d
205
Group 28
Troubleshooting
MID 144 PID 152 VECU, Number of Resets

The software in the VECU contains an internal checking function that restarts the
VECU when there is a fault in the execution o f the software. PID 152 contains inform a
tion about how many such restarts that have been made.
Text M essages


No. o f ECU resets

VCADS Pro Display:

Num ber o f ECU resets
Fault Codes
FMI 12
Faulty unit or component.
If an internal software fault occurs an fault code is

set.
Possible cause:
The system has been switched off by disconnecting

the battery or using a battery m aster switch instead
of switching it off with the ignition key.
The system has been restarted due to an internal

software fault.
Fault code is set.
The system is restarted.
206
Group 28
Troubleshooting
MID 144 PPID 69 Idle Validation Switch

The function is used to be able to drive the vehicle in limp home m ode if a fault has
occurred in the w iring to the engine electronic control unit (EECU).
Text M essages


Buff, idle val. sw.

VCADS Pro Display:

Fault Codes
FMI 4
If the output signal from the buffered idle validation

switch deviates from the input signal from idle vali
dation switch 1, the VECU interprets this as a fault
and an fault code is set.
Note: The fault code is set first when the accelera

to r pedal is depressed.
Possible cause:
S hort circuit to ground, signal wire
Fault code is set.
207
Group 28
Troubleshooting
MID 144 PPID 69 Idle Validation

Switch, Check
J-43234, J-43233, 9998551, J-43340
Wiring harness
6
Group 37.
NOTE!


Pro Tool
N/A
Check of component buffered

idle validation switch
in the w iring harness of the VECU. Therefore, a check of
the wiring harness should be made before connecting a
new component.
1
Disconnect connector (EA and EB) at
the EECU.
No test currently available.

ponent should be made if any of the measurem ents
deviate from the expected values.
1
Disconnect connector (EA and EB) at
the engine electronic control unit
(EECU).
C onnect ju m p e r J-43233 between

EECU's EA (upper) connector and the
w iring harness.
J-43233
3
C onnect the 36-pin breakout box J41132 between the EECU's EB (lower)
connector and the w iring harness.
J-41132
4
tion.
2
C onnect ju m p e r J-43233 between
EECU's EA (upper) connector and the
wiring harness.
J-43233
5
Using ohm m eter J-39200 at the 3 6 pin breakout box, measure resistance
from pin 4 to pin 9.
3
C onnect the 36-pin breakout box J41132 between the EECU's EB (lower)
connector and the w iring harness.
J-41132
Signal Wire:
4
tion.
5
C onnect voltm eter J-39200 to the 36pin breakout box at pin 4 (buffered idle
validation switch) and pin 9 (ground).
Measuring points
Expected value
E B 4 / EB9
0 V (a c c e le ra to r pedal
at idle)
B+ (a c c e le ra to r pedal
abo ve idle)
208
J-39200
Measuring points
Expected value
E B 4 / EB9
2 .9 2 0 % kO
J-39200
Group 28
Troubleshooting
Check of subsystem
C onnect voltm eter J-39200 to the 60pin breakout box and m easure the
voltage.

J-43234
Measuring points
Expected value
P B 17 / PB 22
2
adapter.
Signal Wire:
3
J-39200
a t idle)
9998551
J-43340
B + (a c c e le ra to r pedal
a bo ve idle)
Verification

tion.
209
Group 28
Troubleshooting
MID 144 PPID 70 Pedal Switches, Supply

Voltage supply to pedal switches.
Text M essages


Output supply #3

VCADS Pro Display:

Pedal switches supply
Fault Codes
FMI 4
If the VECU registers a voltage lower than 2.5 V on

the supply wire, the VECU interprets this as a fault
Possible cause:
The supply wire short-circuited to ground.
The signal wire for brakes/clutch short-circuited to

ground.
Signal wire for idle validation switch 1 short-circuited

to ground.
Faulty switch.
Fault code is set.
The cruise control function does not work.
210
Group 28
Troubleshooting
MID 144 PPID 70 Pedal

Switches, Supply, Check
9998551, J-43340, J-41133
5
harness connector and m easure the
voltage.
NOTE!
Expected value
Pin D / a lte rn a te
B+
gro u n d


Pro Tool
27102-8
Measuring points
J-39200
Supply wire, brake pedal switch:

6
tion.
7
C onnect a voltm eter to the wiring harness connector and m easure the
voltage.

test
Measuring points
Expected value
C O M M O N / a lte rn a te
B+
J-39200
gro u n d
27503-8
Cruise control, switch, test
Supply wire, clutch pedal switch:

8

1
end only.
J-4 1 133

tion.
9
C onnect a voltm eter to the wiring harness connector and m easure the
voltage.
Measuring points
Expected value
C O M M O N / a lte rn a te
B+
J-39200
gro u n d
Signal wire, idle validation switch 1:

10
2
Disconnect the connector at the brake
pedal switch (two pin, Com m on-558A
wire and Normal O pen-567B wire).
3
Disconnect the connector at the clutch
pedal switch (two pin, Normal O p e n 571 wire and Common 558B wire).

tion.
11
resistance.
Measuring points
Expected value
Pin C / a lte rn a te
1.2 20% kO
J-39200
gro u n d
Supply wire, idle validation switch 1:
Signal wire, brake pedal switch:
12

tion.

tion.
211
Group 28
Troubleshooting
13
C onnect an ohm m eter to the w iring

resistance.
J-39200
C onnect an ohm m eter to the connecto r and measure the resistance.

Measuring points
Measuring points
Expected value
N o rm a l O p e n / a lte r
1.2 2 0 % kQ
Pin D / Pin C
J-39200
Expected value
O p e n c irc u it (a c c e le ra
to r ped al a t idle)
nate gro u n d
2 0 -9 0 Q (full a c c e le ra
tio n )
Signal wire, clutch pedal switch:

14
Check of the brake pedal switch:

tion.
4
Disconnect the connector at the brake
pedal switch (two pin).
15
C onnect an ohm m eter to the w iring
resistance.
Measuring points
Expected value
N o rm a l O p e n / a lte r
1.2 2 0 % kQ
J-39200
5
tion.
nate gro u n d
C onnect an ohm m eter to the switch

term inals and m easure the resistance.
Wiring harness
Measuring points
16
Group 37.
J-39200
Expected value
C O M M O N / N o rm a l
<1 Q (bra ke ped al not
O pen
d e p re s s e d )
o p e n c irc u it (brake
ped al d e p re s s e d )
Check of component
Check of clutch pedal switch:
Idle validation switch

Brake pedal switch
Clutch pedal switch

in the wiring harness of the VECU. A check of the wiring
Check of idle validation switch 1:

1
pedal harness end only.
2
tion.
212
Disconnect the connector at the clutch

pedal switch (two pin).
8
tion.
9
J-41133

term inals and m easure the resistance.
Measuring points
Expected value
C O M M O N / N o rm a l
<1 Q (c lu tc h pedal not
O pen
d e p re s s e d )
o p e n c irc u it (clutch
ped al d e p re s s e d )
J-39200
Group 28
Troubleshooting
Check of Subsystem
Signal wire, brake pedal switch:

and w iring harness PA/PB.
J-43234

tion.
8
2
9998551
J-43340

Measuring points
PA5 / P A 12
Supply wire:
J-39200
Expected value
B + (bra ke ped al not
d e p re s s e d )
0 V (bra ke ped al d e

tion.
pre sse d )
Signal wire, clutch pedal switch:

4
breakout boxes and m easure the volt
age.
Measuring points
Expected value
P B 19 / PA12
B+
J-39200
9
tion.
10
Measuring points
PA8 / P A 12

tion.
J-39200
Expected value
B + (clutch ped al not
d e p re s s e d )
0 V (c lu tc h ped al d e
pre sse d )
6
breakout box and measure the voltage.
Measuring points
PA23 / P A 12
Expected value
J-39200
Verification
To check that the fault has been corrected, use the test
a t idle)
B + (full a c c e le ra tio n )
213
Group 28
Troubleshooting
MID 144 PPID 71 Cruise Control and Engine Brake, Supply Switch
Voltage supply to the cruise control and exhaust brake control switches. Also voltage
supply to the idle validation switch 3 (on second accelerator pedal), if so equipped
Text M essages


Output supply #4

VCADS Pro Display:

Cruise control and retarder switch supply
Fault Codes
FMI 4

Possible cause:
The supply wire short-circuited to ground.
The signal wire for the cruise control (SET+/SET/R ESU M E/O N ) short-circuited to ground.
The signal wire for the exhaust brake switch

(EPG /VEB) short-circuited to ground.
The signal wire for the idle validation switch 3 shortcircuited to ground.
Fault code is set.
The cruise control does not function.
Exhaust brake does not function.
Idle validation switch 3 does not function.
214
Group 28
Troubleshooting
MID 144 PPID 71 Cruise Con

trol and Engine Brake, Supply
Switch, Check
Supply wire, cruise control switch:

4
tion.

J-41133, J-43340, J-43234
5
and m easure the voltage.
NOTE!

Note: checks concerning VCB only apply to vehicles

equipped with Volvo Com pression Brake.

Pro Tool
27503-8
25336-8
Exhaust brake, switch, test
27104-8

sensor, test
Measuring points
Expected value
Pin A (w ire # 5 9 7 A ) /
B+
J-39200
a lte rn a te gro u n d
Supply wire, exhaust brake switch:

6
tion.
7
Measuring points
Expected value
Pin 1 (w ire # 5 9 7 B ) / a l
B+
J-39200
te rn a te gro u n d
Supply wire, idle validation switch 3

8
tion.
9
J-39200
1
D isconnect the connector at the switch
for the cruise control. M easurem ents
should be taken only on the wiring
harness connector end.
Measuring points
Expected value
B+
g ro u n d
Signal wire, cruise control switch:
2
for the exhaust brake, if the vehicle is
equipped with one. M easurem ents
harness connector end.
10
tion.
3
D isconnect the connector at the second accelerator pedal, if the vehicle is
equipped with one. Install the 5 -p in
w iring harness end only.
J-4 1 133
215
Group 28
Troubleshooting
11
C onnect an ohm m eter to the connecto r and m easure the resistance.
J-39200

Check of the switch for the cruise control:

Measuring points
Expected value
Pin E (w ire # 5 6 3 A ) /
SET+
1.2 2 0 % kQ
Pin G (w ire # 5 6 4 A ) /
SET-
1.2 2 0 % kQ
Pin C (w ire # 5 6 2 A ) /
ON
1.2 2 0 % kQ
Pin H (w ire # 5 6 5 A ) /
RESUME
1.2 2 0 % kQ
1
Disconnect the connector at the switch
for cruise control. M easurem ents
should be taken only on the cruise
control switch connector.
2
tion.
Signal wire, exhaust brake switch:
12
C onnect an ohm m eter to the connecto r pins and m easure the resistance.

tion.
Measuring points
Pin E / Pin A
13
J-39200
Expected value
o p e n c irc u it (S E T + in
a ctive)
J-39200
<1 Q (S E T + active)
Pin H / Pin A
o p e n c irc u it (R E S U M E
Measuring points
Expected value
in active)
<1 Q (R E S U M E active)
Pin 6 (w ire # 6 2 8 ) / a l
EPG
te rn a te g ro u n d
1.2 2 0 % kQ
Pin 5 (w ire # 6 2 9 ) / a l
VCB
te rn a te g ro u n d
1.2 2 0 % kQ
Pin C / Pin A
o p e n c irc u it (O FF )
<1 Q (O N )
<1 Q (R E S U M E active)
Pin G / Pin A
<1 Q (S E T - active)
14
o p e n c irc u it (S E T - in

tion.
a ctive)
Check of the switch for the exhaust brake:

15
Measuring points
Expected value
1.2 2 0 % kQ
J-39200
4
for exhaust brake. Measurem ents
should be taken only on the exhaust
brake switch pins.
gro u n d
Wiring harness:
16
Group 37.
Check of component
Cruise control switch

Exhaust brake switch
Idle validation switch 3

216

tion.
Group 28
Troubleshooting

pins and m easure the resistance.
Measuring points
Pin 1 / Pin 6
J-39200

pins and measure the resistance.
Expected value
Measuring points
Expected value
op e n c irc u it (s w itc h
Pin C / Pin D
o p e n c irc u it
J-39200
(a c c e le ra to r at idle)
O FF)
<1 n (s w itc h positio n 1
- EP G )
2 0 -9 0
<1
tion)
(s w itc h positio n 2
(full a c c e le ra
- VCB)
Pin 1 / Pin 5
op e n c irc u it (sw itch
Check of Subsystem
O FF)
op e n c irc u it (sw itch po
s itio n 1 - EP G )
<1

(s w itc h positio n 2
- VCB)
Check of the idle validation switch 3:

Disconnect the connector at the sec

ond accelerator pedal. Install the 5 -p in
breakout harness J-41133 to the ac
celerator pedal harness end only.
J-43234
9998551
J-43234
J-41133
Supply wire:
3

tion.

tion.
4
Measuring points
Expected value
P B 5 / P A 12
B+
J-39200
217
Group 28
Troubleshooting
Signal wire, cruise control switch:
Signal wire, exhaust brake switch:

tion.

tion.

J-39200

Measuring points
Expected value
Measuring points
Expected value
PA2 / PA12
0 V (S E T + inactive)
PA21 / P A 12
0 V (e x h a u s t brake
sw itc h O FF)
B+ (S E T + active)
PA30 / P A 12
J-39200
B+ (e x h a u s t brake
0 V (R E S U M E in active)
s w itc h pos itio n 1 B+ (R E S U M E active)

PA3 / PA12
EP G )
0 V (c ru is e sw itch
O FF)
s w itc h pos itio n 2 VCB)
B+ (c ru is e sw itch O N)
P A I / PA12
PA20 / P A 12
0 V (S E T - inactive)
s w itc h O F F )
B+ (S E T - active)
PA30 / P A 12
B+ (R E S U M E active)
s w itc h pos itio n 1 EP G )
0 V (R E S U M E in active)
s w itc h pos itio n 2 VCB)

9
tion.
10
Measuring points
Expected value
P B 30 / P A 12
0 V (a c c e le ra to r a t idle)
J-39200
B+ (full a c c e le ra tio n )
Verification
218
Group 28
Troubleshooting
MID 144 PPID 72 Accelerator Pedal, Supply Sensors

The accelerator pedal position sensor is supplied with a reference voltage o f 5.0 V.
Each change o f the accelerator pedal angle controls the input signal to the VECU.
Text M essages


O utput supply #1

VCADS Pro Display:

A ccelerator pedal and retarder sensor supply
Fault Codess
FMI 3
FMI 4
If the VECU registers a voltage higher than 5.5 V on


Possible cause:
Possible cause:
Supply wire short-circuited to higher voltage.
Supply wire short-circuited to ground or lower volt

age.
Fault code is set.
Fault code is set.
Engine does not respond when the accelerator

pedal is depressed.

