Engus V SB2154 00401

Service Bulletin
Volvo Trucks Corporation

Greensboro, NC, USA Trucks
Date Group No Release page
11.2016 2154 004 01 1 (2)
2154-03-02-01 Camshaft, Replacement

VHD
2154030201 Camshaft, Replacement
engUSVSB215400401 SB2154004eng_V
Volvo Trucks Corporation Date Group No Release page
Service Bulletin 11.2016 2154 004 01 1 (178)
Table of contents
2154030201 Camshaft, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CONSTRUC, EM-USA17, ENG-VE11, INT-GEN1, UEBRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2154030201 Camshaft, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

CONSTRUC, EBR-CEBV, EM-USA17, ENG-VE11, INT-GEN1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2154030201 Camshaft, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

CONSTRUC, EM-USA17, ENG-VE13, INT-GEN1, UEBRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2154030201 Camshaft, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

CONSTRUC, EBR-VEB7, EM-USA17, ENG-VE13, INT-GEN1 . . . . . . . . . . . . . . . . . . . . . . . . . . 136
CONSTRUC, EM-USA17, ENG-VE11, INT-GEN1, UEBRAKE
Illustrations may differ slightly from the actual vehicle being serviced. However, key components ad-
dressed in this information are represented as accurately as possible.
CAUTION
Service Information Advisory. If you are not properly trained and certified in this procedure, ask your
supervisor for training before you perform it.
You must read and understand the precautions and guidelines in Service Information, Function
Group 2, "General Safety Practices, Engine" before performing this procedure.
1. Park the vehicle on a level surface.

2. Apply the parking brake.
3. Place the gear lever in neutral.
4. Install the wheel chocks.
5. Disconnect the cable from the battery's negative

terminal.
6. Unlatch and raise the hood.

7. Drain the compressed air tanks.
8. Loosen the clamps.
9. Remove the hose.
CAUTION
Risk of material damage. The turbocharger can be damaged if foreign particles enter the charge air
system. Particles as small as 1 mm can cause damage.
Observe maximum cleanliness when working on the charge air system. Cover or plug openings
immediately.
10. Remove the cable ties.

11. Disconnect the sensor connector.
Note
To avoid damaging the sensor, do not remove
from the pipe.

13. Remove the pipe assembly.
15. Remove the air duct.

16. Remove the screws.
17. Remove the air filter housing.
18. Remove the protecting covers.

20. Remove the panel.
21. Remove the screw cover.

23. Remove the handle.
24. Remove the nut.

26. Remove the seat belt.
27. Disconnect the air tube.

Required material
DISASSEMBLY J-42189
TOOL
28. Disconnect the connector.
WARNING
Risk of serious injury. Heavy component.
Exercise caution when moving the component. Assistance is required.
30. Remove the seat from the cab.
31. Remove the screw covers.


35. Remove the engine cover.

37. Remove the engine cover bezel.


Note
Move the cable harness aside.
41. Remove the pipe.
42. Loosen the screws.

43. Remove the valve cover.
44. Disconnect the connectors.

47. Remove the frame.
48. Remove the gasket.
49. Disconnect the connector (1).

50. Remove the screw (2).
51. Remove the sensor and the heat shield. (3).
52. Remove any shims.

Note
Mark the connector.
54. Cut the cable ties.
55. Move the harness aside.
56. Loosen the fittings.

57. Remove the oil pipe.
58. Discard the seals.
59. Remove the screw.

60. Loosen the pipe.
61. Loosen the fitting.

63. Remove the screw and clamp.


67. Remove the hoses.
68. Remove the coolant pipes and hoses.


72. Move aside the bracket along with the pipe.

Service tip
The screws cannot be removed from the tim-
ing gear cover.
74. Remove the timing gear cover.
CAUTION
Risk of material damage. Dirt and foreign bodies can damage the lubrication system.
Ensure that the work area is clean.
Cover or plug openings immediately. If work on removed parts is disrupted, cover the parts.
Ensure that tools, gloves, and protective clothes are as clean as possible.
77. Clean around the valve.

80. Remove the valve.
81. Blank off the holes to prevent dirt from entering the
system.

Note
The pipe can not be reused.
83. Loosen the adjusting screws.

Note
Loosen the screws on the rocker arm evenly
along the entire length of the shaft to prevent
damage.
85. Install the lifting tool.

Required material
lifting tool 85109050
86. Remove the rocker arm shaft.

88. Remove the gear and sensor wheel.
89. Remove the screws and caps.

Note
Check that the camshaft caps are marked up.
90. Install tool (A).

Required material
LIFTING TOOL 9998264
91. Remove the camshaft.
CAUTION
92. Remove the bearing shells.

93. Check the bearing shells, brackets and caps for damage.
CAUTION
94. Install the bearing shells.

Note
Use new parts.
Note
The surface between the bearing shells and bearing housings must be free of oil.
95. Lubricate all the bearing shells.
96. Install the camshaft.

