IMPACT 3.

0 16 February 2008

Printed by: BILLY ROWAN

Service
Chassis ID Path
  211/Repair/FH12, D12A420/Cylinder
head, install
Model Identity
FH12 109649690
Publish date Operation No.
15 November 2006 21124-1

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IMPACT 3.0 16 February 2008

21124-1 Cylinder head, install

It is important to observe the greatest possible cleanliness when working on the cylinder head.

The cylinder head should be cleaned both externally and internally before it is replaced.

Dirt particles can cause unit injector failure. If the engine is fitted with VEB, the braking function may
be effected!

All cylinder heads to D12A, supplied from Volvo, have the same part number and are fitted with a
plug in the oil channel to the VEB system's control valve.

When replacing the cylinder head on engines fitted with VEB the plug should be removed before
fitting the control valve.

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IMPACT 3.0 16 February 2008

This applies to both new and replacement cylinder heads.

Part number: 1161247, 1161277, 9812546, 282036

Special tools: 9996956, 9996966, 9998250, 9998251, 9998255, 9998264, 9998304, 9998305,
9998318, 9998389, 9998394

Other special equipment: 9999683, 9999696

If necessary, clean the unit injector copper sleeve internally before putting the cylinder head in
place.

Use a hand drill and cleaning brush part no. 9812546. The brush can be ordered from Volvo Truck
Parts AB.

If necessary, use the extractor 9998394 to remove the plugs from the unit injector holes.

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IMPACT 3.0 16 February 2008

Note: Make sure the fuel channel sealing rings 9998250 are in position when cleaning, so that dirt does not enter the
fuel channels.
Remove the sealing rings and refit plug 9998251 in the unit injector hole after cleaning.

Warning
With any cleaning of the unit injectors, under no circumstances may rotary wire brushes,
hand wire brushes or similar tools be used on the injector nozzle. There is a risk that the
injector holes could be damaged and blocked, causing power delivery problems.
Use a rag soaked in paraffin or similar instead.

Part number: 9812546

Special tools: 9998250 9998251 9998394

If the inlet manifold has been removed, clean the contact surfaces thoroughly and apply a 2 mm
bead of sealant to the inlet manifold. Bolt the manifold to the cylinder head within 20 minutes of
sealant application.

Note: If the engine is fitted with VEB, install a new oil seal and check that it is correctly positioned.
Make sure sealant does not enter the oil channel.

Part number: 1161277

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IMPACT 3.0 16 February 2008

Make sure that clamping tool 9996966 is fitted so that the cylinder liner is held in place.

Special tools: 9996966

Install the cranking tool 9996956 and crank the crankshaft in the normal direction of rotation until
the flywheel mark for 0° is aligned with the arrow on the flywheel housing.

Special tools: 9996956

5
Remove the press tool from the cylinder liner, remove the old gasket and clean the cylinder block
sealing surface thoroughly.

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IMPACT 3.0 16 February 2008

Dip the entire length of the cylinder head screws in rust-preventing compound. Place the bolts on a
net so that it runs off.

Part number: 282036

Install new seals and place a new gasket on the cylinder block.

Replace the rubber seal on the timing gear cover.

Install a new sealing ring in the thermostat housing.

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IMPACT 3.0 16 February 2008

Carefully lift the cylinder head into position.

Note: Make sure that the seal against the timing gear cover is in position and that the thermostat is not damaged.

9
Remove the lifting equipment. Remove the washer from the bolt on the exhaust manifold and
tighten the bolt to the specified torque.

10
Install the cylinder head fixing bolts and torque tighten them in accordance with the diagram in the
specifications.

Mark up the tightening sequence on the cylinder head with a marker pen.

11

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IMPACT 3.0 16 February 2008

Cut away any excess material from the rubber seal on the timing gear plate.

12
Install and tighten the thermostat housing bolts.

13
Carefully pull the unit injector cable harness into the cylinder head.

14

Remove the protective plug 9998251 from the unit injector hole.

Note: If necessary, use the extractor 9998394 to remove the plug.

Do not remove all plugs at the same time, insert the unit injector in the hole before proceeding.

