IMPACT 4.04.

00 15/01/2019

Chassis ID Path
B 717876 2111/Repair//Cylinder head, install

Model Identity
FH (4) 136210808

Publish date ID/Operation

10/10/2015 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.

CAUTION
Risk of material damage.
A steel brush, rotating steel brush and similar tools can damage or block the injector tip. A damaged
injector can reduce engine power and result in incorrect exhaust values.

▶ Clean the unit injectors carefully. Use only a soft cloth soaked in paraffin or similar.

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.

CAUTION
Risk of material damage.
Risk of impurities being introduced into the fuel system.

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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▶ Ensure conditions of maximum cleanliness when carrying out any work on the fuel system.

CAUTION
Risk of skin injury.
Grease, oil and chemical substances can cause skin and eye injuries. Oils and grease can cause
acne and eczema. A used lubricant is more harmful than an unused lubricant.

▶ Protective equipment such as gloves and eye protection must be used when working with
grease, oils and chemical substances.

Special tools

21181433 88800014 88800031 88800443 88840317

88840328 88890148 9998264 9998599 9998601

1 Clean the cylinder head screws.

2 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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3 Carefully clean the cylinder block, cylinder head, timing gear cover and timing gear plate.

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

5 Install the cylinder head 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 Perform this procedure when the condition below is met.

Conditions
● If the seal is damaged.

▶ Remove the seal in the damaged area.

▶ Clean the sealing surface in the damaged area.

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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▶ Apply a bead of sealant to the groove.

Tech data

Sealant, bead thickness 3 mm

Note
Use recommended sealant.

Note
The cylinder head must be assembled within twenty minutes after applying the sealant.

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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7 Carefully lower the cylinder head until it is in contact with the cylinder head gasket.

8 Ensure that the guide washers(1) are correctly positioned.

9 Press the cylinder head onto the timing gear plate.

10 Install the screw (1).

11 Torque tighten the screw (1).

Tightening torque

Idler gear, screw 28 ±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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Required material

TORQUE WRENCH 88890148

12 Install the screws (24), (26), (28), (30).

13 Torque tighten the screws (24), (26), (28), (30).

Tightening torque

Cylinder head, screw 25+10 −5 Nm

Required material

TORQUE WRENCH 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
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14 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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15 Install the remaining screws.

16 Torque tighten the screws.

Tightening torque

Cylinder head, screw 1. Tightening sequence: 1-38

100 ±5 Nm

2. Tightening sequence: 1-38

120 ±5°

3. Tightening sequence: 1-38

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

17 Install the screws (1).

18 Torque tighten the screws (1).

Tightening torque

Timing gear plate, screw 28 ±4 Nm

Required material

TORQUE WRENCH 88890148

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

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

20 Install the screws (2).

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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21 Torque tighten the screws (2).

Tightening torque

Timing gear plate, screw 28 ±4 Nm

Required material

TORQUE WRENCH 88890148

22 Install the screws (3).

23 Torque tighten the screws (3).

Tightening torque

Idler gear, screw 1. 35 ±4 Nm

2. 120 ±5°

Required material

TORQUE WRENCH 88890148

Note
Remove the rag.

24 Lubricate all the bearing shells.

Note
Use recommended lubricant.

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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25 Ensure that the marking (0) is in the correct position.

26 Install the camshaft.

Required material

LIFTING_TOOL 9998264

Note
Use 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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Note
Take care not to damage the camshaft.

27 Check that the markings align.

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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28 Perform this procedure when the condition below is met.

Conditions
● If the markings do not align

▶ Lift the camshaft and turn it to the correct position.

▶ Lower the camshaft and check that the markings align.

▶ Remove the tool.

29 Install the caps.

Note
Check the markings.

Service hint
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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Carefully knock down the caps using a plastic mallet.

30 Install the sleeves (A).

Note
These are temporary standard sleeves that are placed over the guide sleeves to
protect the guide sleeves.

31 Install the temporary screws (1).

32 Install the permanent screws (2).

Note
The rocker arm shaft is installed later.

33 Hand tighten the screws (1).

34 Torque tighten the screws (2).

Note
Check that the camshaft can be rotated after the screws are torque 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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35 Remove the temporary screws and sleeves.

36 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.

37 Check the backlash.

Tech data

Gear, backlash 0.05 – 0.15 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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38 Perform this procedure when the condition below is met.

Conditions
● If the backlash is not within specified value.

▶ Re-adjust the gears.

39 Install the tools.

Required material

TOOL_KIT 9998599

A SLEEVE 9998580

B RETAINER 9808607

C HANDLE 9808616

D BRUSH 9808570

40 Clean the sleeve.

41 Remove the tools.

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 O-rings.