97. Remove tool (A).
98. Install the caps.

Note
Check the markings.
Service tip
Carefully knock down the caps using a plastic
mallet.
99. Install the sleeves (A).
Note
These are temporary standard sleeves that
are placed over the guide sleeves to protect
the guide sleeves.
100.Install the temporary screws (1).
101.Install the permanent screws (2).
Note
The rocker arm shaft is installed later.
102.Tighten the screws to torque.

Tightening torque
Camshaft bearing cap, screw 1. Screw 2
Tightening sequence: 1-
2-3-4-5-6-7
40 3 Nm
(30 2 lbfft)
2. Screw 1
9-10-11-12-13-14
60 Nm
(44 lbfft)
3. Screw 2
2-3-4-5-6-7
90 5
Note
Check that the camshaft can be rotated after the screws are torque tightened.
103.Remove the temporary screws and sleeves.
104.Ensure that the marking (0) is in the correct position.
105.Turn the camshaft until the (TDC) mark aligns with

the cap mark.
106.Install the gear and sensor wheel.

107.Install the screws.
Note
Use new screws.
108.Torque tighten the screws.
Tightening torque
Gear, screw 1. Tightening sequence:
16
45 5 Nm
(33 4 lbfft)
2. Tightening sequence:
16
90 5
109.Measure the backlash between gears (1) and (2)

using the tools.
Tech data
Backlash clearance 0.1 0.05 mm
(0.004 0.002 in)
Required material
9999683
ROCKER_INDICATOR
MAGNETIC STAND 9999696
KIT J-35616-41
Note
Hold the idler gear (1) in place using a suitable
tool to correctly check the backlash.
Note
If backlash is out of specification, adjust idler
gear (1).
110.Check the timing mark.

111.Remove the tools.
112.Perform this procedure when the condition below is met.

Conditions
If the backlash is not within specified value adjust the backlash.
Adjust the timing gear backlash 2154050301 Backlash Clearance, Camshaft, Adjustment
[Valve Cover and Rocker Arm Shaft Removed] .
113.Clean the contact surfaces.
114.Install the gasket.

Note
Use a new part.
115.Install the timing gear cover.

Note
The dowels on the timing gear cover act as
guides to avoid damaging the sealing strip
during installation.
116.Lightly tighten the two timing gear cover screws.

Note
Ensure that the timing gear cover is in contact
with the timing gear plate.
117.Install the tools.

Required material
ASSEMBLY TOOL 85109051 2 pcs
118.Press down the timing gear cover with the required
force.
Tightening torque
Tool, adjusting screw 27 3 Nm
(20 2 lbfft)
Note
Ensure that the timing gear cover aligns with
the cylinder head on both sides.

Tightening torque
Upper timing gear casing, screw Tightening sequence:
15
27 3 Nm
(20 2 lbfft)
121.Position the pipe.

122.Install the screw.
123.Tighten the screw to torque.
Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)
124.Install the pipe.

125.Torque tighten the fitting.
Tightening torque
Fitting #4
15 1 Nm
(11 1 lbfft)

127.Torque-tighten the screws.
Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)
128.Position the coolant pipes.
129.Install the hoses and clamps.

130.Torque tighten the clamps.
Tightening torque
Clamp Hose
5.5 0.8 Nm
(4 1 lbfft)
131.Lubricate the seal.

Note
Lubricate with coolant.
132.Install the seal.
Note
Use a new part.
134.Install the clamp and screw.
135.Torque tighten the screw.
Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)

Tightening torque
Fitting #8
49 1 Nm
(36 1 lbfft)

Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)

Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)

Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)
144.Lubricate the seals.

145.Install the seals.
Note
Use new parts.
Note
Use a recommended oil.

147.Torque tighten the fittings.
Tightening torque
Oil hose, nut 30 5 Nm
(22 4 lbfft)
148.Position the harness.

149.Install the cable ties.
Note
Use new parts.
150.Connect the connector.

Note
Use a new part.
153.Install the shim and sensor (3).

154.Tighten the screw (2) to torque.
Tightening torque
Sensor, screw 8 2 Nm
(6 1 lbfft)
155.Connect the connector (1).
156.Install the rocker arm shaft.

157.Remove the lifting tool.
Tightening torque
Rocker arm bridge, screw 1. Repeat the tightening
sequence until the
rocker arm shaft
contacts the bearing
housings.
2-6
90 5 Nm
(66 4 lbfft)
2. Tightening sequence: 1-
3-5-7
90 5 Nm
(66 4 lbfft)
3. Loosen the screws: 4-2-
6
3 pcs
2-6
90 5 Nm
(66 4 lbfft)
2-3-4-5-6-7
Tightening torque
Rocker arm bridge, screw 5. 100 5
CAUTION
Risk of material damage Internal oil leak, low oil pressure in the rocker arm bridge, low effect on the
VEB engine brake, valve cover may melt.
Install the pipe without the screw to avoid unnecessary pre-tensioning. If the pipe has been re-
moved, replace the pipe along with the sealing rings.
160.Clean the valve.

