Service Bulletin

Volvo Trucks North America, Inc.

Greensboro, NC USA Trucks
This Service Bulletin replaces SB 211–59, “Cylinder Date Group No. Page
Head, D12D” (11.02), publication no. 3.2003 211 61 1(7)
PV776–TSP180843.
Cylinder Head
Pressure Test
D12D
Cylinder Head Pressure Test

W2003779

This information covers procedures for pressure testing the cylinder head of the
VOLVO D12D engine.

Contents
• “Special Tools” page 2
• “Cylinder Head, Pressure Test (First)” page 4

NOTE: Information is subject to change without notice.

Illustrations are used for reference only and may differ slightly from the actual vehi-
cle being serviced. However, key components addressed in this information are
represented as accurately as possible.

PV776-TSP188328 USA13369
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 211 61 2(7)

Tools
Special Tools
For special tools ordering information, refer to Tool Information, group 08.

9996159 9996161 9996222

Tap (for 9996161) Hydraulic Cylinder Foot Pump (for 9996161)

9998246 9998249 9998251

Valve Spring Removal/Install Tool Hollow drift Cylinder Head Sealing Plug

9998258 9998260 9998506

Cylinder Head Adapter (use with Stand) Press Tool Valve Spring Compressor Tool

9998666 9998335
Cylinder head pressure test kit Valve Stem Seal Guide Sleeve
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 211 61 3(7)

9998668 9996662
Thermostat housing pressure test kit Pressure tester

9998266 J-41503
Sealing washer Cylinder Head Lifting Fixture
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 211 61 4(7)

Service Procedures
2111-06-04-01 3
Cylinder Head, Pressure Test
(First)
With cylinder head removed. Also removed:

• Thermostat and housing

• Intake manifold
• Exhaust manifold

See also:

• “Cylinder Head Pressure Test” page 1

You must read and understand the precautions and

T2014962
guidelines in Service Information, group 20, "General
Safety Practices, Engine" before performing this pro- Mount the cylinder head adapter plate 9998258
cedure. If you are not properly trained and certified in 9998258 on the head.
this procedure, ask your supervisor for training before
you perform it.
4
Mount the cylinder head on the engine
Special tools: 9609699, 9809697, 9809696, stand.
9809700, 9809701, 9996662, 9998251,
9998258, 9998266
5
1
Remove the cross bridges.

W2004233

Install the injector bore protective 9998251

plugs 9998251 with O-rings removed.
Use the injector hold-down to keep
T2007163 them in place.
Steam clean the cylinder head.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 211 61 5(7)

6 9
Clean the contact surfaces on the
cylinder head where all test plates and
plugs will be used.

T2007040

Close the shut-off valve. The pressure

gauge reading must not drop for 2 min-
utes if it is to be considered reliable.

W2003592 10
Install the sealing plate 9998266, 9998266
9809696 and plugs 9809697, 9809699 9809696
on the cylinder head. 9809697
9809699

T2007040

Make sure the knob on the pressure

test device reduction valve is backed
off to stop the air flow to the flow
gauge.

T2007039

Before using pressure test device 9996662

9996662, it must be calibrated. Con-
nect pressure test device 9996662 to
the compressed air system. Set the
pressure gauge to 100 kPa (14.5 psi)
on the reduction valve.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 211 61 6(7)

11 14

T2017290

Attach hose 9996662, from the pres- 9996662

sure gauge on the connection disc 9809697
9809697, to test the cylinder head. T2007039

Set the reduction valve knob to obtain

a pressure of 50 kPa (7.25 psi) on the
12 pressure gauge. Maintain this pres-
Remove the head from the engine sure for 1 minute.
stand.

15
13 Increase the pressure to 150 kPa
(21.75 psi). Lock the reduction valve
with the locking ring. Close the valve.

16
After one or two minutes, check
whether the pressure is dropping or
there are air bubbles coming from the
head in the water tank.

NOTE: Make sure air bubbles are not

coming from plates or plugs before as-
suming that there is a crack in the
cylinder head; if a leak is found in the
cylinder head, repair or replace.

T2008809
17
With shop air still connected to the Discharge the pressure for the cylinder
head, submerge the head in a water– head by backing off of the knob on the
filled tank with a water temperature of reduction valve.
 
70 C (160 F).
18
Remove the cylinder head from the
tank.

19
Install the pressure gauge connection
on the thermostat housing plate.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 211 61 7(7)

20 25
Install adapter plate 9809698 with 9809698 Mount the cylinder head back on to
plugs 9809700 and 9809701. 9809700 the engine stand.
9809701

26
21

T2008847

Remove the plugs 9998251 from the 9998251

cylinder head.

27
Remove all test equipment from the
cylinder head.

W2004049

Transfer the hose from adapter plate 9809697 28

9809697 to thermostat housing 9809698 Using compressed air, blow all water
9809698. Return the cylinder head to from the cylinder head and prepare
the tank. the head for installation.

22 29
Repeat steps 9 through 15. Follow the approved steps for installa-
tion of components, including
thermostat/housing installation and
23 cylinder head installation; refer to Ser-
If a leak is found, repair or replace the vice Information, group 21.
cylinder head.

24
Remove the cylinder head from the
tank.