21412 2 valves and injectors adjustment veb

7/23/2019 21412 2 Valves and Injectors Adjustment VEB

1/21

21413-2 Valves and Unit Injectors, Adjustment

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, 85108855, 85109037, 85109245, 88800014

1

Apply the parking brake and place the shift lever in neutral.

2

Disconnect electrical power from the vehicle by turning off the main switch or by disconnecting the

batteries.

3

Chassis ID Path

21/Repair/VNL, VERSION2, D16D535/Valves and Injectors, Adjustment

Model Identity

VN 112344223

Publishing Date Operation No

Friday, July 13, 2007 21413-2

1 / 21

Copyright Volvo Group North America

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

IMPACT 3.0 Friday, March 25, 2011


2/21

Begin removing the air filter housing by disconnecting the air filter restriction gauge wiring harness.

4

Remove the wiring harness clamps (3) and tie straps (upper portion of housing). Secure the

harness away from the air filter housing.

5

Loosen the fresh air pipe to air compressor hose clamp and reposition out of the way.

6

Remove the fresh air pipe from the air compressor tube.

2 / 21





3/21

7

Unplug the air temperature sensor wiring harness connector. First, remove the lock tab, then

separate the connector from the sensor. Remove the wire harness clamp.

8

Loosen the clamp from the main fresh air pipe to the turbocharger. Pull the pipe away from the

turbocharger and air compressor fresh air pipe.

9

3 / 21





4/21

Loosen the two upper bolts at the top of the air filter housing.

10

Lift the air filter housing (with fresh air pipe attached) away from the cab.

11

4 / 21





5/21

Disconnect the breather tube from the side of the valve cover.

12

Remove the engine wiring harness support bracket from the front of the valve cover.

13

5 / 21





6/21

Remove the spring- loaded attaching bolts from the valve cover.

14

Lift and remove the valve cover.

15

Assemble the flywheel turning tool as follows:

Remove the snap ring and gear from tool 9996956. Assemble the gear from 9996956 into adapter

tool 85108855 and install the snap ring. Lubricate gear with engine oil or grease before attemptingto turn the flywheel.

Note: Option for turning the flywheel on later production vehicles: 85109245 for VT trucks and 88800014 for VN and VT.

Special tools:85108855 9996956 85109245 88800014

16

6 / 21





7/21

Remove the inspection cover from the bottom of the flywheel housing and install the flywheel

turning tool (85108855 with gear 9996956). Remove the rubber plug in later models for engine

turning tool 88800014.

17

Camshaft markings for setting of valves and unit injectors:

Valve and Injector Settings

Cam

Position

Injector Intake Exhaust

Non

VCB

Exhaust

VCB

5 X X X

V6 X

3 X X X

V2 X

6 X X X

V4 X

2 X X X

V1 X

4 X X X

V5 X

1 X X X

7 / 21





8/21

V3 X

Intake Valves, Adjustment

18

Using the flywheel turning tools, 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

Does not apply to valve bridge without locating pin (non-adjustable):

Begin adjustment by loosening the bridge jam nuts at the valve location of the intended

adjustment.

Loosen the adjusting screw until it no longer contacts the valve stem.Press the valve bridge downward toward the valve stem.

Tighten the adjusting screw until it makes contact, then turn an additional 1 flat or 60 degrees.

Hold the adjusting screw in place and torque-tighten the nut to 38 4 Nm (28 3 ft-lb).

Note: 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 of the valve bridge guide.

Specifications:

38 4 Nm (28 3 ft-lb)

8 / 21





9/21

20

With the engine cold (engine temperature of approximately 60C (140F), continue adjustment on

the same inlet rocker by checking the valve clearance. Push down on the back of the rocker and

insert a feeler gauge of the proper specification of 0.3 0.05 mm (0.012 0.002 in.) between the

bridge and the adjustment screw. If the inlet rocker requires adjustment, loosen the lock nut on the

rocker and adjust the plunger. Tighten the lock on the plunger by holding the adjusting screw in

place and torque-tighten the lock nut to 38 4 Nm (28 3 ft-lb).

Specifications:

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.

Unit Injector, Adjustment

22

9 / 21





10/21

To adjust the injector on the same cylinder location, loosen the lock nut 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 4 flats or 240 degrees of clockwise rotation.

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

Specifications:

52 4 Nm (38 3 ft-lb)

Exhaust Valves, Exhaust Pressure Governor (EPG), Adjustment

26

If the exhaust rocker requires adjustment, loosen the lock nut on the rocker and adjust the plunger.

