Engine assembling Volvo B18 and Volvo B20

A total of four engine blocks have been built. Three B20ís drilled to OD 0.030Ē and one B18 to 0,020Ē dimension.

Cam bearings, as well as the oil pump / distributor brass bushing (p/n 418251) have been replaced.

Click at the picture for an enlargement!

Part 1 & 2 in our series engine assembling - May 2016

The bushing needs to be reamed to the proper 12 mm dimension after installation. All connecting rods are also reconditioned.

New bushings (p/n 418295) have been installed in the small end. Som special tools are required to remove and install these bushings.

Once installed, the bushings needs to be reamed to the proper size. This procedure, along with honing the large end, is best done at a proper engine shop.

Step 1

Clean the block

First step is cleaning the block and all its channels properly to remove any debris or granule left from the machining of the block.

Clean and install fitting, art.nr 418416, which lubes the timing gears.

Step 2

Install the cam shaft

Several grinds are available. From these ones we built, two were equipped with A-cam, p/n 460490, the other two with K-cams, p/n 1218581. First, apply molybdene grease to all cam lobes to protect while breaking in the cam.

The same paste will later be used on the lifters when the time to install those have come. Cam bearings could be lubed at this time as well, with engine oil or assembly grease, art.nr V903.
Which one to use is depending on how long it will take until the engine is started.

Carefully insert the cam shaft in the engine to avoid damages to the bearings. Once itís in place, install spacer, p/n 418363, and the thrust flange. Reusing the old flange is usually OK simply by flipping it over as it only wears down on the inside. Assuming of course that this hasnít already been done in the past.

When securing the flange, one should always use bolts with lock washer, p/n 418422, or apply a little bit of Loctite adhesive. Never use the lock washers more than once!

Step 3

Install the crank shaft

Start by installing the bearings, thereafter apply engine oil or assembly grease to them.

Clean the cups properly before inserting the bearings. We used ACL aluminum bearings, p/n 271215-ACL.

Carefully clean the crank shaft, especially in all oil channels, and then put it in place in the engine.

Put the caps in place, and tighten them to the specified torque (12-13 Kgm).

Do this operation in three steps, making sure the crank rotates freely after each tightning.

Step 4
Mount timing gears

The engines with A-camshaft gets timing gears in fibre/steel, art.nr 270690, and the two engines with K-cam gets timing gears in aluminum/steel p/n 270690AL.

First mount the crank gear. Heat it up a little bit to make it easier to slide it on to the crank. A hotplate works fine.

While you heat up the gear you can mount the index key, p/n 910123 and the index key in the camshaft, p/n 910118. When the gear is hot enough, just slide it on to the crank with the marking facing outwards. If it wasnít hot enough you might have to use a hammer and carefully hit it to make sure itís all the way in. NB! Knock carefully!

Then itís time for the cam gear. Also this gear could use some heat but not like the crank gear. Especially if you use the fibre gear. Easiest is to use a hot air gun.

Mount the cam gear so the marks line up and push it in as far as you can by hand. Then mount the nut p/n 150169 and screw in the gear.

NB! Never use a hammer to mount the cam gear.Finish the job by torque the nut to 13-15 Kgm. Use a plank and put it between the block and crank to avoid the engine from turning over while fastening the nut.

Step 5 A
Assembly piston (p/n 275194-X for the B18 and p/n 272004-X for the B20)/rod and also assembly rod bearings and piston rings.

Remove the cap from the rod. While these have been machined the cap bolts are torqued and itís important to fasten them in a proper way while loosening the nuts to avoid bending the rod.

Mount the bearings in their position.

NB! Dry clean before positioning the bearing. Here we used ACL art.nr 271052-ACL.