Service Manual Trucks - Heavyhhrvresource.com/VolvoDocs/Volvo Eng/PV776-TSP144525.pdf · Service Manual Trucks Group 220–600 Lubricating and ... cautions and warnings are used in

Service ManualTrucks

Group 220–600

Lubricating and Oil System

D12, D12A, D12B, D12C

PV776-TSP144525

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 producedafter 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 ServiceDocumentation:

Note: Indicates a procedure, practice, or condition that must be followed in order tohave 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 theproduct could occur.

Danger: Indicates an unsafe practice where serious personal injury or death could oc-cur.

Volvo Trucks North America, Inc.Greensboro, NC USA

Order number: PV776-TSP144525

© 2000 Volvo Trucks North America, Inc., Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced, stored inretrieval system, or transmitted in any forms by any means, electronic, me-chanical, photocopying, recording or otherwise, without the prior writtenpermission of Volvo Trucks North America, Inc..

ContentsGeneral .................................................................................................... 3

Specifications ......................................................................................... 5Torque Chart .......................................................................................... 5

Tightening Specifications .................................................................... 5

Tools ........................................................................................................ 7Special Tools ......................................................................................... 7Special Equipment ................................................................................. 9

Design and Function ........................................................................... 11Lubricating and Oil System ................................................................... 11

General .............................................................................................. 11D12, D12A, D12B .............................................................................. 12D12C ................................................................................................. 13

Oil Valves ............................................................................................. 14D12, D12A, D12B .............................................................................. 14D12C ................................................................................................. 15

Oil Pump .............................................................................................. 16Oil Filter ............................................................................................... 16Piston Cooling ..................................................................................... 16

Troubleshooting ................................................................................... 17Lube System Fuel Contamination, Checking ...................................... 17Oil Cooler Leak Test, Checking ........................................................... 17

Service Procedures ............................................................................. 19Oil Pan, Installation .............................................................................. 19Lube Oil Pump, Replacement ............................................................. 19

Removal .......................................................................................... 20Installation ....................................................................................... 21

Lube System Pressure, Checking ....................................................... 22Oil Filter, Replacement ........................................................................ 23Piston Cooling Valve, Replacement .................................................... 24Piston Cooling Nozzle, Replacement .................................................. 25Oil Pressure Reduction Valve, Replacement ...................................... 26Oil Cooler Core, Replacement ............................................................ 28

Removal .......................................................................................... 28Installation ....................................................................................... 29

Oil Cooler Bypass Valve, Replacement .............................................. 31Oil System Passages, Cleaning .......................................................... 31Oil Filter Nipple, Replacement ............................................................ 42Oil Filter Overflow Valve, Replacement ............................................... 43

Feedback

Operation Numbers

1

2

Group 22 Lubricating and Oil System General

General

W2003244

This information covers the Lubricating and Oil System for the D12, D12A, D12B, andD12C engines.

3

4

Group 22 Lubricating and Oil System Specifications

SpecificationsTorque Chart

Part Torque

Oil cooler element bolts 27 ± 4 Nm (20 ± 3 ft-lb)

Oil cooler element cover bolts 33 ± 4 Nm (24 ± 3 ft-lb)

Oil pump intermediate gear bolts 24 ± 4 Nm (18 ± 3 ft-lb)

Oil pump main bearing bolts 150 ± 20 Nm (111 ± 14 ft-lb)

Oil pump main bearing cap bolts 24 ± 4 Nm (18 ± 3 ft-lb)

Oil strainer bolts 27 ± 4 Nm (20 ± 3 ft-lb)

Delivery pipe union 10 Nm (7.4 ft-lb)

Oil pan bolts 24 ± 4 Nm (18 ± 3 ft-lb)

Piston cooling nozzle bolts 24 ± 4 Nm (18 ± 3 ft-lb)

Oil filter base 40 ± 5 Nm (30 ± 4 ft-lb)

Tightening Specifications

Part Tighten Until:

Oil filter (full flow) Seal contacts housing then additional 1/2 - 3/4 turn

Oil filter (bypass) Seal contacts housing then additional 3/4 -1 turn

5

6

Group 22 Lubricating and Oil System Tools

ToolsSpecial Tools

The following special tools are required for work on the VE D12 oil system. Tools areavailable from Volvo Trucks North America, Inc. parts department. Unless otherwisenoted, all tool numbers are preceded by ”999”. When requesting tools, provide the ap-propriate part number, for example, 9992873.

T2006803

9992873 Connection union for checking lube oilpressure

9996398 Pressure gauge for checking lube oilpressure

9996662 Pressure gauge for leak test, oil coolerelement

9996672 Removal tool for oil filter

9996845 C-clamp for leak test, oil cooler element

9996956 Cranking tool for flywheel

7


W0001809

J-43051 Reducation valve cap socket

W2003485

9998691 Oil Filter Nipple installation Kit

1 98097062 98097023 98097034 98097055 9809704

8


Special EquipmentLike the special tools, the following are available from the parts department of VolvoTrucks North America, Inc.. When requesting tools, provide the appropriate part num-ber.

