Volvo Trucks North America, Inc.

Greensboro, NC USA
TSI
Date Group No. Supp. Page
This TSI Service Bulletin replaces TSI Service Bulletin
210003, Basic Engine, D12C (11.2001), publication no. 12.2004 210 003 1(11)
PV776TSP158999.
Basic Engine
Design and Function
D12C
Basic Engine

W2003244

This information covers design and function of the VOLVO D12C engine.

Contents
Engine page 2
Product Overview page 4
Components page 6

PV776-20 014810 USA15718

Volvo Trucks North America, Inc. Date Group No. Page
TSI 12.2004 210 003 2(11)

Design and Function

Engine
D Diesel
12 Displacement in liters
C Generation (A, B, C)
425 Power rating in horsepower (345, 385, 425, 465)

Serial Numbers
D 12C * 04759

Serial Number
Engine displacement (L)
Diesel

Typical serial number

W2004521

Fig. 1: Serial number locations

1 Serial number location on D12C

2 ECU Location
Volvo Trucks North America, Inc. Date Group No. Page
TSI 12.2004 210 003 3(11)

Serial No. Designation Horsepower

119503 - 119505, 133764 - 133765, 135970 - 135972, 136794 - 136797, 143526, D12C 345, 385, 425,
146908 - 146910, 151028, 151033, 153523 - 153528, 154272 - 154273, 154342, 465
154344 - 154345, 154347, 154349, 155388 - 155392, 155394 - 155405, 155407 -
155408, 155566, 155568 - 155574, 155577 - 155580, 155582 - 155584, 155586 -
155587, 158434 - 158437, 158530 - 158535, 158538 - 158542, 158544 - 158549,
159138 - 159144, 159146, 159148 - 159151, 159153, 159155, 159157, 159159
- 159160, 159162, 159208, 159210 - 159213, 159215 - 159222, 159226, 159228,
159230, 159232, 159959, 159963, 159966, 159968, 159971 - 159972, 159974,
160619, 160624, 160812 - 160817, 160819, 160821 - 160823, 160825 - 160826,
160857, 160862, 160868 - 160869, 160871, 160877, 160879, 160885 - 160886,
160909, 160911 - 160912, 160915 - 160916, 160924 - 160927, 160930, 160963 -
160971, 160973 - 160975, 160977 - 160983, 160985 - 160987, 160989 - 160990,
160992 - 160996, 160998 - 160999, 161002 - 161003, 161006 - 161010, 161620,
161622, 161624, 161626, 161630 - 161631, 161633, 161680 - 161681, 161683 -
161685, 161688, 161690, 161694 - 161695, 161872, 161913, 161918, 161922,
161928, 161934 - 161935, 161944 - 161945, 161954, 162867, 162869 - 162870,
162876 - 162879, 162883 - 162884, 162886 - 162889, 162892 - 162893, 162897,
162900 - 162901, 162903, 162905 - 162906, 162911, 162916, 162925 - 162926,
162928 - 162929, 163939 - 163642, 163663 - 163668, 163670 - 163683, 163685 -
163722, 164678 - 164741, 165341 - 165346, 165348 - 165352, 165356, 165361 -
165362, 165365 - 165368, 165370, 165372 - 165373, 165376 - 165380, 165383,
165388 - 165390, 165392, 165394 - 165395, 165477 - 165534, 166343 - 166348,
166350 - 166353, 166355, 166437 - 166445, 166447 - 166449, 166451, 166453 -
166454, 166456 - 166458, 166460 - 166464, 166466 - 166467, 166470 - 166484,
166486 - 166493, 167455, 167457 - 167464, 167466 - 167467, 167469 - 167470,
167472, 167474 - 167475, 167627, 167629 - 167631, 167633 - 167634, 167636,
168307 - 168308, 168311 - 168312, 168314 - 168320, 168411, 168413 - 168415,
168418, 168420 - 168421, 168423, 169435 - 169444, 169446 - 169449, 169451 -
169453, 169524 - 169527, 169529 - 169535, 169537 - 169538, 169540 - 169543,
170280 - 170285, 170378 - 170380, 170382 - 170385, 170387 - 170397, 170456 -
170460, 170463 - 170465, 170467 - 170474, 171017 - 171021, 171023 - 171026,
171028 - 171032, 171034, 171067, 171069 - 171076, 171129, 171143 - 171144,
171146 - 171161, 171248 - 171251, 171323 - 171327, 171330 - 171339, 171341,
171343, 172031 - 172043, 172154 - 172158, 172160 - 172164, 172166 - 172171,
172216 - 172222, 172281 - 172282, 172284 - 172292, 172294 - 172297, 172299,
172500 - 172510, 172659 - and higher
Volvo Trucks North America, Inc. Date Group No. Page
TSI 12.2004 210 003 4(11)

