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Service Bulletin

Volvo Trucks North America, Inc.


Greensboro, NC USA Trucks
This Service Bulletin replaces SB 25321, Engine Date Group No. Page
Brake, Fault Tracing, Checklist O, D12D (11.02), publi- 3.2003 253 21 1(21)
cation no. PV776TSP170589.
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 repre-
sented as accurately as possible.

PV776-TSP187872 USA13254
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 2(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 Informa-
tion, 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 infor-


mation 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.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 3(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 non-
defective components.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 4(21)

Component list
Component Description
A12 Control unit, ABS
A14 Control unit, EECU (engine electronic control unit)
A17 Control unit, VECU (vehicle electronic control unit)
A27 Control unit, LCM (external lighting)
B04 Sensor, engine speed, crankshaft
B13-18 Sensor, wheel speed
B25 Sensor, accelerator pedal
B37 Sensor, intake manifold pressure and temperature
B38 Sensor, oil pressure and oil temperature
B68 Sensor, road speed
F80 Fuse, engine solenoid valves, or fuel pump
S07 Switch, engine brake
S58 Position switch, clutch pedal, NC at rest
Y37 Air valve unit (AVU), engine brake/exhaust pressure governor (EPG)
Y39 Solenoid/control valve, VCB (Volvo Compression Brake)
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 5(21)

Engine Brake EPG


For additional information on the design and function Switch (S07)
of the Volvo Engine Brake, refer to Service Informa-
tion, group 25.

There are two options for engine braking:

Exhaust brake, EPG


The exhaust pressure governor (EPG) uses a shutter
mounted in the exhaust outlet from the turbocharger.
This shutter, connected to the EPG plunger, can restrict
the exhaust gas flow. This creates a braking effect dur-
ing the exhaust stroke when the exhaust gases cannot
evacuate freely; they create an overpressure between T0008637

the pistons and the shutter. Two positions.

For a more detailed description of the EPG function, see The position of the Engine brake
Exhaust Pressure Governor (EPG) page 7. switch

Engine brake, VEB 0 (switched off) 0%


The Volvo Engine Brake (VEB) consists of two systems: 1 100 %
the exhaust brake (see Exhaust brake, EPG page 5)
and the compression brake.

The EPG creates an overpressure in the exhaust, mak- Electrical control


ing the compression brake more efficient. With the switch in position 1, the exhaust brake is acti-
vated when the accelerator (B25) is released.
The VEB includes a special rocker arm for the exhaust
valves, a special camshaft with extra cams and a sole- The information from the switch and the accelerator go
noid valve for oil pressure in the rocker arm. For a more via the vehicle control unit (A17) through the data links
detailed technical description, see Compression Brake (J1939 and J1708/J1587) to the engine control unit
page 8. (A14). The engine control unit then sends a PWM signal
(Pulse Wide Modulated) to the AVU (Y37), which sends
The braking effect of the compression brake on the en- out full control pressure (7.5 bar/110 psi) to the EPG.
gine occurs when: The AVU is given voltage via fuse F80.

The exhaust valve opens and allows air in during Requirements


the intake stroke, which gives more air to compress
during the compression stroke. Clutch pedal (S58) is NOT depressed.

The exhaust valve opens immediately before the Engine speed exceeds 900 rpm; engine speed sen-
sor, B04 (deactivates < 800 rpm).
turn of the compression stroke and punctures the
compression in order to reduce the effect with the Speedometer (B68) indicates a speed greater than
5 km/h (3 mph).
working stroke.
ABS wheel sensor (B13-18) indicates NO wheel
lockup (ABS non-active).
Electrical control of engine brake
The engine brake power is determined by the drivers
settings. The power varies for different combinations of
engine brakes.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 6(21)

VEB Electrical control


When the switch is in position 1 the exhaust brake is
Switch (S07) activated when the accelerator pedal (B25) is released.
EPG is activated with full control pressure (7.5 bar/110
psi) from the air valve unit, or AVU, to attain 50% engine
brake.
When the switch is in position 2 the VCB is activated,
when the accelerator pedal (B25) is released. At the
same time, the EPG is activated with full control pres-
sure to attain 100% engine brake.