The engine does not respond w hen the accelerator
pedal is depressed.
219
Group 28
Troubleshooting
MID 144 PPID 72 Accelerator

Pedal, Supply Sensors, Check
9998551, J-43340, J-43234
5
NOTE!


Pro Tool
27102-8

Expected value
Pin A / Pin E
5 .4 2 0 % V
Signal wire:
6
tion.
7
C onnect an ohm m eter to the 5 -p in
breakout harness and m easure the re
sistance.

test

Measuring points
J-39200
Measuring points
Expected value
Pin B / Pin E
100 20% k Q
J-39200
Wiring harness
8
Group 37.
Check of component
1
end only.
J-41133
Accelerator position sensor

Ground wire:
1
Disconnect the connector at the accelerator pedal. Install 5 -p in breakout
pedal harness end only.
2
tion.
J-4 1 133
3
Using ohm m eter J-39200, measure
the resistance from pin E (5 -p in har
ness) to the alternate ground.
Measuring points
Expected value
<1 0
J-39200
2
tion.
3
g ro u n d

tance.
Supply wire:
Measuring points
Expected value
Pin A / Pin E
4 20% kQ

tion.
Pin A / Pin B
220
4 .5 2 0 % kQ (a c c e le r
a to r pedal a t idle)
J-39200
Group 28
Troubleshooting
Check of Subsystem
Supply wire:

J-43234
6
2
adapter.
9998551
J-43340

breakout box and m easure the voltage
from pin PB10 to PB22.
Measuring points
Optim al value
P B 10 / PB 22
5 20% V
J-39200
Ground wire:
Signal wire:
3
tion.
7
tion.
4
breakout box and measure the resis
tance between pin PB22 and the
alternate ground.
J-39200
8
breakout box and m easure the voltage
Measuring points
Optim al value
Measuring points
P B 2 2 / A lte rn a te
<1 0
P B 8 / P B 22
gro u n d
J-39200
Expected value
0 .5 20% V (a c c e le ra
to r ped al at idle)
3 .2 20% V (full a c
ce le ra tio n )
Verification
221
Group 28
Troubleshooting
MID 144 PPID 73 Second Accelerator Pedal, Supply Sensors

The second accelerator pedal position sensor is supplied with a reference voltage of
5.0 V. Each change o f the second accelerator pedal angle controls the input signal to
the VECU.
Note: Applies only to vehicles with a second accelerator

pedal assembly (such as the WX).
Text M essages


Output supply #2

VCADS Pro Display:

Second throttle and w et ta n k sensor supply
Fault Codes
FMI 3
If the VECU registers a voltage higher than 5.5 V on


Possible cause:
Supply wire short-circuited to ground or lower volt

age.
Faulty second accelerator pedal position sensor.
Possible cause:
Supply wire short-circuited to higher voltage.
Fault code is set.
Faulty second accelerator pedal position sensor.
Fault code is set.
Engine does not respond w hen the second acceler

ator pedal is depressed.
The engine does not respond when the second ac

FMI 4
222
Group 28
Troubleshooting
MID 144 PPID 73 Second

Accelerator Pedal, Supply Sen
sors, Check
5

9998551, J-43340, J-43234
Measuring points
Expected value
Pin A / Pin E
5 .4 20% V
J-39200
NOTE!
Read o ff the other fault codes for the VECU.
Signal wire:


Pro Tool
27104-8

tion.
7
C onnect an ohm m eter to the 5 -p in
breakout harness and m easure the re
sistance.
Extra accelerator pedal, switches and

sensor, test
Measuring points
Expected value
Pin B / Pin E
100 20% kO
J-39200
Wiring harness

ponent should also be made if any o f the m easurem ent
1
8
To check the wiring harness, see
Group 37.
Check of component
Second accelerator position sensor
D isconnect the connector at the second accelerator pedal. Install 5-pin

J-4 1 133

Ground wire:
Disconnect the connector at the second accelerator pedal. Install 5 -p in

breakout harness J-41133 to the sec
ond accelerator pedal harness end
only.
2
tion.
3
Using ohm m eter J-39200, m easure
the resistance from pin E (5 -p in har
ness) to the alternate ground.
J-39200
2
tion.
Measuring points
Expected value
<1 0

tance.
gro u n d
J-41133
Supply wire:
Measuring points
Expected value
Pin A / Pin E
4 20% kQ

tion.
Pin A / Pin B
4 .5 20% kQ (a c c e le r
J-39200
a to r ped al a t idle)
223
Group 28
Troubleshooting
Check of Subsystem
Supply wire:

J-43234
6
2
adapter.
9998551
J-43340

Measuring points
Optim al value
P B 26 / P B 23
5 20% V
J-39200
Ground wire:
Signal wire:
3
tion.
7
tion.
4
breakout box and m easure the resis
tance between pin PB23 and the
alternate ground.
J-39200
8
Measuring points
Optim al value
Measuring points
P B 2 3 / A lte rn a te
<1 0
P B 25 / P B 23
g ro u n d
J-39200
Expected value
0 .5 2 0 % V (a c c e le ra
to r ped al a t idle)
3 .2 2 0 % V (full a c
c e le ra tio n )
Verification
224
Group 28
Troubleshooting
MID 144 PPID 75 Range Inhibitor, Solenoid Valve Status

This applies only to vehicles with Volvo transmissions.
Text M essages


Range inhibitor

VCADS Pro Display:

Range inhibitor solenoid valve
Fault Codes
FMI 3
If the VECU registers a voltage higher than 6.5 V

w hen the function is active, the VECU interprets this
as a fault and an fault code is set.
Note: The fault code is set first at the speed when

the inhibitor is to engage at approx 40 km/h (25
mph).
Possible cause:
The wire between the solenoid valve and the VECU
short-circuited to battery voltage (B+).
Faulty solenoid valve.

Fault code is set.

the inhibitor is to be released approxim ately 36

km/h (23 mph).
Possible cause:
The wire between the solenoid valve and the VECU
short-circuited to ground.
Open circuit, wire between solenoid valve and
VECU.
Open circuit, supply wire to solenoid valve.
Faulty solenoid valve.

Fault code is set.

The range inhibitor is not activated or is constantly
active.
The range inhibitor is not activated.
FMI 4
If the VECU registers a voltage lower than 2.3 V

w hen the function is inactive, the VECU interprets
this as a fault and an fault code is set.
Note: The fault code is set first at the speed when

225
Group 28
Troubleshooting
MID 144 PPID 75 Range In

hibitor, Solenoid Valve Status,
Check
J-43340, J-43234, J-42472
NOTE!

Supply wire:
4
tion.
5
C onnect a voltm eter from the breakout
harness term inals to the alternate
ground and m easure the voltage.
Measuring points
Expected value
T e rm in a l 1 (bre akout
B+
J-39200
h a rn e s s ) / a lte rn a te
gro u n d

Pro Tool
N/A
Wiring harness:
6
Group 37.

Check of Component

Disconnect the connector at the range

inhibitor solenoid valve. Install 2 -p in
breakout harness J -4 2 4 7 2 to the
J -4 2 4 7 2
Range Inhibitor Solenoid

Disconnect the connector at the range

inhibitor solenoid valve.
2
Install 2 -p in breakout harness J 42472 between the solenoid valve and
the wiring harness.
Ground wire:
2
tion.
3
tion.
3
C onnect an ohm m eter and m easure
the resistance.
Measuring points
Expected value
T e rm in a l 2 (b re a ko u t
1.5 2 0 % M
h a rn e s s ) / a lte rn a te
g ro u n d
226
J-39200
J-4 2 4 7 2
Group 28
Troubleshooting
Ground the #2 breakout pin to an al

ternate ground. Listen for the range
inhibitor valve to click.

tion.
/ j \ CAUTION

Accidental grounding of pin #1 may blow a fuse or

cause w iring damage.
Check of Subsystem
Expected value
P B 18 / PA12
B+
C o n n e c t a ju m p e r w ire
C lic k a t ra n g e in h ib ito r
fro m P B 18 to an a lte r
so le n o id
nate gro u n d
1
Measuring points
J-39200
J-43234
Verification
2
9998551
J-43340
227
Group 28
Troubleshooting
MID 144 SID 230 Idle Validation Switch 1

Idle validation switch 1 is located at the driver's accelerator pedal assembly.
Text M essages


Idle valid switch

VCADS Pro Display:

Idle validation switch
Fault Codes
FMI 7
Incorrect response from mechanical system.
If the signal from the idle validation switch is not

available, with the accelerator position sensor below
13% travel, the VECU interprets this as a fault and
an fault code is set.
Possible cause:
Incorrect or faulty idle validation switch.
Open circuit in the supply wire.
Open circuit in the signal wire.
The signal wire short-circuited to ground.
The signal wire short-circuited to voltage.
Switch resistance or oxidation.
Fault code is set.
The engine does not respond correctly to

acceleration.
228
Group 28
Troubleshooting
MID 144 SID 230 Idle Validation

Switch 1, Check
J-43340, J-41133, J-43234
5
tance.
NOTE!
Measuring points
Expected value
1.2 20% kO
J-39200
g ro u n d


Pro Tool
Wiring harness
6
To check the wiring harness, refer to
Group 37.
Check of Component
27102-8

test


1
harness J-4 1 133 to the accelerator
pedal harness only.
J -4 1 133
1
D isconnect the connector at the accelerator pedal. Install 5-pin breakout
harness J -4 1 133 to the wiring harness
end only.
J-4 1 133

tion.
3
tance.
Supply wire:
2
Measuring points
Expected value

tion.
Pin C / Pin D
o p e n c irc u it
(a c c e le ra to r at idle)
2 0 -9 0 Q
(full a c c e le ra tio n )

harness pins and measure the voltage.
Measuring points
Expected value
B+
J-39200
gro u n d
Signal wire:
4
tion.
229
Group 28
Troubleshooting
Check of Subsystem


J-43234
Measuring points
Expected value
PA23 / P A 12
2
Signal wire:
3
tion.
230
J-39200
9998551
J-43340
Verification
Group 28
Troubleshooting
MID 144 SID 231 SAE J1939 Control Link

High-speed digital com m unication between different electronic control units takes place
over the J1939 Control Link; this is used to control vehicle operation. If the J1939 Con
trol Link fails, the J1 587/1708 Information Link serves as a back-up control link.
Text Messages

SAE J1939 data link

VCADS Pro Display:

SAE J1939 data link
Fault Codes
FMI 2
If the VECU does not receive confirm ation for the

m essages on the J1939 Control Link, the VECU in
terprets this as a fault and an fault code is set.
Possible cause:
Loose connection.
Open circuit in J1939 Control Link wire.
Fault code is set.
Fault code is set.
FMI 12
Faulty unit or component.
If the expected messages are not available from a

control unit on the J1939 Control Link, the VECU in
Possible cause:
Open circuit in J1939 Control Link wire.

231
Group 28
Troubleshooting
MID 144 SID 231 SAE J1939

Control Link, Check
3
tion.
Other special equipment: J-39200

4
NOTE!

Using a voltmeter, back probe connec

to r PC (Green 5 -p in ) at connectors
PC4 and PC5 with the connector in
stalled in the VECU.
Note: This may require the use of volt

m eter function MIN/MAX.

Pro Tool
Measuring points
Expected value
P C 4 / A lte rn a te gro u n d
2-5 V D C

0-3 V D C
P C 4 / PC 5
0-5 V D C
N/A
Note: The voltage o f the control link

varies and is dependent on the num
ber of electronic control units and
traffic on the control link.
Check of Subsystem
1
tion.
Verification

Using an ohmmeter, back probe connector PC (Green 5 -p in ) at connectors

PC4 and PC5 with the connector in
stalled in the VECU.
Measuring points
Expected value
P C 4 / PC 5
60 10 0
232
J-39200
Group 28
Troubleshooting
MID 144 SID 240 Program Memory

A t startup, a checksum is calculated for the software in the V EC U 's flash memory. This
is compared with the previously stored checksum to verify that the checksum is correct.
Text M essages


Program mem ory

VCADS Pro Display:

Program m mem ory
Fault Codes
FMI 2
If the checksum stored at start up does not agree

with the previously stored checksum, the VECU in
Possible cause:
Internal software fault.
Faulty m em ory circuit.
The VECU continuously restarts.
Yellow lamp is lit by the instrum ent control unit since

the VECU does not respond to the call.
The vehicle can only be run in limp home m ode.
233
Group 28
MID 144 SID 243 Cruise Control Set Switch
Text M essages


CC Set switch

VCADS Pro Display:

CC set switch
Fault Codes
FMI 7
If the VECU receives the signals for SET+ and SETat the same time, the VECU interprets this as a fault
Possible cause:
Faulty switch.
Signal wire short-circuited to voltage.
Fault code is set.
The cruise control function does not work. The

speed cannot be set.
Note: If the speed has been previously set, it can be

resum ed.
234
Troubleshooting
Group 28
Troubleshooting
MID 144 SID 243 Cruise Control

Set Switch, Check
5

J-43340, J-43234
NOTE!
Expected value
W irin g h a rn e s s c o n
1.2 20% kO
n e c to r E / a lte rn a te
g ro u n d


Pro Tool
27503-8
Measuring points
J-39200
RESUME
6
tion.
7
Measuring points
Expected value
1.2 20% kO
J-39200

n e c to r H / a lte rn a te
g ro u n d

ON
8
tion.

harness connector.
Measuring points
Expected value
1.2 20% kO
J-39200
n e c to r C / a lte rn a te
Supply wire:
g ro u n d
SET-

tion.
10
tion.
3
Measuring points
Expected value
B+
n e cto r A / a lte rn a te
gro u n d
J-39200
11
Measuring points
Expected value
1.2 20% kO
J-39200
n e c to r G / a lte rn a te
g ro u n d
Signal wire:
SET+
Wiring harness
12
4
tion.

