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Engine - Overhaul Instructions: Overhaul Volvo S80 II

Mechanical 82 illustrations ~1218 words

CYLINDER HEAD, DISASSEMBLY/ASSEMBLY

Special tools 999 5748 Valve compressor B 4164-B 6304 Tool number: 999 5748 Tool description: Valve compressor B 4164-B 6304 Tool boards: 21 998 6052 VALVE SPRING B21 D16 D24 Tool number: 998 6052 Tool description: VALVE SPRING B21 D16 D24 Tool boards: 20 999 5219 GRIP TOOL (VALVE GUIDE-SEAL)B16-D24 Tool number: 999 5219 Tool description: GRIP TOOL (VALVE GUIDE-SEAL)B16-D24 Tool boards: 21 999 5401 PUNCH (INST.-VALVE SHAFT SEAL)B172 B18E D16 Tool number: 999 5401 Tool description: PUNCH (INST.-VALVE SHAFT SEAL)B172 B18E D16 Tool boards: 21 998 6052 VALVE SPRING B21 D16 D24 Tool number: 998 6052 Tool description: VALVE SPRING B21 D16 D24 Tool boards: 20 999 5748 Valve compressor B 4164-B 6304 Tool number: 999 5748 Tool description: Valve compressor B 4164-B 6304 Tool boards: 21

Scheme 50

Scheme 50: CYLINDER HEAD, DISASSEMBLY/ASSEMBLY
Scheme 50: CYLINDER HEAD, DISASSEMBLY/ASSEMBLY

Scheme 51

Scheme 51
Scheme 51

Scheme 52

Scheme 52
Scheme 52

Scheme 53

Scheme 53
Scheme 53

Scheme 54

Scheme 54: REMOVAL
Scheme 54: REMOVAL

see 9995748 see 9986052

Scheme 55

Scheme 55
Scheme 55

Scheme 56

Scheme 56
Scheme 56

Scheme 57

Scheme 57
Scheme 57

see 9995219

Scheme 58

Scheme 58: INSTALLATION
Scheme 58: INSTALLATION

see 9995401

see 9986052 see 9995748

Special tools 999 7417 Valve compressor Tool number: 999 7417 Tool description: Valve compressor Tool boards: 21 998 6052 VALVE SPRING B21 D16 D24 Tool number: 998 6052 Tool description: VALVE SPRING B21 D16 D24 Tool boards: 20 999 5219 GRIP TOOL (VALVE GUIDE-SEAL)B16-D24 Tool number: 999 5219 Tool description: GRIP TOOL (VALVE GUIDE-SEAL)B16-D24 Tool boards: 21

Scheme 59

Scheme 59: CYLINDER HEAD, DISASSEMBLY/ASSEMBLY
Scheme 59: CYLINDER HEAD, DISASSEMBLY/ASSEMBLY

CRANK MECHANISM, ASSEMBLING (TURBO)

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

Materials
DesignationPart number
Engine oil
Chemical gasket1161771

Scheme 60

Scheme 60: INSTALLATION
Scheme 60: INSTALLATION

See information about storage classification, see ENGINE

CAUTIONMake sure that the area around the component is clean and free of foreign material.

Use: Engine oil

Scheme 61

Scheme 61
Scheme 61
CAUTIONTake extra care when handling the components.
CAUTIONMake sure that the crankshaft is not rotated.

Scheme 62

Scheme 62
Scheme 62
CAUTIONMake sure that the mating faces are clean and free of foreign material.

Use: Chemical gasket, 1161771

Scheme 63

Scheme 63
Scheme 63
CAUTIONMake sure that the mating faces are clean and free of foreign material.

Use: Chemical gasket, 1161771

Use: Engine oil

Scheme 64

Scheme 64
Scheme 64

Torque: Intermediate section for engine block step 1

Stage 1: 5 Nm

Stage 2: 30 Nm

Scheme 65

Scheme 65
Scheme 65

Torque: Intermediate section for engine block step 2

5 Nm

Scheme 66

Scheme 66
Scheme 66

Torque: Intermediate section for engine block step 3

25 Nm

Torque: Intermediate section for engine block step 4

105 degree

Scheme 67

Scheme 67
Scheme 67

Torque: Intermediate section for engine block step 5

25 Nm

Scheme 68

Scheme 68
Scheme 68

Scheme 69

Scheme 69
Scheme 69

Scheme 70

Scheme 70
Scheme 70

Scheme 71

Scheme 71
Scheme 71

Note. Make sure that the classification of the components correspond with each other.

Scheme 72

Scheme 72
Scheme 72

Scheme 73

Scheme 73
Scheme 73
CAUTIONTake extra care when handling the components.

