IMPACT 4.00.51.

00-SNAPSHOT 04/06/11

Chassis ID Path
20/Specifications//Specifications

Model Identity
FH12 131436867

Publish date ID/Operation

13/09/12

R3 - Group 200
Note: As the illustrations in the service literature are used for several different engine variants, certain details may differ
from the variant you are working with. The essential information in the illustrations is, however, always correct.

General

Type designation Output 1 Torque 2

D12C/D 340 250 kW (340 hp) 1700 Nm (173 kpm)

D12C/D 380 279 kW (380 hp) 1850 Nm (189 kpm)

D12C/D 420 309 kW (420 hp) 2000 Nm (204 kpm)

D12C/D 460 338 kW (460 hp) 2200 Nm (224 kpm)

D12D 500 368 kW (500 hp) 2400 Nm (244 kpm)

1
Max output at 30.0 rps (1800 rpm) Net output as per ISO 1585. Smoke requirements comply with ECE reg 24 Federal
Register and Swedish requirements.

2
Max. torque at 20.0 rps (1200 rpm). Net torque as per ISO 1585. Smoke requirements comply with ECE reg 24
Federal Register and Swedish requirements.

Number of cylinders.....6

Cylinder bore.....131 mm

Stroke.....150 mm

Swept volume.....12.13 dm³

Firing sequence.....1-5-3-6-2-4

Compression ratio
D12C340/380/420/460.....18,5:1
D12D340/360.....18,2:1
D12D420/460/500.....18,1:1

Compression test with VCADS, deviation from peak value 100%.....max 20%

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Engine speed during compression test.....min 100 rpm

Low idling.....8.3-10.8 rps (550-650 rpm)

Fast idling.....34.7±3.3 rps (2100±20 rpm)

Max. full load revs.....31.6 rps (1900 rpm)

Weight of engine with flywheel, flywheel housing without starter motor (dry):
with turbocharger.....1155 kg
with Turbo Compound.....1205 kg

Total length:
without Turbo Compound.....1350 mm
with Turbo Compound.....1400 mm

Total width.....768 mm

Total height.....1152 mm

Variants, D12C
D12C engines are available in different variants adapted to various markets. In this SB, the variants are designated
D12C Mark 3, Mark 4 and Mark 5. To distinguish the engine variants, the marking on the engine block has been
supplemented by a variant figure, please refer to the table.
For more information about markings on the engine block, please refer to service information group 21.

Variant Marking on engine block

Mark 3 D12C3

Mark 4 D12C4

Mark 5 D12C5

Engine

Cylinder block

Length.....1052 mm

Height, lower block face - crankshaft centre.....120 mm

Cylinder head bolt

Quantity/cylinder head.....38

Thread size.....M16

Length.....200 mm

Cylinder head

Type.....6 cylinder

Length.....1078 mm
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Width.....397 mm

Height.....135 mm

Max unevenness (base plane).....0.1 mm

Cylinder liner

Type.....Wet, replaceable

Total height.....273 mm

Height of sealing surface above block face.....0.15-0.21 mm

Number of sealing rings per cylinder liner.....1 + 3

Piston

Height above cylinder block face

steel piston.....0.15 - 0.65 mm
aluminium piston.....0.05 - 0.45 mm

Diameter, combustion chamber.....89 mm

Depth piston ball.....17.1 mm

Number of ring grooves.....3

Front marking.....Arrow pointing forwards

Gudgeon pin diameter.....55 mm

Piston rings

Compression rings

Quantity.....2

Specifications Wear
tolerance

Piston ring clearance in grooves:

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

upper compression ring.....(

trapezoidal form)
lower compression ring.....0.09 - 0.13
mm

Piston ring gap measured in ring max 1.0

opening: mm
upper compression ring.....0.4 - 0.7
mm

D12C, D12C Mark 4 max 1.3

lower compression ring.....0.8 - 1.0 mm
mm

D12C Mark 3, D12C Mark 5, D12D max 1.9

lower compression ring.....1.4 - 1.6 mm
mm

Oil scraper ring

Quantity.....1

Specifications Wear
tolerance

Width including spring.....4.3 mm

Piston ring clearance in grooves.....

