Volvo Engine Teardown Reveals How Time And Use Affects Precision Components

[ad_1]

For engine teardown enthusiasts, today we bring you a particularly intriguing case as we delve into the inner workings of a B4204 T11 Volvo engine. Originating from a 2015 XC60 T5, although this configuration can also be found in models such as the S60 and the V70, this engine bears a curious nomenclature chosen by its manufacturers. Despite being labeled a T5, it features a 2.0-liter four-cylinder engine that is turbocharged and direct-injected. It delivers a total output of 240 horsepower and 258 pound-feet of torque.




With meticulous attention to detail, Eric from the I Do Cars YouTube channel embarked on a full teardown of this Volvo engine after numerous requests from his audience. This particular engine has clocked 101,683 miles, a number he obtained based on the VIN number used to extract data from a Carfax report. It’s worth noting that this engine has a significant backstory as it was replaced at a dealership after it was deemed unfit for use.

Today, we embark on a journey to unveil the reasons behind this engine’s condemnation by the dealership. We’ll discover that there are cases where improper maintenance, lack of attention to warning signs, and simply the passage of time can lead to the premature degradation of the engine far sooner than expected.

In order to give you the most up-to-date and accurate information possible, the data used to compile this article was sourced from various manufacturer websites and other authoritative sources, including I Do Cars and Volvo.


Related
Toyota Engineer Shares What Makes The Four-Cylinder Tacoma Engine So Reliable

Sheldon Brown, chief engineer for the 2024 Toyota Tacoma, explains why the iForce I4 engine continues to maintain Toyota’s emblematic reliability.

Thin Traces Of Silver Paste In The Channels Of The Cylinder Head Indicate Bearing Wear

When carrying out the teardown, Eric started entirely from scratch, systematically disassembling the engine part by part in order to fully reveal the causes behind its destruction, and there are several topics to discuss.

First and foremost, there’s a need to delve into the rod bearings, critical components within an engine. Their primary function is to provide a smooth, low-friction support point for the movement of the engine’s connecting rods, which link the pistons to the crankshaft. These bearings are designed to withstand extreme loads and rotational speeds while maintaining a smooth, wear-free contact surface.


All Rod Bearings Are In A Heavily Worn State, With Little Material Left

When referring to rod bearing failure, you may immediately think about a sudden and catastrophic engine destruction without warning. However, in some other cases, bearing failure can occur gradually over time, allowing an engine to continue running for thousands of miles before the eventual failure. This is precisely the scenario that unfolded with this Volvo engine.

Starting from the ones corresponding to the first cylinder, which are the ones in the “best” condition, though still unsatisfactory, and progressing to the ones corresponding to the second cylinder, which are worse, we arrive at those belonging to the third cylinder.


Cylinder 3’s rod bearings exhibit significant wear across the board, as evidenced by their spun and heavily worn condition, nearly depleted to nothing. They can’t even be properly analyzed because they are fused to the rod. This situation is unusual; typically, when bearings spin, they become fused to the crankshaft. However, in this case, they are welded to the rod, a fact that suggests that they have undergone multiple revolutions, as indicated by the discoloration present in the rod.

Finally, we arrive at the rod bearings corresponding to the fourth cylinder, which are remarkably thin, almost resembling razor blades. They barely look like bearings anymore due to the incredible wear they have endured.

The Presence Of A Thin Silver Paste Layer Is An Indicative Of Poor Lubrication

Volvo Engine Teardown
I Do Cars via Youtube


Proper lubrication is crucial for the optimal functioning of rod bearings, as it aids in reducing friction and wear between the connecting rod and the crankshaft. This is achieved through the continuous supply of lubricating oil via the engine’s lubrication system, which clearly didn’t occur here.

An easy way to detect insufficient lubrication is by observing the thin layer of silver paste in the recesses of the cylinder head uncovered by Eric, which starkly indicates significant bearing wear.

Additionally, upon removing the oil pan from the block, Eric discovers more of this metallic residue. Based on the theory that this engine likely operated for a considerable period before reaching failure, there was ample time for the bearing material to degrade and wreak havoc on the engine’s components.


Eventually, the bearings reached a breaking point, succumbing to failure and spinning on the crankshaft, and even atop each other, as seen in the case of the third cylinder, resulting in irreparable damage to the engine.

Related
Engine Tear-Down Reveals What Makes The Chevy LS7 Crate Engine So Special

One of the most powerful naturally aspirated V-8 engines on the planet is also one of the most versatile, and this teardown proves it.

Undersized And Clogged: Inadequate Oil Control Rings Fail To Ensure Proper Lubrication

Volvo Engine Teardown
I Do Cars via Youtube

They Appear To Be The Actual Cause Of The Engine Failure

While the rod bearings proved to be a concern, upon further detailed inspection, the primary suspect behind the final blow appears to be the oil control rings. According to Eric, these tiny components seem ill-suited for the task at hand, and he jokingly remarks that one could argue that even a paperclip might perform a better job.


Despite all the compression rings functioning properly and showing no signs of sticking, the oil rings are noticeably undersized, inadequate for ensuring proper lubrication and oil control within the engine, and even appear to be clogged. Based on this observation, they seem to be the true culprit behind the engine failure due to insufficient lubrication, as they were unable to seal the combustion chamber and maintain the lubricating oil where it was needed.

Noticeable Carbon Accumulation Is Visible On The Piston Sidewalls

This observation is further supported by the significant carbon buildup evident on the sides of the pistons. However, it could also be argued that this is not unusual for a direct-injection engine with this mileage.

