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Volvo XC60 Engine Spark Plugs Replacement Guide
How to change the spark plugs in a 1st generation 2010 to 2017 Volvo XC60 T5 SUV with the 2.0L Turbo I4 engine.

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2017 XC60 T5 2.0L I4
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Loosen Counterclockwise
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Front Right Fastener

This automotive maintenance tutorial was specifically written to assist owners of the first generation (2010, 2011, 2012, 2013, 2014, 2015, 2016 and 2017) Volvo XC60 T5 SUV in checking or changing the spark plugs in the 2.0 liter inline four cylinder turbocharged B4204T11 engine.

Owners of other Volvo vehicles with the 3.0L L6, 3.2L L6 and 2.5L L5 engines such as the XC90, XC70, S90, S80, S60, S40, C30, C70, V90, V70, V60 and V40 may also find these DIY instructions to be helpful.

The original OEM spark plugs in this 2017 Volvo XC60 T5 2.0L Turbo L4 were part number Volvo ZXE24HR7 (also known as 31380014 or VOL31380014).

A few compatible replacement spark plugs with their part numbers are as follows: Autolite XP5682 Iridium XP, Champion REA8MCX (991) Copper and Brisk USA ER15SXC.

The tools needed to complete this procedure include a Torx T40 star bit screwdriver or socket, an 8mm socket, a 1/4" drive ratchet, a 9/16" spark plug socket, extension bars, a 3/8" drive ratchet and a tube of dielectric grease.


Please verify the compatible part numbers for your Volvo XC60 before purchasing new spark plugs by consulting with your dealership or by using the Amazon Part Finder website. The earlier 2010 to 2014 model years with the 3.0L L6, 3.2L L6 or 2.5L L5 engines are equipped with different spark plugs.
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Two Rear Fasteners
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Pull Off Engine Cover
To access the spark plugs, you'll first need to remove the rubber engine cover.

Loosen the four fasteners by turning them counterclockwise with the Torx T40 screwdriver or socket.

The bolts will remain attached to the engine cover.

Pull the rubber cover off the top of the engine and set it aside in a safe place.

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Rubber Cover Removed
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Top of Engine Exposed
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Ignition Coil
Locate the four black plastic ignition coil housings on the top of the engine.

I recommend only checking or changing one spark plug at a time to help reduce the risk of having something fall down in to the cylinder.

If you have access to compressed air or a wet/dry vacuum, thoroughly clean off the top of the engine to help further reduce the chance of having debris fall in to the engine.

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Push Down Release Tab
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Pull Off Electrical Connector
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Loosen Counterclockwise
Use a flathead screwdriver to push down the release tab on the ignition coil's electrical connector.

Gently pull the electrical connector straight off the ignition coil.

Loosen the single bolt that holds the ignition coil assembly in place to the top of the engine by turning it counterclockwise with an 8mm socket, an extension bar and a 1/4" drive ratchet.

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8mm Bolt Removed
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Lift Out Ignition Coil
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Spark Plug Well
Set the 8mm bolt aside in a safe place.

Gently pull the ignition coil straight out of the spark plug well and set it aside in a safe place.

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Spark Plug Socket
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Loosen Counterclockwise
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Spin Out By Hand
Attach your 9/16" spark plug socket to an extension bar (or two) and the 3/8" drive ratchet.

Lower the socket down over the top of the old spark plug.

Carefully loosen the old spark plug by turning it counterclockwise.

Try to avoid using excessive force to loosen the old spark plug to prevent from cracking the ceramic portion of the plug.

If you have trouble loosening the old spark plug, spray a small amount of penetrating oil such as PB Blaster, Liquid Wrench or Kano Kroil and wait at least 15 to 30 minutes before attempting to loosen it again. If you don't have any penetrating oil, try spraying some WD-40 or warm up the engine for a few minutes to help expand the metal engine block.

Once the old spark plug is loose, detach the ratchet and spin it out the rest of the way by hand.



 

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Lift Out Old Spark Plug
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Inspect Old Spark Plug
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Spin In New Spark Plug
Lift the old spark plug out of the well and detach it from the 9/16" socket.

Inspect both ends of the old spark plug.

If the electrode end of the old spark plug appears to be ashy white, the plugs might have been exposed to high temperatures such as overheating or they may be the incorrect heat range for your driving conditions or environment.

If the electrode tip of the old spark plug is grey or covered in dark black soot, the engine might be burning oil and should be inspected by a professional mechanic.

The OEM spark plugs in this 2017 XC60 T5 Turbo 2.0L L4 were the Volvo ZXE24HR7 which are also known as part number 31380014 or VOL31380014.

(An optional step is to apply some anti-seize grease to the threads on the spark plug. Most spark plug manufacturers recommend that you should not use anti-seize lubricant grease since it can lead to over tightening. Although some mechanics believe that using anti-seize grease on the new spark plugs will help prevent them from becoming stuck or "frozen" in the cylinder head if they are not removed again for another 60,000 to 70,000 miles.)

If you have a spark plug gap gauge, check that the new spark plugs are gapped to the manufacturer's specification listed on the box.

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Tighten Clockwise
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Apply Dielectric Grease
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Lower In Ignition Coil
Push the new spark plug in to the socket. Your spark plug socket should have a rubber insert or a strong magnet to hold it securely in place.

If you are re-installing the old spark plug, tighten it to just a fraction of a turn past hand tight.

If you are installing a new spark plug, tighten the spark plug until you feel the new crush washer collapse, which should be about 1/8 to 1/4 of a turn past when it first makes contact with the cylinder head.

Try to avoid over tightening the spark plugs to prevent from cracking the plug or stripping the threads.

Double check that the new spark plug is tight before moving on to the next step.

Apply a small amount of dielectric grease to the opening at the bottom of the rubber dust boot on the ignition coil housing.

The dielectric grease will help keep out any moisture or debris and ensure a reliable electrical connection.

Push the ignition coil back in to the spark plug well and rotate it back and forth a few times to help spread the dielectric grease.

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Push Down In Place
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Spin In 8mm Bolt
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Tighten Clockwise
Line up the bolt hole in the ignition coil housing with its corresponding hole on the top of the engine.

Spin in the 8mm bolt a few turns by hand in the clockwise direction to prevent it from becoming cross threaded.

Tighten the bolt by turning it clockwise with the 8mm socket and a 1/4" drive ratchet until it is snug.

Try to avoid over tightening the bolt to prevent from cracking the plastic ignition coil assembly.

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Push On Power Plug
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Spark Plugs Replaced
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Push On Engine Cover
Push the power plug straight in to its socket on the ignition coil until it clicks securely in to place.

Lower the rubber engine cover back down in to place.

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Tighten Clockwise
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Four Torx T40 Screws
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Engine Cover Replaced
Tighten the four bolts by turning them clockwise with the Torx T40 screwdriver or socket until they are snug.

Start the engine and listen closely for any strange sounds that might indicate a disconnected electrical connector or a loose spark plug.

Don't forget to record the spark plug change in your SUV's service records.

For more, check out all of my 2010-2017 Volvo XC60 DIY Repair & Maintenance Guides.
 

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