162.Remove the sealing ring.

Note
Check that the oil channels are free of impuri-
ties.
163.Install the sealing ring.

Note
Use a new part.
164.Lubricate the O-rings.

Required material
Oil
Note
Use new parts.
166.Install the valve.

Tightening torque
Solenoid valve, screw 24 4 Nm
(18 3 lbfft)

Tightening torque
(18 3 lbfft)

CAUTION
Risk of material damage. The engine may be hot.
Make the adjustment on a cold engine.
WARNING
Risk of serious personal injury. Using the wrong technique when rotating the crankshaft can cause
serious personal injury.
Use the recommended engine barring techniques for manually rotating the crankshaft. Do not ro-
tate the engine by pulling or prying the fan.
171.Remove the plate.
172.Install rotation tool (A).

Required material
CRANKING_TOOL 9996956
173.Note the camshaft marking.

Note
The marking can be for the adjustment of mul-
tiple cylinders.
Note
When checking or adjusting, the mark must be
centered between the lines on the camshaft
cap.
174.Adjust the rocker arms according to the chart.
Camshaft marking
CAM POSITION INLET INJECTOR / PUMP EXHAUST
1/E3 Cylinder 1 _ Cylinder 3
6/PE4 Cylinder 6 Pump 4 Cylinder 4
175.Rotate the crankshaft to the next timing mark on the

camshaft.
Note
Rotate the crankshaft in the normal engine
rotation direction.
Ask another person for help.
176.Check the inlet valve rocker arm clearance.

Tech data
Inlet valve, rocker arm, clearance 0.2 0.05 mm
(0.008 0.002 in)

Conditions
If the valve clearance is not correct.
Loosen the nut (2).
Adjust the screw (1) until the feeler blade can be moved but there is some resistance.
Prevent the screw from turning (1), and tighten the nut (2) to torque.
Tightening torque
Rocker arm, lock nut 38 4 Nm
(28 3 lbfft)
178.Loosen the nut (A).

179.Adjust the screw (B) until there is zero clearance
between the adjusting screw and the injector ball
socket.
180.Angle tighten the screw (B).

Tech data
Injector, adjusting screw 240 20
181.Prevent the screw (B) from turning and torque-tighten the nut (A).
Tightening torque
Injector, rocker arm, lock nut 52 4 Nm
(38 3 lbfft)
182.Check the clearance.

Tech data
Exhaust valves, clearance 0.8 0.05 mm
(0.031 0.002 in)

Conditions
Loosen the nut (2).
Adjust the screw (1) until the feeler blade can be
moved but there is some resistance.
Prevent the screw from turning (1), and torque-
tighten the nut (2).
Tightening torque
(28 3 lbfft)
184.Adjust all the other rocker arms in the same way.

Note
185.Remove the cranking tool (A).
186.Install the plate.

Tightening torque
Screw M6
12 2 Nm
(9 1 lbfft)
188.Clean the groove.

Note
Use a new part.
190.Remove the old sealant from the contact surfaces

(A).
Note
Ensure that the contact surfaces are free of
sealant.
Note
Ensure that the sealant on the timing gear
plate is not damaged (B).
191.Apply sealant (A).

Tech data
Sealant, bead thickness 2 mm
(0.08 in)
Note
Install the valve cover within 20 minutes of
applying the sealant.
192.Clean the contact surfaces carefully.

Note
The surfaces must be perfectly clean from oil
and grease.
Note
Use a new part.
195.Install the frame.

Tightening torque
Lower valve cover, screw 24 4 Nm
(18 3 lbfft)
197.Connect the connectors.

199.Position the screws.

Service tip
Temporarily securing the screws at the rear of
the cover in the uppermost position will aid in
installation.
200.Install the valve cover.
Tightening torque
Valve cover, screw Tightening sequence:
116
24 4 Nm
(18 3 lbfft)

204.Install the panel.

Tightening torque
Interior panel, screw 3.4 0.6 Nm
(30 5 lbfin)
207.Install the engine cover bezel.

Tightening torque
Engine cover, screw M8
24 4 Nm
(18 3 lbfft)
210.Install the engine cover.

Tightening torque
24 4 Nm
(18 3 lbfft)

Tightening torque
(30 5 lbfin)
216.Install the screw covers.
WARNING
217.Position the seat in the cab.

Tightening torque
Seat, screw M10
48 8 Nm
(35 6 lbfft)

220.Connect the seat air hose.
221.Install the seat belt.

Tightening torque
Seat belt, screw M10
64 3 Nm
(47 2 lbfft)

223.Install the nut.
224.Install the grab handle.


Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)
227.Install the screw cover.

Tightening torque
(30 5 lbfin)
231.Install the protecting covers.
232.Install the air filter housing.


