How JustAnswer Works:

  • Ask an Expert
    Experts are full of valuable knowledge and are ready to help with any question. Credentials confirmed by a Fortune 500 verification firm.
  • Get a Professional Answer
    Via email, text message, or notification as you wait on our site.
    Ask follow up questions if you need to.
  • 100% Satisfaction Guarantee
    Rate the answer you receive.

Ask Roy Your Own Question

Roy
Roy, import/domestic specialest
Category: Car
Satisfied Customers: 1602
Experience:  ASE master tech for 40 years
Type Your Car Question Here...
Roy is online now
A new question is answered every 9 seconds

Volvo XC90 T6: How to remove the head on a 04 volvo xc90 t6.

Resolved Question:

How to remove the head on a 04 volvo xc90 t6. Im having a hard time getting the exhaust manifolds off with all the tubo oil and coolant lines.
Submitted: 9 months ago.
Category: Car
Expert:  Roy replied 9 months ago.
good afternoon my name is XXXXX XXXXX I will assist you today

I will attach the procedure for you for this operation but I remove the turbo to get to all the lines for removal.

Roy

Cylinder head/gasket, replacement

Special tools: (NNN) NNN-NNNNCamshaft Adjustment Tool See: Tools and Equipment\999 5452 Camshaft Adjustment Tool (NNN) NNN-NNNNPress Tool See: Tools and Equipment\999 5454 Press Tool (NNN) NNN-NNNNPliers See: Tools and Equipment\999 5670 Pliers (NNN) NNN-NNNNAdjustment Tool See: Tools and Equipment\999 5451 Adjustment Tool (NNN) NNN-NNNNBevel Protractor See: Tools and Equipment\951 2050 Bevel Protractor (NNN) NNN-NNNNRoller See: Tools and Equipment\951 2767 Roller (NNN) NNN-NNNNPunch See: Tools and Equipment\999 5450 Punch (NNN) NNN-NNNNDrift See: Tools and Equipment\999 5718 Drift (NNN) NNN-NNNNDrift See: Tools and Equipment\999 5719 Drift

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.

Note! There are a number of versions of the VVT-unit (variable valve timing). Therefore it is extremely important to always read the information referring to the engine variant/model year to be remedied.

Removal

Preparation





Remove
the radiator breather tube from the expansion tank. Install lock grip pliers
the battery negative lead. First read Battery, disconnecting See: Starting and Charging\Battery\Service and Repair\Procedures\Battery Disconnecting
the right front wheel.
Draining coolant





Raise the car.
Remove the splash guard under the engine.
Open the engine nipple.
Drain the coolant into a container.
Close the nipple.

Removing components





Remove:
the clamp between the oil pressure pipe and the oil return line at the turbocharger (TC)
the pipe screw that holds the oil pressure pipe to the connector on the cylinder block
the oil return line. Seal the opening in the cylinder block
the lower screw that holds the heat deflector plate over the turbocharger (TC)
the nuts for the front exhaust pipe connection to the turbocharger (TC). Lift off the exhaust pipe and tie it up. Seal the opening in the exhaust pipe
Note! The metal hose for the front exhaust pipe is easy to damage if it is twisted. Handle it with care to avoid leakage.

Depressurizing the fuel system
Lower the car.
Depressurize the fuel system acc. to: XXXXX XXXXX pressure release See: Fuel Pressure Release\Service and Repair\Fuel System Pressure Release.

Removing components





Remove
the engine stabilizer brace between the suspension turrets
the ground strips between the engine and the firewall
the heat deflector plate above the turbocharger (TC)
the plastic charge air pipe above the engine. Seal the openings
the cover over the nozzle pipes
the cover over the ignition coils
the upper engine coolant hose for the engine and radiator
the screw holding the dip stick pipe to the intake manifold
the brake vacuum hose from the intake manifold.
Undo the clamp holding the plastic charge air pipe to the electronic throttle module.