0.05 - 0.10 mm

Piston ring gap measured at ring max 1.0

opening.....0.35 - 0.75 mm mm

Valve mechanism

Valves

Valve disc, diameter:

Inlet/Exhaust.....40 mm
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Valve stem, diameter:

Inlet/Exhaust.....8 mm

Valve seat angle (A):

Inlet.....29,5°
Exhaust.....44,5°

Seat angle in cylinder head (B):

Inlet.....30°
Exhaust.....45°

Specifications Wear tolerance

Measurement between valve disc and cylinder head face: Max 1.5 mm
Inlet.....0.9 -1.4 mm Max 1.8
Exhaust.....1.2 -1.7 mm

Note: The valves must also be replaced when replacing the valve seats.

Valve clearance cold engine, adjustment value:

Inlet.....0.2 mm
Exhaust.....0.5 mm
Exhaust, VEB.....1.6 mm

Valve clearance cold engine, check value:

Inlet.....0.15 - 0.25 mm
Exhaust.....0.45 - 0.55 mm
Exhaust, VEB.....1.55 - 1.65 mm

Valve seats

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Standard Oversize

Outside diameter (A): 43.3 mm

Inlet/Exhaust.....43.1 mm

Height (B) :
D12C, D12C Mark 3
Inlet.....8.5 mm
Outlet.....8.0 mm
D12C Mark 4 and 5, D12D
Inlet.....7.3 mm
Outlet.....8.0 mm

Valve seat location

Standard Oversize

Diameter (C): 43.2 mm

Inlet/Exhaust.....43.0 mm

Depth (D):
Inlet/Exhaust.....11.2 mm

Seat bottom radius (R):

Inlet/Exhaust.....max 0.8 mm

Valve guides

Length:
Inlet/Exhaust.....83.3 mm

Inner diameter:
Inlet/Exhaust.....8 mm

Height above cylinder head spring surface:

D12C, D12C Mark 3
Inlet.....26.5±0.4 mm
Exhaust.....18.5±0.4 mm
D12C Mark 4 and 5, D12D
Inlet/Exhaust.....26.5±0.4 mm

Wear tolerance
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Clearance valve stem-guide:1 .....max 0.7 mm

1
The measurements are calculated for the measurement method described in the service literature, see group 214.

Valve springs

A. right-hand coil
B. left-hand coil

Exhaust

Outer valve spring:

Right-hand coil0
Length unloaded.....72 - 73 mm
With 600 N load.....56 mm
With 1076 N load.....43 mm
Rigid length max.....41 mm
Left-hand coil
Length unloaded.....73 - 74 mm
With 590 N load.....58 mm
With 1150 N load.....45 mm
Rigid length max.....40 mm

Inner valve spring:

Left-hand coil
Length unloaded.....67-68 mm
With 243 N load.....52 mm
With 447 N load.....39 mm
Rigid length max.....36 mm
Right-hand coil
Length unloaded.....70-71 mm
With 330 N load.....54 mm
With 630 N load.....41 mm
Rigid length max.....37 mm

Inlet

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Right-hand coil1
Length unloaded.....72 - 73 mm
With 600 N load.....56 mm
With 1076 N load.....43 mm
Rigid length max.....41 mm
Left-hand coil
Length unloaded.....73 - 74 mm
With 590 N load.....58 mm
With 1150 N load.....45 mm
Rigid length max.....40 mm

1
There are two versions of valve spring available with different coil directions. For further information, see group 21.

Rocker arms

Bearing play.....max 0.1 mm

Rocker arm roller, play.....max 0.1 mm

Engine timing gear

Timing gear

Number of teeth:

1. Crankshaft.....38

2. Idler gear.....83

3. Coolant pump.....27
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

4. Air compressor.....29

5. Camshaft.....76

6. Idler gear (adjustable).....97

7. Power steering pump.....23

8. Driving device (pulley and fuel pump).....27

9. Idler gear.....71

10. Hydraulic pump.....39

11. Lubricating oil pump.....23

Backlash.....0.05-0.17 mm

Shaft journal for idler gear, diameter.....99.99±0.01

mm

Idler gear bush, diameter.....100.04±0.01 mm

Diametrical clearance for idler gear.....max 0.07 mm

End float, idler gear.....max 0.17 mm

Timing gears, Turbo Compound

D12D500

Backlash.....0.07-0.37 mm

Shaft journal, diameter.....139.96-139.98 mm

Diametrical clearance for idler gear.....max 0.08 mm

Number of teeth:
Drive gear, crankshaft.....134
Idler gear.....106

Drive gear, output shaft Turbo Compound.....21

Camshaft

Control of camshaft settings, cold engine and valve clearance for cylinder 1 inlet valve = 0.
Inlet valve for cylinder 1 shall be open 1.6±0.3 mm at flywheel position 6° after t.d.c.
When checking, the timing gears must be rotated in the correct direction (clockwise seen from the front) in
order to take up all tooth backlash.

