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volvo Workshop Repair Guides


XC90 2.5T AWD L5-2.5L Turbo VIN 59 B5254T2 (2003)

Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Service and Repair > Page 3338

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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 Specifications/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 999 5451 ADJUSTMENT 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.

Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Service and Repair > Page 3338

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