Remove
the connector from the mass air flow (MAF) sensor
the intake hose from the mass air flow (MAF) sensor. Seal the opening.
Release the hoses from the bracket at the rear of the cylinder head. Remove the bracket.

Remove
the clamp for the positive lead at the rear of the cylinder head
the torque bracket
the pipe screw for the water-heated crankcase ventilation.
Removing the fuel rail




Remove the clamp for the injector wiring at the rear of the cylinder head
Detach the wiring from the injectors
Remove the fuel rail mounting screws
Spray universal oil or similar around the injector connectors on the intake manifold
Gently work the fuel rail and injectors loose
Separate the quick-release connector for the fuel line. See Fuel line, lock See: Powertrain Management\Fuel Delivery and Air Induction\Fuel Rail\Service and Repair.
Carefully put the fuel rail to one side.
Removing ignition coils




Mark up the ignition coils so that their original positions can be established
Remove the mounting screws for the ignition coils and the screws at the two ground terminals
Disconnect the connector for the variable valve timing solenoid
Lift up and place the ignition coils and wiring to one side.
Remove:
the crankcase ventilation hose from the top of the camshaft cover
the camshaft position sensor (CMP) housing and trigger wheel.
Removing intake manifold





Remove:
The EVAP hose from the intake manifold
the by-pass valve vacuum hose. Disconnect the connector for the electronic throttle module (ETM)
the upper row of screws holding the intake manifold to the cylinder head. Slacken off the lower screws. Lift up the intake manifold. Remove the pipe screw for the water heated crankcase ventilation underneath the intake manifold
the pipe screw for the crankcase ventilation from the underside of the intake manifold.
Lift up and remove the intake manifold.

Note! Make sure that the fuel pressure pipe is not damaged.

Removing components




Disconnect the connectors for the ABS sensor and level sensor in the expansion tank.
Lift up the expansion tank and servo oil reservoir. Place them on top of the engine.

Note! Make sure that oil does not leak from the breather hole in the filler cap.

Remove the auxiliaries belt.

Remove:
front timing cover
the hose for the water-heated crankcase ventilation from the thermostat housing.
Separate the connector for the engine coolant temperature (ECT) sensor.

Setting up the engine




Remove the nuts from the cover on the fender liner.
Turn the crankshaft clockwise until the markings on the crankshaft and camshafts correspond.
Remove the upper timing cover.

Removing the timing belt
Slacken off the center screw for the belt tensioner slightly.
Hold the center screw secure and turn the tensioner eccentric clockwise with a 6 mm Allen key to 10 o'clock.

Remove:
the timing belt from the timing gear pulley
the screw that holds the inner timing cover to the cylinder head.
Install tool(NNN) NNN-NNNNCAMSHAFT ADJUSTMENT TOOL See: Tools and Equipment\999 5452 Camshaft Adjustment Tool at the rear of the camshafts.

Removing the timing gear pulley
Remove the cable duct from its mountings on the right-hand suspension turret.

Note! Do not damage the paintwork.

Hold the cable duct out of the way and remove:
the plug at the front of the variable valve timing unit (TX55).
Note! Use paper or similar to absorb oil that drains.

the center screw in the variable valve timing unit (TX55).
Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit.
Remove tool(NNN) NNN-NNNNCAMSHAFT ADJUSTMENT TOOL See: Tools and Equipment\999 5452 Camshaft Adjustment Tool.

Removing components from turbocharger (TC)





Remove:
the heat deflector plate above the manifold
the upper engine coolant pipe. Place it to one side
the oil pressure pipe for the turbocharger (TC)
the pipe screw at the lower coolant pipe for the turbocharger (TC). Put the pipe to one side
the nuts and washers holding the manifold to the cylinder head.
Lift off the turbocharger and manifold. Carefully put them on top of the transmission.