Tighten the lock nut on the plunger by holding the adjusting screw in place and torque-tighten the

lock nut to 38 4 Nm (28 3 ft-lb).

Specifications:

38 4 Nm (28 3 ft-lb)

27

Recheck valve clearance after the nut is tightened.

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

Exhaust Valves, Volvo Compression Brake (VCB), Adjustment

10 / 21





11/21

28

Using the flywheel turning tool, rotate the engine to the next camshaft marking (number plus V) for

the adjustment of exhaust valves.

29

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 it makes contact with the valve

stem.

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

Note: Any oil film left inside the piston is released when the piston loosens from the seat. This makes the setting more

exact.

Note: Make sure that the wire or the screwdriver have been well cleaned before they are used. Impurities between the

rocker 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.

30

11 / 21





12/21

Continue adjustment on the same cylinder location by 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

0.6 0.05 mm (0.024 0.002 in.) for non-VCB or

2.3 0.05 mm (0.091 0.002 in.) for VCB. Place the feeler gauge between the bridge and the

plunger. If the exhaust rocker requires adjustment, loosen the lock nut on the rocker and adjust the

plunger. Tighten the lock nut on the plunger by holding the adjusting screw in place and

torque-tighten the lock nut to 38 4 Nm (28 3 ft-lb).

Specifications:

38 4 Nm (28 3 ft-lb)

31

Measure the clearance between the rocker arm's piston and the bridge. Acceptable clearance is 0.6

0.05 mm (0.024 0.002 in.) for non-VCB or

2.3 0.05 mm (0.091 0.002 in.) for VCB.

32

If the valve clearance needs to be adjusted, loosen the lock nut .without moving the adjusting screw

33

With the engine cold, adjust the exhaust valve lash to the above specification and torque-tighten the

locknut to

38 4 Nm (28 3 ft-lb).

Specifications:

38 4 Nm (28 3 ft-lb)

12 / 21





13/21

34

Recheck valve clearance after the nut is tightened.

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

35

Repeat the above procedure to adjust all other unit injectors and valve locations by rotating the

engine to the next nearest camshaft mark.

36

Adjust the inlet, exhaust and unit injectors using the pattern outlined in the chart below. Use the

assembled flywheel turning tool (85108855 with the gear from 9996956) to advance the engine to

the next setting.


Valve and Injector Settings

Cam

Position

Injector Intake Exhaust

Non

VCB

Exhaust

VCB

5 X X X

V6 X

3 X X X

13 / 21





14/21

V2 X

6 X X X

V4 X

2 X X X

V1 X

4 X X X

V5 X

1 X X X

V3 X

37

After all unit injectors and valves have checked and adjusted if necessary, clean the valve cover

contact surface on the cylinder head.

38

Carefully position the valve cover against the cylinder head, making sure that the seal remains

properly seated.

39

Apply a 2 mm bead of Volvo sealant (P/N 11612314) to the parting lines of the cylinder head and

the timing cover.

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

14 / 21





15/21

40

Install the spring-loaded attaching bolts in the valve cover.

Note: The bolt spring provides even tension on the valve cover gasket.

41

Using the proper tightening sequence, torque-tighten the valve cover bolts to 24 3 Nm (18 2

ft-lb).

Specifications:

24 3 Nm (18 2 ft-lb)

42

Remove flywheel turning tool 85108855 with gear 9996956. Reinstall the inspection cover.

15 / 21





16/21


Special tools:85108855 9996956 85109245 88800014

43

Install the engine electrical wiring harness support brackets to the front of the valve cover. Tighten

the bolts.

44

Install a new breather tube O-ring and position the breather tube against the side of the valve cover.

45

16 / 21





17/21

Connect the breather tube to the side of the valve cover.

46

Position the air filter housing (with fresh air pipe attached) against the cab.

47

17 / 21





18/21

Install the two bolts at the top of the air filter housing.

48

Install the main fresh air pipe to the turbocharger. Tighten the clamps.

49

18 / 21





19/21

Install the air temperature sensor connector to the sensor. Insert and secure the connector lock tab.

Install the harness clamp to secure the sensor harness.

50

Install the fresh air pipe to the air compressor tube.

51

19 / 21





20/21

Install the wiring harness clamps to the air filter housing.

52

Connect the air restriction gauge wiring harness.

53

Reconnect electrical power to the vehicle by turning on the main switch or by reconnecting the

batteries.

54

Start the engine.

55

20 / 21





21/21

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.



21412 2 valves and injectors adjustment veb

Documents