Motor B5244S PDF

2001 Volvo S60
Engine Engine - Overhaul Instructions
Engine
Engine - Overhaul Instructions
CRANK MECHANISM (B5204T5; 2004)

CRANK MECHANISM, ASSEMBLING
Special tools:
9512767
9991801
9995676
9995746
NOTE: Since 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.
List of tightening torques
For tightening torques not in the text, see Tightening torque .
Cleaning
Ensure that the all components are completely clean.
Blow clean the oil ducts in the block, intermediate section and oil pan.
Installing the piston cooling valve and nozzles
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9:28:02 a. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
2001 Volvo S60
Fig. 1: Identifying Piston Cooling Nozzles

Courtesy of VOLVO CARS OF NORTH AMERICA.
Install the piston cooling nozzles. Tighten to 17 Nm .
Fig. 2: Identifying Piston Cooling Valve

Install the piston cooling valve. Use a seal washer. Tighten to 38 Nm .
Classification of main bearings
Fig. 3: Identifying Classification Marking On Block And Crankshaft

Wipe clean the bearing recesses in the block and the intermediate section.
Check that the components are clean and undamaged.
Check the classification of the block and crankshaft.
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2001 Volvo S60
The classification marking is at the rear edge of the block and the crankshaft. The classification is read from
digits 1 to 7. The first letter after digit 1 is the classification of main bearing 1. The bearing positions are
numbered starting at the front of the engine.
Selecting bearings
Cylinder block A small B medium- C large diameter

classification diameter diameter
/
Crankshaft
classification
block intermediate block intermediate block intermediate
section section section
A yellow yellow medium yellow blue thick blue thick blue thick
small medium medium
B red thin yellow medium yellow yellow medium yellow blue thick
medium medium medium
C red thin red thin red thin yellow medium yellow yellow medium
large medium
Install the main bearings in the cylinder block and the intermediate section.
The axial bearing is positioned at bearing recess 5.
CAUTION: When reusing old bearing halves, make sure that they are positioned
correctly with regards to crankshaft's rotational direction.
For example: The marking on the block at bearing recess 1 is B. The marking on the crankshaft at the
corresponding bearing recess is C.
Therefore the bearing in the block is marked red and the bearing in the intermediate section is marked yellow.
NOTE: The thickest bearing halves must always be installed in the intermediate
section. This is in order to obtain a center line that is as straight as possible.
The intermediate section
2001 Volvo S60
Fig. 4: Identifying Liquid Gasket 11 61 059 Applied On Intermediate Section

Wipe the surfaces dry.
Apply liquid gasket 11 61 059 on the intermediate section. The surface must be completely covered without any
excess. Use roller 9512767
Thoroughly lubricate all the bearing shells and the surface of the axial bearing.
Tightening the intermediate section
Fig. 5: Identifying Intermediate Section Bolt Locations

Install the two old screws for the flywheel and carrier plate at the rear edge of the crankshaft.
Lift these and the front of the crankshaft.
Carefully position the crankshaft in the block.
2001 Volvo S60
The crankshaft must not be turned before the intermediate section has been torque tightened. Position the
intermediate section.
Lubricate and install all the screws.
NOTE: Use new M10 bolts.
Install the intermediate section and the screws on the exhaust side at bearing recesses 2 and 5.
CAUTION: The M8 bolts on the exhaust side have two different lengths.
Pull down the intermediate section.
Tighten the screws in the following order:
1. All M10 screws........20 Nm

2. All M10 bolts........45 Nm
3. All M8 bolts........24 Nm
4. All M7 bolts........17 Nm
5. Angle-tighten all M10 screws........90°
Tighten the screws in sequence from the center and outwards.
Marking the connecting rod (where applicable)
Fig. 6: Marking Both Halves With Cylinder Number Using A Center Punch Or Number Punch
Assemble the connecting rod. Check that the cover is facing the correct direction. Tighten to 20 Nm .
Secure the large end of the connecting rod in a vise with soft jaws (copper or aluminum).
2001 Volvo S60
Mark both halves with the cylinder number. Use a center punch or number punch.
The bearing shell with the black color coding on the side must be installed in the connecting rod.
Installing piston rings
Fig. 7: Identifying Compression Ring, Scraper Ring And Oil Ring

Use piston ring pliers.
Turn the piston rings so that the openings are offset as illustrated.
A=Compression ring. The text on the piston ring must be upwards.
B=Scraper ring. Chamfered edge must face downwards.
C=Oil ring. Three sections, identical on all sides.
First install the expander ring (C), then the two other rings over the expander ring.
CAUTION: Make sure that the piston rings are not stuck but can be turned easily.
2001 Volvo S60
NOTE: Incorrect positioning increases oil consumption.
Assembling pistons and connecting rods
Fig. 8: Identifying Snap Ring Positioning

There is an arrow on top of the piston. This must be turned forwards in the cylinder block.
The connecting rods are symmetrical and can be turned freely. Marked rods however must be turned in the
same direction.
Assemble the connecting rod and piston with the piston pin.
Check that the classification of each cylinder/piston diameter and that any numbering of the connecting rod
correspond.
Install both the snap rings on the piston pin. Check that the snap rings are positioned correctly in the piston. The
opening must be vertical.
WARNING: The lock ring can easily fly off. Protect your eyes
2001 Volvo S60
Wipe clean around the bearing recess in the connecting rod and the cap.
Install the bearing shells.
If new bearing shells are used, these must be checked for color coding.
NOTE: Bearing shell with a black color marking on the side shall be installed in the
connecting rod.
CAUTION: If reusing bearing shells, they must be installed in the same position as
before. Make sure that they are positioned correctly with regards to the
crankshaft's rotational direction.
Installing the pistons in the cylinder bores
Fig. 9: Identifying Cylinder Ring Compressor

Use a cylinder ring compressor.
Lubricate the cylinder bore, the pistons and the bearing shells.
Turn the crankshaft so that the connecting rod pin is at bottom dead center (BDC) for the cylinder the piston is
to be inserted in.
Ensure that the engine is in a position where the cylinder bore forms as vertical a line as possible.
NOTE: The piston's arrow (on top of the piston) must point forwards, and make sure
that the classification matches
Carefully press or tap the piston down (using the shaft of a hammer or similar).
When the piston releases from the piston ring compressor, turn the engine 180° in the stand.
2001 Volvo S60
Install tool 9995746 in the connecting rod.
Pull the connecting rod until it secures against the big end journals.
Tightening the connecting rod cover
Fig. 10: Identifying Connecting Rod Cover

Install the cover. Check that any markings correspond.
Lubricate and install new seals. Tighten in two stages:
Tighten the connecting rod cap. Acc. to Tightening torque
Check that the connecting rod can be moved sideways.
NOTE: The crankshaft must not be rotated before the connecting rod cover has been
tightened.
Installing the oil pump suction pipe
2001 Volvo S60
Fig. 11: Identifying Oil Pump Suction Pipe

Install a new sealing ring on the suction pipe.
Carefully press the suction pipe down into the intermediate section.
Check that the sealing ring is correctly positioned.
Tighten.
Install new sealing rings for the oil pan oil ducts.
Installing the oil pan
Fig. 12: Identifying Liquid Gasket Applied To Oil Pan

Apply liquid gasket 11 61 059 on the oil sump. Use roller 9512767 .
2001 Volvo S60
The surface must be completely covered without any excess.
Position the pan and install all screws
CAUTION: Check that the rear edge of the oil pan is in line with the rear edge of the
cylinder block. Permissible tolerance 0.025 mm. Use a steel ruler and
feeler gauge.
Tighten the screws from the rear of the pan and forward.
Installing the oil cooler
Fig. 13: Identifying Oil Cooler

Install
 new sealing rings in the sump

 the oil cooler. Tighten
 the oil filter.
Installing the rear crankshaft seal
2001 Volvo S60
Fig. 14: Identifying Rear Crankshaft Seal

Use standard handle 9991801 and drift 9995676 .
Lubricate the drift face and thread the sealing ring onto the drift.
Tap in the seal until the drift bottoms against the block.
DISASSEMBLING THE CRANKSHAFT ASSEMBLY
Disassembling the crankshaft assembly
Special tools:
9995458
9995679
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.
Preparation
2001 Volvo S60
Fig. 15: Identifying Oil Trap, Knock Sensors, Front Engine Mounting And Oil Pressure Switch
Remove
 oil trap
 knock sensors (KS)
 the front engine mounting
 the oil pressure switch.
Fig. 16: Identifying Oil Cooler And Rubber Seals

Remove
 the bearing retainer for the right drive shaft

 the oil cooler and the rubber seals.
Removing the oil filter and oil pan
2001 Volvo S60
Fig. 17: Identifying Oil Filter

Remove the oil filter. Use tool: 9995679 .
Remove the screws securing the oil pan to the intermediate section.
Carefully tap the side of the oil pan with a rubber mallet.
Lift out the oil pan.
Removing the suction pipe from the oil pump

Remove the O-rings from the oil ducts.
Remove the screws securing the suction pipe to the intermediate section.
Work loose and lift out the suction pipe.
2001 Volvo S60
Remove the suction pipe O-ring.
Check the pipe and the strainer.
Checking markings
Fig. 19: Identifying Check Of Marks On Caps And Connecting Rods

Turn the crankshaft so the piston in cylinder 1 is at bottom dead center (BDC).
Check that there are markings on the cap and connecting rods. Check which way the markings are positioned
(exhaust and intake side). Make a note of this.
If necessary mark with a center punch or a number punch. See Marking the connecting rod (where
applicable).
New connecting rod
2001 Volvo S60
Fig. 20: Identifying Connecting Rod Fracture Surface

A new connecting rod has been introduced on certain engines.
The mating surface between the cap and the connecting rod is not machined. It is aligned through a dedicated
fracture surface.
CAUTION: If the cap is turned the wrong way and tightened, the structure of the
fracture surface will be damaged and the connecting rod must then be
discarded.
NOTE: Blow the fracture surface clean with compressed air before reinstalling the cap.
Removing the pistons from the cylinder block
Fig. 21: Identifying Piston And Connecting Rod Removal Tool

Remove the screws for the connecting rod cover.
Lift off the cover. Ensure that the bearing cover comes with it.
CAUTION: The bearing covers are not interchangeable. Also note the position of the
bearing covers in relation to the rotation of the crankshaft.
Install tool
Hold by hand so that the piston does not fall to the floor. Ensure that the bearing cover comes with it.
Place the piston and connecting rod in such a way that they can be reinstalled in the correct cylinder.
Continue with cylinders 2, 3, 4 and 5 as above.
2001 Volvo S60
bearing covers in relation to the rotation of the crankshaft.
Removing the screwed joint from the intermediate section

First remove the M7 screws from the intermediate section.
Then remove the M8 screws. Start at the outer edges and work alternately towards the center.
Remove the M10 screws in the same way.
Separating the intermediate section from the cylinder block
Fig. 23: Identifying Intermediate Section Pried From Cylinder Block

Carefully pry the intermediate section from the cylinder block so that there is a gap of approximately 6-8 mm.
2001 Volvo S60
Then carefully tap off (on the exhaust side) the intermediate section with a rubber mallet.
Lift out the intermediate section. Ensure that the bearing covers for the intermediate section come with it.
CAUTION: The bearing covers are not interchangeable.
Also not the position of the upper half of the axial bearing for the direction
of rotation of the crankshaft.
The crankshaft must not now be turned.
Ensure that the screws for the flywheel and carrier plate, which were installed earlier, are properly tightened.
Lift them and the front of the crankshaft.
Carefully lift the crankshaft straight up.
Remove the remaining bearing covers.
NOTE: The bearing covers for the different bearing seatings are not interchangeable.
Removing the piston cooling valve and nozzles

Remove the piston cooling valve at the front of the engine.
2001 Volvo S60

Remove the piston cooling nozzles.
Cleaning
Fig. 26: Identifying Cylinder Block, Intermediate Section And Oil Pan
Clean the gasket surfaces on the cylinder block, intermediate section and oil pan.
Use a razor blade or a gasket scraper and / or gasket solvent (P/N 116 1440 ).
WARNING: A fume bonnet or extractor must be used when using gasket solution.
Crank mechanism, assembling
Special tools:
2001 Volvo S60
9512767
9991801
9995676
Cleaning
Blow clean the oil ducts in the block, intermediate section and oil pan.

digits 1 to 7. The first letter after digit 1 is the classification of main bearing 1. The bearing positions are
2001 Volvo S60
Selecting bearings
Cylinder block A small B medium- C large diameter

classification diameter diameter
/
Crankshaft
classification
block intermediate block intermediate block intermediate
section section section
A yellow yellow medium yellow blue thick blue thick blue thick
small medium medium
B red thin yellow medium yellow yellow medium yellow blue thick
medium medium medium
C red thin red thin red thin yellow medium yellow yellow medium
large medium
NOTE: The thickest of the bearing caps must always be installed in the intermediate
section. This is keep the center line as straight as possible.
The intermediate section

2001 Volvo S60
Apply liquid gasket 11 61 059 to the intermediate section. The surface must be completely covered without any
Thoroughly lubricate all the bearing shells and the surface of the axial bearing.

