Engine - Removal, Replacement and Installation (Convertible): Removal & Installation Volvo C70 I

Remove the gearbox cables from the levers on the gearbox

Remove

1. the locking for the inner cable. Pull it upwards
2. the cable from the bracket
3. the 2 screws for the bracket
4. the lever for the outer cable
5. the connector
6. the 2 screws for the cable harness clamps.

Tie up the cables.

Preparations for removal of the gearbox

See Installing fixture to mobile jack .

Cylinder head/gasket, replacement

Special tools

9995452

9995454

9995670

9995451

9512050

9512767

9995450

9995718

9995719

Note. Since the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Note. There are a number of versions of the VVT-unit (variable valve timing). Therefore it is extremely important to always read the information referring to the engine variant/model year to be remedied.

Intake manifold gasket, replacement

The new routing of the charge air pipe affects intake manifold gasket replacement on turbocharged engines.

The new routing has been implemented into production from

Remove

1. Battery negative lead.
2. Throttle pulley cover.
3. Throttle control cable.

Scheme 44

1. Ignition lead cover.
2. Upper hose ( A ) from cylinder head crankcase ventilation oil trap.

Scheme 45

1. Fuel rail cover.
2. Connectors and mountings from injectors.
3. Clamps (2) holding fuel lines.

Scheme 46

Early fuel rail

1. 5 clamps «9995533»(ref-403953-S08590781852011061000000) on the injectors.

Later fuel rail (with bayonet coupling)

1. 4 clamps «9995533»(ref-403953-S08590781852011061000000) and 1 clamp «9995620»(ref-403953-S00420925912011061000000) on the injectors. Position clamp «9995620»(ref-403953-S00420925912011061000000) closest to the fuel pressure line as illustrated below.

Press in the clamps so that they are in good contact with injectors.

1. Screw down adjustment screw so that the contact plate is in contact with the fuel rail, turn the screw another half turn.

Scheme 47

The Figure shows clamp 9995620 positioned closest to the fuel pressure line (late fuel rail).

Scheme 48

1. Vacuum hose from pressure regulator.
2. Screws holding fuel rail.
3. Lift the fuel rail twisting it carefully. Hook the middle injector behind the sealing molding, mounted on the draining channel.

Note. Handle injectors carefully so as not to damage fuel jets and fuel needles. Keep any rubber insulators in the intake manifold.

Scheme 49

1. Front air intake and inlet hose to the air cleaner (ACL).
2. Air duct to the control modules box.
3. Engine coolant fan (FC) screws (4).

Lift the upper air guide with the relay out of position.

Remove the two spacer washers located above.

Scheme 50

1. Charge air pipe between the intercooler (CAC) and hose on the throttle body (TB).
2. Two screws retaining the EVAP valve.
3. EVAP hose from the clips on the FC shroud.

Oil sump replacement

Special tools

9512767

Scheme 51

Remove

1. the oil dipstick and its pipe.
2. the splash guard under the engine.

Drain the engine oil and remove the oil filter.

Release the oil cooler from the sump. Hang up at the rear.

Remove the screw from the bracket for the fuel line.

See Oil sump replacement

See Oil sump replacement

See Oil sump replacement

Remove timing gear pulleys

1. Mark up timing gear pulleys: Both intake and exhaust.
2. Install camshaft adjustment tool «9995452»(ref-403953-S02369714572011061000000) at the rear edge of the camshafts.
3. Remove the screws for the timing gear pulleys.
4. Pull off timing gear pulleys.

Remove/install camshaft seal

1. Carefully press in tool «9995651»(ref-403953-S26733550812011061000000) between sealing ring and camshaft. Pry out seal.

Replace seal

1. Grease and install the new seal. Use drift «9995719»(ref-403953-S10206011822011061000000) to push it on.

Remove the engine coolant fan (FC)

1. Remove brake vacuum hose from intake.
2. Remove control module box air duct and air cleaner (ACL) intake air hose.
3. Remove connectors, relays and canister purge (CP) valve from fan shroud. Place wiring to one side.
4. Remove screws from fan shroud and relay holder mounting.
5. Lift relay holder.
6. Lift up engine cooling fan (FC) with cover.