Note
Use new parts.

43 Install the washer.

Note
Use a new part.

44 Install the unit injector as marked up.

45 Centre the unit injector between the valve springs.

46 Install the screw.

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
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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47 Torque tighten the screw.

Tightening torque

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

2. 180 ±5°

3. Loosen the yoke screw.

≈ −150°

4. 20+5 0 Nm

5. 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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48 Install the valve bridges.

Note
According to the markings.

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49 Connect the connector.

Tech data

The connector is correctly connected when it clicks into place.

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 Clean the cylinder head contact surface.

51 Install the valve and washers.

Note
Use new 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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52 Torque tighten the valve.

Tightening torque

Overflow valve 48 ±5 Nm

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Required material

TORQUE WRENCH 88890148

53 Install the rocker arm bridge.

54 Remove the cable ties.

55 Remove the lifting 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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56 Install the screws.

57 Torque 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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Tightening torque

Rocker arm bridge 1. Repeat the tightening sequence until

the rocker arm bridge contacts the
bearing housings.

Tightening sequence: 8-6-10-4-12-2-13

60 ±5 Nm

2. Tightening sequence: 1-3-5-7-9-11

40 ±3 Nm

3. Tightening sequence: 1-3-5-7-9-11

120 ±5°

4. Remove screws: 2-4-6-8-10-12

6 pcs

5. Tightening sequence: 2-4-6-8-10-12

40 ±3 Nm

6. Tightening sequence: 2-4-6-8-10-12-13

120 ±5°

58 Install the leaf springs.

59 Torque tighten the screws.

Tightening torque
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Leaf springs VEB, screw 25 ±3 Nm

Required material

TORQUE WRENCH 88890148

60 Clean the valve.

61 Clean the contact surfaces.

62 Replace the seal.

Note
Check that the oil channels are free of impurities.

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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63 Replace the O-rings.

64 Lubricate the O-rings.

Note
Use a recommended oil.
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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65 Install the pipe.

66 Install the valve.

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67 Install the screws.

Required material

TORQUE WRENCH 88890148

Note
Replace the cable ties on the control valve if they are damaged.

68 Clean the contact surfaces.

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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69 Install the gasket.

Note
Use a new part.

70 Perform this procedure when the condition below is met.

Conditions
● Timing gear plate without integrated sealing.

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▶ Carefully clean the contact surfaces.

Note
Do not use any tools that may damage the sealing surfaces.

71 Install the timing gear cover.

Note
The dowels on the timing gear cover act as guides to avoid damaging the sealing strip
during installation.

72 Install the screws.

Note
Hand tighten the screws. Ensure that the timing gear cover is in contact with the timing
gear plate.

73 Install the tool (A).

Required material

GUIDE 9998601 2 pcs

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74 Press down the timing gear cover with the required force.

Tightening torque

Tool, adjusting screw 27 ±3 Nm

Note
Ensure that the timing gear cover aligns with the cylinder head on both sides.

75 Torque tighten the screws.

Tightening torque

Upper timing gear casing, screw Tightening sequence: 1-5

27 ±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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Required material

TORQUE WRENCH 88890148

76 Remove the guides.

77 Remove the plug.

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78 Install the cranking adapter (A).

Required material

CRANKING ADAPTER 88840317

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79 Rotate the flywheel so that a tooth on the oscillation damper aligns with the sensor location.

Required material

ROTATION TOOL 88800014

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80 Install the setting tool.

Required material

SETTING_TOOL 88800031

81 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

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82 Remove the setting tool.

83 Install the shims.

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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84 Remove the cranking adapter.

85 Install the plug.

86 Install the O-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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87 Install the sensor and shim (3).

88 Install the heat shield.

89 Torque tighten the screw (2).

Tightening torque

Sensor, screw 8 ±2 Nm

Required material

TORQUE WRENCH 88890148

90 Connect the connector (1).

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 screws.

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92 Install the pipes.

93 Install 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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94 Install the bracket.

95 Install the clamps.

96 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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97 Remove the leaf springs.

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98 Note the camshaft marking.

Tech data

Adjust the inlet valve rocker arm 1-2-3-4-5-6

Adjust the exhaust valve rocker arm (and the exhaust E1-E2-E3-E4-E5-E6
brake rocker arm, if applicable)

Adjust the injector rocker arm 1-2-3-4-5-6

Note
The marking can be for the adjustment of several cylinders.

Note
When checking or adjusting, the mark must be centred between the lines on the
camshaft 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
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99 Rotate the crankshaft to the next mark.

Note
Rotate the crankshaft in the normal engine rotation direction.
Ask another person for help.

