Service Bulletin

Volvo Truck Corporation

Göteborg, Sweden Trucks
Date Group No. Release Page
Discard previous Service Bulletin 200-278 from 11.05.
Changes are indicated by a line (|) in the margin. 4.06 200 278 02 1(34)

Specifications
D13A
Specifications

T2022783

Contents
• “General” page 2
• “Engine” page 2
• “Valve mechanism” page 3
• “Engine timing gear” page 6
• “Crank mechanism” page 7
• “Lubrication and oil system” page 9
• “Fuel system” page 10
• “Inlet and exhaust system” page 11
• “Cooling system” page 12
• “Engine control system” page 14
• “Tightening torques and order” page 19

20 068755
ENG19595 English
Printed in Sweden
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 2(34)

Specifications
Note: Illustrations are used for several different variants. Some details may therefore
differ from the variant you are working on. The essential information in the illustrations
is, however, always correct.

General
Type designation Max power output 1 Max torque
at 26.7-28.3 rps (1600-1700 rpm) at 16.7-21.7 rps (1000-1300 rpm)
D13A 360 265 kW (360 hp) 1800 Nm
D13A 400 294 kW (400 hp) 2000 Nm
D13A 440 323 kW (440 hp) 2200 Nm
D13A 480 353 kW (480 hp) 2400 Nm
D13A 520 382 kW (520 hp) 2500 Nm
1
Net output as per ISO 1585. Smoke requirements comply with ECE reg 24 Federal Register and Swedish requirements.

Number of cylinders 6
Cylinder diameter 131 mm
Stroke 158 mm
Swept volume 12.78 dm³
Firing order 1-5-3-6-2-4
Compression ratio 18.1:1
Low idling 10 rps (600 rpm)
Fast idling 35.8 rps (2150 rpm)
Highest full load engine speed 30 rps (1800 rpm)
Weight, engine (production engine without vehicle details) 1,115 kg
(production engine with vehicle details) 1,143 kg
Total length 1,358.54 mm
Total width 1,358.54 mm
Total height 1,170.76 mm

Engine
Cylinder head
Max unevenness (base plane) 0.1 mm

Cylinder head bolt

Quantity/cylinder head 38
Thread size M16
Length 200 mm

Cylinder block
Length 1,052 mm
Height, upper block face - crankshaft centre 422 mm
Height, lower block face - crankshaft centre 120 mm
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 3(34)

Cylinder liner
Type Wet, exchangeable
Height of sealing surface above block face 0.18 ± 0.03 mm
Number of sealing rings per cylinder liner 1+3

Piston
Number of ring grooves 3
Front marking Arrow facing forwards

Piston rings

Compression rings
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Labelling . . . . . . . . . . . . . . . . On the top (colour
marking to the left of the opening)
Piston ring clearance in grooves:
upper compression ring . . . . . . (trapezoidal form)
lower compression ring . . . . . . . 0.09 — 0.14 mm

Oil scraper ring

Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
T2022726

Labelling . . . . . . . . . . . . . . . . On the top (colour

marking to the left of the opening)
Piston ring clearance in grooves .. 0.05 — 0.10 m

Valve mechanism
Valves

Valve disc, diameter:

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . 40 mm
Valve stem, diameter:
Inlet/Exhaust . . . . . . . . . . . . . . . . . . . . . . . 8 mm
Valve seat angle (A):
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . 24.5 ± 0.2
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . 39.5
Seat angle in cylinder head (B):
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

T2019432
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 4(34)

C2000431

Specifications Wear value

Measurement (A) between valve disc and cylinder head face:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min 0.9 mm Max 1.6 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min 1.25 mm Max 1.4 mm

Valve clearances, cold engine, setting values:

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 mm
Exhaust, VEB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 mm
Valve clearance cold engine, check value:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 - 0.25 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 - 0.85 mm
Exhaust, VEB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55 - 1.65 mm

Valve seats

Standard Oversize
Outside diameter (A):
Inlet . . . . . . . . . . . . . . 45.1 mm 45.3 mm
Exhaust . . . . . . . . . . . 43.1 mm 43.3 mm

