Volvo Trucks North

Service Bulletin
America
Greensboro, NC USA
Trucks
Date Group No. Release Page
This service bulletin replaces bulletin 200-321 dated 11.2016 200 321 16 1(53)
9.2016.

Specifications
D13
Specifications

W2005779

Contents:
• “General”, page 3

• “Engine”, page 5

• “Valve Mechanism”, page 7

• “Engine Timing Gears”, page 11

• “Crank Mechanism”, page 13

• “Lubricating and Oil System”, page 16

• “Fuel System”, page 18

• “Inlet and Exhaust System”, page 18

• “Cooling System”, page 19

• “Engine Control System”, page 22

• “Tightening Torques and Patterns”, page 23

• “Engine Lubricants and Sealants”, page 53

PV776-89273326
USA79641 English
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 2(53)

Note: Information is subject to change without notice.

Illustrations are used for reference only and may differ slightly from the actual vehicle
being serviced. However, key components addressed in this information are represented
as accurately as possible.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 3(53)

Specifications
General
Weights and Dimensions

Engine type In-line direct injection diesel

Number of cylinders 6
Displacement 13 L
Swept volume 12.78 L
Cylinder bore and stroke 131 x 158 mm (5.16 x 6.22 inches)
Emissions level EPA 07: 2.5g NOx; 0.1g Pt maximum
US2010, US2014, US2017, EURO 3/4/5: 0.2 g/hp-hr NOx
maximum
Fuel system US2014, EURO 3/4/5: Dual solenoid electronic injector
US2017: Common rail
Valve actuation Single overhead camshaft, four valves per cylinder
Aspiration Variable geometry turbocharger with sliding nozzle ring
Fixed turbocompound
Cylinder and piston type Wet Sleeve; one-piece steel piston
Electronic control Volvo VECTRO electronic management system
Emission controls EPA 07: Cooled EGR; Diesel Particulate Filter (DPF)
US2010 and US2014: Cooled EGR; Diesel Particulate Filter
(DPF); Selective Catalytic Reduction (SCR)
Peak power ratings 375–505 hp
Peak torque ratings 1965–2373 Nm (1450–1750 ft-lb)

Governed rpm 2100 rpm

Weight Approximately 1,130 kg (2500 lb)
Firing order 1-5-3-6-2-4
Compression ratio 17:1
Fasteners and threads Metric
Flywheel housing (standard) Aluminum
Total length 1366 mm (54 inches)
Total width 971 mm (38 inches)
Total height 1281 mm (50 inches)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 4(53)

Component Features and Materials

Item Description
Air compressor Flange mounted, oil lubricated, water cooled
Camshaft Induction hardened, gear driven
Coolant conditioner Spin-on type, disposable
Connecting rods Forged steel, cracked cap design
Crankshaft Drop forged steel, induction hardened, seven main bearings
Cylinder block In-line six cylinder, cast iron, machined with bearing caps,
stiffener plate, timing gear mounting plate, guide washers for
cylinder head; wet replaceable cylinder sleeves
Cylinder head One-piece cast iron alloy; overhead camshaft, four valves
per cylinder, injectors; replaceable oil seals attached to iron
valve guides; alloy valve seats; copper or stainless steel in-
jector sleeves; integral fuel passages and thermostat
housing
Valve cover Plastic, Pre US2014: 20 spring tension screws; US2014+:
rubber isolators
Cylinder liner Wet Sleeve; replaceable; with EDPM rubber and VFKM
seals
Cylinder head — Valve springs Double springs on each exhaust valves, single springs on in-
let valves
Cylinder head — Valve guides Cast iron, replaceable; with serviceable oil seals
Cylinder head gasket One piece steel plate with attached sealing inserts
Cylinder head bolts M16 (38)
Timing gear cover (rear of cylinder head) Pre-US2010: Steel cover with elastomer seals; US2014+:
Engineered polymer cover with elastomer seals
Flywheel housing Die-cast aluminum
Fuel filters Pre-US2017: One 30-micron primary, one 5-micron secon-
dary; US2017: One 25-micron primary, one 4-micron
secondary
Fuel injection Six individually programmed unit injectors: ECM controlled;
common fuel gallery in head; constant supply pressure;
over-pressure return
Fuel supply pump Gear type pump integral with power steering pump; idler gear
driven
Lubrication system Crankshaft gear driven oil pump; system integrated with
block and head; serves camshaft, rocker arm shaft, pistons,
crankshaft, air compressor, turbocharger, EGR valve; three
oil filters; oil level and temperature sensor in oil pan; pump
pressure tube, strainer and pressure relief valve
Main bearing caps Spheroidal graphite iron; machined with block; No. 7 mounts
oil pump; numbered for reassembly; sleeve guides for
screws; thrust washers at No. 4 main bearing journal; pinned
thrust caps
Exhaust manifold Three-piece connected by two welded bellows, six port
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 5(53)

Item Description
Pistons One-piece steel; three ring grooves

Piston rings — Compression Two: one trapezoidal cross section, one rectangular cross
section
Piston rings — Oil One: garter spring type; scraping
Oil filters Two 40–micron full flow, one 5-micron bypass;
Filter capacity, two full flow:

• 4.0–4.5 liters (4.2–4.8 quarts)

Oil pan 27L plastic, 31L steel; 22 spring tension screws; US2017: 6L
filter change
Sump capacity:

• 36 liters (38 quarts)

Thermostat Sleeve type: 82°C (180°F)
Thermostat housing Integrated in cylinder head
Turbocharger Emissions: US07–US17:
Variable geometry type: Exhaust driven; fixed vanes; sliding
ring nozzle; infinitely variable volume; oil and water cooled
EURO 3/4/5, US17 Turbocompound:
Fixed geometry turbo; exhaust driven; fixed vanes; oil and
water cooled
Valve lifters Roller followers
Valve seat inserts Pressed in head; replaceable
Viscous Torsional Vibration Dampener Internal fluid-filled ring; crank damper; cam damper removed
for F2; EURO 3/4/5 - cam damper
Coolant pump Centrifugal rotor impeller; belt driven; optional 2 speed

Engine
Cylinder Head
Maximum unevenness (bottom face) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.004 inch);
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm/100 mm (0.001 inch/3.9 inch) head bolts and coolant passages

Cylinder Head Bolts

Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Thread size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16
Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 mm (7.87 inches)

Cylinder Block
Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1052 mm (41.42 inches)
Height, upper block face — crankshaft center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422 mm (16.61 inches)
Height, lower block face — crankshaft center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 mm (4.72 inches)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 6(53)

