Volvo 240/740/760/780/940/960 1990-1998

Engine

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REMOVAL & INSTALLATION



In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as disconnect the exhaust system'' or remove the radiator.'' In most instances, a detailed removal procedure can be found elsewhere in this guide.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.

Removal and installation of the engine can be made easier if you follow these basic points:



If you have to drain any of the fluids, use a suitable container.
 
Always tag any wires or hoses and, if possible, the components they came from before disconnecting them.
 
Because there are so many bolts and fasteners involved, store and label the retainers from components separately in muffin pans, jars or coffee cans. This will prevent confusion during installation.
 
After unbolting the transmission or transaxle, always make sure it is properly supported.
 
If it is necessary to disconnect the air conditioning system, have this service performed by a qualified technician using a recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside.
 
When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting apparatus be attached to them.
 
Lift the engine from its compartment slowly, checking that no hoses, wires or other components are still connected.
 
After the engine is clear of the compartment, place it on an engine stand or workbench.
 
After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined in this guide.
 

Although Volvo recommends removing the engine and transmission as an assembly, transmissions can be left in the vehicle if desired. If choosing to remove the engine only and leave the transmission in the vehicle, disregard the transmission, shifter, cables, driveshaft, and mount removal procedures. In place of these procedures, the bell housing bolts must be removed, as well as the torque converter bolts, if equipped with an automatic transmission. Also, a floorjack or other suitable support must be placed under the transmission.

2.3L 4-Cylinder Engine
  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the battery cables, negative lead first.
  4.  
  5. Remove the battery.
  6.  
  7. If equipped with a manual transmission, remove the shifter.
  8.  
  9. Disconnect the windshield washer hose and engine compartment light wire.
  10.  
  11. Scribe marks around the hood mount brackets on the underside of the hood for later alignment.
  12.  
  13. Remove the hood.
  14.  
  15. Remove the overflow tank cap.
  16.  
  17. Remove the gravel shield from the underside of the radiator.
  18.  
  19. Drain the cooling system.
  20.  
  21. Remove the upper and lower radiator hoses.
  22.  
  23. Disconnect the overflow hoses at the radiator.
  24.  
  25. Disconnect the PCV hose at the cylinder head.
  26.  
  27. If equipped with an automatic transmission, disconnect the oil cooler lines at the radiator.
  28.  
  29. Remove the fan assembly.
  30.  
  31. Remove the radiator and fan shroud.
  32.  
  33. Remove the air cleaner.
  34.  
  35. If equipped, disconnect the hoses at the air pump.
  36.  
  37. Remove the air pump and drive belt.
  38.  
  39. Remove the vacuum pump and hoses.
  40.  
  41. Disconnect the power brake booster vacuum hose.
  42.  
  43. Remove the power steering pump, drive belt and bracket. Position aside without disconnecting the hydraulic lines.
  44.  
  45. If equipped with A/C, remove the crankshaft pulley and compressor drive belt. Then install the pulley again for reference.
  46.  
  47. Disconnect the air conditioning wiring and remove the compressor from the bracket. Position the compressor aside without disconnecting the hoses.
  48.  
  49. Remove the bracket.
  50.  
  51. Disconnect the vacuum hoses from the engine.
  52.  
  53. Disconnect the carbon canister hoses.
  54.  
  55. Remove the distributor wire connector, high tension lead, starter cables and the clutch cable clamp.
  56.  
  57. Disconnect the wiring harness at the voltage regulator.
  58.  
  59. Disconnect the throttle cable at the pulley and the wire for the A/C at the manifold solenoid.
  60.  
  61. Remove the gas cap.
  62.  
  63. Disconnect the fuel lines at the filter and return pipe.
  64.  
  65. At the firewall, remove the electrical connectors for the ballast resistor and relays.
  66.  
  67. Disconnect the heater hoses.
  68.  
  69. Unplug the micro-switch connectors at the intake manifold and all remaining harness connectors to the engine.
  70.  
  71. If equipped, disconnect the cruise control cables and hoses.
  72.  
  73. Drain the engine oil.
  74.  
  75. Remove the exhaust manifold flange retaining nuts. Loosen the exhaust pipe clamp bolts and remove the bracket for the front exhaust pipe mount.
  76.  
  77. Remove the exhaust manifolds from the cylinder head.
  78.  
  79. Raise and safely support the vehicle.
  80.  
  81. From underneath, remove the front motor mount bolts.
  82.  
  83. If equipped with an automatic transmission, place the gear selector lever in PARK and disconnect the gear shift control rod from the transmission.
  84.  
  85. On manual transmission vehicles, disconnect the clutch controls.
  86.  
  87. Disconnect the speedometer cable and mark and remove the driveshaft from the transmission.
  88.  
  89. On overdrive equipped vehicles, disconnect the control wire from the shifter.
  90.  
  91. Use a floor jack and a wooden block and support the weight of the engine beneath the transmission.
  92.  
  93. Remove the bolts for the rear transmission mount.
  94.  
  95. Remove the transmission support crossmember.
  96.  
  97. Lift out the engine using the proper lifting equipment.
  98.  

