Volvo Trucks North America, Inc.

Greensboro, NC USA
TSI
Date Group No. Supp. Page
This TSI Service Bulletin replaces TSI Service Bulletin
214–013, “Valves, D12C” (11.2001), publication no. 7.2004 214 020 1(9)
PV776–TSP160587.
Valve and Injector Adjustment with EPG
D12, D12A, D12B, D12C
Valve and Injector Adjustment with EPG

W2003805

This information covers procedures for adjusting valves and injectors on VOLVO D12,
D12A, D12B, and D12C engines.

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.

PV776-20 006218 USA15092

Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 020 2(9)

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.

C0000220 W0000416

9996956 J41610
Cranking tool Feeler Gauge Set

Other Special Equipment

Like special tools, the following items can be ordered directly from Volvo. Please refer to
the specific tool number when ordering.

C2001260

1159794
Torque Wrench
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 020 3(9)

Service Procedures
2140-05-03-01
Valves and Unit Injectors, Adjustment
(Valve cover removed.)

You must read and understand the precautions and

guidelines in Service Information, group 20, "General
Safety Practices" before performing this procedure.
If you are not properly trained and certified in this
procedure, ask your supervisor for training before
you perform it.

T2008968

Note: Variant abbreviations are used to identify an engine

equipped with the following components:

EPG Exhaust Pressure Governor

Special tools: 9996956, J41610

Other special equipment: 1159794
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 020 4(9)

1
Remove the flywheel inspection cover located under
the engine flywheel housing. Install engine turning
tool 9996956.

9996956

C2000183

2
Turn the engine to the camshaft marking to adjust the
corresponding valve (for example, no. 5, as shown in
illustration), as indicated below:

• Marking 1 – 6: Apply to adjustment of valve bridge

intake valves, exhaust valves, and unit injector.

Example:
Adjustments for no. 5 intake clearances, no. 5 injector
preload, and no. 5 exhaust valve clearances would be
made in this engine position.

T2006771
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TSI 7.2004 214 020 5(9)

Valve and Unit injector, adjustment

3
Loosen lock nut and back off adjusting screw until it no
longer makes contact with the injector socket.
Note: Adjust injector before adjusting intake and
exhaust valves.

Valve and Injector Settings

Cam Injector Intake Exhaust
Position
1 X X X
5 X X X
3 X X X
6 X X X
2 X X X
W2004460
4 X X X

4
Adjust the unit injector’s adjusting screw to zero
clearance.

5
Tighten the adjusting screw 4 flats or 240 .

6
Torque-tighten the adjusting screw lock nut to
52 ± 4 Nm (38 ± 3 ft-lb).

Note: Mark the rocker arm and injector rocker when each
valve has been adjusted.

52 ± 4 Nm
(38 ± 3 ft-lb)
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 020 6(9)

Intake and Exhaust Valve Bridge Adjustment

7

T2019496

Valve bridge with guide

W2004467

Valve bridge without guide

Note: A valve bridge design (without guide pin) is used in

D12 engines. These may be installed in combination
with the current valve bridge design with guide pin. The
procedure for adjusting valves remains the same, except
that the valve bridge without guide pin does not need
adjusting. Valve clearances are also unchanged. For
intake valves, the valve bridge without guide pin may
be installed facing either direction. A valve bridge with
guide pin must always be installed as a replacement
component.
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 020 7(9)

Intake and Exhaust Valve Bridge Adjustment

8

W2004433

CAUTION
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 or damage to the
valve bridge guide.

Note: The valve bridge adjustment can only be made

when there is clearance between the valve bridge
and the rockerarm.

Adjust the valve bridge clearance:

• Loosen the adjusting screw lock nut.

• Loosen adjusting screw until it no longer contacts
valve stem.
• Press valve bridge downward toward the valve stem.
• Tighten adjusting screw until it makes contact, then
turn an additional 1 flat or 60 .
• Hold adjusting screw in place and torque-tighten nut to
38 ± 3 Nm (28 ± 2 ft-lb).
W2004468

38 ± 3 Nm
(28 ± 2 ft-lb)

9
Recheck valve clearance after nut is torque-tightened.

10
Rotate the engine to the next cylinder mark on the
camshaft. Adjust unit injector, valve bridges, intake and
exhaust valves on that cylinder.
Volvo Trucks North America, Inc. Date Group No. Page
TSI 7.2004 214 020 8(9)

11
With engine cold (140 F or less), adjust the valve
clearance for exhaust to 0.5 mm (0.020 in.). Hold
adjusting screw in place and torque-tighten lock nut to 38
± 3 Nm (28 ± 2 ft-lb).

Note: Mark each valve rocker lever as you adjust it to

know which valves have already been adjusted.

W2003805

Intake Valves, adjustment

12
With engine cold (140 F or less), adjust valve clearance
to 0.2 mm (0.008 in.). Hold adjusting screw in place and
torque-tighten lock nut to 38 ± 3 Nm (28 ± 2 ft-lb).
Note: Mark each valve rocker lever as you adjust it to
know which valves have already been adjusted.

38 ± 3 Nm
(28 ± 2 ft-lb)

T2008968
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TSI 7.2004 214 020 9(9)

13
Use steps 3 - 13 to adjust the injectors and valves.

Valve Clearance, Cold Engine Setting Valve

Inlet 0.2 mm (0.008 in.)
Exhaust 0.5 mm (0.020 in.)

Valve Clearance, Cold Engine Check Valve

Inlet 0.15 – 0.25 mm (0.006 – 0.010 in.)
Exhaust 0.45 – 0.55 mm (0.018 – 0.22 in.)

Valve and Injector Settings

Cam Injector Intake Exhaust
Position
1 X X X
5 X X X
3 X X X
6 X X X
2 X X X
4 X X X