Tightening torque
Screw M10
48 8 Nm
(35 6 lbfft)
235.Install the air duct.
236.Tighten the clamps to torque.

Tightening torque
Air duct clamp 9 1 Nm
(80 9 lbfin)
CAUTION
immediately.
237.Install the pipe assembly.

Note
Inspect the gaskets and replace as needed.
Tightening torque
(80 9 lbfin)
239.Connect the sensor connector.

240.Secure the harness with the cable ties.
241.Install the hose.


Tightening torque
Clamp, screw 3.95 0.6 Nm
(35.0 5 lbfin)
243.Connect the battery cable to negative (ground) termi-

nal.
DANGER
Risk of serious personal injury or death. Failure to do so may result in serious personal injury or
death.
Ensure the engine cannot start while working around the fan area.
244.Start the engine and check for leaks and proper operation. After shutdown, replenish fluids as neces-
sary.
245.Lower the hood.
Note
Ensure that the hood is latched.
246.Remove the wheel chocks.

CONSTRUC, EBR-CEBV, EM-USA17, ENG-VE11, INT-GEN1
CAUTION


terminal.

9. Remove the hose.
CAUTION
immediately.

Note
from the pipe.




24. Remove the nut.


Required material
DISASSEMBLY J-42189
TOOL
WARNING





Note
Move the cable harness aside.



52. Remove any shims.

Note
Mark the connector.
54. Cut the cable ties.
55. Move the harness aside.
56. Loosen the fittings.

57. Remove the oil pipe.
58. Discard the seals.

61. Loosen the fitting.

63. Remove the screw and clamp.


67. Remove the hoses.
68. Remove the coolant pipes and hoses.


72. Move aside the bracket along with the pipe.

Service tip
The screws cannot be removed from the tim-
ing gear cover.
74. Remove the timing gear cover.
CAUTION
77. Clean around the valve.

80. Remove the valve.
81. Blank off the holes to prevent dirt from entering the
system.

Note
The pipe can not be reused.
84. Remove the screws and leaf springs.

Note
Loosen the screws on the rocker arm evenly
along the entire length of the shaft to prevent
damage.
85. Secure the pistons.

Note
Use cable ties.
86. Install the lifting tool.

Required material
lifting tool 85109050



Note

Required material
CAUTION

CAUTION

Note
Use new parts.
Note


Note
Check the markings.
Service tip
mallet.
100.Install the sleeves (A).
Note
the guide sleeves.
101.Install the temporary screws (1).
102.Install the permanent screws (2).
Note
Tightening torque
2-3-4-5-6-7
40 3 Nm
(30 2 lbfft)
2. Screw 1
9-10-11-12-13-14
60 Nm
(44 lbfft)
3. Screw 2
2-3-4-5-6-7
90 5
Note
104.Remove the temporary screws and sleeves.
105.Ensure that the marking (0) is in the correct position.
106.Turn the camshaft until the (TDC) mark aligns with

the cap mark.
107.Install the gear and sensor wheel.

Note
Use new screws.
Tightening torque
16
45 5 Nm
(33 4 lbfft)
16
90 5
110.Measure the backlash between gears (1) and (2)

using the tools.
Tech data
(0.004 0.002 in)
Required material
9999683
ROCKER_INDICATOR
KIT J-35616-41
Note
Note
gear (1).


Conditions

Note
Use a new part.

Note

Note

Required material
force.
Tightening torque
(20 2 lbfft)
Note
Tightening torque
15
27 3 Nm
(20 2 lbfft)
122.Position the pipe.

124.Tighten the screw to torque.
Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)

Tightening torque
Fitting #4
15 1 Nm
(11 1 lbfft)

Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)
129.Position the coolant pipes.
130.Install the hoses and clamps.

Tightening torque
Clamp Hose
5.5 0.8 Nm
(4 1 lbfft)
132.Lubricate the seal.

Note
Lubricate with coolant.
Note
Use a new part.
135.Install the clamp and screw.
Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)

Tightening torque
Fitting #8
49 1 Nm
(36 1 lbfft)

Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)

Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)

Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)

146.Install the seals.
Note
Use new parts.
Note
Use a recommended oil.

148.Torque tighten the fittings.
Tightening torque
Oil hose, nut 30 5 Nm
(22 4 lbfft)
149.Position the harness.

150.Install the cable ties.
Note
Use new parts.


Note
Use a new part.
154.Install the shim and sensor (3).

155.Tighten the screw (2) to torque.
Tightening torque
Sensor, screw 8 2 Nm
(6 1 lbfft)
156.Connect the connector (1).

158.Remove the cable ties.
159.Remove the lifting tool.

160.Install the leaf springs and screws.

