Engine - Overhaul Instructions: Other Volvo XC70 II

INSTALLING

INSTALL

Scheme 104

Install the following items

1. oil trap. Torque: M6 10 Nm
2. water pipe. Torque: M7 17 Nm
3. thermostat housing. Torque: M6 10 Nm

Scheme 105

Install the following items

1. ignition coils. Torque: M6 10 Nm
2. fuel rails/fuel injectors. Torque: M6 10 Nm
3. the sensor Torque: M6 10 Nm
4. cover crankcase ventilation. Torque: M6 10 Nm
5. lifting eyes. Torque: M10 50 Nm

INSTALL

Scheme 106

Install the cable harness.

Torque: M6

10 Nm

INSTALL

Scheme 107

Install the generator. See ALTERNATOR AND REGULATOR - REMOVAL, REPLACEMENT AND INSTALLATION

INSTALL

Scheme 108

Install the intake manifold. See INDUCTION PIPE

INSTALL

Scheme 109

Remove the engine from the work stand.

INSTALL

Install the carrier plate. See CARRIER PLATE (2008-2009) or CARRIER PLATE (2010-12)

INSTALL

Scheme 110

Install the transaxle. See TRANSMISSION - REMOVAL, REPLACEMENT AND INSTALLATION

INSTALL

Scheme 111

Install the following items

1. water pipe (5). Torque: M6 10 Nm
2. AC-console (4), console transmission (3), front auxiliary unit console (2). See «ACCESSORY DRIVE COMPONENT BRACKET (B6304T2)»(ref-495372-S23624377812012082100000) or «ACCESSORY DRIVE COMPONENT BRACKET (B6324S, B6324S5)»(ref-495375-S28141367232012082100000)
3. radiator hose (1)

INSTALL

Install the engine. See ENGINE, INSTALLING

INSTALL

INSTALL

Install the following items

1. oil trap. Torque: M6 10 Nm
2. water pipe. Torque: M7 17 Nm
3. thermostat housing. Torque: M6 10 Nm

Install the following items

1. ignition coils. Torque: M6 10 Nm
2. fuel rails/fuel injectors. Torque: M6 10 Nm
3. the sensor Torque: M6 10 Nm
4. cover crankcase ventilation. Torque: M6 10 Nm
5. lifting eyes. Torque: M10 50 Nm

INSTALL

Install the cable harness.

Torque: M6

10 Nm

INSTALL

Install the generator. See ALTERNATOR AND REGULATOR - REMOVAL, REPLACEMENT AND INSTALLATION

INSTALL

Scheme 112

Install the intake manifold. See INDUCTION PIPE

Remove the engine from the work stand.

INSTALL

Install the carrier plate. See CARRIER PLATE (2008-2009) or CARRIER PLATE (2010-12)

INSTALL

Install the transaxle. See TRANSMISSION - REMOVAL, REPLACEMENT AND INSTALLATION

INSTALL

Install the following items

1. water pipe (5). Torque: M6 10 Nm
2. AC-console (4), console transmission (3), front auxiliary unit console (2). See «ACCESSORY DRIVE COMPONENT BRACKET (B6304T2)»(ref-495372-S23624377812012082100000) or «ACCESSORY DRIVE COMPONENT BRACKET (B6324S, B6324S5)»(ref-495375-S28141367232012082100000)
3. radiator hose (1)

INSTALL

Install the engine. See ENGINE, INSTALLING (B6324S) or ENGINE, INSTALLING (B6324S2)

ENGINE BLOCK, INSTALLING COMPONENTS (B6324S4, B6324S5)

INSTALL

Install the following items

1. ignition coils. Torque: M6 10 Nm
2. fuel rails/fuel injectors. Torque: M6 10 Nm
3. the sensor Torque: M6 10 Nm
4. cover crankcase ventilation. Torque: M6 10 Nm
5. lifting eyes. Torque: M10 50 Nm

INSTALL

Install the following items

1. oil trap. Torque: M6 10 Nm
2. water pipe. Torque: M7 17 Nm
3. thermostat housing. Torque: M6 10 Nm

INSTALL

Install the cable harness.