The information from the switch and the accelerator go


via the vehicle control unit (A17) through the data links
T0008058

Three positions. (J1939 and J1708/J1587) to the engine ECU (A14). The
engine ECU then sends a signal (-) to the sole-
noid/control valve (Y39) for increased oil pressure in the
The position of the Engine brake
rocker arm shaft and a PWM signal (Pulse Wide Modu-
switch
lated) to the AVU (Y37). Both the control valves are
0 (switched off) 0% supplied voltage via fuse F80.

1 50 % Requirements
2 100 % Clutch pedal (S58) is NOT depressed.
Accelerator pedal (B25) released.
Engine speed exceeds 1100 rpm*; engine speed
sensor, B04 (deactivates < 1000 rpm).
Speedometer (B68) indicates a speed greater than
5 km/h (3 mph).
 
Oil temperature (B38) greater than 55 C (131 F).
Intake manifold pressure (B37) less than 50 kPa
(7.25 psi).
ABS wheel sensor (B13-18) indicates NO wheel
lockup (ABS non-active).

NOTE: *Activation rpm is raised by 300 to 1400 rpm


 
when oil temperature is 55 82 C (131 180 F) or af-
ter the first 5 engine brake requests.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 7(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
To keep the engine warm when idling. pressure governor during start and heat retention, refer
to Service Information, group 25, EPG, Fault Tracing,
To function as exhaust brake on down gradients. Checklist E.

To apply exhaust back pressure during idle EGR Exhaust brake


function. The EPG is activated by control pressure of approxi-
mately 7.5 bar (110 psi). The shutter (2) is forced into
The exhaust pressure governor is situated in direct con- the shutter housing (1) which restricts exhaust flow and
nection to the turbos turbine housing. The exhaust causes back pressure in the exhaust.
pressure governor consists of a shutter housing (1), a
shutter (2) and a compressed air operated cylinder (3). If the engine is equipped with VEB (Volvo Engine Brake),
The compressed air is supplied from the vehicles com- the compression brake and EPG are activated simulta-
pressed air system and is regulated by the AVU, located neously to attain 100% engine brake (switch position 2).
on the intake side of the engine (4), and releases a re-
duced pressure to the exhaust pressure governor. The
PWM-type valve controls the pressure steplessly within
0.5 7.5 bar (7 - 110 psi).

Under normal driving conditions, the AVU (4) is closed.


The shutter (2) is then completely open and the exhaust
passes freely.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 8(21)

Compression Brake

Solenoid/Control Valve

T2019494

The solenoid/control valve has the task of regulating the A: When the engine is running the piston (3) partly
oil pressure to the rocker arm mechanism. covers the outlet (5), which results in reduction of oil
pressure to approximately 100 kPa (14.5 psi) after the
The inlet (1), which is connected to the lubricating oil solenoid valve. This oil pressure is sufficient for lubrica-
passage in the cylinder block, always has system oil tion of the camshaft bearings and the rocker arm
pressure. The outlet (5) is connected to the rocker arm mechanism.
shaft. The compression brake is activated by the sole-
noid valve (2), which is controlled from the EECU. B: With compression braking, voltage to the solenoid
valve (2) opens a draining passage. The oil in the oil
space (6) flows out through the draining passage, allow-
ing the spring (4) to push the piston (3) to the side. 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).
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 9(21)

Camshaft and exhaust rocker arms

W2004196

The camshaft (1) on an engine with VCB has, in addition B: With compression braking, the solenoid/control
to the ordinary exhaust cam (2), a charge cam (3) and a valve increases the oil pressure to > 200 kPa (29 psi).
decompression cam (4) on each exhaust cam lobe.
At high pressure, the piston (11) overcomes the spring
Each rocker arm (5) includes a non-return valve (7) and (14), which means that the spring (12) can push the ball
a rocker arm piston (8). A spring tab (6) holds the rocker (13) towards the seat. The oil, above the rocker arm pis-
arm in its resting position against the valve bridge. The ton (8), can no longer flow past the ball and therefore
non-return valve clearance is adjusted with the help of pushes on the rocker arm piston (8), so that the piston
shim (9) which is situated on the valve bridge. pushes down and eliminates the valve clearance.