Carefully position the crankshaft in the block.
Install all screws. Draw the intermediate section down towards the block.
NOTE: Use new M10 screws.
Tighten in the numerical order illustrated.
Tighten the screws in the following order.

2001 Volvo S60
Secure the large end of the connecting rod in a vise with soft jaws (copper or aluminum).
2001 Volvo S60
C=Oil ring. Three sections, identical on all sides.
First install the expander ring (C), then the two other rings over the expander ring.
CAUTION: Ensure that the piston rings can be turned easily.
2001 Volvo S60
Fig. 32: Identifying Piston, Connecting Rod, And Piston Pin Snap Ring
same direction.
Check that the classification and any numbering for each cylinder and piston diameter correspond.
Install both the snap rings on the piston pin. Check that the snap rings are positioned correctly in the piston.
Install the bearing shells.
If new bearing shells are used, these must be checked for color coding.
NOTE: The bearing shell with a black color coding on the side must be installed in the
connecting rod.
CAUTION: If reusing the bearing shells, they must be installed in the same position
as before.
2001 Volvo S60

to be inserted in.
NOTE: The arrow on top of the piston must point forwards. Ensure that the
classifications correspond
Carefully press or tap the piston down (using the shaft of a hammer or similar).
When the piston has released from the piston ring compressor, remove it and press the piston down until the
connecting rod reaches the connecting rod pin.
2001 Volvo S60

Turn the engine 180° in the stand.
Install the cover. Check that any markings correspond.
Lubricate and install new seals. Tighten in two stages:
1. 20 Nm .
2. Angle-tighten 90° .
tightened.
2001 Volvo S60

Tighten.

Apply liquid gasket 11 61 059 to the oil pan. Use roller 9512767 .
feeler gauge.
2001 Volvo S60

Install new sealing rings in the oil pan.
Install the oil cooler. Tighten.

Lubricate the drift face and thread the sealing ring onto the drift.
MEASURING THE CRANKSHAFT ASSEMBLY
2001 Volvo S60
NOTE: The illustrations in this service information are used for different model years
and / or models. Therefore there may be some variation. However, the essential
Measuring the crankshaft
Fig. 39: Identifying Measurement Of Bearing Journal Out-Of-Round And Taper Using Micrometer
Use a micrometer.
Measure the out-of-round and taper of the bearing journal. Measure at a number of points laterally and
longitudinally.
2001 Volvo S60
Fig. 40: Identifying Measurement Points

For the correct values for the connecting rod bearing journals and main bearing journals, see Crank
mechanism .
Check the out-of-true of the crankshaft
Fig. 41: Identifying Measurement Of Radial Runout Using A Dial Indicator And Magnetic Holder
2001 Volvo S60
Use a dial indicator and magnetic holder.
Position the crankshaft with the two outer main bearings in the V block.
Turn the crankshaft and measure the radial runout on the other main bearing journals.
For the correct values, see Crank mechanism .
Removing the piston rings
Fig. 42: Identifying Piston Rings And Piston Ring Pliers

Remove coke deposits. Scrape the piston ring grooves clean with a groove cleaner or a broken and filed piston
ring.
Check for damage, wear and cracks.
Checking piston ring axial clearance
2001 Volvo S60
Fig. 43: Checking Piston Ring Axial Clearance

Use new piston rings.
For the correct values, see Pistons (engine capacities) .
Checking the piston diameter
Fig. 44: Identifying Piston Dimensions

2001 Volvo S60
Use a micrometer and vernier calliper.
Calculating the running clearance of the piston
Fig. 45: Identifying Running Clearance Of Piston

Disassembling connecting rods and pistons
2001 Volvo S60
Fig. 46: Identifying Lock-Ring And Groove-Cut Chisel

Check first that the piston and connecting rod are marked.
Piston marking: Scrape the piston pin clean. If the marking is unclear, mark the piston with the cylinder
number and an arrow pointing to the front of the engine. Use a marker pen.
Connecting rod marking: See Marking the connecting rod (where applicable).
Carefully push out the lock-ring using a groove-cut chisel.
WARNING: The circlip can easily come off. Wear protective goggles
Press out the piston pin with your thumb.
Clean and check the connecting rods, caps and screws for damage, signs of wear or cracks.
Checking the alignment of the piston pins in the pistons
2001 Volvo S60
Fig. 47: Checking Alignment Of Piston Pin With Piston

The piston pin must not be loose. It should be possible to push it through the hole using thumb pressure.
Replace the piston if the play is too great.
Checking the alignment of the piston pins in the connecting rods
Fig. 48: Checking Alignment Of Piston Pin With Connecting Rod

The piston pin should slide through the hole with light thumb pressure.
If the play is too great measure the piston pin.
Use a micrometer.
See Pistons (engine capacities) for the correct diameter of the gudgeon pin.
New connecting rod
2001 Volvo S60

fracture surface.
discarded.
Checking the bearing recess in the connecting rod big end
2001 Volvo S60
Fig. 50: Identifying Connecting Rod And Bearing Shells

Visually check the bearing shells.
If in doubt measure out-of-round. Use a bore gauge.
For the correct diameter of the bearing recess, see Crank mechanism .
Checking the connecting rod in a connecting rod aligner
Check for out-of-true and twisting.
CAUTION: Check that the aligner fork is unburred and round at the handle.
Remove and apply the expander at the big end between each alignment
2001 Volvo S60
operation.
CRANK MECHANISM (B5204T5; 2005-2007)

Special tools:
9512767
9991801
9995676
9995746
and/or models. Some variation may occur. However, the essential information in
the illustrations is always correct.
NOTE: For tightening torques not in the text, see Tightening torque .
Cleaning
Blow clean the oil ducts in the block, intermediate section and sump.

2001 Volvo S60
Install the piston cooling nozzles. Tighten the screws.

Install the piston cooling valve. Use a seal washer. Tighten. See Summary of specific components and
tightening torques .

digit 1 to 7. The first letter after digit 1 is the classification of main bearing 1. The bearing recesses are
2001 Volvo S60
Selecting bearings
NOTE: Always use new bearings.
Bearing halves with grooves are always installed in the engine block.
Install the main bearings in the cylinder block and the intermediate section. The axial bearing is positioned at
bearing recess 5
Fig. 54: Identifying Classification Chart

1. Classification cylinder block

2. Classification crankshaft
3. cylinder block
4. Intermediate section
2001 Volvo S60
Example. The marking on the block at bearing position 1 is B. The marking on the crankshaft at the
corresponding bearing position is C. This gives a red marked bearing in the block and a yellow marked bearing
in the intermediate section.
NOTE: The thickest of the bearing halves shall always be installed in the intermediate
section. This is to keep the center line as straight as possible.
Applying liquid gasket

Wipe the surfaces dry. Apply liquid gasket 11 61 059 to the intermediate section.
The surface must be completely covered without any excess. Use roller 9512767 . Thoroughly lubricate all the
bearing shells and the thrust bearing's surface.

2001 Volvo S60
Install the two old screws for the flywheel and carrier plate at the rear edge of the crankshaft. Lift these and the
front of the crankshaft.
Carefully position the crankshaft in the block. The crankshaft must not be turned before the intermediate
section has been torque tightened. Position the intermediate section. Lubricate and install all the screws.
CAUTION: The M8-bolts on the exhaust side have two lengths.
Pull down the intermediate section. Tighten the screws. See Summary of specific components and tightening
torques .
Secure the large end of the connecting rod in a vice with soft jaws (copper or aluminum). Mark both halves with
the cylinder number. Use a center punch or number punch.
Selecting piston
2001 Volvo S60
Fig. 58: Identifying Classification Marking

For every cylinder there is a classification letter stamped (C, D, E) on the top of the engine block.
First letter after the digit 1 corresponds to the classification of the cylinder bore in cylinder 1 and is then
followed by cyl. 2, 3, 4, 5.
Cylinder selection is determined by the classification of the cylinder bore. For example: Cylinder class D must
have pistons marked D etc.
2001 Volvo S60
CAUTION: Make sure that the piston rings are not stuck and that they turn easily.
NOTE: Incorrect positioning may result in higher oil consumption.
Use piston ring pliers. Turn the piston rings so that the openings are offset as illustrated.
C=Oil ring. Three sections, identical on all sides. First install the expander ring (C), then the two other rings
over the expander ring.
2001 Volvo S60

WARNING: The lock ring can easily fly off. Wear protective goggles
There is an arrow marking on the upper side of the cylinder. This must be turned forwards in the cylinder block.
same direction.
Assemble the connecting rod and piston with the piston pin. Check that the classification and any numbering for
each cylinder/piston diameter and connecting rod correspond.
Installing the main bearing shells
2001 Volvo S60
Fig. 61: Identifying Bearing Shell Color Code Location

Always use new bearings.
Check these for color marking. The bearing shell with a black color coding on the side (1) must be installed in
the connecting rod.
2001 Volvo S60
NOTE: The arrow (top of the piston) must point forwards, and make sure that the
classification matches.
to be inserted in.
Carefully press or tap the piston down (using the shaft of a hammer or similar). When the piston releases from
the piston ring compressor, turn the engine 180° in the stand.
Install tool 9995746 in the connecting rod. Pull the connecting rod until it secures against the big end journals.

NOTE: The crankshaft must not be rotated before the connecting rod cap has been
tightened.
Install the cap. Check that any markings correspond.
Lubricate and install new screws. Tighten the screws. See Tightening torque .
2001 Volvo S60

Install a new seal ring on the suction line.
Carefully press the suction pipe down into the intermediate section. Check that the sealing ring is correctly
positioned.
Tighten the screws. Install new sealing rings for the oil ducts to the sump.
Installing the sump

CAUTION: Check that the rear edge of the oil sump is in line with the rear edge of the
engine block. Permitted tolerance 0.025 mm . Use a steel ruler and feeler
gauge.
2001 Volvo S60
Apply liquid gasket 11 61 059 on the oil sump. Use roller 9512767 . The surface must be completely covered
without any excess. Install the oil sump and install all bolts.
Tighten the screws. Start with the rear edge of the sump and work alternately forwards.

