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Fuel System - D12,D12A,D12B,D12C

1. e Incorrect camshaft to crankshaft static timing e Refer to Camshaft Timing procedure Group 21 If the answer to any of the following is yes static timing may be the cause of the fault e Have previous repairs been made to the engine that required removing the camshaft e Can you clear the fault code unplug the camshaft sensor start the engine and the fault code does not return e Can you clear the fault code start the engine set the idle above the base idle and the fault code does not return 33 Group 23 Fuel System D12 D12A D12B D12C Locating Air in the Fuel System Air in the fuel being supplied to the engine can cause a number of problems including hard starting poor perfor mance and excessive smoke Air can enter the fuel system at several points suction side fuel supply lines pick up in the fuel tank primary fuel filter copper sleeve to injector seat injector tip fuel supply pump seals Locating the point of entry can be troublesome and time consuming kit has been developed to aid in this process The kit J 42753 consists of two fuel line sight glass assemblies two transparent hose assemblies a clamp a washer a hollow screw copper gaskets O rings 34 Troubleshooting Group 23 Fuel System D12 D12A D12B D12C Troubleshooting Determining Whether There is Air in the Fuel AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutra
2. Service Procedures 2371 03 02 02 Unit Injector Replacement One Not Included e Unit Injector Adjustment page 67 Note Before beginning this service procedure please review General Work Practices page 43 AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death AN DANGER Do not service any part of the fuel system while smoking or in the presence of flames sparks or hot surfaces Failure to follow these precautions can result in fire which can cause serious injury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Fuel oil or coolant leaked spilled onto hot surfaces or electrical components can cause a fire Clean up spills immediately Special tools 9998249 9998511 9998599 J 44515 63 Group 23 Fuel System D12 D12A D12B D12C Prerequisites e Valve cover removed e Control valve removed e Pipe removed between control valve and rocker arm shaft N Release the rocker arm bridge as per the specifications 64 T2008812 T2009070 Service Procedures W2003391 Drain the fuel out of the system to pre vent fuel running down into the c
3. Fuel oil or coolant leaked spilled onto hot surfaces or electrical components can cause a fire Clean up spills immediately Special tools 9996666 9998496 J 39200 Service Procedures 999 8496 J 39200 W2002209 999 6666 I an W2003513 Fig 56 Bleed nipple D12C Remove the bleed nipple at the rear of J 39200 the head install adapter 9996666 and pressure transducer 9998496 Con nect the transducer to the multimeter J 39200 Note The pressure transducer mea surement scale is in kPa 2 Slowly pump the hand pump while monitoring the fuel pressure The pressure should rise to a point deter mined by the opening of the overflow valve then drop quickly Recheck sev eral times to get an accurate reading 59 Group 23 Fuel System D12 D12A D12B D12C 3 The opening pressure should corre spond to specifications found in Fuel Supply Pump and Overflow Valve page 5 Note If the overflow valve opens at a pressure that is less than that given in the specification low fuel pressure will result The valve must be replaced 4 Replace the valve if necessary 60 Service Procedures 2339 03 02 02 Overflow Valve Replacement D12 D12A D12B Note Before beginning this service procedure please review General Work Practices page 43 AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can res
4. 58 Service Procedures Bleed vent the fuel system at the fuel filter Connect a transparent plastic hose to the bleed nipple Open the bleed nipple and pump the hand primer until clean fuel runs out of the hose Tighten the bleed nipple while fuel is still running out see Fuel Sys tem Bleeding page 50 6 Remove the hose and reinstall the protection plug on the bleed nipple 7 Apply parking brake and shift lever into neutral 8 Start the engine Allow it to run at fast idle or with the PTO engaged for about 10 minutes to evacuate any residual air in the fuel system Group 23 Fuel System D12 D12A D12B D12C 2339 06 02 02 Overflow Valve Checking D12 D12A D12B Note Before beginning this service procedure please review General Work Practices page 43 AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death AN DANGER Do not service any part of the fuel system while smoking or in the presence of flames sparks or hot surfaces Failure to follow these precautions can result in fire which can cause serious injury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment
5. eliminating the need for an external fuel return maa Electronic unit injector EUI Overflow valve Fuel tank Fuel filter Group 23 Fuel System D12 D12A D12B D12C D12B Unlike the D12A the EECU on the D12B is fitted with an external fuel cooling coil ES nn A ALE ai ia ve Mn i AA Fig 13 D12B Fuel flow NA 1 Supply pump 4 Fuel gallery 2 EECU 5 Unit injector 3 Bleed line The fuel system s supply pump 1 is attached to the tim ing gear plate and is driven via a groove in the pump shaft from the engine s timing gears The supply pump pulls fuel from the tank 7 through the EECU s cooling coil which cools the EECU The return fuel from the cylinder head is then blended with this fuel and enters the supply pump From the supply pump 1 a bleed line 3 leads back to the fuel tank to provide continuous venting for the system With the bleed line 3 as the only return line to the tank the only fuel passing through the EECU s cooling coil is the amount consumed by the engine From the supply pump 1 the fuel is forced through the fuel filter 8 and then into the cylinder head fuel gallery 4 The fuel gallery is designed so that it surrounds that part of the unit injectors 5 where the fuel holes are lo cated The system s overflow valve 6 is located in the fuel gallery s outlet connection The overflow valve regulates the fuel system s supply pressure All fuel tha
6. 1 Disconnect the two fuel lines from the overflow valve at the rear of the cylin der head and install the sight glass 4 and line assembly onto the overflow valve using hollow screw 941686 from the kit and route into the fuel tank Tie down the line to prevent it from moving out of the tank 2 Remove the fuel supply line from the fuel supply pump and install the alter nate fuel supply line onto the feed pump Route the line back to the fuel tank Tie down the line to prevent it from moving out of the fuel level inside the tank Note For engines equipped with the small line located between the fuel supply pump and the top of the engine electronic control unit EECU this line must be disconnected from the fuel supply pump The port from which the line was removed 5 must be plugged using two copper gaskets and washer 949873 supplied in the fuel line kit 3 Start the engine and allow 3 minutes for the sight glass to clear Take note of the air present in the fuel sight glass 4 4 Stop the engine and remove the valve cover 41 Group 23 Fuel System D12 D12A D12B D12C D W2003027 Fig 26 1 base circle of camshaft Rotate the engine by hand until the rocker arm for the intake valve for num ber 1 cylinder is on the base circle of the cam in other words in position to be adjusted Turn the adjusting screw down clockwise until all clearance has been removed then turn it down an additional 1 4 t
7. 4 smoking or in the presence of flames sparks or hot Remove the hand primer pump mount surfaces Failure to follow these precautions can result ing bolts in fire which can cause serious injury or death 5 Install the new hand primer pump us AN WARNING ing new sealing washers HOT ENGINE Keep yourself and your test equipment 6 clear of all moving parts or hot engine parts and or Reconnect the mounting bolts and fuel fluids A hot engine and or fluids can cause burns or lines can permanently damage test equipment 7 Bleed the fuel system see Fuel Sys AN WARNING tem Bleeding page 50 Fuel oil or coolant leaked spilled onto hot surfaces or electrical components can cause a fire Clean up spills immediately 8 Apply parking brake and place the gear lever into neutral Special tools 9996671 9 1 Start the engine Allow it to run at fast Clean the area around the fuel filter idle or with the PTO engaged for area about five minutes to remove air from the system and check for leaks 57 Group 23 Fuel System D12 D12A D12B D12C SW U DO W2003389 Remove the fuel filter 3 Clean the sealing surface making sure that there is no residual gasket 4 Install the new fuel filter following the instructions on the filter Do not fill the new fuel filter with fuel before installing Doing so may allow foreign objects to get into the fuel and can cause the injectors to malfuction
8. Bulletin Group 23 for accessory drive pulley information Note Refer to Service Bulletin Group 23 for fuel line information 44 Service Procedures Turning the Engine Over with the Starter Motor 1 AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Apply the parking brake block the wheels and place the gear lever in neutral Make sure that the ignition key is in the OFF position W3000459 Fig 28 EECU power supply relay D12A B W5001141 Fig 29 R3 relay location TEC Panel D12C For D12 A B only disconnect the EECU power supply relay 1 for D12C and later versions of D128 disconnect the R3 relay located in the TEC panel Group 23 Fuel System D12 D12A D12B D12C Service Procedures 3 2309 06 02 03 Fuel System Pressure Check ing Note Before beginning this service procedure please review General Work Practices page 43 AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death TD AN DANGER ped nt FIT Do not service any part of the fuel system while W3000458 smoking or in the presence of flames sparks
