Workshop Manual E

Groups 21–26 2(0)

D12C-A, D12D-A, D12D-B, D12D-C,

D12D-D, D12D-E, D12D-F, D12D-G,
D12D-H
 Group 21– 26
Marine Diesel Engines
D12C-A MP • D12D-A MP • D12D-B MP • D12D-C MP • D12D-D MP
D12D-E MP • D12D-F MP • D12D-G MP • D12D-H MP
D12D-A MH • D12D-B MH • D12D-C MH • D12D-E MH • D12D-G MH
D12D-A MG • D12D-E MG

Contents
Safety information ................................................ 3 Group 26:
General information ............................................. 6 Cooling system ................................................... 34
About this Workshop Manual .............................. 6 Thermostat housing ............................................. 36
Standard times (Flat Rate) .................................. 6 Charge air cooler ................................................. 37
Spare parts .......................................................... 6 Fault tracing ......................................................... 38
Certified engines .................................................. 6 Position of measurement connections on engine ... 39
Repair instructions ............................................... 7 Group 23: Fuel system
Our common responsibility .................................. 7 Supply pressure, fault tracing .............................. 41
Torques ............................................................... 8 Fault tracing guide ............................................... 42
Torque-angle tightening ....................................... 8 Group 25: Inlet and exhaust system
Lock nuts ............................................................ 8 Actions for low charge air pressure ..................... 42
Strength classes ................................................. 8 Group 26: Cooling system
Sealant ................................................................ 8 Excessive coolant temperature ........................... 43
Safety rules for fluorocarbon rubber .................... 9 Too low coolant temperature ............................... 43
Special tools ......................................................... 10 Coolant losses ..................................................... 43
Identification numbers ......................................... 18 Repair Instructions
Design and Function Group 21: Short block
Group 21: When working with chemicals, fuel and
Engine ................................................................. 19 lubrication oil ....................................................... 44
Cylinder head ...................................................... 20 Before working in a boat ..................................... 44
Cylinder liner ........................................................ 21 Before lifting the engine ...................................... 44
Pistons ................................................................ 21 Actions after lifting the engine ............................. 45
Con rods .............................................................. 22 General advice for pressure measurement ........ 45
Crankshaft ........................................................... 22 General advice on working with EVC engines .... 45
Camshaft ............................................................. 22 Electric welding ................................................... 46
Timing gear ......................................................... 23 Instructions for operating the starter motor ......... 47
Group 22: Compression test ................................................ 48
Lubrication system .............................................. 24 Cooling system, draining ..................................... 49
Group 23: Fuel system, filter change ................................... 51
Fuel system ........................................................ 26 Fuel system, draining .......................................... 51
Unit injectors, summary ...................................... 27 Engine oil, changing ............................................ 52
Unit injectors, working phases ............................. 28 Exposing the engine ........................................... 53
Group 25: Engine fixture, fixing ............................................ 53
Inlet and exhaust system .................................... 32 Short block, disassembly .................................... 54
Turbocharger ....................................................... 32 Cylinder head, removal ....................................... 54
Closed crankcase ventilation .............................. 33 Cylinder head, fixture installation ........................ 66
Contents

Piston cooling nozzle, removing .......................... 68 Piston cooling oil pressure, check ...................... 161
Pistons, removal ................................................. 69 Lube oil pump, change ....................................... 162
Cylinder liners and piston, inspection .................. 70 Group 23: Fuel system
Cylinder liners, removal ....................................... 71 Control unit, change ........................................... 165
Flywheel housing, removing ................................ 71 Identifying the engine control unit ....................... 168
Crankshaft, removing .......................................... 71 Supply pressure, checking ................................. 169
Timing gear, changing ......................................... 72 Bypass valve, checking ..................................... 170
Pistons, pre-assembly ......................................... 87 Bypass valve, changing ..................................... 170
Cylinder liners, installation ................................... 88 Feed pump, changing (valves) ........................... 171
Crankshaft and main bearings, installing ............. 90 Feed pump, changing ......................................... 172
Flywheel housing, installing ................................. 90 Feed pump, renovation ....................................... 173
Piston with con rod, installing .............................. 91 Unit injector, change ........................................... 175
Cylinder head, fixture removal ............................. 96 Unit injectors, programming of
Cylinder head, installation ................................... 96 trim code ............................................................ 182
Camshaft setting, inspection .............................. 105 Unit injectors, renovation ................................... 183
Valves and unit injectors, adjustment ................ 106 Venting the fuel system ...................................... 187

Overhaul / Change other components Group 25: Inlet and exhaust system
Group 21: Short block Seal, inlet pipe, changing ................................... 188
Cylinder liner seats, inspection .......................... 120 Gasket, exhaust manifold, changing .................. 188
Cylinder liner seat, milling .................................. 121 Pressure drop indicator, check .......................... 190
Cylinder liner seat, milling .................................. 126 Charge air pressure, checking ........................... 190
Crankshaft, inspection and overhaul .................. 128 Wastegate valve, check ..................................... 191
Big end bearing journal, inspection ..................... 129 Turbocharger, bearing clearance, check ........... 192
Pistons and piston rings, measurement ............. 129 Turbocharger, changing ..................................... 193
Exhaust back pressure, checking ...................... 194
Gudgeon pins, removal ...................................... 129
Con rod, inspection ............................................ 130 Group 26: Cooling system
Gudgeon pin bushing, check measurement ....... 130 Coolant pump, change ....................................... 195
Cylinder head, valves, removal/installation ........ 131 Cylinder head, pressure testing ......................... 200
Valve guides, inspection .................................... 133 Piston thermostat, replacement ......................... 202
Valve guides, replacing ...................................... 134 Thermostat, function check ................................ 204
Valve seat, change ............................................ 136 Charge air cooler, removal/installation ............... 205
Valve seats, grinding .......................................... 137 Charge air cooler, cleaning ................................ 208
Valves, grinding .................................................. 138 Charge air cooler, pressure testing .................... 209
Cylinder head, assembly .................................... 139 Heat exchanger, removal/installation ................. 213
Rocker mechanism, change ............................... 139 Heat exchanger, cleaning .................................. 216
Copper sleeve for unit injector, change .............. 140 Heat exchanger, pressure testing ...................... 218
Bearing housing for camshaft, change ............... 144 Coolant filler cap, change .................................. 219
Camshaft, wear check ........................................ 145 Oil cooler, engine, removal/installation .............. 220
Stiffening frame, removal downwards in sump ... 146 Oil cooler, engine, cleaning ................................ 225
Main bearings, change all ................................... 147 Oil cooler, engine, pressure testing ................... 225
Flywheel, removal/installation ............................ 151 Cooling system, cleaning ................................... 226
Flywheel sensor distance, checking ................... 153 Cooling system, filling ........................................ 227
Gear ring, change ............................................... 154 Coolant pressure, check .................................... 228
Crankcase seal rear, change .............................. 155 Cooling system, pressure testing ....................... 229
Crankshaft seal, front, change ........................... 156 Sea water pump, change ................................... 231
Sea water pump, renovation .............................. 233
Group 22: Lubrication system
Sea water pressure, check ................................ 237
Bypass valve, oil filter, change .......................... 157
Oil cooler, reverse gear, cleaning ...................... 237
Reduction valve and safety valve, change ......... 158
Oil cooler, reverse gear, pressure testing .......... 241
By-pass valve for oil cooler, change .................. 158
Piston cooling valve, change ............................. 159 References to Service Bulletins ........................ 242
Lube oil pressure, check .................................... 160 Alphabetical register .......................................... 243

© 2007 AB VOLVO PENTA

We reserve the right to make modifications without prior notice. Printed on environmentally compatible paper.

2
 Safety information

Introduction If work is done adjacent to a running engine, a

careless movement or a dropped tool can lead
This workshop manual contains technical data, de- to personal injury in the worst case.
scriptions and repair instructions for the Volvo Penta
products or product versions noted in the table of Take care to avoid contact with hot surfaces
contents. Check that you have the correct Workshop (exhaust pipes, Turbocharger, air intake pipe,
Manual for your engine. starter heater etc.) and hot fluids in pipes and
hoses in an engine which is running or has just
Read the available safety information, “General infor- been stopped. Reinstall all guards removed dur-
mation” and “Repair instructions” in the Workshop ing service work before starting the engine.
Manual before you start to do any service work.

Never start the engine with the valve cover re-

moved. Apart from the risk of spilling oil, there is
a risk of personal injury. The voltage supplied to
the unit injectors can be as high as 100 V.

Check that the warning or information labels on

the product are always clearly visible. Replace
labels which have been damaged or painted
over.
Important
In this book and on the product you will find the follow-
ing special warning symbols. Never start the engine without installing the air
cleaner filter. The rotating compressor turbine in
WARNING! Warns for the risk of personal injury, the turbocharger can cause severe injury. For-
major damage to product or property, or serious eign objects entering the intake ducts can also
malfunctions if the instruction is ignored. cause mechanical damage.

IMPORTANT! Is used to call attention to things

which could cause damage or malfunctions to Never use start spray or similar products as a
product or property. starting aid. They may cause an explosion in
the inlet manifold. Danger of personal injury.
NOTE: Is used to call attention to important informa-
tion, to facilitate work processes or operation.
Avoid opening the coolant filling cap when the
Below is a summary of the risks involved and safety engine is hot. Steam or hot coolant can spray out
precautions you should always observe or carry out and the system pressure will be lost. Open the
when operating or servicing the engine. filler cap slowly, and release the pressure in the
cooling system if the filling cap or tap has to be
Make it impossible to start the engine by cutting opened, or if a plug or coolant hose has to be re-
system current with the main switch(es) and moved when the engine is hot. Steam or hot
lock it (them) in the off position before starting coolant might spray out in an unexpected direc-
service work. Set up a warning notice by the tion.
helm station.

Hot oil can cause burns. Avoid skin contact with

As a general rule all service operations must be hot oil. Ensure that the lubrication system is not
carried out with the engine stopped. Some under pressure before carrying out any work.
tasks, such as adjustments, need the engine to Never start or operate the engine with the oil fill-
be running, however. Approaching an engine er cap removed, otherwise oil could be ejected.
which is operating is a safety hazard. Remem-
ber that loose clothing or long hair can fasten in
rotating parts and cause serious personal inju- Stop the engine and close the sea cocks before
ry. doing any work on the cooling system.

3
Safety Precautions

Only start the engine in a well- ventilated area. Make sure that oil and fuel soaked rags, and
When operated in a confined space, exhaust used fuel and oil filters are stored in a safe
fumes and crankcase gases must be ventilated place. Rags soaked in oil can spontaneously ig-
from the engine bay or workshop area. nite under certain circumstances.
Used fuel and oil filters are polluting waste and
Always use protective glasses or goggles when must be handed to an approved waste manage-
carrying out work where there is a risk of splin- ment facility for destruction, together with used
ters, grinding sparks, acid splashes or where lubrication oil, contaminated fuel, paint residue,
other chemicals are used. Your eyes are ex- solvents, degreasers and wash residue.
tremely sensitive, injury could cause blindness!
Batteries must never be exposed to open
flames or electric sparks. Never smoke close to
Avoid getting oil on your skin! Repeated expo- the batteries. The batteries generate hydrogen
sure to oil or exposure over a long period can gas when charged, which forms an explosive
result in the skin becoming dry. Irritation, dry- gas when mixed with air. This gas is easily ignit-
ness and eczema and other skin problems can ed and highly volatile. A spark, which can be
then occur. caused by incorrect battery connection, can
Used oil is more dangerous than fresh oil from a cause a single spark which is sufficient to cause
health aspect. Use protective gloves and avoid an explosion with resulting damage. Do not
oil soaked clothes and rags. Wash regularly, move the connections when you attempt to start
especially before eating. There are special skin the engine (risk of arcing), and do not stand and
creams which counteract drying out of the skin lean over one of the batteries.
and make it easier to clean off dirt after work is
completed. Always ensure that the Plus (positive) and Mi-
nus (negative) battery cables are correctly in-
stalled on the corresponding terminal posts on
Most chemicals intended for the product (e.g. the batteries. Incorrect installation can result in
engine and transmission oils, glycol, petrol serious damage to the electrical equipment. Re-
(gasoline) and diesel oil) or chemicals for work- fer to the wiring diagram.
shop use (e.g. degreasers, paints and solvents)
are hazardous. Read the instructions on the
Always use protective goggles when charging
product packaging with care! Always follow the
and handling the batteries. Battery electrolyte
safety precautions for the product (for example
contains sulfuric acid which is highly corrosive.
use of protective mask, glasses, gloves etc.).
Should the battery electrolyte come into contact
Make sure that other personnel are not inad-
with unprotected skin wash off immediately us-
vertently exposed to hazardous chemicals, for
ing plenty of water and soap. If you get battery
example in the air. Ensure good ventilation in
acid in your eyes, flush at once with a generous
the work place. Follow the instructions provided
amount of water, and get medical assistance at
when disposing of used or leftover chemicals.
once.

Exercise extreme care when leak detecting on Turn the engine off and turn off the power at the
the fuel system and testing the fuel injector noz- main switch(es) before carrying out work on the
zles. Use eye protection. The jet which comes electrical system.
from a fuel injector has very high pressure and
considerable penetration ability. Fuel can force Clutch adjustments must be carried out with the
its way deep into body tissue and cause severe engine stopped.
injury. Danger of blood poisoning (septicemia).
The existing lugs on the engine/reverse gear
All fuels, and many chemicals, are flammable. should be used for lifting the assembly.
Do not allow naked flame or sparks in the vicini- Always check that the lifting devices are in good
ty. Petrol (gasoline), some thinners and hydro- condition and that they have the correct capaci-
gen gas from batteries are extremely flammable ty for the lift (the weight of the engine plus the
and explosive when mixed with air in the correct reverse gear and extra equipment).
ratio. No Smoking! Ensure that the work area is The engine should be lifted with a customized
well ventilated and take the necessary safety or adjustable lifting boom for safe handling and
precautions before starting welding or grinding to avoid damaging components on top of the
work. Always ensure that there are fire extin- engine. All chains or cables should be parallel
guishers at hand when work is being carried to each other and should be as square as pos-
out. sible to the top of the engine.

4
 Safety Precautions

If other equipment connected to the engine has Components in the electrical and fuel systems
altered its center of gravity, special lifting devic- on Volvo Penta products have been designed
es may be needed to obtain the correct balance to minimize the risks of explosion and fire. The
and safe handling. engine must not be run in areas where there
Never do any work on an engine which just are explosive materials.
hangs from a lifting device.
Never use a power washer for engine cleaning.
Remember the following when washing other
Never work alone when removing heavy engine components with a power washer: Never aim
components, even when using lifting devices the water jet at seals, rubber hoses or electrical
such as locking tackle lifts. When using a lifting components.
device two people are usually required to do the
work, one to take care of the lifting device and Only use the fuels recommended by Volvo Pen-
another to ensure that components are lifted ta. Refer to the Instruction Book. Use of fuels
clear and not damaged during the lifting opera- that are of a lower quality can damage the en-
tions. gine. On a diesel engine, poor quality fuel can
When you work aboard a boat, always make cause the control rod to bind and the engine to
sure that there is enough space for disassembly overrev with resulting risk of damage to the en-
where you are working, with no risk of personal gine and personal injury. Poor fuel can also
injury or material damage. lead to higher maintenance costs.

5
 General information
About this Workshop Manual damage whatever, occasioned by use of spare parts
other than by Volvo Penta approved spare parts for
This workshop manual contains descriptions and re- the product, will be compensated by the warranty of-
pair instructions for the standard versions of the fered by Volvo Penta.
D12C-A MP, D12D-A MP, D12D-B MP, D12D-C MP,
D12D-D MP, D12D-E MP, D12D-F MP, D12D-G MP, Certified engines
D12D-H MP, D12D-A MH, D12D-B MH, D12D-C MH,
D12D-E MH, D12D-G MH, D12D-A MG and When doing service and repair on emission certi-
D12D-E MG marine diesel engines. fied engines, it is important to be aware of the fol-
lowing:
The engine designation and number are noted on the
number plate and engine decal. The engine designa- Certification means that an engine type has been
tion and number must always be given in all corre- checked and approved by the relevant authority. The
spondence about any product. engine manufacturer guarantees that all engines made
of the same type are equivalent to the certified engine.
The Workshop Manual is produced primarily for the
use of Volvo Penta workshops and service techni- This makes special demands on service and re-
cians. This assumes that people who use the Manual pair work, as follows:
have basic knowledge of marine drive systems and
l Maintenance and service intervals recommended
can do the tasks of a mechanical or electrical nature
by Volvo Penta mu st be complied with.
associated with the trade.
Volvo Penta constantly improves its products, so we l Only by Volvo Penta approved spare parts may
reserve the right to make modifications without prior be used.
notification. All information in this manual is based on l Service to injection pumps, pump settings and in-
product data which was available up to the date on jectors must always be done by an authorized
which the manual was printed. Any material changes Volvo Penta workshop.
l The engine must not be converted or modified,
except for the accessories and service kits which
Volvo Penta has approved for the engine.
introduced into the product or service methods after
l No installation changes to the exhaust pipe and
this date are notified by means of Service Bulletins.
engine air inlet ducts may be done.

Standard times (Flat Rate) l No seals on the engine may be broken by unau-
thorized persons.

The general advice in the instruction book about op-

eration, care and maintenance applies.

In instructions where operation numbers are found in IMPORTANT! Late or inadequate maintenance/
the headings, this is a reference to the Volvo Penta service or the use of spare parts other than by
standard times list (“Flat Rate”). Volvo Penta approved spare parts will invalidate
AB Volvo Penta’s responsibility for the engine
Spare parts specification being in accordance with the certi-
Spare parts for electrical and fuel systems are subject fied version.
to various national safety requirements such as the Volvo Penta accepts no responsibility or liability
US Coast Guard Safety Regulations. Volvo Penta for any damage or costs arising due to the
Original Spare Parts meet these specifications. No above.

6
 Repair instructions
The working methods described in the Workshop Man- Our common responsibility
ual apply to work carried out in a workshop. For this
reason, the engine is lifted out of the boat and mount- Each engine consists of a large number of collaborat-
ed on an equipment support. Renovation work which ing systems and components. Any deviation of a
does not need the engine to be lifted out can be done component from its technical specification can dra-
in situ, with the same work methods, unless otherwise matically increase the environmental impact of an
specified. otherwise good engine. For this reason, it is important
that the specified wear tolerances are observed, that
The warning signs which occur in the workshop manual
systems which are adjustable are correctly adjusted
(please refer to “Safety information” for their meanings).
and that spare parts approved by Volvo Penta are
used for the engine. The stated service intervals in
WARNING! the Maintenance Schedule must be observed.
Some systems, such as the components in the fuel
system, require special expertise and special testing
IMPORTANT! equipment for service and maintenance. For environ-
mental reasons etc., some com po nent s are sealed
at the factory. It is only permissible to work on sealed
NOTE: components if you are authorized to do such work.
are not comprehensive in any way, since we can not of Remember that most chemical products, incorrectly
course foresee everything, because service work is used, damage the environment. Volvo Penta recom-
done in highly varying circumstances. For this reason, mends the use of biodegradable degreasers whenev-
all we can do is to point out the risks which we believe er engine components are de-greased, unless other-
could occur due to incorrect work in a well-equipped wise specified in the workshop manual. When work-
work shop, using work methods and tools tested by us. ing aboard a boat, be careful to ensure that oils, wash
All operations described in the Workshop Manual for residue etc. are processed for destruction, and are
which there are Volvo Penta Special Tools available not inadvertently discharged with bilge water into the
assume that these tools are used when carrying out environment.
the repair. Volvo Penta Special Tools have been de-
veloped to ensure the most safe and rational working
methods possible. It is therefore the responsibility of
anyone using other tools or other working methods
than we recommend to determine that there is no risk
of personal injury or mechanical damage or malfunc-
tion as a result.
In some cases special safety precautions and user
instructions may be required in order to use the tools
and chemicals mentioned in the Workshop Manual.
These rules must always be observed, so there are no
special instructions about this in the workshop manual.
By following these basic recommendations and using
common sense it is possible to avoid most of the
risks involved in the work. A clean workplace and a
clean engine will eliminate many risks of personal in-
jury and engine malfunction.
Above all, when work on fuel systems, lubrication sy
s tems, induction systems, turbocharger, bearing
caps and seals is done, it is extremely important that
no dirt or other kinds of foreign particles are able to
get in, since this would otherwise cause malfunctions
or shortened repair life.

7
Repair instructions

Torques Strength classes

The tightening torque for vital fasteners, which should Screws and nuts are sub-divided into different strength
be tightened with a torque wrench, are listed in “Tech- classes. The classification is shown by a marking on
nical Data: Special tightening torques” and noted in the screw head. Markings of a higher number indicate
the job descriptions in the book. All torque specifica- stronger material. For example, a screw marked 10-9 is
tions apply to clean screws, screw heads and mating stronger than one marked 8-8. For this reason, it is im-
faces. Torque data stated apply to lightly oiled or dry portant when fasteners are dismantled, that the screws
threads. If lubricants, locking fluids or sealants are are put back in the correct places when they are re-
needed on a fastener, the type of preparation to be installed. If a screw must be replaced, check in the
used will be noted in the job description. For fasten- spare parts catalogue to make sure the correct screw is
ers where specific torque values are not given, used.
please refer to “Technical data: General tightening
torques”. General torque specifications are target val-
ues and the fastener does not need to be tightened
with a torque wrench.

Torque-angle tightening Sealant

In torque/angle tightening, the fas- The sealants and locking fluids noted below shall be
tener is tightened to the specified used on the engines covered by this manual.
torque, and tightening then contin- To ensure service work is correctly carried out it is
ues through a pre-determined an- important that the correct sealant and locking fluid
gle. Example; for 90° angle tighten- type is used on the joint where the agents are re-
ing, the fastener is tightened a fur- quired.
ther
1/4 turn in one sequence, after the In this workshop manual, the user will find that each
specified tightening torque has section where these agents are applied in production
been achieved. states which type was used on the engine.
In service work, the same preparations or prepara-
tions of corresponding properties, but of other makes,
shall be used.
When sealants and locking fluids are used, it is im-
portant that the surfaces are free from oil, grease,
Lock nuts paint and rust-protection, and that they are dry. Al-
ways follow the manufacturer’s instructions for use
Disassembled locknuts shall not be re-used, they regarding temperature range, curing time and any
shall be replaced by new ones, since the locking other instructions for the product.
properties are impaired or lost when the nut is used
several times. On locknuts with plastic inserts, such Two different basic types of agent are used on the
as Nylock,® the specified tightening torque must be engine. These are:
reduced if the Nylock® nut has the same nut height as RTV preparations (Room Temperature Vulcanizing).
a standard fully metallic hexagonal nut. Reduce the Used for gaskets, sealing gasket joints or coating
torque by 25% for screw size 8 mm or larger. On Ny- gaskets. RTV is visible when a part has been disas-
lock® nuts with higher nut height (where the fully me- sembled; old RTV must be removed before resealing
tallic thread is as high as on a standard hexagonal the joint.
nut), use the specified tightening torques.

8
 Repair instructions

The following RTV preparations are used on the en- WARNING! Observe the greatest care in working
gine: on engines which might have been exposed to
Volvo Penta sealant (cartridge 0.31 l, part. No. high tempera tures, such as overheating during
1161231, or tube 20 g., part. No. 1161277) and part. flame cutting or a fire. Seals must never be cut
No. 840879 (tube 25 g). with a flame torch during disassembly, or burned
Remove old sealant with denatured alcohol. in uncontrolled circumstances afterwards.

Anaerobic agents. These agents cure in the absence l Always use chloroprene rubber gloves (gloves for
of air. These preparations are used when two solid chemicals handling) and goggles.
components, such as two cast components, are fitted l Handle the removed seal in the same way as cor-
together without a gasket. Common uses are also to rosive acid. All residue, including ash, can be
lock and seal plugs, stud threads, taps, oil pressure highly corrosive. Never use compressed air to
monitors etc. blow anything clean.
Hardened anaerobic preparations are glassy and for l Put the remains in a plastic container, seal it and
this reason, the preparations are colored to make apply a warning label. Wash the gloves under
them visible. running water before removing them.
Hardened anaerobic preparations are highly resistant
to solvents, and old compound can not be removed. The following seals are most probably made from flu-
On re-assembly, it is important to degrease compo- orocarbon rubber:
nents carefully first, wipe off and apply new sealant in Seal rings for the crankshaft, camshaft, drive shafts.
accordance with the instructions.
O-rings, regardless of where they are installed. O-
The following anaerobic preparations are used on the rings for cylinder liner sealing are almost always
engines: made of fluorocarbon rubber.
Volvo Penta thread locking fluid (part. No. 1161053).
Please note that seals which have not been ex-
posed to high temperature can be handled normal-
ly.

Safety rules for

fluorocarbon rubber
Fluorocarbon rubber is a common material in seal
rings for shafts, and in O-rings, for example.
When fluorocarbon rubber is exposed to high temper-
atures (above 300°C), hydrofluoric acid can be
formed, which is highly corrosive. Contact with the
skin can result in severe chemical burns. Splashes in
your eyes can result in severe chemical burns. If you
breathe in the fumes, your lungs can be permanently
damaged.

NOTE: As the illustrations in the service literature refer to

several engine variants, certain details may differ from any
particular engine. The essential information in the illustra-
tions is always correct, however.

9
 Special tools
Special tools in the catalogue are divided into three categories:
– “Special tools category 1” (pages 10 –14) comprise the tools for the most common tasks (in a “mobile” work-
shop, for example).
– “Special tools category 2” (pages 15–16) comprise the tools which can be used as alternatives (hydraulic
tools) and tools for the tasks which are normally done in a larger workshop.
– “Other special tools” (page 17) comprises the tools where similar types of equipment may already be found in
the workshop.

Special tools category 1

885 231 885 232 885 316 885 379 885 380 885 381

383 8620 383 8621 383 8622 383 8623

885 536 885 539 380 9090 383 8619

885231 Seal washer with union, for leakage test- 3809090 Puller for polygon hub and vibration
ing the charge air cooler damper (replaces 884 994)
885232 Seal washer, for leakage testing the 3838619 VODIA complete diagnostic tool
charge air cooler (for programming the trim code for the unit
885 316 Fixture for folding up the cylinder head injectors on D12D-B/D/F/H MP).
885 379 Seal plugs, for pressure testing the Consists of:
charge air cooler 1) 3838620 VODIA – palmtop computer (PDA)
with SD card.
885 380 Seal plate, for pressure testing the
charge air cooler 1) 383 8621 VODIA – docking station. Used with
VODIA PDA (383 8620).
885 381 Seal washers, for pressure testing the 383 8622 VODIA – cable with connector. Used
heat exchanger and lube oil cooler, re- with a docking station (383 8621) on
verse gear the engine’s communication connec-
885 536 Expansion plug for pressure testing the tor.
charge air cooler (D12D-B/D/F/H MP) 383 8623 VODIA – EDC Adapter with external
power supply. Used with a docking
885539 Expansion plug for pressure testing the station 383 8621 and cable 383 8622
charge air cooler (D12D-B/D/F/H MP) connected to the 2-pin connector on
the engine.

1)
Does not apply to D12D-B/D/F/H MP.

10
 Special tools

981 2546 998 6173 998 6177 999 0006 999 0013 999 0114 999 0156

999 0166 999 0185 999 0192 1) 999 0210 999 2000 1)

999 2479 1) 999 2584 999 2955 1) 999 3590 999 5028 999 6049

9812546 Brush for cleaning the copper sleeve/ 999 0192 1) Extractor for rear crankshaft seal (alt.
seat for the copper sleeve for the unit in- method). Use together with 999 6400
jectors (can be used as an alternative to 9990210 Tool for removing/installing valve springs
999 8599)
999 2000 1) Extension for mandrel 999 8238 and for
9986173 Puller for shaft seal in feed pump 999 8261, 999 8262 and 888 00147
9986177 Puller for shaft seal in feed pump 999 2479 1) Stand for dial gauge
9990006 Puller for unit injector 999 2584 Socket for hydraulic cylinder 9992671
(for D12D-B/D/F/H MP)
999 2955 1) Plate for removing or pressing down cyl-
9990013 Slide hammer. Used together with inder liners
999 0006 and 999 0114
999 3590 Turning tool
999 0114 Puller for main bearing cap. Use togeth-
999 5028 Mandrel for installing seal rings in feed
er with 999 0013
pump
999 0156 Adapter (M16/M10). Used together with
9996049 Coolant drain hose (for D12D-A/E MG
999 6400
with radiator)
999 0166 Tool for installing the rear crankshaft
seal
999 0185 Lifting tool for rocker bridge

1)
Means that the tool is also used for other 12-liter engines.

11
Special tools

999 6315 999 6394 2) 999 6395 2) 999 6398 999 6400 1) 999 6591

999 6626 999 6441 999 6645 1) 999 6662 1) 999 6666 999 6845

999 6965 999 6966 999 8248 999 8249 999 8250 999 8251

9996315 Spindle for installation of polygon hub 999 6662 1) Pressure testing device
and crankshaft gear 9996666 Connection nipple (M10 x 1) for checking
999 6394 1) Spacer 2) for removing cylinder liners pressure
999 6395 1) Spacer 2) for removing cylinder liners 9996845 Screw clamp 2) for pressure testing the oil
999 6398 Pressure gauge (1.6 MPa) cooler, engine (2 pcs. needed)
999 6400 1) Slide hammer for removing protective 999 6965 Adapter for installing polygon hub
plug 999 8251 on the cylinder head. 3) To- 999 6966 Press tool 2) for cylinder liner (7 pcs.
gether with 999 0192, also for removing needed)
the camshaft bearing cap and for remov- 999 8248 Adapter 2) for measuring compression
ing the rear crankshaft seal pressure (6 pcs. needed)
999 6591 Connection nipple (1/8"-27 NPSF) for 999 8249 Protective sleeve 2) for unit injector (6
checking pressure pcs. needed)
999 6626 Socket for hydraulic cylinder 999 2671 999 8250 Seal ring 2) for fuel duct in cylinder head
999 6441 Cover with union, for leakage testing the (2 pcs. needed)
cooling system 999 8251 Protective plug 2) for cylinder head, (6
9996645 1) Puller, for cylinder liner pcs. needed)

1)
Means that the tool is also used for other 12-liter engines.
2)
Supplied individually.
3)
Used together with adapter 999 0156.

12
 Special tools

980 9667
980 9668

998 7009
980 9746

999 8252 999 8253 999 8261 999 8262

999 8264

999 8266 999 8267 999 8339 999 8487

999 8511 999 8517 999 8531 999 8583

999 8252 Thread tap. Consists of: 9998264 Lifting yoke for camshaft
980 9667 Threading tool (M9) for removing 9998266 Seal washer for pressure testing the cyl-
the copper sleeve for the unit injec- inder head
tor
999 8267 Guide pins 1) for timing gear plate
998 7009 Threading tool (M8) for removing
the copper sleeve for the unit injec- 999 8339 Pressure gauge (600 kPa)
tor 999 8487 Wrench for removing oil filters
999 8253 Puller for copper sleeve for unit injector. 999 8511 Crowbar
Consists of:
999 8517 Tool for checking/setting flywheel sensor
980 9668 Puller for copper sleeve for unit in- distance
jector (M9)
980 9746 Puller for copper sleeve for unit in- 999 8531 Piston ring compressor
jector (M8) 999 8583 Gauge for setting pre-load, unit injector
999 8261 Mandrel for installing valve guides,
D12C (inlet), D12D (inlet and exhaust)
999 8262 Mandrel for installing valve guides,
D12C (exhaust)

1)
Supplied in pairs (2 pcs. needed).

13
Special tools

980 8618 980 8617

276948 999 8580

980 8570

980 8614

959239

999 8598 999 8599 999 8601 999 8602

980 9696

980 9697

980 9699

999 8624 999 8628 999 8629 999 8666

999 8688 999 9179 1) 888 00011 888 00083

999 8598 Sleeve for changing reduction valve and 9998624 Fixing tool 2) for cylinder head
safety valve (2 pcs needed)
999 8599 Cleaning kit for unit injector. Consists of: 999 8628 Press tool for installing the top timing
276 948 O-ring kit gear cover.
959 239 Screw M10 999 8629 Lifting lug 2) (4 pcs needed)
980 8570 Brush, white
999 8666 Seal kit for pressure testing cylinder
999 8580 Socket
head. Consists of:
Holder
980 9696 Seal washer 3)
980 8634 Brush kit. Consists of:
980 9697 Connection washer 3)
980 8614 Brush, yellow (10 pcs)
980 9699 Seal washer 3)
Holder (2 pcs)
Handle 999 8688 Expansion tool (Ø 7.8 mm / 0.307") for
980 8617 Steel brush, narrow copper sleeve for unit injector
980 8618 Steel brush, coarse 999 9179 1) Filter extractor
999 8601 Fixing tool for cylinder head 888 00011 Guide sleeve for valve stem seal
999 8602 Press tool for installing the top timing (replaces 999 8335)
gear cover 888 00083 Piston ring pliers

1)
Means that the tool is also used for other 12-liter engines.
2)
Supplied individually.
3)
Included in the complete tool (not stocked separately).

14
 Special tools

Special tools category 2

388 3670 388 3671 388 3672 388 3673 388 3674

980 9726 980 9729 980 9771 980 9772 981 2524

999 0160 999 0176 999 2670 999 2671

388 3670 Assembly plate for disassembling /as- 9809729 Hydraulic cylinder for changing cylinder
sembling unit injectors 1) liners, timing gear wheels and valve
388 3671 Installation sleeve for top O-ring for unit guides (replaces 999 6161)
injector 1) 980 9771 Extension for 981 2524
388 3672 Installation sleeve for lower O-ring for 980 9772 Spacer for 981 2524
unit injector 1) 981 2524 Milling cutter for cylinder liner seat
388 3673 Adapter for pressure testing unit injectors (replaces 999 8272)
1)
999 0160 Fixture for fixing cylinder head in engine
388 3674 Ring wrench kit for disassembling /as- stand (replaces 999 8258)
sembling unit injectors 1). Used together 999 0176 Press tool for removing/installing valve
with 384 9611. springs and valve guides
980 9726 Pneumatic hydraulic pump (alt. to 999 2670 Manual hydraulic pump (alt. to 980 9726)
999 2670). Replaces 999 6222
999 2671 Hydraulic cylinder

1)
For unit injectors for all engines except D12D-B/D/F/H MP.

15
Special tools

999 6159 999 8246 999 8648 888 00147 888 00151

9996159 Pin for hydraulic cylinder 980 9729

9998246 Tool for removing/installing valve springs
9998648 Engine fixture
88800147 Mandrel for removing valve guides
(replaces 999 8263)
888 00151 Tool for installing valve stem seals

16
 Special tools

Other special equipment

885 633 885 648 885 811 885 812 115 9794

384 9611 384 9613 998 6485 998 8539 1)

998 9876 1) 999 8493 999 9683 999 9693 1) 999 9696 1)

885 633 Torque amplifier 1/2"–3/4" 9986485 Equipment stand

885 648 Counterhold for torque amplifier 99885391) Compression gauge
885 811 Angle gauge, 3/4” 99898761) Dial gauge
885 812 Angle gauge, 1/2” 9998493 Hose and nipple, for measuring pressure
115 9794 Torque wrench, 3/8" (10-100 Nm) 9999683 Dial gauge
384 9611 Torque wrench (used together with 99996931) Diagram sheet for 998 8539
388 3674) 99996961) Magnetic stand
384 9613 Pressure testing equipment, cooling sys-
tem (replaces 885 531)

1)
Means that the tool is also used for other 12-liter engines.

