Engine/Transmission, Removing/Installing
Engine/transmission, removingSpecial tools: 999 5666, 999 5722
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 in the illustrations is always correct.
Preparation
Remove:
- the battery negative lead. First read Note when disconnecting/connecting the battery lead
- the cross stay between the suspension turrets
- the turbocharger control valve from the air cleaner (ACL). Disconnect the connector for the
- mass air flow (MAF) sensor. Slacken off the hose clamp on the mass air flow (MAF) sensor
- mass air flow (MAF) sensor connector
- the brake vacuum hose from the air cleaner (ACL)
- the air cleaner (ACL) assembly. Seal the openings in the intake pipe for the turbocharger (TC)
- the plastic charge air pipe above the engine. Seal the opening in the turbocharger (TC)
- the ground strip at the top/rear of the cylinder head.
Draining coolant
Open the cap on the expansion tank.
Position a container under the radiator drain cock.
Drain the coolant.
Warning: Avoid skin contact with the coolant.
Close the cock.
Draining the fuel system
Drain the fuel injection system. See Draining the fuel system. See also: Fuel system, quick-release connectors.
Remove:
- the cover over the central electrical unit
- the connector for the engine wiring from the central electrical unit
- the positive lead for the starter motor from the terminal block
- the ground lead at the front frame member.
Removing components from the transmission
Block the hose between brake the fluid reservoir and the clutch master cylinder.
Remove:
- the clutch hose from the junction. Plug the openings against dirt. Wipe up any spilled brake fluid
- the ground lead from the transmission and the sub-frame.
Cars with automatic transmissions
Remove the oil cooler hoses from the transmission. Plug the openings in the radiator and transmission.
Removing the mechanical transmission cables from the transmission
Caution: When working with the mechanical cables, ensure that the cable sleeves do not crack or break.
Manual transmissions
Remove:
- the mechanical transmission cables from the levers. Use jimmy bar 999 7077
- the mechanical cables from the bracket by moving the sleeves back on the cables.
Automatic transmission
Remove the screws for the transmission cable bracket at the transmission
Tie up the cables.
Disconnect the connector for the temperature and pressure sensor on the charge air cooler (CAC) outlet.
Remove:
- the rubber hose at the intake for the charge air cooler (CAC)
- the dip stick pipe
- the brake vacuum hose at the intake manifold
- the lower engine coolant hose from the engine
- the plastic pipe between the throttle body (TB) and the charge air cooler (CAC).
Hint: Carefully heat around the pipe at the charge air cooler (CAC). Use a hot air gun.
Disconnect the wiring from the front heated oxygen sensor (HO2S). Remove the wiring from the clips and clamps.
Removing components
Disconnect the connector for the level sensor in the expansion tank.
Remove:
- the hoses for the heater unit at the terminal in the firewall
- the bleed hose for the radiator at the expansion tank
- the ABS line and clips from the power steering hose. Lift up the expansion tank and servo oil reservoir. Place them on top of the engine.
Remove:
- control module unit cover
- the control modules. Use tool 999 5722
- the surround for the control module box.
Removing the connector with cable and cable protector
Remove:
- the red retaining clip for the connector using a screwdriver
- the connector by releasing the catches at the front edge using pliers. Pry out the connector using a screwdriver.
Lift up the connector with the protection underneath and put it to one side.
Remove the ground lead from the right-hand fender liner. Slide out the wiring between the front cover plate and the air conditioning (A/C) pipe.
Exposing the air conditioning (A/C) compressor
Caution: Handle the compressor carefully.
Ensure that there are no kinks in the air conditioning (A/C) pipes.
Remove the upper radiator hose.
Remove the auxiliaries belt.
Disconnect the one-pin connector for the compressor magnetic clutch.
Remove the four screws holding the air conditioning (A/C) compressor to the engine. Tie up the compressor in the front cover plate.
Removing components
Remove the ignition key.
Raise the car.
Remove:
- the left and right front wheels
- the splash guard under the engine
- the splash guard under the engine (Only applies to cars with automatic transmissions).
Separating the steering shaft
Remove the screw from the joint between the steering gear and the steering shaft.