Axle arrangements.....gear

Number of bearings.....7

Diameter, bearing journals, standard.....69.97-70.00 mm

Note: Check values only, not for machining.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Diameter, bearing journals, undersize:

0,25.....69.72-69.78 mm
0,50.....69.47-69.53 mm
0,75.....69.22-69.28 mm

Valve lift:
inlet.....13.1 mm
exhaust (VEB).....13.1 mm
exhaust (EPG).....12.0 mm

Permitted wear, whole cam profile.....max 0.1 mm

Unit injector, stroke.....17 mm

Wear tolerance

Axial clearance.....< 0.24 mm

Out of round (with new bearings).....< 0.05 mm

Bearing, permitted diametrical wear.....< 0.05 mm

Camshaft bearings

Camshaft bearing thickness, standard.....1.92 mm

Oversize:
0,25.....2.04 mm
0,50.....2.17 mm
0,75.....2.29 mm

Crank mechanism

Crankshaft

Length.....1203 mm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Crankshaft axial clearance1 .....0.10 - 0.40 mm

Main bearing radial play1 .....0.01 - 0.15 mm

Ovality of main bearing journals and big-end

bearing journals.....max 0.08 mm

Taper of main bearing journals and big-end bearing

journals.....max 0.05 mm

Runout of middle bearing.....max 0.15 mm

1
The measurements refer to lubricated components.

Thrust washers (axial bearing)

Width (B) standard.....3.1-3.2 mm

Oversize:
0.1 mm.....3.2-3.3 mm
0.2 mm.....3.3-3.4 mm
0.3 mm.....3.4-3.5 mm

Main bearing shells

Outer diameter (C) .....113.0 mm

Thickness (D) standard.....2.5 mm

Oversize:
0.25 mm.....2.6-2.7 mm
0.50 mm.....2.7-2.8 mm
0.75 mm.....2.8-2.9 mm
1.00 mm.....2.9-3.0 mm
1.25 mm.....3.1-3.2 mm

Main bearing journals

Note: Check values only, not for machining.

Diameter (Ø) standard.....108.0 mm

Undersize:
0.25 mm.....107.73-107.75 mm
0.50 mm.....107.48-107.50 mm
0.75 mm.....107.23-107.25 mm
1.00 mm.....106.98-107.00 mm
1.25 mm.....106.73-106.75 mm

Surface finish, main bearing journal.....Ra 0.25

Surface finish, radius.....Ra 0.4

Width, axial bearing pin (A) standard.....47.0 mm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Oversize:
0.2 mm (axial bearing 0.1).....47.17-47.22 mm
0.4 mm (axial bearing 0.2).....47.37-47.42 mm
0.6 mm (axial bearing 0.3).....47.57-47.62 mm

Recess radius (R) .....3.75-4.00 mm

Big-end bearing journal

Note: Check values only, not for machining.

Diameter (Ø) .....92.0 mm

Undersize:
0.25 mm.....91.73-91.75 mm
0.50 mm.....91.48-91.50 mm
0.75 mm.....91.23-91.25 mm
1.00 mm.....90.98-91.00 mm
1.25 mm.....90.73-90.75 mm

Surface finish, big end bearing journal.....Ra 0.25

Surface finish, radius.....Ra 0.4

Width (A) .....56.9-57.0 mm

Recess radius (R) .....3.75-4.00 mm

Big end bearing shells

Outer diameter (B) .....96.85 mm

Thickness (C) standard.....2.39-2.40 mm

Oversize:
0.25 mm.....2.51-2.52 mm
0.50 mm.....2.64-2.65 mm
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

0.75 mm.....2.76-2.77 mm
1.00 mm.....2.89-2.90 mm
1.25 mm.....3.01-3.02 mm

Diameter, bearing shell bearing seat (D) .....96.84-96.85 mm

Connecting rod

Length centre - centre (E) .....260 mm

Gudgeon bushing internal diameter (G) .....55.022 — 55.028mm

End float, connecting rod - crankshaft1 .....max 0.25 mm

Big-end bearing, radial play1 .....max 0.10 mm

Straightness, max deviation per 100 mm of measured length

.....0.06 mm

Torsion, max deviation per 100 mm of measured length

.....0.15 mm

1
The measurements refer to lubricated components.

Marking:
FRONT on the shaft is turned forward.

Connecting rod and cap1 .....1 to 6. Two-part con rods and caps are marked in pairs with a
three-digit serial number.

