Volvo euro 6 valve /injector adjustment

[newmercman]

Apart from the future use of turbocompounding and other forms of energy recovery, surely it makes sense to having the timing gear at the rear with the other spinning thing, the flywheel?

Ancillary drives for A/C, PAS, compressor, will all be electric before long, so the front end of the engine can be “cleaner” and cast accordingly, saving weight and still retaining the same structural integrity.

CAT were doing research in the 90s to that effect, the ancillaries were electrically powered, but the batteries couldn’t cope, there was talk of going to 48v, but with battery technology moving forward as it is, I can see that idea being resurrected in the future.

[toecutter]

Finally got around to doing the job,similar to previous ohc volvos ,turn flywheel till marks are inline on cam end/cap inlets 0.2mm ,ex 1.6mm there are no shims to change if the tolerance is out as prev engines its a simple adjustment .Injectors are only adjusted on cyl 2,4,6,slacken lock nut off back the screw out ,turn in till 0 cam clearance then angle tighten 240 degrees.

[newmercman]

If you’re up for a visit to Canada then you can come and sort mine out, no ■■■■ here seems to have a clue!

After my top end reset I’ve had a very weak engine brake, no difference between positions 2&3 and they can’t seem to figure out what’s going on.

So far I’ve had the valves set three times, numerous oil pressure sensors, actuators, a turbo and next on the list is the rockers and rocker shaft.

To add insult to injury I’ve been charged for all the diagnostic work so far, although there’s a difference between getting a bill and paying a bill, I’ve informed them that they’ve got no chance of me paying them to fix something that was working fine before they got their greasy mitts on it. Unbelievable…

[toecutter]

newmercman:
If you’re up for a visit to Canada then you can come and sort mine out, no [zb] here seems to have a clue!

After my top end reset I’ve had a very weak engine brake, no difference between positions 2&3 and they can’t seem to figure out what’s going on.

So far I’ve had the valves set three times, numerous oil pressure sensors, actuators, a turbo and next on the list is the rockers and rocker shaft.

To add insult to injury I’ve been charged for all the diagnostic work so far, although there’s a difference between getting a bill and paying a bill, I’ve informed them that they’ve got no chance of me paying them to fix something that was working fine before they got their greasy mitts on it. Unbelievable…

I had same prlem few yrs ago with a D13C i thnk it was, halfway along top of rockers there is a solenoid valve on engine n/s with a tube that pressurises oil for eng brake ,the tube has an o ring on its end ,think it was perished or dislodged ill try to get a picture ,whats your chassis number ■■? position 1 is exhaust brake only,if you disconnect the pipe that feeds the shutter housing ,(after turbo) and you have no retardation at all on position 2 then engine braking isnt working at all.

[bking]

newmercman:
If you’re up for a visit to Canada then you can come and sort mine out, no [zb] here seems to have a clue!

After my top end reset I’ve had a very weak engine brake, no difference between positions 2&3 and they can’t seem to figure out what’s going on.

So far I’ve had the valves set three times, numerous oil pressure sensors, actuators, a turbo and next on the list is the rockers and rocker shaft.

To add insult to injury I’ve been charged for all the diagnostic work so far, although there’s a difference between getting a bill and paying a bill, I’ve informed them that they’ve got no chance of me paying them to fix something that was working fine before they got their greasy mitts on it. Unbelievable…

They have set the exhaust/jake brake wrong.Must admit they are a ■■■■■ to set,better to leave the bloody things alone.
But once you set them wrong what a bleedin nightmare to get right.The settings from Volvo are all to bollox anyway.

[newmercman]

I’ve had that oil feed O ring checked, there’s all kinds of weird stuff going on with it. The turbo replacement is not connected to the engine brake problem, or so they’re saying!

Now I’m not an expert by any means, but I know my way around an engine as I understand what each part does and all that knee bone connected to the thigh bone stuff, I’ve also owned lorries since 1994, so I’ve been under more than my fair share of cabs. I also ask fitters what they’re doing and why so that I understand why I’m getting such a big bill lol.

