Nevada1906 1995 850 S60R m56 build thread

[Nevada1906]

I really don’t know but dissimilar metals in hot conductive Electrolyte can create a battery of potential problems

This is the same reason you do not want to use a galvanized pipe in a copper or brass piping system. It may take years, but a leak will form.
volvolugnut

Here's a thought: I could get three feet of 1/4" steel brake line and a tubing bender. I've already made the template for the line.

[volvolugnut]

The 0.25 brake line would be much smaller area than the original tube size. That might be a problem on the water side especially. Could you get larger (0.5 ?) tubing in steel or aluminum that you can bend?

I did like the idea of the natural finish copper line looks. Sort of steam punk.

volvolugnut

[Nevada1906]

The 0.25 brake line would be much smaller area than the original tube size. That might be a problem on the water side especially. Could you get larger (0.5 ?) tubing in steel or aluminum that you can bend?

I did like the idea of the natural finish copper line looks. Sort of steam punk.

volvolugnut

That's not a bad idea. Off to the McMaster-Carr catalog...

[volvolugnut]

This tubing may be a good choice for forming. I am not sure.
https://www.mcmaster.com/tubing/aluminu ... m-tubes-7/

volvolugnut

[Nevada1906]

Haven't posted any updates for a while - had some more pressing things come up.

I installed the new front cam seals and the o-rings for the CVVT hubs.

And now I've hit a snag: timing the hubs.

I have a factory service manual for the 2001-2009 S60, but it doesn't seem to have a section for timing CVVT hubs. It's mostly OBD trouble codes - by year - and electrical diagnostic instructions. I've downloaded, read through and re-read through F250's PDF on the subject on this site. I've watched every YouTube video I could find on the subject (amazing how many people have the exhaust-only VVT engine), and I'm stuck.

Is there JUST NOT a simple, straightforward way to properly install the CVVT hubs?

Something like:
1: Slide the hub onto the camshaft.
2: Loosen the gear retaining bolts on the hub.
3: Rotate the hub clockwise until the retaining bolts hit the ends of their slots.
4: Tighten them back down.
5: Rotate each hub & gear until the timing mark on the gear lines up with the notch on the upper cover.
6: Torque the hub center bolt down.
7: Do that for both, then install the timing belt by starting from the crank gear and feeding the belt counterclockwise around the pulleys.
8: Tighten the tensioner.

Are the hubs just SUPPOSED to be a pain in the ass to install? Because if that's the case, it raises another question: who the hell designs an engine to be difficult to service correctly?

I mean, besides Ferrari.

[Nevada1906]

I think I figured out how to to reinstall the CVVT hubs.

When I bought the engine, it arrived with the hubs in this position. While these pictures are from yesterday, they show the hubs as they'd been on the engine since it's last timing belt job.

My thinking was that they were already timed correctly as they were, so all I had to do was make sure the gears were phased to the hubs as they had been and line up the gear marks with the cover notches. That part was easy because the bolts left nice bright tool marks on the gears. I reinstalled the hubs, installed the belt, spun the engine with a breaker bar about 10 times to make sure nothing hit, and all the timing marks still lined up.

After that, I installed the cover, serpentine belt, cam triggers and CPS housings.

You can see how the exhaust CPS housing interferes with the upper mount. The area marked in silver Sharpie has to be cut away and a new extension added. Why wouldn't I just use the S60R upper mount? Frankly, I hate the way it looks. And equally frankly, if I wanted an easy project I wouldn't be building a Volvo

I also yanked the copper pipe and the hose clamps. I have Oetikers on the way and I'll be fabricating a new aluminum pipe.

So there it is. Just needs mounts and it can go in the car.

[Sveedy]

Nice ! So clean you could eat off it.
So high up do you have the car in order to do this install ?

[bmdubya1198]

The VVT gears are pretty easy to set up. You just need to make sure the mark is lined up with the gear at its clockwise limit.

[Nevada1906]

Nice ! So clean you could eat off it.
So high up do you have the car in order to do this install ?

The car's up on jackstands. After I get the subframe back in, I'll put the engine in through the top. I've seen how you're "supposed" to install the engine & transmission to the subframe and then drop the car on top of it, but I'm just reversing the removal sequence. My lift has just enough travel to do it, though it does require a load leveler and a bunch of gynmastics to get everything in.

I totally get why 5-cylinder FWD cars are a rarity. The long engine in there sideways makes them basically the cartoon bulldog in the 1940's tough-guy turtleneck.

faf9f6f7e0be91b1a52acad9a947bfd6.jpg (36.01 KiB) Viewed 380 times

[Nevada1906]

The VVT gears are pretty easy to set up. You just need to make sure the mark is lined up with the gear at its clockwise limit.

I tried that at first. Then I thought about the video the junkyard posted its website of the car this engine came out of driving around the lot and figured the hubs were properly phased when I got it. So I just put everything back together.