Product Overview

W2003244

Fig. 2: D12C Engine

Reinforced cylinder head with improved intake and

exhaust passages.

New oil cooler cover accommodates a larger oil cooler.

New unit injectors with longer pump stroke and higher

injection pressure.

New routing of fuel lines on the engine.

New timing gears.

Increased drive outputs for fan, alternator, and AC

compressor.

New thermostat housing integrated into the cylinder

head.

8 sensors with a total of 11 sensor functions.

Cylinder block webbing for additional stiffness.

Oil pans are available for different applications.

Front PTO available.

Volvo Trucks North America, Inc. Date Group No. Page
TSI 12.2004 210 003 5(11)

D12C

W2003244

Fig. 3: D12C Engine

D12C is the designation of Volvos 12-liter C-version engine. The engine is available in
a power rating of 345, 385, 425, or 465 HP.

The engine has been designed to comply with 1999 requirements for low fuel
consumption and high performance in combination with low exhaust emission. The
engine has also been designed for Volvos new automotive electrical system.
Volvo Trucks North America, Inc. Date Group No. Page
TSI 12.2004 210 003 6(11)

Components
Cylinder Head

W2003538

Fig. 4: New Cylinder Head Design

The following modifications have been made to the cylinder head.

The cylinder head has been reinforced and is fabricated using new material.

New intake and exhaust passages.

Only one fuel gallery for the unit injectors.

New thermostat housing integrated into the cylinder head.

The flame edge grooves have been removed. This means a completely new method
and new special tools for installing the cylinder head.

The illustration, New Cylinder Head Design (above), shows three new alignment
blocks (marked with black arrows); two are bolted to the cylinder head and one
to the timing gear plate. These are used to position the cylinder head in place
when it is installed.
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TSI 12.2004 210 003 7(11)

Cylinder Block
D12C
The cylinder block of the D12C is reinforced and modified
at the front to accommodate the new timing gear.

The lower section of the cylinder block has been reinforced

with a frame to give additional stiffness. This means that
the vibration and noise levels have been reduced and the
outer, laminated steel plates are no longer required.

A new oil cooler cover is designed to accommodate the

larger oil cooler.

T2012776

Fig. 5: Cylinder Block

Cylinder Liner
The cylinder block is cast iron and uses wet (replaceable)
cylinder liners. Three sealing rings are used to seal the
cylinder liners against the lower part of the cylinder block.

The upper part of the cylinder liners are sealed by a

sealing ring. This O-ring (sealing ring) groove is located
approximately 11 mm (7/16 in.) below the liner flange
(collar).

Note: The cylinder liners on the D12C have no flame

edge. The number and location of the seal rings are the
same as previous D12A and D12B liners.

T2006875

Fig. 6: Cylinder liner and sealing rings

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TSI 12.2004 210 003 8(11)

Pistons
The pendulum piston crown does not have bushings for
the wrist pin, and has a different surface coating than
the old design.

The engine is equipped with articulated, 2part pistons.

Both parts of the piston are separately journalled on the
wrist pin.

The upper part of the piston (crown) is made of steel; the

lower part (skirt) is made of aluminum. This type of piston
allows higher pressure and temperature in the combustion
chamber, which provides higher efficiency.

The pistons are cooled by engine oil sprayed via a nozzle

against the underside of the piston.

The wrist pin end of the connection rod is trapezoid

shaped.

