Installing Components

Fig 1: Three-Way Catalytic Converter And Exhaust System

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Lubricate the studs on the turbocharger (TC). Use copper paste 116 1408  .
• Lift the three-way catalytic converter (TWC) up into position
• Install the three-way catalytic converter (TWC) against the exhaust system. Use a new gasket  . Install new nuts  but do not tighten.

• Lift the sub-frame until it is against the frame members
• Install new screws  in the sub-frame. Lubricate the screw threads. Install the washers in the front edge and support plates at the rear edge of the sub-frame
• First tighten the screws on the left side of the subframe. Use bevel protractor 9512050 . Then tighten the screws on the right-hand side of the subframe to the same value.
• Tighten the brackets. Tighten to 50 Nm  .
• Remove the lifting table.

Install: 

• the servo reservoir
• the expansion tank
• the charge air pipe between the throttle module and charge air cooler
• the hose on the charge air pipe at the top of the engine.

Fig 1: Exhaust Pipe Bracket Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Install the front SIPS member. Press the brake pipe into place in the member
• Hook the rubber mounting for the three-way catalytic converter (TWC) in the bracket on the sub-frame
• Connect the connector for the rear heated oxygen sensors (HO2S). Clamp the wiring. Tighten the screwed joint between the three-way catalytic converter (TWC) and the exhaust system.