Removing the control system cover

Cleaning

Carry out an engine wash. Then open the expansion tank cap.

Fig 1: Identifying Splash Guard Under Engine

Courtesy of VOLVO CARS OF NORTH AMERICA.

Raise the vehicle.

NOTE:

Position the front lift arms so that they do not obstruct the sub-frame support plates.

Remove:

the splash guard under the engine
both the screws for the front splash guard. Press in the catches at the front edge of the cover. Pull the cover backwards.

Fig 2: Identifying Control System Cover, Harness Clamp, Cooler Return Line And Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Place a container underneath the transmission.

Drain the oil. Measure and note the volume of oil.

Install the plug. Tighten. See: Summary of tightening torques for specific components

Remove the cable harness clamp on the control system cover.

Disconnect the oil cooler return line from the control system cover.

Disconnect the screws for the oil cooler pipe from the transmission. Move the pipe to one side.

Seal the hole in the transmission with a plastic plug.

Position a container under the radiator drain cock. Drain the engine coolant.

NOTE:

Avoid skin contact with the coolant.

Close the nipple.

Fig 3: Identifying Control System Cover, Harness Clamp, Cooler Return Line And Bracket

Courtesy of VOLVO CARS OF NORTH AMERICA.

Disconnect the lower hose for the radiator to provide more space for removing the control system cover.

Fig 4: Identifying Fuel Line Mounting In Sub-Frame

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the screw for the front engine pad and the sub-frame
the screw for the ground lead bracket.

NOTE:

Applies only to cars with parking heaters:

Remove the 3 screws from the heater on the sub-frame.

Hang or tie up the heater on the left front fender.

Unhook the fuel line from its mountings in the sub-frame.

Lower the vehicle.

Fig 5: Identifying Lifting Beam 9995716 And Lifting Hook 9995460

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install 9995716 directly above the engine lifting eye. Position the lifting beam brackets as illustrated.

Connect: 9995460 to the lifting eye at the rear edge of the engine. Raise the rear edge of the engine 20 mm.

Raise the vehicle.

Fig 6: Identifying Sub-Frame Mounting Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Slacken off the front mounting screws on the sub-frame.

Remove the left-hand screw.

Unscrew the right-hand screw until it is secured by approximately 5 threads.

Slacken off the rear mounting screw on the left-hand side. Unscrew it approximately two turns.

Fig 7: Identifying Spacer Inserted Between Bodywork And Sub-Frame At Front Left-Hand Mounting

Courtesy of VOLVO CARS OF NORTH AMERICA.

Insert a spacer between the bodywork and the sub-frame at the front left-hand mounting. There must be a distance of approximately 55 mm.

Cleaning

Use compressed air to blow clean the area around the control system cover. Carefully clean the sub-frame by the cover to prevent dirt entering the transmission.

Fig 8: Removing Control System Cover Using Gasket Wedge 9995477

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the screws for the control system cover.

Clean any sealing compound from the threads. Use a tap, M8x1.25.

Detach the cover. Use: 9995477 . Carefully tap it in between the cover and transmission so as not to bend the seal flange on the cover.

Fig 9: Removing Cover

Courtesy of VOLVO CARS OF NORTH AMERICA.

Slide the cover between the sub-frame and the bodywork. Remove the cover.

Clean the gasket residue from the cover and the transmission.

NOTE:

Wash the cover thoroughly. Ensure that no debris enters the transmission.