Section 48 (Engine - Removal, Replacement And Installation)
WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2009 Volvo S60, 2008 Volvo S60, 2007 Volvo S60, 2006 Volvo S60, and 2005 Volvo S60. However, it is still accessible from the selected car via links, so may be relevant.
- Crank Mechanism (B5204T5, Aw55-50/51SN; 2005-2007)
- Crank Mechanism (B5204T5, Aw55-50/51SN; 2004)
- Crank Mechanism (B5204T5, M56; 2005-2007)
- Crank Mechanism (B5204T5, M56; 2004)
- Crank Mechanism (B5234T3, Aw55-50/51SN; 2001-2004)
- Crank Mechanism (B5234T3, M56; B5244T3, M56; 2001-2002)
- Crank Mechanism (B5234T3, M56; 2003-2004)
- Crank Mechanism (B5244S, Aw55-50/51SN; 2001-2006)
- Crank Mechanism (B5244S, M56; 2001-2002)
- Crank Mechanism (B5244S, M56; 2003-2006)
- Crank Mechanism (B5244S6; 2003-2006)
- Crank Mechanism (B5244T3, Aw50/51 AWD; 2002-2003)
- Crank Mechanism (B5244T3, Aw55-50/51SN; 2001-2003)
- Crank Mechanism (B5244T3, M56; 2003)
- Crank Mechanism (B5244T5, Aw55-50/51SN; 2005-2009)
- Crank Mechanism (B5244T5, M66; 2005-2008)
- Crank Mechanism (B5254T2, Aw50/51 AWD; B5254T2, Aw55-50/51SN; 2005-2009)
- Crank Mechanism (B5254T2, Aw50/51 AWD; B5254T2, Aw55-50/51SN; 2003-2004)
- Crank Mechanism (B5254T2, M56; 2003-2004)
- Crank Mechanism (B5254T2, M56; 2005-2007)
- Crank Mechanism (B5254T4, Aw50/51 AWD; 2004-2005)
- Carrier plate, replacing
- Carrier plate, replacing
- Removing the transmission
- Notes
- Removal
- Notes
- Removing both the front wheels
- Removing components from the sub-frame
- Removing the cross members from the body
- Removing the front mounting for the exhaust pipe
- Removing the screws and nuts for the engine pad, engine stabilizer brace and steering gear
- Detaching the power steering line
- Removing front suspension components (both sides)
- Disconnecting the ball joint pinion from the control arm (both sides)
- Removing fender liner components (both sides)
- Removing the screws for the sub-frame support plates (both sides)
- Removing the right drive shaft
- Removing the collision protection system over the steering gear
- Lowering the sub-frame
- Removing the drive shaft from the wheel hub
- Removing the drive shaft from the transmission
- Removing the rear engine mounting
- Hanging up the steering gear
- Removing the screws from the torque converter
- Removing the oil pipe from the transmission
- Lowering the engine and the transmission
- Installing the fixture on the mobile jack and transmission
- Removing all the screws for the transmission and engine
- Removing the transmission
- Transmission, installing
- Transmission, removing
- Crankshaft seal rear, replacing
- Crankshaft seal, front, replacing
- Carrier plate, replacing
- Crank Mechanism (B5254T4, M66 AWD; 2004-2007)
- Crank Mechanism (B5254T4, TF-80SC AWD; 2006-2007)
- Cylinder Head (B5204T5; 2004-2007)
- Cylinder head/gasket, replacement
- Notes
- Removal
- Preparation
- Draining coolant
- Removing components
- Depressurizing the fuel system
- Removing the fuel rail
- Removing ignition coils
- Removing intake manifold
- Setting up the engine
- Removing the timing belt
- Removing the timing gear pulley
- Removing components from turbocharger (TC)
- Releasing the inlet pipe for the coolant pump
- Removing the camshaft cover and cylinder head
- When replacing or working on the cylinder head
- Installation
- Notes
- Cleaning
- Setting up the engine
- Installing the cylinder head
- Installing valve lifters and camshafts
- Applying liquid gasket
- Installing the camshaft cover
- Installing the manifold and turbocharger (TC)
- Installing the rear camshaft seal
- Installing the front camshaft seals
- Checking and adjusting the variable valve timing unit
- Installing components
- Installing intake manifold
- Installing the fuel rail
- Check
- Cylinder head/gasket, replacement
