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

Installing and tightening front end components (both sides)

Install and tighten the front end components.

Tightening the ball joint pinion

Tighten the ball joint pinion.

Scheme 1

Remove the level plug and fill with oil. Use only Volvo transmission oil P/N 116 1745 (1 liter). Volume in the transmission 2.1 liters.

Install the level plug with a new gasket. Tighten to 35 Nm .

Scheme 2

Applies only to cars with parking heaters

Install

1. the parking heater and the screws. Tighten to 25 Nm
2. the fuel line in the clips on the subframe
3. the screw in the cable conduit
4. the front splash guard
5. the splash guard under the engine.

Scheme 3

Install the nuts for the left wing liner and damping protection.

Rivet the wing liner into place.

Install the wheels. See Installing wheels .

Installing the torque control arm

Install the torque control arm according to Installing the torque control arm.

Scheme 4

Install

1. the screws for the gearbox and engine. Tighten to 50 Nm
2. the screws for the clamps for the wiring.

Scheme 5

Install

1. the bracket and the screws. Tighten to 25 Nm
2. the cable on the bracket. Secure it with the locking
3. the lever on the gearbox. Tap in the expander pin
4. the mechanical cables on the levers. Check the marking
5. the connector.

Scheme 6

Note. The automatic transmission has a gear selector cable while the manual transmission has two gear selector cables.

Ensure that the gear selector cable is engaged before fitting the blue clip. Press the clip into position as illustrated.

Scheme 7

Check that the clip is positioned in the groove as illustrated.

Scheme 8

Install the clutch pipe on the junction. Use a new seal. Ensure that the clip is seated in its groove.

Remove the hose clip.

Bleed the clutch

It may be difficult to bleed the pressure regulator. Use a bleeding unit.

Use only Volvo Genuine parts brake fluid DOT 4+.

Scheme 9

Install

1. a new nut for the exhaust flange. Tighten to 25 Nm
2. the air hose on the turbocharger (TC). Tighten the hose clamp
3. the rubber hose and a new hose clamp on the evacuation pipe. Clamp the hose clamp with pliers
4. the charge air pipe on the manifold. Tighten the hose clamp
5. the rubber hose on the side socket on the air hose.

Scheme 10

Install the coolant hose in the quick-release connector.

Remove the hose clips.

Measure and fill with new glycol and water .

Installing the air cleaner (ACL) housing and the torque rod in the engine compartment

Install the air cleaner (ACL) housing and torque rod in the engine compartment according to INSTALLING THE AIR CLEANER (ACL).

Scheme 11

Check that the steering gear bearing in the boot has not detached from the boot.

If it has become detached apply a little grease to the edge of the boot (around the hole). Press the bearing back down into the boot. See arrow in illustration.

Note. Check that the rubber boot is positioned correctly in the bodywork. Adjust if necessary. There is a risk that noise from the gearbox or engine and road noise may enter the passenger compartment.

Connect the battery lead

First read Battery, disconnecting.

Test driving

Scheme 12

Install

1. the engine cover and the screws
2. the front soundproofing panel.

Test driving

Tightening torque

For tightening torques not in the text, see Tightening torque.

Scheme 13

Position the crankshaft

Remove the starter motor mounting screws. Pull out the starter motor and place it to one side.

Remove the blind cover plug

Turn the crankshaft slightly clockwise .

Install crankshaft stop 9995451 . Ensure that it bottoms out against the cylinder block.

Turn the crankshaft counter-clockwise until it stops against the crankshaft stop

Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.

Scheme 14

Ensure that all studs at the exhaust ports are tightened.

Lubricate the studs with paste 116 1408.

Install a new cylinder head gasket.

Install the cylinder head

Lubricate and install all the screws. Use new screws.

Tighten the screws in the order illustrated

Tighten the screws in the following order

1. 20 Nm
2. 60 Nm
3. Angle tighten 130° . Use protractor «9512050»(/volvo/c70/i-1997-2005/remont/oem-general-information/#special-tools) .

Scheme 15

Lubricate the valve guide wells.

Install all the tappets.

Lubricate the camshaft bearing seats.

Install the intake camshaft. Ensure that the groove at the back of the camshaft is above an imaginary center line.

Position the exhaust camshaft. Ensure that the groove at the back of the camshaft is below an imaginary center line

Scheme 16

Install new O-rings around the spark plug wells at the cylinder head.

Apply liquid gasket 1161 059 to the camshaft cover.

Use roller 9512767 . The surface must be covered without any excess .

Note. Make sure that no liquid gasket gets into the oil channels.

Scheme 17

Lubricate the camshaft lobes, the camshaft bearing surfaces and the tappets.

Install the camshaft cover.

Install press tool 9995454 (2x).

Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools.

Install the intake manifold and lifting eyes, tighten screws from the middle and outwards.

Remove the press tools.

Install

1. the variable valve timing (VVT) solenoid. Use a new gasket
2. the spark plugs. Tighten to 30 Nm .
3. the hose for water-heated crankcase ventilation to the thermostat housing. Tighten the clamp.

Connect the connector for the engine coolant temperature (ECT) sensor.

Install the inlet pipe for the coolant pump on the cylinder head. Use a new gasket.

Note. Apply thread sealant, 116 056 to the screw threads.

Install the screw for securing the coolant pump intake pipe to the cylinder block.

Scheme 18

Install

1. new gaskets.

Lift and install the manifold and turbo.

1. the nuts and washers holding the manifold to the cylinder head
2. the heat deflector plate above the manifold
3. the upper turbocharger (TC) coolant pipes. Tighten the clamp on the rubber hose.
4. the pipe screws for the coolant pipes. Use new seal washers. Tighten to 26 Nm .
5. the oil pressure pipe
6. the pipe screw holding the oil pressure pipe to the turbocharger (TC). Use new seal washers. Do not tighten!

