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Home >> Volvo >> 2000 >> S70 GLT SE >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Mechanical >> 2.3L & 2.4L 5-Cylinder, Turbo >> Removal & Installation >> Cylinder Head >> Installation

Cylinder Head: Installation

  1. Set up the engine. Position the crankshaft. Remove the starter motor mounting bolts. Pull out the starter motor and place it to one side.
  2. Remove the blind cover plug. Turn the crankshaft slightly clockwise. Install Crankshaft Stop (999 5451). See Fig 1. Ensure that it bottoms out against the cylinder block. Turn the crankshaft counterclockwise until it stops against the crankshaft stop. Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.
    Fig 1: Identifying Crankshaft Stop (999 5451)
    G00235277Courtesy of VOLVO CARS OF NORTH AMERICA.
    3. NOTE: Manufacturer recommends using all NEW cylinder head bolts.
  3. Install the cylinder head. Ensure that all studs at the exhaust ports are tightened. Lubricate the studs with Paste (116 1408). Install a new cylinder head gasket. Install the cylinder head. Lubricate and install all the new bolts.
  4. Tighten the bolts in order. See Fig 2. Tighten the bolts in sequence to the following specification;

    1. First Pass

      15 ft. lbs. (20 N.m).

    2. Second Pass

      44 ft. lbs. (60 N.m).