17
 Identification numbers
Position of engine signs and decals*
*Note. Some signs/decals are not found on some engine variants.

1. Engine decal 9. Identification decal, 2. Serial number

2. Warning decal engine control unit 3. Specification number
3. Exhaust emission decal (EPA) 10. Warning decal (six last figures)
4. Exhaust emission decal (EPA)
5. Engine designation and Engine decal (1) Identification de-
engine serial number cal, engine control
Engine designation (1)
(punched on cylinder block) unit (8)
Serial number (2)
6. Type plate, engine Chassis ID number (1)
Specification number (3)
7. Certification plate (RVIR) Serial number, engine (2)
Type plate, engine (6)
8. Identification decal,
1. Engine designation
engine control unit

18
 Design and function
Group 21: Short block

Engine
D12C and D12D are 12-liter engines with cast iron cyl- D12D-B MP is a further development of the D12C-A MP.
inder blocks and wet cylinder liners. They have a The most important difference are:
screwed-in malleable iron reinforcement frame 1) at
the base of the cylinder block plane. The cylinder l New, reinforced pistons.
head is made in one piece and has an overhead cam- l New top piston rings.1)
shaft and a unit injector for each cylinder. l New con rods (“stepped”).
The unit injectors are centrally located above the pis- l New (extended) stiffening frame for cylinder block
tons, and are controlled by the engine control unit. introduced as from engine No. 1012532513. 2)
The control module is located on the left-hand side of
l New unit injectors (type E1) which give higher in-
the cylinder block.
jection pressure.
D12D-A MH, D12D-B MH, D12D-A MP and D12D-A l Updated engine control system (EMS-2) together
MG are further developments of the D12C-A MP. with the new unit injectors gives higher power and
The most important difference are: lower exhaust emissions.
l Closed crankcase ventilation (optional equipment).
l New cylinder block. 2)
l New turbocharger with electronically controlled
l New cylinder liners (a seal ring has been added). 2) wastegate valve.
l New, reinforced, higher compression pistons. 3) l New air filter (lower pressure drop). Not from prod.
l New inlet valves. start.
l New valve yokes without guide pin (inlet). 2) l New heat exchanger with a priority valve that con-
l New valve springs. 2) trols the coolant flow through the heat exchanger. 3)
l New camshaft. 3) l New thermostat. Bypass valve installed in thermo-
l New unit injectors. stat housing.
l New data set. l Improved intercooling thanks to larger, more effi-
cient charge air cooler.
l New turbocharger. 3)
l New, higher power alternator (28 V/80 A).
l New, deep sump (with inspection hatches). 4)
1)
Has also been introduced on D12D-A MG and D12D-B MH in
Apart from this, the D12D-A MP and D12D-B MH dif- current production.
fer from the D12C-A MP and D12D-A MH since they 2)
Also introduced on D12D-A MP as from same engine number.
have a new electrical system. 5) 3)
The majority of the heat exchanger’s capacity is used to cool the
1)
engine. The rest of the capacity cools the coolant further before
Not found on the D12D-A MH and early model D12D-A MG and it is passed on through the charge air cooler.
D12D-B MH.
2)
Has also been progressively introduced on the D12C in current
production.
3)
Applies to D12D-A MG/MH and D12D-B MH.
4)
Standard on D12D-A MG/MH, D12D-B MH. Optional equipment
on D12D-A MP (shallow sump is optional equipment on D12D-A
D12D-C/E/G MH is a further developments of the D12D-B MH.
MH and D12D-C/E/G MP is a further development of the D12D-A MP.
D12D-B MH). D12D-D/F/H MP is a further developments of the D12D-B MP.
5)
Classifiable on D12D-A MG and D12D-B MH (a classifiable elec-
trical system is also available for D12D-A MP as an option). The most important differences are:
l New EVC system introduced.
l Closed crankcase ventilation introduced as standard on
D12D-C/E/G MP and D12D-D/F/H MP engines.

19
Design and function Group 21: Short block

Cylinder head
The cylinder head, which covers all the cylinders, has
one overhead camshaft.
The cylinder head is fixed by 38 screws, which are
evenly distributed around the cylinders.
The cylinder head has separate inlet and exhaust
ducts with so-called “cross flow” for each cylinder.
The cylinder block and cylinder head are manufactured
of alloyed cast iron. All valve guides have valve stem
seals (oil seals). The steel valve seats are replaceable.
The exhaust valves have twin valve springs.
The unit injectors are centrally located, surrounded by
four valves per cylinder. This gives symmetrical ge-
ometry in the combustion chamber. The lower part of
the injector is surrounded by a copper sleeve, and the
fuel duct for the injectors is machined directly in the
cylinder head.
* Note. On the D12D, the valve guides for the exhaust valves
have been moved up in the cylinder head to the same height as
the guides for the inlet valves.

Top: Unit injector

Center: Exhaust valves with twin valve springs
Bottom: Inlet valves*
* Note. New valve yokes without guide pins (1) have been intro-
duced on D12C as from engine No. xxxx/286879 and on D12D.

20
Group 21: Short block Design and function

Cylinder liners
The cylinder block is provided with wet, replaceable
cylinder liners.
The coolant space round the cylinder liner is sealed
by three seal rings at the bottom of the cylinder block.
The top part of the coolant space is sealed with sili-
cone sealant, below the liner collar. D12C as from en-
gine number xxxx/310909* and D12D also have a
seal ring located in the top part of the cylinder liner,
just below the liner collar.
* Note. The seal ring under the liner collar is part of the liner kit,
which is also a spare part for early model D12C, and it should
also be installed on these engines when the liner kit is changed.

Pistons
The pistons are made of aluminum. They are cooled
by lubrication oil which is sprayed up through the pis-
ton cooling nozzles into a duct in the piston, which
leads to a cooling gallery in the piston crown.
Note. On D12D-A/E MG, D12D-B/C/E/G MH and late
model D12D-A MH, the pistons are provided with a
pressed-in bushing for the gudgeon pin (the bushing
can not be changed).

21
Design and function Group 21: Short block

Con rods
New con rods* divided with a fracture-split have been
introduced on D12C as from engine No. xxxx/260606.
The D12D has fracture-split con rods as from produc-
tion start.
The gudgeon pin bushing on these con rods is some-
what narrower than the early model con rods.
Note. It is permissible to mix early model con rods (1)
and late model con rods (2) on the same engine.
On D12D-B MP** and D12D-D/F/H MP**, the gudgeon
pin end of the con rods has been machined
(“stepped”) (3) to leave room for reinforcements on the
piston.
* Note. The big end is divided (“fracture-split”) by a plain,
un-machined surface.
** Only stepped con rods can be used on this engine.

Crankshaft
The crankshaft has 7 bearings, is drop forged and its
bearing surfaces and fillets are induction hardened.
The crankshaft has front and rear seal rings, and is
provided with twin vibration dampers.
Note. On late model crankshafts (4), the number of
counterweights has been reduced from eight to four.

Camshaft
The engine has an overhead camshaft which rotates
inside seven bearing housings, screwed to the cylin-
der head.
There are two variants of bearing housings, the pro-
duction version and the spare part version.
The bearing housings are numbered from the factory
and must not be mixed if the engine is renovated.
Note that the bearing housings and caps are ma-
chined together. This applies to both the production
version and the spare part version.
The camshaft has three lobes per cylinder. One for
the inlet valves, one for the exhaust valves, and a
lobe for the unit injector.

22
Group 21: Short block Design and function

Timing gear
The timing gear is located at the front of the engine, Between the cylinder block and the cylinder head,
mounted on a 10 mm thick steel plate. All gear there is an adjustable idler wheel (7). The wheel
wheels have helical teeth. The idler wheels (4, 7, 10, must be adjusted after all work that affects the timing
12) rotate on pressure lubricated bushes. Other lubri- gear. It is important to ensure the correct flank
cation is supplied via a spray nozzle (14). clearance between the upper and lower gear wheels
which engage on the adjustable idler wheel.

1. Gear, camshaft 8. Gear, hydraulic pump/servo pump (optional)

2. Seal molding 9. Gear for drive belts and fuel pump
3. Gear, power take-off (optional) 10. Idler gear
4. Idler gear 11. Drive, seawater pump
5. Gear, coolant pump 12. Idler wheel, lube oil pump
6. Gear, crankshaft 13. Gear, lube oil pump
7. Idler wheel (adjustable) 14. Spray nozzle

23
 Group 22: Lubrication system

Lubrication system
The engine is pressure lubricated by means of a gear The lube oil pump forces the oil into two full flow filters
wheel pump connected to the engine timing gear. and a bypass filter. The bypass filter has a low flow
The oil flow is controlled by six* valves. rate and high particle collection efficiency. From the full
There are two variants of the lubrication system. flow filter, the oil is lead to the cylinder block and is dis-
There are engines with low mounted oil filter and en- tributed via ducts to lubrication points on the engine.
gines with high mounted oil filter, or with the filter in- The oil cooler is a plate heat exchanger, located un-
stalled at the rear of the engine. Please note that the der a cast iron cover on the right side of the cylinder
number and opening pressure of the oil valves differs block.
between each system. Please refer to “Technical
Data” in the workshop manual.
* Note. Five valves on the engine with high-mounted or rear-
mounted oil filter.

Engines with low mounted oil filter

1. Safety valve, lube oil pressure 5. Bypass valve for by-pass filter*
2. By-pass valve for oil cooler 6. Pressure reduction valve, lube oil pressure
3. Bypass valve for full flow oil filter
* Note. The valve is only found on engines with
4. Piston cooling valve
low-mounted oil filter.

24
Group 22: Lubrication system Design and function

Engines with high mounted oil filter or oil filter installed on rear of engine

1. Safety valve, lube oil pressure 4. Piston cooling valve

The safety valve opens if the lube oil pressure is too The piston cooling valve opens when engine speed in-
high, and leads surplus oil back to the sump. creases just above idling.
Oil then flows through the piston cooling duct to the
six piston cooling nozzles. Oil is sprayed from them,
2. By-pass valve for oil cooler up underneath the pistons.
When the pressure drop across the oil cooler is too
high, such as just after starting when the oil tempera- 5. Bypass valve for by-pass filter*
ture is low, the by-pass valve opens and oil passes
by the oil cooler. When the oil temperature rises and The bypass valve opens (> 1.1 bar (15.9 psi)) if the
pressure drop across the oil cooler falls (< 3.0 bar filter becomes blocked, which thus ensures lubrica-
(43.5 psi)), the valve closes and oil passes through tion to the turbocharger.
the oil cooler before it is forced out into the lubrication * Note. The valve is only found on engines with low-mounted oil
system. filter.

6. Pressure reduction valve, lube oil pressure

3. Bypass valve for full flow oil filter The reduction valve controls the oil pressure by open-
The bypass valve opens (> 2.1 bar (30.4 psi)) if the ing it at high pressure, and directs surplus oil back to
filters become blocked, which thus ensures lubrica- the sump.
tion.

25
 Group 23: Fuel system

General

IMPORTANT! Observe the greatest possible IMPORTANT! Please refer to “Instructions for
cleanliness when working on the fuel system. operating the starter motor” on page 47, if the
Always do an engine wash before you start engine needs to be cranked by the starter mo-
working. Protective plugs must always be in- tor for some reason without risking an inadvert-
stalled when connections are removed, to pre- ent start.
vent contamination from entering the fuel sys-
NOTE: For specifications, please refer to
tem. Removed components must be stored in a
“Technical Data”.
sealed plastic bag until they are re-installed.

26
Group 23: Fuel system Design and function

Unit injectors, summary

The unit injector consists of three main components:
– Pump with cylinder and piston (corresponding to
the pump plunger in an injection pump).
– Injectors with injector sleeve, injector needle and
spring.
– Valve housing with an electromagnetically con-
trolled fuel valve.
The injection time and the amount of fuel to be inject-
ed are determined by the control unit, which supplies
signals to the electromagnetically controlled fuel valve
in the unit injector valve housing. The injection dura-
tion determines the amount of fuel injected into the
cylinder.

D12C-A, D12D-A, D12D-B MH and D12D-C/E/G

1. Camshaft
2. Rocker
3. Electrical terminal, unit injector
4. Fuel gallery

D12D-B/D/F/H MP
1. Camshaft
2. Rocker
3. Electrical terminal, unit injector
4. Fuel gallery

27
Design and function Group 23: Fuel system

Unit injectors, working phases

The working sequence of the unit injector can be di-
vided into four phases:
l Filling phase
l Spill phase
l Injection phase
l Pressure reduction phase

The pump piston always forces the same amount of

fuel back and forwards through the injector. It is only
when the fuel valve is closed that the pressure is built
up and injection takes place. The duration and timing
of the current impulse determines the volume of fuel
injected and its timing.

D12C-A, D12D-A, Filling phase

D12D-B MH, D12D-C/E/G
During the filling phase, the pump piston (1) travels to-
1. Pump piston wards its upper position. The highest point on the
2. Injectors
3. Fuel valve camshaft lobe is passed and the rocker is on the way
down towards the camshaft base circle.
The fuel valve (3) is open, since the solenoid valve is
not powered. Fuel from the fuel duct* in the cylinder
head can therefore flow past the fuel valve and into
the unit injector pump cylinder.
Filling continues until the pump piston reaches its up-
per position.
* Note. The lower fuel duct on D12C.

3
D12D-B/D/F/H MP
1. Pump piston
2. Injector needle
3. Fuel gallery

28
Group 23: Fuel system Design and function

Spill phase
The spill phase starts when the camshaft has turned
to the position where the cam lobe operates the rock-
er and starts to press the pump piston (1) down.
The fuel can now flow backwards through the fuel
valve (3) and back into the fuel duct.
The spill phase continues for as long as the fuel valve
is open.

D12C-A, D12D-A,
D12D-B MH, D12D-C/E/G
1. Pump piston
2. Injectors
3. Fuel valve

3
D12D-B/D/F/H
1. Pump piston
2. Injector needle
3. Fuel gallery

29
Design and function Group 23: Fuel system

Injection phase
The injection phase starts when the solenoid valve is
activated by the control unit, and the fuel valve (3)
closes.
The camshaft lobe continues to press the pump pis-
ton (1) down, via the rocker arm. Since the passage
through the fuel valve is closed, pressure quickly
builds up. The pressure lifts the injector needle and
injection takes place.
The injection phase continues for as long as the fuel
valve is closed.

D12C-A, D12D-A,
D12D-B MH, D12D-C/E/G
1. Pump piston
2. Injectors
3. Fuel valve

D12D-B/D/F/H MP
1. Pump piston
2. Injector needle
3. Fuel gallery

30
Group 23: Fuel system Design and function

Pressure reduction phase

The pressure reduction phase starts when the engine
control unit thinks that the engine has received all the
fuel it needs. The control unit then cuts the electric
impulse to the solenoid valve, the fuel valve opens
and the fuel flows back out to the fuel duct. This
means that the pressure quickly falls below the injec-
tor opening pressure, the injector needle closes and
1 injection is terminated.
Please note that it is the position of the fuel valve,
(closed or open), which determines when injection will
3 start and finish.
D12D-B/D/F/H MP The time that the fuel valve is closed determines the
1. Pump piston
amount of fuel injected for each pump stroke.
2. Injector needle
3. Fuel gallery

31
 Group 25: Inlet and exhaust system

Turbocharger
The turbocharger is driven by the exhaust gas which
passes through the exhaust turbine housing on its
way out of the exhaust system.
The exhaust flow makes the exhaust turbine rotate
and drives the compressor turbine, which is mounted
on the same shaft. The compressor turbine is located
in a housing which is connected between the air filter
and the charge air cooler/engine inlet pipe.
When the compressor wheel rotates, air is sucked in
via the air filter.
The air is compressed and is pressed into the cylin-
ders of the engine, after it has first been cooled by its
passage through the charge air cooler.

Wastegate valve
On the D12D-B/D/F/H MP, the turbocharger is provid-
ed with a wastegate valve. The valve controls the
amount of exhaust gas flow which should pass
through the exhaust turbine.
When the wastegate valve closes, a larger amount of
exhaust gas is forced to pass through the exhaust
turbine, which causes the charge air pressure to rise.
The valve is controlled by a pressure box with a
spring-loaded diaphragm that senses the charge air
pressure 1) via a hose from the inlet pipe. An electroni-
cally controlled solenoid valve 2) controls the pressure
via a signal 3) from the engine control unit.
As the air pressure supplied by the solenoid valve to
the waste gate valve increases, the valve opens wider.
When the loading increases and the charge air pres-
sure approaches the maximum permissible value, a
by-pass duct opens and leads part of the exhaust gas
past the exhaust turbine and straight out into the ex-
D12D-B/D/F/H MP: Principle sketch of haust pipe. This reduces the turbine speed and stabi-
turbocharger with wastegate valve lizes the pressure at the permissible value.
1. Inlet pipe 1)
If the pressure supplied to the wastegate valve disappears for
2. Solenoid valve (control valve) any reason, the valve closes completely.
3. Engine control unit 2)
The solenoid valve has two outlets, one to the wastegate valve
4. Wastegate valve and the other dumps straight to the surrounding atmosphere.
3)
If the signal to the solenoid valve disappears, the wastegate
valve opens completely.

32
Group 25: Inlet and exhaust system Design and function

1 Closed crankcase ventilation

Closed crankcase ventilation has been installed as
standard on D12D-C/E/G MP and D12D-D/F/H MP,
and exist as an option on D12D-C/E/G MH. Further-
more, some engines* have previously been equipped
2 with closed crankcase ventilation.
In these cases, the engine is equipped with a separa-
tor and a centrifugal oil separator that is driven by the
engine oil pressure. The separator separates oil from
the oil mist in the crankcase gases before the gases
are recirculated to the engine.
* Note. Has previously been included as standard on EPA certified
engines. Has also been available as an option on D12D-A MP,
D12D-B MP and D12D-B MH.
EPA = “Environmental Protection Agency”.

4
1. Un-filtered crankcase gas from the engine
2. Filtered crankcase gas is returned to the engine
3. Lube oil under pressure to operate the oil separator
4. Lube oil returned to the sump

33
 Group 26: Cooling system

Cooling system
The engine cooling system is subdivided into two cir- On the D12D-B/D/F/H MP, a priority valve controls the
cuits. 1 ) coolant flow through the heat exchanger. 2)
The engine’s internal cooling system is a sealed fresh The engine can also be equipped with hull cooling. 3)
water system, with a piston thermostat which regu- The coolant then circulates in a single, sealed sys-
lates the coolant temperature. tem, using the engine’s coolant pump.
The sea water system 1) is the engine’s external cool- 1)
Does not apply to D12D-A/E MG (RC), which is equipped with
ing system. In the heat exchanger, heat is transferred a sealed fresh water system with radiator.
2)
from the internal cooling circuit in the engine (fresh The majority of the heat exchanger’s capacity is used to cool
the engine. The rest of the capacity cools the coolant further
water system) to the outer circuit (sea water). before it is passed on through the charge air cooler.
3)
Does not apply to D12D-B/D/F/H MP.

Flow schedule for cooling systems with heat exchanger (D12D-B/D/F/H MP)
1. Oil cooler 5. Expansion tank 9. Sea water pump
2. Coolant filter 6. Thermostat housing 10. Heat exchanger
3. Charge air cooler 7. By-pass valve (“cold start valve”) 11. Priority valve
4. Oil cooler, reverse gear 8. Coolant pump (only on D12D-B/D/F/H MP)

34
Group 26: Cooling system Design and function

Engine built for single-circuit hull cooling

1. Standard expansion tank 5. Oil cooler for reverse gear
2. Venting, thermostat housing 6. From hull cooler
3. Extra expansion tank 7. To hull cooler
4. Venting, charge air cooler

5 4

6
Engine D12D-A/E MG with radiator (RC)
1. Expansion tank 4. Thermostat housing
2. Radiator 5. Coolant pump
3. Charge air cooler 6. Coolant filter

35
Design and function Group 26: Cooling system

Thermostat housing
On D12D-C/E/G MP, D12D-D/F/H MP and on D12D-A
MP and D12D-B as from engine No. 1012445526, a
spring-loaded bypass valve (“cold start valve”) has
been added to the thermostat housing.
Under heavy engine loading and with a cold engine
(thermostat closed) valve (A) opens at a pre-deter-
mined coolant pressure and allows a certain amount
of coolant to bypass the thermostat. The coolant in
the charge air cooler is thus able to circulate and
overheating of the charge air cooler is thus avoided.

On D12D-C/E/G MH and late model D12D-B MH,

there is a plug (B) with a 4 mm hole instead of a by-
pass valve.

By-pass valve (“cold start valve”): Heavy engine load-

ing (high engine speed) and a cold engine (thermo-
stat closed).
By-pass valve (“cold start valve”): Hot engine (thermo-
stat open).

36
Group 26: Cooling system Design and function

Charge air cooler

Engine with heat exchanger or hull cooler
In the charge air cooler, the heat from the induction air
is transferred to the fresh water system. The charge
air cooler is connected to the inlet pipe, behind the ex-
pansion tank on the left side of the engine.
The induction air passes the charge air cooler, after
being compressed in the turbocharger. The charge air
cooler reduces the temperature of the air, thus im-
proving cylinder filling considerably, since the volume
D12C-A, D12D-A and D12D-B/C/E/G MH of the air is reduced. More air (oxygen) can then be
pressed into the engine cylinders and burn a larger
volume of fuel in each working cycle. This means that
the power is increased. Intercooling also contributes
to lowering the thermal loading on the engine.

D12D-B/D/F/H MP

D12D-A/E MG with radiator (RC)

The charge air cooler is located beside the radiator
and is air cooled by a forced air fan.

Charge air cooler D12D-A/E MG (RC)

37
 Fault tracing
A number of symptoms and possible causes of engine malfunctions are described in the table below.

Symptoms and possible causes

The diagnosis button lamp flashes Please refer to “Electrical system” in the
workshop manual

Engine can not be stopped 2, 4, 6, 8

Starter motor does not rotate 1, 2, 3, 4, 5, 6, 7, 9, 10, 11, 12, 38, 41, 44

Starter motor rotates slowly 1, 2

Starter motor rotates normally but engine does not start/is difficult to start 13, 14, 15, 16, 40, 41, 42

Engine starts but stops again 13, 14, 15, 16, 21, 41

Engine does not reach correct operating speed at full throttle 14, 15, 16, 17, 18, 19, 20, 21, 22, 25, 35, 39, 41, 43

Engine runs roughly 15, 16, 20, 43

Engine vibrates 26

High fuel consumption 17, 18, 20, 23, 39

Black exhaust smoke 21

Blue or white exhaust smoke 23, 36, 45

Too low lubrication oil pressure 24

Excessive coolant temperature 27, 28, 29, 30, 31, 32, 33, 34

Too low coolant temperature 33

No, or poor charge 2, 37

1. Flat batteries 16. Water/contamination in fuel 29. Faulty circulation pump

2. Poor contact/open circuit in cables 17. Boat abnormally loaded 30. Closed sea water inlet
3. Main switch turned off 18. Fouling on hull/propeller 31. Blocked sea water inlet/pipe/
4. One of the fuses in the distribution 19. Cables for unit injector damaged filter
box has blown (open circuit) 32. Defective impeller in the sea water
5. Faulty power supply module (“Power 20. Faulty unit injector pump
Module”) 1) 21. Insufficient air supply to engine: 33. Defective thermostat
6. Faulty ignition lock – blocked air filter 34. Blocked heat exchanger insert/radia-
7. The control lever is not in neutral po- – air leakage between turbo and en- tor
sition/control station is not activated gine inlet manifold 35. Blocked charge air cooler
8. Faulty stop relay – fouled compressor section in tur- 36. Too high oil level
9. Faulty main relay bocharger compressor 37. Alternator drive belt slips
10. Faulty starter relay – faulty turbocharger/wastegate valve
2) 38. Water entry into engine
11. Faulty starter motor relay 39. High back pressure in exhaust sys-
– poor engine bay ventilation
12. Faulty starter motor/solenoid tem
22. Excessive coolant temperature
13. Lack of fuel: 40. Faulty engine speed sensor
23. Too low coolant temperature
– fuel taps closed 41. Stored fault codes 3)
24. Too low oil level/faulty lube oil pump
– fuel tank connected to wrong tank 42. Non-return valve in fuel inlet (suction
25. Faulty/wrong propeller
14. Blocked fuel fine/secondary filter side) leaks
(caused by contamination or fuel 26. Faulty engine mounting
43. Non-return valve in feed pump leaks
stratification at low temperature) 27. Coolant level too low
44. Check that the extra stop button is in
15. Air in the fuel system 28. Air in the fresh water system the RUN position (not depressed) 1)

45. Faulty piston ring seals in the turbo-

charger

1)
Applies to D12D-A MP, D12D-B/C/E/G MH and D12D-C/E/G MP.
2)
Wastegate valve applies to D12D-B/D/F/H MP.
3)
Please refer to the “Electrical system” chapter for further information.

38
 Fault tracing

Location of measurement outlets

The figures below and on the next page show where measurement
outlets can be placed on the engine.

1. Seawater temp/pressure (pump suc- 5. Charge air pressure/temperature af- 7. Charge air pressure/temperature be-
tion side) (1/8"-27 NPSF). ter charge air cooler. fore charge air cooler. Cast bosses*
5A. D12D-A/E MG (RC): M10 x 1. on charge air pipe between turbo-
2. Seawater temp/pressure (pump de- 5B. Other engines: 1/8"-27 NPSF. charger and inlet manifold.
livery side) (1/8"-27 NPSF). Note. The top plug has an M10
x 1 thread. * Holes may be tapped and drilled
3. Crankcase pressure (M16 x 1.5).
(1/8"-27 NPSF).
6. Negative pressure, air filter. The
4. Lube oil pressure (M16 x 1.5).
pressure drop indicator is omitted (1/
(Alternative to pos. 12).
8"-27 NPSF).

39
Fault tracing

8. Exhaust back pressure/temperature 11. Fuel supply pressure (after filter). Re- 13. Piston cooling pressure
(1/8"-27 NPSF). move the venting nipple on the filter (1/8"-27 NPSF).
bracket (M10 x 1).
9. Fuel supply pressure (before filter). 14. Coolant pressure/temperature (after
Tap and drill a hole (M10 x 1) in a hol- 12. Lube oil pressure: coolant pump) (1/8"-27 NPSF).
low screw (part No. 190 713). Classifiable engines: 1/8"-27 NPSF
Install the screw beside the inlet to the (in reduction nipple). 15. Lube oil temperature** (M18 x 1.5).
fuel filter(s). Other engines: M12 x 1.5 (in housing).
1/8"-27 NPSF if a reduction nipple,
10. Sea water back pressure/temperature* * Plug in water-cooled exhaust bend.
(part. no 947 899) is used.
after engine (1/8"-27 NPSF). ** Not found on early model D12C.

40
 Fault tracing

Group 23: Fuel system

Supply pressure, fault tracing
Function description, fuel system

* Note. Fuel shut off valve (17) only installed on classifiable engines.

During fault-tracing, it is important to understand There is an annular groove around every unit injector
the function of the system to be fault-traced and (9). The bypass valve (8) maintains constant pres-
that the fault tracing order is followed, to avoid sure in the fuel supplied to the unit injectors.
changing fault-free components.
There are three valves in the feed pump (1):
Schematic description of fuel flow on supply
– The safety valve (11) allows fuel to flow back to the
side:
suction side when the pressure is too high: such as
The fuel is sucked by the feed pump (1) through the when the fuel filter is blocked.
strainer (7) in the tank fitting, past the check valve (6),
– The non-return valve (13) opens when the hand
through the cooling coil (5) for the control unit (4), up
pump (2) is used.
to the bypass valve (8) and from there, it passes to
the suction side of the fuel pump, together with the re- – There is automatic venting via the vent valve (12),
turned fuel that passes through the bypass valve. direct to the fuel tank when the engine is running.
Max 0.3 l/min of the fuel flows back to the tank via
The feed pump forces fuel into the filter housing, past
the venting valve. The check valve (6) prevents
the two non-return valves(10) for the hand pump (2)
fuel from running back to the fuel tank.
and through the fuel filter(s) (3) to the long fuel supply
gallery in the cylinder head.

41
Fault tracing

There are two junction nipples (three on engines with Group 25: Inlet and exhaust
switchable fuel filters):
– Vent nipple (14) on the cylinder head. system
– Vent nipple(s) (15) on fuel filter bracket. Actions for low charge air
At the rear of the filter bracket, there is a pressure pressure
sensor (16), which measures the feed pressure after 1. Air inlet
the fuel filter. A fault code is set if the feed pressure is
Check that the ventilation inlet to the engine room
less than the specified value.
is large enough. Please refer to the installation in-
Classifiable engines have a fuel shut-off valve (17), structions.
which is activated during an emergency stop. The
valve then changes the direction of fuel flow, after
which the supply pressure in the fuel gallery in the 2. Air filter
cylinder head falls and the engine stops. Check that the air filter is not blocked (the pres-
An extra secondary filter (18) with water trap is avail- sure drop indicator shows a red field), and that
able as an option. The filter is connected to the sup- the correct filter has been used. Change filter as
ply pipe between the fuel tank and the check valve necessary.
(6).
3. Sealing
The inlet and exhaust manifolds and other unions
must not have any leaks. Also check that the
joints between the compressor bearing housing
and turbine and the compressor housing itself
seal correctly.

Fault tracing guide 4. Waste gate valve

D12D-B/D/F/H MP: Check the wastegate valve
The figures in brackets refer to the positions in the
function, as in the instruction on page 191, if the
schematic illustration of the fuel system on the previ-
charge air pressure is low at low engine speed or
ous page.
if the pressure is too high at full load.
Supply pressure, pressure sensor (16):
– Please refer to “Supply pressure, checking” on 5. Turbocharger
page 169. Check that the rotor shaft moves without friction
and that the turbine and compressor turbines do
not bind on their housings. First turn the turbine
Bypass valve (8): under light pressure, then with a gentle pull in the
– Please refer to “ Bypass valve, checking” on page axial direction. If the turbine is stiff to turn, the tur-
170. bocharger must be changed or renovated as
soon as possible. Check the turbines for damage.
Feed pump
Safety valve (11):
– Please refer to “Supply pressure, checking” on
page 171.
Check valve, hand pump (13):
– Please refer to “Feed pump, checking” (valves) on
page 171.
Vent valve (12):
– Please refer to “Feed pump, checking” (valves) on
page 171.

42
 Fault tracing

Group 26: Cooling system

Excessive coolant temperature
Excessive coolant temperature can be caused by:
l Blocked sea water filter
l Worn impeller in seawater pump
l Incorrect reading on temperature gauge
l Low coolant level
If the engine is operated in dusty or oily air every l Blocked heat exchanger
day, regular cleaning of the compressor housing
l Faulty thermostat
and compressor turbine is recommended. A
fouled compressor section can cause low charge l Blocked cooling system
air pressure.
The compressor section can be cleaned with the
unit installed, as follows:
Remove the compressor housing. Clean the
compressor housing, compressor turbine and
end wall in white spirit or equivalent substance.
Install the compressor housing and tighten the V-
clamp to 12.2 ±0.7 Nm (9 ±0.5 lbf.ft.).
Measure the charge air pressure again. Too low coolant temperature
5. Charge air cooler Low coolant temperature can be caused by:
Check that the charge air cooler is not blocked. l Incorrect reading on temperature gauge
Clean as necessary, according to the instruction l Faulty thermostat
on page 208.

6. Exhaust back pressure

Check that the back pressure in the exhaust sys-
tem is not too great in the finished installation.
Please refer to “Exhaust back pressure, check-
ing” on page 194.

7. Supply pressure
Change the fuel filter if installed. Fuel leakage
must not occur. Check that no air comes into the Coolant losses
system on the suction side.
There are two types of coolant losses:
l Coolant losses during operation.
8. Unit injector
Check the cables and that the correct unit injec- l Coolant losses after stopping a hot engine.
tor is used. Coolant losses during operation can be caused by
poor sealing in the cooling system, or that air or com-
9. Engine condition bustion gases are forced into the cooling system and
Check the valve clearance and cylinder pressure. force coolant out through the pressure cap. The fault
If the charge air pressure is not approved, al- can be caused by a leaky cylinder head gasket.
though all points have been found to be in or- Coolant losses after stopping a hot engine are gener-
der, the turbocharger should be renovated or ally due to a faulty pressure valve in the filler cap.
changed.

43
 Repair instructions
Group 21: Short block

When working with chemicals, Before lifting the engine

fuel and lubricating oil 1
Turn the main switch off. Undo the connections from
Important! Apply barrier cream to your hands and
the starter motor.
always use protective gloves in work which in-
volves contact with oil, fuel etc.
2
Continuous skin contact with engine oil dries Undo the engine cable and instrumentation connec-
your skin and can be hazardous. tors.

3
Disassmble the seawater or hull cooling connections.

4
Remove the exhaust pipe.
Before working in a boat
1 5
Disconnect the current with the main switch and Close the fuel taps.
check that the engine is not connected to system volt-
age. Remove the fuel connections.

2 6
Clean the outside of the engine. Undo the two cable connections from the distribution
NOTE: Make sure that wash residue is collected for box and the cables to the reverse gear.
destruction and does not inadvertently end up in the
water. 7
Undo the propeller shaft from the reverse gear. Undo
3 the engine mounting pads from the bed and lift the
The work includes the following actions on the cooling engine out.
system:
Close the sea cocks and drain the coolant from the
sea water- and fresh water systems.

WARNING! Make sure that all sea water inlets

are securely closed, so that water can not find
its way in during removal of cooling system sub
- components.

44
Group 21: Short block Repair instructions

Actions after lifting the engine General advice on working

1 with EVC engines
Clean the engine.
The following advice must be followed to avoid
damage to the engine control unit and other elec-
WARNING! Remember the following when
tronics.
washing with a power washer: Be extremely
careful when cleaning, to avoid getting water in-
side engine components. When a power wash- IMPORTANT! The system must be disconnect-
er is used, the water jet must never be aimed at ed from system voltage and the starter key(s)
seals, such as shaft seals, joints with gaskets, must be in position 0 when the engine control
rubber hoses or electrical components. unit connector(s) is/are disconnected or con-
nected. Cut the current with the main switches.

l Never disconnect the current with the main switch-

2 es when an engine is running.
Pump the engine oil out (if necessary).
l Never undo a battery cable when the engine is
running.
3
l Turn the main switches off or disconnect the
Remove the reverse gear (as necessary).
battery cables during quick charging of the
batteries.
NOTE: During normal trickle charging, it is not
necessary to turn the main switches off.

l Only batteries may be used for start help. A help

start device can produce a very high voltage and
damage the engine control unit and other electron-
ics.
General advice for pressure l Be careful to ensure that the connector pins do not
measurement come into contact with oil, water or dirt if a
connector is undone.

999 6398 999 6591 999 6666 999 8493

The same hoses and connection nipples are used to

check oil, water and fuel pressure. Clean the tools
carefully before pressure testing.

IMPORTANT! Be specially careful before

checking the supply pressure. The unit injectors
are sensitive and can easily be damaged by
contamination.

45
Repair instructions Group 21: Short block

Electric welding
IMPORTANT! Undo the connector(s) from the
engine control unit before any electric welding
starts.

