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Volvo Trucks North America

Greensboro, NC USA

This Service Bulletin replaces SB 215-01. Camshaft,


Service (7.2006), publication no. PV776-20 031696 D Service Bulletin
Date

7.2007
Trucks
Group

215
No.

01

Camshaft
Service
D16D
Page

1(31)

Camshaft, Service

W2005134

This information covers the proper replacement and wear check procedures for the
camshaft on the Volvo D16D engine along with replacing (overhauling) factory or
previously replaced camshaft bearing saddles and caps.

Contents
Camshaft, Replacement page 3
Camshaft Bearing, Replacement page 29
Camshaft Wear, Checking page 31

Note: The illustrations are used for several different variants and there will be
differences between details in the illustrations and the vehicle you are working with.
The essential information in the illustrations is, however, always correct.

PV776-20114181 USA26882.ihval
Volvo Trucks North America
Service Bulletin

Special Tools
Tools
D Date
7.2007
Group
215
No.
01

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.
Page
2(31)

W0002295
C0000823
W0001405

85109035 85109034 9999696


Rocker Assembly Lift Tool Camshaft Lifting Tool Magnetic Stand

W2005150 W2005151 C0001436

85109033A 85109033B 9989683


Timing Cover Clamp Tool (Straight) Timing Cover Clamp Tool (Bent) Dial Indicator

C0000220 W0002267 T0012612

9996956 85108855 88800014


Flywheel Turning Tool Flywheel Turning Tool Adapter Alternate Flywheel Turning Tool
Use only gear of this tool with Use only gear from tool 9996956
adapter 85108855

W0002279
W0001814
W0002268

85109208 88800031 J44514-B


Bearing Cap Press Tool Sensor Depth Gauge Camshaft Alignment Tool Kit

W0002313

85109980
Bearing Cap Puller
Use with slide hammer 9990013
Volvo Trucks North America
Service Bulletin

D
Service Procedures
2154-03-02-01
Camshaft, Replacement
Date
7.2007
Group
215
No.
01

You must read and understand the precautions and


guidelines in Service Information, group 20, "General
Safety Practices, Engine" before performing any
Page
3(31)

procedure. If you are not properly trained and certified


in this procedure, ask your supervisor for training
before you perform it.

Special tools: 85109034, 85109035,


9996956, 85108855, 88800014, 85109980,
9999696, J47450, 85109208, 85109033A,
85109033B, 9989683, 88800031

Removal
1
Disconnect power from the vehicle by turning off the main
switch or by disconnecting the batteries.

2
Unplug the air filter restriction gauge wiring harness
connector.

W2003860

3
Remove the wiring harness clamps. Move the harness
out of the way.

W2003861
Volvo Trucks North America
Service Bulletin

D
4
Date
7.2007
Group
215
No.
01

Loosen the clamp and detach the air compressor pipe


hose from the main fresh air pipe.
Page
4(31)

W2004719

5
Loosen the fresh air pipe clamp at the turbocharger and
detach the pipe.

W2004721

6
Detach the air temperature sensor harness connector
(located on the fresh air pipe). Pull out the lock and cut
the tie strap. Remove the bolt and clamp securing the
sensor harness to the fresh air pipe.

W2004720
Volvo Trucks North America
Service Bulletin

D
7
Date
7.2007
Group
215
No.
01

Remove the two upper bolts at the top of the air filter
housing.
Page
5(31)

W2003858

8
Lift the air filter housing away from the cab.

W2003859

9
Dependent upon chassis, remove the splash guard and
the fender extender as an assembly, if required.

W2005189
1 Two fender extender bolts at rear bracket
2 Two fender extender bolts at brace
3 One fender extender brace bolt and nut at
hood release
4 One splash guard bolt at frame
5 Two splash guard bolts at upper brace
Volvo Trucks North America
Service Bulletin

D
10
Date
7.2007
Group
215
No.
01

Remove the clamp at both ends and remove the charge


Page
6(31)

air pipe between the turbocharger and charge air cooler.

