Section 78 (Engine - Removal, Replacement And Installation (Coupe))
WARNING: This page is about a different car, the 2002 Volvo C70, 2001 Volvo C70, 2000 Volvo C70, 1999 Volvo C70, and 1998 Volvo C70. However, it is still accessible from the selected car via links, so may be relevant.
- Adjusting The Mechanical Camshaft Belt TENSIONER (1998-1999)
- Adjusting The Mechanical Camshaft Belt TENSIONER (B5234T3; 2000-2002)
- Adjusting The Mechanical Camshaft Belt TENSIONER (B5244T; 2000-2001)
- Compression Test (B5234T3; B5254T; 1998-1999)
- Compression Test, Checking For Cylinder Leaks And Spark Plugs (1998-1999)
- Compression Test, Checking For Cylinder Leaks And Spark Plugs (B5234T3; 2000-2002)
- Compression Test, Checking For Cylinder Leaks And Spark Plugs (B5244T; 2000-2001)
- Crank Mechanism (M56; 1998-2002)
- Flywheel, replacement
- Replacing the flywheel
- Replacing the flywheel (Gasoline)
- Removing the transmission
- Installing the transmission
- Gearbox, removing
- Notes
- Disconnecting the battery lead
- Removing engine compartment components
- Removing the torque rod
- Continue removing engine compartment components
- Removing the screws from the cable harness clamps
- Removing the torque control arm
- Remove the gearbox cables from the levers on the gearbox
- Plugging the hose as far as the clutch master cylinder
- Removing the mounting screws for the gearbox and starter motor
- Removing the coolant hose from the heater unit
- Installing the lifting beam and lifting hook on the engine
- Removing the air baffle and splash guard under the engine
- Draining the gearbox fluid
- Removing the screw for the cable conduit
- Removing the nuts and screws for the steering gear from the sub-frame
- Hanging up the steering gear
- Removing the charge air pipe
- Removing the control arms and track rod (both sides)
- Removing the nut from the ball joint (both sides)
- Removing the screws from the sub-frame support plates (both sides)
- Removing the stub axle from the control arm
- Removing the drive shaft from the stub axle (right-hand side)
- Removing the sealing ring for the CV joint housing
- Removing the cap for the drive shaft support bearing
- Removing the drive shaft
- Pressing up the sub-frame on the right-hand side
- Removing the screw from the starter motor and the exhaust pipe from the turbocharger (TC)
- Removing the front cross member
- Removing the screw for the rear engine pad
- Removing the rear engine mounting
- Removing the screw and clamp from the gearbox and engine
- Preparatory work for removing the stub axle on the left-hand side
- Removing the left drive shaft from the gearbox
- Lowering the sub-frame
- Lowering the engine and gearbox
- Removing the collision protection system over the steering gear
- Preparations for removal of the gearbox
- Installing the fixture on the mobile jack
- Removing the gearbox
- Pressure plate / clutch driven plate, replacing
- Installing the gearbox
- Cleaning and lubricating the input shaft
- Checking before installing
- Adjusting the position of the engine and gearbox
- Installing and tightening the screws for the gearbox
- Installing the screw and clamp on the gearbox
- Installing the collision protection system over the steering gear (right-hand drive cars)
- Lifting the engine and gearbox to the horizontal position
- Installing the rear engine mounting
- Installing the exhaust pipe on the turbocharger (TC) and the starter motor on the engine
- Installing the subframe on the bodywork
- Installing the sealing ring for the CV joint housing
- Installing the left drive shaft on the gearbox, stub axle and control arm
- Installing the screws for the front engine pad
- Installing the delivery line on the rubber hoses and torque rod screws
- Installing and tightening the screw for the rear engine pad
- Installing the cross member
- Installing the right drive shaft on the gearbox, stub axle and control arm
- Installing new lock nuts on the steering gear
- Installing and tightening front end components (both sides)
- Tightening the ball joint pinion
- Checking the gearbox fluid level
- Installing the screw on the cable conduit
- Installing the wing liner
- Lowering the car and removing the lifting beam and lifting tools from the engine
- Installing the torque control arm
- Installing the remaining screws on the gearbox and starter motor