W0001840

1159794 Torque wrench 10–100 Nm (7 – 73 ft-lb)

W0001841

1159795 Torque wrench 40 – 340 Nm (30 – 250 ft-lb)

W0001842

1159796 Torque wrench 150 – 800 Nm(110 – 590 ft-lb.)

9

10

Group 22 Lubricating and Oil System Design and Function

Design and Function

Lubricating and Oil SystemGeneral

W2003516

1 Reducing valve2 Overflow valve3 Cooling valve4 Overflow valve5 Safety valve6 Thermostatic valve

The engine has a forced lubrication provided by a gearpump driven by the crankshaft through an intermediategear. The lubrication system contains two full flow filtersand a by-pass filter. The oil flow is adjusted by sixvalves. Three of these are individual valves and they areidentified with color codes to avoid an incorrect installa-tion. This color code may be replaced by a number thatrepresents the valve opening pressure.

A flat oil cooler is assembled under a cast aluminumcover in the engine block right side.

The lubrication oil pump impels the oil towards the twofull flow filters and the by-pass filter.The by-pass filter contains a low oil passageway and ahigh degree of filtering.

After passing through the full flow filters, the oil moves tothe cylinder block, where it is distributed through gal-leries to engine points in need of lubrication.

The purpose of the lubrication system is to lubricate theengines movable parts in order to keep friction andwearing to a minimum. The oil transports coal and otherresidues stuck on the cylinder walls after combustion.The oil also functions as a sealer, for the cylinder linershave been projected in such a way that a thin layer of oilis always kept in its walls. This make it easier for the pis-ton rings to seal the combustion chamber. The oil alsocool the engine inner and, at the same time, reduces thesounds produced by the engine.

11


D12, D12A, D12B

T2006823

1 Oil pressure regulator valve2 Oil cooler by-pass valve3 Oil filter by-pass valve4 Piston cooling valve5 By-pass filter6 Full-flow filter7 Full-flow filter8 Oil pipe for engine brake (VEB)

The engine is pressure-lubricated by a gear pump drivenby the engine timing gears. The lube oil is cleaned bytwo full-flow filters and one bypass filter. The flat-type oilcooler is mounted under a cast aluminum cover on theright-hand side of the cylinder block.

The lube oil pump forces the oil to the full-flow filters andthe bypass filter. The bypass filter has a low through flowand provides a high degree of filtration. The oil is ledfrom the full-flow filters to the cylinder block where it isdistributed by passages to the lubricating points of theengine.

The lubricating system incorporates four valves:

• Oil pressure regulator valve

• Oil cooler bypass valve

• Oil filter bypass valve

• Piston cooling valve

12


D12C

W2003517

1 Reducing valve2 Overflow valve3 Cooling valve4 Overflow valve5 Safety valve6 Thermostatic valve7 Filter

8 Filter9 Compressor10 Turbocompressor11 Regulator valve12 Oil cooler13 Pulverizer nozzle14 Oil pump

The oil pump (14) forces the oil through the coolantelement in the oil cooler (12) to the filter casing that con-tains both the full flow filter (7) and the by-pass filter (8).The oil goes then to the gallery in the engine blockwhere it is distributed through the galleries and all theengine lubrication points. A gallery that passes throughthe engine block and the cylinder head lubricates the

camshaft and the rocker arm mechanisms. In the VEBengines, the oil passes through the regulator valve (11).The compressor (9) is lubricated through an externalpipe that comes from the filter casing.The turbocompressor (10) is lubricated through a pipethat comes from the bypass filter.

Valve Functions1 The reducing valve regulates engine oil pressure let-

ting go the oil excess to the oil sump.2 The filter overflow valve (8) opens up if the filters

become clogged, assuring the continuity of the tur-bocompressor lubrication.

3 The piston cooling valve is pressure sensible andopens up as soon as the rotates exceeds idlingspeed pressure.The oil is conducted to the longitudinal gallery onthe block and pulverized by the pulverizer nozzle(13), one for each piston, on the piston flange bot-tom side.

4 The filter overflow valve (7) opens up if the filtersbecome clogged, assuring the continuity of the en-gine lubrication.

5 The safety valve opens up if the pressure in the lu-brication system gets too high.

6 The oil cooling thermostatic valve is used to conductthe oil through the outside of the cooler during theengine heating, so that the engine gets a faster lu-brication during a cold start and heats faster. Thisvalve is thermostatically controlled and it acts as anoil temperature sensor.

13


Oil ValvesD12, D12A, D12B

T2006673

1 Regulator Valve2 Bypass valve for oil cooler

3 Overflow valve for oil filters (bypass)4 Reducing valve

1 Regulator valve — The regulator valve regulates theoil pressure. It does this by opening when the lube oilpressure becomes too high and letting any surplus oilback to the oil pan.

2 Bypass valve for oil cooler — The purpose of thebypass valve is to regulate the oil flow through the oilcooler. When the pressure drop across the oil cooler islow, for example, immediately after starting when oil tem-perature is low, the overflow valve opens and oil is ledpast the oil cooler. When oil temperature rises and pres-sure drops across the oil cooler increases, the bypassvalve closes, and oil flows through the oil cooler beforebeing pressed out into the lubrication system. The by-pass valve is also available with a built-in thermostat.When the oil temperature is under 105–115� C (221–239� F), the by—pass valve opens and oil is led past theoil cooler and directly out into the lubrication system.At higher oil temperatures, the thermostat closes the by-pass valve and the oil passes through the oil coolerbefore it is forced out into the lubrication system.

3 By—pass valve for oil filter — If the filters becomeblocked, the by—pass valve opens guaranteeing lubrica-tion, but with no filtration.

