Question about 2002 Volvo S60

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How do you change the spark plugs on a 02 S-60 2.4T ?

There seems to be a lot of stuff on the top of the motor, do you need to move or remove stuff?

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  • Anonymous Feb 23, 2009

    yeah me too. wtf?



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I just did this. It took me longer than I thought. About 75 minutes.
It took me 5 minutes to determine where the plugs were.

You need a socket drive for the spark plug, 3/8 drive; and socket (forgot the mm size)
Also need a torque bit for an electric screwdriver and for the tight spots on the back toward th efirewall
I used a little small screwdriver drive that is more of a rackets drive (like a 3/8" socket drive),
but much smaller that let me get to those torque screws under the horizontal pipe.

So basically you need to remove the torque screws on the shrouding at the top of the engine
which covers the dual cams. Then on the passenger side of that shrouding, there is a second shrouding that is like a half of a wheel covering the timing belt of the 2 cam shafts.
With those 2 shroud off, you can see the 5 plugs with ignition electronics at the top of each.

Use a 10 mm socket to remove the bolt holding down the ignition electronic component.
It looks like an epoxy potted rectangular box maybe 2.5"x1.5"x3/4". Undo the connector.
Then just pull steadily upward on the rectangular box with a lot of force. The rubber spark plug jacket comes off with a pop, exposing the plug below about 3-4" inches in an aluminum cavity.
replace the plug. I didn't use a torque wrench, put tried to apply about the same force as it took to remove. I used a Bosh plug with two electrodes that didn't require gapping. I removed a standard volve plug with 3 electrodes. Now that I know, I would probable go with a plug that has 3 electrodes, just to be more try to the original. At the time I didn't know and bought the 2 electrode Bosch.

Just put the rubber sleeve with the rectangular ignition box back on and torque down the 10mm bolt.
Replace the shroud. I also added a little high-temp grease on the plugs thread to make removal easier.

After I did a3 plugs, I realized that I could operate more as an assembly line, and remove all 10mm bolts at the same time, and all rubber/ignition boots, then all plugs, etc.

Next time it should take 30 minutes. I'll know exactly what tools I need and have them all there.

Posted on Feb 25, 2009


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