1999-05 - Volvo - S40 - 5 Cylinders 2.5L FI Turbo DOHC - 32993902 PDF

Engine Cooling
Volvo Cars 1999-05
Removal & Installation

Print
1. Before servicing the vehicle, refer to the Precautions section.

2. Drain the cooling system.
3. Remove or disconnect the following:
Negative battery cable

Spark plug cover
Fuel line clips
Expansion tank
Accessory drive belts
Vibration damper guard
Front wheel
Inner fender panel
Front timing cover
Timing belt
Water pump
To install:
1. Install or connect the following:
Water pump with a new gasket. Tighten the bolts to 15 ft. lbs. (20 Nm).
Timing belt
Front timing cover
Inner fender panel
Front wheel
Expansion tank
Fuel line clips
Spark plug cover
2. Fill the cooling system.

3. Start the engine and check for leaks.
1. Before servicing the vehicle, refer to the Precautions Section.

3. Remove the timing belt.
4. Securely attach a lifting device to the engine and raise it slightly to access the top two bolts of the water pump.
5. Lower the engine and remove the remaining bolts.
6. Gently tap the pump wheel with a mallet to remove.
To install:
1. Using a new pump and gasket, tighten the bolts alternately to 13 ft. lbs. (17 Nm).
2. Install the timing belt.
4-Cylinder Engines

Accessory belt
Timing belt cover
Timing belt
Water pump
To install:
Fig. Water pump and gasket
Water pump and gasket
Fig. Water pump installation
Water pump installation
Water pump with a new gasket. Tighten bolts to 13 ft. lbs. (17 Nm).
Timing belt
Timing belt cover. Tighten bolts to 9 ft. lbs. (12 Nm).
Accessory belt



Accessory belt
Timing belt cover
Timing belt
Water pump
To install:
Fig. Water pump and gasket
Water pump and gasket
Fig. Water pump installation
Water pump installation
Water pump with a new gasket. Tighten bolts to 13 ft. lbs. (17 Nm)
Timing belt
Timing belt cover. Tighten bolts to 108 inch lbs. (12 Nm)
Accessory drive belt

6-Cylinder Engines

Timing belt
Water pump
To install:
Water pump with a new gasket. Tighten bolts to 13 ft. lbs. (17 Nm).
Timing belt



Timing belt
Water pump
To install:
Timing belt

Rear Wheel Drive

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Front cover
Timing belt
Water pump
To install:
Timing belt
Front cover

Except Rear Wheel Drive


Spark plug cover
Fuel line clips
Expansion tank
Front wheel
Inner fender panel
Front timing cover
Timing belt
Water pump
To install:
Timing belt
Front timing cover
Inner fender panel
Front wheel
Expansion tank
Fuel line clips
Spark plug cover

5-Cylinder Engines

Engine stabilizer brace
Servo reservoir
Expansion tank
Accessory belt
Front timing belt cover
Front wheel
Inner fender panel
Timing belt
Water pump
To install:
Timing belt
Front timing belt cover. Tighten bolts to 108 inch lbs. (12 Nm)
Accessory belt
Servo reservoir
Expansion tank
Engine stabilizer brace. Tighten the bolts at suspension turrets to 37 ft. lbs. (50 Nm). Tighten bolt for engine bracket to 59 ft. lbs. (80 Nm)
Inner fender panel
Front wheel

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Engine Electrical
Volvo Cars 1999-05
Distributor
Removal & Installation Print
These models use a Distributorless Ignition System (DIS) controlled by the Powertrain
Control Module (PCM).
6-Cylinder Engine And 1999-02 5-Cylinder Engines

