TSI Volvo Trucks North America, Inc. Greensboro, NC USA This TSI Service Bulletin replaces TSI Service Bulletin 211–007, “Cylinder Head, D12, D12A, D12B” (11.2001), publication no. PV776–TSP159904. Date Group No. 9.2003 211 007 Supp. Page 1(41) Cylinder Head D12, D12A, D12B Cylinder Head W2002653 Fig. 1: VOLVO D12B Engine This information covers procedures for repairing the cylinder head of VOLVO D12, D12A, and D12B engines.
Volvo Trucks North America, Inc. TSI Date Group No. Page 9.2003 211 007 2(41) 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.
Volvo Trucks North America, Inc. TSI Date Group No. Page 9.
Volvo Trucks North America, Inc. TSI Date Group No. Page 9.
Volvo Trucks North America, Inc. TSI Date Group No. Page 9.2003 211 007 5(41) Service Procedures 2111-01-01-01 Cylinder Head, Removal (With VEB or EPG; also with coolant drained off) (See also “Cylinder Head, Overhaul” page 27.) You must read and understand the precautions and guidelines in Service Information, group 21, "General Safety Practices" before performing this procedure.
Volvo Trucks North America, Inc. TSI Date Group No. Page 9.2003 211 007 6(41) 2 WARNING Use a hoist or get assistance when lifting components that weight 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.
Volvo Trucks North America, Inc. TSI Date Group No. Page 9.2003 211 007 7(41) 6 Remove small injector wire from injector and move aside to prevent damage. 7 Remove the fuel lines from the cylinder head and plug the connections. Remove the electrical wires for both the engine coolant temperature sensor and the unit injector. Note: Pay close attention to the plastic cable ties/straps and remove any broken pieces to prevent clogging or damage to any components. W2000690 Fig.
Volvo Trucks North America, Inc. TSI Date Group No. Page 9.2003 211 007 8(41) 12 Loosen all adjustment lock nuts and screws. T2006777 Fig. 4: Rocker arm shaft bolts 13 Gradually loosen the rocker arm bolts to avoid distorting the rocker arm shaft. Remove the bolts. Install tool 9998255 and lift off the rocker arm assembly. 9998255 W2002159 Fig. 5: Removing the rocker arm shaft 14 Carefully clean around the unit injectors and remove them.
Volvo Trucks North America, Inc. TSI Date Group No. Page 9.2003 211 007 9(41) 15 Install protective plugs 9998251 in the unit injector bore in the cylinder head. 9998251 W2000689 Fig. 7: Injector bore protector plug 16 Carefully pull the unit injector wiring harness out of the cylinder head. 17 Remove the adjustable idler gear. T2007095 Fig. 8: Idler gear bolts 18 Remove the camshaft cap bolts. Number the caps (1–7) for the respective bearing housings and remove using puller J-44457.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 10(41) 19 Carefully lift off the camshaft, using tool 9998264. 9998264 T2006783 Fig. 10: Removing the camshaft 20 Remove the cylinder head mounting bolts. 21 Remove the #4 lower bearing housing for the camshaft. Remove the stud bolt for the valve cover. Use Kent-Moore socket J–41203 to remove early style stud bolts (oval flange). Use a 14 mm deepwell socket for new style studs (hexagonal flange).
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 11(41) 23 Install adapter 9998258 on the cylinder head. (Applies if work is to be performed on the head. The purpose of the tool is to attach the cylinder head to the overhaul stand.) 9998258 24 Install 9996966 to liners to prevent the liner from loosening the seal when rotating the engine. 9996966 T2007156 Fig.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 12(41) 2111-02-01-01 Cylinder Head, Installation (See also “Cylinder Head, Overhaul” page 27.) You must read and understand the precautions and guidelines in Service Information, group 21, "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.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 13(41) 1 T2007163 Fig. 13: Cleaning the cylinder head Clean all gasket and O-ring surfaces of the cylinder head and block. Make sure all bolt holes in the cylinder head and block are free of oil and debris. T2007087 Fig. 14: Cylinder block sealing surface 2 If debris or carbon is in the cylinder head bolt holes, clean the top of the hole before the threads by using a 17 mm drill. Turn it manually into the hole.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 14(41) 3 Clean the threads with a M16x2 thread tap. Note: To remove residue from bolt holes, use chip vacuum tool PT-2900 M16x2 tap, PT-2900 C2002611 4 Remove the tools used to hold down the liner. WARNING Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids. 5 Clean the cylinder block surface and around the cylinder liner.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 15(41) 8 Install the cylinder head bolts and torque-tighten using proper sequence (see Fig. 15: Cylinder head bolt torque sequence, page 15) and the following steps: 1 Tighten bolts to a torque of 60 ± 10 Nm (44 ± 7 ft-lb). 2 Check tighten to same torque. 3 Turn bolt 90 ± 5 . Make diagonal mark across bolt head with a felt-tip pen after turning or use angle gauge. 4 Turn bolt an additional 90 ± 5 .
