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Volvo Trucks North America, Inc.

Greensboro, NC USA

Service Bulletin Trucks
Date Group No. Page

This Service Bulletin replaces SB 253–21, “Engine Brake, Fault Tracing, Checklist O, D12D” (11.02), publication no. PV776–TSP170589.

3.2003

253 21

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Engine Brake Fault Tracing Checklist O D12D

Engine Brake, Fault Tracing Checklist O

T2019344

This information covers fault tracing the VEB (Volvo Engine Brake) for the Volvo D12D engine.

Contents • “General Guide to Fault Tracing” page 2 • “System Overview” page 3 • “Checklist O, Engine Brake” page 10 • “Engine Brake, Fault Tracing” page 12
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-TSP187872

USA13254

Volvo Trucks North America, Inc. Service Bulletin

Date 3.2003

Group

No.

Page 2(21)

253

21

General Guide to Fault Tracing
(See also “Engine Brake, Fault Tracing” page 1.)

You must read and understand the precautions and guidelines in Service Information, group 20, "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.

. Page 3(21) 253 21 System Overview W2004194 When fault tracing. it is important to understand the function of the system and to follow the fault tracing sequence in the checklist to avoid replacing nondefective components.Volvo Trucks North America. Inc.2003 Group No. Service Bulletin Date 3.

or fuel pump Switch. LCM (external lighting) Sensor. oil pressure and oil temperature Sensor. ABS Control unit. intake manifold pressure and temperature Sensor. engine brake/exhaust pressure governor (EPG) Solenoid/control valve.2003 Group No. crankshaft Sensor. engine brake Position switch. clutch pedal. VCB (Volvo Compression Brake) . Service Bulletin Date 3.Volvo Trucks North America. EECU (engine electronic control unit) Control unit. road speed Fuse. Page 4(21) 253 21 Component list Component A12 A14 A17 A27 B04 B13-18 B25 B37 B38 B68 F80 S07 S58 Y37 Y39 Description Control unit. accelerator pedal Sensor. NC at rest Air valve unit (AVU). wheel speed Sensor. VECU (vehicle electronic control unit) Control unit. Inc. engine solenoid valves. engine speed.

Requirements • • • • Electrical control of engine brake The engine brake power is determined by the driver’s settings. see “Exhaust Pressure Governor (EPG)” page 7. which gives more air to compress during the compression stroke. The information from the switch and the accelerator go via the vehicle control unit (A17) through the data links (J1939 and J1708/J1587) to the engine control unit (A14). Engine speed exceeds 900 rpm. Page 5(21) 253 21 Engine Brake For additional information on the design and function of the Volvo Engine Brake. refer to Service Information.2003 Group No. For a more detailed description of the EPG function. EPG” page 5) and the compression brake. Clutch pedal (S58) is NOT depressed. The EPG creates an overpressure in the exhaust. The power varies for different combinations of engine brakes. which sends out full control pressure (7. group 25. engine speed sensor. There are two options for engine braking: EPG Switch (S07) Exhaust brake. ABS wheel sensor (B13-18) indicates NO wheel lockup (ABS non-active). The braking effect of the compression brake on the engine occurs when: Electrical control With the switch in position 1. This shutter. Inc. . Speedometer (B68) indicates a speed greater than 5 km/h (3 mph).5 bar/110 psi) to the EPG. connected to the EPG plunger. The exhaust valve opens immediately before the turn of the compression stroke and ”punctures” the compression in order to reduce the effect with the working stroke. VEB The Volvo Engine Brake (VEB) consists of two systems: the exhaust brake (see “Exhaust brake. T0008637 Two positions. a special camshaft with extra cams and a solenoid valve for oil pressure in the rocker arm.Volvo Trucks North America. The engine control unit then sends a PWM signal (Pulse Wide Modulated) to the AVU (Y37). see “Compression Brake” page 8. • • The exhaust valve opens and allows air in during the intake stroke. Service Bulletin Date 3. The VEB includes a special rocker arm for the exhaust valves. This creates a braking effect during the exhaust stroke when the exhaust gases cannot evacuate freely. they create an overpressure between the pistons and the shutter. the exhaust brake is activated when the accelerator (B25) is released. can restrict the exhaust gas flow. B04 (deactivates < 800 rpm). EPG The exhaust pressure governor (EPG) uses a shutter mounted in the exhaust outlet from the turbocharger. The AVU is given voltage via fuse F80. For a more detailed technical description. making the compression brake more efficient. The position of the switch 0 (switched off) 1 Engine brake 0% 100 % Engine brake.

