Engine - Overhaul Instructions: Removal & Installation Volvo XC90 I

REMOVAL

REMOVING THE ENGINE COMPONENTS

Scheme 737

Remove

1. the cross stay between the suspension turrets
2. the upper timing belt cover
3. the servo reservoir and expansion tank. Lift them up and place them on top of the engine
4. the auxiliaries belt
5. the front timing belt cover.

ENGINE ADJUSTMENT ACCORDING THE MARKINGS

Scheme 738

Raise the vehicle. See: JACKING POINTS, BODY .

Remove the right-hand front wheel.

Install the upper timing belt cover.

Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulleys correspond.

Turn a further 1/4 turn clockwise and then back counter-clockwise until the markings correspond.

Remove the upper camshaft cover.

REMOVING TIMING BELT

Slacken off the center screw for the belt tensioner slightly.

Hold the center screw in place. Turn the tensioner eccentric clockwise to 10 o'clock. Use a 6 mm Allen key.

Remove the timing belt.

REMOVING THE VIBRATION DAMPER

Scheme 739

Install counterhold: see 9995433 .

Counterhold and remove the crankshaft center nut.

Work the vibration damper loose and remove by hand.

Remove the camshaft belt.

REMOVING THE CRANKSHAFT PULLEY

Scheme 740

Use: see 9986187 and two of the vibration damper screws.

Tighten both the screws by hand to stop in the pulley.

Install the puller so that the claws engage in the screws, not in the camshaft pulley.

WHEN ONLY REPLACING THE FRONT CRANKSHAFT SEAL

Scheme 741

Remove the old seal using a groove-cut chisel or: see 9995919 .

Clean the mating surface.

Grease and install a new seal.

Use tool: see 9995455 .

Press in the seal using a drift and the crankshaft center nut. As illustrated.

REMOVING THE OIL PUMP

Scheme 742

Remove

1. the 4 x oil pump screws
2. the oil pump. Carefully break at the stop lugs. Use a groove-cut chisel.

Clean the gasket face and the mating surfaces.

INSTALLATION

Note. For tightening torques, see: TIGHTENING TORQUE .

INSTALLING THE OIL PUMP

Scheme 743

Install

1. a new oil pump
2. a new gasket.

Carefully insert the oil pump over the end of the crankshaft.

Install 4 x new screws as guides.

Note. Ensure that the crankshaft does not rotate when drawing in the pump.

Pull in the oil pump with drift: see 9995455 and the crankshaft center nut.

Tighten the screws alternately.

Note. The timing gear pulley can only be in one position on the splines on the end of the crankshaft.

Install the crankshaft timing gear pulley.

Carefully tap alternately around the pulley until end position is reached.

INSTALLING THE VIBRATION DAMPER

Install the vibration damper.

Tighten the center nut. See: SUMMARY OF SPECIFIC COMPONENTS AND TIGHTENING TORQUES .

Use: see 9995433 .

Remove the counterhold. Tighten and angle-tighten the screws. Use protractor: see 9512050 .

INSTALLING TIMING BELT

Install the upper timing belt cover.

Check that the markings on the crankshaft and camshaft timing gear pulley correspond.

Install the belt in the following order

1. crankshaft
2. the idler pulley
3. intake camshaft
4. exhaust camshaft
5. water pump
6. belt tensioner.

INSTALLING THE TIMING BELT

This adjustment is to be made with a cold engine. Suitable temperature is approximately 20°C/68°F.

At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.

The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.

Turn the crankshaft carefully clockwise until the timing belt is in tensioned positioned (tensioned between intake cam, idler pulley and crankshaft).

Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position. Turn the eccentric back until the indicator reaches the marked position in the center of the window.

Hold the eccentric secure. Tighten the center screw. See: SUMMARY OF SPECIFIC COMPONENTS AND TIGHTENING TORQUES . Ensure that the indicator is in the correct position.

Scheme 744

Press the belt to, see that the indicator on the tensioner moves easily.

Install the upper camshaft cover.

Turn the crankshaft two turns. Check that the markings on the crankshaft and camshaft pulley correspond.