VNL, VNM Electrical Schematics,
Group 37.
235
Group 28
Troubleshooting
Check of Component
Cruise control set switch

9998551
J-43340

Signal wire:
3
tion.

should be taken only on the cruise
control switch connector.
4
J-39200
2
tion.
Measuring points
PA1 / PA12
Expected value
B+ (O F F and S E T - a c
tive)
0 V (O F F and S E T +
J-39200
a ctive)
0 V (O N and S E T + a c
Measuring points
Expected value
tive)
C ru ise co n tro l sw itch
o p e n c irc u it (S E T + and
0 V (R E S U M E active
c o n n e c to rs E / G
S E T - inactive)
a n d S E T + active)
PA2 / PA12
op e n c irc u it (O N and
B+ (O F F and S E T +
S E T + active)
a ctive)
op e n c irc u it (R E S U M E
0 V (O F F and S E T -
active a n d S E T + a c
a ctive)
tive)
0 V (O N and S E T - a c
tive)
op e n c irc u it (O N and
S E T - active)
0 V (R E S U M E active
a n d S E T - active)
op e n c irc u it (R E S U M E
active a n d S E T - active)
Verification
Check of Subsystem
1
236
J-43234
Group 28
Troubleshooting
MID 144 SID 250 SAE J1587/1708 Information Link

The J1587/1708 Information Link is used to com m unicate gauge information and diag
nostic messages.
High-speed digital com m unication between different electronic control units takes place
over the J1939 Control Link; this is used to control vehicle operation. If the J1939 Con
trol Link fails, the J1587/1708 Information Link serves as a back-up control link.
Text M essages


SAE J1708 data link

VCADS Pro Display:

SAE J1587/1708 data link
Fault Codes
FMI 2
If the VECU registers incorrect messages on the

J1587/1708 Information Link, the VECU interprets
Possible cause:
Several units are sending at the same tim e on the

J1587/1708 Information Link.
Fault code is set.
237
Group 28
Troubleshooting
MID 144 SID 250 SAE

J1587/1708 Information Link,
Check
2
Using a voltmeter, back the probe
connector PC (Green, 5 -p in ) at con
nectors PC1 and PC2 with the
connector installed in the VECU.
J-39200
Note: This may require the use of volt

m eter function MIN/MAX.
NOTE!
Read o ff the other fault codes for the VECU.
Measuring points
Expected value

PC1 / A lte rn a te gro u n d
0-5 V D C
0-5 V D C
PC1 / PC 2
2-5 V D C

Pro Tool
N/A
Note: The voltage of the information

link varies and is dependent on the
num ber o f electronic control units and
traffic on the information link.
Verification
Check of Subsystem
1
tion.
238

Group 28
Troubleshooting
MID 144 SID 253 Data Set Memory EEPROM

A t start-up, a checksum is calculated for the data set in the VEC U 's EEPROM memory.
This is compared with the previously stored checksum to verify that the data set is correct.
Text M essages


Calibration mem ory

VCADS Pro Display:

Calibration m em ory EEPROM
Fault Codes
FMI 2
If the VECU receives an error in calculating the

checksum in the calibration memory, the VECU in
Error when program m ing o f the data sets.
Fault code is set.
Possible cause:
Red lamp lights up.
The m em ory circuit is faulty.
E rror w hen programming.
The vehicle can only be driven in the limp home

m ode.
Fault code is set.
Red lamp lights up.
The vehicle can only be driven in the limp home

m ode.
FMI 13
Values outside calibration values.
If the VECU receives an error when calculating the

checksum s for the data sets, the VECU interprets
Possible cause:
The m em ory circuit is faulty.

239
Group 28
Troubleshooting
MID 144 PSID 3 Idle Validation Switch 3

This applies only to vehicles with a second accelerator pedal assem bly (WX).
Note: Idle validation switch 2 is not used in North Am erican applications.
Text M essages



VCADS Pro Display:

Fault Codes
FMI 7
If the signal from the idle validation switch is not

available with the accelerator position sensor below
13% travel, the VECU interprets this as a fault and
an fault code is set.
Possible cause:
Faulty idle validation switch.
Open circuit in the supply wire.
Open circuit in the signal wire.
The signal wire short-circuited to ground.
The signal wire short-circuited to voltage.
Fault code is set.
The engine does not respond correctly when the

second accelerator pedal is depressed.
240
Group 28
Troubleshooting
MID 144 PSID 3 Idle Validation

Switch 3, Check
Signal wire:
4

J-43340, J-43234, J-41133

tion.
NOTE!


Pro Tool
27104-8

sensor, test


Measuring points
Expected value
1.2 20% kO
J-39200
gro u n d
Wiring harness
6
Group 37.
Check of Component

1
J-4 1 133

breakout harness J-41133 to the ac
celerator pedal harness end only.
Supply wire:

tion.
2
tion.
3
3
J-39200
Measuring points
Pin C / Pin D
Measuring points
Expected value
B+
gro u n d
J-41133
J-39200
Expected value
o p e n c irc u it (a c c e le ra to r a t id le)
2 0 -9 0 Q (full a c c e le ra tio n )
241
Group 28
Troubleshooting
Check of Subsystem


J-43234
Measuring points
Expected value
P B 30 / P A 12
2
C onnect a 60-pin breakout box
adapter.
Signal wire:
3
tion.
242
J-39200
9998551
J-43340
Verification
Group 28
Service Procedures
Service Procedures
2841-03-02-01
Engine ECU, Replacement

1
Note: Make sure that the parking
brake is applied.
2
D isconnect the power with main switch
/ ? \ DANGER
ju ry or death.
/ j \ WARNING
Fuel leaked or spilled onto hot surfaces or electrical
com ponents can cause a fire. Clean up fuel spills im
mediately.
T2014052
Remove the bolts for the cooling coil

on the control unit.
Note: Do not release the fuel lines on

the cooling coil.
6
Remove the control unit's hold-down
bolts (4, see previous illustration ) and
lift o ff the control unit.
7
Install the new control unit.
Note: Make sure that the fram ew ork

line is positioned correctly and that the
mating surface on the engine block is
free from rust.
If the control unit is painted where the
cooling coil is to be installed: Remove
the paint where the cooling coil is in
contact with the control unit to ensure
maximum cooling.
8
Install the cooling coil on the control
unit.
9
Remove the connector from the con
trol unit by pressing the catch and
pushing the handle up.
C heck the clamping force o f the term inal in the connector for the control unit
by means o f gauge 9998482.
10
Cut the clam ps round the cable har

ness under the control unit and fold
away the connector for the control unit.
Install the connector on the control

unit. Make sure that the catch locks on
the connector.
9998482
243
Group 28
11
Clamp the cables under the control
unit.
12
Switch on the power.
Note: When starting the engine with

cab up, make sure that a gear is not
engaged. The parking brake should be
applied.
13
C onduct a function check. Check that
there are no fault codes in the control
unit.
244
Service Procedures
Feedback
One of our objectives is that workshop personnel should have access to correct and
appropriate service manuals where it concerns fault tracing, repairs and maintenance
of Volvo trucks.
In order to maintain the high standards of our literature, your opinions and experience
when using this manual would be greatly appreciated.
If you have any comments or suggestions, make a copy of this page, write down your
comments and send them to us, either via telefax or mailing directly to the address
listed below.
To
From
.........
Dept. 516 Service Publications
.........
7825 National Service Road
.........
P.O. Box 26115
.........
.........
USA
.........
Fax (336) 393-3170
.........
Comments/proposals
Concerns Service Manual:
Operation Numbers
2841-03-02-01
Engine ECU, Replacem ent
243
VOLVO

PV776-TSP144528 (1000) 06.2001 V olvo Trucks North America, Inc., 2001
Service Manual
Trucks
Group
250-610
VOLVO Engine Brake

VE D12, D12A, D12B
PV776-TSP0250610/2
VOLVO
Foreword
signs and m ethods studies carried out up to February 2000.
ence to an V.S.T. (Volvo Standard Times).
eral inform ation and no reference is made to an V.S.T.
D ocum entation:
N o te : Indicates a procedure, practice, or condition that must be followed in order to
cur.

Greensboro, NC USA
O rder num ber: PV776-TSP0250610/2

Contents
G eneral ................................................................................................................... 3
VOLVO Engine Brake (VEB)
.......................................................................... 3
T o o ls ........................................................................................................................ 5
VOLVO Engine Brake, Special Tools ............................................................ 5
O ther special equipm ent ................................................................................. 6
........................................................................................ 7
Engine Brake ...................................................................................................... 7

Exhaust Brake
.................................................................................................. 7
Com pression Brake ........................................................................................ 7

Control Valve (VEB)
C am shaft (VEB)
....................................................................................... 8
.............................................................................................. 9
Exhaust Rocker Arm s (VEB) ...................................................................... 10

Non-Return Valve (VEB) ............................................................................. 10
Rocker Arm Plunger ..................................................................................... 11
Engine Operation
....................................................................................... 11
Com pression Braking ................................................................................ 11

Engine Braking .............................................................................................. 12
Control System, D12 and D12 A
........................................................... 12
Exhaust Brake ............................................................................................. 13

Com pression Brake .................................................................................... 14
Induction Phase
......................................................................................... 14
Decom pression pPhase ............................................................................ 14

............................................................................................... 15
Engine Brake, Fault Tracing
......................................................................... 15
VEB Diagnosis and Troubleshooting ........................................................ 15

Electrical Troubleshooting
.......................................................................... 16
Special tools: J4 1 132 .............................................................................. 16

C onnecting test equipm ent ...................................................................... 16
Voltage m easurem ent
............................................................................... 17
R esistance m easurem ent
........................................................................ 17
Mechanical Troubleshooting ....................................................................... 18

Conditions
.................................................................................................... 18
VEB Troubleshooting, O rder to Follow .................................................... 19

1 ..................................................................................................................... 19
2
..................................................................................................................... 19
..................................................................................................................... 19
..................................................................................................................... 19
VEB Fault Sym ptom s
.................................................................................... 20
Fault sym ptom 1 ......................................................................................... 20

Fault sym ptom 2 ......................................................................................... 20
Fault sym ptom 3 ......................................................................................... 20
Fault sym ptom 4 ......................................................................................... 20
Fault sym ptom 5 ......................................................................................... 20
Fault sym ptom 6 ......................................................................................... 20
Fault sym ptom 7 ......................................................................................... 20
Low Engine Braking Effect (VEB) .............................................................. 21
C heck Before the Test: ................................................................................21
Test Equipment, Installation
...................................................................... 21
Test-driving and M easuring ........................................................................21

Brake Test ...................................................................................................... 22
Evaluation of the Brake Test ..................................................................... 26
Engine Brake, Checking .................................................................................. 27
1
Solenoid Valve, Com pression Brake, Checking ........................................ 29

Exhaust Brake, Electronic Checking
.......................................................... 30
Exhaust Brake, Mechanical Checking ........................................................ 32

Oil Pressure, Com pression Brake, Checking ............................................. 36
Exhaust Temperature, Checking
Rocker Arm Roller, Checking
...................................................................40
.........................................................................46
.......................................................................................... 49
Rocker Arm, Overhaul ......................................................................................49

Solenoid Valve, Com pression Brake, R eplacem ent ................................. 51
Control Valve, Engine Brake, R eplacem ent ............................................... 53
Group 25
General
General
VOLVO Engine Brake (VEB)
Successful troubleshooting of the VOLVO engine brake system requires inform ation re
garding system design and knowledge of how the different com ponents function in
relation to each other.
1
2
Camshaft
Shutter
4
5
Rocker arm
Control valve
Oil pipe
The description, operation and service of the Volvo En

gine Brake is detailed as follows:
The Troubleshooting section is subdivided into E le c tric a l
T ro u b le s h o o tin g and M e ch a n ica l T ro u b le s h o o tin g .
Refer to this information along with the description and
operation inform ation when performing troubleshooting.
Group 25
Tools
Tools
VOLVO Engine Brake, Special Tools
Servicing the Volvo Engine Brake (VEB) requires the following special tools. The tools
are available from the Parts D epartm ent of Volvo Truck North America, Inc. Unless oth
erwise noted, all tool numbers are preceded by 999. Please specify the com plete part
num ber when ordering. Tools with part numbers beginning with J are available only
from Kent-Moore.
9996465
Pressure gauge, O -1O bar (O - 145 psi)
9998338
C onnector for checking oil pressure in the

rocker arm shaft
9812327
M em ory cassette
9989876
Dial indicator
9996716
Drift
9998339
Pressure gauge, 0 - 6 bar (0 - 90 psi)
9996956
9998342
Temperature sensors for measuring ex

haust gas tem perature
9998190
M easuring instrum ent
9998344
Drift, used when changing ball seating in

the rocker arm
9998333
Union, used together with pressure gauge

9996465
9998364
Collation unit for tem perature m easuring
9808001
Bolt
9999696
M agnetic base
Group 25
Tools
W2003381
1
J-38500-1 Pro-Link 9000
J-38500-1000 Cartridge
J-38500-60A Adapter
9510060 Multimeter
Other special equipment

Tools with part numbers beginning with the letter J are available from your local Kent
Moore dealer.
115 9794
999 9708
J 39200
J 41132
W2002195
J-35616-20
Jum per wires
9999708
Torque wrench 0 - 1 7 . 5 Nm ( 0 - 1 5
J-42472
2-pin breakout harness
J - 39200
Fluke 87 digital multim eter
1159794
Torque wrench 10 - 100 Nm

(7.5 - 75 ft-lb)
J - 41132
36-pin breakout box
ft-lb)
G roup 25
Design and Function
Design and Function

