Service Bulletin

Volvo Trucks North America, Inc.

Greensboro, NC USA Trucks
Date Group No. Page
This Service Bulletin replaces SB 25026, Intake and
Exhaust Systems, Fault Tracing, Checklist A, D12D
11.2004 250 26 1(22)
(9.2004), publication no. PV77620 009406.
Intake and Exhaust Systems
Fault Tracing
Checklist A
D12D
Intake and Exhaust Systems, Fault Tracing
Checklist A

W2004441

This information covers fault tracing components of the intake and exhaust systems of
the Volvo D12D engine.

Contents
General Guide to Fault Tracing page 2
Intake and Exhaust System, Fault Tracing page 3
Intake and Exhaust System, 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 represented as
accurately as possible.

PV776-20 019581 USA16280

Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 2(22)

General Guide to Fault Tracing

You must read and understand the precautions and guidelines in Service
Information.1, "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

information 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.

1
IMPACT or ID DVD: Info type General Information group 200
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 3(22)

Intake and Exhaust System, Fault Tracing

See also:

General Guide to Fault Tracing page 2

Symptom See Steps

Low power 1, 2, 3, 4, 5, 6, 7, 8, 9, 10
Black smoke 1, 3, 5, 6, 7, 8, 9, 10, 11
Blue smoke 8, 10, 11
White or gray smoke 2, 3, 8, 11
High fuel consumption 2, 3, 4, 5, 7, 8, 9

Vehicle Chassis Number Mileage Customer YES NO

1 Is the air filter element clean and unrestricted?

Does the air filer restriction gauge indicate a restriction of the air filter?

Action:

2 Main Air Pipe, Checking page 5

Are intake pipes and hoses free of faults between air filter and turbocharger?

Action:

3 Charge Air System, Leak Test page 5

Is charge air system free from leaks between the turbo and cylinder head?

Are the EGR reed valves free from damage or leaks?

Is the EGR system free from leaks?

Action:

4 Charge Air Cooler Pipe, Checking page 10

Are charge air pipes and hoses unobstructed and free of faults?

Action:

5 Charge Air Cooler, Checking page 10

Is the charge air cooler fault free?

Does the charge air cooler appear free of damage or debris?

Action:

6 Intake Manifold Pressure Sensor, Checking page 11

Set value on 9996662 0 kPa 50 kPa 100 kPa 150 kPa 200 kPa
(0 psi) (7 psi) (15 psi) (22 psi) (29 psi)
1.18 V 1.73 V 2.29 V 2.84 V 3.40 V

Measured values in VCADS ___ kPa ___ kPa ___ kPa ___ kPa ___ kPa
Pro ___ (psi) ___ (psi) ___ (psi) ___ (psi) ___ (psi)

Voltage measurement ___ Volts ___ Volts ___ Volts ___ Volts ___ Volts
Intake manifold pressure sensor values are correct?

Is the intake manifold pressure the same in VCADS as the pressure gauge?

Action:
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 4(22)

7 Exhaust Pressure Governor, Checking page 13

Is EPG shutter in retracted position?

Action:

8 Turbocharger, Checking page 15

Is the turbo part no. correct? (Part No. __________)

Is the compressor wheel undamaged (inlet side)?

Is the turbo end play within specifications?

Is the turbine wheel undamaged (exhaust side)?

9 Exhaust System, Checking page 17

Is the exhaust system genuine Volvo parts?

Is the exhaust system free from damage or modifications that can restrict exhaust gases?

Is the exhaust backpressure within the tolerance?

Action:

10 Intake Manifold Pressure Check at 100% Engine Load page 21

Is the expected intake manifold pressure within specification for the horsepower variant?

Refer to specifications, 1 minimum intake manifold pressure at 100% engine load.

Action:

11 Smoke Check page 22

Does the smoke opacity meter indicate excessive smoke?