Releasing the inlet pipe for the coolant pump





Remove:
the screw that holds the coolant pump intake pipe to the engine block a few turns. Leave the screw in place
the two screws for the connection between the coolant pipe and the bypass channel. Carefully turn the pipe to remove it from the cylinder block.
Removing the camshaft cover and cylinder head




Remove the spark plugs from cylinders 1 and 5
Install 2 tools(NNN) NNN-NNNNPRESS TOOL See: Tools and Equipment\999 5454 Press Tool. Leave a 2-3 mm gap to the camshaft cover.
Note! Make sure that the screw in the sparkplug thread is fully tightened. VVT-solenoid (variable valve timing).

The variable valve timing solenoids.
Remove all the screws securing the camshaft cover to the cylinder head.



Use pliers(NNN) NNN-NNNNPliers See: Tools and Equipment\999 5670 Pliers to lift the cover from the cylinder head.
Install the pliers at the stop lugs. Start with cylinder 1 and work alternately backwards
Slacken off the wing nuts approximately 2 turns. Repeat the procedure.



Carefully press out the front and rear camshaft seals.





Remove:
tools(NNN) NNN-NNNNPRESS TOOL See: Tools and Equipment\999 5454 Press Tool
the camshaft cover
the camshafts
the screws holding the cylinder head onto the cylinder block. Start at the sides and work alternately towards the center.
Get some help and lift of the cylinder head. Place the cylinder head on two wooden blocks.

Note! Work carefully to avoid damaging the contact faces.

When replacing or working on the cylinder head
Lift out the valve lifters. Use a magnet or suction cup.
Remove the thermostat housing and transfer it to the new cylinder head.

Note! Work carefully to avoid damaging the contact faces.

Installation

Note! For tightening torques, see Specifications See: Specifications\Mechanical\Tightening Torque.

Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling See: Exhaust System\Exhaust Pipe\Service and Repair\Flanged Joint, Assembling.

Cleaning





Warning! Use a fume hood or extractor when using gasket solvent!

Clean the gasket faces for:
the manifold. Check that the studs are tightened
the coolant bypass channel
the thermostat housing
the intake manifold
the cylinder block
camshaft cover.
Blow the oil ducts clean.

Note! Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440.

Setting up the engine




Position the crankshaft
Remove the starter motor mounting screws. Pull out the starter motor and place it to one side
Remove the blind cover plug
Turn the crankshaft slightly clockwise .
Install crankshaft stop(NNN) NNN-NNNNADJUSTMENT TOOL See: Tools and Equipment\999 5451 Adjustment Tool. Ensure that it bottoms out against the cylinder block.
Turn the crankshaft counter-clockwise until it stops against the crankshaft stop
Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.
Installing the cylinder head




Ensure that all studs at the exhaust ports are tightened
Lubricate the studs with paste(NNN) NNN-NNNN
Install a new cylinder head gasket
Install the cylinder head
Lubricate and install all the screws (use new screws).
Tighten the screws as illustrated. Tighten. See Tightening torque See: Specifications\Mechanical\Tightening Torque. Use protractor(NNN) NNN-NNNNBEVEL PROTRACTOR See: Tools and Equipment\951 2050 Bevel Protractor.
Installing valve lifters and camshafts




Lubricate the valve lifter wells.
Note! If the cylinder head has been replaced, the valve clearance must be adjusted. See Valve clearance See: Valve Clearance\Adjustments.

Install all valve lifters
Lubricate the camshaft bearing positions
Install the intake camshaft. Ensure that the groove at the back of the camshaft is above an imaginary center line
Position the exhaust camshaft. Ensure that the groove at the back of the camshaft is below an imaginary center line.
Applying liquid gasket




Install new O-rings around the spark plug wells at the cylinder head.
Apply liquid gasket 1161 059 to the camshaft cover.
Use roller(NNN) NNN-NNNNRoller See: Tools and Equipment\951 2767 Roller. The surface must be covered without any excess .

Note! Make sure that no liquid gasket ends up in the oil channels.

Installing the camshaft cover




Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters
Install the camshaft cover
Install press tool(NNN) NNN-NNNNPRESS TOOL See: Tools and Equipment\999 5454 Press Tool (2x).
Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools
Install all the screws. Tighten the screws from the middle and outwards
Remove the press tools.




