IMPACT 4.04.

00 11/04/2023

Chassis ID Path
A 776867 21/Description, Design and function//Engine, system description

Model Identity
FM (4) 156802992

Publish date ID/Operation

04/05/2021

Engine, system description

Engine
Cylinder head
Cylinder block
Stiffening frame and oil pan
Sealing joints
Cylinder head, guiding on the block
Piston, cylinder liner and connecting rod
Camshaft and valve mechanism
Camshaft and valve mechanism

Crankshaft, oscillation damper, flywheel

Engine transmission
Engine transmission idler gear
Engine transmission, idler gear

Casings
Engine, suspension
Engine driven power take-off

Engine
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
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.

1 / 21
IMPACT 4.04.00 11/04/2023

The cast iron cylinder head is manufactured in one piece, which provides a stable mounting for the
overhead camshaft.
The camshaft is mounted in seven horizontally separated bearing brackets with replaceable bearing
shells. The bearing shell in the rear bearing bracket is also designed as a thrust bearing.
The coolant thermostat housing is machined directly into the front right corner of the cylinder head (1)
.
Each cylinder has separate inlet ports on one side of the cylinder head and separate exhaust ports on
the other side, known as "crossflow" (2) .
The low-pressure fuel channel for the injectors is drilled longitudinally through the cylinder head with
a circular machined space around each injector (3) .
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.

2 / 21
IMPACT 4.04.00 11/04/2023

There is a plug (4) at the front, which leads to a channel (6) for measuring the oil pressure in the
rocker arm mechanism.
The channel (5) leads lubricating oil to the camshaft and the rocker arms. It is drilled centrally in the
left-hand side of the cylinder head. The pins (7) located on the lower bearing are solid and
replaceable.

A unit injector is located vertically above the centre of each cylinder, between the four valves, and
secured by a yoke (2) . The lower part of the injector is separated from the coolant jacket by a sleeve
that is enlarged at the bottom and sealed with an O-ring at the top. The ring-shaped space around
each injector is sealed with two O-rings on the injector.
For maximum cooling, the coolant space in the cylinder head has a horizontal wall that forces coolant
to the lowest and hottest parts of the cylinder head.
The valve mechanism comprises double inlet and double exhaust valves. The exhaust valves have
double valve springs (1) whereas the inlet valves have single springs (3) . The valves are linked in
pairs with a floating valve caliper that transfers the movement of the rocker arm against the camshaft
to the valve pairs. The valves are a new type with three grooves and matching valve cotters. The
valve cotters are designed so that the valve can rotate in its valve seat. To improve their heat
resistance and dissipation, the exhaust valve discs have greater mass and a slightly smaller diameter
than the inlet valves.
The valve guides are made of cast iron alloy, and all the valves have effective oil/gas seals on the
valve stems.
The valve seats are made of hardened special steel and are replaceable but cannot be remachined.

Cylinder block

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.

3 / 21
IMPACT 4.04.00 11/04/2023

The cylinder block is one piece and is made of cast iron.

Two longitudinal oil channels are drilled in the cylinder block - the main lubrication channel (1) (gallery
channel) on the left side of the engine block and the piston cooling channel (2) on the right side of the
engine block. The main lubrication channel joins a cast channel that supplies lubricating oil to the
engine transmission. There are five cylinder head oil drainage channels (4) drilled vertically into the
left side of the engine block. A centrally located drilled channel (5) through the cylinder block and
cylinder head leads the pressurized lubricating oil up to the VCB (Volvo Compression Brake)
valve/junction housing and the drilled rocker arm shaft, which lubricates the camshaft bearings and
rocker arm bearings via oil channels.

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.

4 / 21
IMPACT 4.04.00 11/04/2023

The dished form of the sides of the block around each cylinder gives the cylinder block a high
torsional rigidity and good acoustic dampening.
The vertical cross-section shows the position of the cylinder liner and the cooling jacket.
To prevent fitting the main bearing caps the wrong way round, they are guided in place with an
asymmetric cast boss (1) to the corresponding chamfer (2) in the cylinder block. The main bearing
caps are made of ductile cast iron and adapted individually. To ensure correct assembly, they are
marked with the numbers 1, 2, 3, 5 and 6 from the front of the engine. The middle and rearmost main
bearing caps have a unique form and do not require marking.

