Techs or DIYers: HELP needed putting together a B8444S

[agent008]

Hello there.

I've joined this forum a couple months ago, as the desire of owning a B8444S-powered prototype took over me.

Searched high and low for information on the engine (which is scarce making it all the more fun) and found a few brave souls dealing with adapting this V8 - for example Alex and Karl Buchka with their 242 "fake racecar" (their own name to it) project.

After a while I found the courage to buy a fairly cheap(for Brazil at least) B8444S. With the caveat that it is completely pulled apart. Everything seems to be OK with the exception of a bent conrod, broken piston and scratched cylinder - seems the engine had a taste of water and didn't feel very well after!

Anyway, the block will be rebored and honed, the conrod will be replaced and a set of 0.4mm oversized pistons will be custom-made. With that the damage it suffered will be fixed.

What is bothering me is that we have no idea on how to set the engine's timing. The heads were already taken apart when I got it so all we have now is this big puzzle of metal parts, putting it all together is not so much the difficulty, but we have no tools to pin the camshafts and the crank, and no reference to set them on the right positions.

The service manual (as per alldataDIY.com) calls for several special tools, however after much searching I could only find for sale the following:

* 9997235 "position setter" - seems to be used for turning the crank while setting the timing
* 9997236 "position setter" - used to lock the cams in the right position

The B8444S has a total of 3 timing chains - 1 main timing chain and 1 in-head chain for each cylinder bank (they link the intake cams to their respective exhaust cams which in turn are linked to the crankshaft sprocket via the main timing chain), and I need to put all of them back together and in sync...

The procedure outlined on the manual is fairly simple,although the text is not very detailed so I'm left to wonder whether I'm not missing anything and if these are the only tools neded to set this engine's correct timing?

Is anyone able to tell me whether these two tools would be enough to put the engine in sync? Or are other tools needed, if so which ones and are they available for non-dealers..?

Thanks

[agent008]

Some images from the manual about the use of both tools:

[agent008]

Just as a follow up, I got this answered on another Volvo forum and think it'd be good to share here for future reference.

qaz996 said: 07-09-2017 09:12 PM

Quote Originally Posted by agent008 View Post

If I understood correctly - all I need to do is align the crankshaft with the "lever/wrench" tool (first picture below) and the cams with the "locking plates" (second picture). Then align the in-head chains - yellow marks with dots on the cams, and the main chain - orange mark with the dot on the crank, yellow marks with the cams & balance shaft?





Yes, you've got it.

The chains that connect the 2 cams in each head must be aligned with the camshafts loose (not installed). Once the 2 are timed together, install the tensioner between them and then fully install the camshafts.

You will install the "cam locking plates" from your second picture only when the camshafts are fully installed and right before you put the timing chain on.

You may already know, but it's worth noting: the camshafts are hollow and fragile. Be very careful installing them or they will break.

2007 S40 T5

[TestPoint]

Like most of the hollow hard cams they can even break if not tightened down very carefully and evenly. Quite a shock when you hear the "TING".

Rotate the cam to a position having the least pressure on the valve springs as you tighten it down.

[agent008]

Damn, why do ours have to be hollow? Anything to do with the oil pressure-controlled VVT gears?

Originally Posted by TestPoint

Like most of the hollow hard cams they can even break if not tightened down very carefully and evenly. Quite a shock when you hear the "TING".

Rotate the cam to a position having the least pressure on the valve springs as you tighten it down.

[agent008]

After sitting on the shop for more than 4 years, my B8444S is finally being put together.

Figured I'd post a few pictures of the process. I do intend to make note of all tolerances/gaps the mechanic has used (we had to figure them from similar engines since there isn't much info around for this engine).





The mechanic will weigh the piston+pin+rod assemblies both original and the new ones in order to calculate the weight difference. I fear that if the new ones are too much lighter than stock, some kind of modification will have to be done to the balance shaft.

EDIT: I had a hard time making the photos appear and don't seem to be able to resize them to a smaller size. Sorry and if anyone knows how to do that just tell me and I'll do it.

[Mr. V]

None of the photos of the engine which you seem to have posted are visible.

[agent008]

Originally Posted by Mr. V

None of the photos of the engine which you seem to have posted are visible.

Thanks and sorry, I really have forgotten how to post images to this forum.
One more try:













Hope it works now!

[Not Naturally Aspirated]

I'm interested.
What vehicle is it going in?

[agent008]

Originally in 2017 I wanted to install it into a Locost (Lotus/Caterham 7 DIY replica), however I haven't even got around to start building that car yet.

Last year I have bought a Pontiac Solstice with the base 2.4 4 cylinder engine and am considering trying to fit the B8444S into this car to make a modern take on the V8 roadster theme. Most/all Solstice V8 swaps use Chevrolet LS engines which are crazy expensive around here due to their rarity (and adaptability to any and all vehicles) in Brazil. Whereas the B8444S I bought it dirt cheap (compared to the local prices) with a hydrolocked bent rod and am now rebuilding.

[agent008]

Update, more photos fresh from the machine shop