NHTSA ID Number: 10126650
Manufacturer Communication Number: SP 214-019
TSB/Document Date: 2017-12-22
Summary
Rocker Arms, Replacement and Injector Re-torque
Service Program
Trucks
Volvo
Trucks North
America
Greensboro, NC USA
Date
11.2014
Group
No.
214 019
Release
Page
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 retorque 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.
W2005872
USA67687
PV729-SP214-019
English
Volvo Trucks North America
Service Program
Date
11.2014
Group
No.
Release
214
019
01
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.
W2005846
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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2(18)
Volvo Trucks North America
Service Program
Date
11.2014
Group
No.
Release
214
019
01
6 Remove the engine brake control valve mounting bolts. Remove the control valve, oil pipe
and valve seal spacer off the cylinder head.
W2004869
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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Page
3(18)
Volvo Trucks North America
Service Program
Date
11.2014
Group
No.
Release
214
019
01
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.
W2005845
9 Remove the plug from the flywheel housing and install the flywheel turning tool.
W0002368
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Volvo Trucks North America
Service Program
Date
11.2014
Group
No.
Release
214
019
01
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.
W2006173
11 Loosen the jam nuts and back off all rocker arm and fuel injector adjusting screws.
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Page
5(18)
Volvo Trucks North America
Service Program
Date
11.2014
Group
No.
Release
214
019
01
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.
W2005513
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.
Page
6(18)
Volvo Trucks North America
Service Program
Date
11.2014
Group
No.
Release
214
019
01
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.
W2006231
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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Volvo Trucks North America
Service Program
Date
11.2014
Group
No.
Release
214
019
01
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.
W2005940
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.
W2006241
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Volvo Trucks North America
Service Program
Date
11.2014
Group
No.
Release
214
019
01
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.
W2005513
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.
Page
9(18)
Volvo Trucks North America
Service Program
Date
11.2014
Group
No.
Release
214
019
01
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TSB/Document ID: SP 214-019
Replacement Service Bulletin Number:
MFR Communication Date: 2014-11-18
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT:MECHANICAL
MFR Component System:
MFR Component Subsystem:
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