Torque: M6

10 Nm

INSTALL

Install the generator. See ALTERNATOR AND REGULATOR - REMOVAL, REPLACEMENT AND INSTALLATION

INSTALL

Install the intake manifold. See INDUCTION PIPE

Remove the engine from the work stand.

INSTALL

Install the carrier plate. See CARRIER PLATE (2008-2009) or CARRIER PLATE (2010-12)

INSTALL

Install the transaxle. See TRANSMISSION - REMOVAL, REPLACEMENT AND INSTALLATION

INSTALL

Install the following items

1. water pipe (5). Torque: M6 10 Nm
2. AC-console (4), console transmission (3), front auxiliary unit console (2). See «ACCESSORY DRIVE COMPONENT BRACKET (B6304T2)»(ref-495372-S23624377812012082100000) or «ACCESSORY DRIVE COMPONENT BRACKET (B6324S, B6324S5)»(ref-495375-S28141367232012082100000)
3. radiator hose (1)

INSTALL

Install the engine. See ENGINE, INSTALLING (B6324S or ENGINE, INSTALLING (B6324S2

ENGINE BODY, EXPOSING (B6304T2, B6304T4)

Special tools 999 2520 FLOOR STAND (TO FIXTURES) Tool number: 999 2520 Tool description: FLOOR STAND (TO FIXTURES) Tool boards: 08 999 5297 ENGINE FIXTURE (UNIVERSAL) Tool number: 999 5297 Tool description: ENGINE FIXTURE (UNIVERSAL) Tool boards: 21 998 9721 SCREW SET (SPECIAL HOLDER) Tool number: 998 9721 Tool description: SCREW SET (SPECIAL HOLDER) Tool boards

ENGINE BODY, EXPOSING (B6324S, B6324S2)

Special tools T9992520 FLOOR STAND (FOR FIXTURES) Tool number: T9992520 Tool description: FLOOR STAND (FOR FIXTURES) Tool boards: T9995297 ENGINE FIXTURE (UNIVERSAL) Tool number: T9995297 Tool description: ENGINE FIXTURE (UNIVERSAL) Tool boards: T9989721 SCREW KIT (SPECIAL HOLDER) Tool number: T9989721 Tool description: SCREW KIT (SPECIAL HOLDER) Tool boards

ENGINE BODY, EXPOSING (B6324S4, B6324S5)

Special tools T9992520 FLOOR STAND (FOR FIXTURES) Tool number: T9992520 Tool description: FLOOR STAND (FOR FIXTURES) Tool boards: T9995297 ENGINE FIXTURE (UNIVERSAL) Tool number: T9995297 Tool description: ENGINE FIXTURE (UNIVERSAL) Tool boards: T9989721 SCREW KIT (SPECIAL HOLDER) Tool number: T9989721 Tool description: SCREW KIT (SPECIAL HOLDER) Tool boards

RECONDITIONING

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

See information about specifications, see ENGINE - SPECIFICATIONS, MECHANICAL

Scheme 113

Scheme 114

REAR END ACCESSORY DRIVE

Special tools 999 5670 Pliers (removing valve/camshaft cover) B4184-B6304 Tool number: 999 5670 Tool description: Pliers (removing valve/camshaft cover) B4184-B6304 Tool boards: 21 999 7315 Puller Tool number: 999 7315 Tool description: Puller Tool boards: 21 999 7258 Counterhold Tool number: 999 7258 Tool description: Counterhold Tool boards: 21 999 7259 Puller Tool number: 999 7259 Tool description: Puller Tool boards: 21 999 7317 Counterhold Tool number: 999 7317 Tool description: Counterhold Tool boards: 21 999 7329 Counterhold Tool number: 999 7329 Tool description: Counterhold Tool boards: 21 999 7318 Press tool Tool number: 999 7318 Tool description: Press tool Tool boards: 21 999 7328 Press tool Tool number: 999 7328 Tool description: Press tool Tool boards: 21 999 7319 Press tool Tool number: 999 7319 Tool description: Press tool Tool boards: 21 999 7320 Press tool Tool number: 999 7320 Tool description: Press tool Tool boards: 21 999 7337 Counterhold Tool number: 999 7337 Tool description: Counterhold Tool boards: 21 999 7322 Counterhold Tool number: 999 7322 Tool description: Counterhold Tool boards: 21 999 7321 Press tool Tool number: 999 7321 Tool description: Press tool Tool boards: 21 999 7324 Press tool Tool number: 999 7324 Tool description: Press tool Tool boards: 21 999 7323 Press tool Tool number: 999 7323 Tool description: Press tool Tool boards: 21 999 7325 Press tool Tool number: 999 7325 Tool description: Press tool Tool boards: 21 999 7326 Press tool Tool number: 999 7326 Tool description: Press tool Tool boards: 21 999 7327 Press tool Tool number: 999 7327 Tool description: Press tool Tool boards: 21 999 7316 Drift Tool number: 999 7316 Tool description: Drift Tool boards: 21 999 7260 Drift Tool number: 999 7260 Tool description: Drift Tool boards: 21