Install:
 new sealing rings in the oil pan

 the oil cooler. Tighten the screws
 the oil filter.
Cleaning
2001 Volvo S60
Fig. 67: Identifying Crankshaft Flange Cleaning

CAUTION: Cleaning shall always be done in the direction around the flange, not in
and out. No grinding tools or similar may be used. It is extremely
important that there is no remaining thread sealant or other dirt, as this
may cause leakage.
NOTE: Use emery cloth 9511024 to clean the crankshaft end.
If necessary, wash off the oil on the rear cylinder block surface. Blow clean using compressed air.
When cleaning, work around the shaft journal, not in and out. It is essential that any residue from the emery
cloth and any other contaminants are completely removed before the new sealing ring is installed.
2001 Volvo S60

Lubricate the drift face. Thread the seal onto the drift. Tap in the seal until the drift bottoms against the block.
CRANKSHAFT ASSEMBLY, DISASSEMBLING
Special tools:
9995458
9995679
Preparation
2001 Volvo S60
Fig. 69: Identifying Oil trap, Knock Sensors, Front Engine Mounting, Oil Pressure Switch, and EVAP
Valve With Hoses
Remove:
 the oil trap

 the knock sensors (KS)
 the oil pressure switch
 Evaporative emission system (EVAP) valve with hoses.
Fig. 70: Identifying Right Driveshaft Bearing Retainer, Oil Cooler And Pipes
Remove:
 the bearing retainer for the right drive shaft

 the oil cooler and the rubber seals including hoses and pipes.
2001 Volvo S60
Fig. 71: Identifying Oil Filter And Oil Pan

Remove:
 the oil filter. Use tool 9995679

 the screws holding the oil pump to the intermediate section.

Remove:
 the O rings for the oil ducts
2001 Volvo S60
 the retaining screws holding the suction pump to the intermediate section. Work / lift out the suction pipe
 the O-ring for the suction pipe.
Check the pipe and the strainer. Check for cracks and impurities.
Checking markings

applicable).
New connecting rod
2001 Volvo S60
Fig. 74: Identifying Piston And Connecting Rod With Bearings

fracture surface.
discarded.
NOTE: Blow the fracture surface clean using compressed air before installing the cap.

2001 Volvo S60
bearing caps in relation to the rotation of the crankshaft.
Install tool
Place the piston and connecting rod in such a way that they will be reinstalled in the correct cylinder.
Check
Fig. 76: Identifying Coolant Guide And Cylinder

Check that the coolant guide is in place. Secure if necessary.
2001 Volvo S60

Fig. 78: Identifying Intermediate Section And Cylinder Block

Also note the position of the upper half of the axial bearing for the
direction of rotation of the crankshaft.
The crankshaft must not rotate.
2001 Volvo S60
Carefully pry the intermediate section from the cylinder block so that there is a gap of approximately 6-8 mm .
NOTE: The bearing covers for the different bearing recesses are not interchangeable.

2001 Volvo S60

Cleaning
WARNING: A fume hood or extractor must be used when using gasket solution.

2001 Volvo S60
See Crank mechanism, assembling
See Disassembling the crankshaft assembly
See Measuring the crankshaft assembly
CRANK MECHANISM (B5244S; 2001-2006)

Special tools:
9512767
9991801
9995676
9995746
and/or models. Some variation may occur. However, the essential information in
the illustrations is always correct.
Cleaning
Blow clean the oil ducts in the block, intermediate section and sump.
2001 Volvo S60

Install the piston cooling nozzles. Tighten to 17 Nm .

Install the piston cooling valve. Use a new seal washer. Tighten to 38 Nm .
2001 Volvo S60

digit 1 to 7. The first letter after digit 1 is the classification of main bearing 1. The bearing recesses are
Selecting bearings
2001 Volvo S60
Fig. 85: Identifying Classification Chart

1. Classification cylinder block

2. Classification crankshaft
3. Cylinder block
4. Intermediate section
CAUTION: When reusing old bearing halves, make sure that they are correctly
positioned with regards to the crankshaft's rotational direction.
2001 Volvo S60
NOTE: The thickest of the bearing halves shall always be installed in the intermediate
section. This is to keep the center line as straight as possible.
Intermediate part

Apply liquid gasket 11 61 059 on the intermediate section. The surface must be completely covered without any
Thoroughly lube all bearing shells and the thrust bearing surface with oil.

2001 Volvo S60
Carefully lay the crankshaft into place in the block.
Pull the intermediate section down against the cylinder block.
CAUTION: The M8 bolts on the exhaust side have two lengths.
Tighten the screws in the following order:

2. All M10 bolts........ 45 Nm
3. All M8 bolts........ 24 Nm
4. All M7 bolts........ 17 Nm
Tighten the screws in sequence from the middle and out.
2001 Volvo S60
Secure the large end of the connecting rod in a vice with soft jaws (copper or aluminum).
A=Compression ring. The text on the piston ring shall face up.
B=Scraper ring. The bevel shall face down.
C=Oil ring. Three parts equilateral.
First install the expander ring (C), then the two upper rings over the expander ring.
2001 Volvo S60
CAUTION: Make sure that the piston rings are not stuck and that they turn easily.

same direction.
Check that the classification and any numbering for each cylinder and piston diameter correspond.
2001 Volvo S60
WARNING: The lock ring can easily fly off. Wear protective goggles
Install the bearing shells. Center the bearing shells in the bearing recess.
CAUTION: If reusing the bearing shells, they must be installed in the same position
as before.
Also, make sure that they are positioned correctly with regards to the
crankshaft's rotational direction.

Turn the crankshaft so that the crank pin is in lower dead center for the cylinder that the piston is to be installed
in.
NOTE: The arrow (top of the piston) must point forwards, and make sure that the
classification matches
Carefully press/tap down the piston (e.g., with the handle of a hammer).
When the piston releases from the piston ring compressor, turn the engine 180° in the stand. Install tool
9995746 in the connecting rod. Tighten the connecting rod until it fixates against the big-end journal.
2001 Volvo S60

Install the cap. Check that the marking, if any, matches.
Lubricate and install new screws. Tighten in two stages:
1. 20 Nm .
2. Angle-tighten 90° .
tightened.
2001 Volvo S60
Tighten.

Apply liquid gasket 11 61 059 on the oil sump. Use roller 9512767 .
feeler gauge.
Installing the oil cooler and oil filter
2001 Volvo S60

Install
 new sealing rings in the sump

 the oil cooler. Tighten
 the oil filter.

Lubricate the drift face. Thread the seal onto the drift.
2001 Volvo S60
Special tools:
9995458
9995679
Preparation
Fig. 97: Identifying Oil Trap, Knock Sensor, Front Engine Mounting And Oil Pressure Switch
Remove
 oil trap
 the knock sensor (KS)
 the oil pressure switch.
2001 Volvo S60
Fig. 98: Identifying Oil Cooler And Rubber Seals

Remove
 the oil cooler and the rubber seals

 the bearing retainer for the right drive shaft.
Fig. 99: Identifying Oil Filter

Remove the oil filter. Use tool: 9995679 .
Remove the screws securing the oil pan to the intermediate section.
2001 Volvo S60

Remove the O-rings from the oil ducts.
Remove the screws securing the suction pipe to the intermediate section.
Work loose and lift out the suction pipe.
Remove the suction pipe O-ring.
Check the pipe and the strainer.
Checking markings

2001 Volvo S60
applicable).
New connecting rod

A new connecting rod has been introduced for engine B5244S/S2.
fracture surface.
discarded.
2001 Volvo S60

Also note the position of the bearing covers for the rotation of the
crankshaft.
Install tool
Place the piston and connecting rod in such a way that they can be reinstalled in the correct cylinder.
Also note the position of the bearing covers for the rotation of the
crankshaft.
2001 Volvo S60

Fig. 105: Identifying Intermediate Section Pried From Cylinder Block

Carefully pry the intermediate section from the cylinder block so that there is a gap of approximately 6-8 mm.
2001 Volvo S60
Also not the position of the upper half of the axial bearing for the direction
of rotation of the crankshaft.
The crankshaft must not now be turned.
NOTE: The bearing covers for the different bearing seatings are not interchangeable.

2001 Volvo S60

Cleaning
WARNING: A fume bonnet or extractor must be used when using gasket solution.
2001 Volvo S60
Measuring the crankshaft
Fig. 109: Identifying Measurement Of Bearing Journal Out-Of-Round And Taper Using Micrometer
Use a micrometer.
Measure the out-of-round and taper of the bearing journal. Measure at a number of points laterally and
longitudinally.
2001 Volvo S60
Fig. 110: Identifying Measurement Points

For the correct values for the connecting rod bearing journals and main bearing journals, see Crank
mechanism .
Check the out-of-true of the crankshaft
Fig. 111: Identifying Measurement Of Radial Runout Using A Dial Indicator And Magnetic Holder
2001 Volvo S60
Use a dial indicator and magnetic holder.
Position the crankshaft with the two outer main bearings in the V block.
Turn the crankshaft and measure the radial runout on the other main bearing journals.
For the correct values, see Crank mechanism .
Removing the piston rings
Fig. 112: Identifying Piston Rings And Piston Ring Pliers

Remove coke deposits. Scrape the piston ring grooves clean with a groove cleaner or a broken and filed piston
ring.
Check for damage, wear and cracks.
Checking the axial clearance of the piston rings
2001 Volvo S60
Fig. 113: Checking Piston Ring Axial Clearance

Use new piston rings.
For the correct values, see Pistons .
Checking the piston diameter
Fig. 114: Identifying Piston Diameter

2001 Volvo S60
Use a micrometer and Vernier caliper.
Calculating the running clearance of the piston
Fig. 115: Identifying Running Clearance Of Piston

Disassembling connecting rods and pistons
2001 Volvo S60
Fig. 116: Identifying Lock-Ring And Groove-Cut Chisel

Check first that the piston and connecting rod are marked.
Piston marking: Scrape the top of the piston clean. If the marking is unclear, mark the piston with the cylinder
number and an arrow pointing to the front of the engine. Use a marker pen.
Connecting rod marking: See Marking the connecting rod (where applicable).
Carefully push out the lock-ring using a groove-cut chisel.
WARNING: The snap ring can easily come off. Wear protective goggles
Press out the piston pin with your thumb. Clean and check the connecting rods, caps and screws for damage,
signs of wear or cracks.
Checking the alignment of the piston pins in the pistons
2001 Volvo S60
Fig. 117: Checking Alignment Of Piston Pin With Piston

The piston pin must not be loose. It should be possible to push it through the hole using thumb pressure.
Replace the piston if the play is too great.
Checking the alignment of the piston pins in the connecting rods
Fig. 118: Checking Alignment Of Piston Pin With Connecting Rod

The piston pin should slide through the hole with light thumb pressure.
If the play is too great measure the piston pin.
Use a micrometer.
For the correct diameter of the piston pin, see Pistons .
New connecting rod
2001 Volvo S60

A new connecting rod has been introduced for engine B5244S/S2.
fracture surface.
discarded.
Checking the bearing recess in the connecting rod big end
2001 Volvo S60
Fig. 120: Identifying Connecting Rod And Bearing Shells

Visually check the bearing shells.
If in doubt measure out-of-round.
Use a bore gauge.
For the correct diameter of the bearing recess, see Crank mechanism .
Checking the connecting rod in a connecting rod aligner
Check for out-of-true and twisting.
CAUTION: Check that the aligner fork is unburred and round at the handle.
2001 Volvo S60
Remove and apply the expander at the big end between each alignment
operation.
CRANK MECHANISM (B5244S6; 2003-2006)


CRANK MECHANISM (B5244T5; B5254T2; 2005-2009)

See Crankshaft assembly, disassembling

2001 Volvo S60

CRANK MECHANISM (B5254T4, TF-80SC AWD; 2006-2007)

CYLINDER BLOCK (B5204T5; 2004)

