Volvo Trucks North America

Greensboro, NC USA

D Service Bulletin
Date

3.2007
Trucks
Group

214
No.

93

Valves and Unit injectors

Adjustment
D13F
Page

1(19)

Valves and Unit Injectors, Adjustment

W2005941

This information covers the correct procedure for adjusting the valves and unit injectors
on 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 engine
version. However, key components addressed in this information are represented as
accurately as possible.

PV776-20177326 USA22955.ihval
Volvo Trucks North America
Service Bulletin

Special Tools
Tools
D Date
3.2007

For special tools ordering instructions, refer to Tool Information, group 08.
Group
214
No.
93
Page
2(19)

W0001924 T0012612 W0000416

3949521 88800014 85111377

VEB Shim Kit Flywheel Turning Tool Feeler Gauge Set

T0010788 W0002414 W0001790

9989876 85111493 9999696

Dial Indicator (or Equivalent) Dial Indicator Angled Extension Magnetic Stand (or Equivalent)
(or Equivalent)
Volvo Trucks North America
Service Bulletin

Service Procedures
D
Valves and Unit Injectors, Adjustment
See also:

•
Date
3.2007
Group
214
No.
93

“Valves and Unit Injectors, Adjustment” page 1

Page
3(19)

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: 3949521, 9989876, 9999696,

85111493, 85111377, 88800014
1
Apply the parking brake and place the shift lever
in neutral.

2
Remove all cables from ground (negative) battery
terminals to prevent personal injury from electrical shock.

W2003815

3
Disconnect and remove the air filter restriction gauge
wiring harness from air filter housing.

W2003861
Volvo Trucks North America
Service Bulletin

D
4
Date
3.2007
Group
214
No.
93

Unplug the air temperature sensor wiring harness

connector. Remove the lock tab and separate the
Page
4(19)

connector from the sensor. Remove the sensor harness

clamp from the main fresh air pipe.

W2004720

5
Loosen the air compressor fresh air hose clamp.

W2004719
Volvo Trucks North America
Service Bulletin

D 6
Date
3.2007
Group
214
No.
93

Loosen the clamps and remove the main fresh air pipe
from the air compressor fresh air hose, the air filter
housing and the turbocharger air inlet elbow.
Page
5(19)

W2006005

7
Remove the fasteners and lift the air filter housing
away from the cab.

W2003858
Volvo Trucks North America
Service Bulletin

D
8
Date
3.2007
Group
214
No.
93

Loosen the V-clamps and remove the EGR crossover

pipe.
Page
6(19)

W2005960
1 Venturi Outlet Pipe
2 Crossover Pipe
3 Mixer Inlet Pipe

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

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

11
Remove the fasteners which secure crankcase ventilation
tube and bracket to valve cover and intake manifold.
Relocate the tube away from the manifold.

W2006122
Volvo Trucks North America
Service Bulletin

D 12
Date
3.2007
Group
214
No.
93

Disconnect the discharge line and mounting brackets

from the air compressor. Move the discharge air line
out of the way and strap in place.

13
Remove the spring-loaded bolts from the valve cover.
Page
7(19)

T2022732

14
Lift and remove the valve cover.

Note: Rotate the valve cover as needed, to clear the

camshaft gear and damper.

Note: Dependent upon chassis, engine cover may need

to be removed for clearance to remove valve cover.

15
Loosen the fasteners retaining the leaf springs to release
spring tension on the Volvo Engine Brake (VEB) rocker
arms.

W2005753
Volvo Trucks North America
Service Bulletin

D
16
Date
3.2007
Group
214
No.
93
Page
8(19)

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

88800014

W0002368

17
Camshaft markings for setting of valves and unit
injectors:

• Without VEB: Markings 1–6 apply to adjustment of

inlet valves, exhaust valves and unit injectors.

• With VEB: Markings 1–6 apply to adjustment of inlet

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

Valve and Injector Settings

Cam Injector Intake/ Exhaust VEB
Position Exhaust (VEB) Rocker
5 X X
E6 X X
3 X X
E2 X X
W2006171
6 X X
E4 X X
2 X X
E1 X X
4 X X
E5 X X
1 X X
E3 X X
Volvo Trucks North America
Service Bulletin

D Date
3.2007
Group
214
No.
93

Intake Valves, Adjustment (with or without

VEB)
18
Page
9(19)

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 camshaft front bearing cap.