Note
Ensure that the leaf springs are correctly posi-
tioned after the screws are tightened.
Tightening torque
Rocker arm bridge, screw 1. Repeat the tightening
sequence until the
rocker arm shaft
housings.
2-6
90 5 Nm
(66 4 lbfft)
3-5-7
90 5 Nm
(66 4 lbfft)
6
3 pcs
2-6
90 5 Nm
(66 4 lbfft)
2-3-4-5-6-7
100 5
CAUTION
Risk of material damage Internal oil leak, low oil pressure in the rocker arm bridge, low effect on the
VEB engine brake, valve cover may melt.
Install the pipe without the screw to avoid unnecessary pre-tensioning. If the pipe has been re-
moved, replace the pipe along with the sealing rings.
162.Clean the valve.

164.Remove the sealing ring.

Note
Check that the oil channels are free of impuri-
ties.
165.Install the sealing ring.

Note
Use a new part.
166.Lubricate the O-rings.

Required material
Oil
Note
Use new parts.
168.Install the valve.

Tightening torque
(18 3 lbfft)

Tightening torque
(18 3 lbfft)
CAUTION
WARNING
173.Remove the plate.
174.Install rotation tool (A).

Required material
CRANKING_TOOL 9996956

Note
tiple cylinders.
Note
cap.
Camshaft marking

camshaft.
Note
rotation direction.

Tech data
(0.008 0.002 in)

Conditions
Loosen the nut (2).

Adjust the screw (1) until the feeler blade can be moved but there is some resistance.
Prevent the screw from turning (1), and tighten the nut (2) to torque.
Tightening torque
(28 3 lbfft)

socket.

Tech data
Tightening torque
(38 3 lbfft)
184.Keep the rocker arm in contact with the camshaft.

Tech data
Exhaust valves, clearance 2 0.05 mm
(0.08 0.002 in)

Conditions
Loosen the nut (A).
Adjust the screw (B) until the feeler blade can be
Prevent the screw from turning (B), and torque-
tighten the nut (A).
Tightening torque
(28 3 lbfft)

Note
188.Remove the cranking tool (A).
189.Install the plate.

Tightening torque
Screw M6
12 2 Nm
(9 1 lbfft)

Note
Use a new part.

(A).
Note
sealant.
Note

Tech data
(0.08 in)
Note

Note
and grease.
Note
Use a new part.

Tightening torque
(18 3 lbfft)

Service tip
installation.
Tightening torque
116
24 4 Nm
(18 3 lbfft)

Tightening torque
(30 5 lbfin)

Tightening torque
24 4 Nm
(18 3 lbfft)

Tightening torque
24 4 Nm
(18 3 lbfft)

Tightening torque
(30 5 lbfin)
WARNING

Tightening torque
Seat, screw M10
48 8 Nm
(35 6 lbfft)

Tightening torque
64 3 Nm
(47 2 lbfft)



Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)

Tightening torque
(30 5 lbfin)

Tightening torque
Screw M10
48 8 Nm
(35 6 lbfft)


Tightening torque
(80 9 lbfin)
CAUTION
immediately.

Note
Tightening torque
(80 9 lbfin)


Tightening torque
(35.0 5 lbfin)

nal.
DANGER
death.
sary.
248.Lower the hood.

Note

CONSTRUC, EM-USA17, ENG-VE13, INT-GEN1, UEBRAKE
CAUTION


terminal.

9. Remove the hose.
CAUTION
immediately.

Note
from the pipe.



19. Remove the ties.

21. Remove the clamp.



30. Remove the nut.



Required material
DISASSEMBLY J-42189
TOOL

WARNING







60. Take up any shims.

63. Remove the cover.
CAUTION
Risk of skin injury. High fuel pressure.
The injection system may be pressurised. When working on the injection system, remove the first
part cautiously
CAUTION
Risk of material damage. Risk of impurities being introduced into the fuel system.
Ensure conditions of maximum cleanliness when carrying out any work on the fuel system.
64. Perform this procedure when the condition below is met.

Conditions
If not previously removed.
Disconnect the connector.
65. Clean around the sensor.

66. Remove the sensor.
CAUTION
Risk of material damage. Component damage
could occur if debris enters.
Cover openings to prevent debris from entering.
67. Cover or plug openings immediately.


Note
The pipe is removed at a later stage along
with the rocker arm shaft.
Tightening torque
Rocker arm shaft, screw 1. Remove screws:
1357911
6 pcs
2. Remove screws:
1321241068
7 pcs
Note
Loosen the screws gradually following the specified order, in stages, until they are completely re-
moved.
72. Install the lifting tool (A).

Required material

Note
Make sure not to damage the oil tube.



Note

Required material
CAUTION

CAUTION

Note
Use new parts.
Note


Note
Check the markings.
Service tip
mallet.
Note
the guide sleeves.
88. Install the temporary screws (1).
89. Install the permanent screws (2).
Note
90. Tighten the screws to torque.
Tightening torque
2-3-4-5-6-7
40 3 Nm
(30 2 lbfft)
2. Screw 1
9-10-11-12-13-14
60 Nm
(44 lbfft)
3. Screw 2
2-3-4-5-6-7
90 5
Note
91. Remove the temporary screws and sleeves.
92. Ensure that the marking (0) is in the correct position.
93. Turn the camshaft until the (TDC) mark aligns with
the cap mark.
94. Install the gear and sensor wheel.

