REMOVAL & INSTALLATION
B27F, B28F and B280F Engines
- Disconnect the negative battery cable.
- Drain the coolant by opening the drain cock on the left side of the engine. A radiator hose may also be disconnected to speed draining.
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.
- After removing any electrical leads to the radiator, disconnect the oil cooler lines to the radiator on cars with automatic transmissions. Remove the fan shroud from the radiator, disconnect the hoses and remove the radiator. Remove the fan shroud.
- Remove the splash shield under the engine. Loosen the alternator and power steering belts.
- Remove the power steering pump from its bracket and secure it with wire out of the way. Do not disconnect any lines or hoses. After the pump is moved and secure, remove the bracket from the engine.
- Detach and secure to one side the air conditioning compressor, if so equipped. Don't disconnect any lines or hoses.
- Remove the fan, fan pulley and drive belts.
- After removing the air intake duct and the vacuum pump, remove the left valve cover.
- Using a 5mm Allen wrench, remove the fuel pressure regulator and lay it on the intake manifold. Disconnect the main ignition wire (near the right side shock tower) and remove the oil filler cap. Remove the right valve cover.
- Turn the crankshaft to the overlap position on cylinder No. 1. This means the rocker arms for cylinder No. 1 do NOT have clearance and the first mark on the crank pulley is aligned with the "0" mark on the pointer.
- Using either Volvo special tool No. 5112 or an acceptable substitute, lock the flywheel in position so that the engine cannot be moved out of position.
- By using a 36mm socket, remove the crankshaft pulley. Take care that the small locking (Woodruff) key on the crankshaft does not fall into the lower part of the engine.
- Move the wiring harness on the timing cover to one side and remove the timing cover.
- Using a plastic (not metal) scraper, clean the gasket surfaces on the timing cover, the valve covers, and the front of the engine block.
- Tap the center seal out of the timing cover and replace it with a new one.
- Install the timing gear cover with a new gasket. Apply a light coat of locking fluid to the four lower bolts; tighten all the bolts to 10-11 ft. lbs. (14-15 Nm).
- Install the crankshaft pulley. Tighten to 190-200 ft. lbs. (258-271 Nm).
- Remove the locking device from the flywheel.
- Apply new gaskets and reinstall both valve covers.
- On the right side of the motor, replace the oil filler cap, the ignition lead and the fuel control pressure regulator.
- Close the drain cock on the left side of the engine.
- On the left side of the motor, reconnect the vacuum pump (with a new gasket) and the air inlet duct.
- Reinstall the fan, pulley, and drive belts. Replace the bracket and the power steering pump with its belt. Adjust all the belts to the correct tension.
- Install the air conditioning compressor and set the belt tension.
- Install the fan shroud and the radiator. Connect the oil cooler lines to the radiator (cars with automatic transmission), and connect all the hoses to the radiator. Reconnect any wiring to sensors on the radiator.
- Install the splash guard under the car.
- Double check all installation items, paying particular attention to loose hoses or hanging wires, loose nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
- Reconnect the battery cable. Fill the cooling system with a 50-50 mixture of coolant and water. Start the engine and check for leaks. After the engine has fully warmed up, check the coolant level and top up as needed.