Engine - Overhaul Instructions: Other Volvo C30 I рестайлинг

CAULKING

Operation Number(s)

Scheme 225

On engines manufactured of aluminum the camshaft bearing housing (1) cylinder block (2) and the intermediate section (3) may be caulked.

Note. The cylinder heads that are chill-cast may not be caulked.

Each individual case is assessed as to whether caulking can be carried out or not depending on the location of the oil leakage.

Scheme 226

Caulking involves in the event of leakage knocking the material together using a special caulking tool.

Two caulking tools are required. Use center punches (1). Grind down the tips so they become round. One is to be ground so the rounded tip (A) is 2 mm. The other is ground so the rounded tip (B) is 4 mm.

Note. Use the protective goggles supplied with the leak tracing kit.

Use: Isopropanol, 1161721

Use an UV light to localize the pore. Carefully wash round the pore with Isopropanol. Check with a UV light that all the oil has been removed.

Scheme 227

If the pore is small, it is sufficient to place the tool (2 mm) directly on the pore and hit it with a copper or plastic hammer. If the pore is larger, angle the tool (2 mm) and drive the material in a circle toward the pore (2). If there is a lip around the pore, caulking (tool 4 mm) should be carried out in a spiral form toward the pore (3).

Scheme 228

Drive the material toward the pore (1) using the 2 mm tool. Seal using the 4 mm tool (2).

Use: Isopropanol, 1161721

Wash with Isopropanol. Check with a UV lamp that there is no oil around the leakage point.

Test drive for 45 minutes as set out below to reach an oil temperature of about 80°C.

1. Allow the engine to idle for 20 minutes.
2. Test drive the car for 15 minutes.
3. Allow the engine to idle for a further 10 minutes.

Check using a UV light that the sealed area no long leaks. If leakage remains, repeat the caulking.

ENGINE BLOCK, INSTALLING COMPONENTS (B5244S4, 2007-10)

Note. As the graphics in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the graphics is always correct.

Scheme 229

The ignition coils' direction and the routing of the cables are shown.

Scheme 230

Install

1. the alternator, alternator bracket and auxiliary unit bracket
2. the thermostat housing with coolant hose
3. the oil filter housing
4. the knock sensors
5. the ignition coils
6. the camshaft sensor
7. the oil filler cap and the VVT-unit's control valve
8. the crankcase ventilation hose
9. cable harness engine, complete
10. the upper and lower intake pipe
11. the dipstick tube

Scheme 231

Install

1. the oil cooler and the rubber seals
2. the coolant pipe (inlet water pump), including hoses, parted at the hoses to the oil cooler
3. the bearing carrier for the right drive shaft
4. the heat shield plate and exhaust manifold
5. the upper and front timing gear casing

Fill oil.

INSTALLING THE FLYWHEEL AND CARRIER PLATE

Install

1. the flywheel according to «FLYWHEEL»(ref-500318-S05417058252012091100000)
2. the carrier plate according to «CARRIER PLATE»(ref-500318-S19906144832012091100000)

ENGINE BLOCK, INSTALLING COMPONENTS (B5254T7, 2008-12)

Note. As the graphics in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the graphics is always correct.

Note. For tightening torques, see Tightening torques

INSTALLING PARTS ON ENGINE BLOCK

The ignition coils' direction and the routing of the cables are shown in the sketch.

Scheme 232

Install

1. alternator, alternator bracket and auxiliary unit bracket
2. thermostat housing with coolant hose
3. the oil filter housing
4. the knock sensors
5. the ignition coils
6. the camshaft sensor
7. oil filler cap and the VVT-unit's control valves
8. the crankcase ventilation hose
9. complete cable harness engine
10. the intake pipe
11. oil dipstick tube

Scheme 233

Install

1. the oil cooler and the rubber seals.
2. the coolant pipe (inlet to water pump) including hoses
3. the bearing carrier for the right drive shaft.
4. exhaust manifold including turbo with control hoses and valve
5. Oil delivery pipe and coolant pipe (outlet to turbo)
6. oil delivery pipe and coolant pipe (inlet to turbo)
7. the lifting eyes
8. upper and front timing gear casing

Fill oil.

INSTALLING THE FLYWHEEL/CARRIER PLATE

Install, see FLYWHEEL

Install, see CARRIER PLATE

ENGINE BODY, EXPOSING (B5244S4, 2007-10)

Special tools

see 9989721

see 9992520

see 9995112

see 9995297

Note. The graphics in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the graphics is always correct.

REMOVING THE GEARBOX

HINT: Suitably, loosen the lower hard-to-reach screws in the transmission/engine before the engine/transmission unit is placed on a suitable surface.

Relieve the transmission.

Loose the remaining screws and carefully remove the transmission.

