Installing components

Fig 1: Identifying Expansion Tank

Courtesy of VOLVO CARS OF NORTH AMERICA.

Connect the engine cable 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
• 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.

Fig 1: Identifying Coolant Hose, Pipe And Fan

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install: 

• the hoses for the heater unit at the terminal in the firewall
• 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. 

Fig 2: Identifying Central Electrical Unit

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install: 

• the connector for the engine cable 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.

Fig 3: Identifying Engine Compartment Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install: 

• the ground strip at the top/rear of the cylinder head
• the charge air cooler pipe over the engine
• the inlet hose for the turbocharger (TC) to the air cleaner (ACL)
• air cleaner (ACL) assembly
• the mass air flow (MAF) sensor connector. Tighten the hose clamps
• the turbocharger control valve on the air cleaner (ACL)
• the intake pipe between the front cover plate and the air cleaner (ACL)
• the engine stabilizer brace between the suspension turrets
• the negative battery cable. First read Battery, disconnecting .