Inc. Both the control valves are supplied voltage via fuse F80. or AVU. EPG is activated with full control pressure (7. Engine speed exceeds 1100 rpm*.Volvo Trucks North America. B04 (deactivates < 1000 rpm). Intake manifold pressure (B37) less than 50 kPa (7. When the switch is in position 2 the VCB is activated. The position of the switch 0 (switched off) 1 2 Engine brake 0% 50 % 100 % Requirements • • • • • • • Clutch pedal (S58) is NOT depressed. engine speed sensor. when the accelerator pedal (B25) is released. NOTE: *Activation rpm is raised by 300 to 1400 rpm   when oil temperature is 55 – 82 C (131 – 180 F) or after the first 5 engine brake requests. Page 6(21) 253 21 VEB Switch (S07) Electrical control When the switch is in position 1 the exhaust brake is activated when the accelerator pedal (B25) is released. . the EPG is activated with full control pressure to attain 100% engine brake.5 bar/110 psi) from the air valve unit. Speedometer (B68) indicates a speed greater than 5 km/h (3 mph).2003 Group No. The information from the switch and the accelerator go via the vehicle control unit (A17) through the data links (J1939 and J1708/J1587) to the engine ECU (A14). ABS wheel sensor (B13-18) indicates NO wheel lockup (ABS non-active).   Oil temperature (B38) greater than 55 C (131 F). At the same time. Accelerator pedal (B25) released. to attain 50% engine brake. Service Bulletin Date 3.25 psi). The engine ECU then sends a signal (-) to the solenoid/control valve (Y39) for increased oil pressure in the rocker arm shaft and a PWM signal (Pulse Wide Modulated) to the AVU (Y37). T0008058 Three positions.

5 bar (7 .” • • • To keep the engine warm when idling. Checklist E. The compressed air is supplied from the vehicle’s compressed air system and is regulated by the AVU. the AVU (4) is closed.Volvo Trucks North America. Under normal driving conditions. “EPG. and releases a reduced pressure to the exhaust pressure governor. To apply exhaust back pressure during idle EGR function. the compression brake and EPG are activated simultaneously to attain 100% engine brake (switch position 2). Service Bulletin Date 3.5 – 7. Inc. a shutter (2) and a compressed air operated cylinder (3). Page 7(21) 253 21 Exhaust Pressure Governor (EPG) W2004195 The exhaust pressure governor has three functions: Start and heat retention For functional description and fault tracing of the exhaust pressure governor during start and heat retention. To function as exhaust brake on down gradients. The shutter (2) is forced into the shutter housing (1) which restricts exhaust flow and causes back pressure in the exhaust.5 bar (110 psi). If the engine is equipped with VEB (Volvo Engine Brake). The exhaust pressure governor is situated in direct connection to the turbo’s turbine housing. The shutter (2) is then completely open and the exhaust passes freely.110 psi).2003 Group No. The PWM-type valve controls the pressure steplessly within 0. group 25. . located on the intake side of the engine (4). The exhaust pressure governor consists of a shutter housing (1). refer to Service Information. Exhaust brake The EPG is activated by control pressure of approximately 7. Fault Tracing.