Action:

Notes:

Completed by: Dealer: Date:

1
IMPACT or ID DVD: Info type Specification group 25 or Service literature binder set, Specifications group 200
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 5(22)

Intake and Exhaust System, Fault Tracing

Main Air Pipe, Checking
1
Check that the intake pipes are clean internally and
undamaged. Crushed, damaged, or dirty intake pipes or
hoses may result in lower intake manifold pressure or
abnormal smoke.

Charge Air System, Leak Test

Special tools: 9996662, 9998288, 9998289,
9990225, 85107488
Charge Air System Pressure Test
1
Remove the fresh air pipe between the air filter housing
and the turbo.

2
Attach test plate 9990225 to the turbo making sure that
feet on tool are properly secured to turbo. Tighten
mounting nuts and jam nuts. Do not overtighten
mounting nuts. Ensure that safety valve is attached
to plate.

CAUTION
Make sure safety pressure valve is installed in the
test plate or damage to the turbo seals could occur if
more than 1.1 bar (16 psi) is applied. The safety valve
relief pressure is 1.1 bar (16 psi).

9990225

W2004444

A. Test Plate 9990225

B. Safety valve
C. Pressure gauge/regulator 9996662

3
Unscrew the reduction valve counter-clockwise on
pressure gauge 9996662. Open the cut-off valve and
connect shop air hose and check that the gauge
is set at 0.

9996662

4
Connect pressure gauge/regulator 9996662 to test
plate 9990225.

9996662, 9990225
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 6(22)

5
Slowly increase pressure on the pressure gauge to
approximately 1 bar (14.5 psi). Shop air line must remain
connected for this test.
If no air pressure is displayed on the pressure gauge after
the reduction valve is turned clockwise, this indicates a
leak in the system. See step 6 for possible leak points.

CAUTION
Do not pressurize the system more than 1 bar
(14.5 psi).

CAUTION
Before the pressure gauge hose is removed, unscrew
the reduction valve to avoid damage to gauge.

1 bar (14.5 psi)

T2006950

6
Check the following for leaks:

Turbo compressor housing.

Charge air pipe and connections between turbo
and charge air cooler.
Joints between charge air cooler and charge air hoses.
Preheater housing gaskets.
Joints between charge air pipes and intake pipes.
Joint between intake manifold and cylinder head.
Connections and sensors on the intake pipe.
EGR pipe and connection between reed valve housing
and mixing chamber.
Damaged charge air cooler

Note:

Spray or brush soapy water onto suspected areas to

help trace leaks.

The pressure cannot be held constant, even if there

is no leakage in the system, since one of the intake
valves may be open.

Charge Air Cooler Pressure Test

7
VN Remove the lower hose between the charge air
cooler and the turbocharger charge air pipe (hot side).
VHD Remove the charge air hose/pipe from right (hot
side) charge air cooler.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 7(22)

8
Check that there is no oil in the charge air pipe or
the charge air cooler.

Note: If there is oil in the charge air pipes and charge air
hoses, the charge air cooler and all pipes and hoses
in the charge air system must be thoroughly cleaned
internally before the engine is started. If oil is found, see
Turbocharger, Checking page 15

9
VN Install sealing washer 9998289 and seal on the
charge air cooler (lower right side).
VHD Use kit 85107488. Attach hose (3) and plug (2)
and tighten hose clamps (1) supplied with kit (connected
to right (hot) side).

W2004454

VHD
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 8(22)

10
Remove the charge air hose (VN) or the elbow and hose
(VHD) from the left side of the charge air cooler (cool
side). Install connection washer 9998288 along with
seal to charge air cooler.

9998288

W2004455

VN

11
Before check is made, check pressure gauge/regulator
9996662. Connect shop air hose to tool 9996662. Open
the shut off valve and set gage to 100 kPa (1 bar)

9996662

T2006950
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 9(22)

12
Close the shut off valve. For the pressure gauge regulator
to be considered reliable, the pressure reading must not
drop during a period of 2 minutes.

T2006951

13
Connect pressure gauge 9996662 to connection
washer 9998288.

9996662, 9998288

14
Turn the reduction valve and set the pressure to 100 kPa
(14.5 psi). Close the shut off valve. For the charge air
cooler to be pressure-approved, the pressure reading
must drop no more than 20 kPa (3 psi) during a period of
one minute.
Note: Spray soapy water on tool connections to verify
that there are no leaks.

