IMPACT 4.04.
00 28/06/2022
Chassis ID Path
21/Description, Design and function//Engine, system description
Model Identity
FH (4) 152424797
Publish date ID/Operation
25/07/2020
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
Crankshaft, oscillation damper, flywheel
Double mass flywheel
Engine transmission
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 / 19
IMPACT 4.04.00 28/06/2022
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 shells in the rear bearing bracket are also designed as a thrust bearing.
The coolant thermostat housing is machined directly into the front right corner of the cylinder head (1)
.
The cylinder head has a cross-flow (2) design meaning that the inlet ports and outlet ports are on
opposite sides of the cylinder head.
The fuel channel for the unit injectors is drilled longitudinally through the cylinder head with a circular
machined space around each unit injector (3) .
There is a plug (4) at the front, on the channel 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.
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 / 19
IMPACT 4.04.00 28/06/2022
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 or guided valve caliper that transfers the movement of the rocker arm against the
camshaft to the valve pairs.
The valve guides are made of cast iron alloy. All the valves have oil seals on the valve stems (4) .
The oil seals have double sealing surfaces.
The valve seats are made of hardened steel and are replaceable but cannot be re-machined.
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 / 19
IMPACT 4.04.00 28/06/2022
The cylinder block is made of cast iron in one piece.
Two longitudinal channels are drilled into the block for the lubrication system. In the block's left-hand
side is the main lubrication duct (distribution duct) (1) and in the right-hand side is the piston-cooling
duct (2) . Both ducts are plugged at the front with plugs (3) containing O-rings. At the rear, the piston
cooling channel is covered by the timing gear plate and the main oil channel opens out into the cast
channel that supplies oil to the engine transmission. There are a five drainage ducts (4) drilled
vertically into the left-hand side of 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.
4 / 19
IMPACT 4.04.00 28/06/2022
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.
The main bearing caps are aligned by sleeves (1) pressed into the cylinder block. The main bearing
caps are made of nodular iron and are matched individually. To prevent incorrect installation, they are
numbered and marked 1,2,3,5,6 and 7. The middle main bearing cap is uniquely shaped and does
not need to be marked. The undersides of the main bearing caps are all also marked, with arrows (2)
which must point to the engine inlet side. Main bearing caps 2 through 6 have bosses that prevent
them from being mounted incorrectly.
Note
For main bearings 1 through 7, it is important that the arrows on the bottom point at the
engine's inlet side.
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 / 19
IMPACT 4.04.00 28/06/2022
To reduce vibration in the cylinder block and thereby reduce engine noise, there is a stiffening frame (
1) mounted on the base of the block. The stiffening frame is made of a thick steel plate and is
screwed onto the bottom surface of the block (3) .
The oil pan (2) is moulded plastic (composite).
The seal for the oil pan consists of a rubber moulding. The oil pan is screwed on with spring-loaded
steel screws (4) . The oil pan is screwed on with spring-loaded steel screws (4) . The oil drain plug (5)
for the oil pan is threaded into a steel reinforcement. The steel reinforcement is replaceable.
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 / 19
IMPACT 4.04.00 28/06/2022
The engine has a cylinder block with wet cylinder liners for efficient thermal dissipation. The cylinder
liners are sealed against the cylinder block with sealing rings. The upper section of the cylinder liner
has a sealing ring located directly below the liner collar (1) . The sealing ring (black) is made of
EPDM rubber. The sealing ring increases the coolant circulation space, which improves the cooling of
the cylinder liner's upper section.
The lower section of cylinder liner has two sealing rings located in the grooves of cylinder liner (2) .
These rings are made of various rubber materials and are different colours in order to avoid
confusion. The upper (black) rings are made of EPDM rubber and are resistant to coolant. The lower
ring (violet) is fluorocarbon rubber and is resistant to oil.