So I was due a service, I asked the head fitter at the local Volvo approved garage, who is a full on Volvo master technician if he advised a top end reset and he said he did, the engine had 480,000kms on it at the time, so in it went.

When I picked it up and headed out with a trailer I noticed my engine brake performance was bad, comparable with the exhaust brake on an F10 or similar. So I told them and took it back after that trip and they readjusted the top end again. I also told them I was using a lot of DEF (adblue) approx 3x normal use and that’s what led to the turbo being replaced.

It didn’t fix my engine brake issues though and as I said, there’s some weird stuff going on. It has a 3 position engine brake, position 1 is exhaust brake only, 2 is 50% engine brake and 3 is 100% engine brake, there’s no noticeable difference between 2 & 3 except I have more turbo boost in position 3, around 30psi to the 15psi in position 2. The boost gauge also flutters and as rpms build boost pressure decreases. So if I start at the top of a hill at 1600rpm with 30psi at 2000rpm I’m down to 15-20psi and the engine brake weakens as rpms increase, before it got stronger the higher the rpms went, as it should.

So now they tell me the next step is to replace the rockers and rocker shaft, but I’m not convinced, I don’t believe in coincidences, not in situations like this, the lorry was fine before they took the valve cover off and now it’s not.

I despair of it and it has far reaching consequences, if it turns out to be incompetence on their part then I won’t use them again, but I’m already boycotting the main dealer as they’re just a joke, I had that timing cover leak that started this thread fixed and had a weird vibration afterwards, I kept stopping to check it out and discovered that they hadn’t tightened the bolts holding the hanger bearing to the crossmember, so the prop was shaking around! They also trashed my cab, busted my phone charger, got grease on my seats and pinched the O ring on a fuel filter so it was losing prime overnight and I had to keep bleeding it, until I got my overalls on and started checking things out. I had a meeting with the service manager and after apologies he said he couldn’t get decent staff, not very confidence inspiring for a customer to hear!

So if this lot can’t sort this out, where can I go to get my work done? Nowhere, so it’s going to be pointless having Volvos if I can’t get them looked after.

[carryfast]

newmercman:
there’s all kinds of weird stuff going on with it.

Has it run ok since the timing cover episode or did the issues appear after that ?.If not did it mean a tear down of all the timing gear to fix the cover leak ?.If so have they got the timing spot on when they reassembled all the timing gear ?.Bearing in mind they don’t even seem to have been able to make sure that the driveline was all put back properly. It would be easy enough to check just by taking the cam/rocker cover off on the usual number 1 is at tdc on the cam as number 6 is on the changeover basis.

[newmercman]

It’s a different truck!

[carryfast]

newmercman:
It’s a different truck!

Somehow I’ve missed that bit when reading through all the different episodes.

[newmercman]

Carryfast:

newmercman:
It’s a different truck!

Somehow I’ve missed that bit when reading through all the different episodes.

[emoji3] [emoji3] [emoji3] [emoji3]

[bking]

TOECUTTER:
4Finally got around to doing the job,similar to previous ohc volvos ,turn flywheel till marks are inline on cam end/cap inlets 0.2mm ,ex 1.6mm there are no shims to change if the tolerance is out as prev engines its a simple adjustment .Injectors are only adjusted on cyl 2,4,6,slacken lock nut off back the screw out ,turn in till 0 cam clearance then angle tighten 240 degrees.

You set them on the flywheel marks.

[bking]

Remove flywheel cover plate,turn engine to tdc mark.Check which cylinder is on the rock 1 or 6. If number 6 on the rock set inlet and exhaust on cylinder 1,inlet on 2 exhaust on 3 inlet on 4 and exhaust on 5.Turn engine 360 degrees then set inlet and exhaust on 6,inlet on 5,exhaust on 4,inlet on 3 and exhaust on 2.Easy way is work out rocker arm ratio and measure gap between rollers and the cam.Set number one by setting gap on crossheads to tappet setting then measure roller/cam gap,set the rest to this gap.Saves faffing about trying to get a feeler gauge under the crossheads.Leave the bloody jake adjusters alone.

