Now the crankshaft was finally back in the block it was time to fit the pistons back in the cylinders. Just carefully put the piston rod in the cylinder, squeeze the piston rings and push the piston back in the cylinder bore.
I've done that a dozen times with bike engines (mainly Honda's and a couple of Kawa's) but this time something went wrong. While putting the pistons and rings back in the cylinders with a piston ring compressor I got a phone call. After that I just tried to push the piston back in the bore. But in the meantime the middle piston ring got out of the claws of the compressor and when I pushed the piston ... it broke..(of course stupid...).
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| Broken piston ring Volvo 122s 0.030" |
Today the new piston ring came in the mail :). I only needed to fit the second one, so first I took out the top ring. I used an old trick to fit the piston rings; take 4 feeler gauge blades and fit them with a rubber band around the piston. Then slide the ring over blades on the piston.
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Fitting piston rings with an old trick -
using feeler gauge blades and a rubber band |
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| Fitting piston ring using feeler gauge blades |
Now it was time to fit the shell bearings to the rod and cap and put the pistons back in the engine. I used assembly lube on the shell bearings before connecting them to the crankshaft and cleaned the bearings with alcohol to remove all the protective grease. Don't use lube between the shell bearing and rod!
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| Piston rod and cap with new shell bearings |
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| Tighten the bolts of the piston rods to a torque of 45 Newton-meter |
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| 3 of 4 Pistons back in engine Volvo 122S B20B |
Whe all the pistons were back in the cylinders I tested if everything was alright by turning the crankshaft. All good and smooth.
Testing the crankshaft and pistons after reassembling
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