Install:
the variable valve timing (VVT) solenoid. Use a new gasket.
the spark plugs. Tighten. See Tightening torque See: Specifications\Mechanical\Tightening Torque
the hose for water-heated crankcase ventilation to the thermostat housing. Tighten the clamp.
Connect the connector for the engine coolant temperature (ECT) sensor.
Install the inlet pipe for the coolant pump on the cylinder head. Use a new gasket.

Note! Apply thread sealant, 116 056 to the screw threads.

Tighten the screw for securing the coolant pump inlet pipe to the cylinder block.

Installing the manifold and turbocharger (TC)





Install:
new gaskets. Lift and install the manifold and turbocharger (TC)
the nuts and washers holding the manifold to the cylinder head
the upper and lower turbocharger (TC) coolant pipes. Tighten the clamp on the rubber hose
the pipe screws for the coolant pipes. Use new seal washers. Tighten
the oil pressure pipe
the pipe screw holding the oil pressure pipe to the turbocharger (TC). Use new seal washers. Do not tighten!
Lubricate the studs on the turbocharger (TC). Use paste(NNN) NNN-NNNN.
Install the front exhaust pipe onto the turbocharger (TC). Use new nuts. Do not tighten! Install the heat deflector plate over the manifold.

Installing the rear camshaft seal




To clean the shaft journal and mating surface, use emery cloth P/N(NNN) NNN-NNNN

Note! For 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 seal ring is installed.

Use drift(NNN) NNN-NNNNPUNCH See: Tools and Equipment\999 5450 Punch.
Lubricate the surface of the seal that the camshaft rotates against.
Press in the seal until the drift bottoms out.

Note! If there are grooves on the camshaft, the seal can be pressed in a further 2 mm: Reverse the sleeve.

Install camshaft adjustment tool(NNN) NNN-NNNNCAMSHAFT ADJUSTMENT TOOL See: Tools and Equipment\999 5452 Camshaft Adjustment Tool at the rear of the camshafts.
Ensure that the screws retaining the adjustment tool to the camshafts and the screws holding the tool together are well tightened.

Installing the front camshaft seals




Use drift(NNN) NNN-NNNNDrift See: Tools and Equipment\999 5718 Drift.
Lubricate the surface of the seal that the camshaft rotates against.
Use the variable valve timing unit / timing belt pulley mounting screws. Tighten the screws until the drift bottoms out
Remove the drift
Install the screw holding the inner timing cover to the cylinder head.
Checking and adjusting the variable valve timing unit
Check and adjust the variable valve timing unit. See: Variable valve timing unit, checking and adjusting See: Variable Valve Timing Actuator\Testing and Inspection

Installing components





Install:
front timing cover
the cable duct to the mountings on the right suspension turret
the auxiliaries belt
the expansion tank
the servo oil reservoir
the bleed hose to the expansion tank. Tighten the clamp.
Check that the hoses are installed correctly.
Connect the connectors for the ABS sensor at the right suspension turret and for the coolant level sensor in the expansion tank.





Install:
the starter motor
the pipe screw for the water heated crankcase ventilation at the rear of the cylinder head. Use new seal washers. Tighten to 26 Nm
the camshaft position sensor (CMP) housing and trigger wheel
the lower engine stabilizer brace bracket in the cylinder head
the upper engine stabilizer brace.




Install:
the bracket and lifting eyelet for the engine stabilizer brace bracket
the ignition coils and ground terminals according to earlier markings. Connect the connector for the variable valve timing solenoid
the clamp for the positive lead at the lifting eyelet bracket
the plastic intake pipe to the mass air flow (MAF) sensor. Tighten the clamp.
Connect the connector to the mass air flow (MAF) sensor. Use a clamp on the wiring at the front of the air cleaner (ACL).

Installing intake manifold




Clean the intake manifold gasket face to the cylinder head.
Install a new gasket on the cylinder head. Secure with the two screws in the lower row.
Lower and twist the intake manifold so that the fuel pressure line goes through the cavity in the intake manifold.