Caution: The steering shaft must not be turned. The contact reel in the SRS system could be damaged.
Remove the nut on the tie rod from the wheel spindle (on the left and right-hand sides).
On one side, measure the length of the tie rod in relation to the steering gear housing. Note the measurement. Press up the joint from the steering gear.
Removing front suspension components (both sides)
Disconnect the ABS line from the mounting in the spring strut.
Remove:
- the screw for the drive shaft using a screwdriver in the brake disc vents
- the link from the anti-roll bar
- the nut for the ball joint and link arm. Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut.
Note: Counterhold using a Torx TX 40 at the ball joint pinion when removing the nut. This is so that the ball joint boot does not turn.
Separating the fuel line
Note: If an engine block heater is installed, mark the position of the fuel lines.
Separate the quick-release connectors for the fuel pressure line and engine block heater (option).
Hint: Use tool 999 5666.
Pull apart the EVAP line at the rubber joint behind the rear right mounting for the sub-frame.
Removing the three-way catalytic converter (TWC)
Remove the three-way catalytic converter (TWC).
See Three-way catalytic converter (TWC), replacing.
Removing the propeller shaft
Remove the propeller shaft. See Propeller shaft, replacing.
Lowering the engine and transmission
Use a post hoist with a lifting table and stud guides. Anchor the lifting table against the subframe.
Note: Ensure that the lifting table is centered under the sub-frame for optimal weight distribution. Check that the lifting table is correctly applied against the sub-frame.
Caution: Ensure that no hoses, wiring or anything else catch in the engine and transmission unit when it is lowered.
Remove:
- the screws for the sub-frame brackets
- the screws for the sub-frame. Lower the engine and transmission approximately 15 cm so that the drive shafts describe a horizontal line between the hub and transmission.
Unhook the control arms from the ball joint pinion.
Hold the constant velocity joint. Pull the drive shaft off the hub.
Let the drive shafts rest against the control arms.
Check that the air conditioning (A/C) compressor is hanging free. Continue lowering the engine and transmission unit.
Removing the engine coolant heater (option)
Remove:
- the bumper cover on the left hand side. Use a weatherstrip tool
- the M8 nut at the top of the left-hand fender liner for the engine coolant heater
- the connector for the engine coolant heater. Press up the engine coolant heater. Lift it out of its upper mounting.
Remove:
- the screws for the sub-frame brackets
- the screws for the sub-frame. Lower the engine and transmission approximately 15 cm so that the drive shafts describe a horizontal line between the hub and transmission.
Caution: Ensure that no hoses, wiring or anything else catch in the engine and transmission unit when it is lowered.
Unhook the control arms from the ball joint pinion.
Hold the constant velocity joint. Pull the drive shaft off the hub.
Let the drive shafts rest against the control arms.
Turn the engine block heater out of its position.
Check that the air conditioning (A/C) compressor is hanging free. Continue lowering the engine and transmission unit.
Engine/transmission, installing
Special tools: 951 2050, 999 5972
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 Specifications.
Note: To ensure that there is no exhaust leakage, see: 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: Ensure that the mating surfaces on the ball joints and control 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: Ensure that no hoses, wiring or anything else catches.
Install:
- a new screw in the lower steering shaft joint. Tighten to
- new screw in the sub-frame. Lubricate the screws
- the washers at the front edge and the support plates at the rear edge of the sub-frame
- engine coolant heater left front (option).
Tighten the screws for the sub-frame. See Specifications. Use bevel protractor 951 2050. Start on the left hand side of the subframe. Continue with the right hand side.
Tighten the screws for the rear bracket at the rear edge of the sub-frame.
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.
Installing the propeller shaft
Install the propeller shaft. See Propeller shaft, replacing.
Installing the three-way catalytic converter (TWC)
Install the three-way catalytic converter (TWC).
See Three-way catalytic converter (TWC), replacing.
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.
Installing the air conditioning (A/C) compressor
Note: Handle the compressor carefully. Ensure that there are no kinks in the air conditioning (A/C) 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
- 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 battery negative lead. First read Note when disconnecting/connecting the battery lead.
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.