Volvo Trucks North America, Inc.

Greensboro, NC USA

Service Bulletin Trucks

Date Group No. Page

This Service Bulletin replaces SB 200239, Specifications, D12D (07.2004), publication no. PV77620 0083235.

11.2004

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Specifications D12D

Specifications

W2004441

Contents: Engine Designation page 2 Engine page 2 Valve Mechanism page 5 Timing Gears and Camshaft page 9 Crank Mechanism page 11 Lubrication and Oil System page 15 Fuel System page 17 Intake and Exhaust System page 18 Cooling System page 23 Engine Control System page 25 Tightening Torques and Patterns page 28
Note: 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 016801

USA15989

Volvo Trucks North America, Inc. Service Bulletin

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Specifications
Engine Engine Designation
Power Output 1 D12D 365 D12D 395 D12D 425 D12D 435 D12D 465
1

Torque 2 (365 hp) (395 hp) (425 hp) (435 hp) (465 hp) 1800 Nm 2000 Nm 2000 Nm 2100 Nm 2237 Nm (1328 ft-lb) (1476 ft-lb) (1476 ft-lb) (1549 ft-lb) (1650 ft-lb)

272 kW 295 kW 317 kW 325 kW 347 kW

Max power output at 30.0 rps (1800 rpm). Net power according to ISO 1585. Smoke requirements met according to ECE reg 24 Federal Register and Swedish Authorities. Max torque at 20.0 rps (1200 rpm). Net torque according to ISO 1585. Smoke requirements met according to ECE reg 24 Federal Register and Swedish Authorities.

Number of cylinders Cylinder diameter Stroke Displacement Firing sequence Compression ratio Compression test using VCADS Pro, deviation from peak value 100% Engine speed during compression test, minimum Low idle High idle Max. full load revs Weight, engine with flywheel, flywheel casing and turbocharger, without starter motor (dry) Max length Max width Max height

6 131 mm (5.16 in.) 150 mm (5.91 in.) 12.1 L 1-5-3-6-2-4 17.3:1 max 20% 16.7 r/s (100 rpm) 8.3 - 10.8 r/s (550 650 rpm) 38.4 r/s (2300 rpm) 35.0 r/s (2100 rpm) 1175 kg (2585 lb) 1350 mm (53.2 in.) 768 mm (30.2 in.) 1152 mm (45.4 in.)

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Cylinder Head
Type Length Width Height Maximum unevenness (bottom face) 6 cylinder 1078 mm (42.4 in.) 397 mm (15.6 in.) 135 mm (5.3 in.) 0.1 mm (0.004 in.)

Cylinder Head Bolts

Number/cylinder head Thread size Length 38 M16 200 mm (7.87 in.)

Cylinder Block
Length Height, lower block face - crankshaft center 1052 mm (41.42 in.) 120 mm (4.72 in.)

Cylinder Liner
Type Height, total Sealing surface height above block face Number of sealing rings per cylinder liner Wet, replaceable 273 mm (10.75 in.) 0.15 - 0.21 mm (0.006 - 0.008 in.) 1+3

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Pistons
Type Height above cylinder block face Diameter, combustion chamber Depth, combustion chamber Number of ring grooves Front marking Wrist pin diameter steel 0.15 - 0.65 mm (0.006 - 0.026 in.) 89 mm (3.50 in.) 18.6 mm (0.73 in.) 3 arrow turned forward 55 mm (2.17 in.)

Piston Rings

T2019958

Compression rings Number Piston ring clearance in grooves: lower compression ring Piston ring gap measured in ring opening: upper compression ring lower compression ring Oil scraper ring Number Width, including spring Piston ring clearance in groove Piston ring gap measured in ring opening

Specification 2

Wear tolerance -

0.09 - 0.13 mm (0.0035 - 0.0051 in.)

0.4 - 0.65 mm (0.016 - 0.026 in.) 1.1 - 1.3 mm (0.043 - 0.051 in.) Specification 1 4.32 mm (0.170 in.) 0.05 - 0.10 mm (0.0019 - 0.0039 in.) 0.35 - 0.65 mm (0.0137 - 0.0260 in.)

< 1.0 mm (0.039 in.) < 1.6 mm\ (0.063 in.) Wear tolerance < 1.0 mm (0.039 in.)

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Valve Mechanism
Valves
Valve disc, diameter: Intake Exhaust Valve stem, diameter: Intake Exhaust Valve seat angle (A): Intake Exhaust Seat angle in cylinder head (B): Intake Exhaust 30 45 29.5 44.5 8 mm (0.315 in.) 8 mm (0.315 in.) 40 mm (1.6 in.) 40 mm (1.6 in.)

T2019432

Specification Clearance between valve head and cylinder head face: Intake Exhaust 0.9 - 1.4 mm (0.035 - 0.055 in.) 1.2 - 1.7 mm (0.047 - 0.067 in.)

Wear tolerance

< 1.5 mm (0.059 in.) < 1.8 mm (0.071 in.)