Note! Work carefully to avoid damaging the fuel pressure pipe.

Route the crankcase ventilation hose through the cavity in the intake manifold.

Install:
the pipe screw for the crankcase ventilation on the underside of the intake manifold. Use new seal washers. Tighten to 26 Nm
the rest of the screws holding the intake manifold to the cylinder head. Tighten to 19 Nm
the hose to the canister purge (CP) valve
the control hose for the turbocharger (TC) by-pass valve
the brake vacuum hose
the crankcase ventilation hose to the top of the camshaft cover. Use a new clamp
the cover over the ignition coils
the upper timing cover
the upper engine coolant hose for the engine and radiator. Tighten the clamp
the screw holding the dip stick pipe to the intake manifold. Connect the connector to the electronic throttle module (ETM)
the charge air pipe between the throttle body (TB) and the charge air cooler (CAC). Remove the seal. Tighten the clamp.
Installing the fuel rail





Install:
the fuel rail. Use new screws. Press the quick-release connector for the fuel pressure line until it clicks. See Fuel line, lock See: Powertrain Management\Fuel Delivery and Air Induction\Fuel Rail\Service and Repair
the clamp for the injector wiring at the rear of the cylinder head
the protective cover over the injector connectors
the charge air pipe over the engine. Tighten the pipe using the three screws on the engine. Tighten the clamps.
Installing components





Raise the car. Install:
the pipe screw that holds the turbocharger (TC) oil pressure pipe to the engine. Use new seal washers. Tighten. See Tightening torque See: Specifications\Mechanical\Tightening Torque
the turbocharger (TC) oil return line. Use a new gasket and sealing ring. Tighten. See Tightening torque See: Specifications\Mechanical\Tightening Torque
the clamp between the oil pressure pipe and the oil return line. Tighten the three nuts that hold the front exhaust pipe to the turbocharger (TC). See Tightening torque See: Specifications\Mechanical\Tightening Torque.
the lower screw for the heat deflector plate over the turbocharger (TC)
the splash guard under the engine
the plastic nuts for the hatch in the right fender liner
the right front wheel. See Installing wheels See: Maintenance\Wheels and Tires\Wheels\Service and Repair.



Lower the car.
Tighten the pipe screw for the turbocharger (TC) oil pressure pipe. See Tightening torque See: Specifications\Mechanical\Tightening Torque.

Install:
the ground strips between the cylinder head and the firewall
the engine stabilizer brace between the suspension turrets Clamp the servo hose at the right-hand engine stabilizer brace mounting
the negative battery lead. First read Battery, disconnecting See: Starting and Charging\Battery\Service and Repair\Procedures\Battery Disconnecting.
Check
Replace the oil and oil filter if necessary.

Check:
the engine oil level
the servo oil level
the coolant level.
Warm up the engine until the thermostat opens.
Check the engine for leaks.
Top up the coolant if necessary.
Roy, import/domestic specialest
Category: Car
Satisfied Customers: 1602
Experience: ASE master tech for 40 years
Roy and 12 other Car Specialists are ready to help you
Customer: replied 9 months ago.

Thanks for the procedure Roy, but you have some pictures to go with them?


 

JustAnswer in the News:

 
 
 
Ask-a-doc Web sites: If you've got a quick question, you can try to get an answer from sites that say they have various specialists on hand to give quick answers... Justanswer.com.
JustAnswer.com...has seen a spike since October in legal questions from readers about layoffs, unemployment and severance.
Web sites like justanswer.com/legal
...leave nothing to chance.
Traffic on JustAnswer rose 14 percent...and had nearly 400,000 page views in 30 days...inquiries related to stress, high blood pressure, drinking and heart pain jumped 33 percent.
Tory Johnson, GMA Workplace Contributor, discusses work-from-home jobs, such as JustAnswer in which verified Experts answer people’s questions.
I will tell you that...the things you have to go through to be an Expert are quite rigorous.
 
