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Engine - Overhaul Instructions: Other Volvo V50 I рестайлинг

Mechanical 25 illustrations ~1236 words

ENGINE BLOCK, INSTALLING COMPONENTS

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 248

Scheme 248: INFORMATION
Scheme 248: INFORMATION

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

Scheme 249

Scheme 249: INSTALLING PARTS ON ENGINE BLOCK
Scheme 249: INSTALLING PARTS ON ENGINE BLOCK

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 250

Scheme 250: INSTALLING PARTS ON ENGINE BLOCK, CONTINUED
Scheme 250: INSTALLING PARTS ON ENGINE BLOCK, CONTINUED

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-466659-S32787000792012042500000)
  2. the carrier plate according to: «CARRIER PLATE»(ref-466659-S15158886612012042500000)

ENGINE BODY, EXPOSING

Special tools

see 9989721

see 9992520

see 9995112

see 9995297

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.

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 251

Scheme 251: REMOVING THE FLYWHEEL AND CARRIER PLATE
Scheme 251: REMOVING THE 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.

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.

CAULKING

See CAULKING

Special tools

see 9989721

see 9992520

see 9995112

see 9995297

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.

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.

Scheme 252

Scheme 252: EXPOSING THE ENGINE
Scheme 252: EXPOSING THE ENGINE

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.

Scheme 253

Scheme 253: EXPOSING THE ENGINE, CONTINUED
Scheme 253: 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.

See CAULKING

ENGINE BLOCK, INSTALLING COMPONENTS (2010)

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.

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.

INSTALLING PARTS ON ENGINE BLOCK, CONTINUED

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

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

See ENGINE BODY, EXPOSING

See ENGINE BLOCK, INSTALLING COMPONENTS (2010)

See ENGINE BODY, EXPOSING

See ENGINE BLOCK, INSTALLING COMPONENTS (2010)

See ENGINE BODY, EXPOSING

INSTALLING THE CYLINDER HEAD

See INSTALLING THE CYLINDER HEAD

REMOVING THE CYLINDER HEAD

See REMOVING THE CYLINDER HEAD

See INSTALLING THE CYLINDER HEAD

See REMOVING THE CYLINDER HEAD

See INSTALLING THE CYLINDER HEAD

See REMOVING THE CYLINDER HEAD

RECONDITIONING

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

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

See information about specifications, see ENGINE

Scheme 254

Scheme 254
Scheme 254

Scheme 255

Scheme 255
Scheme 255

CYLINDER BLOCK, MEASUREMENT

See CYLINDER BLOCK, MEASUREMENT

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

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

See information about specifications, see ENGINE

See CYLINDER BLOCK, MEASUREMENT

TIMING BELT, DISMANTLING

See TIMING BELT, DISMANTLING

CRANK MECHANISM, DISMANTLING

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 256

Scheme 256: REMOVAL
Scheme 256: REMOVAL
CAUTIONTake extra care not to damage the mating faces.

Scheme 257

Scheme 257
Scheme 257

Scheme 258

Scheme 258
Scheme 258

Scheme 259

Scheme 259
Scheme 259

Scheme 260

Scheme 260
Scheme 260

Scheme 261

Scheme 261
Scheme 261
CAUTIONNote the position of the components before removal.

Scheme 262

Scheme 262
Scheme 262
CAUTIONTake extra care when handling the components.

see 9995746

Scheme 263

Scheme 263
Scheme 263

Scheme 264

Scheme 264
Scheme 264

Scheme 265

Scheme 265
Scheme 265

Scheme 266

Scheme 266
Scheme 266
CAUTIONTake extra care not to damage the mating faces.
CAUTIONTake extra care when handling the components.

Note. Only use moderate force.

Scheme 267

Scheme 267
Scheme 267

Scheme 268

Scheme 268
Scheme 268
CAUTIONTake extra care when handling the components.

Scheme 269

Scheme 269
Scheme 269

Scheme 270

Scheme 270
Scheme 270

Scheme 271

Scheme 271
Scheme 271

CHECKING THE CONNECTING ROD IN A CONNECTING ROD ALIGNER

Check for out-of-true and twisting.

CAUTIONCheck that the aligner fork is unburred and round at the handle. Loosen and apply the expander at the big-end between each alignment operation.

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 272

Scheme 272: CRANK MECHANISM, DISMANTLING
Scheme 272: CRANK MECHANISM, DISMANTLING

See CRANK MECHANISM, DISMANTLING

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