Camshaft, Service

Volvo Trucks North America Greensboro, NC USA

D

Service Service Bulletin Bulletin Trucks

This Service Bulletin replaces SB 215-01. “Camshaft, Service” (7.2006), publication no. PV776-20 031696

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215

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Camshaft Service D16D

Camshaft, Service

W2005134

This information covers the proper replacement and wear check procedures for the camshaft on the Volvo D16D engine along with replacing (overhauling) factory or previously replaced camshaft bearing saddles and caps.

Contents • “Camshaft, Replacement” page 3 Replacement” page 29 • “Camshaft Bearing, Replacement” Wear, Checking” page 31 31 • “Camshaft Wear, Note: The Note: The illustrations are used for several different variants and there will be differences between details in the illustrations and the vehicle you are working with. The essential information in the illustrations is, however, always correct.

PV776-20114181

USA26882.ihval

Volvo Trucks North America Service Bulletin

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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.

W0002295

C0000823

W0001405

85109035 Rocker Assembly Lift Tool

85109034 Camshaft Lifting Tool

W2005150

W2005151

85109033A Timing Cover Clamp Tool (Straight)

85109033B Timing Cover Clamp Tool (Bent)

9989683 Dial Indicator

W0002267

T0012612

85108855 Flywheel Turning Tool Adapter Use only gear from tool 9996956

88800014 Alternate Flywheel Turning Tool

C0000220

9996956 Flywheel Turning Tool Use only gear of this tool with adapter 85108855

9999696 Magnetic Stand

C0001436

W0002279 W0002268

85109208 Bearing Cap Press Tool

88800031 Sensor Depth Gauge

W0002313

85109980 Bearing Cap Puller Use with slide hammer 9990013

W0001814

J44514-B Camshaft Alignment Tool Kit


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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.

W0002295

C0000823

W0001405

85109035 Rocker Assembly Lift Tool

85109034 Camshaft Lifting Tool

W2005150

W2005151

85109033A Timing Cover Clamp Tool (Straight)

85109033B Timing Cover Clamp Tool (Bent)

9989683 Dial Indicator

W0002267

T0012612

85108855 Flywheel Turning Tool Adapter Use only gear from tool 9996956

88800014 Alternate Flywheel Turning Tool

C0000220

9996956 Flywheel Turning Tool Use only gear of this tool with adapter 85108855

9999696 Magnetic Stand

C0001436

W0002279 W0002268

85109208 Bearing Cap Press Tool

88800031 Sensor Depth Gauge

W0002313

85109980 Bearing Cap Puller Use with slide hammer 9990013

W0001814

J44514-B Camshaft Alignment Tool Kit


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Service Procedures 2154-03-02-01 Camshaft, Replacement You must read and understand the precautions and guidelines in Service Information, group 20, "General Safety Practices, Engine" before performing any procedure. If you are not properly trained and certified in this procedure, ask your supervisor for training before you perform it.

Special Special tools: 85109034, 85109034, 85109035, 85109035, 9996956, 85108855, 88800014, 85109980, 9999696, J47450, 85109208, 85109033A, 85109033B, 9989683, 88800031

Removal 1 Disconnect power from the vehicle by turning off the main switch or by disconnecting the batteries. 2 Unplug the air filter restriction gauge wiring harness connector.

W2003860

3 Remove the wiring harness clamps. Move the harness out of the way.

W2003861


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4 Loosen the clamp and detach the air compressor pipe hose from the main fresh air pipe.

W2004719

5 Loosen the fresh air pipe clamp at the turbocharger and detach the pipe.

W2004721

6 Detach the air temperature sensor harness connector (located on the fresh air pipe). Pull out the lock and cut the tie strap. Remove the bolt and clamp securing the sensor harness to the fresh air pipe.

W2004720


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7 Remove the two upper bolts at the top of the air filter housing.

