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S80 2001 T6 Spark Plug Replacement - How To

Help, Advice, Owners' Discussion and DIY Tutorials on the Volvo S80 model. Sometimes called an "executive car", the S80 was and continues to be Volvo's top-of-the-line passenger car.
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vegasjetskier
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S80 2001 T6 Spark Plug Replacement - How To

Post by vegasjetskier » Mon Nov 24, 2008 5:13 pm

Here's how to replace the spark plugs in your 2001 T6. I got my genuine Volvo plugs from IPD for $52.

I know there are some cheaper plugs out there, but with the amount of work this entails I decided to go with the real deal so I won't have to do it over (hopefully) in the near future.

Tools and supplies you will need:

T-25 Torx bit (get this ahead of time because you won't get anywhere without it).
10mm socket.
Socket extension.
Ratchet wrench.
Torque wrench.
5/8" Spark Plug socket.
New plug set.
Anti-seize lubricant.
Shotgun cleaning kit (optional).
Flat bit screwdriver.
Needle-nosed pliers.
Disc brake cleaner.
Rags or paper towels.

Start by opening the hood. Here's what you will see. You need to remove all of the plastic turbo tubes that run across the top of the engine.
PB241137.JPG
Remove the cover over the connector on the side of the intake hose by releasing the plastic catches and lifting up on the top from the front (sorry this pic is kinda blurry):
PB241138.JPG
Separate the two cover halves and remove them. Push in on the metal retention clip on the electrical connector, then pull the connector out towards the front of the car. You may need to wiggle it a little:
PB241139.JPG
Pull the aluminum tube out of its connector:
PB241140.JPG
Loosen all the clamps on the air tubes. I just slid them back over the flanges and tightened them gently so they wouldn't get lost. You don't want them sliding down the aluminum turbo tubes because they can be tough to get back into position. Be sure to loosen the clamp holding the Compressor Bypass Valve return hose and remove the hose from the bottom of the intake tube:
PB241141.JPG
You also need to remove the small vacuum hose seen next to the CBV return hose in this pic:
PB2411722.jpg
Use the T-25 Torx bit to remove the 3 screws holding the plastic air tubes to the engine.
PB2411372.jpg
Take the large rubber hose (just behind the radiator) off the front of the twin pressure tube.
PB2411373.jpg
Now pull on the twin pressure tube toward the front of the car. You may need to wiggle it some back and forth. It takes quite a bit of force to get it loose as it has to pop over the flanges on the aluminum tubes. Set the twin pressure tube aside. Disconnect the accordion hose (by the air cleaner) from the intake tube. Now pull on the intake tube until it comes loose from the aluminum turbo tubes. There is a long vacuum hose connected to the bottom. I just left it connected and rotated the tube over to right to get it out of the way. Stuff some rags or paper towels into the turbo tubes. You don't want any screws falling down into those tubes.
PB241142.JPG
Now use the T-25 Torx bit to remove the 7 screws holding the 2 plastic covers to the top of the engine:
PB241143.JPG
Use a finger to release the clips on the front and rear of the timing belt cover:
PB241145.JPG
And remove it:
PB241146.JPG
Then remove the spark plug coils cover:
PB241147.JPG
Use a fingernail or screwdriver to lift the catch on the connector of the first coil:
PB241149.JPG
Then slide the connector out of the coil:
PB241150.JPG
Now use the 10mm socket to remove the coil holddown bolt:
PB241151.JPG
Lift straight up on the coil to remove it. It might take a lot of force because the rubber boot of the coil might be stuck to the spark plug.
PB241152.JPG
Use the 5/8" spark plug socket to unscrew the spark plug:
PB241155.JPG
If the plug does not come out with the socket after you unscrew it, use the needle-nose pliers to remove it:
PB241156.JPG
The spark plug holes in my car we pretty cruddy so I used my shotgun cleaning kit to clean them up. I put the brush on the end of the handle, then put a patch over the brush and soaked it in disc brake cleaner. I then scrubbed out the holes. You could probably do the same thing with some rags and a screwdriver, but I don't think it would be as effective. The main thing you want to do is get the spark plug gasket seat area clean so that you get a good seal when you tighten up the plugs:
PB241166.JPG
Before:
PB241161.JPG
After:
PB241163.JPG
Place a little anti-seize lubricant on the threads of the plug. This is to prevent the plug from stripping out the threads in the head when you remove it the next time you change plugs.
PB241165.JPG
Screw the plug into the hole and tighten to 22 ft-lbs using the torque wrench. Repeat for the remaining 5 plugs.

Assembly is the reverse of disassembly. Before you put the engine covers on, make sure that all the coil connectors are in tight, the retention clips are snapped in place, and that the 10mm hold down bolts are all tight. Don't forget to take the rags out of the turbo tubes before you put the plastic tubes back on.

