Engine - Removal, Replacement and Installation: Maintenance Volvo V70 II

Draining the fuel line

Lower the car.

Drain the fuel line. See Fuel system pressure release .

Scheme 83

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 84

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 85

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 86

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 87

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 88

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 89

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 90

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 91

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 92

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 93

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 94

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 95

Carefully press out the front and rear camshaft seals.

Scheme 96

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.

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.

Drain the fuel line. See Fuel system pressure release .

Scheme 97

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 98

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 99

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 100

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 101

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 102

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 103

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 104

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 105

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 106

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 107

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 108

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-407120-S01809834772011070100000) .

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 109

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.

Draining the fuel system

Lower the vehicle.

Drain the fuel system according to: Fuel system pressure release .

Scheme 110

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 111

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 according 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 112

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 113

Close the engine gas valve on the rear gas tank.

Closing the front gas tank valve

Scheme 114

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

Engine without gas operation

Scheme 115

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 .

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 116

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 117

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.