IMPACT 4.04.

00 13/10/2022

Chassis ID Path
J11MA 20615 2146/Repair//Rocker arm shaft, install

Model Identity
T 145979438

Publish date ID/Operation

09/04/2019 21442-1

21442-1 Rocker arm shaft, install

Illustrations may differ slightly from the actual vehicle being serviced. However, key
components addressed in this information are represented as accurately as possible.

All threaded fasteners that do not have a tightening torque specification in the information are
tightened to a standard torque. Standard torques are available in the following specification.➠ 
Standard tightening torques

DANGER
Risk of serious injury.
The vehicle can be set in motion if appropriate safety precautions have not been taken.

▶ Before starting the engine, place the gear lever in neutral and apply the parking brake.

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
removed, replace the pipe along with the sealing rings.

Special tools

88840317

1 Lubricate the valve bridges and camshaft lobes with engine oil.

2 Position the rocker arm shaft.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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3 Remove the lifting tool (A).

4 Remove the cable ties.

5 Install the leaf springs and screws.

Note
Ensure that the leaf springs are correctly positioned after the screws are tightened.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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6 Torque tighten the screws.

Tightening torque

Rocker arm bridge, screw 1. Tightening sequence: 4-2-6

90 ±5 Nm

2. Tightening sequence: 1-3-5-7

60 ±5 Nm

3. Loosen the screws: 4-2-6

3 pcs

4. Tightening sequence: 4-2-6

60 ±5 Nm

5. Tightening sequence: 1-2-3-4-5-6-7

100 ±5°

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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7 Clean the valve.

8 Clean the contact surfaces.

9 Remove the sealing ring.

Note
Check that the oil channels are free of impurities.

10 Install the sealing ring.

Note
Use a new part.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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11 Lubricate the O-rings.

Required material

Diesel engine oil

12 Install the pipe.

Note
Use new parts.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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13 Install the valve.

14 Install the screws.

15 Torque tighten the screws.

Tightening torque

Solenoid valve, screw 24 ±4 Nm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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16 Install the screw.

17 Torque tighten the screw.

Tightening torque

Solenoid valve, screw 24 ±4 Nm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 13/10/2022

18 Connect the connector.

19 Remove the plug.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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20 Install the cranking adapter (A).

Required material

CRANKING ADAPTER 88840317

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 13/10/2022

21 Rotate the crankshaft to the next mark.

Note
Rotate the crankshaft in the normal engine rotation direction.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 13/10/2022

22 Markings 1-6 apply to the adjustment of the inlet valves. Markings V1-V3-V5 apply to the
adjustment of the exhaust valves. Markings PV2-PV4-PV6 apply to the adjustment of the
exhaust valves and the injectors.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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23 Note the camshaft marking.

Tech data

Adjust the inlet valve rocker arm 1-2-3-4-5-6

Adjust the exhaust valve rocker arm (and the exhaust V1-PV2-V3-PV4-V5-PV6
brake rocker arm, if applicable)

Adjust the injector rocker arm PV2-PV4-PV6

Note
The marking can be for the adjustment of several cylinders.

Note
When checking or adjusting, the mark must be centred between the lines on the
camshaft cap.

24 Perform this procedure when the condition below is met.

Conditions
● Adjust the exhaust valve rocker arm (and the exhaust brake rocker arm, if applicable).

▶ Check the valve clearance.

Tech data

Exhaust valve, rocker arm, clearance 1.6 ±0.05 mm

Note
Use a feeler gauge.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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▶ Perform this procedure when the condition below is met.

Conditions
● If the valve clearance is not correct.

▶ Loosen the nut (A).

▶ Adjust the screw (B) until the feeler blade can be moved but there is some resistance.

▶ Prevent the screw (B) from turning, and torque tighten the nut (A).

Tightening torque

Rocker arm, lock nut 38 ±4 Nm

▶ Rotate the crankshaft to the next mark.

Service hint
Mark the checked or adjusted rocker arm.

25 Perform this procedure when the condition below is met.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 13/10/2022

Conditions
● Adjust the inlet valve rocker arm.

▶ Check the valve clearance.

Tech data

Inlet valve, rocker arm, clearance 0.2 ±0.05 mm

▶ Perform this procedure when the condition below is met.