9. D12A D12B D12C Spill Phase The spill phase begins when the camshaft turns to the position at which the camshaft lobe forces the rocker arm to push the pump plunger 2 down The fuel can now flow through the fuel valve 1 through the holes in the EUI and out through the fuel gallery 4 The spill phase continues as long as the fuel valve 1 is open RON Design and Function Fig 8 Spill phase Fuel valve Pump plunger Fuel outlet overflow Fuel gallery inlet and outlet 72006814 Group 23 Fuel System D12 D12A D12B D12C Design and Function Injection Phase The injection phase begins when the fuel valve 1 closes The camshaft lobe and rocker arm continue to press down the pump plunger 2 and injection occurs as the route through the fuel valve closes The injection phase continues as long as the fuel valve 1 is closed T2006815 Fig 9 Injection phase Fuel valve Pump plunger Fuel outlet overflow Fuel gallery inlet and outlet BON 16 Group 23 Fuel System D12 D12A D12B D12C Pressure Drop Phase The injection phase ends when the fuel valve 1 opens and pressure in the EUI drops below the nozzle opening pressure The fuel flows through the open fuel valve 1 through the electronic unit injector holes and out through the fuel gallery 4 Note that the fuel valve position closed or open determines when the injection
10. a torque of 1 4 0 1 Nm 3 5 0 88 in lb Do not overtorque This will break the stud Install the rocker arm bridge and tighten with a torque as per the speci fications 13 T2008812 Install the control valve 15 Connect the cables on the solenoid 1 4 0 1 Nm valve 3 5 0 88 in lb Note Tighten the nuts with a torque of 1 4 0 1 Nm 3 5 0 88 in lb Do not overtorque This will break the stud Adjust the valves T2009070 Install the pipe between the rocker arm shaft and control valve 17 Install the valve cover and tighten ac cording to the tightening schedule in the specifications 66 Group 23 Fuel System D12 D12A D12B D12C Service Procedures 2371 05 02 01 Unit Injector Adjustment Adjusting pre load Note Before beginning this service procedure please review General Work Practices page 43 AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death AN DANGER Do not service any part of the fuel system while smoking or in the presence of flames sparks or hot surfaces Failure to follow these precautions can result in fire which can cause serious injury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A
11. flywheel make sure that the tool is removed if the engine is to be turned over with the starter motor 68 Service Procedures 2 Loosen the adjustment screw and ad just the unit injector rocker arm to zero clearance against the camshaft Tighten the adjustment screw one full turn and then loosen again Then re turn the rocker arm to zero clearance T2008845 3 4 flats 180 240 Preload the unit injector by screwing down the adjustment screw 3 4 flats 180 240 Torque tighten the lock nut according to the specifications Group 23 Fuel System D12 D12A D12B D12C 2379 03 02 02 Unit Injector Copper Sleeve Replacement Note Before beginning this service procedure please review General Work Practices page 43 AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death AN DANGER Do not service any part of the fuel system while smoking or in the presence of flames sparks or hot surfaces Failure to follow these precautions can result in fire which can cause serious injury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Fuel oil or coolant leaked spilled onto
12. hot engine and or fluids can cause burns or can permanently damage test equipment W2003394 Vent the fuel system on the cylinder head 20 Start the engine and run for approx 10 minutes to evacuate any residual air in the fuel system 21 Check that the engine has reached normal working temperature and then run for another 5 minutes 22 Check to make sure the fuel system is operating properly Check for leaks 67 Group 23 Fuel System D12 D12A D12B D12C Fuel oil or coolant leaked spilled onto hot surfaces or electrical components can cause a fire Clean up spills immediately Do not work near the fan with the engine running or the ignition in the ON position The engine fan can en gage at any time without warning Anyone near the fan when it turns on could be seriously injured Observe the greatest possible cleanliness when work ing on the cylinder head Dirt particles in the fuel and oil channels can cause the unit injectors to malfunc tion and can cause the VEB if equipped to fail Special tools 9996956 Unit Injector Adjusting Pre load T2006935 Check that the camshaft line marking for adjusting the intake valves and unit injector are opposite the marking on the bearing cap tolerance 2 mm al ternatively between the marks Check via the number marking on the camshaft on which cylinder unit injec tor pre loading is to be adjusted Important If tool 6956 is used to crank the
13. hot surfaces or electrical components can cause a fire Clean up spills immediately Do not work near the fan with the engine running or the ignition in the ON position The engine fan can en gage at any time without warning Anyone near the fan when it turns on could be seriously injured Removal 1 Connect a drain hose 9996049 to the engine coolant drain nipple and drain the coolant into a suitable container 9996049 Service Procedures 12006777 Remove the rocker arm bridge bolts Note Loosen the bolts in three equal stages to avoid bending the rocker arm shaft Failure to remove the control valve before removing the rocker arm bridge may result in damage to the control valve and or the pipe If the engine is equipped with a VEB Volvo Engine Brake remove the con trol valve and the pipe Plug the ports and place the valve in a plastic bag to prevent it from being subjected to dirt and contamination To facilitate re moval remove the valve cover stud bolt Note On engines equipped with a VEB Volvo Engine Brake secure the rocker arm plungers with rubber bands so that the plungers do not fall out of the rocker arms 12006776 Lift the rocker arm bridge using lifting 9998255 tool 9998255 69 Group 23 Fuel System D12 D12A D12B D12C Service Procedures 5 8 Drain the fuel from the cylinder head Refer to the procedure Fuel System Draining the service manual 210 600 Bas
14. seat and injector O rings show signs of combustion leakage clean the injector and replace the injector copper sleeve Reinstall the injector with new O rings and adjust all valves and injectors 11 Start the engine and monitor the sight glass for air If no air is present then stop If air is present then test again as required Group 23 Fuel System D12 D12A D12B D12C Service Procedures Service Procedures General Work Practices AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death AN DANGER The D12 engine uses high voltage up to 90 V to the electronic unit injectors Do not come in contact with the injector terminals while the engine is running as there could be as much as 90V going to the electronic injectors Contact may result in electrical shock Per sonal injury or death can occur Extreme cleanliness must be observed when working on the fuel system and the Volvo Engine Brake VEB Always clean the engine before beginning re pairs To prevent dirt from entering the fuel system install protective plugs whenever connections are re moved Store components in sealed plastic bags when feasible until they are to be reinstalled The same procedures apply for VEB components The oil channels for the VEB control system should also be
15. the alternator and fan belts before checking This test is done by simply at tempting to move the accessory drive pulley by hand Radial or axial play in the accessory drive shaft may cause premature failure of the fuel feed pump 25 Group 23 Fuel System D12 D12A D12B D12C Design and Function Hand Primer The hand primer is situated on the fuel filter bracket It is used to pump the fuel and bleed the system when the engine is not running T2006729 Fig 22 Hand primer Engine Electronic Control Unit EECU The electronic control module is the central part of the injection system lt is located on the left hand side of the engine The EECU receives continuous information from the accelerator pedal and from several sensors on the engine It calculates the amount and the time to inject fuel into the cylinders Electrical wiring to the EUI fuel valves transmits control signals to the injectors The EECU uses the flywheel sensor to monitor engine rotation and engine speed variations during a revolution This allows the EECU to ensure that each EUI receives exactly the correct amount of fuel The EECU stores in formation when a fault occurs or if something in the system is abnormal Occassional faults are also stored and can be traced at a later stage For information about the EECU EECU sensors and their functions refer to Service 280 600 Information Control Systems D12 IMPACT Function Group 284 Inform
16. the hose over to the cylinder head bleed nipple and bleed the system in the same way as with the fuel filter housing 5 Apply parking brake and place gear lever into neutral 6 Start the engine and allow it to run at fast idle or with the PTO engaged for about five minutes to remove air from the system Check for leaks 51 Group 23 Fuel System D12 D12A D12B D12C 2331 03 02 01 Fuel Feed Pump Replacement D12 D12A D12B Note Before beginning this service procedure please review General Work Practices page 43 AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death AN DANGER Do not service any part of the fuel system while smoking or in the presence of flames sparks or hot surfaces Failure to follow these precautions can result in fire which can cause serious injury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Do not work near the fan with the engine running or the ignition in the ON position The engine fan can en gage at any time without warning Anyone near the fan when it turns on could be seriously injured Fuel oil or coolant leaked spilled onto hot surfac
17. 1 03 02 01 Fuel Feed Pump Replacement D12C Note Before beginning this service procedure please review General Work Practices page 43 AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death AN DANGER Do not service any part of the fuel system while smoking or in the presence of flames sparks or hot surfaces Failure to follow these precautions can result in fire which can cause serious injury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Fuel oil or coolant leaked spilled onto hot surfaces or electrical components can cause a fire Clean up spills immediately Do not work near the fan with the engine running or the ignition in the ON position The engine fan can en gage at any time without warning Anyone near the fan when it turns on could be seriously injured 53 Group 23 Fuel System D12 D12A D12B D12C Types There are two types of feed pump on the D12C engine 1 W2003386 Fig 49 Feed pump type 1 older version with long drive shaft 1 Seal 2 Shaft journal W2003385 Fig 50 Feed pump type 2 newer version available with one or two