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

DISMANTLING

Special tools 999 7257 Wrench Tool number: 999 7257 Tool description: Wrench Tool boards: 21 999 7261 Position sensor Tool number: 999 7261 Tool description: Position sensor 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: 30 999 7263 Counterhold Tool number: 999 7263 Tool description: Counterhold Tool boards: 21 999 7264 Counterhold Tool number: 999 7264 Tool description: Counterhold Tool boards: 21 999 7272 TORX 60 Tool number: 999 7272 Tool description: TORX 60 Tool boards: 21

Scheme 130

Scheme 131

Rotate the crankshaft until piston No. 1 is at top dead center (TDC).

see 9997257

see 9997261

Scheme 132

Install the following items

1. see «9995760»(ref-460875-S14846499592012040200000)
2. see «9512926»(ref-460875-S09449854762012040200000)

Scheme 133

Install the following items

1. see «9997263»(ref-460875-S03754019592012040200000)
2. see «9997264»(ref-460875-S05288717862012040200000)
3. see «9997272»(ref-460875-S19366173322012040200000)

CRANK MECHANISM, DISMANTLING

Special tools T9997257 WRENCH Tool number: T9997257 Tool description: WRENCH Tool boards: T9995746 HOLDER (REMOVAL-PISTON/CONNECTING ROD) B 200-B 6304 Tool number: T9995746 Tool description: HOLDER (REMOVAL-PISTON/CONNECTING ROD) B 200-B 6304 Tool boards

Note. Removal steps in this procedure may contain installation details.

CLEANING

Clean the gasket surfaces on the cylinder block, intermediate section and oil pan.

Use razor blade or gasket scraper and/or Use: gasket solution, 1161440

Make sure that the all components are completely clean. Blow clean the oil channels in the block, intermediate section and oil sump.

CLASSIFICATION OF MAIN BEARINGS

Wipe clean the bearing positions in the block and intermediate section. Check that the parts are clean and free from damages.

Check classification of the block and crankshaft. See ENGINE - SPECIFICATIONS, MECHANICAL

Install the main bearings in the engine block and intermediate section, according to table.

E. g.: The marking on the block by bearing position 1 is "F", while the marking on the crankshaft at the corresponding bearing position is "M". This gives a red-marked bearing in the block and a yellow-marked in the intermediate section.

The thrust bearing is placed at bearing position 6.

Bearings with small grooves are placed in the engine block's bearing positions 1, 4, 7.

Bearings with complete grooves are placed in the engine block's bearing positions 2, 3, 5.

When reusing old bearing halves, make sure that they are correctly positioned with regards to the crankshaft's rotational direction.

Scheme 134

Use: sealant, 1161771

Apply sealant on the engine block as shown.

Install the following items

1. 2.5 mm ±0.5
2. 1 mm ±0.2
3. Make sure that no sealant is applied longer than the line shows.

Thoroughly lube all bearing shells and the thrust bearing surface with oil.

Scheme 135

Carefully lay the crankshaft into place in the block.

The crankshaft may not be rotated before the intermediate part is torque-tightened.

Lay the intermediate part into place.

Lube all screws with oil and install them.

