Workshop Manual E

Group 20 Technical Data 2(0)

D12C-A, D12D-A, D12D-B, D12D-C,

D12D-D, D12D-E, D12D-F, D12D-G,
D12D-H
 Group 20: Technical Data

Marine Diesel Engines

D12C-A MP • D12D-A MP • D12D-B MP
D12D-C MP • D12D-D MP • D12D-E MP
D12D-F MP • D12D-G MP • D12D-H MP
D12D-A MH • D12D-B MH • D12D-C MH
D12D-E MH • D12D-G MH
D12D-A MG • D12D-E MG

Contents
Safety Precautions ................................................................ 2
General information ................................................................. 5
Technical data:
General ................................................................................. 6
Short block ........................................................................... 7
Reciprocating components ................................................... 9
Valve mechanism ................................................................. 14
Timing gears ........................................................................ 20
Lubrication system ............................................................... 21
Fuel system ......................................................................... 25
Inlet and exhaust system ..................................................... 28
Cooling system .................................................................... 31
Electrical system ................................................................. 33
Tightening torques ................................................................ 34
Tightening schedules ........................................................... 37
Installing seals ..................................................................... 47
References to Service Bulletins ........................................... 50
 Safety Precautions
Introduction
This workshop manual contains technical data, de-
scriptions and repair instructions for the Volvo Penta
products or product versions noted in the table of
contents. Check that you have the correct Workshop
Manual for your engine.
Read the available safety information, “General infor-
mation” and “Repair instructions” in the workshop
manual before you start to do any service work.
Important
In this book and on the product you will find the follow-
ing special warning symbols.
WARNING! Warns for the risk of personal injury,
major damage to product or property, or serious
malfunctions if the instruction is ignored.
IMPORTANT! Is used to call attention to things
which could cause damage or malfunctions to
product or property.
NOTE! Is used to call attention to important informa-
tion, to facilitate work processes or operation.
Below is a summary of the risks involved and safety
precautions you should always observe or carry out
when operating or servicing the engine.
Make it impossible to start the engine by cutting
system current with the main switch(es) and
lock it (them) in the off position before starting
service work. Set up a warning notice by the
helm station.
As a general rule all service operations must be
carried out with the engine stopped. Some
tasks, such as adjustments, need the engine to
be running, however. Approaching an engine
which is operating is a safety hazard. Remem-
ber that loose clothing or long hair can fasten in
rotating parts and cause serious personal inju-
ry.
2
If work is done adjacent to a running engine, a
careless movement or a dropped tool can lead
to personal injury in the worst case.
Take care to avoid contact with hot surfaces
(exhaust pipes, Turbocharger, air intake pipe,
starter heater etc.) and hot fluids in pipes and
hoses in an engine which is running or has just
been stopped. Reinstall all guards removed dur-
ing service work before starting the engine.
Never start the engine with the valve cover re-
moved. Apart from the risk of spilling oil, there is
a risk of personal injury. The voltage supplied to
the unit injectors can be as high as 100 V.
Check that the warning or information labels on
the product are always clearly visible. Replace
labels which have been damaged or painted
over.
Never start the engine without installing the air
cleaner filter. The rotating compressor turbine in
the turbocharger can cause severe injury. For-
eign objects entering the intake ducts can also
cause mechanical damage.
Never use start spray or similar products as a
starting aid. They may cause an explosion in
the inlet manifold. Danger of personal injury.
Avoid opening the coolant filling cap when the
engine is hot. Steam or hot coolant can spray out
and the system pressure will be lost. Open the
filler cap slowly, and release the pressure in the
cooling system if the filling cap or tap has to be
opened, or if a plug or coolant hose has to be re-
moved when the engine is hot. Steam or hot
coolant might spray out in an unexpected direc-
tion.
Hot oil can cause burns. Avoid skin contact with
hot oil. Ensure that the lubrication system is not
under pressure before carrying out any work.
Never start or operate the engine with the oil fill-
er cap removed, otherwise oil could be ejected.
Stop the engine and close the sea cocks before
doing any work on the cooling system.
Group 20
Only start the engine in a well- ventilated area.
When operated in a confined space, exhaust
fumes and crankcase gases must be ventilated
from the engine bay or workshop area.
Always use protective glasses or goggles when
carrying out work where there is a risk of splin-
ters, grinding sparks, acid splashes or where
other chemicals are used. Your eyes are ex-
tremely sensitive, injury could cause blindness!
Avoid getting oil on your skin! Repeated exposure
to oil or exposure over a long period can result in
the skin becoming dry. Irritation, dryness and ec-
zema and other skin problems can then occur.
Used oil is more dangerous than fresh oil from a
health aspect. Use protective gloves and avoid
oil soaked clothes and rags. Wash regularly,
especially before eating. There are special skin
creams which counteract drying out of the skin
and make it easier to clean off dirt after work is
completed.
Most chemicals intended for the product (e.g.
engine and transmission oils, glycol, petrol
(gasoline) and diesel oil) or chemicals for work-
shop use (e.g. degreasers, paints and solvents)
are hazardous. Read the instructions on the
product packaging with care! Always follow the
safety precautions for the product (for example
use of protective mask, glasses, gloves etc.).
Make sure that other personnel are not inad-
vertently exposed to hazardous chemicals, for
example in the air. Ensure good ventilation in
the work place. Follow the instructions provided
when disposing of used or leftover chemicals.
Exercise extreme care when leak detecting on
the fuel system and testing the fuel injector noz-
zles. Use eye protection. The jet which comes
from a fuel injector has very high pressure and
considerable penetration ability. Fuel can force
its way deep into body tissue and cause severe
injury. Danger of blood poisoning (septicemia).
All fuels, and many chemicals, are flammable.
Do not allow naked flame or sparks in the vicini-
ty. Petrol (gasoline), some thinners and hydro-
gen gas from batteries are extremely flammable
and explosive when mixed with air in the correct
ratio. No Smoking! Ensure that the work area is
well ventilated and take the necessary safety
precautions before starting welding or grinding
work. Always ensure that there are fire extin-
guishers at hand when work is being carried
out.
Make sure that oil and fuel soaked rags, and
used fuel and oil filters are stored in a safe
place. Rags soaked in oil can spontaneously ig-
nite under certain circumstances.
Safety information
Used fuel and oil filters are polluting waste and
must be handed to an approved waste manage-
ment facility for destruction, together with used
lubrication oil, contaminated fuel, paint residue,
solvents, degreasers and wash residue.
Batteries must never be exposed to open
flames or electric sparks. Never smoke close to
the batteries. The batteries generate hydrogen
gas when charged, which forms an explosive
gas when mixed with air. This gas is easily ignit-
ed and highly volatile. A spark, which can be
caused by incorrect battery connection, can
cause a single spark which is sufficient to cause
an explosion with resulting damage. Do not
move the connections when you attempt to start
the engine (risk of arcing), and do not stand and
lean over one of the batteries.
Always ensure that the Plus (positive) and Mi-
nus (negative) battery cables are correctly in-
stalled on the corresponding terminal posts on
the batteries. Incorrect installation can result in
serious damage to the electrical equipment. Re-
fer to the wiring diagram.
Always use protective goggles when charging
and handling the batteries. Battery electrolyte
contains sulfuric acid which is highly corrosive.
Should the battery electrolyte come into contact
with unprotected skin wash off immediately using
plenty of water and soap. If you get battery acid in
your eyes, flush at once with a generous amount
of water, and get medical assistance at once.
Turn the engine off and turn off the power at the
main switch(es) before carrying out work on the
electrical system.
Clutch adjustments must be carried out with the
engine stopped.
The existing lugs on the engine/reverse gear
should be used for lifting the assembly.
Always check that the lifting devices are in good
condition and that they have the correct capaci-
ty for the lift (the weight of the engine plus the
reverse gear and extra equipment).
The engine should be lifted with a customized
or adjustable lifting boom for safe handling and
to avoid damaging components on top of the
engine. All chains or cables should be parallel
to each other and should be as square as pos-
sible to the top of the engine.
If other equipment connected to the engine has
altered its center of gravity, special lifting devic-
es may be needed to obtain the correct balance
and safe handling.
Never do any work on an engine which just
hangs from a lifting device.
3
Safety information Group 20

Never work alone when removing heavy engine
components, even when using lifting devices
such as locking tackle lifts. When using a lifting
device two people are usually required to do the
work, one to take care of the lifting device and an-
other to ensure that components are lifted clear
and not damaged during the lifting operations.
When you work aboard a boat, always make
sure that there is enough space for disassembly
where you are working, with no risk of personal
injury or material damage.
Never use a power washer for engine cleaning.
Remember the following when washing other
components with a power washer: Never aim
the water jet at seals, rubber hoses or electrical
components.
Only use the fuels recommended by Volvo Pen-
ta. Refer to the Instruction Book. Use of fuels
that are of a lower quality can damage the en-
gine. Poor fuel can also lead to higher mainte-
nance costs.

