TSI Volvo Trucks North America, Inc. Greensboro, NC USA This TSI Service Bulletin replaces TSI Service Bulletin 215–001, “Camshaft, D12, D12A, D12B” (11.2001), publication no. PV776–TSP160576. Date Group No. 8.2003 215 001 Supp. Page 1(21) Camshaft D12, D12A, D12B Camshaft W2002653 Fig. 1: VOLVO D12B Engine This information covers procedures for camshaft repair on VOLVO D12, D12A, and D12B engines.
Volvo Trucks North America, Inc. TSI Date Group No. Page 8.2003 215 001 2(21) Tools Special Tools The following special tools are used to replace or repair components. The tools can be ordered from Volvo. Please use the specified part number when ordering.
Volvo Trucks North America, Inc. TSI Date Group No. Page 8.2003 215 001 3(21) Service Procedures 2154-03-02-01 Camshaft, Replacement (With EPG or VEB) 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.
Volvo Trucks North America, Inc. TSI Date Group No. Page 8.2003 215 001 4(21) 3 Remove the upper timing gear cover. 4 T2006672 Remove the inspection cover from underneath the flywheel housing and install turning tool 9996956. 9996956 T2008251 5 Turn the flywheel around until the piston in cylinder number 1 is in the Top Dead Center position (0 ) on the flywheel and the camshaft marking (TDC) is opposite the marking on the bearing cap.
Volvo Trucks North America, Inc. TSI Date Group No. Page 8.2003 215 001 5(21) 6 Remove the adjustable idler gear. T2007095 Fig. 3: Bolts holding the idler gear in place 7 If the engine is equipped with VEB, remove the control valve and pipe. Plug the ports and place it in a plastic bag to avoid it being subjected to dirt and contamination. To facilitate removal, remove the valve cover stud bolt.
Volvo Trucks North America, Inc. TSI Date Group No. Page 8.2003 215 001 6(21) 8 T2006777 Fig. 4: Removing the rocker arm shaft assembly bolts Loosen the rocker arm shaft bolts gradually to avoid bending the arm shaft assembly. Remove the bolts, install tool 9998255 and lift off the rocker arm shaft assembly. Note: On engines equipped with VEB, wrap a rubber band around each exhaust rocker lever and slave piston. This is to prevent the VEB slave pistons from falling out of their rocker arm bore.
Volvo Trucks North America, Inc. TSI Date Group No. Page 8.2003 215 001 7(21) 10 Install camshaft counterhold tool 9998270 on the rear of the camshaft. Loosen and remove the camshaft drive gear center bolt and the cam gear. 9998270 T2007148 Fig. 7: Tool 9998270 installed 11 Remove the camshaft cap bolts. Mark the caps for the respective bearing housings, and remove. Note: To facilitate the removal of the camshaft bearing caps, use tool J–44457.
Volvo Trucks North America, Inc. TSI Date Group No. Page 8.2003 215 001 8(21) Installation 15 Position the camshaft bearing housings on the cylinder head by observing the factory marks 1–7. Note: Check that the mating surface is clean under the bearing housings and that the guide pins are in good condition. If installing a new cylinder head, also use the bearing housings supplied with the cylinder head. 16 T2007126 Fig.
Volvo Trucks North America, Inc. TSI Date Group No. Page 8.2003 215 001 9(21) 18 Install the camshaft drive gear. Use tool 9998270 to lock the camshaft into place. Torque-tighten to 645 ± 25 Nm (475 ± 18 ft-lb). Note: Do NOT install the bolts for the rocker arm shaft. 645 ± 25 Nm (475 ± 18 ft-lb) 9998270 T2007148 Fig. 11: Installing the camshaft drive gear 19 Adjust the camshaft timing; refer to “Camshaft Timing, Check and Adjust” page 18.
Volvo Trucks North America, Inc. TSI Date Group No. 8.2003 215 001 Page 10(21) 22 T2006777 Fig.
Volvo Trucks North America, Inc. TSI Date Group No. 8.2003 215 001 Page 11(21) 25 Clean the contact surfaces for the upper timing gear cover. Install a new rubber seal. 26 Apply an even bead of sealant around the timing gear cover. Install the cover. CAUTION Do not allow sealant to harden before installing the cover. The bolts must be torque-tightened within 20 minutes. 27 Install the alignment tool J–41272 on the forward right-hand valve cover stud using an existing valve cover nut.
