Volvo Cars 1999-05

Cylinder Head

Print

Removal & Installation



5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air intake assembly
     
    Accessory drive belts
     
    Front cover
     
    Timing belt
     
    Exhaust manifold
     
    Fuel supply manifold covers
     
    Fuel line retainers
     

  6.  
  7. Install fuel injector holders on the injectors.
  8.  
  9. Remove or disconnect the following:

    Fuel pressure regulator vacuum hose
     
    Fuel supply manifold with injectors attached
     
    Cooling fan
     
    Intake manifold
     
    Upper radiator hose
     
    Camshaft sprockets
     
    Rear timing cover
     
    Distributor, if equipped
     
    Camshaft Position (CMP) sensor, if equipped
     
    Extension arm and brackets
     
    Upper cylinder head
     
    Camshafts
     
    Coolant pipe
     
    Lower cylinder head
     

  10.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-5-cylinder engines

Cylinder head torque sequence-5-cylinder engines

  1. Install the lower cylinder head with a new gasket. Tighten the bolts in sequence as follows:
    1. Step 1: 15 ft. lbs. (20 Nm)
    2.  
    3. Step 2: 44 ft. lbs. (60 Nm)
    4.  
    5. Step 3: Plus 130°
    6.  

  2.  
  3. Install or connect the following:

    Coolant pipe
     
    Camshafts
     
    Upper cylinder head. Tighten the bolts to 13 ft. lbs. (17 Nm)
     
    Extension arm and brackets
     
    CMP sensor, if equipped
     
    Distributor, if equipped
     
    Rear timing cover
     
    Camshaft sprockets
     
    Upper radiator hose
     
    Intake manifold
     
    Cooling fan
     
    Fuel supply manifold with injectors attached and remove the injector holders
     
    Fuel pressure regulator vacuum hose
     
    Fuel line retainers
     
    Fuel supply manifold covers
     
    Exhaust manifold
     
    Timing belt
     
    Front cover
     
    Accessory drive belts
     
    Air intake assembly
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine appearance cover
     
    Air intake assembly
     
    Battery
     
    Expansion tank
     
    Right front wheel
     

  6.  
  7. Separate the exhaust system from the intake manifold.
  8.  
  9. Relieve the fuel pressure.
  10.  
  11. Remove or disconnect the following:

    Engine stabilizer brace
     
    Upper engine coolant hose
     
    Mass air flow (MAF) sensor
     
    Fuel rail
     
    Ignition coils
     
    Intake manifold
     
    Accessory drive belt
     
    Timing belt
     
    Turbocharger, if equipped
     
    Intake pipe for water pump
     
    Camshafts
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-5-cylinder engine

    Cylinder head loosening sequence-5-cylinder engine

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-5-cylinder engines

    Cylinder head torque sequence-5-cylinder engines
     

  12.  

To install:

  1. Install the cylinder head with a new gasket. Tighten the bolts in the following sequence:
    1. Step 1: 15 ft. lbs. (20 Nm)
    2.  
    3. Step 2: 44 ft. lbs. (60 Nm)
    4.  
    5. Step 3: Plus 130°
    6.  

  2.  
  3. Install or connect the following:

    Camshafts
     
    Intake pipe for water pump
     
    Turbocharger, if equipped
     
    Timing belt
     
    Accessory drive belt
     
    Expansion tank
     
    Upper engine stabilizer brace
     
    Intake manifold
     
    MAF sensor
     
    Ignition coils
     
    Fuel rail
     
    Upper engine coolant hose
     
    Battery
     
    Air intake assembly
     

  4.  
  5. Reassemble the exhaust system.
  6.  
  7. Install the right front wheel.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Fill the cooling system.
  12.  
  13. Start the engine and check for leaks.
  14.  

4-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
  6.  
  7. Relieve the fuel system.