The gasket (3) between the cylinder head, block and liner is made of steel and has
integral-vulcanised rubber seals for the coolant and oil channels. The gasket has a number of convex
bosses on which the cylinder head glides in order 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 / 19
IMPACT 4.04.00 28/06/2022
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
lengthways position. The cylinder head can then be positioned exactly.
The convex bosses on the cylinder head gasket mean 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 / 19
IMPACT 4.04.00 28/06/2022
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"). 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 crosshatch 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 split at the lower end (big end) with a method called fracture
[Link] 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.
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.
9 / 19
IMPACT 4.04.00 28/06/2022
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.
10 / 19
IMPACT 4.04.00 28/06/2022
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.
A drive pulley with an integrated hydraulic oscillation damper (4) is mounted on the front flange of the
crankshaft. A second drive pulley (13) is mounted on the front of the pulley-damper. There is an
oscillation weight in the damper housing in the form of a cast iron ring (5) , which can rotate freely on
the bushings (6) . The limited space between the damper housing and the oscillation weight contains
high viscosity silicone oil (14) . 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.
Double mass 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.
11 / 19
IMPACT 4.04.00 28/06/2022
Vehicles with an I-shift gearbox are equipped with a double-mass flywheel. The double-mass flywheel
is used to provide softer shifting by reducing vibration out to the gearbox. The double-mass flywheel
primarily consists of a primary flywheel (A) (closest to the crankshaft), a spring assembly (B) and a
secondary flywheel (C) .
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 / 19
IMPACT 4.04.00 28/06/2022
In the rear crankshaft flange (1), the crankshaft gear (2) is attached to the crankshaft by a locating pin
(3) and two screws (4). There is an adapter plate (5) outside the crankshaft gear. The adapter plate is
screwed to the rear flange of the crankshaft (1) by 14 screws (6) that pass through the crankshaft
gear (2). The adapter plate (5) is located on the crankshaft with the same guide pin (3) as the
crankshaft gear (2). The flywheel (7) is screwed to the adapter plate (5) with 10 screws (8) . The
starter ring gear (9) is shrunk onto the flywheel and can be replaced. The outer edge has milled
grooves (10) for the engine control system flywheel sensor.
Engine transmission
Engine transmission, components
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 / 19
IMPACT 4.04.00 28/06/2022
1 Timing gear plate
2 Crankshaft gear
3 Idler gear, double
4 Drive gear, PTO
If applicable
5 Idler gear, adjustable
6 Camshaft gear
7 Drive gear, air compressor
8 Drive gear, servo pump and fuel pump
9 Idler gear, servo pump and fuel pump
10 Drive gear, lubricating oil pump
11 Oscillation damper with teeth for inductive camshaft position sensor
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 / 19
IMPACT 4.04.00 28/06/2022
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) in order 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.
15 / 19
IMPACT 4.04.00 28/06/2022
(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) .
The intermediate gear wheel is sealed by an O-ring (3) against the timing gear plate and by an O-ring
(4) against the flywheel housing. Some variants have sealing compound against the flywheel housing
instead of the O-ring (4) .
(B) : The lower idler gear is a two-gear assembly. The gears are pre-mounted on a hub (5) on two
tapered roller bearings (6) . A sleeve (7) 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.
16 / 19
IMPACT 4.04.00 28/06/2022
(C) : The adjustable idler gear is mounted with a bushing on (8) the hub (9) . The bushing and thrust
washer (10) are force-feed lubricated through a channel (11) running between the cylinder block and
the timing gear plate. A locating pin (12) in the bottom of the hub prevents backlash between the two
idler gears. Therefore, during adjustment, only the backlash to the camshaft gear needs to be set.
Casings
There are two covers for the timing gears, both of cast aluminium. 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.
Both covers are sealed against the timing gear plate by sealing compound. Sealing between the two
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 / 19
IMPACT 4.04.00 28/06/2022
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, and through the other hole can be read a marking that indicates the position of
the flywheel (4) .
Cover (C) encloses the connection for the engine-driven power take-off.
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.
18 / 19
IMPACT 4.04.00 28/06/2022
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.
19 / 19