Service Bulletin

Volvo Trucks North America, Inc.

Greensboro, NC USA Trucks
Date Group No. Page
This Service Bulletin replaces SB 28403, Camshaft
and Flywheel Signals, Fault Tracing Checklist H (11.02), 11.2003 284 03 1(16)
publication no. PV776TSP170583.
Camshaft and Flywheel Signals
Fault Tracing
Checklist H
D12D
Camshaft and Flywheel Signals, Fault Tracing
Checklist H

T2019072

This information covers fault tracing the camshaft and flywheel sensor signals for the
VOLVO D12D engine.

Contents
General Guide to Fault Tracing page 2

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-TSP193976 USA13975
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2003 284 03 2(16)

General Guide to Fault Tracing

You must read and understand the precautions and guidelines in Service Information,
group 20, "General Safety Practices, Engine" before performing any procedure. If
you are not properly trained and certified in a procedure, ask your supervisor for
training before you perform it.

To use this checklist:

1 Complete basic data gathering

Read fault codes
Check vehicle parameters

2 Use the recommendations in appropriate symptom information, plus the

information gathered above to provide a foundation for continued fault tracing
using this checklist.

One fault often affects other systems. Therefore, it is important to confirm or

eliminate suspected causes of faults at an early stage, using tests in VCADS
Pro.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2003 284 03 3(16)

Camshaft and Flywheel Signals, Fault Tracing

See also:

General Guide to Fault Tracing page 2

Vehicle Chassis No. Mileage Customer

Yes No

1 Camshaft signal
2 Flywheel signal

1 Camshaft Position Sensor, Check page 6

T2012820

Note: Engine running at idle.

Does the sensor have the correct distance to the camshaft tooth wheel?

Signal voltage, measured value V

Action:

2 Flywheel Speed Sensor, Signal Check page 7

T2012821

Note: Engine running at idle.

Does the sensor have the correct distance to the flywheel?

Signal voltage, measured value V

Action:
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2003 284 03 4(16)

Vehicle Chassis No. Mileage Customer

Yes No

3 Harness and Connections, Check page 10

T2012822

Note: Signals depicted in illustration are reversed. (Flywheel signal)

Are the wires, wiring harnesses and connectors fault free?

Are the flywheel sensor wires properly connected?

Action:

4 Camshaft Timing, Check page 10

T2012823

Note: Incorrect indication depicted. Camshaft timing is advanced in illustration.

Is the correct tooth wheel installed?

Is the tooth wheel installed correctly?

Are the teeth for the tooth wheel fault free?

Is the camshaft timing correct?

Action:

5 Road Test page 13

Are the camshaft and the flywheel signals fault free when driving under load?

Action:

Notes:

Completed by: Dealer: Date:

Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2003 284 03 5(16)

Camshaft and Flywheel Signals, Fault Tracing

Camshaft and Flywheel Position Sensor, Signal Check
See Diagram A: Cam and Flywheel Signal, Idle
page 14, Diagram B: Cam and Flywheel Signal
Synchronization, Advanced Idle page 15, and
Diagram C: Cam and Flywheel Sensor Wires
Reversed page 16.

Possible fault codes, camshaft position sensor (refer to

Fault Code Information, group 28):

MID 128 SID 21 FMI 3, 8 Engine position, cam sensor.

MID 128 SID 22 FMI 2, 3, 8 Engine speed, flywheel
sensor.
Special tools: 9998489, 9990014, 9990062,
9998699
1
Connect breakout box 9998699 and adapter 9990014
between EA connection on EECU and wiring harness on
lower connector as shown in illustration.

W2004284
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Service Bulletin 11.2003 284 03 6(16)

2
Connect the PC tool to the vehicle diagnostics connector.
Perform Camshaft and flywheel signals, test; follow
instructions in VCADS Pro.

Note: For best results, disconnect power supply from PC

and run PC on internal battery. External power supply
might interfere with or distort signals.

Connect oscilloscope cable to PC and oscilloscope

interface.