Conditions
● If the valve clearance is not correct

▶ 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 torque tighten the nut (A).

Tightening torque

Rocker arm, lock nut 38 ±4 Nm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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▶ Rotate the crankshaft to the next mark.

Service hint
Mark the checked or adjusted rocker arm.

26 Perform this procedure when the condition below is met.

Conditions
● Adjust the injector rocker arm.

▶ Loosen the nut (A).

▶ Adjust the screw (B) until the rocker arm roller lies against the camshaft.

▶ Angle tighten the screw (B).

Tech data

Injector, adjusting screw 240 ±20°

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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Service hint
Put an alignment mark on the rocker arm to ensure that the adjustment screw is not moving
while tightening the lock nut.

▶ Perform this procedure when the condition below is met.

Conditions
● If an extension bar/adapter are used for torque tightening

▶ The example shows a 450 mm long torque wrench and an extension bar/adapter (1) 50 mm long.
The required assembly torque, T, is 48 +-8 Nm. The calculation based on the example gives a torque
setting, C, of 43 Nm. This results in a tolerance of +- 6 Nm.

Note
The torque wrench setting given in the specifications must be adapted to suit the increased
length of the wrench and tool combination.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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▶ Ensure that the wrench and tool remain aligned during the tightening.

▶ Prevent the screw (B) from turning and torque tighten the nut (A).

Tightening torque

Injector, rocker arm, lock nut 52 ±4 Nm

▶ Rotate the crankshaft to the next mark.

Service hint
Mark the checked or adjusted rocker arm.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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27 Adjust the other rocker arms in the same way.

28 Remove the cranking adapter (A).

29 Install the plug.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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30 Remove the old sealant from the contact surfaces (A) .

Note
Ensure that the surfaces are completely clean from sealant.

Note
Ensure that the sealant on the timing gear plate is not damaged (B).

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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31 Apply the sealant (A).

Tech data

Sealant, bead thickness 2 mm

Required material

Metal adhesive

Note
Install the valve cover within 20 minutes of applying the sealant.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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32 Clean the contact surfaces carefully.

33 Clean the groove.

Note
Ensure that the surfaces are completely clean from oil and grease.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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34 Install the gasket.

Note
Use a new part.

35 Install the frame.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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36 Torque tighten the screws.

Tightening torque

Lower valve cover, screw Tighten diagonally

24 ±4 Nm

37 Connect the connectors.

38 Connect the connectors.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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39 Install the screw.

40 Clean the groove.

41 Clean the gasket.

42 Check the gasket for damage.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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43 Install the gasket.

Note
Use a new part if the part is damaged.

44 Ensure that all the crush sleeves are in place in the frame.

45 Perform this procedure when the condition below is met.

Conditions
● If any crush sleeves are missing.

▶ Replace the frame.

46 Install the valve cover.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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47 Install the screws.

48 Torque tighten the screws.

Tightening torque

Valve cover, screw Tightening sequence: 1–16

24 ±4 Nm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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49 Install the pipe.

50 Connect the connector.

51 Install the pipe.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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52 Tighten the hose clamp.

53 Install the pipe.

54 Tighten the hose clamp.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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55 Install the hose clamp.

56 Install the sound baffles.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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57 Install the sound baffle.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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58 Connect the cable to the negative terminal (1).

59 Apply protectant to battery terminals and cable terminals.

Note
Use recommended anti-corrosion spray.

60 Insert the key (2).

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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61 Perform this procedure when the condition below is met.

Conditions
● If the vehicle has an alarm

▶ Set the key in position II.

▶ Hold down the button (1).

▶ Press the button (2).

Note
Check that the LED lamp for alarm status goes out.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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62 Install the exhaust hose on the exhaust pipe.

63 Place the gear lever in neutral.

Note
Ensure that the handbrake is applied.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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64 Start the engine (3).

65 Check the repair for leakage.

66 Delete the DTC (Diagnostic Trouble Code) according to the diagnostic tool (Tech Tool)
instructions.

WARNING
Risk of serious injury.
A cab that is not tilted to the end position constitutes a safety risk.

▶ Always tilt the cab to the end position. Never perform any work under the cab before it has been
tilted to the end position.

67 Tilt back the cab.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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