IMPACT 4.07.

02 12/01/2019

Chassis ID Path
JPCT 11209 2153/Repair//Timing gears, replace (all)

Model Identity
UD-HDE 144358679

Publish date ID/Operation

10/01/2019 21548-2

21548-2 Timing gears, replace (all)

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

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.

CAUTION
Risk of material damage.
Damage may occur to the cab.

▶ Make sure that there is adequate space in front of the vehicle before tilting the cab.

WARNING
Risk of burn injuries.
Heated components and mechanical parts can cause burns.

▶ Exercise caution when working with heated components. Always use the appropriate protective
equipment.

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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WARNING

Risk of burn injuries.

The coolant may be hot.

▶ Allow the engine to cool before starting work. Do not remove the cover for the coolant tank
before the coolant has had time to cool down.

▶ Remove the coolant tank cap carefully. Use the appropriate protective equipment.

CAUTION
Risk of environmental damage.
Handling and disposal of used engine oils may be subject to national, regional and local laws and
regulations. If in doubt, contact your regional and local environmental authorities or the Environment
Agency for guidance as to proper handling and disposal of used engine oil.

▶ Use authorised waste disposal sites, including civic amenity sites and garages providing
authorised facilities for receipt of used oil.

Special tools

88800502 88840282 88840423 88840489 88840491

9990192 9996049 9996239 9996400 9996876

9999683 9999696

1 Apply the handbrake.

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2 Position the wheel chocks.

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3 This step contains 2 alternatives.

Select one of the valid alternatives below.

Alternative 1 / 2

Conditions
● For electrical cab tilting.

▶ Set the key in position (2).

▶ Turn on the cab tilt switch.

▶ Open the front panel.

▶ Remove the lever.

▶ Turn the control valve clockwise direction.

▶ Open the cap and press the cab tilt switch.

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Note
Hold the switch until the cab is fully tilted.

Alternative 2 / 2

Conditions
● For manual cab tilting.

▶ Open the front panel.

▶ Remove the lever.

▶ Turn the control valve clockwise direction.

▶ Pump until the cab is fully tilted.

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 This step contains 2 alternatives.

Select one of the valid alternatives below.

Alternative 1 / 2
▶ Turn off the main switch.

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Alternative 2 / 2

Conditions
● If the vehicle is equipped with ADR (European Agreement Concerning the International Carriage of
Dangerous Goods by Road).

▶ Turn off the main switch.

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5 Perform this procedure when the condition below is met.

Conditions
● If the vehicle has a sound insulation

▶ Remove the sound insulation.

6 Remove the filler cap.

WARNING
Risk of serious burns.
Contact with a hot engine or hot engine oil can cause serious burns.

▶ Take precautions when draining the oil. Wear gloves and let the engine cool down before
draining.
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7 Position a draining container.

8 Remove the drain plug.

9 Drain the oil.

10 Install the drain plug.

Note
Use a new part if necessary.

Note
Use a new sealing ring.

11 Torque tighten the drain plug.

Tightening torque

Engine, drain plug 60 ±5 Nm

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12 Remove the cap.

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13 Position a draining container.

14 Remove the plug.

15 Loosen the knob.

16 Drain the coolant.

17 Tighten the knob.

18 Install the plug.

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19 Position a draining container.

20 Install the tool.

Required material

DRAIN_HOSE 9996049

21 Drain the coolant.

22 Remove the tool.

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23 Remove the dipstick.

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24 Press the push button.

25 Remove the dipstick tube.

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26 Remove the screws.

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27 Remove the filler pipe.

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28 Remove the gearbox ➠  Gearbox, remove .

29 Move the gearbox backwards.

30 Disconnect the connector.

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31 Remove the screw.

32 Remove the speed sensor.

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33 Disconnect the connector.

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34 Remove the screw.

35 Remove the speed sensor.

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36 Remove the cable tie.

