IMPACT 4.00.51.

00-SNAPSHOT 16/06/16

Chassis ID Path
A 676806 21/Specifications//Engine

Model Identity
FM 132771206

Publish date ID/Operation

26/02/14

Engine
Note: As the same illustrations are reused for different variants, some details may differ for the variant you are working
on. However, the essential information in the illustrations is always correct.

Contents
Engine
Cylinder head
Cylinder head bolt
Cylinder block
Cylinder liner
Piston
Piston rings

Valve mechanism
Valves
Rocker arm brake VEB+
Valve seats
Valve seat position
Valve guides
Rocker arms
Valve springs

Engine transmission
Timing gear
Camshaft
Camshaft bearings

Crank mechanism
Crankshaft
Main bearing journals

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

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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Thrust washers (axial bearing)

Main bearing shells
Main bearing pin
Main bearing shells
Connecting rod
Flywheel, installed
Flywheel housing, installed

Tightening torques and order

Engine mounting
Main bearing- and connecting rod cap
Stiffening frame
Timing gear plate
Timing gear
Flywheel and transmission housing
Timing gear cover, upper
Flywheel
Cover, crankshaft seal
Vibration damper
Cylinder head
Bearing caps, camshaft/rocker arm shaft
Valve cover
Valves/caliper/brake arm VEB
Spring tab

Engine

Cylinder head

Max unevenness (base plane) 0.1 mm

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Cylinder head bolt

Quantity/cylinder head 38

Thread size M16

Length 200 mm

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Cylinder block

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Length 1,052 mm

Height, upper block face - crankshaft centre 422 mm

Height, lower block face - crankshaft centre 120 mm

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Cylinder liner

Type Wet, exchangeable

Height of sealing surface above block face 0.18 ± 0.03 mm

Number of sealing rings per cylinder liner 1+3

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Piston

Height above cylinder block face

0.1 (min) – 0.7 (max) mm

steel piston

-0.1 (min) – 0.5 (max) mm

aluminium piston

Number of ring grooves 3

Front marking Arrow facing forwards

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Piston rings

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Compression rings

Quantity.....2

Labelling..... On the top (colour marking to the left

of the opening)

Piston ring clearance in grooves:

upper compression ring..... (trapezoidal form)
lower compression ring..... 0.09 — 0.14 mm

Piston ring gap measured in ring opening

upper compression ring < 0.7 mm

lower compression ring < 1.7 mm

Oil scraper ring

Quantity.....1

Labelling..... On the top (colour marking to the left

of the opening)

Piston ring clearance in grooves..... 0.05 — 0.10 m

Piston ring gap measured in < 0.7 mm

ring opening

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Valve mechanism

Valves

Valve disc, diameter:

Inlet..... 42 mm
Exhaust..... 40 mm

Valve stem, diameter:

Inlet/Exhaust..... 8 mm
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Valve seat angle (A):

Inlet..... 24.5°± 0.2
Exhaust..... 39.5°

Seat angle in cylinder head (B):

Inlet..... 25°
Exhaust..... 40°

Measurement (A) between valve disc and cylinder head face:

Inlet..... Max. 1.6 mm
Exhaust..... Max. 2.0 mm

Valve clearances, cold engine, setting values:

Inlet..... 0.2 mm
Exhaust..... 0.8 mm
Exhaust, VEB..... 1.6 mm
Exhaust, VEB+..... 0.8 mm

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Rocker arm brake VEB+

Standard setting and control

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

This setting or control of brake clearance is measured at the roller and while using a feeler gauge to totally eliminate
the exhaust valve clearance.

Rocker arm brake VEB+, setting value..... 2.85 mm

Rocker arm brake VEB+, check value1 ..... 2.80 –

2.90 mm

1
Control checks are only valid for engines that are well run in or directly after loading when adjusting.

Fault control

This fault check does not replace the above check that is done without using a feeler gauge to eliminate exhaust valve
clearance.

Feeling gauge thickness..... 3.20 mm

It should be very easy to insert the feeler gauge.