[toecutter]

Bking:

TOECUTTER:
4Finally got around to doing the job,similar to previous ohc volvos ,turn flywheel till marks are inline on cam end/cap inlets 0.2mm ,ex 1.6mm there are no shims to change if the tolerance is out as prev engines its a simple adjustment .Injectors are only adjusted on cyl 2,4,6,slacken lock nut off back the screw out ,turn in till 0 cam clearance then angle tighten 240 degrees.

You set them on the flywheel marks.

tool in flywheel hole ratchet it till marks on rear of cam align with 2 marks on end cap, good exercise if you do it alone ■■■ back n forward getting it inline, u can use alternator pulley on a euro 5 but eng turns backwards !!! the ratchet tool from a D13C ENG doesnt fit a euro 5 but does fit a EURO 6 ■■? FFS.

[toecutter]

newmercman:
I’ve had that oil feed O ring checked, there’s all kinds of weird stuff going on with it. The turbo replacement is not connected to the engine brake problem, or so they’re saying!

Now I’m not an expert by any means, but I know my way around an engine as I understand what each part does and all that knee bone connected to the thigh bone stuff, I’ve also owned lorries since 1994, so I’ve been under more than my fair share of cabs. I also ask fitters what they’re doing and why so that I understand why I’m getting such a big bill lol.

So I was due a service, I asked the head fitter at the local Volvo approved garage, who is a full on Volvo master technician if he advised a top end reset and he said he did, the engine had 480,000kms on it at the time, so in it went.

When I picked it up and headed out with a trailer I noticed my engine brake performance was bad, comparable with the exhaust brake on an F10 or similar. So I told them and took it back after that trip and they readjusted the top end again. I also told them I was using a lot of DEF (adblue) approx 3x normal use and that’s what led to the turbo being replaced.

It didn’t fix my engine brake issues though and as I said, there’s some weird stuff going on. It has a 3 position engine brake, position 1 is exhaust brake only, 2 is 50% engine brake and 3 is 100% engine brake, there’s no noticeable difference between 2 & 3 except I have more turbo boost in position 3, around 30psi to the 15psi in position 2. The boost gauge also flutters and as rpms build boost pressure decreases. So if I start at the top of a hill at 1600rpm with 30psi at 2000rpm I’m down to 15-20psi and the engine brake weakens as rpms increase, before it got stronger the higher the rpms went, as it should.

So now they tell me the next step is to replace the rockers and rocker shaft, but I’m not convinced, I don’t believe in coincidences, not in situations like this, the lorry was fine before they took the valve cover off and now it’s not.

I despair of it and it has far reaching consequences, if it turns out to be incompetence on their part then I won’t use them again, but I’m already boycotting the main dealer as they’re just a joke, I had that timing cover leak that started this thread fixed and had a weird vibration afterwards, I kept stopping to check it out and discovered that they hadn’t tightened the bolts holding the hanger bearing to the crossmember, so the prop was shaking around! They also trashed my cab, busted my phone charger, got grease on my seats and pinched the O ring on a fuel filter so it was losing prime overnight and I had to keep bleeding it, until I got my overalls on and started checking things out. I had a meeting with the service manager and after apologies he said he couldn’t get decent staff, not very confidence inspiring for a customer to hear!

So if this lot can’t sort this out, where can I go to get my work done? Nowhere, so it’s going to be pointless having Volvos if I can’t get them looked after.

Have you an invoice when the valves were set 1st time, ,if so it should state if any ex valve shims were changed ask them what they set the clearances too , as for changing rockers etc wtf is that gonna do they far better try the solenoid valve that feeds the oil …

[newmercman]

They called me yesterday and according to Volvo they’ve been having problems with those solenoids straight out of the box, so they’re going to replace it again.