    3. Final Pass

      Tighten an additional 130 degrees.
    Fig 2: Identifying Cylinder Head Tightening Sequence
    G00235278Courtesy of VOLVO CARS OF NORTH AMERICA.
  5. Install valve lifters and camshafts. Lubricate the valve guide wells. Install all the valve lifters. Lubricate the camshaft bearing seats. Install the intake camshaft. Ensure that the groove at the back of the camshaft is above an imaginary center line. See Fig 3.
    Fig 3: Aligning Camshafts
    G00235279Courtesy of VOLVO CARS OF NORTH AMERICA.
  6. Position the exhaust camshaft. Ensure that the groove at the back of the camshaft is below an imaginary center line. See Fig 3.
  7. Apply liquid gasket. Install new "O" rings around the spark plug wells at the cylinder head. Apply Liquid Gasket (1161 059), or equivalent, to the camshaft cover. The surface must be completely covered without any excess. Ensure that no liquid gasket gets in to the oil ducts.
    Fig 4: Applying Liquid Gasket (1161 059) To Camshaft Cover
    G00235244Courtesy of VOLVO CARS OF NORTH AMERICA.
  8. Install the camshaft cover. See Fig 5. Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters. Install the camshaft cover. Install Cylinder Head Press Tools (999 5454). See Figure.
    Fig 5: Installing Camshaft Cover
    G00235245Courtesy of VOLVO CARS OF NORTH AMERICA.
  9. Tighten the camshaft cover bolts alternately to specification, keeping it parallel to the cylinder head using the press tools. See ENGINE SPECIFICATIONS - 2.3L & 2.4L, 5-CYLINDER article. Install the intake manifold and lifting eyes. Tighten bolts from the middle and outwards. Remove the press tools.
  10. Install the variable valve timing solenoid (if applicable). See Figure and Figure . Use a new gasket. Install the spark plugs and tighten to 22 ft. lbs. (30 N.m). Install the hose for water-heated crankcase ventilation to the thermostat housing. Tighten the clamp.
  11. Connect the connector for the engine coolant temperature sensor. Install the inlet pipe for the coolant pump on the cylinder head. See Figure. Use a new gasket. Apply appropriate thread sealant to the bolt. Install the bolt for mounting the coolant pump inlet pipe to the cylinder block.
  12. Install the manifold and turbocharger. Install new gaskets. Lift and install the manifold and turbocharger. Install the following components;
    • Nuts and washers holding the manifold to the cylinder head.
    • Heat deflector plate above the manifold.
    • Upper turbocharger coolant pipe. Tighten the clamp on the rubber hose. See Figure.
    • Pipe bolts for the coolant pipes. Use new seal washers.
    • Oil pressure pipe.
    • Pipe bolt holding the oil pressure pipe to the turbocharger. Use new seal washers. Do not tightenyet.
  13. Lubricate the studs on the turbocharger. Use Paste (116 1408), or equivalent. Install the front exhaust pipe onto the turbocharger. Use new nuts. Do not tighten.
  14. Install the rear camshaft seal using Drift (999 5450). See Fig 6. Lubricate the surface of the seal that the camshaft rotates against. Press in the seal until the drift bottoms out. If there are grooves on the camshaft, the seal can be pressed in a further 0.08" (2 mm), reverse the sleeve.
    Fig 6: Installing Rear Camshaft Seal
    G00240323Courtesy of VOLVO CARS OF NORTH AMERICA.
  15. Install Camshaft Locking Tool (999 5452) at the rear of the camshafts. See Fig 7. Ensure that the bolts retaining the adjustment tool to the camshafts and the bolts holding the tool together are well tightened.
    Fig 7: Using Locking Tool (5452) To Secure Camshafts
    G93F01243Courtesy of VOLVO CARS OF NORTH AMERICA.
  16. Install the front camshaft seals. Use drift (999 5718) at the camshaft with the variable valve timing unit. Use drift (999 5719) at the camshaft without the variable valve timing unit. See Fig 8. Lubricate the surface of the seal that the camshaft rotates against.
    Fig 8: Installing Front Camshaft Seals
    G00240324Courtesy of VOLVO CARS OF NORTH AMERICA.
  17. Using the variable valve timing unit/timing belt pulley mounting bolts, tighten the bolts until the drift bottoms out. Remove the drift. Install the bolt holding the inner timing cover to the cylinder head.
  18. Install the timing gear pulley. On camshafts with variable valve timing units, loosen, but do not remove the bolts which secure the timing gear pulley to the variable valve timing unit. Press the variable valve timing unit and timing gear on to the camshaft.
  19. Install the center bolt which secures the variable valve timing unit to the camshaft. Do not fully tighten yet. Position the upper timing cover.
  20. Remove the center screw from the variable valve timing unit. Turn the timing gear pulley CLOCKWISE until the screws at the oval holes are in the limit position. Continue turning timing gear pulley CLOCKWISE until the timing gear pulley marking is 1 cog before the marking on the upper timing cover. See Fig 9. DO NOT turn counterclockwise during this procedure.
    Fig 9: Aligning Timing Belt Marks (Variable Valve Timing Unit 1 Cog Before Marking On Upper Timing Cover)
    G00235260Courtesy of VOLVO CARS OF NORTH AMERICA.
  21. Check that the timing gear pulley is still in its limit position at the oval holes. Tighten the center bolt for the variable valve timing unit to 89 ft. lbs. (120 N.m). Check that the variable valve timing unit does not rotate when tightening. Install the center plug of the variable valve timing unit. Tighten to 26 ft. lbs. (35 N.m).
  22. On camshafts with timing gear pulleys without variable valve timing units, install the timing gear pulley on the camshaft with 2 bolts. Do not fully tighten bolts yet. Check that the markings on the timing gear pulley and the upper timing cover correspond. See Figure.
  23. Tighten the center screw on the timing belt tensioner. Tighten to 44 INCH lbs. (5 N.m.).
  24. Turn the variable valve timing unit clockwise to the stop. Use a Tx55 torx wrench applied at the center plug. Hold variable valve timing unit secure in the limit position.
  25. Install the timing belt in the following order;
    • Crankshaft
    • Idler pulley
    • Intake camshaft
    • Exhaust camshaft. See Fig 10.
    • Water pump
    • Belt tensioner. See Figure.
  26. Adjust the timing gear pulleys so that the bolts are not at a limit position in the oval holes. Ensure that the markings correspond. See Figure.
