Engine - Overhaul Instructions: Specifications Volvo S80 I

Tightening Torque

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

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. Lubricate and install all the screws.

Note. Use new M10 bolts.

Install the intermediate section and the screws on the exhaust side at bearing recesses 2 and 5.

Pull down the intermediate section. Tighten the screws. See Summary of specific components and tightening torques.

Tightening The Connecting Rod Cover

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

Install the cap. Check that any markings correspond.

Lubricate and install new screws. Tighten the screws. See Tightening torque.

Check that the connecting rod can be moved sideways.

Tightening Torques

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

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

Lift in 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 in the numerical order shown in the table.

Tighten the screws in the following order

Scheme 389

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.

Scheme 390

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.

Install the screws and tighten.

Install new sealing rings for the oil pan oil ducts.

Scheme 391

Wipe the mating surfaces dry.

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

Note. Ensure that the area around the screw holes is also covered with liquid gasket.

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.

Scheme 392

Install new sealing rings in the oil pan.

Install the oil cooler. Tighten.

Install the screws and tighten.

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

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

Lift in 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.

Lubricate and install all the screws.

Install the intermediate section and the screws on the exhaust side at bearing recesses 2 and 6.

Pull the intermediate section down against the cylinder block.

Note. Use new M10-screws.

Tighten the screws in the following order

Tighten the screws in sequence from the center and outwards.

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.

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

Scheme 393

Turn the crankshaft counter-clockwise (viewed from the rear of the engine) until the piston in cylinder 1 reaches top dead center (TDC).

Continue turning counter-clockwise until the piston in cylinder 1 is approximately 2-3 cm before top dead center (BTDC).

Install the crankshaft stop 9995451. Ensure that it bottoms out against the cylinder block.

Now turn the crankshaft clockwise (viewed from the rear of the engine) until the crankshaft counter-weight is in contact with the crankshaft stop.

Scheme 394

Install a new cylinder head gasket .

Install the cylinder head.

Use new screws .

Lubricate and install all the screws.

Tighten the screws in the following order. Tighten the screws alternately from the center and outwards.

1. 20 Nm
2. 60 Nm
3. Angle-tighten 130°. Use protractor «9512050»(ref-403953-S36645634772011061000000).

Note. If the valves have been replaced, the valve clearance must be adjusted.

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

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

Tightening

For tightening torques not in the text see Tightening torque.

Scheme 395

Install

1. the coolant outlet pipe on the cylinder head. Use a new gasket. Tighten to 17 Nm (12 lb. ft) .
2. the rear timing cover. Screw into place at the three cover mounting points.
3. thermostat housing / cable duct. Use a new gasket. Ensure that the coolant temperature sensor cable / cable duct lies correctly.
4. the thermostat. Use a new gasket.
5. the thermostat cover. Tighten.
6. the water pump with new gasket. Apply thread sealant, P/N 11-61 056, to all the screws for the water pump. Tighten.

Scheme 396

Use a new gasket and new O-ring around the pump housing.

Screw sliding sleeve into place. 9995747 at the front of the crankshaft journal.

Press in the pump over the sliding sleeve.

Apply thread sealant, P/N 11-61 056, to all the screws for the oil pump.

Install the screws as a guide.

Carefully tap in the oil pump with a rubber mallet.

Tighten the oil pump crosswise.

Remove the sliding sleeve 999 5747.

Install the fuel delivery line.

Scheme 397

Note. The timing gear pulley can only be installed in one position on the crankshaft journal.

Carefully tap in the timing gear pulley with a rubber mallet.

Scheme 398

Install

1. idler pulley. Tighten to 25 Nm (18 lb. ft) .
2. tensioner pulley lever Tighten to 30 Nm (22 lb. ft) .
3. the tensioner / damping unit. Tighten to 25 Nm (18 lb. ft) .

Scheme 399

Timing gear pulleys with variable valve timing units

Slacken off, but do not remove the screws which secure the timing gear pulley to the variable valve timing unit.

Press the variable valve timing unit / timing gear on to the camshaft.

Install the center screw which secures the variable valve timing unit to the camshaft. Do not tighten.

Position the upper timing cover.

Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position.

Continue turning clockwise until the timing gear pulley marking is 1 1/2 cog before the marking on the upper timing cover.

