2001 VOLVO S80 Service and Repair Manual
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VOLVO
C70 •S40 •S60• 880 •V40 •V50 •V70 • V70XC • XC70
BRAKES 14-85
DRIVE TRAIN 14-61
ENGINE REPAIR 14-24
FUEL SYSTEM 14-58
SPECIFICATIONS AND
MAINTENANCE CHARTS 14-2
Engine and Vehicle
Identification Chart 14-2
General Engine Specifications 14-3
Engine Tune-Up Specifications 14-5
Accessory Drive Belt Routing 14-6
Capacities 14-7
Valve Specifications 14-9
Crankshaft and Connecting Rod
Specifications 14-11
Piston and Ring Specifications....14-13
Torque Specifications 14-15
Wheel Alignment 14-17
Tire, Wheel and Ball Joint
Specifications 14-19
Brake Specifications 14-21
Scheduled Maintenance
Intervals 14-23
STEERING AND
SUSPENSION 14-67
A
Air Bag 14-67
Disarming 14-67
Alternator 14-24
Installation 14-24
Removal 14-24
B
Bevel Gear 14-66
Removal & Installation 14-66
Brake Caliper 14-85
Removal & Installation 14-85
Brake Pads 14-87
Removal & Installation 14-87
C
Camshaft and Valve Lifters 14-44
Removal & Installation 14-44
Clutch 14-65
Adjustment 14-65
Removal & Installation 14-65
Coil Spring 14-70
Removal & Installation 14-70
CV-Joints 14-67
Overhaul 14-67
Cylinder Head 14-35
Removal & Installation 14-35
D
Distributor 14-24
Removal & Installation 14-24
E
Engine Assembly 14-25
Removal & Installation 14-25
Exhaust Manifold 14-42
Removal & Installation 14-42
F
Final Drive Assembly 14-65
Removal & Installation 14-65
Front Crankshaft Seal 14-43
Removal & Installation 14-43
Fuel Filter 14-58
Removal & Installation 14-58
Fuel Injector 14-60
Removal & Installation 14-60
Fuel Pump 14-58
Removal & Installation 14-58
Fuel System Pressure 14-58
Relieving 14-58
H
Halfshaft 14-66
Removal & Installation 14-66
Heater Core 14-30
Removal & Installation 14-30
Hydraulic Clutch System 14-65
Bleeding 14-65
Ignition Timing 14-25
Adjustment 14-25
Intake Manifold 14-40
Removal & Installation 14-40
L
Lower Ball Joint 14-71
Removal & Installation 14-71
Lower Control Arm 14-74
Control Arm Bushing
Replacement 14-78
Removal & Installation 14-74
0
Oil Pan 14-55
Removal & Installation 14-55
Oil Pump 14-56
Removal & Installation 14-56
P
Piston and Ring 14-58
Positioning ...14-58
R
Rack and Pinion Steering Gear .... 14-67
Removal & Installation 14-67
Rear Main Seal 14-57
Removal & Installation 14-57
S
Shock Absorber 14-69
Removal & Installation 14-69
Starter Motor 14-50
Removal & Installation 14-50
Strut 14-68
Removal & Installation 14-68
T
Timing Belt 14-50
Removal & Installation 14-50
Transaxle Assembly 14-61
Removal & Installation 14-61
Turbocharger 14-38
Removal & Installation 14-38
V
Valve Lash 14-45
Adjustment... ...14-45
W
Water Pump 14-34
Removal & Installation 14-34
Wheel Bearing 14-78
Adjustment 14-78
Removal & Installation 14-78
14-2
VOLVO
C70 • S40 • S60 • S80 V40 • V50 • V7 ) • V70XC • XC70
SPECIFICATIONS AND MAINTENANCE CHARTS
ENGINE AND VEHIl
Engine
Code
B4204T3
B4204T4
B5234T3
B5234T9
B5244S
B5244T3
B5244T7
B5254T
B5254T3
B5254T4
B6294S2
B6294T
Liters (cc)
1.9
1.9
2.3
2.3
2.4
2.4
2.4
2.5
2.5
2.5
2.9
2.9
(1948)
(1948)
(2319)
(2319)
(2435)
(2435)
(2435)
(2521)
(2521)
(2521)
(2922)
(2922)
Cu. in. Cyl. Fui
119 4
119 4
144 5
142 5
149 5
149 5
149 5
154 5
154 5
154 5
178 6
178 6
:LE IDENTIFICATION CHART
d Sys. Type
EFI DOHC
EFI DOHC
EFI DOHC
EFI DOHC
EFI DOHC
IFI DOHC
IFI DOHC
EFI DOHC
EFI DOHC
EFI DOHC
IFI DOHC
HFI DOHC
Eng. Mfg.
