Installing Components

Fig 1: Trigger Wheel, Camshaft Position (CMP) Sensor Housing & Pipe Screw For Water Heated Crankcase Ventilation At Rear Of Cylinder Head

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install 

• the trigger wheel.
• the camshaft position sensor housing, lower screw only.
• the pipe screw for the water heated crankcase ventilation at the rear of the cylinder head. Use new seal washers. Tighten to 26 Nm  .
• the cover at the rear edge of the intake camshaft.

Fig 2: Connectors For Variable Valve Timing Solenoids, Connector For Coolant Temperature Sensor & Screws For Ignition Coils And Two Ground Terminals

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install 

• ignition coils using previous markings.
• the connector for the coolant temperature sensor.
• the connector for the variable valve timing solenoid.
• the screws for the 2 ground terminals between ignition coils 1 and 2 and 5 and 6.

Fig 3: Intake Manifold Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install below the intake manifold 

• the starter motor.
• the throttle body connector to the engine wiring.
• the charge air pipe to the throttle body. Tighten the clamp.
• the control hose to the charge air bypass valve.
• the brake vacuum hose to the intake manifold.
• the bracket and screw to the lower row of screws at the mounting for the intake manifold on the cylinder head.
• the pipe screws at the underside of the intake pipe for the water heated crankcase ventilation. Tighten to 26 Nm  .
• the dipstick tube to the intake manifold.

Fig 1: Front Timing Cover

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install 

• the cable duct on the inside of the right suspension turret.
• the front timing cover.
• the expansion tank. Connect the connector to the coolant level sensor.
• the hose to the expansion tank from the radiator. Secure the clamp and remove the lock grip pliers.

Connect the connector to the ABS sensor.

• servo reservoir. Ensure that the hoses are correctly positioned.

Fig 2: Engine Compartment Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install 

• the upper timing cover.
• the cover over the ignition coils.
• the plastic intake pipe over the engine. Adjust and tighten the intake pipe at the turbocharger. Tighten the clamps and mounting screws on the plastic pipe.
• the plastic charge air pipe over the engine. Tighten the clamps and mounting screws.
• the hose between the charge air cooler and the plastic charge air pipe over the engine. Tighten the clamps.
• the crankcase ventilation hose to the PTC resistor in the plastic intake pipe over the engine. Use a new clamp.
• the connector for the PTC resistor.
• the protective cover over the PTC resistor.
• the EVAP valve hose to the plastic intake pipe.
• the bypass valve outlet hose to the plastic intake pipe. Tighten the clamp.
• the air cleaner assembly. Press the air cleaner intake pipe into the front plate port.
• the plastic intake pipe to the mass air flow sensor. Tighten the clamp.
• the connector to the mass air flow sensor. Clamp the wiring at the front edge of the air cleaner.
• the turbocharger control valve to the mounting on the air cleaner
• the blue-marked hose/turbocharger control system to the intake manifold.
• the red-marked hose/turbocharger control system to the charge air pipe.
• the yellow-marked hose/turbocharger control system to the pressure regulators.
• the cross stay between the suspension turrets
• the suspension turret covers.

Clamp the servo hose to the right mounting on the cross stay.

Fig 1: Battery Negative Lead, Radiator Breather Tube By Expansion Tank, Right-Hand Drive Shaft, Bearing Seat & Pipe Screw

Courtesy of VOLVO CARS OF NORTH AMERICA.

Tighten the pipe screw of the oil pressure pipes to 38 Nm  .

Install the drive shaft bearing seat.

Install 

• the right drive shaft. See: Drive shaft right, replacing .
• the wheels. See Installing wheels .
• the battery negative lead. Also read Battery, disconnecting .