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Volvo 850 Engine Removal & Install

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I have a 1995 850 and the engine is shot. I have new everything, even transmission in the car so I don't want to get rid of it....Please tell me as a "semi-novice repair hound"...how difficult it would be to remove my old engine and drop a used/new one into my 850?

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From VADIS, here are some of the procedures that will give you an idea of what is involved: (This is for a Turbo Engine) (Removal, Transfer, and Reinstall)

Turbocharged engine, removal and installation

Special tools: 999 2810 , 999 5428 , 999 5462 , 999 5474 , 999 5488 , 999 5533

Note! From autumn 1993 onwards lifting arm 998 9734 is included in the kit for tool 999 2810. The lifting arm is required for removing and installing the turbo motor.

Removing engine

Drain coolant

Remove expansion tank cap.

Raise the car.

Automatic: Remove air guide under engine.

Open the engine and radiator nipples. Thread hoses onto the nipple to collect the coolant.

Disconnect the lower charge air pipe from charge air cooler (CAC) lower sleeve connector.

Close the nipples.

Remove:

-front wheels

-tie rod end from left stub axle

-the three nuts holding the ball joint to the control arm on the left-hand side

Remove:

-ABS cable and brake pipe/hose bracket screw

-left drive shaft, a gimmy bar 999 5462  must be used to release the drive shaft (the snap ring may be damaged otherwise)

Remove:

-tie rod end from right stub axle

-the three nuts which hold the ball joint to control arm on right-hand side

-right drive shaft and intermediate bearing cap from drive shaft, carefully place it on the steering servo pipes

-the two screws for the right engine mounting (bend the right fender liner to one side slightly first)

-the transmission torque rod screw

Note! Install sealing plugs 999 5488  in the holes left by the drive shafts.

Remove:

-front exhaust pipe lower nut and screw from the bracket

-speedometer connector

-front and rear engine mountings lower screws.

Lower car to a comfortable working height

Remove:

-battery

-battery shelf, with a clutch slave cylinder for the cruise control (which is removed from the shelf and put to one side)

-fresh air intake hose from air intake to air cleaner (ACL) housing

-ignition cable between distributor/ignition coil

-throttle pulley cover

-throttle cable from throttle pulley

Disconnect hoses/connectors:

-Disconnect inlet hose from the turbocharger (TC) to air cleaner (ACL) at both ends

-disconnect the hose for the PTC valve and connector

-disconnect connector from throttle sensor

-disconnect idle air trim connector.

-disconnect turbocharger control valve (TCV) connector

Remove the air cleaner (ACL) housing

disconnect mass air flow (MAF) sensor connector

Disconnect and raise air cleaner (ACL) housing.

Remove two turbocharger control valve (TCV) bracket screws

Remove:

-torque rod from bracket and cowl panel.

-ground strip from cowl panel

-the two heater hoses from the cowl panel

-heated oxygen sensor (HO2S) connector and clips ((USA variants are equipped with two heated oxygen sensors (HO2S))

-brake servo hose from engine or separate it under the air cleaner (ACL) housing

Remove the engine coolant fan (FC)

Remove relays from the fan shroud, separate the relay and fan connectors, put wiring to one side.

Remove the air duct for cooling the control module box. Disconnect both canister hoses and valve from the radiator.

Remove the four fan shroud screws and the upper charge air pipe from the turbocharger. Slide the fan shroud slightly backward and remove the upper fan shroud. Remove upper charge air pipe.

Remove fresh air intake from radiator and disconnect vacuum hoses to Turbocharger instruments and EGR-regulator.

Caution! Protect the radiator with a hard sheet or similar. Alternative protection 999 5474 .

Remove:

-idle air trim together with lower charge air pipe

-lower radiator hose, from engine

-the protective cover over the starter motor

-battery negative lead, from engine and wheel arch (also from transmission on automatic)

Car with manual transmission:

-clutch slave cylinder snap ring

Note! (Ensure that the piston does not slide out)

-slave cylinder from gear box

Remove:

-air cleaner housing bracket. (Carefully put air cleaner bracket and clutch slave cylinder to one side so that they are not separated.)

