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Contents

Wiring diagrams Section: Engine - Removal, Replacement and Installation

Crankshaft Seal Rear, Replacing

Installing The Sealing Ring

Installing The Gearbox

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

Installing The Carrier Plate

Replacing Front Crankshaft Seal

Oil Pump / Crankshaft Seal, Front, Replacing

Preparation

Final Check

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

Removing The Cylinder Head Gasket

Releasing The Coolant Pump Inlet Pipe

Setting Up The Engine

When Replacing/Machining The Cylinder Head

Installing The Cylinder Head Gasket

Installing Valve Lifters And Camshafts

Installing The Camshaft Covers

Securing The Camshafts

Installing Thermostat Housing

Checking The Variable Valve Timing (VVT) Unit

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

Checking And Filling Media

Separating The Exhaust System

Removing Components

Removing The Fuel Rail

Removing Components From Turbo 1

Removing Components From Turbo 2

Removing The Thermostat Housing

Removing The Camshaft Cover/Cylinder Head

Cleaning the gasket faces

Aligning The Crankshaft

Installing The Cylinder Head

Applying Liquid Gasket

Installing The Rear Camshaft Seal

Installing The Front Camshaft Seal

Installing The Thermostat Housing

Installing The Manifold/Turbo 2

Installing The Manifold/Turbo 1

Installing Components To Turbo 1

Installing Components To Turbo 2

Releasing The Inlet Pipe For The Coolant Pump

Removing The Camshaft Cover And Cylinder Head

Installing The Intake Pipe For The Coolant Pump

Installing The Manifold

Variable Valve Timing Unit, Checking And Adjusting

Installing

Tighten The Timing Belt

Removing The Cylinder Head/Gasket

Installing The Exhaust System

Removing The Cylinder Head / Gasket

Removing The Variable Valve Timing Unit / Timing Gear Pulley

Installing The Cylinder Head / Gasket

Checking The Tensioner Pulley And Idler Pulley

Installing The Turbocharger (TC)

Installing Three-Way Catalytic Converters (TWC) / Front Exhaust Pipe

Installing The Drive Shaft

Removing The Manifold

Compressing The Tensioner / Damping Unit

Auxiliaries Belt / Belt Tensioner, Replacing

Removing The Front Camshaft Seal

Replacing The Rear Camshaft Seal

Cleaning

Replacing The Timing Belt

Installing The Variable Valve Timing (VVT) Control Valve

Camshaft Seal/Variable Valve Timing (VVT) Unit, Replacing

Removing The Rear Camshaft Seal

Removing The Front Camshaft Seal / Variable Valve Timing Unit

Checking The Tensioner And Idler Pulleys

Variable Valve Timing Solenoid, Replacing

Installing The Starter Motor

Replacing The Variable Valve Timing Solenoid

Preparations

Installing The Variable Valve Timing Solenoid

Bushing Sub-Frame, Replacing

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 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)

Replacing Front Engine Pad

Replacing Rear Engine Pad

Replacing Right Engine Pad

Removing Right Engine Pad

Replacing The Front Sub-Frame

Installing The Sub-Frame

Installing Lifting Tools

Removing Lifting Tools

Camshaft Seal / Variable Valve Timing (VVT) Unit, 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

Lifting The Engine And Transmission To The Horizontal Position

Fitting The Sub-Frame To The Body

Installing The Sealing Ring For The CV Joint Housing

Checking The Oil Level In The Transmission

Installing The Water Hose

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)

Lowering The Engine/Transmission Unit

Installing The Engine And Transmission Unit

Installing The Three-Way Catalytic Converter (TWC) And Front Exhaust Pipe

Removing The Oil Sump

Replacing The Oil Pan

Installing The Lifting Fixture

Installing The Lifting Beam And Lifting Hook On The Engine Lifting Eyelet

Removing Components From The Sub-Frame

Lowering Sub-Frame

Disconnecting The Oil Cooler

Removing The Oil Pan

Installing Components On The Sub-Frame

Removing Retaining Straps

Removing The Lifting Beam And The Lifting Hook

Installing The Auxiliaries Belt

Checking work

Aligning The Engine According To The Marking

Replacing The Rear Seal

Timing Belt, Replacing

Position The Engine According To The Marking

Installing The Timing Belt

For Engine Serial No. From 3188689

Reinstall

Removing The Variable Valve Timing (VVT) Control Valve

Applies to B5244Sx model years 1999-2001

Applies To All: Installing VVT-Control Valve

Replacing The Belt Tensioner

All sections

Check Volvo S80 I

Engine - Removal, Replacement and Installation

Check

Replace the oil and oil filter if necessary.

Check

the engine oil level
the servo oil level
the coolant level.

Warm up the engine until the thermostat opens.

Check the engine for leaks.

Top up the coolant if necessary.