4 Piston cooling valve— The piston cooling valveopens when the engine speed (rpm) has increased toslightly over idling speed. Oil flows through the pistoncooling passage to the six piston cooling nozzles whichspray oil against the underside of the pistons.

14


D12C

T2012843

1 Safety valve2 Thermostatic valve3 Overflow valve for oil filters (bypass)

4 Oil valve for pistons cooling5 Overflow valve for oil filters (bypass)6 Reducing valve

1 Safety valveThe safety valve opens up if the pressure in the lubrica-tion system gets too high, for example, during a coldstart in the winter.

2 Thermostatic valveThe thermostatic valve function is to regulate the oil flowthrough the oil cooler.When the pressure in the oil cooler is too low, for in-stance, just after a start with a low oil temperature, thethermostatic valve opens up and the oil passes throughnear to the oil cooler. When the oil temperature increaseand the pressure drop in the oil cooler get higher, thethermostatic valve closes and the oil passes through thecooler before being impelled to the lubrication system.

3 Overflow valve for oil filters (bypass)The overflow valve opens up if the filters becomeclogged, assuring the continuity of the lubricationprocess.

4 Oil valve for pistons coolingThe oil valve for pistons cooling opens up as soon as therotates exceeds idling speed.The oil passes through the piston cooling circulation gal-leries to the six piston cooling oil injectors.

5 Overflow valve for oil filters (bypass)The overflow valve opens up if the filters becomeclogged, assuring the continuity of the lubricationprocess.

6 Reducing valveThe reducing valve regulates oil pressure, opening upwhen the pressure exceeds the specified value, lettinggo the oil excess to the engine oil sump.

15


Oil PumpThe oil pump is a gear pump set in motion by an inter-mediate gear in the synchronized gearing. The pump ismade up of two gears that are turned in a well-sealedcasing. When gears turn, the oil is transported betweenits teeth and the walls of the pump casing. When theteeth are geared, the oil is pumped out and inserted inthe lubrication system.

Oil FilterOne of the purposes of the oil lubrication to clean up im-purities on the engine lubrication points and on thebearings surface. The oil, then, accumulates dirt thatneeds to be cleaned up before it goes back to the lubri-cation points. The oil is roughly filtered while passingthrough the oil manifold filter. In order to get rid of thedirt particles, the D12C engine lubrication system isequipped with three filters.

The oil filters are made up of replaceable filtering ele-ments.All the oil coming through the pump passes through thefilters before entering the engine.

Piston CoolingWhen the engine is running, there usually is a buildup ofheat in the piston that, in some cases, needs an extracooling. The piston cooling is set in motion when the oilpressure gets so high that the piston cooling valve in thecylinder block opens up. The oil is then forced throughthe engine block drilled galleries into the injection noz-zles of piston cooling, one for each piston. The oil isthen pulverized on the bottom of the piston.

16

Group 22 Lubricating and Oil System Troubleshooting

TroubleshootingLube System Fuel Contamina-tion, Checking1When fuel contamination is suspectedin the lube system, use a high-intensity black-light lamp (Kent-Moorepart number J 28428 E) along with afluorescent additive to locate the pointat which fuel is entering the system.

2231-06-05-01Oil Cooler Leak Test, Checking

Before working on a vehicle, set the parking brakes,place the transmission in neutral, and block thewheels. Failure to do so can result in unexpectedvehicle movement and can cause serious personal in-jury or death.

Special tools: 9996662, 9996845

1Flush the coolant side of the oil coolerelement with water-soluble degreasingfluid. Wash the oil side of the coolerelement with degreasing solvent.

2

T2006695

Tools 9996845

Install tools 9996845, making surethey are properly seated.

9996845

3

T2006696

Pressure gauge and bath

Make sure the reduction valve knob ofpressure gauge 9996662 is fully openand that the pressure gauge is in the“0” position.Connect the pressure gauge needle to9996845. Lower the oil cooler elementinto a bath which contains water at 70�

C (160� F).Increase pressure to 250 kPa (35 psi)using the reduction valve knob. Thetest period should last for at least oneminute.Air bubbles emerging from the oilcooler element indicate a leak and theelement should be replaced.

99966629996845

17

18

Group 22 Lubricating and Oil System Service Procedures

Service Procedures2171-02-02-01Oil Pan, Installation1

T2006802

Fig. 1: Oil pan, gasket and rail-D12, D12A, D12B, D12C

W2003249

Fig. 2: Oil pan, gasket and rail-D12C

Make sure the gasket is correctly posi-tioned. Then position the oil pan andtighten the bolts to 24 ± 4 Nm (18 ± 3ft-lb).

Note: Tighten the bolts in the metalrail joints first.

24 ± 4 Nm(18 ± 3 ft-lb)

2Fill the engine with the correct amountof oil.

3Crank the engine with the starter untiloil pressure is recorded on the pres-sure gauge.

4Apply parking brake. Place the shiftlever in neutral.

5Start the engine, check operation andperform a leak test.

2211-03-02-01Lube Oil Pump, Replacement


WARNING

HOT ENGINE! Keep yourself and your test equipmentclear of all moving parts or hot engine parts and/orfluids. A hot engine and/or fluids can cause burns orcan permanently damage test equipment.

WARNING

Always wear appropriate eye protection to prevent therisk of eye injury due to contact with engine debris orfluids.

(Oil Pan Removed)

Not Included:

• “Oil Filter, Replacement” page 23

19


Removal1Drain engine oil into suitable containerand remove the oil pan.

