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.

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

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.

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

Short block progresses , installed new Pistons and rings.

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

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.

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

Volvo S40 2.4 Engine

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