IMPACT 4.04.

00 27/02/2020

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

Model Identity
B5LH (3) 137014122

Publish date ID/Operation

29/04/2016

Engine, system description

Engine, system description
Cylinder head
Cylinder Block
Stiffening frame and oil pan
Cylinder head guides
Piston, cylinder liner and connecting rod
Camshaft and valve mechanism
Crankshaft, vibration damper, flywheel
Engine Transmission
Casings

Engine, system description

Cylinder head
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
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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The valve cover comprises two parts: the top cover and the frame. The assembly is tightened to the
cylinder head with 13 screws. The oil filler cap is replaced by a tube going directly to the oil pan.

Cylinder head, overview

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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1 Thermostat housing

2 Inlet and exhaust ports

3 Injector bore

4 Oil channel plug

5 Oil channel

The cylinder head is made of grey iron to resist high pressures and is cast in one piece. Four bearing
brackets hold the single camshaft. The coolant thermostat housing is fitted at the front of the cylinder
head (1). Inlet and exhaust ports (2) are placed on opposite sides of the cylinder head, meaning that
it is a cross-flow type head. A low pressure channel is drilled lengthwise through the cylinder head to
return the unused fuel to the tank. The cylinder head has a machined, ring-shaped 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.

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The gasket (1) seals the cylinder head, the cylinder block and the cylinder liners.

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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The injectors are placed vertically above the centres of each cylinder, between the four valves, and
each is held in place by a yoke (1). The cylinder head has been designed to force the coolant to go to
the lower and hottest parts of the cylinder head. The valve mechanism comprises double inlet and
exhaust valves. The valves have single valve springs (2) and are linked in pairs with so-called floating
valve calipers, which transfer the camshaft motion via the rocker arms to the valve pairs. Each valve
has a groove and matching valve cotters (3). For better heat resistance and conduction there is more
material in the exhaust valve discs and they have a somewhat smaller diameter than the inlet valves.
The valve guides are made of cast iron alloy and all the valves have oil seals for the valve stems. The
valve seats are made of hardened special steel. The valves and valve guides as well as the seals
and valve seats are replaceable.

Cylinder Block
The cylinder block is manufactured of grey iron and cast in one piece.
All lubrication system channels are machined directly in the block. The main lubrication channel
(gallery channel) is located in the left-hand side of the block, seen from the rear. The channel is
plugged at the front.

Cylinder block 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
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IMPACT 4.04.00 27/02/2020

1 Main oil channel

2 Oil channel to PTO

3 Oil channel to cylinder head

4 Oil channel to gear

5 Oil channel plugs

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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The bulged shape of the cylinder block at each cylinder provides it with good torsional stiffness and
good sound insulation. There are two channels (1) in the right-hand side (seen from the rear) for the
return of oil to the oil pan.
The vertical cross section shows the cylinder liner and the position of the cooling jacket in the block.

Stiffening frame and oil pan

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.

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IMPACT 4.04.00 27/02/2020

1 Stiffening frame

2 Oil pan

3 Screws

4 Drain plug

A stiffening frame (1) is fitted to the underside of the cylinder block to reduce vibration and thereby
noise. It is made of 4 mm steel plate and is screwed to the base of the block with 8 screws.
The oil pan (2) is, in the basic version, made of pressed steel.
The oil pan is fastened with 16 spring loaded screws (3). The standard oil pan (2) is in pressed steel..

Cylinder head guides

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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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There are two hollow pins, one at the front and one at the rear of the cylinder block, for exact
positioning 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.

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Piston, cylinder liner and connecting rod

Piston, cylinder liner and connecting rod

1 Upper compression ring

2 Lower compression ring

3 Oil scraper ring

A Piston

B Cylinder liner

C Connecting rod

The engine has cast alumium, oil cooled pistons. They have an arrow at the front for ensuring correct
installation. 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) at the sliding surface is spring-loaded.
The two compression rings are fitted with the markings facing up, the scrapper ring has no upper
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 4.04.00 27/02/2020

side.
The cylinder liners (B) are dry and replaceable. The inside of each liner is honed with a cross-pattern.
The final fine machining of the liner surface is carried out using a method called plateau honing,
where the sharpest peaks from the initial machining are ground away. The cylinder liners are
available in two outside diameter tolerances: 0 and 1. When replacing cylinder liners, the replacement
liners must have the same marking (0) or (1) as the cylinder barrel.

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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The connecting rod is forged and split at the bottom (the big end) using a method called fracture split
(cracking). The upper end (small end) has a pressed-in bushing that is lubricated via milled grooves
in the upper part of the bushing. The two parts of the big end are screwed together with two screws
and each rod and cap are marked with a 4-figure serial number as identification number (e.g.0012
/0012 A13). The connecting rod is marked with a small raised part in the casting to clearly indicate
the correct fitting direction. Both parts of each connecting rod are marked.

Camshaft and valve mechanism

The 5 litre engine has an overhead camshaft and a four-valve system. The camshaft is induction
hardened and journaled in four bearing brackets with replaceable bearing shells. There are two cams
between each journal: the inlet cam and the exhaust cam. The camshaft is driven by a gear (1) from
the engine transmission.

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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The camshaft gear is marked with a line and the figure 1 for the basic setting (TDC – Top Dead
Centre). This setting can be checked against the markings 1–4 on the flywheel trough the hole (2).