Note: Dispose of oil according to localand state regulations.

2

T2006798

Fig. 3: Oil delivery pipe nuts

Remove the oil delivery pipe nut in thecylinder block, and bolts for the oilstrainer.

3

T2006799

Fig. 4: Oil pump bolts

Remove the bolts for the first mainbearing cap. Lift out the oil pump to-gether with the main bearing cap.

4

T2006800

Fig. 5: O-ring and oil strainer

Remove the O-ring and oil strainerfrom the oil delivery pipe.

5

T2006697

Fig. 6: Remove oil pump

Remove the oil pump from the mainbearing cap.

6

T2006698

Fig. 7: Intermediate gear

Remove the intermediate gear fromthe oil pump housing.

7Clean the oil strainer. Make sure theoil strainer mesh is not damaged.

20


8Clean and check the bushings andteeth on the intermediate gear.

9

T2006699

Fig. 8: Intermediate bushing locations

Intermediate bushings with engine oil.Insert the intermediate gear into thenew oil pump. Tighten the bolts to 24± 4 Nm (18 ± 3 ft-lb).

24 ± 4 Nm(18 ± 3 ft-lb)

Installation1

T2006697

Fig. 9: Mounting oil pump to main bearing cap

Install the new oil pump on the mainbearing cap. Tighten the bolts to 24 ±4 Nm (18 ± 3 ft-lb).

Note: Remember to install the mainbearing cap bolts before fastening thepump to the bearing cap.

24 ± 4 Nm(18 ± 3 ft-lb)

2Clean the main bearing shell and lubri-cate it with engine oil.

3

T2006799

Fig. 10: Installing lube oil pump

Install the lube oil pump, making surethat the teeth in the intermediate gearmake contact with the crankshaft drivegear. Tighten the main bearing bolts to150 ± 20 Nm (111 ± 14 ft-lb). Thenturn a further 120� ± 5�.

150 ± 20 Nm(111 ± 14 ft-lb)

4Check the oil delivery pipe for cracks inthe flange where it contacts the union.

5

T2006801

Fig. 11: Oil strainer installation

Place the oil strainer on the oil deliverypipe and install new O-rings.

21


6

T2006798

Fig. 12: Installing oil strainer and delivery pipe

Install the oil strainer and the oil deliv-ery pipe. Tighten the oil strainer to theoil pump to 27 ± 4 Nm (20 ± 3 ft-lb).

27 ± 4 Nm(20 ± 3 ft-lb)

7

T2006701

Fig. 13: Oil pipe union installation

T2006825

Fig. 14: Union tightening torque

Tighten the union in the cylinder blockuntil it bottoms at about 10 Nm (7.4 ft-lb).For a previously installed pipe, tightenthe union a further 60�. For a new pipe,tighten the union a further 180�. Makesure the pipe is installed properly.

10 Nm(7.4 ft-lb)

2211-06-02-01Lube System Pressure, Check-ing


WARNING

HOT ENGINE! Keep yourself and your test equipmentclear of all moving parts or hot engine parts and/orfluids. A hot engine and/or fluids can cause burns orcan permanently dam age test equipment.

Special tools: 9992873, 9996398

1Place shift lever in neutral and applyparking brake.

2Lubricating oil pressure is checked byconnecting a pressure gauge andhose to the oil pressure sender outleton the left-hand side of the engine.

Note: The oil pressure sender ismounted in the cylinder block frontoutlet. The rear outlet can be pluggedor an oil temperature sender may beinstalled. On some trucks, a hose isconnected to the front outlet, and theoil pressure sender is positioned in anattachment on the frame side.

22


3

W2003484

Fig. 15: Pressure gauge and hose installation-D12C

W2003499

Fig. 16: Pressure gauge and hose installation-D12B

Carefully clean and disconnect the oilpressure sender wiring and remove thesender. Install connect union 9992873into the engine block and then attachthe hose and pressure gauge9996398. Start the engine; engine oilshould be at operating temperature.Take the oil pressure reading at lowidle speed and at high idle. At low idlespeed, the oil pressure should be150 kPa (22 psi) minimum. At highidle, it should be 300–550 kPa (45–80psi).

99928739996398

4Remove the gauge, hose and union.Reinstall the oil sender and reconnectthe sender wiring.

2223-03-02-01Oil Filter, Replacement


WARNING


WARNING


Special tools: 9996672

23


1

W2003413

Fig. 17: Replacing oil filters

1 Bypass filter2 Full-flow filter3 Full-flow filter

Drain the engine oil into suitable con-tainer and clean around the oil filterhousing. Remove the filters, using filtertool 9996672.

Note: Dispose of oil in accordance tolocal and state regulations.

9996672

2Moisten the seals of the new filterswith clean engine oil and screw on thefilters by hand until the seals come incontact with the filter housing. Thentighten the full-flow filters a further1/2–3/4 turn. Tighten the bypass filter3/4–1 turn after making contact withthe filter housing.

1/2–3/4 turn3/4–1 turn

3Fill the engine with oil.

4Crank the engine with the starter untiloil pressure is recorded on the pres-sure gauge.

5Place shift lever in neutral and applyparking brake.

6Start the engine and check for leaksaround the oil filters.

2229-03-02-02Piston Cooling Valve, Replace-ment


WARNING


1Clean the filter housing and removethe cover of the piston cooling valve.Remove the O-ring.