When removing the engine and transmission as an assembly, they must be removed at slightly an angle to clear the engine compartment.

  1. Separate the engine from the transmission.
  2.  

To install:
  1. If the engine was rebuilt, install any components removed such as engine mounts, lifting eyelets, etc.
  2.  
  3. Install the engine to the transmission.
  4.  
  5. Attach the engine and transmission to the hoist, and carefully raise the engine.
  6.  
  7. Place the engine into the engine compartment carefully, and guide into the mounting position.
  8.  
  9. Install and tighten the engine mounts to 37 ft. lbs. (50 Nm).
  10.  
  11. Install the transmission crossmember.
  12.  
  13. Install the rear transmission mount.
  14.  
  15. Remove the hoist.
  16.  
  17. Installation of the remaining components is the reverse of removal.
  18.  

2.8L 6-Cylinder Engine
  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. If equipped with manual transmission, remove the shifter assembly.
  6.  
  7. Remove the battery.
  8.  
  9. Disconnect the windshield washer hose and engine compartment light wire.
  10.  
  11. Scribe marks around the hood mount brackets on the underside of the hood for later hood alignment.
  12.  
  13. Remove the hood.
  14.  
  15. Remove the air cleaner assembly.
  16.  
  17. Remove the splash guard under the engine.
  18.  
  19. Remove the overflow tank cap.
  20.  
  21. Drain the cooling system.
  22.  
  23. Remove the upper and lower radiator hoses and disconnect the overflow hoses at the radiator.
  24.  
  25. If equipped with automatic transmission, disconnect the transmission cooler lines at the radiator.
  26.  
  27. Remove the fan assembly.
  28.  
  29. Remove the radiator and fan shroud.
  30.  
  31. Disconnect the heater hoses, power brake hose at the intake manifold and the vacuum pump hose at the pump.
  32.  
  33. Remove the vacuum pump and O-ring in the valve cover.
  34.  
  35. Remove the gas cap.
  36.  
  37. Properly relieve the fuel system pressure.
  38.  
  39. At the firewall remove the fuel lines at the filter and return pipe, remove the relay connectors and all other wire connectors.
  40.  
  41. Disconnect the distributor wires.
  42.  
  43. Disconnect the evaporative control carbon canister hoses and the vacuum hose at the EGR valve.
  44.  
  45. Remove the voltage regulator wire connector.
  46.  
  47. Disconnect the throttle cable and kickdown cable, on automatic transmission vehicles, the vacuum amplifier hose at the T-pipe and the hoses at the thermostat.
  48.  
  49. If equipped, disconnect the cruise control cables and hoses.
  50.  
  51. Disconnect the air pump hose at the backfire valve, the solenoid valve wire and the micro-switch wire.
  52.  
  53. Remove the exhaust manifold flange retaining nuts (both sides).
  54.  
  55. If equipped with air conditioning, remove the compressor and drive belt and place it aside. Do not disconnect the refrigerant hoses.
  56.  
  57. Drain the crankcase.
  58.  
  59. Remove the power steering pump, drive belt and bracket. Position aside.
  60.  
  61. From underneath, remove the retaining nuts for the front motor mounts.
  62.  
  63. Remove, as required, the front exhaust pipe.
  64.  
  65. On 49 states vehicles, remove the front exhaust pipe hangers and clamps and allow the system to hang.
  66.  
  67. If equipped with automatic transmission, place the shift lever in P .
  68.  
  69. Disconnect the shift control lever at the transmission.
  70.  
  71. On manual transmission vehicles, disconnect the clutch cylinder from the bell housing. Leave the cylinder connected; secure it to the vehicle.
  72.  
  73. Disconnect the shifter linkage.
  74.  
  75. Disconnect the speedometer cable and mark and remove the driveshaft.
  76.  
  77. Raise and safely support the vehicle. Place jackstands under the reinforced box member area to the rear of each front jacking attachment. Then, using a floor jack and a thick, wide wooden block, support the weight of the engine under the oil pan.
  78.  
  79. Remove the bolts for the rear transmission mount.
  80.  
  81. Remove the transmission support crossmember.
  82.  
  83. Lift out the engine and transmission as a unit.
  84.  

