IMPACT 4.07.

03 06/04/2019

Chassis ID Path
JPCT 10811 21/Specifications//Engine

Model Identity
UD-HDE 136417315

Publish date ID/Operation

18/11/2015

Engine
Note: Illustrations are used for several different variants. Some details may therefore differ from the variant you are
working on. The essential information in the illustrations is, however, always correct.

Contents
Engine
Cylinder block
Cylinder head
Cylinder head bolt
Cylinder liner
Piston
Piston rings

Valve mechanism
Valves
Valve guides
Valve seats
Valve seat location
Valve springs
Rocker arms

Engine transmission
Timing gears
Camshaft
Camshaft bearings

Crank mechanism
Crankshaft
Main bearing journals
Thrust washers (axial bearing)

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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Main bearing shells

Big-end bearing journal
Big end bearing shells
Connecting rod
Flywheel, fitted
Flywheel housing (installed)

Tightening torques and order

Engine mounting
Bearing cap
Stiffening frame
Flywheel
Oscillation damper, crankshaft
Flywheel casing
Casing, crankshaft seal
Valve cover
Oil cooler cover
Cylinder head
Lifting eye, cylinder head
Valve EPG/VEB
Bearing caps, camshaft/rocker arm shaft
Timing gear plate
Timing gears
Timing gear cover

Engine

Cylinder block

Length.....967 mm

Height upper block face-crankshaft centre.....379 mm

Height, lower block face - crankshaft centre.....120 mm

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Cylinder head

Maximum runout (at surface of base).....0.4 mm

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Cylinder head bolt

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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Quantity.....26 

Thread size.....M16

Length.....200 mm

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Cylinder liner

Type.....Wet, replaceable

Total height.....250 mm

Height of sealing surface above block face.....0.14 - 0.21 mm

Number of sealing rings per cylinder liner.....3 

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Piston

Type.....steel

Height above cylinder block face.....–0.1 (min) – 0.5 (max) mm 

Number of ring grooves.....3 

Front marking.....Arrow pointing forwards

Gudgeon pin(Ø) .....54 mm

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Piston rings

Compression rings

Quantity.....2 

Piston ring clearance in grooves:

upper compression ring.....(trapezoidal form)
lower compression ring.....0.1 – 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
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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Piston ring gap (measured at the ring opening):

upper compression ring.....0.4 – 0.5 mm
lower compression ring.....1.0 - 1.2 mm

Oil scraper ring

Quantity.....1 

Width including spring.....3.2 – 3.4 mm

Piston ring clearance in the grooves.....0.05 – 0.1 mm

Oil scraper ring aperture (measured at the ring aperture).....0.3 – 0.5 mm

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Valve mechanism

Valves

Valve disc (Ø):

Inlet.....40 mm
Exhaust.....38 mm

Valve stem, l (Ø):

Inlet/Exhaust.....8 mm

Valve clearance with cold engine (adjustment value):

Intake .....0.2 ± 0.05 mm
Exhaust, EPG .....0.8 ± 0.05 mm 
Exhaust, VEB .....1.60 ± 0.05 mm

Valve clearance with cold engine (check value):

Intake .....0.15 - 0.25 mm
Exhaust .....0.75 - 0.85 mm

Valve clearance, shim free (adjustment screw)

Inlet .....0.2 ± 0.05 mm
Exhaust .....0.8 ± 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
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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Valve seat angle (A):

Inlet/Exhaust.....29° 30' 

Seat angle in cylinder head (B):

Inlet/Exhaust.....30° 

Measurement (A) between valve disc and cylinder head face:

Inlet.....min. 1.1 - 1.6 mm
Exhaust.....min. 0.4 - 0.9 mm

Note: When replacing the valve seats, the valves must also be replaced.

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Valve guides
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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Length:
Inlet/Exhaust.....83.5 mm

Inner diameter:
Inlet/Exhaust.....8 mm

Height above cylinder head spring face:

Inlet.....24.5 ± 0.5 mm
Exhaust.....16.5 ± 0.5 mm

Clearance valve stem — guide (dry valve stem):1

Inlet.....max. 0.5 mm
Exhaust.....max. 0.5 mm

1
The measurements are calculated for the measurement method described in the service literature, see group 214.

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Valve seats

Standard Oversize

Outer diameter (A) 42.1 mm

Inlet.....42.0 mm 40.1 mm
Exhaust.....40.0 mm

Height (B): -
Inlet.....7.3 mm -
Exhaust.....6.4 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
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 4.07.03 06/04/2019

Back to Contents.

