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IMPACT 3.

13 February 2008

Printed by:BILLYROWAN

Service
Chassis ID

Path

214/Repair/D12A420 VEB/Valves and


unit injectors, adjust. Valve cover
removed

Model

Identity

FH12

39052968

Publish date

Operation No.

21 February 2006

21414-3

Copyright Volvo Parts Corporation


The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

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IMPACT 3.0

13 February 2008

21414-3 Valves and unit injectors, adjusting


Special tools: 9996956, 9998390
Other special equipment: 9989876, 9999696

Setting marks for engines with VEB


General
1

Setting marks for valves and unit injector

1. Exhaust valves for no. 6 cylinder (VEB)


2. Intake valves and unit injector, no. 5 cylinder

In addition to TDC-top dead centre marking on no. 1 cylinder, there are 12 marks on the camshaft
(2 for each cylinder).
Each marking consists of a number (1-6) and a line marking.
The letter V is stamped in front of six of the number markings.
Only a number marking indicates that the rocker arms for the intake valves and the unit injector, on
Copyright Volvo Parts Corporation
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

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IMPACT 3.0

13 February 2008

the cylinder which corresponds to the number marking is in the position for adjusting when the line
marking on the camshaft is opposite the setting mark on the bearing cap.
The stamped V, together with a number marking indicates that the exhaust valve rocker arm is in
position for adjusting.

Note: If is very important that the line marking on the camshaft is exactly opposite the setting mark on the bearing cap
(tolerance 2 mm) when the valves are being adjusted. Otherwise there is a risk that the rocker arm roller may not lie
against the camshaft basic circle.

Setting mark, bearing cap


2

On later design engines, the camshaft bearing cap has two marks, approx. 5 mm apart.
The camshaft line marking should be between the marks on the bearing cap when carrying out
adjustments on these engines.

Adjusting, general
3

The procedures for adjusting valves and unit injectors deal with the adjustment in the following
order:
Exhaust valves, VEB, adjusting
Intake valves, adjusting
Unit injector, adjusting pre-loading
Copyright Volvo Parts Corporation
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

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IMPACT 3.0

13 February 2008

Note that valves and unit injectors should be adjusted in the order according to the camshaft
marking when the engine is turned over in the direction of rotation.
By adjusting in this order, the crankshaft need not be rotated more than two turns for adjusting all
the valves and unit injectors.
A felt-tip pen can be used to mark the rocker arms that have been checked, alternatively adjusted.

4
Note: If the work is carried out in the truck, make sure that the gear lever is in neutral, the parking brake applied and
that the starting key is in the Off position.
5

Alternative 1. Remove the inspection cover underneath the flywheel and fit cranking tool 9996956.

Special tools: 9996956


6

Copyright Volvo Parts Corporation


The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

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Alternative 2. Remove the fuses for the engine control system and connect up the equipment to
turn over the engine with the starter motor, refer to Procedures when turning the engine over with
the starter motor.

Exhaust valves, VEB, adjusting


7

Copyright Volvo Parts Corporation


The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

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IMPACT 3.0

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Turn the engine over with the starter motor according to the instructions, or crank the flywheel with
tool 9996956, tuntil the nearest line marking for the exhaust valve on the camshaft is opposite the
setting mark on the bearing cap, tolerance 2 mm (alternatively betwen the marks).
Check, via the number marking on the camshaft on which cylinder adjustment is to be carried out.

Note: If tool 9996956 is used to crank the flywheel, make sure that the tool is removed if the engine is to be turned over
with the starter motor.

Special tools: 9996956


8

Copyright Volvo Parts Corporation


The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

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IMPACT 3.0

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Make sure that the camshaft marking which is opposite the setting mark on the bearing cap
concerns the adjustment of the exhaust valves, for example V5.

Adjust to zero clearance on the valve caliper by slackening the adjustment screw so that it does not
lie against the valve stem.
Then screw down the adjustment screw so that it lies against the valve stem, then tighten it a
further flat edge (60). Do not tighten the lock nut.

10
Copyright Volvo Parts Corporation
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

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IMPACT 3.0

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Note: When screwing down the adjustment screw, press the valve caliper down against the valve spindles at the same
time.
It is very important to press on the caliper as near as possible to the adjustment screw, see arrow in the sketch.
11

Copyright Volvo Parts Corporation


The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

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IMPACT 3.0

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Press the rocker arm downwards as shown in the sketch. If there is a springing movement felt in the
rocker arm, pull the rocker arm plunger spring outwards at the same time as the rocker arm is
pressed down to make contact against the valve spindles.
The oil film which may remain behind the plunger is punctured when the plunger lightens from the
seating and the setting will be more accurate.
Use a thick piece of wire or a bent screwdriver to pull out the spring.