- Cylinder Head (B5234T3; B5244T3; 2001-2002)
- Cylinder head/gasket, replacing
- Notes
- Removing the cylinder head gasket
- Preparation
- Draining coolant
- Removing components
- Draining the fuel line
- Removing the intake manifold
- Setting up the engine
- Removing the timing belt
- Removing the timing gear pulley
- Removing components from turbocharger (TC)
- Releasing the inlet pipe for the coolant pump
- Removing the camshaft cover and cylinder head
- When replacing or working on the cylinder head
- Cleaning
- Cylinder head gasket, installing
- List of tightening torques
- Setting up the engine
- Installing the cylinder head
- Installing tappets and camshafts
- Applying liquid gasket
- Installing the camshaft cover
- Installing the manifold and turbocharger (TC)
- Installing the rear camshaft seal
- Installing the front camshaft seals
- Checking and adjusting the variable valve timing unit
- Installing components
- Installing the intake manifold
- Installing the fuel rail
- Check
- Cylinder head/gasket, replacing
- Cylinder Head (B5234T3; 2003-2004)
- Cylinder Head (B5244S; 2001-2006)
- Cylinder head/gasket, replacing
- Notes
- Removal
- Preparation
- Draining the coolant
- Separating the exhaust system
- Removing components
- Draining the fuel line
- Removing the fuel rail
- Removing the intake manifold
- Setting up the engine
- Removing the timing belt
- Removing the timing gear pulley
- Releasing the inlet pipe for the coolant pump
- Removing the camshaft cover and cylinder head
- When replacing or working on the cylinder head
- Cleaning
- Installing the cylinder head
- Notes
- List of tightening torques
- Aligning the crankshaft
- When replacing or working on the cylinder head
- Installing the cylinder head
- Installing valve lifters and camshafts
- Applying liquid gasket
- Installing the camshaft covers
- Installing the intake pipe for the coolant pump
- Installing the rear camshaft seal
- Installing the front camshaft seal
- Checking and adjusting the variable valve timing unit
- Installing components
- Installing the intake manifold and gasket
- Installing the fuel and air distribution pipe
- Assembling the exhaust system
- Finishing
- Check
- Cylinder head/gasket, replacing
- Cylinder Head (B5244S6; 2003-2006)
- Cylinder head/gasket, replacing
- Notes
- Removal
- Preparation
- Removing the three-way catalytic converter (TWC)
- Draining the coolant
- Removing components
- Draining the fuel line
- Removing the intake manifold
- Setting up the engine
- Removing the timing belt
- Removing the timing gear pulley
- Releasing the inlet pipe for the coolant pump
- Removing the camshaft cover and cylinder head
- When replacing or working on the cylinder head
- Cleaning
- Installing the cylinder head
- Notes
- List of tightening torques
- Aligning the crankshaft
- Installing the cylinder head
- Installing valve lifters and camshafts
- Applying liquid gasket
- Installing the camshaft covers
- Installing the intake pipe for the coolant pump
- Installing the rear camshaft seal
- Installing the front camshaft seal
- Checking and adjusting
- Installing components
- Installing the intake manifold and gasket
- Installing the fuel and air distribution pipe
- Installing the exhaust manifold
- Finishing
- Check
- Cylinder head/gasket, replacing
- Cylinder Head (B5244T3; 2003)
- Cylinder Head (B5244T5; 2005-2009)
- Cylinder head/gasket, replacement
- Notes
- Removal
- Preparation
- Draining coolant
- Removing components
- Fuel system, draining
- Removing the fuel rail
- Removing ignition coils
- Removing intake manifold
- Setting up the engine
- Removing the timing belt
- Removing the timing gear pulley
- Removing components from turbocharger (TC)
- Releasing the coolant pump inlet pipe
- Removing the camshaft cover and cylinder head