These models use a Distributorless Ignition System (DIS) controlled by the Powertrain Control Module (PCM).
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Engine Mechanical
Volvo Cars 1999-05
Capacities
Print
CAPACITIES
Year Model Engine Engine Engine Oil with Transmission Transfer Case Drive Axle Fuel Tank Cooling System
Displacement Liters ID/VIN Filter (qts.) (pts.) (pts.) (gal.) (qts.)
5-Spd Auto. Front Rear
(pts.) (pts.)
2001 S40 1.9 B4204T3 5.7 7.5 NA 6.6
S60 2.4 B5244S 5.8 2.2 7.5 NA NA
S60 2.4T2.4 B5244T3 6.1 7.5 NA NA
S60 T5 2.3 B5234T3 6.1 2.2 7.5 NA NA
C70 LPT 2.4 B5244T3 6.2 7.5 18 NA
C70 HPT 2.3 B5234T3 6.2 2.2 7.5 18 NA
S80 2.9 B6294S 7.3 - NA NA
S80 T6 2.8 B6284T 7.3 - NA NA
V40 1.9 B4204T3 5.7 - NA NA
V70 T5 2.3 B5234T3 6.1 2.2 7.5 NA NA
V70
2.4 B5244S 6.1 2.2 - NA NA
2.4M
V70 2.4T2.4 B5244T3 6.1 - NA NA
V70XC
2.4 B5244T3 6.1 - 1.5 NA NA
AWD
1
NA: Information not available
2
- On turbocharged engines, add 0.7 US qts. if the cooler is drained
3
- Start by filling with 5.8 qts., then top up as needed
CAPACITIES
(pts.) (pts.)
2002 S40 1.9 B4204T3 5.7 7.5 NA 6.6
S60 2.4 B5244S 5.8 2.2 - NA NA
S60
2.4 B5244T3 6.1 - NA NA
2.4T
S60 T5 2.3 B5234T3 6.1 2.2 - NA NA
S60
2.4 B5244T3 6.1 - NA NA
AWD
C70
2.4 B5244T3 6.2 - 18 NA
LPT
C70
2.3 B5234T3 6.2 2.2 - 18 NA
HPT
S80 2.9 2.9 B6294S2 7.3 - NA NA
S80 T6 2.8 B6294T 7.3 - NA NA
V40 1.9 B4204T3 5.7 - NA NA
V70 2.4 2.4 B5244S 6.1 2.2 - NA NA
V70
2.4 B5244T3 6.1 - NA NA
2.4T
V70 T5 2.3 B5234T3 6.1 2.2 - NA NA
V70
2.4 B5244T3 6.1 NA NA NA NA
AWD
XC70
2.4 B5244T3 6.1 NA NA NA NA
AWD
1
2
3
CAPACITIES
(pts.) (pts.)
2003 S40 1.9 B4204T3 5.7 8 16 6
S60 2.4 B5244S 5.8 2.2 7.9 18.5 8.5
S60
2.4 B5244T3 6.1 2.2 7.9 18.5 9.3
2.4T
S60 T5 2.3 B5234T3 6.1 2.2 7.9 18.5 9.3
S60
2.3 B5254T 6.1 2.2 7.9 19 9.3
AWD
C70
2.4 B5244T7 6.2 8 17.9 7.4
LPT
C70
2.3 B5234T9 6.2 2.2 8 17.9 7.4
HPT
S80 2.9 2.9 B6294S2 7.3 13.4 21.1 9.3
S80 T6 2.8 B6294T 7.3 13.4 21.1 10.1
V40 1.9 B4204T3 5.7 8 16 6
V70 2.4 2.4 B5244S 6.1 2.2 7.9 18.5 NA
V70
2.4 B5244T3 6.1 7.9 18.5 NA
2.4T
V70 T5 2.3 B5234T3 6.1 2.2 7.9 18.5 NA
V70
2.3 B5254T 6.1 7.9 NA 19 NA
AWD
XC70
2.3 B5254T 6.1 7.9 NA 19 NA
AWD
1
2
3
CAPACITIES
(pts.) (pts.)
2004 S40 1.9 B4204T3 5.7 8 16 6
S60 2.4 B5244S 5.8 2.2 7.9 18.5 8.5
S60
2.4 B5244T3 6.1 2.2 7.9 18.5 9.3
2.4T
S60
2.3 B5234T3 6.1 2.2 7.9 18.5 9.3
T5
S60
2.3 B5254T 6.1 2.2 7.9 19 9.3
AWD
C70
2.4 B5244T7 6.2 8 17.9 7.4
LPT
C70
2.3 B5234T9 6.2 2.2 8 17.9 7.4
HPT
S80
2.9 B6294S2 7.3 13.4 21.1 9.3
2.9
S80
2.8 B6294T 7.3 13.4 21.1 10.1
T6
1
2
3
CAPACITIES
(pts.) (pts.)
2004 V40 1.9 B4204T3 5.7 8 16 6
cont. V70 2.4 2.4 B5244S 6.1 2.2 7.9 18.5 NA
V70
2.4 B5244T3 6.1 7.9 18.5 NA
2.5T
V70 T5 2.3 B5234T3 6.1 2.2 7.9 18.5 NA
V70
2.3 B5254T 6.1 7.9 NA NA 19 NA
AWD
XC70
2.3 B5254T 6.1 7.9 NA NA 19 NA
AWD
1
2
3
CAPACITIES
(pts.) (pts.)
S40
2005 2.4 B5244S 5.8 3.7 13.5 NA NA
2.4i
S40
2.5 B5254T3 NA 3.5 13.5 NA NA
T5
S60
2.4 B5244S 5.8 3.7 12.5 NA NA
2.4
S60
2.5 B5254T NA 3.7 12.5 NA NA
2.5T
S60 R 2.5 B5254T4 5.1 3.5 12.5 1.2 NA NA
S60
2.4 B5244T 5.8 3.5 12.5 NA NA
T5
S80
2.5 B5254T2 NA 12.5 NA NA
2.5T
S80
2.9 B6294T NA 20.9 NA NA
T6
V50
2.4 B5244S 5.8 3.7 13.5 NA NA
2.4i
V50
2.5 B5254T3 NA 3.5 13.5 NA NA
T5
V70
2.4 B5244S 5.8 3.7 12.5 NA NA
2.4
V70
2.5 B5254T2 NA 12.5 NA NA
2.5T
V70 R 2.5 B5254T4 5.1 12.5 1.2 NA NA
XC70 2.5 B5254T2 NA 12.5 NA NA NA
1
2
3
Fig.
Fig.
CAPACITIES
Year Model Engine Displacemnt Engine Oil with Transmission Transter Case Drive Axle Fuel Tank Cooling System Engine ID
Litercs (cc) Filter (qts.) (pts.) (pts.) (gal.) (qts.)
(pts.) (pts.)
1999 S70T-5 2.3 (2319) 6.1 2.2 8.4 18.5 7.6 B5234T3/53
C70 2.3 (2319) 6.1 2.2 8.4 18.5 7.6 B5234T3/53
V70T-5 2.3 (2319) 6.1 2.2 8.4 18.5 7.6 B5234T3/53
V70R
2.3 (2319) 6.1 8.4 1.7 2.9 18.5 7.6 B5234T3/53
AWD
S70 2.4 (2435) 6.1 2.2 8.4 18.5 7.6 B5254S/55
S70GLT 2.4 (2435) 6.1 8.4 18.5 7.6 B5254T/56
V70 2.4 (2435) 6.1 2.2 8.4 18.5 7.6 B5254S/55
V70GLT 2.4 (2435) 6.1 8.4 18.5 7.6 B5254T/56
V70
2.4 (2435) 6.1 8.4 1.7 2.9 18.5 7.6 B5254T/56
AWD
V70XC
2.4 (2435) 6.1 8.4 1.7 2.9 18.5 7.6 B5254T/56
AWD
1
NOTE: All capacities are approximate. Add fluid gradualy and check to be sure a proper fluid level is obtained.
2
A On turbocharged engines, add 0.7 US qts. if the cooler is drained
3
B 1030 axle: 2.8
CAPACITIES
Year Model Engine Displacemnt Engine Oil with Transmission Transter Case Drive Axle Fuel Tank Cooling System Engine ID
Litercs (cc) Filter (qts.) (pts.) (pts.) (gal.) (qts.)
(pts.) (pts.)
2000 S70T-5 2.3 (2319) 6.1 2.2 8.4 18.5 7.6 B5234T3/53
C70 2.3 (2319) 6.1 2.2 8.4 18.5 7.6 B5234T3/53
V70T-5 2.3 (2319) 6.1 2.2 8.4 18.5 7.6 B5234T3/53
V70R
2.3 (2319) 6.1 8.4 1.7 2.9 18.5 7.6 B5234T3/53
AWD
S70 2.4 (2435) 6.1 2.2 8.4 18.5 7.6 B5254S/55
S70GLT 2.4 (2435) 6.1 8.4 18.5 7.6 B5254T/56
V70 2.4 (2435) 6.1 2.2 8.4 18.5 7.6 B5254S/55
V70GLT 2.4 (2435) 6.1 8.4 18.5 7.6 B5254T/56
V70
2.4 (2435) 6.1 8.4 1.7 2.9 18.5 7.6 B5254T/56
AWD
V70XC
2.4 (2435) 6.1 8.4 1.7 2.9 18.5 7.6 B5254T/56
AWD
1
NOTE: All capacities are approximate. Add fluid gradualy and check to be sure a proper fluid level is obtained.
2
A On turbocharged engines, add 0.7 US qts. if the cooler is drained
3
B 1030 axle: 2.8
CAPACITIES
Year Model Engine Engine Displ. Engine Oil with Filter Transmission Transter Case Drive Axle Fuel Tank Cooling System
ID Liters (qts.) A (pts.) (pts.) (gal.) (qts.)
(pts.) (pts.)
1999 S70T-5 B5234T3 2.3 6.1 2.2 8.4 18.5 7.6
C70 B5234T3 2.3 6.1 2.2 8.4 18.5 7.6
V70T-5 B5234T3 2.3 6.1 2.2 8.4 18.5 7.6
V70R
B5234T3 2.3 6.1 8.4 1.7 2.9 18.5 7.6
AWD
S70 B5254S 2.4 6.1 2.2 8.4 18.5 7.6
S70GLT B5254T 2.4 6.1 8.4 18.5 7.6
V70 B5254S 2.4 6.1 2.2 8.4 18.5 7.6
V70GLT B5254T 2.4 6.1 8.4 18.5 7.6
V70 AWD B5254T 2.4 6.1 8.4 1.7 2.9 18.5 7.6
V70XC
B5254T 2.4 6.1 8.4 1.7 2.9 18.5 7.6
AWD
1
2
3
4
- Automatic: 9 qts. / Manual: 8.5 qts.
CAPACITIES
(pts.) (pts.)
2000 S70T-5 B5234T3 2.3 6.1 2.2 8.4 18.5 7.6
C70 B5234T3 2.3 6.1 2.2 8.4 18.5 7.6
V70T-5 B5234T3 2.3 6.1 2.2 8.4 18.5 7.6
V70R
B5234T3 2.3 6.1 8.4 1.7 2.9 18.5 7.6
AWD
S70 B5254S 2.4 6.1 2.2 8.4 18.5 7.6
S70GLT B5254T 2.4 6.1 8.4 18.5 7.6
V70 B5254S 2.4 6.1 2.2 8.4 18.5 7.6
V70GLT B5254T 2.4 6.1 8.4 18.5 7.6
V70 AWD B5254T 2.4 6.1 8.4 1.7 2.9 18.5 7.6
V70XC
AWD B5254T 2.4 6.1 8.4 1.7 2.9 18.5 7.6
1
2
3
4
CAPACITIES
(pts.) (pts.)
2001 S40 B4204T3 1.9 5.7 7.5 NA 6.6
S60 B5244S 2.4 5.8 2.2 7.5 NA NA
S60 2.4T B5244T3 2.4 6.1 7.5 NA NA
S60 T5 B5234T3 2.3 6.1 2.2 7.5 NA NA
C70 LPT B5244T3 2.4 6.2 7.5 18.0 NA
C70 HPT B5234T3 2.3 6.2 2.2 7.5 18.0 NA
S80 B6294S 2.9 7.3 - NA NA
S80 T6 B6284T 2.8 7.3 - NA NA
V40 B4204T3 1.9 5.7 - NA NA
V70 T5 B5234T3 2.3 6.1 2.2 7.5 NA NA
V70 2.4M B5244S 2.4 6.1 2.2 - NA NA
V70 2.4T B5244T3 2.4 6.1 - NA NA
V70XC
B5244T3 2.4 6.1 - 1.5 NA NA
AWD
1
2
3
4
CAPACITIES
(pts.) (pts.)
2002 S40 B4204T3 1.9 5.7 7.5 NA 6.6
S60 B5244S 2.4 5.8 2.2 - NA NA
S60
B5244T3 2.4 6.1 - NA NA
2.4T
S60 T5 B5234T3 2.3 6.1 2.2 - NA NA
S60
B5244T3 2.4 6.1 - NA NA
AWD
C70 LPT B5244T3 2.4 6.2 - 18.0 NA
C70 HPTB5234T3 2.3 6.2 2.2 - 18.0 NA
S80 2.9 B6294S22.9 7.3 - NA NA
S80 T6 B6294T 2.8 7.3 - NA NA
V40 B4204T3 1.9 5.7 - NA NA
V70 2.4 B5244S 2.4 6.1 2.2 - NA NA
V70
B5244T3 2.4 6.1 - NA NA
2.4T
V70 T5 B5234T3 2.3 6.1 2.2 - NA NA
V70
B5244T3 2.4 6.1 NA NA NA NA
AWD
XC70
B5244T3 2.4 6.1 NA NA NA NA
AWD
1
2
3
4
CAPACITIES
(pts.) (pts.)
2003 S40 B4204T3 1.9 5.7 8.0 16 6.0
S60 B5244S 2.4 5.8 2.2 7.9 18.5 8.5
S60
B5244T3 2.4 6.1 2.2 7.9 18.5 9.3
2.4T
S60 T5 B5234T3 2.3 6.1 2.2 7.9 18.5 9.3
S60
B5254T 2.3 6.1 2.2 7.9 19 9.3
AWD
C70 LPT B5244T7 2.4 6.2 8.0 17.9 7.4
C70 HPTB5234T9 2.3 6.2 2.2 8.0 17.9 7.4
S80 2.9 B6294S22.9 7.3 13.4 21.1 9.3
S80 T6 B6294T 2.8 7.3 13.4 21.1 10.1
V40 B4204T3 1.9 5.7 8.0 16 6.0
V70 2.4 B5244S 2.4 6.1 2.2 7.9 18.5 NA
V70
B5244T3 2.4 6.1 7.9 18.5 NA
2.4T
V70 T5 B5234T3 2.3 6.1 2.2 7.9 18.5 NA
V70
B5254T 2.3 6.1 7.9 NA 19 NA
AWD
XC70
B5254T 2.3 6.1 7.9 NA 19 NA
AWD
1
2
3
4
CAPACITIES
(pts.) (pts.)
2004 S40 B4204T3 1.9 5.7 8.0 16 6.0
S60 B5244S 2.4 5.8 2.2 7.9 18.5 8.5
S60
B5244T3 2.4 6.1 2.2 7.9 18.5 9.3
2.4T
S60 T5 B5234T3 2.3 6.1 2.2 7.9 18.5 9.3
S60
B5254T 2.3 6.1 2.2 7.9 19 9.3
AWD
C70 LPT B5244T7 2.4 6.2 8.0 17.9 7.4
C70 HPTB5234T9 2.3 6.2 2.2 8.0 17.9 7.4
S80 2.9 B6294S22.9 7.3 13.4 21.1 9.3
S80 T6 B6294T 2.8 7.3 13.4 21.1 10.1
V40 B4204T3 1.9 5.7 8.0 16 6.0
V70 2.4 B5244S 2.4 6.1 2.2 7.9 18.5 NA
V70
B5244T3 2.4 6.1 7.9 18.5 NA
2.5T
V70 T5 B5234T3 2.3 6.1 2.2 7.9 18.5 NA
V70
B5254T 2.3 6.1 7.9 NA NA 19 NA
AWD
XC70
B5254T 2.3 6.1 7.9 NA NA 19 NA
AWD
1
2
3
4
CAPACITIES
(pts.) (pts.)
S40
2005 B5244S 2.4 5.8 3.7 13.5 NA NA
2.4i
S40 T5 B5254T3 2.5 NA 3.5 13.5 NA NA
S60
B5244S 2.4 5.8 3.7 12.5 NA NA
2.4
S60
B5254T 2.5 NA 3.7 12.5 NA NA
2.5T
S60 R B5254T4 2.5 5.1 3.5 12.5 1.2 NA NA
S60 T5 B5244T 2.4 5.8 3.5 12.5 NA NA
S80
B5254T2 2.5 NA 12.5 NA NA
2.5T
S80 T6 B6294T 2.9 NA 20.9 NA NA
V50
B5244S 2.4 5.8 3.7 13.5 NA NA
2.4i
V50 T5B5254T3 2.5 NA 3.5 13.5 NA NA
V70
B5244S 2.4 5.8 3.7 12.5 NA NA
2.4
V70
B5254T2 2.5 NA 12.5 NA NA
2.5T
V70 R B5254T4 2.5 5.1 12.5 1.2 NA NA
XC70 B5254T2 2.5 NA 12.5 NA NA NA
1
2
3
4
CAPACITIES
(pts.) (pts.)
C70
2006 B5254T3 2.5 6.1 - 8.2 15.9 -
T5
S40
B5244S 2.4 6.1 - 8.2 15.9 -
2.4i
S40 T5 B5254T3 2.5 6.1 - 8.2 15.9 -
S60
B5254T 2.5 6.1 - 18 8.4
2.5T
S60 R B5254T4 2.5 5.8 - - 18 8.4
S60 T5 B5244T 2.4 6.1 - - 18 8.4
S80
B5254T 2.5 6.1 - 18 8.4
2.5T
V50
B5244S 2.4 6.1 - 8.2 15.9 -
2.4i
V50 T5B5254T3 2.5 6.1 - 8.2 15.9 -
V70
B5244S 2.4 6.1 - - 18.5 9.3
2.4
V70
B5254T2 2.5 6.1 - 18 8.5
2.5T
V70 R B5254T4 2.5 5.8 - - 18 8.4
XC70 B5254T2 2.5 6.1 - 18 8.5
1
2
3
4
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Volvo Cars 1999-05
Crankshaft & Connecting Rod Specifications