Note: Valves must be replaced when replacing valve seats. Valve clearance, cold engine, setting value: Intake Exhaust Exhaust, VEB Valve clearance, cold engine, control values: Intake Exhaust Exhaust, VEB 0.15 - 0.25 mm 0.45 - 0.55 mm 1.55 - 1.65 mm (0.006 - 0.009 in.) (0.018 - 0.022 in.) (0.061 - 0.065 in.) 0.2 mm 0.5 mm 1.6 mm (0.008 in.) (0.019 in.) (0.063 in.)

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Valve Seats

T2014128

Outer diameter (A) Standard: Intake Exhaust Oversize: Intake Exhaust Height (B): Intake Exhaust 7.3 mm 8.0 mm (0.287 in.) (0.314 in.) 43.3 mm 43.3 mm (1.705 in.) (1.705 in.) 43.1 mm 43.1 mm (1.697 in.) (1.697 in.)

Valve Seat Location

T2012872

Diameter (C) standard: Intake Exhaust Diameter (C) oversize: Intake Exhaust Depth (D) : Intake Exhaust Seat bottom radius (R): Intake, maximum Exhaust, maximum 0.8 mm 0.8 mm (0.032 in.) (0.032 in.) 11.2 mm 11.2 mm (0.441 in.) (0.441 in.) 43.2 mm 43.2 mm (1.701 in.) (1.701 in.) 43.0 mm 43.0 mm (1.693 in.) (1.693 in.)

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Valve Guides
Specification Length: Intake Exhaust Inner diameter: Intake Exhaust Height above the cylinder head spring plate: Intake Exhaust Clearance, valve stem - guide: 1 Intake Exhaust
1

Wear tolerance

83.4 mm (3.283 in.) 83.4 mm (3.283 in.)

8 mm (0.315 in.) 8 mm (0.315 in.)

26.5 0.4 mm (1.043 0.016 in.) 26.5 0.4 mm (1.043 0.016 in.)

< 0.2 mm (0.008 in.) < 0.2 mm (0.008 in.)

Measurements are calculated for the method described in Service Information, group 21.

Valve Springs
Intake (left-hand coil) Length (unloaded) 590 Nm (435 ft-lb) load 1150 Nm (850 ft-lb) load Butt length max Exhaust Outer valve spring (left-hand coil): Length (unloaded) 590 Nm (435 ft-lb) load 1150 (850 ft-lb) Nm load Butt length max Inner valve spring (right-hand coil): Length (unloaded) 330 Nm (244 ft-lb) load 630 Nm (465 ft-lb) load Butt length max 70 - 71 mm (2.76 - 2.80 in.) 54 mm (2.13 in.) 41 mm (1.61 in.) 37 mm (1.46 in.) 73 - 74 mm (2.87 - 2.91 in.) 58 mm (2.28 in.) 45 mm (1.77 in.) 40 mm (1.57 in.) 73 - 74 mm (2.87 - 2.91 in.) 58 mm (2.28 in.) 45 mm (1.77 in.) 40 mm (1.57 in.)

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Rocker Arms
Bearing play, maximum Rocker arm roller, play, maximum < 0.1 mm (0.0039 in.) < 0.1 mm (0.0039 in.)

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Timing Gears and Camshaft

C2001718

Timing Gears
Backlash Shaft journal for intermediate gear, diameter Bushing for intermediate gear, diameter Diametrical clearance for intermediate gear Axial clearance for intermediate gear Number of teeth: 1 2 3 4 5 6 7 8 9 10 11 12 Drive gear, crankshaft Intermediate gear, coolant pump Drive gear, coolant pump Drive gear, air compressor Drive gear, camshaft Intermediate gear (adjustable) Drive gear, power steering pump Drive gear, (pulley and fuel pump) Intermediate gear Drive gear, hydraulic pump Drive gear, lubrication oil pump Intermediate gear, lubrication oil pump 38 83 27 29 76 97 23 27 71 39 23 44 0.05 - 0.17 mm (0.002 - 0.007 in.) 99.99 0.01 mm (3.937 0.0004 in.) 100.04 0.01 mm (3.939 0.0004 in.) max 0.07 mm (0.003 in.) max 0.17 mm (0.007 in.)

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Camshaft
Checking camshaft settings, cold engine and valve clearance, cylinder 1 = 0. The intake valve for cylinder 1 for flywheel position 6 after TDC must be open 1.6 0.3 mm. When checking, the crankshaft must be turned in the correct direction (clockwise viewed from front) to eliminate any backlash. Specification Drive Number of bearings Diameter bearing journals, standard Gear 7 69.97-70.00 mm (2.754 - 2.760 in.) Wear tolerance -

Note: Use only check values, not for machining. Diameter bearing journals, undersize: 0.25 0.50 0.75 Max axial play Max permitted out-of-roundness (with new bearings) Bearing, permitted wear diametrical Valve lift: Intake Exhaust (VEB) Exhaust (EPG) Decompression and charge profiles (VEB) Permitted wear for the complete cam profile Unit injector, stroke 17 mm (0.67 in.) 13.1 mm (0.52 in.) 13.1 mm (0.52 in.) 12.0 mm (0.47 in.) 1.1 mm (0.043 in.) < 0.1 mm (0.0039 in.) 69.72 - 69.78 mm (2.746 - 2.747 in.) 69.47 - 69.53 mm (2.735 - 2.737 in.) 69.22 - 69.28 mm (2.725 - 2.728 in.) 0.35 mm (0.014 in.) 0.05 mm (0.0019 in.) 0.05 mm (0.0019 in.)