37 Remove the nut.

38 Remove the cables.

Note
Mark the positions.

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39 Disconnect the connector.

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40 Remove the nuts.

41 Remove the starter motor.

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42 Remove the screws.

43 Remove the support.

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44 Remove the screws.

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45 Remove the pump.

46 Remove the O-ring.

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47 Remove the screws.

48 Remove the cover.

49 Remove 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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50 Remove the screws.

51 Move aside the pipe.

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52 Remove the screws along with the springs and caps.

Service hint
Leave one screw in place on each side.

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53 Remove the screws along with the springs and caps.

54 Remove the oil sump.

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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55 Remove the gasket.

56 This step contains 2 alternatives.

Select one of the valid alternatives below.

Alternative 1 / 2 ‒ Crankshaft rear seal, removal

Conditions
● Old variant of seal: Brown or dark blue colour seal

▶ Clean the contact surfaces carefully.

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▶ Lubricate the crankshaft.

Required material

Diesel engine oil

Note
Lubricate the whole surface.

▶ Remove the seal.

Required material

PULLER 88840282

Note
The arms of the tool can be inverted to adapt to different diameters.
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Alternative 2 / 2 ‒ Crankshaft rear seal, removal

Conditions
● New variant of seal: Green colour seal

▶ Clean the contact surfaces carefully.

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▶ Push in the seal.

Note
Outer diameter.

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▶ Cut the lead seal.

Note
Use an appropriate tool.

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▶ Assemble the tools.

Required material

A DISASSEMBLY TOOL 88800502

B DISASSEMBLY TOOL 88840489

Note
Change the flange from (A) to (B) .

Note
Choose the correct tool diameter (B) .

Note
Remove one of the anchorages from (B) .

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▶ Install the tool.

Required material

DISASSEMBLY TOOL 88840489

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▶ Install the tooling.

Note
The following steps require the help of another person.

Note
Install the anchorage.

▶ Remove the inner ring.

▶ Remove the tool.

Required material

DISASSEMBLY TOOL 88840489

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▶ Assemble the tools.

Required material

A IMPACT WRENCH 9996400

B PULLER 9990192

Note
Ensure that the tools are clean and intact.

▶ Insert the puller (B) between the seal and the crankshaft using an impact wrench (A) .

Note
Take care not to damage the crankshaft surface.

▶ Remove the crankshaft seal.

Note
Outer seal.

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57 Install the tool.

Required material

LIFTING CHAIN 9996239

Note
Use suitable lifting equipment.

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58 Remove the screws.

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59 Remove the screws.

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60 Install the tools.

Required material

GUIDE 9996876 2 pcs

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61 Remove the screws.

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CAUTION
Risk of serious injury.
Heavy component.

▶ Exercise caution when moving the component. Use appropriate tools.

62 Remove the flywheel housing.

Service hint
Use a plastic mallet.

63 Remove the flywheel housing.

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64 Remove the pipe.

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65 Remove the screws.

66 Remove the valve cover.

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CAUTION
Risk of material damage.
The cables can be damaged by sharp tools.

▶ Take care when removing the cable ties.

67 Remove the cable ties.

68 Move aside the cable harness.

69 Disconnect the connector.

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70 Loosen the nuts.

71 Disconnect the connectors.

72 Remove the screws.

73 Remove the lower valve cover.

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74 Check the alignment of the mark.

Note
Ensure that the mark (1) is aligned with the cylinder head surface.

75 Remove the screws.

76 Remove the gear.

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77 Remove the screws.

78 Remove the gear.

Note
Do not disassemble.

79 Remove the screws.

80 Remove the gear.

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81 Remove the screws.

82 Remove the hub.

83 Remove the gear.

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84 Remove the screws.

85 Remove the gaskets.

86 Remove the cover.

Service hint
For extraction use two screws.

87 Remove the gasket.

88 Remove the hub.

Service hint
For extraction use one screw.

