Volvo Trucks North America Greensboro, NC USA
D
This Service Bulletin replaces SB 214-52. “Valves and Unit Injectors, Adjustment, D16D” (09.2006), publication no. PV776–20177406.
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Valves and Unit injectors Adjustment D16D
Valves and Unit Injectors, Adjustment This information covers the correct procedure for adjusting the valves and unit injectors on the Volvo D16D engine.
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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.
PV776-20114179
USA26880.ihval
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Tools Special Tools
For special tools ordering instructions, refer to Tool Information, group 08.
85108855 Flywheel Turning Tool Adapter
9996956 Flywheel Turning Tool
85109245 Front Engine Turning Tool
88800014 Flywheel Turning Tool
85109037 Feeler Gauge Set
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Service Procedures 2140-05-02-03 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 Begin removing the air filter housing by disconnecting the air filter restriction gauge wiring harness.
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4 Remove the wiring harness clamps (3) and tie straps (upper portion of housing). Secure the harness away from the air filter housing.
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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.
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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.
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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.
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9 Loosen the two upper bolts at the top of the air filter housing.
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10 Lift the air filter housing (with fresh air pipe attached) away from the cab.
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11 Disconnect the breather tube from the side of the valve cover.
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12 Remove the engine wiring harness support bracket from the front of the valve cover.
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13 Remove the spring- loaded attaching bolts from the valve cover.
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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. 85108855, 9996956, 85109245, 88800014
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16 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.
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17 Camshaft markings for setting of valves and unit injectors: Valve and Injector Settings Cam Position
Injector
Intake
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 V3
Exhaust VCB
X X
X
X X
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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.
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38 ± 4 Nm (28 ± 3 ft-lb) 20 With the engine cold (engine temperature of approximately 60 C (140 F), 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). 38 ± 4 Nm (28 ± 3 ft-lb)
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21 Recheck the valve clearance after the nut is tightened. Note: Mark the rocker arm when the valve has been adjusted.
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Unit Injector, Adjustment 22 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.
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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). 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). 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.
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Exhaust Valves, Volvo Compression Brake (VCB), Adjustment 28 Using the flywheel turning tool, rotate the engine to the next camshaft marking (number plus “V”) for the adjustment of exhaust valves. 29
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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.
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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 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). 38 ± 4 Nm (28 ± 3 ft-lb)
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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). 38 ± 4 Nm (28 ± 3 ft-lb) 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.
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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
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Cam Position
Injector
Intake
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 V3
Exhaust VCB
X X
X
X 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 1161231–4) to the parting lines of the cylinder head and the timing cover. Note: This step is very critical to ensure no oil leaks occur.
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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). 24 ± 3 Nm (18 ± 2 ft-lb)
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42 Remove flywheel turning tool 85108855 with gear 9996956. Reinstall the inspection cover. Note: Option for turning the flywheel on later production vehicles: 85109245 for VT trucks and 88800014 for VN and VT. 85108855, 9996956, 85109245, 88800014
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43 Install the engine electrical wiring harness support brackets to the front of the valve cover. Tighten the bolts.
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44 Install a new breather tube O-ring and position the breather tube against the side of the valve cover.
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45 Connect the breather tube to the side of the valve cover.
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46 Position the air filter housing (with fresh air pipe attached) against the cab.
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47 Install the two bolts at the top of the air filter housing.
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48 Install the main fresh air pipe to the turbocharger. Tighten the clamps.
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49 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.
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50 Install the fresh air pipe to the air compressor tube.
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51 Install the wiring harness clamps to the air filter housing.
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52 Connect the air restriction gauge wiring harness.
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53 Reconnect electrical power to the vehicle by turning on the main switch or by reconnecting the batteries. 54 Start the engine. 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.