18. 6 in 1 D Transparent Hose Sight Glass Hose Assembly R AUNI 37 Group 23 Fuel System D12 D12A D12B D12C E Fig 25 D12C Fuel System Diagram with Fuel Line Kit Installed 3 8 in 1 D Transparent Suction Hose Alternate Fuel Supply Sight Glass Hose Assembly S 3 16 in 1 D Transparent Hose Sight Glass Hose Assembly R WN 38 Troubleshooting W2003500 Group 23 Fuel System D12 D12A D12B D12C Note The numbers within parentheses in the following steps correspond to the accompanying figures D12 D12A See Fig 23 D12 D12A Fuel System Diagram with Fuel Line Kit Installed page 37 D12B See Fig 24 D12B Fuel System Dia gram with Fuel Line Kit Installed page 38 D12C See Fig 25 D12C Fuel System Dia gram with Fuel Line Kit Installed page 39 1 Connect the 3 16 in 1 D transparent hose 3 to the bleed nipple located at the rear of the cylinder head and se cure onto the bleed nipple with the clamp provided in the fuel line kit Route the line back to the fuel tank and secure to prevent it from moving out of the tank Open the bleed nipple 1 1 2 turns and pump the hand primer pump until the transparent hose is free of air If the fuel system can be bled free of air continue to step 3 2 If air continues to exist in the fuel check the following e that there is ample fuel in both tanks e connections from the fuel tank to the fuel supply pump for suction leaks e fuel wat
19. 662 Group 23 Fuel System D12 D12A D12B D12C T2006717 Fig 36 Pressure gauge assembly connected to union D12A B W2003512 Fig 37 Pressure gauge assembly connected to union D12C Check that the pressure gauge indica 9998277 tor is at 0 zero and connect the gauge to union 9998277 Service Procedures T2006718 Fig 38 Draining the remainder of the fuel D12A B Blow the remaining fuel out of the cylinder head by carefully increasing the pressure with the knob on the pressure gauge reduction valve DO NOT EXCEED 50 kPa 7 25 psi 7 When all fuel has been drained Remove the pressure gauge as sembly union and the drain hose Reinstall the bleed nipple and the protective cap onto the cylinder head Do not replace the nipple as the original nipple is fitted to the seating in the cylinder head A new nipple can result in leakage Tighten the drain union on the fuel filter bracket and install the protective cap 49 Group 23 Fuel System D12 D12A D12B D12C Service Procedures 2309 05 03 01 1 Fuel System Bleeding Note Before beginning this service procedure please review General Work Practices page 43 AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause seri
20. C The D12C has new unit injectors with 17 mm pump stroke and higher injection pressure The injector noz zles are new and have a different orifice pattern Unlike the D12A and D12B engines the D12C cylinder head only has one fuel galley for the unit injectors This means that only two sealing rings are needed for each unit injector the D12A and D12B use three rings Fuel enters at the rear of the cylinder head and exits out the front 12012782 Fig 11 Unit Injector D12C 18 Group 23 Fuel System D12 D12A D12B D12C Fuel Flow D12A Design and Function AQ W2000680 Fig 12 Fuel flow D12A 1 Fuel feed pump 2 Engine electronic control unit EECU 3 Bleed line 4 Fuel gallery The fuel feed pump 1 is mounted on the timing gear plate and driven through a recess in the pump shaft by the engine timing gears It picks up fuel from the fuel tank 7 through the fuel system EECU 2 Return fuel from the cylinder head is also routed into the fuel feed pump A bleed line 3 goes from the fuel feed pump back to the fuel tank and is designed to continuously bleed the system From the fuel feed pump fuel first passes through the filter 8 and then into the cylinder head fuel gallery 4 The fuel gallery surrounds the part of the EUI 5 where the fuel holes are placed The system overflow valve 6 is located in the fuel gallery outlet connection Leak off fuel flows from the EUI back to the fuel gallery
21. C Service Procedures 20 22 DW N DD ee W2003438 Pieces of the copper sleeve that fall into the cylinder can seriously damage the piston and or turbocharger 72006821 Install the 2 sealing clamps 9998250 9998250 in the cylinder head fuel gallery When the sleeve is removed the extractor tool should be extended be yond the cooper sleeve at least 3 mm 23 0 125 in see 1 If it is not check to make sure that a piece of the cooper sleeve has not broken off and fallen into the cylinder Cleaning the Copper Sleeve Bore 21 W2003148 Wear safety glasses while using cleaning brushes or compressed air Failure to do so could cause eye in jury from flying debris re Use the 7 16 in diameter brush in side bore C Move the brush up and When replacing the injector copper J 42885 down while turning it at the same time sleeves in the cylinder head it is im portant that the sleeve bore in the J 42885 head is free from any carbon deposits and any other residue i e pieces of the O ring etc before installing the new sleeve Use the cleaning kit J 42885 in the following steps Fig 59 Cleaning kit J 42885 73 Group 23 Fuel System D12 D12A D12B D12C 2 3 E D gt 4 ENE W2003528 Place the injector bore sleeve protec J 42885 tor into injector bore Assemble the Roloc brush 2 the holder 3 and the extension 4 Install the assembly into a drill an
22. NC USA Order number PV776 TSP142867 2000 Volvo Trucks North America Inc Greensboro NC USA All rights reserved No part of this publication may be reproduced stored in retrieval system or transmitted in any forms by any means electronic me chanical photocopying recording or otherwise without the prior written permission of Volvo Trucks North America Inc Contents ET EE 3 SPECIIGCAUONE siii 5 EEE EE EE EE 5 Fuel Supply Pump and Overflow Valve 5 TE ES es ERE 5 E E RR Scare 5 Identifying 450 kPa 65 psi Fuel System Components 6 TOOS cui A F Speca TOS ua A RE x Special RR RE i 9 Design ANG FUNCION ini 11 JE EE EE EE 11 Foel Gine OBS in 12 Dee ARA 13 Insectos Operational PRESSE sesoriconan riada 14 IEA mirra 18 1 REE EEE EE EE EE SR 18 DE sn A RR aa 18 PUSO suplir 19 DMA ae 19 A cicsy estan eee ER Rea 20 VAR GN 21 A SS 22 PP a RR 22 CREI VA ariei 23 EEE ia 23 FJ Food PP siso ndo iara siacis ana Rigg amas RUE dp anais da 24 Fuel Feed Pump Replacement 25 Hand FATET soosvsasmsusauukbusenkskusueaakmdns be 26 Engine Electronic Control Unit EECU mumsmumemninemennenrsimsnmn jm 26 TROUDIBEHOGENG sad ay Fuel Sysiem Paull ACN ia 27 Faul DADO pune a a OEN ar Unit Injector Tronbleshootina csi iria 27 Read and Document Fault Codes sici n 27 Temes Fow PAN aaa aia 29 AMS TT ae 01 sucesso OT 29 Inactive fault codes with high COUNTS meererernvvern
23. Service Manual Trucks Group 230 600 Fuel System D12 D12A D12B D12C PV776 TSP142867 VOLVO Foreword The descriptions and service procedures contained in this manual are based on de signs and methods studies carried out up to August 2000 The products are under continuous development Vehicles and components produced after the above date may therefore have different specifications and repair methods When this is believed to have a significant bearing on this manual supplementary ser vice bulletins will be issued to cover the changes The new edition of this manual will update the changes In service procedures where the title incorporates an operation number this is a refer ence to an S R T Standard Repair Time Service procedures which do not include an operation number in the title are for gen eral information and no reference is made to an S R T The following levels of observations cautions and warnings are used in this Service Documentation Note Indicates a procedure practice or condition that must be followed in order to have the vehicle or component function in the manner intended Caution Indicates an unsafe practice where damage to the product could occur Warning Indicates an unsafe practice where personal injury or severe damage to the product could occur Danger Indicates an unsafe practice where serious personal injury or death could oc cur Volvo Trucks North America Inc Greensboro
24. ation Type Design and Function Sensors 26 Group 23 Fuel System D12 D12A D12B D12C Troubleshooting Fuel System Fault Tracing Correct fault diagnosis is essential to accurate engine re pair The complex design of the engine that is with a cylinder head that covers all the cylinders overhead gear wheel driven camshaft and EUI makes the cylin der head removal on the D12 a comprehensive work operation Fault tracing in the fuel system requires thor ough knowledge on how the system functions as one does not have the opportunity as with a conventional fuel system of seeing and checking directly on the engine As the EECU receives all the information electronically from the different sensors the EECU must gather all the information when the engine is started and then check that the information is correct This means the D12 en gine does not start on the first crankshaft revolution but requires two revolutions in order for the control unit to set the correct values It is important that the starter motor revolutions are not too slow as slow starter motor speed is interpreted by the control unit that the crankshaft does not rotate and as a result the injector fuel valves do not receive the appropriate signals to release fuel The crankshaft must rotate at a minimum of 75 rpm to ensure that the engine starts To facilitate fault tracing in the fuel system D12 is equipped with a diagnostic sys tem which makes it possib
