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IMPACT 3.

0 Monday, 26 December 2016

Chassis ID Path
215/Repair/FH12, D12F390/Camshaft, replace

Model Identity
FH12 55442047

Publish date Operation No.


Tuesday, 21 February 2006 21522-2

21522-2 Camshaft, replace


The meanings for the variants used in this service procedure are presented as follows:

EBR-EPG Exhaust pressure governor

EBR-VEB Volvo engine brake

FUELCS-L Lucas unit injector

FUELCS-B Bosch unit injector

Note: Whenever working on the cylinder head, keep it as clean as possible. Dirt particles may damage the unit
injectors.

Special tools: 9996956, 9998081, 9998255, 9998264, 9998583, 9998658, 9998659

Other special equipment: 1159794, 9989876, 9999696

Remove the valve cover.

Caution
Do not use an impact wrench to remove the bolts. Doing so may loosen the bolts from the cylinder head and
can damage the electrical wiring and the valve cover.

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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 3.0 Monday, 26 December 2016

Remove the inspection cap located under the engine flywheel housing. Install the cranking tool 9996956 to turn the
engine flywheel manually.

Special tools: 9996956

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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 3.0 Monday, 26 December 2016

Crank round the flywheel until the piston in cylinder no. 1 is in the Top Dead Centre position, 0 on the flywheel and the
camshaft marking (TDC) is opposite the marking on the bearing cap.

Items 4 - 6 (valid for EBR-VEB, FUELCS-L, FUELCS-B)

Clean round the VEB control valve and remove the electric connections from the valve.

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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 3.0 Monday, 26 December 2016

Remove the stud bolt positioned in front of the VEB control valve.

Take out the attachment bolts and remove the VEB control valve. Also remove the pipe and seals between the control
valve and rocker arm shaft.

Note: Store the control valve and pipe in a place free from dust and dirt. Install a protective plug in the cylinder head oil
hole.

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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 3.0 Monday, 26 December 2016

Gradually slacken the rocker arm bridge bolts along the length of the shaft so as not to distort the rocker arm bridge.

Remove the bolts, install the tool 9998255 and lift off the rocker arm bridge.

Note: On engines equipped with VEB, secure the rocker arm plungers with rubber bands so that the plungers do not
fall out when the rocker arm bridge is lifted up.

Special tools: 9998255

9
Mark the camshaft bearing caps for the respective bearing bracket.

10
Take out the bolts and remove the bearing caps. Use the tools 9998658 and 9998659 to remove the bearing caps.

Special tools: 99986583 9998659

11

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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 3.0 Monday, 26 December 2016

Carefully lift off the camshaft with tool 9998264.

Special tools: 9998264

12
Remove and examine all the bearing shells.

If any of the bearings have seized, the reason must be established before new bearing shells and camshaft are
reinstalled.

Check the bearing brackets and bearing caps for damage. If one or more of the bearing housings are damaged, refer
to 215243 Camshaft bearing brackets, replacement.

13

Lubricate the valve calipers and camshaft lobes with engine oil. Make sure that bearing shells of the correct size are
installed and that they are positioned correctly in their seats.

14

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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 3.0 Monday, 26 December 2016

Carefully lift the camshaft into place. Remove the tool 9998264.
Install the bearing caps and respective bolts. Do not install the bolts for the rocker arm shaft.
To prevent the bearing caps from moving, screw and tighten a M10x80 bolt in the hole without a guide stud located in
the support bearing cap.

Special tools: 9998264

15
Install the camshaft gear, the pole wheel and the vibration damper.
Tighten the bolts using the torque specified in the Service Publications, Group 20.

Special tools: 1159794

16

Lubricate the valve bridges and camshaft cams with engine oil.
Install the rocker arm assembly. Check that the valve bridges and the rocker arms are lined up.

Special tools: 9998255

17

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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 3.0 Monday, 26 December 2016

Install the bolts for the rocker arm assembly and tighten them gradually along the length of the shaft, a bit at a time, to
avoid the risk of distorting the camshaft shaft. Make sure that the guide-pins fit properly in the support bearings.

Tighten the bolts for the bearings and rocker arm shaft according to the tightening torque and sequence specified in the
Service Publications, Group 20.

Special tools: 1159794

Items 18 - 22 (valid for EBR-VEB, FUELCS-L, FUELCS-B)

18
Remove the rubber bands from the VEB rocker arm plungers.

19

Remove all traces of oil from the pipe for the VEB control valve.
Lubricate the hole in the rocker arm shaft.
Install a new sealing ring on the pipe and press the pipe into the rocker arm shaft with the help of the extension piece.
Make sure that the sealing ring is correctly positioned.

20
Install a new sealing ring on the pipe and install the VEB control valve.

Note: Check that the oil channel plug is removed. Use a new sealing ring between the control valve and cylinder head
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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 3.0 Monday, 26 December 2016

and make sure that it is correctly positioned before securing the control valve.

Tighten the bolts using the torque specified in the Service Publications, Group 20.

Special tools: 1159794

21

Connect the electric cables to the solenoid valve but do not tighten the connections too hard so as to avoid damaging
the valve.

22

Install the stud bolt positioned in front of the control valve.

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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 3.0 Monday, 26 December 2016

23

To check that the camshaft is properly installed, check the valve height on the first cylinder.
Check that the camshaft marking (TDC) is opposite the marking on the bearing cap.
Set to zero the play on the first rocker arm in relation to the valve bridge. Position a dial gauge with its measuring tip
contacting the valve bridge. Set a 2-3 mm pre-load in the dial gauge.
Turn the engine in the revolution direction approximately one turn and a further 6 up to the marking 6 after the TDC on
the flywheel. Read off the value measured by the dial gauge. Compare it with the value specified in the Service
Publications, Group 20.

24

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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 3.0 Monday, 26 December 2016

Alternative 1

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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 3.0 Monday, 26 December 2016

Alternative 2

Turn the engine.


There are two alternatives to do it as described bellow:
Alternative 1:
Install the cranking tool 9996956 to turn the engine flywheel manually.
Alternative 2:
Before turning the engine with the starter motor, do as follows:

Check that the parking brake is applied and that the gear lever is in neutral.
Remove the voltage supply fuse for the control unit to avoid starting the engine accidentally.
Connect a pressure switch between the starter motor positive pole and the ignition switch coil.

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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 3.0 Monday, 26 December 2016

Special tools: 9996956

25
Adjust the valves according to service procedure 21413-2 Valves and unit injectors, adjusting.

26
Remove the starter switch and install the voltage supply fuse for the control unit.

27

Install the valve cover and tighten the bolts according to the tightening sequence.

Note: Check that the nut flanges and rubbers fit the valve cover holes properly to prevent damage to the valve cover.
Tighten the nuts using the torque specified in the Service Publications, Group 20.

Special tools: 1159794

28
Start the engine and allow it to idle for approximately 5 minutes to purge any air remaining in the fuel system.
Check the sealing in all fuel pipe connections.

29
When the engine reaches its normal operating temperature, keep it running for 5 more minutes at idle. The system
finishes adjusting cylinder balancing and fuel injection when the idle speed is stabilized.

Note: Do not connect any power consumption device such as a power take-off or the air conditioning when balancing
the cylinder.

COPYRIGHT 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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