Components in the electrical and fuel systems

on Volvo Penta products have been designed
to minimize the risks of explosion and fire. The
engine must not be run in areas where there
are explosive materials.

© 2007 AB VOLVO PENTA

We reserve the right to make modifications without prior notice.
Printed on environmentally compatible paper.

4
 General information
About this Workshop Manual
This workshop manual contains descriptions and re-
pair instructions for the standard version of the
D12C-A MP, D12D-A MP, D12D-B MP, D12D-C MP,
D12D-D MP, D12D-E MP, D12D-F MP, D12D-G MP,
D12D-H MP, D12D-A MH, D12D-B MH, D12D-C MH,
D12D-E MH, D12D-G MH, D12D-A MG and
D12D-E MG engines.
The engine designation and number are noted on the
number plate and engine decal. In all correspondence
about an engine, the engine designation -and number
must always be given.
The Workshop Manual is produced primarily for the
use of Volvo Penta workshops and service techni-
cians. This assumes that people who use the Manual
have basic knowledge of marine drive systems and
can do the tasks of a mechanical/or electrical nature
associated with the trade.
Volvo Penta constantly improves its products, so we
reserve the right to make modifications without prior
notification. All information in this manual is based on
product data which was available up to the date on
which the manual was printed. Any material changes
introduced into the product or service methods after
this date are notified by means of Service Bulletins.
Spare parts
Spare parts for electrical and fuel systems are subject
to various national safety requirements such as the
US Coast Guard Safety Regulations. By Volvo Penta
approved spare parts meet these specifications. No
damage whatever, occasioned by use of spare parts
other than by Volvo Penta approved spare parts for
the product, will be compensated by the warranty of-
fered by Volvo Penta.
Certified engines
When doing service and repair on emission certified
engines, it is important to be aware of the following:
Certification means that an engine type has been
checked and approved by the relevant authority. The
engine manufacturer guarantees that all engines made
of the same type are equivalent to the certified engine.
This makes special demands on service and re-
pair work, as follows:
l Maintenance and service intervals recommended
by Volvo Penta must be complied with.
l Only by Volvo Penta approved spare parts may
be used.
l Service to injection pumps, pump settings and in-
jectors must always be done by an authorized
Volvo Penta workshop.
l The engine must not be converted or modified,
except for the accessories and service kits which
Volvo Penta has approved for the engine.
l No installation changes to the exhaust pipe and
engine air inlet ducts may be done.
l No seals on the engine may be broken by unau-
thorized persons.
The general advice in the instruction book about op-
eration, care and maintenance applies.
IMPORTANT! Late or inadequate maintenance/
service or the use of spare parts other than by
Volvo Penta approved spare parts will invalidate
AB Volvo Penta’s responsibility for the engine
specification being in accordance with the certi-
fied version.
Volvo Penta accepts no responsibility or liability
for any damage or costs arising due to the
above.
5
 Technical Data

General
Type designation .................................................. D12C-A MP D12D-A/B/C/E/G MH
D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG

No. of cylinders ...................................................... 6

Bore ....................................................................... 131 mm (5.157")
Stroke ..................................................................... 150 mm (5.906")
Swept volume, total ................................................ 12.13 dm3 (740 in3)
Power ..................................................................... Please refer to the sales literature
No. of valves per cylinder ....................................... 4
Direction of rotation (seen from front) .................... Clockwise
Compression ratio .................................................. 16.5:1 17.5:1
Compression pressure at starter motor speed,
240 rpm .................................................................. 3.6 MPa (522 psi) –
Firing sequence (cyl. no. 6 closest to flywheel) ..... 1–5–3–6–2–4
Low idle, (propulsion engines) ............................... 525 ±10 rpm
adjustable in the range ........................................ 500–700 rpm 500–800 rpm
High idle,
D12C 650, 675, 700, 715, D12D 675, 715, 775
and D12D 550:
neutral / gear engaged ........................................ 2000/2460 ±20 rpm 2030/2030 ±20 rpm
D12C 615 or D12D 400, 450:
neutral / gear engaged ........................................ 2000/2250 ±20 rpm 1980/1980 ±20 rpm
D12D-A MG ........................................................... – 1500 or 1800 rpm
Highest full load speed,
D12C 650, 675, 700, 715 and D12D 550 ............... 2350 rpm 1950 rpm
D12C 615 or D12D 400, 450 ................................. 2150 rpm 1850 rpm
Weight, engine with heat exchanger, without
reverse gear, (dry) app. ......................................... 1400 kg (3086 lbs)

6
Group 20 Technical data

Short block
Cylinder head
D12C-A MP D12D-A/B/C/E/G MH
D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG

Type ....................................................................... One cylinder head for all cylinders

(overhead camshaft)
Length .................................................................... 1078 mm (42.441")
Width ...................................................................... 397 mm (15.630")
Height ..................................................................... 135 mm (5.315")
Max. flatness error (base plane) ............................ 0.1 mm (0.0039")

Screws, cylinder head

Quantity .................................................................. 38
Thread dimension .................................................. M16 x 2
Length .................................................................... 200 mm (7.874")

Cylinder block
Height above upper block plane – crankcase
centerline (A) .......................................................... Min. 422 mm (16.614")
Height, lower block plane – crankcase
centerline (B) ......................................................... Min. 120 mm (4.724")

7
Technical data Group 20

Cylinder liner
D12C-A MP D12D-A/B/C/E/G MH
D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG

Type ....................................................................... Wet, replaceable

Cylinder diameter (no overbores) .......................... 131 mm (5.157")
Sealing surface height above block plane ............. 0.15–0.21 mm
(0.0059– 0.0083")
No. of O-rings, upper liner seal .............................. 1* 1
No. of O-rings, lower liner seal ............................... 3
* Note. Upper O-ring introduced as from engine no. xxxx/
310909.
This ring is included in the late model liner kit and must
also be installed on early model engines when the cyl-
inder liners/seals are changed.

Pistons
Piston installed in engine, height above
cylinder block plane ................................................ 0.05–0.45 mm
(0.0020– 0.0177")
No. of ring grooves ................................................. 3
Front marking ......................................................... Arrow towards front

Gudgeon pins
Diameter ................................................................ 55 mm (2.1654")

Combustion chamber (piston bowl)

Diameter (A) .......................................................... 83 mm (3.2677") 89 mm (3.5039")
Depth (B) ................................................................ 22 mm (0.8661") 18.3 mm (0.7205")

8
Group 20 Technical data

Piston rings
D12C-A MP D12D-A/B/C/E/G MH
D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG
Compression rings
Quantity .................................................................. 2
Piston ring clearance in groove:
upper compression ring ...................................... Trapezoidal section
lower compression ring, height ........................... 0.05–0.08 mm
(0.0020–0.0031")
Piston ring gap, measured at ring opening:
upper compression ring ...................................... 0.4–0.6 mm
(0.0157–0.0236")
max. ring gap ................................................... 1.0 mm (0.0394")
lower compression ring* ..................................... 0.8–1.0 mm
(0.0315–0.0394")
max. ring gap* .................................................. 1.3 mm (0.0512")
lower compression ring** .................................... 1.0–1.15 mm
(0.0394–0.0453")
max. ring gap* .................................................. 1.45 mm (0.0571")
* Up to engine number xxxx/307145.
** As from engine number xxxx/307146 (included in late
model cylinder liner kits).

Oil scraper ring

Quantity .................................................................. 1
Width, incl. spring ................................................... 4.3 mm (0.1693")
Piston ring clearance, vertical ................................ 0.03–0.08 mm
(0.0012–0.0031")
Piston ring gap, measured at ring opening ............ 0.35–0.75 mm
(0.0138–0.0295")
max. ring gap ...................................................... 1.0 mm (0.0394")

Reciprocating components
Crankshaft
Length .................................................................... 1203 mm (47.362")
Crankshaft, end float1) ............................................ 0.10–0.40 mm
(0.0039–0.0157")
Main bearings, radial clearance1) ............................ 0.01–0.15 mm
(0.0004–0.0059")
Max permissible ovality on main and big end
bearing journals ...................................................... 0.08 mm (0.0031")
Max permissible taper on main and big end
bearing journals. ..................................................... 0.05 mm (0.0020")
Max. runout at center bearing ................................ 0.15 mm (0.0059")
1)
Note. Dimensions apply to oiled components.