Camshaft Bearings
Camshaft bearing thickness, standard Oversize: 0.25 0.50 0.75 2.04 mm 2.17 mm 2.29 mm (0.079 in.) (0.087 in.) (0.091 in.) 1.92 mm (0.075 in.)

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Crank Mechanism

T2012873

Crankshaft
Length Crankshaft axial clearance
1 1

1203 mm (47.36 in.) 0.10 - 0.40 mm (0.0039 - 0.0158 in.) 0.046-0117mm (0.0018-0.0046 in.) 0.08 mm (0.0031 in.) 0.05 mm (0.0020 in.) 0.15 mm (0.0059 in.)

Main bearing radial clearance

Out-of-round, main bearing and connecting rod bearing pins, maximum Taper on main bearing and connecting rod bearing pins, maximum Run-out of the center bearing, maximum
1

Measurements assume lubricated component.

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Main Bearing Journals

(Use only for check values, not for machining.) Diameter () standard Undersize: 0.25 mm (0.01 in.) 0.50 mm (0.02 in.) 0.75 mm (0.03 in.) 1.00 mm (0.04 in.) 1.25 mm (0.05 in.) Surface finish, main bearing journal Surface finish, radius Width, thrust bearing journals (A), standard Oversize: 0.2 mm (0.008 in.), axial bearing 0.1 mm (0.004 in.) 0.4 mm (0.016 in.), axial bearing 0.2 mm (0.008 in.) 0.6 mm (0.024 in.), axial bearing 0.3 mm (0.012 in.) Fillet radius (R) 47.175 - 47.225 mm (1.8573 - 1.8593 in.) 47.375 - 47.425 mm (1.8652 - 1.8671 in.) 47.575 - 47.625 mm (1.8730 - 1.8750 in.) 3.75 - 4.00 mm (0.148 - 0.157 in.) 107.73 - 107.75 mm (4.2413 - 4.2421 in.) 107.48 - 107.50 mm (4.2315 - 4.2323 in.) 107.23 - 107.25 mm (4.2216 - 4.2224 in.) 106.98 - 107.0 mm (4.2118 - 4.2125 in.) 106.73 - 106.75 mm (4.2020 - 4.2028 in.) Ra 0.25 Ra 0.4 47.0 mm (1.850 in.) 108.0 mm (4.25 in.)

Main Bearing Shells

Outer diameter (C) Thickness (D), standard Oversize: 0.25 mm (0.01 in.) 0.50 mm (0.02 in.) 0.75 mm (0.03 in.) 1.00 mm (0.04 in.) 1.25 mm (0.05 in.) 2.6 2.7 mm (0.102 0.106 in.) 2.7 2.8 mm (0.106 1.110 in.) 2.8 2.9 mm (0.110 0.114 in.) 22.9 3.0 mm (0.114 0.118 in.) 3.1 3.2 mm (0.122 0.126 in.) 113.05 mm (4.445 in.) 2.29 mm (0.098 in.)

Thrust Washers (Axial Bearings)

Width (B) standard Oversize: 0.1 mm 0.2 mm 0.3 mm 3.2 3.3 mm (0.126 0.130 in.) 3.3 3.4 mm (0.130 0.134 in.) 3.4 3.5 mm (0.134 0.138 in.) 3.1 3.2 mm (0.122 0.126 in.)

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Connecting Rods

T2019085 T2012874

FRONT on the shaft is turned forward. Connecting rod and cap are marked as a pair with a three-figure serial number.

Length center - center (E) Connecting rod bushing internal diameter (G) Axial clearance, connecting rod - crankshaft, maximum : Connecting rod bearing, radial clearance, maximum 1: Out-of-true, max deviation on measuring length of 100 mm (330 ft) Torsion, max deviation on measuring length of 100 mm (330 ft)
1 1

260 mm (10.236 in.) 55 mm (2.165 in.) 0.25 mm (0.0059 in.) 0.10 mm (0.0039 in.) 0.06 mm (0.0024 in.) 0.15 mm (0.0059 in.)

Measurements are with lubrication.

Connecting Rod Bearing Pins

(Only for check values, not machining) Diameter () standard Undersize: 0.25 mm (0.01 in.) 0.50 mm (0.02 in.) 0.75 mm (0.03 in.) 1.00 mm (0.04 in.) 1.25 mm (0.05 in.) Surface finish, connecting rod bearing journal Surface finish, radius Width (A) Fillet radius (R) 91.73 - 91.75 mm (3.611 - 3.612 in.) 91.48 - 91.50 mm (3.601 - 3.602 in.) 91.23 - 91.25 mm (3.592 - 3.593 in.) 90.98 - 91.00 mm (3.582 - 3.583 in.) 90.73 - 90.75 mm (3.572 - 3.573 in.) Ra 0.25 Ra 0.4 56.9 - 57.0 mm (2.240 - 2.244 in.) 3.75 - 4.00 mm (0.148 - 0.157 in.) 92.0 mm (3.62 in.)

