Service Bulletin

Volvo Trucks North America, Inc.

Greensboro, NC USA Trucks
Date Group No. Page
This Service Bulletin replaces SB 237-19, “Unit
Injector Replacement, D12D” (11.2002), publication no.
12.2004 237 19 1(17)
PV776-TSP177411.
Unit Injector
Replacement
D12D
Unit Injector Replacement

W2003779

This information covers the proper procedure for replacing unit injectors on the
VOLVO D12D engine.

Contents
• “Special Tools” page 2
• “Injectors, Replacement (All)” page 3

Note: Information is subject to change without notice.

Illustrations are used for reference only, and may differ slightly from the actual engine
version. However, key components addressed in this information are represented as
accurately as possible.

PV776-20 019385 USA16265

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Service Bulletin 12.2004 237 19 2(17)

Tools
Special Tools
For special tools ordering instructions, refer to Tool Information, group 08.

9990006 9990013 9998081

Puller Impact hammer Torque wrench

9998255 9998249 9998251

Lifting tool Protection sleeve Protecting plug

9998511 9998580 J-42885-25

Lever tool Protection sleeve Injector bore cleaning kit

Injector Bore Cleaning Kit, Components

9808570 9808616
Brush Extension
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Service Bulletin 12.2004 237 19 3(17)

Service Procedures
2371-03-02-01
Injectors, Replacement (All)
See also:

• “Unit Injector Replacement” page 1

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.

Special tools: 9990006, 9990013, 9998081,

9998249, 9998251, 9998255, 9998511,
9998580, J-42885–25, VCADS Pro
Other special equipment: 1159794

Removal
1
Unplug air filter restriction gauge wiring harness.

W2003860
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Service Bulletin 12.2004 237 19 4(17)

2
Remove wiring harness clamps.

W2003861

3
Remove fresh air pipe to air compressor.

W2003862

4
Loosen clamp from main fresh air pipe to turbocharger
and pull pipe away from turbo.

W2003782
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Service Bulletin 12.2004 237 19 5(17)

5
Loosen two upper bolts at top of air filter housing.

W2003858

6
Lift air filter housing away from cab.

W2003859

7
Loosen clamp and remove fresh air pipe from air filter
housing.

W2003863

8
Remove the EGR bracket from the valve cover studs.

9
Remove breather tube from side of valve cover.

10
Remove valve cover nuts.

11
Lift and remove the valve cover.
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Service Bulletin 12.2004 237 19 6(17)

12

CAUTION
Be careful not to break plastic wire ties. Broken
wire ties can fall into the oil system and can cause
engine damage.

Disconnect the injector wiring harness at the unit injector.

W2004059

13
Disconnect electrical connectors from VEB control valve.

W2004051
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Service Bulletin 12.2004 237 19 7(17)

14
Remove valve cover stud located next to VEB control
valve.

W2004052

15
Remove the VEB valve and pipe from the rocker
arm shaft.

W2004053

16
Install rubber bands around VEB plungers to hold them in
place during rocker arm shaft removal.

17
Remove the rocker arm bolts.

Note: Loosen the bolts equally in stages to avoid

bending the shaft.
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Service Bulletin 12.2004 237 19 8(17)

18
Install lifting tool 9998255 and remove the rocker arm
assembly from the cylinder head.

Note: Lifting bracket J-45242 should be used on VNM

and VHD models.

9998255, J-45242

W2003621

19
Loosen drain fitting on fuel filter housing and drain fuel
from the cylinder head into an approved container.

20
Note: Carefully clean around the unit injector to be
removed.

21
Remove the injector hold-down bolt.

W2004061
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Service Bulletin 12.2004 237 19 9(17)

22
Install puller 9990006 on the injector. Put the fork of the
puller in the groove on the injector and lock the arm
with the help of the screw at the side. Lock the puller
by screwing down the screw against the injector’s ball
seat. Using impact hammer 9990013, remove the injector
from the injector bore.

9990006, 9990013

T2018395

23
Place the injector in protective sleeve 9998249 to protect
the injector from dirt or damage.

W2004060
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Service Bulletin 12.2004 237 19 10(17)

24
If the unit injector is not being immediately reinstalled,
install plug 9998251 into the injector bore to protect the
bore from debris.

9998251

C2000393

25
Repeat steps 20 – 24 to remove the remaining injectors.

Cleaning the Injector Bore

1
With plug 9998251 removed, place protecting sleeve
9998580 in the injector bore. Using brush 9808570 and
extension 9808616, clean the unit injector’s copper
sleeve .