9
Technical data Group 20

Main bearing journals

D12C-A MP D12D-A/B/C/E/G MH
D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG

Diameter for machining, standard ........................... 108.0 mm (4.2520")

Undersize dimension:
0.25 mm (0.0098") .............................................. 107.73–107.75 mm
(4.2413–4.2421")
0.50 mm (0.0197") .............................................. 107.48–107.50 mm
(4.2315–4.2323")
0.75 mm (0.0296") .............................................. 107.23–107.25 mm
(4.2216–4.2224")
1.00 mm (0.0394") .............................................. 106.98–107.00 mm
(4.2118–4.2126")
1.25 mm (0.0492") .............................................. 106.73–106.75 mm
(4.2020–4.2027")
Surface finish, main bearing journal ....................... Ra 0.25
Surface finish, radius ............................................. Ra 0.4
Width, thrust bearing journal (A) standard ............. 47.0 mm (1.850")
Oversize dimension:
0.2 mm (0.0079") (thrust bearing 0.1 mm) ......... 47.175–47.225 mm
(1.8573–1.8592")
0.4 mm (0.0157") (thrust bearing 0.2 mm) ......... 47.375–47.425 mm
(1.8652–1.8671")
0.6 mm (0.0236") (thrust bearing 0.3 mm) ......... 47.575–47.625 mm
(1.8730–1.8750")
Fillet radius (R) ....................................................... 3.75–4.00 mm
(0.1476–0.1575")

10
Group 20 Technical data

Thrust washers (thrust bearing)

D12C-A MP D12D-A/B/C/E/G MH
D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG

Width (B) standard .................................................. 3.1–3.2 mm

(0.1220–0.1260")
Oversize dimension:
0.1 mm (0.0039") ................................................ 3.2–3.3 mm
(0.1260–0.1299")
0.2 mm (0.0079") ................................................ 3.3–3.4 mm
(0.1299–0.01339")
0.3 mm (0.0118") ................................................ 3.4–3.5 mm
(0.1339–0.1378")

Main bearing shells

Type ....................................................................... Replaceable
Outer diameter (C) ................................................. 113.0 mm (4.4488")
Thickness (D) standard .......................................... 2.5 mm (0.0984")
Oversize dimension:
0.25 mm (0.0098") .............................................. 2.6–2.7 mm
(0.1024–0.1063")
0.50 mm (0.0197") .............................................. 2.7–2.8 mm
(0.1063–0.1102")
0.75 mm (0.0295") .............................................. 2.8–2.9 mm
(0.1102–0.1142")
1.00 mm (0.0394") .............................................. 2.9–3.0 mm
(0.1142–0.1181")
1.25 mm (0.0492") .............................................. 3.1–3.2 mm
(0.1220–0.1260")

11
Technical data Group 20

Big end journals

D12C-A MP D12D-A/B/C/E/G MH
D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG

Diameter (Ø) for machining, standard ..................... 92.0 mm (3.6220")

Undersize dimension:
0.25 mm (0.0098") .............................................. 91.73–91.75 mm
(3.6114–3.6122")
0.50 mm (0.0197") .............................................. 91.48–91.50 mm
(3.6016–3.6024")
0.75 mm (0.0295") .............................................. 91.23–91.25 mm
(3.5917–3.5925")
1.00 mm (0.0394") .............................................. 90.98–91.00 mm
(3.5819–3.5827")
1.25 mm (0.0492") .............................................. 90.73–90.75 mm
(3.5720–3.5728")
Surface finish, big end bearing journal ................... Ra 0.25
Surface finish, radius ............................................. Ra 0.4
Width, bearing journal (A) ...................................... 56.9–57.0 mm
(2.2402–2.2441")
Fillet radius (R) ....................................................... 3.75–4.00 mm
(0.1476–0.1575")

Big end journal shells

Thickness (C) standard .......................................... 2.39–2.40 mm
(0.0941–0.0945")
Oversize dimension:
0.25 mm (0.0098") .............................................. 2.51–2.52 mm
(0.0988–0.0992")
0.50 mm (0.0197") .............................................. 2.64–2.65 mm
(0.1039–0.1043")
0.75 mm (0.0295") .............................................. 2.76–2.77 mm
(0.1087– 0.1091")
1.00 mm (0.0394") .............................................. 2.89–2.90 mm
(0.1138–0.1142")
1.25 mm (0.0492") .............................................. 3.01–3.02 mm
(0.1185–0.1189")
Diameter, bearing shell seat (D) ............................ 96.84–96.85 mm
(3.8126–3.8130")

12
Group 20 Technical data

Con rods
D12C-A MP D12D-A/B/C/E/G MH
D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG

Length, center – center (E) ..................................... 260 mm (10.2362")

Marking:
Con rod and cap1) ................................................... 1 to 6
applies to “split” con rods .................................... Con rods and bearing caps are marked in pairs
with a three digit serial number (see figure)
“FRONT” on the con rod faces .............................. forwards
Big end bearing cap internal
diameter (G) ........................................................... 55.022–55.028 mm
(2.1662–2.1665")
End float, con rod – crankshaft, max.2) .................. 0.35 mm (0.0138")
Big end bearings, radial clearance, max.2) ............. 0.10 mm (0.0039")
Straightness, max. deviation on 100 mm (3.937")
measured length .................................................... 0.06 mm (0.0024")
Twist, max. deviation on 100 mm (3.937")
measured length .................................................... 0.15 mm (0.0059")
1)
Marking on same side.
2)
Dimensions apply to oiled components.

Flywheel, installed
Max permissible runout on measured
radius 150 mm (5.906") .......................................... 0.20 mm (0.0079")
No. of teeth on starter gear ring ............................. 153
Sensor grooves on flywheel ................................... 3 × 18

Flywheel housing, installed

Max permissible runout on mating surface
against transmission .............................................. 0.20 mm (0.0079")
Max. permissible radial runout for guide against
transmission ........................................................... 0.25 mm (0.0098")

13
Technical data Group 20

Valve mechanism
Camshaft
D12C-A MP D12D-A/B/C/E/G MH
D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG

Checking camshaft setting:

Check camshaft setting with cold engine and
valve clearance = 0.
Inlet valve for cylinder 1 should by flywheel
position 6° A.T.D.C. have opened .......................... 1.6 ± 0.3 mm
(0.0630 ± 0.0118")
Note. During the check, the timing gear must be
rotated in the correct direction (clockwise, seen
from the front) to take up any tolerances.
NOTE! Do not forget to re-set the valve clear-
ance to the correct value after the test.

Drive ....................................................................... Gear wheel

No of bearings ........................................................ 7
Diameter, bearing journals, standard ..................... 70 mm (2.7559")
Diameter, bearing journals, undersize dimension:
0.25 mm (0.0098") .............................................. 69.720–69.780 mm
(2.7449–2.7472")
0.50 mm (0.0197") .............................................. 69.470–69.530 mm
(2.7350–2.7374")
0.75 mm (0.0295") .............................................. 69.220–69.280 mm
(2.7252–2.7276")
End float, max. ....................................................... 0.35 mm (0.0138")
Radial clearance, max. .......................................... 0.01 mm (0.0004")
Valve lift:
Inlet ..................................................................... 13.1 mm (0.5157")
Exhaust .............................................................. 13.1 mm (0.5157")
Cam profiles, permissible wear:
Inlet ..................................................................... 0.1 mm (0.0039")
Exhaust ............................................................... 0.1 mm (0.0039")
Unit injector ......................................................... 0.1 mm (0.0039")
Unit injector, stroke ................................................ 17 mm (0.669")

Camshaft bearings
Camshaft bearing thickness, standard ................... 1.9 mm (0.0748")
Oversize dimension:
0.25 mm (0.0098") .............................................. 2.0 mm (0.0787")
0.50 mm (0.0197") .............................................. 2.2 mm (0.0866")
0.75 mm (0.0295") .............................................. 2.3 mm (0.0906")
Diameter, camshaft bearing seat:
Bearings 1 to 7 .................................................... 73.9 mm (2.9094")

14
Group 20 Technical data

Valves
D12C-A MP D12D-A/B/C/D/E/F/G/H MP
D12D-A/B/C/E/G MH
D12D-A/E MG
Valve head diameter:
Inlet ..................................................................... 40 mm (1.575")
Exhaust ............................................................... 40 mm (1.575")
Valve stem diameter:
Inlet ..................................................................... 7.960–7.975 mm
(0.3134–0.3140")
Exhaust ............................................................... 7.947–7.962 mm
(0.3129–0.3135")
Valve seat angle:
Inlet ..................................................................... 29.5°
Exhaust ............................................................... 44.5°
Valve head edge (please refer to illustration below):
Inlet (new valve) .................................................. 1.8 mm (0.0709") –
wear tolerance .................................................... min. 1.4 mm (0.0551") –
Exhaust (new valve) ........................................... 1.6 mm (0.0630") –
wear tolerance .................................................... min. 1.2 mm (0.0472") –
Seat angle in cylinder head:
Inlet ..................................................................... 30°
Exhaust ............................................................... 45°

INLET EXHAUST

Valve clearance, cold engine, setting value,

D12D-B/D/F/H MP:
Inlet ..................................................................... – 0.2 mm (0.0079")
Exhaust .............................................................. – 0.7 mm (0.0276")
Other engines:
Inlet ..................................................................... 0.2 mm (0.0079")
Exhaust .............................................................. 0.5 mm (0.0197")
Valve clearance, cold engine, check value,
D12D-B/D/F/H MP:
Inlet ..................................................................... – 0.15–0.25 mm
(0.0059–0.0098")
Exhaust .............................................................. – 0.65 –0.75 mm
(0.0256–0.0295")
Other engines:
Inlet ..................................................................... 0.15–0.25 mm
(0.0059–0.0098")
Exhaust .............................................................. 0.45–0.55 mm
(0.0177– 0.0217")

