Timing Gear Adjustment
Contents
1. be installed after all crankshaft to camshaft timing and front gear backlash procedures are complete 4 Rotate the camshaft by hand until TDC mark is aligned with the left hash mark on the 1 camshaft bearing cap Note The adjustable idler gear bolts are single use stretch type and must not be reused However the original bolts are used at this time to perform this adjustment procedure and should be replaced with new bolts after this procedure is completed one bolt at a time Volvo Trucks North America Inc Date Group No Page TSI 10 2003 215 003 6 11 5 With the adjustable idler gear bolts finger tight raise the gear by hand and place a 0 1 mm 0 004 in feeler gauge on the loaded side of the adjustable to intermediate idler gear contact area While leaving the camshaft TDC mark on the left hash mark install the cam gear and timing collar J 44514 25 Use 2 camshaft vibration damper cam gear mounting bolts to hold gear and collar in place J 4451 4 25 W2003489 Volvo Trucks North America Inc Date Group No Page TSI 10 203 215 003 7 11 7 Place a 0 1 mm 0 004 in feeler gauge between the loaded side of the cam gear to adjustable idler gear contact area W2003491 8 Using light hand pressure slowly rotate the camgear clockwise until the camshaft TDC mark is between the two hash marks A a Note Check to ensure that the feeler gauge is in place on the loaded side of the camshaft ge2. Volvo Trucks North America Inc Greensboro NC USA This TSI Service Bulletin replaces TSI Service Manual Date lp Se Supp Page 215 003 Timing Gear Adjustment D12C 11 2001 10 2003 215 003 1 11 publication no PV776 TSP 160584 Timing Gear Adjustment D12C Timing Gear Adjustment W2003244 Fig 1 VOLVO D12C Engine This information covers procedures for checking and adjusting the timing gear on Volvo D12C engines Contents e Special Tools page 2 e Timing Gear Clearance Checking All page 3 e Timing Gear Adjustment page 5 PV776 TSP195612 USA14186 Volvo Trucks North America Inc Date Group No Page TSI 10 2003 215 003 2 11 Tools Special Tools The following special tools are used to replace or repair components The tools can be ordered from Volvo Please use the specified part number when ordering W0001774 W0001814 w0001979 J 44514 25 J 44935 2990939 Camshaft Alignment Tool Timing Gear Lash Setting Tool Flywhe l Turning Too includes J 44426 1 Pointer Tool Use with J 44514 25 Volvo Trucks North America Inc Date Group No Page TSI 10 203 215 003 3 11 Service Procedures 2153 06 03 01 Timing Gear Clearance Checking All You must read and understand the precautions and guidelines in Service Information Group 20 General Safety Practices Engine before performing this procedure If you are not p
3. ar and the adjustable idler gear N W2003492 Volvo Trucks North America Inc Date Group No Page TSI 10 2003 215 003 8 11 While using light hand pressure to set the gear last the camshaft timing mark should line up between the two hash marks on the 1 camshaft cap W2003493 10 Using special pointer tool J 44426 1 verify that the camshaft is properly aligned by installing the pointer in the dowel below the camgear J 44426 1 W2003518 Volvo Trucks North America Inc Date Group No Page TSI 10 203 215 003 9 11 11 Tighten the adjustable idler gear bolts do not apply final torque as these bolts must be replaced with new ones when all of the adjustments are made to the adjustable idler gear W2003519 12 Remove both feeler gauges Note Slight resistance should be felt as the feeler gauges are removed 13 Set up a dial indicator on the adjustable idler gear W2003495 Volvo Trucks North America Inc TSI W2003496 NY N W2003498 Date Group No Page 10 203 215 003 10 11 14 Use a pry bar or long screwdriver to hold the intermediate idler gear in place Measure the gearlash between the intermediate to adjustable idler gears by rocking the adjustable idler gear back and forth Acceptable gear backlash is between 0 05 0 17 mm 0 002 0 007 in 0 05 0 17 mm 0 002 0 007 in 15 Set up a dial indicator on the camshaft gear use a pry
4. bar or long screwdriver to hold the adjustable idler gear in place 16 Measure the gearlash between the camshaft gear and the adjustable idler gear by rocking the camshaft gear back and forth Acceptable gear backlash is between 0 05 0 17 mm 0 002 0 007 in Note If either backlash is out of specification the adjustable idler gear must be readjusted by repeating the above steps 0 05 0 17 mm 0 002 0 007 in Volvo Trucks North America Inc TSI W2003493 Date Group No Page 10 203 215 003 11 41 17 Using timing pointer J 44426 1 again verify that the pointer will align with the groove in the timing collar Note If the pointer does not align with the groove in the timing collar the adjustable idler gear must be readjusted J 44426 1 18 Remove all service tools 19 Replace adjustable idler gear bolts one at a time with new bolts tighten the new bolts to 15 Nm 11 ft lb 120 Visually inspect the camshaft and verify that the camshaft TDC mark is between the two hash marks Note After base engine timing and gear backlash adjustments are complete the adjustable timing idler gear bolts should be replaced and torqued one bolt at a time to maintain backlash adjustment 15 Nm 11 ft lb 120 20 Remove the cam gear alignment collar 21 Reinstall camshaft vibration damper Tighten bolts to a torque of 33 Nm 24 ft lb 90 33 Nm 24 ft lb 90 22 Complete engin
5. e assembly according to appropriate service information
6. roperly trained and certified in this procedure ask your supervisor for training before you perform it Volvo Trucks North America Inc Date Group Page TSI No 10 2003 215 003 4 11 ea 1 l l J Fig 2 Axial clearance 72007105 12007104 Fig 3 Radial clearance Clearances for the timing gears are e Axial 0 05 0 17 mm 0 002 0 007 in e Radial 0 026 0 070 mm 0 001 0 003 in e Backlash 0 05 0 17 mm 0 002 0 007 in 72007103 Fig 4 Backlash Volvo Trucks North America Inc Date Group No Page TSI 10 203 215 003 5 11 2153 05 05 01 Timing Gear Adjustment Timing Gear Backlash You must read and understand the precautions and guidelines in Service Information Group 20 General Safety Practices Engine before performing this procedure If you are not properly trained and certified in this procedure ask your supervisor for training before you perform it Special tools 9996956 J 445 14 25 1 Using flywheel turning tool 9996956 rotate the flywheel in normal direction of rotation until the 0 mark on the flywheel aligns with the pointer on the flywheel housing 9996956 C2000183 2 Remove the flywheel turning tool 9996956 9996956 3 Install the camshaft without the camshaft vibration damper or gear installed at this time Note Do not install the rocker lever assemblies at this time Rocker lever assemblies will
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