1
With markings opposite each other.

Flywheel, fitted

Axial runout (manual gearbox) measurement radius 150 mm.....< 0.20 mm

Number of teeth on starter gear ring.....153

Sensor groove on flywheel.....3 x 18

Flywheel housing, fitted

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Axial run-out of contact surface against clutch housing.....< 0.20 mm

Radial run-out of guide against clutch housing.....max 0.25 mm

Lubrication and oil system

Oil

Oil change volume, see service information group 17.

Oil pressure

Operating speed (over 1100 rpm).....300-550 kPa

Idle.....min 150 kPa

Oil Pressure, rocker arm shaft

Non-activated VEB.....100 kPa

Activated VEB.....min 200 kPa

Oil pressure, Turbo compound

Operating speed (over 1100 rpm).....min 250 kPa

Idle.....min 150 kPa

Oil temperature

Cold engine, engine stopped.....ambient temperature

Warm engine, engine running (coolant temperature 75-95° C).....65-105° C, up to 125° C with high engine load

Oil filter

Quantity

Full-flow filter (tighten 1/2 -3/4 turns after contact).....2

Bypass filter (tighten 3/4 -1 revolution after contact).....1

Lubricating oil pump

Type.....Gear driven

Number of teeth:
drive gear.....23
idler wheel.....44

Diameter:
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

hub, idler gear.....69.99±0.01 mm

bush, idler gear.....70.04±0.02 mm

Axial play:
drive gear, pump.....0.11 mm
idler wheel.....0.10 mm

Distance, drive gear-pump housing bracket.....1.0-2.4 mm

Oil valves

D12C and D12D340/380/420/460

1. Safety valve
Marking.....Yellow

2. Control valve, oil cooler

Marking.....124

3 and 5. Overflow valve, oil filter

Spring, free length.....69 mm
With load of 13-15 N (1.3-1.5 kp).....40 mm

4. Piston cooling valve

Marking.....Orange

6. Reduction valve
Marking.....Blue

D12D500

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

1. Safety valve
Marking.....Yellow

2. Control valve, oil cooler

Spring, free length.....69 mm
With load of 13-15 N (1.3-1.5 kgf).....40 mm

3 and 4. Overflow valve, oil filter

Spring, free length.....69 mm
With load of 13-15 N (1.3-1.5 kp).....40.0 mm

5. Control valve, piston cooling

Spring, free length.....122 mm
With 60 N (6 kgf) load.....84 mm

6. Opening valve, piston cooling

Spring, free length.....122 mm
With 95 N (9.5 kgf) load.....63 mm

7. Reduction valve
Marking.....Blue
Opening pressure.....4.4-5.1 kPa

Fuel system

Injection sequence

Firing sequence.....1-5-3-6-2-4

Fuel feed pump

Feed pressure at:

600 rpm.....min 100 kPa
1400 rpm.....min 300 kPa
full load.....min 300 kPa

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Overflow valves

Opening pressure
D12C .....400-450 kPa
D12D .....360-420 kPa

Fuel volume

At low idling speed and unladen engine, the fuel quantity should be in range B. The vehicle must have been run-in for
at least 30.000 km.

Unit injectors

Tighten the adjustment screw to zero clearance against the camshaft, then turn 3-4 flats.

Pre-tension
Bosch1 .....68.9±0.1 mm
Delphi.....3-4 flats (0.75±0.1 mm), see illustration.

1
Setting using gauge.

Cylinder balancing

Cylinder balancing, VCADS

maximum compensation
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

D12C.....±30%
D12D.....±80%

Inlet and exhaust system

Charge pressure and response

Intake pressure 1 Response values 2

D12C/D 340: 101 kpa/1.16 V 2 - 3 sec

1200 rpm..... 124 kpa/1.43 V 2 - 3 sec
1400 rpm..... 117 kpa/1.36 V 2 - 2.5 sec
1600 rpm..... 116 kpa/1.34 V 2 - 2.5 sec
1800 rpm.....

D12C/D 380: 124 kpa/1.43 V 2 - 3 sec

1200 rpm..... 141 kpa/1.62 V 2 - 2.5 sec
1400 rpm..... 138 kpa/1.59 V 2 - 2.5 sec
1600 rpm..... 129 kpa/1.49 V 2 - 2.5 sec
1800 rpm.....

D12C/D 420: 123 kpa/1.42 V 3 - 4 sec

1200 rpm..... 149 kpa/1.72 V 3 - 3.5 sec
1400 rpm..... 149 kpa/1.72 V 2.5 - 3 sec
1600 rpm..... 142 kpa/1.63 V 2.5 - 3 sec
1800 rpm.....