Connect red test lead to EA38 and black lead to

EA37. Attached other end of test lead to A terminal
on the oscilloscope interface. This setup reads the
flywheel signal

Connect red test lead to EA45 and black lead to

EA46. Attached other end of test lead to B terminal
on the oscilloscope interface. This setup reads
the cam signal.

9998489, 9990014, 9998699

If the signal from the flywheel sensor is too low, refer to

Flywheel Speed Sensor, Signal Check page 7.

If the signal from the camshaft sensor is too low, refer

to Camshaft Position Sensor, Check page 6.

Camshaft Position Sensor, Check

1
The camshaft sensor signal must exceed 0.5 V for
proper engine start.

The signal to the control unit will weaken as the distance

increases between the camshaft tooth wheel and the
sensor.

2
Check the distance between the camshaft sensor and a
tooth on the camshafts tooth wheel. Compare the value
with the specifications; 0.3 1.0 mm (0.011 0.039 in.).

3
If necessary, remove shims.

Note: If shims are removed, make sure that the sensor

does not come into contact with the camshafts tooth
wheel.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2003 284 03 7(16)

Sensor Resistance Check

4
Measure sensor resistance by connecting breakout
box 9998699 and adapter 9990014 to EA connector
harness side only. Connect red lead of the DMM to pin 45
and black lead to pin 46 of the breakout box. Sensor
resistance should be 775 945 .

5
After corrective action, use the oscilloscope to verify that
the signal is within specifications.

Flywheel Speed Sensor, Signal Check

Special tools: 9996956, 9998517
1
The signal from the flywheel sensor must exceed 0.5 V
for proper engine start.
If the sensor signal is too low, engine operation is affected
(primarily under load).

2
Check that the flywheel sensor is correctly installed
to the flywheel housing.

3
Remove the sensor from the flywheel housing. Check for
damage or metal debris on the magnetic tip of the sensor.

Note: If there is damage to the sensor, determine

the cause.

W2003846

4
Clean and check that the sensors contact surface is
free from burrs.

5
Remove the flywheel housing inspection cover and install
flywheel turning tool 9996956.

9996956
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Service Bulletin 11.2003 284 03 8(16)

6
Use tool 9996956 to rotate the flywheel. Check that the
flywheel does not have any damage that may have
damaged the sensor.

Check Flywheel Sensor Distance

7
Rotate the flywheel until the wide tooth on the flywheel is
aligned with the sensor bore.

Note: Use a light and mirror to locate the wide tooth.

8
Install the adjustable ring to the center of tool 9998517.

9998517

C2002602

9
Carefully insert tool 9998517 into the sensor bore until it
contacts the wide tooth. At this point, the adjustable ring
should contact the flywheel housing.

T2012720

10
Remove the tool and measure the distance (A) between
the adjustable clip and the tool end. Note the measured
value (A).

C2002603
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Service Bulletin 11.2003 284 03 9(16)

11
Insert the sensor into tool 9998517. Measure the distance
between the sensors contact surface and the end of the
tool (B). Note the measured value (B).

W2003847

12
Calculate the sensor distance using the following formula
(measurements are in mm):

Distance (A) _________

Distance (B) - _________

Tool Depth (C) - 20

Flywheel Sensor Distance (D) = _________

Note: The measured flywheel sensor distance (D) should

be 0.7 2.1 mm (0.028 0.083 in.).

13
If distance (D) is not within specifications, add or remove
a shim as necessary (part no. 1677894) to obtain
the correct value.

14
Remove the flywheel turning tool 9996956 and reinstall
the flywheel housing inspection cover.

Sensor Resistance Check

15
Measure sensor resistance by connecting breakout box
9998699 and adapter 9990014 to EA connector only.
Connect red lead of the DMM to pin 38 and black lead to
pin 37 of the breakout box. Sensor resistance should
be 775 945 .

16
After corrective action, use the oscilloscope to check
that the signal is within tolerances.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2003 284 03 10(16)

Harness and Connections, Check

See Diagram C: Cam and Flywheel Sensor Wires
Reversed page 16. Also refer to Fault Code Information,
group 28.