Scheme 52

1. Remove starter motor mounting screws (x3). Place starter motor to one side.
2. Remove blind cover plug.
3. Turn the crankshaft slightly clockwise.
4. Install camshaft adjustment tool «9995451»(ref-403953-S26663901482011061000000) . Ensure that it reaches down as far as the cylinder block.
5. Carefully turn crankshaft counter-clockwise as far as it will go against the camshaft adjustment tool.
6. Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.

Scheme 53

1. Install the timing gear pulleys with two screws so that they precisely act on the pulleys. Then install the belt in the following order: Idler pulley. Intake cam pulley. Exhaust cam pulley. Water pump. Belt tensioner.
2. Tighten center screw on the camshaft belt tensioner to 5 Nm (3.7 lb.ft). Then install the belt in the following order: Idler pulley. Intake cam pulley. Exhaust cam pulley. Water pump. Belt tensioner.
3. Install new camshaft belt over crankshaft pulley wheel. Then install the belt in the following order: Idler pulley. Intake cam pulley. Exhaust cam pulley. Water pump. Belt tensioner.

Note. Adjust timing gear pulleys so that the screws are not at the limit positions in any of the oval holes.

Remove the rear camshaft seal

1. Carefully pull off the seal with extractor «9995919»(ref-403953-S08553537872011061000000) .

Scheme 54

Install new seal

1. Grease and install the new seal. Use drift «9995450»(ref-403953-S13227500462011061000000) . NOTE: The seal is normally positioned at the same level as the internal beveled edge. If the shaft journal is showing signs of wear, the seal can be pressed in 2 mm (0.079 in) deeper by turning the drift socket.

Remove parts at the engine's trailing edge

Remove

1. air filter housing with hoses.
2. camshaft sensor with trigger wheel.
3. torque arm with bracket.
4. the spark plugs. NOTE: Make sure that no impurities can fall down in the combustion compartment.

Remove timing gear pulley with variable valve timing unit. Applies to turbo engines.

1. Install camshaft adjustment tool «9995452»(ref-403953-S02369714572011061000000) at the rear of the camshafts. First screw in the part of the tool intended for the exhaust camshaft. Then carefully turn the exhaust camshaft clockwise with the tool until the intake camshaft tool can be installed.
2. Screw the camshaft adjustment tools together.
3. Remove the plug at the front edge of the variable valve timing unit (TORX 55).
4. Remove the center screw in the VVT-unit (TORX 55).
5. Carefully pull out the timing gear pulley with the VVT unit.
6. Timing gear pulley without VVT: Remove the screws and remove the timing belt pulley

Remove the timing belt pulleys. Applies to aspiration engine.

1. Mark up the timing belt pulleys. Inlet and exhaust, respectively.
2. Install camshaft adjustment tool «9995452»(ref-403953-S02369714572011061000000) at the rear of the camshafts. NOTE: The following applies to turbo engines: First screw in the part of the tool intended for the exhaust camshaft. Then carefully turn the exhaust camshaft clockwise with the tool until the intake camshaft tool can be installed.
3. Remove the screws.
4. Remove timing belt pulleys.

Scheme 55

Install

1. tool «9995454»(ref-403953-S30108818292011061000000) with 2-3 mm clearance to the camshaft cover. NOTE: Make sure that the screws in the spark plug wells are tightened all the way in.

Remove

1. all screws that hold the camshaft cover.
2. the camshaft cover with pliers «9995670»(ref-403953-S00526374942011061000000) by the snap-in lugs. Start with cylinder 1 and work alternately backward.
3. wing nuts approx. 2 turns. Repeat the procedure with the pliers.

Remove the tools.

Remove the camshaft cover.

Mark up and remove the camshafts.