    Fig 10: Aligning Camshaft Timing Belt Marking (Variable Valve Timing Unit)
    G00240325Courtesy of VOLVO CARS OF NORTH AMERICA.
  27. Tighten the timing belt. This adjustment is always carried out on a cold engine 68°F (20°C). At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right. See Fig 11.
    Fig 11: Adjusting Timing Belt Tension
    G00039903Courtesy of VOLVO CARS OF NORTH AMERICA.
    28. NOTE: The variable valve timing unit must not be released from the limit position until after the timing gear pulleys have been tightened.
  28. Hold the center bolt secure and turn the belt tensioner eccentric counterclockwise until the tensioner indicator passes the marked position. Tighten the 3 bolts on the exhaust camshaft timing gear pulley to 89 INCH lbs. Install the bolt missing on the intake timing belt pulley.
  29. Turn the eccentric back so that the indicator reaches the marked position in the center of the window. Remember to hold the center bolt secure at the same time. Hold the eccentric secure and tighten the center bolt.
  30. Remove Camshaft Adjustment Tool (999 5451). Remove Crankshaft Stop (999 5452). Install the plug with a new sealing washer.
  31. Check the timing belt markings and tension. Press the timing belt to check that the indicator on the tensioner moves easily. See Fig 12. Turn the crankshaft 2 turns. Check that the markings on the crankshaft pulley and timing gear pulley match up with the markings on the oil pump and upper timing cover respectively. Check that the indicator on the belt tensioner is within the marked position.
    Fig 12: Checking Timing Belt Tension
    G00235261Courtesy of VOLVO CARS OF NORTH AMERICA.
  32. Remove the upper timing cover. Install the following components;
    • Front timing cover.
    • Cable duct to the mountings on the right suspension turret.
    • Accessory drive belt. See DRIVE BELT ROUTING .
    • Expansion tank.
    • Servo oil reservoir.
    • Bleed hose to the expansion tank. Tighten the clamp.
  33. Check that the hoses are correctly positioned. Connect the connectors for the ABS sensor at the right suspension turret and for the coolant level sensor in the expansion tank.
  34. Install the following components;
    • Starter motor.
    • Pipe bolt for the water-heated crankcase ventilation at the rear of the cylinder head. Use new seal washers.Tighten to 19 ft. lbs. (26 N.m).
    • Camshaft position sensor housing and trigger wheel.
    • New cover at the rear of the intake camshaft.
    • Upper engine stabilizer brace.
    • Bracket and lifting eyelet for the engine stabilizer brace bracket.
    • Ignition coils and ground terminals according to earlier markings.
    • Connect the connector for the variable valve timing solenoid (if applicable).
    • Clamp for the positive lead at the lifting eyelet bracket.
    • Plastic intake pipe to the mass air flow sensor. Tighten the clamp.
    • Connect the connector to the mass airflow. Clamp the wiring at the front of the air cleaner.
  35. Install the intake manifold. Clean the intake manifold gasket face to the cylinder head. Install a new gasket on the cylinder head. Secure with the three bolts in the lower row. Lower and twist the intake manifold so that the fuel pressure line goes through the cavity in the intake manifold. Take care not to damage the fuel pressure pipe. Route the crankcase ventilation hose through the cavity in the intake manifold.
  36. Pipe bolt for the crankcase ventilation on the underside of the intake manifold. Use new seal washers. Tighten bolt to 19 ft. lbs. (26 N.m).
  37. Install remaining bolts holding the intake manifold to the cylinder head.Starting from the center and working outward, tighten all intake manifold screws to 15 ft. lbs. (20 N.m).
  38. Install the following components;
    • Hose to the canister purge valve.
    • Control hose for the turbocharger by-pass valve.
    • Brake vacuum hose.
    • Crankcase ventilation hose to the top of the camshaft cover. Use a new clamp.
    • Cover over the ignition coils.
    • Upper timing cover.
    • Upper engine coolant hose for the engine and radiator. Tighten the clamp.
    • Bolt holding the dip stick pipe to the intake manifold.
    • Connect the connector for the electronic throttle module.
    • Charge air pipe between the throttle body and the charge air cooler. Remove the seal. Tighten the clamp.
  39. Install the fuel rail, using new bolts. Press the quick-release connector for the fuel pressure line until it clicks. Install the clamp for the injector wiring at the rear of the cylinder head. Install the protective cover over the injector connectors. Install the charge air pipe over the engine. Tighten the pipe using the three bolts on the engine. Tighten the clamps.
  40. Raise the car. Install the following components;
    • Pipe bolt that holds the turbocharger oil pressure pipe to the engine. Use new seal washers. Tighten bolt to specification. See ENGINE SPECIFICATIONS - 2.3L & 2.4L, 5-CYLINDER .
    • Turbocharger oil return line. Use a new gasket and sealing ring.
    • Clamp between the oil pressure pipe and the oil return line.
    • Bolts and spacers at the manifold support bracket and cylinder block.
    • Tighten the three nuts that hold the front exhaust pipe to the turbocharger.
    • Splash guard under the engine.
    • Plastic nuts for the hatch in the right fender liner.
    • Right front wheel.
    41. WARNING: The key must be in position 2. No one must be in the car when the battery is connected. This is a safety precaution in case an airbag module activates when the power is connected.
  41. Lower the car. Tighten the pipe bolt for the turbocharger oil pressure pipe.Install the following components;
    • Heat deflector plate above the turbocharger.
    • Ground strips between the cylinder head and the firewall.
    • Engine stabilizer brace between the suspension turrets.
    • Clamp the servo hose at the right engine stabilizer brace mounting.
    • Battery negative lead.
  42. Some electrical system functions may need a relearn procedure whenever the battery is disconnected. See BATTERY DISCONNECT PRECAUTIONS & RELEARN PROCEDURES .
  43. Replace the oil and oil filter (if necessary). Check the engine oil level, the servo oil level and the coolant level. Warm up the engine until the thermostat opens. Check the engine for leaks. Top up the coolant if necessary.
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