Note: This dimension cannot be used for adjustment!

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Valve seats

Specifications

Outside diameter (A):

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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Inlet..... 45.1 mm
Exhaust..... 43.1 mm

Height (B) :
Inlet..... 7.7 mm
Exhaust..... 7.5 mm

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Valve seat position

Specifications

Diameter (C):
Inlet..... 45.0 mm
Exhaust..... 43.0 mm

Depth (D):
Inlet..... 11.8±0.1 mm
Exhaust..... 11.2±0.1 mm

Seat bottom radius (R):

Inlet/Exhaust..... max 0.8 mm

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Valve guides

Length:
Inlet/Exhaust..... 83.5 mm

Inside diameter:
Inlet/Exhaust..... 8 mm

Height above cylinder head spring surface:

Inlet/Exhaust..... 24.5 ± 0.2 mm

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

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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Wear value

Clearance valve stem-guide ( Dry valve stem ) :1

Inlet..... max 0.5 mm
Exhaust..... max 0.5 mm

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

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Rocker arms

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

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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Bearing play..... max 0.1 mm

Rocker arm roller, play..... max 0.1 mm

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Valve springs

Inlet

Length, without load..... 72.0 — 74.0 mm

Exhaust

Outer valve spring:

Length, without load..... 72.0 — 74.0 mm

Inner valve spring:

Length, without load..... 70.0–71.0 mm

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Engine timing gear

Timing gear

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Gear wheel:

1. Drive gear, crankshaft

2. Idler gear: outer gear wheel

inner gear wheel

3. Idler gear, adjustable

4. Drive gear and oscillation damper, camshaft

5. Idler gear, servo pump

6. Drive gear, steering servo and fuel feed pump

7. Drive gear, air compressor

8. Drive gear, lubricating oil pump

9. Engine power take-off (extra equipment)1

1
For higher power take-off torques than 650 Nm, gear wheels 1, 2 and 9 must be exchanged for case-hardened
versions.

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

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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Backlash adjustable idler gear to camshaft drive

gear..... 0.05 - 0.15 mm

Backlash, oil pump..... 0.05 - 0.40 mm

Backlash, other..... 0.05 - 0.17 mm

Run-out clearance for idler gear..... max 0.05 mm

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Camshaft

Control of camshaft settings, cold engine and valve clearance for cylinder 1 inlet valve = 0.
The inlet valve for cylinder 1 at flywheel position 6° ATDC should be open 1.6 ± 0.3 mm
When checking, the timing gears must be rotated in the correct direction (clockwise seen from the front) in
order to take up all backlash.

Drives..... gear

Number of bearings.....7

Diameter, bearing journals, standard..... 70.0 mm

For any undersize components, refer to the Parts Catalogue.

Valve lift at zero play:

Inlet..... 12.9 mm
Exhaust (VEB)..... 13.1 mm
Exhaust (EPG)..... 12.3 mm

Unit injector, stroke..... 17 mm

Wear value

Max end float..... 0.3 mm

Bearing, max. permitted run-out wear..... 0.1 mm

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Camshaft bearings

Camshaft bearing thickness, standard..... 1.92 mm

For any oversize components, refer to the Parts Catalogue.

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Crank mechanism

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

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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Crankshaft

Wear value

Crankshaft axial clearance1 ..... max 0.4 mm

Machining values

Ovality of main bearing journals and big-end

bearing journals..... max. 0.01 mm

Taper of main bearing journals and big-end bearing

journals..... max 0.02 mm

Run-out of middle bearing..... max 0.15 mm

1
The dimensions refer to oiled parts.

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Main bearing journals

Diameter (Ø) standard..... 108.0 mm

For any undersize components, refer to the Parts Catalogue.

Surface finish, main bearing journal..... Ra 0.25

Surface finish, radius..... Ra 0.4

Width, axial bearing pin (A) standard..... 47.0 mm

For any oversize components, refer to the Parts Catalogue.