- Installing the gearbox cable bracket on the gearbox and the cables on the levers
- Installing service clips
- Installing the clutch pipe on the junction
- Installing the air hose on the turbocharger (TC) and the delivery line on the manifold
- Installing the coolant hose
- Installing the air cleaner (ACL) housing and the torque rod in the engine compartment
- Checking the steering gear bearing in the boot at the firewall
- Installing the engine cover
- Flywheel, replacement
- Cylinder Head (B5234T3; 1998-2002)
- Cylinder head/gasket, replacing
- Replacing the cylinder head/gasket
- Notes
- Removing the cylinder head gasket
- Preparation
- Draining coolant
- Removing components
- Draining the fuel line
- Removing the intake manifold
- Setting up the engine
- Removing the timing belt
- Removing the timing gear pulley
- Removing components from turbocharger (TC)
- Releasing the inlet pipe for the coolant pump
- Removing the camshaft cover and cylinder head
- When replacing or working on the cylinder head
- Cleaning
- Cylinder head gasket, installing
- Tightening torque
- Setting up the engine
- Installing the cylinder head
- Installing tappets and camshafts
- Applying liquid gasket
- Installing the camshaft cover
- Installing the manifold and turbocharger (TC)
- Installing the rear camshaft seal
- Installing the front camshaft seals
- Variable valve timing unit, checking and adjusting
- Installing components
- Installing the intake manifold
- Installing the fuel rail
- Check
- Variable valve timing unit, checking and adjusting
- Replacing the cylinder head/gasket
- Cylinder head/gasket, replacing
- Cylinder Head (B5244T; 2000-2001)
- Cylinder Head (B5254T; 1998-1999)
- Intake Manifold Gasket, Replacement (1998)
- Intake manifold gasket, replacement
- Lifting The Engine In And Out (1999)
- Lifting The Engine In And Out (B5234T3; 2000-2002)
- Lifting The Engine In And Out (B5244T; 2000-2001)
- New Flywheel For Turbocharged Engines (B5234T3, M56; 1998)
- New flywheel introduced on C70. Applies to following engines: B5204T3, B5234TX and B5254T
- Notes
- A new type of twin mass flywheel (TMS) was introduced in production during week 20 1997
- Replacing flywheel
- Removal of clutch
- Installing tool
- Lock flywheel
- Compress clutch
- Relieve clutch
- Install flywheel
- Install centering tool
- Install clutch driven plate and center
- Install clutch
- Remove tools
- Install transmission
- Check and test driving
- New flywheel introduced on C70. Applies to following engines: B5204T3, B5234TX and B5254T
- New Flywheel For Turbocharged Engines (B5254T, M56; 1998)
- New Routing Of Auxiliary Equipment Belt (B5234T3; B5254T; 1998-1999)
- Oil Pan (B5234T3; 1999-2002)
- Oil Pan (B5244T; 2000-2001)
- Oil Pan (B5254T; 1999)
- Replacing Bushing To Torque Control Arm (B5234T3; B5254T; 1998-1999)
- Replacing Camshafts Seal (B5234T3; B5254T; 1998-1999)
- Replacing camshafts seal
- Notes
- Front seal
- Remove expansion tank
- Turn engine crankshaft clockwise
- Remove the timing belt
- Remove and install new camshaft seal
- Remove starter motor
- Install camshaft adjustment tool 9995451, 9995452
- Install timing belt
- Adjusting the mechanical belt tensioner
- Tighten the timing belt
- Install fuel line clamps
- Install engine cooling fan
- Rear seal
- Replacing camshafts seal
- Replacing Cylinder Head Gasket (1998-1999)
- Cylinder head gasket, replacement
- Removing the cylinder head gasket
- Drain the coolant and loosen the front exhaust pipe
- Drain the fuel line
- Removing components
- Set the engine according to the marking
- Removing the timing belt
- Remove parts at the engine's trailing edge
- Remove timing gear pulley with variable valve timing unit. Applies to turbo engines.
- Remove the timing belt pulleys. Applies to aspiration engine.
- Loosen the camshaft cover
- Remove the cylinder head
- Installing cylinder head gasket
- Clean the gasket surfaces
- Secure the crankshaft position
- Change cylinder head gasket
- Apply liquid gasket
- Install the camshaft cover
- Install the front camshaft seal.
- Install timing belt pulley with VVT-unit. Applies to turbo engines.
- Install the timing belt pulley. Applies to aspiration engine.
- Install timing belt.
- Tighten the timing belt
- Check indicator on tensioner
- Install the rear camshaft seal.