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Connecting Rod Bearing Shells

Outer diameter (B) Thickness (C), standard Oversize: 0.25 mm (0.01 in.) 0.50 mm (0.02 in.) 0.75 mm (0.03 in.) 1.00 mm (0.04 in.) 1.25 mm (0.05 in.) Diameter, bearing shell bearing seat (D) 2.51 2.52 mm (0.0988 0.0992 in.) 2.64 2.65 mm (0.1039 0.1043 in.) 2.76 2.77 mm (0.1087 0.1090 in.) 2.89 2.90 mm (0.1138 0.1141 in.) 3.01 3.02 mm (0.1185 0.1188 in.) 96.84 96.85 mm (3.8126 3.8129 in.) 96.85 mm (3.813 in.) 2.39 2.40 mm (0.0941 0.094 in.)

Flywheel
Axial run-out (manual gearbox) measurement radius 150 mm (5.91 in.), maximum Number of teeth on starter motor gear ring Sensor groove in flywheel 0.20 mm (0.008 in.) 153 3 x 18

Flywheel Housing, Installed

Permitted axial runout for mating surface against clutch housing, maximum Permitted axial runout for location against clutch housing, maximum 0.20 mm (0.008 in.) 0.25 mm (0.010 in.)

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Lubrication and Oil System Oil

For proper volumes and oil and filter change intervals for VOLVO components, refer to Service Information, group 175.

Oil Pressure
Operating speed (above 1100 rpm) Idle speed, minimum 300-550 kPa (45 - 80 psi) 150 kPa (22 psi)

Oil Pressure, rocker arm shaft

Non-activated VEB Activated VEB 100 kPa (15 psi) min. 200 kPa (min. 30 psi)

Oil Temperature
Warm engine (running); coolant temperature 75 - 95 F) *Up to 125 C (257 F) at high engine load C (167 - 203 65 - 105 C* (149 - 221 F)*

Oil Pump
Type Number of teeth: drive gear intermediate gear Diameter: hub, intermediate gear bushing, intermediate gear Axial clearance: drive gear, pump intermediate gear Backlash Distance, drive gear oil housing bracket 0.11 mm (0.0043 in.) 0.10 mm (0.0039 in.) 0.05 - 0.17 mm (0.0020 - 0.0067 in.) 1.0 - 2.4 mm (0.0394 - 0.9449 in.) 69.99 0.01 mm (2.7555 0.0004 in.) 70.04 0.02 mm (2.7575 0.0008 in.) 23 44 Gear driven

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Oil Filter
Number Full-flow filter (is tightened 1/2 - 3/4 turn after contact) Fine filter (is tightened 3/4 - 1 turn after contact) 2 1

Oil Valves

W2004453

T2012843

1. Safety valve Marking 2. Control valve, oil cooler (bypass valve) (A) Marking 3, 5. Overflow valve, oil filter Spring, free length With a load of 13 - 15 Nm 4. Piston cooling valve Marking 6. Reduction valve Marking Blue Orange 69 mm (2.72 in.) 40 mm (1.57 in.) 124 Yellow

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Fuel System Fuel Pump

Fuel pressure at: 600 rpm 1400 rpm full load > 100 kPa (15 psi) > 300 kPa (45 psi) > 300 kPa (45 psi)

Overflow Valve
Opening pressure 360 - 420 kPa (53.6 - 62.5 psi)

Unit Injectors

T2012878

Tighten the adjustment screw to zero clearance against the camshaft, then turn an additional 3-4 flats (180 240).

Preload setting, 3 - 4 flats (see illustration) . . . . . . . .

0.75 0.1 mm (0.0295 0.0039 in.)

Cylinder Balancing
Cylinder balancing, VCADS Compensation, maximum 80%

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Intake and Exhaust System Turbocharger

Axial clearance turbine rotor shaft, maximum 0.1 mm (0.0039 in.)

