Engine/Transmission, Installing: Installation

NOTE: As the graphics in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the graphics is always correct.

INSTALLING THE ENGINE AND TRANSMISSION

Fig 1: Identifying Bolts, Washers And Brackets In Sub-Frame

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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.

Fig 2: Drive Shaft And Hub

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CAUTION: Ensure that the mating surfaces on the ball joints and control arms are clean.

Install:

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.

Hang the engine coolant heater in position. Check that the air conditioning (A/C) compressor is correctly positioned
Align the steering shaft joint with the hole in the firewall
Lift the engine and transmission unit up to the frame members.

Fig 3: Identifying Bolts, Washers And Brackets In Sub-Frame

Courtesy of VOLVO CARS CORPORATION

Install new screws in the sub-frame. Lubricate the screws
install washers at the front edge and engine coolant heater and the support plates at the rear edge of the sub-frame
Tighten the screws for the sub-frame. Tighten to 105 Nm . Angle-tighten 120° . Use bevel protractor see 9512050
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 connector and the fuel line to:

the motor
the engine block heater. Use lubricant 1161580 . Also, see FUEL SYSTEM, QUICK-RELEASE CONNECTORS .

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 strip.

ASSEMBLING THE SPRING STRUT

Fig 4: Ball Joint Nut

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Tighten:

the nut for the ball joint and control arm. Tighten to 80 Nm . Counterhold with Torx 40
the center screw in the drive shaft. Tighten to 50 Nm .

Install:

the sound insulation cover for the drive shaft
the tie rods using the markings made during removal. Tighten to 70 Nm
the link rod to the anti-roll bar. Use new nuts. Tighten to 50 Nm . Counterhold with Torx 27 .

Install the front protective plate.

Install the front wheels. See INSTALLING WHEELS .

INSTALLING STEERING SHAFT JOINT

Install:

the steering shaft joint on the steering gear and steering shaft
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

Fig 5: AC Compressor

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CAUTION: Handle the compressor carefully.

Connect the one-pin connector to the compressor magnetic clutch.

Install the auxiliaries belt.

Connect the connectors to:

the pressure and temperature sensors on the charge air cooler (CAC)
the fan shroud
the pressure switch (Pressostat) on the drier bottle
the right-hand headlamp.

Install the right-hand headlamp using the two lock facings.

INSTALL THE ENGINE WIRING IN THE DISTRIBUTION BOX

Fig 6: Engine Control Module

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Connect the engine and transmission wiring connectors to the control module box base plate.

Press the base plate into place in the lower section of the control module box. Install the surround on the distribution box.

INSTALLING CONTROL MODULES

Check that no pins or sockets are damaged on the connector
Carefully press the control module down into the grooves on the inside of the control module box. Press to the limit position
Insert tool see 9995722 around the control module
Move the upper section of the tool forwards as far as it will go. Pull up the tool
Press the cover into place over the control modules
Check that the air ducts are correctly positioned
The ground lead to the body on the right-hand fender liner.

Install:

the engine coolant hose between the engine and expansion tank
the ABS line using the clips for the power steering line
The servo reservoir
the passenger compartment heating hoses
the propeller shaft. See PROPELLER SHAFT, REPLACING .

Fig 7: Identifying Screw For Front Exhaust Pipe And Support Bracket

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Install:

the screw for the front exhaust pipe and support bracket
the 3 nuts that hold the front exhaust pipe to the turbocharger (TC).

WARNING: Avoid skin contact with the paste.

Lubricate the studs on the turbocharger (TC). Use paste 116 1408 .

NOTE: Avoid skin contact with the paste.

INSTALLING COMPONENTS

Install:

the gear selector cables
the wiring for the transmission
the ground lead between the engine and the frame member on the left-hand side
the brake vacuum hose to the vacuum pump on the engine
the charge air hoses
the engine coolant hoses
the oil cooler hoses to the transmission.
NOTE: Remove any seals
the air cleaner (ACL)
the hose between the air cleaner (ACL) and the turbocharger (TC)
The solenoid valve for the engine pads on the air cleaner (ACL)
the intake pipe between the front cover plate and the air cleaner (ACL) housing.

Connect the connectors.

Fig 8: Identifying Positive Lead For Starter Motor, Connector For Engine Cable Harness And Cover Over Central Electrical Unit

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Install:

the positive lead for the starter motor to the terminal block
the connector for the engine cable harness in the central electrical unit
the cover over the central electrical unit.

FINISHING

Fig 9: Identifying Engine Cover

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Install:

the engine cover
the engine stabilizer brace between the suspension turrets
a new tie strap for the servo hose
the cable to the battery negative terminal. First read, see BATTERY, DISCONNECTING .

Top up and check the engine oil and engine coolant.

FUNCTION TEST

CAUTION: To prevent damage to the engine fuel injection pump, the tank pump must be activated for 80 seconds by turning the ignition key to position 2.

Run the engine at fast idle speed until the thermostat opens.

Ensure that the heater control in the passenger compartment is at the maximum position. Check the engine for leaks.

Top up the coolant if necessary. Install the lower engine cover.