W2004686

11
Remove the crankcase ventilation breather tube from
the valve cover.

W2004680

12
Remove the engine cover (back section) from inside the
cab to access the rear of the engine.

13
Remove the valve cover spring-loaded mounting bolts.

T2020552

14
Lift and remove the valve cover.
Volvo Trucks North America
Service Bulletin

D
15
Date
7.2007
Group
215
No.
01

Cut the tie straps of the injector harness at the top of


the Volvo Compression Brake (VCB) control valve, if
equipped.
Page
7(31)

W2004836

16
Clean around the VCB control valve. Unplug the control
valve electrical connector.

W2004837

17
Remove the bolts securing the VCB control valve to
the cylinder head.

W2004838
Volvo Trucks North America
Service Bulletin

D
18
Date
7.2007
Group
215
No.
01

Remove the VCB control valve, along with the pipe


between the valve and rocker arm shaft.
Page
8(31)

W2004839

19
Remove the VCB control valve seal spacer from the
cylinder head.

W2004840

20
Remove the inspection cover from the bottom of the
flywheel housing. Install the flywheel turning tool.

Note: Use the adapter plate that corresponds with the


flywheel housing. Assemble the rotating gear and snap
ring to the adapter plate. Using grease, lubricate the gear
and the adapter before assembly.

9996956, 85108855, 88800014

W2005139
Volvo Trucks North America
Service Bulletin

D
21
Date
7.2007
Group
215
No.
01
Page
9(31)

Turn the flywheel until the piston in cylinder No. 1 is at


Top Dead Center (TDC), with zero degrees on the
flywheel and the TDC/V3 marking on the camshaft
between the markings on the bearing cap.

W2005076

22
Disconnect the camshaft position sensor harness
connector, remove the bolt and pull out the sensor.

W2005104

23
Remove the timing gear cover above the flywheel
housing.

24
Secure the pistons in the exhaust rocker arms using
rubber bands (or tie straps) to prevent piston damage.

Note: Pistons and rocker arms are matched together


and should not be mixed.

W2005107
Volvo Trucks North America
Service Bulletin

D
25

screws.

26
Date
7.2007
Group
215
No.
01

Loosen the jam nuts and back off the rocker adjusting

Loosen the rocker arm shaft bolts evenly along the


length of the shaft to avoid damage to the assembly.
Remove the bolts.
Page
10(31)

C2001720

27
Attach the lifting tool to the rocker arm shaft and carefully
remove the rocker arm assembly.

85109035

W2005077

28
Remove the vibration damper and camshaft timing gear.

29
Mark the camshaft bearing caps (if not factory marked or
identified), so that they can be reinstalled in the original
bearing saddle locations. Remove the camshaft bearing
cap bolts and bearing caps. Use the puller along with the
slide hammer to remove the caps.

85109980, 9990013
Volvo Trucks North America
Service Bulletin

D
30
Date
7.2007
Group
215
No.
01

Carefully remove the camshaft using the lifting tool.

Note: If the camshaft is not being replaced, stand the


camshaft on end for storage.

85109034
Page
11(31)

W2005075

31
Remove the intake and exhaust bridges.

Note: Keep them in the order of removal for proper


reassembly.

32
Remove the bearings from the camshaft bearing saddles
on the cylinder head and from the camshaft bearing caps.
Inspect the bearing caps and cylinder head bearing
saddles for wear or damage.
Volvo Trucks North America
Service Bulletin

D
Installation
1
Date
7.2007
Group
215
No.
01
Page
12(31)

Insert the lower camshaft bearings and lubricate them.

W2005237

2
Lower the camshaft carefully into place and remove the
lifting tool. Rotate the camshaft by hand to ensure the
camshaft is not binding in the lower bearing saddles.