Cylinder Liner
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet, replaceable
Height of sealing surface above block face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15–0.21 mm (0.006–0.008 inch)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 +0.03 - 0.04 mm (0.007 +0.001- 0.002): With liner pressed in place
Number of sealing rings per cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 top, 3 bottom

Piston
Number of ring grooves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Arrow pointing forward
Piston above cylinder deck (at TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1–0.7 mm (0.004–0.027 inch)

Piston Rings

T2022726

Compression Rings
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Up (color marking to left of gap)
Piston ring clearance in grooves:
Upper compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trapezium profile
Lower compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09–0.14 mm (0.0035–0.0055 inch)
Piston ring gap measured in ring opening:
Upper compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4–0.55 mm (0.02–2.2 in)
Lower compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3–1.5 mm (0.05–0.06 in)
Oil Scraper Ring
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Up (color marking to left of gap)
Piston ring clearance in grooves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05–0.10 mm (0.0019–0.0039 inch)
Piston ring gap measured in ring opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4–0.65 mm (0.02–0.03 in)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 7(53)

Valve Mechanism
Valves

T2023980

T2023980

A. Valve Face-to-Deck
Valve-face-to-deck (intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 mm (0.039 inch) minimum
Valve-face-to-deck (intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.85 mm (0.073 inch) maximum
Valve-face-to-deck (exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.35 mm (0.053 inch) minimum
Valve-face-to-deck (exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 mm (0.087 inch) maximum

Note: Do not grind or resurface valves. Grinding valves can Note: Grinding or resurfacing valve seats is not
cause valve failure due to removal of hard facing. recommended.

Valve lash (clearance) cold engine:

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 ±0.05 mm (0.008 ±0.002 inch)
Exhaust without engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 ±0.05 mm (0.031±0.002 inch)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 8(53)

Engine Brake Rocker Arm, Engine Brake

T2027091

Engine brake rocker arm, adjustment:

Adjust the brake rocker arm lash by keeping the exhaust rocker arm feeler gauge in place between the exhaust rocker arm
and exhaust valve caliper. Place the gauge of the specified brake lash thickness between the camshaft and brake rocker
arm roller.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 9(53)

W2005815

Adjust the brake rocker arm lash by keeping the exhaust rocker arm feeler gauge in place between the exhaust rocker arm
and exhaust valve caliper. Place the gauge of the specified brake lash thickness between the camshaft and brake rocker
arm roller.
Exhaust rocker arm with VEB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 mm ± 0.07 (0.06 ± 0.003 inch)
Exhaust rocker arm with VEB+ (2 rocker arm system): Turbocompound only. . . . . . . . . . . . 0.8 ± 0.07 mm (0.03 ± 0.003 inch)
Engine Brake rocker arm EURO3/5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.85 ± 0.07 mm (0.11 ± 0.003 inch)
Exhaust rocker arm with VEB7 2 rocker arm system: US2007–US2017, EURO4 . . . . . . . . 1.0 ± 0.07 mm (0.04 ± 0.003 inch)
Engine Brake rocker arm US2007–US2017, EURO4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 ± 0.07 mm (0.10 ± 0.003 inch)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 10(53)

Valve Guides
Length:
Inlet/Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.4 ± 0.15 mm (3.283±0.006 inch)
Inner diameter:
Inlet/Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ± 0.20 mm (0.315±0.008 inch)
Height above cylinder head spring surface:
Inlet/Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.5 ± 0.2 mm (0.965 ± 0.008 inch)

C2000483

Valve stem-to-guide wear clearance:1

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5 mm (0.020 inch) maximum
Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5 mm (0.020 inch) maximum

1 The measurements are calculated for the measurement method described in the service literature, see Function Group 214.

Valve Springs
Inlet valve spring:
Length unloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.8 mm (2.91 inches)
Exhaust outer valve spring:
Length unloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.8 mm (2.91 inches)
Exhaust inner valve spring:
Length unloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70.5 mm (2.78 inches)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 11(53)

Engine Timing Gears

Timing Gears

T2022797

Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Number of Teeth

1. Drive gear, crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2. Idler gear, outer and inner drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outer: 84, Inner: 56
3. Idler gear, adjustable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4. Drive gear, camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5. Idler gear, power steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6. Drive gear, power steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7. Drive gear, air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8. Drive gear, lubricating oil pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9. Engine power take-off (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Idler gear to camshaft gear backlash (adjustable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05–0.15 mm (0.002–0.006 inch)
Oil pump backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05–0.40 mm (0.002–0.016 inch)
Idler gear axle-to-bushing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 inch) maximum
All other drive and idler gear, backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05–0.17 mm (0.002–0.007 inch)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 12(53)

Camshaft
Drive arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear
Number of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Standard bearing journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.97–70.00 mm (2.754–2.760 inch)
Undersize bearing journal diameters:
0.25 mm (0.010 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.72–69.78 mm (2.746–2.747 inches)
0.50 mm (0.020 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.47–69.53 mm (2.735–2.737 inches)
0.75 mm (0.030 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.22–69.28 mm (2.725–2.728 inches)

Valve lift at zero play:

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 mm (0.520 inch)
Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EURO 3/5: 12.3 mm (0.484 inch); EURO4, US2007–2017: 12.5 mm (0.490 inch)
VEB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EURO 3/4/5: 13.1 mm (0.520 inch)
Injector, stroke . . . . . . . . . . . . . . . . . . . . . . . . . EURO 3/5: 17.0 mm (0.669 inch); EURO4, US2007–2017: 18 mm (0.710 inch)

Wear value
Bearing, permitted diametrical wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 inch) maximum

Camshaft Bearings
Camshaft bearing thickness, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.92 mm (0.075 inch)
Oversize:
0.25 mm (0.010 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.04 mm (0.080 inch)
0.50 mm (0.020 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 mm (0.085 inch)
0.75 mm (0.030 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 mm (0.090 inch)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 13(53)

Crank Mechanism
Crankshaft

T2012873

Wear value:
Crankshaft axial clearance1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.065-0.315 mm (0.0026–0.0124 inch)
Machining value:
Main bearing and connecting rod bearing journal out-of-round . . . . . . . . . . . . . . . . . . . . . . . 0.006 mm (0.0002 inch) maximum
Main bearing and connecting rod bearing journal taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0008 inch) maximum
Runout of middle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 inch) maximum

