Early 5 Cylinder Spark Plug Change

Tools Needed:                

T30 Torx Torque Wrench Sparkplug Socket
Extension Wrench
     

Start by locating the six torx that secure the spark plug cover.  The three front ones are highlighted below, with the corresponding ones on the other side.  They are T30 torx not T25 as several common repair manuals state.  Do not use a T25 on these bolts.  

Volvo 850 cam cover removal

With the 6 torx removed you can lift out the spark plug cover.  Then, remove the spark plug boot.  Volvos have a deep  well design, so the boots may be hard to remove.  Use care not to tear them.  Inspect the spark plug wells and blow out any oil or debris in the wells.  

Spark plug removal

With the wells clean you can remove the spark plug using a spark plug socket on a 3/8 extension.  

Inspect the plu for wear

With the plug removed, inspect it for any damage or unordinary wear.  There are several guides on-line that tell you how to read your plugs.  The above plug still looks good after 8,000 miles of use.  If you are re-using the plugs, clean them and re-gap them to the correct gap.  If you are installing new plugs, check and adjust their gap as needed. Before re-installing, apply anti-seize prep to the threads.  

reinstall the plug and torque it to 22 ft/lb

Carefully thread the plug back in.  When installing plugs you should use a locking extension to avoid the socket coming off in the well.  Once the plug is fully seated torque it to 22lb/ft.

Reinstall cam cover

Start the car and assure it is idleing smoothly.  Once you have looked it over re-install the spark plug cover.  Apply a small amount of anti-seize prep to the torx and thread them back in.  Torque the torx to 7ft/lb to complete the job
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