Volvo Trucks North America, Inc.Greensboro, NC USA

Date Group No. Supp. Page

9.97 371 014 1(4)

TSIFault Tracing & Performance Control

Connectors, Engine ECUVE D12

Connectors, VE D12 Control Unit

T2012118

This Service Bulletin concerns checking the terminals in the connector for the enginewiring harness and the cab wiring harness, as well as replacing wires in the connec-tors. See “Connector Terminal, Checking” page 2.

PV776-TSP103561/1 USA04148

Page 2

Connector Terminal, Ser-vicingConnector Terminal, CheckingNote: The tool used in this procedure can be found inRepair kit: 3947553.Special tools: 9998482

1

CAUTION

If there are other ground cables connected to the bat-tery (such as engine ECU, satellite system, etc.),disconnect those grounds first, then remove the bat-tery ground cable. Electronic modules may bedamaged when additional grounds are con-nected/disconnected without the main battery groundconnected. Always disconnect the main batteryground last.

Turn the ignition key to the OFF posi-tion and disconnect the negativebattery cable.

2Clean the connectors and the controlunit before the removing the connec-tors from the control unit.

3Release the locking clamp and removethe connector from the control unit.

4

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Check the terminals in the connectorusing gauge 9998482.

Insert the gauge into the terminal.Move the gauge in and out of the ter-minals to check that the terminal hasproper clamping force on the gauge.

Important: If the terminal does nothave any clamping force or if it isvery weak, it must be replaced.

Refer to “Faulty ECU Terminal, Re-placement” page 3.Tool 9998482 is from VE D12 engineKit 3947553.

9998482

Volvo Trucks North America, Inc. Date Group No. Page

TSI 9.97 371 014 3(4)

Faulty ECU Terminal, Replace-mentNote: The tools used in this procedure can be found inRepair kit: 3947553.Special tools: 9512636, 9998482, 1078054

1Remove the screws for the connectorhousing locking clamp and the con-nector housing. Cut the tie strapfastening the wiring harness to theconnector housing.

2

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Remove the terminal locking platefrom the connector. Remove the faultyterminal from the connector using tool9512636. Remove the tape from thewiring harness and conduit. Cut thewire that has the faulty terminal to thecorrect length for proper installation.Tool 9512636 is from VE D12 engineKit 3947553.

9512636

3

W2002217

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T2011830

Strip the insulator back on the end andcrimp the replacement terminal splice1078054. Crimp the butt splice con-nector using crimpers 3947557(Packard crimpers 12085115) in the18-20 anvil. Pull gently on the connec-tion to check for a proper crimp. Use aheat gun on the butt splice insulatoruntil the insulator shrinks around thewire and sealant is visible to ensurethe connection is sealed. (1078054from VE D12 engine Kit 3947553.)

10780543947557

4Insert the terminal into the connectoruntil it locks. Pull on the wire gently toinsure the terminal is locked. Install theterminal locking plate in the connector.

Page 4

5Tape the wire harness and conduitfrom where the tape was removed.

6Install the tie strap, fastening the wireharness to the connector housing. In-stall the screws for the connectorhousing and clamp.

7Insert the connector back into the con-trol unit and lock the clamp.

8

CAUTION

If there are other ground cables connected to the bat-tery (such as engine ECU, satellite system, etc.),connect the battery ground cable first, then connectthose grounds. Electronic modules may be damagedwhen additional grounds are connected/disconnectedwithout the main battery ground connected.

Connect the negative battery cableand check for any fault codes. Removeall inactive fault codes.