Service Bulletin

Volvo Trucks North America, Inc.

Greensboro, NC USA Trucks
Date Group No. Page
11.2002 210 114 1(11)

Basic Engine
D12D
Basic Engine

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D12D is the designation for new Volvo 12-liter engines, and includes design enhance-
ments over the D12C and earlier engine variants.

This information covers basic design and function data for the Volvo D12D engine. For
design information that is common to the D12C engine, refer to Service Information,
group 20.

NOTE: For information on the design and function of the EGR system, refer to Service
Information, group 25: “EGR, Design and Function.”

Contents
• “Engine” page 2
• “Lubrication and Oil System” page 6
• “Fuel System” page 7
• “Intake and Exhaust System” page 9
• “Cooling System” page 9
• “Engine Control System” page 10

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-TSP181806 USA12725
Page 2

Design and Function

Engine
(See also “Basic Engine” page 1.)

Engine Designation
D Diesel
12 Displacement in litres
D Generation
435 Power output in horsepower

Identification Markings

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The engine versions can be identified by the markings

on the engine block and the EPA sticker on the top of
the valve cover.

1 Marking block. A displays the production location of

the engine.
(A – Skovde, Sweden; B – Curitiba, Brazil; C – Flen,
Sweden)
2 Engine ECU (see “Engine ECU” page 11).
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2002 210 114 3(11)

Design Modifications

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1 New cylinder head 5 New plastic oil pan

2 New gasket, cylinder head 6 New, larger oil cooler

3 Cylinder liner/piston 7 New E3 unit injectors

4 Cylinder block

NOTE: For engine specifications, refer to Service Infor-

mation, group 20: “Specifications, D12D.”
Page 4

Cylinder Head
New copper sleeve for unit injectors
The new copper sleeve has a narrower lower section
which improves space for greater coolant flow and there-
fore improved unit injector cooling. A new special tool
has been developed for flaring the copper sleeve. See
Group 23.

Nozzle for coolant flow

The nozzle for directing coolant flow has been removed.

Valve guides exhaust valves

The valve guide position for the exhaust valves have
been transferred up into the cylinder head to the same
height as the inlet valves inlet valves valve guides. Same
special tools for installing applies to all valve guides. See
group 21 Valve guides, replacement.

T2019412

Gasket, cylinder head

A new type of gasket has been introduced. The gasket is
made of steel, but has vulcanised rubber seals for oil
and coolant lead-ins.
The new gasket is also suitable for older D12–engines.

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Cylinder Block
Screw holes for brackets have been introduced on the
outside of the engine block.
The plugs for the vertical ducts for the oil cooler (1) have
been removed. The gasket for the cylinder head re-
places the plugs as a seal directly against the cylinder
head face.
Several of the coolant lead-ins to the cylinder head (2)
are not drilled out, as this increases the coolant flow to
the rear section of the engine. There is a threaded hole
(3) on the right-hand side of the engine block in the ter-
minal for the oil filter console mounting which must be
plugged for D12D 340-460.
The rear section (4) of the block has been adapted for
the flywheel housing of the Turbo Compound variants.

T2019003
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2002 210 114 5(11)

Cylinder Liner/Piston
Cylinder liner
The cylinder lining has been modified under the collar of
the cylinder lining which means that the upper sealing
ring has been moved up. The modifications provide im-
proved cooling of the upper section of the cylinder lining
by increasing the space for coolant circulation.

Pistons
The pistons have an upper piston ring groove that has
been slightly moved down. This applies to aluminium
and articulated pistons.

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Connecting rod
New connecting rods are made of forged steel and differ
in design compared to other Volvo D12 engines. The
lower connecting rod end is divided into a flat unma-
chined surface, called a “fractured” connecting rod. The
connecting rod is screwed together using two screws.
The upper part of the connecting rod is trapezoid and
has unmachined sides. The gudgeon pin bushing is
slightly narrower than on earlier D12 engines.

Connecting rod and cap are marked as a pair with a

three-figure serial number.

For more information on the new style of connecting rod,

T2019085
refer to Service Information, group 21.
Page 6

Lubrication and Oil System

Oil Pan
The oil pan is made of molded plastic. The seal against
the engine block consists of a rubber molding located in
a groove in the oil pan. The oil pan is secured in the en-
gine block by 16 spring-loaded screws. The drain plug is
threaded into an integrated cast steel reinforcement.
There is a sensor inside the oil pan to measure the oil
level.