CYLINDER BLOCK, MEASUREMENT
Measuring the cylinder bore
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.
2001 Volvo S60
Fig. 121: Identifying Measurement Of Cylinder Bore

First clean the cylinder bores and check them visually.
Measure the cylinder bores. Use a bore gauge (50-100 mm), a micrometer and a micrometer stand.
Set the micrometer to maximum cylinder bore diameter tolerance using the marking on the cylinder block.
Calibrate the bore gauge in the micrometer.
Checking for wear
Fig. 122: Identifying Check For Wear

Take measurements for the greatest amount of wear across the engine, just before the upper limit position.
Take measurements for the lowest amount of wear along the length of the engine, at the lower limit position.
Classification marking
2001 Volvo S60

Each cylinder is stamped with a classification letter (C, D or E) at the rear edge of the cylinder block.
Cylinder bore diameter: See Specifications, mechanical .
CYLINDER BLOCK (B5234T3; 2001-2004)

See Cylinder block, measurement
CYLINDER BLOCK (B5244S; 2001-2006)

Measuring the cylinder bore
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.
2001 Volvo S60
Fig. 124: Identifying Measurement Of Cylinder Bore

First clean the cylinder bores and check them visually.
Measure the cylinder bores. Use a bore gauge (50-100-mm), a micrometer and a micrometer stand.
Set the micrometer to maximum cylinder bore diameter tolerance using the marking on the cylinder block.
Calibrate the bore gauge in the micrometer.
Checking for wear
Fig. 125: Identifying Check For Wear

Take measurements for the greatest amount of wear across the engine, just before the upper limit position.
Take measurements for the lowest amount of wear along the length of the engine, at the lower limit position.
Classification marking
2001 Volvo S60

Each cylinder is stamped with a classification letter (C, D or E) on the top of the cylinder block.
Cylinder bore diameter: See Cylinder block
CYLINDER BLOCK (B5244S6; 2003-2006)



CYLINDER HEAD (B5204T5; 2004)

INSTALLING THE CYLINDER HEAD
Special tools:
9512050
2001 Volvo S60
9512767
9995450
9995451
9995452
9995454
9995718
9995719
NOTE: Since the illustrations in this service information are used for different model
years and/or models. Some variation may occur. However, the essential
Aligning the crankshaft
Fig. 127: Identifying Crankshaft Stop

Turn the crankshaft counter-clockwise (viewed from the rear of the engine) until the piston in cylinder 1
reaches top dead center (TDC).
Continue turning counter-clockwise until the piston in cylinder 1 is approximately 2-3 cm before top dead
center (BTDC).
Install the crankshaft stop 9995451 . Ensure that it bottoms out against the cylinder block.
2001 Volvo S60
Now turn the crankshaft clockwise (viewed from the rear of the engine) until the crankshaft counter-weight is in
contact with the crankshaft stop.
Installing the cylinder head
Fig. 128: Identifying Cylinder Head Screws Tightening Sequence

Install a new cylinder head gasket .
Install the cylinder head.
Use new screws .
Tighten the screws in the following order. Tighten the screws alternately from the center and outwards.
1. 20 Nm
2. 60 Nm
3. Angle-tighten 130° . Use protractor 9512050 .
Adjusting the valve clearance
NOTE: If the valves have been replaced, the valve clearance must be adjusted.
Installing tappets and camshafts
See.
2001 Volvo S60
Fig. 129: Identifying Liquid Gasket Application

Wipe the oil film off the mating surfaces on the camshaft cover and cylinder head.
Install new O-rings around the spark plug wells at the cylinder head.
Apply liquid gasket 11 61 059 to the camshaft cover. The surface must be fully covered without any excess.
Use roller 9512767
NOTE: Make sure that no liquid gasket gets in to the oil channels.
Installing the camshaft covers
Fig. 130: Identifying Camshaft Covers

Lubricate the camshaft lobes, the camshaft bearing surfaces and the tappets.
Install the camshaft cover.
2001 Volvo S60
Install 2 press tools 9995454 .
Pull the camshaft cover alternately down, keeping it parallel to the cylinder head with the press tools
Install all the screws and tighten.
Remove the press tools.
Install the spark plugs. Tighten to 30 Nm .
Install the control valve for the variable valve timing unit with a new gasket. Tighten.
Installing the front camshaft seal
Fig. 131: Identifying Front Camshaft Seal

Use drift 9995718 on camshafts with VVT units. Use drift 9995719 on camshafts without VVT.
Use new seals. Lubricate the surface of the seal that the camshaft rotates against.
Tap in the seal until the drift bottoms against the end of the camshaft.
Installing the rear camshaft seal
2001 Volvo S60
Fig. 132: Identifying Rear Camshaft Seal

Use drift 9995450 .
Lubricate the surface of the seal that the camshaft rotates against.
Install the seal.
Press in the seal until the drift bottoms out.
NOTE: If there are wear grooves on the camshaft, the seal can be pressed in another 2
mm by reversing the tool's sleeve.
Securing the camshafts
Fig. 133: Identifying Camshaft Adjustment Tool

Use camshaft tool 9995452 .
2001 Volvo S60
NOTE: The camshafts must not be turned more than is listed in the text below. The
valves may be damaged
Screw the adjustment tool sections together into one.
Check that the screws retaining the adjustment tool to the camshafts and the screws holding the tool together are
well tightened.
MEASURING AND RECONDITIONING THE CYLINDER HEAD
Special tools:
9986052
9995219
9995222
9995379
9995748
9995764
Removing tappets
Fig. 134: Identifying Valve Lifters Marked Positions

2001 Volvo S60
Lift out the tappets. Mark up the tappets so that the original positions can be established.
Use a suction cup to remove the tappets.
Check for wear on the tappets. Measure if necessary.
Tappets, dimensions: See Tappets .
Removing valves
Fig. 135: Identifying Special Tools 998 6052 And 999 5748
Use valve spring compressor 9986052 with attachment claw 9995748 .
Remove
 the valve locks

 the upper valve collars
 the valve springs
 the valves.
NOTE: Keep track of the position of the moving parts.
Removing valve stem seals
2001 Volvo S60
Fig. 136: Identifying Valve Stem Seal Special Tool 999 5219
Use tool 9995219 .
Remove the valve stem seals and the lower valve collars.
Clean the cylinder head:
 the gasket faces

 the combustion chambers
 the inlet and exhaust ports
 the valve seats.
Checking the cylinder head
Fig. 137: Identifying Spark Plug Threads

Clean the spark plug threads (tap M14 x 1.25).
2001 Volvo S60
Clean the valves, valve springs and collars.
Visually check for damage.
Regrind the seats if unsure about cracks. See Valve seats .
Checking the cylinder head for distortion
Check the flatness of the cylinder head. Use a steel rule and feeler gauges. See Cylinder head .
Checking for wear in the valve guides
Fig. 138: Identifying Measurement Of Wear In Valve Guides Using A Dial Indicator And Magnetic
Holder
Measure the wear in the valve guides. Use a dial indicator and magnetic holder. Lift the valve approximately 2-
3 mm from the seat when carrying out the check.
Play between the valve and valve guide: See Valve guides .
Checking the height of the valve stems
2001 Volvo S60
Fig. 139: Identifying Camshaft Adjustment Special Tool 999 5222

Use camshaft adjustment tool 9995222 .
Position the camshaft adjustment tool in the camshaft bearing recesses.
Measure the height of the valve stem using Vernier calipers through the hole in camshaft adjustment tool. See
Valves .
Installing valve stem seals
2001 Volvo S60
Fig. 140: Identifying Protective Sleeve And Valve Stem Seal

Lubricate the valve stems and the upper ends of the valve guides.
Install
 the lower valve spring collars

 the valves in their positions.
Install the protective sleeve (included in the gasket kit) on the valve stem.
NOTE: The protective sleeve must be installed on the valve stem when the valve stem
seal is installed.
Lubricate the protective sleeve (1) and install it on the valve stem.
2001 Volvo S60
Fig. 141: Identifying Valve Stem Seal

Lubricate the valve stem seal (2).
Press down the seal past the protective sleeve with your finger.
Press the seal down. Use tool 9995764 . Press with manual force until the tool stops against the lower valve
spring washer.
Remove the tool. Pull off the protective socket.
Installing valve springs
Fig. 142: Identifying Valve Spring Compressor Special Tools 999 6052 And 999 5748
Install the valve spring. Install the valve spring washer.
Compress the valve spring so that the three valve lock tracks are visible. Use valve spring compressor 9986052
with attachment claw 9995748 .
2001 Volvo S60
NOTE: Do not compress more than is absolutely necessary. The valve stem seal may
be damaged.
Install the valve locks.
Check that valve locks are in the correct position when the spring is not loaded.
Repeat the procedure with the remaining valves.
REMOVING THE CYLINDER HEAD
Special tools:
9995199
9995452
9995454
9995670
Removing the camshaft pulleys
Fig. 143: Identifying Camshaft Pulley

Install tool 9995452 on the rear edge of the camshafts.
Slacken off the screws securing the timing gear pulley to the variable valve timing unit.
2001 Volvo S60
Remove the plug at the front edge of the variable valve timing unit (Tx 55).
Remove the center screw from the variable valve timing unit (Tx 55).
Carefully pull out the camshaft pulley with the variable valve timing unit.
The following applies to camshafts without variable valve timing:
Remove the screws.
Pull off the camshaft pulley.
Remove tool 999 5452
CAUTION: The camshafts must not be turned when the timing belt has been removed.
Removing the camshaft cover
Fig. 144: Identifying Camshaft Cover And Variable Valve Timing Unit Control Valve
Remove the control valve from the variable valve timing unit.
Remove the spark plugs from cylinders 1 and 5.
Install 2 tools 9995454 , leaving a 2-3 mm gap to the camshaft cover.
Ensure that the screw in the spark plug well is tightened as far as it will go.
Remove all the screws securing the camshaft cover to the cylinder head
2001 Volvo S60
Fig. 145: Identifying Camshaft Cover, Pliers & Stop Lugs

Remove
 the camshaft cover with pliers 9995670 by the snap-in lugs.
Start with cylinder 1 and work alternately backward
 the wing nuts approximately 2 turns. Repeat the procedure with the pliers.
Remove
 tool 999 5454

 the camshaft seals at both the front and rear edges
 the camshaft cover
 the camshafts. Work loose and lift at the same time.
NOTE: Take care not to damage the axial bearings.
Removing the cylinder head
2001 Volvo S60
Fig. 146: Identifying Cylinder Head

Remove the pipe screw for the water heated crankcase ventilation at the rear edge of the cylinder head.
Slacken off the screwed joint for the cylinder head. Start at the sides and work alternately towards the center.
Lift out the cylinder head.
NOTE: Take care not to damage the mating surfaces.
CYLINDER HEAD (B5204T5; 2005-2007)

CYLINDER HEAD, DISMANTLING/ASSEMBLING
Special tools:
9986052
9995219
9995748
9997012
Removing tappets
2001 Volvo S60

NOTE: Magnets must not be used when lifting out the tappets.
Lift out the tappets. Mark up the tappets so that the original positions can be established.
Use a suction cup to remove the tappets.
Check for wear on the tappets.
Removing valves
Remove:
2001 Volvo S60
 the valve locks

 the valves.
NOTE: Keep careful track of the position of the moving parts.
Use tool 9995219 .

2001 Volvo S60

If you are unsure, replace the cylinder head.
Holder
Clearance between the valve and valve guide:
2001 Volvo S60
Clearance between new components: Inlet/Exhaust: 0.03-0.06 mm .
Maximum play for used components: Inlet/Exhaust: 0.15 mm .

