NHTSA ID Number: 10044325
Manufacturer Communication Number: FSB-255-024-03
TSB/Document Date: 2012-06-12
Summary
VOLVO
: SEVERE FRETTING DAMAGE OF ENGINE VARIABLE GEOMETRY TURBOCHARGER (VGT) ACTUATOR HARNESS CAUSE SIGNAL TO BE UNRELIABLE TO ENGINE VGT ACTUATOR CONNECTOR PIN AND SOCKET CONTACTS WHICH SHOULD BE REPLACED. MODELS VN, VHD, VT, VAH, D11, D13, D16. MODEL YEAR 2008-2012. *PE UPDATED 9/17/12. *PE
Field Service Bulletin
Trucks
Volvo Trucks North America
Greensboro, NC USA
SB-10044325-5447
This Field Service Bulletin replaces bulletin,
“FSB 255-023, Connector Pin Replacement”,
PV729–FSB255-023_V (USA53288) dated
(04/2012).
Date
Group
No.
Release
Page
5.2012
255
024
03
1( 8 )
Engine Variable Geometry Turbocharger
(VGT) Actuator Connector Pin, Replacement
VN, VHD, VT, VAH
D11, D13, D16
FSB 255-024, Engine Variable Geometry
Turbocharger (VGT) Actuator Connector Pin,
Replacement
(May 2012)
Severe fretting damage of the Engine Variable Geometry Turbocharger (VGT) Actuator
harness may cause an unreliable signal to the engine VGT Actuator on certain VOLVO VN,
VHD, VT, and VAH trucks. An unreliable signal to the engine VGT Actuator will generate
Diagnostic Trouble Codes (DTCs). If DTCs are logged and pin fretting is identified as the
cause, the engine VGT Actuator connector pin and socket contacts should be replaced.
Replacement of the pin and socket contacts will eliminate pin fretting and increase the
reliability of the signal to the engine VGT Actuator.
W2073530
Service personnel: Please circulate, read and initial
Service
Manager
Warranty
Administrator
PV729-FSB255-024_V
Workshop
Foreman
Service Technicians
USA53614
Volvo Trucks North America
Field Service Bulletin
Date
5.2012
Group
No.
Release
255
024
03
Required Parts
Connector Pin Replacement Parts
Item #
Part Number
Description
Crimp Jaw Position
1
984945
Pin, Eng VGT Actuator Conn
B
2
3963409
Socket, Eng VGT Actuator Conn
B
3
20734499
Wire Seal, Eng VGT Actuator Conn
N/A
Connector Pin Replacement Tools
Item #
Part Number
Description
1
9808646
Extraction Tool, Connector Socket
2
9809774
Extraction Tool, Connector Pin
3
88890003
Crimp Pliers
4
88890004
Crimp Jaw
Procedure
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.
1 Raise the hood.
2 Disconnect all cables from the negative (ground) battery terminals to prevent personal
injury from electrical shock and prevent damage to electrical components.
3 Disconnect both harness couplers.
Note: The connectors shown are for reference only. Your actual configuration may be
different, depending on truck model and components.
Note: In the event the connectors or harnesses are damaged, replace engine VGT
Actuator component connector (Item 1, Figure below) with part number 984944, engine
VGT Actuator engine harness connector (Item 2) with part number 3963412. Additionally,
plug seal part number 970771 is required to seal any unused pin and socket locations of
the connector housings.
Page
2( 8 )
Volvo Trucks North America
Field Service Bulletin
Date
5.2012
Group
No.
Release
255
024
03
4 Remove harnesses from the mounting bracket.
W2073531
5 Remove the conduit clamps from both harness sections.
Note: The engine VGT Actuator harness connector is shown for reference only.
W2072543
Page
3( 8 )
Volvo Trucks North America
Field Service Bulletin
Date
5.2012
Group
No.
Release
255
024
03
6 Using extraction tool 9808646 or 9809774, remove the defective pins from the connectors.
Note: Before removing terminals, note and document pin locations for reassembly
purposes.
W2072544
7 Cut and remove old pins from the harnesses.
W2072545
Page
4( 8 )
Volvo Trucks North America
Field Service Bulletin
Date
5.2012
Group
No.
Release
255
024
03
8 Assemble the wire and the appropriate wire seal as shown in figure below.
W2072546
9 Using a suitable wire stripper, strip 5 mm (0.2 in) of insulation from the end of each wire.
W2072547
10 Pre-assemble the appropriate pin or socket contact with stripped wire and seal.
W2072548
Page
5( 8 )
Volvo Trucks North America
Field Service Bulletin
Date
5.2012
Group
No.
Release
255
024
03
11 Using crimp pliers 88890003 and crimp jaw 88890004, crimp the pin or socket contact.
Note: See table on page 1 for the proper crimp jaw position.
W2072549
12 Insert the crimped pin or socket in the correct position of the connector.
W2072550
Page
6( 8 )
Volvo Trucks North America
Field Service Bulletin
Date
5.2012
Group
No.
Release
255
024
03
13 Install the conduit clamps.
W2072543
14 Install the harnesses onto the bracket and secure.
15 Connect the harnesses.
W2073531
16 Reconnect all previously removed cables to the negative (ground) battery terminals.
17 Lower hood.
Page
7( 8 )
Volvo Trucks North America
Field Service Bulletin
Date
5.2012
Group
No.
Release
255
024
03
Reimbursement
This repair may be eligible for reimbursement if a product failure was experienced
within time and mileage limits of the applicable Warranty coverage. Reimbursement
is obtained via the normal claim handling process.
Claim Type (used only when uploading from the Dealer Bus. Sys.)
W
Labor Code
Primary Labor Code for engine VGT Actuator Pin Replacement
25578-2-00
0.7 hrs.
Causal Part
984945
VOLVO Trucks North America engages in a continuous program of testing and evaluating to
provide the best possible product. VOLVO Trucks North America, however, is not committed
to, or liable for updating existing chassis.
Page
8( 8 )
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TSB/Document ID: FSB-255-024-03
Replacement Service Bulletin Number: FSB-255-024-04
MFR Communication Date: 2012-08-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, OTHER:FUEL FILTER
MFR Component System:
MFR Component Subsystem:
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