Volvo Trucks North America, Inc.

Greensboro, NC USA
TSI
This TSI Service Bulletin and others in Groups 21 and Date Group No. Supp. Page
33 replace TSI Service Manual 210–600, “Basic Engine, 11.2001 215 004 1(11)
D12, D12A, D12B, D12C” (8.2000), publication no.
PV776–TSP142853. Timing Gears Replacement
D12, D12A, D12B
Timing Gears Replacement

W2002653

Fig. 1: VOLVO D12B Engine

This information covers procedures for replacement of the timing gears on VOLVO
D12, D12A, and D12B engines.

Contents
• “Special Tools” page 2
• “Timing Gears, Replacement (All)” page 4

PV776-TSP160583 USA10309
Page 2

Tools
Special Tools
The following special tools are used to replace or repair components. The tools can be
ordered from Volvo; please use the specified part number when ordering.

9992584 9992658 9992671

Hollow Drift Crankshaft Drive Gear Puller Hydraulic Cylinder, 18-ton capacity

9996160 9996222 9996315

Pins, used with Yoke 9996358 Foot Pump Spindle

9996358 9996401 9996413

Timing Gear Yoke Puller Arms Adapter

9996600 9996603 9996626

Hydraulic Cylinder, 10-ton capacity Adapter Hollow Drift
Volvo Trucks North America, Inc. Date Group No. Page
TSI 11.2001 215 004 3(11)

9996950 9996956 9996958

Flywheel Blocking Tool Flywheel Turning Tool Polygon Hub Puller

9996972 9996973 9998269

Puller Drift Gear Wheel Puller

9998270 9999683 9999696

Counterhold Rocker Dial Indicator Magnetic Stand
Page 4

Service Procedures
2153-03-03-01 CAUTION
Timing Gears, Replacement
Never turn the crankshaft or camshaft when the tim-
(All) ing gears have been removed. Otherwise, the pistons
(Oil pan and timing gear cover removed) can come into contact with the valves resulting in
damage to engine components.

WARNING Special tools: 9992584, 9992658, 9992671,

9996160, 9996222, 9996315, 9996358,
Always wear appropriate eye protection to prevent the 9996401, 9996413, 9996600 , 9996603,
risk of eye injury due to contact with engine debris or 9996626, 9996900, 9996950, 9996956,
fluids. 9996958, 9996965, 9996972, 9996973,
9998270, 9999683, 9999696

Removal of Drive and Idler Gears

T2006672

Fig. 3: Cranking tool installed

T2006852
Remove the inspection cover from be- 9996956
neath the flywheel housing and install
Fig. 2: Timing gear arrangement cranking tool 9996956.

Description (no. of teeth):

1 Crankshaft Drive Gear (36)
2 Idler Gear, 36 mm (87)
3 Coolant Pump Drive Gear (24)
4 Air Compressor Drive Gear (27)
5 Camshaft (72)
6 Adjustable Idler Gear (58)
7 Upper Idler Gear (60)
8 Lower Idler Gear (58)
9 Power Steering Pump Drive Gear (22)
10 Drive Gear Arrangement (Accessory Drive Pul-
ley and Fuel Feed Pump) (26)
11 Power Take Off (PTO) Idler Gear, 28 mm (87)
12 Power Take Off (PTO) Drive Gear for Hydraulic
Pump (37)
13 Oil Pump Drive Gear (24)
14 Oil Pump Idler Gear (57)
Volvo Trucks North America, Inc. Date Group No. Page
TSI 11.2001 215 004 5(11)

2 4

W2000936 T2007076

Fig. 4: Aligning camshaft Fig. 6: Vibration dampener

Rotate the flywheel until number 1 pis-

ton is at TDC and the camshaft
marking is opposite the marking on
the cap.

T2008984
Fig. 7: Removing polygon hub
Remove the vibration dampener. Re- 9996958
move the crankshaft bolt together with 9996413
the washer. Secure the puller 9996958 9996600
on the polygon hub. Fit adapter 9996603
9996603 on hydraulic cylinder
9996600. Screw the hydraulic cylinder
to the puller and pull off the polygon
T2006666 hub using foot pump 9996222.
Fig. 5: Blocking tool installed

Remove cranking tool 9996956 and in- 9996950 5

stall blocking tool 9996950. 9996956 Remove idler gears (see 2, 6 and 11,
Fig. 2: Timing gear arrangement, page
4) from the timing gear plate.

