SB- 10057185-2235
Service Program
Volvo Trucks North
America
Greensboro, NC USA
Trucks
Date Group No. Release Page
11.2014 214 019 01 1(18)
Rocker Arms, Replacement
and Injector Re-torque
D16J
VN
SP 214-019, Rocker Arms, Replacement and
Injector Re-torque
(November 2014)
Volvo Trucks has authorized replacement of the exhaust brake rocker arms and injector re-
torque on vehicles built between 09/03/2014 and 10/27/2014 with VOLVO D16J engines. The
engine brake rocker arms must be changed on all vehicles involved in this campaign. Before
proceeding, verify campaign eligibility by checking Service Program status in VDA.
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PV729-SP214-019
USA67687 English
Volvo Trucks North America Date Group No. Release Page
Service Program 11.2014 214 019 01 2(18)
Procedure
You must read and understand the precautions and guidelines 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.
Special tools: 9989876, 9999696, 85109035, 85111377, 85111493, 88800014
1 Secure the vehicle for service by parking it on a flat level surface, applying the parking
brake, chocking the rear wheels, and placing the transmission in neutral or park.
2 Disconnect all cables from the negative (ground) battery terminals to prevent personal
injury from electrical shock and prevent damage to electrical components
3 Remove the valve cover. Refer to Function Group 21.
4 Cut the tie straps securing the electrical harness to the engine brake control valve.
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5 Clean around the engine brake control valve and remove the control valve electrical
harness connector from the bottom of the control valve.
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Service Program 11.2014 214 019 01 3(18)
6 Remove the engine brake control valve mounting bolts. Remove the control valve, oil pipe
and valve seal spacer off the cylinder head.
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7 To prevent piston damage when removing the rocker arm shaft, secure the pistons in the
exhaust rocker arms with elastic bands or tie straps so that the pistons do not fall out as
the rocker arm shaft is removed.
Note: Pistons and rocker arms are matched together and should not be mixed during
reassembly.
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Service Program 11.2014 214 019 01 4(18)
8 Use an Allen wrench to remove the fasteners securing the leaf springs to the engine brake
control valve rocker arms. Remove the leaf springs.
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9 Remove the plug from the flywheel housing and install the flywheel turning tool.
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Service Program 11.2014 214 019 01 5(18)
10 Use the flywheel turning tool to rotate the camshaft so it is positioned at top dead center
(TDC). Align the TDC mark on the camshaft with the timing marks on the No. 1 camshaft
bearing cap.
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11 Loosen the jam nuts and back off all rocker arm and fuel injector adjusting screws.
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Service Program 11.2014 214 019 01 6(18)
12 Loosen the rocker arm shaft mounting fasteners (evenly in stages to avoid bending the
shaft) until all the fasteners are removed.
13 Carefully attach the rocker assembly lifting tool to the rocker arm shaft assembly.
14 With the aid of an assistant, remove the rocker arm shaft assembly using the rocker
assembly lifting tool. Place the rocker arm shaft assembly in a secure location until time to
disassemble and inspect the components.
Note: Ensure that the pistons are secured in the exhaust rocker arms with elastic bands so
that the pistons do not fall out as the shaft is removed.
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1. Rocker Assembly Lifting Tool
2. Rocker Arm Shaft Assembly
15 Using the rocker assembly lifting tool and the aid of an assistant, place the rocker arm
shaft assembly on a workbench; remove the lifting tool.
Volvo Trucks North America Date Group No. Release Page
Service Program 11.2014 214 019 01 7(18)
16 Note the position of the rocker arms on the shaft and mark them for reassembly at the
same location. When their positions have been noted, remove all the rocker arms from the
rocker arm shaft.
Note: Check that the pistons in the exhaust rocker arms are fastened with elastic bands or
similar to prevent the pistons from falling out. Pistons and rocker arms are matched sets,
so, the one, two or three punch marks on the rocker arm and piston should correspond.
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17 Discard the exhaust brake rocker arms. Inspect all other rocker arms and replace any that
show signs of wear or damage.
Note: Ensure that the pistons are secured in the new exhaust rocker arms with elastic
bands so that the pistons do not fall out.
