Service Bulletin Volvo Trucks North America D … Engine Manuals/D13/Valves...Service Bulletin Volvo Trucks North America ... (28 ± 3 ft-lb) 21 ... Volvo Trucks North America D Date

DService BulletinVolvo Trucks North AmericaGreensboro, NC USA

Date Group No. Page

3.2007 214 93 1(19)

Trucks

Valves and Unit injectorsAdjustment

D13F

Valves and Unit Injectors, Adjustment

W2005941

This information covers the correct procedure for adjusting the valves and unit injectorson 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 engineversion. However, key components addressed in this information are represented asaccurately as possible.

PV776-20177326 USA22955.ihval

DVolvo Trucks North America Date Group No. Page

Service Bulletin 3.2007 214 93 2(19)

ToolsSpecial Tools

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

W0001924 T0012612 W0000416

3949521VEB Shim Kit

88800014Flywheel Turning Tool

85111377Feeler Gauge Set

T0010788 W0002414 W0001790

9989876Dial Indicator (or Equivalent)

85111493Dial Indicator Angled Extension

(or Equivalent)

9999696Magnetic Stand (or Equivalent)



Service ProceduresValves and Unit Injectors, Adjustment

See also:

• “Valves and Unit Injectors, Adjustment” page 1

You must read and understand the precautions andguidelines in Service Information, group 20, "GeneralSafety Practices, Engine" before performing thisprocedure. If you are not properly trained and certifiedin this procedure, ask your supervisor for trainingbefore you perform it.

Special tools: 3949521, 9989876, 9999696,85111493, 85111377, 88800014

1Apply the parking brake and place the shift leverin neutral.

2

W2003815

Remove all cables from ground (negative) batteryterminals to prevent personal injury from electrical shock.

3

W2003861

Disconnect and remove the air filter restriction gaugewiring harness from air filter housing.



4

W2004720

Unplug the air temperature sensor wiring harnessconnector. Remove the lock tab and separate theconnector from the sensor. Remove the sensor harnessclamp from the main fresh air pipe.

5

W2004719

Loosen the air compressor fresh air hose clamp.



6

W2006005

Loosen the clamps and remove the main fresh air pipefrom the air compressor fresh air hose, the air filterhousing and the turbocharger air inlet elbow.

7

W2003858

Remove the fasteners and lift the air filter housingaway from the cab.



8

W2005960

1 Venturi Outlet Pipe2 Crossover Pipe3 Mixer Inlet Pipe

Loosen the V-clamps and remove the EGR crossoverpipe.

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

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

11

W2006122

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



12Disconnect the discharge line and mounting bracketsfrom the air compressor. Move the discharge air lineout of the way and strap in place.

13

T2022732

Remove the spring-loaded bolts from the valve cover.

14Lift and remove the valve cover.

Note: Rotate the valve cover as needed, to clear thecamshaft gear and damper.

Note: Dependent upon chassis, engine cover may needto be removed for clearance to remove valve cover.

15

W2005753

Loosen the fasteners retaining the leaf springs to releasespring tension on the Volvo Engine Brake (VEB) rockerarms.



16

W0002368

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

88800014

17

W2006171

Camshaft markings for setting of valves and unitinjectors:

• Without VEB: Markings 1–6 apply to adjustment ofinlet valves, exhaust valves and unit injectors.

• With VEB: Markings 1–6 apply to adjustment of inletvalves and unit injector.

Markings E1–E6 apply to adjustment of exhaust valves.

Valve and Injector Settings

CamPosition

Injector Intake/Exhaust

Exhaust(VEB)

VEBRocker

5 X X

E6 X X

3 X X

E2 X X

6 X X

E4 X X

2 X X

E1 X X

4 X X

E5 X X

1 X X

E3 X X



Intake Valves, Adjustment (with or withoutVEB)

18Using the flywheel turning tool, rotate the engine to thenext camshaft marking for adjustment of the intake valve.Rotate the engine until the valve and injector mark on thefront end of the camshaft aligns with the stamped markon the camshaft front bearing cap.

19

T2023322

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

20Tighten the locknut on the plunger by holding theadjusting screw in place and torque-tighten the locknut to38 ± 4 Nm (28 ± 3 ft-lb).

38 ± 4 Nm(28 ± 3 ft-lb)

21Recheck the valve clearance after the nut is tightened.

Note: Mark the rocker arm when the valve has beenadjusted.



Unit Injector, Adjustment

22To adjust the injector on the same cylinder location,loosen the locknut and back off the adjusting screw until itno longer makes contact.

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

24

T2023323

Tighten the adjusting screw four flats or 240 degrees ofclockwise rotation.

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

52 ± 4 Nm(38 ± 3 ft-lb)



Exhaust Valves (without VEB), Adjustment

26

T2022277

Continue adjustment on the same cylinder location bychecking the exhaust rocker valve clearance. Push downon the back of the exhaust rocker and insert a feelergauge of the proper specification of 0.80 mm (0.031 inch)between the bridge and the adjustment screw. If theexhaust rocker requires adjustment, loosen the locknut onthe rocker and adjust the plunger.

27Tighten the locknut on the plunger by holding theadjusting screw in place and torque-tighten the locknut to38 ± 4 Nm (28 ± 3 ft-lb).

38 ± 4 Nm(28 ± 3 ft-lb)

28Recheck valve clearance after the locknut is tightened.