Manual:

Remove: gear selector cables from their mountings on the transmission (mark up cable positions).

Remove the rubber mounted section of the gear selector cable mounting.

Automatic:

Disconnect connector and remove gear selector cables from the transmission (and mark up the cable positions). Disconnect the two oil cooler hoses from the radiator, using victory clip tool.

Remove:

-upper radiator hose from thermostat housing

-expansion tank

-auxiliaries belt

-the six power steering pump screws (disconnect the temperature sensor cable from the bracket on the power steering pump)

Hint: Allow power steering pump to remain on hose.

Disconnect the two oil cooler pipes from the radiator.

Remove air conditioning (A/C) compressor

Remove air conditioning (A/C) compressor without removing hoses and put onto sub-frame. (Remove the screws on the right-hand side by bending the fender liner a little to one side.)

Remove the cable duct bracket screws

Remove the cable duct bracket screws

Remove starter motor support bracket.

Remove:

-the protective cover over the fuel rail

-injector connectors

-fuel line clip (upper/lower)

-engine ground strip

Remove the fuel rail

Install holder 999 5533  (5 x) on the injectors

Disconnect fuel pressure regulator vacuum hose.

Lift up and put fuel rail with injectors to one side.

Caution! Take care not to damage the injector nozzles and fuel needles.

Expose the engine cable harness

Disconnect all connectors and clamps from engine.

Note! Note all the cable harness mountings positions.

1. Thermostat

2. Generator (GEN)

3. Air conditioning (A/C) if installed

4. Ground terminal

5. Oil pressure switch

6. Oil level sensor

7. Starter motor (all)

8. Knock sensor (KS)

9. Ground terminal

10. Ground terminal

11. Throttle housing switch

12. Idle air trim

13. Flywheel sensor

14. Injectors

15. Camshaft position (CMP) sensor

16. Back-up (reversing) lamp switch

17. Mass air flow (MAF) sensor

18. Vehicle speed sensor (VSS)

19. Heated oxygen sensor (HO2S) (automatics x 2)

20. PTC element

Remove engine with transmission

Lift power steering pump and put it to one side.

Remove front engine pad when lifting.

Remove engine, use lift yokes 999 2810  (in version with lifting arm 999 5428 .

Adjust lifting angle during the lift (a relatively large angle is required).

Automatic: Remove turbocharger (TC) oil cooler hoses with valve, from oil pan right side.

Caution! Check carefully that the driveline is clear of the bodywork and other optional extras.

Engine replacement, transferring components (Turbo)

Special tools: 999 2520 , 999 2810 , 999 5112 , 999 5297 , 999 5428 , 999 5429 , 999 5463

Exposing engine

Remove transmission

Automatic: Slacken off torque converter screws.

Remove 12 transmission screws from the engine at the flywheel mounting in the cylinder block.

Warning! When the transmission is released use the mobile jack 999 5972  with transmission fixture 999 5463  as a support to avoid damage.

Install engine in stand

Use stand 999 2520  and fixture 999 5297 .

Remove lifting tools.

Install the correct number of washers to compensate transmission guide pins.

Transferring rear components

1. Connector brackets

2. Torque control arm use new screws. Tighten screws in two stages:

Stage 1 50 Nm

Stage 2. 90° angle

3. Camshaft position (CMP) sensor

4. Distributor and ignition cables

5. Heater pipes

6. Engine speed (RPM) sensor

7. Flywheel/carrier plate

Transfer all vacuum hoses

Transferring exhaust side components

1. Heat deflector plate

2. Exhaust pipe bracket

3. Exhaust manifold with turbocharger (TC)

4. Coolant pipe

5. Fuel line mounting brackets

6. Right engine mounting

7. Thermostat housing, oil cooler

8. Drive shaft bearing bracket

Transferring intake side components

1. Lifting eyes

2. Temperature sensor

3. Intake manifold knock sensors (KS) (torque 20 Nm)

4. Dipstick and pipe

5. Oil level sensor and oil pressure sensor

6. Front engine mounting

7. Flame trap with hose

Install carrier plate/flywheel

Lift the engine from the fixture, use mounting 999 5429  and lifting yoke 999 2810 , 999 5428 .