T2006977

15
After completing the checks, remove the test equipment
and reinstall the charge air pipes, hoses and fresh
air pipe.

CAUTION
Be sure that the sealing rings are undamaged and
correctly positioned.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 10(22)

EGR Reed Valve Leak Test

16
Possible fault code. MID 128 SID 281, reed valves
If EGR reed valves are suspected to be leaking, refer to
Service Information.2 Checklist R, EGR System Fault
Tracing (Reed Valve Leak Test).

Charge Air Cooler Pipe, Checking

1
Check the charge air pipes and hoses for leaks. Check
for visible cracks and external damage.

2
Check that there is no oil in the charge air pipes.

Note: If the pipes are damaged or there is leakage in the

connector sealing rings, the intake manifold pressure will
be too low and engine output will deteriorate.
If the inside of the pipes are contaminated with oil, this
indicates oil leakage at the turbo turbine shaft seal and
the entire turbocharger must be replaced.

Note: If there is oil in the charge air pipes and charge air
hoses, the charge air cooler and all pipes and hoses
in the charge air system must be thoroughly cleaned
internally before the engine is started.

Charge Air Cooler, Checking

1
Inspect the charge air cooler for damage in cells and
connections.

If there is damage, replace the charge air cooler; refer

to Service Information.3

2
Check the charge air cooler, the engine radiator and the
air conditioning system condenser. Check for external
blockage. (Winter-front, insects, leaves, etc.)

In the event of blockage, clean according to instructions

in Service Information.4
To check charge air cooler leakage, see Charge Air
Cooler Pressure Test page 6.

2
IMPACT or ID DVD: Info type Diagnostics group 2547
3
IMPACT or ID DVD: Info type Repair group 2651
4
IMPACT or ID DVD: Info type Repair group 2651
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 11(22)

Intake Manifold Pressure Sensor, Checking

Special tools: 9996662, 9998538, 9998699,
9990014
1
Possible fault code. MID 128 PID 102, Intake Manifold
Pressure Sensor. If active fault code, refer to fault
code information.5

2
Remove the pressure sensor from the intake manifold.

3
Connect tool 9998538 (A) to sensor and tighten hose
clamp.

W2004215

4
Attach pressure gauge 9996662 to test hose 9998538.

5
Turn the reduction valve counter-clockwise on pressure
gauge 9996662. Open the shut off valve and connect
shop air hose and check that the gauge is set at 0.

9996662

6
Turn the ignition key to ON position but DO NOT
START ENGINE.

5
IMPACT or ID DVD: Info type Diagnostics group 2841
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 12(22)

7
Connect the PC tool to the vehicle diagnostics connector.
Perform the Sensor values checks, engine not running
test. Check the sensor value for intake manifold pressure.
Follow the instructions in VCADS.

Note: The units should be set to Metric instead of US

to compare values in VCADS Pro and what is read on
pressure gauge 9996662. To change from US to metric
readings, go to the tool bar and select:
Tools
Options
General
Units

8
Increase the pressure on the pressure gauge to 50 kPa
(7 psi).

T2006950

9
Check that the value in VCADS corresponds to the set
value on the pressure gauge.

10

CAUTION
Do not exceed 250 kPa (36 psi) on the sensor. Doing
so can damage the sensor.

Compare the pressure at 50 kPa (7 psi), 100 kPa (14.5

psi), 150 kPa (22 psi), and 200 kPa (29 psi).
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 13(22)

11
Optional Check Sensor voltage check at EECU
Connect the breakout box and adapter.
Conditions

1 Measurement box with adaptor connected between

wiring harness and EECU lower connector (EA
connector).

