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 (CMP) sensor housing
• the pipe screw for the water heated crankcase ventilation at the rear of the cylinder head. Use new seal washers. Tighten to 26 Nm  .

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: 

• the ignition coils according to the earlier markings
• the connector for the coolant temperature sensor
• the connectors for the variable valve timing solenoids
• the screws for the two 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 (TB) connector to the engine wiring
• the charge air pipe to the throttle body (TB). Tighten the clamp
• the control hose to the charge air by-pass 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 pipe onto the intake manifold.

Install: 

• the connector for the heated oxygen sensor (HO2S) (turbocharger (TC) 2)
• the intake and charge air pipes
• the hose from the pressure regulator to the T piece (turbocharger (TC) 2)
• the connector for the heated oxygen sensor (HO2S) (turbocharger (TC) 1).

Clamp the wiring for the heated oxygen sensors (HO2S).

Fig 1: Installing Torque Rod Bracket, Upper Screw Securing Automatic Transmission Dipstick Pipe To Engine & Ground Leads

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install: 

• the torque rod bracket
• the upper screw securing the automatic transmission dipstick pipe to the engine. Tighten the lower screw
• the ground lead between the firewall and the torque rod bracket
• the ground lead between the right-hand frame member and the cylinder head.

Install 

• the cable duct on the inside of the right suspension turret
• the front timing cover. For cars with chassis numbers 203779-  , see Installing the front timing cover .
• 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.

Install the 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 (TC). 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 (CAC) 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 hose to the plastic intake pipe
• the outlet pipe from the by-pass valve to the plastic intake pipe. Tighten the clamp
• the air cleaner (ACL) assembly. Press the air cleaner (ACL) intake pipe into place on the connection on the front cover plate
• the plastic intake pipe to the mass air flow (MAF) sensor. Tighten the clamp
• the connector to the mass air flow (MAF) sensor. Clamp the cable to the front of the air cleaner (ACL)
• the turbocharger (TC) control valve to the mounting on the air cleaner (ACL)
• the blue marked hose and the turbocharger (TC) control system to the intake manifold
• the red marked hose and turbocharger (TC) control system to the charge air pipe
• the yellow marked hose and turbocharger (TC) 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 engine stabilizer brace.

Connect the battery negative lead. Also read Battery, disconnecting .