IMPORTANT! The system must be disconnect-

ed from system voltage and the starter key(s)
must be in position 0 when the engine control
unit connector(s) is/are disconnected or con-
nected.

D12D-B/D/F/H MP

1
Cut the current with the main switches. Undo the
connector(s) from the engine control unit and from the
power supply unit*.
Please refer to the figures or more detailed instruc-
tions under the “Control unit, change” heading on
page 165.
* Note. The power supply unit is only found on D12D-A MP,
D12D-B MH and D12D-C/E/G MP/MH.
D12C-A, D12D-A, D12D-B/C/E/G MH and D12D-E MG
2
Disconnect all connections to the alternator.

3
Connect the welder earth clamp to the component to
be welded, or as close as possible to the weld site.
The clamp must never be connected to the engine or
in such a way that current can pass through a bear-
ing.

IMPORTANT! After welding is completed, the

disconnected components, such as alternator
cables and battery cables must be connected in
the correct order.

46
Group 21: Short block Repair instructions

Instructions for operating the

starter motor
IMPORTANT! The instructions must be followed
carefully, to ensure that the engine can not start
when it is cranked by the starter motor.

NOTE: There are two different ways the starter motor

is connected, “positive connection” and “negative
connection”, please refer to points 4 and 5.

1
D12C-A MP, D12D-A MH:
Remove the two engine speed sensors (the control
unit does not receive a signal then, and the engine
can not start).
NOTE: Save any spacer washers (shims) and fix
them to their sensor, to facilitate re-assembly.

3
Check which type of starter motor is installed before
connection is made as in points 4 or 5.

WARNING! There is a risk of high short-circuit

current if wrongly connected.

Disconnect one of the red cables for the engine con-

trol unit in the junction box.

2
D12D-A MG/MP and D12D-B/C/D/E/F/G/H:

D12C-A MP, D12D-A MH (“positive connected” starter

motor):
Connect a switch (such as part. No. 843 684) with at
least 2.5 mm2 (AWG 13) cables between the signal
current terminal and the positive pole on the starter
solenoid.

47
Repair instructions Group 21: Short block

5 21002
Compression test
Unit injectors removed and fuel drained.

Compression tests can be done in two different ways.

Either with a diagnostic tool, please refer to the “VO-
DIA User’s Guide”, or manually using the instruction
below.
The fuel system must be drained and the rocker arm
bridge and unit injectors must be removed to do a
manual compression test.
NOTE: Install protective sleeves 999 8249 on the unit
injectors to protect them from damage and contami-
nation.
When a manual compression test is done on the en-
gine, the same number of adapters (999 8248) should
be used as the number of cylinders to be tested. This
is so as to avoid repeated removal and installation of
the rocker arm bridge, unit injectors, and doing valve
D12D-A MG/MP, D12D-B/C/D/E/F/G/H: (“negative adjustment six times.
connected” starter motor):
IMPORTANT! Make sure that the area round
Connect a switch (such as part. no 843 684) with at the unit injectors is clean before they are re-
least 2.5 mm2 cables between the signal current ter- moved!
minal and the negative pole on the starter solenoid.
NOTE: Do not operate the starter motor for intervals
longer than 15 seconds. Then allow the batteries and Special tools: 998 8539, 999 8248, 999 8249
starter motor to rest for a few minutes* before opera-
tion is resumed. 1
* Note. The starter motor housing must not be too hot (max.
100°C).

6
Remove the switch and cables after the starter motor
has been operated.

7
D12C-A MP, D12D-A MH:
Re-connect the red cable for the engine control unit in
the junction box.

D12D-A MG/MP, D12D-B/C/D/E/F/G/H:

Install the two engine speed sensors.
NOTE: Be careful to ensure that the existing spacer
washers (shims) are installed together with their en-
gine speed sensors. Install all adapters No. 999 8248 in the cylinder head.

48
Group 21: Short block Repair instructions

2 Cooling system, draining

Oil the valve yokes, camshaft lobes and rocker arm
bridge. Tighten the screws progressively, to prevent Special tools: 999 6049*
the rocker arm bridge from bending or warping, * Note. Applies to D12D-A/E MG with radiator.
please refer to the tightening schedule. Tighten the
screws until it touches the camshaft lobes. Then tight- NOTE: Remove the expansion tank filler cap and close
en as in the tightening schedule in “Technical data”. the sea cocks before draining the cooling system.

3 WARNING! Avoid opening the coolant filling

Check that the valve clearances are within the speci- cap when the engine is hot. Steam or hot cool-
fications on all valves. ant might spray out in an unexpected direction.
Open the filler cap slowly, and release the pres-
sure in the cooling system if the filling cap or tap
4 has to be opened, or if a drain plug has to be
Connect a switch to the starter motor. Please refer to removed when the engine is hot.
“Instructions for operating the starter motor” on page 47.
1
Open all drain points. Drain the coolant with drain hos-
5 es.

2
D12D-A/E MG with radiator:
Drain the coolant from the radiator with drain hose
9996049. The drain tap is located underneath the radia-
tor.

Connect the compression gauge No. 998 8539 to the

relevant cylinder and do the test.

6
Crank the engine with the switch until the needle on
the compression tester has stopped. Read the value.

D
7
Do the corresponding test on the other cylinders.

D D
8
Re-install the unit injector and rocker arm bridge C
when the compression test is completed and ap- C = Coolant filter
proved. Adjust the valves and unit injectors. D = Drain tap/-nipple for coolant
V = Vent tap

9
Do a leakage- and function check.

49
Repair instructions Group 21: Short block

3 4
Other engines:
IMPORTANT! Check that all water drains out.
Deposits may be found inside the drain plug/
tap, and need to be cleared away. There is oth-
erwise a risk that water could remain and cause
severe damage.
Check whether the installation has any further taps or
plugs at the lowest points of the cooling water pipes
and exhaust pipe.

5
Remove the cover on the seawater pump and the
cover on any auxiliary pump. Also remove the pipe
between the heat exchanger and the reverse gear oil
cooler.
S S F* F* F S F
F = Fresh water – drain tap/plug 6
S = Sea water – drain tap/plug
Shut the taps, install the plugs, the cover on the sea-
* Note. Only D12D-B/D/F/H MP. water pump and the cover on any auxiliary pump.

7
V Pump the bilges out as necessary. Check that there
is no leakage before you leave the boat.

S F F C F
C = Coolant filter
F = Fresh water – drain tap/plug
S = Sea water – drain tap/plug
V = Vent tap/plug

50
Group 21: Short block Repair instructions

23341 3

Fuel system, filter change

NOTE: When you change a fuel filter: Only drain the
fuel as in point 5 in the next chapter.

IMPORTANT! Also lubricate the inner rubber

seal (located below the thread in the center of
the filter with engine oil before a new filter is in-
stalled.

Undo the vent nipple on the cylinder head. Let the fuel
run out into a suitable vessel.

4
Switchable fuel filter: Undo the unions (2) about 1-2
turns to release the check valves.

Fuel system, draining Fuel filter, draining

1 5
Carefully clean round the venting nipple on the cylin-
der head and the drain nipple(s) under the fuel
filter(s).

Connect a plastic hose to the drain nipple(s) (1) under-

neath the fuel filter(s). Open the nipple(s).
When the fuel has stopped flowing, undo the vent
nipple(s) (3) on the fuel filter bracket and allow the
fuel to drain into a suitable vessel.
Connect a plastic hose to the drain nipple(s) (1) under- NOTE: Be careful to save this fuel and hand it to a re-
neath the fuel filter(s). Open the nipple(s). cycling station.

51
Repair instructions Group 21: Short block

22231 2

Engine oil, changing

NOTE: Oil changes must be done when the engine is
warm.

WARNING! Hot oil and hot surfaces can cause

burns.

Plugs for oil draining

On engines without an oil drain pump (optional), the
oil can be sucked out once the plug (located at 1, see
the figure under point 2) has been undone.
If the engine has been lifted out of the boat, the oil can
be drained once the drain plug has been loosened.

Electric oil drain pump (optional equipment)

Engine with shallow sump (without inspection hatches). Move the three-way tap to the position for draining the
1 engine lube oil.

3
Pump the oil out into a suitable container.
NOTE: Hand the old oil in to a re-cycling station for
destruction.

4
Engine with shallow sump: Remove the suction pipe
and put the plug back.

Remove the plug and connect the suction pipe (Ø 12

mm) to the drain pipe.

Engines with mechanical oil drain pump: Close the

three-way tap.

Mechanical oil drain pump (optional equipment)

6
Engine with deep sump (with inspection hatches). Top the engine oil up as specified. Please refer to the
“Technical Data” chapter.

52
Group 21: Short block Repair instructions

Exposing the engine Engine fixture, fixing

During complete overhaul Special tools:
Engine stand 998 6485,
1 Engine fixture 999 8648
Check that the lube oil, coolant and fuel have been
drained.
1

2
Remove the reverse gear, clutch, any pumps and oth-
er auxiliaries from the engine. Please refer to the in-
struction page 231 for removing the sea water pump*.

3
Remove cables, alternator etc.
Note. Mark the cables and associated monitors/sen-
sors to facilitate assembly.

4
Remove the heat exchanger*. Please refer to “Heat
exchanger, removal and installation” on page 213.

5
Remove the control module*. Please refer to “Control
unit, changing” on page 165.
* Note. Points 4 and 5 apply if the engine is to be installed on an
Use engine fixture 999 8648 and fix the engine to the
engine stand. engine stand 998 6485.
The heat exchanger, control unit and sea water pump do not
need to be removed if only the cylinder head is to be removed.
2
Screw the fixture to the left side of the engine, as in
the illustration above.
NOTE: Use the following screws:
A. Part. no 965 181 (M8 x 70), 2 pcs.
B. Part. no 965 190 (M10 x 100), 1 pc.
C. D12C: Part. no 965 181 (M8 x 70), 2 pcs.
D. D12D: Part. no 965 181 (M8 x 70), 2 pcs.
E. Part. no 946 472 (M10 x 30), 2 pc.

53
Repair instructions Group 21: Short block

Short block, disassembly 2

21400
Cylinder head, removal
Coolant and sea water drained

IMPORTANT! Observe the greatest possible

cleanliness when working on the cylinder head.

Dirt particles in the fuel ducts can cause failure or

malfunction of the unit injectors.
NOTE: Mark the cables and associated monitors/sen-
sors to facilitate assembly.

D12D-B/D/F/H MP: Undo the hoses under the charge

Special tools: 999 0185, 999 0192, 999 3590,
air cooler.
999 6400, 999 6966, 999 8487, 999 8249, 999 8251,
999 8264, 999 8511, 999 8629 Other engines: Remove the coolant hose between the
charge air cooler and the heat exchanger.

Lift off the cover from the charge air cooler.

Remove the heat radiation guard over the turbocharg-

er. Undo the clamp between the air filter and the tur-
bo. Undo the two screws on the air filter bracket. Lift
away the air filter with bracket.
NOTE: Remove the screw which holds the charge air
pipe and air filter bracket.

54
Group 21: Short block Repair instructions

4 6

Remove the vent pipe/hose between the charge air

Undo the clamp beside the compressor housing. Re- cooler and the expansion tank.
move the charge air pipe. Remove the fixing screws and lift the charge air cooler
off.

WARNING! The charge air cooler for D12C-A,

D12D-A, D12D-B MH and D12D-C/E/G has
sharp edges.

5 7

D12C-A, D12D-A, D12D-B MH and D12D-C/E/G: Remove the clamp (3) on the pipe between the expan-
Remove the coolant hose between the charge air cool- sion tank and thermostat housing.
er and the bracket under the heat exchanger. Remove the pipe (1) between the expansion tank and
the coolant pump.
Remove the pipe (2) between the expansion tank and
the thermostat housing.
Remove the hose (4) for the pressure sensor on the
inlet pipe. Remove the crankcase ventilation pipe (5).
Remove the tie wraps from the cable harness.

55
Repair instructions Group 21: Short block

8 10

Remove the coolant temperature sensor (1) and the

Remove the expansion tank fuel pipes from the cylinder head.

NOTE: Two screws (1) are installed from underneath. IMPORTANT! Protect the fuel ducts from dirt,
water and foreign particles.

9 11

Undo the cable for the charge air temperature/pres- Remove the cable for the water monitor(s). Remove
sure sensor at the cable harness. Remove the upper the fuel filter bracket with filter, and fold it to one side.
brackets for the heat exchanger. Remove the inlet
manifold.

NOTE: The inlet manifold may be difficult to remove,

because of the sealant.

56
Group 21: Short block Repair instructions

12 14

Drive a hole in the oil filters (one at a time) and empty Remove the bracket for the full flow oil filter.
the oil out of the filters. Remove all the oil filters with
puller No. 999 8487. Collect all spilled oil in a collec-
tion vessel.

13 15

Remove the oil pipes between the oil filter bracket and Undo the bracket for the bypass filter and fold it to
sensor bracket. one side.

57
Repair instructions Group 21: Short block

16 18

Undo the clamps and disconnect the two cables.

Undo the cable (1) from the temperature sensor. Undo the bracket for the junction box from the cylin-
der head and fold it to one side.
Remove the cover over the thermostat housing, with
associated coolant pipe. Remove thermostat housing, During complete overhaul: Attempt to undo the ca-
with associated pipe. ble harness complete with brackets and tie wraps, to
make re-assembly easier. Remove the valve cover
NOTE: Cover the hole for the pipe union on the cool-
(see item 22) and undo the cables from the engine
ant pump, to protect against dirt and foreign particles.
(unit injectors). Please refer to items 37-39).

17 19
Engine with classifiable electrical system: Remove
the protective cover over the starter motor.
All engines: Undo the cables from the starter motor.

Undo the exhaust pipe bend from the turbocharger.

58
Group 21: Short block Repair instructions

20 22

Disassemble the valve cover nuts and remove the

valve cover.

IMPORTANT! Do NOT use air-powered tools

when removing the valve cover. The studs can
come undone (rotate) which would damage the
cable harness for the unit injectors.
Remove the coolant and oil unions from the turbo-
charger and plug all openings. Remove the turbo-
charger support stay where appropriate.
NOTE: Be careful to ensure that no dirt particles get
into the unions on the turbocharger.
D12D-B/D/F/H MP: Undo the hose for the wastegate
valve.

21 23

Remove all the screws for the exhaust manifold. An-

WARNING! Fix the turbocharger with tension gle the lower part of the exhaust manifold up (see il-
straps etc. The turbocharger weighs about 41 kg lustration) and lower it down to get it loose from the
(90 lbs). bosses on the cylinder head.
NOTE: The exhaust manifold weighs about 44 kg (97
Undo the rear lifting lug. Unscrew the turbocharger lbs) and should be carried by two people.
nuts and lift it away.
Note. The lifting straps can be places as in the illus-
tration.

59
Repair instructions Group 21: Short block

24 26

Undo the camshaft sensor and fold it to one side.

Install turning tool 999 3590.

25 27

Turn the flywheel until the piston in cylinder No. 1 is at Remove the upper timing gear cover.
top dead center 0° on the flywheel and the camshaft
marking (TDC) is between the markings on the bearing
cap.

60
Group 21: Short block Repair instructions

28 30

Remove the toothed wheel and vibration damper. Remove the joining piece for oil supply to the rocker
NOTE: The camshaft weighs about 9 kg (20 lbs). arm bridge.

IMPORTANT! The vibration damper must not

be subjected to blows or impacts. 31
Undo the screws for the rocker arm bridge, evenly
across the entire bridge, to avoid uneven loading.

29 32

Lift off the rocker arm bridge with lifting tool 999 0185.
Remove the camshaft gear (1). Use a puller as nec- IMPORTANT! In order to avoid personal injury
essary. and material damage, at least two people should help
to remove the rocker arm bridge. The rocker arm
bridge weighs about 27 kg (60 lbs).

61
Repair instructions Group 21: Short block

33 35

Check that the camshaft bearing caps have been fac- Loosen the bearing seats by tapping them carefully
tory-marked 1-7 against each bearing cap. Remove with a plastic faced mallet.
the camshaft bearing caps with the aid of puller Remove the bearing seats with the lower bearing
999 0192 and slide hammer 999 6400. shells and put them in the correct order together with
NOTE: The camshaft bearing caps are located by the appropriate camshaft bearing cap, upper bearing
guide pins. shells and screws.
NOTE: The camshaft bearing seats are located by
guide pins.

34 36

Lift off the camshaft away with lifting tool 9998264.

WARNING! Please note that the camshaft

lobes are extremely sharp.

IMPORTANT!At least two people should help to

remove the camshaft, to avoid personal injury Lift the valve yokes between the inlet valves and the
and material damage, if a lifting device is not exhaust valves for all cylinders. Mark up the yokes
available. The camshaft weighs about 35 kg and put them in the correct order for each cylinder.
(77 lbs).

62
Group 21: Short block Repair instructions

37 39

Remove the cable transition from the cylinder head

and carefully pull out the cables for the unit injectors.
D12C-A, D12D-A, D12D-B MH, D12D-C/E/G:
Remove the electric cables from all unit injectors. NOTE: The cable harness can NOT be pulled
apart at the cable transition, it must be carefully
IMPORTANT! Be very careful when the cables pulled out as one unit.
on the unit injectors are undone or screwed
IMPORTANT! Avoid twisting the cables in the
down.
cable transition, since there is a risk of dam-
Note how the cables are connected. aging the sensitive seals.

38 40

Remove all the studs and screws for the fixing yokes
D12D-B/D/F/H MP:
on all unit injectors.
Remove the connectors from each unit injector.

63
Repair instructions Group 21: Short block

41

D12D-B/D/F/H MP:
Install puller 999 0006 on the unit injector.
Put the puller fork in the groove in the injector and
lock the arm with the screw on the side. Fix the puller
by screwing the center screw down towards the ball
hole in the injector.
Install slide hammer 999 0013 and loosen the injector.
Mark the unit injector and install protective sleeve
999 8249 on the injector. NOTE: Check that the
sleeve is clean.

IMPORTANT! Do NOT take all the unit injectors

out at once. Take out one at a time and put the
protective plug in at once (point 42).

D12C-A, D12D-A, D12D-B MH, D12D-C/E/G: Put the unit injectors in a place where they will not be
Undo the unit injectors one a time with crowbar No. damaged.
9998511. Carefully prise each unit injector up under-
neath to loosen it.
Mark the unit injector and install a protective sleeve
9998249 on the injector. NOTE: Check that the
sleeve is clean.

IMPORTANT! Do NOT take all the unit injectors

out at once. Take out one at a time and put the
protective plug in at once (point 42).

Put the unit injectors in a place where they will not be

damaged.

64
Group 21: Short block Repair instructions

42 NOTE: There is an alternative procedure for removing

the cylinder head. Please refer to the next chapter,
“Cylinder head, installing the fixture”.

WARNING! If no lifting device is available, there

should be at least four people to help lift it care-
fully away (it weighs about 130 kg (287 lbs)).

46
Plug all the ducts in the cylinder head after disassem-
bly.

47

Install protective plugs No. 999 8251 in the holes for

the unit injectors in the cylinder head.

IMPORTANT! Very clean conditions are re-

quired!

43
Undo all the screws in the cylinder head.

44
Wipe up the engine oil that has collected in the “dim-
ples” under the camshaft. The oil could otherwise run
down into the coolant ducts when the cylinder head is
lifted off. Install press tools No. 999 6966 on the cylinder liners
to prevent them from being displaced if the crankshaft
is turned.
45

48
Remove the seals.
Clean the mating surface on the cylinder block careful-
ly.

IMPORTANT! Make sure that no sealant resi-

due or dirt particles can come down into the
coolant and oil ducts.

Install four lifting lugs 999 8629 and thread a lifting

sling through. Carefully lift the cylinder head away.

65
Repair instructions Group 21: Short block

Cylinder head, installation of 3

fixture 885316
Fixture 885316 can be used for work which does not
include machining the cylinder head or cylinder block.
Such as changing valves, pistons, cylinder head gas-
kets etc. The induction manifold and camshaft can
stay in place during this work.

Special tools: 885 316, 999 8629

1
Undo the engine components needed to install the fixture.
Please refer to the “Cylinder head, removing” chapter
on page 54 for instructions.
Install the lower part of fixture 885 316 against the
cover over the oil cooler.

2 4

Undo the top line of screws on the cover of the oil Install the top part of fixture 885 316 to the exhaust
cooler matrix. ports on cylinders 2 and 4.

66
Group 21: Short block Repair instructions

5 7

Install the screws and brackets on each side of the Install a crowbar etc. in the lug. Use the crowbar as a
fixture. lever and carefully lift the cylinder head upwards.
NOTE: The brackets serve as stops and it is impor- WARNING! Pinch risk! Carefully check to en-
tant that they are installed correctly. sure that the safety catch functions so that the
cylinder head can not fall backwards. The cylin-
der head weighs about 130 kg (287 lbs).

6
During complete overhaul:

Install a lifting lug 999 8629 on the center of the cylin- Remove coolant filter with pipe.
der head.

67
Repair instructions Group 21: Short block

9 5
Remove coolant pump, with associated pipe. Please
refer to page 195.

10
Remove the oil filler pipe with dipstick. Remove the oil
drain pump.

11
Remove the oil cooler.

12
Remove the starter motor.

Install turning tool 999 3590.

6
Piston cooling nozzle,
removing
Special tool: 999 3590

1
Pump the engine oil out.
Please refer to “Engine oil, changing”, page 52.

2
Engine with deep sump (with inspection hatches): Re-
move the inspection hatches.

3
Engine with shallow sump (without inspection hatch-
es): Remove the sump.
IMPORTANT! If the engine has been installed with
Volvo Penta minimum dimensions for service access,
the oil strainer must be removed before the sump can Turn the crankshaft round so that the piston cooling
be removed. nozzle to be changed becomes accessible.

4 7
Remove the stiffening frame.* Remove the piston cooling nozzle.
Engine with deep sump: Please refer to the instruc-
tion on the page 146.
* Note. D12D-A MH and early models of D12D-A MG and D12D-B
MH lack the stiffening frame.

68
Group 21: Short block Repair instructions

Pistons, removal 3
Turn the engine 90° if it is installed in engine stand
Cylinder head, lube oil sump, stiffening frame and 998 6485.
piston cooling nozzles removed
Special tools: 999 3590, 999 6966 4

WARNING! It is important that the piston

cooling nozzles are removed before the pis-
tons are removed. Damaged nozzles can
cause extensive engine damage.

Install press tool 999 6966 on the cylinder liners that

will not be removed.

2
Remove the big end bearing cap (1) with bearing shell.
Press the piston up so far that the piston rings come
above the edge of the cylinder liner. (Use a hammer
handle or other wooden object).
Lift the piston and con rod out.

IMPORTANT! Put the big end bearing cap back

on the con rod and tighten it to avoid damage to
the split plane (the “fracture-split” surfaces on
late model con rods are very fragile and can be
easily damaged).

5
Mark up late model con rods (divided with a fracture-
split) so that they can be re-installed in the same cyl-
inder on assembly.
Install turning tool 999 3590 and turn the flywheel until
the con rod to be removed comes into position.

69
Repair instructions Group 21: Short block

Cylinder liners and piston, 2

Measure the cylinder liner at the end of travel of the
inspection top piston ring, and at several places along its travel.
Clean the cylinder liners carefully before inspection At each measurement point, measurements should
and measurement. be done along the length of the engine- and across it.
NOTE: Cylinder liners and pistons are classed to-
gether. This means that pistons and liners must not 3
be mixed. If wear is greater than 0.45–0.50 mm (0.018 –
Pistons and cylinder liners are only supplied as com- 0.020"), a complete new kit should be used (pistons,
plete units for spare part purposes. liners, piston rings, gudgeon pins and seals).
Oil consumption also has a bearing on when the cyl-
inder liners should be changed.

Cylinder liner 4
Measurement of cylinder liner wear can be done with Remove the cylinder liner and do a crack check. Be
the liner installed in the cylinder block. specially careful when checking the liner collars. The
Magnaflux method can be used for this check.
NOTE: The cylinder liners must be taken out of the
cylinder block, to do a careful crack check.

Pistons
Check the piston ring grooves, damaged circlip
grooves, cracks and other damage on the pistons. If
the pistons have deep scratches on the skirts, the
pistons (liner kit) must be scrapped. The same ap-
plies if the piston has one or several cracks in the
gudgeon pin hole or in the bottom of the combustion
chamber. A crack test should be done using the chalk
flour process.

Measure the cylinder liners with a cylinder indicator. In

order to obtain the greatest possible accuracy in the
wear measurement, the cylinder liner must first be set
with a gauge ring or micrometer. Use the original di-
ameter of the cylinder liner as the base value.

70
Group 21: Short block Repair instructions

Cylinder liners, removal Flywheel housing, removing

Cylinder head, lube oil pump and stiffening frame Reverse gear and flywheel removed
removed
Remove the fixing screws and lift the flywheel housing
Special tools: 999 2955, 999 6394, 999 6395,
away.
999 6645
Note. Two screws for the sump are screwed into the
flywheel housing.
1 NOTE: The flywheel housing weighs about 18.5 kg
(41 lbs) for D12C-A MP, D12D-A/B/C/D/E/F/G/H MP
(aluminum), and about 87 kg (192 lbs) for other en-
gines (cast iron).

Mark the position of the cylinder liner in the block with a

marker pen before it is removed. This will allow the liner Crankshaft, removing
to be installed in the correct position if re-installed.
Cylinder head, lube oil sump, stiffening frame, re-
Pull the cylinder liner out with the tool as in the illus- verse gear and flywheel housing removed
tration. Make sure that the liner and any shims are
kept together. Special tool: 999 3590

1
2
Remove the main bearing caps.
Remove all seal rings (3 pcs.) from the cylinder block.
Take the seal ring out of the cylinder liner if there is one. Note. The front bearing cap must be removed togeth-
er with the lube oil pump.

2
Lift the crankshaft out carefully.
NOTE. The crankshaft weighs about:
131 kg (289 lbs) (early model with eight counter-
weights).
121 kg (267 lbs) (late model with four counter-
weights).

71
Repair instructions Group 21: Short block

21531 Special tools: 380 9090, 885 633, 885 648, 999 2584,
999 2671, 999 3590, 999 6315, 999 6626, 999 6965,
Timing gear, changing 999 9683, 999 9696 and 980 9726 or 999 2670

Lube oil pump, valve cover, rocker arm bridge, Removing drives and pulleys
upper timing gear cover, coolant pump and sea-
water pump all removed. 1
Remove the outer vibration damper.

2
Remove the dust shield and holder together with the
crankshaft seal.

3
Remove the fuel pump and the drive connection for
the pump.

4
Remove the lower timing gear cover.

WARNING! The lower timing gear cover weighs

about 23 kg (51 lbs). Two people should help
each other to lift it away.

1. Gear, camshaft
2. Seal molding
3. Gear, power take off (optional equipment)
4. Idler gear
5. Gear, coolant pump
6. Gear, crankshaft
7. Idler wheel (adjustable)
8. Gear, hydraulic pump/servo pump (optional equipment)
9. Gear for drive belts and fuel pump
10. Idler gear
11. Drive, seawater pump
12. Idler wheel, lube oil pump
13. Gear, lube oil pump

Remove the two socket cap screws from the flange. If

WARNING! Never turn the crankshaft or necessary, use tool No. 3809090 and two screws
camshaft when the timing gear wheels (M12 x 60 mm) to loosen the flange.
have been removed, if the rocker arm
WARNING! The flywheel damper is not se-
bridge is in place.
cured when the flange has been removed. The
Pistons and valves might come into con-
vibration damper weighs about 12 kg (26 lbs).
tact with each other and be damaged.
IMPORTANT! The vibration damper must not
be subjected to blows or impacts.

72
Group 21: Short block Repair instructions

6 9

Remove the polygon hub. Use puller 380 9090 and

Install turning tool 999 3590. M10 x 60 mm screws.

10

Turn the flywheel until the piston in cylinder No. 1 is at

top dead center 0° on the flywheel and the camshaft
marking (TDC) is between the markings on the bearing
cap.
Remove the toothed wheel and vibration damper.

8 NOTE: The camshaft weighs about 9 kg (20 lbs).

Use turning tool 999 3590 with a ratchet wrench to IMPORTANT! The vibration damper must not be
stop the flywheel rotation. Lock the ratchet wrench subjected to blows or impacts.
against the cylinder block.

73
Repair instructions Group 21: Short block

11 13
Remove the lube oil pump idler wheel (12).

14

Remove the camshaft gear (1). Use a puller as neces-

sary.

Install the center screw and washer in the crankshaft

nose (possibly making a center punch mark to guide
the puller). Remove the crankshaft gear (6) with a
two-claw puller.

15

The gear wheel numbering in the illustration refer

to the text.

12 Put a center punch mark in the center of an M12x20

Remove the idler wheels (4) and (10) from the timing mm screw to locate the puller. Then put it in the shaft
gear plate and the adjustable idler wheel (7). for the lube oil pump drive (13). Pull the shaft off with
a suitable puller.

74
Group 21: Short block Repair instructions

Cleaning, inspection Timing gear plate, disassembly/assembly

Special tools: 999 8267, 999 9683*, 999 9696*
16 * Note. Applies to installation of a new cylinder block.

Disassembly / assembly of the timing gear plate is

described in the “Alt. 1” method.
NOTE: The timing gear plate should only be removed
if absolutely necessary!

New cylinder blocks are supplied as a spare part

without timing gear plate. The “Alternative 2” method
describes installation of the timing gear plate on a
new cylinder block.

Alternative 1:
Existing cylinder block
19
Clean the timing gear plate and the front of the cylin-
der head.

IMPORTANT! The timing gear plate should

only be removed if absolutely necessary!
Please refer to the instruction on the next
page.

17

Install the two guide dowels 999 8267 so that they are
fixed to the cylinder block through the timing gear
plate. Remove the timing gear plate.
NOTE: The guide dowels must remain in place until
the timing gear has been put back.

Remove the lube oil nozzle from the timing gear plate
and check that the holes have not become blocked.
Put the lube oil nozzle back and torque it to 34 ±4 Nm
(25 ±3 lbf.ft.).

18
Check that the Woodruff key groove in the crankshaft
is not damaged. Make sure that the Woodruff key is
securely seated in the groove.

75
Repair instructions Group 21: Short block

20 21

Install the transmission plate, which is located by the

previously installed guide pins 999 8267. Torque the
screws to 34 ±4 Nm (25 ±3 lbf.ft.).

Alternative 2:
Sealant should be put about 4 mm in from the edge of the cylin-
der block. New cylinder block
22
Put a 1 mm thick line of sealant No. 1161231 at “1” Install the crankshaft gear. Please refer to points 35-
(broken line) on the cylinder block. Put a 2 mm thick 39 on the following pages.
line of sealant all round the cylinder block and round
the three marked holes.
23
NOTE: The timing gear plate must be installed within
20 minutes, since the sealant hardens.
Note. Use a marker pen to mark up where the seal-
ant should be applied.

Install two fixing tools 999 8624 at the front at the low-
er edge of the cylinder block.

76
Group 21: Short block Repair instructions

24 27
Install three of the timing gear screws (two at the bot- Torque the screws in the timing gear plate (3 pcs)
tom and one at the top). Remember to choose screw and two diagonally located screws for each gear
holes which are not covered by the timing gear wheel.
wheels. NOTE: Tighten so hard that the position of the timing
Tighten the screws until they just touch, but not so hard gear plate can not be moved.
that the timing gear plate can not be slid sideways.
NOTE: Do not apply sealant at this point!

25 28

Remove the feeler gauges. Put dial gauge 999 9683 in

magnetic stand 9999696 and measure the gear flank
Install the idler gear wheels.
clearance of the idler wheels. The gear flank clear-
NOTE: Check that the thrust washers have been in- ance for the crankcase gear must be as equal as
stalled with the “OUT” marking facing outwards. possible on each idler wheel. Permissible tolerance
Tighten the screws until they just touch, and check that 0.05–0.17 mm (0.002–0.007").
the timing gear plate can still be moved sideways.

26

Insert two 0.10 mm (0.004") feeler gauges between

the center gears, on each gear wheel.
Tap the timing gear plate sideways with a plastic
faced hammer until the feeler gauges move stiffly be-
tween the gears. Both feeler gauges must move
equally stiffly.

77
Repair instructions Group 21: Short block

29 Installing the timing gear wheels

33

Install the guide dowels 999 8267 and torque them to

60 Nm (44 lbf.ft.) when the gear flank clearance is
within the specified value. Then remove fixing tool
999 8624 from the lower edge of the cylinder block.

The gear wheel numbering in the illustration refer

30 to the text.
Remove the idler wheels.
Note. The timing gear wheels must be installed with
the part number facing outwards (does not apply to
31 the crankshaft gear).
Remove the timing gear plate.
NOTE: The timing gear plate must be pulled straight 34
out so that guide dowels 999 8267 are not damaged
or moved out of position.

32
Do the work noted under points 21 and 22.

Location of crankshaft gear

78
Group 21: Short block Repair instructions

Alternative 1: Alternative 2:
35 37

Install adapter 999 6965 and spindle 999 6315 in the Install adapter 999 6965 and spindle 999 6315 in the
crankshaft nose. The spindle must be placed with the crankshaft nose. The spindle must be placed with the
short thread in the adapter. long thread in the adapter.

36 38

Heat the crankshaft gear up to about 120°C (248°F).

Put the heated crankshaft gear wheel (6) on the spin-
Warm the crankshaft gear to about 120°C (248°F). dle. Install sockets 999 2584 and 999 6626. Install a
Put the heated crankshaft gear wheel (6) on the spin- suitable washer and the nut on the spindle, and tight-
dle. Install sockets 999 2584 and 999 6626. Install hy- en them. Press the heated gear on.
draulic cylinder 999 2671. Install the nut on the spin- NOTE: Make sure that the Woodruff key remains in
dle and tighten it. Connect hydraulic pump 980 9726 the groove in the crankshaft. Leave the tool in place
or 999 2670 to the hydraulic cylinder and press the until the gear has cooled.
heated gear wheel on.
NOTE: Make sure that the Woodruff key remains in
the groove in the crankshaft. Leave the tool in place
until the gear has cooled.

79
Repair instructions Group 21: Short block

39 Alternative 1:
43

Install adapter 999 6965 and spindle 999 6315 in the

crankshaft nose. The spindle must be placed with the
short thread in the adapter.

Heat the lube oil pump gear to about 180°C (356°F)

and press it on the shaft stub. 44

40
Oil the plain bearing and install the idler wheel (12) for
the lube oil pump. Torque the screws to 24 ±4 Nm
(18 ±3 lbf.ft.).

41
Oil the plain bearings and install idler wheels (4) and
(10). Torque the screws to 15 ±3 Nm (11 ±2 lbf.ft.)
and then angle tighten to 120° ±5°.

IMPORTANT! The screws must only be re-

used four times. Mark the screw heads with a
after tightening.
After four center punch marks, the screws Heat the polygon hub up to about 120°C (248°F).
must be changed.
Put the heated polygon hub on the spindle. Install
socket 999 6626 and hydraulic cylinder 999 2671. In-
42 stall the nut on the spindle and connect foot pump
Install the adjustable idler wheel (7) on the cylinder 980 9726 or 999 2670 to the hydraulic cylinder. Press
head. Just tighten the screws by hand until they the polygon hub on.
bottom against the bearing shield. Note. Leave the tool in place until the hub has
cooled.
IMPORTANT! The screws must only be re-
used four times. Mark the screw heads with a
after tightening.
After four center punch marks, the screws
must be changed.

