Engine/Transmission, Removing: Preparation

Fig 1: Air Cleaner Housing Assembly

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove 

• the negative battery cable. First read Battery, disconnecting .
• the air cleaner housing assembly, including intake manifold.

Lift up the power steering fluid reservoir and place it on the engine.

Fig 2: Engine Control Module

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• the engine wiring's ground cable.
• the cover from the control module box.
• the control modules. Use mounting bracket 9995722 .
• the intermediate section of the control module box.

Fig 3: Prying Out Connector Plate From Lower Section Of Control Module Box

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Pry out the connector plate from the lower section of the control module box and pull the connectors of the engine and transmission wiring from the plate.

Place the engine and transmission wiring on top of the engine.

Fig 4: Charge Air Pipe To Charge Air Cooler (CAC), Upper Oil Cooler Hose To Transmission & Transmission Cable To Transmission

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• the screw of the upper torque rod from the engine.
• the engine stabilizer brace from the suspension turret.
• the engine cable from the positive terminal at the left suspension turret.
• the brake vacuum hose from the intake manifold.
• the mechanical transmission cable from the transmission.
  NOTE:

  Take care that the cable does not break or crack.

Fig 5: Identifying Radiator Drain Plug

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Undo the expansion tank cap.

Place a receptacle under the radiator  drain cock.

Drain the coolant. Avoid skin contact. 

Close the cock.

Fig 6: View Of Hose Running From Radiator To Expansion Tank

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Detach the hose running from the radiator to the expansion tank.

Lift up the tank and place it on the engine.

Remove 

• the hoses of the heating system.
• the upper radiator hose.
• the upper oil cooler hose to the transmission.
  NOTE:

  Seal the openings against dirt.

Fig 7: View Of Fan Shroud On Radiator, Connectors To Engine Cooling Fan (FC), Evaporative Emission System (EVAP) Valve And Pulsed Secondary Air Injection System (PAIR) Pump & Wiring To Terminal Block

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Remove 

• the EVAP canister purge valve from the mounting on the fan shroud.
• the connector from the EVAP canister purge valve.
• the supply hose between the turbocharger pipe and the charge air cooler (B6xx4T only).

  Detach the intake manifold from the charge air cooler.

• the connector of the pressure monitor for the dryer bottle.
• the connector to the electric cooling fan.
• the wiring from the terminal. Place it over the engine.

Detach the fan shroud from the wiring.

• the fan shroud from the radiator.

Fig 8: AC Compressor

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Relieve tension on the auxiliaries belt tensioner and hang the belt from the power steering pump.

Unplug the connector of the AC compressor's electromagnetic clutch.

Remove the four screws holding the AC compressor in the engine. Start with the lowest screw.

Remove the AC compressor and bind it up on the front cover plate.

Fig 9: Removing/Installing Lowering Steering Shaft

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Remove the panel below the dashboard on the driver's side.

Turn the steering wheel to gain the best possible access to the steering shaft nut.

Remove the ignition key so that the steering wheel lock is activated.

Undo the joint from the lower steering shaft. Cut the cable tie and remove the bushing from the boot.

Fig 10: Engine Splash Guard

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Remove 

• the front wheels.
• the front splash guard.
• the splash guard under the engine

Detach the anti-roll bar links from the anti-roll bar.

Fig 11: Identifying Steering Arm Track Rod End

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Remove (on both sides) 

• the track rod end from the control arm. Use puller 9995259 .
• the brake pipe bracket from the mounting in the wheel housing.
• the ABS sensor cable from the spring strut.
• the ABS sensor. Hang up the sensor.
• the screw holding the drive shaft to the hub.
• the nut of the ball joint/link arm.
  NOTE:

  Counterhold with Torx 40 so that the ball joint gaiter does not turn when the nut is removed.

Fig 12: SIPS Member

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Detach the brake pipe from the clips on the front crossmember.

Fig 13: Heated Oxygen Sensor Connectors

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Expose the wiring of the heated oxygen sensors.

Disconnect the heated oxygen sensor connectors.

Fig 14: Catalytic Converters

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Remove 

• the nuts of the catalytic converter pipe's front mounting.
• the pop rivets holding the heat deflector plate in the center SIPS member.
• the rear SIPS member.
• the nuts of the catalytic converter's rear mounting.

Fig 15: Mobile Jack With Universal Plates 999 5972 Positioned Under Catalytic Converters

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• Position a mobile jack with universal plate 9995972 below the catalytic converters as support during removal.
• Carefully lower the catalytic converter unit.
  NOTE:

  Routing of heated oxygen sensor wiring.

  Take care so that no breaks or cracks form in the catalytic converter pipe's dust excluders.

Fig 16: Drain Cock And Drain Coolant

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Place a receptacle under the engine  drain cock and drain the coolant.

Move the receptacle to the radiator's drain cock and drain any remaining coolant.

Close the nipples.

Remove 

• the radiator hose from the radiator.
• the lower oil cooler hose from the transmission.

Collect any oil or coolant spill.

Depressurize the fuel system acc. to Fuel system pressure release .

Undo the fuel line's quick-release connector at the engine. See also Fuel system, quick-release connectors .

Put the line to the side.

Detach the EVAP line at the quick-release connector.