Check that the indicator on the belt tensioner is within the marked position.

Install

1. the nuts for the cover in the fender liner
2. the wheel. See: «INSTALLING WHEELS»(ref-476812-S05651003162012060500000) .

FINISHING

Install

1. the front camshaft cover
2. the upper camshaft cover
3. the auxiliaries belt
4. the expansion tank and servo reservoir. NOTE: Ensure that the hoses are correctly positioned.
5. the engine stabilizer brace. Tighten the screws on the suspension turret.

CHECK THE FUNCTION

Check the oil level. Top up as necessary.

Start the engine.

Check that there is no oil leakage.

Stop the engine and give the oil time to run down into the oil pan.

Then check the oil level.

Top up if necessary.

Wipe the engine compartment clean.

Ensure that the steering wheel and the gear selector lever are clean.

Note. For tightening torques, see: GENERAL TIGHTENING TORQUE .

Scheme 745

Note. Ensure that all studs at the exhaust ports are tightened.

Lubricate the studs. Use paste 116 1408.

Install

1. new cylinder head gasket. Apply sealing compound 307 57050 on both sides. See the illustration.
2. the cylinder head
3. the new lubricated screws.

Tighten the screws in a circle from the inside and outwards. Use protractor: see 9512050 . Tighten. See SUMMARY OF TIGHTENING TORQUES FOR SPECIFIC COMPONENTS .

Scheme 746

Install

1. the camshafts
2. the chain tensioner

Note. Adjust the VVT units' marking to the camshaft chain color marking (see illustration).

Scheme 747

Install

1. the intake camshaft caps
2. the 16 x M6 screws. Tighten, see: «SUMMARY OF TIGHTENING TORQUES FOR SPECIFIC COMPONENTS»(ref-476949-S03900293712012060500000) .

Scheme 748

Install

1. new filter, x 2
2. the cap, 4 x M6. Tighten, see: «SUMMARY OF TIGHTENING TORQUES FOR SPECIFIC COMPONENTS»(ref-476949-S03900293712012060500000)
3. the screws for the chain tensioner, 2 x M6. Tighten. See «SUMMARY OF TIGHTENING TORQUES FOR SPECIFIC COMPONENTS»(ref-476949-S03900293712012060500000) .

Scheme 749

Install

1. camshaft adjustment tools

INSTALLING THE CENTERING TOOL FOR THE CLUTCH DRIVEN PLATE

Scheme 750

Use centering tool see 9995663 , or together with see 9995675 . The drift is modified as described in the Tool bulletin. The conversion kit is included.

Remove the cone from the centering tool.

Install the centering tool in the flywheel center as far in as possible.

Use a spanner as a counterhold. Tighten the outer socket so that the drift expander locks the centering tool.

Feel to, see that the centering tool is secured in the crankshaft.

INSTALLING THE CLUTCH DRIVEN PLATE

Scheme 751

Install the cone on the centering tool. Tighten the cone (by hand) . Secure the clutch driven plate.

Note. Tightening tools must not be used on the cone or damage may be caused to the clutch driven plate.

INSTALLING THE TOOLS ON THE CLUTCH

Install counterhold see 9995677, see ALIGNING THE COUNTERHOLD in see scheme 416.

Install the compression tool see 9995662 , see INSTALLING THE COMPRESSION TOOL .

First tighten the center screw on the compression tool to light contact. Then compress the clutch.

Note. When the center screw comes into contact with the diaphragm spring, the screw should, for a loose clutch, be tightened a maximum of 4-4.5 turns.

Applies only to certain engine versions with self adjusting clutches

Note. When the center screw comes into contact with the diaphragm spring, the screw should, for a loose clutch, be tightened 4.5 - 5 turns or until a clear click is heard .

INSTALLING THE CLUTCH

Scheme 752

Applies only to certain engine versions with self adjusting clutches

Check that the clutch automatic adjustment is secured with counterhold see 9995677 .

Applies to all clutch versions

Install the clutch and locate the guide pins.

Check that the clutch is in contact with the flywheel all around its circumference.

Carefully tighten the six screws, crosswise, so that the clutch is guided up onto the guide pins and lies in contact all around with the flywheel.