25. d Overflow Valve Fuel Supply Pressure Engine number viasat up to 98799 from 98800 Minimum supply pressure at full load mmmrrrnnvrnnonrnvenvnrnvnrrnvenrnvrervnrenen 250 kPa 350 kPa 36 psi 51 psi Overflow Valve Engine NUMDEr ua S std eee A eee a eee up to 98799 from 98800 Opening Pressure iniciada e dese hy 300 350 kPa 340 450 kPa 44 51 psi 50 65 psi Group 23 Fuel System D12 D12A D12B D12C Specifications Identifying 450 kPa 65 psi Fuel System Components W2003117 Fig 1 Fuel System Components 1 350 kPa 51 psi overflow valve 2 New 450 kPa 65 psi overflow valve can be identified by the groove cut into the hex portion of the valve as shown above 3 350 kPa 51 psi fuel pump 4 New 450 kPa 65 psi fuel pump can be identified by the additional web in the casting as shown above D12A B location shown Important When changing an overflow valve to the new 450 kPa 65 psi bar version the fuel pump must also be changed to the 450 kPa 65 psi version However when changing a fuel supply pump to the 450 kPa 65 psi ver sion you are not required to change the overflow valve Vw S WE VEND nd W2003394 Fig 2 Overflow valve location D12C Group 23 Fuel System D12 D12A D12B D12C Tools Special Tools The following special tools are used to replace or repair components The tools can be ordered from Volvo Parts North America please use the specified part number when orde
26. d clean the sleeve seal B see illustration page 73 25 Install the 1 5 in diameter brush into J 42885 the drill and clean bore A see illus tration page 78 26 Use the chip vacuum PT 2900 to re PT 2900 move all debris from the copper sleeve bore 27 Inspect the copper sleeve bore for any remaining debris Pay close attention to the O ring area of the bore for any remaining pieces of the O ring that may require scraping with a pocket knife to remove Reclean if needed 28 Remove the 2 sealing clamps 9998250 9998250 from the cylinder head fuel PT 2900 gallery and remove any remaining de bris using chip vacuum PT 2900 14 Service Procedures Installation 1 T2007088 Lubricate the new sealing ring with en gine oil and install it on the new copper sleeve Lubricate the sealing ring again with engine oil 2 ss 9808000 W2003176 Install the copper sleeve on the flaring 9998254 tool 9998254 and lubricate the flaring 9808000 pin 9808000 with engine oil Thread the flaring tool 9998000 to the flaring tool 9998254 until it bottoms Then loosen the flaring pin approximately 180 Note Failure to loosen the flaring tool 180 can result in the pin being twisted or broken 3 Check that the piston is not at T D C if the piston is at T D C the flywheel must be turned Carefully tap down the copper sleeve until it bottoms out against the sleeve seal in the cylinder head 4 Ins
27. drive heads available on newer and re placement engines Feed pumps as spare parts are available in both ver sions Note Both types of feed pumps are interchangeable i e feed pump type 1 can be replaced with feed pump type 2 and vice versa 54 Service Procedures When replacing feed pump Type 1 great care must be taken with the long drive shaft Any damage to the drive shaft can damage the feed pump if it is installed on the engine serious engine damage can result Removal 3 W2003384 Cut the plastic clamps for the cabling and remove the bracket under the al ternator 2 Carefully clean round the feed pump and the fuel connections 3 Remove all fuel pipes from the feed pump 4 Remove the hold down bolts for the feed pump Carefully pull the drive shaft from the drive exhaust and re move the pump from the engine 5 Clean the sealing surface on timing gears plate Check that the gasket for the feed pump is in good condition If necessary replace with new gasket Group 23 Fuel System D12 D12A D12B D12C Installation 1 W2003386 Fig 51 Feed Pump Type 1 1 Seal 2 Shaft journal Feed Pump Type 1 only Check that the seal 1 is in good condition and correctly positioned Also check that the shaft journal 2 is lubricated with graphite grease 2 p pg gt SE I SS ve Seer QU W2003387 Fig 52 Feed pump drive shaft groove Check that th
28. e feed pump s drive in stalls in the groove on the feed pump s drive shaft The groove in the shaft shows which position the feed pump s shaft journal should have when installing applies to both type 1 and 2 Service Procedures T2014660 Fig 53 M8 bolt with sealant Install the seal on the feed pump and install the feed pump on the engine Feed Pump Type 2 Observe great care with the feed pump s drive shaft Damage to the feed pump s drive shaft can permanently damage the engine Note The M8 bolt should be rein stalled with sealant to seal any oil leakage Do not install the old bolt without sealant or leakage can occur 4 Check the seals on the fuel lines The sealing washers for the return line should always be replaced Replace other seals if necessary Install the fuel lines on the feed pump 55 Group 23 Fuel System D12 D12A D12B D12C Service Procedures 5 2331 03 02 02 Hand Primer Pump Replace ment Note Before beginning this service procedure please review General Work Practices page 43 AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Vent the fuel system AN DANGER Do not service any part of the fuel system while smoking or in the presence of flames sparks or hot surfaces Failure to fol
29. ectors must be disconnected from the EECU Note Before disconnecting the connectors the key switch must be turned to the OFF position When oven drying spray paint work any ECUs must be removed from the truck The maximum allowable drying temperature with the control unit in the vehi cle is 80 C 176 F Use only batteries for auxiliary starting Using a starting unit can induce peak voltages that can dam age the electronic components When charging batteries with a rapid charger bat tery cables must be disconnected Normal trickle charging does not require this procedure If a connector is removed make sure it is reinstalled correctly and is not covered with oil or other fluids which can result in a poor connection For maintenance intervals refer to Service 175 001 Bulletin Oil and Filter Change Intervals IMPACT Function Group 175 Information Type Maintenance Engine Maintenance 43 Group 23 Fuel System D12 D12A D12B D12C Clamping the Fuel Lines W2000684 Fig 27 Fuel line routing and securing To avoid damage and operational disturbances in the fuel system the fuel lines should be rerouted and se cured with plastic cable ties Note Always check the fuel lines for cuts abrasions chafing or leakage Diesel fuel that comes in contact with a hot surface can start a fire Note Refer to Service Bulletin Group 23 for oil cooler thermostat plate leak repair Note Refer to Service
30. el Line O Rings W2002168 Fig 4 Removing fuel lines Always replace the fuel line O rings when e troubleshooting for fuel aeration and or e performing any Service Procedure that requires the removal of VE D12 engine fuel lines W2002169 Fig 5 Fuel line O ring locations 1 976020 2 955984 12 Group 23 Fuel System D12 D12A D12B D12C Unit Injectors The fuel injection system of the D12 engine uses electronically governed unit injectors that are electrically activated and mechanically driven via roller rocker arms from the camshaft lobe They are vertically located in the center between the four valves in the cylinder head for each cylinder The electronic unit injector EUI combines an injection pump and an injector An EUI can operate at consider ably higher injection pressure than a conventional injector The EUI consists of three main components e Pump containing a cylinder and piston this corre sponds to the pump assembly in an injection pump e Injector with nozzle body nozzle needle and spring e Valve housing with an electro magnetically con trolled fuel valve The upper part of the electronic unit injector which in cludes the compression spring and valve housing lies above the cylinder head The center part of the electronic unit injector where the intake and outlet holes for the fuel are located lies in the cylinder head fuel gallery The electronic unit injector takes in fuel direc
31. el System D12 D12A D12B D12C Design and Function Fuel System W2003243 Fig 3 Fuel system D12C The Volvo D12 is an electronic engine designed to meet today s high environmental standards Meeting these standards requires optimum combustion This demands among other things injecting the exact amount of fuel into the combustion chamber under very high pressure at precisely the correct time depending on engine speed load temperature and other conditions Because totally mechanical injection systems cannot meet these demands the engine is equipped with an electronically controlled injection system An engine electronic control unit EECU receives impulses from the accelerator pedal and a number of sensors on the engine The sensors read signals which govern the injec tion procedure and send these signals to the EECU The fuel system has a built in diagnostic system which elec tronically detects and traces any faults in the system Each cylinder has four valves Individual differences always occur between the cylinders in an internal com bustion engine The engine has a cylinder balancing system the purpose of which is to even out the amounts of fuel between the cylinders Cylinder balancing takes place with the engine running at idle speed providing certain preconditions have been met Design and Function Group 23 Fuel System D12 D12A D12B D12C Design and Function Fu
32. er separator for restric tions suction side leaks or an incorrect micron element e that the hand primer pump is ca pable of pumping fuel e the fuel supply pump seal for fail ure 3 Close the fuel bleed nipple and start the engine Note It may be necessary to continue to pump the hand primer during crank ing to start the engine If the engine does not start then the fuel system is most likely filling with air during crank ing skip to step 5 4 Once the engine starts open the fuel bleed nipple located at the rear of the cylinder head 1 1 2 turns with the transparent hose connected Monitor for air in the fuel for 3 to 5 minutes If air is present continue to step 5 if not then there is a possibility that air is en tering the fuel system only under loaded conditions If it is suspected that air is entering under loaded condi tions continue to step 5 If not stop here no further testing is required 5 If the engine would not start in step 3 continues aeration during cranking or if air is noted in the transparent hose while the engine is running then install the following hoses and sight glasses to determine where the air is entering the fuel system 6 Install sight glass hose assembly 2 between the outlet port of the fuel sup ply pump and the fuel filter 7 Remove the fuel supply suction line from the fuel supply pump and install the alternate transparent fuel supply line 1 and route back to
