Manuald 13 A

Volvo Truck Corporation
Gteborg, Sweden
Discard previous Service Bulletin 200-278 from 4.06.

Changes are indicated by a line (|) in the margin.
Service Bulletin
Trucks
Date
Group
No.
Release
7.06
200
278 03
Page
1(36)
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 14
Engine control system page 16
Tightening torques and order page 21
20 082017
ENG22844
English
Printed in Sweden

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
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

at 26.7-28.3 rps (1600-1700 rpm)
Max torque
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
Net output as per ISO 1585. Smoke requirements comply with ECE reg 24 Federal Register and Swedish requirements.
Number of cylinders
Cylinder diameter
131 mm
Stroke
158 mm
Swept volume
12.78 dm
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)

(production engine with vehicle details)
1,115 kg
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
Page
2(36)

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
3(36)
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
Front marking
Arrow facing forwards
Piston rings
Compression rings
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Labelling . . . . . . . . . . . . . . . .
marking to the left of the opening)
On the top (colour
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 . . . . . . . . . . . . . . . .
marking to the left of the opening)
Piston ring clearance in grooves
On the top (colour

..
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

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
4(36)
C2000431
Specifications
Measurement (A) between valve disc and cylinder head face:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min 0.9 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min 1.25 mm
Wear value
Max 1.6 mm
Max 1.4 mm
Valve clearances, cold engine, setting values:

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust, VEB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve clearance cold engine, check value:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust, VEB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.2 mm
0.8 mm
1.6 mm
0.15 - 0.25 mm
0.75 - 0.85 mm
1.55 - 1.65 mm
Valve seats
Outside diameter (A):

Inlet . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . .
T2014128
Standard
Oversize
45.1 mm
43.1 mm
45.3 mm
43.3 mm
Height (B) :
Inlet . . . . . . . . . . . . . . 7.65 mm
Exhaust . . . . . . . . . . . . 7.6 mm
Valve seat position

Standard
Diameter (C):
Inlet . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . .
T2012872
45.0 mm
43.0 mm
Depth (D):
Inlet . . . . . . . . . . 11.8 0.13 mm
Exhaust . . . . . . . 11.2 0.13 mm
Seat bottom radius (R):
Inlet/Exhaust . . . . . . max 0.8 mm
Oversize
45.2 H7 mm
43.2 H7 mm

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
5(36)
Valve guides
Length:
Inlet/Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inside diameter:
Inlet/Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Height above cylinder head spring surface:
Inlet/Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83.5 mm
8 mm
24.5 0.2 mm
C2000483
Wear value
1
Clearance valve stem-guide:

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
max 0.2 mm
max 0.2 mm
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
Length, without load . . . . . . . . . . . . . . .
Exhaust
73.8 mm
Outer valve spring:

73.8 mm
Inner valve spring:

70.5 mm

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
6(36)
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter, bearing journals, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69.97 - 70.00 mm
Diameter, bearing journals, undersize:

0.25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69.72 - 69.78 mm
69.47 - 69.53 mm
69.22 - 69.28 mm
Valve lift at zero play:

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust (VEB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust (EPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Permitted wear, whole cam profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit injector, stroke
12.9 mm
13.1 mm
12.3 mm
max 0.1 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 mm
Wear value
Max end float
...............................................................
Bearing, max. permitted run-out wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.24 mm
0.1 mm

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
7(36)
Camshaft bearings
Camshaft bearing thickness, standard
Oversize:
0.25 . . . . . . . . . . . . . . . . . . . . . . .
0.50 . . . . . . . . . . . . . . . . . . . . . . .
0.75 . . . . . . . . . . . . . . . . . . . . . . .
...............................................
1.92 mm
...............................................
...............................................
...............................................
2.04 mm
2.17 mm
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 . . . . . . . .
1
max 0.15 mm
The dimensions refer to oiled parts.
T2012873
Main bearing journals

Diameter () standard
Undersize:
0.25 mm .
0.50 mm .
0.75 mm .
1.00 mm .
1.25 mm .
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108.0 mm
107.75 mm
107.50 mm
107.25 mm
107.00 mm
106.75 mm
Surface finish, main bearing journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Surface finish, radius
Ra 0.25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ra 0.4
Width, axial bearing pin (A) standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47.0 mm
Oversize:
0.2 mm (axial bearing 0.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.4 mm (axial bearing 0.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.6 mm (axial bearing 0.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47.2 mm
47.4 mm
47.6 mm
Recess radius (R)
.............................................................
4.0 mm