Valve seat location

Standard Oversize

Diameter (C) -
Inlet.....42.0 mm -
Exhaust.....40.0 mm

Depth (D) -
Inlet.....11.5 mm -
Exhaust.....9.9 mm

Seat bottom radius (R) -

Inlet/Exhaust.....max 0.8 mm

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Valve springs

Inlet/Exhaust

Outer valve spring:

Length (without load).....73 - 74 mm

Inner valve spring:

Length (without load).....70 - 71 mm

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Rocker arms

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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Bearing play (1).....max 0.1 mm

Rocker arm roller clearance (2).....max 0.1 mm

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Engine timing gear

Timing gears

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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Gear wheels:

1. Drive gear, crankshaft

2. Idler gear, outer bull gear

Idler gear, inner bull gear

3. Idler gear, adjustable

4. Drive gear (with oscillation damper), camshaft

5. Idler gear, servo pump

6. Drive gear, steering servo and fuel feed pump

7. Drive gear, air compressor

8. Drive gear, lubricating oil pump

9. Engine power take-off (extra equipment)

Backlash.....0.05 - 0.17 mm

Shaft journal for idler gear, diameter.....100 mm

Idler gear bush, diameter.....100 mm

Diametrical clearance for idler gear.....max 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
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 4.07.03 06/04/2019

Back to Contents.

Camshaft

Note: Checking the camshaft settings, cold engine and valve clearance for the intake valve of cylinder 1 = 0.
The intake valve for cylinder 1 must be open by 1.7 ± 0.4 mm, with the flywheel positioned at 6° after TDC.
When checking, the timing gears must be turned in the correct direction (clockwise, seen from the front) to
absorb all of the backlash.

Drive.....by gear

Number of bearings.....7 

Bearing journals (standard diameter).....70.0 mm

For any undersize dimensions, refer to the Parts Catalogue.

Valve lift:
inlet.....13.1 mm
exhaust (VEB).....13.1 mm

Permissible wear, entire cam profile.....max 0.1 mm

Unit injector, stroke.....13 mm

Wear tolerance
Max end float.....0.2 mm

Max permitted ovality (with new bearing).....0.1 mm

Bearing, max. permitted run-out wear.....0.1 mm

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Camshaft bearings

Camshaft bearing thickness, standard.....1.9 mm 

For any oversize dimensions, refer to the Parts Catalogue.

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Crank mechanism

Crankshaft

Length.....1066 mm

Crankshaft axial clearance1 .....max. 0.3 mm

Ovality of main bearing journals and big-end bearing journals

.....max 0.01 mm

Taper of main bearing journals and big-end bearing journals.....max 0.01

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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Runout of middle bearing.....0.15 mm

1
Dimensions for lubricated components.

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Main bearing journals

Note: Reference values only, not for machining.

Diameter (Ø)
standard.....108.0 mm

For any undersize dimensions, refer to the Parts Catalogue.

Surface finish, main bearing journal.....Ra 0.25

Surface finish, curvature.....Ra 0.4

Width, axial bearing pin (A) (standard).....42 mm

For any oversize dimensions, refer to the Parts Catalogue.

Fillet radius (R) .....4.5 mm

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Thrust washers (axial bearing)

Width (B) (standard).....3.2 mm

For any oversize dimensions, refer to the Parts Catalogue.

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Main 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
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 4.07.03 06/04/2019

Outer diameter (C) .....113 mm

Thickness ((D) (standard).....2.5 mm

For any oversize dimensions, refer to the Parts Catalogue.

Diametrical clearance, main bearing.....max 0.1 mm

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Big-end bearing journal

Note: Reference values only, not for machining.

Diameter (Ø) .....86 mm 

For any undersize dimensions, refer to the Parts Catalogue.

Surface finish, connecting rod bearing journal.....Ra 0.25

Surface finish, curvature.....Ra 0.4

Width (A) .....54 mm

Fillet radius (R) .....4.5 mm

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Big end bearing shells

Outer diameter (B) .....91 mm 

Thickness ((C) (standard).....2.4 mm

For any oversize dimensions, refer to the Parts Catalogue.

Diameter, bearing shell bearing seat (D) .....90.8 mm 

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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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Connecting rod

Length centre - centre (E) .....225 mm

Internal diameter of connecting rod bushing (G) .....54 mm

End float, connecting rod - crankshaft1 .....max. 0.3 mm

Big-end bearing, radial play1 .....max 0.1 mm

Runout2 .....0.06 mm

Torsion2 .....0.15 mm

1
Measurements are for lubricated components.

2
Maximum deviation in measuring length of 100 mm

Marking:
FRONT on the rod is turned forward.
Connecting rod and cap are marked as a pair with a serial number (see illustration).

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Flywheel, fitted

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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Axial runout (manual gearbox) within a measuring radius of 150 mm

.....max. 0.2 mm 

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Flywheel housing (installed)

Axial run-out of contact surface against clutch housing

.....max. 0.2 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
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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Radial run-out of guide against clutch housing

.....max. 0.2 mm 

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Tightening torques
Engine mounting

Front engine mounting, cylinder block.....275 ± 45 Nm

Front engine mounting, front mounting pad.....140 ± 25 Nm

Front engine pad, cross member.....80 ± 15 Nm

Rear engine mounting, flywheel housing.....300 ± 40 Nm

Rear engine mounting, rear engine pad.....540 ± 90 Nm

Rear engine pad, frame.....140 ± 25 Nm

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Bearing cap

Main bearing cap

Step 1:.....150 ±20 Nm
Step 2 (angle tightening).....120 ± 5°

Connecting rod cap

Step 1:..... 30 ± 3 Nm
Tightening stage 2 (torque to angle):.....180 ± 6°

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 4.07.03 06/04/2019

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Stiffening frame

Reinforcement frame.....48 ± 8 Nm

Note: Tighten the bolts in sequence, from the centre and outwards

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Flywheel

Flywheel

Note: Make sure the flange is dry and clean. Tighten the bolts in the order shown in the illustration.