W2003858

8 Lift the air filter housing away from the cab.

W2003859

9 Dependent upon chassis, remove the splash guard and the fender extender as an assembly, if required.

W2005189

1 Two fender extender bolts at rear bracket 2 Two fender extender bolts at brace 3 One fender extender brace bolt and nut at hood release 4 One splash guard bolt at frame 5 Two splash guard bolts at upper brace


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10 Remove the clamp at both ends and remove the charge air pipe between the turbocharger and charge air cooler.

W2004686

11 Remove the crankcase ventilation breather tube from the valve cover.

W2004680

12 Remove the engine cover (back section) from inside the cab to access the rear of the engine. 13 Remove the valve cover spring-loaded mounting bolts.

T2020552

14 Lift and remove the valve cover.


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15 Cut the tie straps of the injector harness at the top of the Volvo Compression Brake (VCB) control valve, if equipped.

W2004836

16 Clean around the VCB control valve. Unplug the control valve electrical connector.

W2004837

17 Remove the bolts securing the VCB control valve to the cylinder head.

W2004838


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18 Remove the VCB control valve, along with the pipe between the valve and rocker arm shaft.

W2004839

19 Remove the VCB control valve seal spacer from the cylinder head.

W2004840

20 Remove the inspection cover from the bottom of the flywheel housing. Install the flywheel turning tool. Note: Use the adapter plate that corresponds with the flywheel housing. Assemble the rotating gear and snap ring to the adapter plate. Using grease, lubricate the gear and the adapter before assembly. 9996956, 85108855, 88800014

W2005139


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21 Turn the flywheel until the piston in cylinder No. 1 is at Top Dead Center (TDC), with zero degrees on the flywheel and the TDC/V3 marking on the camshaft between the markings on the bearing cap.

W2005076

22 Disconnect the camshaft position sensor harness connector, remove the bolt and pull out the sensor.

W2005104

23 Remove the timing gear cover above the flywheel housing. 24 Secure the pistons in the exhaust rocker arms using rubber bands (or tie straps) to prevent piston damage. Note: Pistons and rocker arms are matched together and should not be mixed.

W2005107


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25 Loosen the jam nuts and back off the rocker adjusting screws. 26 Loosen the rocker arm shaft bolts evenly along the length of the shaft to avoid damage to the assembly. Remove the bolts.

C2001720

27 Attach the lifting tool to the rocker arm shaft and carefully remove the rocker arm assembly. 85109035

W2005077

28 Remove the vibration damper and camshaft timing gear. 29 Mark the camshaft bearing caps (if not factory marked or identified), so that they can be reinstalled in the original bearing saddle locations. Remove the camshaft bearing cap bolts and bearing caps. Use the puller along with the slide hammer to remove the caps. 85109980, 9990013


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30 Carefully remove the camshaft using the lifting tool. Note: If the camshaft is not being replaced, stand the camshaft on end for storage. 85109034

W2005075

31 Remove the intake and exhaust bridges. Note: Keep them in the order of removal for proper reassembly. 32 Remove the bearings from the camshaft bearing saddles on the cylinder head and from the camshaft bearing caps. Inspect the bearing caps and cylinder head bearing saddles for wear or damage.


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Installation

1 Insert the lower camshaft bearings and lubricate them.

W2005237

2 Lower the camshaft carefully into place and remove the lifting tool. Rotate the camshaft by hand to ensure the camshaft is not binding in the lower bearing saddles. 85109034

W2005134

3 Install the camshaft upper bearings into the camshaft bearing caps, lubricate the bearings and install the bearing caps to the respective bearing saddles. Use a soft faced mallet to seat the bearing caps over the dowel pins. 4 Install the exhaust side bearing cap bolts and tighten to 10 Nm (89 in-lb).