Tighten the screws crosswise. Tighten to 25 Nm .

REMOVING THE TOOLS

Scheme 753

Screw out the center screw. Remove the compression tool.

Note. Applies only to certain engine versions with self adjusting clutches: Keep fingers away from the three clutch rivets when relieving a load or removing the compression tool. There is a risk of clamping injuries.

Applies to all clutch versions

Remove the hooks. Remove the counterhold.

Remove the centering cone from the clutch driven plate.

Remove the socket. Tap the centering tool lightly with a rubber mallet so that the expander releases. Use a rubber mallet so that the threads are not damaged. Remove the centering tool.

Remove the flywheel gear sector.

Note. Installing the gearbox: To install the transmission, see TRANSMISSION - REMOVAL, REPLACEMENT AND INSTALLATION .

BLOCKING THE FLYWHEEL

Use gear sector see 9995112 .

Applies only to certain engine versions with self adjusting clutches

Secure the clutch automatic adjustment.

Use counterhold see 9995677 . Locate the counterhold, see below.

ALIGNING THE COUNTERHOLD FOR AUTOMATIC CLUTCH ADJUSTMENT

Applies only to certain engine versions with self adjusting clutches

The three pins on the counterhold lock the automatic adjustment.

Position the tool as illustrated.

Ensure that all the three pins (see the illustration) go into the groove in front of the tensioner springs for the automatic adjuster.

Press the ring against the pressure plate. Pull out the counterhold springs. Secure the three hooks in the center holes of the outer edge.

INSTALLING THE COMPRESSION TOOL

Install compression tool see 9995662 , together with the conversion kit on the clutch. The tool is modified as described in the tool bulletin.

Ensure that the hooks grip correctly, although without clamping the adjuster springs.

Centre the compression tool and tighten the screw to light contact against the diaphragm spring. At the same time, check that the hooks on the tool are in position.

Applies only to clutches without self adjustment

Note the position of the handle with slots. Then screw in by not more than two turns .

Remove the clutch and clutch driven plate

Applies only to certain engine versions with self adjusting clutches

Compress the clutch so that the automatic adjuster is not under load.

If the clutch is worn, the counterhold turns the automatic adjustment to the original position marking.

The marking consists of two stamped arrows.

Then continue to screw in the compression tool until the diaphragm spring has pressed the pressure plate to a free position.

A click can be heard when the clutch pressure plate snaps out.

Remove the clutch and the clutch driven plate .

RELIEVING THE LOAD FROM THE CLUTCH DIAPHRAGM SPRING

Note. Do not allow the diaphragm spring to be under load for a long period of time. Relieve the load as soon as possible. Leave the compression tool in position.

Applies only to certain engine versions with self adjusting clutches

Note. Keep fingers away from the three clutch rivets when relieving a load or removing the compression tool. There is a risk of clamping injuries.

CHECKING THE CLUTCH

Wipe the clutch using a dry cloth.

Check carefully for over heating damage, cracking, scoring or other damage to the friction surface

Check that spring is not damaged or broken.

CHECKING THE PRESSURE PLATE FOR OUT-OF-TRUE

Wipe the pressure plate friction area clean.

Check any out-of-true carefully. Use a ruler and a feeler gauge. Out-of-true is permitted in one direction only.

Out-of-true must not exceed 0.2 mm . If out-of-true is greater, replace the clutch.

The clutch must be replaced as a complete unit.

CHECKING THE CLUTCH DRIVEN PLATE

Wipe off the clutch driven plate using a dry cloth. The cloth must be free of oil and contaminants.

Check the clutch carefully for signs of wear, damage through overheating, cracking or other damage.

Note. The clutch driven plate must always be replaced if there are no radial ripples remaining on the friction coating. The clutch driven plate must also be changed if there is oil or grease on it.

CHECKING THAT THERE ARE NO CRACKS OR LARGE SCRATCHES ON THE FLYWHEEL

Replacing flywheel. See ENGINE - REMOVAL, REPLACEMENT AND INSTALLATION - 2 OF 2 .