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 16(41) 13 Carefully hoist the camshaft into place using camshaft lifting tool 9998264. 9998264 T2006783 Fig. 17: Installing the camshaft 14 Coat the bearing shell halves with clean engine oil and install them in the camshaft caps. Install the caps on their respective bearing housings. Install and hand-tighten the bolts. Note: Do NOT install the bolts for the rocker arm shaft.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 17(41) 16 Remove the inspection cover from underneath the flywheel housing and install cranking tool 9996956. 9996956 T2006672 Fig. 19: Cranking tool installed 17 Rotate the flywheel until it is at 0 . Install idler gear and adjust gear lash and timing. Refer to “Camshaft Timing, Check and Adjust” page 21.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 18(41) 20 Remove each injector from the protector and install new O-rings. Coat the sealing rings with clean engine oil. Note: Remove the bore protector and clean the bore before installing the injector into the bore (9998251) 9998251 21 Install the unit injectors and center them between the valve springs.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 19(41) 23 Apply clean engine oil to the valve bridges and camshaft lobes. Using tool 9998255, hoist the rocker arm assembly into place. Make sure that the valve bridges and the rocker arms are correctly positioned in relation to each other. 9998255 T2006820 Fig.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 20(41) 25 T2006777 Fig. 23: Tightening rocker arm shaft and camshaft together On engines equipped with VOLVO Engine Brake, reinstall the VEB control valve at this time. Slide the valve and pipe into the rocker arm shaft as a unit. Apply Loctite to the mounting bolt threads and torque the bolts to 33 ± 4 Nm (24 ± 3 ft-lb). Note: Make sure that the flywheel is at 0 and the camshaft is at TDC according to the marking.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 21(41) 2154-06-03-02 Camshaft Timing, Check and Adjust You must read and understand the precautions and guidelines in Service Information, group 21, "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.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 22(41) 4 Rotate the flywheel in the opposite direction of rotation approximately 20 , and then in the direction of rotation 20 to the 0 mark exactly. If you pass the mark, repeat this entire step. CAUTION Final rotation of the flywheel in the opposite direction of normal rotation will result in an incorrect setting due to the gear train lash. W2004266 5 Clean all sealant from front of the head.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 23(41) 7 W2002245 Insert the 0.10 mm (0.004 in.) feeler gauge on the load sides of the (A and B) gear teeth. T2008255 8 Torque the bolts to an initial torque of only 15 ± 3 Nm (11 ± 2 ft-lb). Note: An additional 120 ± 5 backlash is confirmed. is required after the correct 15 ± 3 Nm (11 ± 2 ft-lb) 9 Check that both feeler gauges have the same resistance when inserting them and pulling them out. The correct backlash is 0.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 24(41) 10 Tighten the bolts an additional 120 ± 5 per the torque sequence shown. W2002245 11 Re-check camshaft timing. Rotate the engine opposite the direction of rotation approximately 20 . Continue in the direction of rotation until the two dots on the cam gear are equally spaced on both sides of the camshaft alignment tool, J–42773. Verify that the pointer on the flywheel is within specifications (2 mm BTDC to 2 mm ATDC).