T2014128 Height (B) :

Inlet . . . . . . . . . . . . . . 7.65 mm
Exhaust . . . . . . . . . . . . 7.6 mm

Valve seat position

Standard Oversize
Diameter (C):
Inlet . . . . . . . . . . . . . . 45.0 mm 45.2 H7 mm
Exhaust . . . . . . . . . . . 43.0 mm 43.2 H7 mm
T2012872
Depth (D):
Inlet . . . . . . . . . . 11.8 ± 0.13 mm
Exhaust . . . . . . . 11.2 ± 0.13 mm
Seat bottom radius (R):
Inlet/Exhaust . . . . . . max 0.8 mm
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 5(34)

Valve guides
Length:
Inlet/Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.5 mm
Inside diameter:
Inlet/Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mm
Height above cylinder head spring surface:
Inlet/Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.5 ± 0.2 mm

C2000483

Wear value
1
Clearance valve stem-guide:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 0.2 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 0.2 mm
1
The measurements are calculated for the measurement method described in the service literature, see group 214.

Rocker arms
Bearing play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 0.1 mm
Rocker arm roller, play ....................................................... max 0.1 mm

Valve springs
Inlet Exhaust
Length, without load . . . . . . . . . . . . . . . 73.8 mm Outer valve spring:
Length, without load . . . . . . . . . . . . . . . 73.8 mm
Inner valve spring:
Length, without load . . . . . . . . . . . . . . . 70.5 mm
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 6(34)

Engine timing gear

Timing gear

Gear wheel:
1. Drive gear, crankshaft
2. Idler gear: outer gear wheel
inner gear wheel
3. Idler gear, adjustable
4. Drive gear, camshaft
5. Idler gear, servo pump
6. Drive gear, steering servo and fuel feed pump
7. Drive gear, air compressor
8. Drive gear, lubricating oil pump
9. Engine power take-off (extra equipment) 1
1
For higher power take-off torques than 650 Nm, gear wheels 1, 2
and 9 must be exchanged for case-hardened versions.

Backlash adjustable idler gear to camshaft drive

gear . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.15 mm
Backlash, oil pump . . . . . . . . . . . . 0.05 - 0.40 mm

Backlash, other . . . . . . . . . . . . . . 0.05 - 0.17 mm

Run-out clearance for idler gear . . . . max 0.05 mm
T2022797

Camshaft
Control of camshaft settings, cold engine and valve clearance for cylinder 1 inlet valve = 0.
The inlet valve for cylinder 1 at flywheel position 6 ATDC should be open 1.6 ± 0.3 mm
When checking, the timing gears must be rotated in the correct direction (clockwise seen from the front) in order to
take up all backlash.
Drives ....................................................................... gear
Number of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Diameter, bearing journals, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.97 - 70.00 mm
Diameter, bearing journals, undersize:
0.25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.72 - 69.78 mm
0.50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.47 - 69.53 mm
0.75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.22 - 69.28 mm

Valve lift at zero play:

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.9 mm
Exhaust (VEB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 mm
Exhaust (EPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3 mm
Permitted wear, whole cam profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 0.1 mm
Unit injector, stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 mm

Wear value
Max end float ............................................................... 0.24 mm
Bearing, max. permitted run-out wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 7(34)

Camshaft bearings
Camshaft bearing thickness, standard ............................................... 1.92 mm
Oversize:
0.25 . . . . . . . . . . . . . . . . . . . . . . . ............................................... 2.04 mm
0.50 . . . . . . . . . . . . . . . . . . . . . . . ............................................... 2.17 mm
0.75 . . . . . . . . . . . . . . . . . . . . . . . ............................................... 2.29 mm

Crank mechanism

Crankshaft
Wear value
Crankshaft axial clearance 1 . . . . . . . . max 0.4 mm
Machining values
Ovality of main bearing journals and big-end bearing
journals . . . . . . . . . . . . . . . . . . . max 0.006 mm
Taper of main bearing journals and big-end bearing
journals . . . . . . . . . . . . . . . . . . . . max 0.02 mm
Run-out of middle bearing . . . . . . . . max 0.15 mm
1
The dimensions refer to oiled parts.

