IMPACT 3.

Friday, March 25, 2011

Chassis ID

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

Model
VN

Identity
112344223

Publishing Date
Friday, July 13, 2007

Operation No.
21413-2

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

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.

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IMPACT 3.0

Friday, March 25, 2011

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

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

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.
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.

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IMPACT 3.0

Friday, March 25, 2011

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.

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.

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.

3 / 21

IMPACT 3.0

Friday, March 25, 2011

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

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.

4 / 21

IMPACT 3.0

Friday, March 25, 2011

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

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.

5 / 21

IMPACT 3.0

Friday, March 25, 2011

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 attempting
to 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

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.

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IMPACT 3.0

Friday, March 25, 2011

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
Injector Intake Exhaust Exhaust
Position
Non
VCB
VCB
5

V6

V2

V4

V1

V5

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.

7 / 21

IMPACT 3.0

V3

Friday, March 25, 2011

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)
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.

8 / 21

IMPACT 3.0

Friday, March 25, 2011

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

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.

9 / 21

IMPACT 3.0

Friday, March 25, 2011

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.

25

Torque-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

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.

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IMPACT 3.0

Friday, March 25, 2011

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

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.

11 / 21

IMPACT 3.0

Friday, March 25, 2011

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)
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.

12 / 21

IMPACT 3.0

Friday, March 25, 2011

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.

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

Valve and Injector Settings

Cam
Injector Intake Exhaust Exhaust
Position
Non
VCB
VCB
5

V6

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.

13 / 21

IMPACT 3.0

Friday, March 25, 2011

V2

V4

V1

V5

V3

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.

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.

14 / 21

IMPACT 3.0

Friday, March 25, 2011

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.
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.

15 / 21

IMPACT 3.0

Friday, March 25, 2011

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

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
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16 / 21

IMPACT 3.0

Friday, March 25, 2011

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

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.

17 / 21

IMPACT 3.0

Friday, March 25, 2011

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

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.

18 / 21

IMPACT 3.0

Friday, March 25, 2011

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

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.

19 / 21

IMPACT 3.0

Friday, March 25, 2011

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
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.

20 / 21

IMPACT 3.0

Friday, March 25, 2011

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.

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.

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