which is connected to the lubricating oil passage in the cylinder block. The outlet (5) is connected to the rocker arm shaft. Service Bulletin Date 3. The inlet (1). Page 8(21) 253 21 Compression Brake Solenoid/Control Valve T2019494 The solenoid/control valve has the task of regulating the oil pressure to the rocker arm mechanism. . which is controlled from the EECU. This means the outlet (5) becomes free and the oil pressure from the gallery connection provides the rocker arm shaft with full oil pressure — more than 200 kPa (29 psi). which results in reduction of oil pressure to approximately 100 kPa (14. always has system oil pressure. The oil in the oil space (6) flows out through the draining passage. B: With compression braking.2003 Group No. voltage to the solenoid valve (2) opens a draining passage. Inc.Volvo Trucks North America. A: When the engine is running the piston (3) partly covers the outlet (5). The compression brake is activated by the solenoid valve (2). allowing the spring (4) to push the piston (3) to the side.5 psi) after the solenoid valve. This oil pressure is sufficient for lubrication of the camshaft bearings and the rocker arm mechanism.

which allows the oil to flow in both directions through the non-return valve. The non-return valve (7) consists of a piston (11) and spring (14). Page 9(21) 253 21 Camshaft and exhaust rocker arms W2004196 The camshaft (1) on an engine with VCB has. spring (12) and ball (13). can no longer flow past the ball and therefore pushes on the rocker arm piston (8). which means that the spring (12) can push the ball (13) towards the seat. above the rocker arm piston (8). The piston’s pin holds the ball (13) away from the seat. In this position the exhaust valves are not affected by the extra brake cams on the camshaft.Volvo Trucks North America. At high pressure. the piston (11) overcomes the spring (14). Each rocker arm (5) includes a non-return valve (7) and a rocker arm piston (8). Inc. there is a pressure limiting valve (10). The non-return valve clearance is adjusted with the help of shim (9) which is situated on the valve bridge. When the camshaft’s extra brake cams (3) and (4) further affect movement of the rocker arm. in addition to the ordinary exhaust cam (2). the exhaust valves are pushed down and compress (force more air into the cylinder with the help of the back pressure in the exhaust during the compression stroke) and decompression respectively (release compression during the power stroke). The oil. because the oil pressure is not sufficient to overcome the spring force (14). the piston (11) will not move out of its rest position. so that the piston pushes down and eliminates the valve clearance. A spring tab (6) holds the rocker arm in its resting position against the valve bridge. the solenoid/control valve reduces the oil pressure.5 psi). So that the pressure above the rocker arm piston does not push back into the rocker arm shaft when the valve opens. a charge cam (3) and a decompression cam (4) on each exhaust cam lobe.2003 Group No. . This prevents excess oil pressure building up above the rocker arm piston (8). B: With compression braking. A: Under normal engine operation. Service Bulletin Date 3. the solenoid/control valve increases the oil pressure to > 200 kPa (29 psi). At reduced oil pressure of 100 kPa (14.

Engine Brake See also: • • “General Guide to Fault Tracing” page 2 “Engine Brake.180 F)] Is EPG solenoid valve indicator lit in switch position 1 when prerequisites are met? Are VEB and EPG solenoid valve indicators lit in switch position 2 when prerequisites are met? Action: 3 “Air Supply to EPG and AVU. Checking” page 12 Have the fault codes related to the engine brake been corrected? Action: 2 Engine Brake Checks (VCADS Pro: "Engine Brake Function. test") Does the displayed status conform to the actual position of the switch?: No Switch Status Position 1 (EPG) Position 2 (EPG and VCB) Does the switch receive voltage from the VECU? Do EPG and VCB solenoid valves function when activated by VCADS Pro? Does the EECU give signals to the AVU? Does accelerator pedal idling switch indicator light up when pedal is depressed . Inc. 7.Volvo Trucks North America.5 bar/110 psi)? Action: bar (psi) . and go off when pedal is released? Road test — Check the following requirements (for the engine brake to become active) during test driving: Measured accelerator position Is the accelerator position 0% (pedal released)? Does the displayed status conform to the position of the clutch pedal? Is the fuel volume 0 (no fuel injection)? Is vehicle speed above 0 km/h (0 mph)? Is the oil temperature above 55 C (131 F)? Is the charge pressure less than 50 kPa (7 psi)? Is engine speed above 900 rpm for EPG activation?   % Is engine speed above 1100 rpm for VEB activation? [Or 1400 rpm if oil temp is 55 . Checking” page 12   AVU (air valve unit) Does the AVU receive correct air pressure (over 7..5 bar / 110 psi)? Are the air hoses correctly clamped and free from kinks or damage? Does the EPG receive correct air pressure at 100% activation (approx. Service Bulletin Date 3.2003 Group No. Page 10(21) 253 21 Checklist O. Fault Tracing” page 12 Vehicle Chassis no.80 C (131 .. Mileage Customer Yes 1 “Fault Codes.

