Engine VOLVO XC60 D4 - Remanufactured

3. Cooling system

Optimal cooling of the engine is very important, especially during the run-in period when more heat is released than normal. The cooler should be checked, preferably by a specialist. Also check the fan, sensors and expansion vessels. The radiator hoses should be replaced if they have been damaged or become hard, also replace the hose clamps.

Coolant

Never fill the engine cooling system with water alone, but with a mixture of antifreeze and water. Use at least 30% antifreeze, this protects your cooling system from corrosion. Venting the cooling system: see the car's manual. Check the cooling system, preferably by pressing it.

The EGR cooler

Always make sure that the EGR cooler you are moving from the old engine is not defective. Test it to check that it is free of leakage. NOTE! Do not expose the EGR cooler to high pressure when you test it, it is easy to break it. We recommend that you preferably replace the EGR cooler with a new one to be on the safe side. If the EGR cooler is defective, it can cause water to enter the engine or pressure in the cooling system as a result of an overheated engine.

Thermostat

Always install a new thermostat.

Water

If the water pump is not supplied by the Nordic Motor Center, check wear of bearings and that there is no leakage or corrosion. Replace the pump if necessary.

Air-cooled system

Optimal cooling is very important, especially during the run-in period when more heat is released than normal. The air dampers in the fan housing and the rubber seals should be replaced if they have been damaged. The control system * / thermostat and dampers must work flawlessly. Also check that the cooling fan is free from dirt as this can affect the cooling capacity and balance of the engine.

* / In cases where it is mounted.

4. Fuel supply

If the fuel system does not perform optimally, the engine can be damaged. Too much fuel in relation to the air volume causes high fuel consumption but also damage and wear on the cylinders / pistons. Too little fuel in relation to the amount of air leads to high temperature, which in turn can cause overheating of the engine. A new fuel filter must always be fitted.

Air Filter

Always install a new air filter. A blocked air filter increases fuel consumption and can also damage the engine. Incorrect type of air filter or incorrectly fitted air filter can pass through dirt and dust, causing wear on pistons and bearings.

Exhaust system

The vehicle exhaust system and manifold must be checked so that there are no blockages as a result of previous engine failure. A common occurrence is that the catalyst melts and blocks the exhaust system, which causes engine damage.

Inlet manifold

Before installing the inlet maifolt, make sure that no dirt or metal metal chips are left since previous engine failure. Gently tap the suction tube and blow it clean with compressed air.

Intake Gasket

It is important that it becomes absolutely tight between the intake manifold and the cylinder head. Make sure there is no damage to the contact surfaces of the cylinder head and intake pipe, clean thoroughly. Tighten screws / nuts in proper order and tightening torque. A leaking intake gasket can cause incorrect fuel / air mixture, which can damage valves and pistons.

Fuel Filter

Always install a new fuel filter. The smallest particle of dirt can damage the injection pump or spreader. A blocked fuel filter reduces fuel pressure, resulting in incorrect fuel / air mixture, which can cause damage to the pistons as a result of overheating.

Fuel Pump

Make sure there are no cracks in the diaphragm in the fuel pump. If there are cracks in the membrane, the oil can be diluted with the fuel. It can damage the bearings.

Diesel Pump

If the diesel pump is not supplied by the Nordic Motor Center, it should be tested by a specialist. Set the timing of the diesel pump very carefully and according to the original manufacturer's specifications. Make sure the correct overflow valve is fitted. Incorrect overflow valve affects engine performance. Observe the greatest cleanliness when working with the diesel pump. At the first refueling we recommend that 1 liter of oil (SAE 20) is stored in the tank to prevent damage to the diesel equipment.

Fuel injection system adjustment

The fuel injection system must be checked and adjusted by a specialist. Inadequate performance may be due to the engine not getting enough fuel, injection pump failure, fuel pump failure or fuel pump setting.

Injection pipes system

Make sure there is no dirt in the pipes as this can damage the injectors. After installation and before starting the engine, make sure there is no air in the injection system. The injection pipes should be mounted so that they are not in tension, then they can go off due to fatigue. The pipes may only be blown clean with absolutely clean air.

Injectors

Before mounting the injectors, clean them thoroughly and check that the needle in the injectors not have seized. We recommend that you test the injectors to check the opening pressure and spray form.

Cold start valve

Check the opening time of the cold start valve. If the cold start valve opens too long, the oil is diluted, resulting in insufficient lubrication.

