Haha, more cool volvo electronics are in the works. Later though..
First the results of today's work. :)
After asking around a bit, I decided to take off at least one piston ring to check the clearance.
Mahle states that the rings have been pre gapped to the correct size so you should be able to install them.
Measuring them, they came up fine for the 350-400 hp range I'm shooting for.
Then came the time to line everything up to prepare for assembly:
I weighed them again, and again 2 of the piston rod assemblies where ~1 gram lighter than the others.
I put them in position 2 and 4.
To install them, the big end bearing caps have to come off, and that turned out to be a bit of a challenge.
After trying to pull them off for a while, to no avail, we had to come up with a different tactic.
In the end I put some cloth over the handle of a hammer and inserted it through the big end.
Then I screwed the big end bolts in leaving them slightly proud of the hole.
After tapping the bolts lightly with a small hammer, the caps came free:
You have to make sure you put the caps back on in the same orientation as they came off.
Installing them rotated 180 degrees would be disastrous.
Luckely the serial number is stamped on the same side on both the cap, and the conrod, so that can be used as a marker.
Then we proceeded to install them into the block.
I didn't take any photo's of the process, as we were concentrating on not making any mistakes. Especially the first piston took some trying to get it all right.
In the end the process was as following:
-With the block upright, put the crank at bdc.
-Clean bearing races of the big end very thouroughly
-Use oil to lubricate the piston, the bore, and the piston ring tool. Also wet the piston rings with oil.
-Put piston into tool, and tighten the tool until the piston rings are compressed enough to fit in the bore.
-Make sure the tool is square, and put it on top of the bore.
-Make sure the piston is oriented correctly, with the arrow pointing to the timing belt side of the engine.
-Use wooden handle of a hammer to gently tap the piston into the bore
-Push the piston in far enough so the big end bearing can be installed (rotate crank to make a little more room if required).
-Make sure the bearing races, and the backs of both bearings are spotless.
-insert the bearing shells. Mine where marked at one side, I made sure that the marks of both the bearings where pointing at the timing belt side of the engine.
-lubricate the top bearing shell, and push the conrod into position on the crank, with the crank again at bdc.
-lubricate the bottom bearing shell, and insert it into the bearing cap.
-place the bearing cap on the crank, completing the big end. Make sure it is oriented correctly with respect to the conrod.
-Put some arp assembly grease on both the threads, and the bottom of the head of the arp 2000 bolts.
-Screw the bolts in finger tight.
-In my case (lacking a stretch meter) torque them down to 55 lb/ft, which is 75 nm.
Rinse and repeat.
We managed to get 3 pistons in today, the rest will follow later on: