Removing The Control System Cover: Removal

Remove:

the splash guard under the engine. See Fig 1 .
both the screws for the front splash guard. Press in the catches at the front edge of the cover. Pull the cover backwards.

Fig 1: Removing Splash Guard

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Place a container underneath the transmission. Drain the oil. Measure and note the volume of oil. Install the plug. Tighten. Remove the cable harness clamp on the control system cover. See Fig 2 . Disconnect the oil cooler return line from the control system cover. Disconnect the screws for the oil cooler pipe from the transmission. Move the pipe to one side. Seal the hole in the transmission with a plastic plug. Position a container under the radiator drain cock. Drain the engine coolant.

Fig 2: Disconnecting Oil Cooler Components From Cover

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NOTE: Avoid skin contact with the coolant.

Close the nipple. Disconnect the lower hose for the radiator to provide more space for removing the control system cover. See Fig 2 .

Remove:

the screw for the front engine pad and the sub-frame. See Fig 3 .
the screw for the ground lead bracket.

NOTE: Applies only to cars with parking heaters:

Remove the 3 screws from the heater on the sub-frame. Hang or tie up the heater on the left front fender. Unhook the fuel line from its mountings in the sub-frame. Lower the vehicle.

Fig 3: Removing Front Engine Pad & Subframe Screws

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Install 999 5716 directly above the engine lifting eye. See Fig 4 . Position the lifting beam brackets as illustrated. Connect: 999 5460 to the lifting eye at the rear edge of the engine. Raise the rear edge of the engine 20 mm. Raise the vehicle.

Fig 4: Installing Lifting Beam

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Slacken off the front mounting screws on the sub-frame. See Fig 5 . Remove the left-hand screw. Unscrew the right-hand screw until it is secured by approximately 5 threads. Slacken off the rear mounting screw on the left-hand side. Unscrew it approximately two turns.

Fig 5: Locating Subframe Bolts (Screws)

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Insert a spacer between the bodywork and the sub-frame at the front left-hand mounting. See Fig 6 . There must be a distance of approximately 55 mm.

Fig 6: Locating Spacer Between Body and Subframe

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Use compressed air to blow clean the area around the control system cover. Carefully clean the sub-frame by the cover to prevent dirt entering the transmission.

Remove the screws for the control system cover. Clean any sealing compound from the threads. Use a tap, M8x1.25. See Fig 7 . Detach the cover. Use: 999 5477. Carefully tap it in between the cover and transmission so as not to bend the seal flange on the cover.

Fig 7: Removing Control System Cover

Courtesy of VOLVO CARS OF NORTH AMERICA.

Slide the cover between the sub-frame and the bodywork. See Fig 8 . Remove the cover. Clean the gasket residue from the cover and the transmission.

NOTE: Wash the cover thoroughly. Ensure that no debris enters the transmission.

Fig 8: Removing Cover Between Sub-Frame & Body

Courtesy of VOLVO CARS OF NORTH AMERICA.