Volvo d12
Volvo d12
Volvo d12
Greensboro, NC USA
TSI
This TSI Service Bulletin and others in Groups 21 and Date Group No. Supp. Page
33 replace TSI Service Manual 210–600, “Basic Engine, 11.2001 210 004 1(18)
D12, D12A, D12B, D12C” (8.2000), publication no.
PV776–TSP142853. Cylinder Compression
D12, D12A, D12B, D12C
Cylinder Compression
W2003244
This information covers the procedure for checking cylinder compression on VOLVO
D12 engines.
Contents
• “Special Tools” page 2
• “Cylinder Compression, Checking” page 3
PV776-TSP160585 USA10311
Page 2
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.
WARNING
Fuel leaked or spilled onto hot surfaces or electrical
components can cause a fire. Clean up fuel spills im-
Do not service any part of the fuel system while mediately.
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. Clean around the drain plug in the fuel
filter bracket. Connect 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
WARNING head drain into the container.
HOT ENGINE! Keep yourself and your test equipment
clear of all moving parts or hot engine parts and/or 2
fluids. A hot engine and/or fluids can cause burns or
can permanently damage test equipment.
WARNING
Do not work near the fan with the engine running. The
engine fan can engage at any time without warning.
Anyone near the fan when it turns on could be seri-
ously injured. Before turning on the ignition, be sure
that no one is near the fan.
C2001719
Note: A diagnostic test can identify possible variations Remove the valve cover.
between cylinders; refer to VCADS Pro tool. Note: Do not use an impact wrench,
or the studs may loosen from the
cylinder head and damage the electri-
cal installation and the valve cover.
Page 4
3 6
T2008818
T2008812
8 11
Clean around the unit injectors.
12
C2001720
Loosen the bolts in the rocker arm
shaft support uniformly along the en-
tire shaft, so that it is not strained and
risk being warped.
9
T2012932
13
C2001721
Remove the bolts, attach lifting tool 9998255
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 C2000425
suitable device to prevent the pistons Install dust covers 9998249 on the unit 9998249
from dropping when the rocker arm injector to protect them from dirt or
assembly is lifted. possible damage.
Rocker pistons are classified in pack-
ages (2, 3, or 4 points are stamped on
the rocker arms and pistons) and 14
should be kept as an assembly. Use the same procedure to remove
the other unit injectors, one at a time.
15 17
T2014131
C2001726
Clean the copper sleeves in the unit 9808616 Lubricate the valve bridges and 9998255
injectors using tools 9808616, 9808570 camshaft lobes with engine oil. Using
9808570, and 9998580. 9998580
lifting tool 9998255, install the rocker
arm bridge.
CAUTION
18
While 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 damage them or obstruct the nozzle holes,
which can reduce engine power or bind piston rings.
16
C2000411
19
Gradually tighten the bolts so that the
rocker arm shaft does not bend or
warp (also check that the guide pins fit
correctly in the camshaft supports).
Tighten the shaft until it lies against
the camshaft lobes, then torque-
tighten using the proper bolt sequence
(see Fig. 2: Bearing caps and
camshaft/rocker shaft, tightening se-
quence, page 7) and the following
5-step process:
D12C: 1 15 ± 5 Nm
(11 ± 4 ft-lb);
+90 ± 5
2 60 ± 5 Nm
(44 ± 4 ft-lb)
3 15 ± 5 Nm
(11 ± 4 ft-lb);
+120 ± 5
4 60 ± 5 Nm
(44 ± 4 ft-lb);
loosen to 0 Nm T2008958
(0 ft-lb) In VEB engines, install the control
5 15 ± 5 Nm valve.
(11 ± 4 ft-lb);
+120 ± 5
20
D12, D12A, 1 15 ± 5 Nm
D12B: (11 ± 4 ft-lb);
+90 ± 5
2 45 Nm
(33 ft-lb)
3 15 ± 5 Nm
(11 ± 4 ft-lb);
+90 ± 5
4 45 Nm (33 ft-lb);
loosen to 0 Nm
(0 ft-lb)
5 15 ± 5 Nm
(11 ± 4 ft-lb);
+90 ± 5
C2000183
21
Turn the engine to the next marking on
the camshaft for the valve adjustment.
Page 8
22 24
Turn the engine to the next marking on
the camshaft for the exhaust valve ad-
justment.
