IMPACT 4.04.

00 30/04/2019

Chassis ID Path
JPCT 11318 2111/Repair//Cylinder head, install

Model Identity
UD-HDE 139797644

Publish date ID/Operation

07/11/2017 21124-1

21124-1 Cylinder head, install

Illustrations may differ slightly from the actual vehicle being serviced. However, key
components addressed in this information are represented as accurately as possible.

All threaded fasteners that do not have a tightening torque specification in the information are
tightened to a standard torque. Standard torques are available in the following specification.➠ 
Standard tightening torques

CAUTION
Risk of material damage.
Using inappropriate tools when cleaning the cylinder head screws can damage the phosphate
coating. The phosphate coating is necessary to provide adequate corrosion protection.

▶ Do not use rotary wire brushes, hand wire brushes or similar tools when cleaning the cylinder
head screws.

▶ Do not re-use the cylinder head screws more than five times. Mark the screws with a punch.

DANGER
Risk of serious injury.
The vehicle can be set in motion if appropriate safety precautions have not been taken.

▶ Before starting the engine, place the gear lever in neutral and apply the parking brake.

Special tools

88800031 88800550 88840317 88840328 88890148

9996352 9998264 9998389 9998601 9999683

9999696 88800352 88890148

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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1 Clean the cylinder head screws.

2 Remove the tools (A).

3 Carefully clean the cylinder block, cylinder head, timing gear cover and timing gear plate.

4 Check that the guide pins on the engine block and cylinder head are clean and free of rust.

5 Install the gasket.

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

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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6 Check the sealing strip.

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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7 Perform this procedure when the condition below is met.

Conditions
● If the end of the sealing strip is partly loose or the sealing strip is damaged.

▶ Repair the sealing strip ➠  Sealing strip, timing gear plate, repair .

8 Carefully lower the cylinder head.

9 Keep a distance between the cylinder head and timing gear plate (A) so that the string of
sealant on the timing gear plate (3) is not damaged.

10 Carefully lower the cylinder head so that the guide pins (1) enter the wider parts of each guide
hole (2), until the cylinder head makes contact with the cylinder head gasket (B).

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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11 Install the screw (1).

12 Torque tighten the screw (1).

Tightening torque

Idler gear, screw 28 ±2 Nm

13 Install the screws (19) - (22).

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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14 Torque tighten the screws (19) - (22).

Tightening torque

Cylinder head, screw 25+10 −5 Nm

15 Loosen the screw (1) 45°.

Note
There is a risk that the screw will shear off when the cylinder head screws are
tightened.

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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16 Install the remaining screws.

17 Torque tighten the screws.

Tightening torque

Cylinder head, screw 1. Tightening sequence: 1–26

65 ±5 Nm

2. Tightening sequence: 1–26

65 ±5 Nm

3. Tightening sequence: 1–26

120 ±5°
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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4. Tightening sequence: 1–26

90 ±5°

18 Install the screws (1).

19 Torque tighten the screws (1).

Tightening torque

Timing gear plate, screw 28 ±4 Nm

Note
Push a piece of rag into the upper timing gear cover to prevent screws from falling into
the engine.

20 Turn the crankshaft so that the screw in the timing gear plate is accessible.

21 Install the screws (2).

22 Torque tighten the screws (2).

Tightening torque

Timing gear plate, screw 28 ±4 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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23 Install the screws (3).

24 Torque tighten the screws (3).

Tightening torque

Idler gear, screw 1. 35 ±4 Nm

2. 120 ±5°

Note
Remove the rag.

25 Clean the contact surfaces.

26 Check the bearing shells, brackets and caps for damage.

27 Perform this procedure when the condition below is met.

Conditions
● If there is wear and damage in the bearing shell.

▶ Replace all the bearing shells.

28 Clean the bearing seats.

29 Install the bearing shells.

Note
Use new parts.

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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Note
Do not lubricate the bearing shells at this stage.
Install the bearing shells dry.

30 Lubricate the bearing shells.

31 Install the bearing shells.

Note
Use new parts.

Note
Do not lubricate the bearing shells at this stage.
Install the bearing shells dry.

32 Lubricate all the bearing shells.

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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33 Install the camshaft.

Required material

LIFTING_TOOL 9998264

34 Remove the tool.

35 Install the caps.

Note
As marked.

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Service hint
Use a plastic mallet.

36 Install the tools (A).

Required material

MANDREL 9996352 7 pcs

Service hint
The tools are placed on the caps to protect the guide sleeves.

37 Install the temporary screws (1).

38 Install the permanent screws (2).

Note
The rocker arm shaft will be installed later.

39 Torque tighten the screws.

Note
Ensure that the camshaft can be rotated after the screws are torque tightened.