Stiffening frame and oil pan

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.

5 / 21
IMPACT 4.04.00 11/04/2023

To reduce vibration in the cylinder block and by that reduce the engine noise, there is a stiffening
frame (1) mounted on the base of the block. The stiffening frame is in steel plate and is screwed onto
the bottom surface of the block (3) .
In its basic form, the oil pan (2) is moulded plastic (composite), but there is also a variant in pressed
steel available for special applications.
The seal for the plastic oil pan consists of a rubber moulding. The rubber moulding is made in one
piece and is fitted in a groove in the upper edge of the pan. The oil pan is secured with spring-loaded
steel screws (4) . The oil plug (5) is threaded into a steel reinforcement, which is replaceable.
The steel oil pan is sealed against the base of the cylinder block by a flat rubber gasket with a steel
core. The gasket is held in place on the pan by rubber studs. The steel pan is secured with the same
type of spring-loaded steel screws as the plastic pan but they are slightly shorter.

Sealing joints

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.

6 / 21
IMPACT 4.04.00 11/04/2023

The engine has wet cylinder liners for efficient thermal dissipation. They are sealed against the
cylinder block with rubber rings. The upper ring is located directly below the liner collar (1) . The
sealing surface of the liner against the cylinder head gasket is convex. The liner guide on the engine
lies above the liner shelf.
The lower sealing is made up of three O-rings located in grooves in the cylinder block (2) . These
rings are made of various rubber materials and are different colours to avoid confusion. The two
upper (black) rings are made of EPDM rubber and therefore resistant to coolant whereas the lower
ring (violet) is fluorocarbon rubber and is resistant to oil.
The cylinder head gasket (3) installed between the cylinder head and cylinder block is made of steel
and has integral vulcanised rubber seals (4) for the coolant and oil channels. The gasket has several
convex bosses (5) on which the cylinder head glides to protect the rubber seals during cylinder head
installation. These bosses are pressed flat when the cylinder head is tightened down.

Cylinder head, guiding on the block

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.

7 / 21
IMPACT 4.04.00 11/04/2023

No special tools are required to install the cylinder head. To facilitate assembly and to obtain precise
positioning of the cylinder head on the cylinder block, there are three guide washers on the left-hand
side of the engine — two on the cylinder block (1) and one on the cylinder head (2) .These washers
set the sideways position of the cylinder head and the timing gear plate (3) determines the position in
lengthways. The cylinder head can then be positioned exactly.
The convex bosses on the cylinder head gasket mean that the cylinder head can be moved on the
gasket without damaging the rubber seals.

Piston, cylinder liner and connecting rod

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.

8 / 21
IMPACT 4.04.00 11/04/2023

The engine has forged, machined steel pistons. The pistons are oil cooled. The piston (A) has two
compression rings and one oil scraper ring. The upper compression ring (1) has a trapezoidal cross
section ("keystone ring"). The lower compression ring (2) has a rectangular cross section. The oil
scraper ring (3) lowest down is spring loaded.
Both the compression rings and the oil scraper ring are installed with the marking facing up.
The cylinder liners (B) are replaceable. They are centrifugally cast in cast iron alloy. The insides of
the liners are honed with a cross-hatch pattern (4) . The liner surface is finished with a method called
plateau honing (5) , where the sharpest ridges remaining from the initial machining are ground down.
Connecting rods (C) are forged and a split at the lower end (big end) with a method called fracture
splitting. The upper end (small end) has a bushing pressed (6) in for the gudgeon pin, which is
lubricated via a drilled channel (7) . The two parts of the big end are assembled with four screws, and
each part of the connecting rod is marked with a serial number (8) to ensure correct part matching.
The connecting rod is marked "FRONT" to ensure correct assembly.

Camshaft and valve mechanism

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.

9 / 21
IMPACT 4.04.00 11/04/2023

Camshaft and valve mechanism

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.

10 / 21
IMPACT 4.04.00 11/04/2023

The engine has overhead camshafts and a four valve system.

