QuestionI have a 960 Volvo and I live in Jamaica and need to find some specifications and Diagrams so that I can successfully remove and replace my cylinder head as presently, when I start in the mornings my car smokes for about 1 minute amd then it clears up.
I believe that my valve seals need changing and I also want to change my timing belt as I bought the car. If possible I would appreciate it if you could direct me to any websites where I may be able to get information about this car that will be valuable to me.
As I intended to do most of the maintenance work myself.
As this a 3rd world country and I really cannot afford a volvo, I was only able to buy this car because I had about mentioned problems with the engine and It also wants struts for the suspension so the previous owner sold it to me
cheap because no one else would buy it.
Please help a lover.
Urgently awaiting your reply.
Neil
AnswerNeil,
There are many special tools and I would not recomend that you attempt this job with them
1993 Volvo 960 L6-3.0L VIN 95 B6304F
Vehicle Level Engine, Cooling and Exhaust Engine Cylinder Head Assembly Service and Repair Cylinder Head Removal and Installation
Cylinder Head Removal and Installation
SPECIAL TOOLS
Counterhold tool No. 999 5199, or equivalent
Drift tool No. 999 5449, or equivalent
Drift tool No. 999 5450, or equivalent
Crankshaft Locking tool No. 999 5451, or equivalent
Camshaft locking tool No. 999 5452, or equivalent
Holder tool No. 999 5453, or equivalent
Press tool No. 999 5454, or equivalent
PROCEDURE
Disconnect battery ground lead and drain coolant
Disconnect battery ground lead.
Remove expansion vessel cap.
Connect tube to drain cock on right-hand side of engine.
Open cock and collect coolant.
Close drain cock.
Remove components from right-hand side of cylinder head
Remove exhaust manifold as described in steps 1 through 3 of Exhaust Manifold. See: Exhaust System\Exhaust Manifold\Service and Repair
Remove coolant pipe bolts (two).
Remove timing belt/tensioner
Remove Timing Belt as described in Replacement steps 1 through 6. See: Timing Belt\Service and Repair
Remove transmission mounting plate bolt
Remove intake manifold and components from left-hand side of cylinder head
Carry out step 1 through 4 and step 7 of replacement. See: Intake Manifold\Service and Repair
Remove coolant temperature sensor.
Disconnect coolant hose from thermostat housing
Remove:
ignition coils (mark positions)
camshaft pulleys, using counterhold tool No. 999 5199, or equivalent. Mark pulleys (intake and exhaust side).
Remove components at engine rear:
camshaft position sensor
switch mounting bracket
ground terminals 1 and 2
temperature sensor connector
coolant hoses at rear
Remove top half of cylinder head
Undo bolts (46).
Tap top half of cylinder head carefully upwards with copper mallet. Tap joint lugs and camshaft front ends.
Remove camshafts
Remove cylinder head
Undo cylinder head bolts starting at outside edge and working inwards.
Remove head.
Remove head gasket.
Clean:
mating faces between exhaust manifold and cylinder head
cylinder block joint
coolant pipe joint
joint faces between top and bottom halves of cylinder head
NOTE: Use soft putty knife and if necessary gasket solvent part No. 1161 340-3, or equivalent, for this purpose. Do not use a metal blade. A fume hood or extractor must be used if using gasket solvent.
Align timing mark on crankshaft Remove starter motor.
Remove protective plug.
Mount crankshaft locking tool No. 999 5451, or equivalent.
Turn crankshaft counterclockwise until stopped by tool.
Install bottom half of cylinder head
Use new cylinder head gasket.
Oil bolts.
Tighten bolts in three stages as follows: Stage 1:20 Nm (15 ft. lbs.)
Stage 2:60 Nm (44 ft. lbs.)
Stage 3: Tighten an additional130°
Cylinder head gasket, replacement
Install new O-rings in spark plug wells.
Oil camshaft bearing seats.
Apply liquid sealing compound
Apply liquid sealing compound, part No. 1161 059-9, or equivalent to upper section of cylinder head. Use roller.
NOTE: Ensure that compound does not penetrate coolant or oil passages.
Oil camshaft bearing seats.
Install camshafts. Locate at front end using holder tool No. 999 5453, or equivalent, and at rear end with camshaft locking tool No. 999 5452, or equivalent.
Install upper section of cylinder head
Place component in position.
Tighten against lower section using two press tools 999 5454.
Tighten bolts to 17 Nm (13 ft. lbs.) starting from inside and working outwards.
Remove holder tool No. 999 5453 and press tool No. 999 5454.
Install camshaft front seals
Use drift tool No. 999 5449, or equivalent.
Grease seals.
Tap in seals.
Mount camshaft pulleys
Place upper transmission cover in position.
Mount camshaft pulleys.
Align timing marks Tighten each pulley with two bolts.
Remove upper transmission cover.
Insert transmission mounting plate bolt.
Install timing belt
Place belt around crankshaft and right-hand idler.
Place belt over camshaft pulleys, press over tensioner pulley.
Install belt tensioner
Tighten tensioner bolts to 25 Nm (18 ft. lbs.).
Slacken camshaft pulley bolts.
Withdraw tensioner locking pin.
Tighten camshaft pulleys
Insert third bolt and tighten bolts alternately to (20 Nm ft. lbs.).
Use counterhold tool No. 999 5199, or equivalent.
Remove locking tools (999 5451, 999 5452)
Remove crankshaft locking tool refit protective plug and install starter motor.
Remove camshaft locking tool.
Install upper transmission cover.
Check timing marks
Check that timing marks on crankshaft and camshaft pulleys are correctly aligned.
Install new seal
Use drift tool No. 999 5450, or equivalent.
Grease seal.
Press in seal.
NOTE: Seal is normally located in same plane as edge of inside shoulder. If shaft end is worn. seal may be located a further 2 mm (0.08 in).
Install/reconnect:
temperature sensor connector
ground terminals 1 and 2
cover
switch mounting bracket
shutter (note position)
camshaft position sensor
coolant hoses
Install:
ignition coils
spark plug cover
front transmission cover
auxiliaries drive belt
vibration damper guard
splash guard under engine
Assemble components on left side of cylinder head Install intake manifold as per steps 11, 12 and 14 of replacement. See: Intake Manifold\Service and Repair Reconnect coolant hose to thermostat housing.
Reconnect coolant temperature sensor.
Assemble components on right side of cylinder head Install:
coolant pipe with new gasket
exhaust manifold with new gaskets
heat shield
front exhaust pipe
NOTE: Undo bolted joint after catalytic converter and retighten, to 25 Nm (18 ft. lbs.). This is necessary to prevent stresses in the system.
Fill system with coolant/change oil and oil filter Reconnect battery ground lead.
Fill engine with oil.
Oil capacity. incl. filter: 5.75 L (6 US qts)
excl. filter: 5.25 L (5.5 US qts)
Fill cooling system.
Run engine until thermostat opens and top up coolant as required.
Inspect for leaks.
