IMPACT 3.

0 Tuesday, 18 September 2012

Chassis ID Path
2/Repair/NH12, D12D500/Cylinder liners and pistons, replace (All). Cylinder heads and oil
pan removed

Model Identity
NH12 121316940

Publishing Date Operation No.

Wednesday, 5 November
21311-3
2008

21311-3 Cylinder liners and pistons, replace (All)

Cylinder heads and oil pan removed

The cylinder liner o-rings are made of

fluorocarbon rubber.
When fluorocarbon rubber is exposed to high
temperatures (above 300 C) hydrofluoric
acid is formed. Hydrofluoric acid is highly
corrosive!

Contact with skin can result in serious

corrosion injuries.
Splash in the eyes can result in corrosion
sores.
Inhalation of vapours can damage the
respiratory tract.

Warning
Take great care when working on engines
which can have been exposed to high
temperatures, resulting for example from
overheating, cutting or fire.
Cylinder liner o-rings are under no
circumstances to be burnt off when
dismantling or destroyed by burning under
uncontrolled conditions.

Always use neoprene gloves (gloves

approved for handling chemicals) and
protective goggles.
Handle removed o-rings in the same
way as corrosive acids.
Never blow clean using compressed air.
All remnants, including ashes, can be
highly corrosive.
Place all remnants in plastic containers,
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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 18 September 2012

to which warning text is attached.

Before taking the gloves off, they must
be washed under running water.

Special tools: 9996394, 9996395, 9996599, 9996606, 9996645, 9996956, 9996966, 9998511, 9998531,
88800083

Other special equipment: 1159794, 1159795, 9989876, 9992479

Note: As illustrations used in the service literature are used for several different engine variants, certain details may differ from the
variant in question.
The essential information in the illustrations is, however, always correct.

At some trucks, before you remove the connecting rod screws you have to remove the frame.

Remove

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IMPACT 3.0 Tuesday, 18 September 2012

Remove the inspection panel on the flywheel housing and fit tool 9996956. Turn the crankshaft until it is
possible to get at the screws on the connecting rod which is to be removed.

Special tools: 9996956

4
Remove the piston cooling jet.

5
Remove connecting rod caps and bearing shells.

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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 18 September 2012

Remove the piston with the connecting rod.

Use the puller plate 9992955.

Pull the cylinder liner out of the block.

Special tools: 9992955 9996394 9996395 9996645

Copyright Volvo Group North America
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 18 September 2012

8
Remove the cylinder liner's sealing rings.

Remove the circlips from the piston and push out the gudgeon pin. Remove the piston from the connecting
rod.

10
Clean the sealing surfaces on the cylinder block and the groove for the sealing rings. Do not use scrapers or
other tools which can damage the sealing surfaces.

Installation

11

Check the cylinder block's liner seat for damage. Where milling of the cylinder liner seat is necessary, see
service information 21307-3 Cylinder liner seat, milling (first)

IMPACT: Group 2139

.

Fit the cylinder liner, without sealing rings. Secure with two press tools.
Use the tool 9996966.

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IMPACT 3.0 Tuesday, 18 September 2012

Special tools: 9996966

12

Mount dial gauge 9989876 in holder no. 9992479. Place the holder with the dial gauge across the cylinder
liner.
Zero the dial gauge with a couple of millimetres' preload against the cylinder block's surface.

Special tools: 9989876 9992479

13

Copyright Volvo Group North America

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 18 September 2012

Measure the height between the cylinder liner and the cylinder block surface.
Measure the liner's height at two different diagonally opposite positions.
Calculate the average of both the measurements.
For correct liner height above the block surface see specifications, group 20.
If the height of the liner above the surface of the block is outside the specified tolerance, the liner seat on the
cylinder block should be milled Cylinder liner seat, milling (first)

IMPACT: Group 2139

.

Note: Always measure at the highest point on the sealing surface.

Mark the liner's position on the cylinder block with a felt tip pen, so that it will be put back in the same
position on assembly.
Repeat the procedure for the remaining cylinder liners.

14

Copyright Volvo Group North America

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 18 September 2012

Remove the press tool.