There are two types of camshaft available, solid (induction hardened) or hollow. A hollow camshaft is
lighter than a conventional, solid camshaft. Also, depending on the type of engine, a hollow camshaft
can have separate, press-fitted cams. The two types can be identified through the radius (A) on a
solid camshaft and the sharp angle (B) on a camshaft with fitted cams. The camshaft is mounted in
seven bearings; the rear bearing is also a thrust bearing. The bearing shells and brackets are
replaceable. There are four cams between each bearing on VEB+ (Volvo Engine Brake) engines:
inlet, injection, exhaust and brake, and three cams between each bearing on EPG (Exhaust Pressure
Governor) engines: inlet, injection and exhaust, taken from the front. The camshaft gear (1) is driven
by the crankshaft via the timing gears. In order to minimize vibration and noise, a hydraulic oscillation
damper (2) is mounted on the front of the gear. There are teeth on the oscillation damper which drive
the camshaft induction damper.
The illustration (A) shows a cross-section through a pair of exhaust valves. The inlet valves are
principally the same.
An engine with VEB+ has a hydraulic function integrated in the rocker arm. Each rocker arm acts on a
floating valve caliper (3) , which opens the valves. The rocker arm (4) is mounted on the rocker arm
shaft (5) with a bushing (6) . A roller (7) runs against the cam and, at the other end, a ball socket
transfers the motion to the valve caliper (8) , which opens the valve.
The illustration (B) shows the camshaft markings for the basic setting (TDC) and for valve and
injector adjustment. The markings are stamped on the front end of the camshaft (9) in front of the
front bearing bracket (10) and differ depending on the type of engine brake.

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.

11 / 21
IMPACT 4.04.00 11/04/2023

Camshaft, marking

Engine brake Exhaust valves Inlet valves Injectors

EPG 1–6 1–6 1–6

VEB+ E1–E6 1–6 1–6

Note
Valves and valve seats have different dimensions and material depending on engine
specification (EAP-variant) and on production date.

Crankshaft, oscillation damper, flywheel

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.

12 / 21
IMPACT 4.04.00 11/04/2023

The crankshaft is drop forged and has induction-hardened bearing surfaces and channel grooves.
The crankshaft is mounted in seven main bearings with replaceable bearing shells (1) . The main
bearing (B) in the centre also includes the thrust bearing, which comprises four crescent-shaped
washers (2) .
At the front end (A) , the crankshaft (3) flange is sealed by a Teflon seal. At the rear end (C) there is
also a Teflon seal (4) against a machined surface on the crankshaft gear (5) . The gear is attached to
the crankshaft with a locating pin (6) and two screws (7) . An O-ring (8) located in a groove in the rear
crankshaft flange seals the flange against the gear.

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.

13 / 21
IMPACT 4.04.00 11/04/2023

Note
The upper bearing shells and upper main bearings are available in two variants, one
manufactured with lead and the other without lead. The lead variant, illustration example (B1)
and (1A) , is slightly more grey in colour than the lead-free variant, illustration example (B2) an
d (1B) .

The crankshaft is lubricated via separate channels in the cylinder block to each main bearing (1) .
The main bearing journals have drilled lubricating channels (2) , and there is a drilled channel (3)
from each one except the centre one to the nearest rod journal.
The oscillation damper is hydraulic and is screwed directly to the front flange of the crankshaft. The
damper is also used as a pulley for a multi-groove belt that drives the air conditioning compressor
and alternator. There is an oscillation weight in the damper housing (4) in the form of a cast iron ring (
5) that can rotate freely on the bushings (6) . The space between the damper housing and the
oscillation weight is filled with high viscosity silicone oil. When the engine is running, the force
impulses of the pistons cause torsional stress in the crankshaft. The viscous silicone oil equalises the
movement between the pulsing rotation of the crankshaft and the even rotation of the oscillation
weight and thereby reduces this stress.
The flywheel (7) and the intermediate gear (8) are bolted onto the crankshaft's rear flange (9) . The
flywheel is positioned on the crankshaft with the same locating pin (10) as the gear. Around its
periphery are machined grooves (12) for the engine management system inductive flywheel sensor.
The starter gear ring (11) is shrink-fitted to the flywheel and is replaceable.
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.

