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IMPACT 4.00.51.

00-SNAPSHOT 01/06/14

Chassis ID Path
A 252575 2125/Repair//Flywheel housing, replace. Flywheel and air filter housing removed and coolant drained

Model Identity
FH16 130909227

Publish date ID/Operation


08/12/11 21233-3

21233-3 Flywheel housing, replace


Flywheel and air filter housing removed and coolant drained

Note: Since illustrations are used for several different variants, certain details may differ from the variant in question.
The essential information in the illustrations is, however, always correct.

Special tools: 9990166, 9990181, 9996239, 9998318, 9998601, 88800031, 88800046, 88880013

1
Remove all electrical current with the main switch.

2
Release the crankcase ventilation pipe and move it aside.

3
Remove the rocker cover.

4
Detach the pipe to the exhaust pressure governor.

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 4.00.51.00-SNAPSHOT 01/06/14

Remove the clamp between the turbocharger and the shutter housing.
Remove the shutter housing with the exhaust pressure governor and lay them on the frame.

6
Remove the clamps and cable ties from the cabling that runs to the air filter indicator, flywheel and camshaft sensors
and the starter motor.

7
Remove the starter motor from the flywheel housing.

Remove the flywheel sensor from the flywheel housing.

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 4.00.51.00-SNAPSHOT 01/06/14

Remove the camshaft sensor from the upper timing gear cover.

Note: Retain the shims.

10
Remove the pressure pipe from the compressor and remove the pressure pipe clamps from the intake pipe. Move it to
one side.

11
Remove the compressor intake pipe and pressure pipe.
Remove the lubricating oil hose and regulator hose.
Remove the coolant hoses from the compressor.
Remove the compressor.

12
Remove the clamps securing the coolant pipes, the wiring and compressed air line from the flywheel housing and the
upper timing gear cover.
Remove the bracket from the flywheel housing.
Remove the coolant pipe from the flywheel housing.
Remove the clamps from the air piping and move it to one side.

13
Remove the ground cable from the rear engine mounting.

14

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 4.00.51.00-SNAPSHOT 01/06/14

Remove the servo pump screws. Let the fuel pump/servo pump and its connections remain where they are.

15
Remove the oil sump, see Oil sump, remove .

16

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 4.00.51.00-SNAPSHOT 01/06/14

Remove the upper timing gear cover.

Note: Make sure that the rubber seals do not fall down into the engine.

17
Remove the engine bracket screws.

18

Fit the lateral yoke with lifting strap 88800046 to the rear engine brackets.
Lift the engine 20-30 mm, so that the engine brackets are released from the engine mounting pads.

Special tools: 88800046

19

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 4.00.51.00-SNAPSHOT 01/06/14

Fit support 9990181 to the sides of the engine.

Special tools: 9990181

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 4.00.51.00-SNAPSHOT 01/06/14

20

Carefully lower the engine onto the support. Remove the lifting yoke.

Special tools: 9990181

21
Remove the left and right engine brackets from the flywheel housing.
Remove the engine anchorages from the chassis member.

22
Remove the screws from the timing gear plate at the flywheel housing.

23

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 4.00.51.00-SNAPSHOT 01/06/14

Fit the lifting chain 9996239 to the flywheel housing.

Special tools: 9996239

24

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 4.00.51.00-SNAPSHOT 01/06/14

Remove the screws from the inside of the flywheel housing.


Remove the flywheel casing.
Remove the cover from the power take-off.
Remove the lifting chain

25
Fit the PTO cover with a new gasket to the new flywheel housing.
Attach the lifting chain.

Special tools: 9996239

26

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 4.00.51.00-SNAPSHOT 01/06/14

TIP: Manufacture 2 off guide pins.

27
Clean the timing gear plate mating surface.

28
Apply a 2 mm thick bead of sealing compound to the flywheel housing, see Specifications . Sealing compound must
also be applied to the intermediate bearing support in the flywheel housing.

Note: The flywheel housing must be fitted within 20 minutes of the sealant being applied.

29
Install the flywheel housing. Torque tighten according to Specifications .
Remove the lifting chain
Remove any excess sealant.

Special tools: 9996239

30

Note: Thoroughly clean the sealing area in the flywheel casing and the sealing surface against the crankshaft.

31

Fit the plate to the crankshaft and screw it tight.