2Remove the piston cooling valve andclean the valve seat in the filter hous-ing. Make sure to remove the oldO-ring from the filter housing.

3

T2006676

Fig. 18: Piston cooling valve

Make sure the color marking on thenew piston cooling valve is orange.

24


4

T2006684

Fig. 19: Inserting valve

Insert the new valve in the cover.Place new O-rings on the valve andthe filter housing.

5Install the valve in the filter housingand tighten the cover bolts.

6Apply parking brake. Place shift leverin neutral.

7Start the engine and perform a leaktest.

2229-03-02-03Piston Cooling Nozzle, Re-placement


WARNING


(Oil Pan Removed)

Note: To prevent the piston cooling nozzles from beingdamaged, always remove them before removing pistonsand cylinder liners.


1

T2006702

Fig. 20: Cranking tool

Remove the inspection cover from thebottom of the flywheel housing and in-stall cranking tool 9996956.

9996956

2

T2006685

Fig. 21: Piston cooling nozzle

Turn the crankshaft until the pistoncooling nozzle to be replaced is easilyaccessible.

3Remove the piston cooling nozzle.

25


4

T2006686

Fig. 22: Installing new piston cooling nozzle

Install new piston cooling nozzle, us-ing a new bolt. Tighten to 24 ± 4 Nm(18 ± 3 ft-lb)

Note: The piston cooling nozzle at-tachment bolt is coated with afriction-inducing compound. Do notreuse.

Note: Any piston cooling nozzle sus-pected to be damaged or deformedmust be replaced (this even applies toa new nozzle). Always make sure thepiston cooling nozzle fits correctly inits hole in the cylinder block and thatthe attachment plate is flush with thecylinder block.

24 ± 4 Nm(18 ± 3 ft-lb)

5Remove the cranking tool and reinstallthe inspection cover on the flywheelcasing.

2229-03-02-04Oil Pressure Reduction Valve,Replacement


WARNING



1

T2006797

Fig. 23: Removing oil filter

Drain the engine oil into a suitabelconatainer and clean around the oil fil-ter housing. Remove the front oil filter,using filter removal tool 9996672 orequilavent.

Note: Dispose of oil in accodance tolocal and state regulations.

9996672

2

T2006675

Fig. 24: Plug location on engine

Clean around the plug on the cylinderblock. Unfasten the plug and removethe regulator valve.

3Clean the regulator valve seat andmake sure to remove the old O-ring.

26


4

T2006676

Fig. 25: Regulator valve

Check that the color marking on thenew regulator valve is brown.

5

T2006677

Fig. 26: Inserting regulator valve in plug

Insert the regulator valve in the plug.Place new O-rings on the valve andplug. Install the plug into the cylinderblock.

6Install a new oil filter. Moisten the sealof the new filter with engine oil andscrew on the filter by hand until theseal is in contact with the filter hous-ing. Then tighten the filter a further 1

2

– 3

4turn.

1

2– 3

4turn


8Place the shift lever in neutral and ap-ply parking brake.

9

W3000459

Fig. 27: ECM relay location

Remove the ECM relay from enginevalve cover.

10

W3000458

Fig. 28: Connections for remote starter cable

Connect a remote starter switch cable(Snap-On® MT302A or equivalent) be-tween the battery (+) and the positiveconnection (+) on the starter motor so-lenoid. Crank the engine with thestarter until oil pressure is recorded bythe pressure gauge.

Note: Do not run the starter anylonger than 15 seconds at one time.Allow the starter to cool before re-running the starter motor.

11Remove remote starter cable and re-place the ECM relay after completion.

27


12Start the engine and perform an oper-ation and leak check.

2232-03-02-01Oil Cooler Core, Replacement


WARNING


(Coolant Drained, Air Compressor Removed.)

Not Included:

• “Oil Cooler Leak Test, Checking” page 17

Note: Radiator and cooling system must be properlycleaned and flushed in the event of a suspected oilcooler failure. Refer to:

ServiceManual

260–600Cooling System, VE D12–D12C

IMPACT Function Group 2619Information Type: Repair”Cooling System”

Removal1Remove the turbocharger. Plug turbooil lines and outlet openings to preventcontamination. Install cover on turbointake and exhaust openings to pre-vent foreign material from possiblybecoming lodged in turbine wheels.

2

T2006687

Fig. 29: Removing pipes

Remove the pipes between the ther-mostat housing and the coolant pump,and between the coolant pump andthe oil cooler cover.

3Remove the thermostat housing.

4

T2006688

Fig. 30: Inner stud bolts

Remove the turbocharger inner mount-ing stud from the exhaust manifold.

28


5

T2006689

Fig. 31: Oil cooler element cover

Remove the oil cooler element cover.

6

T2006690

Fig. 32: Removing oil cooler element

Remove the oil cooler element.

7Remove the oil cooler element O-ringsand the gasket in the cover. Clean thecontact surfaces of the cylinder blockand cover.

8If a leak test on the oil cooler elementis desired, see “Oil Cooler Leak Test,Checking” page 17.

Installation1

T2006691

Fig. 33: Oil cooler O-rings

Clean and place new O-rings in thecylinder block. Install the oil cooler ele-ment and tighten the bolts to 27 ± 4Nm (20 ± 3 ft-lb).

27 ± 4 Nm(20 ± 3 ft-lb)

2

T2006692

Fig. 34: Gasket inserted

Insert a new gasket in the cover. Re-place and tighten the cover. Tightenthe bolts to 24 ± 4 Nm (18 ± 3 ft-lb).

