Genuine Volvo V50 Cylinder Head

Volvo V50 Cylinder Head Parts and Q&A

• Cylinder Head
  36050502
  Q: How to remove and refit a cylinder head for 2.0 and 2.4 litre 5-cylinder diesel engine on Volvo V50?

  A:

  To remove the cylinder head, first disconnect the battery negative lead, jack up the front of the vehicle, and securely support the vehicle on axle stands. Drain the engine oil and cooling system, remove the timing belt, intake manifold, fuel injectors, fuel rail, glow plugs, high pressure fuel pump and brake vacuum pump. At EGR cooler, loosen the clamp holding the pipe that connects the EGR cooler to the exhaust manifold, remove the bolts holding the EGR valve/cooler assembly to the cylinder head and move it out of the way or remove it completely if needed. Next, undo the securing bolts/nuts and remove the exhaust manifold heat shield then bolts securing the exhaust manifold to the cylinder head. Remove the camshafts and rockers, making sure all wiring plugs and hoses are removed from the cylinder head. Progressively loosen the cylinder head bolts a half-turn until these can be unscrewed by hand, removing the old bolts. Lift the head off the cylinder block without damaging the sealing face, and remove the gasket from the top of the cylinder block, recording the identification holes. For inspection, make sure to clean the mating faces of the cylinder head and block/crankcase, making sure to use a scraper to remove gasket and carbon residue without damaging the aluminium alloy. Check for nicks or scratches on the mating surfaces and if warpage is suspected, use a straight edge to check for distortion. Clean out cylinder head bolt drillings, making sure there is no oil or coolant. For refitting the cylinder head gasket, check the old cylinder head gasket for identification markings and be sure that the new cylinder head gasket matches, unless new pistons have been installed in which case the piston projection should be measured prior to purchasing a new cylinder head gasket. Line up the marks on the crankshaft pulley flange and oil pump housing and position the new head gasket on the cylinder block, using the locating dowels. Place the cylinder head in the center of the block and that the dowels are engaged with the recesses in the cylinder head, and check to see that the gasket is seated properly. Apply some grease to the threads and underside of the heads of the new cylinder head bolts, then carefully insert each bolt separately into its hole, until finger-tight. Tighten the bolts to specified settings using a torque wrench, then angle tighten the bolts through the specified angle using an angle measuring gauge for accuracy. Refit the camshafts and rockers, install a new camshaft oil seal and finish the refit by making sure no retightening of the cylinder head bolts is necessary, tighten all fastening to their recommended torque, refill the cooling system and replenish the engine oil.
• Cylinder Head
  8252302
  Q: How to remove and refit the cylinder head for 1.6 litre diesel engine on Volvo V50?

  A:

  To remove the 80kw engine, first disconnect the battery negative lead, next remove the air cleaner housing, intake manifold, exhaust manifold, brake vacuum pump, thermostat and fuel pump. Next, remove the camshafts, rocker arms and hydraulic tappets. Undo bolts on a cylinder head in a prescribed order, disposing of old cylinder head bolts for new cylinder head bolts. Release the cylinder head from the block by a rocking motion, and avoid prying between mating faces to prevent gasket damage, and lift the cylinder head off and recover the gasket. For 85kw engine, take out the fuel injectors and glow plugs, then brake vacuum pump, camshaft oil seal, thermostat and exhaust manifold. Make sure all pipes and hoses are removed before taking the camshaft cover and camshaft carrier, together with the support bracket bolt. Lift out each rocker arm and use appropriate containers, but have a compartmentalized container filled with engine oil in order to keep those hydraulic tappets, while taking them out of the cylinder head, so that they are submerged in the engine oil. Undo the cylinder head bolts in a sequence, release the cylinder head and lift it off recovering the gasket. Before refitting, thoroughly clean the mating faces of the cylinder head and block, using a hard plastic or wood scraper to remove any and all traces of gasket and carbon, being careful not to damage the surfaces. Seal the water, oil and bolt holes in the cylinder block with adhesive tape and paper and grease in the gap between the pistons and bores to prevent carbon entering. Check the mating surfaces for damage, clean the threads of the cylinder head bolt holes and make sure that the bolts run easily. For gasket selection, determine how thick it should be according to the notches or holes of the gasket, if the crankshaft or pistons have been disturbed, measure the piston protrusion with the help of a dial test indicator. After getting average readings for each piston, make sure the biggest difference in protrusion is not out of limits and then choose the right gasket. For refitting, set pistons 1 and 4 to TDC, clean the surfaces, install the appropriate gasket, lower cylinder head on it, apply grease to bolt threads. Insert and finger-tighten the cylinder head bolts and then tighten them step by step up to the indicated torque values in the sequence, ending with an angle-tightening procedure. Refit the hydraulic tappets, rocker arms and camshaft housing, including the application of sealant to the cylinder head mating surface for the 85kw engine. Complete the refitting by renewing the thermostat, tightening all the fasteners to specified torque, replenishing coolant and engine oil, and allow the engine management system to relearn its values upon initial operation.