Engine - Removal, Replacement and Installation: Maintenance Volvo S60 I

Draining coolant

Raise the car.

Remove the splash guard under the engine.

Open the engine nipple.

Drain the coolant into a container.

Close the nipple.

Draining the fuel line

Lower the car.

Drain the fuel line. See Fuel system pressure release .

Drain the fuel line. See Fuel system pressure release .

Scheme 14

Remove

1. the injector covers
2. the connectors from the injectors. Place the wiring to one side.

Separate the fuel line quick-release connector. Also see Fuel line, lock . Use tool 9512666 .

Remove the screws holding the fuel pipe and air distribution pipe to the intake manifold.

Carefully pull off the fuel pipe and the air distribution pipe as one.

Scheme 15

Remove

1. all 5 vacuum hoses from the intake manifold. (see the illustration)
2. the screw holding the dip stick pipe to the intake manifold
3. the screw at the support bracket (under the intake manifold)
4. the starter motor. Place it to one side.

Disconnect the connector for the electronic throttle module.

Remove

1. the upper coolant hose from the thermostat housing. Fold the hose out of the way
2. the upper screws securing the intake manifold to the cylinder head. Lift up and twist the intake manifold. This is so that the fuel pressure pipe releases from the intake manifold. NOTE: Handle the fuel delivery pipe carefully so that it is not damaged.
3. the hose for the water-heated crankcase ventilation from the thermostat housing.

Disconnect the connector for the coolant temperature sensor.

Scheme 16

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

Lift up the expansion tank and the brake fluid reservoir. Place them on top of engine.

Remove the auxiliaries belt.

Remove the front timing cover.

Position the upper timing cover.

Turn the crankshaft clockwise until the markings at the crankshaft and camshafts are aligned with the markings on the oil pump and the upper timing cover.

Remove the upper timing cover.

Scheme 17

Slacken off the center screw for the belt tensioner slightly.

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

Remove

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

Install tool 9995452 at the rear of the camshafts.

Scheme 18

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. Remove the timing gear pulley.

Remove tool 999 5452.

Reinstall the expansion tank and the brake fluid reservoir at the right wheel arch.

Scheme 19

Remove the two screws at the coolant pipe connection to the bypass channel.

Carefully turn the pipe to remove it from the cylinder block.

Scheme 20

Remove

1. Variable valve timing solenoid
2. spark plugs for cylinders 1 and 5.

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

Ensure that the screw in the spark plug well is fully tightened.

The screws holding the camshaft cover to the cylinder head.

Scheme 21

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 22

Carefully press out the front and rear camshaft seals.

Note. Be very careful so that the sealing faces on the camshafts are not damaged.

Scheme 23

Remove

1. tools 999 5454
2. the camshaft cover
3. the camshafts.

Lift out the valve lifters. Use a magnet or a suction cup.

Note. Mark up and position the lifters so that their original positions can be established.

Scheme 24

Remove the screws holding the cylinder head on 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.

Draining the coolant

Raise the car. Remove the splash guard from under the engine.

Open the engine nipple.

Drain the coolant into a clean container.

Close the nipple.

Drain the fuel line. See Fuel system pressure release .

Scheme 25

Remove

1. the crankcase ventilation hose from the top of the cam cover
2. the protective cover over the injector connectors.

Disconnect the connectors from

1. the injectors
2. the manifold absolute pressure (MAP) sensor in the fuel line
3. the temperature sensor in the thermostat housing. Place the wiring to one side.

1. Remove the mounting screws from the fuel rail
2. Spray universal oil or similar around the injector nozzle at the terminal on the intake manifold
3. Gently work the fuel rail and injector nozzles loose
4. Separate the quick-release fuel line connector by pressing the blue clips on both sides. See «Fuel line, lock»(ref-445696-S39060814602012010600000) .

Remove

1. all 4 vacuum hoses from the intake pipe. (see the illustration). Disconnect the connector on the Positive temperature coefficient (PTC) nipple for crankcase ventilation (5).

Scheme 26

Remove

1. the screw holding the dip stick pipe to the intake manifold
2. the clip for the servo pressure pipe
3. the screw at the support bracket (under the intake manifold). Disconnect the connector for the electronic throttle module (ETM)
4. unscrew the four upper screws completely. Slacken off the lower screws a few turns
5. the intake manifold. Lift the intake manifold approximately 20 mm . Allow the crankcase ventilation hose to run through the intake manifold without disconnecting it from the flame trap
6. the hose on the Positive temperature coefficient (PTC) nipple for crankcase ventilation. Lift out the intake manifold
7. the upper coolant hose.

Raise the car.

Remove the splash guard under the engine.

Open the engine nipple.

Drain the coolant into a container.

Close the nipple.

Fuel system, draining

Lower the vehicle.

Drain the fuel system. Refer to: 3 Fuel system pressure release .

Scheme 27

Remove

1. the engine stabilizer brace between the suspension turrets
2. the ground strips between the engine and the firewall
3. the heat deflector plate above the turbocharger (TC)
4. the charge-air pipe over the engine. Seal the openings
5. cover over the injector lines
6. the upper belt protective cover
7. the cover over the ignition coils

Remove

1. the intake pipe between the air cleaner (ACL) and the front cover plate
2. the hose clamp for the mass air flow sensor. Disconnect the connector for the mass air flow sensor
3. the air cleaner housing assembly, unhook the control valve from the air cleaner housing
4. fresh air hose between air filter and turbo. Disconnect the hoses from bracket at the cylinder head's trailing edge. Remove the bracket
5. the upper engine coolant hose for the engine and radiator
6. the screw holding the dip stick pipe to the intake manifold
7. the brake vacuum hose from the intake manifold.

Remove

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

Scheme 28

Remove the clamp for the injector lines at the cylinder head's trailing edge.

Unplug the connectors for the injector valves and the fuel pressure sensor as well as the water temperature sensor.

Remove the fuel rail's attaching screws. Refer to: Fuel line, lock .

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

Gently work the fuel rail and injectors loose.

Separate the fuel line quick-release connector.

Note. Collect any fuel spill.

Carefully put the fuel rail to one side.

Drain the fuel line. See Fuel system pressure release . See also: Fuel system, quick-release connectors .

Remove the cover from the expansion tank.

Draining the gas pipe

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.

Removing the fuse

Scheme 29

Remove the privacy panel below the dashboard.

Start the engine and make sure that it runs on gas.

Remove the fuse from position 29.

The engine will stop after approx. one minute.

Closing the rear gas tank valve

Scheme 30

Close the engine gas valve on the rear gas tank.

Closing the front gas tank valve

Scheme 31

Close the valves (1) on the two front gas tanks.

Engine without gas operation

Scheme 32

Remove the fuse. See Removing the fuse .

Close the valves of the rear tank. See Closing the rear gas tank valve . Close the valves of the front tanks. See Closing the front gas tank valve .

Detach the regulator connection just enough that any gas starts to hiss out.

Open the cap on the expansion tank.

Position a container under the radiator drain cock.

Drain the coolant.

Close the cock.

Drain the fuel injection system. See Fuel system pressure release . See also: Fuel system, quick-release connectors .