When removing the engine and transmission as an assembly, they must be removed at slightly an angle to clear the engine compartment.

  1. Separate the engine from the transmission.
  2.  

To install:
  1. If the engine was rebuilt, install any components removed such as engine mounts, lifting eyelets, etc.
  2.  
  3. Install the engine to the transmission.
  4.  
  5. Attach the engine and transmission to the hoist, and carefully raise the engine.
  6.  
  7. Place the engine into the engine compartment carefully, and guide into the mounting position.
  8.  
  9. Install and tighten the engine mounts to 37 ft. lbs. (50 Nm).
  10.  
  11. Install the transmission crossmember.
  12.  
  13. Install the rear transmission mount.
  14.  
  15. Remove the hoist.
  16.  
  17. Installation of the remaining components is the reverse of removal.
  18.  

2.9L 6-Cylinder Engine
  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the battery.
  6.  
  7. Remove the ground lead connection to the body at the top of side member.
  8.  
  9. Remove the drive belt.
  10.  
  11. Remove the cooling fan.
  12.  
  13. Release the upper bolts and unfasten the connector at the relay in front of the battery.
  14.  
  15. Disconnect the ground lead at the right-hand ground terminal.
  16.  
  17. Remove the splash shield from the underside of the radiator.
  18.  
  19. Drain the cooling system.
  20.  
  21. Remove the upper and lower radiator hoses from the engine.
  22.  
  23. Remove the radiator overflow hose.
  24.  
  25. Remove the transmission cooler lines from the radiator.
  26.  
  27. Remove the top nut on both left and right side engine mounts.
  28.  
  29. Remove and remove the large and small crankcase ventilation hoses and the idle air hose.
  30.  
  31. Disconnect the idle air valve wiring.
  32.  
  33. Disconnect and remove the two EVAP valve hoses at the intake manifold.
  34.  
  35. Unplug the air mass meter connector, air preheater hose and throttle pulley cover.
  36.  
  37. Remove the air intake hose from the throttle body.
  38.  
  39. Remove the servo pump mounting bolts.
  40.  
  41. Disconnect and remove the fuel return line at the regulator and fuel line at the firewall.
  42.  
  43. Remove the throttle cable, cruise control vacuum hose and fuel line snap catches.
  44.  
  45. Remove the engine wiring harness cover and disconnect the harness. Remove the relay connector. Remove the harness duct retaining nuts.
  46.  
  47. Disconnect the heater hoses at the firewall, ECC hoses at the intake manifold and brake servo vacuum hose.
  48.  
  49. Remove the timing pick up and camshaft sensor connectors.
  50.  
  51. Support the engine at the rear using engine removal tool assembly 5033, 5006, 5115, 5428 and 5429, or equivalent that will support the engine from above.
  52.  
  53. Remove the radiator.
  54.  
  55. Drain the engine oil.
  56.  
  57. Disconnect the hose at the oil thermostat in the cylinder block.
  58.  
  59. Disconnect the A/C compressor wiring. Remove the compressor from the mount and set it aside without disconnecting the hoses.
  60.  
  61. Remove the exhaust pipe flanges at the manifold. Remove the lower section of the air preheater pipe and remove the exhaust pipe shield.
  62.  
  63. Remove the oil pipe connections at the gearbox. Plug the openings.
  64.  
  65. Remove the clips between the gear selector lever and control rod/reaction arm. Withdraw the rods from their mounting.
  66.  

Before separating the driveshaft, mark the coupling halves for reassembly.

  1. Disconnect the driveshaft and transmission support member.
  2.  
  3. Install engine lifting tool (2810 or equivalent) and adjust the lifting yoke to ensure the engine is balanced. Position the wiring harnesses so as to avoid damage when lifting.
  4.  
  5. Remove the engine and transmission assembly from the vehicle.
  6.  
  7. Separate the engine from the transmission.
  8.  