Engine Brake
W2000702
1
Camshaft
Control valve
Shutter
Rocker arm
Oil pipe
The Volvo Engine Brake consists of tw o different sys

tems, the e x h a u s t b ra ke and the c o m p re s s io n brake.
In the VEB, both system s operate at the same time.
Exhaust Brake
The exhaust pressure governor includes a shutter,
m ounted in the exhaust side of the turbocharger. This
shutter, which is connected to the exhaust pressure gov
ernor plunger, restricts the exhaust gas flow when
activated. Braking is achieved during the exhaust stroke
by the backpressure created w hen the exhaust gas flow
is blocked.
Compression Brake
The com pression brake controls the opening of exhaust
valves during the engine com pression and combustion
(operating) stroke. This creates backpressure in the
com bustion cham ber which, in turn, has a braking effect.
On engines with com pression brakes, the cam shaft has
tw o extra lobes on each exhaust cam profile. The lift
height of the extra lobes is very low compared to that of
norm al exhaust lobes. To enable the extra lobes to open
the exhaust valves, the exhaust rocker arm s are ar
ranged in a manner which reduces valve clearance
during the braking sequence.
G roup 25
Design and Function
Control Valve (VEB)
T2007789
Fig. 1: Engine in operation, the control valve solenoid valve not activated
T2007788
Fig. 2: V E B engine braking, the control valve solenoid valve activated

8
G roup 25
Design and Function
The control valve is mounted on the cylinder head under

the valve cover and is connected to the oil system ahead
of the rocker arm shaft. Its purpose is to reduce oil pres
sure to the rocker arm s while the engine is operating.
There is always full system oil pressure to the control
valve inlet (1). A pipe connects the inlet to the lube oil
gallery in the cylinder block. Oil pressure to the rocker
arm shaft can be increased by a solenoid valve (2)
mounted on the control valve, from about 100 kPa (14.5
psi) w hile the engine is operating to over 200 kPa (29
psi) during com pression braking.
During engine operation, the springs' force and oil pres
sure in the oil cham ber hold the control valve plunger in
balance. This action reduces oil pressure.
W hen the solenoid valve is activated, the oil cham ber (6)
is drained and the spring (4) presses the plunger (3) to
its end position. The plunger com pletely opens the oil
outlet (5) and the oil pressure to the rocker arm shaft is
increased.
1
T2006835
Fig. 3: Control valve

1
Oil inlet
2
3
Solenoid valve
Plunger
4
5
6
Spring
Oil outlet
Oil chamber
Camshaft (VEB)
On engines with a com pression brake, the cam shaft has
an induction lobe (1) and decom pression lobe (2) in ad
dition to the normal exhaust lobe (3) on each cam profile
for the exhaust valves. The induction and decom pression
lobe lift height is 0.8 mm (0.032 in.) above the basic cir
cle, which is equivalent to about 1.1 mm (0.043 in.) at
the valve bridge. The induction lobe is positioned to
open the exhaust valves at the end of the intake stroke
and hold them open at the beginning of the compression
stroke. The decom pression lobe is positioned to open
the exhaust valves at the end of the com pression stroke.
The valve clearance must be zero for the induction and
decom pression lobes to open the exhaust valves.
2
T2006826
Fig. 4: C am shaft section

1
Induction lobe
Decompression lobe
Exhaust lobe
Group 25
Design and Function
Exhaust Rocker Arms (VEB)

The exhaust rocker arm s on an engine with a com pres
sion brake are larger than those of a conventional
engine.
The rocker arm is equipped with a non-return valve and
a plunger with a pressure-lim iting valve. Its purpose is to
regulate oil flow during com pression braking.
Spring-tab pressure holds the rocker arm at the rest po
sition against the valve bridge.
Valve clearance is greater on an engine w ithout a com
pression brake, as the induction and decom pression
lobes m ust not open the exhaust valves while the engine
is operating.
Shim s are placed on the valve bridge to adjust valves.
N o te : Do not use more than two shim s to obtain proper
valve clearance.
Fig. 5: Exhaust rocker arm

1
Spring tab
Non-return valve
Rocker arm plunger
Shims
Non-Return Valve (VEB)

There is a non-return valve, consisting of a plunger (1),
spring (2) and ball (3) in the rocker arm. W hen oil from
the rocker arm shaft is forced into the valve, the spring
force and the oil pressure determ ine movem ent of the
plunger.
W hen the oil pressure is low, about 100 kPa (14.5 psi),
the control valve is in its engine operating position. Dur
ing this time, the plunger (1) will not move out of its rest
position because the oil pressure cannot overcom e the
spring force. The plunger pin prevents the ball (3) from
seating and the oil can flow freely through the valve in
both directions.
W2000704
Fig. 6: Non-return valve during engine operation

W hen the control valve takes up the position fo r com
pression braking, oil pressure to the non-return valve
increases. The spring force in the non-return valve is
such that w hen the oil pressure exceeds about 200 kPa
(29 psi), it overcom es the spring force and moves the
plunger (1) to w here it no longer controls the ball (3).
The spring (5) forces the ball against its seat and the oil
contained above the plunger (4) cannot flow past the ball
(3). As a result, high oil pressure is form ed above the
plunger (4).
T2006834
Fig. 7: N on-return valve during V E B operation
10
Plunger
Spring
Ball
Rocker arm plunger
Spring
G roup 25
Design and Function
Rocker Arm Plunger

The purpose of the plunger is to zero-set the valve clear
ance during com pression braking.
Engine Operation
W hen the engine is operating, there is reduced oil pres
sure through the control valve to the rocker arm shaft,
and the rocker arm non-return valve (1) is open. Oil can
flow freely through the non-return valve in both direc
tions. Therefore, no oil pressure is built up between the
rocker arm plunger (2) and the rocker arm.
The set valve clearances are great enough to prevent
the cam shaft induction and decom pression lobes from
opening the exhaust valves.
The valve mechanism operates as it w ould on an engine
w ithout a com pression brake. That is, only the exhaust
lobe opens the exhaust valves.
T2006828
Fig. 8: Rocker arm plunger during engine operation

1
Non-return valve
Rocker arm plunger
Compression Braking
During com pression braking, an oil pressure of at least
200 kPa (29 psi) is delivered to the rocker arm shaft as
the control valve does not reduce the oil pressure.
The pressure in the rocker arm non-return valve (1) in
creases enough to move the plunger in the non-return
valve from its rest position, and the ball now functions as
a non-return valve. Pressure builds up between the
rocker arm plunger (2) and the rocker arm. The plunger
moves out and forces the rocker arm roller against the
lobes on the camshaft. The valve clearance is eliminated
and the lift height on the induction and decom pression
lobes is sufficient to open the exhaust valves. The rocker
arm plunger is equipped with a pressure-lim iting valve
(3). W hen oil pressure between the rocker arm plunger
and the rocker arm becomes too high, the pressurelimiting valve opens and oil can exit through the hole in
the bottom of the plunger. The opening pressure of the
pressure-lim iting valve is governed by the force of the
valve spring.
T2006836
Fig. 9: Rocker arm plunger during com pression braking

1
Non-return valve
Rocker arm plunger
Pressure-limiting valve
11
Group 25
Design and Function
Engine Braking
Control System, D12 and D12 A
W ith the com plete release of the accelerator pedal, the
engine brake is activated according to the selection made
on the dash board, but only if certain conditions are met:
A ccelerator pedal must be fully released (fuel injec

tion must not occur).
Engine speed must be greater than 1100 rpm.
Boost pressure must be lower than 150 kPa (22 psi).
C onstant engine speed mode (PTO) must not be

activated.
Engine brake disabled, input must not be activated

(ABS).
Vehicle speed must be greater than 3.2 km/h (2

mph).
Engine tem perature must be higher than the follow

ing:
Part num ber of Tempera

ture Switch
Temperature measured at
outlet of cooling pump
p/n 8155799
4 3 C (110F)
p/n 3985349
6 7 C (158F)
As an additional option, the engine brake may be en

abled autom atically if the vehicle exceeds a specified
cruise control limit. If this option is selected, the engine
brake may be applied at a selectable speed from 6.4 to
32 km/h (4 to 20 mph) above the cruise control set
speed.
12
W2000877
Fig. 10: Engine brake logic schematic, D12 and D12 A.
Group 25
Design and Function
Switches
On the dash the switches for the engine brake have dif
ferent configurations. W ith the tw o dual-position
switches, the brake system is activated by placing one of
the switches in ON position. The HI/LO switch, in the HI
position, selects both the exhaust brake and the com
pression brake (Volvo engine brake or VEB). In the LO
position, only the exhaust brake is selected.
W3002827
Fig. 11: D ual-position switches for Engine brake
The engine brake switches are on som e truck models re

placed by a single three-position switch. As with the
switches above it also regulates the engine brake for the
cruise control.
The three position switch has the following selection:
1
2
3
No engine brake engaged

Exhaust brake, EPG
Exhaust brake and com pression brake
Fig. 12: Three-position switch for engine brake
Exhaust Brake
D uring exhaust braking, control pressure of about 752
kPa (109 psi) activates the exhaust pressure governor.
The exhaust pressure governor plunger is activated and
the shutter connected to the plunger restricts the flow of
exhaust gases out of the cylinders.
Restricting the flow of exhaust gases creates a back
pressure between the shutter and the piston crowns.
This provides a braking effect on the pistons as the ex
haust valves open.
The higher the engine speed during exhaust braking, the
greater the braking effect.
T2006832
13
Group 25
Design and Function
Compression Brake
T he e x h a u s t b ra ke is a lw a ys e n g a g e d w ith th e c o m
p re s s io n b ra ke . This is because the com pression brake
induction phase fully utilizes the backpressure created
by the exhaust brake in the exhaust manifold.
Induction Phase
The induction phase begins at the end of the intake
stroke and continues slightly into the com pression stroke.
The piston travels downward toward bottom dead center
and the cam shaft induction lobe opens the exhaust
valves long enough to fill the cylinder with the backpres
sure created by the exhaust brake in the exhaust
manifold.
W hen the induction lobe closes the exhaust valves, the
cylinder has a backpressure at the start of the com pres
sion stroke. This backpressure increases com pression
considerably during the com pression stroke which, in
turn, creates a powerful braking effect when the piston
moves upward.
Fig. 14: Induction phase
Decompression pPhase
At the end of the com pression stroke, as the piston ap
proaches top dead center, the cam shaft decom pression
lobe opens the exhaust valves and releases the pressure
from the cylinder. Shortly before bottom dead center, the
ordinary exhaust lobe opens the exhaust valves. During
the exhaust stroke, a backpressure is created in the ex
haust manifold. This has a braking effect because the
exhaust pressure governor shutter is closed.
Fig. 15: D ecom pression phase
14
G roup 25
Troubleshooting
Troubleshooting
Engine Brake, Fault Tracing
/ j \ DANGER
wheels. Failure to do so can result in unexpected ve
hicle movem ent and can cause serious personal
injury or death.
/ j \ DANGER
W hen operating a vehicle on streets and highways,
during data collection procedure, it is m andatory to
have a second person drive while a technician col
lects the data.
/ j \ DANGER
can cause serious bodily injury
Basic knowledge of the system description and operation

is necessary to perform the troubleshooting procedures
in this manual. For basic system knowledge, refer to:
S e rv ic e
M a n u a ls
V 7 7 6 -2 0 0 -8 2 0 S M
S p e c ific a t io n s , V E D 1 2
28 4 -6 1 0 , P V 776-TS P 128229
E n g in e C o n t r o l S y s te m , V E D 1 2
VEB Diagnosis and Troubleshoot

ing
The D12 engine is equipped w ith a diagnostic system to
sim plify troubleshooting.
The first step to take w ith all troubleshooting should be
to check w hether the diagnostic system indicates any
fault codes.
If fault codes are present, these should be corrected be
fore proceeding fu rth e r w ith the troubleshooting, even if
the fault codes do not indicate a fault that w ould affect
the engine brake system.
If the tru ck is equipped w ith ABS, verify that information
code 61 is not displayed during the check.
For details about how the fault codes and inform ation
codes are interpreted, refer to:
WARNING
clear of all moving or hot engine parts. A hot engine
can cause serious burns or can perm anently dam age
test equipm ent.
S e rv ic e
M anual
28 0 -6 0 0 , P V776-TS P 105620/1
F a u lt C o d e s , E n g in e E le c t r o n ic C o n t r o l
U n it
/ j \ WARNING
fluids.
/ j \ CAUTION
Always clean the engine before servicing and keep
the com pression brake com ponents clean during all
service and repair procedures. Lack of cleanliness
during service and repair w o rk could result in a fault
or m alfunction o f the com pression brake system.
15
Group 25
Electrical Troubleshooting

Connecting test equipment
1
Make sure that the ignition key is in the O FF posi

tion.
Clean the area around the EECU and harness con

nectors.
D isconnect the EB harness (lower harness). Inspect

the harness for corrosion and dam age to the con
nector housing, terminals, and seal. R epair as
required.
C onnect the 3 6 -p in breakout box to the EB harness

only.
Make sure the harness connectors are properly
pressed together. Do not force connectors together.
N ote: Do n o t connect the breakout box to the
EECU.
16
Troubleshooting
Group 25
Troubleshooting
Voltage measurement
Clutch pedal released
C o n d itio n s :
ABS not activated
Engine running
Engine brake switch in the ON position
Selector switch in the HI position
Vehicle speed greater than 3.2 km/h (2 mph)
Throttle pedal in idle position
S ufficient coolant tem perature, see table page 12.
V o ltag e M ea su re m e n t
36-P in B o x S e le c tio n
PTO not activated
In te n d e d V alue
P ro b a b le C ause
Faulty connection
Engine brake supply (if all

conditions are met)
2:9
Faulty engine brake

switches
B+
Faulty harness
Resistance measurement
C o n d itio n s f o r R e s is ta n c e M e a s u r e m e n ts :
Ignition off
Engine not running
Engine brake switch in the ON position
N ote: V a lu e s in ta b le a p p ly to s o le n o id v a lve w ith

p a rt no 1610563 and 1610567.
For solenoid valves with part numbers 8143014 and
8143018, please refer to:
S e rv ic e
M anual
P V 7 7 6 -2 8 0 -6 0 0 S M
E le c t r o n ic C o n t r o ls , V E D 1 2 , D 1 2 A ,
D 12 B
R e s ista n ce M e a su re m e n t
36-P in B o x S e
le c tio n
In te n d e d
V alue
P ro b a b le C ause
Faulty connection
Faulty harness
Solenoid valve, exhaust brake (engine
brake selector switch in LOW position
2:9
13 - 16 O
Solenoid valve (exhaust brake)

Faulty exhaust brake
Faulty engine brake switches
Faulty connection
Solenoid valve exhaust brake and

com pression brake (engine brake se
lector in HI position)
Faulty harness
2:9
7.5 - 9.5 O
Solenoid valve (com pression brake)