- When replacing/machining the cylinder head
- Installation
- Notes
- Cleaning
- Setting up the engine
- Installing the cylinder head
- Installing valve lifters and camshafts
- Applying liquid gasket
- Installing the camshaft cover
- Installing the manifold and turbocharger (TC)
- Installing the rear camshaft seal
- Installing the front camshaft seals
- Checking crankshaft setting
- Installing VVT-unit/timing gear pulley on exhaust camshaft
- Installing the variable valve timing (VVT) unit on the intake camshaft
- Finishing
- Installing the timing belt
- Adjusting timing belt
- Adjusting the timing belt
- Checking the markings and belt tension
- Installing components
- Installing intake manifold
- Installing the fuel rail
- Check
- Cylinder head/gasket, replacement
- Cylinder Head (B5254T2; 2003-2009)
- Cylinder Head (B5254T4; 2004-2007)
- Cylinder Head (B5254T4, TF-80SC AWD; 2006-2007)
- Engine Mounting (2001-2009)
- Engine Mounting (B5204T5; 2004-2007)
- Bushing sub-frame, replacing
- Notes
- Important information
- Preparation
- Removing components
- Removing the front engine pad lower screw
- Removing the nuts for the lower torque rod
- Folding out the fender liner
- Removing the screws for the right-hand engine mounting
- Removing the nuts and screw for the steering gear
- Removing the delivery line for the steering gear
- Lowering the sub-frame
- Remove the bracket for the heated oxygen sensor (HO2S)
- Pressing out the bushings
- Installing the bracket for the heated oxygen sensor (HO2S)
- Installing the bushings
- Marking for the bushing on the sub-frame
- Marking the left-hand rear bushing
- Pressing in the bushings
- Lifting the sub-frame
- Installing the nuts and screw for the steering gear
- Installing the delivery line from the steering gear
- Installing the screws for the engine mounting to the engine
- Installing the protective plate
- Installing the screw for the front engine pad
- Tightening the nuts for the lower torque rod
- Installing the air intake cover
- Installing the protective cover
- Removing the lifting tools
- Engine mount rear, replacing
- Engine mount, front, replacing
- Engine mount, right, replacing
- Replacing the engine torque bracket
- Bushing sub-frame, replacing
- Engine Mounting (B5234T3; 2001-2004)
- Engine Mounting (B5244S; 2001-2006)
- Engine Mounting (B5244S6; 2003-2006)
- Engine Mounting (B5244T3; 2001-2003)
- Engine Mounting (B5244T5; 2005-2009)
- Engine Mounting (B5254T2; 2004-2009)
- General (B5204T5; 2004-2007)
- Engine/transmission, installing
- Notes
- Installing the engine and transmission unit
- Installing the propeller shaft (all-wheel drive (AWD) only)
- Installing the three-way catalytic converter (TWC) (all-wheel drive (AWD) only)
- Installing the front exhaust pipe
- Connecting fuel lines
- Assembling the spring strut
- Cars with engine block heaters (option)
- Installing the air conditioning (A/C) compressor
- Installing components
- Installing the transmission cable
- Installing the engine coolant fan (FC)
- Finishing
- Final check
- Engine/transmission, removing
- Notes
- Preparation
- Removing the engine cooling fan (FC)
- Removing the transmission cable
- Draining the fuel line
- Removing components
- Draining coolant
- Cars with engine block heaters (option)
- Preparations for removal of the drive shafts
- Separating the fuel line
- Separating the front exhaust pipe
- Removing the air conditioning aggregate
- Exposing the air conditioning (A/C) compressor
- Separating the steering shaft
- Removing the three-way catalytic converter (TWC) (all-wheel drive (AWD) only)
- Removing the propeller shaft from the transmission and drive distribution box (all-wheel drive (AWD) only)
- Lowering the engine and transmission
- Engine/transmission, installing
- General (B5234T3; 2001-2004)
- General (B5244S; 2001-2006)