1 The measurements refer to lubricated components.

Main Bearing Journals

Standard diameter (Ø) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108.0 mm (4.25 inches)
Undersize diameter:
0.25 mm (0.010 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107.75 mm (4.2421 inches)
0.50 mm (0.020 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107.50 mm (4.2323 inches)
1.00 mm (0.040 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107.00 mm (4.2126 inches)
Surface finish, main bearing journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ra 0.25
Surface finish, radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ra 0.4
Width, axial bearing pin (A), standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.0 mm (1.850 inches)
Oversize:
0.2 mm (0.008 inch), axial bearing 0.1 mm (0.004 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.2 mm (1.858 inches)
0.4 mm (0.016 inch), axial bearing 0.2 mm (0.008 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.4 mm (1.866 inches)
0.6 mm (0.241 inch), axial bearing 0.3 mm (0.012 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.6 mm (1.874 inches)
Recess radius (R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 mm (0.157 inch)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 14(53)

Thrust Washers (Axial Bearing)

Standard width (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 mm (0.125 inch)
Oversize:
0.1 mm (0.004 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28 mm (0.129 inch)
0.2 mm (0.008 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38 mm (0.133 inch)
0.3 mm (0.012 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48 mm (0.137 inch)
0.4 mm (0.016 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58 mm (0.141 inch)

Main Bearings
Standard thickness (D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.48 mm (0.098 inch)
Oversize:
0.25 mm (0.010 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.61 mm (0.103 inch)
0.50 mm (0.020 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.74 mm (0.108 inch)
1.00 mm (0.040 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.98 mm (0.117 inch)
Main bearing maximum permitted diametrical wear value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0008 inch) max.

Connecting Rod Journals

T2022727

Diameter (Ø). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.0 mm (3.898 inches)

Undersize:
0.25 mm (0.010 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.75 mm (3.888 inches)
0.50 mm (0.020 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.50 mm (3.878 inches)
0.75 mm (0.030 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.25 mm (3.868 inches)
1.00 mm (0.040 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.00 mm (3.858 inches)
1.25 mm (0.050 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97.75 mm (3.848 inches)
Surface finish, bearing journal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ra 0.25
Surface finish, radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ra 0.4
Width (A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.0 mm (2.244 inches)
Recess radius (R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 mm (0.157 inch)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 15(53)

Connecting Rod Bearings

Standard thickness (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 mm (0.094 inch)
Oversize:
0.50 mm (0.020 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.89 mm (0.114 inch)
1.00 mm (0.040 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39 mm (0.134 inch)
1.25 mm (0.050 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.64 mm (0.143 inch)

Connecting Rod
Wear Value
End play, connecting rod at crankshaft journal1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.0138 inch) maximum
Big-end bearing, diametrical play1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0008 inch)

1 The measurements refer to lubricated components.

Marking:
The FRONT marking on the connecting rod faces forward

T2019085

The connecting rod and cap are marked as a pair with a three-digit serial number.

Flywheel, mounted
Axial runout (manual transmission) measurement radius 150 mm (5.91 inches) . . . . . . . . . . . Less than 0.21 mm (0.008 inch)

Flywheel Housing, mounted

Axial runout of contact surface against clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.2 mm (0.008 inch) maximum
Radial runout of guide against clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.26 mm (0.010 inch) maximum
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 16(53)

Lubricating and Oil System

Oil
For oil change volume, specification and maintenance inter-
vals, refer to Service Information, Function Group 175.

Oil Pressure
RPM Minimum Oil Pressure
Idle 110 kPa (16 psi)
1100–1200 185 kPa (27 psi)
1900 and above 255 kPa (37 psi)

Oil Pressure, Rocker Arm Shaft

Engine brake non-activated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi) minimum
Engine brake activated (900–2300 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 kPa (29 psi) minimum

Oil Temperature
At operating temperature, engine running (coolant temperature 75–95°C (167–203°F) . . . . . . . . . . . 90–117°C (194–243°F)1

1 Up to 128°C (262°F) with full load

Lubricating Oil Pump

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear driven

Oil Filters
Full flow filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bypass filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 17(53)

Oil Filter Housing Valves

Note: Valves vary by engine.

Item Spring Free Length Spring Length Under Load

Safety valve, oil pump Load: 35 N (7.87 lbf)
74 mm (2.914 inches)
Length: 41 mm (1.61 inches)
Reduction valve marking — purple Load: 85 N (19.1 lbf)
66.5mm (2.618 inches)
Length: 40 mm (1.57 inches)
Control valve, piston cooling (balancing) Load: 95 N (21.36 lbf)
122 mm (4.803 inches)
Length: 63 mm (2.480 inches)
Opening valve, piston cooling Load: 95 N (21.36 lbf)
122 mm (4.803 inches)
Length: 63 mm (2.480 inches)
Overflow valve, full flow filter 69 mm (2.717 inches) Load: 13–15 N (2.92–3.37 lbf)
Length: 40 mm (1.575 inches)

Thermostatic valve, oil cooler:

Opening temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103–107°C (217-225°F)
Total opening length @ 114–118°C (237-244°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 mm (0.354 inch)

Piston cooling jet control solenoid valve: 9 ±1 - 11.5 ohms at 20°C (68°F)
Oil cooler thermostat solenoid valve: 9 ±1 - 11.2 ohms at 20°C (68°F)
Opening temperature set-point (electronically controlled): 117°C (243°F)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 18(53)

Fuel System
Fuel Pump Pressure
600 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 kPa (15 psi) minimum
1200 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 kPa (44 psi) minimum
Full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 kPa (44 psi) minimum

Overflow Valve
Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300–550 kPa (44–80 psi)

Injectors
To adjust the rocker arm pretension for injectors:

W2005262

Tighten the rocker arm adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Obtain zero clearance

Tighten the rocker arm adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional 4 flats (2/3 turn) clockwise

Inlet and Exhaust System

Variable Geometry Turbocharger
Turbine rotor shaft axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040–0.090 mm (0.002–0.004 inch) maximum
Turbine rotor shaft radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.330–0.500 mm (0.013–0.020 inch) maximum

Heat Retention Function

Heat retention activated:
Coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than 60°C (140°F)
Engine load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than approximately half load
Heat retention deactivated:
Coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Greater than 70°C (158°F)
Engine load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Greater than approximately half load
Ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Greater than 13°C (55°F)

Inlet Manifold Air Temperature Sensor

Cold engine, engine off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambient temperature
Warm engine, engine running with
coolant temperature at 75–95°C (167–203°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40°C (104°F) above ambient temperature
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 19(53)

Engine Brake Activation

Braking Force (%) Engine Brake (On/Off)
40% Off
50%1 On
70% On
100% On
Cruise mode On/Off
1 50% braking power can only be obtained in automatic position or with a 3-position switch.