Faulty engine brake switches
Faulty VEB coolant tem perature switch
N ote: If the m ultim eter shows 2 0 -2 2 0 when the engine

brake select switch is in the HI position, the exhaust
brake solenoid valve is damaged.
17
Group 25
Mechanical Troubleshooting
Conditions
The electrical troubleshooting has been carried out,

or any possible faults in the electrical system can be
com pletely eliminated.
The truck has full pressure [827 kPa (120 psi)] in
the air system.
The engine has norm al oil pressure.
The engine coolant tem perature is at operating tem
perature.
C a rry o u t th e te s ts o n th e e x h a u s t b ra ke and c o m
p re s s io n bra ke in n u m e ric a l o rd e r a c c o rd in g to th e
abo ve d ia g ra m , w h e n e ith e r o n e o f th e b ra ke s y s
te m s d o e s n o t w o rk.
If b o th b ra ke s y s te m s w o rk , b u t g iv e p o o r b ra k in g e f
fe c t, see L o w E n g in e B ra k in g E ffe c t (V E B ) page 21.
18
Troubleshooting
S e rv ic e p ro c e d u re s n o t c o n ta in e d in th is in fo rm a
tio n are to be fo u n d in th e s e rv ic e in fo rm a tio n fo r
th e VOLVO D12 e n g in e u n d e r th e re s p e c tiv e g ro u p .
Group 25
Troubleshooting
VEB Troubleshooting, Order to

Follow
If the fault remains after correcting any indicated fault
codes, and the engine and electrical system function
normally, troubleshooting should be performed in the fol
lowing order:
1
Begin troubleshooting by attem pting to establish which of
the brake system s is faulty (exhaust brake, compression
brake, or both systems).
2
Verify that the following preconditions for e x h a u s t b ra k
in g are satisfied, with the switch(es) on the instrum ent
panel in the O N /LO W (exhaust brake only) positions.
A ccelerator pedal position at 0% (idle position)

Clutch pedal not depressed
Engine speed should be greater than 1100 RPM
PTO not activated
Vehicle speed should be greater than
3 km/h (2 mph).
A nti-lock Braking System (ABS) not activated.
Boost pressure less than 150 kPa (22 psi).
N ote: The exhaust brake will engage only w hen all of

these preconditions are satisfied.
N ote: W hen the exhaust pressure governor (EPG) is ac
tivated in conjunction with starting, running the engine
warm, and keeping the engine warm, other preconditions
apply.
3
Verify that the following preconditions for V EB (e x h a u s t
b ra k in g and c o m p re s s io n b ra k in g ) are satisfied, with
the switches on the instrum ent panel in the ON/HI (ex
haust brake and com pression brake, VEB) positions.
A ccelerator pedal position at 0% (idle position)

Clutch pedal not depressed
Engine speed should be over 1100 RPM
PTO not activated
Vehicle speed should be greater than 3 km/h
(2 mph).
A nti-lock Braking System (ABS) not activated.
The coolant tem perature should be over 43 C
(110F), otherwise only the exhaust brake will be
engaged.
Boost pressure less than 150 kPa (22 psi).
N ote: An additional option is to have the VEB enable au

tom atically if the vehicle exceeds a specified cruise
control limit. If this option is selected, the VEB will auto
m atically engage at a selectable speed approxim ately
6.4 to 32 km/h (4 to 20 mph) above the set cruise con
trol speed.
4
A lw a y s be g in w ith e le c tric a l tro u b le s h o o tin g , u n le s s
a fa u lt in th e e le c tric a l s y s te m ca n be c o m p le te ly
ru le d o u t.
19
G roup 25
VEB Fault Symptoms
Troubleshooting
Fault symptom 5
P o o r b ra k in g e ffe c t fro m th e e x h a u s t b ra ke
Fault symptom 1
Probable fault:
T h e e n g in e w ill n o t s ta rt
Probable fault:
The control valve plunger may be stuck in its rest

position. If this is the case, oil is fed to the rocker
arm shaft with full pressure and the plungers in the
rocker arm shafts will be pressed out. This will elim i
nate the valve clearance and the decom pression
lobes will open the exhaust valves. This impairs the
com pression build-up and the engine cannot start.
Carry out mechanical troubleshooting.
Fault symptom 2
N e ith e r th e e x h a u s t b ra k e n o r th e c o m p re s s io n
b ra ke fu n c tio n s
This indicates a fault in the electrical system . The control
signal is not reaching the exhaust pressure governor and
the control valve solenoid valves.
Low control pressure supplied to the EPG

Leaks in the exhaust manifold gaskets
Exhaust pressure governor seizing
Defective or leaking exhaust pressure governor
Fault symptom 6
P o o r b ra k in g e ffe c t fro m th e e n g in e b ra ke (e x h a u s t
b ra ke a n d c o m p re s s io n b ra ke )
Probable fault:
Low control pressure supplied to the EPG

The control valve gives too low oil pressure
Defective non-return valve in one or more of the
rocker arm s
Defective pressure limiting valve in one or more of
the rocker arm plungers
The exhaust brake functions poorly or not at all
Exhaust valve clearance is too large
Carry out electrical troubleshooting.
Fault symptom 3
T h e e x h a u s t b ra ke fu n c tio n s , b u t n o t th e c o m p re s
s io n b ra ke
Probable fault:
No control signal to the com pression brake control

valve
Defective tem perature sensor or diode
Defective control valve or control valve plunger stuck
No ground at coolant tem perature switch
Drain channel is clogged

If the fault remains:
Fault symptom 4
T h e c o m p re s s io n b ra ke fu n c tio n s , b u t n o t th e e x
h a u s t bra ke
Probable fault:
No or low air pressure supplied to the EPG

No control signal to the exhaust pressure governor
solenoid valve
Defective solenoid valve
Defective exhaust pressure governor
Defective quick-release valve
A ir leakage
See the procedures in Low Engine Braking Effect

(VEB) page 21.
Fault symptom 7
T h e c o m p re s s io n b ra k e e n g a g e s b u t w ill n o t d is e n
gage
If the com pression brake rem ains engaged with full ef
fect even though the accelerator pedal is depressed, this
is due to the control valve plunger rem aining in th e VEB
positionand directing full system oil pressure out to the
rocker arms.
/ j \ DANGER
Do not depress the clutch pedal unless necessary.
Engine may stop if com pression brake stays engaged.
This will result in loss of power steering assistance.
If the com pression brake only partly disengages, it is
most probable that one o f the rocker arm plungers has
locked in its outer position. W ith this fault, the engine
runs unevenly due to low com pression pressure in the
cylinder w here the rocker arm plunger has stuck.
The fault generates one o f the fault codes 3 1 -3 6 , as the
control unit com pensates for the loss o f power in the
cylinder by increasing the am ount o f fuel delivered to the
cylinder through the unit injector. W hen the maximum
am ount o f fuel delivered by the unit injector can not com
pensate for the loss of power in the cylinder, the fault
code is generated.
C arry out mechanical troubleshooting.
If the fault remains:

N ote: Fault codes 3 1 -3 6 can also be generated by an

electrical fault in the fuel system.
20
G roup 25
Troubleshooting
Low Engine Braking Effect (VEB)
Test-driving and Measuring
N ote: Before carrying out the following procedure, read

the troubleshooting general inform ation in Engine Brake,
Fault Tracing page 15.
To obtain good test results, the exhaust pressure gover

nor should be disabled when checking the function of
the com pression brake.
Check Before the Test:
That the conditions for exhaust braking and com

pression braking are satisfied.
That the general condition of the engine is good.
That the engine has normal oil pressure.
That both the engine brake system s are functioning.
C heck that both the exhaust brake and engine brake are
functioning by test-driving the truck.
Set the engine brake switch to OFF.
Drive the truck downhill, fully release the accelerator

pedal and set the switches to O N /LO W positions.
If the engine sound does not alter and/or there is no
braking effect, the exhaust brake does not function.
If the engine sound changes and there is a notice
able braking effect, the exhaust brake does function.
Set the switches to ON/HI positions.
If no difference can be noted in the sound or in the

braking effect, the com pression brake does not
function.
If the engine sound changes and there is a notice

able braking effect, the com pression brake does
function.
C heck that the valve clearances are within the tolerance

range.
Test Equipment, Installation

1
Install the equipm ent for measuring the oil pressure in

the rocker arm shaft according to the instructions in Oil
Pressure, C om pression Brake, C hecking page 36.
2
Set the control switches to the OFF position (VEB dis
abled). S tart the engine and m easure the rocker arm
shaft oil pressure. The pressure should be approxim ately
1 bar (14.5 psi).
If the pressure fluctuates or is under 0.5 bar (7.25 psi) or
over 1.5 bar (21.75 psi), the control valve is faulty.
N ote: Low oil pressure in the rocker arm shaft may also
be due to excessive w ear in the rocker arm bushings and
/o r the rocker arm s which result in excessive oil pressure
loss. See Rocker Arm Roller, C hecking page 46.
3
Install the equipm ent for measuring the exhaust gas
tem perature, including the 36-pin breakout box. See
Exhaust Temperature, C hecking page 40.
Route the 36-pin breakout box into the cab and se

cure.
M ake sure the engine brake switch is OFF.
Bridge term inals 2 and 11 of the 36-pin breakout

box.
/ f \ DANGER
W hen term inals 2 and 11 of the 36-pin breakout box
are bridged, the com pression brake will activate any
tim e the VEB control switch is in the ON position,
regardless of status. The com pression brake will re
main ON until the control switch is moved to the OFF
position. W hile the engine brake is activated, do not
depress the accelerator or clutch. If the accelerator is
depressed, engine dam age may result. If the clutch is
depressed a loss o f power steering assist may occur.
Be prepared to switch off the engine brake at any time.
Failure to do so may result in personal injury or death.
/ f \ DANGER
W hen operating a vehicle on streets and highways,
during data collection procedure, it is m andatory to
have a second person drive w hile a technician col
lects the data.
W hen engine braking, the exhaust gas tem perature in
creases on those cylinders w here the com pression brake
functions.
On the cylinder(s) w here there is little or no braking ef
fect there is very little exhaust gas tem perature increase,
thus, the cylinder which gives a very low or no braking
effect can be identified.
N ote: The tem perature difference between cylinders is
not im portant when performing this test. Only note the
difference in tem perature at the beginning and end of the
engine braking function o n each in d iv id u a l c y lin d e r.
For the m easurem ent to be valid, select gears, speed
and section of road w here the braking procedures can
be carried out continuously and w ithout interruption.
S elect a long, at least 1.2 mile (2 km), downhill section
o f road, w here the engine braking procedures can be
carried out w ithout reducing the speed o f the truck.
The truck should be loaded and the road conditions
clear.
Make sure that the engine brake switch(es) on the in

strum ent panel are in the OFF position, until ready to
perform the test at the test location.
21
Group 25
Troubleshooting
Voltage supply to the m easuring instrum ent is provided

by the cigarette lighter socket and the purpose of the in
strum ent back-up mode is to prevent s to re d inform ation
being lost if the external voltage supply is tem porarily
broken.
W hen the external voltage supply is broken, the display

lighting goes out and the text begins to flash. If this oc
curs during measuring, the stored values are retained
and the m easurem ent procedure can continue when the
instrum ent voltage supply is restored.
The instrum ent can store 10 m easurem ent values.
The first m easurem ent value is stored as value A, the
second m easurem ent value is stored as value B, the
third as value C etc.
The instrum ent can also calculate the difference between
two m easurem ent values, for exam ple B - A, D - C, etc.
N ote: It is not possible to carry out m easurem ents or
store m easurem ent values when the instrum ent is in the
back-up mode.
Brake Test
XXX XXX XXX XXX XXX XXX

T2008019
Press
one more time.
The display should now show six tem perature values,
one for each cylinder, with no. 1 cylinder shown on the
extreme left of the display.
The instrum ent will now measure tem perature continu
ously.
4
i
Accelerate the truck and select a gear that enables you
to hold a stable engine speed of approxim ately 1400
RPM when the accelerator pedal is com pletely released
(idle position).
(Use the service brakes as an aid in holding a stable en
gine speed, as this procedure is to be perform ed with
the engine brake OFF.)
T2008010
Check that the m easurem ent instrum ent display shows

the text T e m p e r a t u r e .
TEMP.DISPLAY
T2008011
Press i c once.
The display should now show the text T e m p . D i s p l a y .
22
Group 25
Troubleshooting
C om pletely release the accelerator pedal (idle posi

tion).
W hile viewing the m easurem ent instrum ent, w ait for

the exhaust gas tem perature to drop and begin to
stabilize.
Press i c once.
The m easurem ent value designation A is shown for

approxim ately 1 second on the display and is a confir
mation that the value is registered and stored.
View the m easurem ent instrum ent, w ait for the tem
perature to rise and begin to stabilize.
Press i c once.
The m easurem ent value designation B is shown for

approxim ately 1 second on the display and is a confir
mation that the value is registered and stored.
The m easurem ent instrum ent then returns autom atically
to continuous m easurement.
The m easurem ent instrum ent then returns autom atically

to continuous m easurem ent and shows six m easure
m ent values, one for each cylinder.
C arry out the brake test and m easurem ents at least

three tim es to obtain a valid result.
N ote: R em em ber the engine brake will remain active un

til switched OFF.
/ j \ DANGER
depressed a loss of power steering assist may occur.
Be prepared to switch o ff the engine brake at any time.
Store the m easurem ent values by pressing * .