Checking” page 16 Are the plugs in the rocker arm shaft properly installed? Are the rocker arm shaft’s bolts correctly torque-tightened? Action: 7 “Solenoid/Control Vave. Checking” page 13 Can the EPG shutter move? Is the shutter disc undamaged? Does the shutter disc reach its end positions? Action: 5 “Rocker Arm Shaft Oil Pressure. Mileage Customer Date 3. EPG. VCB. VCB. Page 11(21) 253 21 Yes No 4 “Shutter Travel. Service Bulletin Vehicle Chassis no.2003 Group No. Checking” page 16 kPa (psi) Rocker arm bushing VCB Are clearances within specifications? Bushing rocker arm roller VCB Are clearances within specifications? Is the clearance between the rocker arm piston and valve bridge within specifications? Action: 9 “Rocker Arm Valve. Inc. Checking” page 18 Are the draining hole and draining passage free from debris? Does the solenoid valve open properly? Are the seals free from defects? Action: 8 “Rocker Arm Bushings. Checking” page 14 Is the oil pressure within specifications (with activated engine brake)? Oil pressure in the rocker arm shaft Action: 6 “Rocker Arm Oil Leakage. Checking” page 20 Are the spring and the non-return valve’s piston free from defects? Does the non-return valve’s piston move freely? Are the non-return valve’s ball and spring free from defects? Does the rocker arm piston move freely? Action: Notes: Completed by: Dealer: Date: .Volvo Trucks North America.

If the pressure to control the AVU is not the same as the system pressure. Fault Tracing See also: 2 • • “General Guide to Fault Tracing” page 2 “Checklist O. 5 Check that the hoses are properly connected and do not leak. Hoses and Connections 4 Check that the air hoses are free of kinks and that they are not damaged or have any restrictions that would interrupt air flow. 9992976 9996465 Before beginning any work on any part of the air system. WARNING 9992976 3 Fill the compressed air system to full system air — approximately 8.3 bar (120 psi). Remove the air supply hose from the AVU. be certain that the air pressure has been depleted. 6 Empty the compressed air system and remove gauge and test nipple. refer to Diagnostic Information. Service Bulletin Date 3. Page 12(21) 253 21 2531-20-03-01 Engine Brake. see “Hoses and Connections” page 12. 9996465. . Failure to do so may cause a component to violently separate. Checking 1 Correct any fault codes concerning the engine brake function. Air Supply to EPG and AVU. group 20. which can result in serious personal injury. Inc. Remove the fitting in the AVU and attach to test nipple 9992976. Engine Brake” page 10 Fault Codes. Checking Special tools: 9992976. 9998333 AVU 1 T2019381 Connect pressure gauge 9996465 and nipple 9992976 to the air supply hose of the AVU. check the air hoses.2003 Group No. Remove fitting from test nipple and install fitting into AVU and connect supply hose.Volvo Trucks North America.