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
8(36)
Thrust washers (axial bearing)

Width (B) standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.18 mm
Oversize:
0.1 mm .
0.2 mm .
0.3 mm .
0.4 mm .
.
.
.
.
3.28 mm
3.38 mm
3.48 mm
3.58 mm
Thickness (D) standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.48 mm
Oversize:
0.25 mm
0.50 mm
0.75 mm
1.00 mm
1.25 mm
2.61 mm
2.74 mm
2.86 mm
2.98 mm
3.11 mm
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Main bearing shells
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Main bearing, max. permitted run-out wear
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 0.12 mm
Main bearing pin

Diameter () . . . . . . . . . . . . . . . . . . . .
Undersize:
0.25 mm .
0.50 mm .
0.75 mm .
1.00 mm .
1.25 mm .
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99.0 mm
98.75 mm
98.50 mm
98.25 mm
98.00 mm
97.75 mm
Surface finish, big end bearing journal . . . .

Surface finish, radius
................
Width (A) . . . . . . . . . . . . . . . . . . . . . .
Recess radius (R)
.................
Ra 0.25
Ra 0.4
57.0 mm
4.0 mm
T2022727
Main bearing shells

Thickness (C) standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.39 mm
Oversize:
0.25 mm
0.50 mm
0.75 mm
1.00 mm
1.25 mm
2.14 mm
1.89 mm
1.74 mm
1.39 mm
1.14 mm
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Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
9(36)
Connecting rod
Wear value
Axial clearance, connecting rod - crankshaft
Big-end bearing, diametrical play
1
.......................................
max 0.35 mm
...............................................
max 0.1 mm
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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low idle (min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
650 kPa
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 (9002300 rpm)
.................................................
min 220 kPa
Oil temperature
Warm engine, engine running (coolant temperature 75-95
1
Up to 125C under heavy load
C)
...........................
90 - 110 C 1

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
10(36)
Oil filter
Quantity
Full flow filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bypass-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1200 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
min 100 kPa

min 300 kPa
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.

Service Bulletin
Date
Group
No.
7.06
200
278 03
Inlet and exhaust system

Boost pressure
Euro 3
Boost pressure 1
D13A 400 Eu3

1200 rpm
1400 rpm
1600 rpm
1800 rpm
138
164
144
143
kPa/1.27
kPa/1.51
kPa/1.33
kPa/1.32
V
V
V
V
D13A 440 Eu3

1200 rpm
1400 rpm
1600 rpm
1800 rpm
158
188
170
166
kPa/1.46
kPa/1.74
kPa/1.57
kPa/1.52
V
V
V
V
D13A 480 Eu3

1200 rpm
1400 rpm
1600 rpm
1800 rpm
177
210
198
179
kPa/1.63
kPa/1.94
kPa/1.83
kPa/1.65
V
V
V
V
D13A 500 Eu3

1200 rpm
1400 rpm
1600 rpm
1800 rpm
199
218
201
189
kPa/1.84
kPa/2.01
kPa/1.86
kPa/1.74
V
V
V
V
If environmental diesel fuel is used, reduce the table values by 5 kPa and 0.06 V.
Euro 4
Boost pressure 1
D13A 360 Eu4

1200 rpm
1400 rpm
1600 rpm
1800 rpm
129
157
154
160
kPa/1.43
kPa/1.74
kPa/1.71
kPa/1.78
V
V
V
V
D13A 400 Eu4

1200 rpm
1400 rpm
1600 rpm
1800 rpm
136
162
161
156
kPa/1.51
kPa/1.80
kPa/1.79
kPa/1.73
V
V
V
V
D13A 440 Eu4

1200 rpm
1400 rpm
1600 rpm
1800 rpm
154
184
178
171
kPa/1.71
kPa/2.04
kPa/1.98
kPa/1.90
V
V
V
V
D13A 480 Eu4

1200 rpm
1400 rpm
1600 rpm
1800 rpm
173
198
178
167
kPa/1.92
kPa/2.20
kPa/1.98
kPa/1.86
V
V
V
V
D13A 520 Eu4

