Installing Manifold / Gasket: Finishing

Fig 1: Oil Pressure Pipe

Courtesy of VOLVO CARS OF NORTH AMERICA.

(The car is not correct because the pulsed secondary air injection system (PAIR) pump has been discontinued.)

Install

the oil pressure pipe with pipe screws to turbo 2. Use new gasket washers . Do not tighten yet
the oil pressure pipe with pipe screws to turbo 1. Use new gasket washers . Do not tighten yet
the clamp between the oil pressure pipe for turbo 2 and the intake pipe for the water pump. Do not tighten yet .

Fig 2: Oil Return Lines

Courtesy of VOLVO CARS OF NORTH AMERICA.

(The car is not correct because the pulsed secondary air injection system (PAIR) pump has been discontinued.)

Raise the car.

the pipescrew for the oil pressure pipe in the connection in the cylinder block. Use new gasket washers . Tighten to 38 Nm
the oil return line to turbo 1 with new gasket . Tighten to 12 Nm
the oil return line to turbo 2 with new gasket . Tighten to 12 Nm
the lower coolant pipe to turbo 1 and 2. Use new gasket washers . Tighten to 26 Nm
the right drive shaft. See Drive shaft right, replacing .

Fig 3: Catalytic Converters

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install the catalytic converter with heat deflector plate. Use new nuts and gaskets . Lubricate all studs. Use paste P/N: 116 1408 .

Connect the pipe to the engine. Use a mobile jack with universal plate 9995972 as support.

NOTE:

Ensure that the heated oxygen sensor (HO2S) wiring is above the brake pipe.

Press the brake pipe into place on the front SIPS member.

Connect to the rear exhaust pipe. Install all nuts loosely.

Install the screws for the front SIPS member.

Remove the mobile jack.

Tighten

Fig 4: SIPS Member

Courtesy of VOLVO CARS OF NORTH AMERICA.

Connect the heated oxygen sensor (HO2S) wiring.

Secure the wiring at the rear edge of the sub-frame.

Install the splashguard under the engine.

Install the left front wheel. See Installing wheels .

Lower the car.

Fig 5: Upper Coolant Pipes

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install both the upper coolant pipes with new gasket washers . Tighten to 26 Nm .

Tighten the oil pressure pipes in the central housings. Tighten to 18 Nm .

Close the clamp between the oil pressure pipe and the water pump intake pipe.

Fig 6: Engine And Stabilizer Brace

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install

the screw for the engine stabilizer brace mounting on the engine. Tighten to 80 Nm
the screws for the engine stabilizer brace mountings in the suspension turrets. Tighten to 50 Nm
the automatic transmission dip stick pipe
the heat deflector plate with new screws. Tighten to 25 Nm
the intake and charge air pipe hooks. Align against the plastic pipes and tighten.
Press the plastic pipes into place. Tighten the hose clamps
the mounting screws for the plastic pipes
the expansion tank cap.