Inc.15 – 1. W2003781 WARNING 11 If the control pressure is not within specifications and the supply pressure to the AVU is the same as the system air pressure — approximately 8. 8 Connect the PC tool to the vehicle’s data link connector. NOTE: The stroke travel (A) should be 29 – 33 mm (1. Service Bulletin EPG 7 Date 3.Volvo Trucks North America. EPG.2003 Group No. Failure to do so can result in personal injury. EPG shutter may move without warning.30 in. Keep hands away from EPG shutter during activation. 2 Remove the exhaust pipe by the EPG and check that shutter disc is not damaged. run the “Engine brake function test. 12 Remove the gauge and test nipple.5 ± 0. exhaust brake).” 9996465 9998333 Activate the EPG 10 Activate the AVU for the EPG at 100%. Connect air hose to EPG.3 bar (110 ± 4 psi). begin “Start and heat retention function. Check that the shutter reaches its end positions by activating and shutting off the EPG using the PC tool. Page 13(21) 253 21 Shutter Travel.). NOTE: The control pressure should be approximately 7. 3 Connect the PC tool to the vehicle’s data link connector. 5 T2019382 Check that the EPG receives the correct control pressure: remove the air hose from the EPG and connect pressure gauge 9996465 and nipple 9998333 to the hose.5 bar (110 psi). Checking 1 Check that the system air pressure is more than 7. Note the pressure on the checklist. if this has not already been done. 9 Using VCADS Pro. 4 Using VCADS Pro. if this has not already been done. activate EPG at 30% (corresponds to the same air pressure as with warm-hold function) and at 100 % (corresponds to full control pressure. . test”.3 bar (120 psi) — replace the AVU.

Inc. 6 Route the oil pressure hose from outside and in through the valve cover where the stud was removed. NOTE: Attach oil pressure hose. . 9998338 W2004197 Remove the second bolt on the rocker arm shaft (as viewed from the front of the engine). replace or overhaul EPG. Service Bulletin 6 If stroke travel is not within specifications. refer to Service Information.Volvo Trucks North America. J39200 1 CAUTION Use a hand wrench to loosen the valve cover nuts. 4 Temporarily remove the hose. Make sure that adapter and hose remain clear of the no. 2 W2004198 Install adapter 9998338 and bolt. 1 intake valve rocker arm as the bolt is tightened to 54 Nm (40 ft-lb). group 21.2003 Group No. 9998339. Remove the valve cover. DO NOT USE AN AIR TOOL. 3 Date 3. Checking Special tools: 9998338. 5 Remove the second stud (counting from left front of engine) so hose can be routed through valve cover. refer to Service Information. this will help prevent the studs from loosening from the cylinder head and thus damaging the valve cover and the unit injector’s wiring harness. Page 14(21) 253 21 Rocker Arm Shaft Oil Pressure. group 25.

Inc.400 kPa (30 – 60 psi). Service Bulletin 7 Date 3. 15 ± 5 Nm (11 ± 4 ft-lb). then turn additional 120 ± 5 . Attach pressure transducer to multimeter J2900. VCB non-activated: 100 kPa (15 psi). oil pressure is low. Page 15(21) 253 21 9998496 J39200 9998339 13 Carefully route the hose into the cab. 11 Route and secure the oil pressure hose so that it will not be damaged when the hood is closed. 10 15 Repeat test several times to verify reading. • • If oil pressure is below 200 kPa (30 psi) with VCB active. . If oil pressure is above 100 kPa (15 psi) with VCB inactive and solenoid valve is functioning properly. 20 ± 2 Nm (15 ± 1. Torque-tighten the valve cover to 20 ± 2 Nm (15 ± 1. Activate VCB and note pressure after it stabilizes. Select mV setting on multimeter (reading is displayed in kPa).5 ft-lb).2003 Group No. 14 Test drive the vehicle and bring to operating temperature.  120 ± 5 12 Lower the hood. 2 3 W2004199 • Alternate 2: 1 Connect pressure gauge 9998339. 9 Check that the oil pressure hose is correctly positioned and carefully replace the valve cover. VCB activated: 200 . Connect the hose to the banjo nipple on the adapter 9998338. Oil pressure. remove valve cover and test equipment. Continue fault tracing. 16 If rocker arm shaft oil pressure is within specifications.Volvo Trucks North America. W2004200 Press the seal for the oil pressure hose into the hole on the valve cover. 8 Secure the hose so that it will not be damaged by the rocker arms. replace VCB control valve. refer to VCB solenoid valve check.5 ft-lb) Oil pressure. • Alternate 1: 1 Connect pressure transducer 9998496 to hose. 17 Install rocker arm shaft bolt and torque-tighten to 15 ± 5 Nm (11 ± 4 ft lb).