Possible fault codes:

MID 128 SID 21 FMI 8

MID 128 SID 22 FMI 2, 3, 8

1
If any of the signals have severe interference or open
circuits, the wiring harnesses and connectors must be
examined for damage, poor contact, or a short circuit.

Note: A mirror-inverted signal from the flywheel sensor

indicates that the wiring from the flywheel sensor
is reversed.

Camshaft Timing, Check

See Diagram A: Cam and Flywheel Signal, Idle
page 14 and Diagram B: Cam and Flywheel Signal
Synchronization, Advanced Idle page 15. Also refer
to Fault Code Information, group 28.

Possible fault code:

MID 128 SID 21 FMI 8 Engine position, cam sensor

1
Remove the valve cover.

2
Check that the teeth on the camshaft tooth wheel are not
damaged, and that the tooth wheel is properly installed.

3
Check that the correct tooth wheel is installed; verify
the part number.

Note: Different tooth wheels are used on VN and VHD

models. The camshaft sensor is located in the 4 oclock
position on the VN models and in the 6 oclock position
on VHD models.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2003 284 03 11(16)

T2014923 Check that the camshaft is correctly timed by checking

if the TDC mark on the camshaft corresponds to the
marking on the front bearing cap and that the flywheel
marking 0 is positioned opposite the mark on the
flywheel casing.

T2017010

5
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 calliper for

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

W2004290
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Service Bulletin 11.2003 284 03 12(16)

6
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.).

If the value is not correct, refer to Service Information,

group 21: Camshaft Timing, Check.

T2017011

7
After the check has been made, rotate the engine until no.
1 is between markings on the front bearing cap. Adjust
the valve clearance to 0.2 mm (0.008 in.).

8
Check that the adjustable timing gear is not loose.

9
Remove test equipment and install valve cover.
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Service Bulletin 11.2003 284 03 13(16)

Road Test
1
If the problem with uneven operation only occurs on
specific occasions, a measurement of the camshaft and
the flywheel signals can be carried out during a test drive.

2
As much as possible, try to duplicate the driving
conditions when the problems occur.

3
If the camshaft signal crosses over the signal from the
flywheel sensor very near the limit of the marked area in
diagram B, during a test drive under load it may be shown
that the signals cross over each other outside the marked
area. This entails that engine has an uneven operation.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2003 284 03 14(16)

Signal Diagrams
Use the oscilloscope to check the signal diagram after
taking any action that could change the signals. This
includes replacing or adjusting the adjustable timing
gear, replacing the tooth wheel, replacing the flywheel,
or replacing or adjusting cam and flywheel sensors.

Diagram A: Cam and Flywheel

Signal, Idle

W2003347

A Advanced
B OK
C Retarded

The diagram shows correct signals from the camshaft

sensor and the flywheel sensor. The signal from the
camshaft sensor should cross the flywheel signal within
the marked area (B).
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Service Bulletin 11.2003 284 03 15(16)

Diagram B: Cam and Flywheel

Signal Synchronization, Advanced
Idle

T2012823

The diagram shows that the camshaft signal crosses over

the signal from the flywheel sensor very near the limit
for the marked area in diagram A.
Turning the tooth wheel in the direction of camshaft
rotation will move the curve to the left.

Turning the tooth wheel against the direction of

camshaft rotation will move the curve to the right.

If the curves cross over each other outside the marked

area (B) in Diagram A: Cam and Flywheel Signal, Idle
page 14, the camshaft may be incorrectly timed.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2003 284 03 16(16)

Diagram C: Cam and Flywheel

Sensor Wires Reversed

T2012822

The diagram shows that the curve for the flywheel signal
is mirror-inverted. This means that the wiring from the
flywheel sensor or the wiring from the oscilloscope
is reversed.

Check the oscilloscope connection. If the wiring is

correctly connected, check the wiring for the flywheel
sensor.

Disconnect the flywheel sensor connector and switch

the location of wiring on the sensor harness connector.
Reconnect the sensor connector and use the oscilloscope
to check for correct signal.