D12C/D 460: 142 kpa/1.63 V 3.5 - 4 sec

1200 rpm..... 167 kpa/1.92 V 2 - 3 sec
1400 rpm..... 167 kpa/1.92 V 1.5 - 2.5 sec
1600 rpm..... 151 kpa/1.74 V 2.5 - 3 sec
1800 rpm.....

D12D 500: 179 kpa/2.06 V 2.5 - 3 sec

1200 rpm..... 178 kpa/2.05 V 2.5 - 3 sec
1400 rpm..... 174 kpa/2.00 V 2 - 2.5 sec
1600 rpm..... 161 kpa/1.85 V 2 - 2.5 sec
1800 rpm.....

1
If eco-diesel is being used, the table values must be reduced with 5 kPa and 0.06V.

2
Response times from 0 kPa charge pressure to 90% of max. charge pressure.

Turbocharger

End float turbine rotor shaft.....max 0.1 mm

Exhaust back-pressure

Exhaust back-pressure, max......15 kPa

Charge air temperature sensor

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Cold engine, engine switched off.....Ambient temperature

Warm engine, engine running (coolant temperature 75-95° C).....10-30° C above ambient temperature

Pressure-drop indicator

Pressure drop indicator lights at a vacuum of.....5 kPa

Outside temperature sensor

Cold engine, engine switched off.....Ambient temperature

Warm engine, engine running (coolant temperature 75-95° C).....max 25° C above ambient temperature

Exhaust pressure governor

Stroke, throttle (A).....min 29 mm

Heat retention function

Air pressure for exhaust pressure governor:

D12C .....200±30 kPa
D12D .....230±30 kPa

Air pressure during exhaust braking:

D12C .....750±30 kPa
D12D .....see separate table

Heat retention activated:

coolant temperature.....<70° C
engine load.....<50%
atmospheric pressure.....>80 kPa

Heat retention deactivated:

coolant temperature.....>70° C
engine load.....>50%
atmospheric pressure.....<80 kPa
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Engine brake D12D

2-way switch can give 100% braking power.

3-way switch can give 50% or 100% braking power.
4-way switch can give 100% braking power (only VCB and auto box).
5/6-way switch can give 40, 70 or 100% braking power.

VEB

Braking force (%) EPG pressure (kPa) VCB (on/off)

40% 690 off

60 kPa to EPG and VCB active can
give 40% braking force and can
occur under certain conditions, for
example if 40% brake torque has
been requested at low speed or if
the required braking force is
reduced from 100% brake torque,
for example.

50% 160 on

70% 400 on

100% 750 on

Cruise mode 50-750 auto on/off

EPG / EPGC

Braking force (%) EPG pressure (kPa)

40% 330

50% (410)
It should not be possible to obtain 50% other than in
the automatic position

70% 560

100% 750

Cruise mode 50-750

Activated:
engine speed.....>900 rpm
vehicle speed.....>5 km/h

Deactivated:
engine speed.....<800 rpm
vehicle speed.....<5 km/h

VCB

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Braking force (%) VCB (on/off)

40% off

50% on

70% on

100% on

Cruise mode auto on/off

Activated:
engine speed
The value must be increased with 300 rpm for the first five activations. Applies at engine oil temperatures
55-70° C.
.....>1000 rpm
vehicle speed.....>5 km/h
engine oil temperature.....>55° C
charge pressure.....<50 kPa (not TC) / unlimited (TC)

Deactivated:
engine speed.....<900 rpm
vehicle speed.....<5 km/h
engine oil temperature.....<55° C
charge pressure.....>70 kPa (not TC) / unlimited (TC)

Cooling system

General

Pressure valve opens at.....75 kPa

Volume:
radiator WID.....44 litres
radiator NAR.....42.5 litres

Coolant

Type.....Volvo Original
Contains.....Glycol and anti-corrosion additives
Colour.....Green
Mixed with.....Tap water

Corrosion protection
Use only when anti-freeze is not necessary.
Type.....Volvo Original
Mixed with.....Tap water

Note: Anti-corrosion additive must not be mixed with coolant or anti-corrosion additives of another type.