Check that the timing gear pulley is still in its limit position at the oval holes.

Tighten the center screw for the variable valve timing unit to 120 Nm (88 lb. ft) . Check that the variable valve timing unit does not rotate when tightening.

Install the center plug. Tighten to 35 Nm (26 lb. ft) .

Timing gear pulleys without variable valve timing units

Install the timing gear pulley on the camshaft with 2 screws. Do not tighten.

Scheme 400

Timing gear pulleys with variable valve timing units

Slacken off, but do not remove the screws which secure the timing gear pulley to the variable valve timing unit.

Press the variable valve timing unit / timing gear on to the camshaft.

Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly.

Turn the variable valve timing unit anti-clockwise as far as it will go.

Slacken off the center screw

Position the upper timing cover.

Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position.

Continue turning clockwise until the timing gear pulley marking is 1 1/2 cog before the marking on the upper timing cover.

Note. Do not turn anti-clockwise during this procedure.

Check that the timing gear pulley is still in its limit position at the oval holes.

Tighten the center screw for the variable valve timing unit to 120 Nm (88 lb. ft) . Check that the variable valve timing unit does not rotate when tightening. Install the center plug. Tighten to 35 Nm (26 lb. ft) .

Turn the variable valve timing unit clockwise to the limit position.

Turn the timing gear pulley so that the markings correspond.

Timing gear pulleys without variable valve timing units

Install the timing gear pulley on the camshaft with 2 screws. Do not tighten.

Scheme 401

Note. Applies only to B62x4T.

Turn the variable valve timing unit clockwise until stop.

Hold it secure in limit position.

Install the belt in the following order

1. Crankshaft

2. Idler pulley

3. Intake camshaft

4. Exhaust camshaft

5. Water pump

6. Tensioner pulley

Note. The variable valve timing unit on engines without a turbocharger (TC) does not have a return spring. It is easily dislodged when reinstalling the timing belt. Adjust the timing gear pulleys so that the screws are not at a limit position in the oval holes.

Pull the lock pin out of the tensioner / damping unit.

Optimize the timing belt tension by pressing it between the camshaft timing gear pulleys and between the water pump and exhaust camshaft.

Tighten the three timing gear pulley screws on the variable valve timing unit to 10 Nm (7.4 lb. ft) .

Install the third screw at the timing gear pulley without variable valve timing unit. Tighten to 20 Nm (15 lb. ft) .

Note. Applies to turbocharged engines: The variable valve timing unit must not be released from the limit position until after the timing gear pulleys have been tightened.

Install the deflection limiter washer on the piston rod for the tensioner / damping unit.

Remove

1. The camshaft adjustment tools «9995451»(ref-403953-S26663901482011061000000).
2. The crankshaft stop «9995452»(ref-403953-S02369714572011061000000).

Install plug with a new blind cover plug. Tighten to 40 Nm (29 lb. ft) .

Scheme 402

Install

1. the crankshaft pulley for the auxiliaries belt.
2. counterhold «9995433»(ref-403953-S41906385022011061000000).
3. the crankshaft center nut. Tighten to 300 Nm (221 lb. ft) .

Remove counterhold 999 5433.

Install the vibration damper. Use new screws. Tighten to 35 Nm (26 lb. ft) . Angle tighten 50° . Use the crankshaft center nut as a counterhold.

Scheme 403

Turn the crankshaft two turns.

Check that the markings on the crankshaft and camshaft timing gear pulley correspond with the marking on the upper timing cover and on the oil pump.

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

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

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

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

Scheme 404

Install the rear timing cover.

Screw into place at the three mounting points.

Install the water pump with a new gasket .

Apply thread sealant, P/N 11-61 056, to all the screws for the water pump. Tighten the screws crosswise.

Scheme 405

Use a new gasket and a new O-ring around the oil pump housing and new screws. Alternatively, apply thread sealant 11 61 056 to the underside of the old screw heads.

Screw sliding sleeve 9995747 into place at the front of the crankshaft journal.

Press in the pump over the sliding sleeve.

Install the screws as a guide.

Carefully tap in the oil pump with a rubber mallet.

Tighten the oil pump crosswise. See Summary of specific components and tightening torques.

Remove the sliding sleeve 9995747.

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

See also:
• Jacking points, body