- Installing components
- Install and fill
- Finishing
- Removing the cylinder head gasket
- Cylinder head gasket, replacement
- Replacing Cylinder Head/Gasket (B5234T3; B5254T; 1998-1999)
- Cylinder head/gasket, replacing
- Notes
- Drain the coolant and detach the front exhaust pipe
- Remove the exhaust manifold and fuel rail
- Remove camshaft pulleys
- Remove rear components:
- Remove the upper half of the cylinder head
- Remove the cylinder head
- Clean gasket face between the cylinder head's top/bottom half
- Position the crankshaft according to the marking
- Install the lower cylinder head half
- Apply liquid gasket
- Install the upper cylinder head half
- Install the camshaft seals, front
- Install the camshaft pulleys
- Adjusting the mechanical belt tensioner
- Install the timing belt
- Tighten the camshaft pulleys
- Remove the holding tools
- Check the markings
- Install the rear camshaft seal
- Install the air cleaner (ACL) housing with all hoses and connectors
- Install the splash guard under the engine
- Top up coolant / Change oil and oil filter
- Remove the camshaft pulley
- Remove rear components
- Clean cylinder head gasket surface
- Install ignition components
- Modification of crankcase ventilation with new cylinder head/engine
- Cylinder head/gasket, replacing
- Replacing The Auxiliaries Belt / Belt TENSIONER (1998-1999)
- Replacing The Auxiliaries Belt / Belt TENSIONER (B5234T3; 2000-2002)
- Replacing The Auxiliaries Belt / Belt TENSIONER (B5244T; 2000-2001)
- Replacing The Camshaft Seal / Variable Valve Timing (VVT) Unit (1998-1999)
- Replacing the camshaft seals / variable valve timing (VVT) unit
- Notes
- Removing the camshaft seal
- Position the engine according to the marking
- Removing the camshaft belt
- Removing the timing gear pulley with the variable valve timing (VVT) unit
- Install the adjustment tools
- Remove the timing gear pulley
- Replace the camshaft seal
- Remove the engine cooling fan (FC)
- Secure the crankshaft position
- Reinstall timing belt components
- Installing the timing belt
- Tighten the timing belt
- Checking the markings and belt tension
- Reinstall camshaft components
- Checking work
- Replacing the rear seal
- Replacing the rear camshaft seal
- Reinstall camshaft components and covers
- Checking the engine
- Replacing the variable valve timing (VVT) control valve
- Replacing the camshaft seals / variable valve timing (VVT) unit
- Replacing The Camshaft Seal / Variable Valve Timing (VVT) Unit (B5234T3; 2000-2002)
- Replacing The Camshaft Seal / Variable Valve Timing (VVT) Unit (B5244T; 2000-2001)
- Replacing The Engine Pad (B5234T3; 1998-2002)
- Replacing The Engine Pad (B5244T; 2000-2001)
- Replacing The Engine Pad (B5254T; 1998-1999)
- Replacing The Flame Trap Seals (1999)
- Replacing The Flame Trap Seals (B5234T3; 2000-2002)
- Replacing The Flame Trap Seals (B5244T; 2000-2001)
- Replacing The Intake Manifold / Gasket (B5234T3; 1999-2002)
- Replacing The Intake Manifold / Gasket (B5244T; 2000-2001)
- Replacing The Intake Manifold / Gasket (B5254T; 1999)
- Replacing The Oil / Oil Filter (1998-1999)
- Replacing The Oil / Oil Filter (B5234T3; 2000-2002)
- Replacing The Oil / Oil Filter (B5244T; 2000-2001)
- Replacing The Oil Cooler (1998-1999)
- Replacing The Oil Cooler (B5234T3; 2000-2002)
- Replacing The Oil Cooler (B5244T; 2000-2001)
- Replacing The Rear Crankshaft Seal (1998-1999)
- Replacing The Rear Crankshaft Seal (B5234T3; 2002)
- Replacing The Three-Way Catalytic Converter (TWC) (1999)
- Replacing The Three-Way Catalytic Converter (TWC) (B5234T3; 2000-2002)
- Replacing The Three-Way Catalytic Converter (TWC) (B5244T; 2000-2001)
- Replacing The Timing Belt / Idler Pulley / Belt TENSIONER (1999)
- Replacing The Timing Belt / Idler Pulley / Belt TENSIONER (B5234T3; 2000-2002)
- Replacing The Timing Belt / Idler Pulley / Belt TENSIONER (B5244T; 2000-2001)
- Replacing The Turbocharger (TC) Exhaust Manifold / Gasket (1999)
- Replacing The Turbocharger (TC) Exhaust Manifold / Gasket (B5234T3; 2000-2002)
- Replacing The Turbocharger (TC) Exhaust Manifold / Gasket (B5244T; 2000-2001)
- Replacing Timing Belt (B5234T3; B5254T; 1998)
- Replacing Valve Stem Seal (B5234T3; B5254T; 1998-1999)
- Torque Bracket (1999)
- Torque Bracket (B5234T3; 2000-2002)
- Torque Bracket (B5244T; 2000-2001)
- Turbocharged Engine, Lift In And Out (B5234T3; B5254T; 1998-1999)
- Engine replacement, transferring components (Turbo)
- Lifting engine in
- Notes
- Lift in engine with transmission
- Install the engine cable harness
- Install fuel rail
- Install cooling hoses
- Install intake hose
- Install idle air trim
- Install the engine cooling fan (FC)
- Install air duct
- Install heated oxygen sensor
- Install charge air pipe
- Install air cleaner (ACL) housing
- Install battery
- Install front and rear engine mounting screws
- Install bearing
- Install ABS cable/brake pipe bracket screw
- Reinstall on both sides:
- Lower car
- Top up coolant and engine oil
- Turbocharged engine, removal and installation
- Notes
- Removing engine
- Drain coolant
- Remove control arm nuts
- Remove left drive shaft
- Remove transmission torque rod screw
- Remove front and rear engine mountings lower screws
- Remove throttle cable from throttle pulley
- Disconnect hoses/connectors:
- Remove the air cleaner (ACL) housing
- Remove heated oxygen sensor (HO2S) connector and clips
- Remove the engine coolant fan (FC)
- Remove the protective cover over the starter motor
- Remove gear selector cables
- Remove power steering pump screws
- Remove air conditioning (A/C) compressor
- Remove the cable duct bracket screws
- Remove fuel rail protective cover
- Remove the fuel rail
- Expose the engine cable harness
- Remove engine with transmission