40 Remove the temporary screws (1).

41 Remove the tools (A).

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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42 Install the tools.

Required material

TOOL KIT 88800550

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A SLEEVE 9998580

B RETAINER 9808607

C HANDLE 9808616

D BRUSH 9808570

43 Clean the sleeve.

44 Remove the tools.

45 Install the O-rings and gasket.

Note
Use new parts.

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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46 Install the unit injector along with the yoke.

47 Install the screw.

48 Tighten the screw.

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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Tightening torque

Unit injector, yoke, screw 1. 20+5 0 Nm

2. 180 ±5°

3. Loosen the yoke screw.

≈ −150°

4. 25+5 +0 Nm

5. 90 ±5°

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Required material

TORQUE WRENCH 88890148

49 Connect the connector.

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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50 Install the other injectors in the same way.

51 Remove the plug.

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52 Install the tool.

Required material

CRANKING ADAPTER 88840317

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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53 Rotate the camshaft.

54 Align the camshaft marking with the housing markings.

Note
Mark for the first cylinder.

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55 Install the gear.

56 Align the gear markings with the hole.

Service hint
Ensure that the flywheel is at 0 marking.

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57 Install the vibration damper.

58 Install the screws.

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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59 Torque tighten the screws.

Tightening torque

Camshaft gear, screw 1. Tightening sequence: 1–6

45 ±5 Nm

2. Tightening sequence: 1–6

90 ±5°

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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Required material

TORQUE WRENCH 88890148

60 Check the gear flank clearance using the tools (A) and (B).

Tech data

Gear flank clearance 0.1 ±0.05 mm

Required material

ROCKER_INDICATOR 9999683

MAGNETIC STAND 9999696

Note
Hold the idler gear in place using a suitable tool to correctly check the gear flank
clearance.
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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61 Perform this procedure when the condition below is met.

Conditions
● If the play is more than the specification.

▶ Install the feeler gauge.

Tech data

Feeler gauge, thickness 0.1 mm

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▶ Adjust the clearance.

Note
Adjust the idler gear to adjust the clearance.

Note
Ensure that the feeler gauge is difficult to move between the teeth.

▶ Hand tighten the screws.

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▶ Install the tools.

Required material

MAGNETIC STAND 9999696

ROCKER_INDICATOR 9999683

Note
Ensure that the probe tip touches the gear tooth.

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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A ROCKER_INDICATOR 9999683

B MAGNETIC STAND 9999696

▶ Check the backlash.

Tech data

Gear, backlash 0.05 – 0.17 mm

▶ Perform this procedure when the condition below is met.

Conditions
● If the backlash is not within specified value.

▶ Re-adjust the gears.

62 Install the rocker arm shaft along with the rocker arms.

Required material

LIFTING_TOOL 88800352

63 Remove the tool (A).

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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64 Remove the cable ties.

65 Install the leaf springs.

66 Install the screws.

Note
Tighten equally to avoid rocker shaft bending.

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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67 Torque tighten the screws.

Tightening torque

Camshaft bearing cap, screw 1. Tightening sequence: 1–7

25 ±3 Nm

2. Tightening sequence: 11,9,13

90 ±5 Nm

3. Tightening sequence: 8,10,12,14

60 ±5 Nm

4. Loosening sequence: 11,9,13

0 Nm

5. Tightening sequence: 11,9,13

60 ±5 Nm

6. Tightening sequence: 1–7

90 ±5°

7. Tightening sequence: 8–14

100 ±5°

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Required material

TORQUE WRENCH 88890148

68 Clean the contact surfaces.

69 Clean the sealing surfaces.

70 Install the sealing strip.

71 Install the gaskets.

Tech data

Cover, installation time limit ≤20 min

Note
Install the cover within 20 minutes of
applying the sealant.

Note
Ensure that the cover is fitted and torque tightened within time.

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72 Apply the sealant.

Tech data

Sealant, bead thickness 2 mm

Required material

Glue, tape, sealant and locking fluid

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73 Install the cover.

74 Install the screws.

Note
Do not tighten the screws.

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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75 Install the tool.

Required material

PRESS TOOL 9998389

76 Install the tool.

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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Required material

GUIDE 9998601

77 Press the cover.

78 Install the screws.

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79 Torque tighten the screws.

Tightening torque

Timing gear, cover, screw Tightening sequence: 1-5

24 ±4 Nm

80 Remove the tool.

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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81 Remove the tool.

82 Install the setting tool.

Required material

SETTING_TOOL 88800031

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83 Read off the setting tool.

Impulse sensor, number of shims

Conditions: A: No edge outside the tool. 0 pcs

Conditions: B: One edge outside the tool. 1 pc

Conditions: C: Two edges outside the tool. 2 pcs

84 Remove the setting tool.

85 Ensure that the seal seats properly.

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86 Install the sensor.