    Negative battery cable
     
    Exhaust manifold
     
    Starter motor
     
    Injector cover
     
    Throttle body cover
     
    Upper timing cover
     
    Front timing cover
     
    Throttle cable from the bracket
     
    Vacuum hose for the brake servo
     
    Turbocharger control valve from the air intake assembly
     
    Mass air flow (MAF) sensor
     
    EVAP hose
     
    Upper section of the air intake assembly
     
    Accessory drive belt
     
    Camshaft position (CMP) sensor
     
    Engine coolant temperature sensor
     
    Ignition coils and ignition cables
     
    Rear cover for the camshaft
     
    Camshaft position (CMP) sensor housing
     
    Intake manifold
     
    Timing belt
     
    Water pump inlet pipe
     
    Camshafts
     
    Valve lifters
     
    Cylinder head
     

  8.  


    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-4-Cylinder Engine

    Cylinder head loosening sequence-4-Cylinder Engine

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-4-Cylinder Engine

    Cylinder head torque sequence-4-Cylinder Engine

To install:

  1. Install the cylinder head with a new gasket. Tighten the bolts in the following sequence:
    1. Step 1: 15 ft. lbs. (20 Nm)
    2.  
    3. Step 2: 44 ft. lbs. (60 Nm)
    4.  
    5. Step 3: Plus 130 degrees
    6.  

  2.  
  3. Install or connect the following:

    Valve lifters
     
    Camshafts
     
    Water pump inlet pipe
     
    Timing belt
     
    Accessory drive belt
     
    CMP sensor housing
     
    Intake manifold
     
    Ignition coils and ignition cables
     
    CMP sensor
     
    EVAP hose
     
    MAF sensor
     
    Turbocharger control valve from the air intake assembly
     
    Brake servo vacuum hose
     
    Throttle cable
     
    Front timing cover
     
    Upper timing cover
     
    Exhaust manifold
     
    Starter motor
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
  6.  
  7. Relieve the fuel system.

    Negative battery cable
     
    Exhaust manifold
     
    Starter motor
     
    Injector cover
     
    Throttle body cover
     
    Upper timing cover
     
    Front timing cover
     
    Throttle cable from the bracket
     
    Vacuum hose for the brake servo
     
    Turbocharger control valve from the air intake assembly
     
    Mass air flow (MAF) sensor
     
    EVAP hose
     
    Upper section of the air intake assembly
     
    Accessory drive belt
     
    Camshaft position (CMP) sensor
     
    Engine coolant temperature sensor
     
    Ignition coils and ignition cables
     
    Rear cover for the camshaft
     
    Camshaft position (CMP) sensor housing
     
    Intake manifold
     
    Timing belt
     
    Water pump inlet pipe
     
    Camshafts
     
    Valve lifters
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-4-Cylinder Engine

    Cylinder head loosening sequence-4-Cylinder Engine

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-4-Cylinder Engine

    Cylinder head torque sequence-4-Cylinder Engine
     

  8.  

To install:

  1. Install the cylinder head with a new gasket. Tighten the bolts in the following sequence:
    1. Step 1: 15 ft. lbs. (20 Nm)
    2.  
    3. Step 2: 44 ft. lbs. (60 Nm)
    4.  
    5. Step 3: Plus 130°
    6.  

  2.  
  3. Install or connect the following:

    Valve lifters
     
    Camshafts
     
    Water pump inlet pipe
     
    Timing belt
     
    Accessory drive belt
     
    CMP sensor housing
     
    Intake manifold
     
    Ignition coils and ignition cables
     
    CMP sensor
     
    EVAP hose
     
    MAF sensor
     
    Turbocharger control valve from the air intake assembly
     
    Brake servo vacuum hose
     
    Throttle cable
     
    Front timing cover
     
    Upper timing cover
     
    Exhaust manifold
     
    Starter motor
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

6-Cylinder Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust front pipe
     
    Exhaust manifold heat shield
     
    Exhaust manifold
     
    Accessory drive belt
     
    Coolant pipe
     
    Front cover
     
    Timing belt
     
    Transmission mounting plate bolt
     
    Mass Air Flow (MAF) sensor
     
    Air intake assembly
     
    Accelerator cable and bracket
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve hoses
     
    Throttle body vacuum hoses
     
    Cruise control servo vacuum line
     
    Fuel supply manifold covers
     
    Fuel line retainers
     

  6.  
  7. Install fuel injector holders on the injectors.