Volvo
Volvo
Volvo
Volvo
Volvo
Volvo
Volvo
Volvo
Volvo
Volvo
Volvo
Volvo
Model Year
Code Year
2
3
4
5
6
2002
2003
2004
2005
2006
EFI: Electronic Fuel Injection
DOHC: Double Overhead Camshafts
C70 • 840 • S60 • S80
VOLVO
V40 • V50 • V70 • V70XC • XC70 14-3
GENERAL ENGINE SPECIFICATIONS
Net
Year
2002
2003
2004
Model
S40
S60
S60 2.4T
S60T5
S60 AWD
C70 HPT Coupe
C70 LPT Conv
C70HPTConv
S802.9
S80T6
V40
V70 2.4
V70 2.4T
V70T5
V70 AWD
XC70 AWD
S40
S60
S60 2.4T
|__JS60_T5
I S60AWD
C70 LPT
C70 HPT
S80 2.9
S80T6
V40
V70 2.4
V70 2.4T
V70T5
V70 AWD
XC70 AWD
S40
S60 2.4
S60 2.5T
S60 2.5T AWD-R
S60T5
C70 LPT
C70 HPT
S80 2.9
S80T6
V40
V70 2.4
V70 2.5T
V70T5
V70 AWD
XC70AWD
Engine
Displ.
Liters
1.9
2.4
2.4
2.3
2.4
2.3
2.4
2.3
2.9
2.9
1.9
2.4
2.4
2.3
2.4
2.4
1.9
2.4
2.4
2.3
2.5
2.4
2,3
2.9
2.9
1.9
2.4
2.4
2.3
2.5
2.5
1.9
2.4
2.5
2.5
2.3
2.4
2.3
2.9
2.9
1.9
2.4
2.5
2.3
2.5
2.5
Engine
ID
B4204T3
B5244S
B5244T3
B5234T3
B5244T3
B5234T3
B5244T3
"B5234T3
B6294S2
B6294T
B4204T3
B5244S
B5244T3
B5234T3
B5244T3
B5244T3
B4204T3
B5244S
B5244T3
B5234T3
B5254T
B5244T7
B5234T9
B6294S2
B6294T
B4204T3
B5244S
B5244T3
B5234T3
B5254T
B5254T
B4204T4
B5244S
B5254T
B5254T
B5234T3
B5244T7
B5234T9
B6294S2
B6294T
B4204T4
B5244S
B5254T
B5234T3
B5254T
B5254T
Net
Horsepower
@ rpm
160@5250
168@5700
197@6000
247@5220
197@6000
247@5220
197@6000
247@5220
197@6000
268@5400
160@5250
168@5700
197@6000
247@5220
197@6000
197@6000
190@5500
168@5700
197@6000
247@5220
208@5000
197@5700
242@5400
197@6000
I 268@5400
160@5250
168@5700
197@6000
247@5220
208@5000
208@5000
190@5500
168@6000
208@5000
208@5000
247~@5200
197@5700
242@5400
197@6000
268@5400
190@5500
168@6000
208@5000
247@5200
208@5006
208@5000
Torque
@ rpm
(ft. Ibs.)