Activated:
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Greater than approximately 700–800 rpm
Vehicle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Greater than approximately 5 km/h (3 mph)
Engine oil temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Greater than 20°C (68°F)
Boost pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than 150 kPa (22 psi)
Deactivated:
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than approximately 800–900 rpm
Vehicle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than approximately 5 km/h (3 mph)
Engine oil temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than 15°C (59°F)
Boost pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Greater than 170 kPa (24 psi)

Compression Brake Switch

2-way switch can give 0% or 100% braking power.
3-way switch can give 0%, 50% or 100% braking power.
4-way switch can give 0%, 40%, 70% or 100% braking power.
5/6-way switch can give 0%, 40%, 70% or 100% braking power, and also 50% in A-position.

Exhaust Back Pressure

Exhaust back pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 kPa (4.35 psi) maximum

Cooling System
General
Pressure valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi)

Thermostat
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Opening temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82°C (180°F)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 20(53)

Coolant
For additional cooling system volumes, coolant require-
ments and maintenance intervals, refer to Service Informa-
tion Function Group 18.

Type 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regular Coolant

Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple/fuchia
Contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glycol and anti-corrosion additives
Mixed with. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water (STD 1285,1)
Type 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Extended Life Coolant (ELC)
Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
Contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glycol and anti-corrosion additives
Mixed with. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water (STD 1285,1)
Type 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extended Service Coolant (ESC)
Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue
Contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glycol and anti-corrosion additives
Mixed with. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water (STD 1285,1)

Fan On/Off
Activated System Conditions Fan Engagement
Coolant temperature 100°C (212°F) Activated
Coolant temperature 96°C (205°F) Deactivated
Inlet manifold temperature 85°C (185°F) Activated
Inlet manifold temperature 80°C (176°F) Deactivated
Engine (ECM) temperature Greater than 100°C (212°F) Activated
Engine (ECM) temperature Less than 95°C (203°F) Deactivated
AC system Greater than 20 bar (290 psi) Activated
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 21(53)

Electronically Controlled Viscous Fan

Activated System Conditions Fan Engagement
Coolant temperature 99°C (210°F) Variable fan speed activation
For FAN-VISE (no cold start feature):
Fan starts to come on at 96°C, full on at
99°C.
For FAN-VIE2 (cold start feature): Fan
starts to come on at 99°C, full on at
102°C..
Engine (ECM) temperature Greater than 100°C (212°F) 1200 rpm
Less than 95°C (203°F) Deactivated

Inlet manifold air temperature Greater than 70°C (150°F) 1200 rpm
Greater than half of maximum engine 7 second delay after engine brake
torque activated
AC compressor clutch activated Engine speed greater than 1500 rpm 1200 rpm
Ambient temperature greater than 40°C
(104°F)
Vehicle speed less than 45 km/h (28
mph)
AC compressor clutch activated Engine speed greater than 1200 rpm 1000 rpm
Ambient temperature greater than 30°C
(86°F)
Vehicle speed less than 45 km/h (28
mph)
AC compressor clutch activated Ambient temperature greater than 35°C 1200 rpm
(95°F)
Vehicle speed less than 10 km/h (6
mph)
AC compressor clutch activated Ambient temperature greater than 20°C 600 rpm
(68°F)
Vehicle speed less than 20 km/h (12
mph)
AC compressor clutch activated Refrigerant pressure greater than 20 Full engagement
bar (300 psi)

Note: The A/C compressor RPM triggers are no longer

used; were removed in 2000-2005 time frame. Currently,
head pressure above 20 bar (290 psi) is used to trigger fan
for A/C.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 22(53)

Engine Control System

Engine ECM
Number of pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 x 62

Sensors
Note: Use tech tool for component function and sensor val- Note: Sensors vary by engine.
ues checks.

Charge Air Pressure Sensor

Check values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.07 ± 0.1 volts at 1001 kPa (14.5 psi)

1 Normal atmospheric pressure at sea level.

Camshaft Sensor
Distance to toothed gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 ± 0.4 mm (0.04 ± 0.02 inch)

Crankcase Pressure Sensor

Crankcase pressure, normal value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than 1.0 kPa (0.14 psi)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 23(53)

Tightening Torques and Patterns

Engine Component Torque Specifications (Critical Fasteners)
Note: All components are to be clean and free from foreign applied to the torque wrench settings (readings) in order to
material or corrosion. Assemblies are to be made using suit- obtain accurate fastener torque values.
able tools and procedures so that no permanent damage
occurs as a result of the assembly.
Threads, washers under the head of the screw and the
CAUTION
washer face of the nuts should be lubricated with clean en-
Repeated tightening of fasteners and threaded compo-
gine oil unless otherwise specified.
nents reduces their capacity to function adequately. The
The following listed fasteners require the use of a calibrated
following table describes the various items and the limits
manual torque wrench. If an adaptor is required in combina-
of their reusability. Failure to conform to these limits can
tion with a torque wrench, a correction factor must be
result in severe component damage.

Fasteners Examples Reusable Limit Reuse Recommendations

Highly loaded screws (phosphat- Cylinder head 5 times Apply engine oil on threads and
ing plus oil) Cylinder block under screw head.
Camshaft bearing housing Mark bolt head with an
Transmission indentation.
Flywheel Dry mounting for new screws
(delivered with oil pre-applied
and anti-rust treatment for spare
parts).
If a part is replaced, e.g., cylin-
der head, also replace the
screws.
Highly loaded screws (phosphat- Injector clamp Not reusable
ing plus oil)
Highly loaded screws (phosphat- Connecting rods 5 times
ing plus oil)
Special screws (specific shape) Oil pan and valve cover No limit No limit if no cracks, corrosion or
damage to the flat surfaces.
Stainless steel/bronze studs and Turbocharger Not reusable If turbocharger, exhaust mani-
flange locknuts (Spiralock) Exhaust manifold fold or EGR valve studs or nuts
EGR valve are loosened, they must be
replaced.
Prevailing torque feature screws Piston cooling nozzles Not reusable
(Dri-lock Plastic or Tuflock) Timing gear plate

Standard screws Property class 8.8 Do not reuse Torque and angle tightened or
yield limit tightened bolts.
Standard screws Property class 10.9 No limit No limit if no cracks, corrosion or
Property class 12.9 damage to the flat surfaces.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 24(53)

Fasteners Examples Reusable Limit Reuse Recommendations

V-nipple with taper threads With locking fluid pre-applied Not reusable Before fitting the new nipple,
clean the hole with a nipple tap
and apply sealant on the nipple
thread, or use a new coated
nipple.
Taper plugs or nipples With sealer fluid pre-applied Not reusable Before fitting the new nipple,
clean the hole with a nipple tap
and apply sealant on the nipple
thread, or use a new coated
nipple.