85109034

W2005134

3
Install the camshaft upper bearings into the camshaft
bearing caps, lubricate the bearings and install the
bearing caps to the respective bearing saddles.
Use a soft faced mallet to seat the bearing caps over
the dowel pins.

4
Install the exhaust side bearing cap bolts and tighten to
10 Nm (89 in-lb).
Volvo Trucks North America
Service Bulletin

D
5
Date
7.2007
Group
215
No.
01

Install the bearing cap press tool (2 required) at the


number 7 and number 1 bearing caps as shown in the
illustration.

Note: The tool is used when adjusting the timing gear


Page
13(31)

backlash when the rockershaft assembly is not installed.

85109208

W0002297

6
Make sure the camshaft TDC/V3 marking is aligned
between the two line markings on the front camshaft
bearing cap.

W2005310

7
Install the camshaft timing gear without the damper using
the camshaft alignment spacer block with two bolts.

8
Position the camshaft gear so that the reference hole
in the timing gear plate is between the marks on the
gear. Insert the alignment tool into the hole in the cylinder
head to engage the camshaft gear teeth with the rod
of the tool in the slot of the clamp tool. Rotate the
camshaft until this occurs.

J44514-B

W2005135
Volvo Trucks North America
Service Bulletin

D
9
Date
7.2007
Group
215
No.
01
Page
14(31)

If the gear backlash must be adjusted, slightly loosen the


adjustable idler gear screws. Install a 0.1 mm (0.004
inch) feeler gauge on the loaded side of the gear and turn
the camshaft in a counterclockwise direction to take up
the gear lash. Tighten the screws of the adjustable idler
gear. Install the clamp from the camshaft alignment tool
kit to secure the adjustable idler gear.

J44514-B

T2019208

10
Check and adjust the backlash between the camshaft
timing gear and the adjustable idler gear. Position the dial
indicator against a tooth of the camshaft timing gear and
rock the gear back and forth while holding the adjustable
gear with the clamp from the kit. Note the value on the
dial indicator and compare with the specification of 0.10
0.05 mm (0.004 0.002 inch).

9989683, 9999696, J44514-B

W2005136

11
When the gear backlash is correct, replace all adjustable
idler gear bolts, one at a time and tighten to 35 4 Nm
(26 3 ft-lb), plus 120 5 degrees rotation.

Note: Mark the bolts to aid in tightening the bolts to the


degrees rotation specification.

12
Remove the camshaft alignment spacer block from the
camshaft timing gear and install the vibration damper and
clamp plate using new bolts. Tighten the bolts to 45 5
Nm (33 4 ft-lb), plus 90 5 degrees rotation.
Note: Mark the bolts to aid in tightening the bolts to the
degrees rotation specification.
Volvo Trucks North America
Service Bulletin

D
13
Date
7.2007
Group
215
No.
01
Page
15(31)

Clean the sealing surfaces of the timing gear cover and


replace the cover seals.

T2019475

14
Apply sealant in the bottom corners where the timing
gear plate and the flywheel housing meet. Also apply
sealant at the top of the timing gear plate (in the corner)
next to the cylinder head.

W2005102

15
Apply sealant to the mating surfaces of the timing gear
cover.

W2005137
Volvo Trucks North America
Service Bulletin

D
16
Date
7.2007
Group
215
No.
01
Page
16(31)

Position the timing gear cover, install the fasteners and


loosely tighten.



Install the timing gear cover clamp tools and screw
down the tools so that the cover surface is level (flush)
with the seal surface on the cylinder head.
Tighten the cover bolts to specification.
Remove the cover clamp tools.

85109033A, 85109033B

W2005138

17
Oil the valve bridges and the camshaft lobes with engine
oil. Install the valve bridges over their respective exhaust
and intake valves.

T2007050
Volvo Trucks North America
Service Bulletin

D
18
Date
7.2007
Group
215
No.
01

Adjust the valve bridge clearance as follows:





Loosen the adjusting screw lock nut.
Page
17(31)

Loose the adjusting screw until it no longer contacts


the valve stem.
Place downward pressure on the valve bridge.
Rotate the adjusting screw until it makes contact with
the valve stem and then, turn the screw an additional
one flat (60 degrees).