5. Ignition system

Set the ignition carefully. Incorrectly set ignition can cause damage to the pistons. Check all mechanical parts and that the diaphragm in the vacuum regulator is not damaged. Leakage must not occur. Check that the vacuum hose and the carburetor / injection connections have not been damaged. Always replace spark plugs. Never set the ignition on ear! Always use the equipment required. The control unit should be reset if required.

6. Crankcase ventilation system

Generally speaking, ventilation works via two lines. A coarse hose from crankcase / valve cover to an 'oil trap' and a thinner hose from 'oil trap' to the air cleaner / suction tube. Wires, connections and the 'oil trap' should be cleaned before removal. A blockage can cause excessive pressure in the crankcase, with oil leakage as a result. No part of the crankcase ventilation must be removed, it can cause fire in the crankcase. 

7. Exhaust system

The exhaust manifold and exhaust systems must be checked so that there are no blockages. Tex particles from the old broken engine that ended up in the exhaust pipe / catalytic converter should be removed. If the exhaust resistance is too great, the engine can overheat and the engine's performance also deteriorates.

8. Automatic gearbox

When mounting an automatic transmission, it is easy to make mistakes. Between the torque converter (the converter) and the oil pump, in the gearbox oil sump, there is a hollow shaft. This shaft usually loosens from the oil pump, so make sure the shaft is pressed in properly before installing the new gearbox.

9. Lubrication system

Oil filter

Always install a new oil filter. Change oil and oil filter after 1000 km, some engines require a filter with an overpressure valve, make sure to install the correct type of filter.

Oil

Use an oil that is recommended according to the car manufacturer's recommendation.

10. Run-in advice

Start-up

Before starting the engine after installation, check the following:

• That there is enough oil in the engine.

• All bolts and belts are tightened.

• The timing belt or chain is properly set and properly tensioned.

• That the cooling system is vented and filled with the right kind of coolant.

Drive around the engine on the starter (assuming the original manufacturer allows it) with the ignition cables removed from the spark plugs of a gasoline engine or the cables to the glow plugs removed on a diesel engine. Drive around the starter until the oil pressure lamp goes out and the correct oil pressure is reached. If you are uncertain if the correct oil pressure has been achieved, we recommend that you install an external oil pressure gauge so that you can see and can make sure that the correct oil pressure has been achieved. If the correct oil pressure is not achieved, fill the oil filter with oil and inject oil into the oil channel with an oil can to vent the oil system, try to run around on the starter motor again. Once you have ensured that the correct oil pressure has been reached, you can reconnect the spark plugs on the spark plugs or the cables to the glow plugs again and start the engine. Turn the engine directly up to 1500 rpm, check oil pressure and water temperature. Pay attention to idling. We do not recommend idling during the run-in period, as this can damage the engine. Adjust ignition and carburetor / injection according to original manufacturer's specifications. Check that there is no leakage of coolant or oil. When you air the cooling system, fill with coolant to the recommended level.

Recommendations for running in remanufactured engines

The engine should be runned in by driving the car on the road. Pay attention to idling. We do not recommend idling during the run-in period, as this can damage the engine.

Recommendations for running in remanufactured engines on the road:

• The engine must have reached its working temperature before loading.

• Load the engine 60-80% during the first 750-1000 km.

• The vehicle should not be overloaded or towed.

• Run the engine at varying speeds that do not exceed 2/3 of the maximum engine speed.

• Shift up at a fast pace when driving and avoid low speeds.

• Avoid high speeds, especially on high gears.

• Shift down in time, avoiding high loads at low rpm.

• Avoid prolonged uphill driving with excessive load.

• Avoid prolonged downhill driving (insufficient loading and unwanted overflow).

• Do not drive on motorways or at maximum speed.

• Avoid engine braking at high speeds.

• Avoid driving in congested heavy traffic. Driving on open roads and in free flowing city traffic is best. Always avoid driving in cities at extremely high temperatures and in rush hour traffic with frequent stops at traffic lights and traffic jams.

• Keep constant control of the oil level during the run-in phase, as the oil consumption may be higher during this period, and then decrease to normal level. It is advisable to check the oil level every 50-100 km and add oil if necessary. If there is a noticeable drop in oil level on the dipstick, continue to monitor at shorter intervals.

• Do not overfill the engine with oil.

• Change oil after 1000 km and - extremely important - change the oil filter as well. Use an oil that is recommended according to the car manufacturer's recommendations.

Otherwise, the engine must be serviced according to the car manufacturer's instructions.