The instrum ent can store 10 m easurem ent values (the
results from 5 m easurem ents of Low / High tem pera
tures per cylinder).
Set the engine brake switches to ON/HI. Read the rocker

arm shaft oil pressure on the pressure gauge when the
pressure has stabilized.
Note the value.
23
Group 25
Troubleshooting
10
TEMP.DISPLAY
xx x m
x x x xxx x x x xx x
T2008011
W hen a sufficient num ber of m easurem ents have been

carried out, set the engine brake switch(es) to the OFF
position and remove the bridge between term inals 2 and
11 at the 36-pin connector.
Hold ^ pressed in (approxim ately 2 seconds) until the
text T e m p . D i s p l a y is shown on the display.
Press
and the first stored m easurem ent value is dis
played. The identification letter A appears before the
m easurem ent value.
By pressing ^
or
values on the display.
^ it is possible to view all the
9
By pressing ^ again, the m easurem ent value stored af
ter the letter B is displayed.
the display.
24
Group 25
Troubleshooting
ii
13
The results from the third, and if necessary, the fourth
and fifth m easurem ents are produced in the same way
as with m easurem ents one and two.
By pressing * , it is possible to move between 10 m ea
surem ent values and 5 differences.
14
Note the m easurem ent results and rem em ber that a fully
charged back-up battery retains the stored m easurem ent
values in the instrum ent for m ax. 20 m in u te s after the
external voltage supply has been broken. If possible, do
not break the voltage supply to the instrum ent before all
the m easurem ent results have been noted.
B-fi x x x xx x x x x xxx
T2008022
By pressing * again, the difference between m easure

m ent values B and A is shown.
By pressing ^
or
values on the display.
15
^ it is possible to view all the
N ote: If the first m easurem ent value is greater than the

second, the difference between the values will be shown
as a minus value on the display.
TEMP. EURLUOTION
i2
T2008015
Hold ^ pressed in (approx. 2 seconds), when all measurem*ent results have been noted, until the text T e m p .
E v a l u a t i o n is shown on the display.
16
C XXX XXX XXX XXX XXX XXX
Press
once.
The first stored value from the second m easurem ent

(value C) is shown on the display.
By pressing
one more time, the m easurem ent value
stored after the letter D is displayed.
By pressing ^ again, the difference between m easure
m ent values D and C is shown.
Press
until the display shows the text T e m p . D i s -
p la y .
25
Group 25
Troubleshooting
Evaluation of the Brake Test
17
W hen the switch(es) are moved from position OFF to po

sitions ON/HI, the oil pressure in the rocker arm shaft
should rise to min. 2 bar (29 psi).
If the oil pressure does not exceed 2 bar (29 psi), the
control valve is faulty.
N ote: Low oil pressure in the rocker arm shaft may also
be due to excessive w e a r in the rocker arm bushing
and/or rocker arm s w hich result in excessive oil pressure
loss. See "Rocker A rm Roller, C hecking page 46.
T2008024
By holding ^ pressed in for approxim ately 2 seconds

until the display shows the text T e m p e r a t u r e , the instru
m ent leaves the back-up mode and all th e s to re d
m e a s u re m e n t v a lu e s are cleared.
N ote: M ake s u re th a t th e v a lu e s are n o te d be fo re
th e in s tru m e n t is s e t in p o s itio n T e m p e r a t u r e .
18
Disconnect the electrical plug for the external voltage
supply.
N ote: Switch the instrum ent off by holding * pressed in
for approx. 2 seconds w hen the display shows the text
T e m p . E v a l u a t i o n or T e m p . D i s p l a y , after the external
supply contact has been broken.
Do not leave the instrum ent in battery back-up mode.
The battery will discharge very quickly if the external
voltage supply is broken and the instrum ent has to rely
on battery back-up.
19
Evaluate the test.
The tem perature increase for each individual cylinder

should be between 90C and 1 3 0 C (194F and 266F)
in order to be certain that the com pression brake on
each cylinder is functioning properly.
If there is no tem perature increase, or if the tem perature
increase is less than 80C (176F) on any individual
cylinder, the com pression brake on that cylinder is not
functioning properly.
If the result of a test is not clear, the test must be
repeated. A t least three tests should be carried out in or
der to obtain valid results.
The measured exhaust gas tem perature varies between
the cylinders, depending on the position of the cylinders.
The cylinders that are positioned nearest the tur
bocharger will have a higher measured value than those
at either end o f the cylinder block. This is due to the
tem perature sensors also being influenced by the pass
ing air flow from the cylinders furthest away from the
exhaust manifold outlet.
W hen evaluating the test, this point should also be taken
into consideration.
F o r example, w hen com paring cylinders 1 and 6, the
tem perature increase should more or less be the same,
providing that the com pression brake is functioning prop
erly on both cylinders.
The same com parison can be made between cylinders 2
and 5 and cylinders 3 and 4.
It should be pointed out that it requires repeated brake
testing to be able to obtain an indication that the braking
effect on a cylinder is reduced.
In instances where there is no braking effect on a cylin
der, there is also no reference to com pare an equivalent
cylinder with.
The less the braking effect is reduced on a cylinder, the
greater the difficulty in identifying the cylinder.
26
Group 25
Troubleshooting
2531-06-02-01
Engine Brake, Checking
/ j \ DANGER
injury or death.
/ j \ WARNING
clear of all moving o r hot engine parts. A hot engine
can cause serious burns or can perm anently damage
test equipm ent.
Special tools: J-39200 Fluke 87 Multimeter

Measurem ent 1
3
Set M ultim eter to measure A m p s and
connect it to term inals 2 and 11 on the
3 6 -p in breakout box. This supplies
battery voltage and measures current
draw to the brake circuit (exhaust
brake only).
4
An audible click should be heard
from the exhaust brake solenoid valve
when the m ultim eter is connected.
5
If no click is heard from the exhaust
brake solenoid valve, and the exhaust
brake m easurem ent 1 results were
OK, replace the HI/LO switch. O ther
wise, proceed to step 6.
6
D isconnect the connector on the ex
haust brake solenoid valve.
7
Bridge term inals 3 and 10 on the
breakout box.
8
S et M ultim eter to measure A m p s and
3 6 -p in breakout box.
9
A faint click should be heard from the
com pression brake solenoid valve
w hen the m ultim eter is connected.
W2002218
Move the switch(es) on the instrum ent

panel to ON/HI (exhaust brake and
com pression brake, VEB) positions.
2
breakout box. Doing so energizes the
EECU pow er supply relay by providing
a ground to the coil side o f the relay.
N ote: C oolant tem perature should be

above 43C (110F), otherwise VEB
coolant switch must have a ju m p e r
wire installed.
10
The m ultim eter should show 0.525
A m p.
11
If no click is heard from the com pres
sion brake solenoid valve, or if the
m ultim eter does not show the value
0.525 Amp, carry out M e a s u re m e n t 2.
27
Group 25
Measurement 2
Troubleshooting
Measurement 4
Bridge term inals 2 and 11 on the 3 6 pin breakout box.
Set M ultim eter to measure Voltage.
2
2
D isconnect the 2-pin connector at the
exhaust brake solenoid valve and con
nect the J -4 2 4 7 2 breakout harness
between the solenoid valve and the
wiring harness.
3
Set m ultim eter to m easure V o lta g e
and connect it to pins 1 and 2 on the
com pression brake connector at the
upper timing gear cover.
In te n d e d va lu e : B+
4
If the intended value is correct, re
move the valve cover and carry out
M e a su re m e n t 3.
5
If the intended value is not correct,
carry out M e a su re m e n t 4.
Measurement 3
1
Set m ultim eter to m easure O h m [S I).
2
M easure between 1 and 2 on the com
pression brake solenoid valve.
In te n d e d va lu e : 20 2 O
3
If the intended value is correct, check
the cables between the compression
brake solenoid valve and the connec
to r at the upper tim ing gear cover.
4
If the intended value is not correct, re
place the com pression brake solenoid
valve.
28
M easure between alternate ground

and pin 1 in the connector for the con
trol valve solenoid valve at the upper
tim ing gear cover.
In te n d e d v a lu e : B+
3
If the value is not correct, check the
wire to pin 1 in the connector for the
control valve at the upper timing gear
cover and to pin 2 at the EB connector
including the engine brake switch(es).
Make repairs and retest.
4
If the value is correct, m easure be
tween alternate battery supply and pin
2 in the connector for the control valve
solenoid at the upper timing gear
cover.
5
If the value is correct, clean and in
spect both pins and sockets at the
connector for the control valve sole
noid. R epeat m easurem ent 1.
6
If the value is not correct, check the
wire from pin 2 in the connector for the
control valve at the upper timing gear
c o v e rto its ground location, including
com pression brake coolant tem pera
ture switch.
Group 25
Troubleshooting
2533-06-02-01
Solenoid Valve, Compression
Brake, Checking
Test 1
1
/ j \ DANGER
hicle m ovem ent and can cause serious personal
injury or death.
/ f \ DANGER
T2007704
Rem ove the valve cover and check

that the plugs in the front and rear end
of the rocker arm shaft are in position.
/ ? \ WARNING
test equipm ent.
/K
WARNING

fluids.
the troubleshooting general inform ation in "Engine Brake,
Special tools: 9998338, 9998339
T2007740
Rem ove the control solenoid valve and

check that the drain holes in the sole
noid valve are not clogged.
3
C heck that the drain channel in the
control valve is not clogged.
4
C heck that the valve clearances are
w ithin tolerance.
29
Group 25
Troubleshooting
2531-06-02-02
Exhaust Brake, Electronic
Checking
Test 2
1

Special tools: J-3920 Fluke 87 Multimeter
W2002231
Install the equipm ent for m easuring

the oil pressure in the rocker a rm shaft
according to the instructions in Oil
Pressure, Com pression Brake, C heck
ing page 36.
W2002218
2
Test-drive the vehicle and allow it to
reach operating tem perature.
3
Activate the engine brake by making
sure the sw itch(es) on the instrum ent
panel are in the ON/HI position and
the conditions for engine braking are
satisfied.
4
W hen the oil pressure has stabilized
record the gauge reading during en
gine brake operation.
The pressure should be a t le a s t 2 b a r
(29 psi).
5
R epeat the test a num ber of tim es to
confirm the m easurem ent reading.
6
R eplace the control valve if the m ea
sured pressure is below 2 b a r (29 p si)
and the rocker arms, nozzles for lubri
cating the ball sockets, bushings and
other com ponents on the rocker arm
bridge are not damaged.
30
Measurement 1
1
Move the switch(es) on the instrum ent
panel to O N /LO W (exhaust brake only)
positions.
2
breakout box. Doing so energizes the
EECU pow er supply relay by providing
a ground to the coil side o f the relay.
3
Set M ultim eter to m easure A m p s and
3 6 -p in breakout box. This supplies
battery voltage and measures current
draw to the brake circuit (exhaust
brake only).
4
An audible click should be heard
from the exhaust brake solenoid valve
when the m ultim eter is connected.
5
The m ultim eter should show 0.7 0.1
A m p.
Group 25
Troubleshooting
6
If no click is heard from the exhaust
brake solenoid valve, or if the m ultim e
te r does not show the value 0.7 0.1
Amp, proceed to the next m easure
ment.
4
check the wire between pin 1 in the
connector for the exhaust brake sole
noid valve and pin 2 at connector EB,
including the engine brake switch(es).
Measurement 2
Measurement 4
Bridge term inals 2 and 11 on the 3 6 pin breakout box in addition to the
connections in m easurem ent 1.
N ote: A functional diode allows cur

rent to flow in one direction only.
C onnect the J-42472 2-pin breakout
harness to the exhaust brake solenoid
only.
2
D isconnect the 2-pin connector at the
exhaust brake solenoid valve and con
nect the J -4 2 4 7 2 breakout harness
between the solenoid valve and the
w iring harness.
N ote: Do not connect to the engine

harness.
2
Select the diode test on the Fluke 87
or equivalent multimeter.
3
Set m ultim eter to measure Voltage.
M easure between pins 1 and 2 on the
breakout harness. In te n d e d v a lu e : B+
(b a tte ry p o s itiv e v o lta g e ~12V).
4
If the intended value is correct, replace
the exhaust brake solenoid valve.
5
carry out M e a s u re m e n t 3.
Measurement 3
1
3
Touch the red probe to the positive
side of the diode (pin 1 o f the J-42472
breakout harness) and the black probe
to the negative side of the diode (pin 2
o f the breakout harness).
4
If the diode is good, the voltage drop
should typically be 0.5 V to 0.8 V.
5
Reverse the probes and m easure the
voltage across the diode again. If the
diode is good, the display will show
O L (overload).
Set m ultim eter to measure Voltage.
6
2
M easure between alternate ground
and pin 1 in the breakout harness.
3
If the intended value is correct, check
the cable from pin 2 in the connector
for the exhaust brake solenoid valve to
ground.
If the display shows 0.00 in both direc

tions, the diode is shorted. If the
display shows O L in both directions,
the diode is open. Replace the
solenoid. See Solenoid Valve, C om
pression Brake, R eplacem ent page
51.
31
Group 25
Troubleshooting
2531-06-02-03
Exhaust Brake, Mechanical
Checking
/ \ DANGER
injury or death.
2
Verify correct air regulator valve is
used with the proper system. The ex
haust brake requires the 7.5 bar
regulator, while the EPG utilizes a 2.3
bar regulator.
/ j \ WARNING
clear of all moving o r hot engine parts. A hot engine
test equipm ent.
/ j \ WARNING
W2002198
VN solenoid location other vehicles have

fluids.
Special tools: 9996465, 9998333

Test 1
solenoids located on bulkhead
C onnect the J-4 2 4 7 2 2-pin breakout

harness to the exhaust brake solenoid
valve, using 2 ju m p e r w ires with
alligator type ends, supply the sole
noid with an alternate ground and B+
and listen to hear if the exhaust pres
sure governor shutter moves.
N ote: Make sure that pin 1 of the J 42472 is connected to B+ and pin 2 is
connected to B-.
W2002234
1 EPG solenoid (cold mode)
2 Exhaust brake solenoid
Verify proper w iring to solenoids. W ire

628 to the exhaust brake solenoid and
wire 636k to the exhaust pressure
governor (EPG) solenoid.
32
T2007700
If the exhaust pressure governor shut

te r moves, carry out test 3.
Group 25
Troubleshooting
Test 2
1
C heck that the air hoses are not
twisted or blocked.
R eplace dam aged hoses.
T2007701
If the exhaust pressure governor shut

ter does not move, remove the air
hose from the exhaust pressure gover
nor and activate the exhaust brake
solenoid valve again.
6
If no air com es out of the hose, carry
out T est 2.
If air com es out of the hose, carry out
T est 3.
release valve and activate the exhaust

brake solenoid valve.
If air com es from the hose, the quick
release valve is faulty and should be
replaced.
3
If no air com es out of the hose, check
that air reaches the exhaust brake so
lenoid valve.
If air reaches the exhaust brake sole
noid valve, the valve is faulty and
should be replaced.
4
If no air reaches the exhaust brake so
lenoid valve, check that air reaches the
regulator valve fo r the exhaust brake
solenoid. If no air reaches the air reg
ulator valve, check or replace the air
supply hose. If air reaches the air reg
ulator valve, then the air regulator
valve is faulty and should be replaced.
33
Group 25
Troubleshooting
Test 3
Test 4
1
Check that the hoses are not twisted
or blocked.
Replace dam aged hoses.
999 6465
999 8333
C onnect the pressure gauge to the exhaust pressure governor hose and
activate the exhaust brake solenoid
valve.
N o te : The pressure in the hose should
be 7.5 0.3 bars (109 4.4 psi).
2
If the
carry
If the
carry
pressure is too high or too low,

out Test 4.
pressure is within the tolerances,
out Test 5.
999 6465
999 8333
W2002211
1 EPG solenoid (cold mode)
2 Exhaust brake solenoid
Solenoids are located on the bulkhead; VN vehicles
have solenoids mounted on the engine
Rem ove the hose from the exhaust

brake solenoid valve and m easure the
output pressure. The pressure should
be 7.5 0.3 b ars (109 4.4 psi).
/ f \ DANGER
system pressure has been depleted. Failure to deplete
system pressure before disconnecting hoses or com
ponents m ay result in their violent separation and can
cause serious bodily injury.
3
If the pressure is within the tolerances,
the quick release valve is faulty and
should be replaced.
34
Group 25
Troubleshooting
Test 5
1
Rem ove the exhaust pipe from the
shutter housing.
W2002212
If the pressure is too high, go to step 4.

