Service Bulletin

Volvo Trucks North America, Inc.

Greensboro, NC USA Trucks
This Service Bulletin replaces SB 210116, Low Com- Date Group No. Page
pression, Fault Tracing, Checklist G, D12D (03.03), 4.2003 210 116 1(8)
publication no. PV776TSP188159.
Low Compression
Fault Tracing
Checklist G
D12D
Low Compression, Fault Tracing
Checklist G

W2004204

This information covers fault tracing a low compression condition in the Volvo D12D
engine.

Contents
General Guide to Fault Tracing page 2
Checklist G, Low Compression page 3
Low Compression, Fault Tracing page 5

NOTE: Information is subject to change without notice.

Illustrations are used for reference only, and may differ slightly from the actual
engine version. However, key components addressed in this information are repre-
sented as accurately as possible.

PV776-TSP190338 USA13617
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2003 210 116 2(8)

General Guide to Fault Tracing

You must read and understand the precautions and guidelines in Service Informa-
tion, group 20, "General Safety Practices, Engine" before performing any procedure.
If you are not properly trained and certified in a procedure, ask your supervisor for
training before you perform it.

To use this checklist:

1 Complete basic data gathering

Read fault codes
Check vehicle parameters

2 Use the recommendations in appropriate symptom information, plus the infor-

mation gathered above to provide a foundation for continued fault tracing using
this checklist.

One fault often affects other systems. Therefore, it is important to confirm or

eliminate suspected causes of faults at an early stage, using tests in VCADS
Pro.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2003 210 116 3(8)

Checklist G, Low Compression

See also:

General Guide to Fault Tracing page 2

Low Compression, Fault Tracing page 5

Vehicle Chassis No. Mileage Customer

Yes No

1 Compression Test (Electronic) page 5

Does the test indicate more than 80% on all cylinders?

Action:

2 Sensor Value, Check (Crankcase Pressure) page 5

Does the sensor for the crankcase pressure give a reasonable value, according to the specifications?

Action:

3 Carbon Monoxide (CO) in Cooling System, Check page 5

Is the coolant free from carbon monoxide?

Action:

4 Carbon Monoxide (CO) in Fuel System, Check page 6

Is the fuel free from carbon monoxide?

Action:

5 Operational Test page 7

Is the engine free from abnormal popping noises from intake manifold and exhaust?

Action:

6 Valves and Rocker Arms, Check page 7

Is the valve clearance within the tolerances according to the specification?

Are the rocker arms, valve springs and valve bridge free of faults?

Are VEB pistons fully retracted in the rocker arms?

Action:

7 Compression, Test page 7

Perform a new compression test if corrective action has been taken.

Does the compression test still point out the same cylinder?

Action:

8 Cylinder Pressure, Test page 7

Can the cylinder pressure test be performed without excessive leakage?

Action:

9 Cylinder Head, Check page 8

Is the cylinder head gasket fault free?

Is the cylinder head intact and free from cracks?

Are the valves and valve seats free of faults?

Action:
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2003 210 116 4(8)

Vehicle Chassis No. Mileage Customer

Yes No

10 Piston and Cylinder Liner, Check page 8

Are piston and piston rings free of faults?

Is the cylinder liner free of faults?

Action:

Notes:

Completed by: Dealer: Date:

Volvo Trucks North America, Inc.
Service Bulletin
2103-20-03-01
Low Compression, Fault Trac-
ing
See also:
General Guide to Fault Tracing page 2
Checklist G, Low Compression page 3
Compression Test (Electronic)
Note:The engine is not started during the test.
1 crankcase ventilation, the crankcase
Connect the PC tool to the vehicle di-
agnostics socket. Perform
Compression, Test; follow instruc-
tions in VCADS Pro.
2 Sensor, crankcase pressure
If any cylinder displays less than 80%,
there may be a compression fault.
Proceed with fault tracing.
Sensor Value, Check (Crankcase
Pressure)
(Should be checked under full load.)
1
Connect the PC tool to the vehicle di-
agnostics socket. Perform Sensor
values check, engine running; follow
the instructions in VCADS.
Date Group No. Page
4.2003 210 116 5(8)
2
Check the sensor value for crankcase
pressure. If the value is excessive,
crankcase ventilation could be
blocked, or there could be wear or
damage to the cylinder liner, pistons or
piston rings; see Piston and Cylinder
Liner, Check page 8.
If the value exceeds 8 kPa (1.2 psi) a
fault code (MID 128 PID 153) may be
set; refer to Diagnostic Information,
group 28. If value exceeds specifica-
tion but there are no faults in the
pressure sensor could be faulty.
For continued fault-tracing, refer to the
appropriate wiring diagram:
EECU (A14), terminal EB18 and
EB28
(B54), terminal 1, 2, and 4.
NOTE: If crankcase pressure is
greater than 8 kPa (1.2 psi), fault code
will be set. Possible fault code: MID
128 PID 153; refer to Diagnostic Infor-
mation, group 28.
If sensor is fault free, continue fault-
tracing; see Carbon Monoxide (CO) in
Cooling System, Check page 5.
Carbon Monoxide (CO) in Cool-
ing System, Check
Other special equipment: 3822985
1
Prepare carbon monoxide tester 3822985
3822985 for use; follow instructions
provided with tester.
NOTE: Carbon monoxide tester
3822985 can be ordered directly from
Cummins.
WARNING
Use extreme caution if coolant temperature is over
 
50 C (120 F). Scalding steam and fluid under pres-
sure may escape and can cause serious personal
injury.
Open the pressure cap on the cooling
system expansion tank.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2003 210 116 6(8)

3 2

W2003127

Start the engine. Position the carbon T2019057

monoxide tester over the tank opening.
4 the hose into a suitable container.
Pump the testers bulb so that air from
the expansion tank is drawn into the
tester.
NOTE: Coolant must not be drawn
into the carbon monoxide tester.
Remove the return hose at the cylin- 9990056
der head. Connect transparent hose
9990056 and insert the other end of
3
Start the engine and allow to idle. Rev
the engine several times.

5 Check for air in the hose. If air is
If the fluid in the tester changes to yel-
low, this indicates the presence of
carbon monoxide in the coolant.
NOTE: Carbon monoxide in the
coolant means that exhaust gases are
forced into the cooling system. This
could be due to leakage at a unit in-
jectors copper sleeve, leaking cylinder
head gasket or cracks in the cylinder
head or cylinder liner; these can con-
tribute to low compression.
Carbon Monoxide (CO) in Fuel
System, Check
Special tools: 9990056
Other special equipment: 3822985
1 tor, or a crack in the cylinder head.
Prepare carbon monoxide tester
3822985 for use; follow instructions
provided with tester.
NOTE: Carbon monoxide tester
3822985 can be ordered directly from
Cummins.
4
found, use carbon monoxide tester
3822985 at the opening of the bottle to
check for carbon monoxide in the fuel.
NOTE: Fuel must not be drawn into
the carbon monoxide tester.
5
Switch off the engine.
6
If the fluid in the tester changes to yel-
low, this indicates the presence of
carbon monoxide in the fuel.
NOTE: Carbon monoxide in the fuel
means that combustion gases are be-
ing forced into the fuel system through
a damaged copper sleeve, unit injec-
3822985
7
If the fuel contains air or carbon
monoxide, locate where air is entering
the fuel system; refer to Service Infor-
mation, group 23.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2003 210 116 7(8)

Operational Test Volvo engine brake (VEB) rocker arms

1 3
Disconnect the 7-pin connector from Check that the VCB piston has not be-
the AVU valve to prevent it from acti- come stuck in the piston bore and that
vating. (Fault code will be set; clear it is fully retracted when VEB is non-
code after check.) active.

