Ayoubvaw80@gmail.

com(0695239037)
RS - 214
Volvo Perú S.A.

Referecia Data Grupo Nº Reg.

Recomendaciones de Servicio 27/07/2005 2.14
Emitido por Aprobado por Substituye Página
Dpto. de Servicio – Andrés Ramos Jorge Masias 1/
Asunto
Ajuste de válvulas e inyectores bomba D12D VEB - Mantenimiento
Distribuido para
El Area de Servicio de la Red de Concesionarios y Talleres Autorizados

Procedimientos para el ajuste / regulación de válvulas e inyectores bomba.

NOTA:
La presente Recomendación de Servicio modifica los periodos de ajuste de las
válvulas e inyectores bombas, como parte del mantenimiento normal y mandatorio
para la validez de la garantía, de acuerdo a los intervalos máximos siguientes:

Cada 200,000 Km. o 12 meses, lo que se cumpla primero.

Cada 3,000 Hrs. de funcionamiento del motor.

Valores de ajuste: Marcas en el eje de levas

Válvulas de escape : 1,60 mm. Posición del eje de levas:V1 – V6(VEB)
Ajustar también los inyectores : 180° - 240° Inyectores Delphi(Lucas).
Válvulas de admisión : 0,20 mm. Posición del eje de levas: 1- 6

Youssef reglage
valvulas 0651575427
 Volvo Perú S.A. Data Grupo N° Reg Página
Recomendaciones de Servicio 24/06/05 4000 4.31 2/4

Válvulas de admisión, ajuste.

1
Girar el motor en el sentido de rotación
hasta la siguiente marca del árbol de
levas para el ajuste de las válvulas de
admisión.

Válvulas de admisión, ajuste.

1
Girar el motor en el sentido de rotación hasta la siguiente marca
del árbol de levas para el ajuste de las válvulas de
admisión.

2
Ajustar a la holgura correcta según se
indica lineas arriba y apretar la
contratuerca según la especificación, ver
grupo 20.

Controlar midiendo la holgura de válvulas

Marcar el balancin una vez ajustada la

válvula.
Ajustar a la holgura correcta según se indica lineas
arriba y apretar la
contratuerca según la especificación, ver grupo 20.

Controlar midiendo la holgura de válvulas

Marcar el balancin una vez ajustada la válvula.

Marcar el
balancin Inyector bomba, ajuste.
una vez 3
ajustada la Ajustar el balancín del inyector bomba
válvula. hasta eliminar la holgura. Apretar el
tornillo de ajuste 3-4 hexágonos más.
Apretar la contratuerca al apriete indicado
según las especificaciones, ver grupo 20.

Ayoubvaw80@[Link]
Volvo Perú S.A. Data Grupo N° Reg Página
Recomendaciones de Servicio 24/06/05 4000 4.31 3/4

Válvulas de escape VEB, ajuste.

4
Girar el motor para la siguiente marca del
árbol de levas para el ajuste de las
válvulas de escape.

5
Presionar el balancin hacia abajo, tal
como puede verse en la figura. Si el
balancin “cede”, tirar el resorte del pistón
del balancin hacia fuera y apretar al
mismo tiempo el balancin hasta que entre
en contacto con el vátago de válvula.
La presión de aceite que queda dentro del
pistón desaparece cuando el pistón se
separa del asiento y el ajuste es mas
preciso.
Utilizar un alambre grueso o un
destornillador doblado para sacar el
resorte.

Nota: Comprobar que el alambre o

destornillador están bien limpios antes de
utilazarlos.
Impurezas entre el pistón del balancín y
balancín pueden implicar que el pistón se
atore y la función de frenado no actúe.
Comprobar que la superficie deslizante
del pistón en el balancín no se daña.

6
Medir la holgura entre el pistón y la tapa
de la válvula con la ayuda de una lámina
de espesores.
Comparar el valor medido con el indicado
en las especificaciones, ver grupo 20.

Ayoubvaw80@gmail. Com
Volvo Perú S.A. Data Grupo N° Reg Página
Recomendaciones de Servicio 24/06/05 4000 4.31 4/4

7
Si es necesario ajustar el juego de
válvulas, retirar el tornillo.
Calcular, guiandose por el valor medido,
el espesor del nuevo suplemento de
ajuste.

Como máximo, solo pueden utilizarse

dos suplementos de ajuste.

Seleccionar suplementos de ajuste de

manera que ambos sean de
aproximadamente el mismo espesor si es
necesario utilizar dos.