T2012873

Main bearing journals

Diameter (Ø) standard ........................................................ 108.0 mm
Undersize:
0.25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.75 mm
0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.50 mm
0.75 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.25 mm
1.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.00 mm
1.25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.75 mm
Surface finish, main bearing journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ra 0.25
Surface finish, radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ra 0.4
Width, axial bearing pin (A) standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.0 mm
Oversize:
0.2 mm (axial bearing 0.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.2 mm
0.4 mm (axial bearing 0.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.4 mm
0.6 mm (axial bearing 0.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.6 mm
Recess radius (R) ............................................................. 4.0 mm
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 8(34)

Thrust washers (axial bearing)

Width (B) standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 mm
Oversize:
0.1 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28 mm
0.2 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38 mm
0.3 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48 mm
0.4 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58 mm

Main bearing shells

Thickness (D) standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.48 mm
Oversize:
0.25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.61 mm
0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.74 mm
0.75 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.86 mm
1.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.98 mm
1.25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11 mm
Main bearing, max. permitted run-out wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 – 0.12 mm

Main bearing pin

Diameter (Ø) . . . . . . . . . . . . . . . . . . . . 99.0 mm

Undersize:
0.25 mm . . . . . . . . . . . . . . . . . . . . . . . 98.75 mm
0.50 mm . . . . . . . . . . . . . . . . . . . . . . . 98.50 mm
0.75 mm . . . . . . . . . . . . . . . . . . . . . . . 98.25 mm
1.00 mm . . . . . . . . . . . . . . . . . . . . . . . 98.00 mm
1.25 mm . . . . . . . . . . . . . . . . . . . . . . . 97.75 mm
Surface finish, big end bearing journal . . . . Ra 0.25
Surface finish, radius ................ Ra 0.4
Width (A) . . . . . . . . . . . . . . . . . . . . . . 57.0 mm
Recess radius (R) ................. 4.0 mm

T2022727

Main bearing shells

Thickness (C) standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 mm
Oversize:
0.25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 mm
0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.89 mm
0.75 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.74 mm
1.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.39 mm
1.25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 mm
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 9(34)

Connecting rod
Wear value
1
Axial clearance, connecting rod - crankshaft ....................................... max 0.35 mm
1
Big-end bearing, diametrical play ............................................... max 0.1 mm
1
The dimensions refer to oiled parts.

Marking:
“FRONT” on the shaft is turned forward.

Connecting rod and cap are marked as a pair with a three-digit serial number (see illustration).

Flywheel, installed
Axial run-out (manual gearbox) measurement radius 150 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 0.21 mm

Flywheel housing, installed

Axial mismatch for mating surface against clutch casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 0.2 mm
Radial mismatch for guide against clutch casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 0.26 mm

Lubrication and oil system

Oil
Oil change volume, see service information group 175.

Oil pressure
Operating speed (over 1100 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 - 550 kPa
Cold engine (above 1100 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 650 kPa
Low idle (min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min 250 kPa
Piston cooling pressure, hot engine (above 1100 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 - 300 kPa

Oil Pressure, rocker arm shaft

Non-activated VEB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 - 120 kPa
Activated VEB (900–2300 rpm) ................................................. min 220 kPa

Oil temperature
Warm engine, engine running (coolant temperature 75-95 C) ........................... 90 - 110 C 1
Up to 125C under heavy load
1
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 10(34)

Oil filter
Quantity
Full flow filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bypass-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Oil valves

1. Thermostatic valve, oil cooler

Opening temperature . . . . . . . . . . . 105 – 107 C
2. Safety valve, engine block
Labelling . . . . . . . . . . . . . . . . . . . . . . . . . Yellow
3. Overflow valve, full flow filter
Spring, free length . . . . . . . . . . . . . . . . . . 69 mm
With load of 13-15 N (1.3-1.5 kp) . . . . . . . . 40 mm

T2022159

Fuel system
Feed pump
Feed pressure at:
600 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min 100 kPa
1200 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min 300 kPa
full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min 300 kPa

Overflow valve
Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-550 kPa

Unit injector

Pre-tension 3-4 flats (0.75 ± 0.1 mm), see illustration.