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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87 Install the screw.

88 Connect the connector.

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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89 Install the pipe along with the seals.

Note
Use new seals.

90 Install the seal.

Note
Use a new part.

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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91 Install the valve along with the pipe.

92 Install the screws and washers.

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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93 Insert the harness.

Note
Carefully insert the harness through the timing cover.

94 Connect the connector.

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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95 Install the screw.

96 Connect the connectors.

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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97 Install the cable ties.

98 Check the markings on camshaft.

Tech data

Inlet valve, adjustment, sequence 1–2–3–4–5–6

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Exhaust valve, adjustment, sequence V1–V2–V3–V4–V5–V6

Injector, adjustment, sequence 1–2–3–4–5–6

99 Rotate the flywheel.

100 Align the mark.

Note
Mark for the first cylinder.

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101 Check the valve clearance.

Tech data

Inlet valve, clearance 0.2 ±0.05 mm

Note
Use a feeler gauge.

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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102 Perform this procedure when the condition below is met.

Conditions
● If the valve clearance is not correct.

▶ Loosen the nut (A).

▶ Adjust the screw (B) until the feeler blade can be moved but there is some resistance.

▶ Prevent the screw (B) from turning, and torque tighten the nut (A).

Tightening torque

Rocker arm, lock nut 38 ±4 Nm

103 Check the valve clearance.

Service hint
Mark the checked or adjusted rocker arm.

104 Loosen the nut.

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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105 Adjust the screw until the rocker arm roller lies against the camshaft.

106 Tighten the adjustment screw a further(3–4) flats.

Tech data

Injector, pre-load 0.75 ±0.1 mm

107 Angle tighten the lock nut.

Tightening torque

Injector, lock nut 45 ±5°

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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108 Check the valve clearance.

Tech data

Exhaust valve, clearance 1.60 ±0.05 mm

Note
Use a feeler gauge.

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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109 Perform this procedure when the condition below is met.

Conditions
● If the clearance is out of range.

▶ Adjust the clearance.

▶ Remove the screw.

▶ Remove the shim.

▶ Install the shim with thickness (A).

A=B+C−D

B Old shim, thickness

[mm]

C Measured valve clearance

[mm]

D Correct valve clearance

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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[mm]

▶ Install the screw.

▶ Torque tighten the screw.

Tightening torque

Valve caliper, lock screw 38 ±4 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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▶ Check the valve clearance.

110 Rotate the flywheel.

Note
Rotate till next mark on the camshaft.

111 Adjust the clearance of other valves and injectors in the same way.

Note
Ensure that the clearance is adjusted with respect to the markings on the camshaft.

112 Remove the tool.

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113 Install the plug.

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114 Clean the sealing surface.

115 Check the gasket for damage.

116 Perform this procedure when the condition below is met.

Conditions
● If the gasket is damaged.

▶ Replace the gasket.

Note
Use a new part.

117 Install the gasket.

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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118 Remove the old sealant (A).

Note
Ensure that the surfaces are completely clean from sealant.

119 Apply the sealant (A).

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Tech data

Sealant, bead thickness 2 mm

Note
Use recommended sealant.

120 Install the valve cover.

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121 Install the screws along with the springs and caps.

122 Torque tighten the screws.

Tightening torque

Valve cover, screw Tightening sequence: 1–16

24 ±4 Nm

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123 Install the vent pipe.

124 Install the screws.

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125 Connect the connector.

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126 Install the filler pipe.

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127 Install the screws.

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128 Clean the contact surfaces.

129 Install the gasket.

Note
Use a new part.

130 Install the starter element.

131 Install the gasket.

Note
Use a new part.

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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132 Install the pipe.

133 Install the nuts.

134 Torque tighten the nuts diagonally.

Tightening torque

Starter element, nut 1. 10 ±2 Nm

2. 24 ±4 Nm

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135 Install the bracket.

136 Install the screws.

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137 Install the hose.

138 Tighten the clamp.

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139 Install the sensor.

140 Lubricate the O-ring.

Note
Use recommended grease.

141 Install the screw.

142 Connect the connector.

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143 Clean the cylinder head top contact surface.

144 Install the overflow valve.

Note
Use a new seal.

145 Torque tighten the screw.

Tightening torque

Overflow valve, screw 45+0 −5 Nm

Required material

TORQUE WRENCH 88890148

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Note
On engines with manual hand pump, bleeding of the fuel system is only required when the
whole fuel system has been drained.

146 Pump with the hand pump about 200 times.

Note
Do not open any connections.

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147 Start the engine.

148 Check for correct function.

149 Check for fuel leaks.

150 Connect the connector.

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151 Install the seal.