Note: Tighten the oil cooler coverbolts evenly and in several steps toavoid damaging the oil cooler cover.

33 ± 4 Nm(24 ± 3 ft-lb)

29


3

T2006688

Fig. 35: Inner turbo mounting stud

Install the two inner stud bolts for theturbocharger.

4

T2006693

Fig. 36: Installing pipe

Install the pipe between the coolantpump and the oil cooler cover. Re-place the gasket between the coverand pipe connection. Use new O-rings.

5Replace the thermostat housing, usinga new gasket.

6

T2006694

Fig. 37: Installing pipe

Install the pipe between the thermo-stat housing and the coolant pump.Use new O-rings.

7Replace the turbocharger. Use a newmounting gasket.

8Replace the air compressor. Use anew mounting gasket.

9Fill with coolant. Use only a concen-trated coolant that meets or exceedsASTM D4985 specifications. The rec-ommended coolant is monoethyleneglycol (MEG) based or monopropyleneglycol (MPG) based anti-freeze.


11Pre-lube the turbo unit with engine oil.Add two ounces of engine oil throughturbo lube line opening before connect-ing the lube line. This will ensure turbohas sufficient lubricant at start up.

Note: It is very important to make surethere is an adequate oil supply to theturbo before starting the engine.

12Apply parking brake and place shiftlever in neutral.

30


13Start the engine and perform opera-tion and leak tests.

2239-03-02-02Oil Cooler Bypass Valve, Re-placement


WARNING


1

T2006681

Fig. 38: Installed Plug

Clean around the oil filter housing andremove the plug. Remove the coneand spring.

2Clean and check the valve seat. If thevalve seat shows signs of corrosion,replace the oil filter housing.

3

T2006682

Fig. 39: Inserting cone and spring

Insert the new cone and spring alongwith a new O-ring. Install and tightenthe plug.

4Apply parking brake and place shiftlever in neutral.

5Start the engine and perform a leaktest.

2209-11-02-01Oil System Passages, Cleaning


WARNING


WARNING


31


1Drain coolant into suitable container.

Note: Dispose of coolant in accor-dance to local and state regualtions.

2Note: Before flushing the passage youmyst remove the turbocharger. Referto:

SerivceManual

250–600Intake and Exhaust-Systems, D12, D12A,D12B, D12C

IPMPACT Function GroupInformation Type: Re-pair”Turbocharger”

3

T2006688

Fig. 40: Turbo moutning studs

Remove the inner 2 turbo mountingstuds.

4

W2002380

Fig. 41: Water pump discharge pipe

Remove the 3 bolts fastening the wa-ter pump discharge pipe to the oilcooler cover. Unplug the Volvo EngineBrake (VEB) temperature sensor (ifequipped) and remove the pipe.

5

W2002338

Fig. 42: Air compressor diconnect

1) coolant supply hose2) air compressor discharge line3) coolant return hose

Disconnect the air compressor coolantsupply hose (1) from the oil coolercover.

6Disconnect the air compressordischarge line (2) from the air com-pressor.

32


7Disconnect the air compressor coolantreturn hose (3) from the bypass pipe.

8

T2006694

Fig. 43: Remove bypass pipe

Remove the bolts fastening the bypasspipe and remove pipe.

9

T2007234

Fig. 44: Remove radiator hose neck

Disconnect the wiring harness fromthe cam sensor and remove the 2bolts fastening the upper radiator hoseneck to the thermostat housing. Movethe neck and the upper radiator hoseto the side.

10

W2002339

Fig. 45: Thermostat housing hoses

Remove the 2 hoses from the thermo-stat housing (the heater hose and thebleed hose).

11Remove the lower right front exhaustmanifold bolt.

12For Bendix Air Compressors: Re-move the 4 bolts fastening the outercover of the thermostat housing.Remove the 3 bolts mounting the ther-mostat housing to the head. Separatethe outer cover from the thermostathousing and remove both separately.

Note: For Volvo (Knorr) Air Com-pressors: Remove the compressormounting bolts and rotate the com-pressor for clearance.

33


13

W2002343

Fig. 46: Expansion tank pipe

Remove the 2 bolts fastening the wa-ter pump to the expansion tank pipe.Move the pipe to the side.

14Disconnect the wire to the blockheater (if equipped with block heater).

15Remove the bolt fastening the trans-mission cooler water pipe to the oilcooler cover and move the pipe to theside (if equipped with transmission oilcooler).

16

T2006942

Fig. 47: Remove air supply line

Disconnect the Exhaust Pressure Gov-ernor (EPG) air supply line.

17Remove the clamp fastening the ex-haust pipe to the EPG and remove theEPG and centering ring.

18

T2006689

Fig. 48: Remove oil cooler cover

Remove all of the 27 bolts fasteningthe oil cooler cover and remove thecover.

34


19

T2006690

Fig. 49: Oil cooler element

Remove the 4 bolts fastening the oilcooler element to the engine block andremove the element.

20Remove the turbo oil return line fromthe block.

21Disconnect the lower charge air coolerpipe and remove.

22

W2002340

Fig. 50: Oil filter base removal

Remove the 5 bolts fastening the oilfilter base to the block, and removethe base.

23

T2012843

Fig. 51: Reducation valves

Remove the oil reduction valves (1)and (6).

24Remove the oil pan.

25Remove the oil pump pick-up and de-livery pipe assembly.