Thermostat
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Quantity.....1

Opening temperature.....82° C

Thermostatic fan

Speed, engaged (at engine speed 1800 rpm)

Fan pulley diameter 167 mm.....2400 rpm
Fan pulley diameter 191.....2150 rpm
Fan pulley diameter 214.....1900 rpm

Speed, disengaged.....500-1000 rpm

Engagement temperature.....75° C in front of fan

Electric Visco fan

Activated system Notes Conditions Fan engagement

Coolant temperature I-shift - coolant temperature. 93°C >400 rpm
Geartronic
R/SR-manual

Coolant temperature Compact Retarder - coolant temperature. 90°C >400 rpm

Coolant temperature Powertronic - coolant temperature. 86°C >400 rpm

EECU-temp. -EECU-temp. >95°C 1200 rpm

Charge air temp. - charge air temp. >70°C 1200 rpm1

- engine torque >½ of max Nm

Compact Retarder Request for fan activation is sent: 2 1200 rpm

- vehicle speed >0 m/s5

AND
- retarder torque >0%
AND
propeller shaft speed >400 rpm
AND
- retarders coolant temperature.
>100 °C
OR
retarders oil temperature. >170 °C
Request for fan deactivation is
sent: 3
- vehicle speed =0 m/s5
AND
- retarder torque =0%
OR
propeller shaft speed <300 rpm
AND
- retarders coolant temperature. <
99 °C
OR
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

retarders oil temperature. < 150 °C

Powertronic retarder Request for fan activation is sent: 4 1200 rpm

- vehicle speed >0 m/s5

OR
- retarder torque >0%
OR
retarders oil temperature. >120 °C
OR
- gear box oil temperature. >97 °C
Request for fan deactivation is
sent: 6
- vehicle speed =0 m/s5
OR
- retarder torque =0%
OR
retarders oil temperature. < 115 °C
OR
- gear box oil temperature. < 92 °C

1
1.5 second delay after engine brake has been activated.

2
NOTE! A request for fan activation is sent when the demand for vehicle speed AND retarder torque AND propeller
shaft speed AND (retarders coolant temperature OR retarder oil temperature) is met.

3
NOTE! A request for fan deactivation is sent when the demand for vehicle speed AND (retarder torque OR propeller
shaft speed) AND retarder coolant temperature OR retarder oil temperature) is met.

4
NOTE! Request for fan activation is sent when ANY of the following requirements are met.

5
40 seconds after retarder braking has started

6
NOTE! Request for fan activation is sent when ANY of the following requirements are met.

AC system - engine speed >1500 rpm 1200 rpm

inlet temp. >50 °C
- ambient temp. >40 °C
- vehicle speed <45 kph

AC system - engine speed >1200 rpm 1000 rpm

inlet temp. >40 °C
- ambient temp. >30 °C
- vehicle speed <45 kph

AC system inlet temp. >45 °C 1200 rpm

- ambient temp >35 °C
- vehicle speed <10 kph

AC system inlet temp. >30 °C 600 rpm

- ambient temp >20 °C
- vehicle speed <20 kph

Pneumatic system Vehicles with - engine speed >700 rpm 800 rpm
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

pneumatically controlled - inlet temp. >10 °C

air drying and air - ambient temp. >0 °C
suspension - vehicle speed <45 kph
- system pressure <1020 kPa
- system pressure 1020-1200 kPa
and rising

Pneumatic system Vehicles with - engine speed >700 rpm 800 rpm
pneumatically controlled - inlet temp. >10 °C
air driers and leaf spring - ambient temp. >0 °C
suspension - vehicle speed <45 kph
- pressure switch open
(compressor charging)

Pneumatic system Vehicles with electrically - engine speed >700 rpm 800 rpm
controlled air driers - inlet temp. >10 °C
- ambient temp. >0 °C
- vehicle speed <45 kph
- compressor charging

Engine control system

Engine control unit

Number of pins.....2 x 36

Sensor

Engine oil temperature sensor

Coolant temperature sensor

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Inlet temperature sensor

Charge air temperature sensor

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Charge pressure sensor

Check values.....1.05-1.30 V at 1001 kPa

1
Normal atmospheric pressure at standard sea level.

Pressure-drop indicator

Active.....V=0.48 × Ubat

Inactive.....V=0.12 × Ubat

Camshaft sensor

Distance to camshaft.....0.3-1.0 mm

Flywheel sensor

Distance to flywheel.....0.7-2.1 mm

Crankcase pressure sensor

Sensor alarm limit.....8 kPa1

.....5 kPa2
Crankcase pressure, normal value.....<1.0 kPa

1
up to and including datasets 20534805 and 20543404

2
from dataset 2055709 onwards

Note: These values means the difference between the atmosphere pressure and the crankcase pressure. As
reference, the atmosphere pressure is 100 KPa at sea level.

