Engine - Removal, Replacement and Installation (Coupe): Maintenance Volvo C70 I

Draining the gearbox fluid

Undo the drain plug.

Collect the oil in a container.

Scheme 577

Remove the screw.

Applies only to cars with parking heaters

Remove the 3 screws.

Tie up the engine block heater.

Remove the fuel line from the clips on the sub-frame.

Scheme 578

Remove the nuts and screws from the steering gear.

Scheme 579

Hang up the steering gear in a tie strap.

Use the hole in the body

This must be done so that the steering shaft bearing does not slide out of the steering column.

Scheme 580

Remove the 2 hose clamps for the charge air pipe under the engine.

Remove the 3 screws on the gearbox for the charge air pipe mounting.

Separate and remove the pressure pipe.

Remove

1. the screws for the torque rod from the gearbox
2. the screw for the front engine mounting.

Cleaning and lubricating the input shaft

The input shaft must be lubricated before a manual transmission is installed. See Input shaft, cleaning .

Scheme 581

Check that the transmission and engine mating surfaces are absolutely clean.

Also check that the guide sleeves towards the engine are in position and are free of faults.

Lubricate the holes in the gearbox (for the guide pins). Use a little grease.

Scheme 582

Adjust height and angle with the mobile jack and the gearbox fixture.

Locate the gearbox on the engine.

Ensure that the gearbox goes straight in, in relation to the engine, and that no deviation occurs in the clutch driven plate center.

Checking the gearbox fluid level

Top up the oil in the transmission if necessary. See Checking the oil level .

Draining the fuel line

Lower the car.

Drain the fuel line. See Fuel system pressure release .

Scheme 583

Remove

1. the engine stabilizer brace between the suspension turrets.
2. the ground strips between the engine and the bulkhead
3. the heat deflector plate above the turbocharger (TC).
4. the plastic charge air pipe above the engine. Seal the openings
5. the cover over the ignition coils
6. the upper engine coolant hose for the engine and radiator
7. the screw holding the dip stick pipe to the intake manifold.
8. the brake vacuum hose from the intake manifold.

Undo the clamp holding the plastic charge air pipe to the electronic throttle module.

Scheme 584

Remove

1. the connector from the mass air flow (MAF) sensor.
2. the intake hose from the mass air flow (MAF) sensor. Seal the opening.

Release the hoses from the bracket at the rear of the cylinder head. Remove the bracket.

Remove

1. the clamp for the positive lead at the rear of the cylinder head
2. the torque bracket.
3. the pipe screw for the water-heated crankcase ventilation.

Scheme 585

Removing the fuel rail

Remove the clamp for the injector wiring at the rear of the cylinder head.

Separate the fuel line quick-release connector.

Remove the fuel rail mounting screws.

Spray universal oil or similar around the injector connectors on the intake manifold.

Gently work the fuel rail and injectors loose.

Carefully put the fuel rail to one side.

Removing ignition coils

Mark up the ignition coils so that the original positions can be established.

Remove the mounting screws for the ignition coils and the screws at the two ground terminals.

Disconnect the connector for the variable valve timing solenoid.

Lift up and place the ignition coils and wiring to one side.

Remove

1. the crankcase ventilation hose from the top of the camshaft cover
2. the camshaft position sensor (CMP) housing and trigger wheel
3. the cover at the rear edge of the intake camshaft.

Scheme 586

Remove

1. the EVAP hose from the intake manifold
2. the by-pass valve vacuum hose
3. the upper row of screws holding the intake manifold to the cylinder head. Slacken off the lower screws
4. the pipe screw for the crankcase ventilation from the underside of the intake manifold.

Disconnect the connector for the electronic throttle module.

Lift up and remove the intake manifold.

Note. Make sure that the fuel delivery pipe is not damaged.

Scheme 587

Disconnect the connectors for the ABS sensor and level sensor in the expansion tank.

Lift up the expansion tank and servo oil reservoir. Place them on top of the engine.

Note. Make sure that power steering fluid does not leak from the breather hole in the filler cap.

Take off the auxiliaries belt.

Remove

1. the front timing cover
2. the hose for the water-heated crankcase ventilation from the thermostat housing.