The non-return valve (7) consists of a piston (11) and When the camshafts extra brake cams (3) and (4) fur-
spring (14), spring (12) and ball (13). ther affect movement of the rocker arm, the exhaust
valves are pushed down and compress (force more air
A: Under normal engine operation, the sole- into the cylinder with the help of the back pressure in the
noid/control valve reduces the oil pressure. exhaust during the compression stroke) and decompres-
sion respectively (release compression during the power
At reduced oil pressure of 100 kPa (14.5 psi), the piston
stroke).
(11) will not move out of its rest position, because the oil
So that the pressure above the rocker arm piston does
pressure is not sufficient to overcome the spring force
not push back into the rocker arm shaft when the valve
(14). The pistons pin holds the ball (13) away from the
opens, there is a pressure limiting valve (10).
seat, which allows the oil to flow in both directions
through the non-return valve. This prevents excess oil
pressure building up above the rocker arm piston (8).

In this position the exhaust valves are not affected by the


extra brake cams on the camshaft.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 10(21)

Checklist O, Engine Brake


See also:

General Guide to Fault Tracing page 2


Engine Brake, Fault Tracing page 12

Vehicle Chassis no. Mileage Customer


Yes No

1 Fault Codes, 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?:

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 ... 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 - 80 C (131 - 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

AVU (air valve unit) bar (psi)

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. 7.5 bar/110 psi)?

Action:
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 11(21)

Vehicle Chassis no. Mileage Customer


Yes No

4 Shutter Travel, EPG, 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, Checking page 14

Is the oil pressure within specifications (with activated engine brake)?

Oil pressure in the rocker arm shaft kPa (psi)

Action:

6 Rocker Arm Oil Leakage, Checking page 16

Are the plugs in the rocker arm shaft properly installed?

Are the rocker arm shafts bolts correctly torque-tightened?

Action:

7 Solenoid/Control Vave, VCB, 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 16

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, VCB, Checking page 20

Are the spring and the non-return valves piston free from defects?

Does the non-return valves piston move freely?

Are the non-return valves ball and spring free from defects?

Does the rocker arm piston move freely?

Action:

Notes:

Completed by: Dealer: Date:


Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 12(21)

2531-20-03-01 2

Engine Brake, Fault Tracing


See also:

General Guide to Fault Tracing page 2


Checklist O, Engine Brake page 10

Fault Codes, Checking


1
Correct any fault codes concerning the
engine brake function; refer to Diag-
nostic Information, group 20.

Air Supply to EPG and AVU,


Checking
Special tools: 9992976, 9996465, 9998333
AVU T2019381

Connect pressure gauge 9996465 and


1 nipple 9992976 to the air supply hose
of the AVU.
WARNING 9992976
3
Before beginning any work on any part of the air Fill the compressed air system to full 9992976
system, be certain that the air pressure has been system air approximately 8.3 bar 9996465
depleted. Failure to do so may cause a component (120 psi).
to violently separate, which can result in serious per-
sonal injury. If the pressure to control the AVU is
not the same as the system pressure,
check the air hoses; see Hoses and
Remove the air supply hose from the
Connections page 12.
AVU. Remove the fitting in the AVU
and attach to test nipple 9992976.
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 in-
terrupt air flow.