15
Technical data Group 20

Valve seats
D12C-A MP D12D-A/B/C/D/E/F/G/H MP
D12D-A/B/C/E/G MH
D12D-A/E MG
Outer diameter (dimension A), standard:
Inlet ..................................................................... 43.1 mm (1.6968")
Exhaust .............................................................. 43.1 mm (1.6968")
Outer diameter (dimension A), oversize dimension:
Inlet ..................................................................... 43.3 mm (1.7047") –
Exhaust .............................................................. 43.3 mm (1.7047")
Height (dimension B):
Inlet ..................................................................... 8.4–8.6 mm 7.9–8.1 mm
(0.3307–0.3386") (0.3110–0.3189")
Exhaust .............................................................. 7.9–8.1 mm 7.15–7.35 mm
(0.3110–0.3189") (0.2815–0.2894")
Distance from valve head to cylinder head plane
(check dimension):
Inlet ..................................................................... 0.9–1.4 mm 0.8–1.3 mm
(0.0354–0.0551") (0.0315–0.0512")
wear tolerance ................................................. max. 1.5 mm (0.0591")
Exhaust ............................................................... 1.2–1.7 mm
(0.0472–0.0669")
wear tolerance ................................................. max. 1.8 mm (0.0709")
If the distance is greater, the valve seat must be changed.
NOTE! When the valve seats are changed, the
valves must be changed at the same time.
Spare part valve seats are already machined, and
should not need further grinding.
Valve seat bed

Diameter (dimension C) standard:

Inlet ..................................................................... 43 mm (1.6929")
Exhaust .............................................................. 43 mm (1.6929")
Diameter (dimension C) oversize dimension:
Inlet ..................................................................... 43.200–43.225 mm –
(1.7008–1.7018")
Exhaust .............................................................. 43.200–43.225 mm
(1.7008–1.7018")
Depth (dimension D):
Inlet ..................................................................... 11.2 ±0.1 mm
(0.4409 ±0.0039")
Exhaust .............................................................. 11.2 ±0.1 mm
(0.4409 ±0.0039")
Seat base radius (dimension R):
Inlet ..................................................................... 0.8 mm (0.0315")
Exhaust .............................................................. 0.8 mm (0.0315")

16
Group 20 Technical data

Valve guides
D12C-A MP D12D-A/B/C/D/E/F/G/H MP
D12D-A/B/C/E/G MH
D12D-A/E MG
Length:
Inlet ..................................................................... 83.2–83.5 mm
(3.2756–3.2874")
Exhaust .............................................................. 83.2–83.5 mm
(3.2756–3.2874")
Inner diameter:
Inlet ..................................................................... 8.0 mm (0.3150")
Exhaust .............................................................. 8.0 mm (0.3150")
Height above cylinder head spring plane:
Inlet ..................................................................... 26.5 ±0.4 mm
(1.0433 ±0.0157")
Exhaust .............................................................. 18.5 ±0.4 mm 26.5 ±0.4 mm
(0.7283 ±0.0157") (1.0433 ±0.0157")
Clearance, valve stem – guide:
Inlet ..................................................................... 0.03–0.05 mm
(0.0012–0.0020")
Wear tolerance ................................................. 0.2 mm (0.0079") 1)
Exhaust .............................................................. 0.04–0.07 mm
(0.0016–0.0028")
Wear tolerance ................................................. 0.3 mm (0.0118") 1) 0.2 mm (0.0079") 1)
1)
Max. permissible clearance between valve stem and
valve guide: (in accordance with the method described
in “Workshop Manual, group 21–26, D12C, D12D,
Valve Guides, Inspection”).

17
Technical data Group 20

Valve springs
D12C-A MP D12C-A MP
Early model Late model
Inlet ........................................................................ Single springs
Exhaust .................................................................. Double springs
Valve springs (inlet) and outer valve springs
(exhaust):
Version ................................................................... Right-hand twist (A) Left-hand twist (B)
Unloaded length ..................................................... 72–73 mm 73–74 mm
(2.8346–8740") (2.8740–2.9134")
with 600 N (134.9 lbf) loading ............................. 56 mm (2.2047") –
with 590 N (132.6 lbf) loading ............................. – 58 mm (2.2835")
with 1076 N (241.9 lbf) loading ........................... 43 mm (1.6929") –
with 1150 N (258.5 lbf) loading ........................... – 45 mm (1.7717")
coilbound length, max. ....................................... 41 mm (1.6142") 40 mm (1.5748")

Inner valve spring (exhaust):

Version ................................................................... Left-hand twist (B) Right-hand twist (A)
Unloaded length ..................................................... 67– 68 mm 70–71 mm
(2.6378–2.6772") (2.7559–2.7953")
with 243 N (54.6 lbf) loading ............................... 52 mm (2.0472") –
with 330 N (74.2 lbf) loading ............................... – 54 mm (2.1260")
with 447 N (100.5 lbf) loading ............................. 39 mm (1.5354") –
with 630 N (141.6 lbf) loading ............................. – 41 mm (1.6142")
coilbound length, max. ........................................ 36 mm (1.4173") 37 mm (1.4567")

18
Group 20 Technical data

D12D-A/E MG, D12D-A/B/C/E/G MH

D12D-A/B/C/D/E/F/G/H MP
Valve springs:
Inlet ..................................................................... Single springs
Exhaust ............................................................... Double springs
Valve springs (inlet) and outer valve springs (exhaust):
Version ................................................................... Left-hand twist (B)
Unloaded length ..................................................... 73–74 mm (2.8740 –2.9134")
with 590 N (132.6 lbf) loading ............................. 58 mm (2.2835")
with 1150 N (258.5 lbf) loading ............................ 45 mm (1.7716")
coilbound length, max. ....................................... 40 mm (1.5748")
Inner valve spring (exhaust):
Version ................................................................... Right-hand twist (A)
Unloaded length ..................................................... 70 –71 mm (2.7559 –2.7952")
with 330 N (74.2 lbf) loading ............................... 54 mm (2.1260")
with 630 N (141.6 lbf) loading .............................. 41 mm (2.6142")
coilbound length, max. ........................................ 37 mm (1.4567")

Rocker arms
D12C-A MP D12D-A/B/C/E/G MH
D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG

Bearing clearance ................................................... max. 0.1 mm (0.0039")

Roller cam follower, clearance ............................... max. 0.1 mm (0.0039")

19
Technical data Group 20

Timing gears
D12C-A MP D12D-A/B/C/E/G MH
D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG

1. Gear, camshaft (z=76)

2. Seal molding
3. Gear, power take-off (optional) (z=29)
4. Idler wheel (z=83)
5. Gear, coolant pump (z=27)
6. Crankshaft gear (z=38)
7. Idler wheel, adjustable (z=97)
8. Gear, hydraulic pump (optional) (z=23)
9. Gear for drive belts and fuel pump (z=27)
10. Idler wheel (z=71)
11. Gear, seawater pump (z=39)
12. Idler wheel, lube oil pump (z=44)
13. Gear, lube oil pump (z=23)
14. Nozzle, gear lubrication

Flank clearance, adjustable idler wheel, (7) ............ 0.05–0.17 mm

(0.0020–0.0067")
Shaft stub for idler wheel, diameter ........................ 99.99 ±0.01 mm
(3.9366 ±0.0004")
Bushing for idler wheel, diameter ........................... 100.04 ±0.01 mm
(3.9386 ±0.0004")
Radial clearance for idler wheel, max. diameter .... 0.03–0.07 mm
(0.0012–0.0028")
End float for idler wheel .......................................... 0.07–0.17 mm
(0.0028–0.0067")

20
Group 20 Technical data

Lubrication system
D12C-A MP, D12D-A/B/C/D/E/F/G/H MP:
Oil grade 1) Sulfur content in fuel, by weight
up to 0.5% 0.5–1.0% more than 1.0% 2)
Oil change interval: Reached first in operation
⎫
VDS-3
VDS-2 and ACEA E7 3), 4)
VDS-2 and Global DHD-1 3) ⎬ 400 hours or 12 months 200 hours or 12 months 100 hours or 12 months
VDS-2 and API CH-4 3)
VDS-2 and API CH-4 3) ⎭

⎫
VDS and ACEA E3 3), 5) ⎬ 300 hours or 12 months 150 hours or 12 months 75 hours or 12 months
VDS and API CG-4 3), 6) ⎭

D12D-A/B/C/E/G MH, D12D-A/E MG:

Oil grade 1)
VDS-3
VDS-2 and ACEA E7 3), 4)
VDS-2 and Global DHD-1 3)
VDS-2 and API CH-4 3)
VDS-2 and API CI-4 3)
Sulfur content in fuel, by weight
up to 0.5% 0.5–1.0% more than 1.0% 2)
Oil change interval: Reached first in operation
500 hours or 12 months 250 hours or 12 months 125 hours or 12 months
⎫
⎬ 500 hours or 12 months 200 hours or 12 months 100 hours or 12 months
⎭

3), 5) ⎫
VDS and ACEA E3 ⎬ 300 hours or 12 months 150 hours or 12 months 75 hours or 12 months
VDS and API CG-4 3), 6) ⎭

NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the
quality requirements above.
1)
Lowest recommended oil grade. Higher grade oil can always be used.
2)
For sulfur content >1.0% by weight, oil with TBN >15 must be used.
3)
Lubrication oil must comply with both requirements.
4)
ECEA E7 has replaced ACEA E5. ACEA E5 can be used, however, if this grade is still available.
5)
ACEA E3 can be replaced by ACEA E4, E5 or E7.
6)
API CG-4 can be replaced by API CI-4.