    Fuel pressure regulator vacuum hose
     
    Fuel supply manifold with injectors attached
     
    Intake manifold
     
    Ignition coils
     
    Camshaft sprockets
     
    Camshaft Position (CMP) sensor
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Upper radiator hose
     
    Upper cylinder head
     
    Camshafts
     
    Lower cylinder head
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-6-cylinder engines

Cylinder head torque sequence-6-cylinder engines

  1. Install the lower cylinder head with a new gasket. Tighten the bolts in sequence as follows:
    1. Step 1: 15 ft. lbs. (20 Nm)
    2.  
    3. Step 2: 44 ft. lbs. (60 Nm)
    4.  
    5. Step 3: Plus 130°
    6.  

  2.  
  3. Install or connect the following:

    Camshafts
     
    Upper cylinder head. Tighten the bolts to 13 ft. lbs. (17 Nm).
     
    Upper radiator hose
     
    ECT sensor connector
     
    CMP sensor
     
    Camshaft sprockets
     
    Ignition coils
     
    Intake manifold
     
    Fuel supply manifold with injectors attached
     
    Fuel pressure regulator vacuum hose
     
    Fuel line retainers
     
    Fuel supply manifold covers
     
    Cruise control servo vacuum line
     
    Throttle body vacuum hoses
     
    IAC valve hoses
     
    TP sensor connector
     
    Accelerator cable and bracket
     
    Air intake assembly
     
    MAF sensor
     
    Transmission mounting plate bolt
     
    Timing belt
     
    Front cover
     
    Coolant pipe
     
    Accessory drive belt
     
    Exhaust manifold
     
    Exhaust manifold heat shield
     
    Exhaust front pipe
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Right axle halfshaft
     
    Nuts where the exhaust system connects with the turbocharger exhaust bends
     
    First mounting bracket for the exhaust system downstream of the three-way catalytic converter (TWC) from the car body
     
    Front Side Impact Protection System (SIPS) member from the car body
     

  6.  
  7. Separate the exhaust system from the intake manifold.
  8.  
  9. Remove or disconnect the following:

    Engine stabilizer brace
     
    Intake and charge air pipes above the engine
     
    Upper engine coolant hose
     
    Air intake assembly.
     
    Accessory drive belt
     
    Upper timing cover
     
    Front timing cover.
     
    Cover over the ignition coils.
     

  10.  
  11. Relieve the fuel pressure.
  12.  
  13. Remove or disconnect the following:
    NOTE
     Mark up and position the lifters so that their original positions can be established.



    Intake manifold
     
    Turbochargers, if equipped
     
    Exhaust manifolds
     
    Timing belt
     
    Thermostat housing
     
    Camshafts
     
    Valve lifters
     



    Intake manifold
     
    Coolant outlet pipe
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-6-cylinder engine

    Cylinder head loosening sequence-6-cylinder engine

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-6-cylinder engines

    Cylinder head torque sequence-6-cylinder engines
     

  14.  

To install:

  1. Install the cylinder head with a new gasket. Tighten the bolts in the following sequence:
    1. Step 1: 15 ft. lbs. (20 Nm)
    2.  
    3. Step 2: 44 ft. lbs. (60 Nm)
    4.  
    5. Step 3: Plus 130°
    6.  

  2.  
  3. Install or connect the following:

    Valve lifters
     
    Camshafts
     
    Thermostat housing
     
    Timing belt
     
    Fuel rail
     
    Intake pipe for coolant pump
     
    Exhaust manifolds
     
    Turbochargers, if equipped
     
    Intake manifold
     
    Front timing cover
     
    Cover over ignition coils
     
    Upper timing cover
     
    Air intake assembly
     
    Intake and charge air pipes above the engine
     
    Upper engine coolant hose
     
    Engine stabilizer brace
     
    Assemble the exhaust assembly using new fasteners
     
    Front SIPS member
     
    Right axle halfshaft
     
    Wheels
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

 
label.common.footer.alt.autozoneLogo