Tightening Torques Function Group 20

General Tightening Torques
M6 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ± 1.5 Nm (7.4 ± 1 ft-lb) (89 ± 13 in-lb)
M8 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
M10 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
M12 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 ± 15 Nm (63 ± 11 ft-lb)
M14 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 ± 25 Nm (103 ± 18 ft-lb)
M16 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 ± 35 Nm (162 ± 26 ft-lb)

Bolts that have been torque-tightened only, can be reused.

Torque-tightened, angle-tightened, yield-limit-tightened bolts:
10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Can be reused
12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Can be reused

Note: Check bolts before reusing. There should be no visible change in screw pitch. Bolts showing damage, for example cut
marks on the underside or distortion of the flats, should be discarded.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 25(53)

Tightening Torques Function Group 21

Intermediate front engine mounting brackets (accessories brackets):
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 ± 15 Nm (77.5 ± 11 ft-lb)
Step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ± 5 degrees
Front engine mounting:
Bracket to engine block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 ± 45 Nm (203 ± 33 ft-lb)
Bracket to engine cushion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 ± 25 Nm (103 ± 18 ft-lb)
Cushion to cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 ± 15 Nm (63 ± 11 ft-lb)
Rear engine mounting:
Bracket to flywheel housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 ± 45 Nm (221 ± 33 ft-lb)
Bracket to engine cushion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 ± 90 Nm (398 ± 66 ft-lb)
Cushion to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 ± 30 Nm (148 ± 24 ft-lb)
Crankshaft main bearing cap:
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 ± 20 Nm (111 ± 15 ft-lb)
Step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 ± 5 degrees
Connecting rod cap:
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ± 3 Nm (15 ± 2 ft-lb)
Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ± 3 Nm (44 ± 2 ft-lb)
Step 3 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 ± 5 degrees
Piston cooling nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Engine block plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ± 5 Nm (37 ± 7 ft-lb)

T2022728

Engine stiffening frame:

Step 1: Tighten the bolts 1-24 in numerical order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ± 5 Nm (30 ± 4 ft-lb)
Step 2: Tighten the bolts 1-24 in numerical order (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 ± 5 degrees
Note: These bolts should not be reused.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 26(53)

T2022337

Note: Apply sealant outside the groove as illustrated, maximum 20 minutes before mounting.
Thickness of sealant bead: US2014, US2017: 2 mm (0.079 inch)

W2005945

Timing gear plate, tighten in sequence shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ± 4 Nm (21 ± 3 ft-lb)

Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 27(53)

W2006478

Timing gears:
1. Drive gear, crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
2. Double idler gear:
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 3 Nm (19 ± 2 ft-lb)
Step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 ± 5 degrees
Note: Tighten following the order shown in the illustration.
3. Idler gear, adjustable:
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ± 4 Nm (26 ± 3 ft-lb)
Step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 ± 5 degrees
Note: Tighten following the order shown in the illustration.
4. Drive gear, camshaft (includes vibration damper):
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 ± 5 Nm (33 ± 4 ft-lb)
Step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 ± 5 degrees
Note: Tighten following the order shown in the illustration.
5. Idler gear: 140 ± 10 Nm (103 ± 7 ft-lb)
6. Drive gear, power steering pump: 100 ± 10 Nm (74 ± 7 ft-lb)
7. Drive gear, non-clutched air compressor: 200 ± 50 Nm (147 ± 37 ft-lb)
7. Drive gear, clutched air compressor: 12 ± 2 Nm (9 ± 1.5 ft-lb)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 28(53)

W2006480

T2025683

Flywheel housing:
Step 1: Tighten all M14, M10, M8 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Step 2: Tighten all bolts in numerical order to the following torque:
M14 bolts (1–7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 ± 20 Nm (103 ± 15 ft-lb)
M10 bolts (8–11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (36 ± 6 ft-lb)
M8 bolts (12–22) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Note: Apply sealant in a 2 mm (0.079 inch) thick bead as illustrated.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 29(53)

T2023649

T2022983

Timing gear cover:

Step 1: Position the cover in place with bolts 1 and 2 and install alignment tool.
Step 2: Tighten the bolts in the numerical order shown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Note: Apply sealant in a 2 mm (0.079 inch) thick bead, maximum 20 minutes before mounting, and carefully tighten the con-
tact surfaces shown in the enlarged parts of the illustration.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 30(53)

T2022729

Flywheel:
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ± 5 Nm (44 ± 4 ft-lb)
Step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 ± 10 degrees
Note: Make sure the flange is dry and clean. Tighten the bolts in the numerical order as shown.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 31(53)

T2022739

Cover, crankshaft seal:

Step 1. Position the cover with bolts 2 and 7 and tighten to contact
Step 2: Tighten the bolts in numerical order 1–8 as shown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Note: Apply sealant in a 2 mm (0.079 inch) thick bead as illustrated and tighten bolts in numerical order.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 32(53)

T2022730

Crankshaft vibration damper:

Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ± 5 Nm (26 ± 4 ft-lb)
Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 ± 10 Nm (66 ± 7 ft-lb)
Note: Tighten the bolts in the numerical order 1, 2 ,3, 4, 5, 6, 1.

T2022734

Cylinder head:
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 ± 5 Nm (74 ± 4 ft-lb)
Step 2 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 ± 5 degrees
Step 3 (angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 ± 5 degrees
Note: The cylinder head must be mounted according to instructions, see Cylinder Head, Replacement Function Group 21.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 33(53)

T2022796

Bearing cap, camshaft/rocker arm shaft:

Bearing caps 1 to 6 are attached with one bolt on the engine right side and two bolts on the engine left side, while bearing
cap 7 is attached with only one bolt per side. Tighten the bolts in the following steps as illustrated:
Note: Tighten the bolts in numerical order from bearing cap 1 to 7 or 7 to 1, except in step 2.
Step 1: With camshaft and bearing caps in place, tighten the
marked bolts of bearing caps 1 to 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ± 3 Nm (30 ± 2 ft-lb)
Step 2: With rocker shaft in place, tighten the
marked bolts (in stages) in the order 4, 3, 5, 2, 6, 1, 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ± 5 Nm (44 ± 4 ft-lb)
Note: The bolts must be tightened in stages to ensure that the rocker arm shaft is seated without bending.
Step 3: Angle tighten marked bolts of bearing caps 1 to 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 ± 5 degrees
Step 4: Tighten the marked bolts of bearing caps 1 to 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ± 3 Nm (30 ± 2 ft-lb)
Step 5: Angle tighten the bolts of bearing caps 1 to 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 ± 5 degrees
Step 6: Loosen the marked bolts of bearing caps 1 to 6.
Step 7: Tighten the marked bolts of bearing caps 1 to 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ± 3 Nm (30 ± 2 ft-lb)
Step 8: Angle tighten the bolts of bearing caps 1 to 6 and the bolt of bearing cap 7 . . . . . . . . . . . . . . . . . . . . . . 120 ± 5 degrees
Note: When only the rocker arm has been loosened, step 1 and step 3 are not required.
Engine brake control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 34(53)

