Engine - Removal, Replacement and Installation: Removal & Installation Volvo S80 I

Cylinder Head/Gasket, Replacement

Special tools

See 9995452

See 9995454

See 9995670

See 9995451

See 9512050

See 9512767

See 9995450

See 9995718

See 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 80

Remove

1. the radiator breather tube from the expansion tank. Install lock grip pliers
2. the battery negative lead. First read «Battery, disconnecting»(ref-440259-S31019869382011121400000)
3. the right front wheel.

Scheme 81

Raise the car.

Remove the splash guard under the engine.

Open the engine nipple.

Drain the coolant into a container.

Close the nipple.

Scheme 82

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.

Special tools

9512666

See 9512767

See 9995450

See 9995452

See 9995454

See 9995670

See 9995718

See 9995719

See 9995750

See 9995972

Special tools

9512666

9512767

9995450

9995452

9995454

9995670

9995718

9995719

9995750

9995972

Removal Of Thermostat Housing

Remove

1. the screw for the thermostat housing cable duct.
2. the screws holding the thermostat housing to the cylinder head. Lift out the thermostat housing, gasket and cable duct.
3. screw holding the inner timing cover to the cylinder head.

Scheme 83

Remove

1. spark plugs for cylinders 2 and 5. Install tool 999 5454 (x2). Leave a 2-3 mm gap to the camshaft cover. Ensure that the screw in the spark plug well is fully tightened.
2. Variable valve timing solenoid.
3. the screws holding the camshaft cover to the cylinder head.

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 with the pliers.

Carefully press out the front and rear camshaft seals.

Remove the seals.

Remove

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

Transmission, Installation

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 is always correct.

Note. For tightening torques, see: Tightening torque .

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.

Oil Sump Replacement

Special tools

9512767

Scheme 84

Remove

1. the oil dipstick and its pipe.
2. the splashguard 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.

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.