Nota: El espesor de los suplementos de

ajuste varía a intervalos de 0,05mm. El
espesor esta grabado en los
suplementos.

8
Asegurese de que los suplementos de
ajuste y la tapa de válvulas esten bien
limpias. Colocar los suplementos de
ajuste y apretar la contratuerca al apriete
indicado según las especificaciones, ver
el grupo 20.

9
Controlar midiendo midiendo la holgura
de válvulas.

Marcar el balancin una vez ajustada la

válvula.

0695239037

Ayoubvaw80@gmail. Com
Volvo Trucks North America, Inc.
Greensboro, NC USA
TSI
Date Group No. Supp. Page
This TSI Service Bulletin replaces TSI Service Bulletin
214–013, “Valves, D12C” (11.2001), publication no. 7.2004 214 020 1(9)
PV776–TSP160587.
Valve and Injector Adjustment with EPG
D12, D12A, D12B, D12C
Valve and Injector Adjustment with EPG

W2003805

This information covers procedures for adjusting valves and injectors on VOLVO D12,
D12A, D12B, and D12C engines.

Contents
• “Special Tools” page 2
• “Valves and Unit Injectors, Adjustment” page 3

Note: Information is subject to change without notice.

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

PV776-20 006218
Ayoubvaw80@[Link] USA15092
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 020 2(9)

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.

C0000220 W0000416

9996956 J41610
Cranking tool Feeler Gauge Set

Other Special Equipment

Like special tools, the following items can be ordered directly from Volvo. Please refer to
the specific tool number when ordering.

C2001260

1159794
Torque Wrench

Ayoubvaw80@[Link]
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 020 3(9)

Service Procedures
2140-05-03-01
Valves and Unit Injectors, Adjustment
(Valve cover removed.)

You must read and understand the precautions and

guidelines in Service Information, group 20, "General
Safety Practices" before performing this procedure.
If you are not properly trained and certified in this
procedure, ask your supervisor for training before
you perform it.

T2008968

Note: Variant abbreviations are used to identify an engine

equipped with the following components:

EPG Exhaust Pressure Governor

Special tools: 9996956, J41610

Other special equipment: 1159794

Ayoubvaw80@gmail. Com
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 020 4(9)

1
Remove the flywheel inspection cover located under
the engine flywheel housing. Install engine turning
tool 9996956.

9996956

C2000183

2
Turn the engine to the camshaft marking to adjust the
corresponding valve (for example, no. 5, as shown in
illustration), as indicated below:

• Marking 1 – 6: Apply to adjustment of valve bridge

intake valves, exhaust valves, and unit injector.

Example:
Adjustments for no. 5 intake clearances, no. 5 injector
preload, and no. 5 exhaust valve clearances would be
made in this engine position.

T2006771

Ayoubvaw80@gmail. Com
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 020 5(9)

Valve and Unit injector, adjustment

3
Loosen lock nut and back off adjusting screw until it no
longer makes contact with the injector socket.
Note: Adjust injector before adjusting intake and
exhaust valves.

Valve and Injector Settings

Cam Injector Intake Exhaust
Position
1 X X X
5 X X X
3 X X X
6 X X X
2 X X X
W2004460
4 X X X

4
Adjust the unit injector’s adjusting screw to zero
clearance.

5
Tighten the adjusting screw 4 flats or 240 .

6
Torque-tighten the adjusting screw lock nut to
52 ± 4 Nm (38 ± 3 ft-lb).

Note: Mark the rocker arm and injector rocker when each
valve has been adjusted.

52 ± 4 Nm
(38 ± 3 ft-lb)

Ayoubvaw80@gmail. Com
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 020 6(9)

Intake and Exhaust Valve Bridge Adjustment

7

T2019496

Valve bridge with guide

W2004467

Valve bridge without guide

Note: A valve bridge design (without guide pin) is used in

D12 engines. These may be installed in combination
with the current valve bridge design with guide pin. The
procedure for adjusting valves remains the same, except
that the valve bridge without guide pin does not need
adjusting. Valve clearances are also unchanged. For
intake valves, the valve bridge without guide pin may
be installed facing either direction. A valve bridge with
guide pin must always be installed as a replacement
component.

Ayoubvaw80@gmail. Com
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 020 7(9)

Intake and Exhaust Valve Bridge Adjustment

8

W2004433

CAUTION
The valve bridge must be adjusted prior to the valve
clearance adjustment that is related to it. Failure to
do this can result in breakage or damage to the
valve bridge guide.

