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Service Bulletin

Volvo Trucks North America


Trucks

D
Greensboro, NC USA

Date Group No. Page


This Service Bulletin replaces SB 211–59, “Cylinder
Head Overhaul, D12D” (3.06), publication no. 3.2006 211 59 1(6)
PV776–20175750.
Cylinder Head
Overhaul
D12D
Cylinder Head Overhaul

W2003779

This information covers procedures for overhauling the cylinder head of the VOLVO
D12D engine.

Contents
• “Special Tools” page 2
• “Cylinder Head, Overhaul” page 4

Note: Information is subject to change without notice.


Illustrations are used for reference only and may differ slightly from the actual
vehicle being serviced. However, key components addressed in this information are
represented as accurately as possible.

PV776-20176303 USA21776.ihval
Volvo Trucks North America Date Group No. Page
Service Bulletin 3.2006 211 59 2(6)

Special Tools
Tools

D
For special tools ordering information, refer to Tool Information, group 08.

9996159 9996161 9996222


Tap (for 9996161) Hydraulic Cylinder Foot Pump (for 9996161)

9998246 9998249 9998251


Valve Spring Removal/Install Tool Injector Protective Sleeve Cylinder Head Sealing Plug

J47364 9998260 88800011


Cylinder Head Adapter Plate Press Tool Valve Stem Seal Guide Sleeve

9998666 9996662
Cylinder head pressure test kit Pressure tester
Volvo Trucks North America Date Group No. Page
Service Bulletin 3.2006 211 59 3(6)

9998668
Thermostat housing pressure test kit
D J41503
Cylinder Head Lifting Fixture

9998266 J41989-A
Sealing washer Valve Spring Compressor Tool

2012-A
Head Stand
Volvo Trucks North America Date Group No. Page
Service Bulletin 3.2006 211 59 4(6)

D
Service Procedures
2111-04-04-01
Cylinder Head, Overhaul
Cylinder head removed

See also:

• “Cylinder Head Overhaul” page 1

You must read and understand the precautions and


guidelines in Service Information, group 20, "General
Safety Practices, Engine" before performing this
procedure. If you are not properly trained and certified
in this procedure, ask your supervisor for training
before you perform it.

One or more of the following procedures also may be


used as reference or included as part of this procedure;
for information, see Service Information, group 2:

• Cylinder Head, Replacement


• Cylinder Compression, Checking
• Valve Guide Wear, Checking
• Valve Guide, Replacement
• Valve Seat, Replacement (One)
• Valve, Adjustment
• Valve, Grinding
• Valve Seat, Grinding
Special tools: 9996159, 9996161, 9996222,
9998246, J47364, 9998260, 88800011,
J41989–A, 2012-A
Installation of Cylinder Head in
Engine Stand
Note: Work with the cylinder head is simplified if it is
installed in an engine stand.

Dismantling
1
Remove the valve bridges.

Note: Mark the bridges or place them in order so that they


can be replaced in the same position when reinstalled.

T2008851
Volvo Trucks North America Date Group No. Page
Service Bulletin 3.2006 211 59 5(6)

D
2
Place press tool 9998260 into cylinder head bolt holes
and install backstop plate and nuts on opposite side of
head.

Note: Backstop plate is used to hold valves closed


during valve lock removal.

9998260

T2014953 Install hydraulic cylinder 9996161 in press tool 9998260


and connect foot pump 9996222 . (Alternatively, tool
J41989–A can be used instead of the hydraulic cylinder.)
Note: If using J41989 to remove valve locks, keep
cylinder head on a level surface.

9996161, 9996222, 9998246, 9998260, J41989–A

W2003431

Alternative tool J41989–A; note that cylinder head


should be kept level.

4
Put tap 9996159 in the hydraulic cylinder. Press down the
valve disc with tool 9998246. Remove the valve lock.

9996159

5
Remove the valve disc, springs, and valves.

6
Remove the remaining valves using the press tool using
the same procedure as removing the first valve.

7
Place the valves and springs in a rack, so that they can
be replaced in the same position in the cylinder head
when reinstalled.
Volvo Trucks North America Date Group No. Page
Service Bulletin 3.2006 211 59 6(6)

D
8
Remove the oil seals from the valve guides.

9
Remove the guide pins for the valve bridges.

Assembly
10
Before assembly, cylinder head must be thoroughly
cleaned.

11
Install oil seals on the valve guides.

Note: When installing valve seals, use tool 88800011


to avoid damage to the new seals.

12
Lubricate the valve stems with engine oil and install
the valves.

13
Install valve springs and locks using the same tools
as removal steps.