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.

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1 Section shows

2 Valve caliper

3 Rocker arm

4 Rocker arm shaft

5 Bushing

6 Roller

7 Ball socket

Section (1) shows a cross-section of the valve mechanism for a pair of exhaust valves. Each rocker
arm operates a so-called floating valve caliper (2) which opens the valves. The rocker arm (3) on
journaled in the rocker arm shaft (4) with a bushing (5). The contact with the camshaft is via a roller (6
) and with the valve caliper via a ball socket (7).

Crankshaft, vibration damper, flywheel

Crankshaft bearings, sealings

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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1 Bearing shells

2 Thrust washers

3 Front sealing

4 Rear sealing

The crankshaft is drop forged and has induction hardened bearing surfaces and hollow mouldings.
The crankshaft is journaled in five main bearings with replaceable bearing shells (1). The fourth main
bearing aslo has an axial bearing consisting of four thrust washers (2) .
The front end (A) is sealed against the front crankshaft flange with the seal (3). The rear end is
sealed against a machined surface on the crankshaft gear with the seal (4). The crankshaft gear is
shrunk onto the 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
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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The crankshaft is lubricated via separate channels in the cylinder block to each main bearing (1).

Crankshaft damper flywheel

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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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1 Grooved ring

2 Damping rubber

3 Inner hub

4 Flywheel

5 Screws

6 Locating pin

7 Starter gear ring

8 Machined grooves

The vibration damper is fitted directly onto the crankshaft front flange. There is a rubber ring to
connect the hub to the pulley. The rubber damps the vibration and some of the rotational pulses
caused by each cylinder stroke. It helps reducing accessory belt and components stress and wear.
The flywheel (4) is screwed onto the rear flange of the crankshaft with ten M14 screws (5). Markings
(1–4) on the flywheel are aligned with the marking on the camshaft gear to provide a basic setting.
The flywheel is positioned on the crankshaft with a locating pin (6). The starter gear ring (7) is shrunk
onto the flywheel and can be replaced. There are machined grooves (8) on the outer edge for the
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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engine management system inductive flywheel sensor.

The crankshaft lightweight pulley (1) is fitted directly onto the crankshaft front flange. The fan hub (2)
is fitted in front of the crankshaft lightweight pulley. The assembly is screwed with six M8 screws (3) .
The flywheel (4) is screwed onto the rear flange of the crankshaft with ten M14 screws (5). Markings
(1–4) on the flywheel are aligned with the marking on the camshaft gear to provide a basic setting.
The flywheel is positioned on the crankshaft with a locating pin (6). The starter gear ring (7) is shrunk
onto the flywheel and can be replaced. There are machined grooves (8) on the outer edge for the
engine management system inductive flywheel sensor.

Engine Transmission
The engine transmission is located at the rear of the engine

Engine transmission

1 Crankshaft gear (fitted on the crankshaf)

2 Idler gear, double (This idler gear with its two gear wheels, bearings and hub is a complete
assembly that must not be dismantled but replaced as a complete unit)

3 Idler gear, camshaft (marking R)

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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4 Idler gear, camshaft (marking R)

5 Camshaft gear (marking R)

6 Extra equipment, drive gear, power take-off

7 Extra equipment, idler gear, power take-off

8 Idler gear

9 Extra equipment, drive gear, compressor

10 Extra equipment, drive gear, power take-off (marking R)

11 Drive gear, fuel feed pump

Marking

1 Camshaft gear

2 Idler gear

3 Idler gear double

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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4 Fuel pump drive gear

5 Crankshaft gear

The camshaft gear (1) is line marked for TDC. (Top Dead Centre). The idler gear (2) is marked the
same as the idler gear double (3) , the drive gear for the fuel pump (4) and the crankshaft gear (5).

Engine transmission rotation direction

1 Crankshaft gear, anticlockwise.

2 Idler gear, double, anticlockwise

3 Idler gear, camshaft, clockwise

4 Idler gear, camshaft, anticlockwise

5 Camshaft gear, clockwise

6 Extra equipment, drive gear, power take-off, anticlockwise

7 Extra equipment, idler gear, power take-off, clockwise

8 Idler gear, clockwise

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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9 Extra equipment, drive gear, compressor, anticlockwise

10 Extra equipment, drive gear, power take-off, clockwise.

11 Drive gear, fuel feed pump, anticlockwise

The engine transmission idler gears are screwed and journaled directly in the rear end of the engine.
The figure shows the rotation directions of the transmission gears.

Casings

Flywheel housing

1 Timing gear casing

2 Flywheel sensor

3 Cam position sensor

4 Cranking tool

5 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.

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6 Cover

7 Double aluminum stiffeners

There is a cast alloy housing for the engine transmission. The timing gear casing (1) is a combined
transmission and flywheel housing and has anchorage points for the rear engine mountings.
The housing is sealed against the cylinder block with sealant.
On top of the flywheel housing is an outlet for the flywheel sensor (2) and cam position sensor (3).
There are two holes with rubber plugs in the flywheel housing. One hole is for a cranking tool (4) to
rotate the engine. The other hole (5) is for viewing the flywheel position marking.
The cover (6) covers the connection for the engine-driven power take-off. Below the flywheel housing
are double stiffeners (7) on both sides.

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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