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IMPACT 3.

0 Saturday, 23 November 2013

Chassis ID Path
A 690289 2/Repair/FM, D13A440/Cylinder head, install

Model Identity
FM 131610748

Publish date ID/Operation No.


Thursday, 17 January 2013 21124-1

21124-1 Cylinder head, install

Caution
Always ensure cleanliness while working on the engine charge air system. Remove the dirt particles from the
system, that are even smaller than 1mm (0.04 in) to avoid serious engine damages and cover or plug the
openings immediately.

Note: As the illustrations in the service literature are used for several different engine variants, certain details may differ
from the variant you are working with.
The essential information in the illustrations is, however, always correct.

Special tools: 9990185, 9992669, 9996239, 9996966, 9998264, 9998599, 9998601, 9998628, 9999683, 9999696,
88800014, 88800031

Other special equipment: 1159794, 1159797

COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Check that no old washers remain in the copper sleeve.

COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Carefully clean the unit injector copper sleeves using brush 9808570 and extension 9808616. These tools are available
in kit 9998599

Check that the copper sleeves are properly clean.

Poorly cleaned copper sleeves can cause leaks.

Warning
When cleaning the unit injectors, under no circumstances may rotary wire brushes, wire brushes or similar tools
be used on the injector nozzle. There is a risk that this will damage or block the injector jets, causing loss of
power etc.
If necessary use a rag soaked in paraffin or similar instead.

Special tools: 9998599

Clean the cylinder head bolts before reuse.

When cleaning of the cylinder head bolts under no circumstances may rotary wire brushes, hand wire brushes or
similar tools be used. There is a risk that the phosphate coating of the screws could be damaged which would impair
their corrosion protection.

Note: The cylinder head bolts may not be used more than 5 times. Mark them with a punch.

COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Remove the press tools.

Carefully clean the cylinder block, cylinder head, timing gear cover and timing gear plate.
Check that the guide washers on the engine block and cylinder head are clean and free of rust.

Fit a new cylinder head gasket.

Note: Check that the seals are correctly positioned with their holes all centred.

Special tools: 9996966

5
Fit a new gasket in the coolant pipe.

6
Apply a 2 mm thick string of a Volvo-approved sealant on the side of the groove in the timing gear plate, see
Specifications .

Note: Install all cylinder head bolts and all screws through the timing gear plate in order.
The cylinder head must be fitted and tightened within 20 minutes of the application of the sealant.

COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Carefully lower the cylinder head until it is in contact with the cylinder head gasket. Make sure that the guide washers
(1) are correctly positioned. Press the cylinder head onto the timing gear plate.

Make sure that the gasket in the coolant pipe is not damaged when fitting the cylinder head.

Insert a bolt through the hub of the idler gear bolt and the timing gear plate. Tighten screw to 28 Nm.

Special tools: 9996239

Other special equipment: 1159794

Specifications:
28 Nm

COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Insert 4 cylinder head bolts into locations 24, 26, 28 and 30. Tighten the bolts to 25 +10 5 Nm. /
Slacken off the bolt that goes through the timing gear plate by 45. Otherwise there is a risk that the screw will shear off
when the cylinder head bolts are tightened.

Other special equipment: 1159794

Specifications:

25 +10 5 Nm
/
9
Fit the remaining cylinder head bolts.

Torque and angle tighten the cylinder head bolts according to the tightening diagram, see Specifications .

10

COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Remove the plug from the flywheel casing and fit cranking tool 88800014

Special tools: 88800014

11

Push a piece of rag into the flywheel housing to prevent screws from falling into the engine.

Never turn round the engine whilst the rag is in place.

Note: Use only new screws, pre-treated with locking compound.

Fit the bolts (1) in the timing gear plate. Torque tighten according to Specifications .
COPYRIGHT Copyright Volvo Parts Corporation
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 3.0 Saturday, 23 November 2013

Turn the engine so that the bolt holes in the timing gear plate can be reached through the idler gear hole. Fit the bolts
(2) and torque tighten according to Specifications .

Fit the remaining bolts (3) for the idler gear in the hub. Torque tighten according to Specifications .

Note: Remove the rag.

12

Fit the camshaft lower bearing shells and lubricate them with engine oil.

13

COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Carefully lift the camshaft into place.

Special tools: 9998264

14
Fit the upper bearing shells in the bearing caps. Oil the bearing shells.
Fit the bearing caps in the correct bearing brackets.

15

COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Fit bolts (2) to the right-hand side of the bearing brackets. Tighten according to Specifications .

Fit mandrel, 9992669 to the number 7 bearing bracket to protect the guide sleeve.

Fit shorter extra bolts (1) to the left-hand side of the bearing brackets. Do not fit bolts to the rocker arm bridge guide
sleeves. Torque tighten the bolts according to Specifications .

Turn the camshaft after each tightening. If the camshaft does not rotate easily, check the last tightened bearing cap.

Remove the extra bolts and the mandrel.

Special tools: 9992669

16

COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Fit new O-rings on the unit injectors.

Note: Later version: Replace the washer.

17

COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Fit the unit injectors with the yoke.