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 25(41) 13 Install the cam sensor wheel on the camshaft drive gear. Install and torque tighten the three bolts to 25 Nm (19 ft-lb). 25 Nm (19 ft-lb) T2007096 14 Clean the contact surfaces for the upper timing gear cover. Replace with a new seal. 15 Apply an even bead of sealant around the timing gear cover. Install the cover. Note: Do not allow sealant to harden before installing the cover.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 26(41) 17 Draw the cover down evenly until the cylinder head and cover are aligned. Tighten bolts in the proper sequence and torque to 33 ± 3 Nm (24 ± 3 ft-lb). 33 ± 3 Nm (24 ± 3 ft-lb) 18 Measure the cam sensor-to-pole wheel air gap. Note: Make sure the air gap is between 0.3 – 0.7 mm (0.011 – 0.028 in.). 0.3 – 0.7 mm (0.011 – 0.028 in.) 19 Connect the electrical cable to the cam sensor on the cover. 20 Apply an even 2 mm (0.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 27(41) 2111-04-04-01 Cylinder Head, Overhaul 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.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 28(41) 2 Remove the valve bridges. Note: Mark the bridges and place them in order so that they can be reinstalled in their original positions on the cylinder head. T2007050 Fig. 30: Valve bridges (non-VEB shown) 3 Install pressing tool 9998260 together with the counter hold which holds the valves.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 29(41) Assembly 6 Coat the valve stems with clean engine oil. Place the valves in the valve guides. Position tool 9998335 on the valve stem and push the seal over the tool until the seal bottoms out against the valve guide. Install the springs with regard to whether they are intake or exhaust valve springs. Carefully press down the springs and install the valve locks. Note: Exhaust valves have double springs. T2006782 Fig.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 30(41) 2111-06-04-01 Cylinder Head, Pressure Test (First) (Head removed; thermostat housing and exhaust manifold removed) You must read and understand the precautions and guidelines in Service Information, group 21, "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.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 31(41) 3 Install sealing washers 9998259 and 9998266, using the cylinder head bolts and M16 nuts. 9998259, 9998266 T2007143 Fig. 34: Installing the sealing washers 4 Clean the contact surface and install the connection washer 9998256 on the thermostat housing position on the cylinder head. 9998256 T2007153 Fig.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 32(41) 5 Before using pressure tester 9996662, connect it to the shop air supply and set the pressure gauge to 103 kPa (15 psi) using the reduction valve. Lock the reduction valve knob (2) with the lock ring. 9996662 W2000715 Fig. 36: Pressure reduction knob 6 Close the shut-off valve (1). Verify that the pressure does not drop for two minutes. W2002162 Fig.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 33(41) 8 Remove the cylinder head from the overhaul stand and immerse the head in a tank of water heated to 70 C (160 F). T2007167 Fig. 39: Cylinder head in tank of water 9 Open the shut-off valve. 10 Turn the reduction valve knob (2) clockwise until the gauge shows a reading of 50 kPa (7.25 psi). Maintain this pressure for one minute. W2000715 Fig.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 34(41) 2143-06-05-01 Valve Guide Wear, Checking Cylinder head removed and installed in overhaul stand You must read and understand the precautions and guidelines in Service Information, group 21, "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. 1 Remove the seal from the valve guide.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 35(41) 4 Using a dial indicator with a magnetic base, position it so that the dial indicator tip is against the edge of the valve rotator. Rock the valve in the direction of the exhaust and intake ports. Read the value on the dial indicator. Wear tolerances a Maximum allowable diametrical wear on valve stem — 0.010 mm (0.00039 in). b Maximum allowable clearance between valve stem and valve guide: Intake valve — 0.025 mm (0.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 36(41) 2143-03-05-03 Valve Guides, Replacement (One Cylinder Head) You must read and understand the precautions and guidelines in Service Information, group 21, "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.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 37(41) 2 Press the intake valve guide using tool 9998261. The guide for the exhaust valve is pressed in using tool 9998262. Note: Intake valve tool 9998261 is marked Int, and the exhaust valve tool 9998262 is marked Ex. Press until the tools bottom against the face of the cylinder head. The other guides are pressed into place in a similar way. T2007165 Installing new valve guides 3 Install new seals on the valve guides.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 38(41) 2149-03-05-01 Valve Seat, Replacement (One) You must read and understand the precautions and guidelines in Service Information, group 21, "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.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 39(41) 3 Remove the old valve seat by grinding two diametrical notches in the seat and cracking it with a chisel. 4 Thoroughly clean the seat location and check the cylinder head for cracks. 5 Measure the diameter of the seat location. Check whether a standard size seat or an oversize seat is required. Machine the valve seat location, if necessary.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 40(41) 2149-05-05-01 Valve Seat, Grind (One) You must read and understand the precautions and guidelines in Service Information, group 21, "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. 1 Prior to grinding, check the valve guides and replace them if the wear limits have been exceeded.
Volvo Trucks North America, Inc. TSI Date Group No. 9.2003 211 007 Page 41(41) 2145-03-04-01 Rocker Arms, Replacement (All) You must read and understand the precautions and guidelines in Service Information, group 21, "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.