Inc. 2 Check all rocker arm bolts in order to make sure that there is no oil leakage due to under-torqued bolts. 3 Move the rocker arm. Rotate engine to the position where the rocker arm roller is not in contact with the camshaft cam lobe (base circle).Volvo Trucks North America. so that most of the oil film is thinned out on the upper side of the rocker arm shaft. 20 ± 2 Nm (15 ± 1. 20 Date 3. Apply locking fluid to stud and torque-tighten to 40 ± 3 Nm (29 ± 2 ft-lb). 4 Reset the dial gauge.5 ft-lb). Checking 1 Check that the plugs in the ends of the rocker arm shafts are properly installed and that they are free from defects. Service Bulletin 18 Clean valve cover stud and thread hole in cylinder head. 9999696 9989876 . NOTE: Check that there is clearance between rocker arm rollers and camshaft for the bushing and roller checks. torque-tighten the valve cover to 20 ± 2 Nm (15 ± 1. VCB 1 Install turning tool 9996956 (or use remote starter switch) to rotate engine. 9999696 Other special equipment: 9989876 Rocker Arm Bushing. Page 16(21) 253 21 40 ± 3 Nm (29 ± 2 ft-lb) Rocker Arm Bushings. T2019598 Position magnetic stand 9999696 with dial gauge 9989876 so that the dial gauge’s measurement probe tip is located above the middle of the rocker arm bushing (on the rocker arm not in contact with the camshaft). Checking Special tools: 9996956.5 ft-lb) Rocker Arm Oil Leakage. 9998511.2003 Group No. 19 Install valve cover. 2 9996956 T2012845 Valve cover tightening sequence Following the tightening sequence shown.

9 9999696 9989876 Bushing. by the rocker arm shaft. VCB 7 T2007948 Rotate the roller a few turns.0039 in.). . T2007950 Put a screwdriver between the rocker arm and roller. Page 17(21) 253 21 T2019598 C2002679 Position bar tool 9998511 under the rocker arm.Volvo Trucks North America. Rocker Arm Roller. Set the dial gauge at 2 – 3 mm (0. the rocker arm must be replaced. Note the reading on the dial gauge. permitted clearance is 0. 6 Repeat the check on all other rocker arm bushings. so that the oil film between the bushing and shaft is thinned out. Put the magnetic stand on the rocker arm. and push up the rocker arm. Inc.2003 Group No. 9998511 Place dial indicator 9989876 in magnetic stand 9999696.) tension.1 mm (0. Max. replace the rocker and check the rocker arm shaft for wear. NOTE: Make sure that the probe tip of the dial gauge is set at tension and can move in both directions.080 – 0. In the case of clearance greater than this.118 in. Service Bulletin 5 8 Date 3. Push out the roller as far as possible and read off the value on the dial test indicator. NOTE: If the roller jams and does not rotate freely. Direct the probe tip of the dial gauge so that it lies horizontally against the center of the roller.

refer to Service Information. Acceptable clearance is 1. At the same time.Volvo Trucks North America. Turn the roller while it is being lubricated. Service Bulletin 10 Date 3. 2 T2007951 Using a suitable blunt instrument.0039 in. T2007792 NOTE: When replacing the rocker arm. Also check the draining passage on the control valve. Checking Solenoid valve 1 Remove the solenoid valve from the control valve. . Use an oil can and put the tip into the oil passage. Inc.). If the clearance between the roller and pin is greater than 0. VCB. Make sure that oil runs out on both sides of the roller.65 mm (0.2003 Group No. for information on adjusting valves. Page 18(21) 253 21 12 Check valve clearance between rocker arm piston and valve bridge.1 mm (0.55 – 1. group 21. note the reading on the dial gauge.065 in. replace the rocker arm. push the roller inwards as far as possible. 11 T2019599 Check that the draining hole is not blocked on the solenoid valve.). the new rocker arm bushing should be lubricated with engine oil.051 – 0. Solenoid/Control Vave.