80
Group 21: Short block Repair instructions

Alternative 2: 47
Lock turning tool 999 3590 to the cylinder block with a
45 ratchet wrench. Install the crankshaft screw together
with a washer and torque to 645 ±25 Nm (476 ±18
lbf.ft.).
Use a torque amplifier.
NOTE: The components must have cooled to room
temperature before they are torqued.

48

Install adapter 999 6965 and spindle 999 6315 in the

crankshaft nose. The spindle must be placed with the
long thread in the adapter.

Check that the flywheel marking 0° is centered on the

46
arrow on the flywheel housing.

49

Heat the polygon hub up to about 120°C (248°F).

Put the heated polygon hub on the spindle. Install
sockets 999 2584 and 999 6626. Install a suitable
washer and the nut on the spindle, and tighten them.
Press the polygon hub on.
Note. Leave the tool in place until the hub has Make sure that the marking for top dead center (TDC)
cooled. on the camshaft is between the markings on the
bearing cap.

81
Repair instructions Group 21: Short block

50 52

Install the camshaft drive gear without the vibration

damper. Use suitable sockets (please refer to the fig-
ure) to be able to tighten the screws properly.

Check the flank clearance of the adjustable idler

wheel in the two engagements A and B. Please refer
to the “Technical Data” chapter. The flank clearance
is checked with two feeler gauges.

51

Check that the camshaft gear is correctly installed by

inserting a 7 mm (0.3") pin into the hole (please refer
to the figure). Make sure that the pin is between the
markings on the camshaft drive.

82
Group 21: Short block Repair instructions

53

The figure shows inspection with the timing gear cover

removed.

Adjust the flank clearance as follows:

Undo the adjustable idler gear screws.
Put two 0.10 mm (0.004") feeler gauges in positions A
and B and turn the camshaft in the direction of the ar-
row.

54
Tighten the screws on the adjustable idler wheel light-
ly and check that the two feeler gauges are equally
stiff to move. Then remove the feeler gauges. Torque
the adjustable idler wheel in two stages.
Stage 1: 15 ±3 Nm (11 ±2 lbf.ft.).
Stage 2: Angle tightening 120° ±5°.
Please refer to the torque schedule in “Technical
Data”.

Checking is done through the inspection hole when

the lower timing gear cover is installed.

83
Repair instructions Group 21: Short block

55 56

Check method with a dial gauge:

Install dial gauge 999 9683 on the magnetic stand
999 9696 and put the dial gauge tip against a tooth on
the adjustable idler wheel.
NOTE: The tip of the dial gauge must be at right an-
gles to the gear tooth.

Flank clearance, adjustable idler wheel:

Lock the lower idler gear (4). Turn the camshaft gear
forwards and backwards. Read the value.

84
Group 21: Short block Repair instructions

57 58

Remove the screws and sockets from the camshaft

gear. Install the vibration damper, toothed wheel and
washer/spacer on the camshaft gear. Torque the vi-
bration damper in two stages.
Flank clearance: Stage 1: 35 ±3 Nm (26 ±2 lbf.ft.).
Move the dial gauge to the camshaft gear. Lock the
Stage 2: Angle tightening 90° ±5°.
adjustable idler gear with a screwdriver. Check the
clearance to the adjustable wheel by turning the cam- Please refer to the torque schedule in “Technical
shaft gear back and forwards. Compare the flank Data”.
clearance with the specifications. Please refer to the
IMPORTANT! If there is any damage to, or de-
“Technical Data” chapter.
formation of the toothed wheel or any of the
Alternative: Position the dial gauge at right angles to teeth on the toothed wheel, the toothed wheel
the tooth on the camshaft gear. Lock the adjustable must be changed. The same applies if any of
idler gear. Read off the flank clearance for the cam- the holes for the toothed wheel fixing screws is
shaft gear (0.14 mm (0.0055"))*. damaged.
Lock the idler wheel (4). Read off the gear flank clear-
IMPORTANT! The vibration damper must not
ance for the camshaft gear and the adjustable idler
be subjected to blows or impacts.
gear (0.27 mm (0.0106"))*.
Turn the camshaft gear and read the value for all
gear flank clearances (0.42 mm (0.0165"))*. 59
Install a new O-ring on the polygon hub. Install the in-
Example: ner vibration damper and flange on the crankshaft.
All gear flank clearances: (0.42 mm (0.0165")). Tighten the two socket cap screws in two stages.
Flank clearance, camshaft gear – adjustable idler Stage 1: 60 ±5 Nm (44 ±4 lbf.ft.).
wheel: 0.14 mm (0.0055"). Stage 2: Angle tightening 90° ±5°.
Flank clearance, adjustable idler wheel – lower idler IMPORTANT! The vibration damper must not
wheel: 0.27 – 0.14 = 0.13 mm (0.0106" – 0.0055" = be subjected to blows or impacts.
0.0051").
Flank clearance, lower idler wheel – crankshaft gear:
0.42 – 0.27 = 0.15 mm (0.0165" – 0.0106" = 0.0059").
* Note. The figures in brackets are an example.

85
Repair instructions Group 21: Short block

60 62

Apply a string of sealant, part No. 1161231*, with a di-

ameter of about 2 mm and install the lower timing gear Check that the feed pump drive fits the timing gear.
cover. Torque the screws to standard torque values. Install the oil feed pump with a new seal.
Screw positions, please refer to “Technical Data”. NOTE: The screw (1) must be installed with thread
M8: 24 ±4 Nm (18 ±3 lbf.ft.). sealant. Apply Volvo Penta sealant, part No. 840 879.
M10: 48 ±8 Nm (35 ±6 lbf.ft.).
M12: 85 ±15 Nm (63 ±11 lbf.ft.).
63
WARNING! The lower timing gear cover weighs Install the seal on the flange. Install the holder with
about 23 kg (51 lbs). Two people should help the crankshaft seal ring and the dust shield.
each other to install it.
* Note. Sealant, part no 1161231 (cartridge 0.31 l), or 1161277 64
(tube 20 g). Install the outer vibration damper on the crankshaft.

IMPORTANT! The vibration damper must not

61 be subjected to blows or impacts.
Install the drive connection and fuel pump. Check that
the fuel pump drive spindle engages in the drive cut- Tighten the screws in two stages.
out. Stage 1: 60 ±5 Nm (44.3 ±4 lbf.ft.).
Stage 2: Angle tightening 90° ±5°.

65
Remove turning tool 999 3590 from the flywheel hous-
ing and put the covers back.

86
Group 21: Short block Repair instructions

Pistons, pre-assembly 4
Install the other circlip.
Special tool: 88800083

1
Remove one of the circlips from the new piston. 5
Check that the gudgeon pin does not move stiffly in
the small end, and the piston can be moved easily.
2

Oil the gudgeon pin, the piston bearing seat and the
con rod bearing with engine oil.

IMPORTANT! Always use piston ring pliers

3 88800083 to install /remove the piston rings.
The oil scraper rings are particularly brittle and
can easily be damaged.

Install the con rod so that the arrow on the piston and
the con rod’s “Front” marking face the same way.
Press the gudgeon pin in.
NOTE: It should be easy to press the gudgeon pin in,
it must not be driven in.

87
Repair instructions Group 21: Short block

Cylinder liners, installation

Special tools: 999 2955, 999 6966, 999 8511

NOTE: Check the liner heights before the cylinder lin-

ers are installed. Please refer to “Cylinder liners,
checking” on page 120.

NOTE: Both the upper piston rings are marked with let-
ters or dots. The markings must face upwards. The oil
scraper ring is symmetrical and can face either way.

Align the piston ring gaps with about 120° displace-

ment on the piston. The piston ring openings must not
end up directly over the gudgeon pin, however.
NOTE: New cylinder liner kits are supplied complete
with pistons and piston rings.

88
Group 21: Short block Repair instructions

2 4
Position the upper seal ring in its groove in the cylin-
der liner, under the liner collar. This ring is installed
on D12C as from engine No. xxxx/310909 and on
D12D.
NOTE: The gasket must be installed dry.

5
NOTE: After application of the sealant, the cylinder
liner must be installed within 20 minutes.
If the cylinder head can not be installed and torqued
within 20 minutes, the liner must be pressed down in
the cylinder block with two press tools No. 999 6966.

6
If the cylinder liner is to be installed without an ad-
justment spacer:
Install an even, max 0.8 mm (0.03") thick line of seal-
ant (part No. 116 1231) underneath the cylinder liner
collar.
NOTE: The line of sealant must not be larger than
0.8 mm (0.03").
NOTE: Do not put sealant round the entire liner col-
lar, leave an opening of about 2 mm (0.08") to allow
the air under the liner collar to be evacuated when the
liner is installed. There is otherwise a risk that the top
seal ring could be pressed out of its position.

3
Install one of the screws (A) for the cylinder head. Put
plate No. 999 2955 on top of the cylinder liner togeth-
er with a suitable spacer (B). Press the liner down
with crowbar No. 999 8511.

7
Carefully press the cylinder liner down into the cylin-
der block. Install press tools No. 999 6966 to lock the
cylinder liner in the cylinder block until the cylinder
head is installed.
NOTE: Always install press tool No. 999 6966 on the
If the cylinder liner is to be installed with an adjust- cylinder liners, to ensure that the sealant hardens in
ment spacer: the correct position.
Position the line of sealant on the liner shelf in the cyl-
inder block (with an opening of about 2 mm / 0.08").
NOTE: No sealant must be used between the shims
and the liner collar.

89
Repair instructions Group 21: Short block

Crankshaft and main bearings, 8

Check that the crankshaft does not bind.
installing
1 9
Check the crankshaft drillings, the bearing shell Check the crankshaft end float. Please refer to the
seats, the cylinder block and bearing caps. “Technical Data” chapter for permissible clearance.

2
Install new main bearing shells.

3
Put the bearing shells in their correct places in the
cylinder block and bearing caps. Make sure that the
bearing shells are correctly aligned and that the bear-
ing caps are not damaged.
Be careful to make sure that the upper bearing shells
(the ones that should be put in the cylinder block) are
the ones with oil holes. Flywheel housing, installing
1
4
Lubricate the bearing journals and bearing shells with
engine oil and lift the crankshaft carefully into place.

5
Install the thrust washers for the centre main bearing
(thrust bearing). The thrust washers can only be in-
stalled in one position due to the fixing cutouts.

6
Install the main bearing caps. The bearing caps are
asymmetric and can only be installed in one position.
The center bearing cap (by the thrust bearing) has a
cutout, which should be aligned to come over the
guide pin. Note the numbers on the main bearing
caps, which indicate the positions of the bearing
caps.
Apply a line of sealant* (part No. 1161231*) with a di-
ameter of about 2 mm (0.08").
7 * Note. Sealant, part No. 1161231 (cartridge 0.31 l), or 1161277
Oil the main bearing screws. Let surplus oil drain be- (tube 20 g).
fore installation.
Tightening torque:
Stage 1: 150 ±20 Nm (111 ±15 lbf.ft.).
Stage 2: Angle tightening 120° ±5°.

90
Group 21: Short block Repair instructions

Piston with con rod, installing

Special tools: 999 3590, 999 6966, 999 8531

Note. It is permissible to mix old and new model con

rods (“fracture-split” or “milled”) in one and the same
engine.

1
Oil the piston and piston rings with engine oil and
check that the piston ring gaps are displaced at about
120° centers. The piston ring openings must not end
up directly over the gudgeon pin, however.

Note. Engines with aluminum flywheel casings (D12C-

A MP, D12D-A/B/C/D/E/F/G/H MP):
Apply the seal in the flywheel housing groove instead.

2
Lift the flywheel housing into place and tighten it.
Note. The two rear screws for the sump are screwed
into the flywheel housing.
Please refer to the “Technical Data, Tightening
schedule” chapter for screw lengths and tightening
torques.
Tightening torque: 140 ±14 Nm (103 ±10 lbf.ft.), (fly-
wheel housing) and 24 ±4 Nm (18 ±3 lbf.ft.), (oil Check that the correct bearing dimension is used. Com-
sump). pare the big end journals and compared the measured
values with those specified in “Technical Data”. Install
NOTE: The flywheel housing weighs about 18.5 kg the bearing shells in the con rod and bearing cap.
(41 lbs) for D12C-A MP, D12D-A/B/C/D/E/F/G/H MP
(aluminum), and about 87 kg (192 lbs) for other en- Align the bearing shells flush with the edge of the con
gines (cast iron). rod and bearing cap. This is so that the mating sur-
faces should fit each other.
NOTE: The rear crankshaft seal must be installed with
the flywheel housing in place. Please refer to the in-
struction on the page 155.

91
Repair instructions Group 21: Short block

3 5

Make sure that the bearing shell guide pin is correctly

located in the con rod cutout, and that the oil holes in
the con rod and bearing shell line up.

Oil the cylinder liner, bearing shells and big end bear-
ing journals. Install the piston and con rod with the ar-
4 row and FRONT markings facing forwards. Use tool
No. 999 8531 and carefully guide the piston and pis-
ton rings down into the cylinder liner.
IMPORTANT! Be careful. The oil scraper rings
are brittle and can easily be damaged.
The piston ring compressor must not be opened
once the piston has been placed in the tool,
since the piston rings could then be easily dam-
aged. Always press the piston out first, before
the piston is opened.
NOTE: Temporarily remove press tool 999 6966 for
the cylinder liner when tool No. 999 8531 is used.
Put the press tool back when the piston is in place.
All cylinder liners must be locked with press tools to
prevent movement between the cylinder liners and
cylinder block when the crankshaft is turned round.

Install turning tool 999 3590. 6

Turn the flywheel until the crankshaft comes into posi- Clean the mating surfaces on the con rod and bearing
tion to install each con rod. cap carefully, before the bearing cap is installed.

92
Group 21: Short block Repair instructions

7 11

Measuring the piston height.

Oil the bearing shells and install the bearing caps so If any of the small end bushes has been changed, the
that the markings on the con rod and bearing cap co- piston height must be measured in relation to the cyl-
incide. inder block plane.
NOTE: The bearing caps are numbered for each con Zero the dial gauge against the cylinder block plane.
rod. The markings on the con rod and bearing cap
must face the same way.
The boss on the bearing cap must be in line with the
side of the con rod. 12
Carefully check that the mating surface of the
bearing cap fits against the mating surface of the
con rod.

8
Torque the con rod screws to 275 ±12 Nm (203 ±9
lbf.ft.).
NOTE: A nut tightener must not be used to tighten
the con rod screws. This could damage the mating
surfaces.

9
Turn the flywheel until the crankshaft comes into posi-
tion to install more con rods and repeat points 1-7. Put the measurement tip on the piston and measure
the maximum piston height. For dimensions, please
refer to “Technical Data”.
10
Check that no big end bearing binds.

93
Repair instructions Group 21: Short block

13 14
D12C-A MP, D12D-A MG*, D12D-A MP**,
D12D-B MH* and D12D-B MP**, D12D-E MG and
D12D-C/E/G MH:
* D12D-A MH and early models of D12D-A MG and D12D-B
MH
lack the stiffening frame.
** Applies to D12D-A MP and D12D-B MP up to engine No.
1012532512.

Blow the piston cooling nozzle clean and check that it

is undamaged. Install the new piston cooling nozzle
with new screws. Tightening torque: 24 ±4 Nm (18
±3 lbf.ft.). Install the stiffening frame. Tighten the screws in two
stages.
NOTE: One screw hole (pos. 11) must be left empty
NOTE: The piston cooling nozzle retaining screw has on D12D-A/E MG, D12D-B MH and D12D-C/E/G MH
a friction coating and must only be used once. (if the screw is installed, the stiffening frame can not
WARNING! Faulty piston cooling will cause the be disassembled inside the sump).
pistons to seize.
If you suspect that the piston cooling nozzle
may be damaged or deformed, it should be re- D12D-A MP*, D12D-B MP*, D12D-C/D/E/F/G/H:
placed (applies to new nozzles as well). Always * Applies as from engine No. 1012532513.
check that each piston cooling nozzle is placed
correctly in its hole in the cylinder block, that the Install the stiffening frame. Tighten the screws in two
retaining plate lies flat against the block and stages.
that the nozzle is directed towards the recess in
the piston.
If the piston cooling nozzle is not correctly in-
stalled, the engine will immediately seize when
loaded.

Torque (both stiffening frames):

Stage 1 (M10 screws): 48 ±8 Nm (35.4 ±6 lbf.ft.).
Stage 2 (M8 screws): 15 Nm (11 lbf.ft.)
Stage 3 (M8 screws): Angle tightening 90° ±5°.

94
Group 21: Short block Repair instructions

15
Install the lube oil pump and lube oil pipe if they have
been removed. Note. The oil supply pipe must be in-
stalled before the suction pipe. The oil supply pipe
must be angle tightened. Please refer to the “Techni-
cal Data” chapter.

16
Engine with late model deep sump: Install the baffles.
Torque 24 Nm (18 lbf.ft.).

17
Remove turning tool 999 3590 from the flywheel hous- Apply a 1 mm thick and 15–20 mm long string of sealant 1161231
under and over the ends of the oil sump seal (rubber molding).
ing and put the covers back.

18
IMPORTANT! Cut off superfluous old sealant 19
with a sharp knife. Do not pull it off! Install the sump and torque the sump screws to 24 ±4 Nm
Install the new oil sump seal (rubber molding) in the (18 ±3 lbf.ft.).
groove in the sump, then apply sealant part No.
1161231 as in the illustrations.

IMPORTANT! Do not apply very thick strings of 20

sealant. Excess sealant can deform the rubber Engine with deep sump: Install the inspection hatches
molding and cause leakage. on the sump.

NOTE: The sump must be installed within 20 minutes

after applying the sealant.

Apply an even, app. 1 mm (0.04") thick string of sealant to the 21

joints (A). During complete overhaul:
The illustration shows the joint between the cylinder block and Install the reduction valve, safety valve, lube oil cool-
timing gear cover, or flywheel housing, where sealant 1161231 er, oil filter housing with valves, coolant pump and
should be applied.
starter motor.

95
Repair instructions Group 21: Short block

Cylinder head, removing 1

fixture 885316

1
Install the cylinder head gasket.

2
Pull back the catch on the fixture and carefully lower
the cylinder head.

3
Remove fixture 885 316 and lifting lug 999 8629 from
the cylinder head. Install all the removed engine com- Clean the copper sleeves for the unit injectors with
ponents in reverse order. Please refer to the following cleaning kit 999 8599 if necessary, before the cylinder
chapter “Cylinder head, installation”. head is lifted into place on the cylinder block.
Please refer to the “Unit injector, changing” instruction
on page 175.

2
Remove press tools No. 999 6966 for the cylinder
liners.

21400
Cylinder head, installation
Timing gear wheels installed

IMPORTANT! The cylinder head must be

cleaned on both the outside and inside before it
is put back. Dirt particles in the fuel ducts can
cause failure or malfunction of the unit injectors.

Special tools: 885 633, 885 648, 885 811, 999 0156,
999 3590, 999 6400, 999 6966, 999 8251, 999 8255,
999 8264, 999 8599, 999 8601, 999 8602, 999 8624,
999 8628, 999 8629, 999 9683, 999 9696
Install a new cylinder head gasket.
NOTE: Do not forget to also install a new seal molding
for the timing gear plate (see the arrow).

96
Group 21: Short block Repair instructions

4 5

Install four lifting lugs (999 8629) and thread a lifting

sling through. Carefully lift the cylinder head into place.

WARNING! If no lifting device is available, there

should be at least four people to help lift it care-
fully and one to guide it into the correct position.

The cylinder head weighs about 130 kg (287

lbs).

Install the fixing tool, as in the illustration.

IMPORTANT! Before the tools are installed:

Check the flatness of the tools by laying them
on a flat surface. If the tools are not flat against
the cylinder head or block, the cylinder head will
be incorrectly installed, which will risk a serious
engine failure. Clean off all traces of paint and
silicone sealant from the mating surfaces for the
tools.

97
Repair instructions Group 21: Short block

6 8

Check that the seal between the cylinder head and IMPORTANT! The cylinder head must rest
timing gear plate is correctly installed. against all fixing tools.
Lower the cylinder head until the guide dowels* in the Check that it is not possible to put a 0.10 mm (0.004")
block (for the cylinder head gasket) locate in the feeler gauge between the fixing tool and the cylinder
holes in the cylinder head. Do not lower the cylinder head.
head down fully. Let it hang a few millimeters (a frac- If it is not possible to move the cylinder head against
tion of an inch) above the cylinder block plane. the fixing tool, undo the screws mentioned in the pre-
Press the cylinder head obliquely down by hand so vious point and carefully tap the cylinder head into
that it is fixed against the three fixing tools. Lower the position. Tighten the screws and check the measure-
cylinder head down onto the cylinder block. ments again.
NOTE: Be careful when the cylinder head is moved,
to avoid damaging the gaskets/seals. 9
* NOTE: The guide dowels only locate the gasket, not the cylinder Remove the lifting tools.
head.

10
7 Dip the cylinder head screws in rust preventer (part
No. 116 1346). Put them on a piece of wire net etc. to
allow surplus rust preventer to run off.

11
Install the cylinder head screws and tighten them in
four stages. Please refer to the torque schedule in
“Technical Data”.
Stage 1: 60 ±10 Nm (44 ±7 lbf.ft.).
Stage 2: 60 ±10 Nm (44 ±7 lbf.ft.),
(check tightening).
Stage 3: Angle tightening 90° ±5°.
Stage 4: Angle tightening 90° ±5°.

NOTE: The screw heads and cylinder head should

preferably be marked with a felt tip pen.
Install a screw (M10 x 50 mm) in the upper hole of the Use a torque amplifier for angle tightening.
fixing tool on the timing gear plate, to ensure that the
cylinder head rests against the tool.

98
Group 21: Short block Repair instructions

12 15
Clean the tapped holes for the studs in the cylinder Install new seal rings in the unit injectors. Lubricate
head. Clean the studs, coat them with the seal rings with engine oil. Install the unit injectors
Volvo Penta thread locking fluid 161 053 and torque and yoke as previously marked. Center the injectors
to 40 ±3 Nm (30 ±2 lbf.ft.). so that the do not rest against the valve springs.
NOTE: Carefully wipe any surplus thread locking fluid Tighten the unit injectors as in the following alternative:
away once the studs have been tightened. A. With new copper sleeve,
First tightening
13 Stage 1: 20 ±5 Nm (15 ±4 lbf.ft.).
Stage 2: Angle tightening 180° ±5°.
Second tightening
Note. Loosen the screw before the second tightening.
Stage 1: 20 ±5 Nm (15 ±4 lbf.ft.).
Stage 2: Angle tightening 60° ±5°.

B. With old copper sleeve,

Stage 1: 20 ±5 Nm (15 ±4 lbf.ft.).
Stage 2: Angle tightening 60° ±5°.

16
Pull protection plug 999 8251 out of the hole in the unit
injector. Use slide hammer 999 6400 with adapter
999 0156 if necessary.

IMPORTANT! Do NOT remove all the protec-

tion plugs at the same time. Take out one at a
time, and then install one of the unit injectors.

Note. Put protection plug 999 8251 in sleeve

999 8249 after removal, as a protection against dirt.

14
Check that the hole in the cylinder head for the unit
injector is carefully cleaned. Please refer to “Unit in-
jector, changing” (point 13) on page 178.

Carefully pull the cables for the unit injectors into the
cylinder head. Lubricate the O-ring and press the
adapter into the cylinder head. Tighten the cable tran-
sition on the cylinder head.

IMPORTANT! Avoid twisting the cables in the

cable transition, since there is a risk of dam-
aging the sensitive seals.

99
Repair instructions Group 21: Short block

17 18

IMPORTANT! Fix the cables with Volvo

Penta original tie wraps (part. no 983472)* on
the holders (part. No 28429850) on the studs.

* NOTE: These tie wraps have been specially developed to with-

stand oil and high temperatures.
D12C-A, D12D-A, D12D-B MH and D12D-C/E/G:
Connect the electric cables for the unit injectors.
19
Torque the nuts to max. 1.5 ±0.5 Nm (1.1 ±0.4 lbf.ft.).

IMPORTANT! Be very careful when tightening

the nuts. If the nuts are tightened too hard, the
solenoid valve terminals can be damaged,
which means that the entire unit injector must
be changed.

Install the valve yokes in their original places between

the inlet valves and the exhaust valves for all cylin-
D12D-B/D/F/H MP: ders.
Connect the connector to the unit injector. Press it in
until a clear “click” is heard. NOTE: Valve yokes without guide pins* should be
placed with the oval hole over the valve nearest to the
camshaft.
If a valve yoke is changed, use a yoke of the same
time as was previously installed.
* Please refer to “Cylinder head, assembly” on page 139 for the
valve yokes.

100
Group 21: Short block Repair instructions

20 22

Carefully lift the camshaft into place, using lifting tool

9998264.
Note. Position the camshaft with the marking (TDC)
facing upwards.

WARNING! Please note that the camshaft

lobes are extremely sharp.

IMPORTANT! In order to avoid personal injury-

and material damage, at least two people
should help to lift the camshaft if there is no lift-
ing device. The camshaft weighs about 35 kg
(77 lbs).

23

Check that the bearing seats and bearing caps are not
damaged. If one or several bearing housings are dam-
aged, please refer to “Bearing housing for camshaft,
change” on page 144.
Put the bearing seats on the cylinder head as marked.
NOTE: If a new cylinder head is installed, the bearing
supports that came with it must be used.
Make sure that bearings of the correct dimensions
are installed, and that they are correctly located in
their seats.

21
Lubricate the bearing surfaces with engine oil. Install the bearing caps on each bearing support.
NOTE: Screw the screws in but do not torque them!
Note the length (105 mm (4.1")) and the position of
the screws (1) to the front bearing cap (closest to the
timing gear). Install the other screws as for the bear-
ing cap on the left (please refer to the figure).

101
Repair instructions Group 21: Short block

24 26

Check that the flywheel marking 0° is centered on the

arrow on the flywheel housing.

Install screws (M10 x 90 mm, 7 pcs.) in the holes for

the rocker arm bridge that do not have guide sleeves.
Torque to the M10 standard torque (48 ±8 Nm / 35.4
±6 lbf.ft.).

25 27
Metric:

Imperial:
(11 ±4 lbf.ft.)
+ 90° ±5°

Torque and angle tighten as in the figure above.

NOTE: Torque one bearing cap at a time and make
sure that the camshaft can be turned round easily.
Check the last bearing cap tightened if the camshaft
is stiff to turn.

Check that the markings on the camshaft (TDC) are

centered against the markings on the front bearing
cap.

102
Group 21: Short block Repair instructions

28 31

Remove the extra screws which were installed instead

Install the camshaft drive gear without the vibration of the rocker arm bridge screws.
damper. Use the spacer in front of the vibration Oil the valve yoke and camshaft lobes with engine oil.
damper (D12D) or suitable sockets (D12C), to be
able to tighten the screws properly. Lift the rocker arm bridge into place with 999 0185.
Check that the valve yokes and rockers are correctly
aligned with each other.

IMPORTANT! In order to avoid personal injury-

and material damage, at least two people
should help to lift the rocker arm bridge if there
29 is no lifting device. The rocker arm bridge
weighs about 27 kg (60 lbs).

32

Check that the camshaft gear is correctly installed by

inserting a 7 mm (0.3") pin into the hole (please refer
to the figure). Make sure that the pin is between the
markings on the camshaft drive.

30
Checking and adjustment of gear flank clearance, NOTE: Loosen all adjustment screws for valves and
and installation of the vibration damper, toothed unit injectors before the rocker arm bridge is installed.
wheel, lower timing gear cover, please refer to “Tim- Tighten the rocker arm bridge screws by hand.
ing gear, change” on page 72.

103
Repair instructions Group 21: Short block

33 34

1.
60 ±5 Nm
(44 ±4 lbf.ft.)

2.
15 ±5 Nm
(11 ±4 lbf.ft.)
+ 120° ±5°

3.

60 -> 0 Nm Thread new O-rings over the oil supply pipe for the
rocker arm bridge. Put the pipe in the joining piece
Undo marked screws. and install the joining piece with pipe. Check that the
O-rings on the pipe and the ring under the joining
4. piece are correctly aligned.
15 ±5 Nm
(11 ±4 lbf.ft.)
35
+ 120° ±5°
Check that the camshaft is correctly installed, and ad-
just the valves and unit injectors. See next section:
Torque the screws on the rocker arm bridge and
“Camshaft setting, inspection” and “Valves and unit
camshaft bearing caps in accordance with the tight-
injectors, adjustment”.
ening schedule.
(This chapter then continues with point 36 on page 110).
NOTE: Tightening, stage 1 should be done progres-
sively, to ensure that the rocker arm spindle bottoms
on the bearing housings without bending the spindle.
If the rocker arm shaft has been undone or disassem-
bled, only the screws which hold the shaft should be
tightened in accordance with the schedule on re-assem-
bly.
NOTE: Undo the marked screws in stage 3 before
doing stage 4.

104
Group 21: Short block Repair instructions

Camshaft setting, inspection 4

The inlet valve lift on cylinder No. 1 should be

checked to determine whether the camshaft is cor-
rectly installed.

Special tools: 998 9876, 999 3590, 999 9696

Install dial gauge 998 9876 with its measurement tip in

contact with the valve bridge. Set the dial gauge with
2–3 mm (0.08–0.11") preload.

5
Crank the engine about one turn in the direction of ro-
tation and then a further 6° until the 6° ATDC marking
on the flywheel. Read off the value shown on the dial
Install turning tool 999 3590. gauge. Compare the measured value with the value
specified in “Technical Data”.
2
6
Re-set the valve clearance to the correct value after
the test.

Turn the engine round until the marking on the cam-

shaft, (TDC), is centered against the markings on the
front bearing cap.

3
Zero the clearance for the inlet valves on cylinder No.
1 (the rocker arm closest to the timing gear).

105
Repair instructions Group 21: Short block

21403 Adjustment, general

Valves and unit injectors, 2
This instruction covers adjustment of valves and unit
adjustment injectors in the following order:
Valve cover removed. l Exhaust valves
l Inlet valves
IMPORTANT! Do NOT use air-powered tools l Unit injector
when removing the valve cover. The studs can
come undone (rotate) which would damage the NOTE: Inlet valves, exhaust valves and unit injectors
cable harness for the unit injectors. are adjusted at the same time for each cylinder.
Valves and unit injectors should be adjusted in the or-
Special tools: 998 9876, 999 3590, 999 8583, der marked on the camshaft when the engine is turned
999 9696 in the direction of rotation. By doing adjustments in this
order, the crankshaft does not need to be rotated more
than two turns to adjust all valves and unit injectors.
Timing marks It is a good idea to use a felt tip pen to mark the rock-
1 er arms which have been checked or adjusted.

Setting marks for valves, unit injectors and bear-

ing caps

The engine is marked with numbers (1-6) for valves

and unit injectors. (Cylinder No. 6 is closest to the fly-
wheel). Each mark is used for adjusting inlet valves,
exhaust valves and unit injectors for the appropriate
cylinder.
Install turning tool 999 3590.
NOTE: It is important that the line marked on the
camshaft is centered between the two markings on
the bearing cap when adjustments are done.

106
Group 21: Short block Repair instructions

4 6

Check that the line marked on the camshaft is cen-

tered between the two markings on the bearing cap. Screw the rocker arm adjustment screw down by hand
The number markings indicate the cylinder on which until the ball socket rests against the valve yoke, at
the valves can be adjusted. the same time as the side of the valve yoke without
an adjustment screw rests on the valve spindle.
7

Exhaust valves, adjustment Valve yoke with guide pin:

Note. New valve yokes without guide dowels (floating

yokes) have been introduced for the exhaust valves
on the D12D as from engine No. 1012366729.
This does not affect the valve adjustment procedure,
apart from the fact that balancing of the valve yoke
(items 6 and 7) is deleted. The valve clearance is un-
changed.

5
Undo the adjustment screws on the valve yokes and
rocker arms, so that they do not rest against the valve
yokes or valve spindles.

Screw the adjustment screw on the valve yoke down

so that it just touches the valve spindle, plus a further
spanner flat (60°).
Tighten the lock nut.

107
Repair instructions Group 21: Short block

8 Unit injector, preload adjustment

10

Adjust correct valve clearance between the rocker

Check that the line marked on the camshaft for ad-
arm and valve yoke, then tighten the locknut.
justing the valves and unit injectors is centered be-
Please refer to the “Technical Data” chapter for clear- tween the two marks on the bearing cap.
ance.
The number markings indicate the unit injector which
Check the valve clearance. can be adjusted.

11

Inlet valves, adjustment

9
The inlet valves are adjusted in the same way as the
exhaust valves, but with different clearance.
Note. New valve yokes without guide dowels (floating
yokes) have been introduced for the inlet valves on
the D12C as from engine No. xxxx/286879. The
D12D has these valve yokes (inlet) from produc-
tion start, and from engine No. 1012366729 they
have also been used for the exhaust valves.
This does not affect the valve adjustment proce-
dure, apart from the fact that balancing of the
valve yoke (items 6 and 7) is deleted. The valve
clearance is unchanged.

D12C-A, D12D-A, D12D-B MH and D12D-C/E/G:

Install gauge 999 8583 on dial gauge 998 9876, using
magnetic stand 999 9696.
Locate the dial gauge so that the gauge flange rests
on the unit injector spring retainer and the tip points
towards the flat surface between the spring seat and
the solenoid valve.

108
Group 21: Short block Repair instructions

12

D12D-B/D/F/H MP:
Adjust the unit injector rocker arm to zero clearance
on the camshaft. Then tighten the adjustment screw a
further 3–4 spanner flats (180 –240°).
Tighten the lock nut. Angle tighten 45° ±5° after con-
tact (7–10 Nm / 5–7 lbf.ft.).
NOTE: If wrongly adjusted, the unit injector can bot-
tom, which will damage the camshaft and unit injec-
tor.

D12C-A, D12D-A, D12D-B MH and D12D-C/E/G:

Preload the dial gauge 2–3 mm (0.08–0.11").
Preload the unit injector by screwing the rocker arm
adjuster screw down until the gauge bottoms on the
flat surface and the dial gauge indicator stops mov-
ing.
Tighten the lock nut. Angle tighten 45° ±5° after con-
tact (7–10 Nm / 5–7 lbf.ft.).
If there are no magnetic stand, gauge and dial gauge,
it is possible to measure the distance with a digital
caliper gauge. The distance should be 68.9 ±0.1 mm
(2.713 ±0.004").
NOTE: If wrongly adjusted, the unit injector can bot-
tom, which will damage the camshaft and unit injec-
tor.

109
Repair instructions Group 21: Short block

Cylinder head, installation

(continued from page 104)

36
Clean the upper timing gear cover and mating surfac-
es.

IMPORTANT! Cut off superfluous old sealant

with a sharp knife. Do not pull it off!

37

Note. On late model engines, one end of the timing

cover has a rubber seal molding. Put the sealant on
top of the seal molding.
NOTE: The timing cover must be installed within 20
minutes after applying the sealant.
Please refer to the “Technical Data, Tightening sched-
ule” chapter in the workshop manual for screw posi-
tions.