T2022965

Locknut, valve adjustment screw (inlet/exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ± 4 Nm (28 ± 3 ft-lb)

T2022966

Locknut, valve adjustment screw (exhaust, engine brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ± 4 Nm (28 ± 3 ft-lb)

Note: Hold the valve bridge while tightening.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 35(53)

W2005946

Locknut, engine brake rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 ± 4 Nm (38 ± 3 ft-lb)

T2022951

Camshaft bearing cap spring tab (engine brake only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 3 Nm (18 ± 2 ft-lb)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 36(53)

T2022732

Valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ±3 ft-lb)

Note: Tighten the bolts in the numerical order shown.

W2085322

Valve cover frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ±4 Nm (18 ±3 ft-lb)

Tightening Torques Function Group 22

Oil pump, pickup tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ±4 Nm (18 ±3 ft-lb)
Oil pump attaching screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ±4 Nm (18 ±3 ft-lb)
Oil pressure pipe coupling nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 ±20 Nm (150 ±15 ft-lb)
Oil inlet pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ±3 Nm (18 ±2 ft-lb)
Oil plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 ±13 Nm (100 ±10 ft-lb)
Oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ±4 Nm (18 ±3 ft-lb)
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 - 30 Nm (18.5 - 22 ft-lb)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 37(53)

T2023838

Oil pan (steel and plastic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ±3 ft-lb)

Install the oil pan bolts A and B, and tighten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ±3 ft-lb)
Tighten the bolts from the middle and outwards in order 1–4 as shown . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ±3 ft-lb)
Finish by checking the torque for bolts A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ±3 ft-lb)
Drain plug, oil pan (steel and plastic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ± 10 Nm (44 ± 7 ft-lb)

T2022733

Oil cooler, retaining bolts:

Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ± 1 Nm (44 ± 9 in-lb)
Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 ± 4 Nm (20 ± 3 ft-lb)
Note: Tighten the bolts diagonally and finish by tightening the first bolt again.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 38(53)

T2023837

Oil cooler cover:

Position the cover to the engine block and install bolt (A) into the oval hole. Press the cover against the water pump housing
using an assembly tool and install bolt (B). Check that the cover is positioned correctly.
Install bolts C and D and tighten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Tighten the cover bolts from the middle and outwards in order 1–4 as shown . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Finish by checking the torque for bolts C and D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 39(53)

Tightening Torques Function Group 23

T2022208

Retainer, injector:
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 +5/-0 Nm (15 +4/-0 ft-lb)
Step 2 Angle tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 ±5 degrees
Step 3 Loosen until the torque is 25 +5/-0 Nm (18 +4/-0 ft-lb).
Step 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 ±5 degrees

T2022967

Locknut, injector adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 ± 4 Nm (38 ± 3 ft-lb)

Tandem pump (power steering pump) mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)

Note: Torque all mounting nuts to specification twice.
Fuel pump (mounted on power steering pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 +2/-0 Nm (6 +1/-0 ft-lb)
Fuel filter housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Fuel filter (primary, secondary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ± 3 Nm (13 ± 2 ft-lb)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 40(53)

Fuel line fittings:

A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ± 3 Nm (13 ± 2 ft-lb)
B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ± 4 Nm (20.5 ± 3 ft-lb)
C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ± 4 Nm (22 ± 3 ft-lb)
D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ± 5 Nm (26 ± 4 ft-lb)
E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ± 5 Nm (29.5 ± 4 ft-lb)
F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 5 Nm (35 ± 4 ft-lb)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 41(53)

Tightening Torques Function Group 25

Intake manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ±4 Nm (18 ±3 ft-lb)
Note: Tighten the bolts diagonally from the center outward.
Housing, preheater:
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ± 2 Nm (8 ± 1 ft-lb)
Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 3 Nm (18 ± 2 ft-lb)
Note: Tighten the bolts diagonally.
Preheater terminal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ± 1.5 Nm (8 ± 1 ft-lb)
Plug, M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ± 3 Nm (15 ± 2 ft-lb)
Pressure/temperature sensor, boost air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ± 1 Nm (88 ± 9 in-lb)

T2022740

Exhaust manifold:
Step 1: Tighten bolts 1 through 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10 Nm (4 - 7 ft-lb)
Step 2: Tighten bolts 1 through 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ± 4 Nm (22 ± 3 ft-lb)
Step 3: Tighten bolts 1 through 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 ± 4 Nm (38 ± 3 ft-lb)
Note: Tighten the exhaust manifold bolts following the numbered sequence shown.

W2083738

Exhaust manifold heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)

Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 42(53)

Exhaust gas recirculation (EGR):

EGR valve mounting bolts:
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ±4 Nm (15 ±3 ft-lb)
Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 ±4 Nm (38 ±3 ft-lb)
Note: Tighten the bolts diagonally.

EGR valve rear heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ±4 Nm (18 ±3 in-lb)

EGR cooler mounting brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ±4 Nm (18 ±3 ft-lb)
EGR hot pipe clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Nm (50 in-lb)
EGR cooler mounting screws and locknuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ±4 Nm (9 ±3 ft-lb)
EGR cooler draincock mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ±3 Nm (11 ±2 ft-lb)
EGR cooler draincock valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ±0.5 Nm (27 ±4 in-lb)
EGR cooler hexagon drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ±6 Nm (30 ±4 in-lb)
V-band clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ±4 Nm (15 ±3 ft-lb)
Starter heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ±4 Nm (18 ±3 ft-lb)
Mixing chamber inlet tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ±4 Nm (18 ±3 ft-lb)
Venturi tube mounting fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ±4 Nm (18 ±3 ft-lb)
Crossover pipe support bracket clamp screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ±4 Nm (18 ±3 ft-lb)

W2111111

EGR spring hose clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (90 in-lb)

W2111112

EGR worm-gear hose clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ±0.5 Nm (40 ±4 in-lb)

Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 43(53)

Turbocharger:
Turbocharger mounting screws and nuts:
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ± 4 Nm (15 ± 3 ft-lb)
Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
Note: Tighten diagonally.

