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Service Bulletin

Volvo Trucks North America


Greensboro, NC USA Trucks
Date Group No. Page
This Service Bulletin replaces SB 215-19, Camshaft,
D12D (11.2002), publication no. PV776-TSP180853. 9.2006 215 29 1(16)

Camshaft
D12D
Camshaft

W2003779

This information covers procedures for servicing the camshaft on the VOLVO D12D
engine.

Contents
Special Tools page 2
Camshaft, Replacement page 3
Camshaft Timing, Checking page 15

Note: Information is subject to change without notice.


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

PV776-20177447 USA23126.ihval
Volvo Trucks North America Date Group No. Page
Service Bulletin 9.2006 215 29 2(16)

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

9996049 9996956 9998255


Coolant drain hose Flywheel Turning Tool Rocker Arm Bridge Lifting Tool

9998264 9998602-6/2 J44457


Camshaft Removal Tool Front cover alignment tool Bearing cap removal tool

J44514 J45242 DBT2V700


Camshaft alignment kit Lifting bracket Coolant Extractor
Volvo Trucks North America Date Group No. Page
Service Bulletin 9.2006 215 29 3(16)

Service Procedures
2154-03-02-01
Camshaft, Replacement
See also:

Camshaft 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: 9996049, 9996956, 9998255,


9998264, 99986026/2, J44457, J44514,
DBT2V700

Removal
1

WARNING
When disconnecting battery cables, disconnect the
ground (negative) battery first to prevent personal
injury from electrical shock.

Turn ignition key to OFF position. Disconnect ground


wiring from electrical equipment connected directly to
the batteries, such as ECUs, satellite systems, etc.
Disconnect the main ground cable(s).

Note: If vehicle is equipped with master switch, battery


cable removal is not necessary. If equipped, turn OFF
master switch.

2
Install coolant extraction tool DBT2V700 to drain fitting at
bottom of radiator. Drain Coolant.

Note: An alternate method is to connect coolant drain


hose 996049 to fitting and drain coolant into an approved
container.

DBT2V700, 9996049
Volvo Trucks North America Date Group No. Page
Service Bulletin 9.2006 215 29 4(16)

3
Remove inner fender and bracket on left and right sides.

W2003849

4
Remove air filter housing and fresh air pipe to
turbocharger; refer to Service Information, group 25.

W2003859

5
Remove EGR wiring harness rail bolts from top of
EGR cooler.

W2003828

6
Remove fan ring from upper radiator coolant neck.

7
Remove upper radiator hose.

8
Remove upper radiator coolant neck from cylinder head.
Volvo Trucks North America Date Group No. Page
Service Bulletin 9.2006 215 29 5(16)

9
Remove main discharge line from air compressor.
Remove all support bracket bolts for the discharge line.

W2003816

10
Remove clamp from EGR cooler and hose clamp from
mixing chamber. Remove pipe.

W2003853

11
Remove the valve cover; refer to Service Information
group 211.
Note: On VNM and VHD models, engine cover should be
removed to permit valve cover removal.

12
Disconnect the wiring harness for the VEB control valve.

13
Remove the VEB control valve.

Note: Install rubber bands on VEB plungers to keep them


from accidentally separating during rocker arm removal.

14
Remove the rocker arm assembly bolts.

Note: Gradually loosen the bolts to avoid distorting the


rocker arm shaft.

15
Install lifting tool 9998255. Using a suitable lift, remove
rocker arm assembly.
Note: Lifting bracket J45242 should also be used on
VNM and VHD models.

9998255
, J45242
Volvo Trucks North America Date Group No. Page
Service Bulletin 9.2006 215 29 6(16)

16
Remove camshaft sensor (and shim, if used).

17
Remove camshaft gear and damper.

18
Remove front crankshaft breather tube from upper
front cover.

19
Remove wiring harness clamps from upper front cover.

20
Remove mounting bolts in upper front cover. Remove
cover.

21
Remove the outer camshaft bearing cap bolts and studs.
(Note the position of the studs for the valve cover.)

22
Using tool J44457, remove the camshaft bearing caps.

Note: Mark each bearing caps for its respective bearing


housing before removal.