1200 rpm
1400 rpm
1600 rpm
1800 rpm
182
213
193
181
kPa/2.02
kPa/2.37
kPa/2.14
kPa/2.01
V
V
V
V
Release
Page
11(36)

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
12(36)
Euro 5
Boost pressure 1
D13A 400 Eu5

1200 rpm
1400 rpm
1600 rpm
1800 rpm
142
167
161
159
kPa/1.58
kPa/1.86
kPa/1.79
kPa/1.77
V
V
V
V
D13A 440 Eu5

1200 rpm
1400 rpm
1600 rpm
1800 rpm
161
189
180
175
kPa/1.79
kPa/2.10
kPa/2.00
kPa/1.94
V
V
V
V
D13A 480 Eu5

1200 rpm
1400 rpm
1600 rpm
1800 rpm
177
205
190
182
kPa/1.97
kPa/2.28
kPa/2.11
kPa/2.02
V
V
V
V
D13A 520 Eu5

1200 rpm
1400 rpm
1600 rpm
1800 rpm
186
215
196
180
kPa/2.07
kPa/2.39
kPa/2.18
kPa/2.00
V
V
V
V
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)
T2013094
..............
min. 29 mm

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
13(36)
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
50%
(325)
70%
750
100%
750
Cruise mode
0, 325 or 750
It should not be possible to obtain 50% other than in the automatic position.
Activated:
engine speed
vehicle speed
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . > approx 700 rpm

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < approx 5 kph
VEB
Braking power (%)
VEB (on/off)
EPG pressure (kPa)
40%
off
325
50% 1
on
210
70%
on
580
100%
on
710750
Cruise mode
on/off
210, 325, 580, 710750
50% braking power can only be obtained in automatic position or with a 3-position switch.

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
14(36)
Activated:
engine speed . . . . . . . . .
vehicle speed . . . . . . . . .
engine oil temperature . . .
charge pressure . . . . . . . .
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. > approx 700/800 rpm

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

. . . . . . < approx 5 kph
. . . . . . . . . . < 15 C
. . . . . . . . . . >170 kPa
Exhaust back-pressure
Exhaust back-pressure, max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 kPa
Cooling system
General
Pressure valve opens at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 kPa
Thermostat
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Opening temperature
I-shift, Geartronic, R/SR-manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compact Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C
C
< 82
< 82
Coolant
Type . . . . . . .
Contains . . . . .
Colour . . . . . .
Mixed with . . .
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. . . . . . . . . . . Volvo Coolant VCS

. Glycol and anti-corrosion additives
. . . . . . . . . . . . . . . . . . . . Yellow
. . . . . . . . . . . Water (STD 1285,1)
Electronically-controlled viscous fan

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

Service Bulletin
Activated system
Notes
No.
Release
7.06
200
278 03
Fan engagement
charge air temperature >65 C

charge air temperature >70 C
580 rpm 1
1180 rpm
Request for fan activation sent: 2

-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
1200 rpm
Air conditioning (AC)

system
-engine speed >1500 rpm

inlet temperature >40 C
-ambient temp >40 C
-vehicle speed <45 km/h
1200 rpm

system

-ambient temp >30 C
-vehicle speed <45 km/h
1000 rpm

system

-ambient temp >35 C
-vehicle speed <10 kph
1200 rpm

system

-ambient temp >20 C
600 rpm
Retarder
Group
Conditions
Charge air temp.
Date
Compact Retarder
Powertronic retarder
Pneumatic system
Vehicles with pneumatically

controlled air drying and air
suspension

-ambient temp >12 C
-system pressure <1020 kPa
-system pressure 1020-1200 kPa
and rising
800 rpm
Pneumatic system
Vehicles with pneumatically

controlled air driers and leaf
spring suspension

-ambient temp >12 C
-pressure switch open (compressor
charging)
800 rpm
Pneumatic system
Vehicles with electrically

controlled air driers

-ambient temp >12 C
-compressor charging
800 rpm
1.5 second delay after engine brake has been activated.