6
Remove the washers from the upper
and lower idler gear (see 7 and 8, Fig.
2: Timing gear arrangement, page 4).

7
Remove the socket head bolts and re-
move upper and lower idler gears (see
7 and 8, Fig. 2: Timing gear arrange-
ment, page 4). Use two screwdrivers
to assist in removal.
Page 6

8 10

T2007096 T2007072

Fig. 8: Cam sensor wheel Fig. 10: Removing the crankshaft drive gear

Remove the cam sensor wheel from Using cylinder 9996600, pins 9996160
the camshaft drive gear. 9996160, puller arms 9996401, and 9996222
yoke 9996358 connected to pump 9996358
9996222, remove the crankshaft drive 9996401
9 gear (see 1, Fig. 2: Timing gear ar- 9996600
rangement, page 4).

11
Remove the retaining bolts in the oil
pump idler gear and remove the idler
gear from the oil pump (see 14, Fig. 2:
Timing gear arrangement, page 4).

12

T2007148

Fig. 9: Installing counterhold tool

Attach the camshaft holding tool 9998270

9998270 to the rear camshaft support.
Remove the camshaft gear retaining
bolt and remove the camshaft drive
gear (see 5, Fig. 2: Timing gear ar-
rangement, page 4).

T2007074

Fig. 11: Removing the oil pump drive gear

Install an M12x20 bolt in the shaft for 9996972

the oil pump drive gear (see 13, Fig. 9996973
2: Timing gear arrangement, page 4).
Remove the gear, using tool 9996972
and drift 9996973.
Volvo Trucks North America, Inc. Date Group No. Page
TSI 11.2001 215 004 7(11)

13 Installation of Drive and Idler Gears

Remove the air compressor drive gear
(see 4, Fig. 2: Timing gear arrange- 16
ment, page 4).

14
Remove the power steering pump
drive gear (see 9, Fig. 2: Timing gear
arrangement, page 4).

15
Install puller 9998269 onto the coolant 9998269
pump drive gear (see 3, Fig. 2: Timing
gear arrangement, page 4). Place a
plug on the shaft as a support and pull
off the gear.
T2007151

T2007080

Fig. 12: Installation of crankshaft drive gear

Install adapter and spindle on the 9992584

crankshaft. Install the new crankshaft 9992671
drive gear (see 1, Fig. 2: Timing gear 9996222
arrangement, page 4) on the spindle 9996315
9996315. Install drifts 9992584 and 9996626
9996626 and hydraulic cylinder
9992671. Install the nut and carefully
press on the drive gear, using pump
9996222.

Note: Make sure that the key remains

in position in the keyway. Remove the
tools.
Page 8

17 21

T2007078

T2007082

Idler gears

Lubricate the oil pump idler gear (see 24 ± 4 Nm

14, Fig. 2: Timing gear arrangement, (18 ± 3 ft-lb)
page 4) bearing and install. Torque-
tighten bolts to 24 ± 4 Nm (18 ± 3
ft-lb).

22
Lubricate the bearings for idler gears 15 ± 3 Nm
(see 2 and 11, Fig. 2: Timing gear ar- (11 ± 2 ft-lb)

rangement, page 4). Place them into 120 ± 5
position and torque-tighten bolts to 15
T2007079 ± 3 Nm (11 ± 2 ft-lb). Turn an addi-

Fig. 13: Installation of the oil pump drive gear tional 120 ± 5 .
Heat the oil pump drive gear (see 13,
Note: New bolts must be used each
Fig. 2: Timing gear arrangement, page
  time the idler gear is loosened or re-
4) to approximately 180 C (360 F) and
moved; these bolts are designed for
tap it onto the lube oil pump.
single use only and cannot be torqued
a second time.
18
Install the air compressor drive gear
(see 4, Fig. 2: Timing gear arrange- 23
ment, page 4). Install upper and lower idler gears (see 15 ± 3 Nm
7 and 8, Fig. 2: Timing gear arrange- (11 ± 2 ft-lb)
 
ment, page 4). Torque-tighten the 120 ± 5
19 socket head bolts to 15 ± 3 Nm (11 ±

