Service Bulletin

Greensboro, NC USA
Date Group No. Release Page
This service bulletin replaces bulletin 214-93 dated 7.2013. 11.2014 214 93 03 1(13)

Valves and Engine injectors, Adjustment

D13
Valves and Engine Injectors, Adjustment

W2005941

This information covers the correct procedure for adjusting the valves and engine injectors on
VOLVO D13 engines.

Contents
• “Special Tools”, page 2

• “Valves and Engine 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 engine
version. However, key components addressed in this information are represented as
accurately as possible.

PV776-89174547
USA67432 English
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2014 214 93 03 2(13)

Tools
Special Tools
For special tools ordering instructions, refer to Tool Information, Function Group 08.

T0012612

W0000416

88800014 85111377 or 88880053

Flywheel Turning Tool Feeler Gauge Set

W2055377

88880052 (part of set 88880053)

Feeler Gauges
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Service Bulletin 11.2014 214 93 03 3(13)

Service Procedures
2140-05-03-01
Valves and Engine Injectors, Adjustment
Valve cover removed
You must read and understand the precautions and guide-
lines in Service Information, Function Group 20, "Engine
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.

DANGER
Do not attempt to repair or service this vehicle without suf-
ficient training, the correct service literature and the proper
tools. Failure to follow this could make the vehicle unsafe
and lead to serious personal injury or death.

DANGER
Before working on a vehicle, set the parking brake, place
the shift lever in Neutral, and block the wheels. Failure to
do so can result in unexpected vehicle movement and can
cause serious personal injury or death.

Special tools: 3949521, 85111377 or

88880053, 88800014, 88880052
1
Remove the plug from the lower right side of the flywheel
housing and install the flywheel turning tool.

88800014

W0002368
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Service Bulletin 11.2014 214 93 03 4(13)

2
Remove the fasteners retaining the leaf springs to release
spring tension on the engine brake rocker arms. Remove leaf
springs.

W2005753
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Service Bulletin 11.2014 214 93 03 5(13)

3
Camshaft Marks for Setting Valves and Engine Injectors

• Without engine brake: Markings 1–6 apply to adjustment

of inlet valves, exhaust valves and engine injectors.

• With engine brake: Markings 1–6 apply to adjustment of

inlet valves and engine injector. Markings E1–E6 apply to
adjustment of exhaust valves.

Valve and Injector Settings with Engine Brake

Cam Injector Intake/ Exhaust Engine

Position Exhaust Engine Brake
Brake Rocker
5 X X
E6 X X

W2006171
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

Valve and Injector Settings without Engine Brake

Cam Injector Intake Exhaust

Position
5 X X X
3 X X X
6 X X X
2 X X X
4 X X X
1 X X X

Note: The “V” markings on the camshaft are for cylinder TDC
reference only and are not used for valve adjustment.
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Service Bulletin 11.2014 214 93 03 6(13)

Intake Valves Adjustment (with or without en-

gine brake)
4
Using the flywheel turning tool, 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 cam-
shaft front bearing cap.
Note: Engine must be rotated in the normal direction of oper-
ation when advancing to the next mark.

5
With the engine cold (140°F or less), check the intake valve
clearance. Push down on the back of the rocker and insert a
feeler gauge of the proper specification, 0.20 ± 0.05 mm
(0.008 ± 0.002 inch), between the bridge and the adjustment
screw. If the inlet rocker requires adjustment, loosen the lock
nut on the rocker and adjust the plunger.

T2023322

6
Hold the adjusting screw to prevent it from turning and tighten
the adjusting screw lock nut to 38 ± 4 Nm (28 ± 3 ft-lb).

7
Check the valve clearance again after the nut is tightened.
Note: Mark the rocker arm when the valve has been
adjusted.
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Service Bulletin 11.2014 214 93 03 7(13)

Engine Injector Adjustment

8
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.

9
Adjust the engine injector's rocker arm to zero clearance.
Note: The spring must not be compressed. There should not
be any movement of the spring.

10
Tighten the adjusting screw an additional four flats or 240 de-
grees of clockwise rotation.

T2023323

11
Tighten the adjusting screw lock nut to
52 ± 4 Nm (38 ± 3 ft-lb).
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Service Bulletin 11.2014 214 93 03 8(13)

Exhaust Valves Adjustment (without engine

brake)
12
Continue adjustment on the same cylinder location by check-
ing the exhaust rocker valve clearance. Push down on the
back of the exhaust rocker and insert a 0.80 ± 0.05 mm
(0.031 ± 0.002 inch) feeler gauge between the bridge and the
adjustment screw. If the exhaust rocker requires adjustment,
loosen the lock nut on the rocker and adjust the plunger.

T2022277

13
Hold the adjusting screw to prevent it from turning and tighten
the adjusting screw lock nut to 38 ± 4 Nm (28 ± 3 ft-lb).

14
Check valve clearance again after the lock nut is tightened.
Note: Mark the rocker arm when the valve has been
adjusted.
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Service Bulletin 11.2014 214 93 03 9(13)

Exhaust Valves Adjustment (with engine brake,

with or without shims)
15
Using the flywheel turning tool, rotate the engine to the next
camshaft marking (number plus “E”) for the adjustment of the
exhaust valves. Adjust the exhaust and brake rocker on the
cylinder number following the "E".