T2012878

Tighten the adjustment screw to zero clearance

against the camshaft, then turn 3-4 flats.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 11(34)

Inlet and exhaust system

Turbocharger
End float turbine rotor shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 0.2 mm
Radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 0.6 mm

Actuator (Bypass valve)

Basic setting:
210 ± 1 kPa gives ........................................... 1.5 ± 0.27 mm link arm movement

Pressure drop indicator

The pressure drop indicator control lamp lights with an underpressure relative to ambient air pressure of 5 ± 0.5 kPa

Exhaust pressure governor

Stroke, shutter (A) .............. min. 29 mm

T2013094

Heat retention function

Heat retention activated:
coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 60 C
engine load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 50%
atmospheric pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . >50 kPa
Heat retention deactivated:
coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . >70 C
engine load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . > 50%
atmospheric pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . <100 kPa

Engine brake
2-way switch can give 0% or 100% braking power.
4-way switch can give 0%, 40%, 70% or 100% braking power (only EPC/EPGC).
5/6-way stalk switch can give 0%, 40%, 70% or 100% braking power, and also 50% in position A.

EPG/EPGC
Braking power (%) EPG pressure (kPa)
40% 325
1
50% (325)
70% 750
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 12(34)

100% 750
Cruise mode 0, 325 or 750
1
It should not be possible to obtain 50% other than in the automatic position.

Activated:
engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . > approx 700 rpm
vehicle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . > approx 5 kph
Deactivated:
engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < approx 800 rpm
vehicle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < approx 5 kph

VEB
Braking power (%) VEB (on/off) EPG pressure (kPa)
40% off 325
1
50% on 210
70% on 580
100% on 710–750
Cruise mode on/off 210, 325, 580, 710–750
1
50% braking power can only be obtained in automatic position or with a 3-position switch.

Activated:
engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . > approx 700/800 rpm
vehicle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . > approx 5 kph
engine oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . >20 C
charge pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . <150 kPa
Deactivated:
engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < approx 800/900 rpm
vehicle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < approx 5 kph
engine oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 15 C
charge pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . >170 kPa

Exhaust back-pressure
Exhaust back-pressure, max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 kPa

Cooling system
General
Pressure valve opens at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 kPa

Thermostat
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Opening temperature
I-shift, Geartronic, R/SR-manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 82 C
Compact Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 82 C

Coolant
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volvo Coolant VCS
Contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glycol and anti-corrosion additives
Colour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow
Mixed with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water (STD 1285,1)
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 13(34)

Electronically-controlled viscous fan

Activated system Notes
Coolant temperature I-shift
Geartronic
R/SR-manual
Coolant temperature Compact Retarder
EECU temperature
Conditions Fan engagement
coolant temperature 96 C Activation dependent on
coolant temperature
coolant temperature 93 C Activation dependent on
coolant temperature
EECU temperature >100 C 1200 rpm