Note: The D12C uses reinforced connecting rods.

Compression ratio is 18.5:1.

T2017421
Fig. 7: Exploded view of piston crown, skirt and rod

Valves
The engine has four valves per cylinder and
centrally-located electronic unit injectors (unit injector).
Each cylinder has separate intake and exhaust ports.

The intake valves are constructed of new material, and

the exhaust valves are coated with hard metal on their
seat surfaces.

The exhaust valve seats are made from a harder material

than that used on the D12A and D12B engines.

The bushing in the unit injector rocker arm has been

replaced by a surface-coated steel bushing.

T2006871
Fig. 8: Valves
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TSI 12.2004 210 003 9(11)

Timing Gears
The D12C uses new timing gears. The number of timing
gears has been reduced, and the gears are reinforced to
permit higher injection pressures. The hub on the D12C is
tightened using six screws, compared to four on the D12A
and D12B. The upper idler gear (1) is adjustable to allow
setting of the gear lash between this gear and the top and
bottom fixed gear. The gear lash must be reset each time
any work is performed that may effect this gear lash. The
camshaft gear (2) has a hydraulic vibration damper and
is fastened to the camshaft by 6 bolts. The D12C uses a
new spray nozzle for lubricating the timing gears. The
D12C also has increased drive outputs for fan, alternator,
and AC compressor. It features a new, stronger bearing
housing for engine power take-off. Power take-off torque:
500 Nm (369 ft-lb) stationary
400 Nm (295 ft-lb) while driving

Ref. Description No.

No. Of
Teeth
T2012779

1 Crankshaft drive gear 38 Fig. 9: Timing Gears

2 Idler gear 83
3 Coolant Pump gear 27
4 Air compressor drive gear 29
5 Camshaft gear 76
6 Adjustable Idler gear 97
7 Power Steering Pump Drive gear 23
8 Accessory Drive gear (pulley and fuel 27
pump)
9 Idler gear 71
10 Power take-off (PTO) drive gear 39
11 Oil Pump drive gear 23
12 Oil Pump Idler gear 44

W2004492

Fig. 10: Exploded view of timing gear

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Camshaft
The D12 engine is equipped with an overhead camshaft
that is attached to the cylinder head. The overhead
camshaft is induction hardened. The movement to the
valves and unit injectors is transferred via roller rocker
arms. The camshaft is journalled in seven bearing
housings with separate caps which are bolted to the
cylinder head. The cap and bearing housings are
replaceable.

Each bearing housing assembly consists of an upper

housing (cap) and a lower housing. These two housings
make up the bearing housing assembly and are a
matched pair and must not be mixed. There are 2 types of W2003278

support bearing housing assemblies: one for production Fig. 11: Camshaft
and one for the after market service. Production and after
market service bearing housings must not be mixed in
the same engine. For example, to replace one bearing
housing on an engine that has all original production
bearing housings, you must replace all 7 bearing
housings. After all bearing housings have been replaced
once, then any one housing assembly can be replaced.

The camshaft has three lobes per cylinder: one for the
intake valve, one for the exhaust valve and one for the unit
injector. On engines that are equipped with VEB (Volvo
Engine Brake), the camshaft profile for the exhaust valves
has two extra small lobes in order to control the engine W2004525
compression brake. Fig. 12: Camshaft Cap
Six screws are used to mount the camshaft drive gear to
the camshaft. A hydraulic vibration damper is mounted on
the outside of the camshaft drive gear.

The unit injector cam lift on the D12C gives a stroke of

17 mm.
Note: Replacement bearing housing assemblies are
unmarked. Prior to installation, the bearing housing
assemblies should be marked to identify both upper (cap)
and lower (housing) halves of the assembly to prevent
mixing. The mark should also identify the location on the
cylinder head the assembly is to be used.
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TSI 12.2004 210 003 11(11)

Crankshaft

T2007134

Fig. 13: Crankshaft and journals

The crankshaft is drop forged and induction hardened. It is held in place by 7 main
bearing journals. The front section of the crankshaft (and vibration damper) is located
behind the timing gear housing. The D12C engine is available with front-mounted PTO.