Then apply a 2 mm (0.08") thick string (please refer to

the figure) of seal ant (part No. 1161231)* on the tim-
ing gear cover and in the corners between the lower
timing gear cover and the timing gear plate.
* Sealant: 1161231 – cartridge (0.31 l)
1161277 – tube (20 g)

110
Group 21: Short block Repair instructions

38 39

A = Clearance in mm C = Toothed wheel

B = Adjustment shim D = Camshaft sensor

Turn the flywheel round until one tooth on the cam-

shaft is exactly centered on the sensor hole in the
timing gear housing. Install the camshaft sensor and
measure the distance A with a feeler gauge between
the sensor tip and the toothed wheel.
Permissible clearance A: 0.6 ±0.4 mm (0.024
±0.016").
The clearance between the sensor and the flywheel
must be within the specified tolerance, to get the cor-
Put the upper timing gear cover in place. rect signal from the flywheel sensor. Adjust the dis-
tance with spacer washers as in the table below.
Install the screws in the elongated holes in the cover.
Tighten the screws until they just touch (but do not
tighten them). A B
Install the press tools 999 8602* and 999 8628*. Measured clearance Spacer washers
Screw the tool down so that the timing gear cover
Quantity Part number
against the valve cover is flush with the sealing sur-
face on the cylinder head. Install the other screws 0.2 to 1.0 mm – –
and tighten to the standard torque. (0.008 to 0.039")
M8: 24 ±4 Nm (18 ±3 lbf.ft.). –0.3 to 0.3 mm 1 167 7894
M10: 48 ±8 Nm (35.4 ±6 lbf.ft.). (–0.012 to 0.012")
NOTE: Leave the press tool in place. The sealant –0.6 to –0.3 mm 2 167 7894
needs to harden for about 30 minutes. (–0.024 to –0.012")
* To 999 8602: Use two M12 x 35 mm screws.
999 8628: Use one M8 x 25 mm screw.
Note. The same method can be used, as for check-
ing the flywheel sensor distance. Please refer to the
instruction on the page 153.

111
Repair instructions Group 21: Short block

40 42

Install the coolant temperature sensor (1) and fuel

pipes on the cylinder head, using new seals. IMPORTANT! Cut away old, surplus sealant. Do
Torque the fuel pipes. Please refer to the “Tech- not pull it off.
nical Data, Tightening schedule” chapter.
Then apply a 2 mm (0.08") thick string of sealant
116 1231 to the joint between the upper timing gear
cover and the cylinder head.
41 NOTE: The valve cover must be installed within 20
minutes after applying the sealant.

43

Install the new exhaust manifold with new

gasket(s).
Note. Insert three screws a few turns into the
gasket “threads”, to retain the gasket.
Install the holder for the oil filter bracket (the
screws for the oil filter bracket are 5 mm (0.2")
longer). Torque the screws to 60 ±4 Nm (44 ±3 Install the valve cover and tighten the nuts with
lbf.ft.). 20 ±2 Nm (15 ±1.5 lbf.ft.). Please refer to the torque
NOTE: The exhaust manifold weighs about 44 kg schedule in “Technical Data”.
(97 lbs). If there is no lifting device, two people Note. Grease the rubber sleeves beside the nuts with
should help to lift the exhaust manifold. lubricant (part No. 1141699), to ensure that the valve
cover gasket has the correct press force (it may be
possible to use soapy water). Clean the rubber
sleeves before lubricating them, if the rubber sleeves
are re-used.

112
Group 21: Short block Repair instructions

NOTE: It is important that the valve housing nuts are 45

torqued as in the schedule, to prevent the housing
from cracking, and to prevent the studs in the cylinder
head from coming loose.
Check the cable harness for the unit injectors, if one
of the valve housing studs came loose from the cylin-
der head when the nuts were removed. There is a
risk that the cable holder on the stud might have fol-
lowed the rotation and damaged the cable harness.

44 Install the turbocharger with a new gasket. Torque the

nuts to 60 ±4 Nm (44.3 ±3 lbf.ft.). Install the rear lift-
ing lug.
NOTE: The turbocharger weighs about 41 kg (90
lbs). If there is no lifting device, 2 people should help
to lift the turbocharger.

46

Install the coolant pipes under the exhaust manifold,

using new seal rings.
NOTE: Do NOT tighten the screws on the bracket for
the outer water pipe, since it first has to be inserted
into the thermostat housing.
Pre-assemble the outer coolant pipe and return oil
pipe from the turbocharger compressor.

Install the coolant and oil unions on the turbocharger,

using new seals. Install the turbocharger support stay
where appropriate.

113
Repair instructions Group 21: Short block

47 49

1. From the inlet manifold

2. Out into the ambient air
3. To the wastegate valve
4. Cable connectors

D12D-B/D/F/H MP: Install the solenoid valve (control

valve) for the wastegate valve. Connect the hoses be-
tween the inlet pipe and the solenoid valve, and be-
tween the valve and the wastegate valve.
Install the joining piece for the valve.

Install the thermostat housing with associated pipe for

the coolant pump. Use new seals. Grease the seals
with lubricant (part No. 114 1699).
Connect the cable to the temperature sensor (1).

48 50

Install the exhaust pipe bend on the turbocharger.

Install the two coolant pipes, using new seals.

114
Group 21: Short block Repair instructions

51 53

Install the fuel filter bracket and connect the cables to

the water monitor(s).
Install the coolant pipe on the cover for the thermostat
housing, using a new seal ring.
NOTE: Also tighten the coolant pipe at the bracket
under the turbocharger.

52 54

Install the junction box with associated clamps. Con- Install the bypass filter bracket with associated hoses.
nect the cables.
Classifiable engine: Install the protective plates over
the starter motor.

115
Repair instructions Group 21: Short block

55 59
D12D-A/E MG: The inlet pipe has a seal that can be
re-used several times. Apply sealant if the seal is
damaged (see next point).

60

Other engines: Apply a 2 mm (0.08") wide string of

sealant, part No. 1161231 to the inlet pipe.
The inlet pipe must be installed and tightened within
20 minutes. Tightening torque: 24 ±4 Nm (18 ±3
Install the brackets for the full flow filters. lbf.ft.).
NOTE: The sealant must be applied as in the figure,
3 mm (0.12") from the inner edge of the inlet pipe mat-
ing surface.

56 61

Install the two oil pipes between the brackets.

Install the inlet pipe. Connect the charge air tempera-
ture/pressure sensor to the cable harness. Install the
57
stays (1) for the heat exchanger.
Install new oil and bypass filters.
NOTE: Install two studs in the cylinder head to locate
the inlet manifold. The two screws that hold the stay for
58 the heat exchanger are 5 mm (0.2") longer than the
Clean the mating surfaces on the inlet pipe and the other ten.
cylinder head carefully. Scrape the seal off with a
wood or plastic scraper.

116
Group 21: Short block Repair instructions

62 64

IMPORTANT! On D12C-A, D12D-A, D12D-B MH

and D12D-C/E/G, check that the protective tape
under the lower edge of the charge air cooler is D12D-B/D/F/H MP: Tighten the hose clamps under
still in place. The edge is very sharp! the charge air cooler.
Install the charge air cooler with new seals (O-rings) Other engines: Install the water pipe between the
against the inlet pipe. Place the bracket for the cover charge air cooler and the thermostat housing, using
plates on the charge air cooler and tighten the screws new seals. Grease the seal rings that are installed in
a bit at a time to ensure that it comes into the correct the charge air cooler, with lubricant (part No.
position. Install the vent pipe/hose between the 114 1699).
charge air cooler and the expansion tank. NOTE: Wait until all pipes and clamps for the charge
air cooler have been installed before tightening them.

63 65

D12C-A, D12D-A, D12D-B MH and D12D-C/E/G: In- D12D-B/D/F/H MP: Install the pipe with the priority
stall the coolant pipe between the charge air cooler valve between the charge air cooler and the coolant
and the bracket under the turbocharger, using new pump. Use new seals.
seal rings. Lubricate the seal ring which is installed in
the charge air cooler, using lubricant (part No.
114 1699) to make it easier to install the water pipe.
NOTE: Wait until all pipes and clamps have been con-
nected to the charge air cooler before tightening them.

117
Repair instructions Group 21: Short block

66 69

Install the charge air pipes in the charge air cooler, us- Install the expansion tank. Install the seal ring with
ing new seal rings. Grease the seals with lubricant drain hose on the expansion tank, and put the filler
(part No. 114 1699). Install the clamp for the turbo- cap back.
charger, with a new seal ring. NOTE: Two screws (1) must be installed from under-
neath, together with the fuel pipes and clamp.
67 Install the pipe between the charge air cooler and the
Tighten all pipes and clamps connected to the charge expansion tank.
air cooler.

68 70

Install the pipe (1) between the expansion tank and

the coolant pump. Install the pipe (2) between the ex-
Install the air filter and bracket. Tighten the clamp be- pansion tank and the thermostat housing. Install the
tween the air filter and the turbo. hose (4) for the pressure sensor on the inlet pipe, and
NOTE: Do not forget to install the screw which holds the clamp (3) on the pipe between the expansion tank
the charge air pipe and air filter bracket. and the thermostat housing. Install the crankcase
ventilation pipe (5). Clamp the cable harness as in the
figure.

118
Group 21: Short block Repair instructions

71 73
Fill up with the required amount of oil and coolant, as in
the specification. Please refer to the “Technical Data”
chapter and “Cooling system, filling” on page 227.

74
Vent the fuel system. Please refer to “Fuel system,
venting” on page 187.

75
During complete overhaul:
Remove engine fixture 999 8648. Install the control
unit and fuel shut-off valve*, and join up the fuel hos-
es. Fix the cable harness up. Install the crankcase
ventilation. Install the heat exchanger.
* Note. Refers to the classifiable version of D12D.
Check that the spacer sleeves are in place in the rub-
ber bushings. Install the alternator housing and the
housing over the outer vibration damper. 76
Function check
Start the engine and let it run until it reaches normal
working temperature.
72 Then let the engine run for a further 5 –10 minutes at
idle. When idling is even, the cylinder balancing sys-
tem has adjusted the correct amount of fuel for each
cylinder.
NOTE: Do not engage any type of power consuming
auxiliary (such as a power take-off) when cylinder
balancing is in progress.
Check for leaks.

Check that the spacer sleeves are in place in the rub-

ber bushings. Install the cover over the charge air
cooler.

119
 Overhaul / Change other components
Group 21: Short block

Cylinder liner seats, inspection 4

If the cylinder liner seat is damaged, this is rectified

by milling the liner shelf. The material which is re-
moved by milling is compensated by using shims,
which are available in different thicknesses.

Special tools: 999 2479, 999 6966

1
Make sure that the old seals in the cylinder block and
the cylinder liner, where appropriate, have been re-
moved, and that the sealing surfaces are carefully
cleaned.
Use a brass brush and cleaning fluid 116 1440.
Scraping tools must not be used.

2
Assess the limit of any damage.

3 Install the tools, as in the illustration. Zero the dial

gauge against the cylinder block plane.

Install the cylinder liner without seal rings and screw

it down with two clamping tools No. 999 6966.

120
Group 21: Short block Repair instructions

5 21307
Cylinder liner seat, milling
Alternative 1
Liner removed (shimming included)

Special tools: 999 2479, 999 2955, 999 6394,

999 6395, 999 6645, 999 6966
Other special equipment: 980 9772, 981 2524,
998 9876

Measure the liner height at two different places, and

calculate the amount that needs to be milled away
(thickness of the adjustment shims). Aim to use the
least possible number of shims.
NOTE: Make sure that measurements are always
done on the highest point of the sealing surface.
For sealing surface height, please refer to “Technical
Data”.
Mark the position of the liner in the cylinder block so
that it is put in the same position during installation.

Milling cutter 981 2524 for cylinder liner seat

1. Feed sleeve (vertical feed) 7. Centering roller
2. Lock screw 8. Spindle
3. Scale ring 9. Cutter
4. Solenoid 10. Switch (solenoid)
5. Locking brace 11. Crank
6. Feed ring (horizontal feed)

121
Repair instructions Group 21: Short block

1 4
Remove the cylinder liner and clean the liner seat in
the block. Please refer to the instructions on pages 71
and 120.

2
Install the new cylinder liner without sealing rings in
the block. Fix the cylinder liner with two press tools
999 6966.

Measure the height difference between the cylinder

liner and the plane of the cylinder block.
Measure the height of the liner at two places, diago-
nally to each other. Calculate the average of the two
measurements.
NOTE: Always measure at the highest point of the
sealing surface.
Mark the position of the cylinder liner in the block with
a marker pen before it is removed. This will allow the
liner to be installed in the correct position if re-in-
stalled.

Install dial gauge 998 9876 in holder 999 2479.

Place the holder with dial gauge right across the cyl-
inder liner.
Zero the dial gauge with a couple of millimeters (a
fraction of an inch) pre-load to the plane of the cylin-
der block.

Remove the press tools. Pull the cylinder liner out of

the cylinder block as in the figure.

122
Group 21: Short block Repair instructions

6 9
Three thicknesses of adjustment spacers are avail-
able for adjusting cylinder liner height: 0.20, 0.30 and
0.50 mm (0.0079, 0.0118 and 0.0197").

7
Calculate the amount that the liner seat needs to be
machined, so that when the adjustment spacer is in-
stalled, the correct liner height above the block plane
will be achieved (0.15 – 0.21 mm / 0.0059 –0.0083") as
in the example below.
NOTE: Always attempt to end up at the top end of
the tolerance range.
Machine the liner seat as little as possible, and use
the least number of adjustment spacers possible.

Example:
Correct liner height above
block plane ........................... 0.21 mm (0.0083") If the adjacent cylinders have liners installed, spacer
Minus measured value ......... – 0.12 mm (–0.0047") No. 9809772 must be used.
Difference ............................. 0.09 mm (0.0035") Spacer height is 4 mm (0.16"). If the liner height is
higher, the adjacent liners must be removed.
Thickness of spacers ........... 0.20 mm (0.0079") NOTE: Check that the spacer and the cylinder head
Minus difference ................... – 0.09 mm (–0.0035") plane are carefully cleaned.
Machining required .............. 0.11 mm (0.0043") NOTE: When the cylinder liner beside the timing gear
plate is milled, the milling tool must be extended. Please
refer to “Cylinder liner seats, milling” on page 126.
8

10

Use a suitable size of cutter and check that it is un-

damaged.
Hold up the locking brace and install the cutter. The Position cutting tool 981 2524 so that it is slightly dis-
toothed surface must face the solenoid and the cen- placed in relation to the center of the cylinder.
tering roller on the side of the spindle marked “R”.

123
Repair instructions Group 21: Short block

11 13

Move the switch to position “1” to activate the sole-

noid. Screw the feed sleeve up so that the cutter
passes freely over the liner shelf.

Center the tool by turning the crank clockwise at the

12 same time as the horizontal feed ring is held still.
The tool will now move round the liner seat, since it
was placed with an offset in relation to the center of
the cylinder.
If the centering roller looses contact with the liner seat
wall – turn backwards (counter clockwise), at the
same time as the horizontal feed ring is kept still, until
the centering roller is in contact again.
Continue until the tool movements stop and the cen-
tering roller has light contact with the liner seat wall.

Press the locking brace down and put the centering

roller against the cylinder liner wall, where the dis-
tance to the wall is greatest.
Release the locking brace and move the switch to be-
tween position “1” and “2”.
NOTE: Do not allow the switch to go all the way to
position “2”. The magnetism would then disappear
completely.

124
Group 21: Short block Repair instructions

14 19
Move the switch to position “1” when the tool is cor-
rectly centered.

15

Press the brace down and move the cutter so that it Machine the liner shelf by turning the crank clockwise
moves across the liner shelf plane, without contacting at the same time as the horizontal feed ring is held still.
the wall of the liner seat. The cutter will then machine the liner shelf plane from
the inner diameter and outwards towards the outer
16 wall of the liner seat.
Turn the crank and the vertical feed sleeve until the cut- Turn the crank carefully and allow the ring to slide
ter comes into light contact with the liner shelf plane. slightly between your fingers, when the cutter reach-
Zero, and lock the scale ring. es the wall of the liner shelf. This makes it possible to
stop precisely when the cutter reaches the wall.
NOTE: Do not force the crank backwards (counter
17 clockwise), since this can damage the cutter.
Press the brace down and move the cutter so that its
tip moves just inside the edge of the liner shelf (inner Repeat this procedure until the desired dimension
diameter). has been reached.

18
Turn the vertical feed ring clockwise so that the cutter
starts to machine the liner shelf.
NOTE: Do not feed more than 0.05 mm (0.0020") for
the first cut, to check that the cutter works evenly
across the entire surface.
Then not more than 0.15 mm (0.0059").

125
Repair instructions Group 21: Short block

20 21377
Release the solenoid by moving the switch to position
“2” and remove the milling tool. Cylinder liner seat, milling
Beside the timing gear plate (shimming included)
21
Clean the liner seat carefully. Install the new cylinder Special tools: 999 2479, 999 2955, 999 6394,
liner without seal rings, but with the selected adjust- 999 6395, 999 6645, 999 6966
ment spacer, and re-measure the liner height above Other special equipment: 980 9771, 980 9772,
the block plane, as in items 2-4. 981 2524, 998 9876
NOTE: Fix the cylinder liner with two press tools
999 6966. 1

22
If the cylinder liner height above the cylinder block
plane is within tolerances – install the liner with seal
rings. Please refer to “Cylinder liner, installing” on
page 88.

Remove the plate underneath the milling tool by re-

moving the three socket cap screws.

Install the extension (extension kit 980 9771) on the

miller and screw it in place.

126
Group 21: Short block Repair instructions

3 2

Clean the spacer (extension kit 980 9771) carefully

and put it on the cylinder block. Fix it with the screws.
Screw milling tool 999 8272 to the cylinder block. Make
sure that the feed sleeve does not press against the tool.
4
Do the milling work as described in the “Cylinder liner
3
seat, milling” procedure on page 121.
Screw the feed sleeve down until it presses lightly
against the miller, and zero dial gauge 998 9876.

4
Turn the cutter with an even movement at the same
time as the feed sleeve is turned.
NOTE: The cutter must never be turned anti-clock-
wise! Use a ratchet handle and socket to turn the cut-
ter.

5
Stop feeding and turn the cutter round several turns
Cylinder liner seat, milling when the correct height has been reached.
Alternative 2
Special tools: 998 9876, 999 8272* 6
Remove the milling tool and clean the liner shelf carefully.
* Note. Replaced by 981 2524 (please refer to “Alternative 1”).

Three thicknesses of adjustment spacers are avail- 7

able for adjusting cylinder liner height: 0.20, 0.30 and Check the liner height with shims in place before the
0.50 mm (0.0079, 0.0118 and 0.0197"). cylinder liners are installed.

1
Remove the cylinder liner and roughen up the liner
seat area with emery cloth.

127
Repair instructions Group 21: Short block

Crankshaft, inspection and Renovation

overhaul 1
Inspection as in points A – D in the previous section.
The crankshaft is induction hardened.

2
Inspection Grinding to undersize dimension as specified. When
grinding is done, it is important that fillet radii and
Inspect the crankshaft very carefully to avoid unnec- transitions from fillet radii are kept within the specified
essary renovation. dimensions.
The following applies when the need for renovation is
checked: IMPORTANT! Grinding of the center main bear-
ing requires special attention to dimension “A”.
A. Clean the crankshaft carefully. Measure the bear- Please refer to “Width of thrust bearing journal”
ing journals’ out-of-round, wear and taper. Please in the “Technical Data” chapter.
refer to the “Technical Data” chapter.
B. Check whether there is any surface damage on
3
the bearing journals. If there is any damage on
If sharp edges are formed at the oil duct inlet holes
the surface layer, the shaft must be re-ground.
during grinding, the edges must be removed with a
C. Measure lengthwise crookedness in the crank- small grindstone or emery cloth.
shaft (runout).
Put the shaft on a pair of V-block under No.1 and
4
No.7 main bearing journals.
Check that there are no grinding burns on the shaft.
Alt.: Set the crankshaft up between pins.
Measurement should be done on the 4:th main
bearing. 5
Please refer to the “Technical Data” chapter for Check lengthwise crookedness of the crankshaft
permissible values. (runout). See point C in the left-hand column.
It is not permissible to straighten the crank-
shaft. 6
D. Crack testing must be done before and after any Do a crack check. See point D in the left-hand column.
grinding. Magnetic powder testing is used for this
test, i.e. fluorescent powder which is viewed un- 7
der ultra-violet light. Lapping the bearing journals. Check that the surface
roughness requirement for bearing races and radii has
been met. Please refer to the “Technical Data” chap-
ter.

8
After grinding, any grinding swarf and contamination
must be carefully cleaned off the shaft, including the
oil ducts.
The crankshaft is equipped with tapped plugs, for ef-
fective cleaning of all oil ducts. The plugs must be re-
moved during cleaning and put back afterwards.
Tightening torque: 11 +6 +4.4
–2 Nm (8.1 –1.5 lbf.ft.).

128
Group 21: Short block Repair instructions

Big end bearing journal, 2

inspection
1
Check the big end bearing journals and bearing caps.
If a bearing has seized, the reason must be discov-
ered before new bearing shells are installed.

2
Check the measurements of the big end bearing jour-
nals for taper and ovality. If any of the values exceed
the maximum permissible values, the crankshaft must
be removed and renovated or changed.
Please refer to the “Technical Data” chapter. Measure the piston ring clearance in the piston ring
Also check if the crankshaft has standard or underdi- grooves.
mension, if you are not sure. For dimensions, please refer to “Technical Data” in
the workshop manual.

Pistons and piston rings, Gudgeon pins, removal

measurement
1

Remove the circlips on the old piston and tap the gud-
geon pin out with a suitable mandrel. Remove the con
Check the piston ring gap. During measurement, rod.
press the ring down below the bottom dead center
position using a piston.
Also check the piston ring gap with new rings.

129
Repair instructions Group 21: Short block

Con rod, inspection 2

Important to remember when removing / installing

a fracture-split con rod.
Installing a NEW con rod:
Carefully fix the con rod in a vise with soft jaw pads.
Undo the con rod screws a few turns and carefully
tap the bearing cap with a plastic faced hammer until
it loosens.
The parting line can be difficult to find when the con
rod is assembled.
When the cap is separated from the con rod, it may
occur that a chip is missing or comes loose. This
does not affect the function of the con rod at all.
Handle the con rod and bearing cap carefully. If any Use a new gudgeon pin and measure the straight-
dents occur on the parting line, this can affect ness of the con rod, using a fixture.
strength after torquing.
IMPORTANT! If the con rod or bearing cap are dam- 3
aged, change the con rod.

Gudgeon pin bushing, check

Measure con rod twist.
measurement
1
Check the con rods for cracking, straightness and
twist before considering changing the gudgeon pin
bush.
Discard the connecting rod if it is cracked, bent or
twisted.
When the gudgeon pin bush has been changed, the
bush must be machined (trapezoid shaped gudgeon
pin end).
When the clearance is correct, an oiled gudgeon pin
should slowly slide through the bush under its own
weight.

IMPORTANT! Please refer to Technical data

for maximum permissible twist and crooked-
ness.

130
Group 21: Short block Repair instructions

Cylinder head, valves, Disassembly, valves – Alt. 1

removal/installation Special tools: 980 9729, 999 0176, 999 6159, 999 8246
and 980 9726 or 999 2670
Removal/installation of valves can be done by two
methods.
1
Fixing the cylinder head in an engine
stand
Special tools: 999 0160

Work with the cylinder head is made easier if it is l Install press tool 999 0176 together with the valve
fixed in an equipment stand. The inlet pipe has to be counterhold.
removed first, before tool No. 999 0160 can be fixed
to the cylinder head. Also remove the exhaust mani- l Install hydraulic cylinder 980 9729 in press tool
fold if the cylinder head is to be overhauled. 999 0176 and connect hydraulic pump 980 9726
Screw tool No. 999 0160 to the cylinder head with 4 or 999 2670.
screws (M8 x 50 mm). l Install pin No. 999 6159 in the hydraulic cylinder.
NOTE: It is very important that the greatest possible Press the valve spring washer down and remove
cleanliness is observed during work on the cylinder the collets.
head. NOTE: D12D-B/D/F/H MP: Check that the tool
Dirt particles in the fuel ducts can cause failure or does not damage the unit injector connector, if the
malfunction of the unit injectors. injector is left in place.

l Remove the valve spring collar, springs, valve

yoke guide pins (where appropriate) and the
valves.

l Put the valves and springs in a marked stand, to

so that the components can be put back in the
same places in the cylinder head.

l Remove the remaining valves with the aid of the

press tool in the same way.

l Remove the valve stem seals from the valve

guides.

131
Repair instructions Group 21: Short block

Disassembly, valves – Alt. 2 5

Special tools: 999 0210

Alternatively, tool No. 999 0210 can be used instead

of the hydraulic cylinder. l Install guide sleeve No. 888 00011 on the valve
Note. Put the cylinder head down on a soft, clean stem and press the new valve stem seals down
surface. over the valve guides.

NOTE: Make sure that the cylinder head is not

scratched when the valves are removed.

NOTE: If tool No. 999 0210 is used with the cylinder

head still on the engine (e.g. when the valve stem
seals are changed, the piston must be at TDC when
the valves are loosened. This is to prevent the valves
from falling down into the cylinder. Use turning tool
999 3590 to crank the engine.

Valves, installation l Tap the valve stem seals down carefully with tool
No. 888 00151.
Special tools: 888 00011, 888 00151
NOTE: Check that the seals are pressed down
properly.
Note. Please refer to “Cylinder head, assembly” on
page 139 for guide pins, valve yoke and valve springs. l Install the valve spring or springs.
NOTE: The exhaust valves have double springs.
3
Oil the valve stems and valve stem seals. Install the l Use the same tool as for disassembly, and install
valves. the valve spring washer. Carefully press down
the valve spring(s) and install the collets.

4
Install the valve yoke guide pins (where appropriate).

132
Group 21: Short block Repair instructions

Alternative installation 2
Put the cylinder head on the bench with the valve
discs facing upwards.
6
IMPORTANT! The cylinder head must not be
laid down so that its entire weight bears on the
valve guides (please refer to the figure under
point 4).

3
Put a new valve in the valve guide, with the valve
stem end level with the edge of the valve guide. Use
a suitable counterhold under the valve stem.

Alternatively, tool No. 999 0210 can be used instead 4

of the hydraulic cylinder.
Note. Put the cylinder head down on a soft, clean sur-
face.
NOTE: Make sure that the cylinder head is not dam-
aged when the valves are removed.

21410
Valve guides, inspection Place dial gauge 998 9876 with magnetic stand
999 9696, so that the tip of the dial gauge rests on
Cylinder head removed the edge of the valve.
Move the valve sideways, in the direction of the ex-
Special tools: 998 9876, 999 9696 haust or inlet duct. Read off the value on the dial
gauge.

1
Remove the valve stem seals from the valve guides.
5
Check all valve guides. If the measurement values
exceed the values noted in the specifications, the
valve guide must be changed. Please refer to the
“Technical Data” chapter.

133
Repair instructions Group 21: Short block

21411, 21412 Installation

4
Valve guides, replacing
Oil the valve guides on the outside with engine oil be-
Cylinder head removed fore installation.

Alternative 1
5
Special tools: 980 9729, 999 0176, 999 6159, 999 8261,
999 8262 (D12C), 888 00147 and 980 9726 or 999 2670

Note. If the valve seats are also going to be changed,

this must be done before the valve guides are re-
moved.

Removal
Note. The valve guides are pressed out from under-
neath the cylinder head.

D12C:
Press the valve guide for the inlet valve in with tool
No. 999 8261. Press the valve guide for the exhaust
valve in with tool No. 999 8262.

WARNING! Wear goggles.

NOTE: Tool No. 999 8261 is marked Inl. Tool No.
999 8262 is marked Ex.
Put press tool 999 0176 in the holes for the cylinder Press until the tool bottoms against the cylinder head
head fixing screws. plane.
NOTE: Put washers between the nuts and the cylin-
der head plane. D12D:
Tighten the nuts of the tool. Press the valve guides for both inlet and exhaust
valves in with tool No. 999 8261.

2 WARNING! Wear goggles.

Install pin No. 999 6159 in the hydraulic cylinder.
NOTE: Tool No. 999 8261 is marked Inl. and is used
for all valve guides.
3 Press until the tool bottoms against the cylinder head
Install hydraulic cylinder 980 9729 in tool no 999 0176 plane.
and press the valve guide out with mandrel 888 00147
and hydraulic pump 980 9726 or 999 2670. IMPORTANT! After valve guides have been
changed, the cylinder head has to be cleaned
WARNING! Wear goggles. carefully to prevent dirt particles from coming
into the fuel and oil ducts. Contamination can
Press the other valve guides out in the same way.
cause failure or malfunction of the unit injectors.

134
Group 21: Short block Repair instructions

Alternative 2 Installation
Special tools: 999 2000, 999 8261, 999 8262 (D12C) 3
and 888 00147 Oil the valve guides on the outside with engine oil be-
fore installation.
Note. If the valve seats are also going to be changed,
this must be done before the valve guides are removed.
4
Removal
Note. The valve guides are pressed out from under-
neath the cylinder head.

D12C:
Tap in the valve guide for the inlet valve with mandrel
999 8261, together with extension 999 2000. Tap in
Tap the valve guide out with mandrel 888 00147, to- the valve guide for the exhaust valve in the same
gether with extension 999 2000. way, with mandrel 999 8262 and extension 999 2000.

WARNING! Wear goggles. WARNING! Wear goggles.

NOTE: Tool No. 999 8261 is marked Inl. Tool No.
2 999 8262 is marked Ex.
Tap the other valve guides out in the same way. Tap until the tool bottoms against the cylinder head
plane.

D12D:
Tap the valve guides for both inlet and exhaust valves
in with tool No. 999 8261 and extension No. 999 2000.

WARNING! Wear goggles.

NOTE: Tool No. 999 8261 is marked Inl. and is used
for all valve guides.
Tap until the tool bottoms against the cylinder head
plane.

IMPORTANT! After valve guides have been

changed, the cylinder head has to be cleaned
carefully to prevent dirt particles from coming
into the fuel and oil ducts. Contamination can
cause failure or malfunction of the unit injectors.

135
Repair instructions Group 21: Short block

21405, 21406 3

Valve seat, change

Cylinder head removed
Special tools: 998 9876, 999 2479

Place a suitable socket over the valve/valve guide

and carefully tap the valve seat out.
NOTE: Be careful not to damage the cylinder head.

WARNING! Wear goggles.

The valve seats must be changed if full sealing can

4
not be obtained, or if distance “A” exceeds the value
Clean the seat bed carefully and check the cylinder
given in the specification. Please refer to the “Techni-
head for cracks.
cal Data” chapter.

5
2
Measure the diameter of the valve seat bed in the cyl-
inder head. Investigate whether a standard or over-
size dimension valve seat should be used.
Do any machining needed on the valve seat bed.
Please refer to the “Technical Data” chapter.

6
Cool the seat in carbon dioxide snow between –60°C
and –70°C (–76°F and –94°F) and warm the cylinder
head by flushing with hot water, or some other meth-
od. Press in the valve seat in with a mandrel.
NOTE: Align the seat with the seat angle facing the
tool.
Check sealing against the valve.

Grind the head off an old valve and weld it onto the
valve seat. Use a MAG welder, or a conventional arc
welder with a stainless welding electrode.

IMPORTANT! Carefully cover the other surfac-

es on the cylinder head to stop any weld spatter
from fastening.

136
Group 21: Short block Repair instructions

21401, 21402
Valve seats, grinding
NOTE: Spare part valve seats for the D12C and D12D
engine are already machined, and do not need further
grinding.

1
Before the valve seats are ground, the valve guides
should be checked and changed if the wear toleranc-
es have been exceeded.

2
When the valve seats are ground, do not remove an
unnecessary amount of material, only remove enough
material to give the valve seat the correct shape and
a good mating surface.

Exhaust valve

Check that dimension (A) between the cylinder head

plane and the valve head surface are as specified.
Please refer to the “Technical Data” chapter.

4
Check the valve seat angle with a valve seat gauge,
once the seat mating surface has been coated with a
thin layer of marker dye.

Inlet valve

137
Repair instructions Group 21: Short block

21401, 21402
Valves, grinding
Valve sealing angles, please refer to “Technical Data”.
NOTE: Spare part valves for the D12C and D12D
engine are already machined, and do not need further
grinding.

1
Grind the sealing surface as little as possible, just
enough to grind away all damage.

Exhaust valve
2

Check the dimension (B) on the valve head edge.

Change the valve if this dimension is less than the
specified wear tolerance. Please refer to the “Techni-
cal Data” chapter.
Always change a valve with a bent valve stem.

3
Check valve sealing with marker dye.
If there is any leakage, grind the valve seat again (but
not the valve), then do a new check.
Once the results of grinding have been approved, the
valve and seat can be lapped in with fine grinding paste.
Inlet valve

138
Group 21: Short block Repair instructions

Cylinder head, assembly 21451

New valve yokes without guide pins (floating yoke) Rocker mechanism, change
have been introduced on D12C inlet valves as from
engine No. xxxx/286 879. At the same time, new Rocker arm bridge removed
valve springs were introduced for all valves. The The following components are exchangeable: rocker
D12D has these valve yokes (inlet) and valve springs arm bridge, expansion plugs, complete rocker arms
from production start. and adjustment screws.
On the D12D, a valve yoke without guide pin was
also introduced for the exhaust valves as from engine 1
No. 10123 66729*. Remove the rocker arms from the rocker arm bridge.
Valve yokes without guide pins should be placed with Mark the rockers so that they can be put back in the
the oval hole over the valve nearest to the cam- right order.
shaft**.
If a valve yoke is changed, use a yoke of the same 2
design as was previously installed. Clean all components, be specially careful with the oil
Note. The exhaust valves have twin valve springs. ducts in the bearing housings and the oil drillings in
* From production start on D12D-B MP, D12D-C/D/E/F/G/H. the rocker bridge and rockers.
** The yoke can face either way.

3
Check the wear on the rocker bridge and ball screws.
The threads on the ball headed screws and lock nuts
should be undamaged. Change the complete rocker if
any rocker has a bushing that has worn oval.

Inlet and exhaust valves

A. Early model valve yoke without
guide pin
B. Late model valve yoke without
guide pin (floating yoke)

NOTE: When valve springs are changed, all the

springs under any one yoke must be changed at
the same time. Early and late model valve springs
must not be mixed under the same valve yoke.

Oil the rocker bridge and put the rockers back in the
correct order.

IMPORTANT! It is extremely important that the

rocker arms and rocker arm bridge are carefully
cleaned and oiled with engine oil before the
rocker arms and shafts are assembled.
Lubricate the rocker arm bushes with engine oil.
Turn the rollers round at the same time as the
C: Right-hand twist valve spring: oil is squirted in. Check that oil runs out from
D12C-A MP (early model) – Inlet and outer spring (ex- both sides of the roller.
haust)
Other engines – Inner spring (exhaust)
D: Left-hand twist valve spring:
D12C-A MP (early model) – Inner spring (exhaust)
Other engines – Inlet and outer spring (exhaust)

139
Repair instructions Group 21: Short block

21191 4

Copper sleeve for unit injector,

change
NOTE: Two different variants of copper sleeve can
occur on the D12C. Always check the variant of
copper sleeve that is installed in the cylinder
head before work starts, to ensure that the cor-
rect special tool is used. Please refer to item 7 on
the next page.