Note: Make sure that the wire or screwdriver is properly cleaned before being used.
Dirt between the rocker arm plunger and rocker arm can cause the plunger to fasten resulting in a loss of braking
function on the cylinder.
Make sure that the plunger sliding surface in the rocker arm is not damaged.
12

Measure the valve clearance with a feeler gauge, note the value and compare it with the value in
the specifications.

Note: Turn the rocker arm pressure sleeve so that it does not tip over when carrying out the measurement.

If the valve clearance corresponds with the specifications, torque-tighten the lock nut according to
the specifications.
13

Copyright Volvo Parts Corporation


The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

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If it is necessary to adjust the valve clearance, remove the lock nut and shims, but do not move the
adjustment screw out of position.
Calculate, on the basis of the value, the thickness for the new shims.
Max. two shims may be used.
(Select the shims so that they are both approx. the same thickness, if it is necessary to use two
shims.)

Note: The shims are available in thickness intervals of 0.05 mm and the thickness is stamped on the shims.
14

Make sure that the shims and the valve caliper are well cleaned. Fit the shims and torque-tighten
the adjustment screw lock nut according to the specifications.
Note: Make sure that the adjustment screw is not moved out of position when tightening the nut.
15

Re-check the valve clearance.


Copyright Volvo Parts Corporation
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

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IMPACT 3.0

13 February 2008

16

Adjust the other exhaust valves for VEB in the same manner.

Intake valves, adjusting


17

The intake valves on all engines, both with and without VEB, are adjusted in the same way as the
exhaust valves on engines not equipped with VEB.
Note: Make sure that the marking on the bearing cap is opposite the line marking on the camshaft which indicates
adjustment of intake valves and unit injectors on engines equipped with VEB.

Unit injectors
18
Note: The unit injectors are supplied by two different manufacturers.
Check the manufacture of the unit injectors in the engine in question as the adjusting procedures differ between the
injectors from the different manufacturers.

Unit injector, adjusting pre-loading


19

Check that the camshaft line marking for adjusting the intake valves and unit injector are opposite
the marking on the bearing cap, tolerance 2 mm (alternatively between the marks).
Check, via the number marking on the camshaft on which cylinder unit injector pre-loading is to be
adjusted.
Copyright Volvo Parts Corporation
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

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Note: If tool 9996956 is used to crank the flywheel, make sure that the tool is removed if the engine is to be turned over
with the starter motor.
20

Slacken the adjustment screw and adjust the unit injector rocker arm to zero play against the
crankshaft.
21

Note: Step 21 only applies to Lucas unit injectors.

Preload the unit injector by screwing down the adjustment screw 3-4 flats , (180- 240).
Torque-tighten the lock nut according to the specifications.

22

Copyright Volvo Parts Corporation


The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

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Note: Steps 22 and 23 only apply to Bosch unit injectors.

Place gauge 9998390 on a dial indicator together with a magnetic foot.


Position the dial indicator so that the gauge flange rests against the unit injector spring disc and the
probe is directed towards the flat surface between the spring seat and the fuel valve.

Special tools: 9998390


Other special equipment: 9989876 9999696
23

Copyright Volvo Parts Corporation


The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

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Preload the dial indicator 2-3 mm.


Preload the unit injector by screwing down the adjustment screw until the gauge bottoms against
the flat surface and the dial indicator pointer has stopped.
Torque-tighten the lock nut according to the specifications.

24

Adjust the other unit injectors in the same way.

Function check
25
Copyright Volvo Parts Corporation
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

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Carry out a function check by starting the engine and letting it run until it reaches normal working
temperature.
Then allow the engine to idle for a further 4-10 minutes.
When the idle speed is even, the cylinder balancing system has set the correct fuel volume for the
unit injectors.

Note: Cylinder balancing can only take place as long as no power consuming components, for example a pto, are
engaged.
The exhaust pressure governor must not be activated.
(Remove the el. connection from the solenoid valve if the parking brake is applied.)
If the parking brake is not applied, make sure in some other way that the truck cannot move.
26

Check that no fault codes have been generated. If fault codes have been generated, note the codes
and then erase them. Check that the fault codes are not generated again.

Copyright Volvo Parts Corporation


The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

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