INSTALLING THE CENTERING TOOL FOR THE CLUTCH DRIVEN PLATE

Use centering tool see 9995663 , or together with see 9995675 . The drift is modified as described in the Tool bulletin. The conversion kit is included.

Remove the cone from the centering tool.

Install the centering tool in the flywheel center as far in as possible.

Use a spanner as a counterhold. Tighten the outer socket so that the drift expander locks the centering tool.

Feel to, see that the centering tool is secured in the crankshaft.

INSTALLING THE CLUTCH DRIVEN PLATE

Install the cone on the centering tool. Tighten the cone (by hand) . Secure the clutch driven plate.

Note. Tightening tools must not be used on the cone or damage may be caused to the clutch driven plate.

INSTALLING THE TOOLS ON THE CLUTCH

Install counterhold see 9995677, see ALIGNING THE COUNTERHOLD in see scheme 416.

Install the compression tool see 9995662 , see INSTALLING THE COMPRESSION TOOL .

First tighten the center screw on the compression tool to light contact. Then compress the clutch.

Note. When the center screw comes into contact with the diaphragm spring, the screw should, for a loose clutch, be tightened a maximum of 4-4.5 turns.

Applies only to certain engine versions with self adjusting clutches

Note. When the center screw comes into contact with the diaphragm spring, the screw should, for a loose clutch, be tightened 4.5 - 5 turns or until a clear click is heard .

INSTALLING THE CLUTCH

Applies only to certain engine versions with self adjusting clutches

Check that the clutch automatic adjustment is secured with counterhold see 9995677 .

Applies to all clutch versions

Install the clutch and locate the guide pins.

Check that the clutch is in contact with the flywheel all around its circumference.

Carefully tighten the six screws, crosswise, so that the clutch is guided up onto the guide pins and lies in contact all around with the flywheel.

Tighten the screws crosswise. Tighten to 25 Nm .

REMOVING THE TOOLS

Screw out the center screw. Remove the compression tool.

Note. Applies only to certain engine versions with self adjusting clutches: Keep fingers away from the three clutch rivets when relieving a load or removing the compression tool. There is a risk of clamping injuries.

Applies to all clutch versions

Remove the hooks. Remove the counterhold.

Remove the centering cone from the clutch driven plate.

Remove the socket. Tap the centering tool lightly with a rubber mallet so that the expander releases. Use a rubber mallet so that the threads are not damaged. Remove the centering tool.

Remove the flywheel gear sector.

Note. Installing the gearbox: To install the transmission, see TRANSMISSION - REMOVAL, REPLACEMENT AND INSTALLATION .

Install

1. engine cable harness, note the position of the connectors
2. manifold, see: «EXHAUST MANIFOLD/GASKET, CYLINDER 1, 3, 5 AND 7 (BANK 1), REPLACING»(ref-476768-S21666858272012060500000)
3. manifold, see: «EXHAUST MANIFOLD/GASKET, CYLINDER 2, 4, 6 AND 8 (BANK 2), REPLACING»(ref-476768-S03971953522012060500000)
4. the alternator, see: «GENERATOR (GEN), REPLACEMENT»(ref-476783-S17337479832012060500000) .

Remove the following items

1. Gasket, inner timing cover, see «GASKET, INNER TIMING COVER»(ref-476775-S14200769632012060500000)
2. alternator, see «ALTERNATOR AND REGULATOR - REMOVAL, REPLACEMENT AND INSTALLATION»(ref-476783)

see 9995670

see 9997315

Scheme 754

Use: Chemical gasket, 1161771

Scheme 755

Use: Chemical gasket, 1161771

see 9997316

Scheme 756

Note. Only tighten the bolt finger tight at this stage.

Scheme 757

1. Use: Thread sealant, 1161056

Torque: Gear housing

Stage 1: 10 Nm

Stage 2: 24 Nm

Install the following items

1. alternator, see «ALTERNATOR AND REGULATOR - REMOVAL, REPLACEMENT AND INSTALLATION»(ref-476783)
2. Gasket, inner timing cover, see «GASKET, INNER TIMING COVER»(ref-476775-S14200769632012060500000)