Charge air temp. charge air temperature >65 C 580 rpm 1

1
charge air temperature >70 C 1180 rpm
1
Retarder Compact Retarder Request for fan activation sent: 2 1200 rpm
Powertronic retarder -vehicle speed >0 m/s 3
AND
-retarder torque >0%
AND
propeller shaft speed >400 rpm
AND
-retarder coolant temperature
>100 C
OR
-retarder oil temperature >170 C
Request for fan deactivation is sent: 4
-vehicle speed = 0 m/s 3
AND
-retarder torque = 0%
OR
propeller shaft speed <300 rpm
AND
-retarder coolant temperature <99 C
OR
-retarder oil temperature <150 C
1
Air conditioning (AC) -engine speed >1500 rpm 1200 rpm
system inlet temperature >40 C
-ambient temp >40 C
-vehicle speed <45 km/h
1
Air conditioning (AC) -engine speed >1200 rpm 1000 rpm
system inlet temperature >30 C
-ambient temp >30 C
-vehicle speed <45 km/h
1
Air conditioning (AC) inlet temperature >35 C 1200 rpm
system -ambient temp >35 C
-vehicle speed <10 kph
1
Air conditioning (AC) inlet temperature >20 C 600 rpm
system -ambient temp >20 C
-vehicle speed <20 kph
1
Pneumatic system Vehicles with pneumatically -engine speed >750 rpm 800 rpm
controlled air drying and air inlet temperature >12 C
suspension -ambient temp >12 C
-vehicle speed <35 kph
-system pressure <1020 kPa
-system pressure 1020-1200 kPa
and rising
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 14(34)

1
Pneumatic system Vehicles with pneumatically -engine speed >750 rpm 800 rpm
controlled air driers and leaf inlet temperature >12 C
spring suspension -ambient temp >12 C
-vehicle speed <35 kph
-pressure switch open (compressor
charging)
1
Pneumatic system Vehicles with electrically -engine speed >750 rpm 800 rpm
controlled air driers inlet temperature >12 C
-ambient temp >12 C
-vehicle speed <35 kph
-compressor charging
1
1.5 second delay after engine brake has been activated.
2
NOTE! A request for fan activation is sent when the demands for vehicle speed AND retarder torque AND propeller shaft speed AND
(retarders coolant temperature OR retarder oil temperature) are met.
3
40 seconds after retarder braking has started
4
NOTE! A request for fan deactivation is sent when the demands for vehicle speed AND (retarder torque OR propeller shaft speed) AND
retarders coolant temperature AND retarder oil temperature are met.

Engine control system

Sensors
Engine oil temperature sensor
Tempera- Impedance Impedance Impedance
ture ( C) Rmin ( ) Rnom ( ) Rmax ( )
- 50 89 496.5 105 290.0 121 083.5
- 40 45 163.6 52 394.0 59 624.4
- 30 23 871.0 27 375.0 30 879.0
- 20 13 181.5 14 945.0 16 708.5
- 10 7 555.7 8 480.0 9 404.3
0 4 477.9 4 981.0 5 484.1
10 2 747.3 3 029.0 3 310.7
20 1 736.6 1 900.0 2 063.4
30 1 127.3 1 224.0 1 320.7
40 750.0 809.1 868.2
50 510.4 547.0 583.6
T2022835 60 354.5 377.9 401.3
70 251.6 266.5 281.4
80 181.4 191.2 201.0
90 133.1 139.7 146.3
100 99.2 103.6 108.0
110 75.0 78.0 81.0
120 57.6 59.6 61.6
130 44.7 46.1 47.5
140 34.8 36.0 37.2
150 27.4 28.5 29.6
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 15(34)

Coolant temperature sensor

Tempera- Impedance Impedance Impedance
ture ( C) Rmin ( ) Rnom ( ) Rmax ( )
- 40 40 490 45 313 50 136
- 30 23 580 26 114 28 647
- 20 14 096 15 462 16 827
- 10 8 642 9 377 10 152
0 5 466 5 896 6 326
10 3 542 3 792 4 043
20 2351 2 500 2 649
25 1941 2 057 2 173
30 1615 1 707 1 798
40 1118 1 175 1 231
50 798 834 870
60 573 596 618
70 421 435 451
T2022836
80 313 323 332
90 237 243 250
100 182 186 191
110 140 144 148
120 109 113 116
130 86 89 93
140 68 71 74
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 16(34)