Minimum Charge Air Pressure at 100% Engine Load Response Values

Minimum @ 100% engine load D12D365: 1200 rpm 1400 rpm 1600 rpm 1800 rpm D12D395: 1200 rpm 1400 rpm 1600 rpm 1800 rpm D12D425: 1200 rpm 1400 rpm 1600 rpm 1800 rpm D12D435: 1200 rpm 1400 rpm 1600 rpm 1800 rpm D12D465: 1200 rpm 1400 rpm 1600 rpm 1800 rpm 175 kPa (25.3 psi) 206 kPa (29.9 psi) 224 Kpa (32.5 psi) 226 Kpa (32.8 psi) 3.12 V 3.47 V 3.67 V 3.69 V 4 - 5 sec 3.5 - 4.5 sec 3.5 - 4.5 sec 3.5 - 4.5 sec 153 kPa (22.2 psi) 190 kPa (27.5 psi) 205 Kpa (29.7 psi) 206 kpa (29.9 psi) 2.88 V 3.29 V 3.46 V 3.47 V 4.5 - 5.5 sec 4 - 5 sec 3.5 - 4.5 sec 3.5 - 4.5 sec 145 kPa (21 psi) 185 kPa (26.8 psi) 193 kPa (28 psi) 199 kPa (28.9 psi) 2.88 V 3.23 V 3.32 V 3.39 V 4.5 - 5.5 sec 3.5 - 4.5 sec 3.5 - 4.5 sec 3.5 - 4.5 sec 140 kPa (20.3 psi) 180 kPa (26.1 psi) 187 kPa (27.1 psi) 193 kPa (28 psi) 2.73 V 3.18 V 3.26 V 3.32 V 4.5 - 5.5 sec 3.5 - 4.5 sec 3.5 - 4.5 sec 3.5 - 4.5 sec 125 kPa (18.1 psi) 176 kPa (25.5 psi) 183 kPa (26.5 psi) 187 kPa (27.1 psi) 2.57 V 3.12 V 3.21 V 3.25 V 3.5 - 4.5 sec 3.5 - 4.5 sec 3.5 - 4.5 sec 3.5 - 4.5 sec Pins EA22 (signal) & EA11 (sensor ground)1 Response Values2

Charge Air Temperature Sensor

Cold engine (off) Warm engine (running, vehicle standing still); coolant temperature 75 - 95 C (167 - 203 F) Ambient temperature 10 - 30 C (50 - 86 temperature F) above ambient

1 2

Test run with normal diesel fuel (type 2) and below 1500 m (4500 ft.) altitude. Response times from 0 kPa (0 psi) charge air pressure to 90% of max charge air pressure.

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Exhaust Pressure Governor (EPG)

T2013094

EPG travel (A), minimum

29 mm (1.14 in.)

Heat Retention Function

Air pressure for exhaust pressure governor (EPG) Heat retention activated: Coolant temperature (minimum) < 70 80 C/ 4 (158 176 F / 2 ) < approx. 50% 1 at rest (released) 155 8 kPa (23 2 psi)

Engine load Accelerator pedal Heat retention deactivated: Coolant temperature Engine load Accelerator pedal
1

> 70

C (158

F) 2

> approx. 50% off idle (depressed)

Engine load could be more or less depending on engine speed. Check should be made with engine at idle speed. This value can be programmed from 70 C (158  F) to 80 C (176  F). Parameter AZN, MID 128 (Engine ECU).

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EPG Activation for Idle EGR

Air pressure for exhaust pressure governor (EPG) Activation: Coolant temperature Clutch pedal Accelerator pedal Engine speed Ambient temperature EGR temperature
1

approx. 100 kPa (14.5 psi)

> 65

C (> 149

F)

at rest (released) at rest (released) idle >4 > 98 C ( > 25 C ( > 208 F) F) 1

Idle EGR is active when all conditions listed are met. After the first 3 minutes of idle time, the EMS reads the EGR temperature. If below 98  C (208 F), idle EGR is not active. If above value, it remains active.

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Engine Brake
EPG Inlet Pressure

T0008637

Exhaust brake only 100% (high) Engine brake, switch position 1

1

Braking force in % Pressure of EPG in kPa (psi) Cruise mode 50 - 750 kPa (7 - 109 psi)

750 kPa (109 psi)

2way switch can give 100% (high) EPG only

T0008058

VEB

Brake force in % 1 Pressure of EPG in kPa (psi) 50% (low) 100% (high) 750 kPa (109 psi) Cruise mode 2 50 750 kPa (7 109 psi) 50 750 kPa (7 109 psi)

EPG

VCB

VEB Switch position 1 VEB switch position 2

1 2

750 kPa (109 psi) 750 kPa (109 psi)

On On

Off On

3way switch can give 50% (low) or 100% (high) EPG and VCB Cruise control overspeed protection. Engine brake activation. Parameter AF in VECU MID 144

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EPG Activated: engine speed vehicle speed Deactivated: engine speed vehicle speed VCB Activated: engine speed 1 vehicle speed engine oil temperature engine oil temperature charge air pressure Deactivated: engine speed1 vehicle speed engine oil temperature charge air pressure
1 2 3

> 900 rpm > 5 km/h (3 mph)

< 800 rpm < 5 km/h (3 mph)

> 1100 rpm > 5 km/h (3 mph) > 55 > 60 C (131 C (140 F) 2 F) 3

< 50 kPa (7 psi)

< 1000 rpm < 5 km/h (3 mph) < 55 C (131 F)

> 70 kPa (10 psi)

The value is increased to 1400 rpm for the first five activations. Applies at engine oil temperatures 55 - 82  C (131 - 180  F). Oil temperature sensor combined with oil pressure sensor Oil temperature sensor combined with oil level sensor in oil pan

Exhaust Backpressure
Standard muffler, maximum Tuned muffler (D12D-465), maximum
1 1

15 kPa (2.18 psi) 20 kPa (2.9 psi)

or 4.4 in. Hg or 6 in. Hg

Oct. 02 - Jan. 04

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Cooling System
For cooling system volumes and coolant requirements, refer to Service Information, group 18: Coolant Requirements, Volvo Engines. Pressure valve opens at 75 kPa (10.9 psi)

