Turbocharger, Replacing: Installation

NOTE:

For tightening torques, see: Tightening torque .

NOTE:

To ensure that there is no exhaust leakage, see: Flanged joint, assembling .

Installing the manifold/gasket

Fig 1: Identifying Inner Heat Shield And Manifold

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

new gaskets
the manifold. Use new nuts at the manifold. Tighten.
the inner heat shield.

Fitting of turbo unit

Fig 2: Identifying Turbocharger And Pipe Fittings

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the turbo control hoses according to the earlier markings
the turbo to the manifold with a new gasket
the upper nuts at the turbo's connection to the manifold. Tighten
the inlet hose to the inlet manifold on the turbo and tighten the hose clamp
the screws, 2 pcs, to the oil delivery pipe. Use a new gasket. Tighten.
the pipe screws for the upper coolant pipe. Tighten.

Raise the vehicle. See: Jacking points, body .

Fig 3: Identifying Turbocharger Oil Delivery Pipe And The Oil Return Pipe

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the lower screws, 2 pcs, between the turbocharger and manifold. Tighten
the oil return pipe in the cylinder block with new sealing ring
the screws, 2 pcs, to the oil return pipe in the turbocharger as well as new gasket. Tighten.
the pipe screws for the lower coolant pipe. Use new copper washers. Tighten
the pipe screws for the lower oil delivery pipe in the engine block. Use new copper washers. Tighten
the clamp between the turbocharger oil delivery pipe and the oil return pipe. Tighten.

Installing the bevel gear

Fig 4: Angle Gear Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Before installing the bevel gear, lubricate the spline joint between the transaxle and the bevel gear using grease. See: Splines greasing .

Check that the mating surfaces on the transaxle and bevel gear are clean. Install the bevel gear. Tighten the screws, M10, crosswise to light contact. Tighten.

Installing the propeller shaft

Fig 5: Identifying Front Propeller Shaft And Special Tool 999 7057

Courtesy of VOLVO CARS OF NORTH AMERICA.

Check that the mating surfaces on the propeller shaft and flange are clean. Install the propeller shaft according to the previous marking. Use new screws. Tighten.

Fitting of catalytic converter

Install the catalytic converter. See Replacing the three-way catalytic converter (TWC) .

Installing the drive shaft and bearing cap on the pilot bearing for the shaft

Fig 6: Drive Shaft

Courtesy of VOLVO CARS OF NORTH AMERICA.

Tighten the screws.

Installing the drive shaft

Fig 7: Identifying Wheel Knuckle, Special Tools 999 7076 And 999 5562

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE:

Check that the seal on the end of the driveshaft is correctly positioned. See: Seal CV joint housing, replacing .

Press out the strut and spring assembly.

Align the drive shaft in the hub.

Remove the protective socket, 9995562 .

Align the control arm with the ball joint stud. Use: 9997076 .

Install:

the nut for the ball joint and control arm. Tighten according to: Tightening torque . Counterhold using a Torx wrench to prevent the ball joint boot from turning.
the center screw for the driveshaft. Use a new screw. Tighten according to: Tightening torque . Use a screwdriver as a counterhold in the brake disc.

Installing wheels

Install the wheel acc. to: Installing wheels

Installing components

Fig 8: Engine Compartment Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the screws for the heat shield above the turbo and screws for the oil delivery pipe. Tighten
the pipe screws for the upper coolant pipe. Tighten
the upper charge air pipe. Tighten the screws and clamps
the cross stay between the suspension turrets. Tighten the screws, 5 pcs.
the battery negative lead. See: Battery, disconnecting