5
Check that the hoses are properly
connected and do not leak.

6
Empty the compressed air system and
remove gauge and test nipple. Re-
move fitting from test nipple and install
fitting into AVU and connect supply
hose.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 13(21)

EPG Shutter Travel, EPG, Checking


7 1
Check that the system air pressure is
more than 7.5 bar (110 psi).

2
Remove the exhaust pipe by the EPG
and check that shutter disc is not dam-
aged.

3
Connect the PC tool to the vehicles
data link connector, if this has not al-
ready been done.

4
Using VCADS Pro, begin Start and
heat retention function, test; activate
T2019382
EPG at 30% (corresponds to the same
Check that the EPG receives the cor- 9996465 air pressure as with warm-hold func-
rect control pressure: remove the air 9998333 tion) and at 100 % (corresponds to full
hose from the EPG and connect pres- control pressure, exhaust brake).
sure gauge 9996465 and nipple
9998333 to the hose.
5

8
Connect the PC tool to the vehicles
data link connector, if this has not al-
ready been done.

9
Using VCADS Pro, run the Engine
brake function test.

Activate the EPG


10
Activate the AVU for the EPG at 100%.
Note the pressure on the checklist.

NOTE: The control pressure should be


approximately 7.5 0.3 bar (110 4 W2003781

psi).
WARNING
11
If the control pressure is not within EPG shutter may move without warning. Keep hands
specifications and the supply pressure away from EPG shutter during activation. Failure to
to the AVU is the same as the system do so can result in personal injury.
air pressure approximately 8.3 bar
(120 psi) replace the AVU. Check that the shutter reaches its end
positions by activating and shutting off
the EPG using the PC tool.
12
Remove the gauge and test nipple. NOTE: The stroke travel (A) should be
Connect air hose to EPG. 29 33 mm (1.15 1.30 in.).
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 14(21)

6 3
If stroke travel is not within specifica-
tions, replace or overhaul EPG; refer
to Service Information, group 25.

Rocker Arm Shaft Oil Pressure,


Checking
Special tools: 9998338, 9998339, J39200
1

CAUTION
Use a hand wrench to loosen the valve cover nuts;
this will help prevent the studs from loosening from
the cylinder head and thus damaging the valve cover
and the unit injectors wiring harness. DO NOT USE
AN AIR TOOL.

Remove the valve cover; refer to Ser-


W2004198
vice Information, group 21.
Install adapter 9998338 and bolt. 9998338

NOTE: Attach oil pressure hose. Make


2
sure that adapter and hose remain
clear of the no. 1 intake valve rocker
arm as the bolt is tightened to 54 Nm
(40 ft-lb).

4
Temporarily remove the hose.

5
Remove the second stud (counting
from left front of engine) so hose can
be routed through valve cover.

6
Route the oil pressure hose from out-
side and in through the valve cover
W2004197
where the stud was removed.
Remove the second bolt on the rocker
arm shaft (as viewed from the front of
the engine).
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 15(21)

7 13
Carefully route the hose into the cab. 9998496
J39200
Alternate 1: 9998339

1 Connect pressure transducer


9998496 to hose.

2 Attach pressure transducer to


multimeter J2900.

3 Select mV setting on multi-


meter (reading is displayed in
kPa).

W2004199
Alternate 2:

Connect the hose to the banjo nipple 1 Connect pressure gauge


on the adapter 9998338. 9998339.

14
8
Test drive the vehicle and bring to op-
Secure the hose so that it will not be
erating temperature. Activate VCB and
damaged by the rocker arms.
note pressure after it stabilizes.

Oil pressure, VCB activated: 200 - 400


9 kPa (30 60 psi).
Check that the oil pressure hose is 20 2 Nm
correctly positioned and carefully re- (15 1.5 ft-lb) Oil pressure, VCB non-activated: 100
place the valve cover. Torque-tighten kPa (15 psi).
the valve cover to 20 2 Nm (15 1.5
ft-lb).
15
Repeat test several times to verify
10 reading.