VDS = Volvo Drain Specification

ACEA = Association des Constructeurs Européens d’Automobiles
Global DHD = Global Diesel Heavy Duty
API = American Petroleum Institute
TBN = Total Base Number

−30 −20 −10 ±0 +10 20 30 40 o

C
Viscosity −15oC SAE 15W/40
All engines: −25oC SAE 10W/30
Select viscosity from the adjacent table. ✱ SAE 5W/30
(The temperature values refer to stable ambient −10oC SAE 20W/30
temperatures).
±0oC SAE 30
* SAE 5W/30 is only synthetic or semi- synthetic oil. +10oC SAE 40
o
−22 −4 +14 32 50 68 86 104 F

21
Technical data Group 20

D12C-A MP D12D-A/B/C/E/G MH**

D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG**
D12D-A MH*
Lubrication oil volume
Change volume, including changing three filters,
no engine inclination ............................................ 44 liters 56 liters
(11.6 US gals) (14.8 US gals)
volume difference, min. – max. ........................... 12 liters 12 liters
(3.2 US gals) (3.2 US gals)
engine inclination backwards 8° .......................... 33 liters 48 liters
(8.7 US gals) (12.7 US gals)
volume difference, min. – max. ........................... 12 liters 12 liters
(3.2 US gals) (3.2 US gals)
engine inclination backwards 18° ........................ – 38 liters
(10.0 US gals)
volume difference, min. – max. ........................... – 12 liters
(3.2 US gals)
* Shallow sump (optional).
** Deep sump with inspection hatches.

D12C-A MP D12D-A/B/C/E/G MH
D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG
Lube oil pressure
Operation speed (1100 rpm or higher) .................... 400–550 kPa
(58–80 psi)
Idling (propulsion engine) ....................................... min. 175 kPa (25.3 psi)

Oil pressure, piston cooling

Operation speed (1100 rpm or higher) ................... min. 200 kPa (29 psi)

Oil filter
Full flow filter, qty. .................................................. 2
(tighten ½-¾ turn after it just touches)
By-pass filter, qty. .................................................. 1
(tighten ¾-1 turn after it just touches)

Lube oil pump

Type ....................................................................... Gear driven

22
Group 20 Technical data

Oil valves
D12D-A/B/C/D/E/F/G/H MP* D12D-A/B/C/E/G MH*
D12D-A/E MG

Engines with low mounted oil filters*

* Note. High mounted or rear mounted oil filters occur as alter-

native equipment.

1. Safety valve, lube oil pressure

Marking ................................................................... Yellow
Opening pressure .................................................. 690 kPa (100 psi)

2. By-pass valve, oil cooler

Marking .................................................................. 124
Opening pressure .................................................. 300 kPa (43.5 psi)

3. Bypass valve (full flow oil filter)

Marking on spring .................................................. Green/white
Opening pressure .................................................. 210 kPa (30.4 psi)
Spring, free length .................................................. 68.8 mm (2.7087")
loaded by 25–29 N (5.6–6.5 lbf) .......................... 40.0 mm (1.5748")

4. Piston cooling valve

Marking .................................................................. Orange
Opening pressure .................................................. 190 kPa (27.5 psi)

5. Bypass valve (by-pass filter)

Marking on spring .................................................. Blue /yellow
Opening pressure .................................................. 110 kPa (15.9 psi)
Spring, free length .................................................. 68.8 mm (2.7087")
loaded by 13– 15 N (2.9– 3.4 lbf) ......................... 40.0 mm (1.5748")

6. Pressure reduction valve, lube oil pressure

Marking ................................................................... Blue
Opening pressure .................................................. 480 kPa (69.6 psi)

23
Technical data Group 20

D12C-A MP* D12D-A/B/C/E/G MH*

D12D-A/B/C/D/E/F/G/H MP*

Engine with high mounted oil filters, or with

filters installed on rear edge of engine*

* Note. Low-mounted oil filters occur as alternative

equipment.

1. Safety valve, lube oil pressure

Marking ................................................................... Violet
Opening pressure ................................................... 860 kPa (124.7 psi)

2. By-pass valve, oil cooler

Marking .................................................................. 124
Opening pressure .................................................. 300 kPa (43.5 psi)

3. By-pass valve (full-flow oil filter)

Marking on spring .................................................. Green/white
Opening pressure .................................................. 210 kPa (30.4 psi)
Spring, free length .................................................. 68.8 mm (2.7087")
loaded by 25–29 N (5.6–6.5 lbf) .......................... 40.0 mm (1.5748")

4. Piston cooling valve

Marking:
early model. ........................................................ Gray –
late model. .......................................................... White 1) White
Opening pressure:
early model. ........................................................ 300 kPa (43.5 psi) –
late model. .......................................................... 250 kPa 1) (36.2 psi) 1) 250 kPa (36.2 psi)
1)
Note. As from engine no. 1101058889/245083 and
piston cooling valve as a spare part.

6. Pressure reduction valve, lube oil pressure

Marking .................................................................. Black
Opening pressure .................................................. 570 kPa (82.6 psi)

24
Group 20 Technical data

Fuel system
D12C-A MP D12D-A/B/C/E/G MH
D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG

Fuel specification
The fuel must comply with national and international standards for commercially supplied fuels, such
as:
EN 590 (with nationally adapted environmental and cold requirements)
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulfur content: Complying with legal requirements in each country.
Low density fuel (urban diesel in Sweden and city diesel in Finland) can cause a loss of power of about 5% and an in-
crease in fuel consumption of about 2–3%.

Injection sequence ................................................. 1–5–3–6–2–4

Feed pump
Supply pressure after fuel filter at 1000 rpm .......... min. 350 kPa (50.7 psi)
Supply pressure after fuel filter at full load ............. min. 350 kPa (50.7 psi)

By - pass valve
Opening pressure .................................................. 400–450 kPa
(58–65.2 psi)

25
Technical data Group 20

Unit injectors
D12C-A MP D12D-A/B/C/E/G MH
D12D-A/C/E/G MP D12D-A/E MG

Pre-load (setting with gauge) .................................. 68.9 ±0.1 mm

(2.7126 ±0.0039")

D12D-B/D/F/H MP –

Pre-load .................................................................. 3 – 4 nut flats –

(0.75 ±0.1 mm /
0.0295 ±0.0039")
Adjust the unit injector rocker arm to zero clear-
ance on the camshaft. Then tighten the adjust-
ment screw another 3 – 4 nut flats (180 – 240°).

26
Group 20 Technical data

D12D-B/D/F/H MP –

Position of the unit injectors trim code* .................. –

* Note. The trim code defines each unit injector’s tolerances
for the engine control unit.
In the illustration the trim code is ”5D008A”.

D12C-A MP
Unit injector, Volvo Penta part No. ......................... 3827636
Nozzle, Volvo Penta part No. ................................. 3827638
type designation ....................................... DLLA 152 P 996
marking ..................................................... 996
Setting pressure (new spring) ................................ 36.4 ±0.5 MPa (5279 ±72 psi)

D12D-A/C/E/G MP
Unit injector, Volvo Penta part No. ......................... 3836007
Nozzle, Volvo Penta part No. ................................ 3827638
type designation ....................................... DLLA 152 P 996
marking ..................................................... 996
Setting pressure (new spring) ................................ 33.4 ±0.5 MPa (4844 ±72 psi)

D12D-A MH
Unit injector, Volvo Penta part No. ......................... 3832980
Nozzle, Volvo Penta part No. ................................ 3832994
type designation ....................................... DLLA 152 P 1075 /
marking ..................................................... 1075
Setting pressure (new spring) ................................ 36.4 ±0.5 MPa (5279 ±72 psi)

D12D-B MH, D12D-C MH, D12D-A MG

Unit injector, Volvo Penta part No. ......................... 3835257
Nozzle, Volvo Penta part No. ................................ 3835299
type designation ....................................... DLLA 150 P 1244
marking ..................................................... 1789
Setting pressure (new spring) ................................. 36.4 ±0.5 MPa (5279 ±72 psi)

D12D-E/G MH, D12D-E MG

Unit injector, Volvo Penta part No. ......................... 21160093
Nozzle, Volvo Penta part No. ................................. 21165753
type designation ........................................ DLLA 146 P 1823
marking ..................................................... 1823
Setting pressure (new spring) ................................. 36.4 ±0.5 MPa (5279 ±72 psi)

D12D-B/D/F/H MP*
* Note. These engines are equipped with a different type of
unit injector which can not at present be renovated.