14 / 21
IMPACT 4.04.00 11/04/2023

Engine transmission

Engine transmission, components

1 Timing gear plate

2 Crankshaft gear

3 Idler gear, double

4 Drive gear, PTO (Power Take-Off)

If applicable

5 Idler gear, adjustable

6 Camshaft gear

7 Drive gear, air compressor

8 Drive gear, servo pump and fuel pump

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.

15 / 21
IMPACT 4.04.00 11/04/2023

9 Idler gear, servo pump and fuel pump

10 Drive gear, lubricating oil pump

11 Oscillation damper with teeth for inductive camshaft position sensor

The engine transmission is located on the rear of the engine on a thick steel plate (1).
The timing gear plate is screwed onto the cylinder block and cylinder head. The plate has a rubber
gasket on each side (C), which is vulcanised into a groove. The gasket seals against the cylinder
block and cylinder head on one side and against the timing gear casings on the other side.
There is a hole drilled in the timing gear plate that is used together with the marking on the camshaft
gear (A) to mount the camshaft gear in the correct position.
The crankshaft gear and the double idler gear have alignment marks (B) to ensure correct assembly.

Note
A special tool must be fitted before the timing gear plate is dismantled, see repair instructions.

Engine transmission idler gear

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.

16 / 21
IMPACT 4.04.00 11/04/2023

Engine transmission, idler gear

(A): The small idler gear that drives the steering servo and fuel feed pump is mounted on a
double-row ball bearing (1) and secured by a screw (2) that also fastens the flywheel housing.
(B): The lower idler gear is a two-gear assembly. The gears are pre-mounted on a hub (3) on two
tapered roller bearings (4). A sleeve (5) guides the idler gear in the timing gear plate.
This idler gear with two gears, bearing and hub is a complete unit that cannot be dismantled and
must be replaced as a complete component.
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.

17 / 21
IMPACT 4.04.00 11/04/2023

(C): The adjustable idler gear is mounted with a bushing on (6) the hub (7). The bushing and thrust
washer (8) are force-feed lubricated through a channel (9) running between the cylinder block and the
timing gear plate. A locating pin (10) in the bottom of the hub creates sufficient backlash between the
two idler gears. Therefore, during adjustment, only the backlash to the camshaft gear needs to be
set.

Casings

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.

18 / 21
IMPACT 4.04.00 11/04/2023

There are two casings for the engine transmission. The upper timing gear casing (A) , moulded in
plastic, has an integrated oil trap for the crankcase ventilation. The lower flywheel housing (B) is a
combined timing gear casing and flywheel housing, and has attachment points for the rear engine
suspension. The flywheel housing has two guide sleeves that locate it on the timing gear plate.
Each casing is fitted to the timing gear plate with sealant. The two casings are sealed to each other
with a rubber moulding (1) located in a groove in the upper 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.

19 / 21
IMPACT 4.04.00 11/04/2023

There are two holes with rubber plugs in the flywheel housing. One hole is intended for a crank tool (2
) for turning the engine with the position of the flywheel seen on a mark through the second hole (3) .
The cover (C) is used by engines without PTO.

Engine, suspension

The front engine anchorages (1) are screwed onto the cylinder block.
On the front edge, they are each screwed onto a bracket (2) made in pressed metal plate.
The brackets are screwed underneath the cross member (3) and have shock absorbent rubber
cushions (4) .
The two rear anchorages (5) are cast in one piece and screwed to the timing gear casing and the
brackets (6) .
The brackets have rubber cushioning and are screwed to the inside of the frame members.

Engine driven power take-off

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.

20 / 21
IMPACT 4.04.00 11/04/2023

An engine driven power take-off for mounting on the rear of the flywheel housing is available as extra
equipment. The power take-off is driven by the outer gear in the lower idler gear and the gear mesh is
lubricated through a hole in the idler gear bearing shield.
The power take-off is available in different variants, as a hydraulic pump and as a mechanical power
take-off.
The illustration shows a hydraulic pump.
If a greater power take-off is required, the gear for the extra power take-off as well as the crankshaft
gear and the double idler gear must be replaced with gears with case-hardened teeth.

Tech data

Power take-off, torque (gear with case-hardened teeth) 650 – 1,000 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.

21 / 21