W2004433
Hold the adjusting screw and tighten the lock nut to 38
3 Nm (28 2 ft-lb).

CAUTION
The valve bridge must be adjusted prior to valve
clearance adjustment for the related intake or exhaust
valve. Failure to do this can result in valve bridge
guide pin damage.

W2004468

19
Install the rocker arm assembly. Install and tighten the
rocker arm shaft bolts a little at a time, evenly across
the entire shaft so that the shaft does not become
distorted, bent or fractured.

Note: Make sure that the rocker arm shaft is seated


properly in the guide dowels of the camshaft bearing
caps. On engines equipped with the VCB, remove the
restraints (rubber bands or tie straps) securing the
exhaust rocker arm pistons.

85109035

W2005077
Volvo Trucks North America
Service Bulletin

D
20
Date
7.2007

following specification:
Group
215
No.
01

Note: Tighten the bolts in the following steps to ensure


Page
18(31)

Torque tighten and angle tighten all camshaft bearing cap


and rocker arm shaft bolts in the sequence shown, to the

that the rocker arm shaft is fully seated without bending.


1 Torque tighten bolts 17 to 15 3 Nm (11 2 ft-lb).
2 Angle tighten bolts 17 to 90 5 degrees.
3 Torque tighten bolts 813 to 100 10 Nm (74 7 ft-lb).
4 Torque tighten bolts 1520 to 50 5 Nm (37 4 ft-lb).
5 Torque tighten bolt 21 to 60 5 Nm (44 4 ft-lb).
6 Angle tighten bolts 1520 to 120 5 degrees.
7 Angle tighten bolt 21 to 100 5 degrees.
8 Loosen bolts 813.
9 Torque tighten bolts 813 to 50 5 Nm (37 4 ft-lb).
10 Angle tighten bolts 813 to 120 5 degrees.

CAUTION
Gradually tighten the bolts in two or three steps to
avoid damaging the rocker arm shaft.

W2005266

21
Replace the O-ring at the bottom of the VCB control valve.

W2004855
Volvo Trucks North America
Service Bulletin

D
22
Date
7.2007
Group
215
No.
01

Clean the VCB control valve oil pipe and replace the
Page
19(31)

O-rings. Lubricate the pipe hole in the rocker arm shaft


and the O-rings on the pipe.

W2004853

23
Insert the pipe into the oil hole of the VCB control valve.

Note: Make sure that the O-ring is seated fully in the


valve.

W2004854

24
Position a new VCB control valve seal spacer to the
cylinder head. Make sure that the seal spacer is correctly
seated with the lip of the spacer facing the cylinder head
and correctly aligned in the hole.

W2004840
Volvo Trucks North America
Service Bulletin

D
25
Date
7.2007
Group
215
No.
01

Position the VCB control valve on the cylinder head.


Page
20(31)

W2004839

26
Align the VCB valve with the seal spacer on the cylinder
head.

W2004856

27
Align the VCB oil tube and O-ring with the hole in the
rocker shaft.

W2004857
Volvo Trucks North America
Service Bulletin

D
28
Date
7.2007
Group
215
No.
01

Install the VCB control valve bolts and tighten to 20


3 Nm (15 2 ft-lb).

Note: Make sure the VCB oil tube O-ring is fully seated
in the rocker arm shaft.
Page
21(31)

W2004858

29
Plug-in the VCB control valve harness connector.

W2004837

30
Reposition the fuel injector harness over the VCB control
valve and secure with two tie straps.

31
When adjusting the valves, make sure to start off with the
camshaft at the TDC/V3 marking between the two lines
on the front camshaft bearing cap.