Lubricate:
 the upper end of the valve guides

 the valve stem seal.
Install:

 the valve stem seal.
Press down the seal. Use tool 9997012 . Press with hand force until the tool stops against the lower valve spring
washer. Remove the tool.
Repeat the procedure with the remaining valve stem seals.
Installing the valve / valve springs
2001 Volvo S60
Lubricate the valve stem.
Install:
 the valve
 the valve spring
 the upper valve spring washer.
CAUTION: Do not compress more than is absolutely necessary, the valve stem seal
may be damaged.
Compress the valve spring so that the three valve lock tracks are visible.
Use valve spring compressor 9986052 and press foot 9995748 . Install the valve collets. Check that valve
collets are in the correct position when the spring is not loaded.
CYLINDER HEAD, INSTALLING
Special tools:
9512767
9995450
9995451
9995452
2001 Volvo S60
9995454
9995718
NOTE: For tightening torques not in the text, see Tightening torque .

center (BTDC).
Install the crankshaft stop 9995451 Ensure that it bottoms out against the cylinder block.
2001 Volvo S60

Use new screws .
Tighten. See Tightening torque .
Installing valve lifters and camshafts
See Valve clearance .

2001 Volvo S60
Apply liquid gasket 11 61 059 to the camshaft cover. The surface must be completely covered without any
NOTE: Ensure that no liquid gasket gets in to the oil ducts.

Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters.
Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools.
Install the spark plugs. Tighten. See Tightening torque .
Install the control valve for the variable valve timing unit with a new gasket. Tighten.
Cleaning
To clean the camshaft journal and mating surface, use emery cloth P/N 951 1024 .
2001 Volvo S60
NOTE: When cleaning work around the shaft journal, not in and out. It is essential that
any residue from the emery cloth and any other contaminants are completely
removed before the new sealing ring is installed.
Fig. 158: Identifying Special Tool Drift 999 5718

Use drift 9995718 .
Use new seals.
Tap in the seal until the drift bottoms against the end of the camshaft.
2001 Volvo S60

Use drift 9995450 .
Install the seal.
Continue the work with the next sealing ring.
NOTE: If there are grooves on the camshaft, the seal can be pressed in a further 2 mm
by reversing the sleeve.

2001 Volvo S60
NOTE: The camshafts must not be turned more than is listed in the text below. The
valves may be damaged
well tightened.
CYLINDER HEAD, REMOVING
Special tools:
9995452
9995454
9995670
Fig. 161: Identifying Camshaft Pulleys

Install tool 9995452 at the rear of the camshafts.
2001 Volvo S60
Continue with the next variable valve timing unit.
Remove:
 rear timing cover

 tool 9995452 .
Remove:
 the control valves for the variable valve timing units

 the spark plugs for cylinders 1 and 5.
Install tool 9995454 (2 x). Leave a 2-3 mm gap to the camshaft cover.
Remove all the screws securing the camshaft cover to the cylinder head.
2001 Volvo S60

Remove:
 camshaft cover with pliers 9995670 at the stop lugs. Start with cylinder 1 and work alternately backwards
NOTE: Do not damage the axial bearings.
Remove:
 tool 9995454
 the camshaft seals at both the front and rear edges
 the camshaft cover
2001 Volvo S60

NOTE: Do not damage the mating surface.
Slacken off the screwed joint for the cylinder head. Start at the sides and work alternately towards the center.

See Installing the cylinder head
See Measuring and reconditioning the cylinder head
See Removing the cylinder head
CYLINDER HEAD (B5244S; 2001-2006)

Special tools:
9512050
9512767
9995450
9995451
9995452
9995454
9995718
9995719
2001 Volvo S60

center (BTDC).
Install the crankshaft stop 9995451 Ensure that it bottoms out against the cylinder block.
2001 Volvo S60

Use new screws .
Tighten the screws in the following order. Tighten the screws alternately from the center and outwards.
1. 20 Nm
2. 60 Nm
3. Angle-tighten 130° . Use protractor 9512050 .
Installing valve lifters and camshafts
See.
2001 Volvo S60

Apply liquid gasket 11 61 059 to the camshaft cover. The surface must be completely covered without any
NOTE: Ensure that no liquid gasket gets in to the oil ducts.

Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters.
2001 Volvo S60
Pull the camshaft cover alternately down, keeping it parallel to the cylinder head with the press tools
Install the variable valve timing solenoid with a new gasket. Tighten.
Install the spark plugs. Tighten to 30 Nm .
Fig. 169: Identifying Front Camshaft Seal

Use drift 9995718 on camshafts with variable valve timing units. Use drift 9995719 on camshafts without
variable valve timing. Use the drifts together with the mounting screws for the variable valve timing unit and
timing gear pulley.
Use new seals. Lubricate the surface of the seal that the camshaft rotates against.
Press in the seals until the drift bottoms out.
2001 Volvo S60

Use drift 9995450 .
Install the seal on the intake camshaft.
NOTE: If there are grooves on the camshaft, the seal can be pressed in a further 2 mm
by reversing the sleeve.

2001 Volvo S60
NOTE: The camshafts must not be turned more than is absolutely necessary to install
the adjustment tools. The valves may be damaged
well tightened.
Special tools:
9986052
9995219
9995222
9995379
9995748
9995764
Removing valve lifters from the cylinder head

2001 Volvo S60
Lift out the valve lifters. Mark up the valve lifters so that the original positions can be established.
Use a suction cup to remove the valve lifters.
Check for wear on the valve lifters. Measure if necessary.
Valve lifters, dimensions: See Tappets .
Removing valves
Remove
 the valve locks

 the valves.
NOTE: Keep track of the position of the moving parts.
2001 Volvo S60
Use tool 9995219 .


2001 Volvo S60
Regrind the seats if unsure about cracks. See Valve seats .
Checking the cylinder head for distortion
Measure cylinder head distortion Use a steel ruler and feeler gauge. See Cylinder head .
Holder
Clearance between the valve and valve guide: See Valve guides .
Checking the vertical position of the valve stem
2001 Volvo S60
Fig. 177: Identifying Camshaft Adjustment Special Tool 999 5222

Position the camshaft adjustment tool in the camshaft bearing recesses.
Measure the height of the valve stem using a feeler gauge through the hole in the camshaft adjustment tool. See
Valves .
2001 Volvo S60
Fig. 178: Identifying Protective Sleeve And Valve Stem Seal

Lubricate the valve stems and the upper ends of the valve guides.
Install

 the valves in their positions.
Install the protective sleeve (included in the gasket kit) on the valve stem.
NOTE: The protective sleeve must be installed on the valve stem when the valve stem
seal is installed.
Lubricate the protective sleeve (1) and install it on the valve stem.
Lubricate the valve stem seal (2).
Press down the seal past the protective sleeve with your finger.
2001 Volvo S60

Press the seal down. Use tool 9995764 . Press down by hand until the tool stops against the lower valve spring
washer.
Remove the tool. Pull off the protective socket.
Installing valve springs
Install the valve spring. Install the valve spring washer.
Compress the valve spring so that the three valve lock tracks are visible. Use valve spring compressor 9986052
with attachment claw 9995748 .
NOTE: Do not compress more than is absolutely necessary. The valve stem seal may
be damaged.
2001 Volvo S60
Install the valve locks.
Check that valve locks are in the correct position when the spring is not loaded.
Special tools:
9995199
9995452
9995454
9995670
Fig. 181: Identifying Camshaft Pulley

Install tool 9995452 at the rear of the camshafts.
2001 Volvo S60
The following applies to camshafts without variable valve timing:
Remove the screws.
Pull off the camshaft pulley.
Remove tool 999 5452
Remove the variable valve timing unit control valve.
Remove the spark plugs from cylinders 1 and 5.
Install 2 tools 9995454 . Leave a 2-3 mm gap to the camshaft cover.
Remove all the screws securing the camshaft cover to the cylinder head
2001 Volvo S60

Slacken off
 camshaft cover with pliers 9995670 at the stop lugs.
Start with cylinder 1 and work alternately backward.
Remove
 tool 999 5454.

 the camshaft seals at both the front and rear edges.
 the camshaft cover.
NOTE: Take care not to damage the axial bearings.
2001 Volvo S60

Slacken off the cylinder head screwed joint. Start at the sides and work alternately towards the center.
NOTE: Take care not to damage the mating surfaces.
CYLINDER HEAD (B5244S6; 2003-2006)


2001 Volvo S60
CYLINDER HEAD (B5244T5; B5254T2; 2005-2009)

See Cylinder head, dismantling/assembling
See Cylinder head, installing
See Cylinder head, removing


See Cylinder head, dismantling/assembling
2001 Volvo S60
CYLINDER HEAD (B5254T4, TF-80SC AWD; 2006-2007)

DRIVE TRAIN/BELT DRIVE (B5254T4; 2004-2007)

BELT DRIVE, ASSEMBLY
Special tools:
9995747
9995451
9995452
9995433
Installing the water pump
2001 Volvo S60
Fig. 185: Identifying Water Pump

Install the rear timing cover.
Screw into place at the three mounting points.
Install the water pump with a new gasket .
Apply thread sealant, P/N 11-61 056, to all the screws for the water pump. Tighten the screws crosswise.
Installing the oil pump
Fig. 186: Identifying Oil Pump And Special Tool 999 5747
Use a new gasket and a new O-ring around the oil pump housing and new screws. Alternatively, apply thread
sealant 11 61 056 to the underside of the old screw heads.
Screw sliding sleeve 9995747 into place at the front of the crankshaft journal.
2001 Volvo S60
Press in the pump over the sliding sleeve.
Install the screws as a guide.
Carefully tap in the oil pump with a rubber mallet.
Tighten the oil pump crosswise. See Summary of specific components and tightening torques .
Remove sliding sleeve 9995747 .
Installing front crankshaft seal
See When only replacing the front crankshaft seal .
Installing the crankshaft timing gear pulley
Fig. 187: Identifying Crankshaft Timing Gear Pulley

NOTE: The timing gear pulley can only be installed in one position on the crankshaft
journal splines (see the illustration).
Carefully tap in the timing gear pulley with a rubber mallet.
2001 Volvo S60
Installing the idler pulley and belt tensioner
Fig. 188: Identifying Idler Pulley And Belt Tensioner

Install:
 idler pulley. Tighten

 the belt tensioner and the center screw so that the tensioner fork is centered over the cylinder block rib.
Do not tighten
 the lower belt guard at the oil pump
 the fuel delivery line.
Installing the timing gear pulley for the camshafts
NOTE: The purpose of the "Installing the timing gear pulley" section described here is
to ensure that the VVT unit is correctly positioned and to reset the camshaft
timing gear pulley to the correct position using the markings made at the
factory. This is to ensure that the conditions are correct for any later fault-
tracing.
2001 Volvo S60
Fig. 189: Identifying Timing Gear Markings

NOTE: Do not turn counter clockwise during this procedure.
Slacken off, but do not remove, the screws which secure the timing gear pulley to the variable valve timing unit.
Press the variable valve timing unit and timing gear pulley onto the camshaft.
Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly. Turn the
variable valve timing unit counter-clockwise as far as it will go. Remove the center screw.
Position the upper timing cover.
Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position. Continue
turning clockwise until the timing gear pulley marking is 1 cogs before the marking on the upper timing cover.
Check that the timing gear pulley is still in the limit position in the oval holes. Tighten the center screw in the
variable valve timing unit. Tighten. See Summary of specific components and tightening torques .
Check that the variable valve timing unit does not rotate when tightening. Install and tighten the center plug.
See Summary of specific components and tightening torques .
2001 Volvo S60
Turn the variable valve timing unit clockwise to the limit position.
Turn the timing gear pulley so that the markings correspond.
Installing the variable valve timing (VVT) unit on the intake camshaft

Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly.
Turn the variable valve timing unit counter-clockwise as far as it will go. Remove the center screw. Position
the upper timing cover.
turning clockwise until the timing gear pulley marking is 1 1/2 cogs before the marking on the upper timing
cover.
2001 Volvo S60
Fig. 191: Identifying Timing Gear Pulley & Upper Timing Cover Markings Aligned
Check that the timing gear pulley is still in the limit position in the oval holes.
Tighten the center screw in the VVT unit. See Summary of specific components and tightening torques .
Check that the variable valve timing unit does not rotate when tightening. Install the center plug. Tighten. See
Summary of specific components and tightening torques .
Turn the variable valve timing unit clockwise to the limit position. Turn the timing gear pulley so that the
markings correspond.
Finishing
Tighten the center screw on the timing belt tensioner. Tighten to 5 Nm .
Installing the timing belt
2001 Volvo S60
Fig. 192: Identifying Timing Belt Routing

Install the belt in the following order:
 crankshaft
 the idler pulley
 intake camshaft
 exhaust camshaft
 coolant pump
 belt tensioner.
NOTE: The variable valve timing units does not have a return spring and is easily
dislodged when reinstalling the timing belt. Check that the markings are
2001 Volvo S60
correct.
Adjusting the timing belt
Fig. 193: Identifying Needle Position At Varying Temperatures

This adjustment is to be made with a cold engine. A suitable temperature is approximately 20°C/68°F .
At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the
indicator is further to the right.
The illustration shows the position of the indicator when aligning the timing belt tensioner at different
temperatures.
Hold the center screw secure and turn the belt tensioner eccentric clockwise until the tensioner indicator passes
the marked position and reaches the limit position.
Tighten the 3 screws on the exhaust camshaft timing gear pulley. Tighten. See Tightening torque .
Tighten the 3 screws on the intake camshaft timing gear pulley. Tighten. See Tightening torque .
2001 Volvo S60
Fig. 194: Identifying Belt Between Intake Camshaft Pulley, Idler Pulley And Crankshaft
NOTE: Check that the variable valve timing units are in the limit position.
Turn the eccentric back so that the indicator reaches the marked position in the center of the window.
Remember to hold the center screw secure at the same time.
Hold the eccentric secure. Tighten the center screw. Tighten. See Summary of specific components and
Check that the indicator is in the correct position.
Fig. 195: Identifying Camshaft Adjustment Tool 999 5452 Installed

Remove:
 camshaft adjustment tools 9995452 from the rear edge of the camshafts
2001 Volvo S60
 crankshaft stop 9995451

 the plug with a new sealing washer. Tighten. See Tightening torque .
Checking the markings and belt tension
Fig. 196: Pressing Belt To Check Indicator On The Tensioner Moves Easily
Press the timing belt to check that the indicator on the belt tensioner moves easily.
Turn the crankshaft 2 rotations and check that the markings on the crankshaft and camshaft pulleys correspond.
Check that the indicator on the belt tensioner is within the marked area.
2001 Volvo S60
Remove the upper timing cover.
Installing the vibration damper
Fig. 197: Identifying Vibration Damper And Special Tool 999 5433
Install:
 the vibration damper. Use counterhold 9995433

 the crankshaft center nut. Tighten. See Summary of specific components and tightening torques .
Remove counterhold 9995433
 the 4 screws. Tighten. See Summary of specific components and tightening torques . Use the
crankshaft center screw as a counterhold.
2001 Volvo S60
Turn the crankshaft two turns. Check that the markings on the crankshaft and timing gear pulley match up with
the markings on the oil pump and upper timing cover respectively.
BELT DRIVE, DISMANTLING
Special tools:
2001 Volvo S60
9995304
9995433
9995747
Aligning the engine according to the marking
Fig. 199: Identifying Alignment Markings On Upper Timing Belt Cover And Pulleys
Install the upper timing belt cover.
Turn the crankshaft clockwise until the markings on the crankshaft belt pulley and the timing belt pulley are
aligned with the markings on the oil pump and the upper timing belt cover.
Removing the vibration damper
2001 Volvo S60
Remove the 4 screws. Use the crankshaft center nut as a counterhold.
Install counterhold 9995433 . Remove the center nut.
Remove counterhold 9995433 .
Work the vibration damper loose.
Removing the timing belt
Fig. 201: Identifying Belt Tensioner And Timing Gear Pulley

Slacken off the center screw for the belt tensioner slightly.
Hold the center screw in place. Turn the belt tensioner eccentric clockwise to 10 o'clock using a 6mm Allen
key.
2001 Volvo S60
Remove the timing belt from the timing gear pulley for the camshafts.
Remove the timing belt.
Removing the crankshaft pulley
Fig. 202: Identifying Crankshaft Pulley And Special Tool 999 5304
CAUTION: The crankshaft must not rotate.
Use puller 9995304 and two 45 mm M8 screws with washers.
Pull off the timing gear pulley.
Removing the belt tensioner and idler pulley
Fig. 203: Identifying Belt Tensioner And Idler Pulley

2001 Volvo S60
Remove the belt tensioner and idler pulley.
Check the rolling surface and the bearings.
Check for any noise. Check for any play in the bearings.
Check that the rolling surfaces are smooth and clean.
Removing the oil pump
Remove the belt protection from the oil pump.
Remove the 4 screws for the oil pump.
Carefully work the oil pump out. Use a groove-cut chisel with stop lugs.
Carefully draw the oil pump past the end of the crankshaft.
Carefully clean the gasket face and mating surfaces.
Remove tool 9995747 .
Checking the oil pump
2001 Volvo S60
Fig. 205: Identifying Oil Pump Replacement Components

Unscrew the oil pump. Note the position of the outer/inner pump wheel and the piston/spring for the relief
valve.
Clean and check all components.
Check for damage and wear. Replace the oil pump in the event of a fault.
When replacing the sealing ring.
Carefully tap the sealing ring out. Use a carefully selected drift and hammer.
A new sealing ring is first installed after the pump has been installed in the cylinder block.
Assembling the oil pump
Fig. 206: Identifying Oil Pump Assembly

2001 Volvo S60
Place the inner and outer pump wheels in the oil pump housing.
The inner pump wheel has a inset surface around the hole for alignment to the crankshaft. The inset surface
should be positioned towards the sealing ring in the oil pump housing.
Install the spring and piston for the relief valve. Screw the pump together. Tighten the screws. See: Tightening
torque .
Removing the coolant pump/timing belt cover
Fig. 207: Identifying Coolant Pump And Timing Belt Cover

Remove the screws.
Carefully tap the pump pulley with a rubber mallet.
Work the pump loose.
Remove the inner timing belt cover.
Removing the thermostat and thermostat housing
Remove the cover over the thermostat (Tx40).
Lift out the thermostat
Remove the hose for the water heated crankcase ventilation.
Remove the thermostat housing from the cylinder head.
2001 Volvo S60
Remove the fuel pressure line.
Checking the opening function of the thermostat
Fig. 208: Identifying Thermostat

The thermostat can be tested in warm water.
Maximum opening must occur within 2 minutes in water at opening temperature.
Marking........90° C
Starts to open at........90°C
Fully open at........105°C
DRIVE TRAIN/BELT DRIVE (B5254T4, TF-80SC AWD; 2006-2007)

See Belt drive, assembly
See Belt drive, dismantling
DRIVE TRAIN/BELT DRIVE (B5244S; 2001-2006)

Special tools:
9995747
2001 Volvo S60

Apply thread sealant, P/N 11-61 056, to all the screws for the water pump. Tighten crosswise.
Fig. 210: Identifying Oil Pump

2001 Volvo S60
Use a new gasket and a new O-ring around the oil pump housing.
Screw sliding sleeve 999 5747 into place at the front of the crankshaft journal.
Install new screws as a guide.
Tighten the oil pump crosswise. Tighten to 10 Nm .
Remove sliding sleeve 999 5747 .

NOTE: The timing gear pulley can only be in one position at the splines on the
crankshaft journal (see the illustration).
2001 Volvo S60

Install the idler pulley. Tighten.
Install the belt tensioner and the center screw so that the fork on the tensioner is centered over the cylinder
block rib. Do not tighten.
Install the lower belt guard at the oil pump.
Install the fuel delivery line.
Checking and adjusting the variable valve timing unit
Check and adjust the variable valve timing unit. See: Variable valve timing unit, checking and adjusting .
2001 Volvo S60
Install the vibration damper. Use counterhold 9995433 .
Tighten the center nut to 180 Nm .
Remove counterhold 999 5433.
Tighten the four screws. Tighten to 25 Nm . Angle tighten 30° . Use the crankshaft center nut as a counterhold.
Check
2001 Volvo S60
Press the toothed belt to check that the indicator on the tensioner moves easily.
Turn the crankshaft two turns. Check that the markings on the crankshaft and camshaft pulleys match up with
the markings on the oil pump and upper timing cover.
Check that the indicator on the belt tensioner is within the marked position.
DISMANTLING THE BELT TRANSMISSION
Special tools:
9995304
9995433
2001 Volvo S60
Fig. 215: Identifying Markings On Crankshaft Belt Pulley, Timing Belt Pulley, Oil Pump, And Upper
Timing Belt Cover
Turn crankshaft clockwise until the markings on the crankshaft belt pulley and the timing belt pulley are aligned
with the markings on the oil pump and the upper timing belt cover
Remove the upper timing belt cover.
Install the counterhold 9995433 and remove the center nut.
2001 Volvo S60
Fig. 217: Identifying Timing Belt

There are two variants of the belt tensioner.
Up to engine number 3188688 the eccentric must be turned clockwise when loosening.
From engine number 3188689 the eccentric must be turned counter-clockwise to loosen the belt tension.
Hold the center screw in position and, depending on the model, turn the eccentric on the tensioner to 10 o'clock
(clockwise) or 2 o'clock (counter-clockwise) using a 6 mm Allen key.
2001 Volvo S60
Use puller 9995304 and two screws (M8 x 45 mm) with washers.
CAUTION: The crankshaft must not rotate

Removing oil pump
2001 Volvo S60

Remove the four oil pump screws.
Carefully work the oil pump out. Use a groove-cut chisel with stop lugs.