The valve should open. so the piston should be at its end position (via the spring). cover one side of opening and apply low air pressure. Service Bulletin 3 Date 3. i.Volvo Trucks North America. It is highly unlikely that the piston (1) has jammed or stuck in the driving position. 6 T2019600 Check that the solenoid valve opens and closes properly (battery power [B+] and ground are required to perform this check): • • • With solenoid activated. The seals in the pipe between the control valve and the rocker arm shaft. the VCB is not active (A). With B+ and ground removed. when the solenoid is activated and the oil chamber (2) is drained and the spring presses the piston to its end position. .e. Inc. Replace solenoid valve if it does not open and close properly. If the piston jams or sticks. Do not apply full shop air pressure. the solenoid valve should close. the VCB can become active for a short period after starting. The piston (1) in the control valve is in active position (B). There is risk of oil splash that can cause personal injury. Page 19(21) 253 21 5 With low oil pressure in the rocker arm shaft. check: • • The seal between the control valve and the cylinder head. T2019601 Control Valve 4 If the engine oil is very contaminated.2003 Group No. there is no oil pressure on either side of the piston. WARNING Wear eye protection. When the engine is switched OFF. remove the control valve and clean it internally.

If no tension is felt. Non-return valve 3a. Ball 3c. Spring Rocker arm piston 6 Push the non-return valve piston (3a) to end position while pressing the rocker arm forward (towards the valves).Volvo Trucks North America. VCB. The marking for TDC on the camshaft will be between the markings on the forward cap. causing the VCB not to function when activated. 2 Heat the plug (1) on VEB rocker cylinder 3 so that the locking fluid ceases to grip. 1 Date 3. Rocker arm piston . 5 Check the non-return valve ball (3b) and spring (3c) by pressing the nonreturn valve piston (3a) to end position in order to feel whether there is a spring tension. Service Bulletin 7 During engine operation. If debris or a foreign object has lodged in the oil chamber (2). the spring’s force and oil pressure in the oil chamber (2) hold the piston in the balance position which reduces oil pressure. 4.2003 Group No. Inc. Non-return valve 3 Remove the spring (2) and the nonreturn valve piston (3a) and check spring and piston for damage. Push piston forward and back to verify that piston moves freely in piston bore. Checking T2014923 Turn the engine to top dead center (TDC). the spring is faulty and should be replaced. Remove the plug. Page 20(21) 253 21 Rocker Arm Valve. 4 Place the non-return valve piston (3a) back in the piston bore. this could prevent the piston from returning to its end position. Plug 2. The control valve must then be disassembled and carefully cleaned or replaced. T2019602 1. Spring 3. Piston 3b.

NOTE: Apply thread locking fluid to plug before installation. replace the rocker arm. Date 3. Release the negative pressure by pushing in the non-return valve piston (3a). Inc. Service Bulletin 7 When the rocker arm piston (4) contacts the valve caliper.2003 Group No. install spring (2) and plug (1). Negative pressure will then be created in the rocker arm piston (4).Volvo Trucks North America. release the non-return valve piston (3a). . Page 21(21) 253 21 10 If no faults were found. The rocker arm piston (4) should drop toward the valve caliper when negative pressure is released. 9 Continue to hold the rocker arm toward the camshaft. 8 Push the rocker arm back (towards the camshaft). If piston does not move freely. 11 Check the remaining VEB rocker arms: rotate the engine to the next VEB marking and repeat steps 2 – 10.