Replacing The Front Sub-Frame Volvo S80 I

Replacing The Front Sub-Frame

Special tools

See 9995716

See 9995460

See 9995045

See 9512050

(6 cylinder engines only) Installing the lifting tools. See Lifting Tools Removing/Installing For 6 Cylinder Cars .

1. Install lifting beam «9995716»(ref-403953-S41765249862011061000000) . Install lifting hooks «9995460»(ref-403953-S32932431362011061000000)
2. Lift the engine to relieve the load on the engine pads.

Remove

1. the front wheels
2. the splash guard under the engine.

Scheme 260

1. the air duct cover.

1. the cable duct screw.

Remove

1. the oil pipes from the steering gear from the snap fasteners on the sub-frame
2. the hose for the EVAP canister
3. the fuel line for the engine block heater and the engine block heater (if applicable) on the left side of the sub-frame.

Scheme 261

1. the hose for the EVAP canister in the joint by pulling apart the hose. Route the hose under the anti-roll bar.

Scheme 262

Remove

1. the mounting for the exhaust pipe on the bracket
2. the screws holding the exhaust pipe bracket. Disconnect the brake pipe from the snap fasteners on the bracket
3. the bracket.

Scheme 263

1. Remove the cable harness from the rear edge of the sub-frame. Disconnect the connectors. (Applies only to cars with 6-cylinder engines)
2. Remove the heated oxygen sensor (HO2S) bracket from the mounting.

Scheme 264

1. Remove the anti-roll bar links from the anti-roll bar. Counterhold with a Torx wrench so that the ball joint boot is not damaged.

1. Remove both the nuts retaining the lower torque rod
2. Remove the screw and bend up the bushing with the holder towards the torque rod.

1. Remove the front engine pad screw.

1. Slacken off the right lower front part of the fender liner.
2. Remove the plastic nuts on the fender liner
3. Remove the splash guard
4. Bend out the fender liner.

Remove the four vibration damper screws. Counterhold the crankshaft central nut.

Remove

1. the vibration damper (applies to 6-cylinder cars).

Scheme 265

1. Remove both the right hand engine mounting screws.

1. Remove the four nuts and the screw holding the steering gear to the sub-frame
2. Remove the delivery line from the clips on the sub-frame

Scheme 266

1. Remove the nuts from the ball joints. Counterhold with a Torx wrench so that the ball joint boot is not damaged.

Scheme 267

1. Position a lifting table under the sub-frame
2. Remove the screws holding the sub-frame brackets to the bodywork on both sides
3. Remove the four screws from the sub-frame
4. Carefully lower the sub-frame. NOTE: Ensure that the steering gear screws are released from the sub-frame.

Scheme 268

Hang the steering gear from a hook 9995045 so that the lower steering shaft does not come apart.

Scheme 269

Transfer

1. the control arms. Use new screws and new nut. Tighten the front screws. Tighten to 65 Nm . Angle-tighten 90° . Use bevel protractor «9512050»(ref-403953-S36645634772011061000000) . Tighten the rear screw. Tighten to 105 Nm . Angle-tighten 90°
2. the anti-roll bar. Tighten to 60 Nm
3. the right-hand engine mounting. Tighten the screws. Tighten to 65 Nm . Angle-tighten 60°
4. the mounting for the heated oxygen sensor (HO2S) wiring
5. the engine pad.

Install new pipe / hose holders.