Inlet elbow hose clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ± 1 Nm (80 ± 9 in-lb)

Charge air cooler V-clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 ± 1 Nm (62 ± 9 in-lb)
Diffuser V-clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ± 2 Nm (9 ± 1.5 ft-lb)
Turbocharger oil supply and return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Turbocharger coolant supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 5 Nm (35 ± 4 ft-lb)
Turbocharger coolant return:
Hollow screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 5 Nm (35 ± 4 ft-lb)
Fitting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ± 6 Nm (44 ± 5 ft-lb)
SRA coolant supply and return:
At turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ± 3 Nm (9 ± 2 ft-lb)
At block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 5 Nm (35 ± 4 ft-lb)
Closed crankcase ventilation (CCV):
Mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Hose clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ± 0.6 Nm (35 ± 5 in-lb)

US2007–US2014 Emissions

Diesel Particulate Filter (DPF):

Compact (under cab):
Lower mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
Mounting strap fastener. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 ± 4 Nm (20 ± 3 ft-lb)
Vertical (back of cab):
Mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 ± 15 Nm (63 ± 11 ft-lb)
Mounting strap fastener. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 ± 1 Nm (17 ± 1 ft-lb)
Exhaust V-band clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ± 2 Nm (62 ± 18 in-lb)
DPF V-band clamp:
Step 1 – Tighten to specification listed below.
Step 2 – Using a plastic hammer, firmly tap around the clamp in 4 places in sequence shown.

W2103266
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 44(53)

Step 3 – Retighten to specification listed below.

• 2007 – 2009: 15 ± 1 Nm (132 ± 9 in-lb)

• 2010 – 2016: 20 ± 1 Nm (177 ± 9 in-lb)

Note: Years listed above are vehicle build dates, not model years.
US2010-2014 Emissions
Selective Catalytic Reduction (SCR), vertical:
Mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 Nm (200 ft-lb)
Cage fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Nm (50 ft-lb)
Heat shield fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Exhaust V-band clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ± 2 Nm (62 ± 18 in-lb)
V-band clamps (DPF to SCR pipe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ± 0.5 Nm (60 ± 5 in-lb)
Selective Catalytic Reduction (SCR), horizontal:
Mounting strap nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 ± 5 Nm (400 ± 45 in-lb)
Frame rail mounting bracket nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 ± 25 Nm (103 ± 18 ft-lb)
Heat shield screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Exhaust V-band clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ± 2 Nm (62 ± 18 in-lb)
V-band clamps (DPF to SCR pipe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ± 0.5 Nm (60 ± 5 in-lb)

US2010– forward Emissions

Diesel Exhaust Fluid (DEF) tank:

DEF pump screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
ACM bracket screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
ACM mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Solenoid valve mounting bracket screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ± 0.5 Nm (27 ± 4 in-lb)
Tank cover screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
goofTank bracket to bracket screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Tank bracket to tank screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
Frame rail mounting bracket to tank bracket fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 ± 15 Nm (63 ± 11 ft-lb)
Frame rail mounting bracket to frame fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 ± 25 Nm (103 ± 18 ft-lb)
Diesel Exhaust Fluid (DEF) Pump
Filter cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 ± 2.5 Nm (16.5 ± 2 ft-lb)
Coolant connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 ± 0.5 Nm (50 ± 5 in-lb)
Inlet connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ± 0.5 Nm (35 ± 5 in-lb)
Backflow connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ± 0.5 Nm (40 ± 5 in-lb)
Outlet connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ± 0.5 Nm (35 ± 5 in-lb)
Note: When a connector is replaced, a new O-ring must be used.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 45(53)

US2017–forward Emissions

W2116655

1 Torque: 200± 30 Nm (148 ± 22 ft-lb )

2 Torque: 300 ± 30 Nm (221 ± 22 ft-lb )
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 46(53)

W2116654

1 Large V-clamp for DPF service cover: 15 ± 1 Nm (11 ± 0.7 ft-lb)

2 Small V-clamp for DPF service cover: 15 ± 1 Nm (11 ± 0.7 ft-lb )
3 Pressure pipe: 30 ± 5 Nm (22 ± 4 ft-lb)
4 Pressure pipe: 30 ± 5 Nm (22 ± 4 -lb) ft
5 Inspection plug: 30 ± 5 Nm (22 ± 4 ft-lb)
6 Bracket for clamping pressure pipes: 6± 1 Nm (4.4 ± 0.7 ft-lb)
7 Differential pressure sensor: : 6± 1 Nm (4.4 ± 0.7 ft-lb)
8 Temperature sensors: 45± 5 Nm (33 ± 4 ft-lb)
9 NOx-sensors: 50± 10 Nm (37 ± 7) ft-lb
10 Urea (DEF) injector: 10± 1 Nm (7 ± 0.7 ft-lb)
11 PM sensor: 35± 5 Nm (26 ± 4 ft-lb)
12 Ammonia sensor: 50± 10 Nm (37 ± 7 ft-lb)
13 Bracket for urea (DEF) injector pipes: 10± 1.5 Nm (7 ± 1ft-lb)
14 Heat shield for wire harness and sensor-ECU;s bracket: 24± 4 Nm (18 ± 3 ft-lb)
15 Mounting straps to chassis bracket: 48 ± 10 Nm (35 ± 7 ft-lb)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 47(53)

W2005926

Aftertreatment hydrocarbon doser (non-integrated):

Doser:
Aftertreatment hydrocarbon doser fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ± 2 Nm (53 ± 18 in-lb)
Mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ± 0.5 Nm (125 ± 4.5 in-lb)
Fuel line fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ± 2 Nm (195 ± 18 in-lb)
Cooling lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 5 Nm (35 ± 4 ft-lb)
Two-way check valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Nm (18 ft-lb)
Air line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm (20 ft-lb)
Shut-off Valve:
Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 ± 3 Nm (120 ± 24 in-lb)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 48(53)

W2116722

Aftertreatment hydrocarbon doser (integrated)

Doser:
Mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ± 0.5 Nm (125 ± 4.5 in-lb)
Air/Fuel line fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ± 2 Nm (195 ± 18 in-lb)
M10 P-clamp flange screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ± 4 Nm (21 ± 3 ft-lb)
Connection joint between left and right fuel pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ± 2 Nm (135 ± 18 in-lb)
Aftertreatment hydrocarbon dosing module:
Air/Fuel line fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ± 2 Nm (195 ± 18 in-lb)
Fuel line from housing to module fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ± 3 Nm (186 ± 27 in-lb)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 49(53)

Tightening Torques Function Group 26

W2005979

Coolant pump (Note: Tighten in sequence twice) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)

Coolant pump pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Coolant pump housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)

W2031416

Front and side cover, thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Nm (21 ft-lb)

Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
Drive belt idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Fan hub:
15mm hex (wrench size) nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
VHD with 13L engine, 45mm stud length and 16mm hex (wrench size) nut . . . . . . . . . . . . . . . . . . . . . 70 ± 12 Nm (52 ± 9 ft-lb)
Viscous fan drive:
Drive-to-hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Upper radiator hose clamp:
Screw-type band clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm (45 in-lb)
Screw-type band clamp with spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (90 in-lb)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 50(53)

Tightening Torques Function Group 28

Note: Sensors vary by engine.

