Valves and Unit Injectors, Adjustment

Volvo Trucks North America
Greensboro, NC USA
This Service Bulletin replaces SB 214-52. Valves and

Unit Injectors, Adjustment, D16D (09.2006), publication
no. PV77620177406.
Service Bulletin
Trucks
Date
Group
No.
Page
7.2007
214
52
1(17)
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.
W2004977
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

Service Bulletin
D
Date
Group
No.
Page
7.2007
214
52
2(17)
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

Service Bulletin
Date
Group
No.
Page
7.2007
214
52
3(17)
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.
W2003860

Service Bulletin
Date
Group
No.
Page
7.2007
214
52
4(17)
4
Remove the wiring harness clamps (3) and tie straps
(upper portion of housing). Secure the harness away
from the air filter housing.
W2003861
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.
W2004719
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.
W2004720

Service Bulletin
Date
Group
No.
Page
7.2007
214
52
5(17)
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.
W2004721
9
Loosen the two upper bolts at the top of the air filter
housing.
W2003858
10
Lift the air filter housing (with fresh air pipe attached)
away from the cab.
W2003859
11
Disconnect the breather tube from the side of the valve
cover.
W2004680

Service Bulletin
Date
Group
No.
Page
7.2007
214
52
6(17)
12
Remove the engine wiring harness support bracket from
the front of the valve cover.
W2004679
13
Remove the spring- loaded attaching bolts from the
valve cover.
T2020552
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

Service Bulletin
Date
Group
No.
Page
7.2007
214
52
7(17)
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.
W2005139
17
Camshaft markings for setting of valves and unit
injectors:
Valve and Injector Settings
Cam
Position
Injector
Intake
Exhaust
Non
VCB
V6
3
X
X
V2
6
X
X
V4
2
X
X
V1
4
X
X
V5
1
V3
Exhaust
VCB
X
X
X
X

Service Bulletin
Date
Group
No.
Page
7.2007
214
52
8(17)
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.
T2009075
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)
W2005145
21
Recheck the valve clearance after the nut is tightened.
Note: Mark the rocker arm when the valve has been
adjusted.

Service Bulletin
Date
Group
No.
Page
7.2007
214
52
9(17)
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.
W2005148
23
Adjust the unit injectors 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.

Service Bulletin
Date
Group
No.
7.2007
214
52
Page
10(17)
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
T2009074
Push the rocker arm down as shown. If the rocker arm

springs, the rocker arm pistons 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.
T2009009
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 pistons 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)
W2005146

Service Bulletin
Date
Group
No.
7.2007
214
52
Page
11(17)
31
Measure the clearance between the rocker arms 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.

Service Bulletin
Date
Group
No.
7.2007
214
52
Page
12(17)
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.
VN and VT.
Valve and Injector Settings
W2005139
Cam
Position
Injector
Intake
Exhaust
Non
VCB
V6
3
X
X
V2
6
X
X
V4
2
X
X
V1
4
X
X
V5
1
V3
Exhaust
VCB
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 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.
W2005157

Service Bulletin
Date
Group
No.
7.2007
214
52
Page
13(17)
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)
T2020552
42
Remove flywheel turning tool 85108855 with gear
9996956. Reinstall the inspection cover.
VN and VT.
85108855, 9996956, 85109245, 88800014
W2005139
43
Install the engine electrical wiring harness support
brackets to the front of the valve cover. Tighten the bolts.
W2004679

Service Bulletin
Date
Group
No.
7.2007
214
52
Page
14(17)
44
Install a new breather tube O-ring and position the
breather tube against the side of the valve cover.
W2004681
45
Connect the breather tube to the side of the valve cover.
W2004680
46
Position the air filter housing (with fresh air pipe attached)
against the cab.
W2003859

Service Bulletin
Date
Group
No.
7.2007
214
52
Page
15(17)
47
Install the two bolts at the top of the air filter housing.
W2003858
48
Install the main fresh air pipe to the turbocharger. Tighten
the clamps.
W2004721
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.
W2004720
50
Install the fresh air pipe to the air compressor tube.
W2004719

Service Bulletin
Date
Group
No.
7.2007
214
52
Page
16(17)
51
Install the wiring harness clamps to the air filter housing.
W2003861
52
Connect the air restriction gauge wiring harness.
W2004249

Service Bulletin
Date
Group
No.
7.2007
214
52
Page
17(17)
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.

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What are the steps to remove the air filter housing?

Volvo Trucks North America

This Service Bulletin replaces SB 214-52. Valves and