Home/Volvo/XC90/Volvo XC90 I (2002-2006)/Repair manual/Engine - Overhaul Instructions/ENGINE BODY, EXPOSING

Contents

Wiring diagrams Section: Engine - Overhaul Instructions

BALANCE SHAFT BEARING

INSTALLING FRONT CRANKSHAFT SEAL

INSTALLING THE TIMING GEAR PULLEY FOR THE CAMSHAFTS

FINISHING

CHECKING THE MARKINGS AND BELT TENSION

OIL PUMP / CRANKSHAFT SEAL, FRONT, REPLACING

BELT DRIVE, DISMANTLING

REMOVING THE OIL PUMP

REMOVING THE THERMOSTAT AND THERMOSTAT HOUSING

INSTALLING THE CRANKSHAFT TIMING GEAR PULLEY

INSTALLING THE IDLER PULLEY AND BELT TENSIONER

CHECKING AND ADJUSTING THE VARIABLE VALVE TIMING UNIT

DISMANTLING THE BELT DRIVE

ALIGNING THE ENGINE ACCORDING TO THE MARKING

REMOVING THE BELT TENSIONER AND IDLER PULLEY

CHECKING THE OPENING FUNCTION OF THE THERMOSTAT

INSTALLING THE WATER PUMP

DISMANTLING THE BELT TRANSMISSION

REMOVING THE CRANKSHAFT PULLEY

CHECKING THE OIL PUMP

REMOVING THE COOLANT PUMP / TIMING BELT COVER

CAULKING

CLEANING

SELECTING BEARINGS

REMOVING THE SCREWED JOINT FROM THE INTERMEDIATE SECTION

REMOVING THE PISTON COOLING VALVE AND NOZZLES

NEW CONNECTING ROD

CHECKING THE CONNECTING ROD IN A CONNECTING ROD ALIGNER

INSTALLING THE PISTON COOLING VALVE AND NOZZLES

CLASSIFICATION OF MAIN BEARINGS

APPLYING LIQUID GASKET

MARKING THE CONNECTING ROD (WHERE APPLICABLE)

INSTALLING PISTON RINGS

INSTALLING THE PISTONS IN THE CYLINDER BORES

INSTALLING THE OIL PUMP SUCTION PIPE

INSTALLING THE SUMP

INSTALLING THE REAR CRANKSHAFT SEAL

REMOVING THE SUCTION PIPE FROM THE OIL PUMP

CHECKING MARKINGS

REMOVING THE PISTONS FROM THE CYLINDER BLOCK

SEPARATING THE INTERMEDIATE SECTION FROM THE CYLINDER BLOCK

MEASURING THE CRANKSHAFT

CHECK THE OUT-OF-TRUE OF THE CRANKSHAFT

REMOVING THE PISTON RINGS

CHECKING PISTON RING AXIAL CLEARANCE

CALCULATING THE RUNNING CLEARANCE OF THE PISTON

CHECKING THE BEARING RECESS IN THE CONNECTING ROD BIG END

CRANK MECHANISM, DISMANTLING

RECONDITIONING

MEASURING THE CYLINDER BORE

CLASSIFICATION MARKING

CHECKING FOR WEAR

INSTALLING THE CYLINDER HEAD

INSTALLING TAPPETS AND CAMSHAFTS

MEASURING AND RECONDITIONING THE CYLINDER HEAD

CHECKING FOR WEAR IN THE VALVE GUIDES

CHECKING THE HEIGHT OF THE VALVE STEMS

REMOVING THE CYLINDER HEAD

REMOVING TAPPETS

REMOVING VALVES

REMOVING VALVE STEM SEALS

CHECKING THE CYLINDER HEAD

INSTALLING VALVE STEM SEALS

INSTALLING THE VALVE / VALVE SPRINGS

CYLINDER HEAD, INSTALLING

ALIGNING THE CRANKSHAFT

INSTALLING VALVE LIFTERS AND CAMSHAFTS

INSTALLING THE REAR CAMSHAFT SEAL

SECURING THE CAMSHAFTS

CYLINDER HEAD, REMOVING

REMOVING THE CAMSHAFT COVER

CHECKING THE VERTICAL POSITION OF THE VALVE STEM

INSTALLING VALVE SPRINGS

PREPARATORY WORK

ENGINE BLOCK, INSTALLING COMPONENTS

INSTALLING ENGINE BLOCK COMPONENTS

CRANKSHAFT SEAL REAR, REPLACING

ENGINE BODY, EXPOSING

REMOVING THE GEARBOX

PRESSURE PLATE / CLUTCH DRIVEN PLATE, REPLACING

SEALING MICRO-ENCLOSED SCREWS

EXPOSING THE ENGINE BODY

REMOVING THE TRANSMISSION

REMOVING THE FLYWHEEL AND CARRIER PLATE

PLACE THE ENGINE IN A STAND

EXPOSING THE ENGINE

GEAR HOUSING, RECONDITIONING

REAR END ACCESSORY DRIVE

All sections

ENGINE BODY, EXPOSING Volvo XC90 I

Engine - Overhaul Instructions

ENGINE BODY, EXPOSING

Special tools

see 9989721

see 9992520

see 9995112

see 9995297

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.