Home ReviewsRefund
Home/Volvo/S60/Volvo S60 I (2000-2004)/Repair manual/Engine - Removal, Replacement and Installation/Tool list
Contents Wiring diagrams Section: Engine - Removal, Replacement and Installation All sections

Tool list Volvo S60 I

Engine - Removal, Replacement and Installation 10 illustrations ~1034 words

Tool list

Special tools

9995562

9995462

9995488

9995474

9995722

9992810

9995185

9995464

9995428

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Remove

  1. the battery negative cable. First read «Battery, disconnecting»(ref-415278-S03862267492011081500000)
  2. the expansion tank cap
  3. the air pre-heating hose
  4. the cross stay between the suspension turrets
  5. the engine positive lead from the terminal at the left suspension turret.

Drain the fuel system. See Fuel system pressure release .

Drain the fuel system, applies only to B5xx4S6 . See Fuel system pressure release .

Separate the fuel line and EVAP line quick-release connector at the right rear subframe mounting. See also Fuel system, quick-release connectors .

Only applies to B5244SG and B5244SG2

Drain the gas line acc. to Draining the gas pipe .

Drain the fuel system acc. to Draining the fuel system

Note. Protect the openings against dirt. Place the lines to one side. Make sure that all cleanliness conditions for working with the fuel injection system are followed.

Scheme 200

Scheme 200
Scheme 200

Remove the splash guard under the engine.

Position a container at the drain nipples to collect the coolant.

Open the nipples on the engine and the radiator.

Thread hoses onto the relevant nipple to collect the coolant.

Close the nipples.

Remove

  1. the right-hand drive shaft. See «Drive shaft left, replacing»(ref-445723-S24390762452012010600000)
  2. the left-hand drive shaft. See «Drive shaft left, replacing»(ref-445723-S24390762452012010600000)
  3. the screw for the lower torque rod in the transmission.

Note. Install sealing plugs 9995488 in the holes where the drive shafts were positioned.

  1. the lower screws of the front and rear engine mountings.

Scheme 201

Scheme 201
Scheme 201

Separate the heated oxygen sensor (HO2S) connectors.

Remove the clamp for the mounting for the heated oxygen sensor wiring at the steering gear.

Release the heated oxygen sensor (HO2S) wiring from the rear engine mounting.

Remove the nuts where the manifold and the front exhaust pipe divide.

Scheme 202

Scheme 202
Scheme 202

Remove the screws holding the SIPS member to the bodywork.

Press the brake pipe out of the holders on the SIPS member.

Press the exhaust system backwards. Remove the exhaust system from the manifold.

Ensure that you do not damage the heated oxygen sensor (HO2S) or the wiring.

Note. The metal hose for the front exhaust pipe is damaged very easily. Therefore it should be handled with great care to avoid leakage later on.

Scheme 203

Scheme 203
Scheme 203
  1. the connector from the mass air flow (MAF) unit
  2. the connector from the air assisted control valve
  3. the intake hose between the air cleaner housing and the front panel.
  4. the intake hose from the air cleaner (ACL)
  5. the vacuum hose for control of preheated air
  6. the air cleaner assembly.
  7. the braided ground cable between the engine and the cowl panel.
  8. the heater hoses from the cowl panel
  9. the brake vacuum hose from the intake manifold. Place it to one side.

Scheme 204

Scheme 204
Scheme 204

Disconnect the connectors from the fan shroud.

Remove the canister purge (CP) valve.

Remove the manifold absolute pressure (MAP) sensor from the mounting at the front panel.

Disconnect the vacuum hose for the EVAP canister from the canister purge (CP) valve.

Place the wiring to one side.

Lift the hose for the expansion tank from the holders at the top edge of the fan shroud

Remove the screws for the fan shroud.

Lift up the engine cooling fan (FC) with the fan shroud.

Install radiator protection 9995474 .

Applies to cars with manual transmissions

Scheme 205

Scheme 205
Scheme 205

Remove

  1. the lower radiator hose
  2. the ground lead on the transmission
  3. the mechanical transmission cables. Mark up the cables
  4. the rubber mounted section of the mounting for the mechanical gear selector cable. Plug the hose between the brake fluid reservoir and the clutch master cylinder using hose pliers. Disconnect the clutch cable. Separate the terminal block at the bracket for the air filter
  5. the air filter bracket.

Applies to cars with automatic transmissions

Scheme 206

Scheme 206
Scheme 206

Remove

  1. the lower radiator hose
  2. the two oil cooling hoses for the transmission from the radiator
  3. the ground lead on the transmission
  4. the mechanical gear selector cable. Separate the terminal block at the bracket for the air filter
  5. the air filter bracket.

Scheme 207

Scheme 207
Scheme 207

Remove

  1. the upper radiator hose from the thermostat housing
  2. the expansion tank
  3. the auxiliaries belt
  4. the three screws retaining the power steering pump.

Disconnect the temperature sensor cable from the bracket on the power steering pump.

Note. Leave the power steering pump in place for the moment.

Scheme 208

Scheme 208
Scheme 208

Unplug the connector of the AC compressor's electromagnetic clutch.

Remove the four screws retaining the air conditioning (A/C) compressor in the engine.

Start with the lowest screws.

Note. Be careful so that the pipe does not break or crack when the upper screws are loosened.

Remove the compressor and hang it up on the front cover plate.

Note. Do not touch the pins on the control module with fingers. Static electricity may damage components in the control module.

Remove the cover from the control module box.

Insert tool 9995722 around the control module.

Insert the upper section of the tool as far as it will go. Raise the tool.

Carefully pull up the control module.

Remove the intermediate section of the control module box.

Pry out the connector plate from the lower section of the control module box.

Disconnect the engine and transmission wiring connectors.

Place the engine and transmission wiring on top of the engine.

Scheme 209

Scheme 209: Lifting out the engine and transmission
Scheme 209: Lifting out the engine and transmission

Lift up the power steering pump and put it to one side.

Use lifting yoke 9992810 .

Fit hook 9995185 between the engine's lifting lugs at the auxiliaries bracket and the upper torque rod bracket.

Fit lifting lug 9995464 in the exhaust manifold.

Fit mounting bracket 9995428 to the hooks and lifting lug.

Lift out the engine.

Remove the front engine pad when lifting.

Adjust the lift angle throughout the lift.

A relatively large angle is required.

Note. Check carefully that the drivetrain goes clear of the bodywork and any optional equipment. Also make sure that no engine or transmission wiring catches during the lift.

Note. For tightening torques, see: Tightening torque .

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