IMPACT 3.

0 Sunday, 23 August 2009

Chassis ID Path
21/Description, Design and function/FH,
D16C550/Engine
Model Identity
114654791
Publish date Operation No.
Saturday, 20 October 2007

Engine

D16C3 and D16C4 engines

The D16C3 and D16C4 engine models entered production in the spring of 2006 and are modified
versions of the previous D16C model. The main changes are that both the D16C3 and D16C4 are
equipped with new cylinder heads and engine blocks. Both models also have new oil coolers. The
D16C3 and D16C4 have controlled valve yokes for the exhaust valves and floating yokes for the
inlet valves. The D16C3 and D16C4 have new reinforced inlet pipes, while just the D16C4 is
equipped with a new flywheel housing. Both engine models meet the Euro 3 emissions
requirements.

© Copyright Volvo Parts Corporation

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

1 / 12
IMPACT 3.0 Sunday, 23 August 2009

Cylinder head

Both the D16C3 and D16C4 are equipped with new cylinder heads. The principal difference from
the earlier cylinder head is a new intermediate divider in the coolant space in the cylinder head. The
horizontal divider forces the coolant to pass the lower and hottest parts of the cylinder head,
thereby increasing the cooling effect.

© Copyright Volvo Parts Corporation

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

2 / 12
IMPACT 3.0 Sunday, 23 August 2009

The camshafts on the D16C3 and D16C4 are similar to those on the earlier D16C model, except
that the camshaft markings are now read from the front instead of the rear edge of the camshaft. A
new feature in the D16C3 and D16C4 is that the inlet valve yokes are floating, while the exhaust
valve yokes are controlled. The D16C3 and D16C4 also have new valve stem seals with double
sealing surfaces.

© Copyright Volvo Parts Corporation

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

3 / 12
IMPACT 3.0 Sunday, 23 August 2009

Cylinder block

Both the D16C3 and D16C4 are equipped with new engine blocks. The new type of block is
adapted to closed crankcase ventilation with oil channels on the left side of the engine.

Oil cooler

There is a new oil cooler on the D16C3 and D16C4 compared to the earlier D16C models. The oil
cooler is bolted directly to the engine block and is completely surrounded by coolant. Channels in
the block ensure that the coolant runs in the correct direction.

© Copyright Volvo Parts Corporation

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

4 / 12
IMPACT 3.0 Sunday, 23 August 2009

Flywheel housing

The D16C4 has a new and lighter flywheel housing. The upper timing gear cover (A) has a built-in
oil trap for crankcase ventilation. The lower cover (B) is a combined transmission cover and
flywheel housing and includes securing points for the rear engine mountings. The flywheel casing
has two guide sleeves that position it with respect to the timing gear plate.

Both covers are sealed against the timing gear plate by sealing compound. Sealing between the
two covers is by means of a rubber strip (1) placed in a groove in the upper cover. Two rubber
cushions (2) seal against the cylinder head. The upper timing gear cover is also sealed by sealing
compound in the joint between the rubber strip and the timing gear plate.

There are two holes with rubber plugs in the flywheel casing. One of the holes is for a cranking tool
(3) to rotate the engine flywheel, and through the other hole (4) can be read a marking that
indicates the position of the flywheel.

Cover (C) encloses the connection for the engine-driven power take-off.

On the right side of the flywheel housing is a bracket for the starter motor connections.

© Copyright Volvo Parts Corporation

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

5 / 12
IMPACT 3.0 Sunday, 23 August 2009

Fuel system

© Copyright Volvo Parts Corporation

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

6 / 12
IMPACT 3.0 Sunday, 23 August 2009

New for the D16C3 and D16C4 is that the bleed valve is now located on a bracket next to the fuel
filter housing, and bleeding takes place directly from the fuel filter housing via a line (15) to the tank.
Previously, the bleed valve was built into the overflow valve and located near the cylinder head fuel
gallery.

Inlet pipe

Both the D16C3 and D16C4 are equipped with new reinforced inlet pipes.

Crankcase ventilation

Since some of the combustion products enter the crankcase after passing the pistons and piston
rings (blow-by), the crankcase must be ventilated.

The D16C engine is available with three different variants of crankcase ventilation:

Open crankcase ventilation (CCV-O)

Closed crankcase ventilation (CCV-C), removes the risk of oil drops and is an environmental
requirement in many markets.
Partly open crankcase ventilation (CCV-OX), for cold market regions.

Crankcase ventilation

© Copyright Volvo Parts Corporation

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

7 / 12
IMPACT 3.0 Sunday, 23 August 2009

The D16C engine has two oil traps located in the upper timing gear cover (1) and the valve cover
(2), as well as an external pipe (3) to lead the warm air away.

The oil trap in the timing gear cover is designed as a labyrinth, with the connection from the
crankcase (4) at the centre of the idler gear. The rotation of the idler gear generates a relatively
oil-free area here.

Inside the valve cover is an oil trap (5). The inside of the valve cover has a cast in channel (5) with
three drains (6) for condensation fluid.

Closed crankcase ventilation (CCV-C)

© Copyright Volvo Parts Corporation

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

8 / 12
IMPACT 3.0 Sunday, 23 August 2009

The main component in the new closed crankcase ventilation system is a separator (A) directly
mounted on the left side of the cylinder block. Oil from the engine lubrication system drives a
turbine (3) via an oil channel to drive the separator. The turbine is connected to a drive shaft (4)
with a number of discs (5) rotating at approximately 8 000 rpm during normal engine operation. On
the side of the separator is a pressure regulator (6) with a diaphragm (7), which closes the oil flow

© Copyright Volvo Parts Corporation

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

9 / 12
IMPACT 3.0 Sunday, 23 August 2009

to the turbine if the pressure falls too low.

The crankcase gases are led to the top of the separator via a hose connection (1). After passing
through the oil traps in the upper timing gear cover, the crankcase gases are led to the intake at the
top of the separator via a hose connection (1) and enter the separator over the centre of the
rotating discs. Oil and heavier particles are thrown centrifugally towards the periphery and are led
from there back to the oil sump together with the oil which drives the turbine.

The clean gases are led to the turbocharger inlet side via connector (2).

Partly open crankcase ventilation (CCV-OX)

The partly open and closed crankcase ventilation system is identical to the closed system apart
from that the purified gases from the separator are led out into the atmosphere via the pipe (1)

Turbocharger

© Copyright Volvo Parts Corporation

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

10 / 12
IMPACT 3.0 Sunday, 23 August 2009

On the D16C3 and D16C4 the turbocharger actuator is located on top of the turbocharger housing.
In the earlier D16C models the actuator is underneath.

Exhaust manifold

© Copyright Volvo Parts Corporation

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

11 / 12
IMPACT 3.0 Sunday, 23 August 2009

Both the D16C3 and D16C4 are equipped with new exhaust manifolds with sliding joints. The
surfaces (A) are coated with graphite paste.

Engine cabling

The D16C4 has new engine wiring, but the same engine management system (EMS 1.0) as
previously. On the other hand the D16C3 engine wiring is unchanged compared to the earlier D16C
models.

© Copyright Volvo Parts Corporation

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are
uncontrolled.

12 / 12