NOTE: Disabling the EPG will improve

the accuracy of the operational test.
Compression, Test
If any corrective action has been taken to this point, per-
2 form a new compression test; see Compression Test
Run the engine and check for the fol- (Electronic) page 5
lowing:
NOTE: Carry out the compression test, before fault trac-
A Popping sound or compression ing the cylinder head, pistons, piston rings, or cylinder
leak in intake manifold. This liner.
may indicate valve leak. Check
valve and valve seats (if valve
adjustment and valve springs Cylinder Pressure, Test
are okay). Special tools: 9990123, 9998242, 9996950
B Popping sound or compression
leak in exhaust. This may indi- 1
cate exhaust valve leak. Check Remove valve cover.
valve and valve seats (if valve
adjustment and valve springs
2
are okay).
Remove rocker arm shaft assembly.
C Excessive combustion in the
crankcase. This may indicate
excessive wear or damage to 3
cylinder liners, pistons, or piston Using an acceptable container, drain
rings. fuel from injector fuel passages at
drain fitting on fuel filter housing.

4
3 Remove injector on the cylinder identi-
After test, connect 7-pin connector to fied in VCADS compression test as
AVU valve; clear fault code. having low compression (less than
80%).

Valves and Rocker Arms, Check 5

Valves
1 tool 9996950.
Check the valve clearance; refer to
Service Information, group 21.
Rocker arms, valve springs and valve bridges
2
Check the camshaft, rocker arms,
valve springs, and valve bridges for
damage or excessive wear; refer to
Service Information, group 21.
Remove inspection plate on flywheel 9996950
housing and intall flywheel blocking
6
Install injector adapter 9998242 into 9998242
injector bore and torque-tighten attach- 20 4 Nm
ment bolt to 20 4 Nm (15 3 ft-lb). (15 3 ft-lb)
7
Turn reduction valve on pressure 9990123
gauge 9990123 counter-clockwise and
open cut-off valve. Attach pressure
gauge to adapter 9998242. Connect
shop hose and supply pressurized air;
tighten reduction valve until 5 bar (70
psi) is read.
Volvo Trucks North America, Inc.
Service Bulletin
8 3
If pressure will not build in cylinder, re-
move charge air hose between charge
air cooler and EGR mixing chamber.
Listen for air leaks from intake valves.
9
If no leakage is found on intake side,
remove the exhaust pipe at EPG
housing. Listen for air leaking out of
the EPG housing.
10
If no leakage is found on intake or ex-
haust valves and cylinder will not hold
any pressure, the cylinder head must
be removed for further checks.
NOTE: If cylinder condition is ques-
tionable, a mechanical compression
test can be performed as an option;
refer to Service Information, group 21:
Cylinder Compression, Checking.
Cylinder Head, Check
1 compression test; refer to Service In-
Remove the cylinder head; refer to
Service Information, group 21:
Cylinder Head, Removal.
2 Check the piston and piston rings for
Check the cylinder head gasket for
damage. Carefully check the area
around the cylinder indicated in the
compression test. If there are signs of
leakage, the cylinder liner heights
must be checked. Refer to Service In-
formation, group 21: Cylinder Liner
Height, Checking.
Date Group No. Page
4.2003 210 116 8(8)
Check the cylinder head for damage
or leaks. Also check the head gasket
contact surface for any unevenness.
4
Remove the valves; refer to Service
Information, group 21. Start with the
valves in the cylinder indicated in the
compression test.
5
Check the valves and valve seats for
damage or excessive wear.
NOTE: Valve and valve seat leakage
should have been detected in
Cylinder Pressure, Test page 7.
Piston and Cylinder Liner, Check
1
Remove the piston and cylinder liner
from the cylinder indicated in the
formation, group 21.
2
damage or excessive wear.
3
Check the cylinder liner for damage or
excessive wear. Refer to Service Infor-
mation, group 21: Cylinder Liner
Wear, Checking.