Furthermore, one could assume that the quality of the fuel used may not have been adequate, or that the oil was not changed regularly, leading to the accumulation of dirt and residue. Nevertheless, the extent of this carbon buildup suggests that this issue may have persisted for an extended period without detection.

Despite The Dirtiness, There Are No Indications Of Severe Damage

Additionally, the second cylinder presents a concerning level of contamination. A piston retrieved from this cylinder displays visible signs of dirtiness, likely due to contact with the cylinder head.


Despite the presence of shiny spots indicative of such contact, the piston itself remains structurally intact with no visible damage or cracks. Moreover, there are minimal signs of skirt wear, with no noticeable gouges or grooves present. Similar observations are made with regard to the other pistons examined. Although there is some wear on the piston skirts, it is not excessive, and there are no indications of severe damage.

Related
This Time Lapse Porsche Flat-6 Teardown is Pure Gear Head Therapy

Many Surfaces Showed Signs Of Both Rusting And Wearing Over Time

Volvo Engine Teardown
I Do Cars via Youtube

Another detail worth noting is the amount of rust found in various parts of the engine. The first sighting of rust occurred on the intake valves, and they didn’t look good. Eric also found them excessively dirty, but given that we’re dealing with a direct-injected engine, this can be somewhat understandable.


Presence Of Water In The Coolant Pipe Might Explain The Rust Found On The Intake Valves

This observation was made early in the process. As the teardown progressed and the turbocharger was being moved, Eric noticed something peculiar about the coolant pipe. Upon lifting it, he couldn’t shake the suspicion that there might be water trapped inside. Sure enough, upon turning it over, water unexpectedly began to trickle out.

The presence of water in the coolant pipe would certainly explain the rust found on the intake valves. However, this discovery puzzled him further because this pipe was part of the exhaust system.

It’s Possible That The Engine Was Left Outside, Potentially Exposed To Rain

Moving on to the cylinders, it was also discovered that there was rust in each of them, along with the pistons being covered in a lot of debris. Upon analyzing each one individually, it was observed that, in the third cylinder, the piston had definitely made contact with the cylinder head, resulting in clean spots. A similar pattern was noted in the fourth cylinder, with numerous rusticles present.


Continuing with the process, clean spots were observed on the combustion chamber, indicating that water had been present in the engine for quite some time. This confirms the previous theory that the engine was likely stored outside, possibly exposed to rain. However, Eric does not believe that this directly contributed to the failure but rather occurred after the fact.

Related
10 Cars That Had A V4 Engine, Ranked By Horsepower

From old-school classics to modern hybrid race cars, here are some of the rarest and most unique models to feature a V4 engine.

Ultimate Verdict: Main Cause Behind The Failure And Simple Strategies To Avoid It

Volvo Engine Teardown
I Do Cars via Youtube

After completing the teardown and highlighting each of the most important and relevant points, Eric expressed confidence in his understanding of why this engine had to be replaced prematurely.


The Engine Under Analysis Displays All The Indicators Of Having Undergone Severe Oil Starvation

As he explains, he’s come across multiple sources indicating that many Volvo engines from this era, particularly the four-cylinders, are prone to oil burning. This becomes evident when inspecting the spark plugs and the tops of the pistons, especially upon removing the pistons and observing the thin oil control rings. While Eric dislikes seeing such issues, manufacturers often resort to using these thin, low-tension rings for fuel efficiency. They are compelled to meet certain standards or face penalties per vehicle sold, prompting them to employ sometimes unconventional measures to comply.

Unfortunately, this often comes at the expense of those who neglect basic maintenance tasks, such as checking oil levels regularly. They remain reactive rather than proactive, driving their vehicles until they fail.

According to Eric, with proper maintenance and keeping the oil topped up, it’s possible to prevent such issues, even if the engine burns oil for up to 150,000 miles. The main casualties in this scenario are typically the spark plugs and converters, both costly to replace.


The specimen analyzed bears all the hallmarks of having suffered severe oil starvation, resulting in damage throughout the entire oiling system. This must definitely have been unfortunate for the owner because this engine is quite expensive to replace. Let’s hope that the warranty covered it!

Regular Maintenance Is Key To Ensuring Longevity And Reliability

It can be concluded that the Volvo engine did not receive adequate maintenance, as reflected in the numerous problems encountered throughout the process.

The owner of this Volvo failed to maintain the engine oil level properly, leading to insufficient lubrication and eventual excessive wear of engine components such as bearings, connecting rods, and pistons. This resulted in a series of serious issues, including oil ring wear, leading to oil burning and sediment buildup in the engine.

This serves as an example to exercise greater care when operating your vehicle. Regular maintenance, including oil and filter changes, will ensure proper lubrication, as well as periodically checking the engine oil level and ensuring it remains within the recommended range (once a month or before long trips).


Moreover, other precautions can be taken, such as conducting regular visual inspections of the engine for oil leaks, signs of corrosion or oxidation, and any other indications of problems. Additionally, practicing careful driving, avoiding sudden accelerations and abrupt braking, can reduce engine wear and the likelihood of lubrication issues.

[ad_2]

Source link

Leave a Comment

Ads Blocker Image Powered by Code Help Pro

Ads Blocker Detected!!!

We have detected that you are using extensions to block ads. Please support us by disabling these ads blocker.

Powered By
100% Free SEO Tools - Tool Kits PRO