W2005076
Volvo Trucks North America
Service Bulletin

D
32
Date
7.2007
Group
215
No.
01
Page
22(31)

Adjust the intake and exhaust valve clearance, as well as


the fuel injector preload to specification.




Intake Valve Clearance: 0.3 0.05 mm (0.012
0.002 inch)
Exhaust Valve Clearance, Non VCB: 0.6 0.05 mm
(0.024 0.002 inch)
Exhaust Valve Clearance, VCB: 2.3 0.05 mm
(0.091 0.002 inch)
Fuel Injector Preload: Adjust to zero lash plus 240
degrees clockwise rotation

Valve and Injector Settings


Camshaft Fuel Intake Exhaust Exhaust
Position Injector Valve Non VCB VCB
W2005147 5 X X X
V6 X
3 X X X
V2 X
6 X X x
V4 X
2 X X X
V1 X
4 X X X
V5 X
1 X X X
V3 X

33
Remove the flywheel turning tool and install the flywheel
inspection cover.

W2005139
Volvo Trucks North America
Service Bulletin

D
34
Date
7.2007
Group
215
No.
01

Check for proper camshaft position sensor clearance


using the sensor depth gauge to determine if shims are
Page
23(31)

required for sensor depth. The camshaft position sensor


clearance specification is 0.31.0 mm (0.0110.039 inch).
1 Rotate the engine until a tooth of the camshaft toothed
wheel is aligned with the sensor bore.
2 Insert the tool into the sensor bore until the outer part
of the tool is fully seated against the timing gear cover.
3 Loosen the thumb screw of the tool and push the inner
part of the tool in until it contacts a tooth of the
toothed wheel.
4 Tighten the thumb screw to secure the inner part
of the tool.
5 Carefully remove the tool from the camshaft sensor
bore and observe the location of steps between the
W2005068 inner and outer portions of the tool:

Both steps below the surface of the tool = no shims


required.
One step below the surface of the tool = one shim
required.
Both steps above the surface of the tool = two shims
required.

88800031

35
Install the camshaft position sensor with appropriate
shim(s), new O-ring, secure with bolt and plug in harness
connector.

The camshaft position sensor shim part number is:


20556179

W2005104
Volvo Trucks North America
Service Bulletin

D
36
Date
7.2007
Group
215
No.
01

Apply a 2mm bead of sealant across the parting line


on the valve cover sealing surface between the timing
gear cover and the cylinder head.
Page
24(31)

W2005157

37
Install the valve cover and fasteners and tighten to the
specification of 24 3 Nm (18 2 ft-lb).

T2020552

38
Inspect the crankcase ventilation tube O-ring for damage
and replace as necessary. Lubricate the O-ring.

W2004681
Volvo Trucks North America
Service Bulletin

D
39
Date
7.2007
Group
215
No.
01
Page
25(31)

Install the crankcase ventilation tube to the left side of the


valve cover and securely tighten the fasteners.

W2004680

40
Position the air pipe between the turbocharger discharge
and the charge air cooler inlet. Position a new clamp at
each end of the pipe and tighten to secure.

W2004686

41
Lift the air filter housing into position on the cab.

W2003859
Volvo Trucks North America
Service Bulletin

D
42
Date
7.2007
Group
215
No.
01

Install the two upper bolts at the top of the air filter
housing and tighten to secure.
Page
26(31)

W2003858

43
Attach the fresh air pipe from the air filter housing to the
turbocharger. Position the clamp and tighten to secure.

W2004721

44
Reattach the air temperature sensor (located on the fresh
air pipe) harness connector to the sensor. Push in the
lock and install a new tie strap to secure the connector.
Install the bolt and clamp to secure the sensor harness to
the fresh air pipe.

W2004720
Volvo Trucks North America
Service Bulletin

D
45
Date
7.2007
Group
215
No.
01

Connect the air compressor pipe hose to the main fresh


air pipe, position the clamp and tighten to secure.
Page
27(31)

W2004719

46
Route the air filter restriction gauge wiring harness under
the air filter housing and secure with the harness clamps.