9808570, 9808616, 9998580

T2014131
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Service Bulletin 12.2004 237 19 11(17)

Installation

T2019241

1. Part number (may not match illustration)

2. Calibration number (will not match illustration — shown only for location)

Note: You must record the 9 digit calibration number

of each new injector installed. These codes will be
utilized in step 25.

1
Install new injector O-rings. Lubricate O-rings with
clean engine oil.

• Upper ring - large diameter, violet

• Lower ring - small diameter, violet

2
Install injector (with hold-down) into injector bore, making
sure that it is centered between the valve springs.
Push until it bottoms out.

Note: Injector must be positioned so that 4–pin connector

faces the wiring harness.

3
Install the hold-down bolt and torque-tighten using the
following steps:

• If using new copper sleeve:

Step 1 20 ± 5 Nm (15 ± 4 ft-lb)

Step 2 Turn additional 180 ± 5
Step 3 Loosen hold-down bolt.
Step 4 20 ± 5 Nm (15 ± 4 ft-lb)
Step 5 Turn additional 60 ± 5

• If reusing copper sleeve:

Step 1 20 ± 5 Nm (15 ± 4 ft-lb)

Step 2 Turn additional 60 ± 5
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Service Bulletin 12.2004 237 19 12(17)

4
Repeat steps 1 – 3 for the remaining injectors.

5
Using lifting tool 9998255, install the rocker arm assembly
to the cylinder head.

Note: Lifting bracket J-45242 should be used on VNM

and VHD models.

9998255, J-45242

W2003621

6
Remove the rocker arm assembly lifting tool. Make sure
the cross bridges are still in place.

7
Using the proper tightening sequence and the following
steps, torque-tighten the rocker arm bolts:
Step 1 15 ± 5 Nm (11 ± 4 ft-lb), then 90 ± 5
Step 2 60 ± 5 Nm (44 ± 4 ft-lb)
Step 3 15 ± 5 Nm (11 ± 4 ft-lb), then 90 ± 5
Step 4 Loosen bolts
Step 5 15 ± 5 Nm (11 ± 4 ft-lb), then 120 ± 5

Note: Bolts must be tightened in stages to ensure that

the rocker arm shaft comes down without bending.

T2012850

Rocker arm shaft, tightening sequence

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Service Bulletin 12.2004 237 19 13(17)

8
Note: Replace O-ring seals before installation.
Install VEB valve and pipe to the rocker arm shaft and
torque bolts to 24 ± 4 Nm (18 ± 3 ft-lb).

W2004053

9
Install VEB electrical connectors to valve and carefully
tighten terminal nuts.

10
Install valve cover stud next to VEB control valve.
Note: Use Loctite to secure threads.

W2004055
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Service Bulletin 12.2004 237 19 14(17)

11

CAUTION
Be careful not to break plastic wire ties. Broken
wire ties can fall into the oil system and can cause
engine damage.

Carefully connect wiring harness to injectors making

sure connectors are properly locked.

W2004084

12
Adjust the valves and injectors; refer to Service
Information1.
Note: You must record the programming number of each
new injector installed. These codes will be utilized
in step 25.

T2019241

1. Part number (may not match illustration)

2. Programming number (will not match illustration
— shown only for location)

13
Install the valve cover gasket.

1
IMPACT or ID DVD: Info type “Repair”, group 2140
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Service Bulletin 12.2004 237 19 15(17)

14
Install the valve cover nuts. Using the proper tightening
sequence, torque-tighten to 20 ± 2 Nm (15 ± 1.5 ft-lb).

T2012845

Valve cover, tightening sequence

15
Install EGR cooler bracket studs. Torque-tighten to 40
± 3 Nm (29 ± 2 ft-lb).

16
Install the EGR cooler brackets to the valve cover.

17
Install the breather tube to the side of the valve cover.

18
Install fresh air pipe to air filter housing and tighten clamp.

W2003863

19
Position air filter housing against cab.

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Service Bulletin 12.2004 237 19 16(17)

20
Install the 2 bolts at top of air filter housing.

W2003858

21
Install main fresh air pipe to turbocharger. Tighten
clamps.

W2003782

22
Install fresh air pipe to air compressor.

W2003862
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Service Bulletin 12.2004 237 19 17(17)

23
Install wiring harness clamps to air filter housing.

W2003861

24
Connect air restriction gauge wiring harness.

W2003860

25
Using injector programming codes recorded in step 12,
perform injector trim code update. Refer to "Parameter,
programming" in VCADS Pro (MID 128).

26
Turn ignition key to DRIVE position and activate the fuel
priming switch. Wait until the fuel primer pump stops
priming the fuel system.

Note: The fuel primer pump will pump for approximately

5 minutes.

W3005378

27
Start engine and check for leaks.