Inlet temperature sensor

Tempera- Impedance Impedance Impedance
ture ( C) Rmin ( ) Rnom ( ) Rmax ( )
- 40 156 966.60 168 600.00 180 233.40
- 30 83 106.80 88 600.00 94 093.20
- 20 45 796.79 48 565.00 51 333.21
- 10 26 258.83 27 670.00 29 081.17
0 15 562.49 16 330.00 17 097.51
10 9 532.10 9 950.00 10 367.90
20 6 013.93 6 245.00 6 476.07
30 3 891.05 4 028.00 4 164.95
40 2 585.77 2 663.00 2 740.23
50 1 755.97 1 801.00 1 846.03
60 1 215.88 1 244.50 1 273.12
70 860.72 876.50 892.28
T2022837
80 619.56 629.00 638.44
90 452.74 458.70 464.66
100 336.50 339.90 343.30
110 252.69 255.50 258.31
120 191.58 194.70 197.82
130 147.55 150.25 152.95
140 114.89 117.35 119.81
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 17(34)

Charge air temperature sensor

Tempera- Impedance Impedance Impedance
ture ( C) Rmin ( ) Rnom ( ) Rmax ( )
- 40 45 301.0 48 153.0 51 006.0
- 30 25 350.0 26 854.0 28 359.0
- 20 14 785.0 15 614.0 16 443.0
- 10 8 951.0 9 426.0 9 901.0
0 5 605.0 5 887.0 6 168.0
10 3 618.7 3 791.1 3 963.5
20 2 401.9 2 510.6 2 619.3
30 1 644.7 1 715.4 1 786.2
40 1 152.4 1 199.6 1 246.7
50 819.1 851.1 883.0
60 590.3 612.3 634.2
70 431.0 446.3 461.6
80 318.68 329.48 340.27
90 238.43 246.15 253.86
100 180.42 186.0 191.58
T2022838
110 137.63 142.08 146.52
120 106.09 109.65 113.21
130 82.58 85.45 88.32
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 18(34)

Charge pressure sensor

Check value ..................................................... 1.07 ± 0.1 V at 100 1 kPa
1
Normal atmospheric pressure at 0 metres above sea level

Pressure drop indicator

Active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V = 0.48 × Ubat ± 10%

Inactive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V = 0.12 × Ubat ± 10%

Camshaft sensor
Distance to camshaft ......................................................... min. 1 mm

Flywheel sensor
Distance to flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min. 1 mm

Crankcase pressure sensor

Sensor alarm limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 kPa
Crankcase pressure, normal value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . <1.0 kPa
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 19(34)

Tightening torques and order

Tightening torques group 20
General tightening torques
M6 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10±1.5 Nm
M8 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24±4 Nm
M10 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48±8 Nm
M12 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85±15 Nm
M14 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140±25 Nm
M16 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 ± 35 Nm

Only torque-tightened bolts can be refitted.

Torque and angle tightened/yield limit tightened bolts:
8.8 . . . . . . . . . . . . . . . . . . . . .......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . must/should not be refitted
10.9 . . . . . . . . . . . . . . . . . . . .......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . can be refitted
12.9 . . . . . . . . . . . . . . . . . . . .......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . can be refitted

Note: Check bolts before refitting. Damaged bolts, for example with cut marks on the underside, should be discarded.

Tightening torques group 21

Front engine anchorage, cylinder block ........................................... 275 ± 45 Nm
Front engine mounting, front engine pad
normal and severe road conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 ± 25 Nm
very severe road conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 ± 25 Nm (CONC-NAM 160 ± 25 Nm)
Front engine pad, vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm
Front engine pad, cross member ............................................... 175 ± 30 Nm
Rear engine mounting, flywheel housing .......................................... 300 ± 45 Nm
Rear engine mounting, rear engine pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 ± 90 Nm
Rear engine pad, frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 ± 25 Nm
Main bearing cap:
step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 ± 20 Nm
step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120±5
Connecting rod cap:
step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ± 3 Nm
step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ± 3 Nm
step 3 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90±5
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 20(34)

Stiffening frame

Stiffening frame:
step 1: Tighten the bolts 1-24 in numerical order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ± 5 Nm
step 2: Tighten the bolts 1-24 in numerical order (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90±5

Note: Tighten the bolts in the numerical order shown in the illustration. The bolts must not be reused.