W2003861

47
Plug the wiring harness connector into the air filter
restriction gauge.
Volvo Trucks North America
Service Bulletin

D
48
Date
7.2007
Group
215
No.
01
Page
28(31)

Depending upon chassis, install the left and right splash


guard and fender extender as an assembly, if required.

W2005189
1 Two fender extender bolts at rear bracket
2 Two fender extender bolts at brace
3 One fender extender brace bolt and nut at
hood release
4 One splash guard bolt at frame
5 Two splash guard bolts at upper brace

49
Check all sensors, tubing, coolant lines, air tubes,
hoses, lines, brackets and the various electrical system
harnesses and connectors for proper installation and
tightness.

50
Install the engine cover.

51
Reconnect the vehicle batteries or turn on the main
power switch.

52
Check the coolant level in the cooling system. Make sure
the engine oil is at the proper level.

53
Start the engine and let it reach normal operating
temperature. Inspect the engine for oil, coolant or
fuel leaks.

WARNING
When starting the engine, the parking brake must be
applied and the gear shift selector should be in neutral.
Volvo Trucks North America
Service Bulletin

D
2155-03-03-01
Camshaft Bearing, Replacement
Camshaft removed
Date
7.2007
Group
215
No.
01

You must read and understand the precautions and


Page
29(31)

guidelines in Service Information, group 20, "General


Safety Practices, Engine" before performing any
procedure. If you are not properly trained and certified
in this procedure, ask your supervisor for training
before you perform it.

W2005292

Note: Camshaft bearing housings are numbered 17,


with matching numbers for upper and lower halves.
Be sure to note and mark the corresponding housing
numbers and install them in the correct sequence with
matched upper and lower halves. When replacing
new camshaft bearing housings, numbers should be
stamped onto the housing.

W2005291

When replacing factory-installed


housings
If a camshaft housing has seized, DO NOT MIX a
replacement housing with the original factory-installed
housing (bearing saddle and bearing cap). This is
because the original housings have been align-bored
when the engine was manufactured. ALL 7
HOUSINGS MUST BE REPLACED.
When replacing a cylinder head, do not mix new
housings with original housings from the old cylinder
head. Use only new housings on a replacement
cylinder head.
Volvo Trucks North America
Service Bulletin

D Date
7.2007
Group
215

When replacing/installing previously


replaced housings
No.
01

If there are already replacement housings on the


housings can be replaced individually.
Page
30(31)

engine, and either half of the housing is damaged, the

If a new replacement bearing housing is used, torque


all other bearing housings first, to properly align the
new replacement housing.
Mark the bearing caps to indicate that aftermarket
housings have been installed.
Volvo Trucks North America
Service Bulletin

D
2154-06-02-01
Camshaft Wear, Checking
Date
7.2007
Group
215
No.
01

You must read and understand the precautions and


Page
31(31)

guidelines in Service Information, group 20, "General


Safety Practices, Engine" before performing any
procedure. If you are not properly trained and certified
in this procedure, ask your supervisor for training
before you perform it.

Surface irregularities may appear on VOLVO engine


camshaft lobes in normal operation. This does not mean
that the camshaft must be replaced. These marks do
not adversely affect the engines performance nor the
durability of the engine or any of its components.
Fig. 1: Camshafts with acceptable wear, page 31
provides examples of camshaft lobes exhibiting this
condition. These camshafts may be reused.

Fig. 2: Camshafts with unacceptable wear, page 31


provides examples of lobes exhibiting unacceptable wear
and deterioration. These camshafts and the rocker arms
corresponding to the worn lobes must be replaced.
Note: If there is any measurable wear, such as shown in
Fig. 2: Camshafts with unacceptable wear, page 31,
the camshaft should be replaced.

W2002219
Fig. 1: Camshafts with acceptable wear

W2002221
Fig. 2: Camshafts with unacceptable wear