Special tools: 9998394

15
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IMPACT 3.0 16 February 2008

Install new sealing rings on the unit injectors. Install the unit injectors and centre them so that they
do not rub against the valve springs.
Torque tighten the unit injectors as specified.

Note: The unit injector tightening torque differs depending on the use of a new or existing copper sleeve. If the copper
sleeve is new, a higher torque is used, see the specifications.

16

Connect the electrical wiring for the unit injectors.

Note: The nuts shall be torqued as specified.

If the threads break, the entire unit injector must be replaced!

17

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IMPACT 3.0 16 February 2008

Connect the fuel lines to the cylinder head.

Note: Use new copper washers.

18
Place the camshaft bearing housings on the cylinder head.

Note: Make sure the housing seating is clean and that the guide sleeves are undamaged.
If a new cylinder head is fitted, the bearing housings included with it should be used.

19

Oil the bearing shells with engine oil and position in the bearing housings.

20

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IMPACT 3.0 16 February 2008

Carefully lift the camshaft into place and remove the lifting tool.

Make sure the camshaft's TDC mark is turned upwards so that it aligns with the mark on the front
bearing cap.

Check that the camshaft gear engages with the adjustable idler gear.

Special tools: 9998264

21

Oil the bearing shells and place in the bearing caps. Fit each cap the associated bearing housing.

Place the front bearing cap first and check that the camshaft TDC mark aligns with the notch in the
cap.

Tighten by hand only and do not install the rocker arm shaft bolts.

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IMPACT 3.0 16 February 2008

22

Lubricate the valve calipers and camshaft lobes with engine oil.

Lift the rocker arm bridge into place. Make sure the valve yokes and rocker arms engage.

Special tools: 9998255

23

Install and tighten the rocker arm shaft bolts for hand, until they bottom on the bearing housings.

Tighten the rocker arm shaft and camshaft bearing cap bolts to torque according to the tightening
diagram in specifications.

24
Remove the rubber bands from the VEB rocker arm pistons.

25

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IMPACT 3.0 16 February 2008

Wipe all the oil off the pipe for the VEB's control valve.

Oil the hole in the rocker arm shaft.

Use a 1/2" short extension and a 12 mm socket. Fit a new sealing ring onto the pipe and press the
pipe into the rocker arm shaft using the extension piece.

Make sure the sealing rings locate properly.

26

Fit a new sealing ring on the pipe and fit the control valve.

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IMPACT 3.0 16 February 2008

Note: Check that the oil channel's plug is removed.

Use a new sealing ring between the control valve and cylinder head and make sure it locates properly before screwing
the control valve in place.

27

Clean the threaded hole for the removed stud in the cylinder head.

Clean the stud, apply locking fluid and torque tighten according to the specification.

Note: Carefully wipe off any excess locking fluid once the stud is tightened.

28

Check that the flywheel marking for 0° is exactly opposite the arrow on the flywheel housing.

29

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IMPACT 3.0 16 February 2008

Make sure the camshaft's TDC mark aligns with the mark on the front bearing cap.

30

Place a dial gauge on a magnetic stand and put the probe against a tooth on the roller-bearing
supported idler.

Other special equipment: 9999683 9999696

31

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IMPACT 3.0 16 February 2008

Turn the adjustable idler gear clockwise and secure it in that position.

Check the backlash by turning the lower gear back and forth and reading off the values.

Note: The probe should be aligned with the inclination of the teeth.

32

Move the dial gauge to the adjustable gear.

Check the backlash with the camshaft gear by turning the adjustable gear back and forth.

Compare the backlashes with the values in the specification.

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IMPACT 3.0 16 February 2008

33

If the backlash needs to be adjusted, loosen the adjustable gear bolts just enough to allow it to
move sideways.

Then tighten the bolts by hand.

34

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IMPACT 3.0 16 February 2008

Put 2 x 0.10 mm feeler gauges on the thrust side of the gear (A and B).

Check that both gauges are equally difficult to extract/insert between the teeth.

35

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IMPACT 3.0 16 February 2008

Tighten two bolts (see arrows) and check that both gauges are equally difficult to extract/insert.

Then remove the feeler gauges.