Scheme 136

Torque: Intermediate section for engine block step 1

Stage 1: 5 Nm

Stage 2: 30 Nm

Scheme 137

Torque: Intermediate section for engine block step 2

5 Nm

Scheme 138

Torque: Intermediate section for engine block step 3

25 Nm

Torque: Intermediate section for engine block step 4

105 degree

Scheme 139

Torque: Intermediate section for engine block step 5

25 Nm

There is a classification letter stamped in for every cylinder. See ENGINE - SPECIFICATIONS, MECHANICAL

The first letter corresponds to the classification of the cylinder diameter in cylinder 1 and is then followed by cyl. 2, 3, 4, 5, 6. Choice of piston is decided by the cylinder bore's classification. E. g.: Cylinder class D shall have piston marked D, etc.

Scheme 140

Use piston ring pliers. Turn the piston rings so that the openings are offset as illustrated.

A=Compression ring. The text on the piston ring shall face up.

B=Scraper ring. The bevel shall face down.

C=Oil ring. Three parts equilateral.

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

Make sure that the piston rings are not stuck and turn easily.

Incorrect positioning increases oil consumption.

Scheme 141

The lock ring shoots away easily.

There is a marking on top of the piston. It shall face forward in the engine block. The connecting rods are symmetrical and can face either way. However, marked connecting rods shall face the same way.

Assemble connecting rod and piston with the piston pin. Check that the classification of each cylinder/piston diameter and any numbering of connecting rod match. Install both lock rings for the piston pin. Check that the lock rings are positioned correctly in the piston. The opening shall be in a vertical line.

Wipe clean at the bearing position in the connecting rod and cap, and blow with compressed air on the connecting rod's/cap's fracture surface.

Scheme 142

see 9995746

The piston's arrow (top of piston) shall point forward and make sure that the classification matches. Use piston ring compressor. Lube the cylinder bores, pistons and bearings shells with oil. Turn the crankshaft so that the crank pin is at lower dead center for the cylinder the piston is to be installed in. Make sure that the engine hangs so that the cylinder bores are as vertical as possible.

Carefully press/tap down the piston (e. g., with a hammer handle). When the piston has released the piston ring compressor, turn the engine 180° in the work stand. Tighten the connecting rod until it is fixed against the big-end bearing journal.

The crankshaft may not be rotated before the connecting rod's cap is tightened. Install the cap. Check that any marking matches. Lube the new screws with oil and install them. Tighten the screws according to the following sequence

Torque: Cap connecting rod

Stage 1: 30 Nm

Stage 2: 90 degree

Check that the connecting rods can be moved sideways.

Torque: M6

10 Nm

Install the following items

1. oil pump and line. See «LUBRICATING AND OIL SYSTEM - REMOVAL, REPLACEMENT AND INSTALLATION»(ref-495630)
2. oil sump. See «OIL PAN»(ref-495375-S06334076002012082100000)
3. front crankshaft seal. See «CRANKSHAFT FRONT SEAL»(ref-495375-S35229623872012082100000)
4. rear crankshaft seal. See «CRANKSHAFT SEAL, REAR»(ref-495375-S41933837722012082100000)
5. other parts. See «ENGINE BLOCK, INSTALLING COMPONENTS (B6324S, B6324S2, 2008-2010)»(ref-495651-S28482656602012082100000)

Install the following items

1. oil pump, see «LUBRICATING AND OIL SYSTEM - REMOVAL, REPLACEMENT AND INSTALLATION»(ref-495630)
2. pan, see «OIL PAN»(ref-495375-S04233411172012082100000)
3. Crankshaft front seal, see «CRANKSHAFT FRONT SEAL»(ref-495375-S35229623872012082100000)
4. Crankshaft seal, rear, see «CRANKSHAFT SEAL, REAR»(ref-495375-S41933837722012082100000)

Scheme 143

Scheme 144

See information about engine, see ENGINE - SPECIFICATIONS, MECHANICAL

Scheme 145

Scheme 146

Note. Make sure that new components are installed.

See information about engine, see ENGINE - SPECIFICATIONS, MECHANICAL

Scheme 147

See information about engine, see ENGINE - SPECIFICATIONS, MECHANICAL

Scheme 148

Scheme 149

See information about engine, see ENGINE - SPECIFICATIONS, MECHANICAL

Scheme 150

See information about engine, see ENGINE - SPECIFICATIONS, MECHANICAL

Scheme 151

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

Scheme 152

Note the dial indicator gauge reading.

See information about engine, see ENGINE - SPECIFICATIONS, MECHANICAL