Engine/Transmission, Installing
Engine/transmission, installing
Special tools:
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
999 5972 FIXTURE 999 5972 Fixture
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.
Note! For tightening torques, see: Tightening torque Tightening Torque.
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Flanged Joint, Assembling.
Installing the engine and transmission unit
Raise the engine and the transmission unit. Use a lifting table with locating pins.
Stop when the sub-frame is approximately 15 cm below the frame members.
Install (left and right-hand sides):
- the drive shaft to the hub. Install the center screws. Do not tighten yet!
- the ball joint to the control arm. Install the nuts. Do not tighten yet!
Note! Make sure that the contact faces on the ball joints and link arms are clean.
Twist the engine block heater (option) into position. Check that the air conditioning (A/C) compressor is correctly positioned.
Check that the tie rod is in the correct position. Check that the transmission cable is routed between the steering shaft and the firewall.
Align the steering shaft joint with the hole in the firewall.
Lift the engine and transmission unit up to the frame members.
Note! Make sure that no hoses, wiring, or anything else catches.
Install the sub-frame's four screws together with the sub-frame's brackets and engine heater, if installed.
Use new screws. Lube the screws with oil.
Tighten, see: Tightening torque Tightening Torque.
First tighten the screws on the sub-frame's left side, then on the right.
Tighten the screws for the brackets M10.
Remove the lifting table.
Install a new screw on the steering shaft joint. Torque tighten.
Connecting fuel lines
Connect the quick-release connectors and fuel line to the engine and engine block heater (option). Press the EVAP line together at the rubber joint. See also: Fuel system, quick-release connectors Description and Operation.
Installing the propeller shaft
Install the propeller shaft. See Propeller shaft, replacing, B5254T2, M58, B5254T2, AW50/51 AWD Propeller Shaft.
Installing the three-way catalytic converter (TWC)
Install the three-way catalytic converter (TWC). See Three-way catalytic converter (TWC), replacing, B5244T5, B5254T2 Service and Repair.
Assembling the spring strut
Install:
- the tie rods. Use new nuts
- the link rod to the anti-roll bar. Use new nuts. Counterhold using Torx 27
- the bracket for the brake pipe to the body. Tighten
- the ball joint nut and the control arm. Tighten. Counterhold using Torx40
- the center screw for the drive shaft. Tighten.
Install:
- the lower engine splash guard, only applies to cars with automatic transmissions
- the front wheels. See Installing wheels Service and Repair
Installing the air conditioning (A/C) compressor
Note! Handle the compressor carefully to make sure that there are no kinks in the AC-pipes.
Install the 4 screws whilst the compressor is loose.
Raise the compressor and screw it into place.
Connect the one-pin connector to the compressor magnetic clutch.
Installing the connector
Install:
- the connector on the pressostat in the air conditioning (A/C) receiver drier
- the cable in the clips and the clamps on the fan shroud
- the connectors for the pressure and temperature sensors on the charge air cooler (CAC).
Installing components
Connect the engine cable to the control module box.
Install:
- the ground lead to the ground terminal at the right fender edge in the engine compartment
- the auxiliaries belt
- the intermediate piece for the control module box
- the control modules. See Engine control module (ECM), replacing Service and Repair
- the cover for the control module box
- expansion tank. Connect the radiator breather tube to the expansion tank. Tighten the clamp. Connect the connector for the level sensor in the expansion tank
- servo oil reservoir. Check that the hoses are correctly positioned.
Clamp the ABS cable to the power steering hose.
Installing components on the transmission
Applies to cars with manual transmissions.
Install:
- the pipe junction
- the clutch pipe in the junction. Use a new seal. Ensure that the clip locates in its channel. Remove the hose clip
- the transmission cables.
Bleed the clutch.
Use Volvo Genuine parts brake fluid.
Applies to automatic transmissions.
Install:
- the transmission cable
- the oil cooler hoses. Remove the seals.
Installing components
Install:
- the hoses for the heater unit at the terminal in the firewall
- the lower and upper coolant hoses for the engine
- the rubber hose on the charge air pipe on the intake for the charge air cooler (CAC)
- the dip stick pipe
- the brake vacuum hose to the intake
- the plastic charge air pipe between the throttle body (TB) and the charge air cooler (CAC). Tighten both the clamps.
Hint: Use a hot air gun to facilitate installation.
Install:
- the connector for the engine cable to the central electrical unit
- the positive lead for the starter motor to the terminal block
- the cover over the central electrical unit
- the ground lead between the engine and body in the front frame member.
Install:
- the ground strip at the top/rear of the cylinder head
- the charge air cooler pipe over the engine
- the inlet hose for the turbocharger (TC) to the air cleaner (ACL)
- air cleaner (ACL) assembly
- the mass air flow (MAF) sensor connector. Tighten the hose clamps
- the turbocharger control valve on the air cleaner (ACL)
- the intake pipe between the front cover plate and the air cleaner (ACL)
- the engine stabilizer brace between the suspension turrets
- the negative battery cable. First read Battery, disconnecting Battery Disconnecting.
Final check
Install:
- coolant
- engine oil
- power steering fluid.
Start the engine.
Warm up the engine until the thermostat opens.
Check for leakage.
Check the oil and coolant levels. Adjust if necessary.
Check the transmission oil level (automatic transmissions only). Top up if necessary.