27
Technical data Group 20

Inlet and exhaust system

Turbocharger
D12C-A MP D12D-A/B/C/E/G MH
D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG

Make and type:

D12D-B/D/F/H MP ............................................... Schwitzer S500WG –
Other engines ...................................................... Schwitzer S500W Schwitzer S410W
Lubrication system ................................................. Pressure lubrication
Max. permissible end float ..................................... 0.18 mm (0.0071")
Max. permissible radial clearance
(compressor side) .................................................. 0.92 mm (0.0362")

Wastegate valve (D12D-B/D/F/H MP)

Checking the wastegate valve function:*
Pressurize the wastegate valve to the specified
value. The valve should then move: A = B – C
mm (inch).
Check values:
Pressurization ........................................................ 2.05 ±0.02 bar –
(29.7 ±0.3 psi)
Valve movement (A) .............................................. 4.0 ±0.2 mm –
(0.1575" ±0.0079")

* NOTE: This is only a functional check of the diaphragm

and valve, and should not be used for adjustment.
The wastegate valve must not be adjusted. If any fault is
discovered, the entire wastegate valve must be changed
as a unit. An incorrectly adjusted wastegate valve can
cause engine failure. The engine warranty ceases to be
valid if the valve has been adjusted.
A = Valve movement
B = Not pressurized

C = Pressurized

Exhaust back pressure

Max. permissible back pressure in exhaust pipe
at max. power (max. operating speed):
D12D-A/E MG ..................................................... – 10 kPa/1.45 psi
(1020 mm water pillar)
Other engines ...................................................... 15 kPa /2.17 psi
(1530 mm water pillar)

Pressure drop indicator, air filter

Level for indication (low pressure) .......................... 500 mm water pillar
(19.685" water pillar)

28
Group 20 Technical data

Charge pressure and exhaust temperatures

Charge air pressure, (measured at inlet manifold) at 100% load and full throttle.
Exhaust back pressure 10 kPa (1.45 psi). If full power can not be developed, the pressure will be considerably
lower.
The charge air pressure in the following table shall be read with a tolerance of ±15 kPa (±2.1 psi).
(100 kPa = 14.5 psi).

Exhaust temperatures are measured at rated power. Temperature of inlet air +27°C (80.6°F) and exhaust
back pressure 10 kPa (1.45 psi / 1020 mm water pillar).

D12D-A/B/C/E/G MH Charge air pressure Exhaust temperature

Power – Rating 1 (400, 450)
1800 rpm (400) ....................................................... 200 kPa (29.0 psi) 290°C (554°F)
1800 rpm (450) ....................................................... 215 kPa (31.2 psi) 315°C (599°F)

Power – Rating 2 (550)

1900 rpm ................................................................ 270 kPa (39.2 psi) 340°C (644°F)

D12C-A MP, D12D-A/C/E/G MP

Power – Rating 3 (615)
2100 rpm ................................................................ 235 kPa (34.1 psi) 370°C (698°F)

Power – Rating 4 (650)

2300 rpm ................................................................ 240 kPa (34.8 psi) 370°C (698°F)

Power – Rating 5 (675/700/715)

2300 rpm (675) ...................................................... 245 kPa (35.5 psi) 380°C (716°F)
2300 rpm (700/715) ............................................... 265 kPa (38.4 psi) 400°C (752°F)

D12D-B/D/F/H MP
Power – Rating 5 (675/715/775)
2300 rpm (675) ...................................................... 210 kPa (30.5 psi) 390°C (734°F)
2300 rpm (715) ...................................................... 230 kPa (33.4 psi) 400°C (752°F)
2300 rpm (775) ....................................................... 255 kPa (37.0 psi) 425°C (797°F)

29
Technical data Group 20

D12D-A/E MG (HE/KC)*
Power – ISO Standard Power
1500 rpm ................................................................ 184 kPa (26.7 psi) 352°C (666°F)
1800 rpm ................................................................ 262 kPa (38.0 psi) 335°C (635°F)

Power – Overload Power**

1500 rpm ................................................................ 203 kPa (29.4psi) 362°C (684°F)
1800 rpm ................................................................ 273 kPa (39.6 psi) 350°C (662°F)

D12D-A/E MG (RC)*
Power – ISO Standard Power
1500 rpm ................................................................ 184 kPa (26.7 psi) 340°C (644°F)
1800 rpm ................................................................ 246 kPa (35.7 psi) 317°C (603°F)

Power – Overload Power**

1500 rpm ................................................................ 202 kPa (29.3 psi) 350°C (662°F)
1800 rpm ................................................................ 266 kPa (38.6 psi) 347°C (657°F)

* HE = Engine equipped with heat exchanger.

KC = Keel cooled engine.
RC = Engine with radiator.
** 110% of ISO Standard Power.

30
Group 20 Technical data

Cooling system
D12C-A MP D12D-A/B/C/E/G MH
D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG

General
Type ....................................................................... Pressurized, sealed
Pressure cap opens at ........................................... 75 kPa (10.8 psi)
Coolant volume:
D12D-A/E MG (RC) (incl. radiator) approx. .......... – 56 liters (14.8 US gals)
D12D-B/D/F/H MP approx. .................................. 65 liters (17.2 US gals) –
other engines (incl. heat exchanger),
approx. ................................................................ 60 liters (15.9 US gals)

Thermostat
Type ....................................................................... Piston thermostat
Quantity .................................................................. 1
D12D-B/D/F/H MP:
Thermostat starts to open at .................................. 80–84°C (176–183°F) –
fully open at ........................................ 90–94°C (194–201°F) –
Other engines:
Thermostat starts to open at .................................. 74 –78°C (165 –172°F)
fully open at ........................................ 84–88°C (183–190°F)

Coolant filter
Quantity .................................................................. 1

Coolant pump
Type ....................................................................... Gear wheel driven centrifugal pump
Pressure after coolant pump:
2300 rpm ............................................................. 300 kPa (43.5 psi) –
2100 rpm ............................................................. 260 kPa (37.7 psi) –
1900 rpm ............................................................. – 245 kPa (35.5 psi)
1800 rpm ............................................................. – 230 kPa (33.3 psi)
1500 rpm ............................................................. – 180 kPa (26.1 psi)

31
Technical data Group 20

Coolant
D12C-A MP D12D-A/B/C/E/G MH
D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG

“Volvo Penta Coolant, Ready Mixed” ...................... Ready-mixed coolant

Consists of .......................................................... 40% ethylene glycol with corrosions protection
additives and 60% water
Protects against freezing down to approx. .......... – 28°C (–18°F)
Alternative:
“Volvo Penta Coolant” ............................................ Concentrated coolant
Consists of .......................................................... Ethylene glycol + anti-corrosion additives
Color ................................................................... Blue-green
Concentrated Mix with Gives frost protection
Mixture ratio ........................................................ coolant water* down to approx.
* IMPORTANT! The concentrated coolant must be 40% 60% –28°C (–18°F)
mixed with clean water. Use distilled – de-ionized
50% 50% –40°C (–40°F)
water. The water must comply with the demands
specified in ASTM D4985 (see under heading 60%** 40% –54°C (–65°F)
“Water quality” below).
“Volvo Penta Coolant” (ethylene glycol) must not be
mixed with other types of glycol.
IMPORTANT! A coolant mixture with at least 40%
concentrate (“Volvo Penta Coolant”) must be used
all year round, even if there is no risk for freezing.
This is to ensure that the engine is adequately pro-
tected against corrosion and cavitation damage.
** Never mix more than 60% concentrate (“Volvo Penta
Coolant”) in the coolant. A higher concentration causes
reduced cooling effect with the risk of overheating and
gives less frost protection.

