Engine - In-Car Piston Replacement
S60/V70 (01-)/V70 XC (01-)/S801999-
Section
2
Group
21
No.
0040
Year
03
Month
04
Pistons, replacing
Background
This method describes how to replace the pistons with the engine in the car.
Special Tools Required
Description P/N
Engine Lifting Hook (used with 9995716, See Special Tool 9995460
Bulletin 71 and 114)
Lifting Beam (See Special Tool Bulletin 114) 9995716
Piston Holder (Suggested, available from SPX) 9995746
Piston Ring Compressor Generic
Cylinder liner and piston
Piston, replacement
1
Ensure that necessary special tools are available to carry out
this work. Attention to detail and cleanliness is required
to ensure proper repair
2
Removing the oil sump
Remove the oil sump, see VADIS:
Repair and Installation
Function group 21
Oil sump, replace
S80 6cyl. automatic: After oil sump has been removed lift the
transmission jack. Hand tighten the four subframe mounting
screws. Remove the lifting hook 999 5460 and lifting yoke
999 5716.
3
Removing the cylinder head
All variants:
Remove the cylinder head, see VADIS:
Installation Function
Function group 21
Replacing the cylinder head/gasket.
4
Removing the pistons
Note!
On later version engines the connecting rod and the end cap
mating surfaces are aligned by a dedicated fracture surface. Note the
markings on the connecting rod and the end caps
and the direction in which they are installed, forward,
rearward, left, right.
On earlier version engines the connecting rod and end cap mating
surfaces are aligned by serrations. NOT all connecting rods and
end caps may be marked as described above. If markings are in place
then note location as described above. If NO markings exist stamp
or etch the appropriate cylinder number on each all facing the
same direction.
Turn the crankshaft to bottom dead center to access the two
connecting rod cap bolts.
Remove the end cap bolts.
5
Carefully press the pistons upwards. Use special tool 999 5746.
Ensure that the connecting rod and end cap is marked as
described previously.
Remove the remaining connecting rods and pistons in the
same manner.
Check for vertical abrasions or other damage in the cylinder liner.
6
Removing the piston from the connecting rod
Note the direction of the arrow on top of the piston in relationship to the markings on the connecting rod and end cap. Arrow location may vary from that shown in the illustration.
Remove the circlips and press out the wrist pin. Clean the connecting rods and bearing caps before installing new pistons.
Warning!
The circlips can easily spring out. Wear appropriate eye protection when removing circlips.
Note the piston classification for each cylinder and
on each piston (A). The cylinder classification is etched
into the cylinder block deck in the right rear.
The arrows should always point at the timing belt transmission.
7
Installing the piston rings
Note!
The new pistons must have the same classification as the replaced pistons for each cylinder
Use piston ring pliers.
Turn the piston rings so that the piston ring gaps are positioned as illustrated.
A = Compression ring. The text on the piston ring faces upwards.
B = Scraper ring. Bevelling facing downwards
C = Oil ring Separated three ways equilaterally
Caution
Ensure that the piston rings freely in the piston ring grooves.
Note!
The position of the rings is on can result in high oil consumption.
8
Assembling the pistons and connecting rods
Note the location of the arrow on top of the piston and the markings on the connecting rod and end cap. Install the piston with the arrow in the same relationship to the markings as when disassembled in step 6.
Assemble the connecting rod and the piston using the new wrist pin supplied with the piston. The wrist pin should slide through the connecting rod small end bearing with light thumb pressure.
Press in the wrist pin by hand.
Check the class of each cylinder/piston diameter. Check that any markings / numbering of the connecting rods correspond.
Install both circlips for the wrist pin. Check that the circlips are correctly positioned in the piston. The gap must be vertical.
The circlips can easily spring out off. Wear appropriate eye protection when installing circlips.
Wipe clean the bearing recess in the connecting rod and cap.
Install new bearing shells.
9
Installing the pistons in the cylinder bores
Using a piston ring compressor install piston and connecting rod assembly. Follow manufactures recommended procedures for proper use of ring compressor
Lubricate the cylinder bore, the pistons and the bearing shells with engine oil.
Turn the crankshaft so the connecting rod is at bottom dead center for the cylinder piston.
Note!
The arrow on top of the piston should point forward. Ensure that the classification corresponds.
Carefully press / tap the piston downwards (using a hammer handle).
When the piston dears the ring compressor and is at head surface level stop. Put ring compressor aside. Install holder 999 5746 in the connecting rod.
Pull the connecting rod downwards until it lies against the crankshaft connecting rod bearing journals. Remove 999 5746.
10
Tightening the cap for the connecting rod!
Install the end cap. Check that markings correspond. On late types of connecting rods the mating surface between the cap and the connecting rod are not machined. It is aligned through a dedicated fracture surface.
Earlier types have serrated surfaces that only align one way.
Caution!
If the cap is turned the wrong way and tightened, the structure of the fracture surface will be damaged and the connecting rod must then be discarded.
Blow the fracture surfaces of the connecting rod and end cap clean using compressed air before installing the cap.
Lubricate and install the new screws. Tighten in two stages
1 20 Nm
2 Angle-tighten 90°
Check that the connecting rod can be moved laterally
The crankshaft must not be rotated before the connecting rod cap has been tightened
11
Installing the cylinder head
Install the cylinder head, see VADIS:
Repair and Installation
Function group 21
Replacing the cylinder head/gasket.
12
Installing the oil sump
Install the oil sump, see VADIS;
Repair and Installation
Function group 21
Oil sump, replace
S80 6 cyl. automatic:
After cylinder head has been installed reinstall the lifting hook 999 5460 and lifting yoke 999 5716. Remove the screws on the left-hand side of the sub-frame.
Lower the left-hand side of the sub-frame.
13
Topping up
Top up the oil and coolant.
Run the engine to operating temperature.
Check coolant and oil levels.
Check for leakage
WARRANTY STATEMENT: Claims may be submitted under the New Car Warranty when there is a documented customer complaint, using claim type 01.