Home/Volvo/XC90/Volvo XC90 I (2002-2006)/Repair manual/Engine - Removal, Replacement and Installation - 2 of 2/INSTALLING SPLASHGUARD UNDER ENGINE

Contents

Wiring diagrams Section: Engine - Removal, Replacement and Installation - 2 of 2

CARRIER PLATE, REPLACING

PREPARATORY WORK

REMOVING THE CARRIER PLATE

FINISHING

CRANKSHAFT SEAL REAR, REPLACING

INSTALLING THE SEALING RING

INSTALLING THE GEARBOX

CHECKING THE ENGINE

CRANKSHAFT SEAL, FRONT, REPLACING

INSTALLING THE CARRIER PLATE

REMOVING THE FLYWHEEL AND CARRIER PLATE

REMOVING THE SEAL

INSTALLING FLYWHEEL AND CARRIER PLATE

PREPARATION

FINAL CHECK

REMOVING THE TRANSMISSION AND CARRIER PLATE

REMOVING THE REAR SEALING RING

INSTALLING THE REAR SEALING RING

REMOVING THE AUXILIARIES BELT

REMOVING THE RIGHT FRONT WHEEL

INSTALLING THE RIGHT FRONT WHEEL

INSTALLING THE AUXILIARIES BELT

CHECK

DEPRESSURIZING THE FUEL SYSTEM

INSTALLING THE LOCK

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

CYLINDER HEAD/GASKET, REPLACING

PREPARATIONS

RELEASING THE INLET PIPE FOR THE COOLANT PUMP

INSTALLING THE CYLINDER HEAD GASKET

INSTALLING VALVE LIFTERS AND CAMSHAFTS

INSTALLING THE CAMSHAFTS

INSTALLING THE CAMSHAFT COVERS

SECURING THE CAMSHAFTS

INSTALLING THE THERMOSTAT HOUSING

CHECKING THE TENSIONER PULLEY AND IDLER PULLEY

ADJUSTING THE TIMING BELT

REMOVING TOOLS

CHECKING THE MARKINGS AND BELT TENSION

INSTALLING THE FUEL RAIL

INSTALLING THE INTAKE PIPE FOR THE COOLANT PUMP

CHECKING AND TOPPING UP

CYLINDER HEAD/GASKET, CYLINDER 1, 3, 5 AND 7 (BANK 1), REPLACING

EXPOSING THE CYLINDER HEAD, CYLINDERS 1, 3, 5 AND 7 (BANK 1)

REMOVING THE CYLINDER HEAD

CLEANING

INSTALLING THE VALVE LIFTERS

INSTALLING THE MANIFOLD

CYLINDER HEAD/GASKET, CYLINDER 2, 4, 6 AND 8 (BANK 2), REPLACING

REMOVING THE VARIABLE VALVE TIMING (VVT) UNIT

REMOVING COMPONENTS

REMOVING THE MANIFOLD

INSTALLING THE CYLINDER HEAD

INSTALLING VVT-UNITS

VALVE COVER/GASKET, REPLACING

REMOVING THE FRONT CAMSHAFT SEAL

REPLACING THE REAR CAMSHAFT SEAL

INSTALLING THE FRONT CAMSHAFT SEAL

REPLACING THE ACCESSORY DRIVE BELT / BELT TENSIONER

REPLACING THE VARIABLE VALVE TIMING SOLENOID

INSTALLING THE VARIABLE VALVE TIMING SOLENOID

TIMING BELT, REPLACING

INSTALLING THE TIMING BELT

TENSIONING THE TIMING BELT

BUSHING SUB-FRAME, REPLACING (2003-2008)

MARKING THE LEFT-HAND REAR BUSHING

PRESSING IN THE BUSHINGS

LIFTING THE SUB-FRAME

INSTALLING THE NUTS AND SCREW FOR THE STEERING GEAR

INSTALLING THE SCREWS FOR THE ENGINE MOUNTING TO THE ENGINE

INSTALLING THE SCREW FOR THE FRONT ENGINE PAD

INSTALLING THE PROTECTIVE COVER

REMOVING LIFTING TOOLS

ENGINE PAD FRONT, REPLACING

INSTALLING LIFTING TOOLS

INSTALLING THE BRACKET AND ENGINE PAD

INSTALLING THE SCREW ON THE CABLE CONDUCT

INSTALLING THE AIR INTAKE

ENGINE PAD REAR, REPLACING

REMOVING THE SPLASH GUARD UNDER ENGINE

REMOVING THE SKID PLATE

REMOVING THE ENGINE COVER

INSTALLING THE ENGINE PAD

INSTALLING THE SUB-FRAME

INSTALLING THE EXHAUST MOUNTING

INSTALLING THE SIPS MEMBER

INSTALLING THE SKID PLATE

INSTALLING THE RIGHT-HAND ENGINE MOUNTING

INSTALLING THE UPPER NUT FOR THE ENGINE PAD

STEERING SHAFT JOINT LOWER INSTALLING

ENGINE PAD RIGHT, REPLACING (2005-2007)

DETACHING THE FENDER LINER

INSTALLING THE FENDER LINER

SUB-FRAME FRONT, REPLACING (2003-2006)

REMOVING THE RIGHT ENGINE MOUNTING

INSTALLING REMOVED COMPONENTS

INSTALLING THE DRIVE SHAFT

INSTALLING THE CLAMP FOR THE SERVO PRESSURE HOSE

SUB-FRAME FRONT, REPLACING (2007)