Print
CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

Year Engine Displacement Engine Crankshaft Connecting Rod
Liters ID/VIN
Main Brg. Journal Main Brg. Oil Shaft End- Thrust on Journal Oil Side
Dia. Clearance play No. Diameter Clearance Clearance
2001 1.9 B4204T3 NA NA NA NA NA NA NA
2.3 B5234T3 2.5589 - NA 0.003- NA 1.9679- NA 0.006-
2.5597 0.007 1.9685 0.018
2.4 B5244S 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
2.4 B5244T3 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
2.8 B6284T 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
2.9 B6294S 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
1
2
All measurements are given in inches.

Liters ID/VIN
2.3 B5234T3 2.5589 - NA 0.003- NA 1.9679- NA 0.006-
2.5597 0.007 1.9685 0.018
2.4 B5244T3 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
2.4 B5244S 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
2.9 B6294S2 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
2.9 B6294T 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
1
2

Liters ID/VIN
2.3 B5234T3 2.5589 - NA 0.003- NA 1.9679- NA 0.006-
2.5597 0.007 1.9685 0.018
2.4 B5244T3 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
2.4 B5244S 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
2.5 B5254T 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
2.3 B5234T9 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
2.4 B5244T7 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
2.9 B6294S2 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
2.9 B6294T 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
1
2

Liters ID/VIN
2.3 B5234T3 2.5589 - NA 0.003- NA 1.9679- NA 0.006-
2.5597 0.007 1.9685 0.018
2.4 B5244S 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
2.5 B5254T 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
2.3 B5234T9 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
1
2

Liters ID/VIN
2004 2.4 B5244T7 2.5589 - NA 0.003- NA NA NA NA
1
2

Liters ID/VIN
cont. 2.5597 0.007
2.9 B6294S2 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
2.9 B6294T 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
1
2
Liters ID/VIN
2005 2.4 B5244S 2.5584 - NA 0.003- NA NA NA NA
2.5592 0.007
2.5 B5254T3 2.5584 - NA 0.003- NA NA NA NA
2.5592 0.007
2.5 B5254T 2.5584 - NA 0.003- NA NA NA NA
2.5592 0.007
2.5 B5254T4 2.5584 - NA 0.003- NA NA NA NA
2.5592 0.007
2.5 B5254T2 2.5584 - NA 0.003- NA NA NA NA
2.5592 0.007
2.4 B5244T 2.5584 - NA 0.003- NA NA NA NA
2.5592 0.007
2.9 B6294T 2.5584 - NA 0.003- NA NA NA NA
2.5592 0.007
1
2
Fig.
Fig.

all measurements are given in inches.
Year Engine Engine Displacement Chankshaft Connecting Rod
ID/VIN Liters (cc)
1999 B5234T3/53 2.3 (2319) 2.5584- 0.0007- 0.003- 5 1.9679- NA 0.006-
2.5592 0.0017 0.007 1.9685 0.018
B5254S/55 2.4 (2435) 2.5584- 0.0007- 0.003- 5 1.9679- NA 0.006-
2.5592 0.0017 0.007 1.9685 0.018
B5254T/56 2.4 (2435) 2.5584- 0.0007- 0.003- 5 1.9679- NA 0.006-
2.5592 0.0017 0.007 1.9685 0.018
1
NA: Not Available

Year Engine Engine Displacement Chankshaft Connecting Rod
ID/VIN Liters (cc)
2000 B5234T3/53 2.3 (2319) 2.5584- 0.0007- 0.003- 5 1.9679- NA 0.006-
2.5592 0.0017 0.007 1.9685 0.018
B5254S/55 2.4 (2435) 2.5584- 0.0007- 0.003- 5 1.9679- NA 0.006-
2.5592 0.0017 0.007 1.9685 0.018
B5254T/56 2.4 (2435) 2.5584- 0.0007- 0.003- 5 1.9679- NA 0.006-
2.5592 0.0017 0.007 1.9685 0.018
1
NA: Not Available

Year Engine Engine Displacement Crankshaft Connecting Rod
ID Liters
1999 B5234T3 2.3 2.5584- 0.0007- 0.003- 5 1.9679- NA 0.006-
2.5592 0.0017 0.007 1.9685 0.018
B5254S 2.4 2.5584- 0.0007- 0.003- 5 1.9679- NA 0.006-
2.5592 0.0017 0.007 1.9685 0.018
B5254T 2.4 2.5584- 0.0007- 0.003- 5 1.9679- NA 0.006-
2.5592 0.0017 0.007 1.9685 0.018
1

ID Liters
2000 B5234T3 2.3 2.5584- 0.0007- 0.003- 5 1.9679- NA 0.006-
2.5592 0.0017 0.007 1.9685 0.018
B5254S 2.4 2.5584- 0.0007- 0.003- 5 1.9679- NA 0.006-
2.5592 0.0017 0.007 1.9685 0.018
B5254T 2.4 2.5584- 0.0007- 0.003- 5 1.9679- NA 0.006-

2.5592 0.0017 0.007 1.9685 0.018
1
ID Liters
2001 B4204T3 1.9 NA NA NA NA NA NA NA
B5234T3 2.3 2.5589 - NA 0.003- NA 1.9679- NA 0.006-

2.5597 0.007 1.9685 0.018
B5244S 2.4 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
B5244T3 2.4 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
B6284T 2.8 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
B6294S 2.9 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
1

ID Liters
B5234T3 2.3 2.5589 - NA 0.003- NA 1.9679- NA 0.006-

2.5597 0.007 1.9685 0.018
B5244T3 2.4 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
B5244S 2.4 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
B6294S22.9 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
B6294T 2.9 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
1

ID Liters
B5234T3 2.3 2.5589 - NA 0.003- NA 1.9679- NA 0.006-

2.5597 0.007 1.9685 0.018
B5244T3 2.4 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
B5244S 2.4 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
B5254T 2.5 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
B5234T9 2.3 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
B5244T7 2.4 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
B6294S22.9 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
B6294T 2.9 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
1

ID Liters
B5234T3 2.3 2.5589 - NA 0.003- NA 1.9679- NA 0.006-

2.5597 0.007 1.9685 0.018
B5244S 2.4 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
B5254T 2.5 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
B5234T9 2.3 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
B5244T7 2.4 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
B6294S22.9 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
B6294T 2.9 2.5589 - NA 0.003- NA NA NA NA
2.5597 0.007
1

ID Liters
2005 B5244S 2.4 2.5584 - NA 0.003- NA NA NA NA
2.5592 0.007
B5254T3 2.5 2.5584 - NA 0.003- NA NA NA NA
2.5592 0.007
B5254T 2.5 2.5584 - NA 0.003- NA NA NA NA
2.5592 0.007
B5254T4 2.5 2.5584 - NA 0.003- NA NA NA NA
2.5592 0.007
B5254T2 2.5 2.5584 - NA 0.003- NA NA NA NA
2.5592 0.007
B5244T 2.4 2.5584 - NA 0.003- NA NA NA NA
2.5592 0.007
B6294T 2.9 2.5584 - NA 0.003- NA NA NA NA
2.5592 0.007
1

ID Liters
2006 B5244S 2.4 NA NA NA NA NA NA NA
B5244T 2.4 NA NA NA NA NA NA NA
B5254T 2.5 2.5590- NA 0.0030- NA NA NA NA

2.5596 0.0070
B5254T2 2.5 2.5590- NA 0.0030- NA NA NA NA
2.5596 0.0070
B5254T3 2.5 2.5590- NA 0.0030- NA NA NA NA
2.5596 0.0070
B5254T4 2.5 2.5590- NA 0.0030- NA NA NA NA
2.5596 0.0070
1
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Volvo Cars 1999-05
Gasoline Engine Tune-Up Specifications

Print
ENGINE TUNE-UP SPECIFICATIONS

Year Engine Displacement Engine Spark Plug Gap Ignition Timing Fuel Pump Idle Speed Valve Clearance
Liters ID/VIN (in.) (deg.) (psi) (rmp) (in.)
MT AT MT AT In. Ex.
2001 1.9 B4204T3 0.03 NA NA 32-45 NA NA HYD HYD
2.3 B5234T3 0.03 NA NA 55 670 670 HYD HYD
2.4 B5244S 0.03 NA NA 55 670 670 HYD HYD
2.4 B5244T3 0.03 NA NA 55 670 670 HYD HYD
2.8 B6284T 0.03 NA NA 55 650 650 HYD HYD
2.9 B6294S 0.03 NA NA 55 650 650 HYD HYD
1
HYD: Hydraulic lash adjusters