Exhaust Valves (VEB), Adjustment

29

W2006171

Using the flywheel turning tool, rotate the engine tothe next camshaft marking (number plus “E”) for theadjustment of the exhaust valves.

30

T2023324

VEB Exhaust Bridge Shim Check:

• Push down on the back of the exhaust rocker andinsert a feeler gauge of the proper specification of 1.00± 0.05 mm (0.039 ± 0.002 inch) between the bridgeand the brake plunger.

• If clearance is not within specification, adjust theclearance as required, using shims placed on top ofthe valve bridge.

• Remove the shim retaining screw and removethe shim.

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

T2009008

• Determine the thickness of the shim(s) required tomatch 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 areavailable (shim kit No. 3949521) in 0.05 mm(0.002 inch) increments with the thickness markedon the surface. If two shims are required totake up the clearance, the shims should be ofnearly equal thickness.

Allow feeler gauge to remain in place between therocker arm and the valve bridge during the followingbrake rocker check.

394952138 ± 4 Nm(28 ± 3 ft-lb)



31

W2006212

Engine Brake Rocker Adjust:

• Loosen the locknut on the brake rocker arm “A”.• 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 indicatorextension to set onto the valve bridge as close to thebrake rocker plunger as possible.

• Tighten the adjusting screw “B” clockwise until thedial indicator shows that the valve bridge has beenpressed down by 0.60 ± 0.05 mm (0.024 ± 0.002 inch).

• Loosen the adjusting screw “B” counterclockwise 720degrees (two revolutions).

• Torque-tighten retention locknut “A” to 52 ± 4 Nm (38± 3 ft-lb).

• Remove the dial indicator, magnetic stand and feelergauge.

9989876, 85111493, 999969652 ± 4 Nm(38 ± 3 ft-lb)

32

W2005815

VEB Engine Brake Check:Check the engine brake rocker arm clearance betweenthe rocker arm roller and the camshaft with the 3.6 mmfeeler gauge 85111377.

• With the dial indicator, magnetic stand and feelergauge removed, insert a shim and feeler gaugebetween the camshaft lob and the rocker arm roller.

• Clearance between the camshaft and rocker rollershould meet a specification of 3.60 ± 0.10 mm (0.142± 0.004 inch).

• If the clearance is not within the specification, theadjustment must be repeated per the previousadjustment.

85111377

33Recheck valve clearance after the locknut is tightened.


34Repeat the above procedure to adjust all other unitinjectors and valve locations by rotating the engine to thenext nearest camshaft mark.



35

W0002368

Adjust the inlet, exhaust and unit injectors using thepattern outlined in the chart below. Use the flywheelturning tool (88800014) to advance the engine to thenext setting.

Valve and Injector Settings

CamPosition

Injector Intake/Exhaust

Exhaust(VEB)

VEBRocker

5 X X

E6 X X

3 X X

E2 X X

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

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

37

T2022951

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

25 ± 3 Nm(18 ± 2 ft-lb)



38Clean the gasket sealing surface of the valve cover andthe cylinder head. The surfaces should be clear of anydirt or debris and free of any oil.

39

W2005162

Carefully inspect the valve cover gasket for damage andreplace with a new gasket if necessary. Make sure thatthe gasket is properly seated and follows the contourof the channel.

40

W2005157

Apply a 2 mm (0.079 inch) bead of Volvo sealant to thearea 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 headand make sure that the seal remains properly seated.

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

41

T2022732

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 thevalve cover gasket.

Note: Install the engine cover if removed for clearance.

24 ± 4 Nm(18 ± 3 ft-lb)



42

W2005960

1 Venturi Outlet Pipe2 Crossover Pipe3 Mixer Inlet Pipe

Inspect the crossover pipe V-band clamps for wear ordamage, replace as necessary. Position the crossoverpipe (with new O-rings) between the venturi outletpipe and the mixer inlet pipe. Lubricate V-band clampthreads and v-inserts.

43

W2005804

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

Note: Make sure the O-rings remain in place whilepositioning the pipe.

44Remove the strap used to temporarily hold the aircompressor discharge line. Connect the discharge lineto the air compressor and secure the pipe mountingbrackets to the cylinder head.

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

46Install the aftertreatment fuel injector harness clips onthe valve cover.



47

W2006122

Install the fasteners securing crankcase ventilationtube 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-ringand replace if necessary.

Note: Ensure that the same bolts that were removedat disassembly are reinstalled in the same location.Damage to the valve cover will result if the bolts installedare too long.

24 ± 4 Nm(18 ± 3 ft-lb)

48

W2003858

Position the air filter housing against the cab and installfasteners to secure.

49

W2006005

Install the main fresh air pipe between the air filterhousing and the turbocharger air inlet elbow. Positionthe clamps and tighten to secure.



50

W2004719

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

51

W2004720

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

52

W2003861

Connect and secure the air filter restriction gauge wiringharness to air filter housing.



53

W2003815

Install all previously removed cables to the ground(negative) battery terminals.

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

55Bring the engine to normal operating temperature. Letthe engine idle for approximately 5 minutes; the systemperforms its own cylinder balancing in order to attaineven idling.

Note: During cylinder balancing, do not use any form ofpower-consuming equipment, such as power take-off orair conditioning.

Documents

Service Bulletin Volvo Trucks North America D … Engine Manuals/D13/Valves...Service Bulletin Volvo Trucks North America ... (28 ± 3 ft-lb) 21 ... Volvo Trucks North America D Date