26

T2006685

Fig. 52: Remove piston cooling jets

Remove all 6 piston cooling jets.

27Inspect the pistons and liners from thebottom side for damage due to metalcontamination.

35


28Position the catch pan under the en-gine.

29

W2002426

Fig. 53: Piston cooling oil galley

WARNING

Most solvents are flammable, stay away from openflame and observe extreme caution when using theseso as to prevent fire.

WARNING

Always wear eye protection and protective gloveswhen working with solvent. Exposure to eyes and/orbare skin will cause burns.

Flush out the piston cooling oil galleyusing clean solvent and a siphon typespray gun. Flush from the top side andalso up from the bottom.

Note: Do not attempt to remove metalcontaminants using shop air only.

Note: Clean solvent must also beused whenever flushing is required.

30Flush out the oil reduction valve galleyfrom the side and underside of theblock.

31

W2002427

Fig. 54: Oil cooler element oil galleys

Flush out both oil cooler element oilgalleys.

32

WARNING


Blow dry all flushed oil galleys withcompressed air.

33

W2002341

Fig. 55: Oil pump cover removal

Remove the rear cover of the oil pump.

34Flush out the oil pump and inspect thepump housing and gears for damage.Replace if needed.

36


35Pre-lube and install the rear cover onthe oil pump. Torque bolts 27 ± 4 Nm(20 ± 3 ft-lb).

27 ± 4 Nm(20 ± 3 ft-lb)

36Flush out all piston cooling jets and in-stall with new bolts. Torque to24 ± 4 Nm (18 ± 3 ft-lb).

Note: The piston cooling jet attach-ment bolt is coated with a frictioninducing compound. Do not reusebolts.

24 ± 4 Nm(18 ± 3 ft-lb)

37

WARNING


Flush out and blow dry the oil pipepick-up and delivery pipe assembly. In-spect the screen for trapped metalchips.

38Install the oil pump pick-up and deliv-ery pipe assembly with new O-rings.Torque for delivery pipe to block union10 Nm (7.4 ft-lb) plus an additional 60�

for a used pipe, 180� for a new pipe.Torque for strainer to oil pump bolts 27± 4 Nm (20 ± 3 ft-lb).

10 Nm(7.4 ft-lb) +60� used or180� new27 ± 4 Nm(20 ± 3 ft-lb)

39

T2006675

Fig. 56: D12, D12A, D12B Engines

T2012843

Fig. 57: D12C Engine

Flush and blow dry the reduction valveand inspect for damage or trapped de-bris.

40Install the oil reduction valve with anew O-ring on the valve as well as thecover. Torque the cover to 50 Nm(37 ft-lb).

50 Nm(37 ft-lb)

41Remove oil filters and clean the exte-rior of the filter base.

37


42

W2002342

Fig. 58: Remove the piston cooling valves

1) piston cooling valve2) overflow valve, oil filter3) overflow valve, oil cooler

Remove the piston cooling valve (1)and the 2 overflow valves (2)(3). Flushout and blow dry the filter housingvalve ports and valves.

43Install the 2 overflow valves (2)(3) andthe piston cooling valve (1). Torque thebolts to 10 ± 2 Nm (7 ± 1 ft-lb). Torqueplug to 55 ± 5 Nm (41 ± 4 ft-lb).

10 ± 2 Nm(7 ± 1 ft-lb)55 ± 5 Nm(41 ± 4 ft-lb)

44

W2002340

Fig. 59: Torquing the mounting bolts

Attach the oil filter base to the blockwith a new gasket. Torque the mount-ing bolts to 24 ± 4 Nm (18 ± 3 ft-lb).

24 ± 4 Nm(18 ± 3 ft-lb)

45Install new oil filters.

46Install the oil pan.

47Install new engine oil.

38


48

T2006691


Install a new oil cooler element withnew seals. Torque bolts to 27 ± 4 Nm(20 ± 3 ft-lb).

Note: Once inside the oil cooler ele-ment, metal contamination cannot beflushed out. If this happens, replacethe element.

27 ± 4 Nm(20 ± 3 ft-lb)

49

T2006692


Clean the oil cooler element cover andmounting gasket surface of the block.

50

T2006689

Fig. 62: Element cover gaskets

Install the cover with a new gasket.Torque bolts to 24 ± 4 Nm(18 ± 3 ft-lb).

24 ± 4 Nm(18 ± 3 ft-lb)

51Connect the block heater (if equipped).

52Install the transmission water coolerpipe to the cover with a new seal (ifequipped).

39


53

W2002343

Fig. 63: Water pump installation

Install the water pump to the expan-sion tank water pipe with a new seal.Install retaining clamp and bolt assem-bly.

54Clean all gasket surfaces on the ther-mostat housing.

55Install the thermostat housing with anew seal. Torque the 4 M6 bolts to10 ± 1.5 Nm (7.4 ± 1 ft-lb), and the 3M8 bolts to 24 ± 4 Nm (18 ± 3 ft-lb).For Volvo (Knorr) Air Compressor:re-align the compressor with mountingbolts and tighten to 85 ± 15 Nm(63 ± 11 ft-lb).

10 ± 1.5 Nm(7.4 ± 1 ft-lb)24 ± 4 Nm(17.7 ± 3 ft-lb)Knorr:85 ± 15 Nm(63 ± 11 ft-lb)

56

T2006694

Fig. 64: Installing the bypass pipe

Install the bypass pipe using a newseal and gasket.