Water quality
ASTM D4985:
Total solid particles ............................................. < 340 ppm
Total hardness .................................................... < 9.5° dH
Chloride ............................................................... < 40 ppm
Sulfate ................................................................. < 100 ppm
pH value .............................................................. 5.5 – 9
Silica (acc. to ASTM D859) ................................. < 20 mg SiO2/l
Iron (acc. to ASTM D1068) ................................. < 0.10 ppm
Manganese (acc. to ASTM D858) ...................... < 0.05 ppm
Conductivity (acc. to ASTM D1125) .................... < 500 µS/cm
Organic content, CODMn (acc. to ISO8467) ........ < 15 mg KMnO4/l

Sea water pump

Type ....................................................................... Rubber impeller
Pressure after sea water pump:
2300 rpm ............................................................. 100 kPa (14.5 kPa) –
2100 rpm ............................................................. 90 kPa (13.0 kPa) –
1900 rpm ............................................................. – 80 kPa (11.6 kPa)
1800 rpm ............................................................. – 76 kPa (11.0 kPa)
1500 rpm ............................................................. – 60 kPa (8.7 kPa)

32
Group 20 Technical data

Electrical system
D12C-A MP D12D-A/B/C/E/G MH
D12D-A/B/C/D/E/F/G/H MP D12D-A/E MG

System voltage ...................................................... 24 V

Battery capacity ..................................................... 2 pcs. series connected 12 V,
max. 152 Ah
Battery electrolyte density at + 25°C (77°F):
fully charged battery ............................................. 1.28 g/cm3 (0.0462 lb/in3)
(1.24 g/cm3 = 0.0448 lb/in3)*
re-charge battery at .............................................. 1.24 g/cm3 (0.0448 lb/in3)
(1.20 g/cm3 = 0.0434 lb/in3)*
* Note. Applies to batteries with tropical acid.

Speed sensor, sensor distance:

Upper timing gear cover ...................................... 0.6 ± 0.4 mm (0.0236 ± 0.0157")
Flywheel housing ................................................ 0.75–2.1 mm (0.0295–0.0827")

Alternator
D12D-B/D/F/H MP:
Make ...................................................................... Mitsubishi –
Voltage/max. current density ................................. 28 V / 80 A –
Power app. ............................................................. 2240 W –

Other engines:
Make ...................................................................... Valeo
Voltage/max. current density ................................. 28 V/60 A
Power app. ............................................................. 1700 W
Brush length ........................................................... min. 8 mm (0.3150")

All engines:
Make (alternative equipment) ................................ Prestolite
Voltage/max. current density ................................. 28 V/100 A
Power app. ............................................................. 2800 W
Brush length ........................................................... min. 5 mm (0.1969")

Make (alternative equipment) ................................ Prestolite

Voltage/max. current density ................................. 14 V/130 A
Power app. ............................................................. 1820 W
Brush length ........................................................... min. 5 mm (0.1969")

Starter motor
Make ...................................................................... Bosch
Brush length ........................................................... min. 13 mm (0.5118")

33
Technical data Group 20

Tightening torques

General tightening torque values Nm (lbf.ft) Angle tightening

M6 standard screw 8.8 ........................................... 10 ±1.5 (7.4 ±1) –
M8 standard screw 8.8 ........................................... 24 ±4 (17.7 ±3) –
M10 standard screw 8.8 ......................................... 48 ±8 (35.4 ±6) –
M12 standard screw 8.8 ......................................... 85 ±15 (62.7 ±11) –
M14 standard screw 8.8 ......................................... 140 ±25 (103.3 ±18) –

Note. Only torqued screws can be re-installed.

Torque and angle tightened /plastic limit tightened
screws:
8.8 ....................................................................... should not be re-installed
10.9 ..................................................................... can be re-installed
NOTE: Check screws which are to be re-in-
stalled. Damaged screws, with marks of seizure
etc. under the heads, must be scrapped.

Special tightening torques

Group 21: Short block
Front engine mounting, cross member (M14) ........ 180 ±15 (133 ±11) –
Front engine mounting (M16) ................................. 220 ±35 (162 ±26) –
Rear engine mounting, flywheel housing (M16) ..... 220 ±35 (162 ±26) –
Rear engine mounting, reverse gear (M16) ........... 220 ±35 (162 ±26) –
Cylinder head (please refer to tightening schedule
“Cylinder head” on page 37).
Core plugs, cylinder head ...................................... 60 ±10 (44.3 ±7) –
Valve cover (please refer to tightening schedule
“Valve cover” on page 38).
Stud, valve housing ................................................ 40 ±3 (29.5 ±2) –
Main bearing:
Stage 1 ................................................................ 150 ±20 (111 ±15) –
Stage 2 ................................................................ – 120° ± 5°
Big end bearing cap ............................................... 275 ±15 (203 ±11) –
Center screw, crankshaft ....................................... 645 ±25 (476 ±18) –
Stiffening frame, cylinder block:
(please refer to tightening schedule, “Stiffening
frame, cylinder block”, pages 41– 42)
Flywheel housing .................................................... 140 ±14 (103.3 ±10) –

34
Group 20 Technical data

Special tightening torques

Nm (lbf.ft) Angle tightening
Flywheel:
(please refer to tightening schedule,
“Flywheel”, page 44).
Vibration damper – inner (2 socket cap screws):
Stage 1 ................................................................ 60 ±5 (44.3 ±4) –
Stage 2 ................................................................ – 90° ± 5°
Vibration damper – outer (10 screws):
(please refer to tightening schedule, “Outer
vibration damper” on page 44).
Screws for camshaft bearing caps must be tight-
ened in 5 stages:
(please refer to tightening schedule, “Bearing
caps, camshaft/rocker arm shaft”, page 37).
Timing gear plate:
(please refer to “Timing gear” tightening sched-
ule page 38).
Timing gear wheels incl. toothed wheel and vibra-
tion damper, camshaft:
(please refer to “Timing gear” tightening sched-
ule, page 40).
Timing gear cover, upper:
(please refer to tightening schedule, “Timing
gear cover, upper”, page 39).
Timing gear cover, lower:
(please refer to tightening schedule, “Timing
gear cover, lower ”, page 39).
+6 +4.4
Cleaning plugs in crankshaft .................................. 11 –2 (8.1 –1.5 ) –

Group 22: Lubrication system

Oil nozzle in timing gear ......................................... 34 ±4 (25.1 ±3) –
Lube oil cooler, retaining screws ............................ 27 ±4 (19.9 ±3) –
Cover, lubrication oil cooler (please refer to
tightening schedule, “Cover, lubrication oil cooler”,
page 43).
Oil supply pipe (please refer to “Oil supply pipe”,
page 43).
Screw, piston cooling nozzle:
(please refer to tightening schedule, ”Piston cooling
nozzles” on page 42).
Lube oil cooler, retaining screws:
Stage 1 ................................................................ 25 (18.4) –
Stage 2 ................................................................ – 90°
Sump:
Stage 1 ................................................................ 24 ±4 (17.7 ±3) –
Stage 2 (check tightening) .................................. 24 ±4 (17.7 ±3) –
Removable baffle*, shallow sump .......................... 24 ±4 (17.7 ±3) –
Drain plug, sump .................................................... 120 ±30 (88.5 ±22) –
* Applies to D12D-A/E MG and D12D-B MH as from
engine No. xxxx/402632 and D12D-C/E/G MH.

35
Technical data Group 20

Special tightening torques

Nm (lbf.ft) Angle tightening
Group 23: Fuel system
Unit injector, screw for fixing yoke:
With old copper sleeve
Stage 1 ................................................................ 20 ±5 (14.8 ±4) –
Stage 2 ................................................................ – 60° ± 5°
With new copper sleeve
First tightening:
Stage 1 ................................................................ 20 ±5 (14.8 ±4) –
Stage 2 ................................................................ – 180° ± 5°
Note. Undo the screw for the unit injector fixing
yoke before the second tightening.
Second tightening:
Stage 1 ................................................................ 20 ±5 (14.8 ±4) –
Stage 2 ................................................................ – 60° ± 5°
Nut for electrical connection, unit injector .............. 1.5 ±0.5 (1.1 ±0.4) –

IMPORTANT! Be careful, do NOT tighten

the nuts on the electrical connections to
greater torque values than specified above.
Clamping and tightening torque for fuel pipes,
please refer to “Fuel pipes” on page 46.

Group 25: Inlet and exhaust system

Inlet manifold .......................................................... 24 ±4 (17.7 ±3) –
Exhaust manifold ................................................... 60 ±4 (44.3 ±3) –
Turbocharger ......................................................... 60 ±4 (44.3 ±3) –
Lock nut, V-clamp ............................................... 12.2 ±0.7 (9 ±0.5) –

Group 26: Cooling system

Gear wheel, sea water pump ................................. 200 ±30 (148 ±22) –
Charge air cooler (D12D-B/D/F/H MP)* ................... 5–7 (3.7–5.2) –

* IMPORTANT! The charge air cooler must not be

disassembled. Individual nuts and studs can be
changed, however.

36
Group 20 Technical data

Tightening schedules
Cylinder head

Nm (lbf.ft) Angle tightening

Stage 1 ................................................................ 60 ±10 (44.3 ±7) –
Stage 2 (check tightening) .................................. 60 ±10 (44.3 ±7) –
Stage 3 ................................................................ – 90° ±5°
Stage 4 ................................................................ – 90° ±5°

Bearing caps, camshaft /rocker arm spindle

Imperial:
1. 11 ±4 lbf.ft + 90° ±5°
2. 44 ±4 lbf.ft
3. 11 ±4 lbf.ft + 120° ±5°
4. Undo marked screws.
5. 11 ±4 lbf.ft + 120° ±5°

NOTE: Tightening, stage 2 should be done progressively, to ensure that the rocker arm spindle bottoms on the
bearing housings without bending the spindle.
NOTE: Undo the marked screws in stage 4 before doing stage 5. If the rocker arm spindle has been undone or has
been removed, only the screws which hold the spindle should be tightened in accordance with the schedule on re-
assembly.

