Section 43 (Engine - Removal, Replacement And Installation)
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2006 Volvo S80, 2005 Volvo S80, 2004 Volvo S80, 2003 Volvo S80, and 2002 Volvo S80. However, it is still accessible from the selected car via links, so may be relevant.
- Crank Mechanism (1999-2005)
- Crank Mechanism (B5254T2, Aw50/51 AWD; B5254T2, Aw55-50/51SN; 2004)
- Crank Mechanism (B5254T2, Aw50/51 AWD; B5254T2, Aw55-50/51SN; 2005-2006)
- Crank Mechanism (B6284T, 4T65EV-Gt; B6294S, 4T65EV; B6294S, 4T65EV-Gt; 2000-2001)
- Crank Mechanism (B6284T, 4T65EV-Gt; B6304S3, 4T65EV; 1999)
- Crank Mechanism (B6294S2; B6294T; 2002-2006)
- Cylinder Head (B5254T2; 2004-2006)
- Cylinder Head/Gasket, Replacement
- Notes
- Removal
- Preparation
- Draining Coolant
- Removing Components
- Depressurizing The Fuel System
- Removing The Fuel Rail
- Removing Ignition Coils
- Removing Intake Manifold
- Setting Up The Engine
- Removing The Timing Belt
- Removing The Timing Gear Pulley
- Removing Components From Turbocharger (TC)
- Releasing The Inlet Pipe For The Coolant Pump
- Removing The Camshaft Cover And Cylinder Head
- When Replacing Or Working On The Cylinder Head
- Installation
- Notes
- Cleaning
- Setting Up The Engine
- Installing The Cylinder Head
- Installing Valve Lifters And Camshafts
- Applying Liquid Gasket
- Installing The Camshaft Cover
- Installing The Manifold And Turbocharger (TC)
- Installing The Rear Camshaft Seal
- Installing The Front Camshaft Seals
- Checking And Adjusting The Variable Valve Timing Unit
- Installing Components
- Installing Intake Manifold
- Installing The Fuel Rail
- Check
- Cylinder Head/Gasket, Replacement
- Cylinder Head (B6284T; 1999)
- Cylinder Head/Gasket, Replacing
- Notes
- Removing The Cylinder Head Gasket
- Notes
- Preparation
- Draining Coolant
- Separating The Exhaust System
- Removing Components
- Draining The Fuel Line
- Removing The Fuel Rail
- Removing Components From Turbo 1
- Removing Components From Turbo 2
- Releasing The Coolant Pump Inlet Pipe
- Setting Up The Engine
- Compressing The Tensioner / Damping Unit
- Removing The Timing Gear Pulley
- Removal Of Thermostat Housing
- Removing The Camshaft Cover/Cylinder Head
- When Replacing/Machining The Cylinder Head
- Cleaning
- Installing The Cylinder Head Gasket
- Notes
- Tightening
- Aligning The Crankshaft
- Installing The Cylinder Head
- Installing Valve Lifters And Camshafts
- Applying Liquid Gasket
- Installing The Camshaft Covers
- Installing The Rear Camshaft Seal
- Securing The Camshafts
- Installing The Front Camshaft Seal
- Installing Thermostat Housing
- Checking The Variable Valve Timing (VVT) Unit
- Installing Components
- Installing The Fuel Rail
- Installing The Coolant Pump Intake Pipe
- Installing The Manifold And Turbo 2
- Installing The Manifold And Turbo 1
- Installing Components At Turbo 1
- Installing Components At Turbo 2
- Exhaust System Assembly
- Checking And Filling Media
- Cylinder Head/Gasket, Replacing
- Cylinder Head (B6284T; 2000-2001)
- Cylinder Head/Gasket, Replacement
- Notes
- Removing The Cylinder Head Gasket
- Notes
- Preparation
- Draining Coolant
- Separating The Exhaust System
- Removing Components
- Draining The Fuel Line
- Removing The Fuel Rail
- Removing Components From Turbo 1
- Removing Components From Turbo 2
- Releasing The Coolant Pump Inlet Pipe
- Setting Up The Engine
- Removing The Timing Belt
- Removing The Timing Gear Pulley
- Removing The Thermostat Housing
- Removing The Camshaft Cover/Cylinder Head
- When Replacing/Machining The Cylinder Head