33. es or electrical components can cause a fire Clean up spills immediately 1 Clean the area around the fuel feed pump area and remove the bleed line 52 Service Procedures T2006724 Fig 45 Removing fuel line Remove the plastic straps securing the fuel line on the ECM and cylinder block Remove the lines at the unions from the fuel feed pump as indicated by arrows in figure Fig 46 Removing fuel pump page 52 12006723 Fig 46 Removing fuel pump Remove the bolts indicated by arrows in figure Fig 46 Removing fuel pump page 52 and lift out the fuel feed pump 4 Clean the contact surface on the tim ing gear plate Group 23 Fuel System D12 D12A D12B D12C 72006722 Fig 47 Install fuel feed pump Check to make sure that the fuel feed pump drive engages in the drive slot Install a new gasket and tighten the fuel feed pump mounting bolts 6 Connect the fuel lines and the bleed line Use new sealing washers Secure the fuel lines with plastic tie straps 12006728 Fig 48 Bleeding fuel system Bleed the fuel system at the fuel filter as shown in illustration Fig 48 Bleeding fuel system page 53 See also Fuel System Bleeding page 50 8 Apply parking brake and place gear lever into neutral Service Procedures 9 Start the engine Allow it to run at fast idle or with the PTO engaged for about five minutes to remove air from the system Check for leaks 233
34. feed pres sure Opening pressure is about 345 kPa 50 psi The high feed pressure ensures that the injectors are filled with fuel D12C The D12C has a new overflow valve The valve is inte grated with the hollow screw in the fuel outlet at the front of the cylinder head Design and Function W2000681 Fig 17 Overflow Valve Location D12A B 12012784 Fig 18 Overflow Valve D12C W2003527 Fig 19 Overflow Valve location D12C 23 Group 23 Fuel System D12 D12A D12B D12C Design and Function Fuel Feed Pump The capacity of the pump has been adapted to give the correct pressure and flow to the EUI Filling the EUls re quires relatively high pressure The flow must be large enough to even out any fuel temperature differences in the cylinder head fuel gallery T2006725 Fig 20 Fuel Feed Pump 24 Group 23 Fuel System D12 D12A D12B D12C Design and Function Fuel Feed Pump Replacement W2002891 Fig 21 A Radial Play When replacing a D12 fuel supply pump for any reason the accessory drive must also be inspected There should be no radial or axial play in the accessory drive shaft Radial play is movement parallel side to side to the face of the pulley Do not confuse with backlash which is measured by turning the pulley Axial play is movement perpendicular in and out to the face of the pulley Release the tension on
35. ic Engine D12 6 Carefully clean around the electronic unit injector EUI to be removed 72006708 Remove the EUI and check that no dirt 9998249 enters the injector well in the cylinder head Install a dust cover on the EUI and install protective plug 9998249 in the injector well in the cylinder head T2006709 Disconnect the electrical wires from the EUI Pay close attention to the wire terminals If one breaks remove the broken pieces Failure to do so may result in pieces falling into the cylinder which can cause component damage 72007050 Remove the valve bridges at the cop per sleeve that is to be changed and make note of location for reassembly 10 Make sure that the piston correspond ing to the copper sleeve being removed is in the down position 70 Group 23 Fuel System D12 D12A D12B D12C 11 12007157 This step is for D12C only Check 9998252 whether the copper sleeve has an 8 mm or 9 mm hole in the tip Install the 8 mm tap in tool 9998252 and try threading the copper sleeve If it turns too easily replace the 8 mm tap with the 9 mm tap and continue with the procedure 12 Using tool 9998252 turn tap approxi 9998252 mately 1 4 of a turn then back off at least a full turn to remove shavings Turn forward again until you feel ten sion then repeat this step Continue until the tap has passed through the bottom of the copper sleeve Note Apply grease to the ta
36. l and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death AN DANGER Do not service any part of the fuel system while smoking or in the presence of flames sparks or hot surfaces Failure to follow these precautions can result in fire which can cause serious injury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment After using the fuel aeration test kit thoroughly drain all remaining fuel from the test hoses then install plugs end caps and washers This will prevent accidental spillage which could result in fuel contami nation 35 Group 23 Fuel System D12 D12A D12B D12C Troubleshooting EEE E es Y e dl e EEE HE a W2003008 Fig 23 D12 D12A Fuel System Diagram with Fuel Line Kit Installed 3 8 in 1 D Transparent Suction Hose Alternate Fuel Supply Sight Glass Hose Assembly S 3 16 in 1 D Transparent Hose Sight Glass Hose Assembly R Vent Line Port Washer 949873 ARON 36 Group 23 Fuel System D12 D12A D12B D12C Troubleshooting NAAA a Vianne re OG EN VE AA AA W2003009 Fig 24 D12B Fuel System Diagram with Fuel Line Kit Installed 3 8 in 1 D Transparent Suction Hose Alternate Fuel Supply Sight Glass Hose Assembly S 3 1
37. le to localize faults in the fuel system without having to perform extensive dismantling work With the fault codes stored in the control unit it is possi ble through the diagnostic system to quickly establish which fault or faults have occurred Fault Codes It is important to delete a fault code from the diagnostic system after the fault code has been corrected and be fore the truck leaves the workshop Fault codes remain in the system until they are removed They do not automatically clear when the fault has been corrected Unit Injector Troubleshooting The following information will aid in troubleshooting of Electronic Unit Injector EUI fault codes Read and Document Fault Codes Connect the MPSI tool to the vehicle s diagnostic con nector to determine whether any active or inactive fault codes are set Document all set fault codes below Troubleshooting 27 Group 23 Fuel System D12 D12A D12B D12C Troubleshooting Code Occurred counts Active Inactive PID SID FMI Description icc isi rakke eat Code Occurred counts Active Inactive PID SID FMI Description a A GERA ei endt Code Occurred counts Active Inactive PID SID FMI Description ASR RR RR RODE RR RR RD RNA DEAR RD AR COOPER RR RR ERRO DRE RO RR RR Code Occurred counts Active Inactive PID SID FMI Description ssa secas ethan Ben
38. low these precautions can result in fire which can cause serious injury or death 6 Start the engine and run it at high revs 800 1000 approx 800 1000 rpm for approx rpm 10 min to evacuate any remaining air approx 10 in the fuel system min N WARNING Conduct leakage check 7 HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or 8 fluids A hot engine and or fluids can cause burns or Check that no fault codes exist can permanently damage test equipment Fuel oil or coolant leaked spilled onto hot surfaces or electrical components can cause a fire Clean up spills immediately 1 Open the fuel tank cap to release any pressure in the fuel tank 2 Clean around the hand primer fuel fit tings 56 Group 23 Fuel System D12 D12A D12B D12C Service Procedures 3 2334 03 02 01 Fuel Filter Replacement Prerequisite e Container for fuel under filter Note Before beginning this service procedure please review General Work Practices page 43 Z AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death T2006720 Fig 54 Removing hand primer pump Remove the hand primer pump fuel AN DANGER lines at the unions Do not service any part of the fuel system while
39. m 20 5 Nm 15 4 ft lb 15 4 ft lb Note If the injector is not to be in stalled at once install a protective plug in the cylinder head 15 Turn the retainer bolt an additional 60 5 60 5 76 Service Procedures 16 Connect the electronic unit injector EUI electrical wires and tighten the nut to a torque of 1 4 Nm 1 ft lb The EUI electrical wires should be routed to the outside of the valve cover bolts Pay close attention to the cable hold ers If one breaks remove the broken pieces to prevent clogging or damage to any components Note Be careful not to pinch the EUI wiring cable harness when installing the valve cover Note Hold the wires while tightening If the screw gets damaged the com plete electronic unit injector must be replaced Note Applies to engines equipped with VEB Volvo Engine Brake The VEB control valve should be rein stalled at this time Reconnect sliding valve and pipe into the rocker arm shaft as a unit Apply Loctite 242 to threads and tighten the bolts to a torque of 33 4 Nm 24 3 ft lb 72006709 1 4 Nm 1 ft lb 33 4Nm 24 3 ft lb Group 23 Fuel System D12 D12A D12B D12C Service Procedures 17 19 12006777 Install all rocker arm shaft bolts mak ing sure they are hand tight before continuing Note When reinstalling a rocker arm EEE shaft which has been removed or loos Coat the valve bridges and camshaft ened
40. new sealing washer review General Work Practices page 43 6 AN DANGER Reconnect the fuel line Use new seal ing washer Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected 7 vehicle movement and can cause serious personal in Bleed the fuel system jury or death 8 Apply parking brake and place the AN DANGER gear lever into neutral Do not service any part of the fuel system while 9 smoking or in the presence of flames sparks or hot Start the engine and allow it to run at surfaces Failure to follow these precautions can result fast idle or with the PTO engaged for in fire which can cause serious injury or death about ten minutes to remove air from the system sa N WARNING Perform leak and operation checks HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Fuel oil or coolant leaked spilled onto hot surfaces or electrical components can cause a fire Clean up spills immediately 1 Remove the overflow valve from the intake pipe 2 Clean the sealing surfaces 62 Group 23 Fuel System D12 D12A D12B D12C Ny TT EO IS W2003390 Install a new overflow valve with new copper washers and tighten the over flow valve to 55 5 Nm 40 4 ft lb