19
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 locknut on the rocker and adjust the plunger.

T2023322

20
Tighten the locknut on the plunger by holding the
adjusting screw in place and torque-tighten the locknut to
38 ± 4 Nm (28 ± 3 ft-lb).

38 ± 4 Nm
(28 ± 3 ft-lb)

21
Recheck the valve clearance after the nut is tightened.

Note: Mark the rocker arm when the valve has been
adjusted.
Volvo Trucks North America
Service Bulletin

D Date
3.2007

Unit Injector, Adjustment

22
Group
214
No.
93

To adjust the injector on the same cylinder location,

Page
10(19)

loosen the locknut and back off the adjusting screw until it
no longer makes contact.

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

24
Tighten the adjusting screw four flats or 240 degrees of
clockwise rotation.

T2023323

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

52 ± 4 Nm
(38 ± 3 ft-lb)
Volvo Trucks North America
Service Bulletin

D Date
3.2007
Group
214
No.
93

Exhaust Valves (without VEB), Adjustment

26
Continue adjustment on the same cylinder location by
Page
11(19)

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 0.80 mm (0.031 inch)
between the bridge and the adjustment screw. If the
exhaust rocker requires adjustment, loosen the locknut on
the rocker and adjust the plunger.

T2022277

27
Tighten the locknut on the plunger by holding the
adjusting screw in place and torque-tighten the locknut to
38 ± 4 Nm (28 ± 3 ft-lb).

38 ± 4 Nm
(28 ± 3 ft-lb)

28
Recheck valve clearance after the locknut is tightened.

Note: Mark the rocker arm when the valve has been
adjusted.
Volvo Trucks North America
Service Bulletin

D
29
Date
3.2007
Group
214

Exhaust Valves (VEB), Adjustment

No.
93

Using the flywheel turning tool, rotate the engine to

the next camshaft marking (number plus “E”) for the
adjustment of the exhaust valves.
Page
12(19)

W2006171

30
VEB Exhaust Bridge Shim Check:

• Push down on the back of the exhaust rocker and

insert a feeler gauge of the proper specification of 1.00
± 0.05 mm (0.039 ± 0.002 inch) between the bridge
and the brake plunger.
• If clearance is not within specification, adjust the
clearance as required, using shims placed on top of
the valve bridge.

• Remove the shim retaining screw and remove

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

T2023324
• Determine the thickness of the shim(s) required to
match 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 are
available (shim kit No. 3949521) 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.
T2009008

Allow feeler gauge to remain in place between the

rocker arm and the valve bridge during the following
brake rocker check.

3949521
38 ± 4 Nm
(28 ± 3 ft-lb)
Volvo Trucks North America
Service Bulletin

D 31
Date
3.2007
Group
214

Engine Brake Rocker Adjust:

•
•
•
No.
93

Loosen the locknut on the brake rocker arm “A”.

Page
13(19)

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 indicator
extension to set onto the valve bridge as close to the
brake rocker plunger as possible.
• Tighten the adjusting screw “B” clockwise until the
dial indicator shows that the valve bridge has been
pressed down by 0.60 ± 0.05 mm (0.024 ± 0.002 inch).
• Loosen the adjusting screw “B” counterclockwise 720
degrees (two revolutions).
• Torque-tighten retention locknut “A” to 52 ± 4 Nm (38
± 3 ft-lb).
• Remove the dial indicator, magnetic stand and feeler
gauge.

9989876, 85111493, 9999696

52 ± 4 Nm
(38 ± 3 ft-lb)
W2006212

32
VEB Engine Brake Check:
Check the engine brake rocker arm clearance between
the rocker arm roller and the camshaft with the 3.6 mm
feeler gauge 85111377.