- General (B5244S6; 2003-2006)
- General (B5244T3; 2001-2003)
- General (B5244T5; 2005-2009)
- Engine/transmission, installing
- Notes
- Installing the engine and transmission unit
- Connecting fuel lines
- Installing the propeller shaft
- Installing the three-way catalytic converter (TWC)
- Assembling the spring strut
- Installing the air conditioning (A/C) compressor
- Installing the connector
- Installing components
- Installing components on the transmission
- Final check
- Engine/transmission, removing
- Notes
- Preparation
- Draining coolant
- Fuel system, draining
- Remove
- Removing components from the transmission
- Removing the mechanical transmission cables from the transmission
- Removing components around expansion tank
- Removing the connector with cable and cable protector
- Exposing the air conditioning (A/C) compressor
- Removing components
- Separating the steering shaft
- Removing front suspension components (both sides)
- Separating the fuel line
- Removing the three-way catalytic converter (TWC)
- Removing the propeller shaft
- Lowering the engine and transmission
- Removing the engine coolant heater (option)
- Engine block, installing components
- Engine body, exposing
- Engine/transmission, installing
- General (B5254T2; 2003-2009)
- General (B5254T4; 2004-2007)
- General (B5254T4, TF-80SC AWD; 2006-2007)
- Oil Pan (B5244T5; 2005-2009)
- Oil Pan (B5254T4; 2004-2007)
- Oil Pan (B5254T4, TF-80SC AWD; 2006-2007)
- Oil Sump (B5204T5; 2004-2007)
- Oil Sump (B5234T3; 2001-2004)
- Oil Sump (B5244S; 2001-2006)
- Oil Sump (B5244S6; 2003-2006)
- Oil Sump (B5244T3; 2001-2003)
- Oil Sump (B5254T2; 2003-2009)
- Timing Gear (B5204T5; 2005-2007)
- Auxiliaries belt / belt tensioner, replacing
- Camshaft seal/variable valve timing (VVT) unit, replacing
- Timing belt, replacing
- Variable valve timing solenoid, replacing
- All models
- Removing the variable valve timing (VVT) control valve
- Applies to B5244Sx model years 1999-2001
- Open the casing to pull out the connector pins
- Remove the lock
- Installing the connector pins
- Install the catch and casing
- Splice the cables
- Clamping the excess cable with cable ties
- Applies to all: Installing VVT-control valve
- All models
- Timing Gear (B5204T5; 2004)
- Timing Gear (B5234T3; B5244T3; 2001)
- Auxiliaries belt / belt tensioner, replacing
- Camshaft seal/variable valve timing (VVT) unit, replacing
- Timing belt, replacing
- Variable valve timing solenoid, replacing
- All models
- Removing the variable valve timing (VVT) control valve
- Applies to B5244Sx model years 1999-2001
- Open the casing to pull out the connector pins
- Remove the lock
- Install the connector pins
- Install the catch and casing
- Splice the cables
- Clamping the excess cable with cable ties
- Applies to all: Installing VVT-control valve
- All models
- Timing Gear (B5234T3; 2002-2004)
- Timing Gear (B5244S; 2002)
- Timing Gear (B5244S6; 2003-2006)
- Timing Gear (B5244T3; 2002-2003)
- Timing Gear (B5244T5; B5254T2; 2005-2009)
- Timing Gear (B5254T2; 2003-2004)
- Timing Gear (B5254T4; 2004-2007)
- Auxiliaries belt / belt tensioner, replacing
- Camshaft seal/variable valve timing (VVT) unit, replacing
- Notes
- Removal
- Installation
- Notes
- Cleaning
- Installing the front camshaft seal
- Installing the crankshaft adjustment tool
- Aligning the crankshaft
- Installing the variable valve timing (VVT) unit on the exhaust camshaft
- Installing the variable valve timing (VVT) unit on the intake camshaft
- Finishing
- Installing the timing belt
- Adjusting the timing belt
- Checking the markings and belt tension
- Installing components
- Checking the engine
- Rear camshaft seal
- Timing belt, replacing
- Variable valve timing solenoid, replacing
- Transmission (B5244S; 2001)
- Transmission (B5244S; 2003-2006)