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Note
Mark the position of the lubrication holes.

89 Remove the gear.

90 Clean the face of the engine block.

91 Clean the other gears.

92 Install the gear.

Note
The intermediate gear mark (Y) must be between the fuel pump marks.

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Note
The mark on the crankshaft must be between the intermediate gear marks.

Note
The mark on the crankshaft tooth comprises a notch and a paint mark.

93 Install the screws.

94 Torque tighten the screws.

Tightening torque

Idler gear, screw 63 ±3 Nm

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95 Install the gear.

96 Install the hub.

Note
Check the alignment of the lubrication holes.

Service hint
Use a screw to position the hub.

97 Install the gasket.

Note
Use a new part.

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98 Install the cover.

99 Install the gaskets.

Note
Use new parts.

100 Install the screws.

101 Torque tighten the screws.

Tightening torque

Idler gear, screw 24 ±2 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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102 Install the gear.

103 Install the hub.

104 Install the screws.

105 Torque tighten the screws.

Tightening torque

Idler gear, screw 24 ±2 Nm

106 Install the gear.

Note
The double intermediate gear mark (X) must be between the intermediate gear marks.

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Note
Check the hub for correct position.

Note
The hub mark must be facing upwards.

107 Install the screws.

108 Torque tighten the screws.

Tightening torque

Idler gear, screw 63 ±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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109 Install the gear.

Note
Ensure that the mark (1) is aligned with the cylinder head surface.

110 Install the screws.

111 Torque tighten the screws.

Tightening torque

Gear, camshaft, screw 32 ±2 Nm

112 Ensure that the timing gears alignment is correct.

Note
The marks (1) on the flywheel and the camshaft gear must be aligned after two engine
revolutions.

113 Position the tooling.

Required material

MAGNETIC STAND 9999696

ROCKER_INDICATOR 9999683

114 Check the backlash.

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
Turn the gear in the both directions.

115 Perform the same operation for the other timing gears.
Gears, backlash

A Gears, backlash 0.08 ±0.05 mm

B Gears, backlash 0.08 ±0.05 mm

C Gears, backlash 0.08 ±0.05 mm

D Gears, backlash 0.08 ±0.05 mm

E Gears, backlash 0.07 ±0.04 mm

F Gears, backlash 0.1 ±0.06 mm

G Gears, backlash 0.07 ±0.04 mm

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IMPACT 4.07.02 12/01/2019

A MAGNETIC STAND 9999696

B ROCKER_INDICATOR 9999683

116 Remove the gasket.

117 Clean the groove in the valve cover.

118 Clean the gasket.

119 Install the gasket.

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120 Clean the contact surfaces.

121 Install the lower valve cover.

122 Torque tighten the screws diagonally.

Tightening torque

Lower valve cover, screw Tighten diagonally

24 ±4 Nm

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123 Connect the connectors.

124 Torque tighten the nuts.

Tightening torque

Connector, injector, nut 2.2 ±0.2 Nm

125 Connect the connector.

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126 Position the cable harness.

127 Install the cable ties.

Note
Use new parts.

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128 Remove the gasket.

129 Clean the groove in the valve cover.

130 Clean the gasket.

131 Install the gasket.

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132 Clean the contact surface.

133 Install the valve cover.

134 Install the screws.

135 Torque tighten the screws.

Tightening torque

Valve cover, screw Tightening sequence: 1–17

24 ±4 Nm

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IMPACT 4.07.02 12/01/2019

136 Install the pipe.

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137 Clean the contact surfaces.

Note
Ensure that the surfaces are completely clean from sealant.

138 Apply a bead of sealant.

Tech data

Sealant, bead thickness 2 mm

Required material

Metal adhesive

Note
Install the gasket within twenty minutes of sealant application.

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CAUTION
Risk of serious injury.
Heavy component.

▶ Exercise caution when moving the component. Use appropriate tools.