If the pressure is too low, go to step 5.
N ote: Trucks with a higher system
pressure than 7.5 bar (109 psi) are
equipped with an adjustable reduction
valve to reduce the pressure to the ex
haust pressure governor.
5
A djust the valve setting to specified
pressure. If pressure will not respond
to adjustm ent, replace regulator. A fter
adjustm ent, the knob on the valve
should be sealed or made tam per
proof.
6
Check the outlet pressure of the regu
lator going to the exhaust brake
solenoid.
In te n d e d va lu e : 752 30 kPa (109
4.4 psi)
7
Pressure OK:
Restriction in line from regulator

valve to exhaust brake solenoid.
(VN series)
Faulty solenoid.
W2002189
M easure the opening between the

shutter disk and shutter housing (A),
to check that the EPG shutter has not
jam m ed in the closed or half-closed
position.
The va lu e (m e a s u re m e n t A ) s h o u ld
be 30 2 m m (1.18 .08 in).
3
If the value is correct, replace or over
haul the EPG in accordance with the
procedures found in:
S e rv ic e
M anual
V 7 7 6 -2 5 0 -6 0 0 S M
In t a k e a n d E x h a u s t
S y s te m s , V E D 1 2
4
Activate the exhaust brake solenoid
valve .
8
Pressure not OK:
R egulator valve out of adjustm ent

or faulty.
Insufficient supply pressure.
35
Group 25
Troubleshooting
2533-06-02-02
Oil Pressure, Compression
Brake, Checking
/ f \ DANGER
w heels. Failure to do so can result in unexpected ve
injury or death.
/ f \ DANGER
T2007703
Check if the exhaust pressure gover

nor shutter seals against the shutter
housing.
6
If the shutter does not seal against the
housing, replace or overhaul the ex
haust pressure governor according to
the procedures found in:
S e rvice
M anual
/ ? \ WARNING
can cause serious burns or can perm anently dam age
test equipm ent.
V 7 7 6 -2 5 0 -6 0 0 S M
In ta k e a n d E x h a u s t
S y s te m s , V E D 1 2
7
If the shutter seals against the hous
ing, remove the exhaust pressure
governor and check the shutter and
shutter housing.
36
N ever disconnect an air system com ponent unless all

/ ? \ WARNING
fluids.
Group 25
Troubleshooting
(M easured a t ro c k e r s h a ft.)
Special tools: 9998338, 9998339, J-41203

(Kent Moore)
Installation
1
Set the parking brake.
T2008278
T2006731

N ote: With older engines avoid
dam age to the valve cover and internal
injector cable harness by making sure
the mounting screws do not unscrew
from the cylinder head during removal.
Do n o t use im pact tools to remove the
nuts securing the valve cover.
Reinstall the front bolt w ith o u t the

spring washer. Install bolt 9808001
with connector 9998338 into the rear
bolt hole and tighten both bolts.
9998338
N ote: Bolt 9808001 m ust be used. It

has been modified and is shorter than
the previous version and does not use
a sleeve.
5
3
between no. 4 and 5 injector solenoids.
J-41203
N ote: Use Kent Moore tool J-4 1 2 0 3 to

remove the stud on earlier D12 en
gines.
T2008279
Remove the bolts retaining the rocker

arm bridge between cylinders 4 and 5.
Remove the spring washer.
37
Group 25
Troubleshooting
Install the seal for the oil pressure

hose into the hole in the valve cover.
Make sure the seal fits into the stud
hole in the valve cover.
Route the oil pressure hose through

the hole in the valve cover w here the
stud has been removed. C onnect the
oil pressure hose to connector
9998338.
10
N ote: C heck that connector 9998338

and the oil pressure hose do not ob
struct the rocker arms. If necessary,
use cable ties to prevent the oil pres
sure hose from being dam aged by the
rocker arms.
7
Install the valve cover and make sure
the oil pressure hose does not interfere
with any part of the valve mechanism.
W2002213
Route the oil pressure hose into the

cab as shown. Install pressure gauge
9998339
N ote: Secure the oil hose with cable
ties to prevent kinks that would restrict
flow.
30 3 Nm (22 2 ft-lb). Follow the

tightening sequence shown.
38
(22 2 ft-lb)
9998339
Troubleshooting
Group 25
Testing
Removal
1
Set the control switches to the OFF
position (VEB disabled). S tart the en
gine and measure the rocker arm shaft
oil pressure. The pressure should be
approxim ately 1 bar (14.5 psi).
1
Set the parking brake. Remove the
pressure gauge and oil pressure hose
from the cab. Cut the oil hose free
from the cable ties and disconnect the
pressure gauge.
2
If the pressure fluctuates or is under
0.5 bar (7.25 psi) or over 1.5 bar
(21.75 psi), the control valve is faulty.
N ote: Low oil pressure in the rocker

arm shaft may also be due to exces
sive w ear in the rocker arm bushings
and/or the rocker arm s w hich result in
excessive oil pressure loss. See
Rocker Arm Roller, C hecking page
46.
T2006731

3
Install the equipm ent for measuring
the exhaust gas tem perature, including
the 36-pin breakout box. See Exhaust
Temperature, C hecking page 40.
/ j \ CAUTION
W ith older engines avoid dam age to the valve cover
and internal injector cable harness by making sure the
m ounting screws do not unscrew from the cylinder
head during removal. Do n o t use im pact tools to re
move the nuts securing the valve cover.
3
Remove the oil pressure hose from
connector 9998338. Pull the oil pres
sure hose through the valve cover and
remove the oil seal.
T2007708
Remove connector 9998338 and bolt

9808001 from the rocker arm shaft. In
stall the spring w asher and the two
rocker arm bridge bolts.
39
Group 25
5
Tighten the rocker arm bridge bolts in
tw o steps:
1 Torque to 15 Nm (11 ft-lb).
2 Tighten both bolts an additional
90.
6
C lean the threaded hole in the cylinder
head where the valve cover stud was
removed. Clean the valve cover stud
bolt and apply locking fluid. Torque the
stud to 48 8 Nm (35 6 ft-lb).
Troubleshooting
15 Nm
(11 ft-lb)
2515-06-02-01
Exhaust Temperature, Check
ing
/ | \ DANGER
injury or death.
J-41203
48 8 Nm
(35 6 ft-lb)
Carefully remove any excess locking

fluid after the stud bolt has been tight
ened.
/ j \ WARNING
clear o f all moving or hot engine parts. A hot engine
test equipment.
N ote: Use Kent Moore tool J-41203 on

early D12 engines to torque the stud.
7
P ress the electronic cable clam p onto
the stud bolt.
/ j \ WARNING
fluids.
N ote: The electronic cable must be

positioned on the outside o f the valve
cover studs.
Special tools: 9998190, 9998342, 9998364,

J-41132
8
Installation
9
1
T2007003
Tighten the valve cover nuts to

30 3 Nm (22 2 ft-lb). Follow the
tightening sequence shown.
30 3 Nm
(22 2 ft-lb)
10
Test run engine and check for oil leaks.
W2002214
Disconnect the pipe from the air com

pressor and remove the intake pipe
between the air cleaner and tu r
bocharger.
40
Group 25
Troubleshooting
3
Remove bolts and spacers fastening
the heat shield to the exhaust m ani
fold.
4
D isconnect the air com pressor dis
charge line and lay aside.
5
U nbolt the oil supply line at the turbo
only.
In se rt the tem perature sensors be

tween the exhaust manifold and the
cylinder head.
In se rt the tem perature sensors far
enough that the guide pins are against
the edge o f the exhaust manifold.
9998342
N ote: The tem perature sensors are

num bered from one to six for the re
spective cylinders.
M ake sure that the sensors are in
stalled to the correct cylinders.
The sensors can be installed on either
side of the gasket.
(The gaskets are replaced after the
test.)
T2007719
Loosen the exhaust manifold bolts just

enough so that some threads remain
in the cylinder head.
8
Tighten the exhaust manifold bolts.
9
Tighten the oil supply line at the turbo.
10
C onnect the air com pressor discharge
line.
11
S ecure the tem perature sensor cables
with cable ties away from the exhaust
manifold and to avoid dam age during
testing.
Route the cables into the cab for con
nection to the measuring instrument.
12
Install the intake pipe between the air
cleaner and the turbocharger. Connect
the pipe to the air compressor.
41
Group 25
13
Make sure that the ignition key is in
the OFF position.
Troubleshooting
17
14
Clean the area around the EECU and
harness connectors.
15
Disconnect the EB harness (lower har
ness) from the EECU and connect the
36-pin breakout box between the EB
harness and the EECU.
Make sure the harness connectors are
properly pressed together. Do not
force the connectors together.
W2002215
1 EPG solenoid wiring harness
2 Exhaust brake solenoid wiring harness
16
Route the 36-pin breakout box into the
cab and secure.
/ j \ DANGER
depressed a loss of power steering assist may occur.
Be prepared to switch off the engine brake at any time.
Remove the connector from the ex

haust brake solenoid valve.
N ote: A more reliable measurem ent
result is obtained when the exhaust
brake is disabled.
Measurement instrument 9998190

1
8190
T2008016
Check that the correct program unit is

installed in m easurem ent instrum ent
9998190.
N ote: W hen tem perature measuring,
program unit 9812327 is required.
42
9998190
9812327
Group 25
Troubleshooting
T2008010
T2008017
C onnect the collation unit electrical ca

ble to the cigarette lighter socket and
turn the ignition key to O N position.
M ake sure that a back-up battery is in

stalled in m easurem ent instrum ent
9998190.
The back-up function is there to make
sure that the stored inform ation is not
lost in the event o f a tem porary loss o f
supply voltage.
N ote: Check that the text T e m p e r a

t u r e is shown on the m easurem ent
instrum ent display.
The m easurem ent instrum ent auto
m atically selects the tem perature
m easurem ent function w hen the colla
tion unit is connected.
With a fully charged battery, the stored

values in the instrum ent are retained
for m ax. 20 m in u te s after the external
voltage supply has been broken. A l
ways make sure that the battery is
fully charged w hen tem perature m ea
surem ent is to be carried out.
N ote: Only use a 9 Volt rechargeable
nickel-cadm ium battery in the mea
surem ent instrum ent.
Collation unit 8364

1
8364
T2008018
C onnect the collation unit to the measurem ent instrum ent and plug in the
num bered electrical connectors from
the tem perature sensors to the num
bered positions in the collation unit
connection panel.
9998364
43
Group 25
Troubleshooting
Removal
1
Set the parking brake. Take the m ea
surem ent instrum ent and tem perature
sensor electrical cables out of the cab.
2
Remove the cable ties and the electri
cal sensor cables.
/K
CAUTION
In order to prevent personal injury, always w ear safety

glasses when w orking with com pressed air.
10
drain back tube to the turbo.
3
D isconnect the pipe from the air com
pressor and remove the intake pipe
between the air cleaner and tur
bocharger.
11
Remove the 4 bolts mounting the
turbo to the exhaust manifold and lift
off the turbo.
4
Remove the 4 mounting bolts and lift
away the air filter housing.
12
Remove the exhaust manifold m ount
ing bolts and lift the manifold away
from the engine.
5
D isconnect the oil supply line to the air
com pressor at the oil filter housing
and remove the line clamp.
13
Remove all of the tem perature sen
sors.
N o te : C over the fitting and the end of

the line to keep out any debris.
14
6
Remove the 2 bolts attaching the
lower charge air cooler pipe to the
turbo and the bolt supporting the lower
end of the pipe.
7
P ry the charge air cooler pipe away
from the turbo and remove the end
adapter for more clearance.
8
Remove the shutter housing turbo
clamp. Move the shutter housing away
from the turbo and let it rest on the
frame.
9
Blow all debris away from the area
w here the turbocharger oil supply line
enters the oil filter base. Remove the 2
bolts fastening the supply line to the
turbocharger and remove the line.
N ote: Cover the open hole in the oil
filter base to prevent debris from
entering.
44
T2007717
C lean the cylinder head and exhaust

manifold contact surfaces.
Blow clean with com pressed air.
Group 25
15
Troubleshooting
17
Tighten all the exhaust manifold bolts

to a torque o f 48 8 Nm
(35 6 ft-lb).
48 8 Nm
(35 6 ft-lb)
Use the torque tightening sequence

shown.
Glue the new gaskets onto the ex

haust manifold with the correct side
facing the manifold.
N ote: The marking MANIFOLD SID E
should be turned toward the exhaust
manifold.
16
18
N ote: Make sure that all gasket surfaces on the turbocharger are free o f
gasket m aterial and clean. Make sure
that there is nothing inside the exhaust
manifold or air piping e.g. debris from
a previous failure.
Install the turbocharger with a new
m ounting gasket onto the exhaust
manifold. Torque m ounting nuts to
48 8 Nm (35 6 ft-lb).
19
Position the shutter housing and
exhaust piping onto the rear of the turbocharger. Install clam p and torque to
24 2 Nm (18 2 ft-lb).
20
C onnect the oil return tube (using a
new gasket) to the turbocharger.
Torque bolts to 24 4 Nm
(18 3 ft-lb).
Install 2 alignm ent dowels in the cylin

der head to help position the manifold.
Install the exhaust manifold and the
corresponding bolts.
N ote: Make sure that the sleeves are
properly positioned in the counterbore
of the manifold flange.
21
Install the oil supply tube with a new
seal and gasket. Torque bolts to
24 4 Nm (18 3 ft-lb).
48 8 Nm
(35 6 ft-lb)
24 2 Nm
(18 2 ft-lb)
24 4 Nm
(18 3 ft-lb)
24 4 Nm
(18 3 ft-lb)
N ote: Make sure the port in the oil fil

ter housing for the oil supply tube and
seal assem bly is clean and sm ooth,
also before installing the supply tube,
pre-lubricate the turbo with clean en
gine oil.
45
Group 25
22
C onnect the lower charge air cooler
pipe and adapter with new O-ring
seals to the turbo. Install and torque
the 3 charge air cooler pipe support
bolts to 24 4 Nm (18 3 ft-lb).
Troubleshooting
24 4 Nm
(18 3 ft-lb)
2145-06-02-02
Rocker Arm Roller, Checking
/ j \ DANGER
injury or death.
N ote: To make installation easier, ap

ply a soapy solution to the O-rings
prior to installation.
23
C onnect the air com pressor oil supply
line and support clamp. Torque the
clam p bolt to 24 4 Nm (18 3 ft-lb).
24
Install the heat shield and all o f the air
com pressor discharge line support
brackets. C onnect the discharge line
to the air compressor. Torque the heat
shield bolts to 48 8 Nm (35 6 ft-lb).
24 4 Nm
(18 3 ft-lb)

