2006 S60 Intake Manifold

JohanD · Post by **JohanD** » 27 Apr 2012, 17:07

I am busy replacing the crankcase ventilation system and I ran into a problem.
I cannot access the manifold bolt closest to the timing gear end.
The bolt is tucked in behind what seems to be the thermostat housing?
Do i have to strip off the thermostat housing to get the manifold off?
Or, is there a way to get the manifold off without without having to do this?
I will appreciate any advice on this topic, thanks.

JohanD · Post by **JohanD** » 29 Apr 2012, 05:20

Here's an update - with some creative use of extensions and a 10mm crowfoot wrench I managed to loosen the bolt.
However, it won't come out completely - it seems to back up against the thermostat housing anyway.
Looks like the only option is to remove the thermostat first.
You will save a lot of time if you remove the thermostat right from the start.

Post by **jimmy57** » 29 Apr 2012, 11:33

Isn't that bolt hole on intake slotted where the intake will slip off if raised a little first?

JohanD · Post by **JohanD** » 29 Apr 2012, 12:42

Yes indeed, it is!!
Discovered that just now, after removing the thermostat.
No worries though, I may just replace the thermostat as well.
Thanks for the feedback, appreciate it.

JohanD · Post by **JohanD** » 12 May 2012, 17:51

OK, the job is done & here's my final update.
Even though the far left manifold bolt-hole is slotted you still have to remove the thermostat to replace the manifold gasket.
The bolt does not back out all the way with the thermostat in place, it pushes up against the thermostat housing.
This means you can't replace the manifold gasket without removing the thermostat unit.
I made the mistake of removing the front half of the thermostat housing at first.
When you do this you still can't get the mainifold bolt out, you have to remove the entire thermostat unit.
My Volvo dealer does not sell the gasket for the front half of the thermostat seperately.
So, i had to buy the entire thermostat unit with a new gasket for the engine block end - cost $155 which was not too bad.
To remove the far left manifold bolt you will need a 10mm crowfoot wrench secured to a 12" extension.
I taped the crowfoot wrench to the extension with masking tape to prevent it from dislodging.
Ended up replacing the crankcase ventilation system and in installed a set of re-manufactured fuel injectors.
Polished the intake ports and washed out the manifold with throttle body cleaner - removed a lot of gunk.
Incidentally, my crankcase ventilation system was completely blocked with sludge and gunk.
This was the rsult of quicklube shops not replacing the oil filter when they did the oil changes.
The oil filter was rock hard and brittle - fell apart when I removed it. This sludged up my engine.
My S60 now runs perfectly, very happy with the outcome.

Post by **jimmy57** » 12 May 2012, 19:57

Volvo techs cut a piece out of gasket below the existing bolt hole unless the t-stat housing needs to come off for another reason.

JohanD · Post by **JohanD** » 13 May 2012, 05:27

Ah, that makes sense and would have made the job easier...and cheaper!!
Thanks for the advice, it is great to have this resource.

Post by **asc325is** » 13 May 2012, 17:10

I found it easier for the whole process to remove the ps pump and alternator. so much more room in there!

JohanD · Post by **JohanD** » 21 May 2012, 06:15

In fact, twice during the course of the job I considered removing at least the PS pump & if I ever had to repeat this repair I definitely will do so. I wasted a lot of time trying to get this single bolt removed & much of it due to the very limited access.
Would have saved a lot of aggrevation by removing the steering pump from the start.
Thanks.