Removing the engine with the transmission

WARNING: This page is about a different car, the 2004 Volvo S40, 2003 Volvo S40, 2002 Volvo S40, 2001 Volvo S40, and 2000 Volvo S40. However, it is still accessible from the selected car via links, so may be relevant.

Special tools:

9992810

9995185

Draining the coolant from the radiator and the engine

See Draining the coolant from the radiator and the engine .

Removing the left-hand side drive shaft nut

Remove the hub cap. Remove the nut

Disconnect the air conditioning (A/C) hose from the fan shroud

The front and rear splash guards under the engine

Fig 1: Removing/Installing Front/Rear Splash Guards Under Engine

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the lateral strut

Fig 2: Removing/Installing Cross Stay Member

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the screws and the lateral strut.

Removing the front-rear member

Fig 3: Removing/Installing Longitudinal Member

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the heat deflector plate from the engine
the nuts for the engine pads
the front and rear screws
the two screws that run through the engine pads. Lift the front-rear member down from the car.

Remove the front exhaust pipe from the exhaust manifold

Fig 4: Identifying Front Pipe And Gasket

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Remove the 6 nuts
Pull the front exhaust pipe downwards
Remove the gasket.

Removing the rear engine mounting

Fig 5: Removing/Installing Rear Engine Mounting

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Remove the four screws. Remove the engine bracket.

Removing the front engine mounting

Fig 6: Removing/Installing Front Engine Mounting

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the clamp from the charge air cooler (CAC) hose.

Remove the three screws. Remove the engine bracket.

Removing the auxiliaries belt

Fig 7: Removing/Installing Auxiliaries Belt

Courtesy of VOLVO CARS OF NORTH AMERICA.

Relieve the load on the belts by turning the belt tensioner counter-clockwise
Remove the auxiliaries belt and move it upwards.

Removing the air conditioning (A/C) compressor

Fig 8: Identifying Air Conditioning Compressor, Connector And Mounting Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the connector (A)
four mounting screws
the compressor. Turn the compressor upwards as far as possible.

Tie the front edge of the compressor to the car body.

NOTE: Do not damage the A/C hoses and pipes.

Disconnect the oil pressure sensor and generator (GEN) connectors

Fig 9: Checking Engine Oil Pressure Sensor

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the connector from the oil pressure sensor
the cable clamp from the bracket
the connector in the middle.

Removing the right-hand drive shaft from the transmission

Fig 10: Identifying Special Tool 9995488

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the drive shaft bearing cap on the engine side
both the front wheels
the brake hose clips. Lift out the hoses from their mountings
The ABS lines from its mountings
the two nuts. The upper screw from the spring strut
the stub axle from the spring strut (turn it)
the drive shaft from the transmission
the lower screw. Move the drive shaft to one side.

Insert special tool 9995488 into the transmission.

Secure the stub axle using the lower spring strut screw.

Tie the drive shaft to the wheel arm.

Remove the side panel on the left-hand side

Remove the screws. Lift off the cover.

Removing the left-hand side drive shaft assembly

Fig 11: Removing Left-Hand Side Drive Shaft Assembly

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the brake hose clips. Lift out the hoses from their mountings
The ABS lines from the mountings
the center nut from the drive shaft
the two nuts. The upper screw from the spring strut.

Disconnect the drive shaft from the transmission. Use special tool 9995462 .

Remove the drive shaft assembly.

Insert special tool 9995488 into the transmission.

Secure the stub axle using the lower spring strut screw.

Automatic transmission: Disconnect the transmission oil pipes

Fig 12: Disconnecting/Installing Transmission Oil Pipes

Courtesy of VOLVO CARS OF NORTH AMERICA.

Disconnect the oil pipes from the transmission. Move the pipes to one side.

Ensure that no dirt gets into the transmission and hoses.

Seal all openings using plastic plugs.

NOTE: Do not remove the hoses from the pipes.

Drain the injection system

See Draining the fuel injection system .

Remove the battery and the battery shelf

Fig 13: Battery And Shelf

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the battery.

NOTE: If the car has cruise control, remove the vacuum hose and the connector before the vacuum pump is detached.

Remove the screws from the battery shelf.

Release the cable harness from the clamp.

Remove the hose clamp from the battery shelf.

Removing the air cleaner (ACL) housing assembly

Remove the air cleaner (ACL) housing. See Replacing the air cleaner (ACL) .

Remove the battery positive and negative leads

Fig 14: Identifying Connector And Battery Positive Lead

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Disconnect the connector (A).