Timing gear plate

Timing gear plate ............................................................ 28±4 Nm

Note: Apply a bead of silicon outside the groove as illustrated, max 20 minutes before mounting.
Silicon bead thickness: 2 mm.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 21(34)

Timing gear

1. Drive gear, crankshaft ....................................................... 24±4 Nm

2. Idler gear, outer bull gear:
step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 3 Nm
step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110±5

Note: Tighten in the order shown in the illustration.

3. Idler gear, adjustable:
step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ± 4 Nm
step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120±5

Note: Tighten in the order shown in the illustration.

4. Drive gear, camshaft:
step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45±5 Nm
step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90±5

Note: Tighten in the order shown in the illustration.

6. Drive gear, steering servo and fuel feed pump .................................... 100 ± 10 Nm
7. Drive gear, air compressor ................................................ 200+50/-0 Nm
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 22(34)

Flywheel and transmission housing

Flywheel housing:
step 1: Tighten all bolts in numerical order with the following torque:
M14 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 ± 20 Nm
M10 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm
M8 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24±4 Nm

Note: Apply silicon in a 2 mm thick bead as illustrated below.

Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 23(34)

Timing gear cover, upper

Fit the housing in two stages:

step 1: Secure the housing with screws 1 and 2 and use the special tool to press the housing into place.
step 2: Tighten the screws in the numerical order shown in the illustration. . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm

Note: Apply a 2 mm thick bead of silicon as shown in the illustration, no more than 20 minutes before installation, and
take special care to seal the contact points shown in the enlarged illustrations.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 24(34)

Flywheel

Flywheel:
step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ± 5 Nm
step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120±10

Note: Make sure the flange is dry and clean. Tighten the screws in the numerical order shown in the illustration.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 25(34)

Cover, crankshaft seal

Cover, crankshaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm

Note: Apply silicon in a 2 mm thick bead as illustrated and tighten the screws in numerical order.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 26(34)

Vibration damper

Oscillation damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 ± 10 Nm

Note: Tighten the screws in the numerical order shown in the illustration.
The vibration damper 8.8 bolts must not be reused.

Cylinder head

Cylinder head:

Note: The cylinder head must be installed in accordance with
install” in Group 21.
step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . .
step 3 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . .
the instructions, refer to “21124–1 Cylinder head,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 ± 5 Nm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120±5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90±5
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 27(34)

Bearing caps, camshaft/rocker arm shaft

Bearing caps 1–6 sre secured by one screw on the right side of the engine and two screws on the left side, although
bearing cap 7 is secured by only one screw on each side. Tighten the screws in the following 8 steps as illustrated:

Note: Tighten the screws in numerical order from bearing cap 1 to 7 or in reverse — from bearing cap 7 to 1 —
as illustrated, except in step 2.
Step 1:
With the camshaft and bearing caps in place, torque tighten the marked screws fron bearing caps 1 to 7. 25 ± 3 Nm
Step 2:
With the rocker shaft in place torque tighten the marked screws one after the other in the order 4, 3, 5, 2, 6, 1,
7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ± 5 Nm

Note: In step 2, the bolts must be tightened in stages to ensure that the rocker arm shaft is screwed home without
bending.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 28(34)

Step 3:
Angle-tighten the marked screws from bearing cap 1 to 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90±5
Step 4:
Torque tighten the marked screws from bearing cap 1 to 6 ................................ 25 ± 3 Nm
Step 5:
Angle-tighten the same screws from bearing cap 1 to 6 .................................... 120±5
Step 6:
Slacken the marked screws 1-6 (those which were tightened in stages in step 2, to secure the rocker arm shaft).
Step 7:
Torque tighten the marked screws from bearing cap 1 to 6 ................................ 25 ± 3 Nm
Step 8:
Angle-tighten the same screws from bearing cap 1 to 6, and screw 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 120±5

Note: When only the rocker arm has been removed, Steps 1 and 3 above do not apply.

