VOLVO D12 D12A D12B D12C Engine Workshop Service Manual

Volvo Trucks North America, Inc. Greensboro, NC USA Date Group No. Supp. Page 3.2004 215 002 1(2) TSI This TSI Service Bulletin replaces TSI Service Bulletin 215–002, “Camshaft Wear, D12, D12A, D12B, D12C” (11.2001), publication no. PV776–TSP160575. Camshaft Wear, Check D12, D12A, D12B, D12C Camshaft Wear W2004342 Fig. 1: Camshaft This information covers procedures for checking camshaft wear in VOLVO D12, D12A, D12B, and D12C engines. Contents • “Camshaft, Wear Check” page 2 PV776-TSP197442 USA14441

Volvo Trucks North America, Inc. Date Group No. Page TSI 3.2004 215 002 2(2) General Camshaft, Wear Check Surface irregularities may appear on VOLVO engine camshaft lobes in normal operation. This does not mean that the camshaft must be replaced. These marks do not adversely affect the engine’s performance nor the durability of the engine or any of its components. Fig. 2: Camshafts with acceptable wear, page 2 provides examples of camshaft lobes exhibiting this condition. These camshafts may be reused. Fig. 3: Camshafts with unacceptable wear, page 2 provides examples of lobes exhibiting unacceptable wear and deterioration. These camshafts and the rocker arms corresponding to the worn lobes must be replaced. Note: If there is any measurable wear, such as shown in Fig. 3: Camshafts with unacceptable wear, page 2, the camshaft should be replaced. W2002219 Fig. 2: Camshafts with acceptable wear W2002221 Fig. 3: Camshafts with unacceptable wear

Volvo Trucks North America, Inc. Greensboro, NC USA Date Group No. Supp. Page 8.2003 215 001 1(21) TSI This TSI Service Bulletin replaces TSI Service Bulletin 215–001, “Camshaft, D12, D12A, D12B” (11.2001), publication no. PV776–TSP160576. Camshaft D12, D12A, D12B Camshaft W2002653 Fig. 1: VOLVO D12B Engine This information covers procedures for camshaft repair on VOLVO D12, D12A, and D12B engines. Contents • “Special Tools” page 2 • “Camshaft Timing, Checking” page 12 • “Camshaft Timing, Check and Adjust” page 18 • “Camshaft, Replacement” page 3 PV776-TSP193344 USA13899

Volvo Trucks North America, Inc. Date Group No. Page TSI 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 part number when ordering. 9996956 Flywheel Turning Tool 9998255 Rocker Arm Bridge Lifting Tool 9998264 Camshaft Removal Tool 9998270 Counterhold J-41272 Front Cover Tool J-42773 Camshaft Alignment Tool J-44457 Camshaft Bearing Cap Removal Tool 9996950 Flywheel Stop Tool

Volvo Trucks North America, Inc. Date Group No. Page TSI 8.2003 215 001 3(21) Service Procedures 2154-03-02-01 Camshaft, Replacement (With EPG or VEB) You must 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. CAUTION Observe the greatest possible cleanliness when working 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 T2006731 Fig. 2: Valve cover WARNING Use a hoist or get assistance when lifting components 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 warnings may result in personal injury. Remove the valve cover (valve cover should be removed from the exhaust side of the engine). Note: On WIA, bring the valve cover towards the radiator to remove. On WG, it is necessary to remove the engine cover (doghouse). Note: Be careful that the stud bolts do not loosen. Otherwise, the unit injector wiring harness can be damaged. 2 Disconnect the connector for the electrical wires on the upper timing gear cover. Remove the clamp and the cover.

Volvo Trucks North America, Inc. Date Group No. Page TSI 8.2003 215 001 4(21) 3 Remove the upper timing gear cover. 4 T2006672 T2008251 Remove the inspection cover from underneath the flywheel housing and install turning tool 9996956. 9996956 5 T2008250 Turn the flywheel around until the piston in cylinder number 1 is in the Top Dead Center position (0 ) on the flywheel and the camshaft marking (TDC) is opposite the marking on the bearing cap.

Volvo Trucks North America, Inc. Date Group No. Page TSI 8.2003 215 001 5(21) 6 T2007095 Fig. 3: Bolts holding the idler gear in place Remove the adjustable idler gear. 7 T2008812 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 dirt and contamination. To facilitate removal, remove the valve cover stud bolt. Note: Failure to remove the control valve before removing the rocker arm shaft assembly may result in damage to the control valve and/or the pipe.

Volvo Trucks North America, Inc. Date Group No. Page TSI 8.2003 215 001 6(21) 8 T2006777 Fig. 4: Removing the rocker arm shaft assembly bolts W2000937 Fig. 5: Removing the rocker arm shaft assembly 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. Note: On engines equipped with VEB, wrap 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 9 T2007096 Fig. 6: Cam sensor wheel Remove the cam sensor wheel from the camshaft drive gear.

Volvo Trucks North America, Inc. Date Group No. Page TSI 8.2003 215 001 7(21) 10 T2007148 Fig. 7: Tool 9998270 installed Install camshaft counterhold tool 9998270 on the rear of the camshaft. Loosen and remove the camshaft drive gear center bolt and the cam gear. 9998270 11 Remove the camshaft cap bolts. Mark the caps for the respective bearing housings, and remove. Note: To facilitate the removal of the camshaft bearing caps, use tool J–44457. Note: Failure to match the correct camshaft cap with the respective bearing housing will cause engine damage. J–44457 12 C2000508 Fig. 8: Lifting the camshaft Carefully lift off the camshaft using tool 9998264. 9998264 13 Remove the bearing shells from the bearing housings. 14 Inspect the bearings and housings for damage. Note: When replacing the camshaft on the D12 engine, remember that the bearing shells are available in different sizes. Refer to Group 20, Specifications.

Volvo Trucks North America, Inc. Date Group No. Page TSI 8.2003 215 001 8(21) Installation 15 Position the camshaft bearing housings on the cylinder head by observing the factory marks 1–7. Note: 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 T2007126 Fig. 9: Bearing shell halves C2000508 Fig. 10: Installing the camshaft Coat the bearing shell halves with clean engine oil and install them in the bearing housings. Carefully lower the camshaft into place. Note: Make sure that bearing shells of the correct size are installed and correctly positioned in the bearing housing. 17 Coat the bearing shell halves with clean engine oil and install them in the camshaft caps. Install the caps on their respective bearing housings. Hand-tighten the bolts.

VOLVO D12 D12A D12B D12C Engine Workshop Service Manual

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