Remove the battery lead. See Note when disconnecting/connecting the battery lead .

Fold the hose aside.

Clamp the hoses with hose clips.

Turn the quick-coupling a little in the arrow's direction, so that the lock opens.

At the same time, pull the inner coolant hose from the coolant pipe, straight out.

Block the hose between the brake fluid reservoir and the clutch cylinder with hose pliers.

Remove the lock from the quick-coupling on the junction at the clutch cover and remove the hose.

Collect the brake fluid that runs out, protect the openings from contamination.

Use jimmy bar 999 7077 to detach the ball joint for the gearbox cable from the lever.

Detach the casing for the gearbox cables from the bracket in the gearbox by pressing the locking sleeve backwards.

Lift up the gearbox cables.

Position lifting beam 999 5716 on the wheel arch and directly above the engine's lifting eyes on the left and right side.

Use lifting hook 999 5460 on the engine's right side with a clearance of approx. 10 mm.

Tighten to light contact on the left side. Lift up the car.

Unhook the cable duct from the sub-frame.

Remove the 2 screws for the heater, unhook the heater from the mounting and leave the heater hanging freely in its upper mounting.

Detach the heater's fuel line from its holders on the sub-frame.

On one side, measure the length of the track rod in relation to the steering gear housing. Note the measurement.

Remove the screw, 1, to the joint between the steering gear and the steering wheel shaft.

Press the joint up from the steering shaft.

Disconnect the ABS cable from the mounting in the strut.

Remove the screws from the sub-frame support plates (both sides).

Apply the mobile jack 998 5972 together with fixture 999 5972 lightly under the sub-frame's right side.

Slacken off the screws for the sub-frame on the right hand side and check that the nuts are still secured by at least 5 revolutions.

Remove the jack.

Unhook the control arm from the ball joint. Install protective sleeve 999 5562 . Hold the sleeve in place with the nut for the ball joint.

Fold out the strut and remove the drive shaft from the wheel hub, be careful so that the rubber gaiter is not damaged.

Hold the strut aside using a tensioning strap for more space when removing the drive shaft.

Install seal plug 999 5488 for the transmission.

Position the mobile jack lightly applied under the left side of the sub-frame. Remove the sub-frame screws.

Fold out the strut and loosen the drive shaft from the wheel hub. Hold aside the strut with a tensioning strap for more space when removing the transmission.

Remove the drive shaft from the transmission. Use pry par 999 5681 .

Install seal plug 999 5488 for the transmission.

Lower the engine and gearbox on the left-hand side using the hook.

Check that no hoses or cables are being stretched or trapped when the engine is lowered.

Lower the engine so that 100 mm of the lifting hook's free threads can be seen.

Raise the car.

Carefully pull out the coolant hose past the connection on the EGR cooler.

Raise the car.

Install the fixture 999 5463 for fixture 999 5972 . Use both fixtures together with mobile jack 998 5972 .

Fit the support plate (part number 5463-2) and the transmission, see figure.

Tighten the fixture with the two torque rod screws.

Apply the mobile jack lightly against the gearbox.

Remove the remaining 6 screws for the transmission-engine.

Make sure that the transmission is removed straight out in relation to the engine, so that no stresses are created in the disc's center.

Remove the gearbox.

The input shaft must be lubricated before a manual transmission is installed. See Cleaning and lubricating the input shaft for manual transmissions .

Check that the transmission and engine mating surfaces are absolutely clean.

Check that the guide sleeves towards the engine are in position and are free of faults.

Lubricate the holes in the transmission (for the guide pins and the starter motor). Use a little grease.

Adjust height and angle with the mobile jack and the transmission fixture.

Locate the transmission on the engine.

Ensure that the transmission goes straight in, in relation to the engine, and that no deviation occurs in the clutch driven plate center.

Guide the transmission cover onto the guide sleeves on the engine and the starter motor.

Install the 6 screws for the transmission - engine.

Tighten the screws alternately and crosswise to light contact.

At the same time, check that the whole of the transmission is in contact with the engine.

Following which, tighten the screws crosswise.

Remove the fixture from the transmission.

Lower the car.

Position the coolant hose inside the hose for the EGR cooler.

Lift the engine and transmission to slightly above horizontal for better access when installing the engine pad on the engine mounting.

Raise the car.

Check and if necessary align the bearing for the steering shaft in the boot when installing the steering gear. See Installing the gearbox .

Install the charge air pipe and the hose on the turbocharger (TC) and engine.

Install the sealing ring for the constant velocity joint housing. See Seal CV joint housing, replacing .

Press in the constant velocity joint housing firmly so that the snap ring engages in its groove in the transmission. Pull the constant velocity joint to check that the drive shaft is secure.

Locate the drive shaft in the wheel hub. Install a new screw loosely in the drive shaft.

Lift up the sub-frame until it is about 150 mm from the side member. Secure the power steering pipe at the front edge of the upper side of the sub-frame using the rubber covered clamp. Install the screw. Finger tighten.

Tighten the sub-frame screws. Tighten to light contact.

Remove the mobile jack.

Install the cap for the drive shaft's support bearing. Tighten

Install the sealing ring for the constant velocity joint housing. See Seal CV joint housing, replacing .

Locate the drive shaft in the wheel hub. Install a new screw loosely in the drive shaft.

Press down the control arm. Locate the spring strut in the ball joint pinion for the spring strut in the control arm.

Position the mobile jack lightly applied under the right side of the sub-frame. Remove both the sub-frame screws.

Tighten the sub-frame screws. Tighten to light contact.

Remove the mobile jack.

First tighten the frame's screws, see Tightening torque . Use angle gauge 951 2050 .

Then tighten the screws for the frame's brackets.

Applies only to right-hand drive cars

Install both screws. Tighten.

Fit the steering shaft universal joint on the steering gear. Install a new steering shaft screw. Tighten according to: Tightening torque .

Connect the cable to the step motor/solenoid. Check the tie rod's position according to: Transmission, removing .

Top up if necessary.

P/N: 116 1423-7. Volume: 2.1 liters.

Tighten the plug.

Install the nut for the ball joint pinion. Counterhold the ball joint pinion while tightening so that the ball joint boot cannot turn. Use a new nut. Tighten. See: Tightening torque .

Tighten the screw for the drive shaft. Use new screw. Counterhold with a pry bar in the brake disc. Tighten according to Tightening torque . Use angle gauge 951 2050 .

Lower the car.

Remove the lifting beams and hooks from the engine.

First push the catch in the junction. Then press the hose nipple into place. Ensure that the clip is seated in its groove.

Remove the hose clip.

Bleed the clutch.

Use only Volvo Genuine parts brake fluid DOT 4+.

Tighten nut for the engine pad.

Start the engine and bleed the cooling system.

Install the battery lead. See Note when disconnecting/connecting the battery lead .

Top up and check the engine coolant level.

Remove the rubber seal from the clutch cover. Move it inwards on the pipe towards the clutch cylinder.

Pull out the retaining clip locking the quick-release connector on the pipe to the junction.

Remove the adapter. Keep it in a plastic bag to prevent contamination. Install a protective plug in the end of the pipe.

Remove the clutch cylinder.

Clean the mating surfaces in the clutch cover. Check any leakage from the gearbox.

Tap in the extractor for the primary shaft seal.

Use extractor 9997003 .

Tighten the screws. Tighten to 10 Nm.

Remove the protective plug. Install the junction. Always use a new quick-release connector with a rubber seal.

Lubricate the rubber seal using a drop of brake fluid. This facilitates joining.

Press the pipe into the junction. Lock the pipe using the clip.

Ensure that the rubber seal locates all the way around.