41. njectors and inspect the copper sleeve to the injec tor seat for signs of leakage Group 23 Fuel System D12 D12A D12B D12C Determining which Cylinder is In troducing Air into the Fuel AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death AN DANGER Do not service any part of the fuel system while smoking or in the presence of flames sparks or hot surfaces Failure to follow these precautions can result in fire which can cause serious injury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment After using the fuel aeration test kit thoroughly drain all remaining fuel from the test hoses then install plugs end caps and washers This will prevent accidental spillage which could result in fuel contami nation Troubleshooting Note The numbers within parentheses in the following steps correspond to the accompanying figures D12 D12A See Fig 23 D12 D12A Fuel System Diagram with Fuel Line Kit Installed page 37 D12B See Fig 24 D12B Fuel System Dia gram with Fuel Line Kit Installed page 38 D12C See Fig 25 D12C Fuel System Dia gram with Fuel Line Kit Installed page 39
42. only the bolts which hold the lobes with engine oil rocker arm shaft should be tightened 12006776 Remove all oil from the rocker arm bridge bolt holes to prevent a hydraulic lock that may result in damage to the cylinder head Install the rocker arm bridge using lift ing tool 9998255 9998255 77 Group 23 Fuel System D12 D12A D12B D12C 20 Fig 60 Bearing caps and camshaft rocker shaft W2003520 tightening sequence D12C EB ON 15 5 Nm 1 60 5 Nm 4 1 4 11 4 ft lb 15 5 Nm b 4 4 ft lb 1 4 ft lb 4 4 ft lb 90 5 120 5 loosen to was 60 5 Nm 0 Nm 0 ft lb 15 5 Nm 11 4 ft lb 120 5 D12 D12A D12B AUN 5 15 5 Nm 11 4 ft lb 90 5 45 Nm 33 ft lb 15 5 Nm 11 4 ft lb 90 5 45 Nm 33 ft lb loosen to 0 Nm 0 ft lb 15 5 Nm 11 4 ft lb 90 5 Gradually tighten the bolts so that the rocker arm shaft does not bend or warp Tighten the shaft until it lies against the camshaft lobes then torque tighten using the 5 step torque sequence shown 21 Adjust the valves and the electronic unit injector EUI 78 Service Procedures Feedback One of our objectives is that workshop personnel should have access to correct and appropriate service manuals where it concerns fault tracing repairs and maintenance of Volvo trucks In order to maintain the high standards of o
43. or hot Fig 30 Remote starter switch and wiring surfaces Failure to follow these precautions can result in fire which can cause serious injury or death Connect a switch between the battery positive and the positive con nection on the starter solenoid Z N WARNING 4 Do not run the starter for more than HOT ENGINE Keep yourself and your test equipment 15 seconds at any one time However clear of all moving parts or hot engine parts and or if the starter is run for 15 seconds or fluids A hot engine and or fluids can cause burns or longer wait at least one minute before can permanently damage test equipment reusing the starter motor Fuel oil or coolant leaked spilled onto hot surfaces or electrical components can cause a fire Clean up spills immediately Do not work near the fan with the engine running or the ignition in the ON position The engine fan can en gage at any time without warning Anyone near the fan when it turns on could be seriously injured Special tools 9996666 9998496 J 39200 45 Group 23 Fuel System D12 D12A D12B D12C J 39200 999 8496 W2002209 999 6666 SY W2003513 Fig 32 Bleed nipple D12C Remove the bleed nipple at the rear of 9996666 the head on the D12A B or at the 9998496 front of the head on the D12C install J 39200 adapter 9996666 and pressure trans ducer 9998496 Connect the transducer to multimeter J 39200 Note The pressure
44. ous personal in jury or death AN DANGER Do not service any part of the fuel system while smoking or in the presence of flames sparks or hot surfaces Failure to follow these precautions can result in fire which can cause serious injury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Fuel oil or coolant leaked spilled onto hot surfaces or electrical components can cause a fire Clean up spills immediately 12006713 Fig 39 Cylinder head bleed nipple D12A B location KZ 7353 N E TREND E Fig 40 Cylinder head bleed nipple D12C location 72006712 Fig 41 Fuel filter bleed nipple Clean around the bleed nipples on the fuel filter housing and cylinder head 50 Group 23 Fuel System D12 D12A D12B D12C Service Procedures T2006728 T2006711 Fig 43 Bleeding the cylinder head D12A B Connect a transparent plastic hose to 24 NS so the fuel filter housing bleed nipple g tH Er y 1 Fig 42 Installing bleed line Open the bleed nipple and pump the hand primer until clean fuel runs out of AJ the hose Tighten the bleed nipple a while fuel is still running out A 3 Eg TG Remove the hose and install the pro tection plug on the bleed nipple W2003510 Fig 44 Bleeding the cylinder head D12C Move
45. p to pre vent shavings from falling down into the cylinder Service Procedures 13 o D W2003433 Using the Allen wrench loosen the 9998253 Allen set screw on the extractor tool 9992853 14 Adjust the bolt in the end of the tool until the bolt extends approximately 22 mm 0 875 in beyond the end of the tool A 15 Tighten the Allen set screw and make sure that the screw is seated against the flat part of the extractor bolt 71 Service Procedures Group 23 Fuel System D12 D12A D12B D12C 16 W2003436 Hand turn the retaining nut clockwise until it is firmly seated against the bottom of the extracting cup 1 W2003434 Install the extractor tool into the cop per sleeve and hand tighten until it bottoms out in the sleeve 9 1 17 W2003437 ZN CAUTION W2003435 Back off the retaining nut 1 and turn the extractor bolt 2 so that the o n gt g gt D D n x D Q Q Q o o lt o gt o E D x o e 2 e o g o YN 3 om O c o QO of air tools can damage engine components threaded end passes completely through the copper sleeve tip Using a wrench turn the retaining nut 1 clockwise until the copper sleeve is removed sleeve the tip of the sleeve may break pass completely through the copper off as it is removed Note If the threaded end does not 72 Group 23 Fuel System D12 D12A D12B D12
46. pair the dam only Check the EA harness and the injector solenoid for the aged terminals in EA harness correct resistance To determine the correct resistance value Use tool 9998482 to check subtract the resistance of the Digital Multimeter DMM from tension If the terminals are the total resistance of the injector solenoid circuit Measure damaged in the EECU other the resistance of the DMM by touching the leads together and than slightly straightening the noting the resistance EECU must be replaced Continued see table page 30 29 Group 23 Fuel System D12 D12A D12B D12C Troubleshooting Continued from table page 29 Measure the circuit resistance between the injector supply and return pins into the EA harness and note the reading Subtract the DMM lead resistance from the injector circuit resistance This will give you the true circuit resistance Compare to the specifications below Note The ECU must NOT be connected to the breakout harness during these checks Specifications Solenoid circuit to ground mmrerenenvnnenvvnenvrrnvenrvrervrerenverenensrsevenveesnvene OL open circuit Solenoid circuit resistance oo eee een 1 3 3 5 0 Return circuit to block errar OL open circuit Supply cir uit to block cidad bn OL open circuit Record the values Remove the valve cover check the harness to solenoid connection Is connection tigh
47. phase begins and ends The time during which the fuel valve is closed determines the amount of fuel injected at each pump stroke RON Design and Function 72006816 Fig 10 Pressure drop phase Fuel valve Pump plunger Fuel outlet overflow Fuel gallery inlet and outlet Group 23 Fuel System D12 D12A D12B D12C Design and Function D12A One unit injector is used for the 345 385 and 425 horsepower variants The spray angle has been modi fied These injectors are NOT interchangeable with the D12 injectors D12B The unit injectors on the D12B have a longer pump stroke length than earlier injectors on the D12A They are not interchangeable with other engine versions The engine electronic control unit EECU receives sig nals both from the engine s own sensors and from the vehicle control unit The EECU then controls the unit in jectors and determines the timing of the injection as well as the amount of fuel to be injected into the cylinders With the adaptation to the new vehicle electronics the throttle position sensor signal on the D12B is now linked to the engine control unit via the vehicle control unit Using incorrect injectors i e D12A injectors in a D12B engine can cause engine damage and or poor performance Injector identification can only be made using the injector part number located on the injector solenoid valve D12
48. plugged Dirt in the fuel system and in the VEB sys tem can affect engine operation Note After removing or replacing any EUI or after ad justing preload start the engine and allow it to reach normal operation temperature Then let the engine idle for an additional five minutes This will enable the ECM through the cylinder balancing system to set the correct amount of fuel for delivery to the EUI No power consuming components for example a PTO should be engaged The exhaust pressure governor must not be activated Remove wire 636K from the solenoid valve and apply the parking brake to ensure that the truck can not move When the engine runs evenly at idle speed the cylinder balancing function has been carried out Note If the engine is turned over with the starter motor for example when adjusting the valves the fuse for the engine control system B6 must first be removed and the ignition key must be in the OFF position in order to eliminate any risk of the engine starting unintentionally Also check that the gear lever is in neutral and the park ing brake is applied Never remove the EECU connectors or any other electrical wires from the sensors while the engine is running The ignition key must be in the OFF posi tion and the engine stopped Never turn the battery master switch OFF or discon nect the battery cables while the engine is running When performing electric welding work on the truck the EECU conn