Scheme 56

1. Remove the coolant pipe's both screws.
2. Loosen the cylinder head's screws, from the outside and in. As shown.
3. Remove the cylinder head.
4. Remove the cylinder head gasket.

Scheme 57

Clean

1. exhaust connections on manifold/cylinder head.
2. engine block's gasket face.
3. coolant pipe's gasket face.
4. gasket face between the cylinder head's top and bottom half.

Note. Use a soft putty knife and gasket solvent, if needed, part no.: 116 1440 . A metal scraper may not be used. A fume hood or extractor must be used when using gasket solvent. The surfaces must be completely clean .

Remove rear components

1. air filter housing with hoses
2. camshaft sensor with trigger wheel
3. distributor cap with wiring and rotor
4. torque arm with brackets

Remove upper half of the cylinder head

Install tool 9995453 (4 valve engine) or 9995508 (2 valve engine) to secure the front of the camshafts.

Install the tools 9995454 with a play of a few millimeters between them and the camshaft housing cover.

Slacken off the screws (from outside and in) from the upper half, remove all screws.

Disconnect the camshaft cover at the stop lugs with tool 9995670 . Start with cylinder 1 and work alternately backward.

Open and slacken off the tools 9995454 step by step so that parallel movement is ensured when removing camshaft housing cover.

Mark up and remove the camshafts.

Remove cylinder head

Remove the coolant pipe's two screws.

Loosen the cylinder head's screws, (from the outside and in).

Remove the cylinder head.

Remove the cylinder head gasket.

Remove the holding tools

Remove crankshaft adjustment tool ( 9995451 ) for the crankshaft and install the blind cover plug

Install the starter motor.

Remove the camshaft adjustment tool ( 9995452 ).

Scheme 58

Turn the engine crankshaft two turns.

Check that markings on the crankshaft and the timing gear pulley correspond.

Install the outer timing cover.

Remove the exhaust manifold and fuel rail

Remove

1. the exhaust pipe according to procedure «Replacing exhaust manifold»(ref-404035-S33164449652011061000000) .
2. the belt transmission according to procedure «Remove»(ref-404029-S24369847902011061000000) .

Lift up and put the fuel rail with injectors to one side. Use holder 9995533 , for the injectors.

Remove the two ground strips from the engine.

Remove

1. the engine cooling fan (FC) and the intake manifold.
2. the radiator hose from the thermostat housing
3. the camshaft pulleys, use counterhold «9995199»(ref-403953-S15123702502011061000000) mark up the pulleys (inlet/outlet)
4. the inner timing cover screw

1. air filter housing with hoses
2. camshaft sensor with trigger wheel
3. distributor cap with wiring and rotor
4. torque arm with brackets

Remove upper half of cylinder head

Install tool 9995453 (4 valve engine) or 9995508 (2 valve engine) to secure the front of the camshafts.

Install the tools 9995454 with a play of a few millimeters between them and the camshaft housing cover.

Slacken off the screws (from outside and in) from the upper half, remove all screws.

Disconnect the camshaft cover at the stop lugs with tool 9995670 . Start with cylinder 1 and work alternately backward.

Open and slacken off the tools 9995454 step by step so that parallel movement is ensured when removing camshaft housing cover.

Mark up and remove the camshafts.

Remove the cylinder head

Remove the coolant pipe's two screws.

Loosen the cylinder head's screws, (from the outside and in).

Remove the cylinder head.

Remove the cylinder head gasket.

Remove crankshaft adjustment tool ( 9995451 ) for the crankshaft and install the blind cover plug

Install the starter motor.

Remove the camshaft adjustment tool ( 9995452 ).

Remove the timing gear pulley

Remove

1. Exhaust camshaft pulley
2. The plug at the front edge of the variable valve timing (VVT) unit (TORX 55). The center screw from the variable valve timing (VVT) unit (TORX 55). Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit.

Intake camshaft pulley

Remove the screws and remove the timing gear pulley.