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5 Install the bearing cap press tool (2 required) at the number 7 and number 1 bearing caps as shown in the illustration. Note: The tool is used when adjusting the timing gear backlash when the rockershaft assembly is not installed. 85109208

W0002297

6 Make sure the camshaft TDC/V3 marking is aligned between the two line markings on the front camshaft bearing cap.

W2005310

7 Install the camshaft timing gear without the damper using the camshaft alignment spacer block with two bolts. 8 Position the camshaft gear so that the reference hole in the timing gear plate is between the marks on the gear. Insert the alignment tool into the hole in the cylinder head to engage the camshaft gear teeth with the rod of the tool in the slot of the clamp tool. Rotate the camshaft until this occurs. J44514-B

W2005135


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9 If the gear backlash must be adjusted, slightly loosen the adjustable idler gear screws. Install a 0.1 mm (0.004 inch) feeler gauge on the loaded side of the gear and turn the camshaft in a counterclockwise direction to take up the gear lash. Tighten the screws of the adjustable idler gear. Install the clamp from the camshaft alignment tool kit to secure the adjustable idler gear. J44514-B

T2019208

10 Check and adjust the backlash between the camshaft timing gear and the adjustable idler gear. Position the dial indicator against a tooth of the camshaft timing gear and rock the gear back and forth while holding the adjustable gear with the clamp from the kit. Note the value on the dial indicator and compare with the specification of 0.10 ± 0.05 mm (0.004 ± 0.002 inch). 9989683, 9999696, J44514-B

W2005136

11 When the gear backlash is correct, replace all adjustable idler gear bolts, one at a time and tighten to 35 ± 4 Nm (26 ± 3 ft-lb), plus 120 ± 5 degrees rotation. Note: Mark the bolts to aid in tightening the bolts to the degrees rotation specification. 12 Remove the camshaft alignment spacer block from the camshaft timing gear and install the vibration damper and clamp plate using new bolts. Tighten the bolts to 45 ± 5 Nm (33 ± 4 ft-lb), plus 90 ± 5 degrees rotation. Note: Mark the bolts to aid in tightening the bolts to the degrees rotation specification.


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13 Clean the sealing surfaces of the timing gear cover and replace the cover seals.

T2019475

14 Apply sealant in the bottom corners where the timing gear plate and the flywheel housing meet. Also apply sealant at the top of the timing gear plate (in the corner) next to the cylinder head.

W2005102

15 Apply sealant to the mating surfaces of the timing gear cover.

W2005137


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16 Position the timing gear cover, install the fasteners and loosely tighten.

• • •

Install the timing gear cover clamp tools and screw down the tools so that the cover surface is level (flush) with the seal surface on the cylinder head. Tighten the cover bolts to specification. Remove the cover clamp tools.

85109033A, 85109033B

W2005138

17 Oil the valve bridges and the camshaft lobes with engine oil. Install the valve bridges over their respective exhaust and intake valves.

T2007050


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18 Adjust the valve bridge clearance as follows:

• • • •

•

W2004433

Loosen the adjusting screw lock nut. Loose the adjusting screw until it no longer contacts the valve stem. Place downward pressure on the valve bridge. Rotate the adjusting screw until it makes contact with the valve stem and then, turn the screw an additional one flat (60 degrees).

Hold the adjusting screw and tighten the lock nut to 38 ± 3 Nm (28 ± 2 ft-lb).

CAUTION The valve bridge must be adjusted prior to valve clearance adjustment for the related intake or exhaust valve. Failure to do this can result in valve bridge guide pin damage.

W2004468

19 Install the rocker arm assembly. Install and tighten the rocker arm shaft bolts a little at a time, evenly across the entire shaft so that the shaft does not become distorted, bent or fractured. Note: Make sure that the rocker arm shaft is seated properly in the guide dowels of the camshaft bearing caps. On engines equipped with the VCB, remove the restraints (rubber bands or tie straps) securing the exhaust rocker arm pistons. 85109035