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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100 Check the valve clearance.

Tech data

Inlet valve, rocker arm, clearance 0.2 ±0.05 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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101 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 from turning (B), and torque tighten the nut (A).

Tightening torque

Rocker arm, lock nut 38 ±4 Nm

Required material

TORQUE WRENCH 88890148

102 This step contains 2 alternatives.

Select one of the valid alternatives below.

Alternative 1 / 2
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Conditions
● Rocker arm with adjusting screw.

▶ Check the valve clearance.

Tech data

Exhaust valve, rocker arm, clearance 1.6 ±0.05 mm

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

Tightening torque

Rocker arm, lock nut 38 ±4 Nm

Required material

TORQUE WRENCH 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
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Alternative 2 / 2

Conditions
● Rocker arm with shim.

▶ Check the valve clearance.

Tech data

Exhaust valve, rocker arm, clearance 1.6 ±0.05 mm

Note
Use a feeler gauge.

▶ If the valve clearance is not correct.

▶ Remove the screw.

▶ Remove the shim.

▶ Install the shim with thickness (A).

A=B+C−D

B Old shim, thickness

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[mm]

C Measured valve clearance

[mm]

D Correct valve clearance

[mm]

▶ Install the screw.

▶ Torque tighten the screw.

Tightening torque

Valve caliper, lock screw 38 ±4 Nm

Required material

TORQUE WRENCH 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
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▶ Check the valve clearance.

103 Loosen the nut (A).

104 Adjust the screw (B) until the rocker arm roller lies against the camshaft.

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105 Angle tighten the screw (B).

Tech data

Injector, adjusting screw 240 ±20°

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

Tightening torque

Injector, rocker arm, lock nut 52 ±4 Nm

Required material

TORQUE WRENCH 88890148

107 Adjust the other rocker arms in the same way.

Service hint
Ask another person for help.

108 Install the leaf springs.

109 Torque tighten the screws.

Tightening torque

Leaf springs VEB, screw 25 ±3 Nm

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Required material

TORQUE WRENCH 88890148

110 Remove the old sealant from the contact surfaces (A).

Note
Ensure that the contact surfaces are free of sealant.

Note
Do not use any tools that may damage the sealing surfaces.

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111 Apply sealant (A).

Tech data

Sealant, bead thickness 2 mm

Note
Use recommended sealant.

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112 Install the valve cover.

113 Torque tighten the screws.

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Tightening torque

Valve cover, screw Tightening sequence: 1-20

24 ±4 Nm

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Required material

TORQUE WRENCH 88890148

114 Install the pipe.

115 Install the bracket.

116 Install the screws.

117 Install the cable tie.

118 Install the clamps.

119 Install the screws.

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120 Install the cables.

121 Install the screw and nuts.

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122 Connect the connector.

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123 Install the screw and spacer plate.

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124 Apply assembly compound to the V-clamps.

Note
Use new parts.

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125 Install the charge air hose.

126 Install the V-clamps.

127 Install the seal.

Note
Use a new part.

Note
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Apply vaseline to the seal.

128 Install the housing along with the seal.

Note
Use a new seal.

Note
Apply vaseline to the seal.

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129 Install the screws.

130 Install the hose.

131 Install the clamp.

Note
Use a new part.

132 Connect the connector.

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133 Install the seal.

Note
Use a new part.

134 Clean the thermostat seat.

135 Install the thermostat.

136 Install the housing.

137 Install the screws.

138 Torque tighten the screws diagonally.

Required material

TORQUE WRENCH 88890148

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139 Install the hose.

140 Tighten the clamp.

141 Install the cooling coil.

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142 Connect the connector.

143 Install the clamps.

144 Clean the contact surfaces.

145 Install the gasket.

Note
Use a new part.

146 Install the turbocharger.

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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147 Install the spacers and nuts.

148 A special tool (extension bar/adapter) must be used for torque tightening due to the limited
space. Different sized nuts or screws are used so different tools with different spanner ring
sizes are required. Two lengths are also required.

Note
Ensure that the wrench and tool remain aligned during the tightening.

Note
The torque wrench setting given in the specifications must be adapted to suit the
increased length of the wrench and tool combination.

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149 The example shows a 450 mm (0.45 m) long torque wrench, two tools, B1, 185 mm and B2,
134 mm long, and a required assembly torque, T, of 48 +-8 Nm. The calculation based on
these examples gives torque settings, C, of 34 Nm for B1 and 37 Nm for B2. This lower setting
results in a tolerance of +- 6 Nm.

Note
Entering these and similar calculation results in the graph provides the settings for any
torque wrench between 250 and 700 mm long.