REMOVING THE CLAMP FOR THE SERVO PRESSURE HOSE

EXPOSING THE SUB-FRAME

REMOVING THE DRIVE SHAFT

REMOVING THE SUB-FRAME

TRANSFERRING COMPONENTS

REMOVING THE AIR INTAKE

REMOVING THE CHARGE AIR PIPE

REMOVING THE LOWER ENGINE PAD SCREW

REMOVING THE SCREW FOR THE CABLE DUCT

REMOVING THE BRACKET AND ENGINE PAD

INSTALLING THE CHARGE AIR PIPE

STEERING SHAFT JOINT LOWER REMOVING

REMOVING THE UPPER NUT FOR THE ENGINE PAD

REMOVING THE SIPS MEMBER

REMOVING THE EXHAUST MOUNTING

REMOVING THE ENGINE PAD SCREW

LOWERING THE SUB-FRAME

SUB-FRAME FRONT, REPLACING

BUSHING SUB-FRAME, REPLACING (2009-2012)

REMOVING THE LOWER SCREW FROM THE FRONT ENGINE PAD

REMOVING THE SCREWS FOR THE RIGHT-HAND ENGINE MOUNTING

REMOVING THE NUTS AND SCREW FOR THE STEERING GEAR

REMOVING THE DELIVERY LINE FOR THE STEERING GEAR

PRESSING OUT THE BUSHINGS

MARKING FOR THE BUSHING ON THE SUB-FRAME

INSTALLING THE DELIVERY LINE FROM THE STEERING GEAR

ENGINE MOUNT REAR, REPLACING

INSTALLING THE EXHAUST PIPES BETWEEN FRONT AND REAR CATALYTIC CONVERTERS

INSTALLING THE PROTECTIVE COVER UNDER THE ENGINE

REMOVING THE LIFTING TOOL

INSTALLING THE ENGINE PAD, CONTINUED

ENGINE MOUNT, FRONT, REPLACING

REMOVING THE PROTECTIVE COVER UNDER THE ENGINE

REMOVING THE ENGINE PAD

INSTALLING THE LIFTING TOOL

INSTALLING SPLASHGUARD UNDER ENGINE

INSTALLING THE AIR CLEANER (ACL) INLET PIPE

INSTALLING THE WING LINER

SUB-FRAME FRONT, REPLACING (2005, 2006)

REMOVING THE WING LINER

REMOVING THE SCREWS FOR THE RIGHT-HAND ENGINE PAD

REMOVING THE PROTECTIVE PLATE

REMOVING THE EXHAUST PIPES BETWEEN FRONT AND REAR CATALYTIC CONVERTERS

REMOVING THE LOWER BOLT TO THE FRONT ENGINE PAD

REMOVING THE LINK ARM FROM THE WHEEL SPINDLE ON BOTH SIDES

REMOVING THE STEERING GEAR FROM THE SUBFRAME

REMOVING THE SUBFRAME

TRANSFERRING THE COMPONENTS

INSTALLING THE SUBFRAME

INSTALLING THE STEERING GEAR ON THE SUBFRAME

FITTING THE LOWER BOLT TO THE FRONT ENGINE PAD

INSTALLING THE LINK ARM ON BOTH SIDES

INSTALLING THE ANTI-ROLL BAR LINK ON BOTH SIDES

INSTALLING THE PROTECTIVE PLATE

FITTING THE BOLTS TO THE RIGHT-HAND ENGINE PAD

SUB-FRAME FRONT, REPLACING (2007, 2008)

REMOVING THE ANTI-ROLL BAR LINK FROM THE ANTI-ROLL BAR ON BOTH SIDES

REMOVING THE ENGINE BRACKET

ENGINE / GEARBOX, REMOVING

REMOVING THE LOWER STEERING SHAFT JOINT

REMOVING THE FRONT SPLASH GUARDS

REMOVING THE THREE-WAY CATALYTIC CONVERTER (TWC)

REMOVING THE PROPELLER SHAFT (ALL-WHEEL DRIVE (AWD) ONLY)

REMOVING THE ENGINE COOLANT HEATER (OPTION)

ENGINE/TRANSMISSION, INSTALLING

CONNECTING FUEL LINES

INSTALLING THE ENGINE COOLANT HEATER

INSTALLING THE PROPELLER SHAFT

INSTALLING THE THREE-WAY CATALYTIC CONVERTER (TWC)

INSTALLING STEERING SHAFT JOINT

INSTALLING THE AIR CONDITIONING (A/C) COMPRESSOR

INSTALLING THE CONNECTOR

INSTALLING COMPONENTS ON THE TRANSMISSION

ENGINE/TRANSAXLE, INSTALLING

INSTALLING THE ENGINE AND TRANSMISSION UNIT

INSTALLING TRACK RODS

INSTALLING THE STEERING WHEEL SHAFT JOINT

INSTALLING COMPONENTS CONTINUED

INSTALLING THE BATTERY LEAD

FINAL CHECKS

ENGINE/TRANSAXLE, REMOVING

REMOVING HEATED OXYGEN SENSORS (HO2S)

REMOVING HEAT DEFLECTOR PLATES

REMOVING CONTROL MODULES

REMOVING HEADLAMP

PAY ATTENTION TO THE FOLLOWING WHEN REMOVING PROPELLER SHAFT

REMOVING THE PROPELLER SHAFT

LOWERING THE ENGINE/TRANSMISSION UNIT

All sections

INSTALLING SPLASHGUARD UNDER ENGINE Volvo XC90 I

Engine - Removal, Replacement and Installation - 2 of 2

INSTALLING SPLASHGUARD UNDER ENGINE

Install

the protective cover under the engine
the bolts, M8 x6.

Remove the lifting tool see 9995716 , kit see 9997070 and lifting hooks see 9995460 .

Tighten

the 3 x M10 screws for the engine pad bracket
the M10 upper nut for the engine pad.