Engine/transmission, removing/installing: Finishing

Fig 1: Installing Engine Control Module Using Special Tool 999 5722

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install the engine and transmission wiring.

Plug in the engine and transmission wiring connectors to the connector plate.

Press the connector plate into place in the lower section of the control module box.

Install the intermediate section. Align the ventilation pipe at the rear edge of the control module box.

Screw the control module box into place in the fender liner.

Press the control modules down carefully.

Lock into place using mounting bracket 9995722 .

Press the cover into place.

Fig 2: Identifying A/C Compressor

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install 

• the air conditioning (A/C) compressor. Tighten to 25 Nm  .

  Plug in the connector of the AC compressor's electromagnetic clutch.

• the engine and transmission wiring in the mountings on the subframe.
• the power steering pump. Tighten to 25 Nm  .
• the expansion tank and coolant hoses
• the upper radiator hose
• the auxiliaries belt

Applies to cars with manual transmissions 

Fig 3: Identifying Mechanical Transmission Cables

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install 

• the air filter bracket. Connect the terminal block at the bracket for the air filter
• the ground lead on the transmission
• the lower radiator hose
• the rubber mounted mounting for the mechanical gear selector cables
• the mechanical transmission cables.

Fig 4: Identifying Clutch Cable

Courtesy of VOLVO CARS OF NORTH AMERICA.

Connect the clutch cable. Use a new seal  .

Remove the lock grip pliers.

Bleed the clutch.

Applies to cars with automatic transmissions 

Fig 5: Identifying Automatic Transmission Cables

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install 

• the air filter bracket

  Connect the terminal block at the bracket for the air filter

• the ground lead on the transmission
• the lower radiator hose
• the two oil cooler pipes to the radiator
• the mechanical transmission cable.

Fig 6: View Of Engine Compartment Components - Front

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove radiator protection 9995474 .

Install 

• the engine cooling fan assembly with shroud.
• the air cleaner (ACL) assembly
• the canister purge (CP) valve in its bracket and connect the EVAP canister vacuum hose
• the manifold absolute pressure (MAP) sensor to the mounting in the front cover plate
• connect the engine cooling fan (FC) connectors. Clamp the wiring.

Install: 

• the brake vacuum hose on the inlet pipe
• the heater hoses on the cowl panel
• the braided ground cable between the engine and cowl panel.

Fig 7: Identifying Air Cleaner Housing

Courtesy of VOLVO CARS OF NORTH AMERICA.

• the air cleaner (ACL) assembly
• the air preheating hose
• the vacuum hose for control of preheated air
• the intake hose between the air cleaner (ACL) housing and the front panel
• the inlet hose between the air cleaner (ACL) and the throttle body (TB).

Connect the connector for the HFM unit and the assisted air control valve.

Fig 8: Identifying Engine Mount And Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install: 

• the front and rear screws for the engine mountings (A).

  Tighten to 50 Nm  .

• the screw for the torque rod in the transmission.

  Use a new  screw and nut.

  Tighten the screws. Tighten to 35 Nm  . Angle-tighten 90°  .

• both the screws for the right engine mounting (B).

  First bend the right fender liner slightly so that it is out of the way.

Fig 9: Identifying SIPS Member And Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Lubricate the studs at the manifold. Use paste (P/N 116 14 08  ).

Install 

• the front exhaust pipe on the manifold. Use a new  gasket and new  nuts.
  NOTE: Do not tighten. 
• the screws securing the SIPS member to the bodywork
• the brake pipe in the holders at the SIPS member

  Tighten the nuts where the manifold and the front exhaust pipe separate. Tighten the screws securing the SIPS member. Tighten to 25 Nm  .

  Secure the wiring for the heated oxygen sensors (HO2S) at the rear engine mounting and at the steering gear

• the right-hand drive shaft. See Drive shaft left, replacing
• the left-hand drive shaft. See Drive shaft left, replacing
• the wheels. See Installing wheels .

Install the engine positive cable on the terminal at the left suspension turret.

Install the support brace between the suspension turrets. Tighten the screws at the suspension turrets. Tighten to 50 Nm  . Tighten the engine bracket screw. Tighten to 80 Nm  .

Top up the coolant. Coolant volume approximately: 7 liters  .

Connect the negative battery cable. First read Battery, disconnecting .

Fill with engine oil. Oil volume including filter: 5.8 liters  .

Fig 10: Connecting VIDA Station

Courtesy of VOLVO CARS OF NORTH AMERICA.

Check the function 

• Connect a VIDA station.
• Start the engine and run it until the thermostat opens.
• Read off any diagnostic trouble codes (DTCs)
• Check sealing.
• Check and if necessary adjust the oil and coolant levels
• Wipe clean.

Automatic transmissions:  Check the transmission fluid level.