Special tools: 999 0185, 999 3590, 999 8249,

999 8250, 999 8252*, 999 8253, 999 8599**, 999 8688
* Threading tool 999 8252 includes thread tap 980 9667 (M9) and
998 7009 (M8).
** Cleaning kit 999 8599 includes: 276 948, 959 239, 980 8570, Install two seal rings 999 8250 in the cylinder head
999 8580 with holder, and brush kit 980 8634. fuel gallery, as a protection against dirt.

1
5
Drain the coolant as appropriate. “Cooling system,
draining” on page 49.

2
Remove the unit injector when the copper sleeve is to
be changed. Please refer to “Unit injector, changing”,
page 175.

Install turning tool 999 3590.

6
Crank the engine until the piston is at TDC for the cyl-
inder where the copper cylinder is to be changed.
NOTE: This must be done to prevent the drill from
falling down into the cylinder when the sleeve diame-
ter is checked (next task).
Remove the valve yokes beside the copper sleeve to
be changed.
NOTE: Mark the valve yokes so that they can be put
back in the right places.

140
Group 21: Short block Repair instructions

7 9

Check diameter “A” of the copper sleeve to be

changed, using a drill (Ø 7.5 mm / 0.295").
NOTE: The copper sleeve must be free from soot.
If the drill can be passed through the hole, this means
that the copper sleeve has a diameter “A” = 7.8 mm
(0.307").
If the drill does not pass through the hole, or only with
some resistance, the copper sleeve diameter “A” =
7.4 mm (0.291").

IMPORTANT! Turn the piston away from TDC M in.20mm

Min. 20 mm
once the correct diameter has been found, to
prevent the tools from touching the piston
crown. Carefully tap a thread in the copper sleeve, using tool
999 8252 and a suitable tap, as in point 8.
8 NOTE: Grease the thread tap, to prevent swarf from
Put tap No. 980 9667 (M9) in tool 999 8252 if diameter falling down into the cylinder.
“A” was measured as 7.8 mm (0.307"). Screw the tap in at least 20 mm (0.8") past the tip of
Use tap No. 998 7009 (M8) if the diameter is 7.4 mm the copper sleeve.
(0.291").
The tip of the tap should project 20 mm (0.8") beyond 10
the tip of the tool rod. Remove the tap.

141
Repair instructions Group 21: Short block

11 13

Carefully clean the seat for the copper sleeve in the

cylinder head. Use brush 980 8614 together with a
shaft and holder.
NOTE: Install sleeve 999 8580 with holder must re-
NOTE: Screw the nose of extractor 999 8253 in at
main in the injector well, to prevent dirt from coming
least 15 mm (0.6") into the copper sleeve.
down into the fuel duct.
Remove the copper sleeve by carefully turning the
nut at the same time as the spindle is held tight.
NOTE: Use 980 9668 (M9) or 980 9746 (M8), depend-
ing on the diameter of the hole in the copper sleeve.

12 14

Carefully clean the sealing surface in contact with the Carefully clean the seat for the copper sleeve tip, with
O-ring on the copper sleeve. Use cleaning kit brush No. 980 8617.
999 8599 and an electric drill NOTE: Sleeve 999 8580 with holder must remain in
NOTE: Install sleeve 999 8580 with holder* into the the injector well, to prevent dirt from coming down
injector well, to prevent dirt from coming down into into the fuel duct.
the fuel duct.
* Note. The “lugs” must be cut off the holder to get the tool to fit.

142
Group 21: Short block Repair instructions

15 17
Check that there is no contamination left in the cylin-
der head. Remove sleeve 999 8580 and holder.
Undo the two seal rings 999 8250 from the fuel gallery
in the cylinder head.

16

Lubricate the new seal ring for the copper sleeve with
soapy water and put it on the copper sleeve.
NOTE: Always use a new O-ring.

18
Put the copper sleeve on expansion tool 999 8688.
Lubricate the expansion tool with oil.
Crank the engine until the piston is in its lower posi-
tion in the cylinder.
19
IMPORTANT! This must be done so that tool Carefully press the copper sleeve down so that the
No. 999 8688 will not damage the piston, due to expansion tool locates against the area for the unit in-
its length, when the copper sleeve is expanded. jector (edge) in the cylinder head.
Install the unit injector yoke and tighten it. Check that
the copper sleeve “bottoms” in the cylinder head.

143
Repair instructions Group 21: Short block

20 Bearing housing for camshaft,

change

Spread the copper sleeve by turning the nut at the

same time as the spindle is kept still, until the expan- The production-installed bearing housings are machined
sion tool has been completely pulled through. together with the cylinder head, and can therefore not
be moved from one cylinder head to another one.
21 If a bearing housing is damaged, a replacement hous-
Remove the expansion tool. ing can be installed. All bearing housings must
then be changed, so that the bearing housing po-
sitions can be aligned.
22
Put the valve yoke back in accordance with the previ- The holes in the replacement housings are oval,
ous marking. which allows the center bearing housings to be ad-
justed radially, and the front and rear housings to be
adjusted axially.
23 If the cylinder head is already equipped with replace-
Install the unit injector. Please refer to “Unit injector, ment housings, a damaged housing can be changed
changing”, page 175. without needing to change the other housings.

24
Install the rocker arm bridge and check the clearance
of the valves and unit injectors. Please refer to the in-
struction on the page 106.

25
Install the valve cover. Please refer to the torque 1
schedule in “Technical Data”. Tightening torque: 20 ±2
Nm (15 ±1.5 lbf.ft.).
2-6
26 7
Fill up with coolant and do a leakage test if the work
has not been done on a loose cylinder head.
Replacement housings can be recognized since they
have oval holes for the guide sleeves.
If a replacement housings are installed, mark them
with their numbers, so they can be put back in the
same place as before, if they have to be removed.

144
Group 21: Short block Repair instructions

Camshaft, wear check Guidelines for replacement

2
See “Crankshaft, inspection and overhaul”, page 128.
Unevenness can occur on the faces of the cam lobes
NOTE: The thrust bearing face on the camshaft must in the engine, under normal conditions. This does not
not be ground. mean that the camshaft has to be changed. These
For oversize camshaft bearing dimensions, please re- marks do not have any negative influence on either
fer to “Technical Data”. engine performance or durability of the engine and its
components.

Acceptable wear
Checking wear
Rocker arm bridge removed.

Examples of camshaft lobes showing scratches that

do not affect engine functioning.
These camshafts can be used again.

Put a steel rule across the camshaft lobes, parallel

with the camshaft axis, to check whether the cam
profiles have been worn.
Measure the wear with a feeler gauge or wire gauge.
Alternatively, a digital caliper gauge can be used.
Compare the measured values with those specified in
“Technical Data”.

145
Repair instructions Group 21: Short block

3 Stiffening frame, removal

Damaged camshaft that must be changed
downwards in sump
Applies to an engine* with deep sump (with in-
spection hatches)
* Note. D12D-A MH and early models of D12D-B MH/MG do not
have the stiffening frame.

1
Remove inspection hatches from the sump.

2
Remove the baffles.

3
Remove the oil strainer and then the oil supply pipe.

Examples of camshaft lobes with a type of damage

which mean that the shaft should not be used again.
These camshafts and the rockers which belong to the
worn lobes must be changed.

Undo the stiffening frame from the cylinder block and

lay it down in the sump in three stages, as in the se-
quence of illustrations below.
Note. The inspection hatches are on the right of the
figures.

WARNING! The stiffening frame weighs 16 kg.

Risk of pinch injury!

146
Group 21: Short block Repair instructions

Installing the stiffening frame Main bearings, change all

5 Sump removed (without inspection hatches)
This method describes how the main bearings are
changed with the crankshaft left in the engine.

Special tools: 999 0013, 999 0114, 999 3590

Removal
1

Lift the stiffening frame up in three stages, as in the

sequence of illustrations above. Tighten the frame
against the cylinder head in two stages, in accor-
dance with the tightening schedule. Install turning tool 999 3590.

2
Remove the oil suction pipe, oil supply pipe and stiff-
ening frame.
NOTE: The oil pump does not need to be removed
from the main bearing cap.

NOTE: One screw hole (pos. 11) must be left empty

on D12D-A/E MG D12D-B/C/E/G MH (if the screw is
installed, the stiffening frame can not be disassem-
bled inside the sump.
Torque:
Stage 1 (M10 screws): 48 ±8 Nm (35.4 ±6 lbf.ft.).
Stage 2 (M8 screws): 15 Nm (11 lbf.ft.).
Stage 3 (M8 screws): Angle tightening 90° ±5°.

147
Repair instructions Group 21: Short block

3 4

Remove one main bearing cap at a time. use slide Remove the upper main bearing shell by putting a pin
hammer No. 999 0013 together with extractor in the crankshaft oil hole and roll the bearing shell out
999 0114. by turning the crankshaft in the direction of rotation
with turning tool 999 3590.

5
Clean and check the bearing seat, bearing cap, shaft
journal and bearing shell.
If the bearing has seized, the reason must be discov-
ered before a new bearing is installed.

6
Check that the correct bearing dimension is used
when the bearing shells are changed.
NOTE: If there is any doubt, check the oversize di-
mensions used in the specification. Please refer to
the “Technical Data” chapter.

148
Group 21: Short block Repair instructions

Installation 10
Change the other main bearings (one a time) in the
7 same way as the first one. After each bearing shell is
Oil the bearing journal and the new bearing shells. changed, check that the crankshaft does not bind, by
rotating it with turning tool No. 999 3590.
8
11
Check the crankshaft end float and change the thrust
washers (thrust bearings) if the end float is too large,
or the thrust washers are damaged.
NOTE: Measure the end float with a dial gauge.
Thrust washers are available in a number of overdi-
mensions. Please refer to the “Technical Data” for
overdimensions and end float.

12

The upper bearing shell is installed by rotating the

crankshaft with tool No. 999 3590, against the direc-
tion of rotation, with the pin in the oil hole.
NOTE: Check that the pressed out heel in the bearing
shell is correctly aligned in the bearing seat cutout.
Be careful to make sure that the upper bearing shells
(the ones that should be put in the cylinder block) are
the ones with oil holes.
NOTE: Remove the pin after the bearing shell has
been installed.

9
Install the main bearing cap together with the bearing The crankshaft thrust bearing is located in the center
shell. main bearing. The thrust washers can only be in-
NOTE: The main bearing caps are asymmetric and stalled in one position due to the fixing cutouts.
can only be installed in one position. Note the number
of the main bearing caps, which specify their posi-
tions, if more than one bearing cap has been re-
moved at the same time.
Torque in two stages.
Stage 1: 150 ±20 Nm (111 ±15 lbf.ft.).
Stage 2: Angle tightening 120° ±5°.

149
Repair instructions Group 21: Short block

13 14
Check the crankshaft end float after all main bearing
caps have been torqued as in the specification.
Please refer to the “Technical Data” chapter.

15
Install the stiffening frame and tighten the screws in
two stages. Please refer to the torque schedule in
“Technical Data”.
Stage 1: 48 ±8 Nm (35.4 ±6 lbf.ft.) (M10 screws).
Stage 2: 15 Nm (11 lbf.ft.) and angle tightening
90° ±5° (M8 screws).

16
Install the oil suction pipe and oil supply pipe. Please
refer to the “Lube oil pump, changing” points 15 –21
on pages 163–164.

17
Remove turning tool 999 3590.

Use a small plastic- or wood pin to remove the thrust

washers from the cylinder block bearing seat.
NOTE: The thrust washers (thrust bearing) are locat-
ed in milled grooves.

150
Group 21: Short block Repair instructions

21661 3

Flywheel, removal / installation

Reverse gear removed

Removal
1

Unscrew the flywheel fixing screws.

IMPORTANT! Remove the flywheel sensor to

avoid damaging it with the flywheel during dis-
assembly.

2
4

Undo the vibration damper from the flywheel.

Install 2 lifting lugs (M 10) and lift the flywheel away with
a lifting sling which is threaded through the lifting lugs.

WARNING! Risk of pinch injury.

NOTE: The flywheel weighs about 60 kg (132 lbs).

151
Repair instructions Group 21: Short block

Installation 9

Clean the mating face of the crankshaft against the Install the flywheel and tighten the screws in two stages.
flywheel very carefully. Stage 1: 60 ±5 Nm (44.3 ±4 lbf.ft.).
Stage 2: Angle tightening 60° ±5°.
6 Please refer to the torque schedule in “Technical Data”.
Clean the mating face of the flywheel against the
crankshaft very carefully and check that the surface
where the sensor grooves are located is completely
free from contamination.

7
Check that the flywheel guide pin in the crankshaft is
in position and is undamaged.

10
8

Install the vibration damper.

Lift the flywheel with 2 lifting lugs and a lifting sling. 11

Install the flywheel sensor. Check/adjust the distance
WARNING! Risk of pinch injury. between sensor and flywheel. Please refer to “Fly-
wheel sensor distance, checking” in the next section.
NOTE: The flywheel weighs about 60 kg (132 lbs).

152
Group 21: Short block Repair instructions

Flywheel sensor distance, 6

checking
Special tools: 999 3590, 999 8517
1
Install turning tool 999 3590 and turn the engine fly-
wheel to 0°.

2
Remove the engine speed sensor from the flywheel
housing.

Put the sensor in the tool and measure the distance

between the mating surface of the sensor bracket
and the end of the tool. Note the measurement value
(B).

7
Calculate the existing sensor distance (D) as follows:

Metric: Imperial:
Move the locking ring on the setting tool so that it is
located round the center of the tool. D = A – (B + 20) mm D = A – (B + 0.787) in.

Example:
4 Distance A = 28.2 mm Distance A = 1.110"
Insert the tool into the sensor hole and carefully press
Distance B = 8 mm Distance B = 0.315"
the tool in until it touches the grooves on the flywheel.
D = 28.2 – (8 + 20) mm D = 1.110 – (0.315 + 0.787)"
D = 0.2 mm D = 0.008"
5
Compare the distance with the correct value: 0.75 –
2.1 mm (0.030 – 0.083").
The measured distance can be increased to the cor-
rect value by putting spacer washers (part No.
1677894 – thickness 0.6 mm / 0.024") between the
sensor and the flywheel housing.

8
Install the engine speed sensor on the flywheel hous-
Remove the tool and measure the distance between ing together with any spacer washers.
the locking ring and the end of the tool. Note the mea-
surement value (A).
9
Remove the turning tool.

153
Repair instructions Group 21: Short block

21687 3

Gear ring, change

Reverse gear and flywheel removed
1

Heat the new gear ring up to 180 –200°C (356 – 392°F)

with a welding torch or in an oven. The gear ring must
be evenly heated. Be careful not to heat the gear ring
up too far and anneal it.
Check the heat by polishing the ring bright at several
places. Stop heating when the polished surfaces
have become blued.

4
Drill 1-2 holes between teeth on ring gear.
Split the gear ring at the drilled hole, using a cold
chisel. Lift the gear ring away from the flywheel.

2
Brush the flywheel bed clean with a steel wire brush.

Put the heated gear ring onto the flywheel and tap it
into correct position with a soft mandrel and hammer.
Leave the gear ring to cool.

154
Group 21: Short block Repair instructions

21671 3
Install the seal as follows (the sealing surfaces must
Crankcase seal rear, change be completely clean and dry).

Reverse gear and flywheel removed IMPORTANT! Be careful when handing the seal
NOTE: There are two types of shaft seals. There is an ring without spring (PTFE). It is difficult for this
early model seal with a sprung ring and a rubber seal ring to regain its original shape after deformation.
lip, and a late model version that has an un-sprung
ring and a PTFE seal lip.
NOTE: The seal must not be pre-installed in the cov-
er, installation must be done with the flywheel housing
in place.

Special tools: 999 0166, 999 0192, 999 6400

Install tool No. 999 0166 on the crankshaft and screw

it down with the screws. Check that the tool rests
against the crankshaft before the tool is screwed
down.
Put the washer as a spacer on the center screw (the
washer determines how far the seal is pressed into
the cover).

Drive the seal out with extractor 999 0192 together

with slide hammer 999 6400.
Press or drive the extractor in with a slide hammer.
NOTE: Be careful with the crankshaft by leaning the
tool inwards, so as to get a good grip on the seal.

2
Clean the seal seat in the flywheel housing and the Install the plastic ring that the new seal is mounted on
mating surface on the crankshaft. and install the cover together with the screw handle.

155
Repair instructions Group 21: Short block

5 21672
Crankshaft seal, front, change
1
Remove the outer vibration damper.

2
Remove the dust shield and holder together with the
crankshaft seal.

Press the seal in, using the tool. The seal will be in 3
the correct position when the cover bottoms on the Lubricate the sealing lip of the new crankshaft seal
washer. with engine oil.
NOTE: Cleaned surfaces. No lubricant must be used.
IMPORTANT! Carefully check that there is no
contamination on the seal or its contact surface
on the hub.
6
Remove the tool.
4

Install the holder with the new crankshaft seal (1) and
dust cover (2).

5
Put a new seal ring (3) on the hub and install the out-
er vibration damper.

IMPORTANT! The vibration damper must not

be subjected to blows or impacts.

Tighten the screws in two stages.

Stage 1: 60 ±5 Nm (44.3 ±4 lbf.ft.).
Stage 2: Angle tightening 90° ±5°.

156
 Group 22: Lubrication system

22020 3
Clean and check the valve seal. If the valve seat is
Bypass valve, oil filter, change damaged, the entire bracket must be changed.

1 4

Install the new ball (1) and spring (2).

Use a new seal ring (3). Install and tighten the lid on
the bypass valve.

5
Start the engine and check sealing.
Clean and remove the plug (1) over the bypass valve
for the full flow filters.
Engines with low mounted oil filters also have a bypass
valve for the bypass filter underneath the plug (2).

2
Remove the ball and spring.

IMPORTANT! Engines with low mounted oil fil-

ter: Do not mix the two valves up after disas-
sembly. The springs for the two valves have dif-
ferent hardness. Please refer to “Technical
data” in the workshop manual.

157
Repair instructions Group 22: Lubrication system

22020 4
Install the new reduction valve (1) and safety valve
Reduction valve and safety (2) in the cylinder block, with new O-rings. Use socket
No. 999 8598 to tighten the covers.
valve, change
Special tools: 999 8598

IMPORTANT! Check that the inner O-ring (3)

does not come loose from the valve when the
valve is installed.
Grease the ring to make it stay in place better
on the valve.

5
Start the engine and do a function and sealing check.

Clean round the covers on the cylinder block. Remove

the covers with tool No. 999 8598 and remove the re-
duction valve (1) and safety valve (2).
NOTE: Do not mix the valves up if they are to be re-
installed. 22020

2
By-pass valve for oil cooler,
Clean it and make sure that the old seal ring does not change
remain.
1

Check in the specifications that the new safety valve

or reduction valve has the correct color marking.
Please refer to the “Technical Data” chapter.

Clean and remove the bypass valve cover.

158
Group 22: Lubrication system Repair instructions

2 2
Take the bypass valve out and clean it. Make sure Remove the piston cooling valve, clean it and make
that no residue from old sealant is left behind. sure that the old seal ring does not remain in the oil
filter bracket.

3
3

Check that the new bypass valve is correct, as in the

specification. Please refer to the “Technical Data”
chapter. Install the new bypass valve with new seals.

4
Start the engine and check sealing. Check in the specifications that the piston cooling
valve has the correct color marking. Please refer to
the “Technical Data” chapter.

22020
Piston cooling valve, change
1
Install the new valve together with a new O-ring (1) on
the oil filter bracket.

IMPORTANT! Check extremely carefully that

the O-ring does not come loose from the pis-
ton cooling valve when the valve is installed.
Grease the ring to make it stay in place bet-
ter on the valve.

5
Install the lid with a new seal ring.
Connect the sensor connector.

6
Start the engine and check sealing.
Clean the oil filter bracket and disconnect the sensor
connector. Remove the cover over the piston cooling
valve. Remove the seal ring.

159
Repair instructions Group 22: Lubrication system

22002 D12D-A MP, D12D-B MH and D12D-C/E/G MP/MH

(not classifiable engines)
Lube oil pressure, check 1
Special tools: 999 6398, 999 6591. A multimeter can
also be used together with pressure measurement
module 999 8496* and hose 999 8493.
* Note. The tool has been deleted from our range, but can of
course be used if it is already in the workshop.

D12C-A MP, D12D-A MH

Remove the plug from the oil filter housing and install
a nipple (part. No. 947899) together with a copper
washer.

2
Install connection nipple 999 6591 and connect pres-
sure gauge 999 6398.

3
Make sure that the engine is warmed up to operating
temperature and measure the oil pressure at idling-
Undo the joining piece with the oil pressure sensor to and operating speeds.
access the plug on the joining piece. Remove the
plug and install connection nipple 999 6591. Connect
pressure gauge 999 6398. 4
Compare the measured oil pressure values with
those noted in the specification. Please refer to work-
2 shop manual “Technical Data”.
Make sure that the engine is warmed up to operating
temperature and measure the oil pressure at idling-
and operating speeds.

3
Compare the measured oil pressure values with
those noted in the specification. Please refer to the
“Technical Data” chapter.

160
Group 22: Lubrication system Repair instructions

D12D-B/C/E/G MH (classifiable engines) 22002

1 Piston cooling oil pressure,
check
Special tools: 999 6398, 999 6591. A multimeter can
also be used together with pressure measurement
module 999 8496* and hose 999 8493.
* Note. The tool has been deleted from our range, but can of
Start the engine. Close the valve (vertical position) on course be used if it is already in the workshop.
the sensor housing for lube oil pressure (lower housing).
1

Remove the plug from the oil filter housing. Install

connection nipple 999 6591 on the oil filter housing
Remove the hose between the oil filter housing and and connect pressure gauge 999 6398.
sensor housing. Install connection nipple 999 6591 on
the oil filter housing and connect pressure gauge
999 6398. 2
Make sure that the engine is warmed up to operating
temperature and measure the oil pressure at operat-
3 ing speed.
Make sure that the engine is warmed up to operating
temperature, and measure the oil pressure at idling
and operating speeds. 3
Compare the measured oil pressure values with
those noted in the specification. Please refer to the
4 “Technical Data” chapter.
Compare the measured oil pressure values with
those noted in the specification. Please refer to the
“Technical Data” chapter.

161
Repair instructions Group 22: Lubrication system

22111 7

Lube oil pump, change

Note. On engines with a deep sump, the oil pump can
be removed together with the front main bearing cap
through the inspection opening in the sump.

1
Pump the engine oil out.
Please refer to “Engine oil, changing”, page 52.

2
Remove the cover over the vibration damper.

3
Engine with deep sump: Remove inspection hatches
from the sump. Remove the baffles. Remove the lube oil pump from the main bearing cap.

4 8
Engine with shallow sump: Remove the sump. Clean the oil strainer.
IMPORTANT! If the engine has been installed with NOTE: Check that there are no cracks in the oil strain-
Volvo Penta minimum dimensions for service access, er.
the oil strainer must be removed before the sump can
be removed.
9

5
Remove the oil strainer and then the oil supply pipe.

Install the new lube oil pump on the main bearing cap.
Torque the screws to 25 Nm (18.4 lbf.ft.) and angle
tighten 90°.
NOTE: Remember to install the screws for the main
Remove the screws for the front main bearing cap and
bearing cap before the lube oil pump is screwed to
lift the lube oil pump down together with the main
the bearing cap.
bearing cap.

162
Group 22: Lubrication system Repair instructions

10 14
Clean the main bearing cap and lubricate it with en-
gine oil.

11

NOTE: If the oil strainer and oil supply pipe were re-
moved before the sump was lifted away, the sump
with oil strainer and oil supply pipe must be slid in un-
Install the lube oil pump and make sure that the teeth der the engine before you start on the next step.
on the idler gear engage with the crankshaft gear.
Torque the main bearing cap. 15
Stage 1: 150 ±20 Nm (111 ±15 lbf.ft.).
Stage 2: Angle tightening 120° ±5°.

12
Check the oil supply pipe for cracks in the flange
against the fitting.

13
Install new seal rings for the oil strainer and oil supply
pipe.

Put the oil supply pipe in place.

163
Repair instructions Group 22: Lubrication system

16 19
Screw the oil strainer to the lube oil pump and install Install the oil pan with a new seal. Please refer to
the associated clamp. Torque the screws in the lube page 95.
oil pump to 27 Nm (20 lbf.ft.).

17 20
Engine with deep sump: Install the inspection hatches
on the sump.

21
Top the engine oil up as specified. Please refer to the
“Technical Data” chapter.

22
Crank the engine with the starter motor as instructed,
until the oil pressure gauge gives a reading. Please
Stage 1: Tighten the oil supply pipe union in the cylin-
refer to “Instructions for operating the starter motor”
der block until it bottoms (approx. 10 Nm / 7.4 lbf.ft.).
on page 47.
Stage 2: Angle tighten as follows:
– new oil supply pipe ........................................... 180°
– oil supply pipe that has been installed
23
previously .......................................................... 60°
Start the engine and do a function and sealing check.

18
Engine with deep sump: Install the baffles. Torque 27 Nm
(20 lbf.ft.).

164
 Group 23: Fuel system

34300 4

Control unit, change

1
NOTE: Cut the current with the main switch.

IMPORTANT! The system must be disconnect-

ed from system voltage and the starter key(s)
must be in position 0 when the engine control
unit connector(s) is/are disconnected or connect-
ed.

2
Remove the front bracket for the heat exchanger.
Alternative: Remove the heat exchanger. Please refer
to “Heat exchanger, removal / installation” on page
213. Unto the cooling loop from the control unit and hang it up.
Note. The illustrations show the control unit when the NOTE: Do not remove the fuel pipes from the cooling
heat exchanger has been removed. loop.

If the cooling loop also has to be removed: Close the

3 fuel taps. Carefully clean round the cooling loop fuel
unions. Undo the fuel pipes (1) to and from the cool-
ing loop and plug the fuel pipes.
NOTE: Put a collection vessel beneath the control
unit, to collect the fuel in the hoses/cooling coil.

D12D-A MP/MG, D12D-B MH and D12D-C/E/G: Pull

the catch (1) upwards and remove the connector from
the power supply unit (“Power module”). Remove the
power supply unit.

D12C-A, D12D-A, D12D-B MH and D12D-C/E/G:

Undo the 2 x 36 pin connector from the control unit.
Press the catch (1) in and move the locking loop (2)
upwards.

165
Repair instructions Group 23: Fuel system

Move the cooling loop (if it is not left hanging on the

D12D-B/D/F/H MP:
engine) and the rubber pads to the new control unit.
Move the locking loop (1) backwards and remove the
appropriate connector. NOTE: Remove any paint on the control unit surfaces
that come into contact with the cooling loop, for best
possible cooling.
NOTE: The cooling loop fixing screws are self-tap-
ping (there are no tapped threads in the control unit).
Make installation easier by tightening the screws and
forming threads in the control unit before it is installed
on the engine.

6 8

Remove all four screws on the control unit. Install the control unit on the engine.*
NOTE: A decal with various engine data has been Tighten the cooling loop to the control unit if it is still
placed on the control unit. hanging on the engine.
* Note. on the D12D-B/D/F/H MP, the cooling loop has the fuel
unions facing forwards.

166
Group 23: Fuel system Repair instructions

9 10
Connect the connector(s) to the control module.

Connect the fuel pipes (1) with to the control unit with
D12C-A, D12D-A, D12D-B MH and D12D-C/E/G: new seals, if the pipes have been undone. Open the
Move the locking loop (1) down until the catch (2) fuel taps.
locks. Tighten the clamp.

11

D12D-B/D/F/H MP: D12D-A MP/MG, D12D-B MH and D12D-C/E/G:

Lock each connector by moving the locking loop (2) Install the power supply module. Connect the connec-
forwards. Tighten the clamps. tor to the power supply module.

167
Repair instructions Group 23: Fuel system

12 Identifying the engine control unit

Vent the fuel system if the fuel pipes have been un-
done. Please refer to “Fuel system, venting”, page On D12D-A MP, D12D-B/C/D/E/F/G/H, identification
187. is done via the CHASSIS ID number.

IMPORTANT! The CHASSIS ID number on the

13 decal must coincide with the CHASSIS ID num-
D12D-A MP, D12D-B/C/D/E/F/G/H: ber on the protective cover above the engine,
Do an auto-configuration. Please refer to “Workshop and the decals on each PCU and HCU.
manual Group 30, Electrical System”.
NOTE: The engine can not be started until auto-con-
figuration has been done.*
* Note. When the engine control unit is changed (or re-pro-
grammed), fault codes MID 187, PSID 17 and MID 164, PSID 99
“Data bus network, configuration fault” will be generated.

14
Start the engine and do a leakage and function
check.
If the new engine control unit has recently been pro-
grammed:
Check if the fault codes related to the engine control
unit are generated after starting.

D12D-A MP, D12D-B MH and D12D-C/E/G

D12D-B/D/F/H MP

168
Group 23: Fuel system Repair instructions

23315 Other engines:

Supply pressure, checking

Special tools: 999 6398, 999 6666

IMPORTANT! Clean the union and hose careful-

ly before they are connected to the fuel system.
The unit injectors are sensitive and can easily
be damaged by contamination.

1
Clean the filter bracket carefully.

2
Engine with switchabe fuel filter:

Remove vent nipple and install connection nipple

999 6666. Connect pressure gauge 999 6398.

3
Make sure that the control is in neutral.

4
Start the engine and run at about 1000 rpm until the
supply pressure in the pressure gauge has been sta-
bilized.

5
Compare the maximum feed pressure achieved with
the value in “Technical data”.
Remove vent nipple and install connection nipple
999 6666. Connect pressure gauge 999 6398. The measured value is the supply pressure after the
filter.

6
After you have completed the check, remove the
measurement equipment and vent the fuel system.
Please refer to “Fuel system, venting”, page 187.

169
Repair instructions Group 23: Fuel system

23315 23390
Bypass valve, checking Bypass valve, changing
Special tools: 999 6398, 999 6666 1
Clean carefully round the bypass valve.
1
2
Drain the fuel system. Please refer to “Fuel system,
draining” on page 51.

Remove the vent screw from the front of the cylinder

head and install connection nipple 999 6666 and pres-
sure gauge 999 6398.

Remove the bypass valve.

2
Pump with the hand pump on the supply pipe and
read the pressure on the pressure gauge when the 4
bypass valve opens. Clean the fuel hose connections.
Compare the opening pressure with the specification Install a new bypass valve and seals.
in “Technical Data”.
NOTE: If the bypass valve is tightened too hard, it
can be deformed.
NOTE: If the bypass valve opens at a pressure which
is less than that specified in “Technical Data”, the
supply pressure will be too low. 5
Vent the fuel system. Please refer to “Fuel system,
If the opening pressure is higher than the measured
venting”, page 187.
supply pressure, it is not probable that the bypass
valve is the reason for the low supply pressure. Try to
fault trace other components in the fuel system. 6
The bypass valve does not seal completely. This Run the engine at raised idle for 10 minutes to get
means that the pressure in the system falls when the any remaining air out of the system.
engine is shut off. The high capacity of the feed pump
allows feed pressure to be built up again in a few sec-
7
onds when the engine is cranked before starting.
Do a leakage check.

170
Group 23: Fuel system Repair instructions

23301 3
Check the feed pump vent valve (3). If the valve is
Feed pump, changing (valves) faulty, too much of the feed pressure will go back to
the fuel tank.
Before the feed pump is removed, the feed pump
valves must be carefully checked and cleaned since Follow the instructions to check its function.
there could be contamination which is not visible to
the naked eye. 4
NOTE: Before the valve seats are cleaned with com-
pressed air, all fuel pipes must be undone from the
feed pump to prevent air from being forced into the
fuel system.

Special tools: 999 8339, 999 8494

Other special equipment: Spacer sleeve 158 7821

Remove the return hose to the tank from the fuel pump.
NOTE: Do not remove the venting valve. Install a nut
(M10) with seal washers instead, together with the
original hollow screw.

5
Start the engine and check the supply pressure. If the
pressure is within tolerance with the vent valve dis-
connected, this indicates that the vent valve is releas-
1. Safety valve
2. Check valve for hand pump ing the supply pressure.
3. Vent valve (return valve)

Unscrew the safety valve plug (1) on the feed pump

and remove the valve ball and spring. Check the
valve ball sealing surface for damage and contamina-
tion. Change the valve ball as necessary.

2
Check the hand pump valve (2) in the same way as
the safety valve. Change the valve ball as necessary.

171
Repair instructions Group 23: Fuel system

6 23311
Feed pump, changing
1
Carefully clean around the fuel pump. Undo the fuel
pipes.

Remove the vent valve.

Note. The vent valve does not seal as completely as
a non-return valve. It is possible to blow right through
it from both directions when it is not faulty. Remove the feed pump.

Press the valve ball from the lower side with a suit-
able object, to check that the valve ball springs back 3
and has not got stuck (see the figure). Clean the mating surface on the timing gear plate.
Press the valve ball back from the other side if the
valve ball does not spring back.
4
Finish off by cleaning the valve by blowing through it
with compressed air from both sides.
Then press the valve ball from underneath again.
Change the venting valve if the valve ball does not
spring back, despite being cleaned.

7
Install the venting valve and return pipe to the tank.
Use new seal washers.
Check the supply pressure again.
Check that the O-ring (1) on the drive shaft is undam-
aged and correctly placed. Lubricate it with engine oil.
Check that the drive shaft coupling (2) is lubricated
with graphite grease.

172
Group 23: Fuel system Repair instructions

5 23312
Feed pump, renovation
Special tools: 998 6173, 998 6177, 999 5028, 999 6626

The position figures in the illustration below refer to in

the following instruction.

Check all components for wear and damage.

Change all worn or damaged components. Clean oth-
er components very carefully.

1
Check that the new feed pump drive fits the timing
gear. Install the feed pump with a new gasket and a
new O-ring on the drive shaft.
NOTE: The screw (1) is coated with thread sealant.
During renovation: Apply thread locking fluid (Volvo
Penta part. no 840 879) to the screw if it has not been
replaced by a new one.

6
Connect the fuel pipes with new seals.

7
Vent the fuel system with fuel filter. Please refer to
“Fuel system, venting”, page 187.

8
Run the engine at raised idle for 10 minutes to get
any remaining air out of the system.

9 Remove the valves (4 and 8).

Do a leakage and function check.

2
Remove the screws (1) and take the housing apart.

3
Remove the pump gears (7 and 9). Remove the O-
ring (5) and seal (6).

173
Repair instructions Group 23: Fuel system

6
Dip the pump impellers (7 and 9) in diesel oil and in-
sert them into the housing.

Remove the seal rings from each end of the pump im- 7
peller shaft (2 and 3) with 998 6173 and extractor Install a new seal (6). Check that the seal is correctly
998 6177. Use sleeve drift 999 6626. aligned in the groove, and screw the housing togeth-
er.

8
5 Install the valves (4 and 8). Use new seal washers.

9
Install a new O-ring (5) on the polygon hub.

10
Insert protective plugs in the fuel pipe connections.

Press the pump shaft inner and outer seals (3 and 2)

with mandrel 999 5028.
Press the inner seal as far as it goes, and press the
outer seal ring to be flush with the housing.
NOTE: The seal rings must be aligned with the seal-
ing lips away from each other.

174
Group 23: Fuel system Repair instructions

23710, 23711 3

Unit injector, change

NOTE: Once a unit injector has been changed on en-
gines D12D-B/D/F/H MP, the new unit injector’s trim
code must be programmed into the engine control unit.
Please refer to the instruction on the page 182.