Note
Use a new part.

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152 Install the connection pipe.

153 Install the screws.

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154 Install the pipe.

155 Tighten the clamp.

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156 Clean the contact surface.

157 Install the seal.

Note
Use a new part.

158 Install the thermostat.

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159 Install the cover.

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160 Install the screws.

161 Torque tighten the screws.

Tightening torque

Thermostat, cover, screw 24 ±4 Nm

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162 Install the hose.

163 Tighten the clamp.

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164 Install the pipe.

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165 Tighten the nuts.

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166 Install the clamps.

167 Install the screws.

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168 Install the gasket.

Note
Use a new part.

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169 Install the assembly.

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170 Install the spacer sleeves.

171 Install the nuts (1–4).

172 Torque tighten the nuts.

Tightening torque

Turbocharger, nut 1. Tightening sequence: 1–4

20 ±4 Nm

2. Tightening sequence: 1–4

48 ±8 Nm

Required material

TORQUE WRENCH 88890148

WRENCH 88840328

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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173 Install the pipe.

174 Tighten the connector.

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175 Install the gasket.

Note
Use a new part.

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176 Install the pressure pipe.

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177 Install the screw.

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178 Install the screws.

Note
Hand tighten the screws.

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179 Lubricate the sealing ring.

Required material

Oil

180 Install the sealing ring.

Note
Use a new part.

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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181 Install the pipe.

182 Install the screw.

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183 Install the gasket.

Note
Use a new part.

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184 Install the pipe.

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185 Install the screws.

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186 Torque tighten the screw.

Tightening torque

Oil pipe, screw 24 ±4 Nm

Required material

TORQUE WRENCH 88890148

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187 Torque tighten the screw.

Tightening torque

Oil pipe, screw 24 ±4 Nm

Required material

TORQUE WRENCH 88890148

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188 Torque tighten the screws.

Tightening torque

Oil pipe, screw 1. Tightening sequence: 1

12 Nm

2. Tightening sequence: 2

24 ±4 Nm

3. Tightening sequence: 1

24 ±4 Nm

4. Tightening sequence: 3

10 ±2 Nm

5. Tightening sequence: 3

60 ±5°

6. Tightening sequence: 4
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10 ±2 Nm

7. Tightening sequence: 4

60 ±5°

Required material

TORQUE WRENCH 88890148

WRENCH 88840328

189 Install the exhaust pipe.

190 Torque tighten the V-clamp.

Tightening torque

V-clamp 12 ±1 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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Required material

TORQUE WRENCH 88890148

191 Connect the inlet hose.

192 Tighten the clamp.

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193 Connect the charge air pipe.

194 Torque tighten the clamp.

Tightening torque

Charge air pipe, clamp 7 ±1 Nm

Required material

TORQUE WRENCH 88890148

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195 Install the housing.

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196 Install the screws.

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197 Tighten the clamp.

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198 Tighten the clamp.

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199 Install the intermediate pipe.

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200 Tighten the clamp.

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201 Install the screw.

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202 Install the screw.

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203 Torque tighten the screws on both sides.

Tightening torque

Intermediate pipe, bracket, screw 24 ±4 Nm

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204 Install the pipe.

205 Tighten the clamps.

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206 Tighten the clamp.

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207 Install the clamp.

208 Install the screw.

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209 Install the inlet pipe.

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210 Install the lock braces.

211 Install the screws.

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212 Install the clamp.

213 Install the screw.

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214 Tighten the hose clamp.

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215 Fill the coolant up to the (MAX) mark.

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216 This step contains 2 alternatives.

Select one of the valid alternatives below.

Alternative 1 / 2
▶ Turn on the main switch.

Alternative 2 / 2

Conditions
● If the vehicle is equipped with ADR.

▶ Turn on the main switch.

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217 Install the exhaust hose on the exhaust pipe.

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218 Apply the parking brake.

219 Place the gear lever in neutral.

220 Start the engine (III).

221 Check the repair for leakage.

222 Check the coolant level.

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223 Fill the coolant up to the (MAX) mark.

224 Perform this procedure when the condition below is met.

Conditions
● If the vehicle has a sound insulation

▶ Install the sound insulation.

225 Perform this procedure when the condition below is met.

Conditions
● If the vehicle has a sound insulation

▶ Install the sound insulation.

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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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226 Perform this procedure when the condition below is met.

Conditions
● If the vehicle has a sound insulation

▶ Install the sound insulation.

WARNING
Risk of serious injury.
A cab that is not tilted to the end position constitutes a safety risk.

▶ Always tilt the cab to the end position. Never perform any work under the cab before it has been
tilted to the end position.

227 Lower the cab.

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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228 Close the front panel.

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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