Volvo Trucks North America

Greensboro, NC USA

This Service Bulletin replaces Bulletin 254–06, “EGR

Valve Replacement, D12D” (12.2007), publication no.
PV776–20126585.

EGR Valve, Replacement

D Date
Service Bulletin

3.2009
Trucks
Group

293
No.

18

EGR Valve Replacement

D12D
Page

1(16)

T2019478

This information covers the proper replacement procedure for the EGR valve on the
D12D engine.

Note: For information on the design and function of the EGR system, refer to Service
Information, group 29.

Contents
• “EGR Valve, Replacement” page 3

Note: Information is subject to change without notice.

Illustrations are used for reference only and can differ slightly from the actual vehicle
being serviced. However, key components addressed in this information are
represented as accurately as possible.

PV776-88910086 USA34387.ihval
Volvo Trucks North America
Service Bulletin

Special Tools
D Date
3.2009

For special tools ordering information, refer to Tool Information, group 08.
Group
293
No.
18
Page
2(16)

W0001795

W2004191

9996049 DBT2V700
Coolant Drain Hose Coolant Extractor
Volvo Trucks North America
Service Bulletin

D
2931-03-02-01
EGR Valve, Replacement
Date
3.2009
Group
293
No.
18

You must read and understand the precautions and

guidelines in Service Information, group 20, "General
Safety Practices, Engine" before performing this
Page
3(16)

procedure. If you are not properly trained and certified

in this procedure, ask your supervisor for training
before you perform it.

Special tools: 9996049, DBT2V700

Removal
1
If equipped, remove left chassis side fairing. Turn the
master switch OFF (if equipped) or disconnect the
batteries. Refer to Service Information in Group 31 for
additional information regarding disconnection and
re-connection of the batteries.

W2003815
Volvo Trucks North America
Service Bulletin

D
2

DANGER
Date
3.2009
Group
293
No.
18

Coolant is toxic; risk of poisoning. Do not drink

coolant. Use proper hand protection when handling.
Keep coolant out of reach of children and animals.
Page
4(16)

Failure to follow these precautions can cause serious

illness or death.

Use the coolant extractor to remove the coolant from the

engine. An alternate method is to drain the coolant into a
suitable container using the drain hose.

DBT2V700, 9996049

W2004191

3
Raise the hood.

4
Remove splash shield and inner fender with bracket on
both sides of the vehicle.

W2004243
Volvo Trucks North America
Service Bulletin

D 5
Date
3.2009
Group
293
No.
18
Page
5(16)

Disconnect the fresh air pipe from the turbo and remove
the air filter housing.

W2003859

6
Remove belt from alternator, A/C compressor, and
adjuster pulleys. Remove alternator and A/C compressor
belt tensioner.

W2006370

7
Remove P-clip fasteners that secure the suction A/C hose.

W2006365
Volvo Trucks North America
Service Bulletin

D
8
Date
3.2009
Group
293
No.
18

Remove the A/C compressor mounting fasteners and let

the compressor drop down inside of the frame.
Page
6(16)

W2006367

9
Remove the alternator wires.

W2006368

10
Leaving the tubes attached, remove the dipstick and fill
tube mounting bracket. Place the assembly to the side.

W2006369
Volvo Trucks North America
Service Bulletin

D 11
Date
3.2009
Group
293
No.
18

Remove the power steering pump mounting fasteners

Page
7(16)

(leaving lines attached). Place the pump to the side.

12
Remove alternator mounting bolts and remove the
alternator from the engine.

W2006366

13
Cut all ties on the left side of the engine. Remove
the clips which secure the harness on the front of the
engine. Loosen EGR wiring harness on the right side of
the engine.

14
Remove EGR pipe heat shield.

W2006396
Volvo Trucks North America
Service Bulletin

D
15
Date
3.2009
Group
293
No.
18

Remove the exhaust pipes and clamps between the EGR

Page
8(16)

valves and EGR cooler. EGR valve 1 is the front valve,

nearest the turbocharger compressor. EGR valve 2 is the
rear valve, nearest the EPG actuator. Inspect the area
around the EGR cooler to pipe connections for signs
of soot or fractures in the pipes. Soot could indicate a
loose clamp or a fracture in the EGR cooler flange weld
or pipe. If a failed flange weld or pipe is found, replace
the failed component.