Special tools: 388 3671, 388 3672, 999 0185,

999 8249, 999 8250, 999 8251, 999 8511, 999 8599
Remove the rocker arm bridge screws.
1 NOTE: Undo the screws progressively, equal amounts
each time, to avoid bending the rocker shaft.

Remove the valve cover.

IMPORTANT! Do NOT use air-powered tools

when removing the valve cover. The studs can
come undone (rotate) which would damage the
cable harness for the unit injectors.
2
Remove the joining piece for oil supply to the rocker
Lift off the rocker arm bridge with lifting tool 999 0185.
NOTE: If lifting devices are not available: At least two
people should help to remove the rocker arm bridge,
to avoid personal injury and material damage.

arm bridge.

175
Repair instructions Group 23: Fuel system

5 8

Mark up and remove the valve yoke for the unit injec-
tor to be changed.
D12C-A, D12D-A, D12D-B MH and D12D-C/E/G:
Remove the electric cables from the unit injector.
6
IMPORTANT! Be very careful when the cables
Empty the fuel gallery in the cylinder head as instruct-
on the unit injector are undone or screwed
ed. Please refer to “Fuel system, draining” on page 51.
down.

NOTE: Clean very carefully round the unit injec-

tor to be changed.

D12D-B/D/F/H MP:
Remove the connector from the unit injector.

176
Group 23: Fuel system Repair instructions

IMPORTANT! Drain some of the coolant before

the unit injector is removed. If the unit injector is
stuck, there is a risk that the copper sleeve
could come with it, which would risk getting wa-
ter in the engine.

10
Remove the screw for the unit injector fixing yoke and
remove the unit injector.

D12D-B/D/F/H MP:
Install puller 999 0006 on the unit injector.
Put the puller fork in the groove in the injector and
lock the arm with the screw on the side. Fix the puller
by screwing the center screw down towards the ball
hole in the injector.
Install slide hammer 999 0013 and loosen the injector.

11
D12C-A, D12D-A, D12D-B MH and D12D-C/E/G: Check to ensure that no contamination has got into
Use crowbar 9998511 if necessary. the fuel galleries in the cylinder head.
Install protective sleeve 999 8249 on the unit injector.

177
Repair instructions Group 23: Fuel system

12 Installation
13

Install a protective plug No. 999 8251 in place of the Clean the unit injector hole in the cylinder head.
unit injector, if the unit injector is not going to be in- Use cleaning kit 999 8599. Install cleaning sleeve
stalled at once. 999 8580 in the injector well, and fix it with holder
980 8607. Clean carefully with brush 980 8570 and
IMPORTANT! Very clean conditions are re-
extension 980 8616.
quired!
Note. As an alternative, brush 981 2546 can be used
together with two seal rings No. 999 8250.

178
Group 23: Fuel system Repair instructions

14 15

D12D-B/D/F/H MP:
NOTE: If a new unit injector is installed:
Install new seal rings on the unit injectors and check
Note the trim code of the new unit injector and the
that they are correctly located.
cylinder involved, before installation.
Use installation socket 388 3671* for the top O-ring,
The code consists of six characters and is noted on
and installation socket 388 3672* for the lower O-ring.
the unit injector (the trim code is “5D008A” in the fig-
ure above). Lubricate the rings with engine oil.
* Note. Applies to all engines except D12D-B/D/F/H.
Note. One a unit injector has been changed, the new
trim code for the relevant cylinder must be pro-
grammed into the engine control module. Please refer
to “Unit injector, programming the trim code” on page
182. 16
Install unit injectors and yoke. Center the unit injector
between the valve springs.
Tighten the unit injector as follows:
NOTE: Different tightening torques are used, depend-
ing on whether the unit injector copper sleeve has
been replaced or not.
New copper sleeve:
First tightening
Stage 1: 20 ±5 Nm (15 ±4 lbf.ft.).
Stage 2: Angle tightening 180° ±5°.
Note. Undo the screw for the unit injector fixing yoke
before doing the second tightening.
Second tightening
Stage 1: 20 ±5 Nm (15 ±4 lbf.ft.).
Stage 2: Angle tightening 60° ±5°.

Old copper sleeve:

Stage 1: 20 ±5 Nm (15 ±4 lbf.ft.).
Stage 2: Angle tightening 60° ±5°.

179
Repair instructions Group 23: Fuel system

17 18

Oil the valve yoke and camshaft lobes with engine oil.
Install the valve yokes in their original places.
Note. Put valve yokes without guide pins with the
oval hole over the valve nearest to the camshaft.
If a valve yoke is changed, use a yoke of the same
design as was previously installed.

D12C-A, D12D-A, D12D-B MH and D12D-C/E/G:

Connect the electric cables for the unit injectors.
Torque the nuts to max. 1.5 ±0.5 Nm (1.1 ±0.4 lbf.ft.).

IMPORTANT! Be very careful when tightening

the nuts. If the nuts are tightened too hard, the
solenoid valve terminals can be damaged,
19
which means that the entire unit injector must
be changed.

Lift the rocker arm bridge into place, using lifting tool
999 0185.
Make sure that the valve yokes and rockers are cor-
rectly aligned with each other.
NOTE: If lifting devices are not available: At least two
D12D-B/D/F/H MP:
people should help to install the rocker arm bridge, to
Connect the connector to the unit injector. Press it in
avoid personal injury and material damage.
until a clear “click” is heard.

180
Group 23: Fuel system Repair instructions

20 23

Tighten the rocker bridge screws progressively, equal

amounts each time, to avoid bending the rocker shaft.
Make sure that the rocker arm shaft is correctly
aligned on the guide sleeves in the camshaft bearing
beds, and tighten the screws so that the shaft rests
on the bearing beds.
Then torque the rocker arm bridge screws to the val- IMPORTANT! Cut off superfluous old sealant
ue specified on the torque table in the specifications. with a sharp knife. Do not pull it off!
Please refer to the “Technical Data” chapter.
Apply a 2 mm (0.08") thick string of sealant 1161231
in the joints between the upper timing gear cover and
21 the cylinder head.
Adjust the valves and unit injectors. Please refer to NOTE: The valve cover must be installed within 20
“Valves and unit injectors, adjustment”, page 106. minutes after applying the sealant.

22

Thread new O-rings over the oil supply pipe for the
rocker arm bridge. Put the pipe in the joining piece
and install the joining piece with pipe. Check that the
O-rings on the pipe and the ring under the joining
piece are correctly aligned.

181
Repair instructions Group 23: Fuel system

24 25
If any stud has come loose, it must be removed and
coated with Volvo Penta thread-locking fluid (part No.
116 1053) before it is re-installed and torqued to 40
±3 Nm (29.5 ±2 lbf.ft.).

26
Fill up with coolant and vent the system if the coolant
has been drained.

27
Vent the fuel system. Please refer to “Fuel system,
venting” on page 187.

Install the valve cover and tighten the nuts with 28

20 ±2 Nm (15 ±1.5 lbf.ft.). Please refer to the torque Run the engine at raised idle for 10 minutes to get
schedule in “Technical Data”. any remaining air out of the fuel system.
Note. Grease the rubber sleeves beside the nuts with
lubricant (part No. 114 1699), to ensure that the valve 29
cover gasket has the correct press force (it may be Do a leakage and function check.
possible to use soapy water). Clean the rubber
sleeves before lubricating them, if the rubber sleeves
are re-used.
NOTE: It is important that the valve housing nuts are
torqued as in the schedule, to prevent the housing
from cracking, and to prevent the studs in the cylinder
head from coming loose.
Check the cable harness for the unit injectors, if one
of the valve housing studs came loose from the cylin-
der head when the nuts were removed. There is a
risk that the cable holder on the stud might have fol-
lowed the rotation and damaged the cable harness.

Unit injectors, programming the

trim code
(only applies to D12D-B/D/F/H MP)

Special tool: VODIA 383 8619

One a unit injector has been changed, a new trim

code* for the relevant cylinder must be programmed
into the engine control module. This is done by
means of the VODIA tool.
* Note. The trim code defines each unit injector’s tolerances for
the engine control unit.

182
Group 23: Fuel system Repair instructions

1 9
Connect VODIA and switch on the current for the engine. Programming must be reported back to Volvo Penta
within 28 days.

2 Log in to Volvo Penta Partner Network’s web site:

Go into the “Service and maintenance” menu in VO-
DIA. http://www.vppn.com

3 10
Select “Parameter, programming”. Choose “VODIA” in the left-hand menu.

4 11
Press “Play”. Choose “ Report software” in the left-hand menu.

5 12
Select the cylinder number where the new unit injec- Follow the instructions for “Report software/parame-
tor has been installed. ter”. Click “Report software/parameter”.

Unit injectors, renovation

Note. For unit injectors for all engines except
D12D-B/D/F/H MP*.

Special tools: 384 9611, 388 3670, 388 3671,

388 3672, 388 3673, 388 3674

NOTE: Inspection of unit injectors requires special

equipment* and training. If this is not available, the
work must be done by an authorized Diesel work-
shop.
Enter the trim code for the new unit injector and press We offer the following general advice, to avoid unnec-
“OK”. essary removal and changing of unit injectors:
Note. Each unit injector has a unique trim code. The Unit injectors should not be checked unless there are
code consists of six characters and is noted on the clear indications that one functions abnormally, such
unit injector (the trim code is “5D008A” in the example as considerably increased exhaust smoke.
above). Setting pressure and sealing are the most important
factors in testing.

7 NOTE: Observe the greatest possible cleanliness in

Close “Parameter, programming”. work on unit injectors. Dirt particles can damage the
injector and lead to malfunctions. Install protective
caps on all unions to prevent dirt from getting in.
8 Components in the fuel system should always be
VODIA will ask you to “Turn off the main switch”, then overhauled in a special room, separate from other en-
follow the instructions. gine service work.
* These engines are equipped with a different type of unit injector
which can not at present be renovated.
** The injector tester should be able to provide a pressure of up to
38 MPa (380 bar / 5512 lbf/in2).

183
Repair instructions Group 23: Fuel system

1 3

Clean the unit injector as necessary, using lint-free

cloths which have first been dipped in cleaning fluid.
Check that no contamination has got into the fuel
holes (by the arrows).
Note. Suck the holes out with a suction pistol after
cleaning them with a cloth.
NOTE: Cleaning with compressed air must not be
done under any circumstances.

1. Injectors
2. Tension nut
3. Guide pin
4. Compression spring
5. Spacer washer
6. Joining piece
7. Compression screw
8. Adapter plate

Fix assembly plate 388 3670 in a vise. Fix the unit in- Carefully lift the tension nut (2) away. Remove the in-
jector to the plate, with the nozzle upwards. Remove jector (1), adapter plate (8), compression screw (7)
the O-rings from the unit injector. and joining piece (6) complete with compression
Undo the tension nut on the injector. Use torque spring (4).
wrench 384 9611 together with ring wrench set Remove the compression spring. Remove the spacer
388 3674. washer (5) with a suitable magnet.

184
Group 23: Fuel system Repair instructions

4 7
Clean the components carefully in an ultrasound bath
(app. 10 min at 45°C / 113°F).
NOTE: Cleaning must only be done in an ultrasound
bath. Injectors must not be cleaned with metal objects
under any circumstances.
Note. Dilute the cleaner with water at a ratio of 1:20.
The injector body must be kept as vertical as possible,
with the injector needle downwards during cleaning.
NOTE: Make sure that the injector needle and injector
sleeve which belong with each other, and fit together,
are not mixed up if several injectors are cleaned at the
same time. To avoid mixing up, the injectors should be
put in an injector stand or in different compartments.

5
Rinse the components with cold cleaning compound,
blow them dry with compressed air and then dip them
in clean test oil after cleaning. Put the joining piece (6) on the adapter. Put the spac-
er washer (5) in the joining piece (6) and insert the
compression spring (4). Put the compression screw
(7) on the spring, with the tapered section facing up-
wards. Install the adapter plate (8) and check that the
guide pins (3) engage.
Assemble the injector (1). Carefully put the tension
nut (2) in place and tighten it by hand.

6
8

Put adapter 388 3673 in assembly plate 388 3670.

Use torque wrench 384 9611 together with ring wrench

set 388 3674 and torque to 95 ±5 Nm (70.1 ±4 lbf.ft).

185
Repair instructions Group 23: Fuel system

9 11
Test the injector in an injector tester.
Note. The injector opening pressure can be corrected
by means of spacer washer (5), which is available in
various sizes.
For opening pressure/setting pressure, please refer
to “Technical Data” in the workshop manual.

WARNING! Be careful when testing injectors,

avoid getting the fuel jet from an injector on un -
protected parts of your body. The jet has such
powerful penetration ability that it can force its
way in under your skin and cause blood poison-
ing (septicemia).

10

Install new O-rings on the unit injector. Use installa-

tion socket 388 3671 for the large O-ring, and installa-
tion socket 388 3672 for the smaller O-ring.

Put the nozzle on assembly plate 388 3670 after it has

been checked and approved. Remove the tension nut
and carefully transfer the complete nozzle from the
adapter to the unit injector.
Check that the guide pins in the adapter plate engage
on the joining piece, and carefully put the tension nut
(2) in place. Tighten the tension nut by hand.
Use torque wrench 384 9611 together with ring
wrench set 388 3674 and torque to 95 ±5 Nm (70.1
±4 lbf.ft).

186
Group 23: Fuel system Repair instructions

Venting the fuel system 4

1
Clean around the vent nipples on the cylinder head
and fuel filter bracket. Remove the protective cap(s)
from the venting nipple(s)

Transfer the hose the vent nipple on the cylinder head

and vent in the same way as for the fuel filter bracket.

5
Run the engine at raised idle or with the power take-
off engaged for about 10 minutes to get any remain-
ing air out of the system.

6
Do a leakage and function check.
Vent the fuel system with fuel filter. Connect a trans-
parent plastic tube between the venting nipple(s) (1)
on the fuel filter bracket and a collection vessel.
Single filter: Open the venting nipple. Twin filter (following filter change in operation)
Twin filters: Open the venting nipple for one of the 1
filters. Remove the protective cap from vent nipple (1) and
Press the hand pump (2) until air-free fuel flows out. open the nipple ½ – 1 turn.
Tighten the venting nipple while fuel is flowing out.
Twin filters: Vent the other filter in the same way. 2
Slowly turn the knob (3) to normal operating position,
but not all the way. This allows a limited flow of fuel to
3
the filter, which drives the air out through the venting
Remove the hose and install (a) protective cap(s) on
nipple. Tighten the venting nipple while fuel is flowing
the vent nipple(s).
out.
NOTE: No more venting is normally needed when the
fuel filter is changed.
3
Vent the other filter in the same way.

187
 Group 25: Inlet and exhaust system

25113 Installation
5
Seal, inlet manifold, changing Install the inlet manifold, charge air cooler, air filter
1 and expansion tank. Please refer to “Cylinder liner,
Empty the cooling system. Please refer to “Cooling installing”, points 58-71, starting on page 116.
system, draining”, page 49.
6
2 Top the coolant up as specified. Please refer to “Tech-
Do the work specified under the heading of “Cylinder nical Data” and “Cooling system, filling” on page 227.
head, removing”, points 1 to 7. Please refer to pages
54 –55. 7
Start the engine and do a function and sealing check.
3

25111
Gasket, exhaust manifold,
changing
Remove the filler cap on the expansion tank (1). Re-
move the seal ring (2) with drain hose and put them Special tool: 999 8487
on one side.
NOTE: Pull the drain hose up a bit and put the seal 1
ring on the valve cover. The drain hose could other- Empty the cooling system. Please refer to “Cooling
wise be difficult to install again. system, draining”, page 50.

4 2
Do the work specified under the heading of “Cylinder Do the work specified under the heading of “Cylinder
head, removing”, points 8 and 9. Please refer to page head, removing”, points 1, 3, 11–16, 18–21 and 23.
56. Please refer to page 55 and pages 57– 60.

188
Group 25: Inlet and exhaust system Repair instructions

3 Installation
5
Install the exhaust manifold and turbocharger. Please
refer to “Cylinder head, installing”, points 41 and 44-
46, on pages 112-113.

6
Install the clamp between the charge air pipe and tur-
bocharger, using a new gasket (please refer to the
figure under point 3 in the left-hand column).

7
Do the work specified under the heading of “Cylinder
head, installing”, points 68 and 72. Please refer to
pages 118-119.
Undo the clamp beside the compressor housing.
8
Do the work specified under the heading of “Cylinder
4 head, installing”, points 48 to 57. Please refer to pag-
es 114-116.

9
Top the coolant up as specified. Please refer to “Tech-
nical Data” and “Cooling system, filling”, page 227.

10
Start the engine and do a function and sealing check.

Remove the gasket(s) between the exhaust manifold

and cylinder head. Clean the mating surfaces carefully.

189
Repair instructions Group 25: Inlet and exhaust system

Pressure drop indicator, check 25502

1 Charge air pressure, checking

Please refer to the “Diagnostic key” user manual for
instructions about doing “Charge air pressure, check”.

Alternative method 1
Special tools: 999 6398, 999 6591.

Remove the pressure drop indicator. Check the pres-

sure drop indicator by sucking out air (partial vacuum)
until the indicator shows red. Press the indicator but-
ton in to reinstate the pressure drop indicator.

2
When the air filter is blocked and pressure drop oc-
curs, the pressure drop indicator shows this by indi-
cating red. Change the pressure drop indicator if it
does not function as in item 1 above.

3
Install the pressure drop indicator.

Install connection nipple 999 6591 at the front edge of

the inlet manifold (lower union). Connect pressure
gauge 999 6398 to the nipple.

2
Run the engine at full power (maximum operating
speed) and read off the charge air pressure. If full
power can not be developed, the pressure will be
considerably lower.
Please refer to the “Technical Data” chapter for the
charge air pressure.

190
Group 25: Inlet and exhaust system Repair instructions

Alternative method 2 Wastegate valve, check

Special tools: Multimeter together with pressure mea- (only applies to D12D-B/D/F/H MP)
surement module 999 8496*, 999 6591 and 999 8493.
NOTE: This is only a functional check of the dia-
* Note. The tool has been deleted from our range, but can of phragm and valve, and should not be used for adjust-
course be used if it is already in the workshop.
ment.
1 The wastegate valve must not be adjusted. If any fault
is discovered, the entire wastegate valve must be
changed as a unit. An incorrectly adjusted wastegate
valve can cause engine failure. The engine warranty
ceases to be valid if the valve has been adjusted.

Pressurize the wastegate valve to the specified value.

The valve should then move: A = B – C mm.

Check values:
Pressurization ............................. 2.05 ±0.02 bar
(29.7 ±0.3 psi)
Valve movement (A) app. ........... 4.0 ±0.2 mm
(0.1575" ±0.0079")

Install connection nipple 999 6591 at the front edge of

the inlet manifold (lower union). Connect hose No.
999 8493 to pressure measurement module 999 8496,
connected to a multimeter.

2
Run the engine at full power (maximum operating
speed) and read off the charge air pressure. If full
power can not be developed, the pressure will be
considerably lower.
Please refer to the “Technical Data” chapter for the
charge air pressure.
A = Valve movement
B = Not pressurized
C = Pressurized

191
Repair instructions Group 25: Inlet and exhaust system

Turbocharger, bearing Checking the radial clearance

Special tools: 999 9683, 999 9696
clearance, check
Axial clearance and end float are normally only 1
checked during renovation, when you want to mea-
sure the amount of wear in the unit.

Checking the end float

Special tools: 998 9876, 999 9696

Install dial gauge 999 9683 on the magnetic stand. Put

the measurement tip on the round surface on the com-
pressor turbine’s locknut.

2
Press the compressor turbine down at the same time
as the other end of the shaft (the exhaust turbine end)
is moved upwards. Zero the dial gauge.

3
Move the compressor turbine upwards, at the same
Put magnetic stand 999 9696 with dial gauge 998 9876 time as the other end of the shaft is pressed down.
on a suitable place. Read off the radial clearance on the dial gauge. Then
Put the measurement tip on the center of the shaft. rotate the shaft 90° and repeat the measurement.
NOTE: Be careful to ensure that the shaft is not rotat-
ed during measurement.
2
Press the exhaust turbine (A) in by hand. Zero the
dial gauge. Permissible radial clearance (compressor side): Max.
0.92 mm (0.0362").
3 Change/overhaul the turbocharger if the wear limits
Press the compressor turbine (A) in by hand. Read have been exceeded.
the end float on the dial gauge.

Permissible end float: max. 0.18 mm (0.0071").

Change/overhaul the turbocharger if the wear limits
have been exceeded.

192
Group 25: Inlet and exhaust system Repair instructions

25512 3

Turbocharger, changing
Always find out and rectify the reasons for why the
turbocharger has failed, before a new turbocharger is
installed.
One condition for satisfactory functioning of the turbo-
charger is that the engine’s oil system and inlet sys-
tem are kept in good condition, i.e. that oil changes
and filter changes are done at specified times, the
right grade of oil is used and the air filter is correctly
maintained. The first action should therefore be to
check the engine oil, and if necessary, change the oil
filters and preferably run the engine for a few minutes
before the new oil filter is installed.
Blow any rust and soot flakes out of the exhaust pipe
when the turbocharger is changed. Flakes of soot can
damage the exhaust turbine on the new unit. Undo the clamp beside the compressor housing.

It is important that the inlet pipe from the air filter is

also cleaned. Pieces from a failed turbine wheel can 4
remain in place and cause instant destruction of the Do the work specified under the heading of “Cylinder
new turbocharger. head, removing”, points 19 to 21. Please refer to pag-
es 58 and 59.
1
Close the sea cock and empty the cooling system.
Please refer to “Cooling system, draining”, page 49.

Installation
2
Do the work specified under the heading of “Cylinder 5
head, removing”, points 1 and 3. Please refer to page Clean the mating surfaces.
54.

6
Do the work specified under the heading of “Cylinder
head, installing”, points 45 and 46. Please refer to
page 113.

7
Install the clamp between the charge air pipe and tur-
bocharger, using a new gasket (please refer to the
figure under point 3 above).

8
Do the work specified under the heading of “Cylinder
head, installing”, points 68, 48 and 72. Please refer to
pages 118, 114 and 119.

9
Start the engine and do a function and sealing check.

193
Repair instructions Group 25: Inlet and exhaust system

Exhaust back pressure, Alternative method

checking Special tools: Multimeter together with pressure mea-
surement module 999 8496*, 999 6591 and 999 8493.
Special tools: 999 6398, 999 6591. * Note. The tool has been deleted from our range, but can of
course be used if it is already in the workshop.
1
1

Install connection nipple 999 6591 on the exhaust pipe

bend, by the turbocharger. Connect hose No. 999 8493
to pressure measurement module 999 8496, connect-
Install connection nipple 999 6591 on the flange on the ed to a multimeter.
exhaust pipe bend. Connect pressure gauge 999 6398
to the nipple.
2
Run the engine at full load and max speed long
2 enough to obtain a stable value during the check.
Run the engine at full load and max speed long Check that the back pressure does not exceed the
enough to obtain a stable value during the check. permissible value. Please refer to “Technical Data” in
Check that the back pressure does not exceed the the workshop manual.
permissible value. Please refer to “Technical Data” in
the workshop manual.

194
 Group 26: Cooling system

26211, 26000 4

Coolant pump, change

Special tool: 999 8487

1
Close the sea cock and empty the cooling system.
Please refer to “Cooling system, draining”, page 49.

2
Remove the right-hand oil filter as necessary. Use
puller No. 9998487 and collect all spilled oil in a col-
lection vessel.

3
Remove the coolant pipe between the thermostat and
the oil cooler.

Remove the oil pipes between the upper and lower oil
filter brackets.

Remove the two coolant pipes from the thermostat

housing.

195
Repair instructions Group 26: Cooling system

6 8

Undo the coolant pipe between the bracket under the

turbocharger and the thermostat housing. Remove the coolant hose between the coolant pump
and the bracket under the heat exchanger.

7 9

Remove the cable to the temperature sensor (1). Remove the screws for the coolant pipe between the
Remove the thermostat housing with associated cool- coolant pump and the expansion tank. Also loosen
ant pipe. the clamp at the front and fold the pipe to one side.

NOTE: Cover over the hole for the coolant pump.

196
Group 26: Cooling system Repair instructions

10 12
Clean the mating surface on the cylinder block. Be
careful to ensure that no contamination gets into the
timing gear.

13
Install the new coolant pump with a new O-ring.
NOTE: Turn the coolant pump a further 1/4 turn. In-
sert the coolant pump drive gear into the timing gear.
When the gear engages, turn counter-clockwise and
press the coolant pump in until it reaches its correct
position.

Undo the two coolant pipes from the coolant pump.

11 14

Unscrew the coolant pump fixing screws and lift the Tighten the coolant pump.
pump away.

197
Repair instructions Group 26: Cooling system

15 17

Install the coolant pipe between the coolant pump and Install the thermostat housing with associated pipe for
the expansion tank. Use new seals. Also install the the coolant pump. Use new seals. Grease the seals
clamp at the front of the engine. with lubricant (part No. 1141699).
Connect the cable to the temperature sensor (1).
NOTE: Do not forget to install the clamp for the cable
harness on the thermostat housing.

16 18

Install the coolant pipe between the bracket under the

Install the coolant hose between the coolant pump turbocharger and the thermostat housing. Use new
and the bracket under the heat exchanger. Use new seals.
seals.

198
Group 26: Cooling system Repair instructions

19 21
Install new oil filters if necessary.

22
Top the engine oil up as specified, if necessary.
Please refer to the “Technical Data” chapter.

23
Top the coolant up as specified. Please refer to “Tech-
nical Data” and “Cooling system, filling” on page 227.

24
Install the coolant pipe between the oil cooler and the
Start the engine and do a function and sealing check.
coolant pump, using new seals.

20

Install the oil pipes between the brackets, with associ-

ated clamps.

199
Repair instructions Group 26: Cooling system

21111 Pressure testing unit, checking

Cylinder head, pressure 4

testing
Cylinder head removed

Special tools: 998 6485, 999 0160, 999 6662,

999 8266, 999 8666*, 999 8668*
* Note. 999 8666 includes: 980 9696, 980 9697 and 999 9699.
999 8668 includes: 980 9698, 980 9700 and 980 9701.

1
Wash the cylinder head in a washing bath.

2
Fix the cylinder head to engine stand 998 6485, using
fixture 999 0160.
Check pressure testing device 999 6662 as follows,
before it is taken into service:
3 Connect the pressure testing device to the com-
pressed air mains. Set the pressure gauge to 100
kPa (14.5 psi) with the reduction valve.
Note. The knob on the reduction valve can be locked
with a lock ring which is moved axially.
NOTE: Always observe the relevant safety rules.

Clean the mating surfaces of the cylinder head.

Install seal washers 999 8266 and 980 9696 on the cylin-
der head, using the cylinder head screws (M16, 13 pcs.).
Install sealing washer 980 9697 with air union instead
of the thermostat housing.
Install the seal washer in the hole for the temperature
sensor (at the rear of the cylinder head).
Remove the pipe unions and install plugs.
Close the shut-off tap. The pressure in the pressure
gauge must not fall during 2 min. for the pressure
testing unit to be regarded as being reliable.

200
Group 26: Cooling system Repair instructions

6 9

Check that the knob on the reduction valve is screwed

out.
Remove the hanging fixture from the cylinder head.
Immerse the cylinder head in a water bath (+70°C /
+158°F).

7
10
Connect air to the pressure testing unit. Open the tap.

11
Set the reduction valve knob so that a pressure of
50 kPa (7.3 psi) is shown on the pressure gauge.
Maintain the pressure for 1 minute.

12
Then raise the pressure to 150 kPa (21.8 psi). Lock
the reduction valve knob with the locking ring.
Connect the hose from the pressure gauge to the con- Close the tap.
nection washer. Wait for one or two minutes, then check whether the
pressure falls, or if water bubbles rise in the water
bath.
8
Remove the cylinder head from the equipment stand.

201
Repair instructions Group 26: Cooling system

13 26271, 26000
Piston thermostat, replacement
1
Close the sea cock and empty the cooling system.
Please refer to “Cooling system, draining”, page 49.

Eliminate excess pressure in the cylinder head by un-

screwing the valve on the reduction valve.

14
Take the cylinder head up out of the water bath. In-
stall the suspension fixture.

Undo the coolant pipe.

15
Install the cylinder head in the equipment stand.

16 3
Blow all the water out of the cylinder head. Be extra
careful with the fuel galleries.
Make sure that no dirt gets into the fuel galleries,
since this could damage the unit injectors.

17
Remove all seal washers.

18
Remove the plugs from the thermostat housing.
Install the hose unions.

Undo the coolant pipe.

202
Group 26: Cooling system Repair instructions

4 8

Remove the screws for the thermostat housing.

5
Remove the thermostat. Check that by-pass valve (A)* does not bind.
Check that the hole (Ø 4 mm / 0.157") in the plug
6 (B)** is not blocked.
Clean all mating surfaces. * D12D-C/D/E/F/G/H MP, plus D12D-A MP and D12D-B as from
engine No. 1012445526.
** D12D-C/E/G MH and late model D12D-B MH.

7 9

Late model engines: By-pass valve (1) or plug with hole Install the cover on the thermostat housing.

Install the new piston thermostat with a new seal ring.

203
Repair instructions Group 26: Cooling system

10 26273
Thermostat, function check
1
Close the sea cock and empty the cooling system.
Please refer to “Cooling system, draining”, page 49.

2
Remove the piston thermostat. Please refer to “Piston
thermostat, changing” on page 202.

Install the coolant pipe on the cover for the thermostat

housing, using a new seal ring.

11

Closed thermostat

Install the coolant pipe.

Open thermostat

12
Top the coolant up as specified. Please refer to “Tech- Put the thermostat in a large saucepan full of water
nical Data” and “Cooling system, filling” on page 227. and heat up to the specified temperature when it
should open. Please refer to the “Technical Data,
Thermostat” chapter.
13
Start the engine and check for leaks.
4
If the thermostat does not open at the specified tem-
perature, it must be changed.

204
Group 26: Cooling system Repair instructions

25060 4

Charge air cooler, removal /

installation
Fresh water cooled charge air cooler
1
Disconnect the current with the main switch and
check that the engine is not connected to system volt-
age.

2
Close the sea cock and empty the cooling system.
Please refer to “Cooling system, draining” on page
49.
Remove the vent pipe/hose between the charge air
cooler and the expansion tank. Undo the charge air
3 cooler and remove it.

WARNING! The charge air cooler for D12C-A,

D12D-A, D12D-B MH and D12D-C/E/G has
sharp edges.

5
Remove the old O-rings and clean the mating surface
against the inlet manifold.
NOTE: Be careful to prevent contamination from get-
ting into the engine’s inlet manifold.

Remove the cover over the charge air cooler.

Installation
6
D12C-A, D12D-A, D12D-B MH, D12D-E MG: Install
new seal rings on the coolant pipes that are connect-
ed to the charge air cooler. Grease the seal rings with
lubricant (part No. 1141699) to make installation of the
charge air cooler easier.

205
Repair instructions Group 26: Cooling system

IMPORTANT! On D12C-A, D12D-A, D12D-B MH

and D12D-C/E/G, check that the protective tape
under the lower edge of the charge air cooler is
still in place. The edge is very sharp!
D12C-A, D12D-A, D12D-B MH and D12D-C/E/G:
Install the charge air cooler with new seals against the
inlet manifold. Place the bracket for the cover plates
on the charge air cooler and tighten the screws a bit at
Tighten the charge air cooler in the following order:
a time to ensure that it comes into the correct posi-
tion. 1. Check that the stud on the rear edge of the charge
Install the vent pipe between the charge air cooler and air cooler is in the groove in the sheet metal
the expansion tank. bracket.
Tighten the four front fixing screws.
2. Install nut (A) on the stud at the rear of the charge
8 air cooler and tighten it against the air filter brack-
et.
3. Tighten screw (B) at the rear of the charge air
cooler.

D12D-B/D/F/H MP:
Install the charge air cooler together with the charge
air pipe between the charge air cooler and the turbo-
charger. Use a new seal against the inlet manifold.
Note. Align the hose clamps so they can be tightened
through the holes in the bracket.

206
Group 26: Cooling system Repair instructions

Install the cover over the charge air cooler.

9
Fill up with coolant and vent the system. Please refer
to “Cooling system, filling” on page 227.

10
Start the engine and do a function and sealing check.
Tighten the charge air pipe to bracket (A). Tighten the
V-clamp (B) at the union with the compressor hous-
ing.
Tighten the hose clamps under the charge air cooler
and install the vent pipe between the charge air cool-
er and the expansion tank.
Install the panel between the charge air cooler and
the air filter bracket.

207
Repair instructions Group 26: Cooling system

25061 5
Install the charge air cooler. Please refer to the
Charge air cooler, cleaning instruction on the previous page.

Fresh water cooled charge air cooler

6
The charge air cooler is connected to the fresh water Top the coolant up as specified. Please refer to
system. This means that the water side is cleaned “Cooling system, filling”, page 227.
when the engine cooling system is cooled. Please re-
fer to “Cooling system, cleaning” on page 226.
7
Note. Water can condense in the charge air cooler
Start the engine and do a function and sealing check.
during operation. The condensate is drained via a
hose connected to a nipple under the rear of the inlet
manifold.

WARNING! If a large amount of water flows out

of the drain hole, from the inlet pipe, the charge
air cooler must be removed and proof tested.

Air cooled charge air cooler*

* Note. Applies to D12D-A/E MG (RC).

1
Empty the cooling system. Please refer to “Cooling
system, draining”, page 49.

Check that the drain nipple is not blocked. 2

Remove the engine cooling package and lift the
2 charge air cooler off.
Close the sea cock and empty the cooling system.
Please refer to “Cooling system, draining”, page 49. 3
Clean the charge air cooler both inside and outside.
3 Clean the inside with degreaser. Rinse both the air
Remove the charge air cooler. Please refer to and coolant pipes with fresh water blow the charge air
“Charge air cooler, removal/installation” on page 205. cooler clean with compressed air (or leave it to drain
off).
NOTE: Be careful to prevent contamination from get-
ting into the engine’s inlet manifold.
4
Install the charge air cooler and the radiator package.
4
Clean the charge air cooler both inside and outside.
Clean the air passages with degreaser. Rinse both the 5
air and coolant pipes with fresh water and blow the Top the coolant up as specified. Please refer to
charge air cooler clean with compressed air (or leave it “Cooling system, filling”, page 227.
to drain off).

IMPORTANT! D12D-B/D/F/H MP: 6

The charge air cooler must not be disassem- Start the engine and do a function and sealing check.
bled.

208
Group 26: Cooling system Repair instructions

Charge air cooler, pressure 4

Pump the pressure up to 150 kPa (1.5 bar / 21.8 psi).
testing
Charge air cooler for D12D-B/D/F/H MP
5
Special tools: 384 9613, 885 536, 885 539 Lower the charge air cooler down into a water bath.
Make sure that the air loop is fully filled with water
and that no air is left inside.
1
Close the sea cock and empty the cooling system.
Please refer to “Cooling system, draining”, page 49.
6
2 Pressure test the charge air cooler for 1 minute and
Remove the charge air cooler. Please refer to check that no air comes out of the air loop or from the
“Charge air cooler, removal/installation” on page 205. joints.

7
Repeat the leakage check a few times to be sure that
Leakage test, water side there is no suspicion of leakage.

Install expander plugs 885 536 and 885 539 on the

charge air cooler. Connect hand pump 384 9613 to
expander plug 885 536.
Plug the union for the venting hose.