Replace the camshaft seal

Replacing the camshaft seal

1. Carefully press in tool «9995651»(ref-403953-S26733550812011061000000) between the sealing ring and the camshaft. Carefully pry out the seals.

Scheme 59

Install a new seal

1. Grease the new seal.
2. Install the new seal for the intake camshaft using drift «9995719»(ref-403953-S10206011822011061000000) .
3. Install the new seal for the exhaust camshaft using drift «9995718»(ref-403953-S24775656662011061000000) .

Remove the engine cooling fan (FC)

Remove

1. detach the brake vacuum hose from the intake.
2. the air duct for the control module box and the air cleaner (ACL) air intake hose.
3. the connectors, relays and canister purge (CP) valve from the fan shroud. Place the wiring to one side.
4. the screws for the fan shroud and the relay holder mounting.

Lift up the relay holder and remove the upper hose between the charge air cooler and the intake.

Seal the openings.

Slacken off the screw clip on the throttle body (TB) (electronic throttle module) so that the charge air pipe can be pressed backwards.

Press the charge air pipe backward and lift up the engine cooling fan (FC) with its cover.

As illustrated.

Front engine pad, replacement, Manual transmission

Note. As the illustrations in the information are used for different model years and / or models, certain variations may occur. However, the essential information in the illustrations is always correct.

Scheme 60

Remove the torque rod screw from the engine.

Slacken off the torque rod screw from the bodywork mounting slightly and place to one side.

Scheme 61

Scheme 62

1. the torque rod screw
2. the engine pad screw

Scheme 63

Lift the engine slightly using a mobile jack 9985972 .

Remove the old engine pad and install the new pad.

Scheme 64

1. the engine pad screw
2. the lower torque rod screws (new screws).
3. the engine pad nut
4. the upper torque rod screws (new screws).

1. the torque rod screw
2. the engine pad screw

1. the engine cooling fan (FC), according to operation «Remove engine cooling fan (FC)»(ref-403969-S18507455042011061000000)
2. the torque rod screw on the engine and slacken off the torque rod screw (slightly) in the bodywork mounting, push it to one side

Remove the nut from the engine pad and lift up the engine

Remove the nut from the engine pad.

Lift up the engine so that the engine pad can be removed.

Use a wooden block to protect the oil pan.

Flame trap seals, replacement

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Remove the inlet pipe

Remove the intake manifold according to procedure Replacing intake manifold .

Remove

1. the hose from the flame trap
2. the bracket for the intake manifold
3. the two screws for the flame trap
4. oil trap

Check that the flame trap's mating surfaces are clean.

Scheme 65

Connect the two flame trap hoses to the cylinder block connecting sleeves.

Install a new hose clamp for the upper hose. Tighten the lower clamp.

Install and tighten the screws to 20 Nm .

Install the intake manifold bracket loosely with the lower screw.

Install the intake manifold

Install the intake manifold according to procedure INSTALL .

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Remove the intake manifold according to procedure Intake manifold/gasket, replacing .

Remove

1. the hose from the flame trap
2. the bracket for the intake manifold
3. the two screws for the flame trap
4. oil trap

Check that the flame trap's mating surfaces are clean.

See Flame trap seals, replacement

See Flame trap seals, replacement

Replacement of intake manifold/gasket

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Remove components

Note. The crankshaft or camshaft must not be rotated under any circumstances other than those listed below. Failure to follow these instructions may cause damage to the valves.

Remove

1. the upper timing belt cover.
2. the servo reservoir and the expansion tank. Lift up and place on top of the engine. NOTE: Take care not to spill servo oil from the bleed hole in the cap. Place paper wipe around the reservoir and then cover with a plastic bag as protection. Spilled servo oil is highly inflammable.
3. the auxiliaries belt.
4. the front camshaft belt cover.

Turbocharger, exhaust manifold/gasket, replacement.

Note. As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct.

1. the heat shield plate over the turbo.
2. the charge-air pipe over the engine.
3. inlet pipe for turbo.

