Engine - Overhaul Instructions (Xc): Overhaul Volvo V70 II

Crank mechanism, assembling

Special tools

9512767

9991801

9995676

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

9995458

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 748

Remove

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

Scheme 749

Remove

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

Scheme 750

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 751

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 752

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 753

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 754

Remove the screws for the connecting rod cover.

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

Install tool

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.

Special tools

9512767

9991801

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.

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 755

Use a micrometer.

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

Scheme 756

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

Scheme 757

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 758

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 759

Use new piston rings.

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

Scheme 760

Use a micrometer and vernier calliper.

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

Scheme 761

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

Scheme 762

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 763

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 764

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.

See Crank mechanism, assembling

See Disassembling the crankshaft assembly

See Measuring the crankshaft assembly

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 765

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

9995458

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 766

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 767

Remove

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

Scheme 768

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.

Cylinder head, dismantling/assembling

Special tools

9986052

9995219

9995748

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.

Belt drive, assembly

Special tools

9995747

9995451

9995452

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

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.

See Belt transmission, assembly