07 Volvo S40 2.4i Engine Rebuild

2007 Volvo S40 2.4i Engine Rebuilding

On the menu this week, complete long block rebuild on a 2007 Volvo S40 2.4i engine.

The crank was twisted and it had 3 broken connecting rods.  Needless to say, it needed some machine services.  We dove right in, tearing it down and inspecting all the components.

I missed the initial teardown and inspection, but I caught a few pics of the cylinder head before we started the Valve Job. Hot tank rinse, clearance measurements and valve check before we proceed with the Valve Job.

Cylinder head before rebuild.

Hot tank 2007 Volvo S40 2.4i engine components

Measuring clearances before valve job.

Cleaned up all the engine components in preparation for the rebuild.

Cleaned head and block

Engine block cleaned

Valve job in progress.

Ready to rebuild

block and oil pan.

Block and oil pan.

2007 Volvo S40 2.4i engine block and oil pan.

Time to assemble the Short Block.

We had the Crank straightened out, ground and polished. Installing new Rod and Main bearings and dropping in the crank.

Short block assembly

2007 Volvo S40 2.4i engine bearings installed

07 Volvo S40 2.4i Short Block rebuild.

07 Volvo S40 2.4i crankshaft

Crank install

Assembling the cylinder head during the Valve Job.  We put in new Guides and Seals, Valve grind, surfaced, clean and assemble.

07 Volvo S40 2.4i cylinder head

07 Volvo S40 2.4i cylinder head.

Cylinder head assembly

Valve Job in progress 07 Volvo S40 2.4i

Short block progresses , installed new Pistons and rings.

Volvo S40 2.4i short block rebuilding

New pistons 07 Volvo S40 2.4i short block

Bottom end rebuild Volvo S40

Time to finish up and build the Volvo S40 2.4i Long Block

2007 Volvo S40 2.4i engine rebuilding

Volvo S40 2.4i Long Block assembly

2007 Volvo S40 2.4i timing belt and gears.

Remanufactured 2007 Volvo S40 2.4i long block engine.

07 volvo S40 2.4 timing specs

Timing marks on 2007 Volvo S40 2.4i engine

2007 Volvo S40 2.4i timing marks on lower gear

The long block is assembled, just needs the external parts, gaskets and covers.

Let’s recap. This engine had a twisted crank and some broken connecting rods.
We rebuilt it with new pistons, rings, gaskets, engine bearings,  and timing set.
Bore and honed the block, Valve job on cylinder head, cleaned, painted, and assembled the Long Block.

2007 Volvo S40 2.4i remanufactured engine

Fully assembled

Rebuilt Remanufactured 2007 Volvo S40 2.4i engine, ready to install.

There you have it, a Remanufactured 2007 Volvo S40 2.4i Long Block engine, ready to install.

Volvo S40 2.4 Engine

We no longer rebuild the Volvo engines.
Everyone still likes to see how we rebuild engines, so we leave up the post.

Thanks for looking!

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