W2005077


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20 Torque tighten and angle tighten all camshaft bearing cap and rocker arm shaft bolts in the sequence shown, to the following specification: Note: Tighten the bolts in the following steps to ensure that the rocker arm shaft is fully seated without bending. 1 Torque tighten bolts 1–7 to 15 ± 3 Nm (11 ± 2 ft-lb). 2 Angle tighten bolts 1–7 to 90 ± 5 degrees. 3 Torque tighten bolts 8–13 to 100 ± 10 Nm (74 ± 7 ft-lb). 4 Torque tighten bolts 15–20 to 50 ± 5 Nm (37 ± 4 ft-lb). 5 Torque tighten bolt 21 to 60 ± 5 Nm (44 ± 4 ft-lb). 6 Angle tighten bolts 15–20 to 120 ± 5 degrees. 7 Angle tighten bolt 21 to 100 ± 5 degrees. 8 Loosen bolts 8–13. 9 Torque tighten bolts 8–13 to 50 ± 5 Nm (37 ± 4 ft-lb). 10 Angle tighten bolts 8–13 to 120 ± 5 degrees.

CAUTION Gradually tighten the bolts in two or three steps to avoid damaging the rocker arm shaft.

W2005266

21 Replace the O-ring at the bottom of the VCB control valve.

W2004855


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22 Clean the VCB control valve oil pipe and replace the O-rings. Lubricate the pipe hole in the rocker arm shaft and the O-rings on the pipe.

W2004853

23 Insert the pipe into the oil hole of the VCB control valve. Note: Make sure that the O-ring is seated fully in the valve.

W2004854

24 Position a new VCB control valve seal spacer to the cylinder head. Make sure that the seal spacer is correctly seated with the lip of the spacer facing the cylinder head and correctly aligned in the hole.

W2004840


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25 Position the VCB control valve on the cylinder head.

W2004839

26 Align the VCB valve with the seal spacer on the cylinder head.

W2004856

27 Align the VCB oil tube and O-ring with the hole in the rocker shaft.

W2004857


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28 Install the VCB control valve bolts and tighten to 20 ± 3 Nm (15 ± 2 ft-lb). Note: Make sure the VCB oil tube O-ring is fully seated in the rocker arm shaft.

W2004858

29 Plug-in the VCB control valve harness connector.

W2004837

30 Reposition the fuel injector harness over the VCB control valve and secure with two tie straps. 31 When adjusting the valves, make sure to start off with the camshaft at the TDC/V3 marking between the two lines on the front camshaft bearing cap.

W2005076


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32 Adjust the intake and exhaust valve clearance, as well as the fuel injector preload to specification.

• • • •

Intake Valve Clearance: 0.3 ± 0.05 mm (0.012 ± 0.002 inch) Exhaust Valve Clearance, Non VCB: 0.6 ± 0.05 mm (0.024 ± 0.002 inch) Exhaust Valve Clearance, VCB: 2.3 ± 0.05 mm (0.091 ± 0.002 inch) Fuel Injector Preload: Adjust to zero lash plus 240 degrees clockwise rotation

Valve and Injector Settings

W2005147

Camshaft Position

Fuel Injector

Intake Valve

Exhaust Non VCB

5

X

X

X

V6 3

X X

X

X

V2 6

X X

X

x

V4 2

X X

X

X

V1 4

X X

X

X

V5 1

X X

X

X

V3

33 Remove the flywheel turning tool and install the flywheel inspection cover.

W2005139

Exhaust VCB

X


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34 Check for proper camshaft position sensor clearance using the sensor depth gauge to determine if shims are required for sensor depth. The camshaft position sensor clearance specification is 0.3–1.0 mm (0.011–0.039 inch).

W2005068

1 Rotate the engine until a tooth of the camshaft toothed wheel is aligned with the sensor bore. 2 Insert the tool into the sensor bore until the outer part of the tool is fully seated against the timing gear cover. 3 Loosen the thumb screw of the tool and push the inner part of the tool in until it contacts a tooth of the toothed wheel. 4 Tighten the thumb screw to secure the inner part of the tool. 5 Carefully remove the tool from the camshaft sensor bore and observe the location of steps between the inner and outer portions of the tool:

• • •

Both steps below the surface of the tool = no shims required. One step below the surface of the tool = one shim required. Both steps above the surface of the tool = two shims required.