When you install the intake hose, make sure you connect the small hose to the bottom near the CBV return hose. You can see the small hose between the intake manifold and the CBV return hose in the center of this pic:
PB241168.JPG
Also, be sure the CBV return hose clamp is tight.

You will have to push quite hard to get the plastic turbo tubes back onto the aluminum tubes as they have to pop over the flanges. Push them on until they snap into place. Reinstall all the clamps and make sure they're tight. Double check to make sure everything looks like the first pic at the top and you're done!
Last edited by vegasjetskier on Tue Nov 25, 2008 4:55 pm, edited 3 times in total.
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MadeInJapan
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Re: S80 2001 T6 Spark Plug Replacement - How To

Post by MadeInJapan » Mon Nov 24, 2008 6:21 pm

Thanks! Pinned in the repair database. :D
'98 S70 T5 Emrld Grn Met/Beige Tons of Upgrades Mobil-1
'04 V70 2.5T Red/Taupe Some Upgrades Mobil-1
'07 S40 T5 AWD 6 speed manual! Silver/Black Stage1 Heico & Elevate
'07 S60 2.5T Blue/Taupe- my kid's Volvo

John Callahan
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Re: S80 2001 T6 Spark Plug Replacement - How To

Post by John Callahan » Thu Mar 26, 2009 1:17 pm

Excellent! How do you keep the debris out of the cylinder while doing the cleaning?
Thanks

MadeInJapan
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Posts: 13273
Joined: Thu Mar 31, 2005 7:14 am
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Re: S80 2001 T6 Spark Plug Replacement - How To

Post by MadeInJapan » Thu Mar 26, 2009 3:44 pm

I use a vacuum cleaner if there is loose debris...otherwise, I wipe carefully.
'98 S70 T5 Emrld Grn Met/Beige Tons of Upgrades Mobil-1
'04 V70 2.5T Red/Taupe Some Upgrades Mobil-1
'07 S40 T5 AWD 6 speed manual! Silver/Black Stage1 Heico & Elevate
'07 S60 2.5T Blue/Taupe- my kid's Volvo

vegasjetskier
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Location: Fernandina Bch, FL Formerly - Las Vegas, NV

Re: S80 2001 T6 Spark Plug Replacement - How To

Post by vegasjetskier » Thu Mar 26, 2009 4:18 pm

John Callahan wrote:Excellent! How do you keep the debris out of the cylinder while doing the cleaning?
Thanks
The area should be relatively clean because it's sealed by the coil pack. Any large loose material should be vacuumed away. For the crud you see at the bottom of my spark plug holes, there really is no way to prevent it from dropping into the cylinders. It is probably dried oil that dripped down, possibly combined with some carbon that has come up from the cylinder around the spark plug threads. This stuff will probably dissolve and be absorbed into the cleaning cloth. Any particles that might drop into the cylinder will be small and will be blown out of the exhaust ports when the engine is started.
.

SOLD - 2001 Volvo S80 T6: Mobil 1 Oil & Synthetic ATF, Brake Performance drilled and slotted front rotors, Akebono Euro Ceramic pads and Yokohama Avid V4S tires, 91K miles.

Help this site: Amazon.com link, Tirerack.com link, Donate

emk
Posts: 40
Joined: Thu Aug 12, 2010 2:41 pm
Year and Model: 1999 S80 T6
Location: Toronto, Canada

Re: S80 2001 T6 Spark Plug Replacement - How To

Post by emk » Wed Nov 10, 2010 8:15 am

Hey Vegas, thanks for the How To - used it on the weekend to change out my sparkies. Great write up.

You mentioned that a Torx T-25 was used to remove the 7 bolts of the top plastic cover - Mine were T-30 size bolts, just to let you know.
1999 Volvo S80 T6 - 210K kms

elmo_allen
Posts: 43
Joined: Sun Dec 07, 2008 5:20 pm
Year and Model: 1999 S80 2.9LNT
Location:

Re: S80 2001 T6 Spark Plug Replacement - How To

Post by elmo_allen » Fri Oct 26, 2012 11:44 am

Is this the same for the 1999 Volvo S80 2.9? I know it would be a lot easier without the hoses, I just wanted to make sure it was the same process after the hoses.

Thanks!
Proud Owner of a Silver 1999 Volvo S80 2.9

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trojanrabbit
Posts: 1
Joined: Sat Mar 22, 2014 8:38 am
Year and Model: 2001 S80 T6
Location: MA

Re: S80 2001 T6 Spark Plug Replacement - How To

Post by trojanrabbit » Sat Apr 05, 2014 6:16 pm

Thanks for the excellent write-up. I had to use a T-27 on my top covers, but everything else was right on. My problem was a totally misfiring cylinder, which didn't go away until I substituted the last coil pack, as Murphy would have it.

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