 
 

What Customers are Saying:

 
 
 
  • I would (and have) recommend your site to others I was quite satisfied with the quality of the information received, the professional with whom I interacted, and the quick response time. Thanks, and be sure that I'll be back whenever I need a question answered in a hurry. Stephanie P Elm City, NC
< Last | Next >
  • I would (and have) recommend your site to others I was quite satisfied with the quality of the information received, the professional with whom I interacted, and the quick response time. Thanks, and be sure that I'll be back whenever I need a question answered in a hurry. Stephanie P Elm City, NC
  • used your service this weekend with "Trecers" help. thank you ,thank you, thank you. replaced an A/C fan motor. Local Auto Zone had part. $15.00 "tracer" fee and $40.00 for parts, I saved several hundreds of dollers at a shop. i will recommend you and use you in the future. David L. Richmond, TX
  • 9 dollars, 2 hours of my time, and I drove away. Your diagnosis was right on the mark. Thank you so much. Phil Marysville, CA
  • Lurch. Thank you very much. I had real doubts about this website but your promptness of response, quick followup and to the point answer with picture was incredible. Charles Walnut Creek, CA
  • As a single woman, I really appreciate an excellent and affordable opinion.
    Thank you Geordie, I will not hesitate to contact justanswer in the future!
    Sue Charleston, WV
  • Another great insight to what may be the problem. I will have my mechanic take a look at it tomorrow. Thanks again, Frank...you do indeed know your stuff. Jim Castleberry, FL
  • Excellent reply, and also very quick. Really sounds like the Expert knows what he is talking about. I will be back to use your service when I need more help with my RV. Dutch USA
 
 
 

Meet The Experts:

 
 
 
  • Chris (aka-Moose)

    Technician

    Satisfied Customers:

    846
    16 years of experience
< Last | Next >
  • http://ww2.justanswer.com/uploads/MU/muddyford/2012-6-13_1204_1.64x64.png Chris (aka-Moose)'s Avatar

    Chris (aka-Moose)

    Technician

    Satisfied Customers:

    846
    16 years of experience
  • http://ww2.justanswer.com/uploads/TE/TedG/2012-6-15_14759_avaLarge.64x64.jpg Ted G.'s Avatar

    Ted G.

    ASE Certified Technician

    Satisfied Customers:

    1596
    20 years auto repair experience, ASE Master Tech, Mechanical Failure consultant, Expert Witness
  • http://ww2.justanswer.com/uploads/joecamel90/2008-11-13_03615_head_shot.jpg George H.'s Avatar

    George H.

    ASE Certified Technician

    Satisfied Customers:

    1311
    ASE Master Tech 15+ yrs, AAS Automotive Technology, Factory trained Asian specialist
  • http://ww2.justanswer.com/uploads/AM/amedee/2013-10-24_23656_Amedee1.64x64.jpg Amedee's Avatar

    Amedee

    ASE Master Tech

    Satisfied Customers:

    2367
    ASE Master Tech advanced level specialist
  • http://ww2.justanswer.com/uploads/SU/supermechanic/2013-8-23_03546_500.64x64.jpg Jerry's Avatar

    Jerry

    Master Mechanic

    Satisfied Customers:

    1906
    ASE master, 30+ years. All makes and models. Trouble shooter, shop forman, service manager
  • http://ww2.justanswer.com/uploads/CR/crzydrvr00/2013-11-3_12123_246347.64x64.jpg Richard's Avatar

    Richard

    ASE Certified Technician

    Satisfied Customers:

    942
    12 years Ford Lincoln/Mercury Jaguar dealership as a technician and shop foreman reparing all makes
  • http://ww2.justanswer.com/uploads/ST/Steve7654/2012-6-5_215929_japic800x660.64x64.jpg Steve's Avatar

    Steve

    Auto Service Technician

    Satisfied Customers:

    1980
    25+ yrs experience as a professional working technician; ASE L1 master technician