Remove:

the nut and the battery positive lead (B)
remove the ground lead from the transmission.

Removing the gear selector mechanism cables

Automatic transmission

Fig 15: Installing Gear Selector Mechanism Cables (Automatic Transmission)

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove: the gear selector cable mountings.

Disconnect the connector.

Remove the gear selector cable from the gear selector bevel arm on the transmission.

Remove the connectors from the transmission:

the gear selector cable from the transmission
the ground lead from the transmission
remove the connector bracket from the transmission
disconnect the connectors from each other.

Removing the vacuum hose from the canister purge (CP) valve

Fig 16: Removing Vacuum Hose From Canister Purge (CP) Valve

Courtesy of VOLVO CARS OF NORTH AMERICA.

Removing the air intake hose

Fig 17: Identifying Air Intake Hose

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Remove:

the hose connectors for the valve
the air hose (upper edge)
the vacuum hose (underneath)
the crankcase ventilation hose (underneath)
both the hose clamps. Lift out the air intake hose.

Removing the throttle cable

Fig 18: Removing/Installing Throttle Cable

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the cover by removing the screw and the two plugs
the cable with the throttle in the wide open position
the retaining clip. Remove the cable sleeve.

Removing the cover, the mounting and the connectors

Fig 19: Removing Cover, Mounting And Connectors

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the connectors for:

the engine speed (RPM) sensor
the camshaft position (CMP) sensor
the knock sensor (KS)
the cable harness.

Remove:

the protective tube from the 3 clips
the brake servo hose from the power brake booster (press in the snap ring and pull out the hose)
the hose from the valve for the air cleaner (ACL).

Removing the fuel line from the engine

Fig 20: Removing/Installing Fuel Line From Engine

Courtesy of VOLVO CARS OF NORTH AMERICA.

Press the lugs together. Pull out the fuel line
Disconnect the line from clamps. Move the line to one side.

Removing the cable harness

Fig 21: Engine Cable Harness

Courtesy of VOLVO CARS OF NORTH AMERICA.

Disconnect the connector from the engine.

NOTE: Note the position of all the mounting points for the cable harness.

Remove:

the engine coolant temperature (ECT) sensor
the cable from the bracket
the cover over the injectors (pull the cover off)
the injectors
the throttle position (TP) sensor
the idle air control (IAC) valve
the cable guide (slacken off the screws one by one)
the backup lamp switch
move the entire cable harness to one side.

Removing the coolant hoses

Fig 22: Identifying Coolant Hoses

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Remove:

the clamps
the upper radiator hose
the lower radiator hose on the engine side.

Removing the heater hoses from the engine connections

Fig 23: Installing Heater Hoses

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

slacken off the hose clamps (make a note of how the hoses are routed)
pull off the heater hoses.

Manual transmissions: Removing the clutch hose connection at the transmission

Fig 24: Identifying

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the retaining clip at the transmission side
pull the hose out of the bracket
the hose. Close the hose opening using the protective cap from the bleed nipple.

Reinstall the retaining clip. Wipe up any spilled hydraulic fluid.

Remove the bracket for the clutch pipe from the body

Fig 25: Identifying Bracket For Clutch Pipe

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Removing the power steering pump from the engine

Fig 26: Identifying Power Steering Pump Components

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Remove the bracket between the power steering pump and the intake manifold. See Removing the fuel line
Remove the auxiliaries belt
Remove the mounting screws between the spokes on the pulley
Remove the fluid reservoir from the bodywork. Release the hose from the clips
Remove the power steering pump. Place the pump to one side.

Place the hood in the service position

Fig 27: Placing Hood In Service Position

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Remove the two screws.

Remove the support on the body side.

Support the hood.

Removing the engine with the transmission

Fig 28: Identifying Lifting Hooks And Lifting Yoke

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Hang lifting hooks 9995185 and 9995642 on lifting yoke 9992810 .

Raise the lifting equipment until it takes the strain off the engine.

Remove the engine mounting on the transmission side.

Remove the screw and nut from the engine bracket on the body
Remove the three screws. Remove the engine mounting assembly from the transmission.

Remove the engine mounting from the upper timing belt cover.

NOTE: Check carefully that the driveline is clear of the bodywork and other optional equipment. Turn the clamp at the oil cooler if necessary.

Lift the engine straight up.

Adjust the lifting equipment continuously throughout the lift.

Return the hood to the normal position.