139 Position the flywheel housing.

Required material

LIFTING CHAIN 9996239

GUIDE 9996876 2 pcs

Service hint
Use the guide tools to position.
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140 Install the flywheel housing.

141 Install the screws.

Note
Start with the screws located inside the flywheel housing.

Note
Do not torque tighten the screws.

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IMPACT 4.07.02 12/01/2019

142 Remove the tools.

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143 Install the screws.

144 Torque tighten the screws.

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Tightening torque

Flywheel housing, screw 1. M12 screw

Tightening sequence: 1–9

85 ±15 Nm (Guide value)

2. M10 screw

Tightening sequence: 10–12

48 ±8 Nm (Guide value)

3. M12 screw

Tightening sequence: 13–14

85 ±15 Nm (Guide value)

145 Install the screws.

146 Torque tighten the screws.

Tightening torque

Stiffener, screw 85 ±15 Nm

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147 Remove the tool.

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148 This step contains 2 alternatives.

Select one of the valid alternatives below.

Alternative 1 / 2 ‒ Crankshaft seal, installation

Conditions
● Old variant of seal: Brown or dark blue colour seal

▶ Clean the contact surfaces carefully.

Note
Remove any adhesive residue from the crankshaft.

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▶ Position the tool.

Required material

ASSEMBLY TOOL 88840423

Note
Use (2) screws.

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▶ Machine the protrusion.

Note
Depending on the equipment

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▶ Apply a bead of sealant.

Tech data

Crankshaft, sealant, distance to apply (X) 16.2 mm

Required material

Metal adhesive

Note
Apply the bead on the entire circumference of the crankshaft.

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▶ Clean the internal surface of the seal.

Note
Use a new part

Note
Check the condition of the seal.

Note
Do not lubricate the seal.

▶ Apply a bead of sealant.

Required material

Metal adhesive

Note
Apply the sealant on the internal surface of the metal deflector.

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▶ Position the seal.

Note
Note the direction of assembly.

Service hint
The text on the seal must be turned away from the engine.

▶ Position the cover and crank of the tool (A).

▶ Install the seal.

Note
Turn the crank until the cover reaches a stop.

▶ Maintain the tool in position.

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Note
Maintain the position for 10 seconds minimum.

▶ Remove the tool.

▶ Clean the sealant residues.

Alternative 2 / 2 ‒ Crankshaft seal, installation

Conditions
● New variant of seal: Green colour seal

▶ Clean the contact surfaces carefully.

Required material

Cleaning agent
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Note
Remove any adhesive residue from the crankshaft.

▶ Position the tool.

Required material

ASSEMBLY TOOL 88840491

Note
Use (2) 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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▶ Position the seal.

Note
Use a new part.

Note
Check the condition of the seal.

Note
Do not lubricate the seal.

Note
Note the direction of assembly.

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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Service hint
The text on the seal must be turned away from the engine.

▶ Position the cover and crank of the tool (A).

▶ Install the seal.

Note
Turn the crank until the cover reaches a stop.

▶ Maintain the tool in position.

Note
Maintain the position for ten seconds minimum.

▶ 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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149 Clean the contact surfaces.

150 Apply a bead of sealant.

Tech data

Sealant, bead thickness 2 mm

Required material

Metal adhesive

Note
Install the gasket within twenty minutes of sealant application.

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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151 Install the gasket.

Note
Use a new part.

Note
Keep the gasket clean, dry and with no cleaning product residue.

Note
Ensure that the gasket holding dowels are positioned correctly.

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152 Install the oil sump.

Note
Ensure that the gasket is positioned correctly during installation.

153 Install the screws along with the springs and caps.

154 Hand tighten the screws.

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155 Install the screws along with the springs and caps.

156 Torque tighten the screws.

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Tightening torque

Oil pan, screw Tightening sequence: 1–20

24 ±4 Nm

157 Position the pipe.

158 Install the screws.

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159 Clean the contact surfaces.