2 Voltage measured with mulitmeter.

3 Ignition key in ON position.

4 Measurement points: EA22 (signal) EA11 (ground)

Manifold Pressure Voltage

0 kPa (0 psi) 1.18 v
50 kPa (7 psi) 1.73 v
100 kPa (14.5 psi) 2.29 v
150 kPa (22 psi) 2.84 v
T2021201 200 kPa (29 psi) 3.40 v

Note: Voltage values may vary depending the accuracy

of the pressure gauge. If this check is made with VCADS
Pro, the voltage listed should yield the pressure listed
when reading information from VCADS Pro.

9990014, 9998699

12
If the values are incorrect, but the sensor wiring and
connections are correct, replace the sensor.

Exhaust Pressure Governor, Checking

1
Remove the exhaust pipe from the EPG shutter housing.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 14(22)

2
Check whether the EPG shutter has become stuck in the
closed or half-closed position. If it is, replace or overhaul
the EPG according to instructions in Service Information.6.

Note: If a function check is needed, refer to Service

Information: EPG, Fault Tracing, Checklist E.7

W2003781

A 29 33 mm (1.15 1.30 in.)

6
IMPACT or ID DVD: Info type Repair group 2538
7
IMPACT or ID DVD: Info type Diagnostics group 2538
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 15(22)

Turbocharger, Checking
1
Check that the turbo unit part number corresponds to that
for the engine variant. Verify using the chassis ID (last 6
digits of VIN) in IMPACT.

The wrong turbo unit for the engine variant can produce
intake manifold pressure that is too low; this will reduce
engine output.

T2019239

2
Remove the intake pipe from the turbocharger.

W2003782

3
Check the turbo inlet, ensure that:

Shaft rotates freely without any resistance

No damage to the compressor wheel (bent, chipped,

or missing vanes).

Compressor wheel is not coming in contact with

housing.

Turbine wheel shaft end play, maximum axial clearance

is 0.1 mm (0.0039 inches).
Note: If damage to the compressor wheel or compressor
housing is found, or excessive end play or turbine shaft
doesnt rotate freely, the entire turbo must be replaced.

4
Remove the charge air pipe from the turbo and check
for signs of oil in the turbo outlet.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 16(22)

5
Remove the shutter housing from the turbo and check
the turbine wheel.

W2003783

6
Check turbo outlet:

Check for signs of oil leakage

Inspect turbine wheel for damage.

Note: Since the entire turbine cant be seen from the

exhaust outlet, it will be necessary to remove the turbo
cartridge from the turbo housing to inspect the turbine
wheel thoroughly.

7
If there is damage to turbine wheel or if turbine shaft oil
seal is leaking, the entire turbo must be replaced. Refer
to service information, Turbocharger Replacement. 8

8
IMPACT or ID DVD: Info type Repair group 2551
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 17(22)

Exhaust System, Checking

1
Check that the exhaust system has genuine Volvo parts.
Verify with the chassis ID (last 6 digits of VIN) in IMPACT.

2
Check whether the exhaust system has been modified.
Check for bends or damage that can prevent exhaust
gases from flowing freely.

If the exhaust system is not a genuine Volvo part or

has been modified or damaged, excessive exhaust
backpressure can lower engine output.

3
Check exhaust system backpressure if suspected to be
a problem; see:

Exhaust System Backpressure, Checking (Standard

Muffler) page 18
Exhaust System Backpressure, Checking (Tuned
Muffler, D12D-465 only) page 20 Trucks produced
from Oct. 2002 Jan. 2004
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 18(22)

Exhaust System Backpressure, Checking (Standard Muffler)

Special tools: 9998496, J39200, J44403
1
Install backpressure tool J44403 to the exhaust pipe
between turbocharger and muffler.

Note: Use an easily accessible location before the

muffler inlet. Tool should be securely installed on a
straight section of pipe. Do not install on flex pipe.

J44403

W2004212

2
Drill a 2 mm (0.08 in.) hole through the test fitting
into the exhaust pipe.

W2004213

3
Connect pressure transducer 9998496 to the test fitting
on tool J44403. Attach transducer to multimeter J39200.

9998496, J39200

W2004214

Backpressure Reading

4
Run the engine under full load conditions.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 19(22)

5
Check maximum exhaust backpressure under full engine
load; refer to Dyno Test (preferred method) page 21 or
Road Test page 21.

