Engine - Overhaul Instructions: Overhaul Volvo C30 I рестайлинг

CYLINDER HEAD, DISASSEMBLY/ASSEMBLY

Special tools

see 9986052

see 9995219

see 9995748

see 9997012

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

Scheme 204

Note. Magnets must not be used when lifting out the tappets.

Lift out the tappets. Mark up the tappets so that the original positions can be established.

Use a suction cup to remove the tappets.

Check for wear on the tappets.

Scheme 205

Use valve spring compressor see 9986052 with attachment claw see 9995748 .

Remove

1. the valve locks
2. the upper valve collars
3. the valve springs
4. the valves.

Note. Keep careful track of the position of the moving parts.

Scheme 206

Use tool see 9995219 .

Remove the valve stem seals and the lower valve collars.

Clean the cylinder head

1. the gasket faces
2. the combustion chambers
3. the inlet and exhaust ports
4. the valve seats.

Scheme 207

Clean the spark plug threads (tap M14 x 1.25).

Clean the valves, valve springs and collars.

Visually check for damage.

If you are unsure, replace the cylinder head.

Scheme 208

Measure the wear in the valve guides. Use a dial indicator and magnetic holder. Lift the valve approximately 2-3 mm from the seat when carrying out the check.

Clearance between the valve and valve guide

Clearance between new components: Inlet/Exhaust: 0.03 -0.06 mm .

Maximum play for used components: Inlet/Exhaust: 0.15 mm .

Scheme 209

Lubricate

1. the upper end of the valve guides
2. the valve stem seal.

Install

1. the lower valve spring collars
2. the valve stem seal.

Press down the seal. Use tool see 9997012 . Press with hand force until the tool stops against the lower valve spring washer. Remove the tool.

Repeat the procedure with the remaining valve stem seals.

Scheme 210

Lubricate the valve stem.

Install

1. the valve
2. the valve spring
3. the upper valve spring washer.

Compress the valve spring so that the three valve lock tracks are visible.

Use valve spring compressor see 9986052 and press foot see 9995748 . Install the valve collets. Check that valve collets are in the correct position when the spring is not loaded.

Repeat the procedure with the remaining valves.

CRANK MECHANISM, ASSEMBLING (B5244S4, 2007-10)

Special Tools 951 2767 Roller (Applying liquid gasket) B234, 5234, 6304 Tool number: 951 2767 Tool description: Roller (Applying liquid gasket) B234, 5234, 6304 Tool boards: 08 999 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: 21 999 7273 Guide pin Tool number: 999 7273 Tool description: Guide pin Tool boards: 21 999 7174 Drift Tool number: 999 7174 Tool description: Drift Tool boards: 23

Scheme 211

Scheme 212

CRANK MECHANISM, ASSEMBLING (B5254T7, 2008-12)

Special Tools 951 2767 Roller (Applying liquid gasket) B234, 5234, 6304 Tool number: 951 2767 Tool description: Roller (Applying liquid gasket) B234, 5234, 6304 Tool boards: 08 999 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: 21 999 7273 Guide pin Tool number: 999 7273 Tool description: Guide pin Tool boards: 21 999 7174 Drift Tool number: 999 7174 Tool description: Drift Tool boards: 23

MEASURING CRANKSHAFT ASSEMBLY (B5244S4, 2007-10; B5254T7, 2008-12)

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

Scheme 213

Use a micrometer.

Measure the out-of-round and taper of the bearing journal. Measure at a number of points laterally and longitudinally.

Scheme 214

For the correct values for the connecting rod bearing journals and main bearing journals, see ENGINE (B5254T3; 2007-08, B5254T7; 2008-12) or ENGINE (B5244S4; 2007-10) .

Scheme 215

Use a dial indicator and magnetic holder.

Position the crankshaft with the two outer main bearings in the V block.

Turn the crankshaft and measure the radial runout on the other main bearing journals.

For the correct values, see ENGINE (B5254T3; 2007-08, B5254T7; 2008-12) or ENGINE (B5244S4; 2007-10) .

Scheme 216

Use piston ring pliers.

Remove coke deposits. Scrape the piston ring grooves clean with a groove cleaner or a broken and filed piston ring.

Check for damage, wear and cracks.

Scheme 217

Use new piston rings.

For the correct values, see ENGINE (B5254T3; 2007-08, B5254T7; 2008-12) or ENGINE (B5244S4; 2007-10) .

Scheme 218

Use a micrometer and vernier calliper.

For the correct values, see ENGINE (B5254T3; 2007-08, B5254T7; 2008-12) or ENGINE (B5244S4; 2007-10) .

Scheme 219

For the correct values, see ENGINE (B5254T3; 2007-08, B5254T7; 2008-12) or ENGINE (B5244S4; 2007-10) .

Scheme 220

Check first that the piston and connecting rod are marked.

Piston marking: Scrape the piston pin clean. If the marking is unclear, mark the piston with the cylinder number and an arrow pointing to the front of the engine. Use a marker pen.

Connecting rod marking: See ENGINE (B5254T3; 2007-08, B5254T7; 2008-12) or ENGINE (B5244S4; 2007-10) .

Carefully push out the lock-ring using a groove-cut chisel.

Press out the piston pin with your thumb.

Clean and check the connecting rods, caps and screws for damage, signs of wear or cracks.

Scheme 221

The piston pin must not be loose. It should be possible to push it through the hole using thumb pressure.

Replace the piston if the play is too great.

Scheme 222

The piston pin should slide through the hole with light thumb pressure.

If the play is too great measure the piston pin.

Use a micrometer.

See ENGINE (B5244S4; 2007-10) or ENGINE (B5254T3; 2007-08, B5254T7; 2008-12) for the correct diameter of the gudgeon pin.

Scheme 223

A new connecting rod has been introduced on certain engines.

The mating surface between the cap and the connecting rod is not machined. It is aligned through a dedicated fracture surface.

Note. Blow clean the fracture surfaces with compressed air before reinstalling caps.

Scheme 224

Visually check the bearing shells.

If in doubt measure out-of-round. Use a bore gauge.

For the correct diameter of the bearing recess, see ENGINE (B5244S4; 2007-10) or ENGINE (B5254T3; 2007-08, B5254T7; 2008-12) .