If oil pressure is below 200 kPa


(30 psi) with VCB active, oil pres-
sure is low. Continue fault tracing.
If oil pressure is above 100 kPa
(15 psi) with VCB inactive and
solenoid valve is functioning prop-
erly, replace VCB control valve;
refer to VCB solenoid valve check.

W2004200 16
If rocker arm shaft oil pressure is
Press the seal for the oil pressure
within specifications, remove valve
hose into the hole on the valve cover.
cover and test equipment.

11
17
Route and secure the oil pressure
Install rocker arm shaft bolt and 15 5 Nm
hose so that it will not be damaged
torque-tighten to 15 5 Nm (11 4 ft- (11 4 ft-lb),
when the hood is closed.  
lb), then turn additional 120 5 . 120 5

12
Lower the hood.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 16(21)

18 Rocker Arm Bushings, Checking


Clean valve cover stud and thread 40 3 Nm
hole in cylinder head. Apply locking (29 2 ft-lb) Special tools: 9996956, 9998511, 9999696
fluid to stud and torque-tighten to 40 Other special equipment: 9989876
3 Nm (29 2 ft-lb).
Rocker Arm Bushing, VCB
19 1
Install valve cover. Install turning tool 9996956 (or use re- 9996956
mote starter switch) to rotate engine.
Rotate engine to the position where
20 the rocker arm roller is not in contact
with the camshaft cam lobe (base cir-
cle).
NOTE: Check that there is clearance
between rocker arm rollers and
camshaft for the bushing and roller
checks.

T2012845

Valve cover tightening sequence

Following the tightening sequence 20 2 Nm


shown, torque-tighten the valve cover (15 1.5 ft-lb)
to 20 2 Nm (15 1.5 ft-lb).

Rocker Arm Oil Leakage, Check-


ing
1
Check that the plugs in the ends of the
rocker arm shafts are properly installed
and that they are free from defects.

2
Check all rocker arm bolts in order to
T2019598
make sure that there is no oil leakage
Position magnetic stand 9999696 with 9999696
due to under-torqued bolts.
dial gauge 9989876 so that the dial 9989876
gauges measurement probe tip is lo-
cated above the middle of the rocker
arm bushing (on the rocker arm not in
contact with the camshaft).

3
Move the rocker arm, so that most of
the oil film is thinned out on the upper
side of the rocker arm shaft.

4
Reset the dial gauge.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 17(21)

5 8

C2002679
T2019598

Position bar tool 9998511 under the 9998511 Place dial indicator 9989876 in mag- 9999696
rocker arm, by the rocker arm shaft, netic stand 9999696. Put the magnetic 9989876
and push up the rocker arm. Note the stand on the rocker arm.
reading on the dial gauge.
Direct the probe tip of the dial gauge
Max. permitted clearance is 0.1 mm so that it lies horizontally against the
(0.0039 in.). In the case of clearance center of the roller.
greater than this, replace the rocker Set the dial gauge at 2 3 mm (0.080
and check the rocker arm shaft for 0.118 in.) tension.
wear.
NOTE: Make sure that the probe tip of
the dial gauge is set at tension and
6 can move in both directions.
Repeat the check on all other rocker
arm bushings.
9

Bushing, Rocker Arm Roller, VCB


7

T2007948
T2007950
Rotate the roller a few turns, so that
the oil film between the bushing and Put a screwdriver between the rocker
shaft is thinned out. arm and roller.
NOTE: If the roller jams and does not Push out the roller as far as possible
rotate freely, the rocker arm must be and read off the value on the dial test
replaced. indicator.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 18(21)

10 12
Check valve clearance between rocker
arm piston and valve bridge. Accept-
able clearance is 1.55 1.65 mm
(0.051 0.065 in.); for information on
adjusting valves, refer to Service Infor-
mation, group 21.

Solenoid/Control Vave, VCB,


Checking
Solenoid valve
1
Remove the solenoid valve from the
control valve.