Use gear sector 999 5112 .

Use new screws and thread sealant.

Tighten in two stages:

1. Tighten to: 45 Nm

2. Angle-tighten: 50°

Install transmission

Automatic:

Tighten torque converter to: 50Nm.

Manual:

Torque clutch driven plate and pressure plate to: 30 Nm

The old motor is plugged in the same way as the new plug.

Lifting engine in

Special tools: 999 2810 , 999 5428 , 999 5462 , 999 5474 , 999 5488 , 999 5533

Note! From autumn 93 onwards lifting arm 998 9734 is included in the kit for tool 999 2810. The lifting arm is required for removing and installing the turbo motor.

Lift in engine with transmission

Use lifting yoke 999 2810  (in version with lifting arm 999 5428 .

Locate lifting yoke so that the engine is balanced.

Adjust lift angle during the lift.

Caution! Check that the driveline is clear of the bodywork and other equipment.

Tighten the front engine mounting nut.

Install:

-A/C compressor

-power steering pump and collision protection system

Install the engine cable harness

Install cable duct bracket. Connect all connectors as marked earlier.

1. Thermostat

2. Generator (GEN)

3. Air conditioning (A/C) if installed

4. Ground terminal

5. Oil pressure switch

6. Oil level sensor

7. Starter motor (all)

8. Knock sensor (KS)

9. Ground terminal

10. Ground terminal

11. Throttle housing switch

12. Idle air trim

13. Flywheel sensor

14. Injectors

15. Camshaft position (CMP) sensor

16. Back-up (reversing) lamp switch

17. Mass air flow (MAF) sensor

18. Vehicle speed sensor (VSS)

19. Heated oxygen sensor (HO2S) (automatics x 2)

20. PTC element

Install fuel rail

Grease O-rings for injectors.

Tighten fuel rail.

Remove holder 999 5533 .

Install:

-the protective cover over the fuel rail

-fuel line clip (upper/lower)

-auxiliaries belt

-expansion tank with radiator pipes

-upper and lower oil cooling hoses

Install:

-starter motor bracket and its splash guard

-cold air hose

-radiator hoses to the cowl panel

-fresh air intake hose to the turbocharger (TC)

Install:

-negative lead to the engine, and install the clamp on the frame member

-lower radiator hose

-clutch slave cylinder to the gearbox

Note! (Take care that the piston does not slide out)

-slave cylinder snap ring

-the rubber air filter mountings and tighten bracket.

-idle air trim, connect connector

Install the engine cooling fan (FC)

Remove shroud (999 5474 ) from radiator.

Lift out the engine cooling fan (FC) with the cover. Connect the connector, clamp the wiring.

Install the upper charge air pipe, between charge air cooler and turbocharger (TC).

Install the fresh air intake.

Install the upper fan shroud. Tighten the fan shroud to the radiator (ensure that the clip is in place.

Connect the pressure pipe (to the turbo instruments).

USA: Connect the vacuum hoses to the EGR-regulator.

Install the EVAP canister shut-off valve in the bracket and connect the canister vacuum hose.

Install:

-the air duct for cooling the control module box.

-both relays on the fan shroud and connect connectors. Clamp the wiring

-idle air trim

Install:

-cable to the PTC-element and heated oxygen sensor (HO2S)

Car with manual transmission:

-back-up (reversing) light switch cable

-the gear selector cables rubber mounting.

-gear selector cables to their mounting on the transmission.

Note! Color marking mounting/cable.

Cars with automatic transmission:

Connect connector to the transmission.