Install the power steering pump drive 2 ft-lb). Turn an additional 120 ± 5 .
gear (see 9, Fig. 2: Timing gear ar-
rangement, page 4).
24
Install the washers for the idler gears 10 ± 2 Nm
20 and torque-tighten to 10 ± 2 Nm (7 ± 1 (7 ± 1 ft-lb)
Apply assembly paste to the coolant  
ft-lb). Turn an additional 60 ± 3 . 60 ± 3
pump shaft. Install the spindle into the
shaft. Place the coolant pump drive Note: New bolts must be used each
gear (see 3, Fig. 2: Timing gear ar- time the idler gear is loosened or re-
rangement, page 4) onto the spindle moved; these bolts are designed for
and press the gear on with the help of single use only and cannot be torqued
the hydraulic cylinder. a second time.
Volvo Trucks North America, Inc. Date Group No. Page
TSI 11.2001 215 004 9(11)

25 28

T2007155

Fig. 14: Installing polygon hub

T2007083

Apply assembly paste to the crank- 9996626 Fig. 16: Torque-tightening the camshaft drive gear bolt
shaft. Place the polygon hub, tool 9992671
9996626 and hydraulic cylinder 9996315
9992671 on 9996315. Install the nut 9996222
onto the spindle and use tool 9996222
to press on the polygon hub.

26

T2007148

Fig. 17: Installing the camshaft drive gear

Install the camshaft drive gear. Use 645 ± 25 Nm

tool 9998270 as a support. Torque- (475 ± 18 ft-lb)
tighten to 645 ± 25 Nm (475 ± 18 ft-lb). 9998270

T2007125

Fig. 15: Torque-tightening the crankshaft drive gear bolt

Remove the tools. Install the bolt and 645 ± 25 Nm

washer and torque-tighten to 645 ± 25 (475 ± 18 ft-lb)
Nm (475 ± 18 ft-lb).

27
Remove blocking tool 9996950 from 9996950
the flywheel housing and install fly- 9996956
wheel turning tool 9996956.
Page 10

29 32

W2000936

Fig. 18: Aligning the camshaft


Make sure the flywheel is at 0 and W2000723

that the camshaft is at TDC (see Fig. 20: Torque-tightening sequence for adjustable idler
marking). gear
Use a two-step process to torque- 15 ± 3 Nm
30 tighten the idler gear bolts: (11 ± 2 ft-lb)

Install the adjustable idler gear (see 6, 120 ± 5
Fig. 2: Timing gear arrangement, page
• Tighten to 15 ± 3 Nm
(11 ± 2 ft-lb).
4). 
• Turn bolts an additional 120 ± 5 .
Note: Hand-tighten the bolts until they
bottom against the bearing shield Note: The bolts for the adjustable idler
(these bolts will be individually re- gear are NOT reusable. If they are
placed in a later step). loosened or removed, they MUST be
replaced with new bolts.

31
33

T2007158
T2007084
Fig. 19: Idler gear adjustment
Fig. 21: Checking the backlash
Adjust the idler gear using two feeler After adjustment, check the backlash 9999683
gauges. The correct backlash is 0.05 – with rocker dial indicator 9999683 9999696
0.17 mm (0.002 – 0.007 in.). By using mounted on magnetic base 9999696.
feeler gauges, an equal amount of
backlash between cam gear and the Note: It is important that backlash is
nonadjustable upper idler gear can be the same for both gear wheels which
obtained. mesh with the adjustable idler gear.
Volvo Trucks North America, Inc. Date Group No. Page
TSI 11.2001 215 004 11(11)

34
Install the cam sensor wheel on the 25 Nm
camshaft drive gear. Install and (19 ft-lb)
torque-tighten the three bolts to 25 Nm
(19 ft-lb).

35
Install the vibration damper and 50 ± 5 Nm
torque-tighten bolts to 50 ± 5 Nm (37 (37 ± 4 ft-lb)
± 4 ft-lb).
Note: New bolts should be used.