Note: Ensure that the plate is positioned properly on the crankshaft internal guide and is right up against the crankshaft
before tightening the screws.

Special tools: 9990166

32

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 4.00.51.00-SNAPSHOT 01/06/14

The sealing ring is supplied with a plastic installation ring. The plastic ring acts both as transport protection and as a
mounting tool.

Note: The plastic ring must not be removed before installing the seal.

33

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 4.00.51.00-SNAPSHOT 01/06/14

Fit the spacer ring, seal with plastic ring and then the cover together with the handle.

Note: The spacer ring on the stud determines how far in the seal will sit.

Special tools: 88880013, 9990166

34

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 4.00.51.00-SNAPSHOT 01/06/14

Press the seal into place by turning the handle.


When the cover bottoms out the seal is in its correct position.

Special tools: 9990166

35
Remove the tool and the plastic ring.

36
Fit the engine mounting to the chassis member. Torque tighten according to Specifications .
Fit new cable ties to pull the pipes together.

37
Fit the left and right engine brackets on to the flywheel housing. Torque tighten according to Specifications .

38

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 4.00.51.00-SNAPSHOT 01/06/14

Fit the lifting tool 88800046. Lift the engine 20-30 mm so that supports at right and left can be removed.

Special tools: 88800046

39
Carefully lower the engine and fit the bolts into the engine mountings. Torque tighten according to Specifications .

40
Fit the ground connection on the right hand engine mounting.

41
Fit the oil sump, see Oil sump, install .

42

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 4.00.51.00-SNAPSHOT 01/06/14

Fit the servo pump screws. Torque tighten according to Specifications Group 20.

43
Fit the compressor with a new sealing ring. Torque tighten according to Specifications .

Note: Lubricate the sealing ring before fitting it, and check carefully that it is positioned correctly.

44
Fit the coolant hoses to the compressor.
Fit the air connection and lubricating oil pipe.
Fit the compressor intake pipe and delivery pipe.

45

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 4.00.51.00-SNAPSHOT 01/06/14

Fit the flywheel sensor. See Flywheel sensor distance, check .

46
Fit the clamps for hoses, cabling and piping.
Fit the bracket on the flywheel housing.
Fit the coolant pipe from the oil cooler housing, using a new sealing ring.
Fit the air line and clamps.

47
Fit the starter motor.
Fit the cables according to their markings.

48

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 4.00.51.00-SNAPSHOT 01/06/14

Fit the shutter housing on the turbocharger. Turn the housing to the correct position according to the marks and tighten
the clamp.

49
Fit the pipe to the exhaust pressure governor.

50

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 4.00.51.00-SNAPSHOT 01/06/14

Clean the mating surfaces of the timing gear cover and timing gear plate.
Fit new seals.

51
Apply a 2 mm thick bead of sealing compound to the upper timing gear cover in accordance with Specifications .

Note: The upper timing gear cover must be fitted within 20 minutes of the sealant being applied.

52

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 4.00.51.00-SNAPSHOT 01/06/14

Fit the upper transmission cover.


Fit the screws in the oval holes. Tighten until the cover makes contact.
Fit press tools 9998601 and 9998318. Press down the transmission cover so that it is level.
Install the remaining screws. Torque tighten in accordance with the tightening diagram, see Specifications, Group 20.

Special tools: 9998601, 9998318

53
Remove the press tool for the upper transmission casing and wipe off any excess sealing compound.

54

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 4.00.51.00-SNAPSHOT 01/06/14

Turn the engine so that a tooth on the camshaft gear wheel is in the middle of the camshaft sensor hole in the upper
transmission casing. Check the distance to the camshaft gear wheel with tool 88800031.
1. No edge = no adjustment shim.
2. One edge = one adjustment shim.
3. Two edges = two adjustment shims.

Fit the camshaft sensor with the correct number of adjustment shims.

Special tools: 88800031

55

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 4.00.51.00-SNAPSHOT 01/06/14

Clean the mating surfaces for the rocker cover.


Apply a 2 mm thick bead of sealant to the mating surface (A) between the upper timing gear cover and the cylinder
head.

Note: The timing gear cover must be fitted within 20 minutes after the sealant has been applied.

56
Replace the rocker cover and tighten to the torque given in Specifications, Group 20.
Install the crankcase ventilation pipe.

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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