J44457

23
Using camshaft lifting tool 9998264, remove camshaft
from the cylinder head.

Note: Lifting bracket J45242 should also be used on


VNM and VHD models.

9998264
, J45242
Volvo Trucks North America Date Group No. Page
Service Bulletin 9.2006 215 29 7(16)

Installation
1
Inspect upper and lower cam bearing housings for
excessive wear or damage. Replace if necessary.

2
Clean camshaft with solvent and compressed air.

3
Install lower camshaft bearing shells to lower bearing
caps. Lubricate bearings with oil or lithium grease.

4
Using camshaft lifting tool 9998264, carefully lower
camshaft into place without gear attached. Remove
lifting tool.
Note: Lifting bracket J45242 should also be used on
VNM and VHD models.

9998264
, J45242

5
Install bearing shells to their corresponding upper
camshaft bearing caps.

6
Install all 7 upper camshaft bearing caps to their
respective positions. Gently tap into place using a
deadblow hammer.

W2004006

7
Install outer camshaft bearing cap bolts and studs.
Hand-tighten only. Note location of valve cover studs.

8
Using a rag to protect the camshaft, hand-turn the
camshaft to make sure that it rotates freely and does
not bind. Axial play should be no more than 0.35 mm
(0.014 in.).

W2004008
Volvo Trucks North America Date Group No. Page
Service Bulletin 9.2006 215 29 8(16)

9
Remove flywheel inspection cover.

10
Install flywheel turning tool 9996956 and rotate engine
to 0 TDC.

Note: Make sure TDC mark on camshaft is between


the two hash marks on front cam bearing cap before
gear is installed.

W2003493

11
Position camshaft gear against camshaft.

W2004022

12
Using alignment kit J44514, install camshaft alignment
collar (A) to front of gear. Install camshaft alignment tool
(B) to verify that camshaft is aligned at TDC.

J44514

W2004023
Volvo Trucks North America Date Group No. Page
Service Bulletin 9.2006 215 29 9(16)

13
Set up a dial indicator on the adjustable idler gear.

W2003495

14
Use a pry bar or long screwdriver to hold the intermediate
idler gear in place. Measure the gearlash between the
intermediate-to-adjustable idler gears by rocking the
adjustable idler gear back and forth. Acceptable gear
backlash is between 0.05 0.17 mm (0.002 0.007 in.).

W2004075

15
Set up a dial indicator on the camshaft gear; use a pry
bar or long screwdriver to hold the adjustable idler
gear in place.

W2003497
Volvo Trucks North America Date Group No. Page
Service Bulletin 9.2006 215 29 10(16)

16
Measure the gearlash between the camshaft gear and
the adjustable idler gear by rocking the camshaft gear
back and forth. Acceptable gear backlash is between
0.05 0.17 mm (0.002 0.007 in.).

Note: If either backlash is out of specification, the


adjustable idler gear must be adjusted; refer to Service
Information, group 21.

W2003498

17
Remove camshaft alignment collar.

18
Install camshaft damper (A) and cam sensor tooth
wheel (B).

W2004024

19
Install spacer and new bolts. Using proper tightening
sequence, torque-tighten bolts to 35 3 Nm (26 2 ft-lb),
then turn an additional 90 5 .

Note: Do not reuse bolts.

35 3 Nm
(26 2 ft-lb);
then 90 5

W2004025

20
Using lifting tool 9998255, install rocker arm shaft
to cylinder head.

Note: Lifting bracket J45242 should also be used on


VNM and VHD models.

9998255
, J45242
Volvo Trucks North America Date Group No. Page
Service Bulletin 9.2006 215 29 11(16)

21
Using a crossover pattern, tighten the rocker arm shaft
bolts just until the rocker arm shaft bottoms out against
the bearing housings.