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.
40 seconds after retarder braking has started
Page
15(36)

Service Bulletin
4
Date
Group
No.
Release
7.06
200
278 03
Page
16(36)
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
T2022835
Temperature ( C)
Impedance
Rmin ( )
Impedance
Rnom ( )
Impedance
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
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
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

Service Bulletin
Coolant temperature sensor
T2022836
Date
Group
No.
Release
7.06
200
278 03
Page
17(36)
Temperature ( C)
Impedance
Rmin ( )
Impedance
Rnom ( )
Impedance
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
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
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

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
18(36)
Inlet temperature sensor
T2022837
Temperature ( C)
Impedance
Rmin ( )
Impedance
Rnom ( )
Impedance
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
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
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

Service Bulletin
Charge air temperature sensor
Date
Group
No.
Release
7.06
200
278 03
Page
19(36)
Temperature ( C)
Impedance
Rmin ( )
Impedance
Rnom ( )
Impedance
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
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
110
137,63
142,08
146,52
120
106,09
109,65
113,21
130
82,58
85,45
88,32
T2022838

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
20(36)
Charge pressure sensor

Check value
1
.....................................................
1.07 0.1 V at 100 1 kPa
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
Distance to flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
min. 1 mm
Flywheel sensor
Crankcase pressure sensor

Sensor alarm limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 kPa
Crankcase pressure, normal value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . <1.0 kPa

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
21(36)
Tightening torques and order

Tightening torques group 20
General tightening torques
M6 standard bolt 8.8 .
M8 standard bolt 8.8 .
M10 standard bolt 8.8
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.
. 101.5 Nm
. . 244 Nm
. . 488 Nm
. 8515 Nm
14025 Nm
190 35 Nm
Only torque-tightened bolts can be refitted.

Torque and angle tightened/yield
8.8 . . . . . . . . . . . . . . . . . . . .
10.9 . . . . . . . . . . . . . . . . . . .
12.9 . . . . . . . . . . . . . . . . . . .
limit tightened
..........
..........
..........
bolts:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . must/should not be refitted
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . can be refitted
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . can be refitted
Note: Check bolts before refitting. Damaged bolts, for example with cut marks on the underside, should be discarded.

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front engine pad, cross member
...............................................
Rear engine mounting, flywheel housing
48 8 Nm
175 30 Nm
..........................................
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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1205
Connecting rod cap:
step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3 Nm
step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 3 Nm
step 3 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
22(36)
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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
Note: Tighten the screws in the numerical order shown in the illustration. The bolts must not be reused.
Timing gear plate
Timing gear plate
............................................................
Note: Apply a bead of silicon outside the groove as illustrated, max 20 minutes before mounting.
Silicon bead thickness: 2 mm.
284 Nm

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
23(36)
Timing gear
1. Drive gear, crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
244 Nm
2. Idler gear, outer bull gear:

step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 3 Nm
Note: Tighten in the order shown in the illustration.
3. Idler gear, adjustable:
step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 4 Nm
4. Drive gear, camshaft:
step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455 Nm
6. Drive gear, steering servo and fuel feed pump
....................................
7. Drive gear, air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
100 10 Nm
200+50/-0 Nm

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
24(36)
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Nm
Note: Apply silicon in a 2 mm thick bead as illustrated below.

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
25(36)
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. . . . . . . . . . . . . . . . . . . . . . .
244 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.

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
26(36)
Flywheel
Flywheel:
step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 5 Nm
step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12010
Note: Make sure the flange is dry and clean. Tighten the screws in the numerical order shown in the illustration.

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
27(36)
Cover, crankshaft seal
Cover, crankshaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Note: Apply silicon in a 2 mm thick bead as illustrated and tighten the screws in numerical order.
244 Nm

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
28(36)
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 211241 Cylinder head,

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 5 Nm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1205
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
29(36)
Bearing caps, camshaft/rocker arm shaft
Bearing caps 16 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.

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
30(36)
Step 3:
Angle-tighten the marked screws from bearing cap 1 to 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
Step 4:
Torque tighten the marked screws from bearing cap 1 to 6
Step 5:
Angle-tighten the same screws from bearing cap 1 to 6
................................
25 3 Nm
....................................
1205
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 . . . . . . . . . . . . . . . . . . . . . . . . . . .
1205
Note: When only the rocker arm has been removed, Steps 1 and 3 above do not apply.
Valve cover
Valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Note: Tighten the screws in the numerical order shown in the illustration.
244 Nm

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
31(36)

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Nm
Drain plug, oil sump (sheet metal and plastic respectively)
...............................
60 10 Nm

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
32(36)
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Nm

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
33(36)
Tightening torques Group 23
Fixing yoke, unit injector (when changing copper sleeve) 1