177@1800
170@4500
2"10@1800
241@2520
210@1800
241@2520
210@1800
241@2520
277@2100
206@4200
177@1800
170@4500
210@1800
241@2520
210@1800
210@1800
177@1800
170@4500
210@1800
241@2520
235@1500
210@1800
243@2400
277@2100
206@4200
177@1800
170@4500
210@1800
241@2520
235@1500
235@1500
177@1800
166@4500
236@15bO
236@1500
243@2400
210@1800
243@2400
277"@2100
206@4200
177@1800
166@4500
236@1500
243@2400
236@1500
236@1500
Bore x
Stroke
(in.)
NA
3.27 x 3.54
3.27 x 3.54
3.19x3.54
3.27x3.54
3.19x3.54
3.27 x 3.54
3.19x3.54
3.27 x 3.54
3.19x3.54
NA
3.27 x 3.54
3.27 x 3.54
3.19x3.54
3.27 x 3.54
3.27x3.54
NA
3.27 x 3.54
3.27 x 3.54
3.19x3.54
NA
3.27 x 3.54
3.19x3.54
3.27 x 3.54
3.19x3.54
NA
3.27 x 3.54
3.27 x 3.54
3.19x3.54
NA
NA
NA
NA
NA
NA
3.19x3.54
3.27 x 3.54
3.19x3.54
3.27 x 3.54
3.19x3.54
NA
NA
NA
3.19x3.54
NA
NA
Com-
pression
Ratio
10.3:1
10.3:1
9.0:1
8.5:1
9.0:1
8.5:1
9.0:1
8.5:1
10.3:1
8.5:1
10.3:1
10.3:1
9.0:1
8.5:1
9.0:1
9.0:1
9.0:1
10.3:1
9.0:1
8.5:1
9.5:1
9.0:1
8.5:1
10.3:1
8.5:1
10.3:1
10.3:1
9.0:1
8.5:1
9.5:1
9.5:1
9.0:1
NA
NA
NA
8.5:1
9.0:1
8.5:1
10.3:1
8.5:1
9.0:1
NA
NA
8.5:1
NA
NA
Oil
Pressure
@ rpm
NA
51@4000
51(^4000
51@4000
51^4000_
51@4000
51@4000
51@4000
51@4000
51@4000
NA
51@4000
51@4000
51@4000
51@4000
51@4000
NA
51@4000
51@4000
51@4000
NA
NA
NA
51@4000
51@4000
NA
51@4000
51@4000
51@4000
NA
NA
NA
NA
NA
NA
NA
NA
NA
51@4000
51@4000
NA
NA
NA
NA
NA
NA
NA: Information not available
14-4
VOLVO
C70 • S40 • S60 S80 • V40 • V50 • v; 0 • V70XC • XC70
GENERAL EN GINE SPECIFICATIONS
Net
Engine
Displ. Engine 1
Year Model Liters ID
2005
2006
S40 2.4i
S40T5
S60 2.4
S60 2.5T
S60R
i___S60T5
S80 2.5T
S80T6
V50 2.4i
' V50 T5
V70 2.4
V70 2.5T
V70R
XC7CT
C70T5
S40 2.4i
S40T5
S60 2.5T
S60R
S60T5
S80 2.5T
V50 2.4i
V50T5
V70 2.4
V70 2.5T
V70R
XC70
2.4
2.5
2.4
2.5
2.5
2.4
2.5
2.9
2.4
2.5
2.4
2.5
2.5
2.5
2.5
2.4
2.5
2.5
2.5
2.4
2.5
2.4
2.5
2.4
2.5
2.5
2.5
B5244S
B5254T3
B5244S
B5264T
B5254T4
B5244T
B5254T
B6294T
B5244S
B5254T3
B5244S
B5254T2
B5254T4
B5254T2
B5254T3
B5244S
B5254T3
B5254T
B5254T4
B5244T
B5254T
B5244S
B5254T3
B5244S
B5254T2
B5254T4
B5254T2
~
Net Torque Bore x Com- Oil
orsepower @ rpm Stroke pression Pressure
@ rpm (ft. Ibs.) (in.) Ratio @ rpm
169@6000
218@5000
165@6000
208@5000
300@5500
?57@5500
?08@5000
?68@5200~
168@6000
?18@5060
I65@6000
208@5000
300@5500
>08@500b
ns@50oo
I68@6000
J18@5000
!08@5000
J00@5500
!57@5500
>08@5000
68@6000
!18@5000
65@6000
08@5000
00@5500
08@5000
170@4400
236@4800