Volvo Trucks North America, Inc. TSI Date Group No. 8.2003 215 001 Page 12(21) 29 Rotate the camshaft until the cam sensor wheel tooth aligns with the cam sensor. Verify that the air gap is between 0.3 – 0.7 mm (0.012 – 0.028 in.). Adjust if needed by removing or adding shims between the sensor and the cover. Relocate the timing cover, before the sealant hardens, if necessary to aid in obtaining the proper air gap. Note: Make sure the air gap is between 0.3 – 0.7 mm (0.011 – 0.028 in.). 0.3 – 0.
Volvo Trucks North America, Inc. TSI • Date Group No. 8.2003 215 001 Page 13(21) Use the portion of the pointer that is fastened to the tool shaft as a reference surface since this part is protected from being bent (4). Special tools: 9996956, J–41272, J–42773 1 Steam clean around the valve cover and the upper front cover. 2 Disconnect the negative battery lead. 3 VN model only Drain coolant and then remove the top right fan ring support and the top radiator neck from the thermostat housing.
Volvo Trucks North America, Inc. TSI Date Group No. 8.2003 215 001 Page 14(21) 12 Install camshaft alignment tool J–42773 by inserting the guide pin into the hole under the camshaft drive gear. Rotate the tool to position the lever against the drive gear teeth to ensure that the tool is positioned correctly. Rotate engine in the direction of rotation until the 2 dots on the camshaft gear are equally spaced on both sides of the camshaft alignment tool. J–42773 T2012262 Fig.
Volvo Trucks North America, Inc. TSI Date Group No. 8.2003 215 001 Page 15(21) 18 Install the front cover positioning tool, J–41272. Tighten bolts to align front cover. Torque the cover mounting bolts to 33 ± 4 Nm (24 ± 3 ft-lb). Verify that the cover is flush with the head. Note: Tighten positioning tool, J-41272 until upper front cover is flush with cylinder head on both sides. J–41272 33 ± 4 Nm (24 ± 3 ft-lb) 19 Remove tool, J–41272.
Volvo Trucks North America, Inc. TSI Date Group No. 8.2003 215 001 Page 16(21) 24 Install the valve cover and torque-tighten the bolts to specifications using the proper sequence (see Fig. 18: Valve cover tightening sequence, page 16). T2007003 Fig. 18: Valve cover tightening sequence Note: Tighten the valve cover nuts according to the proper sequence and torque. This is to prevent the valve cover from cracking and also to keep the studs in the cylinder head from loosening.
Volvo Trucks North America, Inc. TSI Date Group No. 8.2003 215 001 Page 17(21) 30 Run the engine until the coolant reaches operating temperature. Allow to idle for approximately 10 minutes for cylinder balancing. For cylinder balancing to take place, the following conditions must be satisfied: • • • • • • • • Idling speed must be below 650 RPM. • No fault codes present. Fuel requirement must be below a specific rating. Idling adjustment function must not be active.
Volvo Trucks North America, Inc. TSI Date Group No. 8.2003 215 001 Page 18(21) 2154-06-03-02 Camshaft Timing, Check and Adjust 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.
Volvo Trucks North America, Inc. TSI Date Group No. 8.2003 215 001 Page 19(21) 3 Using flywheel turning tool 9996956, turn the flywheel opposite to the direction of engine rotation (A) approximately 15 BTDC. Then turn the flywheel in direction of engine rotation (B) until the 0 mark on the flywheel lines up exactly with the pointer on the flywheel housing without passing the 0 mark. CAUTION If the flywheel is turned past 0 TDC, repeat the above step, completely. Do not just back up the flywheel.
Volvo Trucks North America, Inc. TSI Date Group No. 8.2003 215 001 Page 20(21) 6 W2002245 Insert two 0.10 mm (0.004 in.) feeler gauges on the load sides of the (A and B) gear. T2008255 7 Torque the bolts to an initial torque of 5 ± 3 Nm (11 ± 2 ft-lb). Note: An additional 120 ± 5 backlash is confirmed. is required after the correct 15 ± 3 Nm (11 ± 2 ft-lb) 8 Check that both feeler gauges have the same resistance when inserting them and pulling them out. The correct backlash is 0.05 - 0.
Volvo Trucks North America, Inc. TSI Date Group No. 8.2003 215 001 9 Tighten the bolts an additional 120 ± 5 sequence shown. Page 21(21) per the torque W2002245 10 Re-check camshaft timing; refer to “Camshaft Timing, Checking” page 12. For information on valve adjustment and injector installation, also refer to Service Information, Group 21.