36
Recheck the backlash with the dial gauge as point 30, 31and 32.

37

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IMPACT 3.0 16 February 2008

Loosen one bolt at a time and then tighten to the specified torque.

38
Remove the camshaft sensor from the upper timing gear cover.

Clean the cover and contact surfaces.

Replace the seal against the lower timing gear cover.

39

Note: If there is damage or deformation on the gear wheel or any of the teeth, the gear must be replaced. The same
applies if the holes for the gear fixing bolts are damaged.

40

Apply a 2 mm bead of sealant to the upper timing gear cover and to the corner between the lower
timing gear cover and the cylinder head.

Install a new rubber seal.

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IMPACT 3.0 16 February 2008

Note: From and including engine number 11421, a new upper timing gear cover and seal have been introduced into
production.
Make sure the correct seal is used.

Note: The timing gear cover must be installed within 20 minutes of the sealant having been applied.

Part number: 1161247

41
Install the upper timing gear cover and fit the bolts. Tighten the bolts so that they touch the cover.

42

Apply the clamping tool and press the timing gear cover down so that the cylinder head and timing
gear cover sealing surfaces against the valve cover are aligned.

Torque tighten the timing gear cover bolts according to the specification.

Do not remove the clamping tool, the sealant requires 30 minutes to cure.

Special tools: 9998318 9998389

43

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IMPACT 3.0 16 February 2008

A = clearance mm

B = shim

C = gear wheel

D= camshaft sensor

A B

Measured Adjusting plate

clearance

  Number Part number

0.2 to 1.0 mm - -

-0.3 to 0.3 mm 1 1677894

-0.6 to - 0.3 mm 2 1677894

Crank the flywheel until a tooth on the camshaft gear is in front of the sensor hole in the timing gear
cover

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IMPACT 3.0 16 February 2008

Insert the camshaft sensor and measure distance A between the end of the sensor and the gear
tooth.

Permitted clearance A: 0.6±0.4 mm

To obtain the correct signal from the camshaft sensor, the clearance between the sensor and the
gear teeth must be within tolerance.

Adjust the sensor with shims according to the table above.

44
Clean the sealing surfaces and install the starter element with new gaskets

45
Install the charge air pressure sensor on the inlet manifold and attach the connecter.

46
Install the solenoid valves on the inlet manifold.

47
Attach the connectors to the sensors on the inlet manifold, expansion tank, thermostat housing,
temperature sensor on the coolant pipe and to the camshaft sensor.

Clamp the electric cables.

48

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IMPACT 3.0 16 February 2008

Install the VEB oil pressure pipe between the cylinder block and inlet manifold.

49
Install the gear lever plate and adjust the alternator belt tension as specified.

Special tools: 9998304 9998305

50
Install the oil filler pipe, with a new sealing ring, to the upper timing gear cover and screw the
dipstick holder clamp in place.

51
Clean and connect the coolant pipe to the thermostat housing, use a new sealing ring.

Install the fixing bolt for the pipe from the cab heater to the timing gear cover.

52
Install the air compressor oil pressure pipe clamp.

Install the fan ring bracket and tighten the air compressor cooling coil bolts.

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IMPACT 3.0 16 February 2008

53

Remove the clamping tool from the upper timing gear cover and wipe off excess sealant.

Connect the wires to the VEB solenoid valve but do not tighten so hard that the valve is damaged.

Fit the cable holder clamps to the studs and clamp the cables.

54
Install the turbocharger.

Refer to Service Manual Group 25, Turbocharger, replace.

55
Adjust the valves and unit injectors.
Refer to Function group 214, Information type Repair, 21414-3 Valves and unit injectors, adjust.

56
Install the valve cover and tighten the bolts according to the diagram in the specification.

57
Install the air cleaner fixing bolts to the flywheel housing and tighten the bolts in the cab latch beam
crossmember.

58

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IMPACT 3.0 16 February 2008

On vehicles with front air intake, install the front air intake pipe to the valve cover.

59
Fill with required amounts of oil and coolant.

60
Purge the fuel system according to instructions in Service Manual Group 23 Fuel system.

61
Perform cylinder balancing and leakage checks.

© Copyright Volvo Parts Corporation

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

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