Disassemble the oil pump.
2001 Volvo S60
Check for damage and wear.
Replace the oil pump in the event of a fault.
Assemble the oil pump. Tighten to 6 Nm .
Removing the coolant pump / timing belt cover

Remove the screws.
Removing the thermostat / thermostat housing
2001 Volvo S60
Fig. 223: Identifying Thermostat And Thermostat Housing


2001 Volvo S60
Maximum opening must happen within 2 minutes in water at opening temperature.
DRIVE TRAIN/BELT DRIVE (B5244S6; 2003-2006)

Special tools:
9995747

2001 Volvo S60

Install new screws as a guide.
2001 Volvo S60

NOTE: The timing gear pulley can only be in one position at the splines on the
crankshaft journal (see the illustration).
2001 Volvo S60

Install the idler pulley. Tighten.
Install the belt tensioner and the center screw so that the fork on the tensioner is centered over the cylinder
block rib. Do not tighten.
Install the lower belt guard at the oil pump.
Install the fuel delivery line.
Checking and adjusting the variable valve timing unit
Check and adjust the variable valve timing unit. See: Variable valve timing unit, checking and adjusting .
Tighten the four screws. Tighten to 25 Nm . Angle tighten 30° . Use the crankshaft center nut as a counterhold.
2001 Volvo S60
Check
Turn the crankshaft two turns. Check that the markings on the crankshaft and camshaft pulleys match up with
the markings on the oil pump and upper timing cover.
Check that the indicator on the belt tensioner is within the marked position.
2001 Volvo S60
See Dismantling the belt transmission
ENGINE BLOCK COMPONENTS - FLYWHEEL, TRANSMISSION (B5204T5;

2004-2007)
ENGINE BLOCK, INSTALLING COMPONENTS
Installing engine block components
NOTE: Always use new seal washers and gaskets
Install
 thermostat housing (B52x4x)

 knock sensor (KS)
 flame trap
 the pipe screw for the water-heated crankcase ventilation.
If in doubt about the order of assembly see:

B5xx4x ........Engine body, exposing
B6xx4x ........Engine body, exposing
Install the flywheel and carrier plate. See Crankshaft seal rear, replacing .
For the correct tightening torques see:

B5xx4x ........Tightening torque
B6xx4x ........Tightening torque
The ignition coil alignment and the wiring routing follows the illustrations below.
B5xx4x
2001 Volvo S60
Fig. 231: Identifying Ignition Coils

B6xx4x
2001 Volvo S60
Fig. 232: Identifying Ignition Coils - B6xx4x

ENGINE BODY, EXPOSING
Special tools:
9989721
9992520
9995112
9995297
Removing the gearbox
HINT: Remove the lower screws (these are difficult to access) between the gearbox and engine before
removing the engine and gearbox unit. The engine and gearbox unit must be placed on a suitable surface.
2001 Volvo S60
HINT: Relieve the transmission. Loose the remaining screws and remove the transmission carefully.
Remove the clutch. See Pressure plate / clutch driven plate, replacing .
Removing the flywheel and carrier plate
Fig. 233: Identifying Flywheel And Carrier Plate

Install gear sector 9995112 .
Remove all screws except for the uppermost screw which secures the flywheel to the crankshaft. Slacken off the
uppermost screw. Leave it in place, screwed in a few turns.
Carefully work the flywheel and carrier plate loose. If necessary, use 2 groove-cut chisels. Apply these between
the cylinder block and the flywheel and carrier plate.
Hold the flywheel and carrier plate and remove the final screw.
Install the engine in a stand
Use mounting stand 9992520 , fixture 9995297 and screw set 9989721 .
Exposing the engine
2001 Volvo S60
Fig. 234: Identifying Engine Components To Be Removed (1 Of 2)

Remove
1. The heat deflector plate. 6. The exhaust manifold including the turbocharger
(TC).
2. The oil pressure pipe. 7. The coolant pipe (water pump inlet).
3. The coolant pipes, (turbocharger (TC) inlet / 8. The upper and front timing covers and the cover
outlet). over the ignition coils.
4. The oil return line. 9. Drain the engine oil.
5. The turbocharger (TC) control hoses and the
valve.
2001 Volvo S60

Remove
1. The generator (GEN) and the auxiliary equipment 7. The torque rod bracket.
bracket.
2. The dipstick pipe. 8. The engine wiring assembly.
3. The fuel rail. 9. The ignition coils.
4. The pipe screw for the water heated crankcase 10. The camshaft position sensor (CMP) housing
ventilation. and trigger wheel.
5. The crankcase ventilation hose on top of the 11. The cover.
camshaft cover.
6. The intake manifold.
SEALING MICRO-ENCLOSED SCREWS
2001 Volvo S60
NOTE: Micro-enclosed screws are used where the seal requirements are high. Loose
screws are replaced or sealed with new sealing compound. Sealant
"HYDRAULIC THREADSEAL" has P/N 11 61 056-5 and sealing must be carried
out according to the instructions on the packet.
The screws to be sealed with "HYDRAULIC THREAD SEAL" and their positions
are shown below.
Sealant
Fig. 236: Identifying Hydraulic Thread Sealant

"Hydraulic thread sealant"
 P/N 11 61 056-5
 Use a brush and/or the packet spout to apply the sealant to the screw.
 Avoid skin contact with the sealant.
Engine intake side
2001 Volvo S60
Fig. 237: Identifying Engine Intake Side

Location Designation Number P/N

A Auxiliary equipment 1 946671-5
bracket screw
B Air conditioning (A/C) 1 965180-3
stay screw (for cars with
air conditioning (A/C))
B Intake manifold stay 1 946173-2
screw (cars without AC)
C Starter motor mounting 1 946173-2
screw
D Engine mounting screw 1 946470-2
Engine exhaust side
2001 Volvo S60
Fig. 238: Identifying Engine Exhaust Side


A Coolant manifold screw 2 975880-6
(M7 X 20) with flange
height 7mm including
gasket
A Coolant manifold screw 2 979090-8
(M7 X 25) with flange
height 9mm including
gasket
B Plug water pump housing 1 968144-6
C Drain cock 1 9135268-2
Rear of engine
2001 Volvo S60
Fig. 239: Identifying Rear Of Engine


A Nipple 1 976040-6
Engine front
2001 Volvo S60
Fig. 240: Identifying Engine Front


A Coolant pump screw 7 977744-2

2001-2004)
See Engine block, installing components
See Engine body, exposing
See Sealing micro-enclosed screws
ENGINE BLOCK COMPONENTS - FLYWHEEL, TRANSMISSION (B5244S;
2001 Volvo S60
2001-2006)
EXPOSING THE ENGINE BODY
Special tools:
9989721
9992520
9995112
9995297
Removing the transmission
HINT: Remove the lower screws (these are difficult to access) between the transmission and engine
before removing the engine / transmission unit. The engine / transmission unit must be placed on a
suitable surface.
HINT: Take the weight off the transmission. Remove the remaining screws and carefully remove the
transmission.
Remove the clutch. See Pressure plate / clutch driven plate, replacing .
Removing the flywheel / carrier plate
2001 Volvo S60
Fig. 241: Identifying Flywheel And Carrier Plate

Remove the flywheel sensor.
Carefully work the flywheel / carrier plate loose. If necessary, use 2 groove-cut chisels. Apply these between
the cylinder block and the flywheel / carrier plate.
Hold the flywheel / carrier plate and remove the final screw.
Exposing the engine
2001 Volvo S60

Remove
1. Heat deflector plate and manifold. 3. The upper and front timing covers and the cover
over the ignition coils
2. Coolant intake pipe. 4. Drain the engine oil.
2001 Volvo S60

Remove
1. The generator (GEN) and the auxiliary equipment 7. The torque rod bracket.
bracket.
2. The dipstick pipe. 8. Engine wiring assembly
3. Crankcase ventilation hose. 9. The ignition coils.
4. Vacuum hose (crankcase ventilation). 10. The camshaft position sensor (CMP) housing
and trigger wheel.
5. The fuel rail. 11. The cover.
6. The intake manifold.
2001 Volvo S60
ENGINE BLOCK COMPONENTS - FLYWHEEL, TRANSMISSION (B5244S6;

2003-2006)
EXPOSING THE ENGINE BODY
See Exposing the engine body

2001-2003)

2003-2009)
2001 Volvo S60

2004-2007)
INSTALLING ENGINE BLOCK COMPONENTS
Special tools:
9989721
9992520
9995112
9995297
Removing the transmission
HINT: Remove the lower screws (these are difficult to access) between the transmission and engine
before removing the engine and transmission unit. The engine and transmission unit must be placed on a
suitable surface.
HINT: Take the weight off the transmission. Remove the remaining screws. Carefully remove the
transmission.
Remove the clutch. See Clutch disc and pressure plate .
Removing the flywheel and carrier plate
Remove the flywheel sensor.
Carefully work the flywheel and carrier plate loose. If necessary, use 2 groove-cut chisels. Apply these between
the cylinder block and the flywheel and carrier plate.
Hold the flywheel and carrier plate and remove the final screw.
2001 Volvo S60
Exposing the engine

1. Drain the engine oil. 5. Disconnect the turbocharger (TC) control hoses
and valve from the holders on the rear edge of the
cylinder head.
2. Remove the heat deflector plate. 6. Remove the exhaust manifold including the
turbocharger with control hoses and valve.
3. Remove the oil pressure pipe, the coolant pipes 7. Remove the coolant pipes (inlet water pump)
(turbocharger (TC) outlet) including hoses, separated at the hoses for the oil
cooler.
4. Remove the oil return line, the coolant pipes 8. Remove the upper and front timing covers and
(turbocharger (TC) intake) the cover over the ignition coils.
2001 Volvo S60

1. Remove the generator (GEN), the auxiliary 5. Remove the crankcase ventilation hose from the
equipment bracket and the thermostat housing top of the camshaft cover
together with the coolant hose.
2. Remove the dip stick pipe. 6. Remove the intake manifold and the thermostat
housing
3. Remove the cover and the fuel rail including the 7. Remove the engine stabilizer brace, engine wiring
injectors assembly. Ignition coils.
4. Disconnect the water heated crankcase ventilation 8. Remove the camshaft position (CMP) sensor
from the intake manifold and the thermostat housing housings and the trigger wheels.
ENGINE BLOCK COMPONENTS - FLYWHEEL, TRANSMISSION (B5254T4,

TF-80SC AWD; 2006-2007)
INSTALLING ENGINE BLOCK COMPONENTS

2001 Volvo S60
BELT TRANSMISSION - OIL PUMP, TIMING GEAR, VARIABLE VALVE

TIMING, WATER PUMP (B5204T5; 2005-2007)
Special tools:
9995747
9995451
9995452
9995433
Fig. 246: Identifying Water Pump

2001 Volvo S60
Apply thread sealant, P/N 11-61 056, to all the screws for the water pump. Tighten the screws crosswise.
Use a new gasket and a new O-ring around the oil pump housing and new screws. Alternatively, apply thread
sealant 11 61 056 to the underside of the old screw heads.
Screw sliding sleeve 9995747 into place at the front of the crankshaft journal.
Tighten the oil pump crosswise. See Summary of specific components and tightening torques .
Remove the sliding sleeve 9995747 .
Installing front crankshaft seal
See Oil pump / crankshaft seal, front, replacing .
2001 Volvo S60

2001 Volvo S60

Install:

Do not tighten
NOTE: The purpose of the "Installing the timing gear pulley" section described here is
to ensure that the VVT unit is correctly positioned and to reset the camshaft
timing gear pulley to the correct position using the markings made at the
factory. This is to ensure that the conditions are correct for any later fault-
tracing.