- Cleaning
- Installing the cylinder head gasket
- Notes
- Tightening
- Aligning The Crankshaft
- Installing The Cylinder Head
- Installing Valve Lifters And Camshafts
- Applying Liquid Gasket
- Installing The Camshaft Covers
- Installing The Rear Camshaft Seal
- Securing The Camshafts
- Installing The Front Camshaft Seal
- Installing The Thermostat Housing
- Checking The Variable Valve Timing (VVT) Unit
- Installing Components
- Installing The Fuel Rail
- Installing The Coolant Pump Intake Pipe
- Installing The Manifold/Turbo 2
- Installing The Manifold/Turbo 1
- Installing Components To Turbo 1
- Installing Components To Turbo 2
- Exhaust System Assembly
- Checking And Filling Media
- Cylinder Head/Gasket, Replacement
- Cylinder Head (B6294S; 2000-2001)
- Cylinder Head/Gasket, Replacing
- Notes
- Removing The Cylinder Head Gasket
- Notes
- Preparation
- Draining Coolant
- Separating The Exhaust System
- Removing Components
- Draining The Fuel Line
- Removing The Fuel Rail
- Removing The Manifold
- Releasing The Inlet Pipe For The Coolant Pump
- Setting Up The Engine
- Removing The Timing Belt
- Removing The Timing Gear Pulley
- Removing The Thermostat Housing
- Removing The Camshaft Cover And Cylinder Head
- When Replacing Or Working On The Cylinder Head
- Cleaning
- Installing The Cylinder Head Gasket
- Notes
- Tightening
- Aligning The Crankshaft
- Installing The Cylinder Head
- Installing Valve Lifters And Camshafts
- Applying Liquid Gasket
- Installing The Camshaft Covers
- Installing The Rear Camshaft Seal
- Securing The Camshafts
- Installing The Front Camshaft Seal
- Installing The Thermostat Housing
- Checking The Variable Valve Timing (VVT) Unit
- Installing The Intake Pipe For The Coolant Pump
- Installing The Manifold
- Installing Components
- Assembling The Exhaust System
- Checking And Filling Media
- Variable Valve Timing Unit, Checking And Adjusting
- Cylinder Head/Gasket, Replacing
- Cylinder Head (B6294S2; 2002-2006)
- Cylinder Head/Gasket, Replacing
- Notes
- Removing The Cylinder Head/Gasket
- Notes
- Preparation
- Draining Coolant
- Separating The Exhaust System
- Removing Components
- Removing The Manifold
- Releasing The Coolant Pump Inlet Pipe
- Setting Up The Engine
- Removing The Timing Belt
- Removing The Timing Gear Pulley
- Removing The Thermostat Housing
- Removing The Camshaft Cover/Cylinder Head
- When Replacing/Machining The Cylinder Head
- Cleaning
- Installing The Cylinder Head Gasket
- Notes
- Aligning The Crankshaft
- Installing The Cylinder Head
- Installing Valve Lifters And Camshafts
- Applying Liquid Gasket
- Installing The Camshaft Covers
- Installing The Rear Camshaft Seal
- Checking The Variable Valve Timing (VVT) Unit
- Installing The Coolant Pump Intake Pipe
- Installing The Manifold
- Installing Components
- Installing The Exhaust System
- Checking And Filling Media
- Cylinder Head/Gasket, Replacing
- Cylinder Head (B6294T; 2002-2006)
- Cylinder Head/Gasket, Replacement
- Notes
- Removing The Cylinder Head / Gasket
- Notes
- Preparation
- Draining Coolant
- Removing Components
- Removing Three-Way Catalytic Converters (TWC) / Front Exhaust Pipe
- Removing The Turbocharger (TC)
- Draining The Fuel Line
- Removing The Fuel Rail
- Releasing The Inlet Pipe For The Coolant Pump
- Setting Up The Engine
- Removing The Timing Belt
- Removing The Variable Valve Timing Unit / Timing Gear Pulley
- Removing The Thermostat Housing
- Removing The Camshaft Cover And Cylinder Head
- When Replacing Or Working On The Cylinder Head