209
Repair instructions Group 26: Cooling system

Fresh water cooled charge air cooler 6

(other engines) Lower the charge air cooler down into a water bath.

Special tools: 885 379, 885 380, 999 6662

7
Pressure test the charge air cooler for 5 minutes and
1 check that no air comes out of the charge air cooler.
Close the sea cock and empty the cooling system.
Please refer to “Cooling system, draining”, page 49.
8
Repeat the leakage check a few times to be sure that
2 there is no suspicion of leakage.
Remove the charge air cooler. Please refer to
“Charge air cooler, removal/installation” on page 205.

Leakage test, air side Leakage test, water side

3 9

Install sealing plate 885 380 on the charge air cooler,

using the existing screws.
Grease the seal rings for plugs No. 885 379 with lubri-
4 cant (part No. 1141699). Install the plugs with the ex-
Check pressure testing device 999 6662 before it is isting screws for the charge air cooler, as in the figure
taken into service. Please refer to the instruction on above.
the page 200.

5
Connect the pressure testing unit to the compressed
air mains and raise the pressure to 150 kPa (1.5 bar /
21.8 psi).

210
Group 26: Cooling system Repair instructions

10 13
Lower the charge air cooler down into a water bath.
Make sure that the air loop is fully filled with water
and that no air is left inside.

14
Pressure test the charge air cooler for 1 minute and
check that no air comes out of the air loop or from the
joints.

15
Repeat the leakage check a few times to be sure that
there is no suspicion of leakage.

Install the plug with sealing washer (included in 885 379)

on the junction for the vent pipe on the charge air cooler.

11 Air cooled charge air cooler*

Check pressure testing device 999 6662 before it is
taken into service. Please refer to the instruction on * Note. Applies to D12D-A/E MG (RC).
the page 200.
Special tools: 885 231, 885 232, 999 6662

12 1

Connect the pressure testing unit to the compressed Remove the charge air pipe between the turbo and the
air mains and fill up with compressed air to 150 kPa charge air cooler. Install pressure plate 885 232 and
(1.5 bar / 21.8 psi). tighten the clamp.

211
Repair instructions Group 26: Cooling system

2 5
Connect the pressure test device to the compressed
air system and open tap (B). Set reduction valve (A)
so that a pressure of 100 kPa (14.5 psi) is shown on
the pressure gauge. Close tap (B).

6
The pressure must not fall for two minutes for the
charge air cooler with unions to be regarded as sealing
correctly.
NOTE: If the pressure falls, check that no leakage oc-
curs at the charge air pipe unions. Spray or brush wa-
ter and washing up liquid on the unions to ensure that
there is no leakage.

7
Change the charge air cooler if the pressure falls, al-
though the unions do not leak. Repeat the leakage
test to check whether the charge air cooler leaks.

8
Shut the compressed air off after pressure testing.
Unscrew the reduction valve (A) and release the air.

9
Remove pressure testing device 999 6662 and pres-
Remove the charge air pipe between the inlet manifold sure plate 885 231. Install the charge air pipe to the
and the charge air cooler. Install pressure plate inlet manifold, using new seal rings. Tighten the
885 231 to the junction and tighten the clamp. clamp.

3 10
Check pressure testing device 999 6662 before it is Remove pressure plate 885 232. Install the charge air
taken into service. Please refer to the instruction on pipe between the turbocharger and the union. Tighten
the page 200. the clamp.

4 11
Check that the tap (A) on the reduction valve is Start the engine and check for leaks.
screwed out. Connect pressure test device 999 6662
to the union on the pressure plate.

212
Group 26: Cooling system Repair instructions

26112, 26000 4

Heat exchanger, removal and

installation
1
Close the sea cock and empty the cooling system.
Please refer to “Cooling system, draining”, page 49.

Undo the coolant pipe at the rear of the heat exchanger.

Undo the connection flange at the front of the heat ex-

changer.

3 5

Remove the coolant hose(s) between the charge air Remove the sea water pipe between the reverse gear
cooler and the heat exchanger. oil cooler and the heat exchanger.

213
Repair instructions Group 26: Cooling system

6 9

Unscrew the screws for the heat exchanger and re-

move it.
Remove the left-hand bracket.
NOTE: The heat exchanger is heavy. If no lifting de-
vice is available, 2 people should join forces to lift the
7 heat exchanger.

Installation
10
Install the taps and unions for the heat exchanger.
Use new seals.

11

Remove the right-hand bracket.

Install the heat exchanger but do not tighten it until all

pipes have been installed and are in their correct po-
sitions.
NOTE: The heat exchanger is heavy. If no lifting de-
vice is available, 2 people should join forces to lift the
heat exchanger.
D12D-B/D/F/H MP: Undo the union with the priority
valve under the heat exchanger.

214
Group 26: Cooling system Repair instructions

12 14

Install the seat water pipe between the heat exchanger D12D-B/D/F/H MP: Connect the coolant hose to the
and the reverse gear oil cooler, but do not tighten it. heat exchanger, and tighten the hose clamp.
Other engines: Connect the coolant pipe to the heat
exchanger, but do not tighten it. Use a new seal ring.

13 15

Connect the coolant pipe to the heat exchanger, but Connect the flange on the front of the heat exchanger,
do not tighten it. Use a new seal ring. but do not tighten it. Use a new O-ring.

16
Tighten all water pipes. Tighten the heat exchanger
NOTE: To avoid incorrect assembly, tighten all the
water pipes first, then tighten the heat exchanger.

215
Repair instructions Group 26: Cooling system

17 20

Install the right-hand bracket on the heat exchanger. Install the cover over the charge air cooler.

18 21
Top the coolant up as specified. Please refer to “Tech-
nical Data” and “Cooling system, filling”, page 227.

22
Do a leakage and function check.

Heat exchanger, cleaning

The water side is cleaned when the engine cooling
Install the left-hand bracket on the heat exchanger. system is cooled. Please refer to “Cooling system,
cleaning” on page 226.
19
1
Close the sea cock and empty the cooling system.
Please refer to “Cooling system, draining”, page 50.

2
Remove the heat exchanger. Please refer to “Heat
exchanger, removal and installation” on page 213.
NOTE: The heat exchanger insert (seawater side)
can also be cleaned with the heat exchanger still on
the engine, once the two end pieces have been re-
moved.

D12D-B/D/F/H MP: Install the pipe with

the priority valve between the charge air cooler and
the coolant pump. Use new seals.

216
Group 26: Cooling system Repair instructions

3 5
Clean the entire length of the heat exchanger insert.
Use fresh water and suitable brushes. Flush the pipes
and keep brushing until no more loose particles come
away with the water. Also flush and clean the outside
of the insert. Also clean the housing and the end caps.

6
Check the zinc anodes in the end caps. Change the
zinc anodes if more than 50% of their original size
has been used up. If not, clean the zinc anodes to re-
move the oxide layer before re-installing them.
IMPORTANT! Use an emery cloth for cleaning.
Do not use steel tools, since this could impair
the galvanic protection.
Make sure that good metallic contact is obtained be-
Remove the end pieces from the heat exchanger. tween the anode and the casting during installation.
(First remove the screws on the end pieces, then the
two screws for the insert).

4 7

Remove the O-rings (2 pcs at the front, one at the Install the insert in the housing, using new seal rings
rear) and press the insert out.
NOTE: The insert can only be pressed out backwards
since it has a flange at the rear edge.
The insert can also be pressed out of the housing by
screwing two M10 screws into the threaded holes in
the flange.

217
Repair instructions Group 26: Cooling system

8 Fresh water side

4

Install the end caps, using new seal rings.

26010
Heat exchanger, pressure
testing
Special tools: 885 381*, 999 6662 Install pressure plates 885 381 with seals as in the fig-
ures above. Use the existing screws.

* Note. Cut off part of the rubber seal on the seal washer without
union nipple (hatches area on the figure below). The washer
would otherwise catch on the end cap and cause leakage.

1
Close the sea cock and empty the cooling system.
Please refer to “Cooling system, draining”, page 49.
D12D-B/D/F/H MP: Install a cover* over the remaining
opening in the heat exchanger housing.
2
* Use cover (part. no 382 7303) with O-ring (part. no 925 255).
Remove the heat exchanger. Please refer to “Heat Note. These components are installed under the coolant pump
exchanger, removal and installation” on page 213. and can be taken off when needed, and used together with a
couple of screws (part. no 946173), (M8 x 20) during pressure
testing.
3
Check pressure testing device 999 6662 before it is
taken into service. Please refer to the instruction on
the page 200.

218
Group 26: Cooling system Repair instructions

5 10
Connect the pressure testing unit 999 6662 to the Lower the heat exchanger down into a water bath.
compressed air mains and fill up with compressed air Make sure that the water channel that is not pressur-
to 150 kPa (1.5 bar / 21.8 psi). ized is completely filled with water.

6 11
Lower the heat exchanger down into a water bath. Pressure test the heat exchanger for 1 minute. Check
Make sure that the water channel that is not pressur- that no air comes out of the water ducts or from the
ized is completely filled with water. joints.

7 12
Pressure test the heat exchanger for 1 minute and Repeat the pressure test if you suspect leakage.
check that no air comes out of the water channel or
from the joints.

8
Repeat the pressure test if you suspect leakage.

Seawater side
9 Coolant filler cap, change
NOTE: Always change the coolant filler cap on an en-
gine that has been overheated. The pressure relief
valve in the cap (plastic cap) might have been dam-
aged by the heat.

Install pressure plates 885 381 with seals as in the fig-

ures above. Use the existing screws.
Connect the pressure testing unit 999 6662 to the
compressed air mains and fill up with compressed air
to 150 kPa (1.5 bar / 21.8 psi).

219
Repair instructions Group 26: Cooling system

22311 5

Oil cooler, engine, removal /

installation
Special tool: 999 8487

1
Empty the cooling system. Please refer to “Cooling
system, draining” on page 49.

2
Disconnect the current with the main switch and check
that the engine is not connected to system voltage.

3 Remove the pipe between the coolant pump and the

oil cooler cover.
NOTE: Cover over the hole for the coolant pump.

Remove all oil filters. Use puller No. 999 8487. Collect
all spilled oil in a collection vessel.

Disconnect the sensor, undo the fuel filter bracket and

fold it to one side.

Remove the oil pipes between the upper and lower oil
filter brackets.

220
Group 26: Cooling system Repair instructions

7 9

Remove the sensor bracket and the bracket for the Remove the inner coolant pipe by the coolant pump
coolant filter, with associated supply pipe. and by the bracket under the turbocharger.

10
8

Remove the outer coolant pipe by the thermostat Remove the cable to the temperature sensor (1).
housing and by the bracket under the turbocharger. Remove thermostat housing, with coolant pipe.
NOTE: Cover the hole for the pipe union on the cool-
ant pump, to protect against dirt and foreign particles.

221
Repair instructions Group 26: Cooling system

11 14
Remove the oil cooler.

15
Remove the oil cooler seal rings and the gasket in the
cover over the oil cooler. Clean the mating surfaces
on the cover.

16
Clean and pressure test the oil cooler. Please refer to
the instructions on pages 225-226.

Remove the starter motor.

Installation
12 17

Remove the coolant pipe under the turbo. Clean and install new seal rings in the cylinder block.
Torque the oil cooler to 27 ±4 Nm (20 ±3 lbf.ft.).

13
Unscrew the remaining screws and remove the cover 18
over the oil cooler. Be careful, so it does not fall down Put a new seal in the cover and lift it into place.
and damage the oil cooler. Torque the screws to 24 ±4 Nm (18 ±3 lbf.ft.).
Please refer to the torque schedule in “Technical
Data”. Also install the sensor bracket on the cover.

222
Group 26: Cooling system Repair instructions

19 22

Install the coolant pipe under the turbo. Install the pipe between the coolant pump and the
bracket under the turbocharger, using new seal rings.

20
Install the starter motor.

21 23

Install the thermostat housing and associated pipes Install the pipe between the thermostat housing and
with new seals. the bracket under the turbocharger, using new seal
NOTE: Do not forget to install the clamp for the cable rings.
harness on the bottom right-hand screw on the ther-
mostat. Install the cable for the temperature sensor
on the exhaust manifold.

223
Repair instructions Group 26: Cooling system

24 26

Install the bracket to the coolant filter with associated Install the hoses on the bracket for the by-pass filter.
pipes. Use new seal rings. Install the fuel filter bracket and connect the sensor.
NOTE: Do not forget the sensor bracket and the two
clamps for the cable harness. Check that the cables
27
reach all the sensors and that the cable harness ends
up behind the coolant filter.

25

Install the oil pipes and screw the clamps down.

28
Check that all cables from the cable harness are cor-
rectly connected.

29
Install the pipe between the coolant pump and the Install new oil filters.
cover over the oil cooler with a new seal ring and
seal.

224
Group 26: Cooling system Repair instructions

30 22312
Top the engine oil up as specified. Please refer to the
“Technical Data” chapter. Oil cooler, engine, pressure
testing
31
Top the coolant up as specified. Please refer to “Tech- Special tools: 999 6662, 999 6845
nical Data” and “Cooling system, filling”, page 227.
1
Remove the oil cooler. Please refer to “Oil cooler, en-
32 gine, Removal/installation” on page 220.
Start the engine and check for leaks.
2
Clean the oil cooler. Please refer to previous section:
“Oil cooler, engine, cleaning”.

3
Check pressure testing device 999 6662 before it is
taken into service. Please refer to the instruction on
the page 200.

22312
Oil cooler, engine, cleaning
The oil cooler is connected to the fresh water system.
This means that the water side is cleaned when the
engine cooling system is cooled. Please refer to
“Cooling system, cleaning” on the next page.

1
Remove the oil cooler. Please refer to “Oil cooler, en- Install screw clamps 9996845 and check that they are
gine, removal/installation” on page 220. correctly installed.

2
Clean the oil cooler both inside and outside. Clean
the oil channels with degreaser. Rinse both the oil
and coolant pipes with fresh water blow the oil cooler
clean with compressed air (or leave it to drain off).

225
Repair instructions Group 26: Cooling system

5 2
Flush the fresh water and sea water sides with fresh
water.

3
Fill the fresh water side with a mixture of radiator
cleaner (kit No. 114 1658) and fresh water (please re-
fer to the instruction included with the kit).
NOTE: Alternately, the fresh water system can be
filled with a mixture of 15-20% Volvo Penta glycol and
water which is drained after 1-2 days’ operation.

4
Empty the fresh water system. Then flush the fresh
Check that the reduction valve knob on pressure water side with a mixture of neutralizer (kit No.
gauge 999 6662 is fully screwed out and that the 114 1658) and fresh water (please refer to the instruc-
pressure gauge shows 0. Connect the pressure test- tion included with the kit).
ing unit to a screw clamp 999 6845.
Lower the oil cooler into a vessel containing water at
room temperature. 5
If any contamination is still left, repeat the cleaning
Increase the pressure to 250 kPa (2.5 bar / 36.3 psi) procedure until the system is completely free from
with the knob on the reduction valve. contamination.
Wait for at least one minute.
NOTE: If an even stream of air bubbles comes from 6
the oil cooler matrix, there is leakage and the oil cool- Fill up with new coolant when the fresh water system
er should then be changed. is completely free from contamination.

IMPORTANT! Use a coolant mixture recom-

mended by Volvo Penta. Please refer to the
“Coolant” heading in the “Technical Data” chap-
ter.

IMPORTANT! A coolant mixture with at least

40% concentrate (“Volvo Penta Coolant”) must
be used all year round, even if there is no risk
for freezing. This is to ensure that the engine is
adequately protected against corrosion and
26000 cavitation damage.
Cooling system, cleaning NOTE: Mix the correct volume in advance, to ensure
that the system is filled.
Part numbers: Kit 114 1658

WARNING! Chemicals for the cooling system

are hazardous (dangerous to swallow).

1
Close the sea cock and empty the cooling system.
Please refer to “Cooling system, draining”, page 49.

226
Group 26: Cooling system Repair instructions

Cooling system, filling Open the venting tap beside/on the turbocharger when
an empty system is being filled, or if the coolant level
WARNING! Open the pressure cap and venting has fallen for any reason, so that it is no longer visible
tap very carefully if the engine is hot. Steam or through the filling opening.
hot coolant could spray out.
IMPORTANT! Only use the coolant and mixture 3
ratio recommended by Volvo Penta. Remove the filler cap on the expansion tap and fill up
with Volvo Penta recommended coolant mixture.*
Fill slowly, to allow the air which is forced out a
1 chance to flow out of the venting nipples or filling
NOTE: Filling should be done with the engine station- hole. Also ensure that the heating system, tap water
ary. heater etc. if connected to the engine cooling system,
Mix the correct volume of coolant in advance, to en- are also vented (open the heater control valve).
sure that the system is filled. Please note that if a * Please refer to the “Technical Data” chapter for coolant. “Cooling
heating system, water heater etc. is connected to the system”.
engine cooling system, a correspondingly greater
amount of coolant will be needed.
4
Close the vent tap(s) as and when air-free coolant
2 flows out.

5
Continue to fill up with coolant until the max level in
the expansion tank is met.

6
Wait for a few minutes so that the remaining air in the
engine can be evacuated.

7
Continue topping with coolant until the expansion tank is
completely full and the level does not fall any longer.

8
D12C-A, D12D-A, D12D-B MH and D12D-C/E/G: Venting tap
Warm the engine up.
IMPORTANT! Do not start the engine until the
system is vented and completely filled.

D12D-B/D/F/H MP: Venting tap

227
Repair instructions Group 26: Cooling system

9 26001
Stop the engine and let it cool. Check the coolant lev-
el. Top up as necessary up to the max. level (lower Coolant pressure, check
edge of the filler pipe) in the expansion tank.
Special tools: 999 6398, 999 6591

D12D-A/E MG with radiator (RC): 1

Other engines: Install connection nipple 999 6591 on the right side of
the cylinder block, in front of the coolant filter (please
refer to the figure). Connect pressure gauge
999 6398.

WARNING! Coolant will flow out when the plug

in the cylinder block is undone. Warning for
burns if the engine is hot.

2
Run the engine at maximum speed and read the cool-
ant pressure. Coolant pressure, please refer to
“Technical Data”.

228
Group 26: Cooling system Repair instructions

26001 4

Cooling system, pressure

testing
WARNING! Open the pressure cap very care-
fully if the engine is hot. Steam or hot coolant
could spray out.

Alternative 1:
Special tools: 999 6441, 999 6662

Check pressure testing device 999 6662 before it is

taken into service. Please refer to the instruction on
the page 200.
Connect the pressure test device to the compressed
air system and open tap (B). Set reduction valve (A)
1 so that a pressure of 70 kPa (10.2 psi) is shown on
Check that all hoses and clamps are undamaged. the pressure gauge. Close tap (B).

2 5
The pressure must not fall for two minutes if the
cooling system is to be regarded as being free from
leakage.

NOTE: Repeat the pressure test if there is any doubt

about whether the cooling system leaks or not.

Check that the tap on the reduction valve is screwed

out.

3
Replace the filler cap on the expansion tank with cov-
er No. 999 6441. Connect the pressure test device to
the nipple to cover.

Shut the compressed air off after pressure testing.

Eliminate excess pressure in the system by unscrew-
ing the valve on the reduction valve.

229
Repair instructions Group 26: Cooling system

7 4
Remove the pressure testing device. Pump up a pressure of about 70 kPa (10.2 psi).

8 5
Check the coolant level in the expansion tank. Install The pressure must not fall for two minutes if the
the ordinary filler cap. cooling system is to be regarded as being free from
leakage.

9 NOTE: Repeat the pressure test if there is any doubt

Start the engine and check carefully that no leakage about whether the cooling system leaks or not.
occurs.

6
Release the excess pressure and remove the pres-
sure testing unit.

Alternative 2:
7
Special tools: 384 9613 Check the coolant level in the expansion tank. Install
the ordinary filler cap.
1
Check that all hoses and clamps are undamaged.
8
Start the engine and check carefully that no leakage
2 occurs.
Check the coolant level in the expansion tank.

Replace the filler cap on the expansion tank with the

cap from pressure testing equipment 384 9613. Con-
nect the pressure test device to the union on the cover.

230
Group 26: Cooling system Repair instructions

26213 5

Sea water pump, change

1
Close the sea cock and empty the seawater system.
Please refer to “Cooling system, draining”, page 49.

Undo the inner fixing screw (1) a couple of turns.

Undo the lock screw (2) so that the tensioning screw
(3) can move freely. Remove the drive belt.

Remove the water inlet from the sea water pump.

3 6

Remove the water pipe between the seawater pump Remove the pulley.
and the heat exchanger.

4
Remove the covers over the alternator and vibration
damper.

231
Repair instructions Group 26: Cooling system

7 11
Insall the protective covers over the vibration damper
and alternator.

12

Remove the sea water pump.

8
Install the water pipe between the seawater pump and
the heat exchanger, using new seal rings.
NOTE: Grease the seal for the heat exchanger with lu-
bricant (part No. 1141699) to make installation easier.

13

Fix the old seawater pump in a vice etc. Remove the

nut from the timing gear wheel and pull the gear off
with a suitable puller. Install the timing gear wheel on
the new seawater pump.
Tightening torque: 200 ±30 Nm (147.5 ±22 lbf.ft.).

9
Install the new seawater pump with a new O-ring.
NOTE! Check that the O-ring is in the correct position
when installing.
Install the water inlet and the clamp on the sea water
10 pump. Use a new O-ring.
Install the pulley and the alternator drive belt. Tension
the belt with tensioner screw. It should be possible to
press the belts down about 5 mm between the pulleys
when the tension is correct.

232
Group 26: Cooling system Repair instructions

26214 6
Remove the deflector ring (10) from the output shaft.
Sea water pump, renovation
Seawater pump removed 7

Disassembly
Note. The figures in brackets refer to the figure on
page 235.

1
Mark up the positions of the pipe bends in relation to
the pump housing. Remove the pipe bends.

2
Remove the cover over the seawater pump together
with the O-ring. Pull the impeller out with a suitable
universal puller. Remove the rubber washer (19) from
the pump.

Pull the gear wheel off with a universal puller.

3

Remove the cam screw (5), camp disk (3) and wear
ring (7).

4
Mark up the position of the pump housing in relation
to the bearing housing. Undo the four screws and
carefully pull the pump housing. Remove the pump Remove the lock ring (15) in the bearing housing and
housing (4), support washer (6) and shaft seal (8) pull the shaft out with bearing.
from the pump shaft.

5
Tap the ceramic ring (9) with rubber cover out of the
pump housing. Use a suitable socket.

233
Repair instructions Group 26: Cooling system

9 Assembly
1

Pull the bearings off the shaft with a universal puller.

Grease the seal ring (11) with water-resistant grease
(Volvo Penta part. no 828250) and tap it into the
bearing housing.
Note. Put the old support washer (6) over the ring to
protect it. The side of the seal with the spring should
face inwards towards the bearing housing.

10 2

Tap the seal ring (11) out of the bearing housing with a Install the inner circlips on the pump shaft and press
suitable socket. the bearings on. Note. Mandrel 884167 can be used.
Alternatively, the bearings can be heated to about
11 100°C (212°F) and then tapped into place.
Inspect all components. Change worn or damaged Fill the bearings with grease (after they have cooled).
components.

234
Group 26: Cooling system Repair instructions

1. Lid 10. Thrower ring

2. O-ring 11. Seal ring
3. Cam disc 12. Ball bearing
4. Pump housing 13. Circlip
5. Screw 14. Bearing housing
6. Support washer 15. Circlip
Install the gear wheel and tighten it.
7. Wear ring 16. Pump shaft Tightening torque: 200 ±30 Nm (147.5 ±22 lbf.ft.).
8. Shaft seal with carbon ring 17. Gear wheel
9. Ceramic ring with rubber 18. Impeller
cover 19. Rubber washer

3 5

Install the pump spindle with bearing in the bearing Put the thrower ring (10) on the spindle closes to the
housing. Install the outer circlip (15). bearing housing.

235
Repair instructions Group 26: Cooling system

6 11
Moisten the rubber cover and install the ceramic ring Install the cam disk (3) and tighten it. Use white seal-
(9) with rubber cover in the pump housing. ant (Volvo Penta part. No. 114 1570).
NOTE: The sealing surfaces in the seal must not
come into contact with grease or be touched by your 12
fingers. Put a piece of clean plastic foil on a hammer Grease the pump housing with water resistant grease
handle and carefully press the ceramic ring into (Volvo Penta part No. 828 250).
place.
Note. The impeller can be put in hot water before in-
stallation, to facilitate installation.

13

Press the impeller in with a rotating movement (anti-

clockwise).
NOTE: On D12D and late model D12C, the pump
Install the pump housing on the bearing housing, as spindle has an internal thread (M8). Screw a stud into
previously marked, without tightening it. the spindle stub and press the impeller in with a nut
8 and washer.

Carefully place the shaft seal (8) on the pump shaft

and press the sleeve with carbon ring until contact is 14
made with the fixed ceramic ring in the housing. Install the rubber washer (spline seal) on the end of
Note. Mandrel 999 4034 can be used. the impeller. Install the cover with a new O-ring and
torque it to the standard torque value 10 Nm (7.4
lbf.ft.).
9
Install the support washer (6) over the seal and the
wear ring (7). 15
Install the pipe bends on the pump housing in accor-
dance with the previous markings.
10
Tighten the pump housing to the bearing housing, us-
ing standard torque values 24 Nm (18 lbf.ft.).

236
Group 26: Cooling system Repair instructions

Sea water pressure, check 44240, 44239

Special tools: 999 6398, 999 6591 Oil cooler, reverse gear,
cleaning
1
NOTE: The oil cooler insert (seawater side) can also
be cleaned with the oil cooler still on the engine, once
the sea cock has been closed and the two end pieces
have been removed.

1
Close the sea cock and empty the seawater system.
Please refer to “Cooling system, draining”, page 49.

Install connection nipple 999 6591 in the coolant pipe

between the sea water pump and the heat exchang-
er. Connect pressure gauge 999 6398.

WARNING! Sea water in the heat exchanger

will flow out when the plug in the sea water pipe
is undone. Sea water can also flow in if the im-
peller is faulty.

2
Run the engine at maximum running speed and read Remove the water pipe between the reverse gear oil
the sea water pressure. Please refer to the “Technical cooler and the exhaust pipe bend.
Data” chapter for sea water pressure.

Remove the oil hoses between the reverse gear and

the oil cooler.

237
Repair instructions Group 26: Cooling system

4 6

Remove the fixing screws. Remove the fixing screws and lift the oil cooler off.

7
NOTE: Empty the oil into a suitable collection vessel.

5 8

Undo the water pipe between the reverse gear oil cool- Remove both end wall covers.
er and the heat exchanger.

238
Group 26: Cooling system Repair instructions

9 12

Press the insert out.

10
Wash the insert in white spirit etc., and blow it clean
with compressed air. (or leave it to drain). Clean the
insides of the tubes and the end walls of the insert
with suitable brushes. Also clean the housing.

11
Install the components in reverse order. Use new
seal rings. Install the oil cooler.

239
Repair instructions Group 26: Cooling system

13 15

Install the oil hoses. Install the water pipe between the oil cooler and the
heat exchanger, with a new seal.

14

16
Open the sea cock. Start the engine and do a leak-
age check.

17
Check the oil level in the reverse gear. Top the oil up
as specified, if necessary. Please refer to the instruc-
tion manual for the relevant engine.

Install the water pipe between the oil cooler and the
exhaust pipe bend, with a new seal.

240
Group 26: Cooling system Repair instructions

44239 4
Lower the oil cooler down into a water bath. Make
Oil cooler, reverse gear, sure that the oil duct is fully filled with water and that
no air is left inside.
pressure testing
If there is any suspicion of leakage, oil cooler must be
pressure tested before it is changed.
5
Special tools: 885 381, 999 6662 Pressure test the oil cooler for 1 minute and check that
no air comes out of the oil channel or from the joints.
1
Remove the reverse gearbox oil cooler. Please refer to
“Cooling system, reverse gear, cleaning” on page 237.
6
Repeat the pressure test several times if you suspect
2 leakage.
Check pressure testing device 999 6662 before it is
taken into service. Please refer to the instruction on
the page 200.

Install pressure plates 885 381 with seals as in the fig-

ure above. Use the existing screws on each side of
the oil cooler.
NOTE: There are different screws on each flange
(M8 and 5/16").
Connect the pressure testing unit 999 6662 to the
compressed air mains and fill up with compressed air
to 150 kPa (1.5 bar / 21.8 psi).

241
 References to Service Bulletins

Group No. Date Refers to

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242
 Contents

A
About this Workshop Manual ................................ 6 Cylinder liners and piston, inspection ................... 70
Actions after lifting the engine .............................. 45 Cylinder liners, installation .................................... 88
Actions for low charge air pressure ....................... 42 Cylinder liners, removal ......................................... 71
B D
Bearing housing for camshaft, change .................. 144 Design and Function ............................................. 19
Before lifting the engine ........................................ 44
E
Before working in a boat ........................................ 44
Electric welding ..................................................... 46
Big end bearing journal, inspection ....................... 129
Engine fixture, fixing ............................................. 53
By-pass valve for oil cooler, change ..................... 158
Engine oil, changing .............................................. 52
Bypass valve, changing ........................................ 170
Excessive coolant temperature ............................ 43
Bypass valve, checking ........................................ 170
Exhaust back pressure, checking ......................... 194
Bypass valve, oil filter, change ............................. 157
Exposing the engine .............................................. 53
C
F
Camshaft setting, inspection ................................ 105
Fault tracing guide ................................................. 42
Camshaft ............................................................... 22
Fault tracing .......................................................... 38
Camshaft, wear check .......................................... 145
Feed pump, changing (valves) .............................. 171
Certified engines ................................................... 6
Feed pump, changing ............................................ 172
Charge air pressure, checking .............................. 190
Feed pump, renovation .......................................... 173
Compression test .................................................. 48
Flywheel housing, installing .................................. 90
Con rod, inspection ............................................... 130
Flywheel housing, removing .................................. 71
Con rods ................................................................ 22
Flywheel sensor distance, checking ..................... 153
Control unit, change .............................................. 165
Flywheel, removal/installation ............................... 151
Coolant filler cap, change ..................................... 219
Fuel system .......................................................... 26
Coolant losses ...................................................... 43
Fuel system, draining ............................................ 51
Coolant pressure, check ....................................... 228
Fuel system, filter change .................................... 51
Coolant pump, change .......................................... 195
Cooling system ..................................................... 34 G
Cooling system, cleaning ...................................... 226 Gasket, exhaust manifold, changing ..................... 188
Cooling system, draining ....................................... 49 Gear ring, change .................................................. 154
Cooling system, filling ........................................... 227 General advice for pressure measurement ........... 45
Cooling system, pressure testing ......................... 229 General advice on working with EVC engines ...... 45
Copper sleeve for unit injector, change ................. 140 General information ............................................... 6
Crankcase seal rear, change ................................ 155 Gudgeon pin bushing, check measurement .......... 130
Crankshaft and main bearings, installing .............. 90 Gudgeon pins, removal ......................................... 129
Crankshaft seal, front, change .............................. 156
H
Crankshaft ............................................................. 22
Heat exchanger, cleaning ...................................... 216
Crankshaft, inspection and overhaul ..................... 128
Heat exchanger, pressure testing ......................... 218
Crankshaft, removing ............................................ 71
Heat exchanger, removal/installation .................... 213
Cylinder head ........................................................ 20
Cylinder head, assembly ....................................... 139 I
Cylinder head, fixture installation .......................... 66 Identification numbers ........................................... 18
Cylinder head, fixture removal .............................. 96 Identifying the engine control unit ......................... 168
Cylinder head, installation ..................................... 96 Inlet and exhaust system ...................................... 32
Cylinder head, pressure testing ............................ 200 Instructions for operating the starter motor ........... 47
Cylinder head, removal .......................................... 54 Charge air cooler ................................................... 37
Cylinder head, valves, removal/installation .......... 131 Charge air cooler, cleaning .................................... 208
Cylinder liner seat, milling ............................. 121/126 Charge air cooler, pressure testing ....................... 209
Cylinder liner seats, inspection ............................. 120 Charge air cooler, removal/installation .................. 205
Cylinder liner ......................................................... 21

243
Alphabetical register

L Short block ............................................................ 19

Lock nuts .............................................................. 8 Short block, disassembly ...................................... 54
Lube oil pressure, check ....................................... 160 Spare parts ............................................................ 6
Lube oil pump, change ......................................... 162 Special tools ......................................................... 10
Lubrication system ................................................ 24 Standard times (Flat Rate) .................................... 6
Stiffening frame, removal downwards in sump ..... 146
M
Strength classes ................................................... 8
Main bearings, change all ..................................... 147
Supply pressure, checking ................................... 169
O Supply pressure, fault tracing ............................... 41
Oil cooler, engine, cleaning .................................. 225
T
Oil cooler, engine, pressure testing ...................... 225
Thermostat housing .............................................. 36
Oil cooler, engine, removal/installation ................. 220
Thermostat, function check .................................. 204
Oil cooler, reverse gear, cleaning ......................... 237
Timing gear ........................................................... 23
Oil cooler, reverse gear, pressure testing ............ 241
Timing gear, changing .......................................... 72
Our common responsibility ................................... 7
Too low coolant temperature ................................ 43
P Torque ................................................................... 8
Piston cooling nozzle, removing ........................... 68 Torque-angle tightening ........................................ 8
Piston cooling oil pressure, check ........................ 161 Turbocharger ........................................................ 32
Piston cooling valve, change ................................ 159 Turbocharger, bearing clearance, check .............. 192
Piston thermostat, replacement ............................ 202 Turbocharger, changing ....................................... 193
Piston with con rod, installing ............................... 91
U
Pistons and piston rings, measurement ............... 129
Unit injector, change ............................................. 175
Pistons .................................................................. 21
Unit injectors, programming of
Pistons, pre-assembly .......................................... 87
trim code ............................................................... 182
Pistons, removal ................................................... 69
Unit injectors, renovation ...................................... 183
Position of measurement connections on engine .... 39
Unit injectors, summary ........................................ 27
Pressure drop indicator, check ............................. 190
Unit injectors, working phases .............................. 28
R
V
Reduction valve and safety valve, change ........... 158
Valve guides, inspection ....................................... 133
References to Service Bulletins ........................... 242
Valve guides, replacing ........................................ 134
Repair instructions .............................................. 7/44
Valve seat, change ............................................... 136
Rocker mechanism, change ................................. 139
Valve seats, grinding ............................................ 137
S Valves and unit injectors, adjustment ................... 106
Safety Precautions ............................................... 3 Valves, grinding .................................................... 138
Safety rules for fluorocarbon rubber ..................... 9 Venting the fuel system ........................................ 187
Sea water pressure, check ................................... 237
W
Sea water pump, change ...................................... 231
Waste gate valve .................................................. 32
Sea water pump, renovation ................................. 233
Wastegate valve, check ....................................... 191
Seal, inlet manifold, changing ............................... 188
When working with chemicals, fuel and
Sealant .................................................................. 8
lubrication oil ......................................................... 44
Sealed crankcase ventilation ................................ 33

244
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Suggestion /Motivation: .............................................................................................................................................

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AB Volvo Penta
Service Communication
Dept. CB22000
SE-405 08 Gothenburg
Sweden
7745073 English 08– 2012