Service Bulletin

Volvo Trucks North America

Greensboro, NC USA Trucks
Date Group No. Page
This Service Bulletin replaces SB 255-27, “Turbocharger
Replacement, D12D” (11.2002), publication no. 9.2006 255 27 1(10)
PV776-TSP175140.
Turbocharger
Replacement
D12D
Turbocharger Replacement

W2003779

This information covers the proper replacement procedure for the turbocharger on the
VOLVO D12D engine.

Contents
• “Special Tools” page 2
• “Turbocharger, Replacement” page 3

Note: Information is subject to change without notice.

Illustrations are used for reference only, and may differ slightly from the actual engine
version. However, key components addressed in this information are represented as
accurately as possible.

PV776-20177430 USA23107.ihval
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Service Bulletin 9.2006 255 27 2(10)

Special Tools
For special tools ordering information, refer to Tool Information, group 08.

9996049 DBT2V700
Drain hose for coolant Coolant extractor
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Service Bulletin 9.2006 255 27 3(10)

2551-03-02-02
Turbocharger, Replacement
See also:

• “Turbocharger Replacement” page 1

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: 9996049, DBT2V700

Removal
1
Install coolant extraction tool DBT2V700 to the drain
fitting at the bottom of the radiator. Drain coolant.

Note: An alternate method is to connect coolant drain

hose 996049 to fitting and drain coolant into an approved
container.

DBT2V700, 9996049

W2003849

2
Remove inner fender and bracket.

3
Remove air filter housing and fresh air pipe to
turbocharger; refer to Service Information, group 25..

W2003859

4
Remove EGR pipe heat shield.
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Service Bulletin 9.2006 255 27 4(10)

5
Remove EGR valve exhaust pipes and clamps between
EGR valves and EGR cooler.

W2004257

6
Remove EGR wiring harness rail from the top of
the EGR cooler.

W2003828

7
Remove the EGR harness rail and shield from the
EGR valve assembly.

W2004216

8
Disconnect coolant line and bracket from front EGR valve.
Disconnect coolant line from rear EGR valve.
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Service Bulletin 9.2006 255 27 5(10)

9
Remove EGR valve clamps to exhaust manifold.

W2003822

10
Move aside the EGR valve assembly to enable access to
the turbocharger.

Note: Tie straps may help keep assembly away from

turbocharger area.

11
Remove clamp from EPG housing to turbocharger.

W2003871

12
Remove turbocharger oil supply line (upper).

W2003864
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Service Bulletin 9.2006 255 27 6(10)

13
Remove oil return line (lower).

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14
Remove lower charge air pipe from turbocharger and
midpipe support fastener..

15
Remove turbocharger flange mounting nuts and spacers.

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16
Lower turbocharger away from exhaust manifold and
lift out.

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Installation
1
Clean contact surface on exhaust manifold, oil supply
pipe, and drain pipe.
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Service Bulletin 9.2006 255 27 7(10)

2
Position turbocharger and gaskets against exhaust
manifold.

Note: Be sure to install exhaust restriction plate between

turbocharger and exhaust manifold. Ports in the plate
are somewhat smaller to direct more exhaust pressure
toward the EGR cooler.

W2003868

3
Install turbocharger flange nuts and spacers to exhaust
manifold and torque-tighten to specifications.

W2003867

4
Install lower charge air pipe to turbocharger.

5
Install turbocharger oil return pipe (lower) with new
gasket.

W2003865
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Service Bulletin 9.2006 255 27 8(10)

6
Install oil supply line (upper) with new gasket.
Torque-tighten bolts to 24 ± 2 Nm (18 ± 1.5 ft-lb).

CAUTION
Pre-fill turbocharger with clean engine oil. Starting
engine without oil pressure and a “dry” turbocharger
can damage the turbo.

24 ± 2 Nm
(18 ± 1.5 ft-lb)

W2003864

7
Install clamp from EPG housing to turbocharger.

W2003871

8
Position EGR valve assembly against exhaust manifold.

9
Install EGR valve clamps to exhaust manifold.
Torque-tighten to 13 ± 3 Nm (10 ± 2 ft-lb).

Note: Use new clamps and sealing rings.

13 ± 3 Nm
(10 ± 2 ft-lb)

W2003822
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Service Bulletin 9.2006 255 27 9(10)

10
Install EGR harness rail to EGR cooler brackets. Torque
tighten to 10+/-NM (7+/-1ftlb). Start rail fastener at
EGR valve assembly.

W2003828

11
Install EGR valve exhaust pipes and clamps to EGR
cooler. Torque-tighten to 13 ± 3 Nm (10 ± 2 ft-lb).

Note: Use new sealing rings.

Note: Orientate upper clamp fasteners forward and

vertical.

13 ± 3 Nm
(10 ± 2 ft-lb)

W2003826

12
Install EGR pipe heat shield.

13
Reconnect coolant lines to the front and rear EGR valves.

14
Install air filter housing and fresh air pipe; refer to Service
Information, group 25.

W2003859
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Service Bulletin 9.2006 255 27 10(10)

15
Install inner fender and bracket.

W2003849

16
Start engine and check for leaks.