166@4500
236@1500
295^1950
258@2100
236@1500
280@1800
170@4400
236@4800
166@4500
236@1500
295@1950
236@1500
236@4800
170@4400
236@4800
236@1500
295@1950
258@2100
236@1500
170@4400
236@4800
166@4500
236@1500
295@1950
236@1500
3.24 x 3.54
3.27x3.67
NA
NA
NA
NA
3.27x3.67
3.28 x 3.56
3.27x3.54
3.27x3.67
3.27x3.54
NA
3.27x3.67
_ _ NA
3.27x3.67
3.24 x 3.54
3.27x3.67
3.27x3.67
3.27x3.67
3.20 x 3.67
3.27x3.67
3.27x3.54
3.27x3.67
3.27x3.54
3^27 x 3.67
3.27x3.67
3.27x3.67
10.3:1
9.0:1
NA
NA
8.5:1
NA
9.0:1
8.7:1
10.3:1
9.0:1
10.3:1
8.5:1
8.5:1
NA
9.0:1
10.3:1
9.0:1
9.0:1
8.5:1
8.5:1
9.0:1
10.3:1
9.0:1
10.3:1
8.5:1
[_8.5:1
8.5:1
NA
51@4000
NA
NA
NA
NA
NA
5i@4000 "
NA
51@4000
NA
51@4000
NA
h 51@4000
51@4000
51@4000
51@4000
51@4000
51@4000
51@4000
51@4000
51@4000
51@4000
|51@4000
51@4000
51@4000
51@4000
NA: Information not available
C70 • S40 • S60 • S80 • V40
VOLVO
V50 • V70 • V70XC • XC70 14-5
ENGINE TUNE-UP SPECIFICATIONS
Engine Spark Plug
Displacement Engine Gap
Liters ID (in.)
2002
2003
2004
2005
2006
1.9
2.3
2.4
2.4
2.9
2.8
1.9
2.3
2.4
2.4
2.5
2.3
I 2-4
2.9
2.9
1.9
2.3
2.4
2.5
2.3
2.4
2.9 _
2^9
2.4
2.5
2.5
2.5
2.4
2.9
2.5
2.4
2.4
2.5
2.5 _
2.5
2.5
B4204T3
B5234T3
B5244T3
B5244S
B6294S2
B6294T
B4204T3
B5234T3
B5244T3
B5244S
B5254T
B5234T9
B5244T7
B6294T
B6294S2
B4204T3
B5234T3
B5244S
B5254T
B5234T9
B5244T7
B6294S2
B6294T
B5244S
B5254T3
B5254T
B5254T4
B5244T
B6294T
B5254T2
B5244S
B5244T
B5254T
B5254T2
B5254T3
B5254T4
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
NA
NA
NA
NA
NA
NA
Ignition
Timing
(deg.)
MT AT
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA ]
NA
NA
NA
NA
NA
NA
NA _
""NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
~ NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Fuel
Pump
(psi)
32-45
55
55
55
55
55
32-45
55
55
55
55
55
55
55
55
32-45
55
55
55
55
55
55
55
NA
NA
NA
NA
NA
55
NA
NA
NA
NA
NA
NA
"MA
Idle
Speed Valve
(rpm) Clearance (in.)
MT AT In. Ex.
NA
670
670
670
650
650
NA
670
670
670
850
I 670
670
650
650
NA
670
670
850
i 670
670
650
650
670
NA
NA
720
670
NA
850
720
770
670
670
NA
NA
NA
670
670
670
650
650
NA
670
670
670
850
670
670
650
650
NA
670
670
850
670
670
650
650
670
NA
NA
L 72°
670
650
850
720
770
NA
NA
NA
NA
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
I HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD: Hydraulic lash adjusters
B: Before top dead center
NA: Information not available
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