Engine - Overhaul Instructions: Overhaul Volvo S80 I

Crank Mechanism, Assembling

Special tools

See 9512767

See 9991801

See 9995676

See 9995746

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

Disassembling The Crankshaft Assembly

Special tools

See 9995458

See 9995679

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

Scheme 426

Remove

1. oil trap
2. knock sensors (KS)
3. the front engine mounting
4. the oil pressure switch.

Scheme 427

Remove

1. the bearing retainer for the right drive shaft
2. the oil cooler and the rubber seals.

Scheme 428

Remove the oil filter. Use tool: 9995679 .

Remove the screws securing the oil pan to the intermediate section.

Carefully tap the side of the oil pan with a rubber mallet.

Lift out the oil pan.

Scheme 429

Remove the O-rings from the oil ducts.

Remove the screws securing the suction pipe to the intermediate section.

Work loose and lift out the suction pipe.

Remove the suction pipe O-ring.

Check the pipe and the strainer.

Scheme 430

Install the two old screws for the flywheel and carrier plate at the rear edge of the crankshaft.

Turn the crankshaft so the piston in cylinder 1 is at bottom dead center (BDC).

Check that there are markings on the cap and connecting rods. Check which way the markings are positioned (exhaust and intake side). Make a note of this.

If necessary mark with a center punch or a number punch. See Marking The Connecting Rod (Where Applicable) .

Scheme 431

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 the fracture surface clean with compressed air before reinstalling the cap.

Scheme 432

Remove the screws for the connecting rod cover.

Lift off the cover. Ensure that the bearing cover comes with it.

Install tool in the connecting rod. Press out the connecting rod and piston.

Hold by hand so that the piston does not fall to the floor. Ensure that the bearing cover comes with it.

Place the piston and connecting rod in such a way that they can be reinstalled in the correct cylinder.

Continue with cylinders 2, 3, 4 and 5 as above.

Check that the coolant guide is in place. Secure if necessary.

Special tools

See 9512767

See 9991801

See 9995676

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

Tightening torque

For tightening torques not in the text, see Tightening torque .

Cleaning

Ensure that the all components are completely clean.

Blow clean the oil ducts in the block, intermediate section and oil pan.

Classification of main bearings

Wipe clean the bearing recesses in the block and the intermediate section.

Check that the components are clean and undamaged.

Check the classification of the block and crankshaft.

The classification marking is at the rear edge of the block and the crankshaft. The classification is read from digits 1 to 7. The first letter after digit 1 is the classification of main bearing 1. The bearing positions are numbered starting at the front of the engine.

Selecting bearings

Install the main bearings in the cylinder block and the intermediate section. See the table.

The axial bearing is positioned at bearing recess 5.

For example: The marking on the block at bearing recess 1 is B. The marking on the crankshaft at the corresponding bearing recess is C.

Therefore the bearing in the block is marked red and the bearing in the intermediate section is marked yellow.

Note. The thickest of the bearing caps must always be installed in the intermediate section. This is keep the center line as straight as possible.

The intermediate section

Wipe the surfaces dry.

Apply liquid gasket 11 61 059 to the intermediate section. The surface must be completely covered without any excess. Use roller 9512767

Thoroughly lubricate all the bearing shells and the surface of the axial bearing.

Tightening the intermediate section

Install the two old screws for the flywheel and carrier plate at the rear edge of the crankshaft.

Lift these and the front of the crankshaft.

Carefully position the crankshaft in the block.

The crankshaft must not be turned before the intermediate section has been torque tightened. Position the intermediate section.

Install all screws. Draw the intermediate section down towards the block.

Note. Use new M10 screws.

Tighten the screws in the following order

Marking the connecting rod (where applicable)

Assemble the connecting rod. Check that the cover is facing the correct direction. Tighten to 20 Nm .

Secure the large end of the connecting rod in a vise with soft jaws (copper or aluminum).

Mark both halves with the cylinder number. Use a center punch or number punch.

Installing piston rings

Scheme 433

Use piston ring pliers.