Note: The valve bridge adjustment can only be made

when there is clearance between the valve bridge
and the rockerarm.

Adjust the valve bridge clearance:

• Loosen the adjusting screw lock nut.

• Loosen adjusting screw until it no longer contacts
valve stem.
• Press valve bridge downward toward the valve stem.
• Tighten adjusting screw until it makes contact, then
turn an additional 1 flat or 60 .
• Hold adjusting screw in place and torque-tighten nut to
38 ± 3 Nm (28 ± 2 ft-lb).
W2004468

38 ± 3 Nm
(28 ± 2 ft-lb)

9
Recheck valve clearance after nut is torque-tightened.

10
Rotate the engine to the next cylinder mark on the
camshaft. Adjust unit injector, valve bridges, intake and
exhaust valves on that cylinder.

Ayoubvaw80@gmail. Com
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 020 8(9)

11
With engine cold (140 F or less), adjust the valve
clearance for exhaust to 0.5 mm (0.020 in.). Hold
adjusting screw in place and torque-tighten lock nut to 38
± 3 Nm (28 ± 2 ft-lb).

Note: Mark each valve rocker lever as you adjust it to

know which valves have already been adjusted.

W2003805

Intake Valves, adjustment

12
With engine cold (140 F or less), adjust valve clearance
to 0.2 mm (0.008 in.). Hold adjusting screw in place and
torque-tighten lock nut to 38 ± 3 Nm (28 ± 2 ft-lb).
Note: Mark each valve rocker lever as you adjust it to
know which valves have already been adjusted.

38 ± 3 Nm
(28 ± 2 ft-lb)

T2008968

Ayoubvaw80@gmail. Com
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 020 9(9)

13
Use steps 3 - 13 to adjust the injectors and valves.

Valve Clearance, Cold Engine Setting Valve

Inlet 0.2 mm (0.008 in.)
Exhaust 0.5 mm (0.020 in.)

Valve Clearance, Cold Engine Check Valve

Inlet 0.15 – 0.25 mm (0.006 – 0.010 in.)
Exhaust 0.45 – 0.55 mm (0.018 – 0.22 in.)

Valve and Injector Settings

Cam Injector Intake Exhaust
Position
1 X X X
5 X X X
3 X X X
6 X X X
2 X X X
4 X X X

Ayoubvaw80@gmail. Com
Volvo Trucks North America, Inc.
Greensboro, NC USA
TSI
Date Group No. Supp. Page
This TSI Service Bulletin replaces TSI Service Bulletin
214–013, “Valves, D12C” (11.2001), publication no. 7.2004 214 019 1(11)
PV776–TSP160587.
Valve and Injector Adjustment with VEB
D12, D12A, D12B, D12C
Valve and Injector Adjustment with VEB
‫ﻳﻤﻜﻦ ﺍﻻ ﻋﺘﻤﺎﺩ ﻋﻠﻰ ﻫﺪﺍ ﺍﻻ ﻧﻤﻮﺩﺝ ﻓﻲ ﺍﻏﻠﺐ ﺷﺎﺣﻨﺎﺕ ﺍﻟﻔﻮﻟﻔﻮ‬

W2004459

This information covers procedures for adjusting valves and injectors on VOLVO D12,
D12A, D12B, and D12C engines.

Contents
• “Special Tools” page 2
• “Valves and Unit Injectors, Adjustment” page 3

Note: Information is subject to change without notice.

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

PV776-20 005870
Ayoubvaw80@gmail USA15071
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 019 2(11)

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

W0001924 W0001774 W0000416

3949521 9996956 J41610

VEB shim kit Engine turning tool Feeler gauge set

Other Special Equipment

Like special tools, the following items can be ordered directly from Volvo. Please refer to
the specific tool number when ordering.

C2001260

1159794
Torque Wrench
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 019 3(11)

Service Procedures
2140-05-03-01
Valves and Unit Injectors, Adjustment
(Valve cover removed.)

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.

Note: Variant abbreviations are used to identify an engine

equipped with the following components:
VEB Volvo Engine Brake

Special tools: 3949521, 9996956, J41610

Other special equipment: 1159794
1
Remove the flywheel inspection cover from the flywheel
housing. Install engine turning tool 9996956.

9996956

T2006672

2
Camshaft markings for setting of valves and unit
injectors:

• Markings 1–6, apply to adjustment of intake valves

and unit injector.

