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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 >> Removal

Cylinder Head: Removal

  1. Remove the radiator breather tube from the expansion tank. Install lock grip pliers. See Fig 1. Remove the battery negative lead. Remove the right front wheel.
    Fig 1: Securing Radiator Breather Tube
    G00235269Courtesy of VOLVO CARS OF NORTH AMERICA.
  2. Drain coolant. Raise the car. Remove the splash guard under the engine. See Figure. Open the engine nipple. Drain the coolant into a container. Close the nipple.
  3. Remove the following components;
    • Clamp between the oil pressure pipe and the oil return line at the turbocharger. See Figure.
    • Pipe bolt that holds the oil pressure pipe to its connector on the cylinder block.
    • Oil return line. Seal the opening in the cylinder block.
    • Bolts and spacers at the exhaust manifold support bracket.
    • Lower bolt that holds the heat deflector plate over the turbocharger.
    • Nuts for the front exhaust pipe connection to the turbocharger.
    4. NOTE: The metal hose for the front exhaust pipe is easy to damage if it is twisted. Handle the exhaust hose with care to avoid leakage later.
  4. Lift off the exhaust pipe and secure out of the way. Seal the opening in the exhaust pipe.
  5. Drain the fuel line. See DRAINAGE OF FUEL SYSTEM  under FUEL PRESSURE RELEASE.
  6. Remove the following components;
    • Engine stabilizer brace between the suspension turrets.
    • Ground strips between the engine and the firewall.
    • Heat deflector plate above the turbocharger.
    • Plastic charge air pipe above the engine. Seal the openings.
    • Cover over the ignition coils.
    • Upper engine coolant hose for the engine and radiator.
    • Bolt holding the dip stick pipe to the intake manifold.
    • Brake vacuum hose from the intake manifold.
    • Undo the clamp holding the plastic charge air pipe to the electronic throttle module.
  7. Remove the connector from the mass air flow sensor. Remove the intake hose from the mass air flow sensor. Seal the opening.
  8. Release the hoses from the bracket at the rear of the cylinder head. Remove the bracket. Remove the clamp for the positive lead at the rear of the cylinder head.
  9. Remove the torque bracket. Remove the pipe bolt for the water-heated crankcase ventilation.
  10. Remove 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 bolts.
  11. 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.
  12. Remove ignition coils. Mark the ignition coils so that the original positions can be established. Remove the mounting bolts for the ignition coils and the bolts at the two ground terminals. Disconnect the connector for the variable valve timing solenoid (if equipped). Lift up and place the ignition coils and wiring to one side.
  13. Remove the crankcase ventilation hose from the top of the camshaft cover. Remove the camshaft position sensor housing and trigger wheel. Remove the cover at the rear of the intake camshaft.
  14. Remove the intake manifold. Remove the EVAP hose from the intake manifold. Remove the by-pass valve vacuum hose. Remove the upper row of bolts holding the intake manifold to the cylinder head. Loosen the lower bolts.
  15. Remove the pipe bolt 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. Ensure that the fuel pressure pipe is not damaged.
  16. 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. Ensure that oil does not leak from the ventilation hole in the filler cap. Take off the accessory drive belt (fan belt). See DRIVE BELT ROUTING .
  17. Remove the front timing cover. Remove the hose for the water-heated crankcase ventilation from the thermostat housing. Separate the connector for the engine coolant temperature sensor.
  18. Set up the engine. Remove the nuts from the cover on the fender liner. Position the upper timing cover. Turn the crankshaft clockwise until the markings on the crankshaft and camshafts correspond. See Fig 2. Remove the upper timing cover.
    Fig 2: Aligning Camshaft & Crankshaft Timing Belt Marks
    G00283838Courtesy of VOLVO CARS OF NORTH AMERICA.
  19. Remove the timing belt. Loosen the center bolt for the belt tensioner slightly. Hold the center bolt secure and turn the tensioner eccentric clockwise with a 6 mm Allen key to 10 o'clock. See Fig 3.
    20. CAUTION: To prevent engine damage, DO NOT turn crankshaft or camshafts while timing belt is removed.
    Fig 3: Identifying Timing Belt Tensioner
    G00240329Courtesy of VOLVO CARS OF NORTH AMERICA.