Turn the piston rings so that the openings are offset as shown in the illustration.

A = Compression ring. The text on the piston ring must be upwards.

B = Scraper ring. Chamfered edge must face downwards.

C = Oil ring. Three sections, identical on all sides.

First install the expander ring (C), then the two other rings over the expander ring.

Note. Incorrect positioning increases oil consumption.

Assembling pistons and connecting rods

Scheme 434

There is an arrow on top of the piston. This must be turned forwards in the cylinder block.

The connecting rods are symmetrical and can be turned freely. Marked rods however must be turned in the same direction.

Assemble the connecting rod and piston with the piston pin.

Check that the classification and any numbering for each cylinder and piston diameter correspond.

Install both the snap rings on the piston pin. Check that the snap rings are positioned correctly in the piston.

Wipe clean around the bearing recess in the connecting rod and the cap.

Install the bearing shells.

If new bearing shells are used, these must be checked for color coding.

Note. The bearing shell with a black color coding on the side must be installed in the connecting rod.

Installing the pistons in the cylinder bores

Use a cylinder ring compressor.

Lubricate the cylinder bore, the pistons and the bearing shells.

Turn the crankshaft so that the connecting rod pin is at bottom dead center (BDC) for the cylinder the piston is to be inserted in.

Ensure that the engine is in a position where the cylinder bore forms as vertical a line as possible.

Note. The arrow on top of the piston must point forwards. Ensure that the classifications correspond

Carefully press or tap the piston down (using the shaft of a hammer or similar).

When the piston has released from the piston ring compressor, remove it and press the piston down until the connecting rod reaches the connecting rod pin.

Tightening the connecting rod cover

Turn the engine 180° in the stand.

Install the cover. Check that any markings correspond.

Lubricate and install new seals. Tighten in two stages

1. 20 Nm .

2. Angle-tighten 90° .

Check that the connecting rod can be moved sideways.

Note. The crankshaft must not be rotated before the connecting rod cover has been tightened.

Installing the oil pump suction pipe

Install a new sealing ring on the suction pipe.

Carefully press the suction pipe down into the intermediate section.

Check that the sealing ring is correctly positioned.

Tighten.

Install new sealing rings for the oil pan oil ducts.

Installing the oil pan

Wipe the surfaces dry.

Apply liquid gasket 11 61 059 to the oil pan. Use roller 9512767 .

The surface must be completely covered without any excess.

Position the pan and install all screws

Tighten the screws from the rear of the pan and forward.

Installing the oil cooler

Install new sealing rings in the oil pan.

Install the oil cooler. Tighten.

Installing the rear crankshaft seal

Use standard handle 9991801 and drift 9995676 .

Lubricate the drift face and thread the sealing ring onto the drift.

Tap in the seal until the drift bottoms against the block.

Measuring The Crankshaft Assembly

Note. The illustrations 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 illustrations is always correct.

Scheme 435

Use a micrometer.

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

Scheme 436

For the correct values for the connecting rod bearing journals and main bearing journals, see Crank mechanism .

Scheme 437

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 Crank mechanism .

Scheme 438

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 439

Use new piston rings.

For the correct values, see Pistons (engine capacities) .

Scheme 440

Use a micrometer and vernier calliper.

For the correct values, see Pistons (engine capacities) .

Scheme 441

For the correct values, see Pistons (engine capacities) .

Scheme 442

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 Marking the connecting rod (where applicable) .

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 443

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 444

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 Pistons (engine capacities) for the correct diameter of the gudgeon pin.

Special tools

9512767

9991801

9995676

9995746

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

Note. For tightening torques not in the text, see Tightening torque .

Assembling Pistons And Connecting Rods

There is an arrow marking on the upper side of the cylinder. This must be turned forwards in the cylinder block.

The connecting rods are symmetrical and can be turned freely. Marked rods however must be turned in the same direction.

Assemble the connecting rod and piston with the piston pin. Check that the classification and any numbering for each cylinder/piston diameter and connecting rod correspond.