37
Technical data Group 20

Valve cover

Torque .................................................................... 20 ±2 Nm (14.8 ±1.5 lbf.ft)

Timing gear plate

Centered with tool No. 999 8267 (no special tightening sequence for marked screws)

Torque .................................................................... 34 ±4 Nm (25.1 ±3 lbf.ft)

38
Group 20 Technical data

Timing gear cover, upper

General tightening torque values

M8 standard screw 8.8 ........................................... 24 ±4 Nm (17.7 ±3 lbf.ft.)
M10 standard screw 8.8 ......................................... 48 ±8 Nm (35.4 ±6 lbf.ft.)

Timing gear cover, lower

General tightening torque values

M8 standard screw 8.8 ........................................... 24 ±4 Nm (17.7 ±3 lbf.ft.)
M10 standard screw 8.8 ......................................... 48 ±8 Nm (35.4 ±6 lbf.ft.)

Screw dimensions:
A .......................................................................... M8 x 65 mm (2.56")
B .......................................................................... M8 x 90 mm (3.54")
C ......................................................................... M10 x 80 mm (3.15")
D.......................................................................... M10 x 130 mm (5.12")

39
Technical data Group 20

Timing gear
(26 ±2 lbf.ft)

(11 ±2 lbf.ft)

(11 ±2 lbf.ft)

(11 ±2 lbf.ft)

(476 ±18 lbf.ft)

(18 ±3 lbf.ft)

IMPORTANT! The screws for the three idler wheels, (A, B

and C), must only be re-used four times. Mark the screw
heads with a center punch mark after tightening.
After four center punch marks, the screws must be changed.

40
Group 20 Technical data

D12C-A MP, D12D-A MP*/ MG**, D12D-B MP*/ MH**,

D12D-C/E/G MH, D12D-E MG
Stiffening frame, cylinder block

Stage: Tightening sequence Screw dimension Torque Angle tightening

1. 1– 6 M10 48 ±8 Nm (35.4 ±6 lbf.ft) –
2. 7– 26*** M8 15 Nm (11.1 lbf.ft) 90° ± 5°
* Applies to D12D-A MP and D12D-B MP up to engine no.
1012532512.
** D12D-A MH and early models of D12D-A MG and D12D-B MH
lack the stiffening frame.
*** NOTE: One screw hole (pos. 11 must be left empty on D12D-A/E
MG D12D-B MH and D12D-C/E/G MH (if the screw is installed, the
stiffening frame can not be disassembled inside the sump).
Note. D12D-A/E MG and D12D-B MH are equipped with a stiffen-
ing frame as from engine no. xxxx/402632.

41
Technical data Group 20

D12D-A MP*, D12D-B MP*, D12D-C/D/E/F/G/H MP

Stiffening frame, cylinder block
* Note. Applies as from engine no. 1012532513.

Stage: Tightening sequence Screw dimension Torque Angle tightening

1. 1– 8 M10 48 ±8 Nm (35.4 ±6 lbf.ft) –
2. 9– 32 M8 15 Nm (11.1 lbf.ft) 90° ± 5°

Piston cooling nozzles

Fixing screw ........................................ 24 ±4 Nm
(17.7 ±3 lbf.ft)
NOTE: The piston cooling nozzle retaining screw has
a friction coating and must only be used once.

WARNING! Faulty piston cooling results in pis-

ton seizure.
If you suspect that the piston cooling nozzle
may be damaged or deformed, it must be
changed (applies to new nozzles as well).
Always check that each piston cooling nozzle is
placed correctly in its hole in the cylinder block,
that it is directed towards the recess in the pis-
ton and that the retaining plate lies flat against
the block.
If the piston cooling nozzles are not correctly in-
stalled, the engine will immediately seize when
loaded.

42
Group 20 Technical data

Oil supply pipe

Stage 1:
Tighten the union in the cylinder block until it
bottoms (approx. 10 Nm / 7.4 lbf.ft).
Stage 2 – angle tighten as follows:
New oil supply pipe ............................................. 180°
Oil supply pipe that has been installed previously ... 60°

Cover, lubrication oil cooler

1. Install screws A and B.

2. Tighten screws C and D.
3. Tighten the cover screws in number order,
from the center and outwards (1– 4).
4. Check tighten screws C and D.

Torque .................................................................... 24 ±4 Nm (17.7 ±3 lbf.ft)

43
Technical data Group 20

Outer vibration damper

Torque: Nm (lbf.ft) Angle tightening

Stage 1 ................................................................... 60 ±5 (44.3 ±4) –
Stage 2 ................................................................... – 90° ±5°
For engines with a power take-off (pulley /
shaft stub) at front, the following applies:
Stage 1 ................................................................... 40 ±5 (29.5 ±4) –
Stage 2 ................................................................... 60 ±5 (44.3 ±4) –
Stage 3 ................................................................... – 120° ±5°

Flywheel

Torque: Nm (lbf.ft) Angle tightening

Stage 1 60 ±5 (44.3 ±4) –
Stage 2 – 60° ±5°

44
Group 20 Technical data

Flywheel housing

Torque .................................................................... 140 ±20 Nm (103 ±15 lbf.ft)

Screw lengths:
1, 10 .................................................................... 90 mm (3.543")
11, 12 .................................................................. 140 mm (5.512")
2–9 ...................................................................... 70 mm (2.756")

45
Technical data Group 20

Fuel pipes

D12C-A, early model***

Tightening torque, fuel pipes Nm (lbf.ft)

A. By-pass valve .................................................. 55 ±5 (40.6 ±4)
B. Hollow screw .................................................... 55 ±5 (40.6 ±4)
C. Hollow screw .................................................... 35 ±4 (25.8 ±3)
D. Hollow screw .................................................... 55 ±5 (40.6 ±4)
E. Hollow screw .................................................... 35 ±4 (25.8 ±3)
F. Venting nipple ................................................... 14 ±3 (10.3 ±2)

1. Rubber clamp
2. Plastic clip
3. Tension strap
* The clamp is missing on D12D-B/D/F/H MP.
** On D12D-B /D/F/H MP, the cooling coil is turned 180°, so
the hollow screws (inlet and outlet) are turned forwards.
*** Note. During renovation, the fuel pipes should be clamped
in the same way as on late model engines (lower illustra-
tion).

D12C-A, late model,

D12D-A/B/C/D/E/F/G/H

46
Group 20 Technical data

Installing seals
Cylinder block, front D12D-C MP /MH, D12D-D MP

Put an approx. 1 mm (0.039") thick line of sealant, part No. 1161231*, at 1 (broken line).
Put an approx. 2 mm (0.079") thick line of sealant all round the cylinder block and round the
three marked holes.
* Note. Sealant 1161231 (cartridge 0.31 l), or 1161277 (tube 20 g).

Cylinder block, rear Flywheel housing, front

Apply a string of sealant, part No. 1161231 and with a diameter of about 2 mm (0.079").
Note. Engines with aluminum flywheel casings (D12C-A MP, D12D-A/B/C/D/E/F/G/H MP):
Apply the seal in the flywheel housing groove instead.

47
Technical data Group 20

Timing gear cover, upper

Apply a string of sealant, part No. 1161231*, with a diameter of about 2 mm (0.079").
Note. On late model engines, one end of the timing cover has a rubber seal molding.
Put the sealant on top of the seal molding.
* Note. Sealant 1161231 (cartridge 0.31 l), or 1161277 (tube 20 g).

Timing gear cover, lower

Apply a string of sealant, part No. 1161231 and with a diameter of about 2 mm (0.079").

48
Group 20 Technical data

Cylinder block, underneath

A. Apply an even, approx. 1 mm (0.039") thick string of sealant to the joints.

The illustration shows the joint between the cylinder block and timing gear
cover, or flywheel housing, where sealant, part No. 1161231 should be
applied.

Oil sump

B. Apply an approx. 1 mm (0.039") thick and 15–20 mm (0.591–0.787") long

string of sealant, part No. 1161231 under and over the ends of the oil
sump seal (rubber molding).

Valve cover

C. Apply an approx. 2 mm (0.079") thick string of sealant, part No. 1161231 in

the joints between the upper timing gear cover and the cylinder head.

49
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of this page, write your comments on it and send it to us. The address is at the
bottom. We would appreciate it if you were to write in English or Swedish.

From: ..............................................................................

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Refers to publication: ................................................................................................................................................

Publication No: ............................................................... Date of issue: ...................................................................

Suggestion/Motivation: .............................................................................................................................................

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Date: ..................................................................

Name: ................................................................

AB Volvo Penta
Service Communication
Dept. CB22000
SE-405 08 Gothenburg
Sweden
7746635 English 09–2012