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

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.

Scheme 6

Remove

1. the radiator breather tube from the expansion tank. Install lock grip pliers
2. the battery negative lead. First read «Battery, disconnecting»(ref-415278-S03862267492011081500000)
3. the right front wheel.

Scheme 7

Raise the car.

Remove the splash guard under the engine.

Open the engine nipple.

Drain the coolant into a container.

Close the nipple.

Scheme 8

Remove

1. the clamp between the oil pressure pipe and the oil return line at the turbocharger (TC)
2. the pipe screw that holds the oil pressure pipe to the connector on the cylinder block
3. the oil return line. Seal the opening in the cylinder block
4. the lower screw that holds the heat deflector plate over the turbocharger (TC)
5. the nuts for the front exhaust pipe connection to the turbocharger (TC). Lift off the exhaust pipe and tie it up. Seal the opening in the exhaust pipe NOTE: The metal hose for the front exhaust pipe is easy to damage if it is twisted. Handle it with care to avoid leakage.

See Cylinder head/gasket, replacement

See Cylinder head/gasket, replacement

Special tools

9995452

9995454

9995670

9995451

9512050

9512767

9995450

9995718

9995719

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.

See Cylinder head/gasket, replacement

See Cylinder head/gasket, replacement

See Cylinder head/gasket, replacement

Removal (the illustrations may vary per model)

Raise the car.

Remove

1. the right front wheel
2. both the plastic nuts and the reinforcement panel holding the cover in the right fender liner. Bend the fender liner out of the way.

Scheme 9

Remove

1. the four screws for the right engine pad
2. the splash guard under the engine.

Scheme 10

1. Position a mobile jack with universal plate «9995972»(ref-403953-S08076234722011061000000) under the oil pan on the right side of the engine
2. Check that the plate does not catch in the sub-frame
3. Carefully lift the engine slightly so that the engine pad can be removed.

Scheme 11

Install

1. the new engine pad
2. use new screws for the mounting in the sub-frame and engine. Do not tighten yet .

1. Carefully lower the engine and remove the mobile jack
2. Tighten the screws against the engine. Tighten to 35 Nm . Angle-tighten 90° . Use bevel protractor «9512050»(ref-403953-S36645634772011061000000)
3. Tighten the screws to the sub-frame. Tighten to 65 Nm and angle-tighten 60° . Use bevel protractor «9512050»(ref-403953-S36645634772011061000000) .

1. the splash guard under the engine. Tighten to 25 Nm
2. both the plastic nuts and the reinforcement panel holding the cover in the right fender liner
3. the right front wheel. See «Installing wheels»(ref-415307-S16574462602011081500000)

Preparations for removal of the drive shafts

Remove on the left and right-hand sides

1. the tie rod from the wheel spindle
2. the link rod from the anti-roll bar
3. the screw that holds the brake pipe bracket to the bodywork
4. the nut holding the control arm to the ball joint
5. the center screw from the end of the drive shaft.

Remove

Remove

1. the cover over the central electrical unit
2. the connector for the engine wiring from the central electrical unit
3. the positive lead for the starter motor from the terminal block
4. the ground lead at the front frame member.

Scheme 12

Block the hose between brake the fluid reservoir and the clutch master cylinder.

Remove

1. the clutch hose from the junction. Plug the openings against dirt. Wipe up any spilled brake fluid
2. the ground lead from the transmission and the sub-frame.

Cars with automatic transmissions

Remove the oil cooler hoses from the transmission. Plug the openings in the radiator and transmission.

Scheme 13

Manual transmissions

Remove

1. the gear selector cables from the levers. Use jimmy bar «9997077»(ref-403953-S08742937252011061000000)
2. the mechanical cables from the bracket by moving the sleeves back on the cables.

Automatic transmission

Remove the screws for the transmission cable bracket at the transmission

Tie up the cables.

Disconnect the connector for the temperature and pressure sensor on the charge air cooler (CAC) outlet.

Remove

1. the rubber hose at the intake for the charge air cooler (CAC)
2. the dip stick pipe
3. the brake vacuum hose at the intake manifold
4. the lower engine coolant hose from the engine
5. the plastic pipe between the throttle body (TB) and the charge air cooler (CAC). HINT: Carefully heat around the pipe at the charge air cooler (CAC). Use a hot air gun.

Disconnect the wiring from the front heated oxygen sensor (HO2S). Remove the wiring from the clips and clamps.

Oil sump replacement

Special tools

9512767

See Oil sump replacement

See Oil sump replacement

See Oil sump replacement

See Oil sump replacement

See Oil sump replacement

Remove components

Remove

1. the cross stay between the suspension turrets
2. the upper timing belt cover
3. the servo reservoir and the expansion tank. Lift up and place on top of the engine. WARNING: Ensure that no power steering fluid is spilled. Extremely flammable.
4. the auxiliaries belt
5. the front timing belt cover.

Remove the lock

Remove the lock

Remove

1. the cross stay between the suspension turrets
2. the upper camshaft belt cover
3. the servo reservoir and expansion tank. Lift them up and place them on top of the engine WARNING: Ensure that no power steering fluid is spilled. It is extremely flammable
4. the auxiliaries belt
5. the front camshaft belt cover.

Remove the engine cooling fan (FC)

Remove

1. slacken off the brake vacuum hose from the intake
2. the air cleaner (ACL) housing intake pipe from the connection above the radiator. Twist the pipe up
3. the manifold absolute pressure (MAP) sensor from the front cover plate
4. the evaporative emission system (EVAP) valve from the engine cooling fan (FC) shroud
5. release the wiring from the fan shroud.

Lift out the hose for the expansion tank from the holders on top of the fan shroud.

Disconnect both the engine cooling fan (FC) connectors.

1. both screws holding the fan shroud.

Carefully lift up the engine cooling fan (FC).

Install radiator protection 9995474 .