First tightening:
step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . .
Slacken the fixing yoke screw before the second tightening.
Second tightening:
step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 +5/-0 Nm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1805
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 +5/-0 Nm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Fixing yoke, unit injector (when reusing the copper sleeve)

step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 +5/-0 Nm
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
Steering servo pump (fuel pump included) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel pump (mounted on servo pump)
1
after contact
...............................................
24 2 Nm
8 2 Nm

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
34(36)
Lock nut, valve adjustment screw (inlet/exhaust, EPG):

step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 4 Nm
step 2 (angle tightening) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
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

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
35(36)

Inlet pipe
..................................................................
244 Nm
Preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.5 Nm
Plug, M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 3 Nm
Exhaust manifold:
Step 1 . . . . . . . . . . . . .
Step 2:
Tighten screws 3 and 2 . .
Tighten screws 11 and 10
Tighten screws 9 and 12 .
48 8 Nm
48 8 Nm
48 8 Nm
48 8 Nm
48 8 Nm
48 8 Nm
Control valve (VEB)
..................
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Tighten screws 1, 4 and 5, 8 and 9, 12 to contact (10 1.5 Nm)

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.........................................................
21+2/1 Nm
Fan hub 1, dowels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Note: Tighten the dowels in the order shown in the illustration.
1
only applies to part number 20855514 for FM
14 3 Nm

Service Bulletin
Date
Group
No.
Release
7.06
200
278 03
Page
36(36)
1. Level sensor for water separator

2. Engine oil level/temperature sensor
3. Fuel pressure sensor
. . . . . . . . . . . . . . . . . . . . . . . . . . . not replaceable, integrated in the cabling

...................................
torque for standard screw
.......................................................
4. Cooling fan speed sensor
...........................................
threaded on to the shaft
5. Coolant level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Coolant temperature sensor
8. Camshaft position sensor
10. Flywheel position/speed sensor
22 3 Nm
. . . . . . . . . . . . . . . . . . . . . . . . . . . M5 standard screw, max. 3.3 Nm
.......................................
9. Air underpressure/air temperature sensor
11. Oil pressure sensor
plug-in model
..................................................
7. Charge air pressure/temperature sensor
30 5 Nm
M6 standard screw, 8 2 Nm
............................................
..................................
clamp
M6 standard screw, 8 2 Nm
.......................................................
30 5 Nm
12. Crankcase pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 5 Nm

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Volvo Truck Corporation

Discard previous Service Bulletin 200-278 from 4.06.

Volvo Truck Corporation

Max power output 1

265 kW (360 hp)

294 kW (400 hp)

323 kW (440 hp)

353 kW (480 hp)

382 kW (520 hp)

10 rps (600 rpm)

35.8 rps (2150 rpm)

Highest full load engine speed

30 rps (1800 rpm)

Weight, engine (production engine without vehicle details)

Cylinder head bolt

Height, upper block face - crankshaft centre

Height, lower block face - crankshaft centre

Volvo Truck Corporation

Height of sealing surface above block face

Number of sealing rings per cylinder liner

Arrow facing forwards

On the top (colour

Piston ring clearance in grooves:

On the top (colour

Volvo Truck Corporation

Valve clearances, cold engine, setting values:

Outside diameter (A):

Valve seat position

Volvo Truck Corporation

Clearance valve stem-guide:

Rocker arm roller, play

Outer valve spring:

Inner valve spring:

Volvo Truck Corporation

Engine timing gear

Backlash adjustable idler gear to camshaft drive

Run-out clearance for idler gear . . . .

Diameter, bearing journals, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter, bearing journals, undersize:

Valve lift at zero play:

Max end float

Bearing, max. permitted run-out wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Volvo Truck Corporation

The dimensions refer to oiled parts.

Main bearing journals

Surface finish, main bearing journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width, axial bearing pin (A) standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recess radius (R)

Volvo Truck Corporation

Thrust washers (axial bearing)

Thickness (D) standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main bearing shells

Main bearing, max. permitted run-out wear

Main bearing pin

Surface finish, big end bearing journal . . . .

Main bearing shells

Volvo Truck Corporation

The dimensions refer to oiled parts.

Flywheel housing, installed

Radial mismatch for guide against clutch casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication and oil system

Oil Pressure, rocker arm shaft

min 220 kPa

Up to 125C under heavy load