T2007951

Using a suitable blunt instrument,


push the roller inwards as far as possi-
ble. At the same time, note the
reading on the dial gauge.

If the clearance between the roller and


pin is greater than 0.1 mm (0.0039
in.), replace the rocker arm.

11

T2019599

Check that the draining hole is not


blocked on the solenoid valve. Also
check the draining passage on the
control valve.

T2007792

NOTE: When replacing the rocker


arm, the new rocker arm bushing
should be lubricated with engine oil.
Use an oil can and put the tip into the
oil passage. Turn the roller while it is
being lubricated. Make sure that oil
runs out on both sides of the roller.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 19(21)

3 5
With low oil pressure in the rocker arm
shaft, check:

The seal between the control


valve and the cylinder head.

The seals in the pipe between the


control valve and the rocker arm
shaft.

T2019600

Check that the solenoid valve opens


and closes properly (battery power
[B+] and ground are required to per-
form this check):

With solenoid activated, cover one


side of opening and apply low air
pressure. The valve should open.

With B+ and ground removed, the


solenoid valve should close.

Replace solenoid valve if it does


not open and close properly.

WARNING
Wear eye protection. Do not apply full shop air pres-
sure. There is risk of oil splash that can cause T2019601
personal injury.
The piston (1) in the control valve is in
active position (B), when the solenoid
is activated and the oil chamber (2) is
drained and the spring presses the
Control Valve piston to its end position.
4 When the engine is switched OFF,
If the engine oil is very contaminated, there is no oil pressure on either side
remove the control valve and clean it of the piston, so the piston should be
internally. at its end position (via the spring). If
the piston jams or sticks, the VCB can
become active for a short period after
starting.
It is highly unlikely that the piston (1)
has jammed or stuck in the driving po-
sition, i.e. the VCB is not active (A).
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 20(21)

7
During engine operation, the springs 1
force and oil pressure in the oil cham-
ber (2) hold the piston in the balance
position which reduces oil pressure.

If debris or a foreign object has lodged


in the oil chamber (2), this could pre-
vent the piston from returning to its
end position, causing the VCB not to
function when activated. The control
valve must then be disassembled and
carefully cleaned or replaced.

Rocker Arm Valve, VCB, Check-


ing
T2014923

Turn the engine to top dead center


(TDC). The marking for TDC on the
camshaft will be between the markings
on the forward cap.

2
Heat the plug (1) on VEB rocker cylin-
der 3 so that the locking fluid ceases
to grip. Remove the plug.

Non-return valve
3
Remove the spring (2) and the non-
return valve piston (3a) and check
spring and piston for damage.

4
Place the non-return valve piston (3a)
back in the piston bore. Push piston
forward and back to verify that piston
moves freely in piston bore.

5
Check the non-return valve ball (3b)
and spring (3c) by pressing the non-
return valve piston (3a) to end position
in order to feel whether there is a
spring tension. If no tension is felt, the
spring is faulty and should be replaced.
T2019602

1. Plug
2. Spring Rocker arm piston
3. Non-return valve 6
3a. Piston Push the non-return valve piston (3a)
3b. Ball to end position while pressing the
3c. Spring rocker arm forward (towards the
valves).
4. Rocker arm piston
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 21(21)

7 10
When the rocker arm piston (4) con- If no faults were found, install spring
tacts the valve caliper, release the (2) and plug (1).
non-return valve piston (3a).
NOTE: Apply thread locking fluid to
plug before installation.
8
Push the rocker arm back (towards the
camshaft). Negative pressure will then 11
be created in the rocker arm piston (4). Check the remaining VEB rocker
arms: rotate the engine to the next
VEB marking and repeat steps 2 10.
9
Continue to hold the rocker arm
toward the camshaft. Release the neg-
ative pressure by pushing in the
non-return valve piston (3a). The
rocker arm piston (4) should drop to-
ward the valve caliper when negative
pressure is released. If piston does not
move freely, replace the rocker arm.