160 Install the gasket.

Note
Replace the gaskets if necessary.

161 Install the cover.

162 Install the screws.

163 Torque tighten the screws.

Tightening torque

Cover, power take-off, screw 48 ±8 Nm

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164 Clean the contact surfaces.

165 Install the O-ring.

Note
Use a new part.

166 Lubricate the O-ring.

Required material

Lubricating oil

167 Install the pump.

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168 Install the screws.

169 Torque tighten the screws.

Tightening torque

Steering pump, screw 60 Nm  ±10 nm

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170 Install the supports.

171 Install the screws.

172 Tighten the screws.

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173 Install the starter motor.

174 Install the nuts.

175 Torque tighten the nuts.

Tightening torque

Starter motor, nut M10

48 ±8 Nm

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176 Connect the connector.

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177 Install the cables.

Note
Install as marked up.

178 Install the nut.

179 Torque tighten the nut.

Conditions
● For MELCO brand

Tightening torque

Starter motor, terminal, nut 18 ±2 Nm

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Conditions
● For HEG brand

Tightening torque

Starter motor, terminal, nut 25 ±3 Nm

180 Install the cable tie.

Note
Use a new part.

181 Clean the contact surfaces.

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182 Install the guide pin.

Note
Use an appropriate guide pin.

183 Lubricate the O-ring.

Required material

Liquid lubricant

Note
Ensure that the O-ring is not damaged.

Note
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IMPACT 4.07.02 12/01/2019

Ensure that the O-ring is positioned correctly.

184 Install the sensor.

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185 Remove the guide pin.

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186 Install the screw.

187 Torque tighten the screw.

Tightening torque

Sensor, screw 8 ±2 Nm

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188 Connect the connector.

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189 Clean the contact surfaces.

190 Install the guide pin.

Note
Use an appropriate guide pin.

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191 Lubricate the O-ring.

Required material

Liquid lubricant

Note
Ensure that the O-ring is not damaged.

Note
Ensure that the O-ring is positioned correctly.

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192 Install the speed sensor.

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193 Remove the guide pin.

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194 Install the screw.

195 Torque tighten the screw.

Tightening torque

Sensor, screw 8 ±2 Nm

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196 Connect the connector.

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197 Install the O-rings.

Note
Use new parts.

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198 Install the filler pipe.

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199 Install the screws.

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200 Install the dipstick tube.

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201 Insert the dipstick.

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

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203 Remove the cap.

204 Fill the engine with oil.

205 Install the cap.

206 Install the gearbox ➠  Gearbox, install .

207 Perform this procedure when the condition below is met.

Conditions
● If the vehicle has a sound insulation

▶ Install the sound insulation.

▶ Install the screws.

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208 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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209 Perform this procedure when the condition below is met.

Conditions
● If the vehicle has a sound insulation

▶ Install the sound insulation.

210 This step contains 2 alternatives.

Select one of the valid alternatives below.

Alternative 1 / 2
▶ Turn on the main switch.

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Alternative 2 / 2

Conditions
● If the vehicle is equipped with ADR.

▶ Turn on the main switch.

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 4.07.02 12/01/2019

211 This step contains 2 alternatives.

Select one of the valid alternatives below.

Alternative 1 / 2

Conditions
● For electrical cab tilting.

▶ Turn the control valve anti-clockwise direction.

▶ Press the cab tilt switch.

Note
Hold the switch until the cab is fully tilted.

▶ Close the cap.

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 4.07.02 12/01/2019

▶ Install the lever.

▶ Close the front panel.

▶ Turn off the cab tilt switch.

▶ Set the key in position (0).

Alternative 2 / 2

Conditions
● For manual cab tilting.

▶ Turn the control valve anti-clockwise direction.

▶ Pump until the cab is fully lowered.

▶ Install the lever.

▶ 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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IMPACT 4.07.02 12/01/2019

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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