88800031 35 Install the camshaft position sensor with appropriate shim(s), new O-ring, secure with bolt and plug in harness connector. The camshaft position sensor shim part number is: 20556179

W2005104


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36 Apply a 2mm bead of sealant across the parting line on the valve cover sealing surface between the timing gear cover and the cylinder head.

W2005157

37 Install the valve cover and fasteners and tighten to the specification of 24 ± 3 Nm (18 ± 2 ft-lb).

T2020552

38 Inspect the crankcase ventilation tube O-ring for damage and replace as necessary. Lubricate the O-ring.

W2004681


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39 Install the crankcase ventilation tube to the left side of the valve cover and securely tighten the fasteners.

W2004680

40 Position the air pipe between the turbocharger discharge and the charge air cooler inlet. Position a new clamp at each end of the pipe and tighten to secure.

W2004686

41 Lift the air filter housing into position on the cab.

W2003859


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42 Install the two upper bolts at the top of the air filter housing and tighten to secure.

W2003858

43 Attach the fresh air pipe from the air filter housing to the turbocharger. Position the clamp and tighten to secure.

W2004721

44 Reattach the air temperature sensor (located on the fresh air pipe) harness connector to the sensor. Push in the lock and install a new tie strap to secure the connector. Install the bolt and clamp to secure the sensor harness to the fresh air pipe.

W2004720


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

W2004719

46 Route the air filter restriction gauge wiring harness under the air filter housing and secure with the harness clamps.

W2003861

47 Plug the wiring harness connector into the air filter restriction gauge.


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48 Depending upon chassis, install the left and right splash guard and fender extender as an assembly, if required.

W2005189

1 Two fender extender bolts at rear bracket 2 Two fender extender bolts at brace 3 One fender extender brace bolt and nut at hood release 4 One splash guard bolt at frame 5 Two splash guard bolts at upper brace

49 Check all sensors, tubing, coolant lines, air tubes, hoses, lines, brackets and the various electrical system harnesses and connectors for proper installation and tightness. 50 Install the engine cover. 51 Reconnect the vehicle batteries or turn on the main power switch. 52 Check the coolant level in the cooling system. Make sure the engine oil is at the proper level. 53 Start the engine and let it reach normal operating temperature. Inspect the engine for oil, coolant or fuel leaks.

WARNING When starting the engine, the parking brake must be applied and the gear shift selector should be in neutral.


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2155-03-03-01 Camshaft Bearing, Replacement Camshaft removed

You must read and understand the precautions and guidelines in Service Information, group 20, "General Safety Practices, Engine" before performing any procedure. If you are not properly trained and certified in this procedure, ask your supervisor for training before you perform it.

W2005292

Note: Camshaft bearing housings are numbered 1–7, with matching numbers for upper and lower halves. Be sure to note and mark the corresponding housing numbers and install them in the correct sequence with matched upper and lower halves. When replacing new camshaft bearing housings, numbers should be stamped onto the housing.

W2005291

When replacing factory-installed housings • If a camshaft housing has seized, DO NOT MIX a

•

replacement housing with the original factory-installed housing (bearing saddle and bearing cap). This is because the original housings have been align-bored when the engine was manufactured. ALL 7 HOUSINGS MUST BE REPLACED. When replacing a cylinder head, do not mix new housings with original housings from the old cylinder head. Use only new housings on a replacement cylinder head.


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When replacing/installing previously replaced housings • If there are already replacement housings on the • •

engine, and either half of the housing is damaged, the housings can be replaced individually. If a new replacement bearing housing is used, torque all other bearing housings first, to properly align the new replacement housing. Mark the bearing caps to indicate that aftermarket housings have been installed.

Camshaft, Service

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