49. ring Tools with part numbers beginning with J are available directly from Kent Moore telephone 1 800 328 6657 9996390 9996534 9996662 9996666 9996671 9996956 9998249 9998250 9998251 9998277 9812546 J 41603 J 41196 8249 Tools 8250 W0000404 Drift indicator extension for setting electronic unit injector Gauge for checking fuel feed pressure Pressure gauge Union for checking fuel feed pressure Fuel filter removal tool Cranking tool for flywheel Protective sleeve for electronic unit injector Sealing rings for the fuel gallery 2 Sealing plug for cylinder head Union for draining fuel system Cleaning brush Socket Dial indicator Group 23 Fuel System D12 D12A D12B D12C Tools W0001802 9998511 Lever tool W2003530 9998599 Cleaning kit 1 9808614 brush 2 9808615 holder 3 9808613 holder 4 9808616 handle 5 J 42885 25 protecting sleeve 9808617 brush 7 9808618 brush o W0001837 J 44515 Fuel vacuum tool W2003529 J 42885 25 Injector bore protecting sleeve Group 23 Fuel System D12 D12A D12B D12C Tools Special Equipment Like the special tools the following equipment will aid in servicing the D12 engine When ordering equipment specify the appropriate number W0001840 1159794 Torque wrench 10 100 Nm 7 70 ft lb W0000399 MT302A SNAP ON Remote Starter Cable Switch 10 Group 23 Fu
50. s SL Si Dead na 28 Group 23 Fuel System D12 D12A D12B D12C Troubleshooting Troubleshooting Flow Path Active fault codes Troubleshoot the active fault codes first Inactive fault codes with high counts If inactive fault codes are recorded follow the trou bleshooting path for that same active code This should be done however only when there is a driver complaint in conjunction with the inactive fault code Fault code 31 32 33 34 35 or 36 Active Inactive Electronic Mechanical code code Refer to TSI Service Manual Electronic Con See Unit Injector Mechanical trol System D12 Fault codes 31 36 Faults page 32 Electronic unit injectors This will help you determine the supply and or return pin for each code If inactive fault codes have been reported along with a driver complaint follow the trou Remove the EA harness from the ECU bleshooting path for the active code If the remove the white shield and inspect the ter inactive code was not reported with a minals for damage push back tension complaint no further troubleshooting is nec and or corrosion Use tool 9998482 to check essary Be sure to clear inactive codes tension check ECU for pin damage Is there damage NO YES Connect the J41132 36 pin breakout box to the EA harness Replace or re
51. s or hot engine parts and or location shown fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Carefully clean around the cylinder head bleed nipple and the fuel filter bracket drain union located on the right side of the filter housing N WARNING 2 Fuel oil or coolant leaked spilled onto hot surfaces or E Connect a 7 9 mm 5 16 in drain electrical components can cause a fire Clean up hose and open the fuel filter bracket spills immediately drain union Remove the bleed nipple N WARNING from the cylinder head Make sure that gauge pressure never exceeds 50 kPa 7 25 psi Excessive pressure may cause personal in jury Note Before using check the function of pressure gauge 6662 by attaching it to an air supply and setting the pressure to 50 kPa 7 25 psi with the regulator valve Special tools 9996662 9998277 47 Group 23 Fuel System D12 D12A D12B D12C 8277 T2006715 W2003511 Fig 35 Tool installation D12C When the fuel has completely drained 9998277 out of the cylinder head install union 9998277 into the bleed nipple hole 48 Service Procedures Check the pressure gauge assembly 1 Reduction valve 2 Air supply shut off Make sure the reduction valve knob is completely open rotate counterclock wise Open the shut off tap Connect pressure gauge 9996662 assembly to the shop air supply T2006716 9996
52. t YES NO Remove the supply and return wiring from the injector solenoid Tighten the connection re and test the solenoid for open or short circuit to ground assemble and check for Does the solenoid check within specifications active code YES NO The injector is good Do not replace the injector Replace the injector Continued see table page 31 30 Group 23 Fuel System D12 D12A D12B D12C Troubleshooting Continued from table page 30 Continue to test the EA harness for open circuits wiring shorted to ground or shorted wire to wire in EA harness Perform pull test during testing Is the harness within specifications YES NO Possible EECU failure Contact Volvo with Repair or replace the EA harness documented information before replacing the EECU For VN call 1 800 52 VOLVO For VHD call 1 887 97 VOLVO Start the engine and check to be sure that the codes are inactive Clear the inactive fault codes 31 Group 23 Fuel System D12 D12A D12B D12C Unit Injector Mechanical Faults Note A mechanical fault indicates low performance of that cylinder not just the injector Determine the correct troubleshooting flow path Fault codes 31 32 33 34 35 36 Troubleshooting 1 Active code or misfiring occur immediatel
53. t 2 2 200200 2 22 2 ee 67 Unit Injector Copper Sleeve Replacement 69 VOLVO Volvo Trucks North America Inc P O Box 26115 Greensboro NC 27402 6115 Volvo Trucks Canada Ltd 6490 Vipond Drive Mississauga Ontario L5T 1W8 http www volvotrucks volvo com PV776 TSP142867 1000 08 200 Volvo Trucks North America Inc 2000
54. t exits the overflow valve leak off fuel is then blended with the fuel entering the supply pump 20 Design and Function W2002628 6 Overflow valve 7 Fueltank 8 Fuel filter Group 23 Fuel System D12 D12A D12B D12C Design and Function D12C W2003243 Fig 14 External fuel line installation and fuel flow D12G 1 Bypass valve 2 Fuel passage in cylinder head The D12C uses a fuel line through the cylinder head The bypass valve is also located toward the front of the cylinder head 21 Group 23 Fuel System D12 D12A D12B D12C Fuel Filter The system is equipped with a large fuel filter located on the left hand side of the engine The filter insert consists of a special corrugated filter paper with a high resistance to water and very good filtering properties In addition a fine gauge net filter on the fuel suction line in the fuel tank separates any possible solid impurities before the fuel is pumped up into the system D12C The D12C uses a new fuel filter base with hand pump mounted directly on the base The base has a port for a fuel pressure sensor 22 1 2 Design and Function 12006726 Fig 15 Fuel filter Drain nipple Bleed nipple 12012783 Fig 16 Fuel Filter D12C Group 23 Fuel System D12 D12A D12B D12C Overflow Valve The overflow valve located in the outlet from the cylinder head fuel gallery regulates the fuel system
55. tall and tighten the retainer for the electronic unit injector Group 23 Fuel System D12 D12A D12B D12C Service Procedures Ile Y RED gq Ham Os C gt RN E lt a w REN T2006707 O codec Install the new sealing rings on the tooro electronic unit injector EUI Lubricate Flare the copper sleeve Do this by 9998254 the sealing rings with grease and in turning the nut while counterholding stall the electronic unit injector the spindle until the flaring pin 9998254 has been completely pulled through the copper sleeve Note Failure to counterhold the spin AN dle will result in a twisted or broken CAUTION flaring pin Remove all oil from the injector retainer bolt holes to prevent a hydraulic lock that may result in damage to 6 the cylinder head Remove the flaring tool 9998254 and 9998254 pin 9808000 9808000 Tighten the electronic unit injector New Copper Sleeve 9 Tighten retainer bolt to a torque of 20 20 5Nm 5 Nm 15 4 ft lb 15 4 ft lb 75 Group 23 Fuel System D12 D12A D12B D12C 10 W2003181 Turn the retainer bolt an additional 180 180 5 15 11 Loosen the retainer bolt for the unit in jector prior to the second tightening 12 Tighten bolt to a torque of 20 5 Nm 20 5 Nm 15 4 ft lb 15 4 ft lb 13 Turn the retainer bolt an additional 60 5 60 5 Old Copper Sleeve 14 Tighten the retainer bolt to a torque of 20 5 N
56. the fuel tank 8 Remove the two fuel lines at the over flow valve and install sight glass assembly 4 onto the overflow valve using hollow screw 941686 from the kit and route the line to the fuel tank 9 Remove the transparent hose 3 from the bleed nipple at the rear of the cylinder head to the fuel tank and close the bleed nipple Secure all three lines to prevent them from mov ing out of the fuel inside the tank Note For engines equipped with the small line located between the fuel supply pump and the top of the engine electronic control unit EECU this line must be disconnected from the fuel supply pump and the port from which the line was removed 5 must be plugged using two copper gaskets and washer 949873 supplied in the fuel line kit Troubleshooting 39 Group 23 Fuel System D12 D12A D12B D12C 10 Using the hand primer pump attempt to purge all air from the fuel system and start the engine Note Purging time may vary 11 Repeat the conditions in which aera tion was previously noted or test under loaded conditions i e dyno test 12 Monitor the two sight glasses and transparent hose for aeration allowing 3 to 5 minutes for the sight glasses to clear Note Shining a flashlight into the backside of the sight glass will im prove visibility 13 If no air is noted in either sight glass and air was noted in previous steps the air entry is most likely in the suc tion lines bet
57. tly from the fuel gallery The lower part of the EUI is located in a copper sleeve against the bottom of the cylinder head similar to a standard injector The EECU calculates injection timing and the amount of fuel to inject into the cylinder and transmits signals to the electromagnetically controlled fuel valve in the valve housing The length of the injection time determines the amount of fuel injected into the cylinder Design and Function Ua ie LA TE De MA REN ud Ng Els a AS AL dg T N w j T2006848 Fig 6 Electronic unit injector EUI 1 Pump part 2 Injector part 3 Valve housing Group 23 Fuel System D12 D12A D12B D12C Injector Operational Phases Fill Phase During the filling phase the pump plunger 2 is on its way up the camshaft lobe is passing its highest point and the rocker arm is on its way toward the camshaft ba sic circle The fuel valve 1 is open allowing fuel to flow into the EUI from the lower fuel gallery 4 It flows into the cylin der head and the EUI pump cylinder Filling continues until the pump plunger reaches its upper position 14 Design and Function HUL eo Jr R O 3 ea E eo GE E i LE i Fig 7 Filling phase T2006813 Fuel valve Pump plunger Fuel outlet overflow Fuel gallery inlet and outlet RON Group 23 Fuel System D12