MT AT MT AT In. Ex.
2.3 B5234T3 0.03 NA NA 55 670 670 HYD HYD
2.4 B5244T3 0.03 NA NA 55 670 670 HYD HYD
2.4 B5244S 0.03 NA NA 55 670 670 HYD HYD
2.9 B6294S2 0.03 NA NA 55 650 650 HYD HYD
2.8 B6294T 0.03 NA NA 55 650 650 HYD HYD
1

MT AT MT AT In. Ex.
2.3 B5234T3 0.03 NA NA 55 670 670 HYD HYD
2.4 B5244T3 0.03 NA NA 55 670 670 HYD HYD
2.4 B5244S 0.03 NA NA 55 670 670 HYD HYD
2.5 B5254T 0.03 NA NA 55 850 850 HYD HYD
2.3 B5234T9 0.03 NA NA 55 670 670 HYD HYD
2.4 B5244T7 0.03 NA NA 55 670 670 HYD HYD
2.9 B6294T 0.03 NA NA 55 650 650 HYD HYD
2.9 B6294S2 0.03 NA NA 55 650 650 HYD HYD
1

MT AT MT AT In. Ex.
2.3 B5234T3 0.03 NA NA 55 670 670 HYD HYD
2.4 B5244S 0.03 NA NA 55 670 670 HYD HYD
2.5 B5254T 0.03 NA NA 55 850 850 HYD HYD
2.3 B5234T9 0.03 NA NA 55 670 670 HYD HYD
2.4 B5244T7 0.03 NA NA 55 670 670 HYD HYD
2.9 B6294S2 0.03 NA NA 55 650 650 HYD HYD
2.9 B6294T 0.03 NA NA 55 650 650 HYD HYD
1

MT AT MT AT In. Ex.
2005 2.4 B5244S 0.03 NA NA NA 670 670 HYD HYD
2.5 B5254T3 0.03 NA NA NA NA NA HYD HYD
2.5 B5254T 0.03 NA NA NA NA NA HYD HYD
2.5 B5254T4 0.03 NA NA NA 720 720 HYD HYD
2.4 B5244T 0.03 NA NA NA 670 670 HYD HYD
2.9 B6294T 0.03 NA NA 55 NA 650 HYD HYD
2.5 B5254T2 0.03 NA NA NA 850 850 HYD HYD
1
Fig.

Year Engine Displacement Liters Engine Spark Plug Gap Ignition Timing Fuel Pump Idle Speed Valve Clearance
(cc) ID/VIN (in.) (deg.) (psi) (rmp) (in.)
MT AT MT AT In. Ex.
1999 2.3 (2319) B5234T3/53 0.030 6B 6B 58 800-900 800-900 HYD HYD
2.3 (2319) B5234T3/53 0.030 6B 6B 58 800-900 800-900 HYD HYD
2.4 (2435) B5254S/55 0.020 10B 10B 43 800-900 800-900 HYD HYD
2.4 (2435) B5254T/56 0.030 10B 10B 58 800-900 800-900 HYD HYD
1

Year Engine Displacement Liters Engine Spark Plug Gap Ignition Timing Fuel Pump Idle Speed Valve Clearance
(cc) ID/VIN (in.) (deg.) (psi) (rmp) (in.)
MT AT MT AT In. Ex.
2000 2.3 (2319) B5234T3/53 0.030 6B 6B 58 800-900 800-900 HYD HYD
2.3 (2319) B5234T3/53 0.030 6B 6B 58 800-900 800-900 HYD HYD
2.4 (2435) B5254S/55 0.020 10B 10B 43 800-900 800-900 HYD HYD
2.4 (2435) B5254T/56 0.030 10B 10B 58 800-900 800-900 HYD HYD
1

Year Engine ID Engine Displacement Liters Spark Plug Gap (in.) Fuel Pump (psi) Ignition Timing (deg.) Idle Speed (rpm) Valve Clearance
MT AT MT AT In. Ex.
1999 B5234T3 2.3 0.030 58 6B 6B 800-900 800-900 HYD HYD
B5234T3 2.3 0.030 58 6B 6B 800-900 800-900 HYD HYD
B5254S 2.4 0.020 43 10B 10B 800-900 800-900 HYD HYD
B5254T 2.4 0.030 58 10B 10B 800-900 800-900 HYD HYD
1

MT AT MT AT In. Ex.
2000 B5234T3 2.3 0.030 58 6B 6B 800-900 800-900 HYD HYD
B5234T3 2.3 0.030 58 6B 6B 800-900 800-900 HYD HYD
B5254S 2.4 0.020 43 10B 10B 800-900 800-900 HYD HYD
B5254T 2.4 0.030 58 10B 10B 800-900 800-900 HYD HYD
1

MT AT MT AT In. Ex.
2001 B4204T3 1.9 0.030 32-45 NA NA NA NA HYD HYD
B5234T3 2.3 0.030 55 NA NA 670 670 HYD HYD
B5244S 2.4 0.030 55 NA NA 670 670 HYD HYD
B5244T3 2.4 0.030 55 NA NA 670 670 HYD HYD
B6284T 2.8 0.030 55 NA NA 650 650 HYD HYD
B6294S 2.9 0.030 55 NA NA 650 650 HYD HYD
1

MT AT MT AT In. Ex.
B5234T3 2.3 0.030 55 NA NA 670 670 HYD HYD
B5244T3 2.4 0.030 55 NA NA 670 670 HYD HYD
B5244S 2.4 0.030 55 NA NA 670 670 HYD HYD
B6294S2 2.9 0.030 55 NA NA 650 650 HYD HYD
B6294T 2.8 0.030 55 NA NA 650 650 HYD HYD
1

MT AT MT AT In. Ex.
B5234T3 2.3 0.030 55 NA NA 670 670 HYD HYD
B5244T3 2.4 0.030 55 NA NA 670 670 HYD HYD
B5244S 2.4 0.030 55 NA NA 670 670 HYD HYD
B5254T 2.5 0.030 55 NA NA 850 850 HYD HYD
B5234T9 2.3 0.030 55 NA NA 670 670 HYD HYD
B5244T7 2.4 0.030 55 NA NA 670 670 HYD HYD
B6294T 2.9 0.030 55 NA NA 650 650 HYD HYD
B6294S2 2.9 0.030 55 NA NA 650 650 HYD HYD
1

MT AT MT AT In. Ex.
B5234T3 2.3 0.030 55 NA NA 670 670 HYD HYD
B5244S 2.4 0.030 55 NA NA 670 670 HYD HYD
B5254T 2.5 0.030 55 NA NA 850 850 HYD HYD
B5234T9 2.3 0.030 55 NA NA 670 670 HYD HYD
B5244T7 2.4 0.030 55 NA NA 670 670 HYD HYD
B6294S2 2.9 0.030 55 NA NA 650 650 HYD HYD
B6294T 2.9 0.030 55 NA NA 650 650 HYD HYD
1

MT AT MT AT In. Ex.
2005 B5244S 2.4 0.030 NA NA NA 670 670 HYD HYD
B5254T3 2.5 0.030 NA NA NA NA NA HYD HYD
B5254T 2.5 0.030 NA NA NA NA NA HYD HYD
B5254T4 2.5 0.030 NA NA NA 720 720 HYD HYD
B5244T 2.4 0.030 NA NA NA 670 670 HYD HYD
B6294T 2.9 0.030 55 NA NA NA 650 HYD HYD
B5254T2 2.5 0.030 NA NA NA 850 850 HYD HYD
1

MT AT MT AT In. Ex.
2006 B5244S 2.4 NA NA NA NA 720 720 HYD HYD
B5244T 2.4 NA NA NA NA 770 770 HYD HYD
B5254T 2.5 NA NA NA NA 670 NA HYD HYD
B5254T2 2.5 NA NA NA NA 670 NA HYD HYD
B5254T3 2.5 NA NA NA NA NA NA HYD HYD
B5254T4 2.5 NA NA NA NA NA NA HYD HYD
1
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Volvo Cars 1999-05
General Engine Specifications

Print
GENERAL ENGINE SPECIFICATIONS

Year Model Engine Displacement Engine Net Horsepower @ Net Torque @ rpm Bore x Stroke Compression Oil Pressure @
Liters ID/VIN rpm (ft. lbs) (in.) Ration rpm
2001 S40 1.9 B4204T3 160@5100 170@1800 NA 10.3:1 NA
S60 2.4 B5244S 168@5700 170@4500 3.27 x 3.54 10.3:1 50@4000
S60 2.4T 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 50@4000
S60 T5 2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 50@4000
C70 LP 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 50@4000
C70 HP 2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 50@4000
S80 2.9 B6294S 197@6000 277@2100 3.27 x 3.54 10.3:1 50@4000
S80 T6 2.8 B6284T 268@5400 206@4200 3.19 x 3.54 8.5:1 50@4000
V40 1.9 B4204T3 160@5250 177@1800 NA 10.3:1 NA
V70 T5 2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 50@4000
V70 2.4M 2.4 B5244S 168@5700 170@4500 3.27 x 3.54 10.3:1 50@4000
V70 2.4T 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 50@4000
V70XC
2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 50@4000
AWD
1
2

2002 S40 1.9 B4204T3 160@5250 177@1800 NA 10.3:1 NA
S60 2.4 B5244S 168@5700 170@4500 3.27 x 3.54 10.3:1 51@4000
S60 2.4T 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 51@4000
S60 T5 2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 51@4000
S60 AWD 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 51@4000
C70 HPT
2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 51@4000
Coupe
C70 LPT
2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 51@4000
Conv
C70 HPT
2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 51@4000
Conv
S80 2.9 2.9 B6294S2 197@6000 277@2100 3.27 x 3.54 10.3:1 51@4000
S80 T6 2.9 B6294T 268@5400 206@4200 3.19 x 3.54 8.5:1 51@4000
V40 1.9 B4204T3 160@5250 177@1800 NA 10.3:1 NA
V70 2.4 2.4 B5244S 168@5700 170@4500 3.27 x 3.54 10.3:1 51@4000
V70 2.4T 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 51@4000
V70 T5 2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 51@4000
V70 AWD 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 51@4000
XC70 AWD 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 51@4000
1
2