To install:
  1. If the engine was rebuilt, install any components removed such as engine mounts, lifting eyelets, etc.
  2.  
  3. Install the engine to the transmission.
  4.  
  5. Attach the engine and transmission to the hoist, and carefully raise the engine.
  6.  
  7. Place the engine into the engine compartment carefully, and guide into the mounting position.
  8.  
  9. Install and tighten the engine mounts to 37 ft. lbs. (50 Nm).
  10.  
  11. Install the transmission crossmember.
  12.  
  13. Install the rear transmission mount.
  14.  
  15. Remove the hoist.
  16.  
  17. Installation of the remaining components is the reverse of removal.
  18.  

2.3L and 2.4L 5-Cylinder Engines

See Figure 1


WARNING
After the engine is removed, do not move the vehicle or the wheel bearings will be damaged.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the battery and tray.
  6.  
  7. Raise and safely support vehicle.
  8.  
  9. On vehicles with automatic transaxles, remove the air baffle from below the engine.
  10.  
  11. Remove the radiator expansion cap.
  12.  
  13. Drain the coolant into a suitable container.
  14.  
  15. Remove the front wheels and disconnect both track rods from the axle.
  16.  
  17. Remove both ball joints from the control arm.
  18.  
  19. Remove the ABS/brake hose bracket bolt.
  20.  
  21. Remove both halfshafts.
  22.  
  23. Remove the right side engine mount retainer bolts.
  24.  
  25. Remove the torque rod bolt in the gearbox.
  26.  

Install plugs in the axle shaft holes to prevent fluid leakage.

  1. Remove the front exhaust pipe lower nut and bolt from the bracket.
  2.  
  3. Remove the two carriage bolts and skid plate.
  4.  
  5. Remove the speedometer connection and remove the front and rear lower engine mount bolts.
  6.  
  7. Lower the vehicle.
  8.  
  9. Remove the fresh air intake to the air cleaner, coil wires, throttle pulley cover and throttle cable from the pulley.
  10.  
  11. Tag and remove the throttle body inlet hose, idle air control valve, crankcase ventilation, preheat hoses and mass air flow sensor connector.
  12.  
  13. Disconnect the torque rod from the bracket and firewall.
  14.  
  15. Disconnect the ground strap from the firewall.
  16.  
  17. Unfasten the heated oxygen sensors and clips.
  18.  
  19. Remove the brake booster hose from the engine.
  20.  
  21. Remove the upper air charge pipe and fresh air intake from the radiator then disconnect the vacuum hoses to the turbocharger and EGR regulator.
  22.  
  23. Remove the radiator and coolant hoses
  24.  
  25. Remove the clutch slave cylinder retaining ring, if equipped. Make sure that the piston does not slip out.
  26.  
  27. Remove the gear cable selector, after marking the position.
  28.  
  29. On automatic transaxle, mark the position and then remove the gear selector cable.
  30.  
  31. Remove the accessory drive belt
  32.  
  33. Remove the A/C compressor without disconnecting the lines and set it aside
  34.  
  35. Properly relieve the fuel system pressure.
  36.  
  37. Remove the fuel distribution manifold cover, injector covers, upper and lower fuel line clips and engine ground strap.
  38.  
  39. Install holders 999-5533 or equivalent on the injectors.
  40.  
  41. Disconnect the fuel pressure regulator vacuum hose. Lift the fuel distribution manifold off and lay it aside.
  42.  

Make sure that the injectors and needles are not damaged.

  1. Disconnect and remove the wiring harness from the engine.
  2.  
  3. Lift up the air pump and lay it to one side.
  4.  
  5. Install engine lifting yoke 999-2810 and arm 999-5428, or equivalents, and connect to hoist.
  6.  
  7. Remove the front engine mount when the engine/transaxle is secured.
  8.  
  9. Lift the engine out of the vehicle.
  10.  
  11. On vehicles with automatic transaxles remove the turbo oil cooler lines and valve (if equipped) from the right side of the oil sump.
  12.  
  13. Separate the engine from the transaxle.
  14.  

To install:
  1. If the engine was rebuilt, install any components removed such as engine mounts, lifting eyelets, etc.
  2.  
  3. Install the engine to the transaxle.
  4.  
  5. Install the valve and turbo oil cooler lines to the oil sump.
  6.  
  7. Attach the engine and transaxle to the hoist, and carefully raise the engine.
  8.  
  9. Place the engine into the engine compartment carefully, and guide into the mounting position.
  10.  
  11. Install and tighten the engine mounts to 37 ft. lbs. (50 Nm).
  12.  
  13. Installation of the remaining components is the reverse of removal.
  14.  



Click image to see an enlarged view

Fig. Fig. 1: Typical engine mount on the 2.3L and 2.4L 5-cylinder engine

 
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