• Markings V1–V6, apply to adjustment of exhaust

valves only.

W2004440
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 019 4(11)

Valve and Unit injector, adjustment

3
Loosen lock nut and back off adjusting screw until it no
longer makes contact with the injector socket.
Valve and Injector Settings
Cam Injector Intake Exhaust
Position
5 X X
V6 X
3 X X
V2 X
6 X X
V4 X

W2004460
2 X X
V1 X
4 X X
V5 X
1 X X
V3 X

4
Adjust the unit injector’s adjusting screw to zero
clearance.

5
Tighten the adjusting screw 4 flats or 240 .

6
Torque-tighten the adjusting screw lock nut to
52 ± 4 Nm (38 ± 3 ft-lb).
Note: Mark the rocker arm and injector rocker when each
valve has been adjusted.

52 ± 4 Nm
(38 ± 3 ft-lb)

Ayoubvaw80@gmail. Com
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 019 5(11)

Intake and Exhaust Valve Bridge Adjustment

7

T2019496

Valve bridge with guide

W2004467

Valve bridge without guide

Note: A valve bridge design (without guide pin) is used in

D12 engines. These may be installed in combination
with the current valve bridge design with guide pin. The
procedure for adjusting valves remains the same, except
that the valve bridge without guide pin does not need
adjusting. Valve clearances are also unchanged. For
intake valves, the valve bridge without guide pin may
be installed facing either direction. A valve bridge with
guide pin must always be installed as a replacement
component.
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 019 6(11)

W2004433

CAUTION
The valve bridge must be adjusted prior to the valve
clearance adjustment that is related to it. Failure to
do this can result in breakage or damage to the
valve bridge guide.

Note: The valve bridge adjustment can only be made

when there is clearance between the valve bridge
and the rockerarm.

Adjust the valve bridge clearance:

• Loosen the adjusting screw lock nut.

• Loosen adjusting screw until it no longer contacts
valve stem.
• Press valve bridge downward toward the valve stem.
• Tighten adjusting screw until it makes contact, then
turn an additional 1 flat or 60 .
• Hold adjusting screw in place and torque-tighten nut to
38 ± 3 Nm (28 ± 2 ft-lb).
W2004468

38 ± 3 Nm
(28 ± 2 ft-lb)

9
Recheck valve clearance after nut is torque-tightened.
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 019 7(11)

Intake Valves, adjustment

10
With engine cold (140 F or less), adjust valve clearance
to 0.2 mm (0.008 in.). Hold adjusting screw in place and
torque-tighten lock nut to 38 ± 3 Nm (28 ± 2 ft-lb).

Note: Mark each valve rocker lever as you adjust it to

know which valves have already been adjusted.

38 ± 3 Nm
(28 ± 2 ft-lb)

W2004459

11
Turn the engine to the next camshaft marking before
adjusting another cylinder.

Note: Engine temperature at 140 F or less.

Valve Clearance, Cold Engine Setting Valve

Inlet 0.2 mm (0.008 in.)
Exhaust VEB 1.6 mm (0.063 in.)

Valve Clearance, Cold Engine Check Valve

Inlet 0.15 – 0.25 mm (0.006 – 0.010 in.)
Exhaust VEB 1.55 – 1.65 mm (0.061 – 0.065 in.)
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 019 8(11)

Exhaust valves (VEB), adjustment

12
Turn the engine to the next camshaft marking (“V” plus
number) for the adjustment of exhaust valves.

13
Loosen the adjusting screw until the valve bridge does
not make contact with the valve stem.

Valve and Injector Settings

Cam Injector Intake Exhaust
Position
5 X X
V6 X
3 X X
V2 X
6 X X
V4 X
2 X X
V1 X
4 X X
W2004464
V5 X
1 X X
V3 X

14
Tighten the adjusting screw until it makes contact (zero
clearance) against the valve stem. Turn an additional
1 flat or 60 . Do not tighten the adjusting screw lock
nut at this point.

Note: When the adjusting screw is screwed down, the

valve bridge must be pushed down at the same time until
it makes contact with the valve stems.

W2004427

Ayoubvaw80@gmail
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 019 9(11)

15

T2009074

Push the rocker arm down as

shown. If the rocker arm “springs,” the rocker arm piston’s
spring should be pulled outward while the rocker
arm is pushed down until the piston makes contact
with the VEB housing.

Note: Use a strong wire or a bent screwdriver to pull out

the spring.