Recess radius (R) ..... 4.0 mm

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

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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Thrust washers (axial bearing)

Width (B) standard..... 3.2 mm

For any oversize components, refer to the Parts Catalogue.

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Main bearing shells

Thickness (D) standard..... 2.5 mm

For any oversize components, refer to the Parts Catalogue.

Main bearing, max. permitted run-out wear..... 0.05–0.12 mm

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Main bearing pin

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Diameter (Ø) ..... 99 mm

For any undersize components, refer to the Parts

Catalogue.

Surface finish, big end bearing journal..... Ra 0.25

Surface finish, radius..... Ra 0.4

Width (A) ..... 57 mm

Recess radius (R) ..... 4 mm

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Main bearing shells

Thickness (C) standard..... 2.4 mm

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Connecting rod

Axial clearance, connecting rod - crankshaft1 ..... max 0.4 mm

Big-end bearing, diametrical play1 ..... max 0.2 mm

1
The dimensions refer to oiled parts.

Marking:
FRONT on the shaft is turned forward.

Connecting rod and cap are marked as a pair with a three-digit identification number (see illustration).

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Flywheel, installed

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

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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Axial run-out (manual gearbox) measurement radius 150 mm..... < 0.2 mm

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Flywheel housing, installed

Axial mismatch for mating surface against clutch casing..... max 0.2 mm

Radial mismatch for guide against clutch casing..... max. 0.3 mm

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Tightening torques
Engine mounting

Front engine anchorage, cylinder block..... 275 ± 45 Nm

Front engine mounting, front engine pad

normal and severe road conditions..... 140 ± 25 Nm
very severe road conditions..... 140 ± 25 Nm (CONC-NAM 160 ± 25 Nm)

Front engine pad, vibration damper..... 48 ± 8 Nm

Front engine pad, cross member..... 175 ± 30 Nm

Rear engine mounting, flywheel housing..... 300 ± 45 Nm

Rear engine mounting, rear engine pad..... 540 ± 90 Nm

Rear engine pad, frame..... 140 ± 25 Nm

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Main bearing- and connecting rod cap

Main bearing cap:

step 1..... 150 ± 20 Nm
step 2 (angle tightening)..... 120±5°

Connecting rod cap:

step 1..... 20 ± 3 Nm
step 2..... 60 ± 3 Nm
step 3 (angle tightening)..... 90±5°

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Stiffening frame

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Stiffening frame:
step 1: Tighten the bolts 1-24 in numerical order..... 45±5 Nm
step 2: Tighten the bolts 1-24 in numerical order (angle tightening)..... 60±5°

Note: Tighten the screws in the numerical order shown in the illustration. The bolts must not be reused.

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Timing gear plate

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Alternative 1, (Previous version –30 screws): Alternative

Timing gear plate..... 28±4 Nm

Note: Apply a bead of silicon outside the groove as illustrated, max 20 minutes before mounting.
Silicon bead thickness: 2 mm.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Timing gear plate:

Tighten all bolts in numerical order with the following torque:

M8 bolts.....28±4Nm

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Timing gear

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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Old system without hex. socket screw. New system with hex. socket screw

1. Drive gear, crankshaft..... 24±4 Nm

2. Idler gear, outer bull gear:

step 1..... 25 ± 3 Nm
step 2 (angle tightening)..... 110±5°

Note: Tighten in the order shown in the illustration.

3. Idler gear, adjustable:

step 1..... 35 ± 4 Nm
step 2 (angle tightening)..... 120±5°

Note: Tighten in the order shown in the illustration.

4. Drive gear, camshaft:

step 1..... 45±5 Nm
step 2 (angle tightening)..... 90±5°

Note: Tighten in the order shown in the illustration.

5. Idler gear:
hex. socket screw..... 140±10 Nm
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

(No hex. socket screws on older models).