58. transducer mea surement scale is in kPa 46 Service Procedures AN DANGER When operating a vehicle on streets and highways during a data collection procedure it is mandatory to have a second person drive while a technician col lects the data Monitor fuel pressure under full load i e Dyno test or road test with load 3 Compare measurements with specifi cations found in Fuel Supply Pump and Overflow Valve page 5 Note If measurements are found to be within specifications no further testing is required However if mea surements do not meet specifications refer to the Diagnostics Checklist B Fuel System Group 23 Fuel System D12 D12A D12B D12C Service Procedures 2309 11 03 01 1 Fuel System Draining Note Before beginning this service procedure please review General Work Practices page 43 AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death AN DANGER Do not service any part of the fuel system while smoking or in the presence of flames sparks or hot surfaces Failure to follow these precautions can result in fire which can cause serious injury or death HOT ENGINE Keep yourself and your test equipment Fig 33 Draining the fuel system D12A B bleed nipple clear of all moving part
59. ult in unexpected vehicle movement and can cause serious personal in jury or death AN DANGER Do not service any part of the fuel system while smoking or in the presence of flames sparks or hot surfaces Failure to follow these precautions can result in fire which can cause serious injury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment Fuel oil or coolant leaked spilled onto hot surfaces or electrical components can cause a fire Clean up spills immediately Group 23 Fuel System D12 D12A D12B D12C Overflow valve Carefully clean the area around the overflow valve area T2006730 Service Procedures T2006710 Draining fuel Drain the fuel by connecting a hose to the fuel filter housing drain nipple Re move the protection plug and open the bleed nipple on the cylinder head Route the fuel from the fuel filter hous ing into a suitable container T2006714 Removing fuel lines Remove the fuel line from the overflow valve 61 Group 23 Fuel System D12 D12A D12B D12C Service Procedures ee 2339 03 02 02 nd Overflow Valve Replacement 7 D12C Clean the contact surface on the cylin der head and install a new overflow Note Before beginning this service procedure please valve Use a
60. ur literature your opinions and experience when using this manual would be greatly appreciated If you have any comments or suggestions make a copy of this page write down your comments and send them to us either via telefax or mailing directly to the address listed below To From Volvo Trucks North America Inc 0000 urrrrerererererrrererrrrrrrsrsrrsrrrrrrrrrrrrrrrrrrnrrrnrnnrnnrnnnnnnnnnnn Dept 516 Service Publications 0000 uvvererrenevnerrrersrrnreversnnnsensnnsnvnesnvnerevrerveessvresenvesenen 7825 National Service Road 00000000 cnc PO Box26115 00 aida frede Greensboro NC 27402 6115 000 umarsnssnnnerrrsssnnnnnnnnssnnnnnnvnnssssssnnnnnnnnnsssnnnnnnnssssrssnnnn USA Fax 336 393 3170 Comments proposals 2309 05 03 01 2309 06 02 03 2309 11 03 01 2331 03 02 01 2331 03 02 02 2334 03 02 01 2339 03 02 02 2339 06 02 02 2371 03 02 02 2371 05 02 01 2379 03 02 02 Operation Numbers Fuel System Bleeding 0 00 eee eee eee 50 Fuel System Pressure Checking 0 0 00 0008 45 Fuel System Draining 222222 vrak eee ee ee 47 Fuel Feed Pump Replacement 2 22 arr e 52 53 Hand Primer Pump Replacement 2 22 aa rar rar 56 Fuel Filter Replacement 2 20002 eee ee eee 57 Overflow Valve Replacement 202 55022005 60 62 Overflow Valve Checking vara rava rer arken 59 Unit Injector Replacement One rn 63 Unit Injector Adjustmen
61. urn 90 Install the valve cover and secure with 4 nuts Do not turn the adjusting screw down more than 1 4 turn 90 after all clearance has been removed En gine damage will result 6 Using the hand primer pump purge all air from the fuel system Run the engine only at idle speed with no load for this test High engine speed or load could cause engine damage 42 Troubleshooting 7 Restart the engine and monitor the sight glass 4 in the rear of the cylin der head If the air that was noted in step 3 is gone then the problem is most likely in the number 1 cylinder injector tip or injector to copper sleeve seat Remove the number 1 injector and inspect the injector to the copper sleeve seat If the seat appears to be OK replace the injector and perform the test again 8 If the air that was noted in step 3 is not gone stop the engine remove the valve cover back out counterclock wise the adjusting screw for the intake valve at the number 1 cylinder 1 2 round 180 and repeat the pro cedure starting with step 5 on the number 2 cylinder 9 Continue the procedure until the cylin der that is introducing air into the fuel system has been determined 10 When the cylinder that is introducing air into the fuel system has been lo cated remove that injector and inspect the injector to copper sleeve seat If the seat appears to be O K replace the injector and perform the test again If the
62. vvererenevnernnerernener 29 Unit Injector Mechanical FANS circa macia 32 1 Active code or misfiring occur immediately after start up 32 2 Active code at normal operating temperature and high idle 32 3 Active code and misfiring at BASE IDLE ONLY 33 Locating Air in the Fuel Systainer 34 Determining Whether There is Air in the Fuel sassen 35 Determining which Cylinder is Introducing Air into the Fuel 41 Servite Procedures isaac 43 Creed REE ened 43 Campa te MA LINES lt a 44 Turning the Engine Over with the Starter Motor rrrnnrnnrnnnnrnnnn 44 Fuel System Pressure ChECRI O cir 45 PUE SOS DANNO ia 47 Fue tem Bleeding Fuel Feed P Repla D12 D12A Feedback Operation Numbers Group 23 Fuel System D12 D12A D12B D12C General W2003244 This information covers the fuel system of the Volvo D12 engine and includes engine versions D12 D12A D12B and D12C General Group 23 Fuel System D12 D12A D12B D12C Specifications Specifications Fuel System Retainer bolt unit injector w NEW COPPER SLEEVE First tightening 20 5 15 4 Step 1 First tightening Turn an additional 180 5 Step 2 Loosen the retainer bolt for the unit injector prior to the second tightening Second tightening 2015 15 4 Step 1 Second tightening Turn an additional 60 5 Step 2 Retainer bolt unit injector w OLD COPPER SLEEVE Fuel Supply Pump an
63. ween the fuel supply pump and the fuel tank including the primary fuel filter copper washers O rings and pick up inside of the fuel tanks 14 If air is noted in sight glass 2 be tween the fuel supply pump and fuel filter and the alternate fuel supply is supplying the fuel supply pump with a good flow of air free fuel the problem is most likely in the fuel pump seals Note The fuel in sight glass 2 is un der pressure This compresses the air bubbles and they will appear to be small 40 Troubleshooting 15 If air is noted in the sight glass 4 at the rear of the cylinder head but not in sight glass 2 at the outlet of the fuel supply pump with no engine load the problem is most likely within the cylinder head i e copper sleeve to injector seat or injector tip leakage See Determining which Cylinder is Introducing Air into the Fuel page 41 Note Sight glass 4 will show small bubbles due to the turbulence created by the opening and closing of the overflow valve To determine whether normal or abnormal aeration is occur ring use the transparent hose 3 at the bleed nipple at the rear of the cylinder head Open the bleed nipple 1 1 2 turns and monitor for air If the line is clear then the aeration in the sight glass 4 is normal If the transparent hose indicates aeration then the aera tion in sight glass 4 is abnormal 16 If air is noted only under loaded condi tions remove all six i
64. y after start up Cause Corrective action e Incorrect valve or injector adjustment e Check the valve and injector adjustment as required e Injector problem e Perform cylinder balancing or manual compression test before replacing the injector refer to appropriate ser vice literature or diagnostics checklists for information e Base engine problem e Visual inspection of the camshaft and high crankcase pressure Perform cylinder balancing or manual com pression test before replacing the injector for piston and valve condition Repair as required 2 Active code at normal operating temperature and high idle Cause Corrective action e Incorrect valve or injector adjustment e Check the valve and injector adjustment as required e Poor quality fuel or excessive fuel additives e Test with auxiliary fuel and retest e Aeration e Check for fuel restriction air or compression intro duced into the fuel system and repair as required e Injector problem e Perform cylinder balancing test or manual compres sion test If within specifications replace injector e Base engine problem e Visual inspection of camshaft and high crankcase 32 pressure Perform cylinder balancing or manual com pression test before replacing injector for piston and valve condition Repair as required Group 23 Fuel System D12 D12A D12B D12C Troubleshooting 3 Active code and misfiring at BASE IDLE ONLY Cause Corrective action
65. ylinder when a unit injector is dismantled 4 T2008956 Remove the injector hold down bolt 5 Clean very carefully round the unit in jector to be changed Group 23 Fuel System D12 D12A D12B D12C Service Procedures 9 Wy ud GE Gi praj SS a CA 4 gt gt ATTEN f Va 9998511 W2003392 W2003393 Remove the electrical cables from the 9998511 Fig 58 Cleaning the copper sleeve unit injector and the bolt for the unit in jector s attachment yoke Install cleaning sleeve 9998580 in the 9998580 Remove the unit injector with tool injector well and carefully clean the 9998251 9998511 copper sleeve Leave cleaning sleeve 9998580 on the 7 cylinder head until the dirt is removed from the injector well Note If the unit injector is not installed immediately install the protective plug 9998251 in the cylinder head 10 Check the sealing rings on the unit in jector Install the unit injector and centre it between the valve springs Tighten with a torque as per the speci fications W0001837 Fig 57 Vacuum pump J 44515 Remove fuel from the top of the piston J 44515 using vacuum pump J 44515 8 Install protective sleeve J 42885 25 J 42885 25 on the unit injector 65 Group 23 Fuel System D12 D12A D12B D12C Service Procedures 11 14 Connect the electric cables to the in 1 4 0 1 Nm jector 3 5 0 88 in lb Note Tighten the nuts with

Fuel System - D12,D12A,D12B,D12C

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