Remove the clutch, according to CLUTCH DISC AND PRESSURE PLATE

Scheme 234

Remove the impulse sensor.

Install: see 9995112 .

Remove all screws, except the top screw which holds the flywheel to the crankshaft. Loose the top screw and leave it in place, screwed in a few revolutions.

It is suitable to use two screwdrivers. Fit these between the engine block and the flywheel/carrier plate.

Hold the flywheel/carrier plate, and screw out the last screw.

Install the engine in a stand. Use: see 9992520 , see 9995297 and see 9989721 .

Drain the engine oil.

EXPOSING THE ENGINE

Remove

1. the heat shield plate and exhaust manifold
2. the coolant pipe (inlet water pump), including hoses, parted at the hoses to the oil cooler
3. the oil cooler and the rubber seals
4. the bearing carrier for the right drive shaft
5. the lifting eyes
6. the upper and front timing gear casing.

Remove

1. the alternator, alternator bracket and auxiliary unit bracket
2. the upper and lower intake pipe
3. the dipstick tube
4. the knock sensors
5. the thermostat housing with coolant hose
6. the crankcase ventilation hose
7. cable harness engine, complete
8. the oil filter housing
9. the ignition coils
10. the camshaft sensor
11. the oil filler cap and the VVT-unit's control valve.

ENGINE BODY, EXPOSING (B5254T3, 2007-08; B5254T7, 2008-12)

Special tools

see 9989721

see 9992520

see 9995112

see 9995297

Note. The graphics in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the graphics is always correct.

HINT: Suitably, loosen the lower hard-to-reach screws in the transmission/engine before the engine/transmission unit is placed on a suitable surface.

HINT: Relieve the transmission. Loose the remaining screws and carefully remove the transmission.

HINT: Remove the clutch according to CLUTCH DISC AND PRESSURE PLATE .

REMOVING FLYWHEEL AND CARRIER PLATE

Remove the impulse sensor.

Install: see 9995112

Remove all screws except the top screw which holds the flywheel to the crankshaft. Loose the top screw and leave it in place, screwed in a few revolutions.

Carefully wiggle loose the flywheel and the carrier plate. It is suitable to use 2 screwdrivers. Fit these between the engine block and the flywheel/carrier plate.

Hold the flywheel and carrier plate, and screw out the last screw.

INSTALLING ENGINE IN STAND

Use: see 9992520 , see 9995297 and see 9989721

Drain the engine oil.

Remove

1. the oil delivery pipe and the coolant pipe (at the outlet to the turbo)
2. the oil delivery pipe and coolant pipe (at the inlet to the turbo)
3. the exhaust manifold including turbo with control hoses and valves
4. the coolant pipe (at the inlet to the water pump) including hoses. The hoses are parted at the oil cooler
5. the oil cooler and the rubber seals
6. the lifting eyes
7. upper and front timing gear casing as well as the cover over the ignition coils.

EXPOSING THE ENGINE, CONTINUED

Remove

1. the alternator, alternator bracket and auxiliary unit bracket
2. the intake pipe
3. the dipstick tube
4. the knock sensors
5. the thermostat housing with the coolant hose
6. the crankcase ventilation hose
7. complete engine cable harness
8. the oil filter housing
9. the ignition coils
10. the camshaft sensor
11. the oil filler cap and the VVT-unit's control valves.

RECONDITIONING

Note. If the specified value is exceeded, a new component must be installed.

For information about specifications. See ENGINE

Scheme 235

Scheme 236

Note. If the specified value is exceeded, a new component must be installed.

For information about specifications. See ENGINE

CRANK MECHANISM, DISMANTLING (B5244S4, 2007-10)

Special Tools 999 5746 Holder remove. piston/connecting rod) B 200-B 6304 Tool number: 999 5746 Tool description: Holder remove. piston/connecting rod) B 200-B 6304 Tool boards: 21

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

Scheme 242

Scheme 243

see 9995746

Scheme 244

Scheme 245

Scheme 246

Scheme 247

Note. Only use moderate force.

Scheme 248

Scheme 249

Scheme 250

Scheme 251

Scheme 252

CRANK MECHANISM, DISMANTLING (B5254T3, 2007-08; B5254T7, 2008-12)

Special Tools 999 5651 Extractor (crankshaft rear seal) D5252T Tool number: 999 5651 Tool description: Extractor (crankshaft rear seal) D5252T Tool boards: 21 999 5746 Holder remove. piston/connecting rod) B 200-B 6304 Tool number: 999 5746 Tool description: Holder remove. piston/connecting rod) B 200-B 6304 Tool boards: 21

Scheme 253

CHECKING THE CONNECTING ROD IN A CONNECTING ROD ALIGNER

Check for out-of-true and twisting.