W2006171

16
Push down on the back of the exhaust rocker and insert a
1.00 ± 0.05 mm (0.039 ± 0.002 inch) feeler gauge between
the bridge and the brake plunger.

T2023324

17
If clearance is not within specification, adjust the clearance
as required, using shims placed on top of the valve bridge.
For engines without shims, loosen the lock nut on the rocker
and adjust the plunger. Hold the adjusting screw to prevent it
from turning and tighten the adjusting screw lock nut to
38 ± 4 Nm (28 ± 3 ft-lb).
Note: For engines without shims, go to Step 22.

18
Remove the shim retaining screw and remove the shim.
Note: When loosening or tightening the shim retaining screw
to change the shim, the yoke must be kept fixed with a tool to
avoid bending the valve stem.

19
Make sure that the valve bridge and shim(s) are clean.
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Service Bulletin 11.2014 214 93 03 10(13)

20
Determine the thickness of the shim(s) required to match the
measured clearance.
Note: DO NOT use more than two shims. Shims are avail-
able in 0.05 mm (0.002 inch) increments with the thickness
marked on the surface. If two shims are required to take up
the clearance, the shims should be of nearly equal thickness.

3949521 (Shim Kit)

T2009008

21
Place the shim(s) in position on the valve yoke, install the re-
taining screw and tighten to 38 ± 4 Nm (28 ± 3 ft-lb).
Note: When loosening or tightening the shim retaining screw
to change the shim, the yoke must be kept fixed with a tool to
avoid bending the valve stem.

22
Check valve clearance again after lock nut is tightened or
shim is fastened. Allow feeler gauge to remain in place be-
tween the exhaust rocker arm and the valve bridge during
the following engine brake rocker check.

Engine Brake Rocker Adjustment (with or with-

out shims)
23
Using a 2.5 mm feeler gauge, check the exhaust brake rock-
er arm clearance by placing the feeler gauge between the
brake rocker arm roller and the cam lobe. The clearance
should be 2.5 ± 0.07 mm (0.1 ± 0.003 inch).
Note: 1.00 ±0.05 mm feeler gauge should still be between
exhaust rocker arm and valve bridge.

88880053

W2005815
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Service Bulletin 11.2014 214 93 03 11(13)

24
If the clearance is not within specification, loosen the brake
rocker arm lock nut (A) and turn the adjuster screw (B) 1/2 to
1 turn counter-clockwise. With the 2.5 mm feeler gauge in po-
sition between the rocker arm roller and cam lobe, tighten the
adjuster screw (B) until it makes contact and then a further
1/2 turn until the valve yoke clearly moves down and the ex-
haust valve opens slightly. The engine brake mechanism is
now preloaded.

T2027091

25
Loosen the adjusting screw slowly until the 2.5 mm gauge
can be pushed in and out with some effort. Hold the adjusting
screw to prevent it from turning and tighten the lock nut to
52 ± 4 Nm (38 ± 3 ft-lb).

Engine Brake Check

26
Allow 1.00 ± 0.05 mm (0.039 ± 0.002 inch) feeler gauge to re-
main in place between the exhaust rocker arm and the valve
bridge during the following brake rocker check.

27
Check the engine brake rocker arm clearance between the
rocker arm roller and the camshaft with the 2.5 mm feeler
gauge between the camshaft lobe and the rocker arm roller.

88880053

W2005815
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Service Bulletin 11.2014 214 93 03 12(13)

28
Clearance between the camshaft and rocker roller should
meet a specification of 2.5 ± 0.07 mm (0.1 ± 0.003 inch).

29
If the clearance is not within the specification, the adjustment
must be repeated per the previous adjustment.

30
Check valve clearance again after the lock nut is tightened.
Note: Mark the rocker arm when the valve has been
adjusted.

31
Remove the feeler gauge from between the exhaust rocker
arm and valve bridge. Check the clearance between the
camshaft and the brake rocker roller using a 3.20 mm shim -
this shim should pass with no resistance. If there is resist-
ance then the adjustment is incorrect. Repeat the adjustment
procedure.

32
Repeat the above procedure to adjust all other engine injec-
tors and valve locations by rotating the engine to the next
nearest camshaft mark.

W0002368

33
After all engine injectors and valves have been checked and
adjusted if necessary, clean the valve cover contact surface
on the cylinder head.

34
For engines with engine brake, install brake rocker leaf
springs and tighten the retaining screws on the exhaust rock-
er arms to 25 ± 3 Nm (18 ± 2 ft-lb). Ensure that the brake
rocker arm push rod is centered and properly seated into leaf
spring socket before tightening retaining screws.

T2022951
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Service Bulletin 11.2014 214 93 03 13(13)

35
Install the valve cover. Refer to Function Group 211, “Valve
Cover, Replacement”, for this procedure.

36
Bring the engine to normal operating temperature. Let the en-
gine 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.