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.

Volvo S40 head before rebuild — Cylinder head before rebuild.

Volvo 2.4i-cylinder head rinse — Hot tank 2007 Volvo S40 2.4i engine components

Valve measure Volvo s40 2.4 — Measuring clearances before valve job.

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

Volvo cleaned parts — Cleaned head and block

Hot tanked vovo S40 block — Engine block cleaned

Cylinder head volvo s40 — Valve job in progress.

Volvo S40 engine parts — Ready to rebuild

Volvo s40 oil pan and block — block and oil pan.

07 Volvo 2.4i block and pan — Block and oil pan.

volvo s40 2.4 block — 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.

Install bearings Volvo s40 — Short block assembly

2007 Volvo S40 2.4i engine bearings installed

Short block rebuild Volvo S40 — 07 Volvo S40 2.4i Short Block rebuild.

Volvo S40 2.4 crank — 07 Volvo S40 2.4i crankshaft

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

07 Volvo S40 2.4 head — 07 Volvo S40 2.4i cylinder head

Volvo S40 valve job — 07 Volvo S40 2.4i cylinder head.

Volvo cylinder head assembly — Cylinder head assembly

valve job volvo s40 — Valve Job in progress 07 Volvo S40 2.4i

Short block progresses , installed new Pistons and rings.

Volvo S40 short block rebuild — Volvo S40 2.4i short block rebuilding

Volvo S40 pistons — New pistons 07 Volvo S40 2.4i short block

bottom end volvo s40 2.4 — Bottom end rebuild Volvo S40

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

Long block rebuild components — 2007 Volvo S40 2.4i engine rebuilding

Long block Volvo S40 2.4i engine — Volvo S40 2.4i Long Block assembly

Volvo S40 timing — 2007 Volvo S40 2.4i timing belt and gears.

Remanufactured 2007 Volvo S40 2.4i long block engine.

07 volvo S40 2.4i timing gear marks — Timing marks on 2007 Volvo S40 2.4i engine

Lower gear timing marks Volvo S40 — 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.