150 The C value can be calculated using the equation or read off in the graph.

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151 This step contains 3 alternatives.

Select one of the valid alternatives below.

Alternative 1 / 3
▶ Ensure that the tool is in the correct position.

Note
Risk for incorrect torque tightening if the tool is not in the correct position.

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▶ Torque tighten the nuts.

Tightening torque

Turbocharger, nut (when using the special tool) 1. Tightening sequence: 1-4

14 ±2 Nm

2. Tightening sequence: 1-4

34 ±6 Nm

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Required material

KEY 21181433

TORQUE WRENCH 88890148

Alternative 2 / 3
▶ Ensure that the tool is in the correct position.

Note
Risk for incorrect torque tightening if the tool is not in the correct position.

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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▶ Torque tighten the nuts.

Tightening torque

Turbocharger, nut (when using the special tool) 1. Tightening sequence: 1-4

14 ±2 Nm

2. Tightening sequence: 1-4

37 ±6 Nm

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Required material

WRENCH 88840328

TORQUE WRENCH 88890148

Alternative 3 / 3
▶ Ensure that the tool is in the correct position.

Note
Risk for incorrect torque tightening if the tool is not in the correct position.

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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▶ Torque tighten the nuts.

Tightening torque

Turbocharger, nut (when using the special tool) 1. Tightening sequence: 1-4

14 ±2 Nm

2. Tightening sequence: 1-4

37 ±6 Nm

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Required material

WRENCH 88800443

TORQUE WRENCH 88890148

152 Clean the contact surfaces.

153 Install the O-ring.

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Note
Use a new part.

154 Lubricate the O-ring.

Note
Use a recommended lubricant.

155 Install the gasket.

Note
Use a new part.

156 Install the pipe.

157 Install the screws.

DANGER
Risk of material damage, serious personal injury or death.
Connections that are not tightened in accordance with specified tightening torques may cause
leakage.

▶ Tighten connections according to service information.

158 Torque tighten the screws.

Tightening torque

Oil return pipe, screw 1. Screw 1

12 Nm

2. Screw 2

24 ±2.4 Nm

3. Screw 1

24 ±2.4 Nm

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Required material

TORQUE WRENCH 88890148

159 Fill the turbocharger and hose with engine oil.

Note
Use recommended oil.

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160 Install the gasket.

Note
Use a new part.

161 Install the pipe.

DANGER
Risk of material damage, serious personal injury or death.
Connections that are not tightened in accordance with specified tightening torques may cause
leakage.

▶ Tighten connections according to service information.

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162 Torque tighten the screws.

Tightening torque

Oil feed hose, screw 1. Tightening sequence: 1-2

10 ±2 Nm

2. Tightening sequence: 2-1

60 ±5°

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Required material

TORQUE WRENCH 88890148

163 Install the hose.

164 Install the screw.

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165 Install the hose (2).

166 Install the clamps (1).

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167 Apply assembly compound to the clamps.

Note
Use a recommended assembly paste.

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168 Install the exhaust brake.

169 Turn the exhaust brake to the correct position.

170 Install the clamp.

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171 Tighten the clamp.

Tightening torque

Turbocharger, clamp 12 ±2 Nm

Required material

TORQUE WRENCH 88890148

172 Install the hose.

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 Install the screw.

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175 Install the exhaust pipe.

176 Install the clamp (A).

177 Tighten the clamp.

Tightening torque

Exhaust brake, clamp 20 ±4 Nm

Required material

TORQUE WRENCH 88890148

178 Install the pipe.

Note
Check that the heat shield is correctly located.

179 Tighten the clamps (2).

180 Tighten the clamp (1).

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181 Install the air filter housing.

182 Install the screws.

183 Install the screw (A).

184 Connect the connector.

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185 Install the air bellows.

186 Install the air hose.

187 Tighten the hose clamp.

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188 Install the sound baffle.

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189 Connect the cable to the negative terminal (1).

190 Insert the key (2).

191 Perform this procedure when the condition below is met.

Conditions
● If the vehicle has an alarm.

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▶ Deactivate service mode.

192 Fill coolant up to the mark (MAX).

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

193 Pump with the hand pump about 200 times.

Note
Do not open any connections.

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194 Install the exhaust hose on the exhaust pipe.

195 Apply the parking brake.

196 Place the gear lever in neutral.

197 Start the engine (III).

198 Check the repair for leakage.

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199 Check the coolant level.

200 Fill the cooling system up to the mark (MAX) on the expansion tank.

201 Install the sound baffles.

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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.

202 Lower the cab.

203 Lower the front cover.

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97 / 98
IMPACT 4.04.00 15/01/2019

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
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