Install gear selector cable (as marked earlier)

Install two transmission oil cooler hoses and negative lead to the transmission.

Install:

-upper torque rod from the engine with new screws. Tighten to 50 Nm and 90° angle

-both ground strips

-throttle cable to the throttle pulley and cover

-charge air pipe to the turbocharger (TC) (adjust the distance to 15 mm)

Install air cleaner (ACL) housing

Connect the connector and vacuum hoses to the idle air control (IAC) valve.

Ignition cable between distributor/ignition coil.

Note! Yellow marking first rib on cleaner cover.

Install the air hose and the air cleaner (ACL) housing. Connect mass air flow (MAF) sensor connector.

Connect fresh air intake.

Install the bracket for the turbocharger control valve (TCV) on the air cleaner (ACL) housing.

Install:

-the battery shelf and battery with the cables

Caution! If the car is equipped with a cruise control connect the vacuum hose and vacuum motor wiring before the battery shelf is screwed into place.

Install:

-two upper exhaust pipe nuts (do not tighten them), raise the car

-exhaust pipe lower nut (do not tighten them)

-screw for exhaust pipe bracket. Torque to 30 Nm.

-speedometer connector.

-front and rear engine mounting screws. Torque to 50 Nm.

-torque arm screw in the transmission, use a new screw and nut. Tighten to 35 Nm + 90°.

Install:

-the two screws for the right engine mounting (bend the right fender liner to one side slightly first)

-right drive shaft and pilot bearing

Install:

-left drive shaft, this should be easily installed with hand pressure (the snap ring is easy to damage)

-ABS cable/brake pipe bracket screw

Reinstall on both sides:

-control arm to ball joint. Use new nuts.

-wheels

Note! Ensure that mating faces on ball joint and link are clean and free of grease.

Tighten the nuts in order from inside and outwards.

Tighten to: 18 Nm + 120° Use protractor 951 2050 .

Rust protect the area between the ball joint, link and nuts carefully, using plenty of compound. Use rustproofing agent P/N: 1 161 432-8.

(New ball joint nut torque 70 Nm.)

Lower car

Torque the three exhaust pipe nuts and check that the planes are parallel. Torque to 30 Nm.

Install heat deflector plate, with turbocharger (TC) bracket.

Top up coolant and engine oil

Coolant volume approximately: 7.20 liters.

Oil capacity including filter: 5.3 liters.

Test function

Start engine run until thermostat opens.

Check for leaks.

Check and if necessary adjust oil and coolant levels.

Automatic: Check automatic transmission oil level.

I have a 1995 850 and the engine is shot.  I have new everything, even transmission in the car so I don't want to get rid of it....Please tell me as a "semi-novice repair hound"...how difficult it would be to remove my old engine and drop a used/new one into my 850?

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Posted

I have a 1995 850 and the engine is shot.  I have new everything, even transmission in the car so I don't want to get rid of it....Please tell me as a "semi-novice repair hound"...how difficult it would be to remove my old engine and drop a used/new one into my 850?

I looked into this in depth (as I am going to do the same thing over the summer I expect), and I came to the conclusion that it's not difficult, per se, but it'll take up a lot of time as a novice. Follow the instructions above by the letter and take lots of pics (or even video it), that way you will always know how a particluar component goes back correctly!

Once you've done it once I'm sure the second time etc would be a lot easier!

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Once you've done it once I'm sure the second time etc would be a lot easier!

This is true long as there is not a lot of time inbetween your engine removals. I've done a few, but it has been over a year so the next one that comes in, all the basics are there but you always forget something thats not a big deal, but not doing things like this every day, an engine removal doesn't go as smooth as an Oil change. :P

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Haynes manual has a procedure where you dont need to take out trans, it sounds alot easier.

i'll let you know how mine goes.

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Remember to bag and label your bolts, nuts, washers, small parts etc...

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Use ziplock bags to label screws and nuts and washers for different parts. ;)

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