6
If backpressure is greater than 15 kPa (2.18 psi or 4.4
in. Hg), check the exhaust piping for damage or other
possible sources of restriction. If no faults are found in
the exhaust piping, replace muffler.

7
Remove test equipment and plug hole in exhaust pipe
with sheet metal screw.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 20(22)

Exhaust System Backpressure, Checking (Tuned Muffler, D12D-465

only)
Note: This check is for the exhaust backpressure of
the tuned muffler only; this is available only with the
D12D-465 engines produced from Oct. 2002-Jan. 2004.
465 hp engines produced after Jan. 2004 utilize a
turbo restrictor outlet pipe instead of the tuned
muffler. For these engines refer to Exhaust System
Backpressure, Checking (Standard Muffler) page 18.
Special tools: 9998496, 85105034, J39200
1
Remove the 1/8 in. pipe plug from the test port on
the tuned muffler.
Note: The test port is located on the bottom of the
vertical tuned muffler, and on the lower rear end of the
horizontal tuned muffler.

W2004448

2
Install test fitting 85105034 into the test port.
Note: Backpressure measurement is made between the
turbocharger and the internal catalyst of the tuned muffler.

3
Connect transducer 9998496 to test fitting 85105034
and transducer multimeter J39200.
Note: If transducer and multimeter are not available,
use a gauge with minimum 3% accuracy and a range
of up to 10 in. Hg (140 in. H2O).

W2004449

WARNING
HOT COMPONENTS! Keep yourself and your test
equipment clear of all hot exhaust components. Hot
exhaust components can cause serious burns or can
permanently damage test equipment.

Tie test leads away from tuned muffler and any other part
of the exhaust system.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 21(22)

5
Run engine at operating temperature with engine fully
loaded to record a maximum exhaust backpressure.
Test using:

Dyno Dyno Test (preferred method) page 21

Road Test Road Test page 21

Note: Whichever test is selected, the goal is to run the

engine fully loaded and at operating temperature, at an
engine speed of 1800 rpm; a maximum power of 465 hp
is achieved at this engine speed.

Dyno Test (preferred method)

6
Operate engine until it reaches normal operating
temperature.

7
With accelerator pedal fully depressed, run engine
at rated speed (1800 rpm) for max hp output under
full load. Note the maximum exhaust backpressure
and compare with specifications (see Backpressure
Reading page 21).

Road Test
8
If a chassis dyno test is unavailable, select a SAFE road
test area.

9
Operate engine until it reaches normal operating
temperature.

10
Drive vehicle up a long hill with maximum gross vehicle
weight. With accelerator pedal fully depressed, run
engine at rated speed (1800 rpm) under full load. Note
the maximum exhaust backpressure and compare with
specifications (see Backpressure Reading page 21).

Backpressure Reading
11
Replace tuned muffler if backpressure is greater than
20 kPa (or 6 in. Hg or 80 in. H2O).

Intake Manifold Pressure Check at 100% Engine Load

1
After any repair is made, or if no fault is found, an
Intake Manifold Pressure Check should be performed
under loaded conditions.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2004 250 26 22(22)

2
Dyno or road test under full load at:

1200 RPM
1400 RPM
1600 RPM
1800 RPM
and compare values with specifications.9

Smoke Check
1
Note: Always check and adhere to applicable federal,
state and local laws or regulations for smoke opacity
requirements.
Check smoke opacity with Kent Moore smoke opacity
meter RM1020. Use operators manual provided with the
meter for proper operation of equipment.
Smoke opacity should be less than 40%. If smoke opacity
is greater than 40%, this may indicate a fault in one of the
components. If no faults are found after performing this
checklist, refer to symptom fault tracing.10

RM1020

W2004452

9
IMPACT or ID DVD: Info type Specs group 25 or service literature binder set Specs group 200.
10
Impact or ID DVD: info type "Diagnostics" Abnormal Smoke Development, group 2000