95. Install the screws.
Note
Use new screws.
96. Torque tighten the screws.
Tightening torque
18
45 5 Nm
(33 4 lbfft)
18
90 5
97. Measure the backlash between gears (1) and (2)

using the tools.
Tech data
(0.004 0.002 in)
Required material
9999683
ROCKER_INDICATOR
KIT J-35616-41
Note
Note
gear (1).
98. Check the timing mark.

99. Remove the tools.

Conditions

Note
Use a new part.

Note

Note

Required material
force.
Tightening torque
(20 2 lbfft)
Note
Tightening torque
15
27 3 Nm
(20 2 lbfft)
109.Install the harness.

Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)
110.Install the pipes.

Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)

Required material
Oil
Note
Use new parts.
Note
Use a new part.

Note
114.Remove the lifting tool (A).

Required material
Tightening torque
Camshaft bearing cap, screw 1. Tightening sequence:
14-15-16-17-18-19-20
40 3 Nm
(30 2 lbfft)
2. Repeat the tightening
sequence until the
rocker arm bridge
housings.
6-10-4-12-2-13
60 5 Nm
(44 4 lbfft)
14-15-16-17-18-19-20
90 5
3-5-7-9-11
40 3 Nm
(30 2 lbfft)
3-5-7-9-11
120 5
6-8-10-12
6 pcs
4-6-8-10-12
40 3 Nm
(30 2 lbfft)
4-6-8-10-12-13
120 5

Tightening torque
Oil pipe, screw M8
24 4 Nm
(18 3 lbfft)
119.Remove the protecting cover and plug.

120.Install the sensor.
Note
No sealant or thread locker should be used.
121.Torque tighten the sensor.
Tightening torque
Pressure sensor, common rail 40 5 Nm
(30 4 lbfft)

Conditions
If not previously installed
Connect the connector.
CAUTION
WARNING

Conditions
If not previously installed.
Remove the plug.
Install the cranking adapter (A).

Required material
CRANKING TOOL 88840317

Note
tiple cylinders.
Note
cap.
Camshaft marking

camshaft.
Note
rotation direction.

Tech data
(0.008 0.002 in)

Conditions
Loosen the nut (A).

Adjust the screw (B) until the feeler blade can be moved but there is some resistance.
Prevent the screw from turning (B), and tighten the nut (A) to torque.
Tightening torque
(28 3 lbfft)

socket.

Tech data
Tightening torque
(38 3 lbfft)
Note
134.Remove the cranking adapter (A).

Required material
135.Install the plug.
CAUTION
WARNING

Conditions
Remove the plug.

Required material

Note
tiple cylinders.
Note
cap.
Camshaft marking
1/3 Cylinder 1 _ Cylinder 3
6/P4 Cylinder 6 Pump 4 Cylinder 4

camshaft.
Note
rotation direction.

Tech data
(0.008 0.002 in)

Conditions
Loosen the nut (A).
Tightening torque
(28 3 lbfft)

socket.

Tech data
Tightening torque
(38 3 lbfft)

Tech data
Exhaust valve, rocker arm, clear- 0.8 0.05 mm
ance (0.031 0.002 in)
Note
Use a set of feeler gauges.

Conditions
Loosen the nut (1).
Adjust the screw (2) until the feeler blade can be
Tech data
Exhaust valve, rocker arm, clear- 0.80 0.05 mm
ance (0.0315 0.002 in)
Prevent the screw from turning (2), and tighten
the nut (A) to torque.
Tightening torque
(28 3 lbfft)
Adjust all the other rocker arms in the same way.

Required material

Note
Use a new part.

(A).
Note
sealant.
Note

Tech data
(0.08 in)
Note

Note
and grease.
Note
Use a new part.

Tightening torque
(18 3 lbfft)


Note
Inspect the gasket, replace as needed.
Service tip
installation
Tightening torque
120
24 4 Nm
(18 3 lbfft)

Note
Inspect the internal sealing ring.

Tightening torque
(30 5 lbfin)

Tightening torque
24 4 Nm
(18 3 lbfft)

Tightening torque
24 4 Nm
(18 3 lbfft)

Tightening torque
(30 5 lbfin)
WARNING

Tightening torque
Seat, screw M10
48 8 Nm
(35 6 lbfft)

Tightening torque
64 3 Nm
(47 2 lbfft)



Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)

Tightening torque
(30 5 lbfin)

Note
Check the sealing ring and hose for damage;
replace as needed.

Tightening torque
V band clamp screw 10.2 1 Nm
(90 9 lbfin)
Tightening torque
Hose clamp 11.9 2 Nm
(105 18 lbfin)
195.Install the clamp.

Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)

198.Install the ties as needed.

Tightening torque
Screw M10
48 8 Nm
(35 6 lbfft)

Tightening torque
(80 9 lbfin)
CAUTION
immediately.

Note
Tightening torque
(80 9 lbfin)


Tightening torque
(35.0 5 lbfin)

nal.
DANGER
death.
sary.
212.Lower the hood.
Note

CONSTRUC, EBR-VEB7, EM-USA17, ENG-VE13, INT-GEN1
CAUTION


terminal.

9. Remove the hose.
CAUTION
immediately.

Note
from the pipe.



19. Remove the ties.

21. Remove the clamp.



30. Remove the nut.



Required material
DISASSEMBLY J-42189
TOOL

WARNING







60. Take up any shims.

63. Remove the cover.
CAUTION
Risk of skin injury. High fuel pressure.
The injection system may be pressurised. When working on the injection system, remove the first
part cautiously
CAUTION
Risk of material damage. Risk of impurities being introduced into the fuel system.
Ensure conditions of maximum cleanliness when carrying out any work on the fuel system.
64. Perform this procedure when the condition below is met.

Conditions
If not previously removed.
Disconnect the connector.
65. Clean around the sensor.

66. Remove the sensor.
CAUTION
Risk of material damage. Component damage
could occur if debris enters.
Cover openings to prevent debris from entering.
67. Cover or plug openings immediately.

68. Remove the leaf springs.

Note
The pipe is removed at a later stage along
with the rocker arm shaft.

Tightening torque
Rocker arm shaft, screw 1. Remove screws:
1357911
6 pcs
2. Remove screws:
1321241068
7 pcs
Note
Loosen the screws gradually following the specified order, in stages, until they are completely re-
moved.
73. Secure the pistons.

Note
Use cable ties.
74. Install the lifting tool (A).

Required material

Note


Note

Required material
CAUTION

CAUTION

Note
Use new parts.
Note



Note
Check the markings.
Service tip
mallet.
Note
the guide sleeves.
90. Install the temporary screws (1).
91. Install the permanent screws (2).
Note
92. Tighten the screws to torque.
Tightening torque
2-3-4-5-6-7
40 3 Nm
(30 2 lbfft)
2. Screw 1
9-10-11-12-13-14
60 Nm
(44 lbfft)
3. Screw 2
2-3-4-5-6-7
Tightening torque
Camshaft bearing cap, screw 3. 90 5
Note
93. Remove the temporary screws and sleeves.
94. Ensure that the marking (0) is in the correct position.
95. Turn the camshaft until the (TDC) mark aligns with
the cap mark.
96. Install the gear and sensor wheel.

97. Install the screws.
Note
Use new screws.
98. Torque tighten the screws.
Tightening torque
18
45 5 Nm
(33 4 lbfft)
18
90 5
99. Measure the backlash between gears (1) and (2)

using the tools.
Tech data
(0.004 0.002 in)
Required material
9999683
ROCKER_INDICATOR
KIT J-35616-41
Note
Note
gear (1).


Conditions

Note
Use a new part.

Note

Note

Required material
force.
Tightening torque
(20 2 lbfft)
Note

Tightening torque
15
27 3 Nm
(20 2 lbfft)
111.Install the harness.

Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)
112.Install the pipes.

Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)

Required material
Oil
Note
Use new parts.
Note
Use a new part.

Note
116.Remove the cable ties.
117.Remove the lifting tool (A).

Required material

Tightening torque
Camshaft bearing cap, screw 1. Tightening sequence:
14-15-16-17-18-19-20
40 3 Nm
(30 2 lbfft)
2. Repeat the tightening
sequence until the
rocker arm bridge
housings.
6-10-4-12-2-13
60 5 Nm
(44 4 lbfft)
14-15-16-17-18-19-20
90 5
3-5-7-9-11
40 3 Nm
(30 2 lbfft)
3-5-7-9-11
120 5
6-8-10-12
6 pcs
4-6-8-10-12
40 3 Nm
(30 2 lbfft)
4-6-8-10-12-13
120 5

Tightening torque
Oil pipe, screw M8
24 4 Nm
(18 3 lbfft)
122.Remove the protecting cover and plug.

123.Install the sensor.
Note
No sealant or thread locker should be used.
124.Torque tighten the sensor.
Tightening torque
Pressure sensor, common rail 40 5 Nm
(30 4 lbfft)

Conditions
If not previously installed
Connect the connector.
CAUTION
WARNING

Conditions
Remove the plug.

Required material

Note
tiple cylinders.
Note
cap.
Camshaft marking

camshaft.
Note
rotation direction.

Tech data
(0.008 0.002 in)

Conditions
Loosen the nut (A).
Tightening torque
(28 3 lbfft)

socket.