25
T2009075
26
W2002165
27 28
W2003734
T2009009
While compressing the coil spring, Checking exhaust valve play with tool 9998248 in-
press down firmly on the exhaust stalled
rocker arm. This will force out any oil Insert a feeler gauge, with the speci-
and properly seat the power piston to fied measure, between the valve
its innermost position in the rocker bridge and the rocker piston end. Turn
arm. the piston to prevent it from tilting.
Note: Be sure there is no oil on the
Acceptable valve clearance (play)
rocker arm preventing the piston from
reaching the end of its stroke. This Exhaust 0.50 ± 0.05 mm (0.0196 ±
can act as a hydraulic wedge and pre- 0.0019 in.)
vent correct adjustment.
Exhaust with 1.60± 0.05 mm (0.063 ± 0.002
VEB in.)
29 32
T2009008
A - B = shims required 33
A = Measured play
31
Use the same procedure to check the
play of the other valves.
Volvo Trucks North America, Inc. Date Group No. Page
TSI 11.2001 210 004 11(18)
34 37
C2000412
pression tester 9988539 to cylinder 9998248 Remove the complete rocker arm shaft 9998255
number 1 and perform the test. Note using lifting tool 9998255.
that compression gauge adapter J-
44621 must be installed on 9998248
before connecting it to the compres- 38
sion tester.
Run the engine with the starter motor
until the compression gauge needle
stops (compression maximum value).
Write down the maximum value for the
cylinder compression.
35
Repeat the test for all cylinders.
Reassembly 39
36
Remove the bolts and remove the
VEB control valve.
C2000183
40 43
C2001726
41
Use the same procedure to install the
other unit injectors.
42
Connect the wire to the unit injector 1.4 Nm
terminal. Torque-tighten the nut to 1.4 (1.0 ft-lb)
Nm (1.0 ft-lb).
CAUTION
Do not over-tighten. Over-tightened nuts may perma-
nently damage the unit injector.
Volvo Trucks North America, Inc. Date Group No. Page
TSI 11.2001 210 004 13(18)
44 D12C: 1 15 ± 5 Nm
(11 ± 4 ft-lb);
+90 ± 5
2 60 ± 5 Nm
(44 ± 4 ft-lb)
3 15 ± 5 Nm
(11 ± 4 ft-lb);
+120 ± 5
4 60 ± 5 Nm
(44 ± 4 ft-lb);
loosen to 0 Nm
(0 ft-lb)
5 15 ± 5 Nm
(11 ± 4 ft-lb);
+120 ± 5
D12, D12A, 1 15 ± 5 Nm
D12B: (11 ± 4 ft-lb);
+90 ± 5
2 45 Nm
(33 ft-lb)
3 15 ± 5 Nm
(11 ± 4 ft-lb);
+90 ± 5
4 45 Nm (33 ft-lb);
loosen to 0 Nm
(0 ft-lb)
5 15 ± 5 Nm
W2003520
(11 ± 4 ft-lb);
Fig. 4: Bearing caps and camshaft/rocker shaft, tighten-
+90 ± 5
ing sequence
46 47
T2009070
48 51
To set the play to zero in the valve 38 ± 4 Nm
bridge, loosen the bolt until valve (28 ± 3 ft-lb)
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).
52
T2008960
53
T2008959
54 58
Use the same procedure to adjust the
other unit injectors.
55
Turn the engine until the next marking
on the camshaft for the exhaust valve
adjustment.
56
T2009009
T2009073
57
W2002165
59 60
T2009008
62
Use the same procedure to check the
play of the other valves and unit injec-
tors.
63
Install the engine ECU fuse.
Page 18
64 66
T2012845
67
Start the engine and keep it running at
idling speed for approximately 10 min-
utes to purge any air remaining in the
fuel system. Check the seals in all fuel
pipe connections.
68
Check that the engine reaches the
normal operating temperature and let
it run for another 5 minutes at idling
speed. When the idle speed stabilizes,
T2012934
the cylinder balancing is finished and
Connect a hose to the air bleed nipple the correct amount of fuel the unit in-
in the fuel filter bracket. Open the jector should inject in each cylinder is
drain plug and pump fuel with the defined.
manual pump until the fuel comes out
with no air bubbles through the hose. Note: Disconnect all power-
Tighten the drain plug in the fuel filter consumption components, such as
bracket, remove the hose, and place power take-off, air conditioning, etc., to
the protection cap on the drain plug. allow the cylinder balancing to occur.