Engine - Removal, Replacement and Installation: Specifications Volvo S80 I

Tightening

For tightening torques not in the text see Tightening torque.

Scheme 74

Remove

1. the mounting screws for the starter motor. Pull out the starter motor and place to one side.
2. the blind cover plug.

Turn the crankshaft clockwise slightly.

Install the crankshaft stop 9995451. Ensure that it bottoms out against the engine block.

Turn the crankshaft counterclockwise until it stops against the crankshaft stop.

Check that the marking on the crankshaft timing belt pulley aligns with the marking on the oil pump.

Scheme 75

Install a new cylinder head gasket.

Install the cylinder head. Use new screws.

Lubricate and install all the screws.

Tighten the screws in the order illustrated.

Tighten the screws in the following order.

1. 20 Nm .

2. 60 Nm .

3. Angle tighten 130°. Use a bevel protractor 9512050.

For tightening torques not in the text see Tightening torque.

For tightening torques not in the text see Tightening torque.

For tightening torques not in the text see Tightening torque.

Tightening The Nuts For The Lower Torque Rod

Tighten the two nuts for the lower torque rod. Tighten to 80 Nm .

Removing Cross Stay/Upper Torque Rod

Remove

1. the torque rod mounting screw in the bracket on the engine.
2. screws at suspension turrets.
3. cross member.

Scheme 76

Transfer

1. the brackets on the left and right-hand sides. Do not tighten yet .
2. the torque rod. Do not tighten yet .

Installing Cross Stay/Upper Torque Rod

Install

1. cross member.
2. screws at suspension turrets. Tighten to 50 Nm (36.9 lb. ft) .
3. torque rod mounting screw in the bracket on the engine.

Tighten the torque rod to 80 Nm (59.0 lb. ft) .

Tighten the screws between the cross stay and brackets at the suspension turrets to 80 Nm (59.0 lb. ft) .

Removing The Torque Bracket

Note. As 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.

Scheme 77

Remove

1. the engine stabilizer brace
2. the charge air pipe (only turbocharged (TC) engines)
3. the screw for the dip stick pipe (6 cylinder automatics only)
4. the oil filler cap
5. the cover over the ignition coils
6. the torque bracket.

Scheme 78

Install

1. the torque bracket. Tighten the screws (A). Tighten to 50 Nm
2. the screw for the dip stick pipe (6 cylinder automatics only)
3. the cover over the ignition coils
4. the oil filler cap
5. the charge air pipe (only turbocharged (TC) engines)
6. the engine stabilizer brace.

Tighten the screws on the suspension turrets. Tighten to 50 Nm . Tighten the screw in the torque bracket (B). Tighten to 80 Nm .

Removing The Lower Torque Rod

Raise the car.

Remove

1. the splash guard under the engine
2. the torque control arm
3. engine bracket
4. sub-frame bracket.

Scheme 79

Install

1. new engine bracket. Tighten to 50 Nm
2. new sub-frame bracket. Tighten to 65 Nm . Angle-tighten 60°
3. torque rod. Tighten to 80 Nm
4. the splash guard under the engine.

Replacing Cross Stay/Upper Torque Rod

See Replacing cross stay/upper torque rod

Replacing The Engine Torque Bracket

See Replacing the engine torque bracket

Torque Rod, Lower, Replacing

See torque Rod, Lower, Replacing

See Replacing cross stay/upper torque rod

See Replacing the engine torque bracket

See Torque rod, lower, replacing

See Replacing cross stay/upper torque rod

See Replacing the engine torque bracket

See Torque rod, lower, replacing

Installing The Upper Torque Rod

Install

1. the torque rod. See «Install the upper torque rod»(/volvo/s80/i-1998-2003/remont/mechanical/#upper-engine-stabilizer-brace-removal-and-installation__upper-engine-stabilizer-brace-installing) . NOTE: Use a new lock nut for the cross member mounting on the engine.
2. the air cleaner (ACL) housing with all hoses and electrical terminals.

See also:
• Installing the gearbox
• Summary of tightening torques for specific components
• Summary of tightening torques for specific components
• Summary of tightening torques for specific components
• Fuel line, lock
• Flanged joint, assembling
• Installing wheels
• Removing the front timing cover
• Installing the front timing cover
• Tightening torque
• Propeller shaft - removal, replacement and installation
• Central electrical unit, engine compartment, replacing
• Tightening torque
• Install the upper torque rod