Fan
Viscous Fan (Air Sensing Fan) Speed, engaged (engine speed @ 1800 rpm) Fan pulley diameter 167 mm (6.57 in.) Fan pulley diameter 191 mm (7.52 in.) 2400 rpm 2150 rpm Fan pulley diameter 214 mm (8.43 in.) Speed, not engaged Engagement temperature 1900 rpm 500 - 1000 rpm 75 C (167 of fan F) in front

Electronically Controlled Viscous Fan Activated system Coolant temperature Coolant temperature Engine ECU temperature Condition Start temperature 90 > 93 C (199F) C (194 F) Fan RPM Requested 600 rpm Variable fan speed activation 1200 rpm

Activation ECU temperature > 100 C (212 F), deactivates < 95 C (203 F) Refrigerant pressure > 20 bar (300 psi) Engine speed > 1500 rpm, ambient temp > 40 C (104F), vehicle speed < 45km/h (28 mph) Engine speed > 1200 rpm, ambient temp > 30 C (86F), vehicle speed < 45km/h (28 mph) Ambient temp > 35 C (95F), vehicle speed < 10km/h (6 mph) Ambient temp > 20 C (68F), vehicle speed < 20km/h (12 mph)

AC system

Full engagement (120% of engine speed) example engine speed 1500 rpm x 120% = 1800 approx. fan speed 1200 rpm

1000 rpm

AC system (a/c compressor magnetic clutch activated)

1200 rpm 600 rpm

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On-off Fan
Activation temperature Deactivation temperature Activated System Coolant temperature Engine ECU temperature Intake manifold air temperature (VHD 465 hp only) AC system 91 87 C (196 C (189 F) F) Condition Activation > 91 C (196 F), deactivation 87 C (212 C (189 F) C (203 F) F)

ECU temperature > 100

F), deactivates < 95

> 80 C(176 F) for more than 2.5s, deactivates below 70 for more than 5s Refrigerant pressure > 20 bar (300 psi)

C(158

Thermostat
Quantity Opening temperature 1 82 C (179 F)

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Engine Control System Engine Electronic Control Unit (EECU)

Note: The EECU may not be replaced without prior authorization from Volvo; refer to Service Information, Engine ECU, IMPACT or ID DVD: Info type Diagnostics group 2841.

Number of pins

2 x 62

Sensors
Charge air sensor
Check value 1.05 1.30 V (normal atmospheric pressure)

Intake air temperature sensor

T2019008

Volvo Trucks North America, Inc. Service Bulletin

Date 11.2004

Group

No.

Page 26(42)

200

239

Coolant temperature sensor

T2019009

Intake temperature sensor

T2019010

Volvo Trucks North America, Inc. Service Bulletin

Date 11.2004

Group

No.

Page 27(42)

200

239

Engine oil temperature sensor

T2019011

Camshaft sensor
Distance to camshaft Resistance measurement 0.3 - 1.0 mm (0.012 - 0.039 in.) 775 - 945

Flywheel sensor
Distance to flywheel Resistance measurement 0.7 - 2.1 mm (0.028 - 0.083 in.) 775 - 945

Crankcase Pressure Sensor

Sensor alarm limit Crankcase pressure: normal value (VEB not active) regardless of engine speed, maximum > 8 kPa (1.2 psi) 1.0 kPa (0.13 psi)

Volvo Trucks North America, Inc. Service Bulletin

Date 11.2004

Group

No.

Page 28(42)

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239

Tightening Torques and Patterns Group 20

Tightening M6 standard screw 8.8 M8 standard screw 8.8 M10 standard screw 8.8 M12 standard screw 8.8 M14 standard screw 8.8 M16 standard screw 8.8 Only torque-tightened screws may be reinstalled. Torque and angle tightened / yield point screws: 8.8 10.9 12.9 must not be reinstalled may be reinstalled may be reinstalled Torque 10 1.5 Nm (7.4 1ftlb) (89 13 in-lb) 24 4 Nm (18 3 ftlb) 48 8 Nm (35 6 ftlb) 85 15 Nm (63 11 ftlb) 140 25 Nm (103 18 ftlb) 190 35 Nm (140 26 ftlb)

Note: Check the screw that is being reinstalled. A damaged screw (e.g. with tear damage under the head) must be replaced.

Volvo Trucks North America, Inc. Service Bulletin

Date 11.2004

Group

No.

Page 29(42)

200

239

Group 21
Tightening: Front engine mounting, cylinder block Front engine mounting, crossmember Rear engine mounting, flywheel casing Rear engine mounting, rubber cushion step 1 step 2 Main bearing cap step 1 step 2 Connecting rod cap step 1 275 15 Nm (204 11 ft-lb) 150 20 Nm (110 15 ft-lb) 120 5 175 5 Nm (129 4 ft-lb) 255 38 Nm (188 28 ft-lb) Torque 175 20 Nm (129 15 ft-lb) 85 15 Nm (63 11 ft-lb) 245 35 Nm (181 27 ft-lb) Angle

T2014149

Stiffening frame, tightening sequence

Tightening: Stiffening frame step 1: tighten screws 1-6 in sequence step 2: tighten screws 7-26 in sequence Piston cooling valve, screw* *screws may not be reused.