2001 Volvo S60
Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly. Turn the
variable valve timing unit counter-clockwise as far as it will go. Remove the center screw.
turning clockwise until the timing gear pulley marking is 1 cogs before the marking on the upper timing cover.
Check that the timing gear pulley is still in the limit position in the oval holes. Tighten the center screw in the
variable valve timing unit. Tighten. See Summary of specific components and tightening torques .
Check that the variable valve timing unit does not rotate when tightening. Install and tighten the center plug.
See Summary of specific components and tightening torques .
Turn the variable valve timing unit clockwise to the limit position.
Turn the timing gear pulley so that the markings correspond.
Installing the variable valve timing (VVT) unit on the intake camshaft
2001 Volvo S60

Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly.
Turn the variable valve timing unit counter-clockwise as far as it will go. Remove the center screw. Position
the upper timing cover.
turning clockwise until the timing gear pulley marking is 1 1/2 cogs before the marking on the upper timing
cover.
2001 Volvo S60
Fig. 252: Identifying Timing Gear Pulley & Upper Timing Cover Markings Aligned
Tighten the center screw in the VVT unit. See Summary of specific components and tightening torques .
Check that the variable valve timing unit does not rotate when tightening. Install the center plug. Tighten. See
Summary of specific components and tightening torques .
Turn the variable valve timing unit clockwise to the limit position. Turn the timing gear pulley so that the
markings correspond.
Finishing
2001 Volvo S60
Fig. 253: Identifying Timing Belt Routing

Install the belt in the following order:
 crankshaft
 the idler pulley
 intake camshaft
 exhaust camshaft
 coolant pump
 belt tensioner.
NOTE: The variable valve timing units do not have a return spring and are easily
dislodged when reinstalling the timing belt. Check that the markings are
2001 Volvo S60
correct.
Adjusting the timing belt

This adjustment is to be made with a cold engine. A suitable temperature is approximately 20°C/68°F .
At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the
indicator is further to the right.
temperatures.
Hold the center screw secure and turn the belt tensioner eccentric clockwise until the tensioner indicator passes
the marked position and reaches the limit position.
Tighten the 3 screws on the exhaust camshaft timing gear pulley. Tighten. See Tightening torque .
Tighten the 3 screws on the intake camshaft timing gear pulley. Tighten. See Tightening torque .
2001 Volvo S60
Fig. 255: Identifying Belt Between Intake Camshaft Pulley, Idler Pulley And Crankshaft
NOTE: Check that the variable valve timing units are in the limit position.
Turn the eccentric back so that the indicator reaches the marked position in the center of the window.
Remember to hold the center screw secure at the same time.
Hold the eccentric secure. Tighten the center screw. Tighten. See Summary of specific components and
Fig. 256: Identifying Camshaft Adjustment Tool 999 5452 Installed

Remove:
 camshaft adjustment tools 9995452 from the rear edge of the camshafts
2001 Volvo S60
 crankshaft stop 9995451

 the plug with a new sealing washer. Tighten. See Tightening torque .
Turn the crankshaft 2 rotations and check that the markings on the crankshaft and camshaft pulleys correspond.
2001 Volvo S60
Install:
 the vibration damper. Use counterhold 9995433

 the crankshaft center nut. Tighten. See Summary of specific components and tightening torques .
Remove counterhold 9995433
 the 4 screws. Tighten. See Summary of specific components and tightening torques . Use the
crankshaft center screw as a counterhold.
2001 Volvo S60
2001 Volvo S60

TIMING, WATER PUMP (B5244T5; B5254T2; 2005-2009)
See Belt drive, assembly

TIMING, WATER PUMP (B5204T5; 2004)
BELT TRANSMISSION, ASSEMBLY
Special tools:
9995747

2001 Volvo S60

Apply thread sealant, P/N 11-61 056, to all the screws for the oil pump.
2001 Volvo S60

2001 Volvo S60

Install

Do not tighten
Timing Belt Cover
Timing gear pulleys with variable valve timing unit
Check that the screws holding the timing gear pulley to the variable valve timing unit have been slackened off.
2001 Volvo S60
Install the center screw which secures the variable valve timing unit to the camshaft. Do not tighten.
Turn the timing gear pulley clockwise until the screws at the oval holes are in their respective limit positions.
Hold the variable valve timing unit. Turn clockwise until the timing gear pulley marking is 1 cog before the
marking on the upper timing cover.
Tighten the center screw for the variable valve timing (VVT) unit. Tighten to 120 Nm .
NOTE: Check that the VVT unit does not rotate when tightening.
Install the center plug. Tighten to 35 Nm .
Timing gear pulleys without variable valve timing units
Install the timing gear pulley on the camshaft with two screws. Do not tighten.
Adjust the timing gear pulley so that the markings on the timing gear pulley and the upper timing cover
correspond.
2001 Volvo S60
Timing Belt Cover
Turn the variable valve timing unit clockwise until stop. Use a Tx 55 torx wrench applied at the center plug.
Hold the variable valve timing unit secure in the limit position.
Install the timing belt in the following order:
1. Crankshaft
2. Idler pulley
3. Intake camshaft
4. Exhaust camshaft
5. Coolant pump
6. Belt tensioner
2001 Volvo S60
NOTE: Adjust the timing gear pulleys so that the screws are not at a limit position in
the oval holes.
Check that the markings on the timing gear pulleys and the upper timing cover correspond.

Tighten the timing belt
This adjustment is carried out on a cold engine. A suitable temperature is approximately 20°C/68°F.
At a higher temperature, for example with a warm engine or a higher ambient temperature, the needle is further
to the right.
temperatures.
2001 Volvo S60
Fig. 267: Identifying Belt Tensioner, Timing Gear Pulley And Timing Belt
Hold the center screw secure and turn the eccentric on the belt tensioner anti-clockwise until the tensioner
indicator reaches the limit position.
Tighten the three screws securing the timing gear pulley for the exhaust camshaft to the variable valve timing
unit. Tighten to 10 Nm .
Install the third screw at the timing gear pulley for the intake camshaft. Tighten the screws. Tighten to 20 Nm .
NOTE: The VVT unit must not be released from the limit position until after the timing
gear pulleys have been tightened.
Turn the eccentric back (clockwise) so that the indicator reaches the marked position in the center of the
window. Remember to hold the center screw secure at the same time.
Hold the eccentric secure and tighten the center screw. Tighten to 20 Nm .
Remove
 the camshaft adjustment tools 9995451

 the crankshaft stop 9995452
Install the plug with a new blind cover plug . Tighten to 40 Nm .
Check
2001 Volvo S60
Tighten the four screws. Tighten to 25 Nm . Angle tighten 30° . Use the crankshaft center screw as a
counterhold.
2001 Volvo S60
Special tools:
2001 Volvo S60
9995304
9995433
Fig. 270: Identifying Crankshaft And Camshafts Markings

Turn the crankshaft clockwise until the markings on the crankshaft belt pulley and the timing belt pulley are
aligned with the markings on the oil pump and the upper timing belt cover
Remove the upper timing belt cover.
2001 Volvo S60
Install the counterhold 9995433 and remove the center nut.
Fig. 272: Identifying Timing Belt

Hold the center screw secure. Turn the belt tensioner eccentric clockwise with a 6mm Allen key to 10 o'clock.
2001 Volvo S60
Use puller 9995304 and two screws (M8 x 45 mm) with washers.
CAUTION: The crankshaft must not rotate

2001 Volvo S60
Removing oil pump

Remove the four oil pump screws.
Carefully wiggle out the oil pump. Use a screwdriver at the pry lugs.
2001 Volvo S60

Disassemble the oil pump.
Check for damage and wear.
Replace the oil pump in the event of a fault.
Assemble the oil pump. Tighten to 6 Nm .
Removing the coolant pump / timing belt cover

Remove the screws.
2001 Volvo S60
Removing the thermostat and thermostat housing
Fig. 278: Identifying Thermostat And Thermostat Housing

2001 Volvo S60

Maximum opening must occur within 2 minutes in water at opening temperature.

See Belt transmission, assembly

2001 Volvo S60

ENGINE BLOCK - GENERAL INFORMATION (B5204T5; B5254T4; 2004-2007)

CAULKING
Operation Number(s):
Camshaft bearing housing, cylinder block. and intermediate section
Fig. 280: Identifying Bearing Housing, Cylinder Block And Intermediate Section
On engines manufactured of aluminum the camshaft bearing housing (1) cylinder block (2) and the intermediate
section (3) may be caulked.
NOTE: The cylinder heads that are chill-cast may not be caulked.
Each individual case is assessed as to whether caulking can be carried out or not depending on the location of
the oil leakage.
Center punch
2001 Volvo S60
Fig. 281: Identifying Center Punch And Rounded Tips

Caulking involves in the event of leakage knocking the material together using a special caulking tool.
Two caulking tools are required. Use center punches (1). Grind down the tips so they become round. One is to
be ground so the rounded tip (A) is 2 mm. The other is ground so the rounded tip (B) is 4 mm.
Pore preparation
NOTE: Use the protective goggles supplied with the leak tracing kit.
Use an UV light to localize the pore. Carefully wash around the pore with Isopropanol. Check with a UV light
that all the oil has been removed.
Different sized pores
Fig. 282: Identifying Tool Angle And Pores

WARNING: Use protective goggles.
2001 Volvo S60
If the pore is small, it is sufficient to place the tool (2 mm) directly on the pore and hit it with a copper or plastic
hammer. If the pore is larger, angle the tool (2 mm) and drive the material in a circle toward the pore (2). If
there is a lip around the pore, caulking (tool 4 mm) should be carried out in a spiral form toward the pore (3).
Drive the material toward the pore
Fig. 283: Identifying Pore And 2mm Tool

Drive the material toward the pore (1) using the 2 mm tool. Seal using the 4 mm tool (2).
Finishing
Wash with Isopropanol. Check with a UV lamp that there is no oil around the leakage point.
Test drive for 45 minutes as set out below to reach an oil temperature of about 80°.C.
1. Allow the engine to idle for 20 minutes.

2. Test drive the car for 15 minutes.
3. Allow the engine to idle for a further 10 minutes.
Check using a UV light that the sealed area no long leaks. If leakage remains, repeat the caulking.
ENGINE BLOCK - GENERAL INFORMATION (B5234T3; 2001-2004)

CAULKING
See Caulking
ENGINE BLOCK - GENERAL INFORMATION (B5244S; 2001-2006)
2001 Volvo S60
CAULKING
See Caulking
ENGINE BLOCK - GENERAL INFORMATION (B5244S6; 2003-2006)

CAULKING
See Caulking

CAULKING
See Caulking

CAULKING
See Caulking

CAULKING
See Caulking

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2001 Volvo S60

Engine Engine - Overhaul Instructions

Engine - Overhaul Instructions

CRANK MECHANISM (B5204T5; 2004)

List of tightening torques

For tightening torques not in the text, see Tightening torque .

Ensure that the all components are completely clean.

Installing the piston cooling valve and nozzles

viernes, 3 de julio de 2020 9:28:48

Fig. 1: Identifying Piston Cooling Nozzles

Install the piston cooling nozzles. Tighten to 17 Nm .

Fig. 2: Identifying Piston Cooling Valve

Install the piston cooling valve. Use a seal washer. Tighten to 38 Nm .

Classification of main bearings

Fig. 3: Identifying Classification Marking On Block And Crankshaft

Check that the components are clean and undamaged.

Check the classification of the block and crankshaft.

Cylinder block A small B medium- C large diameter

The axial bearing is positioned at bearing recess 5.

The intermediate section

Fig. 4: Identifying Liquid Gasket 11 61 059 Applied On Intermediate Section

Wipe the surfaces dry.

Tightening the intermediate section

Fig. 5: Identifying Intermediate Section Bolt Locations

Lift these and the front of the crankshaft.

Carefully position the crankshaft in the block.

Lubricate and install all the screws.

NOTE: Use new M10 bolts.

Pull down the intermediate section.

Tighten the screws in the following order:

1. All M10 screws........20 Nm

Tighten the screws in sequence from the center and outwards.

Marking the connecting rod (where applicable)

Installing piston rings

Fig. 7: Identifying Compression Ring, Scraper Ring And Oil Ring

Use piston ring pliers.

A=Compression ring. The text on the piston ring must be upwards.

B=Scraper ring. Chamfered edge must face downwards.

C=Oil ring. Three sections, identical on all sides.

NOTE: Incorrect positioning increases oil consumption.

Assembling pistons and connecting rods

Fig. 8: Identifying Snap Ring Positioning

Install the bearing shells.

Installing the pistons in the cylinder bores

Fig. 9: Identifying Cylinder Ring Compressor

Use a cylinder ring compressor.

Install tool 9995746 in the connecting rod.

Tightening the connecting rod cover

Fig. 10: Identifying Connecting Rod Cover

Install the cover. Check that any markings correspond.

Lubricate and install new seals. Tighten in two stages:

Tighten the connecting rod cap. Acc. to Tightening torque

Check that the connecting rod can be moved sideways.

Installing the oil pump suction pipe

Fig. 11: Identifying Oil Pump Suction Pipe

Install a new sealing ring on the suction pipe.

Check that the sealing ring is correctly positioned.

Installing the oil pan

Fig. 12: Identifying Liquid Gasket Applied To Oil Pan

Wipe the surfaces dry.

The surface must be completely covered without any excess.

Position the pan and install all screws

Installing the oil cooler