Home/Volvo/S60/Volvo S60 I (2000-2004)/Repair manual/Engine - Removal, Replacement and Installation/Removing the lifting tools

Contents

Wiring diagrams Section: Engine - Removal, Replacement and Installation

Crankshaft seal rear, replacing

Installing the sealing ring

Gearbox, installing

Checking the engine

Crankshaft seal, front, replacing

Replacing the carrier plate

Preparatory work

Removing the carrier plate

Finishing

Removing the flywheel and carrier plate

Removing the seal

Installing flywheel and carrier plate

Flywheel

Removing the flywheel

Checking the crankshaft seal

Installing the flywheel

Install the gearbox

Flywheel, replacing

Removing transmission and clutch

Replacing flywheel

Preparations

Carrier plate, replacing

Installing the carrier plate

Removing the transmission

Transmission, installing

Transmission, removing

Checking crankshaft seal

Depressurizing the fuel system

Removing the timing belt

Removing the timing gear pulley

When replacing or working on the cylinder head

Installing the camshaft cover

Checking and adjusting the variable valve timing unit

Installing components

Check

Cylinder head/gasket, replacing

Preparation

Removing components

Removing the intake manifold

Setting up the engine

Removing components from turbocharger (TC)

Releasing the inlet pipe for the coolant pump

Removing the camshaft cover and cylinder head

Cleaning

Installing the cylinder head

Installing tappets and camshafts

Applying liquid gasket

Installing the manifold and turbocharger (TC)

Installing the rear camshaft seal

Installing the front camshaft seals

Installing the intake manifold

Installing the fuel rail

Cleaning the gasket faces

Installing valve lifters and camshafts

Installing the intake pipe for the coolant pump

Installing the intake manifold and gasket

Installing the fuel and air distribution pipe

Aligning the crankshaft

Installing the camshaft covers

Installing the front camshaft seal

Checking and adjusting

Installing the exhaust manifold

Removing ignition coils

Removing intake manifold

Releasing the coolant pump inlet pipe

When replacing/machining the cylinder head

Checking crankshaft setting

Installing VVT-unit/timing gear pulley on exhaust camshaft

Installing intake manifold

Replacing the front sub-frame

Installing the sub-frame

Bushing sub-frame, replacing

Folding out the fender liner

Removing the nuts and screw for the steering gear

Removing the delivery line for the steering gear

Installing the bracket for the heated oxygen sensor (HO2S)

Marking the left-hand rear bushing

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 protective plate

Installing the screw for the front engine pad

Installing the air intake cover

Installing the protective cover

Removing the lifting tools

Removing the rear engine pad

Installing the rear engine pad

Engine mount, right, replacing

Engine mount rear, replacing

Engine mount, front, replacing

Engine/transmission, installing

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

Installing the transmission cable

Final check

Engine/transmission, removing

Removing the transmission cable

Cars with engine block heaters (option)

Separating the fuel line

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)

Tool list

Reinstalling the engine and transmission

Engine/transmission, removing/installing

Installing the engine and transmission unit

Connecting fuel lines

Installing the propeller shaft

Installing the three-way catalytic converter (TWC)

Installing the air conditioning (A/C) compressor

Installing the connector

Removing components around expansion tank

Removing the three-way catalytic converter (TWC)

Removing the propeller shaft

Lowering the engine and transmission

Removing the engine coolant heater (option)

Engine block, installing components

Installing the components for the engine pad

Installing the flywheel and carrier plate

Engine body, exposing

Oil pan, replacing

Removing the oil pan

Removing the oil sump

Installing the oil pan

Auxiliaries belt / belt tensioner, replacing

Installing the auxiliaries belt

Camshaft seal/variable valve timing (VVT) unit, replacing

Aligning the engine according to the marking

Removing the camshaft components

Replacing the rear seal

Timing belt, replacing

Position the engine according to the marking

Installing the timing belt

Tighten the timing belt

For engine serial no. up to 3188688

For engine serial no. from 3188689

Reinstall

Checking work

Applies to B5244Sx model years 1999-2001

Applies to all: Installing VVT-control valve

Disconnecting the battery lead

Removing the timing gear pulley with the variable valve timing unit

Installing the battery lead

Replacing the rear camshaft seal

Variable valve timing solenoid, replacing

Replacing the belt tensioner

Removing the front camshaft seal

Removing the variable valve timing (VVT) control valve

Install the connector pins

Install the catch and casing

Clamping the excess cable with cable ties

Removing the camshaft seal

Replacing the camshaft seal

Rear camshaft seal

Removing the camshaft belt

Checking the tension pulley and idler pulley

Installing the camshaft belt

Installing the variable valve timing (VVT) unit on the exhaust camshaft

Installing the variable valve timing (VVT) unit on the intake camshaft

Adjusting the timing belt

Removing the rear camshaft seal

All sections

Removing the lifting tools Volvo S60 I

Engine - Removal, Replacement and Installation

Removing the lifting tools

Lower the car.

Remove the lifting tools.

Install the wheels. See Installing wheels .