Note: For correct reading or measurement, make sure

that the wire or the screwdriver has been well cleaned
before they are used. Impurities between the rocker
T2009009 arm piston and the rocker arm can lead to the piston
seizing and the brake function on the cylinder failing to
work. Make sure that the piston’s sliding surface in the
rocker arm is not damaged.

W2004446
W2004447

VEB Compressed Piston in Housing VEB Plunger Piston with oil trapped
(Correct valve lash adjustment) (Incorrect valve lash adjustment)

16
Measure the clearance between the rocker arm’s piston
and the valve bridge. Acceptable clearance is
1.55 – 1.65 mm (0.061 – 0.065 in.).

1.55 – 1.65 mm (0.061 – 0.065 in.)

Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 019 10(11)

17

W2004465

T2009008 Note: The exhaust valve rockers do not have adjusting

screws. The exhaust valve clearance is adjusted by
adding and/or removing the correct VEB shims.
Note: Shims are available in intervals of 0.05 mm. The
thickness is stamped on the shim. VEB shim kit is
tool no. 3945921.

If the valve clearance needs to be

adjusted, remove the lock nut without moving
the adjusting screw.

Note: If the shim is wearing on one side, turn it over

and reuse.

Note: If the adjusting screw turns while removing the lock

W2004423
nut, repeat steps for Valve Bridge Adjustment.

3945921

18
Use the measured value to calculate the thickness of
the new shims.

If two shims must be used, select

shims of approximately the same thickness.

Note: A maximum of two shims can be used.

Ayoubvaw80@gmail .com.0695239037
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 019 11(11)

19
Make sure that the shim(s) and the valve bridge have
been properly cleaned. Install shims and torque-tighten
the adjusting screw lock nut to 38 ± 4 Nm (28 ± 3 ft-lb).

Note: The adjusting screw must not be moved on the

valve bridge when the lock nut is tightened.

38 ± 4 Nm (28 ± 3 ft-lb).

W2004464

20
After tightening the adjusting screw, recheck the valve
clearance.

Note: Mark the rocker arm when the valve has been
adjusted.

21
After work has been completed, start the engine and
check for incorrect valve adjustment and leaks.

22
Bring engine to normal operating temperature. Let engine
idle for approximately 5 minutes; the system performs its
own cylinder balancing in order to attain smooth idling.

Note: During cylinder balancing, do not use any form of

power-consuming equipment, such as power take-off or
air conditioning.
Volvo Trucks North America
Greensboro, NC USA

D Service Bulletin
Date

3.2007
Trucks
Group

214
No.

93

Valves and Unit injectors

Adjustment
D13F
Page

1(19)

Valves and Unit Injectors, Adjustment

W2005941

This information covers the correct procedure for adjusting the valves and unit injectors
on the Volvo D13F engine.

Contents
• “Special Tools” page 2
• “Valves and Unit Injectors, Adjustment” 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.

PV776-20177326 [Link]
Volvo Trucks North America
Service Bulletin

Special Tools
Tools
D Date
3.2007

For special tools ordering instructions, refer to Tool Information, group 08.
Group
214
No.
93
Page
2(19)

W0001924 T0012612 W0000416

3949521 88800014 85111377

VEB Shim Kit Flywheel Turning Tool Feeler Gauge Set

T0010788 W0002414 W0001790

9989876 85111493 9999696

Dial Indicator (or Equivalent) Dial Indicator Angled Extension Magnetic Stand (or Equivalent)
(or Equivalent)
Volvo Trucks North America
Service Bulletin

Service Procedures
D
Valves and Unit Injectors, Adjustment
See also:

•
Date
3.2007
Group
214
No.
93

“Valves and Unit Injectors, Adjustment” page 1

Page
3(19)

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: 3949521, 9989876, 9999696,

85111493, 85111377, 88800014
1
Apply the parking brake and place the shift lever
in neutral.

2
Remove all cables from ground (negative) battery
terminals to prevent personal injury from electrical shock.

W2003815

3
Disconnect and remove the air filter restriction gauge
wiring harness from air filter housing.

W2003861
Volvo Trucks North America
Service Bulletin

D
4
Date
3.2007
Group
214
No.
93

Unplug the air temperature sensor wiring harness

connector. Remove the lock tab and separate the
Page
4(19)

connector from the sensor. Remove the sensor harness

clamp from the main fresh air pipe.