Use the puller plate 9992955.

Pull the cylinder liner out of the block.

Place cylinder liners in the same sequence that they are fitted, together with their adjustment spacers.

Special tools: 9992955 9996394 9996395 9996645

15

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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 18 September 2012

D12C

D12C Mark 3, D12D

Grease the sealing rings with the grease that is included in the liner kit and fit them into the cylinder block.
Note that the upper sealing ring sits at a different heights depending on the type of liner (see picture).

Note: The violet sealing ring should sit in the lowest groove.

16

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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 18 September 2012

Where the cylinder liner is fitted without a spacer, an even strand of jointing compound, approximately 0.8
mm thick, should be applied to the underside of the cylinder liner's collar.

17

If the liner is fitted with a spacer, the strand of jointing compound should be applied to the cylinder block's
liner seat.

Note: No sealant is to be used between the adjustment spacer and the cylinder liner's collar.

18

Note: After all the sealant has been applied, the liner must be fitted within 20 minutes.
If the cylinder head cannot be fitted and torque tightened within 20 minutes, the liner must be fixed in the engine block with two
press tools.

Special tools: 9996966

19

Use the tool 9996599. Fit one of the cylinder head bolts (A). Place the press tools 9996599 above the cylinder
liner together with a suitable spacer (B) and press the cylinder liner with lever tool 9998511.

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IMPACT 3.0 Tuesday, 18 September 2012

Special tools: 9996599 9996966 9998511

20

Lubricate the gudgeon pin and the piston bush with engine oil.

21

Fit the connecting rod in the piston with the marking FRONT on the connecting rod and the arrow on the
piston facing the same direction.
Push the gudgeon pin in.

Note: The gudgeon pin should go in when pushed without any great force. If the resistance is too great, the piston needs to be
heated.
The connecting rod should rotate freely on the gudgeon pin.

Fit the circlips.

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IMPACT 3.0 Tuesday, 18 September 2012

22

Fit the piston rings. Use piston ring pliers.

The piston ring gaps should be situated with the equal spacing in relation to one another.
As regards the oil ring, the gap in the spring should be situated diametrically opposite the ring gap.

Note: Both the upper piston rings are marked with letters or point marks. The markings should be face upwards.
The oil ring is symmetrical and can face in either direction.

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IMPACT 3.0 Tuesday, 18 September 2012

Special tools: 88800083

23
Lubricate the piston and the piston rings with engine oil. Check that the piston rings gaps are radially
displaced.

Caution
Do not install ARTICULATED PISTONS and NON-ARTICULATED PISTONS in the same
engine. As these two types of pistons has different behaviour, they should not be mounted together to
avoid damages to the engine.

24

Use the tools 9998531 and 9996966

Insert the piston with its connecting rod. Use a piston ring compressor.

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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 3.0 Tuesday, 18 September 2012

Note: The connecting rods should be fitted in their respective original positions.

Note: Regardless of the engine variant (with the transmission either in front of or behind the engine), the connecting rod and
connecting rod cap are fitted facing in the same direction. The arrow on the piston and the FRONT marking on the connecting rod
shall always face towards the front.

Note: Depending on the engine variant, connecting rods may have the parting line between the rod and the cap facing either way,
as in the illustration.

Remove the press tool temporarily when the piston is fitted. Refit the press tools when the piston is in
position.

Special tools: 9996966 9998531

25
Lubricate the crankshaft bearing shells and crankshaft pin with engine oil. Fit the connecting rod caps. Check
that they sit correctly in the connecting rod and caps.
Fit the connecting rod cap according to the markings and torque tighten according to specifications, see group
20. Use a torque wrench 1159795.

Other special equipment: 1159795

26
Blow clean the piston cooling jet and check that it is not damaged. Fit the jet and torque and torque tighten
according to specification, see group 20. Use a torque wrench 1159794.

Note: Make sure that the jet is directed towards the outlet in the piston.

Other special equipment: 1159794

27
Install the frame with new screws and tighten according to specifications.

28
Remove cranking tool 9996956 and fit the inspection cover.

Copyright Volvo Group North America

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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