Valves, adjusting

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Valid for option/configuration

Model Option no. Option Configuration
A25E 4x4 Volvo 81277 Engine D9B EU/US
A25E 4x4 Volvo 81345 Engine D9B EU

Op nbr 214-012

Total procedure time (hr): 5.50

Tools:
11668024 Rotation tool
88820016 Setting tool

NOTE!
As alternative to 11668024 Rotation tool, 9993590 Gear wheel can be used. Primarily Volvo recommends using
11668024 Rotation tool as it means considerable time-savings.
This operation also includes required tools and times for applicable parts of the following operations:

Service positions

1. Place the machine in service position, see Service positions.

2. Lower the front grill and open the engine hood.

3. Secure the expansion tank with a strap, and then loosen the bracket for the expansion tank .

Figure 1

4. Remove the rubber gaiter between the inlet pipe and the turbocharger.

NOTICE
Always cover open air connections with a plastic bag and rubber bands. Gravel, dust and other
particles in these connections may result in engine failure!
 Figure 2

5. Remove the protective plug in the flywheel housing. Install 11668024 Rotation tool alt. 9993590 Gear
wheel. Install a 1/2" universal joint and approx. 700 mm (27.6 in) extension to rotate the crankshaft.

Figure 3

6. Loosen and remove the valve cover.

NOTE!
Make sure that the edges of the valve cover are well cleaned.

Figure 4
 7. Rotate the engine to the nearest camshaft marking. The digit indicates on which the cylinder that the
valves and unit injectors shall be adjusted.
NOTE!
The camshaft marking shall be between the camshaft cap's markings.

Figure 5

1. Camshaft marking

8. Adjust the valve clearance for the exhaust and inlet valves that match the camshaft marking. Cylinder
number 1 is the cylinder at the front of the engine, closest to the filters. See Valve cover, tightening
torques.

Figure 6

Checking, double rocker arm (IEGR)

9. Loosen the air nipple to drain the double rocker arm of air and oil.
 Figure 7
Air nipple

10. Insert the go-side of 88820016 Setting tool between the double rocker arm's contact surface and the
camshaft's basic circle. The checking tool must be able to pass between the contact surface and the
camshaft, if the IEGR-"lift" is not too great.

Figure 8
Go and stop gauge

1. Stop-side of gauge
2. Go-side of gauge

11. Insert the stop-side of 88820016 Setting tool between the double rocker arm's contact surface and the
camshaft's basic circle. The checking tool must not be able to pass between the contact surface and
the camshaft. If it does, the IEGR-"lift" is too small.

12. If the go-side of the gauge passes between the double rocker arm's contact surface and the camshaft's
basic circle and if the stop-side does not, the clearance for the double rocker arm is correct. If not, the
double rocker arm must be adjusted as follows.

13. Repeat the above four (4) steps for all cylinders.
Figure 9
Double rocker arm

1. IEGR rocker arm

2. Exhaust valve tappet
3. Stop nut
4. Sleeve
5. Nipple
6. Lock nut
7. Piston

Adjusting, double rocker arm (IEGR)

14. Keep the camshaft in the same position as when adjusting valve clearance. Loosen the lock nut and
counterhold the piston with an Allen head wrench.

15. Insert 88820016 Setting tool between the double rocker arm's contact surface and the camshaft's basic
circle. Screw on the adjusting screw so that zero clearance is obtained between the double rocker arm,
the adjusting tool, and the camshaft.
NOTE!
Zero clearance means that the adjusting tool does not slide smoothly between the double rocker arm
and the camshaft.

Figure 10

16. Tighten the lock nut at the same time as the adjusting screw is held in its correct position.
 Tightening torque: see Valve system, specification

17. Adjust each unit injector's rocker arm to zero clearance. Then tighten down the adjusting screw another
3–4 bolt edges (180° – 240°). Angle-tighten the lock nut 45°.
NOTE!
This only has to be done when work has been performed on the rocker arm shaft that may have
changed the unit injector's adjustment, e.g., changing valve yoke.

Figure 11

18. Adjust the remaining valves and unit injectors according to the above.

19. Install the valve cover with a new gasket. Tighten the bolts according to the tightening diagram, see
Engine, tightening torques.

20. Remove 11668024 Rotation tool alt. 9993590 Gear wheel and install the protective plug.

21. Install the rubber gaiter between the inlet pipe and the turbocharger.

22. Install the expansion tank's bracket.

23. Raise the front grill and pump down the engine hood.