Installing The Turbocharger (TC) For Cylinders 4, 5, 6: Finishing

Fig 1: Oil Return Lines

Courtesy of VOLVO CARS OF NORTH AMERICA.

(The illustration is not entirely accurate because the pulsed secondary air injection system (PAIR) pump is discontinued)

Raise the car.

Install 

• the lower nuts for the turbocharger (TC) / manifold. Use new nuts  . Tighten to 25 Nm 
• the pipe screw for the pressure oil outlet on the engine. Use new gasket washers  . Tighten to 38 Nm 
• the oil return line. Use a new  gasket
• lower coolant pipe. Use new gasket washers  . Tighten to 26 Nm  .

Install the right drive shaft. See Drive shaft right, replacing .

Fig 2: Mobile Jack With Universal Plates 999 5972 Positioned Under Catalytic Converters

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install the catalytic converter unit with the heat deflector plate. Use new nuts and gaskets  .

Lubricate all the studs. Use paste, P/N: 116 1408  . Avoid skin contact with the paste. 

Connect the pipe to the engine. Use a mobile jack with universal plate 9995972 as support.

Press the brake pipe into place on the front SIPS member.

Connect to the rear exhaust pipe. Install all nuts loosely.

Install the screws for the front SIPS member.

Remove the mobile jack.

Fig 3: Catalytic Converters

Courtesy of VOLVO CARS OF NORTH AMERICA.

Tighten 

• the nuts for the front flange seal. Tighten alternately. Tighten to 25 Nm 
• the front SIPS member. Tighten to 25 Nm 
• the rear flange seal nuts. Tighten to 25 Nm 
• the rear SIPS member. Tighten to 25 Nm  .

Fig 4: SIPS Member

Courtesy of VOLVO CARS OF NORTH AMERICA.

Connect the heated oxygen sensor (HO2S) wiring connectors.

Secure the wiring at the rear edge of the sub-frame.

Install the splashguard under the engine.

Install the left front wheel. See Installing wheels .

Install the right drive shaft. See Drive shaft right, replacing .

Lower the car.

Install the pipe screw for the upper coolant pipe. Use new gasket washers  . Tighten to 26 Nm  .

Tighten the pipe screw for the oil pressure pipe. Tighten to 18 Nm  .

Fig 5: Upper Coolant Pipes

Courtesy of VOLVO CARS OF NORTH AMERICA.

Close the clamp between the oil pressure pipe and the water pump intake pipe.

Fig 6: Engine And Stabilizer Brace

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install 

• the heat deflector plate. Use new screws. Tighten to 25 Nm 
• the intake and charge air hooks. Align against the plastic pipes and tighten.

  Press the plastic pipes into place. Tighten the hose clamps

• the mounting screws for plastic pipes and tighten
• the hose from the pressure regulator to the T piece
• the screw for the engine stabilizer brace mounting on the engine
• the cross stay between the suspension turrets
• the expansion tank cap.