- Cleaning
- Installing The Cylinder Head / Gasket
- Notes
- Aligning The Crankshaft
- Installing The Cylinder Head
- Installing Valve Lifters And Camshafts
- Applying Liquid Gasket
- Installing The Camshaft Covers
- Installing The Rear Camshaft Seal
- Securing The Camshafts
- Installing The Front Camshaft Seal
- Installing The Thermostat Housing
- Checking The Tensioner Pulley And Idler Pulley
- Checking The Variable Valve Timing (VVT) Unit
- Installing Components
- Installing The Fuel Rail
- Installing The Intake Pipe For The Coolant Pump
- Installing The Turbocharger (TC)
- Finishing
- Installing Three-Way Catalytic Converters (TWC) / Front Exhaust Pipe
- Installing The Drive Shaft
- Checking And Filling Media
- Cylinder Head/Gasket, Replacement
- Cylinder Head (B6304S3; 1999)
- Cylinder Head/Gasket, Replacing
- Notes
- Removing The Cylinder Head Gasket
- Notes
- Preparation
- Draining Coolant
- Separating The Exhaust System
- Removing Components
- Draining The Fuel Line
- Removing The Fuel Rail
- Removing The Manifold
- Releasing The Coolant Pump Inlet Pipe
- Setting Up The Engine
- Compressing The Tensioner / Damping Unit
- Removing The Timing Gear Pulley
- Removal Of Thermostat Housing
- Removing The Camshaft Cover/Cylinder Head
- When Replacing/Machining The Cylinder Head
- Cleaning
- Installing The Cylinder Head Gasket
- Notes
- Tightening
- Aligning The Crankshaft
- Installing The Cylinder Head
- Installing Valve Lifters And Camshafts
- Applying Liquid Gasket
- Installing The Camshaft Covers
- Installing The Rear Camshaft Seal
- Securing The Camshafts
- Installing The Front Camshaft Seal
- Installing Thermostat Housing
- Checking The Variable Valve Timing (VVT) Unit
- Installing The Coolant Pump Intake Pipe
- Installing The Manifold
- Installing Components
- Assembling The Exhaust System
- Checking And Filling Media
- Cylinder Head/Gasket, Replacing
- Drive Train (B6284T; 2000-2001)
- Drive Train (B6284T; 1999)
- Drive Train (B6294S2; 2002-2006)
- Engine Mounting (1999-2006)
- Bushing Sub-Frame, Replacing
- Overview
- Notes
- Important Information
- Preparation
- Removing The Charge Air Pipe And Hose (6-Cylinder Turbocharged Engines Only)
- Removing The Spark Plug Cover (6-Cylinder Engines Only)
- Installing The Lifting Eyelet (6-Cylinder Engines Only)
- Removing Components
- Removing The Front Engine Pad Lower Screw
- Removing The Nuts For The Lower Torque Rod
- Folding Out The Fender Liner
- Removing The Screws For The Right-Hand Engine Mounting
- Removing The Vibration Damper (6-Cylinder Engines Only)
- Removing The Screws For The Right-Hand Engine Mounting (6-Cylinder Engines)
- Removing The Nuts And Screw For The Steering Gear
- Removing The Delivery Line For The Steering Gear
- Lowering The Sub-Frame
- Pressing Out The Bushings
- Marking For The Bushing On The Sub-Frame
- Marking The Left-Hand Rear Bushing
- Pressing In The Bushings
- Installing The Wiring For The Heated Oxygen Sensor (HO2S)
- Lifting The Sub-Frame
- Installing The Nuts And Screw For The Steering Gear
- Installing The Delivery Line From The Steering Gear
- Installing The Screws For The Engine Mounting To The Engine
- Installing The Vibration Damper (6-Cylinder Engines Only)
- Installing The Protective Plate
- Installing The Screw For The Front Engine Pad
- Tightening The Nuts For The Lower Torque Rod
- Installing The Air Intake Cover
- Installing The Protective Cover
- Removing The Lifting Tools
- Removing The Lifting Lug And The Lifting Hook From The Engine And The Car (6- Cylinder Engines Only)