W2004720

5
Loosen the air compressor fresh air hose clamp.

W2004719
Volvo Trucks North America
Service Bulletin

D 6
Date
3.2007
Group
214
No.
93

Loosen the clamps and remove the main fresh air pipe
from the air compressor fresh air hose, the air filter
housing and the turbocharger air inlet elbow.
Page
5(19)

W2006005

7
Remove the fasteners and lift the air filter housing
away from the cab.

W2003858
Volvo Trucks North America
Service Bulletin

D
8
Date
3.2007
Group
214
No.
93

Loosen the V-clamps and remove the EGR crossover

pipe.
Page
6(19)

W2005960
1 Venturi Outlet Pipe
2 Crossover Pipe
3 Mixer Inlet Pipe

9
Loosen the clamp and mounting brackets to allow air
compressor fresh air pipe to be removed.

10
Remove the aftertreatment fuel injector harness clips at
the valve cover.

11
Remove the fasteners which secure crankcase ventilation
tube and bracket to valve cover and intake manifold.
Relocate the tube away from the manifold.

W2006122
Volvo Trucks North America
Service Bulletin

D 12
Date
3.2007
Group
214
No.
93

Disconnect the discharge line and mounting brackets

from the air compressor. Move the discharge air line
out of the way and strap in place.

13
Remove the spring-loaded bolts from the valve cover.
Page
7(19)

T2022732

14
Lift and remove the valve cover.

Note: Rotate the valve cover as needed, to clear the

camshaft gear and damper.

Note: Dependent upon chassis, engine cover may need

to be removed for clearance to remove valve cover.

15
Loosen the fasteners retaining the leaf springs to release
spring tension on the Volvo Engine Brake (VEB) rocker
arms.

W2005753
Volvo Trucks North America
Service Bulletin

D
16
Date
3.2007
Group
214
No.
93
Page
8(19)

Remove the plug from the lower right side of the flywheel
housing and install the flywheel turning tool (88800014).

88800014

W0002368

17
Camshaft markings for setting of valves and unit
injectors:

• Without VEB: Markings 1–6 apply to adjustment of

inlet valves, exhaust valves and unit injectors.

• With VEB: Markings 1–6 apply to adjustment of inlet

valves and unit injector.
Markings E1–E6 apply to adjustment of exhaust valves.

Valve and Injector Settings

Cam Injector Intake/ Exhaust VEB
Position Exhaust (VEB) Rocker
5 X X
E6 X X
3 X X
E2 X X
W2006171
6 X X
E4 X X
2 X X
E1 X X
4 X X
E5 X X
1 X X
E3 X X
Volvo Trucks North America
Service Bulletin

D Date
3.2007
Group
214
No.
93

Intake Valves, Adjustment (with or without

VEB)
18
Page
9(19)

Using the flywheel turning tool, rotate the engine to the

next camshaft marking for adjustment of the intake valve.
Rotate the engine until the valve and injector mark on the
front end of the camshaft aligns with the stamped mark
on the camshaft front bearing cap.

19
With the engine cold (140 F or less), check the intake
valve clearance. Push down on the back of the rocker and
insert a feeler gauge of the proper specification, 0.20 ±
0.05 mm (0.008 ± 0.002 inch), between the bridge and the
adjustment screw. If the inlet rocker requires adjustment,
loosen the locknut on the rocker and adjust the plunger.

T2023322

20
Tighten the locknut on the plunger by holding the
adjusting screw in place and torque-tighten the locknut to
38 ± 4 Nm (28 ± 3 ft-lb).

38 ± 4 Nm
(28 ± 3 ft-lb)

21
Recheck the valve clearance after the nut is tightened.

Note: Mark the rocker arm when the valve has been
adjusted.
Volvo Trucks North America
Service Bulletin

D Date
3.2007

Unit Injector, Adjustment

22
Group
214
No.
93

To adjust the injector on the same cylinder location,

Page
10(19)

loosen the locknut and back off the adjusting screw until it
no longer makes contact.

23
Adjust the unit injector’s rocker arm to zero clearance.

24
Tighten the adjusting screw four flats or 240 degrees of
clockwise rotation.

T2023323

25
Torque-tighten the adjusting screw locknut to 52 ± 4
Nm (38 ± 3 ft-lb).

52 ± 4 Nm
(38 ± 3 ft-lb)
Volvo Trucks North America
Service Bulletin

D Date
3.2007
Group
214
No.
93

Exhaust Valves (without VEB), Adjustment

26
Continue adjustment on the same cylinder location by
Page
11(19)

checking the exhaust rocker valve clearance. Push down

on the back of the exhaust rocker and insert a feeler
gauge of the proper specification of 0.80 mm (0.031 inch)
between the bridge and the adjustment screw. If the
exhaust rocker requires adjustment, loosen the locknut on
the rocker and adjust the plunger.