Scheme 74

Scheme 74
Scheme 74
CAUTIONTake extra care when handling the components.

see 9995746

CAUTIONMake sure that the crankshaft is not rotated.

Note. Make sure that the classification of the components correspond with each other.

Torque: Cap connecting rod

Stage 1: 30 Nm

Stage 2: 90 degree

Torque: M6

10 Nm

Install the following items

  1. oil pump, see «OIL PUMP AND LINE»(ref-499525-S10136309422012090500000)
  2. pan, see «OIL PAN»(ref-499273-S25834876472012090500000)
  3. Crankshaft front seal, see «CRANKSHAFT FRONT SEAL»(ref-499273-S36219388582012090500000)
  4. Crankshaft seal, rear, see «CRANKSHAFT SEAL, REAR»(ref-499273-S01028885802012090500000)

CRANK MECHANISM, ASSEMBLING

Special tools 999 5746 Holder (remov. piston/connecting rod) B 200-B 6304 Tool number: 999 5746 Tool description: Holder (remov. piston/connecting rod) B 200-B 6304 Tool boards: 21 999 5679 Oil filter spanner (D-version) Tool number: 999 5679 Tool description: Oil filter spanner (D-version) Tool boards: 20 999 7194 Drift Tool number: 999 7194 Tool description: Drift Tool boards: 21

Scheme 75

Scheme 75
Scheme 75
Materials
DesignationPart number
Engine oil
Chemical gasket30757050

Scheme 76

Scheme 76: INSTALLATION
Scheme 76: INSTALLATION

See information about specifications, see ENGINE

Scheme 77

Scheme 77
Scheme 77

See information about specifications, see ENGINE

Scheme 78

Scheme 78
Scheme 78

See information about specifications, see ENGINE

Scheme 79

Scheme 79
Scheme 79

Note. Make sure that the classification of the components correspond with each other.

Note. Make sure that these components are installed to the noted removal position.

See information about storage classification, see ENGINE

Scheme 80

Scheme 80
Scheme 80
CAUTIONMake sure that the area around the component is clean and free of foreign material.

Use: Engine oil

CAUTIONTake extra care when handling the components.

Scheme 81

Scheme 81
Scheme 81
CAUTIONMake sure that the mating faces are clean and free of foreign material.

Note. The component must be installed within 5 minutes of applying the sealant.

Use: Chemical gasket, 30757050

Scheme 82

Scheme 82
Scheme 82
CAUTIONMake sure that the mating faces are clean and free of foreign material.

Torque: Intermediate section to engine block

40 Nm

Scheme 83

Scheme 83
Scheme 83

Torque: Intermediate section for engine block step 1

90 Degree

Scheme 84

Scheme 84
Scheme 84

Torque: Intermediate section for engine block step 2

110 Degree

Scheme 85

Scheme 85
Scheme 85

Torque: Intermediate section for engine block step 3

20 Nm

Scheme 86

Scheme 86
Scheme 86

Torque: Intermediate section for engine block step 4

24 Nm

Scheme 87

Scheme 87
Scheme 87

Note. Make sure that the classification of the components correspond with each other.

Scheme 88

Scheme 88
Scheme 88

Note. Make sure that the classification of the components correspond with each other.

Note. Make sure that these components are installed to the noted removal position.

See information about storage classification, see ENGINE

CAUTIONTake extra care when handling the components.
CAUTIONTake extra care when handling the components.

see 9995746

Torque: Cap connecting rod

Stage 1: 20 Nm

Stage 2: 85 Degree

Torque: M6

10 Nm

Torque: M8

24 Nm

Scheme 89

Scheme 89
Scheme 89
  1. Torque: M6 10 Nm
  2. Torque: M8 24 Nm

Scheme 90

Scheme 90
Scheme 90
CAUTIONMake sure that the mating faces are clean and free of foreign material.

Note. The component must be installed within 5 minutes of applying the sealant.

Use: Chemical gasket, 30757050

Scheme 91

Scheme 91
Scheme 91
CAUTIONMake sure that the mating faces are clean and free of foreign material.
  1. Torque: M6 10 Nm
  2. Torque: M8 24 Nm

Scheme 92

Scheme 92
Scheme 92

Note. The component must be installed within 5 minutes of applying the sealant.

Use: Chemical gasket, 30757050

Torque: M6

10 Nm

Torque: M6

10 Nm

see 9995679

Torque: M10

50 Nm

Scheme 93

Scheme 93
Scheme 93

see 9997194

Use: Engine oil

Scheme 94

Scheme 94
Scheme 94
CAUTIONMake sure that the mating faces are clean and free of foreign material.