2003 S40 1.9 B4204T3 190@5500 177@1800 NA 9.0:1 NA
S60 2.4 B5244S 168@5700 170@4500 3.27 x 3.54 10.3:1 51@4000
S60 2.4T 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 51@4000
S60 T5 2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 51@4000
S60
2.5 B5254T 208@5000 235@1500 NA 9.5:1 NA
AWD
C70 LPT 2.4 B5244T7 197@5700 210@1800 3.27 x 3.54 9.0:1 NA
C70 HPT 2.3 B5234T9 242@5400 243@2400 3.19 x 3.54 8.5:1 NA
S80 2.9 2.9 B6294S2 197@6000 277@2100 3.27 x 3.54 10.3:1 51@4000
S80 T6 2.9 B6294T 268@5400 206@4200 3.19 x 3.54 8.5:1 51@4000
V40 1.9 B4204T3 160@5250 177@1800 NA 10.3:1 NA
V70 2.4 2.4 B5244S 168@5700 170@4500 3.27 x 3.54 10.3:1 51@4000
V70 2.4T 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 51@4000
V70 T5 2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 51@4000
V70
2.5 B5254T 208@5000 235@1500 NA 9.5:1 NA
AWD
XC70
2.5 B5254T 208@5000 235@1500 NA 9.5:1 NA
AWD
1
2

2004 S40 1.9 B4204T4 190@5500 177@1800 NA 9.0:1 NA
S60 2.4 2.4 B5244S 168@6000 166@4500 NA NA NA
S60 2.5T 2.5 B5254T 208@5000 236@1500 NA NA NA
S60 2.5T
2.5 B5254T 208@5000 236@1500 NA NA NA
AWD-R
S60 T5 2.3 B5234T3 247@5200 243@2400 3.19 x 3.54 8.5:1 NA
C70 LPT 2.4 B5244T7 197@5700 210@1800 3.27 x 3.54 9.0:1 NA
C70 HPT 2.3 B5234T9 242@5400 243@2400 3.19 x 3.54 8.5:1 NA
S80 2.9 2.9 B6294S2 197@6000 277@2100 3.27 x 3.54 10.3:1 51@4000
S80 T6 2.9 B6294T 268@5400 206@4200 3.19 x 3.54 8.5:1 51@4000
V40 1.9 B4204T4 190@5500 177@1800 NA 9.0:1 NA
V70 2.4 2.4 B5244S 168@6000 166@4500 NA NA NA
V70 2.5T 2.5 B5254T 208@5000 236@1500 NA NA NA
V70 T5 2.3 B5234T3 247@5200 243@2400 3.19 x 3.54 8.5:1 NA
V70 AWD 2.5 B5254T 208@5000 236@1500 NA NA NA
XC70 AWD 2.5 B5254T 208@5000 236@1500 NA NA NA
1
2

Year Model Engine Displacement Engine Net Horsepower @ Net Torque @ rpm (ft. Bore x Stroke Compression Oil Pressure @
Liters ID/VIN rpm lbs) (in.) Ration rpm
S40
2005 2.4 B5244S 169@6000 170@4400 NA 10.3:1 NA
2.4i
S40 T5 2.5 B5254T3 218@5000 236@4800 NA 9.0:1 51@4000
S60
2.4 B5244S 165@6000 166@4500 NA NA NA
2.4
S60
2.5 B5254T 208@5000 236@1500 NA NA NA
2.5T
S60 R 2.5 B5254T4 300@5500 295@1950 NA 8.5:1 NA
S60 T5 2.4 B5244T 257@5500 258@2100 NA NA NA
S80
2.5 B5254T 208@5000 236@1500 3.27 x 3.67 9.0:1 NA
2.5T
S80 T6 2.9 B6294T 268@5200 280@1800 3.28 x 3.56 8.7:1 51@4000
V50
2.4 B5244S 168@6000 170@4400 3.27 x 3.54 10.3:1 NA
2.4i
V50 T5 2.5 B5254T3 218@5000 236@4800 3.27 x 3.67 9.0:1 51@4000
V70
2.4 B5244S 165@6000 166@4500 3.27 x 3.54 10.3:1 NA
2.4
V70
2.5 B5254T2 300@6000 258@1850 NA 8.5:1 51@4000
2.5T
V70 R 2.5 B5254T4 300@5500 295@1950 3.27 x 3.67 8.5:1 NA
XC70 2.5 B5254T2 208@5000 236@1500 NA NA 51@4000
1
2
Fig.
Fig.

Year Model Engine Displacement Engine Fuel Net Horsepower Net Torque @ rpm Bore x Stroke Compression Oil Pressure @
Liters (cc) ID/VIN System @ rpm (ft. lbs) (in.) Ratio rpm
1999 S70T-5 2.3 (2319) B5234T3/53EFI 236@5100 243@2100 3.19 x 3.54 8.5:1 49.8@4000
C70 2.3 (2319) B5234T3/53EFI 236@5100 243@2700 3.19 x 3.54 8.5:1 49.8@4000
V70T-5 2.3 (2319) B5234T3/53EFI 236@5100 243@2100 3.19 x 3.54 8.5:1 49.8@4000
V70R
2.3 (2319) B5234T3/53EFI 236@5100 243@2100 3.19 x 3.54 8.5:1 49.8@4000
AWD
S70 2.4 (2435) B5254S/55 EFI 168@6100 162@4700 3.27 x 3.54 10.5:1 49.8@4000
S70GLT 2.4 (2435) B5254T/56 EFI 190@5200 199@1800 3.27 x 3.54 10.5:1 49.8@4000
V70 2.4 (2435) B5254S/55 EFI 168@6100 162@4700 3.27 x 3.54 10.5:1 49.8@4000
V70GLT 2.4 (2435) B5254T/56 EFI 190@5200 199@1800 3.27 x 3.54 10.5:1 49.8@4000
V70
2.4 (2435) B5254T/56 EFI 190@5200 199@1800 3.27 x 3.54 10.5:1 49.8@4000
AWD
V70XC
2.4 (2435) B5254T/56 EFI 190@5200 199@1800 3.27 x 3.54 10.5:1 49.8@4000
AWD
1
EFI: Electronic Fuel Injection

Year Model Engine Displacement Engine Fuel Net Horsepower Net Torque @ rpm Bore x Stroke Compression Oil Pressure @
Liters (cc) ID/VIN System @ rpm (ft. lbs) (in.) Ratio rpm
2000 S70T-5 2.3 (2319) B5234T3/53EFI 236@5100 243@2100 3.19 x 3.54 8.5:1 49.8@4000
C70 2.3 (2319) B5234T3/53EFI 236@5100 243@2700 3.19 x 3.54 8.5:1 49.8@4000
V70T-5 2.3 (2319) B5234T3/53EFI 236@5100 243@2100 3.19 x 3.54 8.5:1 49.8@4000
V70R
2.3 (2319) B5234T3/53EFI 236@5100 243@2100 3.19 x 3.54 8.5:1 49.8@4000
AWD
S70 2.4 (2435) B5254S/55 EFI 168@6100 162@4700 3.27 x 3.54 10.5:1 49.8@4000
S70GLT 2.4 (2435) B5254T/56 EFI 190@5200 199@1800 3.27 x 3.54 10.5:1 49.8@4000
V70 2.4 (2435) B5254S/55 EFI 168@6100 162@4700 3.27 x 3.54 10.5:1 49.8@4000
V70GLT 2.4 (2435) B5254T/56 EFI 190@5200 199@1800 3.27 x 3.54 10.5:1 49.8@4000
V70
2.4 (2435) B5254T/56 EFI 190@5200 199@1800 3.27 x 3.54 10.5:1 49.8@4000
AWD
V70XC
2.4 (2435) B5254T/56 EFI 190@5200 199@1800 3.27 x 3.54 10.5:1 49.8@4000
AWD
1
EFI: Electronic Fuel Injection

Liters ID rpm lbs) (in.) Ratio rpm
1999 S70T-5 2.3 B5234T3 236@5100 243@2100 3.19 x 3.54 8.5:1 49.8@4000
C70 2.3 B5234T3 236@5100 243@2700 3.19 x 3.54 8.5:1 49.8@4000
V70T-5 2.3 B5234T3 236@5100 243@2100 3.19 x 3.54 8.5:1 49.8@4000
V70R
2.3 B5234T3 236@5100 243@2100 3.19 x 3.54 8.5:1 49.8@4000
AWD
S70 2.4 B5254S 168@6100 162@4700 3.27 x 3.54 10.5:1 49.8@4000
S70GLT 2.4 B5254T 190@5200 199@1800 3.27 x 3.54 10.5:1 49.8@4000
V70 2.4 B5254S 168@6100 162@4700 3.27 x 3.54 10.5:1 49.8@4000
V70GLT 2.4 B5254T 190@5200 199@1800 3.27 x 3.54 10.5:1 49.8@4000
V70 AWD 2.4 B5254T 190@5200 199@1800 3.27 x 3.54 10.5:1 49.8@4000
V70XC
2.4 B5254T 190@5200 199@1800 3.27 x 3.54 10.5:1 49.8@4000
AWD
1
2000 S70T-5 2.3 B5234T3 236@5100 243@2100 3.19 x 3.54 8.5:1 49.8@4000
C70 2.3 B5234T3 236@5100 243@2700 3.19 x 3.54 8.5:1 49.8@4000
V70T-5 2.3 B5234T3 236@5100 243@2100 3.19 x 3.54 8.5:1 49.8@4000
V70R
2.3 B5234T3 236@5100 243@2100 3.19 x 3.54 8.5:1 49.8@4000
AWD
S70 2.4 B5254S 168@6100 162@4700 3.27 x 3.54 10.5:1 49.8@4000
S70GLT 2.4 B5254T 190@5200 199@1800 3.27 x 3.54 10.5:1 49.8@4000
V70 2.4 B5254S 168@6100 162@4700 3.27 x 3.54 10.5:1 49.8@4000
V70GLT 2.4 B5254T 190@5200 199@1800 3.27 x 3.54 10.5:1 49.8@4000
V70 AWD 2.4 B5254T 190@5200 199@1800 3.27 x 3.54 10.5:1 49.8@4000
V70XC
2.4 B5254T 190@5200 199@1800 3.27 x 3.54 10.5:1 49.8@4000
AWD
1