Step 1:.....60 ±5 Nm
Step 2 (angle tightening).....135 ± 10°

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Oscillation damper, crankshaft

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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Oscillation damper/pulley, crankshaft

Note: Tighten the bolts in the sequence shown in the diagram.

Class 8.8 bolts used in the vibration damper must not be reused.

Step 1:.....40 ±4 Nm
Step 2:.....90 ± 10 Nm

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Flywheel casing

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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Flywheel housing
Step 1: M8, M12, M14 bolts.....24 ±14 Nm
Step 2: M12 bolts.....85 ±15 Nm
Step 3: M14 bolts.....140 ± 25 Nm

Note: Apply silicone as shown in figure below

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Casing, crankshaft seal

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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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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Note: Apply a 2 mm-thick bead of silicone, as shown above, no more than 20 minutes before installation.

Casing crankshaft seal

Step 1: Fit the cover with bolts 2 and 7 and tighten until contact.
Step 2: Tighten bolts 2 and 7.....24 ±4 Nm
Step 3: Tighten the bolts in numerical sequence 1, 3–6, 8, as shown.....24 ± 4 Nm

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Valve cover

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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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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Valve cover.....24 ± 4 Nm

Note: Tighten the bolts in the order shown in the illustration.

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Oil cooler cover

Oil cooler cover

Note: Check that the gasket is within its groove before tightening the screws.

Tighten the bolts in sequence as illustrated.....24 ± 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
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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Cylinder head

Cylinder head

Torque tighten the bolts in the number sequence shown in the illustration.
Step 1:.....65 ±5 Nm
Step 2 (tighten until contact):.....65 ±5 Nm
Step 3 (angle tightening).....120 ± 5°
Step 4 (angle tightening).....90 ± 5°

Note: The cylinder head screws can be reused 5 times. If this is done, do not apply locking fluid to the bolts. Do
not apply locking fluid to new bolts as these are pretreated.

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Lifting eye, cylinder head

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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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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Lifting eye
Step 1:.....30 ±3 Nm
Step 2 (angle tightening).....80 ± 5°

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Valve EPG/VEB

Lock nut (A), valve.....38 ± 4 Nm

.....(Angular torque 60 ± 5° after contact)

Lock nut (B), gauge.....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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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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.....(Angular torque 30 +15 –0 ° after contact)

/
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Bearing caps, camshaft/rocker arm shaft

Note: To prevent the rocker arm from misaligning during installation, the bolts must be tighten according to the steps
described below.

Step 1:
Tighten bolts 1-7.....25 ± 3 Nm

Step 2:
Tighten bolts 11, 9 and 13.....90 ± 5 Nm

Step 3
Tighten bolts 8, 10, 12, 14.....60 ± 5 Nm

Step 4:
Loosen bolts 9, 13 and 11.

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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Step 5:
Tighten bolts 11, 9 and 13.....60 ± 5 Nm

Step 6:
Use angle tightening to tighten bolts 1–7.....90 ± 5°

Step 7:
Use angle tightening to tighten bolts 8–14.....100 ± 5°

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Timing gear plate

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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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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Timing gear plate.....28 ± 4 Nm

Note: Apply silicone and tighten the bolts in the order shown in the illustration.

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Timing gears

1. Drive gear (with oscillation damper), crankshaft.....24 ± 4 Nm

2. Idler gear
Torque tighten the bolts in the number sequence shown in the illustration.
Step 1:.....25 ±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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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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Step 2 (angle tightening).....110 ± 5° 

3. Idler gear, adjustable

Torque tighten the bolts in the number sequence shown in the illustration.
Step 1:.....35 ±4 Nm
Step 2 (angle tightening).....120 ± 5°

4. Drive gear, camshaft

Torque tighten the bolts in the number sequence shown in the illustration.
Step 1:.....45 ±5 Nm
Step 2 (angle tightening).....90±5°

5. Drive gear, steering servo and fuel feed pump.....100 ± 10 Nm

6. Drive gear, air compressor..... 200 + 50 – 0 Nm /

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Timing gear cover

Apply a 2 mm thick bead of silicone, as shown above, max. 20 minutes before 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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Install the cover in two steps.

Step 1: Fasten the cover with bolts 1 and 21 .....4 ± 1 Nm
Tighten the bolts in the numeric sequence shown in the diagram.....24 ± 4 Nm

1
Use the special tool to press the cover into place.

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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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