Scheme 95

Scheme 95
Scheme 95

TIMING CHAIN, ASSEMBLING

Special tools 999 7261 Position sensor Tool number: 999 7261 Tool description: Position sensor Tool boards: 21 999 7264 Counterhold Tool number: 999 7264 Tool description: Counterhold Tool boards: 21 999 7263 Counterhold Tool number: 999 7263 Tool description: Counterhold Tool boards: 21 999 7272 TORX 60 Tool number: 999 7272 Tool description: TORX 60 Tool boards: 21 999 7257 Wrench Tool number: 999 7257 Tool description: Wrench Tool boards: 21 999 7266 Position sensor Tool number: 999 7266 Tool description: Position sensor Tool boards: 21 999 7267 Position sensor Tool number: 999 7267 Tool description: Position sensor Tool boards: 21 999 7265 Drift Tool number: 999 7265 Tool description: Drift Tool boards: 21 999 5760 Counterhold (rem/inst/freewheel gener.)Bosch, Denso Tool number: 999 5760 Tool description: Counterhold (rem/inst/freewheel gener.)Bosch, Denso Tool boards: 30 951 2926 Bit Torx 50 Tool number: 951 2926 Tool description: Bit Torx 50 Tool boards: 30

Scheme 96

Scheme 96: TIMING CHAIN, ASSEMBLING
Scheme 96: TIMING CHAIN, ASSEMBLING

Scheme 97

Scheme 97
Scheme 97

Scheme 98

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Scheme 98

Scheme 99

Scheme 99
Scheme 99

Scheme 100

Scheme 100
Scheme 100

Scheme 101

Scheme 101: INSTALLATION
Scheme 101: INSTALLATION

see 9997261

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Scheme 103

Scheme 103
Scheme 103

Torque: M6

10 Nm

Scheme 104

Scheme 104
Scheme 104

Install the following items

  1. see «9997264»(ref-460875-S05288717862012040200000) see «9997263»(ref-460875-S03754019592012040200000) see «9997272»(ref-460875-S19366173322012040200000)
  2. Torque: Centre bolt, exhaust camshaft • Stage 1: 75 Nm • Stage 2: 90 degree
  3. Torque: Centre bolt, intake camshaft 110 Nm

see 9997261

see 9997263 see 9997264 see 9997272

Remove the tools.

Scheme 105

Scheme 105
Scheme 105

see 9997257

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Scheme 107

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Scheme 108
Scheme 108

Install the following items

  1. see «9997266»(ref-460875-S23587216892012040200000)
  2. see «9997267»(ref-460875-S32604520112012040200000)

Scheme 109

Scheme 109
Scheme 109

Note. Install all the bolts finger tight before final tightening.

Scheme 110

Scheme 110
Scheme 110

Torque: M7

17 Nm

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Scheme 111

Torque: M7

17 Nm

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Scheme 112

Torque: M8

24 Nm

Scheme 113

Scheme 113
Scheme 113

Install the following items

  1. Torque: M6 10 Nm
  2. Torque: M7 17 Nm
  3. Torque: M8 24 Nm

Scheme 114

Scheme 114
Scheme 114

see 9997265

Scheme 115

Scheme 115
Scheme 115

see 9997265

Scheme 116

Scheme 116
Scheme 116

see 9997265

Scheme 117

Scheme 117
Scheme 117

see 9997265

Scheme 118

Scheme 118
Scheme 118

see 9995760 see 9512926

Torque: Belt pulley auxiliary unit

60 Nm

Scheme 119

Scheme 119
Scheme 119
Materials
DesignationPart number
Chemical gasket30757050

Scheme 120

Scheme 120: INSTALLATION
Scheme 120: INSTALLATION

Scheme 121

Scheme 121
Scheme 121

Note. Make sure that these components are installed to the noted removal position.

Scheme 122

Scheme 122
Scheme 122

Torque: M8

24 Nm

Scheme 123

Scheme 123
Scheme 123

Torque: M6

10 Nm

Scheme 124

Scheme 124
Scheme 124
CAUTIONTake extra care not to damage the mating faces.

Note. Make sure that the mating faces are clean and free of foreign material.

Note. The component must be installed within 5 minutes of applying the sealant.

Use: Chemical gasket, 30757050

Scheme 125

Scheme 125
Scheme 125

Scheme 126

Scheme 126
Scheme 126

Torque: M8

24 Nm

Scheme 127

Scheme 127
Scheme 127

Torque: Center nut vibration damper (crankshaft)

Stage 1: 120 Nm

Stage 2: Loosen the screw 360 degree

Stage 3: 50 Nm

Stage 4: 90 degree

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Scheme 128
Scheme 128

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Scheme 131

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