W2006883
1 EGR Valve 1 Mounting Position
2 EGR Valve 2 Mounting Position

16
Remove wiring harness rail from the EGR valve assembly
and EGR cooler.

W2003828

17
Remove EGR heat shield.

18
Remove coolant lines and support fasteners from EGR
valves.
Volvo Trucks North America
Service Bulletin

D 19
Date
3.2009
Group
293
No.
18

Remove EGR valve clamps from the exhaust manifold.

Page
9(16)

W2003822

20
Disconnect EGR valve harness from cable box.

Note: There are two connectors, the upper connector is

for EGR valve 1 (front valve) the lower connector is for
EGR valve 2 (rear valve). Clearly mark them (upper and
lower or valve 1 and valve 2) so they can be reinstalled in
the same position at the cable box.

W2004432

21
Remove EGR valve assembly (valves and wiring
harness).
Volvo Trucks North America
Service Bulletin

D
Installation
1
Date
3.2009
Group
293
No.
18

Using new clamps and seals, install the EGR valve and
harness assemblies back to exhaust manifold. Check the
Page
10(16)

valve wire harness routing during installation. To protect

the wiring, the wire harness must be installed into the
wire harness support rail so that the loom extends past
the end of the wire harness rail a small amount.

CAUTION
The valve wiring closest to the motor and position
sensor must not touch the heat shield, the motor, or
the valve body. Secure with cable ties as necessary to
prevent rubbing.

W2006884

2
Tighten EGR valve clamps at exhaust manifold to 13
Nm (10 ft-lb).

13 Nm (10 ft-lb)

W2003822

3
Install coolant lines and support fasteners back to
EGR valves.

4
Install EGR heat shield.
Volvo Trucks North America
Service Bulletin

D 5
Date
3.2009
Group
293
No.
18

Install wiring harness rail to EGR valve assembly and

EGR cooler.
Page
11(16)

W2003828

6
Install EGR valve exhaust pipes and clamps and tighten
clamps to 13 Nm (10 ft-lb).

Note: Upper tube clamps must be positioned as shown to

insure the heat shield will fit over the pipes properly.

Note: EGR valve 2 tube clamp must be positioned as

shown to allow heat shield installation over the EGR
pipes without interference.

Note: Tubes must be installed as shown, with the

bellows end connected to the EGR valves. Tubes will
only fit correctly if installed this way. Incorrect installation
of tubes will cause exhaust leaks.

13 Nm (10 ft-lb)

W2006885
Volvo Trucks North America
Service Bulletin

D
7
Date
3.2009
Group
293

Install EGR pipe heat shield.

No.
18
Page
12(16)

W2006396

CAUTION
It is mandatory that EGR valve cables be connected
in the proper position. Reversing valve 1 and valve
2 connections will cause fault codes to be reported
incorrectly.

Install EGR wiring harness to left side of engine and

connect to cable box.

Note: Attach connectors in the same position in which

they were removed. The front facing connector must be
connected to the front EGR valve (EGR valve 1) and the
bottom facing connector must be connected to the rear
EGR valve (EGR valve 2).

W2004432
Volvo Trucks North America
Service Bulletin

D 9
Date
3.2009
Group
293
No.
18
Page
13(16)

Use tie straps or cable ties to secure wiring harness to

rail, along the top of the EGR cooler and behind the
alternator. Install clips along front of engine.

W2005609

10
Install alternator and mounting bolts.

W2006366

11
Install power steering pump and mounting fasteners.

12
Connect alternator wires.

W2006368
Volvo Trucks North America
Service Bulletin

D
13
Date
3.2009

Install the A/C compressor.

Group
293
No.
18
Page
14(16)

W2006367

14
Secure suction line with p-clamps.

W2006365

15
Install belt tensioner. Install belt.

W2006370
Volvo Trucks North America
Service Bulletin

D 16
Date
3.2009
Group
293
No.
18

Install dipstick and fill tube mounting bracket.

Page
15(16)

W2006369

17
Install air filter housing.

18
Install splash shield and inner fender with brackets on
both sides.

W2004243
Volvo Trucks North America
Service Bulletin

D
19
Date
3.2009

Install engine coolant.

Group
293
No.
18
Page
16(16)

W2004191

20
Connect batteries, then install left chassis side fairing.

W2003815

21
Start engine and check for leaks.

22
Close and latch hood.