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Service Program 11.2014 214 019 01 8(18)
18 Inspect the rocker arm shaft for wear or damage and repair or replace as needed.
19 Lubricate the rocker arms and rocker arm shaft with clean engine oil. When replacing a
rocker arm, lubricate the new rocker arm bearing. Using an oil can, insert the oil can nozzle
into the oil channel hole and rotate the roller while injecting the oil and checking that the oil
comes out on both sides of the roller.
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20 Install all the rocker arms on the rocker arm shaft at the proper locations and check that
they move freely. All reused rocker arms should be installed at their original locations.
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Service Program 11.2014 214 019 01 9(18)
21 Before installing the rocker arm shaft assembly, re-torque the injectors. Loosen the hold
down bolts 100 to 110 degrees until torque is 10 to 15 Nm (7 to 11 ft-lb). Tighten the hold
down bolts to 20 ±5 Nm (15 ±4 ft-lb). Tighten hold down bolts an additional 90 ±5 degrees.
Note: Do not completely loosen the injector hold down bolts to prevent components from
moving. Do not remove the injectors.
22 With all the rocker arms in place on the rocker arm shaft, carefully attach the lifting tool to
the rocker arm shaft assembly.
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1. Rocker Assembly Lifting Tool
2. Rocker Arm Shaft Assembly
23 Before installing the rocker arm shaft assembly on the engine, oil the valve bridges and
camshaft lobes with clean engine oil.
24 Using the rocker assembly lifting tool and the aid of an assistant, position the rocker arm
shaft assembly over the camshaft bearing caps.
25 Remove the rocker assembly lifting tool from the rocker arm shaft assembly.
26 Install the rocker arm shaft mounting bolts by tightening the mounting bolts a little at a time,
evenly across the entire shaft so that the shaft does not become distorted, bent or
fractured.
Note: Verify that the rocker arm shaft is properly seated in the guide dowels of the
camshaft bearing caps.
27 Remove the elastic bands or tie straps retaining the exhaust rocker arm pistons.
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Service Program 11.2014 214 019 01 10(18)
28 To ensure that the rocker arm shaft, camshaft bearing caps and bearing saddles are fully
seated, tighten all camshaft bearing cap and rocker arm shaft bolts to specification.
Tighten the bolts in the numbered steps to make sure that the rocker arm shaft is installed
without bending or distortion.
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Step 1. Tighten bolts 1–7 to 1.5 ± 3 Nm (11 ± 2 ft-lb)
Step 2. Angle tighten bolts 1–7 to 90 ± 5 degrees
Step 3. Tighten bolts 11, 10, 12, 9, 13, 8 in gradual steps to contact, then tighten to 100
± 10 Nm (74 ± 7 ft-lb)
Step 4. Tighten bolts 15–20 to 50 ± 5 Nm (37 ± 4 ft-lb)
Step 5. Tighten bolt 21 to 6.0 ± 5 Nm (44 ± 4 ft-lb)
Step 6. Angle tighten bolts 15–20 to 120 ± 5 degrees
Step 7. Angle tighten bolt 21 to 100 ± 5 degrees
Step 8. Loosen bolts 8–13
Step 9. Tighten bolts 8–13 to 50 ± 5 Nm (37 ± 4 ft-lb)
Step 10. Angle tighten bolts 8–13 to 120 ± 5 degrees
Volvo Trucks North America Date Group No. Release Page
Service Program 11.2014 214 019 01 11(18)
29 Replace the O-ring at the bottom of the engine brake control valve, if equipped.
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30 Clean the engine brake control valve oil pipe and replace the O-rings. Lubricate the oil pipe
hole in the rocker arm shaft and the O-rings on the oil pipe.
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Service Program 11.2014 214 019 01 12(18)
31 Insert the oil pipe into the oil hole of the engine brake control valve. Make sure that the oil
pipe O-ring is fully seated in the engine brake control valve.
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32 Install a new engine brake control valve seal spacer onto the cylinder head. Make sure
that the seal spacer is correctly seated with the lip of the spacer against the cylinder head.