Valve cover

Valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm

Note: Tighten the screws in the numerical order shown in the illustration.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 29(34)

Tightening torques group 22

Oil pan

The rubber gasket for a sheet metal oil sump is held in place by rubber claws.

Oil sumps, sheet metal and plastic respectively

Secure the oil sump with screws A and B, and fully torque tighten them . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm
Tighten the screws from the centre outwards, in accordance with 1-4 in the illustration above. . . . . . . . . . 24 ± 4 Nm
Finish by check-tightening screws A and B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm
Drain plug, oil sump (sheet metal and plastic respectively) ............................... 60 ± 10 Nm
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 30(34)

Oil cooler

Oil cooler, securing screws ..................................................... 27 ± 4 Nm

Note: Tighten the screws diagonally and finish by tightening the first screw again.

Oil cooler cover

Place the cover on the engine block and fit screw A into the oval hole. Press the cover against the water pump housing
with the special tool and insert screw B. Check that the cover is located correctly, refer to the service instructions.
Insert screws C and D and tighten them to full torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm
Tighten the cover screws from the centre outwards (1-4), refer to the illustration below . . . . . . . . . . . . . 24 ± 4 Nm
Finish by check-tightening screws C and D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 31(34)

Tightening torques Group 23

Fixing yoke, unit injector (when changing copper sleeve) 1

First tightening:
step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 +5/-0 Nm
step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180±5
Slacken the fixing yoke screw before the second tightening.
Second tightening:
step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 +5/-0 Nm
step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60±5
Fixing yoke, unit injector (when reusing the copper sleeve)
step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 +5/-0 Nm
step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60±5
1
The tightening procedure only applies when a new copper sleeve is fitted, when the first tightening ’seats’ the copper sleeve.

Lock nut for adjusting screw, unit injector:

step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 ± 4 Nm
step 2 (angle tightening) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45±5
Steering servo pump (fuel pump included) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 2 Nm
Fuel pump (mounted on servo pump) ............................................... 8 ± 2 Nm
1
after contact
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 32(34)

Lock nut, valve adjustment screw (inlet/exhaust, EPG):

step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ± 4 Nm
step 2 (angle tightening) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60±5
1
after contact

Lock nut, valve adjustment screw (exhaust, VEB):

step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ± 4 Nm
step 2 (angle tightening) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 + 1.5/-0
1
after contact
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 33(34)

Tightening torques Group 25

Inlet pipe ................................................................. 24 ± 4 Nm
Preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10±1.5 Nm
Plug, M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ± 3 Nm

Exhaust manifold:
Step 1 . . . . . . . . . . . . . .................. Tighten screws 1, 4 and 5, 8 and 9, 12 to contact (10 ± 1.5 Nm)
Step 2:
Tighten screws 3 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm
Tighten screws 7 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm
Tighten screws 11 and 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm
Tighten screws 1 and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm
Tighten screws 5 and 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm
Tighten screws 9 and 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm
Control valve (VEB) ......................................................... 21+2/–1 Nm

Tightening torques Group 26

Fan hub 1, dowels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ± 3 Nm

Note: Tighten the dowels in the order shown in the illustration.

1
only applies to part number 20855514 for FM
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 200 278 02 34(34)

Tightening torques Group 28

1. Level sensor for water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . not replaceable, integrated in the cabling
2. Engine oil level/temperature sensor ................................... torque for standard screw
3. Fuel pressure sensor ....................................................... 30 ± 5 Nm
4. Cooling fan speed sensor ........................................... threaded on to the shaft
5. Coolant level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug-in model
6. Coolant temperature sensor .................................................. 22 ± 3 Nm
7. Charge air pressure/temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . M5 standard screw, max. 3.3 Nm
8. Camshaft position sensor ....................................... M6 standard screw, 8 ± 2 Nm
9. Air underpressure/air temperature sensor ............................................ clamp
10. Flywheel position/speed sensor .................................. M6 standard screw, 8 ± 2 Nm
11. Oil pressure sensor ....................................................... 30 ± 5 Nm
12. Crankcase pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ± 5 Nm