Install both the snap rings on the piston pin. Check that the snap rings are positioned correctly in the piston. The opening must be vertical.

Wipe clean around the bearing recess in the connecting rod and the cap.

Scheme 445

Always use new bearings.

Check these for color marking. The bearing shell with a black color coding on the side (1) must be installed in the connecting rod.

Crankshaft Assembly, Disassembling

Special tools

See 9995458

See 9995679

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

Scheme 446

Remove

1. the oil trap
2. the knock sensors (KS)
3. the front engine mounting
4. the oil pressure switch
5. Evaporative emission system (EVAP) valve with hoses.

Scheme 447

Remove

1. the bearing retainer for the right drive shaft
2. the oil cooler and the rubber seals including hoses and pipes.

Scheme 448

Remove

1. the oil filter. Use tool «9995679»(ref-403953-S39389221832011061000000)
2. the screws holding the oil pump to the intermediate section.

Carefully tap the side of the oil pan with a rubber mallet.

Lift out the oil pan.

Assembling The Crank Mechanism

Special tools

9512767

9991801

9995676

Note. The illustrations 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 illustrations is always correct.

There is an arrow on top of the piston. This must be turned forwards in the cylinder block.

The connecting rods are symmetrical and can be turned freely. Marked rods however must be turned in the same direction.

Assemble the connecting rod and piston with the piston pin.

Check that the classification and any numbering for each cylinder / piston diameter correspond.

Install both the snap rings on the piston pin. Check that the snap rings are positioned correctly in the piston.

Wipe clean around the bearing recess in the connecting rod and the cap.

Install the bearing shells.

Disassembling The Crank Mechanism

Special tools

See 9995458

See 9995679

Note. As the illustrations in the information are used for different model years and / or models, certain variations may occur. However, the essential information in the illustrations is always correct.

Scheme 449

Remove

1. the flame trap.
2. the knock sensors (KS).
3. the front engine mounting.
4. the transmission mounting bracket.
5. the right drive shaft bearing seat.
6. the oil cooler and rubber seals.

Scheme 450

Remove the oil filter. Use tool 9995679 .

Remove

1. the lower torque rod bracket.
2. the retaining screws holding the oil pump to the intermediate section.

Carefully tap the side of the oil pan with a rubber mallet.

Lift the oil pan off.

Note. The illustrations 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 illustrations is always correct.

Disassembling Connecting Rods And Pistons

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 Marking the connecting rod (where applicable) .

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.

Special tools

See 9512767

See 9991801

See 9995676

See 9995746

Note. The illustrations 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 illustrations is always correct.

There is an arrow on top of the piston. This must be turned forwards in the cylinder block.

The connecting rods are symmetrical and can be turned freely. Marked rods however must be turned in the same direction.

Assemble the connecting rod and piston with the piston pin.

Check that the classification and any numbering for each cylinder / piston diameter correspond.

Install both the snap rings on the piston pin. Check that the snap rings are positioned correctly in the piston. The opening must be vertical.

Wipe clean around the bearing recess in the connecting rod and the cap.

Install the bearing shells.

Special tools

See 9995679

Note. The illustrations 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 illustrations is always correct.

Note. The illustrations 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 illustrations is always correct.

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 Assembling the crank mechanism .

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.

See Assembling the crank mechanism

See Disassembling the crankshaft assembly

See Measuring the crankshaft assembly

Cylinder Head, Dismantling/Assembling

Special tools

See 9986052

See 9995219

See 9995748

See 9997012

Note. The illustrations 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 illustrations is always correct.

Assembling The Belt Drive

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

Belt Drive, Assembling

Note. The illustrations 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 illustrations is always correct.

Note. The illustrations 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 illustrations is always correct.

See Belt drive, assembling

Note. The illustrations 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 illustrations is always correct.

Belt Drive, Assembly

Special tools

See 9995747

See 9995451

See 9995452

See 9995433

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

Belt Transmission, Assembly

Special tools

See 9995747

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