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33 Position the engine brake control valve on the cylinder head.
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Service Program 11.2014 214 019 01 13(18)
34 Align the engine brake control valve with the seal spacer.
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35 Align the engine brake control valve oil pipe and O-ring with the hole in the rocker shaft.
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36 Install the engine brake control valve bolts and tighten to 20 ± 3 Nm (15 ± 2 ft-lb). Make
sure the engine brake control valve oil pipe O-ring is fully seated in the valve and rocker
arm shaft.
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Service Program 11.2014 214 019 01 14(18)
37 At the bottom of the engine brake control valve, plug in the control valve harness electrical
connector.
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38 Position the fuel injector electrical harness over the engine brake control valve and secure
with tie straps.
39 Before adjusting the valves, verify that the camshaft alignment marks are between the two
lines on the camshaft bearing cap.
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Service Program 11.2014 214 019 01 15(18)
40 Adjust the valves and injectors. Refer to Function Group 21. Use the flywheel turning tool
as needed to rotate the engine.
41 Place the leaf springs in position on the camshaft bearing caps and install the fasteners.
Tighten the fasteners to 25 ± 3 Nm (18 ± 2 ft-lb).
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42 Remove the flywheel turning tool from the flywheel housing and install the dust plug.
43 Carefully inspect the valve cover gasket for damage and replace with a new gasket if
necessary. Make sure that the gasket is properly seated in the valve cover channel and
follows the contour of the channel.
44 Apply a 2 mm (0.079 inch) bead of approved sealant across the parting line between the
timing gear cover and the cylinder head. This parting line is on both sides of the cylinder
head.
Note: This step is critical to prevent leaks.
Note: The valve cover must be installed within 20 minutes of applying the sealant to the
parting line area.
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Service Program 11.2014 214 019 01 16(18)
45 Carefully position the valve cover on the cylinder head, making sure that the gasket
remains properly seated.
46 Install the spring-loaded fasteners in the valve cover and tighten in sequence to 24 ±3 Nm
(18 ±2 ft-lb).
Note: The fastener springs provide even tension on the valve cover gasket.
T2022732
47 Place the engine wiring harness and support bracket in position at the front of the valve
cover and install the mounting screws to secure the bracket.
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Service Program 11.2014 214 019 01 17(18)
48 Inspect the crankcase ventilation tube O-ring and replace if necessary. Lubricate the O-
ring.
49 Position the crankcase ventilation tube onto the valve cover. Install the fasteners and
tighten to 24 ± 3 Nm (18 ± 2 ft-lb). Install the clamp to secure the tube to the inlet manifold.
50 Connect the air compressor discharge line and tighten the fitting to 130 ± 20 Nm (96 ± 15
ft-lb). Install the clamp to secure the line to the bracket on the inlet manifold.
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51 Install all components removed to access the valve cover.
52 Install all previously removed cables to the ground (negative) battery terminals.
53 Start the engine. Check for proper operation and leaks.
Volvo Trucks North America Date Group No. Release Page
Service Program 11.2014 214 019 01 18(18)
Reimbursement
This repair is covered by an authorized Service UCHP eWarranty
Program. Reimbursement is obtained via the Reimburse- Reimburse-
normal claim handling process. ment ment
Claim Type (used only when uploading from the B B
Dealer Bus. Sys.)
Recall Status
Vehicle inspected, repair not required 1- Inspected
OK
Vehicle repaired per instruction 2- Modified
per instruction
Labor Code
Primary Labor Code 2145-03-09-01 21445-0-02
4.2 hrs 4.2 hrs.
Take to take charge and determine campaign status 1700–16–01–01 17003–0–01
0.3 hrs 0.3 hrs
Causal Part 21415409 21415409
Parts Disposition
All parts to be scraped locally
SCC Code S6506 NA
Authorization Number NA SP214019
Expiration Date 1-July-2015 1-July-2015
Note: Take Charge Time is not included in the Labor Code for this operation. Take charge
may be eligible but can only be used once per repair visit. If vehicle is having other warranty
repairs performed, take charge should be charged to the warranty repair, otherwise take
charge can be charged to this service program.