Lubricate the bolts. Fit the bolts. Torque tighten the bolts according to Specifications .

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COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Ensure that the camshaft mark (TDC) lies between the markings on the bearing cap.

Check that the flywheel is at 0.

19

Fit the camshaft gear, note the mark on the timing gear plate.

Fit the vibration damper, spacer washer and bolts. Torque tighten according to Specifications .

Other special equipment: 1159794

20

COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Check the backlash between the camshaft gear and the adjustable idler gear.

Fit a rocker indicator against one of the teeth on the camshaft gear and turn the gear forwards and backwards. Read
COPYRIGHT Copyright Volvo Parts Corporation
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 3.0 Saturday, 23 November 2013

off the value on the rocker indicator and compare with the value in Specifications . If the backlash is not correct
according to specifications, loosen the adjustable middle gear and fit a feeler gauge between the middle gear and the
camshaft gear, according to the illustration.
Torque tighten the middle gear screws according to Specifications .

Check the backlash again. Adjust if necessary.

Note: Make sure the idler gear is locked during measurement.

Special tools: 9999683, 9999696

21
Install the rocker arm shaft according to 21442-1 Rocker arm shaft, install

22

Fit the electrical contact piece to the charge air sensor.

Fit a new sealing ring to the groove in the cable grommet.

Carefully thread the cable into the cylinder head.

Connect the unit injector connectors and the solenoid valve connector.
Push in the connectors until there is a distinct click.

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COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Fit new Volvo recommended tie straps to hold the wiring onto the control valve.

24
Clean the contact surfaces on the timing gear cover, timing gear plate and cylinder head.

25

Install new seals in the upper timing gear cover.

Apply sealing compound in accordance with Specifications .

Note: The timing gear cover must be fitted within 20 minutes of the sealant being applied.

26

COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Fit the upper timing gear cover.

Fit screws in the oval holes. Do not tighten too hard.

Fit press tools 9998601 and 9998628. Press down the timing cover so that it is level.

Fit the other bolts. Torque tighten according to the tightening diagram, see Specifications .

Special tools: 9998601, 9998628

Other special equipment: 1159794

27

COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Wipe off any excess sealant from the joint (A) between the cylinder head and the upper timing gear cover.

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Turn the engine so that a tooth on the camshaft gear wheel is in the middle of the camshaft sensor hole in the upper
timing gear cover.

Special tools: 88800014


COPYRIGHT Copyright Volvo Parts Corporation
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 3.0 Saturday, 23 November 2013

29

Check the distance to the camshaft gear wheel with tool 88800031.

1. No edge = no adjustment shim.


2. One edge = one adjustment shim.
3. Two edges = two adjustment shims.

Special tools: 88800031

30

COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Fit the camshaft sensor with the correct number of adjustment shims.

31
Adjust valves and unit injectors according to 21414-3 Valves and engine injectors, adjust .

32

Fit the fuel line hollow screws with new seals onto the front edge and left-hand side of the cylinder head.
COPYRIGHT Copyright Volvo Parts Corporation
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 3.0 Saturday, 23 November 2013

33
Fit the pre-heater wiring (if the engine is equipped with a pre-heater).

34
Fit the charge air hose between the mixing chamber and charge air cooler.

35

Fit the screws securing the compressor pressure pipe and the crankcase ventilation feedback pipe in the inlet pipe.

36
Fit the turbo according to 25518-2 Engine turbocharger, replace .

37
Fit the air filter housing.
Fit the sensor connector.

38
Fit the inlet pipe between the turbocharger and the air filter housing.

39
Fit the oil filler pipe on the intake pipe. Tighten the hose clamp.

40
Fit screws in the fan ring attachment, left and right-hand sides.

41
Connect the connector to the temperature sensor.

42

COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Clean the contact surface on the valve cover, check the gasket. If damaged replace with a new gasket.

Apply a 2 mm thick bead of sealant to the contact surface (A) between the timing gear cover and the cylinder head.

Note: The timing gear cover must be fitted within 20 minutes after the sealant has been applied.

43

COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Fit the valve cover.


Torque tighten according to Specifications .

Fit the crankcase ventilation pipe.

Other special equipment: 1159797

44

COPYRIGHT Copyright Volvo Parts Corporation


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 3.0 Saturday, 23 November 2013

Check that the thermostat and gasket are in place. Fit the thermostat housing cover.

45
Fit the screws to the coolant pipe.

46
Fit the coolant hose to the thermostat housing cover.

47
Fill with coolant.

48
Vent the fuel system according to 23003-3 Fuel system, bleeding .
Clean up any spillage.

49

Warning
Make sure that the parking brake has been applied and that neutral is selected.

Start the engine and check the function and see if there is any leakage.

Allow the engine to run at low idle for about 5 minutes to allow the cylinder balancing system to set the correct amount
COPYRIGHT Copyright Volvo Parts Corporation
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 3.0 Saturday, 23 November 2013

of fuel for the fuel injectors.

Note: For cylinder balancing to take place, no power demanding components such as PTOs should be connected.

50

Refit the sound baffles.

Lower the cab.

COPYRIGHT Copyright Volvo Parts Corporation


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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