Lubricate the studs on the turbocharger (TC). Use paste 116 1408 .

Install the front exhaust pipe onto the turbocharger (TC). Use new nuts. Do not tighten!

Scheme 19

Use drift 9995450 .

Lubricate the surface of the seal that the camshaft rotates against.

Press in the seal until the drift bottoms out.

Note. If there are grooves on the camshaft, the seal can be pressed in a further 2 mm: Reverse the sleeve.

Install camshaft adjustment tool 9995452 at the rear of the camshafts.

Ensure that the screws retaining the adjustment tool to the camshafts and the screws holding the tool together are well tightened.

Scheme 20

Use drift 9995718 for camshaft with variable valve timing unit and drift 9995719 for camshaft without variable valve timing unit.

Lubricate the surface of the seal that the camshaft rotates against.

Use the variable valve timing unit/timing belt pulley mounting screws. Tighten the screws until the drift bottoms out.

Remove the drift.

Install the screw holding the inner timing cover to the cylinder head.

Replacement of bushing in torque arm

Special tools

9995668

9995576

9995575

9995588

9999708

Scheme 21

Actions for turbocharged engines of model year 1995 and later, as well as older turbocharged engine that have been modified.

1. Remove the nut for bracket (A) on the charge air pipe by the torque rod.
2. Loosen the clamp's screw (B) slightly.
3. Move the bracket to one side so that it detaches from the mounting by the torque rod. Leave the bracket on the pipe.

On a modified turbocharged engine the charge air pipe is routed differently than shown, see Remove the engine coolant fan (FC). When installing in this case, see Install.

Scheme 22

1. Remove the upper clamp (C) on the hose by the turbocharger.

Scheme 23

1. Loosen the charge air pipe (D), see the illustration. NOTE: Cover the hole in the turbocharger outlet when the charge air pipe has been removed so that foreign objects cannot fall into the outlet.
2. Disconnect the ignition cable from the holder on the reverse of the cover for the air cleaner.
3. Detach and place the cover (E) as far forward as possible.

Scheme 24

On right-hand drive cars, the brake master cylinder must be detached to give room for the tool (puller cylinder).

1. Detach the brake tubes from the mountings on the firewall.
2. Remove the brake master cylinder from the brake booster.
3. Raise the brake master cylinder carefully to prevent damaging the brake tubes. (Hold the brake master cylinder in place using a cable tie.)

Scheme 25

Note. Check cars with chassis numbers lower than those below. Replace the master cylinder if the seat has jammed on the push rod end. The seat must not be reinstalled in the master cylinder.

*) Loose push rod seat not found on cars with higher push rod seat or master cylinder in spare parts version.

Scheme 26

1. Remove the engine cover.
2. Remove the EGR valve with pipe.
3. Fold the EGR valve with pipe to one side.

Scheme 27

1. Remove the screw from above the torque rod mounting by the engine.
2. Fold up and place the torque rod above the bracket for the torque rod bushing.
3. Take the hydraulic pump «9995576»(/volvo/c70/i-1997-2005/remont/oem-general-information/#special-tools) and puller cylinder «9995575»(/volvo/c70/i-1997-2005/remont/oem-general-information/#special-tools) .
4. Insert «9995588»(/volvo/c70/i-1997-2005/remont/oem-general-information/#special-tools) the puller cylinder.

Scheme 28

1. Press out the bushing from the bracket using the press tool «9995668»(/volvo/c70/i-1997-2005/remont/oem-general-information/#special-tools) .

Scheme 29

1. Press out the bushing from the bracket using the press tool «9995668»(/volvo/c70/i-1997-2005/remont/oem-general-information/#special-tools) .

Scheme 30

1. Install the bushing loosely with arrow marking (G) opposite the recess (H) on the torque arm's engine mount bracket.

Scheme 31

1. Use press tool «9995668»(/volvo/c70/i-1997-2005/remont/oem-general-information/#special-tools) .
2. Press as far as possible towards the end of the press tool.

Scheme 32

1. Use crimp sleeve «9995668»(/volvo/c70/i-1997-2005/remont/oem-general-information/#special-tools) together with press tool «9995668»(/volvo/c70/i-1997-2005/remont/oem-general-information/#special-tools) .
2. Press as far as possible towards the end of the press tool.

Scheme 33

1. Install the torque rod. Use new screws (D).
2. Tighten the nut (D) to a torque of 35 Nm + 90° NOTE: New screws and nuts must be used.

Torque bracket

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.

Removing the torque bracket, turbocharged engines

Remove

1. Applies to turbocharged engines.
2. the charge air pipe over the engine.
3. the upper camshaft belt cover.
4. the cover over the ignition coils.
5. the screw for the torque rod.
6. the torque bracket.

Removing the torque bracket, naturally aspirated engines

Remove

1. Applies to naturally aspirated engines.
2. the upper camshaft belt cover.
3. the cover over the ignition coils.
4. the screw for the torque rod.
5. the torque bracket.

Scheme 34

Install

1. the torque bracket (A). Tighten to 50 Nm (37 lb.ft) .
2. the screws for the torque rod (B). Tighten to 35 Nm (26 lb.ft) +90° .
3. the cover over the ignition coils.
4. the upper camshaft belt cover.
5. any charge air pipe over the engine.

Wipe clean and check.

See Torque bracket

See Torque bracket

See Torque bracket

See also:
• 9992810
• Tightening the wheel studs
• Installing wheels