Engine - Cylinder Block Seal Plug Installation
S60/V70 (01-)/S802002
Section
2
Group
21
No.
0052
Year
04
Month
01
Vehicles involved: B52x4S, B6294S
Installing the seal plug in the cylinder block
Background:
The previous rubber coated metal plugs have been replaced by all metal plugs.
Materials
Description Only B6294S Quantity P/N
Flanged nut 12 948645
Gasket set 1 271734
Flanged nut 8 945408
Gasket 2 9207969
Cable tie 2 983750
Description All variants
Seal plug 6 cylinder 2 8687868
Seal plug 5 cylinder 1 8687868
Copper paste 1 1161408
Special tools
Description Special Tool P/N
Bulletin #
Socket, NV-22 for R&I of oxygen sensor STB 76 999 5543
Cylinder block
Installing the seal plug in the cylinder block
Note! 1
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.
5 cylinder engines 2
The illustration is of a 5 cylinder engine seen from below. The plug can be accessed from below on 5 cylinder engines.
Remove the shield under the engine (where applicable).
Clean any oil and dirt from around the existing plug.
Remove the plug by pressing a hole in the rubber in the center of the plug and then prying it out. Use a small screwdriver.
Installing the plug 3
Thoroughly clean any oil from in or around the hole. Use isopropyl alcohol or similar.
Install a new plug by tapping it in. Use a long socket with a maximum outer diameter of 16.5 mm. When the socket bottoms out the tone will change. See the following step.
4
When the plug is at the bottom the measurement (A) from the upper edge of the plug to the upper edge of the hole must be approximately 8 mm (there may be some variation due to casting irregularity).
6 cylinder engines 5
Remove:
- the splash guard under the engine
Note!
Clean and spray the exposed threads using rustproofing agent prior to removal.
- the nuts at the manifold and front exhaust pipe flange
- the screws for the front SIPS member. Disconnect the brake pipe from the clips on the SIPS crossmember
Release the exhaust system from the manifold. Leave the exhaust system resting on the rear SIPS members.
6
Remove:
- the four screws in the spring strut turret
- the screw and nut for the engine stabilizer bracket
- the tie strap for the power steering hose
- the engine stabilizer brace.
7
Removing heated oxygen sensors (HO2S)
Remove:
- The preheating pipe between the heat deflector plate and the air cleaner (ACL)
- the bracket for the right-hand heated oxygen sensor (HO2S) cable
- the tie strap holding the wiring for the heated oxygen sensor (HO2S) to the transmission dipstick.
- the heated oxygen sensors (HO2S). Use tool 999 5543, Socket NV 22
Caution!
The heated oxygen sensors (HO2S) must not be mixed up.
- the heat deflector plate.
Caution! 8
When unscrewing the heated oxygen sensors (HO2S) without disconnecting the connector, the cables will become twisted. They must be untwisted the same amount upon reassembly. Mark the location of the sensors and tape them to the top of the engine. The sensors must not be mixed up.
Removing the manifold 9
Note!
Clean and spray the exposed stud threads using rustproofing agent prior to removal.
Remove:
- the nuts for the manifold
- the manifold
- the gaskets.
Removing the plug 10
The illustration displays the position of the plugs on the cylinder block.
Clean any oil and dirt from around the existing plug.
Both the plugs must be replaced at the same time.
Remove the plug by pressing a hole in the rubber in the center of the plug and then prying it out. Use a small screwdriver
Installing the plug 11
Thoroughly clean any oil from in or around the hole. Use isopropyl alcohol or similar.
Install a new plug by tapping it in. Use a long socket with a maximum outer diameter of 16.5 mm. When the socket bottoms out the tone will change. See the following step.
12
When the plug is at the bottom the measurement (A) from the upper edge of the plug to the upper edge of the hole must be approximately 8 mm (there may be some variation due to casting irregularity).
13
Installing the exhaust manifold
Clean the gasket faces thoroughly. Use a razor blade or a gasket scraper.
Check that all the studs are tightened in the cylinder head. Tighten to 20 Nm.
Install:
- new gaskets.
Lubricate the threads on the studs and heated oxygen sensors (HO2S) before installation. Use paste 1161408.
Note!
The paste must not come into contact with the probe section of the heated oxygen sensor.
Install:
- the manifold. Use new nuts. Tighten to 25 Nm.
14
Installing heated oxygen sensors (HO2S)
Install:
- the heat deflector plate
- the heated oxygen sensors (HO2S). Use tool 999 5543, Socket NV -22. Tighten to 45Nm
- the bracket for the right-hand heated oxygen sensor (HO2S) cable
- the tie strap holding the wiring for the heated oxygen sensors (HO2S) to the transmission dipstick
- the preheating pipe.
15
Installing the crossmember
Install:
- the engine stabilizer brace. Tighten the four screws on the suspension turrets. Tighten to 50Nm.Tighten the screw in the torque bracket. Tighten to 80Nm
- the servo hose to the engine stabilizer brace using a tie strap.
16
Installing the exhaust system
Install:
- new gaskets on the manifold flanges. Connect the front exhaust pipe to the manifolds. Lubricate the threads. Use paste 1161408. Use new nuts. Tighten to 25 Nm.
Press the brake pipe into the clip on the front SIPS member.
Press up and install the front SIPS member. Tighten to 25 Nm.
Install:
- the lower engine cover.
WARRANTY STATEMENT:
Claims may be submitted under the New Car Warranty when there is a documented customer complaint, using claim type 01.