22
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 is not distorted when bolted down.

T2012850

Rocker arm shaft, tightening sequence

23
Install VEB valve to the rocker arm shaft, using new O-ring
seals. Torque-tighten bolts to 24 4 Nm (18 3 ft-lb).
Note: Remove all rubber bands from VEB plungers.

24 4 Nm
(18 3 ft-lb)

W2004053

24
Adjust the valves and injectors according to
specifications; refer to Service Information, group 21.
Also check the VEB exhaust valve clearances.

25
Clean sealing surface on cylinder head and top of
lower front cover.
Note: Cover opening to prevent debris from entering
engine.

W2004026
Volvo Trucks North America Date Group No. Page
Service Bulletin 9.2006 215 29 12(16)

26
Clean sealing surface of upper front cover. Using
pressurized air, blow off any debris (wear appropriate
eye protection).

27
Install gasket between upper and lower front covers. Note:
sealant must be placed at front corners of upper cover
and at indentation along side of cover to prevent leaks.

W2004027

28
Apply a 2 mm bead of sealant to the contact surface
of the upper front cover. Make sure that the sealant
completely surrounds the bolt holes.

Note: Cover should be torque-tightened within 20


minutes after applying sealant.

W2004028

29
Install the upper front cover. Position bolts, but do
not tighten.
Volvo Trucks North America Date Group No. Page
Service Bulletin 9.2006 215 29 13(16)

30

W2004029 Install front cover alignment tool 9998602-6/2. Tighten


bolts to align the front cover.

Note: Tighten until upper front cover is flush with cylinder


head on both sides.

W2004030

31
Torque-tighten upper front cover bolts in order as follows:
M8: 24 4 Nm
(18 3 ft-lb)

M10: 48 8 Nm
(36 6 ft-lb)

T2019925

32
Remove upper front cover alignment tool.
Volvo Trucks North America Date Group No. Page
Service Bulletin 9.2006 215 29 14(16)

33
Install camshaft sensor to upper front cover.

Note: The distance between sensor and sensor tooth


wheel should be 0.3 1.0 mm (0.012 0.039 in.)

34
Install wiring harness and clamps to upper front cover.

35
Install main air compressor line to air compressor and
support brackets.

36
Install crankcase breather tube to upper front cover.

37
Install EGR pipe between reed valve housing and
mixing chamber.

Note: Use new O-ring seal.

W2003853

38
Replace the valve cover gasket.

39
Clean the valve cover sealing surface and install the valve
cover; refer to Service Information, group 211.

40
Install upper radiator coolant neck.

41
Install fan ring to upper coolant neck.

42
Install upper coolant hose from radiator to cylinder block.
Volvo Trucks North America Date Group No. Page
Service Bulletin 9.2006 215 29 15(16)

43
Install air filter housing and fresh air pipe to turbocharger;
refer to Service Information, group 25.

W2003859

44
Install left and right inner fenders.

45
Fill cooling system with approved coolant to specified
level.

46
Turn on master switch (if equipped), or reconnect battery
cables.

47
Start engine and check for leaks.

2154-06-03-01
Camshaft Timing, Checking
See also:

Camshaft 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: 9996956


Volvo Trucks North America Date Group No. Page
Service Bulletin 9.2006 215 29 16(16)

1
Perform a valve lift check on the intake valves for cylinder
1 to check that the camshaft is correctly installed.

Before adjusting, ensure that the camshaft is set to TDC.


Temporarily adjust the no. 1 intake valve to zero
clearance.

Position a dial indicator toward the intake valve caliper for


cylinder 1. Pretension the dial indicator and reset to 0.

T2019068

2
Using tool 9996956, turn engine in direction of rotation to
6 ATDC on the flywheel. The valve must open 1.6 0.3
mm (0.063 0.001 in.).

9996956

T2017011

3
After completing the check, rotate the engine until no. 1
is between markings on the front bearing cap. Adjust
valve clearance to 0.2 mm (0.008 in.).