Tightening torques and patterns

Tightening torques group 20

General tightening torques

M6 standard bolt 8.8.....10±1,5 Nm

M8 standard bolt 8.8.....24±4 Nm
M10 standard bolt 8.8.....48±8 Nm
M12 standard bolt 8.8.....85±15 Nm
M14 standard bolt 8.8.....140±25 Nm
M16 standard bolt 8.8.....190±35 Nm

Only torque-tightened bolts can be refitted.

Torque-tightened and angle-tightened/yield-limit-tightened bolts:

8.8.....should not be refitted
10.9.....can be refitted
12.9.....can be refitted
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Note: Check bolts before refitting. Bolts showing damage, for example cut marks on the underside, should be
discarded.

Tightening torques group 21

Front engine mounting, cylinder block.....175±20 Nm

Front engine mounting, front mounting pad

normal and hard road surfaces.....140±25 Nm
very hard road surface.....160±25 Nm

Front engine pad, cross member.....80±15 Nm

Rear engine mounting, flywheel housing.....300±45 Nm

Rear engine mounting, flywheel housing TC (D12D500).....300±45 Nm

Note: Apply silicone sealant to the bolt before assembly.

Rear engine mounting, rear engine pad:

Screw union with 4 screws
step 1.....190±10 Nm
step 2.....255±37 Nm

Note: Tighten the bolts diagonally.

Screw union with 2 screws

.....540±80 Nm

Rear engine pad, frame.....140±25 Nm

Main bearing cap:

step 1.....150±20 Nm
step 2.....120±5° Angle-tightening

Connecting rod cap

step 1.....150±25 Nm
step 2.....90±3° Angle-tightening

Piston cooling valve, screw.....24±4 Nm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Reinforcement frame:
step 1: Tighten the bolts 1-6 in numerical order......48±8 Nm
step 2: Tighten the bolts 7-26 in numerical order......15 Nm + 90±5° Angle of tightening

D12D 500
step 1: Tighten the bolts 1-8 in numerical order......48±8 Nm
step 2: Tighten the bolts 9-33 in numerical order......24±4 Nm + 90±5° Angle of tightening

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Flywheel

Note: Tighten the bolts in the numerical order shown in the illustration.
The bolts must not be reused!

D12C/D 340/380/420/460
step 1.....60±5 Nm
step 2.....60±5° Angle-tightening
For engines fitted with PTO-fly, the following applies:
step 1.....70±5 Nm
step 2.....140±5° Angle-tightening

D12D 500
step 1.....60±5 Nm
step 2.....120±10° Angle-tightening

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Oscillation damper
step 1.....20±3 Nm
step 2.....90±5° Angle-tightening

The bolts for the vibration damper must be tightened in numerical order.
All bolts must be tightened to step 1, before being tightened to step 2.

Note: The vibration damper's 8.8 bolts must not be reused.

Flywheel housing

D12C/D 340/380/420/460 D12D500

Apply a string of silicone sealant between the flywheel Apply a bead of silicone sealant between the flywheel
housing and the cylinder block as shown in the picture. housing and the TC timing gear plate as illustrated and
Thickness ∅2 mm. Max 20 minutes before assembly. also around both the marked holes. Thickness ∅2 mm.
Max 20 minutes before assembly.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Tighten bolts in numerical order

as illustrated......140±14 Nm

Valve cover.....20±2 Nm

Note: Tighten the bolts in the numerical order shown in the illustration.

Stud, valve cover.....30±3 Nm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Oil cooler, cover

Note: Always use guide pins when installing the cover on the engine.

Fit bolts A and B.....24±4 Nm

Tighten bolts C and D......24±4 Nm
Tighten the cover bolts in numerical order from the centre and outwards (1–4), see illustration .....24±4 Nm
Re-tighten bolts C and D......24±4 Nm

Cylinder head:

Note: Tighten the bolts in the numerical order shown in the illustration.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

stage 1.....60±10 Nm
stage 2 (check tighten).....60±10 Nm
stage 3.....90±5° Angle-tightening
stage 4.....90±5° Angle-tightening