6. Drive gear, steering servo and fuel feed pump..... 100 ± 10 Nm

7. Drive gear, air compressor..... 200+50/-0 Nm

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Flywheel and transmission housing

Flywheel housing later version:

step 1: Tighten all bolts in numerical order to the corresponding torques that follow:
M14 bolts..... 140 ± 20 Nm
M10 bolts..... 48 ± 8 Nm
M8 bolts..... 24±4 Nm

Note: Apply silicon in a 2 mm thick bead as illustrated below.

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

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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Flywheel housing previous version:

step 1: Tighten all bolts in numerical order to the corresponding torques that follow:
M14 bolts..... 140 ± 20 Nm
M10 bolts..... 48 ± 8 Nm
M8 bolts..... 24±4 Nm
X = Plug..... 40±4 Nm

Note: Apply silicon in a 2 mm thick bead as illustrated below (max. 20 minutes before assembly).

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

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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Timing gear cover, upper

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Apply silicon in a 2 mm thick bead as illustrated above, max 20 minutes before assembly.
Fit the casing in two steps:
Step 1: Secure the casing with bolts 1 and 2. Use the special tool to press the casing into place. ..... 4±1 Nm
Step 2: Tighten the bolts in numerical order as shown in the illustration...... ..... 24±4 Nm

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Flywheel

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Flywheel:
step 1..... 60 ± 5 Nm
step 2 (angle tightening)..... 120±10°

Note: Make sure the flange is dry and clean. Tighten the screws in the numerical order shown in the illustration.

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Cover, crankshaft seal

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Casing crankshaft seal

Step 1: Tighten bolts 2 and 7 ..... 24±4 Nm
Step 2: Make sure the casing lies flush with the engine block, checking with a steel rule. (Version A) .....
Step 3: Tighten all bolts in order 1-8..... 24±4 Nm

Note: Apply silicone as shown in the illustration (max. 20 minutes before assembly).

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Vibration damper

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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Oscillation damper on the crankshaft

Step 1:..... 35±5 Nm
Step 2:..... 90 ± 10 Nm.....

Note: Tighten the screws in the numerical order shown in the illustration.
The vibration damper 8.8 bolts must not be reused.

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Cylinder head

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Cylinder head:

Note: The cylinder head must be installed in accordance with the instructions, refer to “21124–1 Cylinder head,
install” in Group 21.

step 1..... 100 ± 5 Nm

step 2 (angle tightening)..... 120±5°
step 3 (angle tightening)..... 90±5°

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Bearing caps, camshaft/rocker arm shaft

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Camshaft: (camshaft and bearing caps in place)

Fit a mandrel onto the number 7 bearing bracket, to protect the guide sleeve.
step 1: Tighten bolts 1-7..... 25 ± 3 Nm
step 2: (with shorter additional bolts) Tighten bolts 8-13 and 20..... 60±5 Nm
step 3: Angle-tighten bolts 1-7..... 90±5 °
step 4: Remove the extra bolts 8-13 and 20
Remove the mandrel from the number 7 bearing bracket.

Rocker arm shaft: (rocker arm shaft in place)

step 5: Tighten bolts 8-13 and 20 consecutively in the order 11, 10, 12, 9, 13, 8, 20..... 60±5 Nm
step 6: Tighten bolts 14-19..... 25 ± 3 Nm
step 7: Angle-tighten bolts 14-19..... 120±5 °
step 8: Loosen bolts 8-13
step 9: Tighten bolts 8-13..... 25 ± 3 Nm
step 10: Angle tighten screws 8–13 and 20..... 120±5 °

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

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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Valve cover

Valve cover..... 24±4 Nm

Note: Tighten the screws in the numerical order shown in the illustration.

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Valves/caliper/brake arm VEB

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Lock nut (A), valve..... 38±4Nm

Lock screw (B), yoke..... 38±4Nm

Lock nut (C), brake arm VEB+..... 52±4Nm

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Spring tab

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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Spring tab, VEB..... 25 ± 3 Nm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.00.51.00-SNAPSHOT 16/06/16

Spring tab, VEB+..... 25 ± 3 Nm

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

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