Torque

Angle

48 8 Nm (36 6 ft-lb) 15 Nm (11 ft-lb) 24 4 Nm (18 3 ft-lb) 90 5

Volvo Trucks North America, Inc. Service Bulletin

Date 11.2004

Group

No.

Page 30(42)

200

239

T2006973

Flywheel, tightening sequence (ensure that flange is dry and clean).

Tightening: Flywheel (tighten screws in numerical order as illustrated): step 1 step 2

Nm

ft-lb

Angle

60 5

44 4 60 5

T2019062

Flywheel housing, tightening sequence.

Tightening: Flywheel housing Note: Apply a string of silicone as illustrated, thickness 2 mm (0.08 in.), max. 20 minutes before assembly.

Torque 140 14 Nm (105 10 ft-lb)

Volvo Trucks North America, Inc. Service Bulletin

Date 11.2004

Group

No.

Page 31(42)

200

239

T2014027

Vibration damper, VN tightening sequence.

W2004219

Vibration damper, VHD tightening sequence.

Tightening: Vibration damper step 1* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . step 2

Torque

Angle

20 5 Nm (15 4 ft-lb) 90 5

...........................................................

* Following the numerical order, tighten screws according to step 1 before tightening according to step 2. NOTE: Screws may NOT be reused if they have been tightened with torque and angle.

T2012845

Valve cover, tightening sequence

Note: If the valve cover is replaced, a new Engine Certification Label must be printed and affixed to the new valve cover via VCADS Pro Engine Label Print, group 2841. Tightening: Valve cover (tighten screws in order as illustrated) Stud, valve cover Torque 20 2 Nm (15 1.5 ft-lb) 40 3 Nm (29 2 ft-lb)

Volvo Trucks North America, Inc. Service Bulletin

Date 11.2004

Group

No.

Page 32(42)

200

239

T2007004

Cylinder head, tightening sequence

Tightening: Cylinder head (tighten screws in order as illustrated): step 1 step 2 (check tightening) step 3 step 4 (turn additional) Cleaning plug, cylinder head Lock nut, valve adjustment screw: Option 1 Option 2 Lock nut, valve yoke (EPG) Lock nut, valve yoke (VEB)

Torque

Angle

60 10 Nm (44 7 ft-lb) 60 10 Nm (44 7 ft-lb) 90 5 90 5 60 10 Nm (44 7 ft-lb)

38 4 Nm (28 3 ft-lb) 60 5 after contact 60 5 after contact 60 +10/-0 after contact

Volvo Trucks North America, Inc. Service Bulletin

Date 11.2004

Group

No.

Page 33(42)

200

239

T2012850

Bearing cap, camshaft/rocker arm shaft, tightening sequence

Tightening: Bearing cap, camshaft/rocker arm shaft step 1 step 2* step 3 step 4 (loosen the screws) step 5

Torque

Angle

15 5 Nm (11 4 ft-lb) 60 5 Nm (44 4 ft-lb) 15 5 Nm (11 4 ft-lb) 0 15 5 Nm (11 4 ft-lb)

90 5

120 5

120 5

*screws must be tightened in stages to ensure that the rocker arm shaft comes down without bending.

Volvo Trucks North America, Inc. Service Bulletin

Date 11.2004

Group

No.

Page 34(42)

200

239

T2019046

Timing gear cover, lower

Tightening: Timing gear cover, lower: Step 1: Apply a thin bead* of silicone as illustrated, including around the marked hole no more than 20 minutes before assembly. Step 2: Working from center outward, tighten to * Solid line = 2 mm bead; dashed line (area A) = 1 mm bead.

Torque

34 4 Nm (24 3 ft-lb)

Volvo Trucks North America, Inc. Service Bulletin

Date 11.2004

Group

No.

Page 35(42)

200

239

T2019925

Timing gear cover, upper

Note: When the upper timing gear cover is

installed, the top section must be flush with the cylinder head.

Tightening: Timing gear cover, upper:

Torque

Step 1: Apply a thin bead of silicone* as illustrated, including around the marked holes, no more than 20 minutes before assembly. Step 2: Tighten screws in order as illustrated: M8 M10 * Thickness 2 mm. 24 4 Nm (18 3 ft-lb) 48 8 Nm (36 6 ft-lb)

Volvo Trucks North America, Inc. Service Bulletin

Date 11.2004

Group

No.

Page 36(42)

200

239

W2004477

Gear train

Timing gears: use the following torques (and angles, when indicated) for the corresponding gear; follow the tightening sequence for each gear as illustrated. Tightening: A. B. C. D. E. F. Camshaft gear Adjustable idler (intermediate) gear Intermediate gear Idler/intermediate gear Crankshaft gear (polygon hub) Idler gear Torque 35 3 Nm (26 2 ft-lb) 15 3 Nm (11 2 ft-lb) 15 3 Nm (11 2 ft-lb) 24 4 Nm (18 3 ft-lb) 645 25 Nm (476 18 ft-lb) 15 3 Nm (11 2 ft-lb) 120 5 Angle 90 5 120 5 120 5

Volvo Trucks North America, Inc. Service Bulletin

Date 11.2004

Group

No.

