Service Bulletin
Volvo Truck Corporation
Göteborg, Sweden Trucks
Date Group No. Release Page
4.06 211 76 02 1(12)
Cylinder head, removal
D13A
Cylinder head, removal
T2019470
Contents
• “Cylinder head, remove” page 2
20 069204
ENG22046 English
Printed in Sweden
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 211 76 02 2(12)
Service Procedures
21122-1
Cylinder head, remove
Note: Since illustrations are used for several different variants, certain details may differ
from the variant in question. The essential information in the illustrations is, however,
always correct.
Special tools: 9990006, 9990185, 9990262,
9996046, 9996239, 9996400, 9996966,
9998249, 9998251, 9998264, 88800014
1
Disconnect power from the vehicle by turning off the
main switch.
2
Drain coolant into a suitable vessel. Use drain hose
9996046.
9996046
T2022127
3
Loosen the hose to the charge air cooler and move
to one side.
Remove the cover for the thermostat housing and
the thermostat.
WARNING
Watch out for hot coolant!
T2022128
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 211 76 02 3(12)
4
Remove the fan ring bracket.
5
Remove the by-pass pipe bolts. Remove the coolant pipe
fixture bolts. Pull the by-pass pipe out a little so that it
clears the cylinder head.
Remove the coolant temperature sensor connector from
below the thermostat housing.
T2022605
6
Clean around the fuel filter housing nipple and around
the overflow valve.
Open the fuel filter housing nipple and the fuel pipe
connection on the front edge of the cylinder head. Let the
fuel drain into a suitable collection container.
Tighten the fuel filter housing nipple.
T2022606
7
Remove the crankcase ventilation pipe from the valve
cover.
Remove the rubber clamp from the inlet pipe and bend
aside.
8
Remove the rocker cover.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 211 76 02 4(12)
9
Remove the camshaft position sensor.
Note: Retain any shims.
T2021625
10
Remove the wiring and rubber clamps from the inlet pipe.
11
Remove the pipe between the turbo and the air filter
housing.
T2021618
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 211 76 02 5(12)
12
Remove the flexible hose from the air intake.
Remove the bolt holding the air filter housing to the
flywheel casing. Remove the bolts holding the air filter
housing to the cab-latch cross member. Remove the
sensor connector from the air filter housing.
Move aside the air filter housing to improve access to
the cylinder head.
T2021619
13
Remove the clamp between the turbocharger and the
shutter housing.
Remove the shutter housing and put to one side.
Comments: Do not remove the shutter housing from
the exhaust pipe.
T2022787
14
Remove the charge air pipe from under the turbocharger.
15
Detach the air hose from the actuator.
T2022214
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 211 76 02 6(12)
16
Remove the oil pressure and return lines from the
turbocharger.
Remove the turbocharger.
WARNING
Risk of crushing between chassis and turbocharger.
T2022360
17
Loosen the union nuts on the compressor pressure pipe.
Remove the pressure pipe clamps.
18
Clean carefully around the fuel line connection on the
cylinder head. Remove the banjo bolts from the fuel line.
Note: Protect openings in pipes and the cylinder head
from dirt.
19
Remove the positive connection from the preheater.
20
Remove the oil filler pipe attachment from the inlet pipe.
Move aside the oil filler pipe.
21
Remove the rear clamp on the upper charge air hose.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 211 76 02 7(12)
22
Remove the plugs from the flywheel casing. Fit the
rotation tool 88800014.
Crank the flywheel until the piston in cylinder 1 is at
TDC, 0 on the flywheel.
88800014
T2022114
23
Clean and dry around the control valve.
Remove the electrical connector from the solenoid valve.
Remove the cable ties.
T2022123
24
Remove the VEB control valve and the pipe to the
rocker arm shaft.
T2022124
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 211 76 02 8(12)
25
Remove the spring plate from the camshaft bearing cap
(applies to VEB engines).
T2022139
26
Loosen the bolts on the rocker arm shaft evenly along the
entire shaft so that it does not bend.
Remove the bolts and fit lifting tool 9990185. Use the tool
that is suitable for the particular type of engine.
9990185
T2022140
27
Carefully lift off the rocker arm bridge.
Note: For VEB, fix the pistons in the exhaust rocker arms
with rubber bands or similar, so that they do not fall out
when the rocker arm bridge is lifted.
The pistons and rocker arms are matched. One, two
or three punch marks shall match between the rocker
arm and piston.
9990185
T2022618
28
Mark and remove the valve yokes.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 211 76 02 9(12)
29
Remove the electrical connections from the unit injectors.
Remove the cable ties holding the wiring to the control
valve.
Remove the plastic plugs that secure the cabling, without
cutting off the cable tie.
Remove the bolts holding the cable conduit to the cylinder
head. Carefully extract the wiring from the cylinder head.
30
Note: Clean very thoroughly around the unit injectors.
Remove the bolts from the unit injector yokes.
Fit puller 9990006 onto the injector. Place the puller’s fork
in the groove in the injector and lock the arms with the
screw on the side. Fix the puller by screwing down the
screw against the injector’s ball socket. Fit slide hammer
9996400 with adapter 9990262 and loosen the injector.
9990006, 9990262 , 9996400
T2022099
31
Fit the protective sheath 9998249 to the removed unit
injector.
9998249
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 211 76 02 10(12)
32
Put a protective plug 9998251 in the hole in the cylinder
head left by the unit injector.
Repeat the procedure for the remaining unit injectors.
9998251
T2022206
33
Remove the camshaft bearing caps.
T2022284
34
Carefully lift away the camshaft with lifting tool 9998264.
9998264
C2000508
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 211 76 02 11(12)
35
Turn the crankshaft so that a bolt in the timing gear plate
is accessible, and remove it. Turn the crankshaft a little
and remove the other bolt.
T2022362
36
Remove the upper screws from the idler gear hub.
T2022363
37
Remove the cylinder head bolts.
T2022364
38
Remove engine oil from the “hollows” beneath the
camshaft to prevent oil running into the coolant channels.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 4.06 211 76 02 12(12)
39
40
Fit two lifting chains 9996239.
Note: Use washers between the cylinder head and
chains to protect the sealing surfaces of the cylinder head.
Carefully lift off the cylinder head.
9996239
T2019470
41
Remove the cylinder head gasket.
Secure the cylinder liners with clamping tool 9996966.
9996966
T2019374
42
Remove the cranking tool.