Tech data
Tightening torque
(38 3 lbfft)

Tech data
Exhaust brake, rocker arm, setting 1.00 0.07 mm
gauge (0.0394 0.0028 in)

Conditions
If the clearance is not in specification.
Adjust the rocker screw.
Loosen the nut (A) and screw (B).
Adjust the rocker arm to specification.
Tightening torque
(28 3 lbfft)
138.Keep the gauge in place.
139.Check the clearance using the setting tool (C).

Tech data
Setting Tool 2.50 mm
(0.0984 in)
Required material
SETTING TOOL 88800232

Conditions
Loosen the nut (A) and screw (B).
Install the setting tool (C).
Tighten the screw (B) until the exhaust valve just
begins to open.
Loosen the screw (B) until the setting tool (C) can
be moved but with some resistance.
Tightening torque
Exhaust, rocker arm, lock nut 52 4 Nm
(38 3 lbfft)
Remove the feeler gauge and setting tool.
Check the clearance using the mistake gauge(C).

Tech data
Control gauge 3.20 mm
(0.126 in)
Required material
SETTING TOOL 88800232
Note
The mistake gauge should pass between
the rocker arm and camshaft without resis-
tance.

Note
142.Install the leaf springs.

Note
Ensure that the push rod is correctly placed.
Tightening torque
Leaf spring, screw 25 3 Nm
(18 2 lbfft)

Required material

Note
Use a new part.

(A).
Note
sealant.
Note

Tech data
(0.08 in)
Note

Note
and grease.
Note
Use a new part.

Tightening torque
(18 3 lbfft)


Note
Inspect the gasket, replace as needed.
Service tip
installation
Tightening torque
120
24 4 Nm
(18 3 lbfft)

Note
Inspect the internal sealing ring.

Tightening torque
(30 5 lbfin)

Tightening torque
24 4 Nm
(18 3 lbfft)

Tightening torque
24 4 Nm
(18 3 lbfft)

Tightening torque
(30 5 lbfin)
WARNING

Tightening torque
Seat, screw M10
48 8 Nm
(35 6 lbfft)

Tightening torque
64 3 Nm
(47 2 lbfft)



Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)

Tightening torque
(30 5 lbfin)

Note
Check the sealing ring and hose for damage;
replace as needed.

Tightening torque
V band clamp screw 10.2 1 Nm
(90 9 lbfin)
Tightening torque
Hose clamp 11.9 2 Nm
(105 18 lbfin)
192.Install the clamp.

Tightening torque
Screw M8
24 4 Nm
(18 3 lbfft)

195.Install the ties as needed.

Tightening torque
Screw M10
48 8 Nm
(35 6 lbfft)

Tightening torque
(80 9 lbfin)
CAUTION
immediately.

Note
Tightening torque
(80 9 lbfin)


Tightening torque
(35.0 5 lbfin)

nal.
DANGER
death.
sary.
209.Lower the hood.
Note

Engus V SB2154 00401

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Service Bulletin

Volvo Trucks Corporation

11.2016 2154 004 01 1 (2)

2154-03-02-01 Camshaft, Replacement

2154030201 Camshaft, Replacement

2154030201 Camshaft, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2154030201 Camshaft, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

2154030201 Camshaft, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

2154030201 Camshaft, Replacement

CONSTRUC, EM-USA17, ENG-VE11, INT-GEN1, UEBRAKE

1. Park the vehicle on a level surface.

4. Install the wheel chocks.

5. Disconnect the cable from the battery's negative

6. Unlatch and raise the hood.

7. Drain the compressed air tanks.

8. Loosen the clamps.

9. Remove the hose.

10. Remove the cable ties.

12. Loosen the clamps.

14. Loosen the clamps.

15. Remove the air duct.

16. Remove the screws.

17. Remove the air filter housing.

18. Remove the protecting covers.

21. Remove the screw cover.

24. Remove the nut.

26. Remove the seat belt.

27. Disconnect the air tube.

28. Disconnect the connector.

29. Remove the screws.

30. Remove the seat from the cab.

31. Remove the screw covers.

34. Remove the screws.

36. Remove the screws.

38. Remove the screws.

40. Disconnect the connector.

41. Remove the pipe.

42. Loosen the screws.

44. Disconnect the connectors.

45. Loosen the screws.

48. Remove the gasket.

49. Disconnect the connector (1).

52. Remove any shims.

53. Disconnect the connector.

56. Loosen the fittings.

58. Discard the seals.

59. Remove the screw.

61. Loosen the fitting.

63. Remove the screw and clamp.

64. Remove the screws.

65. Remove the screws.

66. Loosen the clamps.

68. Remove the coolant pipes and hoses.

69. Remove the screws.

70. Remove the pipe.

71. Remove the screw.

73. Loosen the screws.

75. Remove the gasket.

76. Disconnect the connector.

77. Clean around the valve.

78. Remove the screw.

79. Remove the screws.

82. Remove the pipe.