Loosen the turbocharger's upper pipe for return coolant, clamp the coolant hose using pliers, then put the pipe/hose aside.

Loosen inlet-oil pipe's nipple.

Raise the car .

Remove

Scheme 66

1. the clamp between the pipes.
2. the oil return line.
3. the nuts from the exhaust manifold/turbocharger.

Place clamping pliers on the hose by the coolant inlet.

Lower the car.

See Turbocharger, exhaust manifold/gasket, replacement.

See Turbocharger, exhaust manifold/gasket, replacement.

Timing Belt/Idler roller/Belt tensioner, replacement

Special tools

9995433

Note. Since the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct.

Note. Crankshaft or camshaft must not under any circumstances be rotated more than is stated below since the valves may be damaged.

Remove

1. upper timing belt casing.
2. the servo reservoir and expansion tank. Lift them up and place them on top of the engine. NOTE: Take care not to spill power steering fluid from the breather hole in the cap. Place wiping paper around the reservoir and then cover with a plastic bag as protection. Spilled power steering fluid is highly inflammable.
3. the auxiliaries belt
4. the front timing belt cover

Scheme 67

Raise the car.

1. Remove the right front wheel.
2. Loosen the nut for the cover in the fender liner.
3. Install the upper camshaft belt cover.
4. Turn the crankshaft clockwise until the markings on the crankshaft and camshaft gear match.
5. Turn the crankshaft a further 1/4 turn clockwise and then back again until the markings correspond.
6. Remove the upper camshaft belt cover.

Remove the vibration damper.

Raise the car

1. Remove the vibration damper. Use counterhold «9995433»(ref-403953-S41906385022011061000000) . Work the vibration damper loose.
2. Remove the timing belt

Engine replacement, transferring components (Turbo)

Special tools

9992520

9992810

9995112

9995297

9995428

9995429

9995463

Scheme 68

Automatic: Slacken off torque converter screws.

Remove 12 transmission screws from the engine at the flywheel mounting in the cylinder block.

Scheme 69

Use stand 9992520 and fixture 9995297 .

Remove lifting tools.

Install the correct number of washers to compensate transmission guide pins.

Scheme 70

1. Connector brackets
2. Torque control arm use new screws. Tighten screws in two stages: Stage 1 50 Nm Stage 2 90° angle
3. Camshaft position (CMP) sensor
4. Distributor and ignition cables
5. Heater pipes
6. Engine speed (RPM) sensor
7. Flywheel/carrier plate

Transfer all vacuum hoses

Scheme 71

1. Heat deflector plate
2. Exhaust pipe bracket
3. Exhaust manifold with turbocharger (TC)
4. Coolant pipe
5. Fuel line mounting brackets
6. Right engine mounting
7. Thermostat housing, oil cooler
8. Drive shaft bearing bracket

Scheme 72

1. Lifting eyes
2. Temperature sensor
3. Intake manifold knock sensors (KS) (torque 20 Nm )
4. Dipstick and pipe
5. Oil level sensor and oil pressure sensor
6. Front engine mounting
7. Flame trap with hose

Scheme 73

Lift the engine from the fixture, use mounting 9995429 and lifting yoke 9992810 , 9995428 .

Use gear sector 9995112 .

Use new screws and thread sealant.

Tighten in two stages

1. Tighten to: 45 Nm
2. Angle-tighten: 50°

Scheme 74

Automatic

Tighten torque converter to: 50 Nm .

Manual

Torque clutch driven plate and pressure plate to: 30 Nm

The old motor is plugged in the same way as the new plug.

Turbocharged engine, removal and installation

Special tools

9992810

9995428

9995462

9995474

9995488

9995533

Note. From autumn 1993 onwards lifting arm 998 9734 is included in the kit for tool 999 2810. The lifting arm is required for removing and installing the turbo motor.