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Oil cooler/cover
The cooling capacity of the oil cooler has been in-
creased by the addition of a plate. The oil cooler has
seven plates. This results in the increased depth of the
oil cooler. The cover has also been enlarged.

NOTE: The larger oil cooler/cover is not interchangeable

with older versions.

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Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2002 210 114 7(11)

Fuel System
Overview

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The fuel supply pump (1) draws fuel through the fuel tank
unit strainer (2) via the fuel filter housing (3), the engine
ECU cooling circuit (4) and the distribution housing (5) to
the suction side of the fuel pump. From the fuel pump,
the fuel is forced via the fuel filter housing and main filter
(6) to the longitudinal channel (7) in the cylinder head,
which supplies the unit injectors (8) with fuel. The by-
pass valve (9) controls the fuel supply pressure. The fuel
return line leads to the tank via the fuel filter housing.

Fuel filter housing with filters

A new type of fuel filter housing has been introduced on
the D12D with a built-in electric pump (1). This is used
for bleeding the fuel injection system and water
drainage. The relief valve (2) is built into the pump and
prevents fuel from flowing back when the engine is
switched off. The bleed valve (3) is connected to the re-
turn line to the tank. The fuel pressure sensor (5) is
mounted under the cover with the electrical connection
(4). The nipple (6) is used for manually draining fuel. The
fuel filter (7) is mounted to the housing.
Bleeding of the fuel system is activated using a dash
switch.

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Page 8

Unit Injector
A new version of unit injector has been introduced on
the D12D engine versions.
Unit injectors consist of three main parts:

1 Pump

2 Valves (spill valve and needle lift valve)

3 Injector

The visible difference is that the solenoid valve (2) is po-

sitioned inside the injector body. The injectors respond
more quickly as the inner ducts for the fuel valves are
shorter. The function of the injectors is generally the
same as previous versions.

The unit injectors are manufactured using a tolerance

classification. Each unit injector is marked with a code
(1) on the top of the electrical connection.
When replacing one or more unit injectors the new
codes must be programmed for the cylinder for which
the unit injector is replaced. This is carried out using pa-
rameter programming in VCADS Pro. The codes need to
be specified only for replaced injectors.

T2018772
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2002 210 114 9(11)

Intake and Exhaust System

EPG
The exhaust pressure governor (EPG) on the D12D has
a new air valve. The valve is called an air valve unit and
is of the pulse width modulation (PWM) type. The pres-
sure can be controlled within 2.0 – 7.5 bar with this type
of valve. The pressure is continuously controlled when
the exhaust pressure governor (EPG) is used as an ex-
haust brake when driving using cruise control. The valve
is located on the left (cold) side of the engine block and
is controlled by the engine ECU.

T2019004

Cooling System
A new type of cooling fan has been introduced for the
D12D cooling system. This is a viscous-type fan; fan
RPM is controlled by a solenoid valve (1), rather than a
temperature-sensitive bi-metal strip. Fan speed is pri-
marily controlled by the engine ECU (2), although other
control units on the vehicle may activate the fan.

The fan has a lower idle speed, and fan speed is contin-
ually adjustable. This makes the fan more efficient and
lowers fuel consumption.

Fan function test is described in VCADS Pro.

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Page 10

Engine Control System

The illustration shows the position of different engine
sensors and their appearance. The designation in brack-
ets shows the component number.

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1 Crankcase pressure sensor (B54) 6 Engine coolant temperature sensor (B21)

2 Sensor for the engine coolant level (S68) 7 Speed (RPM) sensor, flywheel (B04)

3 Camshaft position (CMP) sensor, engine position 8 Fuel feed pressure sensor (A44)
(B05)
9 Oil level sensor (B10)
4 Oil pressure/oil temperature sensor (B38)

5 Boost pressure/charge air temperature sensor (B37)

Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2002 210 114 11(11)

Engine ECU
The engine ECU has been updated to a new version
(EMS2). The most visible difference is that the EA and
EB connections are located on the face of the EECU.

NOTE: The certification label has been moved from the

EECU to the top of the valve cover.

W2003778