2001 S40 1.9 B4204T3 160@5100 170@1800 NA 10.3:1 NA
S60 2.4 B5244S 168@5700 170@4500 3.27 x 3.54 10.3:1 50@4000
S60 2.4T 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 50@4000
S60 T5 2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 50@4000
C70 LP 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 50@4000
C70 HP 2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 50@4000
S80 2.9 B6294S 197@6000 277@2100 3.27 x 3.54 10.3:1 50@4000
S80 T6 2.8 B6284T 268@5400 206@4200 3.19 x 3.54 8.5:1 50@4000
V40 1.9 B4204T3 160@5250 177@1800 NA 10.3:1 NA
V70 T5 2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 50@4000
V70 2.4M 2.4 B5244S 168@5700 170@4500 3.27 x 3.54 10.3:1 50@4000
V70 2.4T 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 50@4000
V70XC
2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 50@4000
AWD
1

2002 S40 1.9 B4204T3 160@5250 177@1800 NA 10.3:1 NA
S60 2.4 B5244S 168@5700 170@4500 3.27 x 3.54 10.3:1 51@4000
S60 2.4T 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 51@4000
S60 T5 2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 51@4000
S60 AWD 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 51@4000
C70 HPT
2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 51@4000
Coupe
C70 LPT
2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 51@4000
Conv
C70 HPT
2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 51@4000
Conv
S80 2.9 2.9 B6294S2197@6000 277@2100 3.27 x 3.54 10.3:1 51@4000
S80 T6 2.9 B6294T 268@5400 206@4200 3.19 x 3.54 8.5:1 51@4000
V40 1.9 B4204T3 160@5250 177@1800 NA 10.3:1 NA
V70 2.4 2.4 B5244S 168@5700 170@4500 3.27 x 3.54 10.3:1 51@4000
V70 2.4T 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 51@4000
V70 T5 2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 51@4000
V70 AWD 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 51@4000
XC70 AWD 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 51@4000
1

2003 S40 1.9 B4204T3 190@5500 177@1800 NA 9.0:1 NA
S60 2.4 B5244S 168@5700 170@4500 3.27 x 3.54 10.3:1 51@4000
S60 2.4T 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 51@4000
S60 T5 2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 51@4000
S60 AWD2.5 B5254T 208@5000 235@1500 NA 9.5:1 NA
C70 LPT 2.4 B5244T7 197@5700 210@1800 3.27 x 3.54 9.0:1 NA
C70 HPT 2.3 B5234T9 242@5400 243@2400 3.19 x 3.54 8.5:1 NA
S80 2.9 2.9 B6294S2 197@6000 277@2100 3.27 x 3.54 10.3:1 51@4000
S80 T6 2.9 B6294T 268@5400 206@4200 3.19 x 3.54 8.5:1 51@4000
V40 1.9 B4204T3 160@5250 177@1800 NA 10.3:1 NA
V70 2.4 2.4 B5244S 168@5700 170@4500 3.27 x 3.54 10.3:1 51@4000
V70 2.4T 2.4 B5244T3 197@6000 210@1800 3.27 x 3.54 9.0:1 51@4000
V70 T5 2.3 B5234T3 247@5220 241@2520 3.19 x 3.54 8.5:1 51@4000
V70 AWD2.5 B5254T 208@5000 235@1500 NA 9.5:1 NA
XC70
2.5 B5254T 208@5000 235@1500 NA 9.5:1 NA
AWD
1
1

2004 S40 1.9 B4204T4 190@5500 177@1800 NA 9.0:1 NA
S60 2.4 2.4 B5244S 168@6000 166@4500 NA NA NA
S60 2.5T 2.5 B5254T 208@5000 236@1500 NA NA NA
S60 2.5T
2.5 B5254T 208@5000 236@1500 NA NA NA
AWD-R
S60 T5 2.3 B5234T3 247@5200 243@2400 3.19 x 3.54 8.5:1 NA
C70 LPT 2.4 B5244T7 197@5700 210@1800 3.27 x 3.54 9.0:1 NA
C70 HPT 2.3 B5234T9 242@5400 243@2400 3.19 x 3.54 8.5:1 NA
S80 2.9 2.9 B6294S2197@6000 277@2100 3.27 x 3.54 10.3:1 51@4000
S80 T6 2.9 B6294T 268@5400 206@4200 3.19 x 3.54 8.5:1 51@4000
V40 1.9 B4204T4 190@5500 177@1800 NA 9.0:1 NA
V70 2.4 2.4 B5244S 168@6000 166@4500 NA NA NA
V70 2.5T 2.5 B5254T 208@5000 236@1500 NA NA NA
V70 T5 2.3 B5234T3 247@5200 243@2400 3.19 x 3.54 8.5:1 NA
V70 AWD 2.5 B5254T 208@5000 236@1500 NA NA NA
XC70 AWD 2.5 B5254T 208@5000 236@1500 NA NA NA
1

S40
2005 2.4 B5244S 169@6000 170@4400 NA 10.3:1 NA
2.4i
S40 T5 2.5 B5254T3 218@5000 236@4800 NA 9.0:1 51@4000
S60 2.4 2.4 B5244S 165@6000 166@4500 NA NA NA
S60
2.5 B5254T 208@5000 236@1500 NA NA NA
2.5T
S60 R 2.5 B5254T4 300@5500 295@1950 NA 8.5:1 NA
S60 T5 2.4 B5244T 257@5500 258@2100 NA NA NA
S80
2.5 B5254T 208@5000 236@1500 3.27 x 3.67 9.0:1 NA
2.5T
S80 T6 2.9 B6294T 268@5200 280@1800 3.28 x 3.56 8.7:1 51@4000
V50
2.4 B5244S 168@6000 170@4400 3.27 x 3.54 10.3:1 NA
2.4i
V50 T5 2.5 B5254T3 218@5000 236@4800 3.27 x 3.67 9.0:1 51@4000
V70 2.42.4 B5244S 165@6000 166@4500 3.27 x 3.54 10.3:1 NA
V70
2.5 B5254T2 300@6000 258@1850 NA 8.5:1 51@4000
2.5T
V70 R 2.5 B5254T4 300@5500 295@1950 3.27 x 3.67 8.5:1 NA
XC70 2.5 B5254T2 208@5000 236@1500 NA NA 51@4000
1

2006 C70 T5 2.5 B5254T3 218@5000 236@4800 3.27 x 3.67 9.0:1 51@4000
S40
2.4 B5244S 168@6000 170@4400 3.24 x 3.54 10.3:1 51@4000
2.4i
S40 T5 2.5 B5254T3 218@5000 236@4800 3.27 x 3.67 9.0:1 51@4000
S60
2.5 B5254T 208@5000 236@1500 3.27 x 3.67 9.0:1 51@4000
2.5T
S60 R 2.5 B5254T4 300@5500 295@1950 3.27 x 3.67 8.5:1 51@4000
S60 T5 2.4 B5244T 257@5500 258@2100 3.20 x 3.67 8.5:1 51@4000
S80
2.5 B5254T 208@5000 236@1500 3.27 x 3.67 9.0:1 51@4000
2.5T
V50
2.4 B5244S 168@6000 170@4400 3.27 x 3.54 10.3:1 51@4000
2.4i
V50 T5 2.5 B5254T3 218@5000 236@4800 3.27 x 3.67 9.0:1 51@4000
V70 2.42.4 B5244S 165@6000 166@4500 3.27 x 3.54 10.3:1 51@4000
V70
2.5 B5254T2 208@5000 236@1500 3.27 x 3.67 8.5:1 51@4000
2.5T
V70 R 2.5 B5254T4 300@5500 295@1950 3.27 x 3.67 8.5:1 51@4000
XC70 2.5 B5254T2 208@5000 236@1500 3.27 x 3.67 8.5:1 51@4000
1
Back to Top
Volvo Cars 1999-05
Piston & Ring Specifications

Print
PISTON AND RING SPECIFICATIONS
Year Engine Displacement Engine Piston Ring Gap Ring Side Clearance
Liters ID/VIN Clearance
Top Bottom Oil Top Bottom Oil
Compression Compression Control Compression Compression Control
2.3 B5234T3 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.4 B5244S 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.4 B5244T3 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.8 B6284T 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.9 B6294S 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
1
2

2.3 B5234T3 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.4 B5244T3 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.4 B5244S 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.9 B6294S2 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.9 B6294T 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
1
2

2.3 B5234T3 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.4 B5244T3 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.4 B5244S 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.5 B5254T 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.3 B5234T9 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.4 B5244T7 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.9 B6294S2 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.9 B6294T 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
1
2

2.3 B5234T3 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.4 B5244S 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.5 B5254T 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.3 B5234T9 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
1
2
2004 2.4 B5244T7 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
1
2

cont. 0.0012 0.0028 0.0028 0.0056
2.9 B6294S2 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.9 B6294T 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
1
2

2005 2.4 B5244S 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.5 B5254T3 0.0004- NA NA NA NA NA NA
0.0012
2.5 B5254T 0.0004- NA NA NA NA NA NA
0.0012
2.5 B5254T4 0.0004- NA NA NA NA NA NA
0.0012
2.5 B5254T2 0.0004- NA NA NA NA NA NA
0.0012
2.4 B5244T 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.9 B6294T 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
1
2
Fig.
Fig.