T2022277

27
Tighten the locknut on the plunger by holding the
adjusting screw in place and torque-tighten the locknut to
38 ± 4 Nm (28 ± 3 ft-lb).

38 ± 4 Nm
(28 ± 3 ft-lb)

28
Recheck valve clearance after the locknut is tightened.

Note: Mark the rocker arm when the valve has been
adjusted.
Volvo Trucks North America
Service Bulletin

D
29
Date
3.2007
Group
214

Exhaust Valves (VEB), Adjustment

No.
93

Using the flywheel turning tool, rotate the engine to

the next camshaft marking (number plus “E”) for the
adjustment of the exhaust valves.
Page
12(19)

W2006171

30
VEB Exhaust Bridge Shim Check:

• Push down on the back of the exhaust rocker and

insert a feeler gauge of the proper specification of 1.00
± 0.05 mm (0.039 ± 0.002 inch) between the bridge
and the brake plunger.
• If clearance is not within specification, adjust the
clearance as required, using shims placed on top of
the valve bridge.

• Remove the shim retaining screw and remove

the shim.
• Make sure that the valve bridge and shim(s)
are clean.

T2023324
• Determine the thickness of the shim(s) required to
match the measured clearance
• Place the shim(s) in position on the valve yoke,
install the retaining screw and tighten to 38 ±
4 Nm (28 ± 3 ft-lb).
DO NOT use more than two shims. Shims are
available (shim kit No. 3949521) in 0.05 mm
(0.002 inch) increments with the thickness marked
on the surface. If two shims are required to
take up the clearance, the shims should be of
nearly equal thickness.
T2009008

Allow feeler gauge to remain in place between the

rocker arm and the valve bridge during the following
brake rocker check.

3949521
38 ± 4 Nm
(28 ± 3 ft-lb)
Volvo Trucks North America
Service Bulletin

D 31
Date
3.2007
Group
214

Engine Brake Rocker Adjust:

•
•
•
No.
93

Loosen the locknut on the brake rocker arm “A”.

Page
13(19)

Assemble the dial indicator angled extension onto the

dial indicator and tighten the extension locknut.
Position a magnetic stand and dial indicator with
angled extension to allow the shaft of indicator
extension to set onto the valve bridge as close to the
brake rocker plunger as possible.
• Tighten the adjusting screw “B” clockwise until the
dial indicator shows that the valve bridge has been
pressed down by 0.60 ± 0.05 mm (0.024 ± 0.002 inch).
• Loosen the adjusting screw “B” counterclockwise 720
degrees (two revolutions).
• Torque-tighten retention locknut “A” to 52 ± 4 Nm (38
± 3 ft-lb).
• Remove the dial indicator, magnetic stand and feeler
gauge.

9989876, 85111493, 9999696

52 ± 4 Nm
(38 ± 3 ft-lb)
W2006212

32
VEB Engine Brake Check:
Check the engine brake rocker arm clearance between
the rocker arm roller and the camshaft with the 3.6 mm
feeler gauge 85111377.

• With the dial indicator, magnetic stand and feeler

gauge removed, insert a shim and feeler gauge
between the camshaft lob and the rocker arm roller.
• Clearance between the camshaft and rocker roller
should meet a specification of 3.60 ± 0.10 mm (0.142
± 0.004 inch).
• If the clearance is not within the specification, the
adjustment must be repeated per the previous
adjustment.

W2005815 85111377

33
Recheck valve clearance after the locknut is tightened.

Note: Mark the rocker arm when the valve has been
adjusted.

34
Repeat the above procedure to adjust all other unit
injectors and valve locations by rotating the engine to the
next nearest camshaft mark.
Volvo Trucks North America
Service Bulletin

D
35
Date
3.2007
Group
214
No.
93

pattern outlined in the chart below. Use the flywheel

turning tool (88800014) to advance the engine to the
next setting.

Valve and Injector Settings

Cam
Position
Injector Intake/
Exhaust
Exhaust
(VEB)
VEB
Rocker
Page
14(19)

Adjust the inlet, exhaust and unit injectors using the

5 X X
E6 X X
3 X X
E2 X X
W0002368
6 X X
E4 X X
2 X X
E1 X X
4 X X
E5 X X
1 X X
E3 X X

88800014

36
After all unit injectors and valves have been checked
and adjusted if necessary, clean the valve cover contact
surface on the cylinder head.