Page 37(42)

200

239

Group 22

T2017885

Oil pan, tightening sequence

Tightening: Oil pan (tighten bolts in order as illustrated) Drain plug, oil pan Bracket, oil pump/main bearing cap Oil strainer, mounting screws in pump Oil cooler, mounting screws

Torque 24 3 Nm (18 2 ft-lb) 60 10 Nm (44 7 ft-lb) 24 3 Nm (18 2 ft-lb) 27 3 Nm (20 2 ft-lb) 27 3 Nm (20 2 ft-lb)

Volvo Trucks North America, Inc. Service Bulletin

Date 11.2004

Group

No.

Page 38(42)

200

239

T2006825

T2006701

Delivery pipe

Delivery Pipe Step 1: Tighten fitting in cylinder block until it bottoms; approximately Step 2: New pipe Pipe being reinstalled

Torque

Angle

10 Nm (88 inch-lb)

180 60

T2014088

Oil cooler, cover; always use guide pins when installing the cover on the engine.

Tightening: Oil cooler, cover Mount screws A and B Tighten C and D Tighten cover screws in numerical order from the middle outwards (14); see illustration Check tighten screws A and D

Torque

24 4 Nm 24 4 Nm 24 4 Nm 24 4 Nm

(18 3 ft-lb) (18 3 ft-lb) (18 3 ft-lb) (18 3 ft-lb)

Volvo Trucks North America, Inc. Service Bulletin

Date 11.2004

Group

No.

Page 39(42)

200

239

Group 23
Tightening: Retainer, unit injector (new copper sleeve) First tightening step 1 step 2 Loosen the retainer screw before the second tightening. Second tightening step 1 step 2 Retainer, unit injector (reused copper sleeve) step 1 step 2 Lock nut for adjustment screw, unit injector: Option 1 Option 2 Banjo screw, 10 mm Banjo screw, 14 mm Banjo screw, 16 mm 12 2 (108 22 inch-lb) 35 4 (26 3 ft-lb) 40 5 (30 4 ft-lb) 52 4 Nm (38 3 ft-lb) 45 5 20 5 Nm (15 4 ft-lb) 60 5 20 5 Nm (15 4 ft-lb) 60 5 20 5 Nm (15 4 ft-lb) 180 5 Torque Angle

Volvo Trucks North America, Inc. Service Bulletin

Date 11.2004

Group

No.

Page 40(42)

200

239

Group 25

W2004483

Exhaust manifold

Exhaust manifold (refer to illustration for tightening sequence): 1. 2. 3. 4. 5. 6. Tighten bolts 1 to maximum Tighten bolts 2 to maximum Tighten bolts 3 to Tighten bolts 2 to Tighten bolts 4 to Tighten bolts 1 to

Torque 10 Nm 10 Nm 52 4 Nm 52 4 Nm 52 4 Nm 52 4 Nm Torque 10 1 Nm (71 8 inch-lb) 24 2 Nm (18 1.5 ft-lb) 20 3 Nm (15 2 ft-lb) 1.5 0.5 Nm (13 4 inch-lb) 8.5 Nm (75 inch-lb) (88 inch-lb) (88 inch-lb) (38 3 ft-lb) (38 3 ft-lb) (38 3 ft-lb) (38 3 ft-lb)

Tightening Clamp, exhaust manifold (A in illustration) Exhaust pressure governor (EPG) turbine housing Control valve (VEB) Nut electrical connector, VEB-valve V-clamp, turbocharger housing

Volvo Trucks North America, Inc. Service Bulletin

Date 11.2004

Group

No.

Page 41(42)

200

239

EGR System

W2004292

Tightening EGR Pipes: V-clamp Hose clamp, mixing chamber Vibration Damper Assembly: Bracket Vibration Damper

Torque

10 2 Nm (88 17 inch-lb) 5 1 Nm (35 9 inch-lb)

15 3 Nm (133 3 inch-lb) 24 4 Nm (18 3 ft-lb)

W2004261

Tightening sequence for EGR cooler mounting brackets

Note: Older version shown. Newer engine version number 1 in the image has been removed. Front and rear bracket are the same on newer engines. Tightening Sequence EGR cooler mounting bracket, rear tensioning band: 1. 2. Screw (against washer) Screw/lock nut 24 4 Nm (18 3 ft-lb) 12 2 Nm (106 17 inch-lb) Torque

EGR cooler mounting bracket, front tensioning band: 3. Screw/lock nut 12 2 Nm (106 17 inch-lb)

Volvo Trucks North America, Inc. Service Bulletin

Date 11.2004

Group

No.

Page 42(42)

200

239

Group 26
Thermostat, mounting bolts Bolt grade 8.8 Bolt grade 10.9 Torque 24 4 Nm (18 3 ft-lb) 30 4 Nm (22 3 ft-lb)