Liters (cc) ID/VIN Clearance
1999 2.3 (2319) B5234T3/53 0.0004- 0.047 0.069 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.4 (2435) B5254S/55 0.0004- 0.047 0.069 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.4 (2435) B5254T/56 0.0004- 0.047 0.069 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022

Liters (cc) ID/VIN Clearance
2000 2.3 (2319) B5234T3/53 0.0004- 0.047 0.069 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.4 (2435) B5254S/55 0.0004- 0.047 0.069 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.4 (2435) B5254T/56 0.0004- 0.047 0.069 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022

Liters ID Clearance
1999 2.3 B5234T3 0.0004- 0.047 0.069 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.4 B5254S 0.0004- 0.047 0.069 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.4 B5254T 0.0004- 0.047 0.069 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
1

Liters ID Clearance
2000 2.3 B5234T3 0.0004- 0.047 0.069 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.4 B5254S 0.0004- 0.047 0.069 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.4 B5254T 0.0004- 0.047 0.069 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
1

Liters ID Clearance
2.3 B5234T3 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-

0.0012 0.0033 0.0026 0.0022
2.4 B5244S 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.4 B5244T3 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.8 B6284T 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.9 B6294S 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
1

Liters ID Clearance
2.3 B5234T3 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-

0.0012 0.0033 0.0026 0.0022
2.4 B5244T3 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.4 B5244S 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.9 B6294S2 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.9 B6294T 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
1
Liters ID Clearance
2.3 B5234T3 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-

0.0012 0.0033 0.0026 0.0022
2.4 B5244T3 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.4 B5244S 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.5 B5254T 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.3 B5234T9 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.4 B5244T7 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.9 B6294S2 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.9 B6294T 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
1

Liters ID Clearance
2.3 B5234T3 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-

0.0012 0.0033 0.0026 0.0022
2.4 B5244S 0.0004- 0.047 0.059 0.118 0.0020- 0.0011- 0.0008-
0.0012 0.0033 0.0026 0.0022
2.5 B5254T 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.3 B5234T9 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.4 B5244T7 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.9 B6294S2 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.9 B6294T 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
1

Liters ID Clearance
2005 2.4 B5244S 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.5 B5254T3 0.0004- NA NA NA NA NA NA
0.0012
2.5 B5254T 0.0004- NA NA NA NA NA NA
0.0012
2.5 B5254T4 0.0004- NA NA NA NA NA NA
0.0012
2.5 B5254T2 0.0004- NA NA NA NA NA NA

0.0012
2.4 B5244T 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.9 B6294T 0.0004- 0.047 0.059 NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
1

Liters ID Clearance
2006 2.4 B5244S 0.0004- NA NA NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.4 B5244T 0.0004- NA NA NA NA NA NA
0.0012
2.5 B5254T 0.0004- NA NA NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.5 B5254T2 0.0004- NA NA NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.5 B5254T3 0.0004- NA NA NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
2.5 B5254T4 0.0004- NA NA NA 0.0012- 0.0012- 0.0015-
0.0012 0.0028 0.0028 0.0056
1
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Volvo Cars 1999-05
Torque Specifications
Print
TORQUE SPECIFICATIONS
Year Engine Engine Cylinder Head Main Bearing Rod Brearing Crankshaft Flywheel Manifold Spark Oil Pan
Displacement ID/VIN Bolts Bolts Bolts Damper Bolts Bolts Plugs Drain Plug
Liters
IntakeExhaust
2001 1.9 B4204T3 - - - 132- - 14 18 22 81
134
2.3 B5234T3 - - - 132- - 14 18 22 81
134
2.4 B5244S - - - 132- - 14 18 22 81
134
2.4 B5244T3 - - - 132- - 14 18 22 81
134
2.8 B6284T - - - 220- - 14 18 22 81
222
2.9 B6294S - - - 220- - 14 18 22 81
222
1
- Step 1: 15 ft. lbs.
2
- Step 1: M10 bolts:15 ft. lbs.
3
4
5
All readings in ft. lbs.
Liters
IntakeExhaust
2002 1.9 B4204T3 - - - 132- - 14 18 22 81
134
2.3 B5234T3 - - - 132- - 14 18 22 81
134
2.4 B5244T3 - - - 132- - 14 18 22 81
134
2.4 B5244S - - - 132- - 14 18 22 81
134
2.9 B6294S2 - - - 220- - 14 18 22 81
222
2.9 B6294T - - - 220- - 14 18 22 81
222
1
2
3
4
5
Liters
IntakeExhaust
2003 1.9 B4204T3 - - - 132- - 14 18 22 81
134
2.3 B5234T3 - - - 132- - 14 18 22 81
134
2.4 B5244T3 - - - 132- - 14 18 22 81
134
2.4 B5244S - - - 132- - 14 18 22 81
134
2.5 B5254T - - - 132- - 14 18 22 81
134
2.3 B5234T9 - - - 132- - 14 18 22 81
134
2.4 B5244T7 - - - 132- - 14 18 22 81
134
2.9 B6294S2 - - - 220- - 14 18 22 81
222
2.9 B6294T - - - 220- - 14 18 22 81
222
1
2
3
4
5
Liters
IntakeExhaust
2004 1.9 B4204T3 - - - 132- - 14 18 22 81
134
2.3 B5234T3 - - - 132- - 14 18 22 81
134
2.4 B5244S - - - 132- - 14 18 22 81
134
2.5 B5254T - - - 132- - 14 18 22 81
134
2.3 B5234T9 - - - 132- - 14 18 22 81
134
2.4 B5244T7 - - - 132- - 14 18 22 81
134
2.9 B6294S2 - - - 220- - 14 18 22 81
222
2.9 B6294T - - - 220- - 14 18 22 81
222
1
2
3
4
5
Liters
IntakeExhaust
2005 2.4 B5244S - - - 132 - 14 18 22 103
2.5 B5254T3 - - - 132 - 14 18 22 103
2.5 B5254T - - - 132 - 14 18 22 103
2.5 B5254T4 - - - 132 - 14 18 22 103
2.5 B5254T2 - - - 132 - 14 18 22 103
2.4 B5244T - - - 132 - 14 18 22 103
2.9 B6294T - - - 221 - 15 15 22 103
1
2
3
4
5
Fig.
Fig.
all readings in ft. lbs.
Year Engine Displacement Engine Cylinder Head Main Bearing Rod Brearing Crankshaft Flywheel Manifold Spark Lug
Liters (cc) ID/VIN Bolts Bolts Bolts Damper Bolts Bolts Plugs Nuts
IntakeExhaust
1999 2.3 (2319) B5234T3/53- - - 133 - 15 18 18 81
2.4 (2435) B5254S/55 - - - 133 - 15 18 18 81
2.4 (2435) B5254T/56 - - - 133 - 15 18 18 81
1
A Step 1: 14 ft. lbs.
2
B Tighten cylinder block, intermediate section, in stages:
3
C Step 1: 15 ft. lbs.
4
D Step 1: 33 ft. lbs.
Year Engine Displacement Engine Cylinder Head Main Bearing Rod Brearing Crankshaft Flywheel Manifold Spark Lug
Liters (cc) ID/VIN Bolts Bolts Bolts Damper Bolts Bolts Plugs Nuts
IntakeExhaust
2000 2.3 (2319) B5234T3/53- - - 133 - 15 18 18 81
2.4 (2435) B5254S/55 - - - 133 - 15 18 18 81
2.4 (2435) B5254T/56 - - - 133 - 15 18 18 81
1
A Step 1: 14 ft. lbs.
2
B Tighten cylinder block, intermediate section, in stages:
3
C Step 1: 15 ft. lbs.
4
D Step 1: 33 ft. lbs.
Year Engine Engine Displacement Cylinder Head Main Bearing Rod Bearing Crankshaft Damper Flywheel Manifold Spark Lug
ID Liters Bolts Bolts Bolts Bolts Bolts Plugs Nuts
IntakeExhaust
1999 B5234T3 2.3 - - - 133 - 15 18 18 81
B5254S 2.4 - - - 133 - 15 18 18 81
B5254T 2.4 - - - 133 - 15 18 18 81
1
2
3
4
5
IntakeExhaust
2000 B5234T3 2.3 - - - 133 - 15 18 18 81
B5254S 2.4 - - - 133 - 15 18 18 81
B5254T 2.4 - - - 133 - 15 18 18 81
1
2
3
4
5
IntakeExhaust
2001 B4204T3 1.9 - - - 132- - 14 18 22 81
134
B5234T3 2.3 - - - 132- - 14 18 22 81
134
B5244S 2.4 - - - 132- - 14 18 22 81
134
B5244T3 2.4 - - - 132- - 14 18 22 81
134
B6284T 2.8 - - - 220- - 14 18 22 81
222
B6294S 2.9 - - - 220- - 14 18 22 81
222
1
2
3
4
5
IntakeExhaust
2002 B4204T3 1.9 - - - 132- - 14 18 22 81
134
B5234T3 2.3 - - - 132- - 14 18 22 81
134
B5244T3 2.4 - - - 132- - 14 18 22 81
134
B5244S 2.4 - - - 132- - 14 18 22 81
134
B6294S22.9 - - - 220- - 14 18 22 81
222
B6294T 2.9 - - - 220- - 14 18 22 81
222
1
2
3
4
5
IntakeExhaust
2003 B4204T3 1.9 - - - 132- - 14 18 22 81
134
B5234T3 2.3 - - - 132- - 14 18 22 81

134
B5244T3 2.4 - - - 132- - 14 18 22 81
134
B5244S 2.4 - - - 132- - 14 18 22 81
134
B5254T 2.5 - - - 132- - 14 18 22 81
134
B5234T9 2.3 - - - 132- - 14 18 22 81
134
B5244T7 2.4 - - - 132- - 14 18 22 81
134
B6294S22.9 - - - 220- - 14 18 22 81
222
B6294T 2.9 - - - 220- - 14 18 22 81
222
1
2
3
4
5
IntakeExhaust
2004 B4204T3 1.9 - - - 132- - 14 18 22 81
134
B5234T3 2.3 - - - 132- - 14 18 22 81
134
B5244S 2.4 - - - 132- - 14 18 22 81
- 134
B5254T 2.5 - - - 132- - 14 18 22 81
134
B5234T9 2.3 - - - 132- - 14 18 22 81
134
B5244T7 2.4 - - - 132- - 14 18 22 81
134
B6294S22.9 - - - 220- - 14 18 22 81
222
B6294T 2.9 - - - 220- - 14 18 22 81
222
1
2
3
4
5
IntakeExhaust
2005 B5244S 2.4 - - - 132 - 14 18 22 103
B5254T3 2.5 - - - 132 - 14 18 22 103
B5254T 2.5 - - - 132 - 14 18 22 103
B5254T4 2.5 - - - 132 - 14 18 22 103
B5254T2 2.5 - - - 132 - 14 18 22 103
B5244T 2.4 - - - 132 - 14 18 22 103
B6294T 2.9 - - - 221 - 15 15 22 103
1
2
3
4
5
IntakeExhaust
2006 B5244S 2.4 - - - 132 - 15 19 22 66
B5244T 2.4 - - - 132 - 15 19 22 66
B5254T 2.5 - - - 132 - 15 19 22 66
B5254T2 2.5 - - - 132 - 15 19 22 66
B5254T3 2.5 - - - 132 - 15 19 22 66
B5254T4 2.5 - - - 132 - 15 19 22 66

