Installation
Engine, Installation
Special tools: 2810, 5006, 5033, 5035, 5715, 5186, 5244
Procedure applies to cars with manual gearboxes
Removal of automatic gearbox is similar.
CAUTION: Since procedure is carried out with engine freely suspended, ensure that lifting equipment is securely attached and in perfect condition.
Attach lifting equipment
Use attachment 5035 with side arm bolted to hole configuration No.2.
Attach tool first to front left lifting lug, hook in position at rear and finally attach to side lifting lug.
NOTE: Position wiring harnesses so as to avoid damage when lifting.
Lower engine and gearbox into position
Use lifting tool 2810.
Adjust lifting yoke to ensure engine is balanced.
Adjust angle of lift throughout operation.
NOTE: Carefully check that drive unit is free of radiator, body and extra equipment (if any).
Guide front engine mountings into position
Guide mountings into brackets on front crossmember.
Support gearbox on jack
Remove lifting yoke 2810 and attachment 5035.
Raise rear of engine slightly
Use two support bars 5033, lifting yoke 5006, lifting hooks 5115 and 5186.
Lift engine using rear left lifting lug. Remove jack under gearbox.
Replace gearbox support member
Tighten bolts securing member to side members. Tighten bump stop nut.
Ensure that oxygen sensor lead is positioned above member.
Remove lifting attachments
Remove items 5006, 5033, 5115 and 5186.
Install front exhaust pipe
Use new gasket in joint between pipe and exhaust manifold.
Secure pipe to exhaust manifold and to flanged joint at front of catalytic converter.
Secure oxygen sensor lead in clip.
Install gear lever
Insert gear lever sleeve in mounting.
Install:
- bearing bushings and 0-ring on gear selector rod; install circlip on rod
- selector rod/gear lever pivot pin; tighten set screw
- circlip on gear lever sleeve; pull selector rod downwards when fitting circlip
Reconnect gearbox wiring
Reconnect wiring connectors and replace cable tie.
Install propeller shaft
Use socket 5244.
Tighten front and rear universal joints.
Reattach intermediate bearing to member.
Install clutch slave cylinder
Secure cylinder with circlip.
Tighten left-hand engine mounting
On cars equipped with AC: Replace compressor.
Reconnect battery leads
Run wiring between anti-roll bar support and front crossmember.
Install cable clips on crossmember and right-hand side member.
Install splashguard under engine.
Install/reconnect:
- earth lead to top of right-hand side member
- right-hand engine mounting nut
- upper heat shield
- air preheating hose on lower heat shield
- exhaust manifold front mounting bolt
Reconnect:
- bottom coolant hose to coolant pump
- upper coolant hose to thermostat
Important! Note marking on upper hose. Clearance between hose and alternator belt must be at least 25 mm (1 in).
Install servo pump
Mount pump on auxiliary equipment bracket.
Refit belt and adjust tension.
Tighten pump housing.
On cars equipped with AC: Refit twin drive belts.
Install:
- cable ties under fan shroud
- fan shroud
- air preheating hose; tighten ties
- belt pulley and fan
- alternator drive belt; adjust belt tension and tighten alternator
Reconnect rear wiring harness
Secure wiring in cable clips on bulkhead.
Reconnect connectors behind right-hand suspension strut tower and reconnect lead to terminal 1 on ignition coil.
Use cable tie to secure lead to rear left lifting lug.
Install/reconnect:
- distributor rotor
- distributor cap
- high-tension lead between ignition coil and distributor cap
- ignition leads in correct firing order
- ignition lead cover plate
- braided earth lead to distributor
Reconnect left-hand wiring harness
Attach cable clips to wheel housing.
Reconnect connectors at suspension strut tower.
Secure wiring in cable clips.
Install servo reservoir.
Reconnect knock sensor lead
Reconnect connector at diagnostic unit.
Secure cable in clips around suspension strut tower.
Reconnect speed pick-up lead
Reconnect connectors on bulkhead.
Secure lead in clip on bulkhead.
Reconnect:
- brake servo vacuum hose to branch on intake manifold
- EVAP valve hose to branch on intake manifold
- return line to fuel distribution pipe
Secure servo hoses and wiring harness with cable tie.
Reconnect hoses to left-hand side of bulkhead
Reattach heater hoses to branches on bulkhead.
Reconnect union between pipe and hose on fuel line.
Reattach throttle cable to pulley
Hook cable onto pulley.
Attach clip to cable tensioner.
Check stop functions and throttle switch operation.
Install air mass meter, complete with air inlet hose and connections
NOTE: Connect hose from oil trap under inlet hose.
Fill engine with coolant
Use genuine type C Volvo coolant.
Approx. capacity 9 l (9.5 US qt)
Set heater control in car to max. heat.
Check system for leaks.
Fill engine with engine oil
Capacity excluding filter 3.5 l (3.7 US qt)
including filter 4.0 l (4.2 US qt)
Reconnect battery leads
Reconnect positive lead, and lead between right-hand wheel housing and positive terminal.
Install protective cap on positive terminal. Reconnect earth lead.
Check operation
Start and run engine until thermostat opens.
Check and top up oil and coolant levels as required.
Important! Some noise may be heard from tappets when replacement engine is started for the first time. This will disappear as tappets are filled with oil.