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 Specifications 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! 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:
- 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 Tightening torque Tightening Torque. Use bevel protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor. Start on the left hand side of the sub-frame. Continue with the right hand side.
Tighten the screws for the brackets at the rear of the sub-frame. Tighten to 50 Nm.
Remove the lifting table.
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.
Installing the engine coolant heater
Install and tighten the M8 nut in the upper mounting for the engine coolant heater. Connect the connector. Install the front bumper cover.
Installing the propeller shaft
Install the propeller shaft. See Propeller Shaft
Installing the three-way catalytic converter (TWC)
Install the three-way catalytic converter (TWC). See Three-way catalytic converter (TWC), replacing Service and Repair.
Assembling the spring strut
Install:
- the tie rods. Use new nuts. Tighten to 70 Nm
- the link rod to the anti-roll bar. Use new nuts. Tighten to 50 Nm. Counterhold using Torx 27
- the bracket for the brake pipe to the body. Tighten
- the nut for the ball joint and control arm. Tighten to 80 Nm. Counterhold using Torx40
- the center screw in the drive shaft. Tighten to 50 Nm.
Install:
- the front skid plate
- the lower engine splash guard
- the front wheels. See Installing wheels Service and Repair.
Installing steering shaft joint
Install the steering shaft joint on the steering gear and steering shaft.
Install:
- the new screw. Tighten to 25 Nm
- the steering shaft boot and snap ring. Fold back the carpet
- soundproofing panel.
Installing the air conditioning (A/C) compressor
Install the 4 screws whilst the compressor is loose.
Raise the compressor and screw it into place.
Note! Handle the compressor carefully. Ensure that there are no kinks in the air conditioning (A/C) pipes.
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 gray connector for the fan shroud
- the wiring in the clips and clamps on the fan shroud
- the connectors for the pressure and temperature sensors on the charge air cooler (CAC)
- the right-hand headlamp using two lock facings.
Installing components
Connect the engine wiring 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 only Volvo Genuine parts brake fluid DOT 4+.
Applies to automatic transmissions.
Install:
- the transmission cable
- the oil cooler hoses.
Installing components
Install:
- 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 wiring 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 plastic charge air pipe over the engine
- air cleaner (ACL) assembly
- the inlet hose for the turbocharger (TC) to the air cleaner (ACL)
- mass air flow (MAF) sensor connector
- the turbocharger control valve on the air cleaner (ACL)
- the brake vacuum hose in the clamp on the air cleaner (ACL) housing
- 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 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.