S80XC90

Volvo XC90 & S80 V8 – Spark Plug Replacement

Time to change spark plugs has come. The job is to be relatively easy. Like most things with the V8, it seems access is the biggest hurdle for maintenance work. The front bank of plugs couldn’t have been easier. The back is easy, but you’re doing lots of reaching and you can only kind of see what you’re doing. The front bank can be done standing in front of the XC. The rear bank must be done from the side of the XC. I did the rear three nearest the passenger’s side from the passenger’s side and the one nearest the driver’s side from the driver’s side. I would recommend starting this job with the front bank so that you’ll be comfortable with the process by the time you do the rear bank.

Parts:
Volvo Spark Plugs (Qty. 8) for 8 Cyl B8444S – 30731383 – Qty. 1 (Or your favorite spark plug manufacturer’s equivalent)

Tools:
10mm Socket (I used 1/4″ Drive with Medium and Long Extensions)
13mm, 18mm Sockets (I used 1/2″ Drive sometimes with a Long Extension)
14mm Deep Socket (I used 1/2″ Drive sometimes with a Long Extension)
3/4″ Spark Plug Socket with Rubber or Magnetic Retainer (Mine is 3/8″ Drive)
Torque Wrench (Same Drive as Spark Plug Socket)
Spark Plug Gapper
Small/Thin Flathead Screwdriver
Medium Flathead Screwdriver
Anti-Seize Paste
Air Compressor with Blower Gun

Process:
Remove Upper Engine Brace Bar (18mm Engine Mount Bolt & Four 13mm Bracket Bolts)

spark-1

spark-2

Remove Front and Rear Engine Covers by Pulling Upwards on Them – They Pop Off Easily Enough
Use Compressor to Blow Dust/Dirt Off Block Around Front and Rear Coils

spark-3

Front Bank
Remove Two 14mm Bolts to Allow Movement of Wiring
Disconnect Electrical Connectors from Coils (I used two screwdrivers to accomplish this. I used the small screwdriver in one hand to prop up the clip and the medium screwdriver in the other hand to back the plug off the coil. Once I figured out one, the rest were easy.)

spark-4

Remove the 10mm Bolt Holding the First Coil
Remove the Coil and Clean It with a Rag (Watch that the seal does not stick to the block. If so, remove it from the block and install it back on the coil. All but one seal stayed on the coil but most had the seal partially out of place. The seal can be put back into place by lightly pulling away from coil shaft and then spinning the seal to get it set back on the ring.)
Use Spark Plug Socket to Back Out Spark Plug a Few Turns
Use Compressor to Blow Out Dust/Dirt from Cylinder Before Completely Removing Plug (Absolutely critical in front bank! All four front cylinders had a fair amount of dust blow out, presumably from their exposure to the elements at the front of the engine. The rear bank had almost nothing blow out.)

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Prepare New Spark Plug by Applying Light Coat of Anti-Seize to Threads (Do not get any anti-seize on sparking area of plug.)
Remove Old Plug

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Install New Plug (Place new plug in spark plug socket, insert into cylinder, turn backwards until plug is seated correctly, tighten plug by hand to verify correct mating of threads, and then finish tightening by hand or with ratchet.)
Torque New Plug to 18ft-lbs
Reinstall Cleaned Coil
Install 10mm Bolt (I placed my finger next to the plug end of the coil to keep the coil centered in the valley.)
Repeat Process on Remaining Three Coils/Plugs
Reinstall Electrical Connectors to Coils
Reinstall Two 14mm Bolts

Rear Bank
Remove Two 10mm and Two 14mm Bolts to Allow Movement of Wiring
Pull Two Hoses/Lines Out of Brackets to Allow Movement of Wiring
Disconnect Electrical Connectors from Coils (Same Method as Above)

spark-7

Remove the 10mm Bolt Holding the First Coil
Remove the Coil and Clean It with a Rag
Use Spark Plug Socket to Back Out Spark Plug a Few Turns

spark-8

Use Compressor to Blow Out Dust/Dirt from Cylinder Before Completely Removing Plug
Prepare New Spark Plug by Applying Light Coat of Anti-Seize to Threads
Remove Old Plug
Install New Plug
Torque New Plug to 18ft-lbs**
Reinstall Cleaned Coil
Install 10mm Bolt
Repeat Process on Remaining Three Coils/Plugs
Reinstall Electrical Connectors to Coils
Reinstall Two 10mm and Two 14mm Bolts

Finishing Up
Reinstall Front and Rear Engine Covers
Reinstall Upper Engine Brace Bar (18mm Engine Mount Bolt & Four 13mm Bracket Bolts)

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