Sensor and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specification

Flywheel position/speed, top of flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 ± 2 Nm (6 ± 1 ft-lb)
Camshaft position, timing gear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 ± 2 Nm (6 ± 1 ft-lb)
Turbocharger speed, top middle of turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 ± 2 Nm (75 ± 18 in-lb)
Turbocharger discharge temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 ± 4.5 Nm (33 ± 3 ft-lb)
Oil level/temperature, inside sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ± 1 Nm (89 ± 9 in-lb)
Oil pressure, block, front of air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ± 5 Nm (22 ± 4 ft-lb)
Coolant level, surge tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plug-in
Coolant temperature, front right side cylinder head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ± 3 Nm (16 ± 2 ft-lb)
Fuel pressure, fuel filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 3 Nm (18.5 ± 2 ft-lb)
Aftertreatment fuel injector fuel pressure, behind fuel filter housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 3 Nm (18.5 ± 2 ft-lb)
Crankcase pressure, block, front of air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 3 Nm (18.5 ± 2 ft-lb)
Charge air pressure, mixing chamber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ± 1 Nm (89 ± 9 in-lb)
Charge air temperature, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ± 1 Nm (89 ± 9 in-lb)
Humidity, fresh air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 ± 3 Nm (20 ± 2 ft-lb)
Charge air temperature and pressure, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ± 1 Nm (89 ± 9 in-lb)
EGR temperature, EGR venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 ± 4.5 Nm (33 ± 3 ft-lb)
EGR differential pressure, EGR venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ± 3 Nm (15 ± 2 ft-lb)
Piston cooling jet pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 3 Nm (18.5 ± 2 ft-lb)
DPF temperature, DPF inlet, catalyst, outlet modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 ± 4.5 Nm (33 ± 3 ft-lb)
DPF differential pressure, DPF inlet, catalyst, outlet modules:
Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ± 1 Nm (53 ± 9 in-lb)
Fitting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3 ± 2.7 Nm (12 ± 2 ft-lb)
NOx sensor, exhaust pipe after DPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ± 10 Nm (37 ± 7 ft-lb)
NOx sensor, exhaust pipe after SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ± 10 Nm (37 ± 7 ft-lb)
NOx module, frame bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 51(53)

US2007, 2010, 2014 Emissions

W2116754

1. Level sensor for water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . not replaceable, integrated in the cabling
2. Engine oil level/temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . torque for standard screw
3. Fuel pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 3 Nm (18 ± 2 ft-lb)
4. Coolant level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plug-in model
5. Charge air pressure/temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6 standard bolt, 8 ± 2 Nm (6 ± 1 ft-lb)
6. Camshaft position sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6 standard screw, 8 ± 2 Nm (6 ± 1 ft-lb)
7. Flywheel position/speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6 standard screw, 8 ± 2 Nm (6 ± 1 ft-lb)
8. Oil pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 3 Nm (18 ± 2 ft-lb)
9. Crankcase pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 3 Nm (18 ± 2 ft-lb)
10. Coolant temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ± 3 Nm (16 ± 2 ft-lb)
11. Exhaust counter-pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 3 Nm (18 ± 2 ft-lb)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 52(53)

Tightening Torques Function Group 3

Starter motor mounting nuts:
M12 nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 ± 15 Nm (63 ± 11 ft-lb)
Note: Torque all mounting nuts to specification twice.
Starter cables (Bat+, E-):
M12 nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 5 Nm (18.5 ± 4 ft-lb)
Starter control wire:
M6 nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ± 1 Nm (35 ± 9 in-lb)
Alternator:
Mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
Pad mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.5 ± 7.5 Nm (48 ± 5.5 ft-lb)
Pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.5 ± 6.5 Nm (75 ± 5 ft-lb)
Battery terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.5 ± 0.25 Nm (57.5 ± 2.5 in-lb)
Ground terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 ± 0.5 Nm (55 ± 5 in-lb)
I, R terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 ± 0.5 Nm (20 ± 5 in-lb)
AC refrigerant compressor mounting bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Wiring harness conduit to block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 3 Nm (18 ± 2 ft-lb)
Wiring harness conduit cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 ± 0.5 Nm (31 ± 4.4 in-lb)
Cable channel cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 ± 0.5 Nm (31 ± 4.4 in-lb)

Tightening Torques Function Group 5

Air compressor mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 ± 15 Nm (63 ± 11 ft-lb)
Note: Torque all mounting nuts to specification twice.
Air compressor out connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 ± 20 Nm (96 ± 15 ft-lb)
Non-Clutched Air compressor gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 ± 50 Nm (147 ± 37 ft-lb)
Clutched Air compressor gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ± 2 Nm (9 ± 1.5 ft-lb)
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 11.2016 200 321 16 53(53)

Engine Lubricants and Sealants

Use only the following recommended sealing compounds Note: All genuine cylinder head gaskets are pre-coated and
and lubricants. do not require any type of sealing compound. When instal-
ling new gaskets, clean and degrease gasket sealing surfa-
ces to avoid leaks.

Location Sealant or Lubricant

Cup plugs/threaded plugs Loctite® 277 or equivalent/Teflon® thread sealer
Cylinder liner seat 1161231 sealant
Oil filter seal Clean engine oil
Holding metal parts in place Petroleum jelly
Valve stems and guides Clean engine oil

Engine front cover/flywheel housing/timing gear cover 3092340 sealant

Engine parts, fasteners and washers Clean engine oil
Exhaust manifold studs and NOx sensors High temperature 1161929 anti-seize
Oil cooler assembly O-ring Clean engine oil
Oil cooler cover Permatex 85409 or equivalent gasket dressing
O-rings, coolant, EPDM Clean coolant, or Dow Corning® 55
O-rings (except as noted) Dow Corning® 55 O-ring lubricant
Threaded sensors Sealing compound on threads
Turbocharger mounting nuts 1161929 anti-seize