- Installing All Charge Air Pipes (Only 6-Cylinder Turbo Engines)
- Bushing Sub-Frame, Replacing
- Engine Mounting (B6284T; 1999-2001)
- Engine Mounting (B6294S; 2000-2001)
- Engine Mounting (B6294S2; B6294T; 2002-2006)
- Engine Mounting (B6304S3; 1999)
- Variable Valve Timing & Timing Belt (B6294S; 2000-2001)
- Variable Valve Timing & Timing Belt (B6304S3; 1999)
- Transmission (B5254T2; 2004-2006)
- Engine/Transmission, Installing
- Notes
- Installing The Engine And Transmission Unit
- Installing The Propeller Shaft (All-Wheel Drive (AWD) Only)
- Installing The Three-Way Catalytic Converter (TWC) (All-Wheel Drive (AWD) Only)
- Installing The Front Exhaust Pipe
- Connecting Fuel Lines
- Assembling The Spring Strut
- Cars With Engine Block Heaters (Option)
- Installing The Air Conditioning (A/C) Compressor
- Installing Components
- Installing The Transmission Cable
- Installing The Engine Coolant Fan (FC)
- Finishing
- Final Check
- Transmission, Installation
- Notes
- Cleaning And Lubricating The Input Shaft
- Checking Before Installing
- Adjusting The Position Of The Transmission And Engine
- Installing And Tightening Screws For The Transmission
- Lifting The Engine And Transmission To The Horizontal Position
- Installing The Rear Engine Mounting
- Installing The Bevel Gear
- Installing The Front Propeller Shaft (Applies to AWD)
- Fitting The Sub-Frame To The Body
- Installing The Sealing Ring For The CV Joint Housing
- Installing The Left Hand Drive Shaft To The Transmission, Wheel Spindle And Link Arm
- Installing New Lock Nuts And Screws On The Steering Gear
- Installing The Screw In The Rear Engine Pad
- Installing Screws For The Bracket For The Heated Oxygen Sensor (HO2S) Wiring
- Installing The Crossmembers
- Installing The Right-Hand Drive Shaft To The Gearbox, Wheel Spindle And Link Arm
- Installing The Screw For The Front Engine Pad And The Torque Rod Mounting In The Transmission
- Installing And Tightening Front Suspension Components
- Tightening The Ball Joint Pinion
- Installing The Nuts On The Fender Liner
- Checking The Oil Level In The Transmission
- Checking the oil level
- Installing The Screws For The Transmission And Engine
- Installing The Pipe Junction
- Installing The Bracket And Lever For The Transmission
- Installing The Water Hose
- Installing The Upper Torque Rod
- Finishing
- Engine/Transmission, Removing
- Notes
- Preparation
- Removing The Engine Cooling Fan (FC)
- Removing The Transmission Cable
- Draining The Fuel Line
- Removing Components
- Draining Coolant
- Cars With Engine Block Heaters (Option)
- Preparations For Removal Of The Drive Shafts
- Separating The Fuel Line
- Separating The Front Exhaust Pipe
- Removing The Air Conditioning Aggregate
- Exposing The Air Conditioning (A/C) Compressor
- Separating The Steering Shaft
- Removing The Three-Way Catalytic Converter (TWC) (All-Wheel Drive (AWD) Only)
- Removing The Propeller Shaft From The Transmission And Drive Distribution Box (All-Wheel Drive (AWD) Only)
- Lowering The Engine And Transmission
- Engine/Transmission, Installing
- Transmission (B6284T; 1999-2001)
- Transmission (B6294S; 2000-2001)
- Transmission (B6294S2; B6294T; 2002-2005)
- Transmission (B6304S3; 1999)
- Oil Sump (B5254T2; 2004-2006)
- Oil Sump (B6284T, 4T65EV-Gt; 1999-2001)
- Replacing The Oil Pan
- Oil Sump (B6294S, 4T65EV; B6294S, 4T65EV-Gt; 2000-2001)
- Oil Sump (B6294S2; B6294T; 2002-2006)
- Oil Sump (B6304S3, 4T65EV; 1999)
- Timing Gear (B5254T2; 2004)
- Timing Gear (B5254T2; 2005-2006)
- Timing Gear (B6294T; 2002-2006)