37
For engines with VEB, tighten the leaf spring retaining
screws on the exhaust rocker arms to 25 ± 3 Nm (18 ±
2 ft-lb).

25 ± 3 Nm
(18 ± 2 ft-lb)

T2022951
Volvo Trucks North America
Service Bulletin

D 38
Date
3.2007
Group
214

dirt or debris and free of any oil.

39
No.
93
Page
15(19)

Clean the gasket sealing surface of the valve cover and

the cylinder head. The surfaces should be clear of any

Carefully inspect the valve cover gasket for damage and

replace with a new gasket if necessary. Make sure that
the gasket is properly seated and follows the contour
of the channel.

W2005162

40
Apply a 2 mm (0.079 inch) bead of Volvo sealant to the
area where the timing cover and the cylinder head meet.
This parting line is on both sides of the cylinder head.
Carefully position the valve cover on the cylinder head
and make sure that the seal remains properly seated.

Note: This step is very critical to ensure no oil leaks

occur.

W2005157

41
Install the spring-loaded bolts in the valve cover.
Torque-tighten the valve cover bolts to 24 ± 4 Nm (18
± 3 ft-lb) in the sequence shown.

Note: The bolt springs provide even tension on the

valve cover gasket.
Note: Install the engine cover if removed for clearance.

24 ± 4 Nm
(18 ± 3 ft-lb)
T2022732
Volvo Trucks North America
Service Bulletin

D
42
Date
3.2007
Group
214
No.
93

Inspect the crossover pipe V-band clamps for wear or

damage, replace as necessary. Position the crossover
pipe (with new O-rings) between the venturi outlet
pipe and the mixer inlet pipe. Lubricate V-band clamp
threads and v-inserts.
Page
16(19)

W2005960
1 Venturi Outlet Pipe
2 Crossover Pipe
3 Mixer Inlet Pipe

43
Secure the V-band clamp at each end of the crossover
pipe and tighten the clamps to specification.

Note: Make sure the O-rings remain in place while

positioning the pipe.

W2005804

44
Remove the strap used to temporarily hold the air
compressor discharge line. Connect the discharge line
to the air compressor and secure the pipe mounting
brackets to the cylinder head.

45
Install the air compressor fresh air pipe to the air
compressor. Secure the mounting brackets to the
cylinder head.

46
Install the aftertreatment fuel injector harness clips on
the valve cover.
Volvo Trucks North America
Service Bulletin

D 47
Date
3.2007
Group
214
No.
93

Install the fasteners securing crankcase ventilation

tube and bracket to valve cover and intake manifold.
Torque-tighten fasteners to 24 ± 4 Nm (18 ± 3 ft-lb).

Note: Inspect the crankcase ventilation tube O-ring

and replace if necessary.

Note: Ensure that the same bolts that were removed

at disassembly are reinstalled in the same location.
Page
17(19)

Damage to the valve cover will result if the bolts installed

are too long.

24 ± 4 Nm
(18 ± 3 ft-lb)

W2006122

48
Position the air filter housing against the cab and install
fasteners to secure.

W2003858

49
Install the main fresh air pipe between the air filter
housing and the turbocharger air inlet elbow. Position
the clamps and tighten to secure.

W2006005
Volvo Trucks North America
Service Bulletin

D
50
Date
3.2007
Group
214
No.
93
Page
18(19)

Install the air compressor fresh air hose to the main fresh
air pipe, position the clamp and tighten to secure.

W2004719

51
Install the air temperature sensor connector to the sensor.
Insert and secure the connector lock tab. Install the
sensor harness clamp to the main fresh air pipe.

W2004720

52
Connect and secure the air filter restriction gauge wiring
harness to air filter housing.

W2003861
Volvo Trucks North America
Service Bulletin

D
53
Date
3.2007
Group
214
No.
93

Install all previously removed cables to the ground

(negative) battery terminals.
Page
19(19)

W2003815

54
Start the engine, check for leaks and proper operation.

55
Bring the engine to normal operating temperature. Let
the engine idle for approximately 5 minutes; the system
performs its own cylinder balancing in order to attain
even idling.

Note: During cylinder balancing, do not use any form of

power-consuming equipment, such as power take-off or
air conditioning.