1. front wheels
2. tie rod end from left stub axle
3. the three nuts holding the ball joint to the control arm on the left-hand side

1. ABS cable and brake pipe/hose bracket screw
2. left drive shaft, a gimmy bar «9995462»(ref-403953-S38748499762011061000000) must be used to release the drive shaft (the snap ring may be damaged otherwise)

1. tie rod end from right stub axle
2. the three nuts which hold the ball joint to control arm on right-hand side
3. right drive shaft and intermediate bearing cap from drive shaft, carefully place it on the steering servo pipes
4. the two screws for the right engine mounting (bend the right fender liner to one side slightly first)
5. the transmission torque rod screw

Note. Install sealing plugs 9995488 in the holes left by the drive shafts.

1. front exhaust pipe lower nut and screw from the bracket
2. speedometer connector
3. front and rear engine mountings lower screws.

Lower car to a comfortable working height

Scheme 75

1. battery
2. battery shelf, with a clutch slave cylinder for the cruise control (which is removed from the shelf and put to one side)
3. fresh air intake hose from air intake to air cleaner (ACL) housing
4. ignition cable between distributor/ignition coil
5. throttle pulley cover
6. throttle cable from throttle pulley

Scheme 76

1. Disconnect inlet hose from the turbocharger (TC) to air cleaner (ACL) at both ends
2. disconnect the hose for the PTC valve and connector
3. disconnect connector from throttle sensor
4. disconnect idle air trim connector.
5. disconnect turbocharger control valve (TCV) connector

Scheme 77

disconnect mass air flow (MAF) sensor connector

Disconnect and raise air cleaner (ACL) housing.

Remove two turbocharger control valve (TCV) bracket screws

Scheme 78

1. torque rod from bracket and cowl panel.
2. ground strip from cowl panel
3. the two heater hoses from the cowl panel
4. heated oxygen sensor (HO2S) connector and clips ((USA variants are equipped with two heated oxygen sensors (HO2S))
5. brake servo hose from engine or separate it under the air cleaner (ACL) housing

Scheme 79

Remove relays from the fan shroud, separate the relay and fan connectors, put wiring to one side.

Remove the air duct for cooling the control module box. Disconnect both canister hoses and valve from the radiator.

Remove the four fan shroud screws and the upper charge air pipe from the turbocharger. Slide the fan shroud slightly backward and remove the upper fan shroud. Remove upper charge air pipe.

Remove fresh air intake from radiator and disconnect vacuum hoses to Turbocharger instruments and EGR-regulator.

1. idle air trim together with lower charge air pipe
2. lower radiator hose, from engine
3. the protective cover over the starter motor
4. battery negative lead, from engine and wheel arch (also from transmission on automatic)

Car with manual transmission

1. clutch slave cylinder snap ring NOTE: (Ensure that the piston does not slide out)
2. slave cylinder from gear box

Scheme 80

1. air cleaner housing bracket. ( Carefully put air cleaner bracket and clutch slave cylinder to one side so that they are not separated.)

Manual

Remove: gear selector cables from their mountings on the transmission (mark up cable positions).

Remove the rubber mounted section of the gear selector cable mounting.

Automatic

Disconnect connector and remove gear selector cables from the transmission (and mark up the cable positions). Disconnect the two oil cooler hoses from the radiator, using victory clip tool.

1. upper radiator hose from thermostat housing
2. expansion tank
3. auxiliaries belt
4. the six power steering pump screws (disconnect the temperature sensor cable from the bracket on the power steering pump)

HINT: Allow power steering pump to remain on hose.

Disconnect the two oil cooler pipes from the radiator.

Scheme 81

Remove air conditioning (A/C) compressor without removing hoses and put onto sub-frame. (Remove the screws on the right-hand side by bending the fender liner a little to one side.)

Scheme 82

Remove the cable duct bracket screws

Remove starter motor support bracket.

1. the protective cover over the fuel rail
2. injector connectors
3. fuel line clip (upper/lower)
4. engine ground strip

Scheme 83

Install holder 9995533 (5x) on the injectors

Disconnect fuel pressure regulator vacuum hose.

Lift up and put fuel rail with injectors to one side.