Cleaning plug, cylinder head.....60±10 Nm

Lock nut, valve adjustment screw.....60±5° Angle-tightening

Lock nut, valve calliper (EPG).....60±5° Angle-tightening

after contact

Lock nut, valve calliper (VEB).....30 +10 –0 ° Angle-tightening

/
after contact

Timing gear plate.....33±4 Nm D12D 500

Timing gear plate, Turbo Compound timing gear.....24±4
Note: Apply silicon to the front of the cylinder block as
shown in the illustration. Also apply around the marked Note: Apply silicon to the back of the cylinder block as
holes. shown in the illustration.
Continuous line = ∅2mm Thickness ∅2 mm.
Dotted line (area A) = ∅1 mm Max 20 minutes before assembly.
Max 20 minutes before assembly.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Bearing cap, camshaft/rocker arm shaft:

stage 1.....15±5 Nm + 90±5°
stage 2.....60±5 Nm

Note: In step 2, the bolts must be tightened in stages to ensure that the rocker arm shaft is screwed home without
bending.

stage 3.....15±5 Nm + 120±5°

stage 4 (loosen the bolts).....60-0 Nm
stage 5.....15±5 Nm + 120±5°

Timing gear

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the Volvo Group
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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

D12D 500
TC timing gear:

Drive gear, crankshaft.....50±12 Nm

Idler gear.....50±12 Nm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Timing gear cover, upper:

M8.....24±4 Nm
M10.....48±8 Nm

Note: Tighten the bolts in the numerical order shown in the illustration.
Apply silicone sealant as illustrated. Thickness ∅2 mm. Max 20 minutes before assembly.

Tightening torques group 22

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the Volvo Group
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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Oil sump (pressed steel).....24±4 Nm

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the Volvo Group
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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Note: The bolts at the joints of the metal profiles (marked with an X must be tightened first.

Oil sump (plastic).....24±4 Nm

Note: Tighten the bolts in the numerical order shown in the illustration.

Drain plug, oil sump.....60±10 Nm

Bracket, oil pump/main bearing cap.....24±4 Nm

Oil strainer, retaining screws on pump.....27±4 Nm

Oil jet, transmission.....33±4 Nm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Oil cooler, securing screws:

Step 1: Tighten the screws in order 1, 2, 3, 4.....10±4 Nm
Step 2: Tighten the screws in order 1, 2, 3, 4, 1.....27±4 Nm

Pressure pipe

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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Step 1:
Tighten the fitting in the cylinder block until it bottoms (approx. 10 Nm)

Step 2:
New pipe.....180° Angle-tightening
Pipe being refitted.....60° Angle-tightening
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Safety valve.....50±2 Nm

Reduction valve.....50±2 Nm

Oil filter, bracket.....24±4 Nm

Tightening torques group 23

Fixing yoke, unit injector (when changing copper sleeve) 1

First tightening:
step 1.....20±5 Nm
step 2.....180±5° Angle-tightening
Loosen the retaining yoke screw before the second tightening.
Second tightening:
step 1.....20±5 Nm
step 2.....60±5° Angle-tightening

Fixing yoke, unit injector (when not changing copper sleeve)

step 1.....20±5 Nm
step 2.....60±5° Angle-tightening

1
The tightening method applies only when fitting a new copper sleeve, since the first tightening bottoms the copper
sleeve.

Lock nut for adjusting bolt, unit injector:

alt.1.....52±4 Nm
alt.2.....45±5° Angle-tightening

Nut, electrical connector, unit injector.....1,5±0,5 Nm

Hollow screw, overflow valve.....55±5 Nm

Fuel filter, bracket.....40±5 Nm

Tightening torques group 25

D12C and D12D 340/380/420/460

D12D 500

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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41 / 43
IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Exhaust manifold:
Step 1.....Tighten bolts 1 to 10 Nm (maximum)
Step 2.....Tighten bolts 2 to 10 Nm (maximum)
Step 3.....Tighten the bolts 3 to 52±4 Nm
Step 4.....Tighten the bolts 2 to 52±4 Nm
Step 5.....Tighten the bolts 4 to 52±4 Nm
Step 6.....Tighten the bolts 1 to 52±4 Nm

Clamp, exhaust manifold.....28±4 Nm

Exhaust pressure governor/turbine housing.....12±2 Nm

Control valve (VEB).....20±3 Nm

Electrical connection nut, VEB valve.....1,5±0,5 Nm

Turbocharger.....48±5 Nm

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the Volvo Group
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42 / 43
IMPACT 4.00.51.00-SNAPSHOT 04/06/11

Tightening torque, turbo

X Studs in exhaustmanifold and turbo..... 24±2,4 Nm

Step 1, tighten nuts 1–4..... 20±4 Nm

Step 2, tighten nuts 1–4..... 48±8 Nm

Tightening torques group 26

Thermostat connection
Bolt 8.8.....24±4 Nm
Bolt 10.9.....30±4 Nm

D12D 340/380/420/460
Fan hub, stud.....14±3 Nm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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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