Other special equipment: 9989876, 9999696
1
48 8 Nm
(35 6 ft-lb)
25
Install the air filter housing and all air
piping.
26
Install the cranking tool and rotate the

flywheel around until the cam shaft is
in a position where the rocker arm
roller is not resting on any o f the
cam shaft lobes.
2
C heck that there is a gap between the
rocker arm roller and the camshaft.
Attach the connector to the exhaust

pressure governor solenoid valve.
27
Remove the 36-pin breakout harness
and reconnect the EB harness con
nector to the EECU.
Rotate the roller a num ber o f turns to
disperse the oil film between the bush
ing and shaft.
N ote: If the roller seizes, the rocker
arm m ust be replaced.
46
9996956
Group 25
Troubleshooting
T2007949
Install a dial indicator on a m agnetic

base and position the m agnetic base
as level as possible on the rocker arm .
A djust the dial indicator probe horizon
tally against the center of the roller.
S et the dial indicator to zero.
N ote: Check that the dial indicator
measuring probe is pre-loaded and
perm its movem ent in both directions.
9999876
9999696
T2007951
Using a blunt object, press the roller

inwards as far as possible and read
the m easurem ent value on the dial in
dicator.
Max. 0.1 mm
(0.004 in)
The max. perm itted play between the

bushing and the shaft is 0.1 mm
(0.004 in). If the play is greater, the
rocker arm should be replaced.
5
7
T2007950
P lace a screw driver between the

rocker arm and roller.
Press out the roller as far as possible
and read the value on the dial indica
tor.
T2007792
If it is necessary to replace a rocker

arm, lubricate the new rocker arm
bushing with engine oil. Use a manual
pump oil can and insert the nozzle in
the oil channel hole.
R otate the roller w hile pumping oil into
the channel hole. Continue until oil
runs out both sides of the roller.
47
48
Group 25
Service Procedures
Service Procedures
2145-04-04-02
Rocker Arm, Overhaul
Special tools: 9996716, 9998344

Repair kit: 8148353
T2007725
Remove the plunger from the rocker

arm.
T2007727
Press out the ball seat with drift

9998344.
N ote: The plunger and rocker arm are

a matched pair and are punch-m arked
for identification. They are not to be
mixed when reassembled.
9998344
N ote: Press the ball seating out in the

direction as shown.
2
4
Clean and check the rocker arm.
M ake sure that all dirt is removed be
fore assembling.
N ote: If the rocker arm shaft bushing
or roller is dam aged, the com plete
rocker arm must be replaced.
T2007726
Carefully heat the rocker arm plugs.

Remove the plugs and take the
springs, plunger, ball and spring guide
out of the rocker arm.
49
Group 25
Service Procedures
T2007730
Lubricate the non-return valve plunger

with engine oil, check that the plunger
moves easily in the rocker arm and in
stall the spring. A pply o n e d ro p of
locking fluid to the threads o f the new
plug and install the plug.
T2007728
Use drift 9996716 as a counter-hold in

the hole for the non-return valve
plunger. Lubricate the new ball seat
with g e a r o il and press in the seat
with drift 9998344 until it bottoms
against the counter-hold.C heck the
m easurem ent fo r the ball seat position
in the rocker arm.
N ote: Make sure that the ball seat is
positioned with the ring groove
towards the ball and that no metal par
ticles remain after pressing in the seat.
9996716,
9998344
0 0.1 m m
(0 0.003 in.)
N ote: Make sure that the plug and

rocker arm threads are clean and dry
before the locking fluid is applied.
Carefully wipe o ff any excess locking
fluid after the plug is installed.
T2007725
T2007729
Lubricate the com ponents with engine

oil and install the ball, spring guide
and spring. A pply o n e d ro p of locking
fluid to the threads of the new plug
and install the plug.
N ote: Make sure that the plug and
rocker arm threads are clean and dry
before the locking fluid is applied.
Carefully w ipe o ff any excess locking
fluid after the plug is installed.
50
Make sure the rocker arm and rocker

arm plunger punch marks are the
sam e. Lubricate the rocker arm
plunger with engine oil and install it in
the rocker arm .
N ote: Place a rubber band around the
rocker arm and plunger to prevent the
plunger from falling out.
Group 25
Service Procedures
2533-03-02-05
Solenoid Valve, Compression
Brake, Replacement
/ f \ DANGER
injury or death.
/ ! \ WARNING
test equipm ent.
T2007792
Lubricate the journaling fo r the rocker

arm roller with engine oil. Use a man
ual pump oil can and insert the nozzle
in the oil channel hole. Rotate the
roller w hile pumping oil into the chan
nel. C ontinue until oil runs out both
sides of the roller.
/ l \ WARNING
Always w e a r appropriate eye protection to prevent the
fluids.
1
T2006731
51
Group 25
Service Procedures
/ l \ CAUTION
With older engines, avoid dam age to the valve cover
and injector cable harness by making sure the m ount
ing screws do not unscrew from the cylinder head
during removal. Do n o t use im pact tools to remove
the nuts securing the valve cover.
3
Clean the area round the solenoid
valve.
T2007732
Remove the mounting bolt and flange.

Lift off the old solenoid valve.
N o te : C heck that the drain channel in
the VEB control valve is not clogged.
T2007731
Remove the electrical connections

from the solenoid valve.
Install the new solenoid valve, flange,

and mounting bolt.
N o te : The solenoid mounting angle is
im portant. The term inals of the sole
noid should be at a 0 to 45 angle to
the VEB control valve oil pipe.
Torque the solenoid mounting screw to
12.2 Nm (9 ft-lb).
52
12.2 Nm
(9 ft-lb)
Group 25
Service Procedures
2531-03-02-02
Control Valve, Engine Brake,
Replacement
/ f \ DANGER
w heels. Failure to do so can result in unexpected ve
injury or death.
/ ! \ WARNING
test equipm ent.
T2007733
C onnect the electrical cables to the

solenoid valve and tighten the nuts to
a torque of 1.4 Nm (1 ft-lb).
1.4 Nm
(1 ft-lb)
/ l \ WARNING
Always w e a r appropriate eye protection to prevent the
fluids.
8
1
T2007003
Tighten the valve cover nuts to 30 3

Nm (22 2 ft-lb). Follow the tightening
sequence shown.
30 3 Nm
(22 2 ft-lb)
T2006731
10
Test run engine and check fo r oil leaks.

N ote: With older engines, avoid
dam age to the valve cover and injector
cable harness by making sure the
mounting screws do not unscrew from
the cylinder head during removal. Do
n o t use im pact tools to remove the
nuts securing the valve cover.
3
Clean the area around the solenoid
valve.
53
Group 25
Service Procedures
T2007731
Remove the electrical connections

from the solenoid valve.
T2007734
Loosen the attaching bolts and re

move the control valve.
A lso remove the oil pipe and seals be
tween the control valve and rocker
arm shaft.
5
7
T2007722

beside the VEB control valve.
N ote: Use Kent Moore tool J -4 1 2 0 3 to
torque the studs on early D12 engines.
J-4 1 2 0 3
T2007794
Transfer the solenoid valve to the new

control valve, if it is to be re-used.
Torque the solenoid mounting screw to
12.2 Nm (9 ft-lb).
N ote: C heck that the drain holes in the
VEB solenoid valve are not clogged.
The solenoid mounting angle is im por
tant. The term inals of the solenoid
should be at a 0 to 45 angle to the
VEB control valve oil pipe.
54
12.2 Nm
(9 ft-lb)
Group 25
Service Procedures
10
Install new seals on the pipe between

the control valve and rocker arm shaft.
Press the pipe (together with the seal)
into the control valve. Install a new
seal in the control valve oil inlet hole
w here it m ates with the cylinder head.
20 3 Nm
(15 2 ft-lb)
T2007733
C onnect the electrical cables to the

solenoid valve and tighten the nuts to
a torque of 1.4 Nm (1 ft-lb).
Install and bolt down the control valve.

Make sure that the seals against the
cylinder head and rocker arm shaft are
positioned correctly.
Torque the control valve mounting
bolts to 20 3 Nm (15 2 ft-lb).
1.4 Nm
(1 ft-lb)
11
Press the electrical cable clamp onto
the stud bolt.
9
N ote: The electrical cable m ust be po
sitioned on the outside of the valve
cover stud.
12
13
Clean the threaded hole in the cylinder

head located beside the VEB control
valve. Clean the valve cover stud bolt
and apply locking fluid. Torque the
stud to 48 8 Nm (35 6 ft-lb).
N ote: Use Kent Moore tool J-4 1 2 0 3 to
torque the studs on early D12 engines.
C arefully remove any excess locking
fluid after the stud bolt has been tight
ened.
J -4 1 2 0 3
48 8 Nm
(35 6 ft-lb)
T2007003
Tighten the valve cover nuts to 30 3

Nm (22 2 ft-lb). Follow the tightening
sequence shown.
30 3 Nm
(22 2 ft-lb)
14
Test run engine and check for oil leaks.
55
56
Operation Numbers
2145-04-04-02
Rocker
Arm, Overhaul
2145-06-02-02
Rocker
Arm Roller, Checking
2515-06-02-01
............................................................................................................ 49
................................................................................................ 46
Exhaust Temperature, C h e c k in g .................................................................................................40
2531-03-02-02
Control
Valve, Engine Brake, R e p la c e m e n t......................................................................... 53
2531-06-02-01
Engine
Brake, C h e c k in g .............................................................................................................27
2531-06-02-02
Exhaust Brake, Electronic C h e c k in g .........................................................................................30
2531-06-02-03
Exhaust Brake, Mechanical Checking
2533-03-02-05
Solenoid Valve, Com pression Brake,
R e p la c e m e n t............................................... 51
2533-06-02-01
Solenoid Valve, Com pression Brake,
C h e c k in g .......................................................29
.....................................................................................32
2533-06-02-02 Oil Pressure, Com pression Brake, C h e c k in g ......................................................................... 36
VOLVO

PV776-TSP0250610/2 () 2.2000 V olvo Trucks North America, Inc., 2000

Volvo d12 Workshop Manual Less Specifications Abby

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What are the special tools needed for camshaft repair?

What are the special tools needed for camshaft repair?

What are the steps to remove the camshaft?

What are the steps to remove the camshaft?

VOLVO

Volvo Trucks North America, Inc.

This TSI Service Bulletin replaces TSI Service Bulletin

Fig. 1: VOLVO D12B Engine

Special Tools page 2

C am shaft Timing, C hecking page 12

C am shaft Timing, C heck and A djust page 18

Camshaft, R eplacem ent page 3

Volvo Trucks North America, Inc.

Flywheel Turning Tool

Rocker Arm Bridge Lifting Tool

Camshaft Removal Tool

Camshaft Bearing Cap Removal Tool

Flywheel Stop Tool

Volvo Trucks North America, Inc.

Special tools: 9996956, 9998255, 9998264,

Volvo Trucks North America, Inc.

Remove the inspection cover from underneath the

Volvo Trucks North America, Inc.

Volvo Trucks North America, Inc.

Fig. 4: Removing the rocker arm shaft assem bly bolts

Loosen the rocker arm shaft bolts gradually to avoid

N ote: On engines equipped w ith VEB, w rap a rubber

Fig. 5: Removing the rocker arm shaft assembly

Fig. 6: Cam sensor wheel

Volvo Trucks North America, Inc.

Fig. 7: Tool 9998270 installed

Fig. 8: Lifting the cam shaft

Volvo Trucks North America, Inc.

Fig. 9: Bearing shell halves

Fig. 10: Installing the cam shaft

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Fig. 11: Installing the cam shaft drive gear

Fig. 12: Installing the rocker arm bridge

Volvo Trucks North America, Inc.

Fig. 13: Tightening rocker arm shaft and cam shaft

Tighten the rocker arm shaft to g e th e r with the camshaft,

W hen reinstalling a rocker arm shaft that has been

Fig. 14: Bearing caps and cam shaft/rocker shaft,

Volvo Trucks North America, Inc.

Fig. 15: Installing alignm ent tool J -4 1 2 7 2

Upper gear cover

Valve cover nut

Bolt supplied with J-41272

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Hold the tool with the pointer horizontal (1).

Place a straight edge 90 degrees to the pointer

If light can be seen between the straight edge

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Use the portion of the pointer that is fastened to the

Special tools: 9996956, J-41272, J-42773

Steam clean around the valve cover and the upper

Volvo Trucks North America, Inc.

Fig. 16: Installing cam shaft alignm ent tool

Fig. 17: Flywheel direction of rotation