• With the dial indicator, magnetic stand and feeler

gauge removed, insert a shim and feeler gauge
between the camshaft lob and the rocker arm roller.
• Clearance between the camshaft and rocker roller
should meet a specification of 3.60 ± 0.10 mm (0.142
± 0.004 inch).
• If the clearance is not within the specification, the
adjustment must be repeated per the previous
adjustment.

W2005815 85111377

33
Recheck valve clearance after the locknut is tightened.

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

34
Repeat the above procedure to adjust all other unit
injectors and valve locations by rotating the engine to the
next nearest camshaft mark.
Volvo Trucks North America
Service Bulletin

D
35
Date
3.2007
Group
214
No.
93

pattern outlined in the chart below. Use the flywheel

turning tool (88800014) to advance the engine to the
next setting.

Valve and Injector Settings

Cam
Position
Injector Intake/
Exhaust
Exhaust
(VEB)
VEB
Rocker
Page
14(19)

Adjust the inlet, exhaust and unit injectors using the

5 X X
E6 X X
3 X X
E2 X X
W0002368
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

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

37
For engines with VEB, tighten the leaf spring retaining
screws on the exhaust rocker arms to 25 ± 3 Nm (18 ±
2 ft-lb).

25 ± 3 Nm
(18 ± 2 ft-lb)

T2022951
Volvo Trucks North America
Service Bulletin

D 38
Date
3.2007
Group
214

dirt or debris and free of any oil.

39
No.
93
Page
15(19)

Clean the gasket sealing surface of the valve cover and

the cylinder head. The surfaces should be clear of any

Carefully inspect the valve cover gasket for damage and

replace with a new gasket if necessary. Make sure that
the gasket is properly seated and follows the contour
of the channel.

W2005162

40
Apply a 2 mm (0.079 inch) bead of Volvo sealant to the
area 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 head
and make sure that the seal remains properly seated.

Note: This step is very critical to ensure no oil leaks

occur.

W2005157

41
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 the

valve cover gasket.
Note: Install the engine cover if removed for clearance.

24 ± 4 Nm
(18 ± 3 ft-lb)
T2022732
Volvo Trucks North America
Service Bulletin

D
42
Date
3.2007
Group
214
No.
93

Inspect the crossover pipe V-band clamps for wear or

damage, replace as necessary. Position the crossover
pipe (with new O-rings) between the venturi outlet
pipe and the mixer inlet pipe. Lubricate V-band clamp
threads and v-inserts.
Page
16(19)

W2005960
1 Venturi Outlet Pipe
2 Crossover Pipe
3 Mixer Inlet Pipe

43
Secure the V-band clamp at each end of the crossover
pipe and tighten the clamps to specification.

Note: Make sure the O-rings remain in place while

positioning the pipe.

W2005804

44
Remove the strap used to temporarily hold the air
compressor discharge line. Connect the discharge line
to the air compressor and secure the pipe mounting
brackets to the cylinder head.

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

46
Install the aftertreatment fuel injector harness clips on
the valve cover.
Volvo Trucks North America
Service Bulletin

D 47
Date
3.2007
Group
214
No.
93

Install the fasteners securing crankcase ventilation

tube 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-ring

and replace if necessary.

Note: Ensure that the same bolts that were removed

at disassembly are reinstalled in the same location.
Page
17(19)

Damage to the valve cover will result if the bolts installed

are too long.

24 ± 4 Nm
(18 ± 3 ft-lb)

W2006122

48
Position the air filter housing against the cab and install
fasteners to secure.

W2003858

49
Install the main fresh air pipe between the air filter
housing and the turbocharger air inlet elbow. Position
the clamps and tighten to secure.

W2006005
Volvo Trucks North America
Service Bulletin

D
50
Date
3.2007
Group
214
No.
93
Page
18(19)

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

W2004719

51
Install the air temperature sensor connector to the sensor.
Insert and secure the connector lock tab. Install the
sensor harness clamp to the main fresh air pipe.

W2004720

52
Connect and secure the air filter restriction gauge wiring
harness to air filter housing.

W2003861
Volvo Trucks North America
Service Bulletin

D
53
Date
3.2007
Group
214
No.
93

Install all previously removed cables to the ground

(negative) battery terminals.
Page
19(19)

W2003815

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

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.