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

Scheme 588

Remove the nuts from the cover on the wing liner.

Position the upper timing cover.

Turn the crankshaft clockwise until the markings on the crankshaft and camshafts correspond.

Remove the upper timing cover.

Scheme 589

Slacken off the center screw for the belt tensioner slightly.

Hold the center screw secure and turn the tensioner eccentric clockwise with a 6 mm Allen key to 10 o'clock.

Remove

1. the timing belt from the timing gear pulley
2. the screw that holds the inner timing cover to the cylinder head.

Install tool 9995452 at the rear of the camshafts.

Scheme 590

Remove the cable duct from its mountings on the right-hand suspension turret.

Note. Do not damage the paintwork.

Hold the cable duct out of the way and remove

1. the plug at the front of the variable valve timing unit (TX55)
2. the center screw in the variable valve timing unit (TX55).

Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit.

Timing gear pulleys without variable valve timing units

Remove the screws and remove the timing belt pulley.

Remove tool 9995452 .

Scheme 591

Remove

1. the upper coolant pipe with the hose
2. the heat deflector plate above the manifold
3. the oil pressure pipe for the turbocharger (TC)
4. the pipe screw at the lower coolant pipe for the turbocharger (TC). Put the pipe to one side.
5. the nuts and washers holding the manifold to the cylinder head.

Lift off the turbocharger and manifold. Carefully put them on top of the gearbox.

Scheme 592

Remove

1. the screw that holds the inlet pipe for the coolant pump on the cylinder block
2. the two screws for the connection between the coolant pipe and the bypass channel. Carefully turn the pipe to remove it from the cylinder block.

Scheme 593

Remove the spark plugs from cylinders 1 and 5.

Install 2 tools 9995454 . Leave a 2-3 mm gap to the camshaft cover.

Make sure that the screw in the spark plug thread is tightened all the way down. VVT-solenoid.

Remove all the screws securing the camshaft cover to the cylinder head.

Scheme 594

Use pliers 9995670 to lift the cover from the cylinder head.

Install the pliers at the stop lugs. Start with cylinder 1 and work alternately backward.

Slacken off the wing nuts approximately 2 turns. Repeat the procedure.

Scheme 595

Carefully press out the front and rear camshaft seals.

Scheme 596

Remove

1. tools «9995454»(ref-403953-S30108818292011061000000) .
2. the camshaft cover
3. the camshafts
4. the screws holding the cylinder head onto the cylinder block. Start at the sides and work alternately towards the center.

Get help to lift off the cylinder head.

Note. Work very carefully to avoid damaging the contact faces.

Drain the coolant and loosen the front exhaust pipe

1. Remove the cable from the battery negative terminal. First read «Battery, disconnecting»(ref-438953-S33389199492011120700000) .
2. Remove the cap on the expansion tank.
3. Remove the splash guard under the engine.
4. Place a container under the engine's drain valve and drain the coolant.
5. Move the container to the radiator's drain valve and drain any remaining coolant.
6. Close the nipples.
7. Remove the nuts for the manifold/front exhaust pipe.

Drain the fuel line

The illustration above does not match completely since the power steering fluid tank now has another placement.

1. Depressurize the fuel system acc. to: «Fuel system pressure release»(ref-438956-S24441587062011120700000) .
2. Disconnect the fuel line quick-release connector at the engine NOTE: Protect the openings against impurities in a suitable way. Make sure that all cleanliness conditions for working with the fuel injection system are followed.
3. Put the line to the side.
4. Detach the EVAP line at the quick-release connector.

Drain the coolant and detach the front exhaust pipe

Detach the negative battery cable.

Remove the cap on the expansion tank.

Remove the engine splash guard.

Open the nipples on the engine and radiator. Use hoses to lead off coolant.

Close the nipples.

Remove the nuts for the manifold/front exhaust pipe.

Drain coolant

Remove expansion tank cap.

Raise the car.

Automatic: Remove air guide under engine.

Open the engine and radiator nipples. Thread hoses onto the nipple to collect the coolant.

Disconnect the lower charge air pipe from charge air cooler (CAC) lower sleeve connector.

Close the nipples.