57

T2007234

Fig. 65: Radiator hose for thermostat housing

Install the top radiator hose neck tothe thermostat housing using a newO-ring. Connect the cam sensor wiringharness.

40


58

T2006693

Fig. 66: Installing the water pump

Clean and install the water pump tothe oil cooler cover pipe using a newgasket and seal. Connect the VEBtemperature sensor wiring harness.Torque the 3 mounting bolts to24 ± 4 Nm (18 ± 3 ft-lb).

24 ± 4 Nm(18 ± 3 ft-lb)

59

W2002338

Fig. 67: Hoses for the air compressor

Connect the air compressor coolantsupply hose (1) to the oil cooler cover.Hand-tighten the hose clamp.

60Connect the air compressor dischargeline (2) to the air compressor.

61Connect the air compressor coolantreturn hose (3) to the bypass pipe.Hand-tighten clamp.

62

W2002339

Fig. 68: Hoses to the thermostat housing

Connect the 2 hoses (heater andbleed hoses) to the thermostat hous-ing. Hand-tighten the hose clamps.

63Install the lower right exhaust manifoldbolt and torque to 47 ± 8 Nm(35 ± 6 ft-lb).

47 ± 8 Nm(35 ± 6 ft-lb)

64Add coolant and inspect for leaks.

65

T2006942

Fig. 69: Connecting the EPG air line

Position the centering ring and EPGagainst the exhaust pipe. Hand-tightenthe clamp bolt only. Connect the EPGair line.

41


66

T2006688

Fig. 70: Turborcharger mounting studs

Install the turbocharger mountingstuds.

67Install the turbocharger , see;

SerivceManual

250–600Intake and Exhaust-Systems, D12, D12A,D12B, D12C

IPMPACT Function GroupInformation Type: Re-pair”Turbocharger”

68Tighten the EPG to exhaust pipeclamp. Torque the clamp bolt to60 ± 10 Nm (44 ± 7 ft-lb).

60 ± 10 Nm(44 ± 7 ft-lb)

69Start the engine, check for proper op-eration, and inspect for leaks.

2229-03-02-06Oil Filter Nipple, Replacement1Remove oil filters.

2If the oil filter nipples are loose removethem.

3Clean the filter base with appropriatecleaning solution.

4Use an air gun to blow the dirt out ofthe oil filter base threads.

5Install thread lock 577 on the nipplethreads.

6Thread the nipple back into the oil fil-ter base by hand until it stops.

7Thread the nipple installer into the nip-ple.

8Use the nipple installer wrench,9998691, to hold the outer nut.

9998691

9Using a torque wrench on the jam nut,torque the nut to 40 nm ± 5 (30 ± 4 ft-lb). Remove the torque wrench.

10Use a pull bar to loosen the jam nutwith the wrench holding the outer nut.

11Remove the nipple installer from thefilter base.

12Let the locktite set up for about 5 min-utes before putting the filter back on.

13Moisten the o-ring on the oil filter withclean engine oil. Put the filter in placeand torque to 15 nm ± 5 (10 ± 3 ft-lb).

42


2229-03-02-01Oil Filter Overflow Valve, Re-placement1

C2000653

Overflow valve (bypass)

Clean oil filters bracket and removevalves caps (1).Remove valves needles and springs.

2Clean and check valve seats. If valveseat is corroded, oil filters bracketmust be changed.

3

C2000646

Fig. 71: Valve needles and springs

Assemble new valve needles andsprings.Assemble and tighten cap. Use a newseal ring.

4Start engine and check for leaks.

43

44

Feedback

One of our objectives is that workshop personnel should have access to correct andappropriate service manuals where it concerns fault tracing, repairs and maintenanceof Volvo trucks.In order to maintain the high standards of our literature, your opinions and experiencewhen using this manual would be greatly appreciated.If you have any comments or suggestions, make a copy of this page, write down yourcomments and send them to us, either via telefax or mailing directly to the addresslisted below.

To

Volvo Trucks North America, Inc.

Dept. 516 Service Publications

7825 National Service Road

P.O. Box 26115

Greensboro, NC 27402-6115

USA

Fax (336) 393-3170

From

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Concerns Service Manual: ...............................................................................................................................

Operation Numbers

2171-02-02-01 Oil Pan, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192209-11-02-01 Oil System Passages, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 312211-03-02-01 Lube Oil Pump, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 192211-06-02-01 Lube System Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . 222223-03-02-01 Oil Filter, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232229-03-02-01 Oil Filter Overflow Valve, Replacement . . . . . . . . . . . . . . . . . . . . . . 432229-03-02-02 Piston Cooling Valve, Replacement . . . . . . . . . . . . . . . . . . . . . . . 242229-03-02-03 Piston Cooling Nozzle, Replacement . . . . . . . . . . . . . . . . . . . . . . . 252229-03-02-04 Oil Pressure Reduction Valve, Replacement . . . . . . . . . . . . . . . . . . . 262229-03-02-06 Oil Filter Nipple, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 422231-06-05-01 Oil Cooler Leak Test, Checking . . . . . . . . . . . . . . . . . . . . . . . . . 172232-03-02-01 Oil Cooler Core, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 282239-03-02-02 Oil Cooler Bypass Valve, Replacement . . . . . . . . . . . . . . . . . . . . . . 31

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-TSP144525 (300) 8.2000 © Volvo Trucks North America, Inc., 2000

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