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IMPACT 4.00.51.

00-SNAPSHOT 01/06/14

Chassis ID Path
A 252575 2109/Repair//Engine parts, transferring

Model Identity
FH16 107662407

Publish date ID/Operation


23/01/07 21035-4

21035-4 Engine parts, transferring


Note: Before parts are transferred to the new engine, clean them carefully and check them for damage and correct
function.
Use new gaskets and sealing rings.
Transfer plugs and caps from the new to the old engine.

Removal from the old engine

1
Connect up to the old control unit and save the parameters.

Thermostat fan

Remove:

Fan ring with upper and lower brackets.


Connector from fan speed sensor. Remove the cable ties.

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

Thermostat fan lock nuts and remove the thermostat fan from the fan hub.

Note: The fan must be kept upright.

Fan belt.
Fan belt pulley from the fan hub.
Fan hub and spacer from the engine block.

Alternator

3
Remove:

Alternator belt.
Alternator belt tensioner.
Alternator cabling.
Alternator.

Compressor

4
Remove:

Cooling loop and pressure pipe from the compressor with brackets.
Compressor intake pipe from the bracket.
Compressor coolant hose.
Lubrication oil hose.
The compressor.

Clutch

Remove the clutch, see 411033 Friction plate, remove (removed gearbox) group 41.

Flywheel

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 4.00.51.00-SNAPSHOT 01/06/14

Remove the flywheel, see 21621-3 Flywheel, replace group 21.


Remove the flywheel bearing, see 21607-3 Flywheel bearings, replace group 21.

Thermostat housing (only vehicles with retarder RET-TH)

Old engine

New engine
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:

Cap (1), connecting pipe (2) and thermostat housing (3) from the old engine.
Cap (4), thermostat (5) and hood (6) from the new engine.
Coolant pipe, coolant hoses, clamps and brackets.

Crankcase ventilation

On vehicles with closed crankcase ventilation (CCV-C) remove:

Separator, pipes and hoses.

On vehicles with open crankcase ventilation (CCV-O) remove:

Crankcase ventilation pipe.

Note: Transfer the cap from the new to the old engine.

Water separator and filter

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:

Cabling to the water separator sensor.


Water separator filter from the filter housing.
Lower section of water separator from the filter.
Sealing.

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

Note: Wash the chassis and blow clean with compressed air.

Other

10

Remove:

Turbo charge air pipe (1).


Lower coolant pipe (2).
Starter element and connection pipe (3) from the inlet pipe.
Starter motor (4) with ground cable.
Shutter housing (5) with AT regulator and control cylinder if fitted.
Coolant pipe (6) from the flywheel casing.
Dipstick pipe (7) with dipstick from the oil sump.
Oil filler pipe (8) from the oil sump and inlet pipe.
Solenoid exhaust brake (AVU) (9) (applies only to Euro 3 engines).
Suction pipe (10) to the servo pump.

Note: There can be oil left in the pipe.

Servo and fuel pump (11) with intermediate coupling.


The two rear engine mountings (13) from the flywheel housing.

Assembly to the new engine

Other
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

11

Fit:

The two rear engine mountings (12) onto the flywheel housing. Torque tighten according to Specifications group
21.
Servo and fuel pump (11) with intermediate coupling and new sealing washers. Torque tighten according to
Specifications group 21.
Suction pipe (10) to the servo pump.
Solenoid exhaust brake (AVU) (9) (applies only to Euro 3 engines).
Oil filler pipe (8) on the oil sump and inlet pipe.
Dipstick pipe (7) with dipstick on the oil sump.
Coolant pipe (6) on the flywheel housing with a new sealing ring.
Shutter housing (5) with AT regulator and control cylinder if fitted.
Starter motor (4) with ground cable.
Starter element and connection pipe (3) from the inlet pipe.
Lower coolant pipe (2) with new sealing ring.
Turbo charge air pipe (1).

Water separator and filter

12

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:

New seal in the water separator lower section. Lubricate the seal with engine oil.
Lower section of the new filter. Lubricate the filter seal with engine oil. Transfer the cap to the old engine.
The filter on the filter housing according to the instructions on the filter.
Cabling to the water separator sensor.

Crankcase ventilation

13

On vehicles with closed crankcase ventilation (CCV-C), fit:


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

Separator, pipes and hoses.

On vehicles with open crankcase ventilation (CCV-O), fit:

Crankcase ventilation pipe.

Note: Transfer the cap from the new to the old engine.

Thermostat housing (only vehicles with retarder RET-TH)

14

New engine

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

Old engine

Fit:

Connecting pipe (2), cap (1) and thermostat housing (3) on the new engine.
Thermostat (5), cap (4) and hood (6) on the old engine.
Coolant pipe, coolant hoses, clamps and brackets.

Warning
To avoid damage to the engine, check that the new engine has the connection pipe (2) fitted in cap (1).

Flywheel

15

Fit the flywheel bearing, see 21607-3 Flywheel bearing, replace group 21.
Fit the flywheel, see 21621-3 Flywheel, replace group 21.

Clutch

16

Fit the clutch, see 411033 Friction plate, replace (Removed gearbox) group 41.

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

Compressor

17
Fit:

Compressor with new sealing ring. Torque tighten according to Specifications group 21.
Lubrication oil hose.
Compressor coolant hose.
Compressor intake pipe on the bracket.
Cooling loop and pressure pipe on the compressor with brackets.

Alternator

18
Fit:

Alternator.
Alternator cabling.
Alternator belt tensioner.
Alternator belt. Use a drawbar handle. Make sure the belt sits correctly in the grooves.

Note: Check the belt for cracks and chafing.

Thermostat fan

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:

Fan hub and spacer on the engine block. Torque tighten according to Specifications group 21.

Note: Check the different situations for FH and FM vehicles respectively.

Fan belt pulley on the fan hub.


Fan belt. Use a drawbar handle. Make sure the belt sits correctly in the grooves.

Note: Check the belt for cracks and chafing.

Thermostat fan on the fan hub with new lock nuts. Torque tighten diagonally according to Specifications group
21.
Connector for the fan speed sensor. Clamp using cable ties.
Fan ring with upper and lower brackets.

Note: Make sure the ring is centred in the thermostat fan.

20
Connect to the new control unit and download the saved parameters.

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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