    Fig 4: Identifying Timing Belt Routing
    G00039902Courtesy of VOLVO CARS OF NORTH AMERICA.
  20. Remove the timing belt from the timing gear pulley. See Fig 4. Remove the bolt that holds the inner timing cover to the cylinder head. Install Tool (999 5452) at the rear of the camshafts.
  21. Remove the timing gear pulley. Remove the cable duct from its mountings on the right-hand suspension turret. Do not damage the paintwork. Hold the cable duct out of the way and remove.
  22. Remove the plug at the front of the variable valve timing unit (if equipped). See Fig 5 and Fig 6 . Remove the center bolt in the variable valve timing unit. Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit.
    Fig 5: Locating Variable Valve Timing Unit
    G00235270Courtesy of VOLVO CARS OF NORTH AMERICA.
    Fig 6: Exploded View Of Variable Valve Timing Unit
    G00240326Courtesy of VOLVO CARS OF NORTH AMERICA.
  23. On models without variable valve timing units, remove bolts and remove the timing gear pulley using Removal Tool (999 5452).
    Fig 7: Identifying Timing Gear Removal Tool (999 5452)
    G00235259Courtesy of VOLVO CARS OF NORTH AMERICA.
  24. On all models, remove the following components from turbocharger;
    • Upper coolant pipe with the hose.
    • Heat deflector plate above the manifold.
    • Oil pressure (intake) pipe for the turbocharger. See Figure.
    • Pipe bolt at the lower coolant pipe for the turbocharger. Put the pipe to one side.
    • Nuts and washers holding the manifold to the cylinder head.
    Lift off the turbocharger and manifold. Carefully put them on top of the transmission.
    Fig 8: Locating Turbocharger Unit
    G00235271Courtesy of VOLVO CARS OF NORTH AMERICA.
  25. Release the inlet pipe for the coolant pump. Remove the bolt that holds the inlet pipe for the coolant pump on the cylinder block. Remove the two bolts for the connection between the coolant pipe and the bypass channel. See Fig 9. Carefully turn the pipe to remove it from the cylinder block.
    Fig 9: Identifying Coolant Pump Inlet Pipe
    G00235272Courtesy of VOLVO CARS OF NORTH AMERICA.
  26. Remove the camshaft cover and cylinder head. Remove the spark plugs from cylinders 1 and 5. Install 2 Cylinder Head Press Tools (999 5454). See Fig 10. Leave a 0.08-0.12" (2-3 mm) gap to the camshaft cover. Ensure that the bolt in the spark plug well is fully tightened. Remove variable valve timing solenoid. Remove all the bolts securing the camshaft cover to the cylinder head.
    Fig 10: Installing Cylinder Head Press Tools (999 5454)
    G00235273Courtesy of VOLVO CARS OF NORTH AMERICA.
  27. Use Pliers (999 5670) to lift the cover from the cylinder head. Install the pliers at the stop lugs. See Fig 11. Start with cylinder 1 and work alternately backward. Loosen the wing nuts approximately 2 turns. Repeat the procedure. Carefully press out the front and rear camshaft seals. See Fig 12.
    Fig 11: Lifting Off Cylinder Head Cover
    G00235274Courtesy of VOLVO CARS OF NORTH AMERICA.
    Fig 12: Pressing Out Camshaft Seals
    G00235275Courtesy of VOLVO CARS OF NORTH AMERICA.
  28. Remove Cylinder Head Press Tools (999 5454). Remove the camshaft cover. Remove the camshafts. Remove the bolts holding the cylinder head onto the cylinder block. Start at the sides and work alternately towards the center. See Fig 13.
    Fig 13: Identifying Cylinder Head Bolt Loosening Sequence
    G00235276Courtesy of VOLVO CARS OF NORTH AMERICA.
  29. Use assistance to lift off the cylinder head. Do not damage the mating surfaces.
    30. NOTE: Keep the valve lifters in a container filled with oil to stop them draining.
  30. When replacing or working on the cylinder head. Lift out the valve lifters. Use a magnet or suction cup.
  31. Remove the thermostat housing.
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