Now a separate issue, they tell me I should see approx 38psi at max boost, well I’m seeing over 45psi on the gauge, so my new turbo is not set correctly. Will this lead to problems? I know that my Cosworth had to have different head bolts to stop the head lifting because of an uprated turbo (it was done by the previous owner)

[bking]

TOECUTTER:

Bking:

TOECUTTER:
4Finally got around to doing the job,similar to previous ohc volvos ,turn flywheel till marks are inline on cam end/cap inlets 0.2mm ,ex 1.6mm there are no shims to change if the tolerance is out as prev engines its a simple adjustment .Injectors are only adjusted on cyl 2,4,6,slacken lock nut off back the screw out ,turn in till 0 cam clearance then angle tighten 240 degrees.

You set them on the flywheel marks.

tool in flywheel hole ratchet it till marks on rear of cam align with 2 marks on end cap, good exercise if you do it alone ■■■ back n forward getting it inline, u can use alternator pulley on a euro 5 but eng turns backwards !!! the ratchet tool from a D13C ENG doesnt fit a euro 5 but does fit a EURO 6 ■■? FFS.

So two of you have to set the tappets?Or up and down out the pit to get the right position then again for second set point.Good Idea FFS.
TDC is marked on the flywheel never noticed?

[fly_sheet]

This is an interesting read, I’ve had a couple of top end resets on these newer type Volvo engines & all have been fine, the engine brakes have been useless on all 8 I’ve owned & driven & I’m sad to say if Your looking for top class engine braking Volvo isn’t the truck for You.

Regarding rockers & issues this 2015 I’m currently in needed a rocker replacing due to the engine brake coming on during cold cranking when it was a few weeks old. Don’t ask Me how what or why as compared to most postings on here can’t hope to compete with Your understanding of engineering.

Fly sheet

[toecutter]

Bking:
Remove flywheel cover plate,turn engine to tdc mark.Check which cylinder is on the rock 1 or 6. If number 6 on the rock set inlet and exhaust on cylinder 1,inlet on 2 exhaust on 3 inlet on 4 and exhaust on 5.Turn engine 360 degrees then set inlet and exhaust on 6,inlet on 5,exhaust on 4,inlet on 3 and exhaust on 2.Easy way is work out rocker arm ratio and measure gap between rollers and the cam.Set number one by setting gap on crossheads to tappet setting then measure roller/cam gap,set the rest to this gap.Saves faffing about trying to get a feeler gauge under the crossheads.Leave the bloody jake adjusters alone.

Please explain how YOU adjust Volvo "JAKE BRAKE "

[toecutter]

fly sheet:
This is an interesting read, I’ve had a couple of top end resets on these newer type Volvo engines & all have been fine, the engine brakes have been useless on all 8 I’ve owned & driven & I’m sad to say if Your looking for top class engine braking Volvo isn’t the truck for You.

Regarding rockers & issues this 2015 I’m currently in needed a rocker replacing due to the engine brake coming on during cold cranking when it was a few weeks old. Don’t ask Me how what or why as compared to most postings on here can’t hope to compete with Your understanding of engineering.

Fly sheet

Totally agree they are poor at best ,ive driven a euro 6 with ishift and voith retarder ,that was poor also compared to the Man zf and scanias own …

[newmercman]

fly sheet:
This is an interesting read, I’ve had a couple of top end resets on these newer type Volvo engines & all have been fine, the engine brakes have been useless on all 8 I’ve owned & driven & I’m sad to say if Your looking for top class engine braking Volvo isn’t the truck for You.

Regarding rockers & issues this 2015 I’m currently in needed a rocker replacing due to the engine brake coming on during cold cranking when it was a few weeks old. Don’t ask Me how what or why as compared to most postings on here can’t hope to compete with Your understanding of engineering.

Fly sheet

Told you it was a good thread!