1
2
3
4
5
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Volvo Cars 1999-05
Valve Specifications
Print
VALVE SPECIFICATIONS
Year Engine Engine Seat Angle Face Angle Spring Test Pressure Spring Installed Stem-to-Guide Stem
Displacement ID/VIN (deg.) (deg.) (lbs. @ in.) Height (in.) Clearance (in.) Diameter
Liters
Intake Exhaust Intake Exhaust
2001 1.9 B4204T3 NA NA NA NA NA NA NA NA
2.3 B5234T3 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.275 0.2746
2.4 B5244S 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.275 0.2746
2.4 B5244T3 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.275 0.2746
2.8 B6284T 44.5 44.5 NA NA NA NA 0.2344-0.2344-
0.235 0.235
2.9 B6294S 44.5 44.5 NA NA NA NA 0.2344-0.2344-
0.235 0.235
1
2
- Intake valve: 150@1.00
Liters
2.3 B5234T3 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.275 0.2746
2.4 B5244T3 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.275 0.2746
2.4 B5244S 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.275 0.2746
2.9 B6294S2 44.5 44.5 NA NA NA NA 0.2344-0.2344-
0.235 0.235
2.9 B6294T 44.5 44.5 NA NA NA NA 0.2344-0.2344-
0.235 0.235
1
2
Liters
2.3 B5234T3 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.275 0.2746
2.4 B5244T3 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.275 0.2746
2.4 B5244S 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.275 0.2746
2.5 B5254T 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.275 0.2746
2.3 B5234T9 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.275 0.2746
2.4 B5244T7 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.275 0.2746
2.9 B6294S2 44.5 44.5 NA NA NA NA 0.2344-0.2344-
0.235 0.235
2.9 B6294T 44.5 44.5 NA NA NA NA 0.2344-0.2344-
0.235 0.235
1
2
Liters
2.3 B5234T3 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.275 0.2746
2.4 B5244S 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.275 0.2746
2.5 B5254T 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.275 0.2746
1
2
Liters
2004 2.3 B5234T9 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
1
2
Liters
cont. 0.0024 0.0028 0.275 0.2746
2.4 B5244T7 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.275 0.2746
2.9 B6294S2 44.5 44.5 NA NA NA NA 0.2344-0.2344-
0.235 0.235
2.9 B6294T 44.5 44.5 NA NA NA NA 0.2344-0.2344-
0.235 0.235
1
1
2
Liters
Intake Exhaust IntakeExhaust
2005 2.4 B5244S 45 44.5 NA NA 0.0012- 0.0012- NA 0.2344-
0.0024 0.0024 0.235
2.5 B5254T3 45 44.5 NA NA 0.0012- 0.0012- NA 0.2344-
0.0024 0.0024 0.235

2.5 B5254T 45 44.5 NA NA 0.0012- 0.0012- NA 0.2344-
0.0024 0.0024 0.235
2.5 B5254T4 45 44.5 NA NA 0.0012- 0.0012- NA 0.2344-
0.0024 0.0024 0.235
2.5 B5254T2 45 44.5 NA NA 0.0012- 0.0012- NA 0.2344-
0.0024 0.0024 0.235
2.4 B5244T 45 44.5 NA NA 0.0012- 0.0012- NA 0.2344-
0.0024 0.0024 0.235
2.9 B6294T 45 44.5 NA NA 0.0012- 0.0012- NA 0.2344-
0.0024 0.0024 0.235
1
2
Fig.
Fig.
Year Engine Displacement Engine Seat Angle Face Angle Spring Test Pressure Spring Installed Stem-to-Guide Stem
Liters (cc) ID/VIN (deg.) (deg.) (lbs. @ in.) Height (in.) Clearance (in.) Diameter
1999 2.3 (2319) B5234T3/5345 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
2.4 (2435) B5254S/55 45 44.5 - NA 0.0012- 0.0012- 0.2738-0.2734-
0.0024 0.0024 0.2750 0.2746
2.4 (2435) B5254T/56 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
1
Note: Exhaust valves for turbocharged engines are stellite-coated and must not be machined. They may be ground against the valve seat.
2
A Intake valve: 150@1.00
Year Engine Displacement Engine Seat Angle Face Angle Spring Test Pressure Spring Installed Stem-to-Guide Stem
Liters (cc) ID/VIN (deg.) (deg.) (lbs. @ in.) Height (in.) Clearance (in.) Diameter
2000 2.3 (2319) B5234T3/5345 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
2.4 (2435) B5254S/55 45 44.5 - NA 0.0012- 0.0012- 0.2738-0.2734-
0.0024 0.0024 0.2750 0.2746
2.4 (2435) B5254T/56 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
1
Note: Exhaust valves for turbocharged engines are stellite-coated and must not be machined. They may be ground against the valve seat.
2
A Intake valve: 150@1.00
Displacement ID (deg.) (deg.) (lbs. @ in.) Height (in.) Clearance (in.) Diameter (in.)
Liters
1999 2.3 B5234T3 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
2.4 B5254S 45 44.5 - NA 0.0012- 0.0012- 0.2738-0.2734-
0.0024 0.0024 0.2750 0.2746
2.4 B5254T 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
1
2
Liters
2000 2.3 B5234T3 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
2.4 B5254S 45 44.5 - NA 0.0012- 0.0012- 0.2738-0.2734-
0.0024 0.0024 0.2750 0.2746
2.4 B5254T 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
1
2
Liters
2.3 B5234T3 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-

0.0024 0.0028 0.2750 0.2746
2.4 B5244S 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
2.4 B5244T3 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
2.8 B6284T 44.5 44.5 NA NA NA NA 0.2344-0.2344-
0.2350 0.2350
2.9 B6294S 44.5 44.5 NA NA NA NA 0.2344-0.2344-
0.2350 0.2350
1
2
Liters
2.3 B5234T3 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-

0.0024 0.0028 0.2750 0.2746
2.4 B5244T3 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
2.4 B5244S 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
2.9 B6294S244.5 44.5 NA NA NA NA 0.2344-0.2344-
0.2350 0.2350
2.9 B6294T 44.5 44.5 NA NA NA NA 0.2344-0.2344-
0.2350 0.2350
1
2
Liters
2.3 B5234T3 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-

0.0024 0.0028 0.2750 0.2746
2.4 B5244T3 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
2.4 B5244S 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
2.5 B5254T 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
2.3 B5234T9 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
2.4 B5244T7 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
2.9 B6294S244.5 44.5 NA NA NA NA 0.2344-0.2344-
0.2350 0.2350
2.9 B6294T 44.5 44.5 NA NA NA NA 0.2344-0.2344-
0.2350 0.2350
1
2
Liters
2.3 B5234T3 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-

0.0024 0.0028 0.2750 0.2746
2.4 B5244S 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
2.5 B5254T 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
2.3 B5234T9 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
2.4 B5244T7 45 44.5 - NA 0.0012- 0.0015- 0.2738-0.2734-
0.0024 0.0028 0.2750 0.2746
2.9 B6294S244.5 44.5 NA NA NA NA 0.2344-0.2344-
0.2350 0.2350
2.9 B6294T 44.5 44.5 NA NA NA NA 0.2344-0.2344-
0.2350 0.2350
1
2
Liters
Intake Exhaust IntakeExhaust
2005 2.4 B5244S 45 44.5 NA NA 0.0012- 0.0012- NA 0.2344-
0.0024 0.0024 0.2350
2.5 B5254T3 45 44.5 NA NA 0.0012- 0.0012- NA 0.2344-
0.0024 0.0024 0.2350
2.5 B5254T 45 44.5 NA NA 0.0012- 0.0012- NA 0.2344-
0.0024 0.0024 0.2350
2.5 B5254T4 45 44.5 NA NA 0.0012- 0.0012- NA 0.2344-
0.0024 0.0024 0.2350
2.5 B5254T2 45 44.5 NA NA 0.0012- 0.0012- NA 0.2344-
0.0024 0.0024 0.2350
2.4 B5244T 45 44.5 NA NA 0.0012- 0.0012- NA 0.2344-
0.0024 0.0024 0.2350
2.9 B6294T 45 44.5 NA NA 0.0012- 0.0012- NA 0.2344-
0.0024 0.0024 0.2350
1
2
Liters
2006 2.4 B5244S 45 44.5 NA NA 0.0012- 0.0012- NA NA
0.0024 0.0024
2.4 B5244T 45 44.5 NA NA 0.0012- 0.0012- NA NA
0.0024 0.0024
2.5 B5254T 45 44.5 NA NA 0.0012- 0.0012- 0.2344-0.2735-
0.0024 0.0024 0.2356 0.2746
2.5 B5254T2 45 44.5 NA NA 0.0012- 0.0012- 0.2344-0.2735-
0.0024 0.0024 0.2356 0.2746
2.5 B5254T3 45 44.5 NA NA 0.0012- 0.0012- 0.2344-0.2735-
0.0024 0.0024 0.2356 0.2746
2.5 B5254T4 45 44.5 NA NA 0.0012- 0.0012- 0.2344-0.2735-
0.0024 0.0024 0.2356 0.2746
1
2
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Fuel System
Volvo Cars 1999-05

Print
CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not
allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a
container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

2. Relieve the fuel system pressure.
3. Drain the fuel tank.
4. Block the parking brake pedal in the neutral position.
5. Remove or disconnect the following on both sides:
Rear wheels
Rear brake calipers
Rear brake discs
Rear tension spring and expander
6. Lift the brake shoe slightly. Grip the expander. Pull the expander outwards.
7. Unhook the expander from the metal bracket.
Fig. Removing expansion spring from rear brake
Removing expansion spring from rear brake

The guide sleeve for the cable sleeve. Apply a screwdriver between the guide sleeve lug and wheel arch. Pry apart slightly to remove the
sleeve.
The parking brake cable from the tie rod and the sub-frame
9. Remove 2 bolts from the cable clips and 2 bolts from the front mounting for the heat deflector plate.
10. Fold out the cables from the heat deflector plate. Hang the cables up at the front of the car.
11. Remove the exhaust system from the three-way catalytic converter and backwards.
NOTE
Hang up the three-way catalytic converter to prevent damaging the flex boot.
12. Remove the rear driveshaft:
A. Mark up the position of the joint on the flange on the final drive and at the center bearing.
B. Remove bolts from the joints. Use counterhold 999 7057.
C. Remove the rear section of the driveshaft.
13. Lower the rear suspension:
A. Place the mobile jack: 999 5972 with plate: 999 5972 under the rear suspension.
B. Raise to light contact.
The 2 bolts for the mounting bracket

The mounting bolt for the sub frame bushing
The brake pipe on both sides from the plastic clips on the bracket
15. Lower the rear suspension carefully.

16. Place a lifting table under the fuel tank.
The upper quick-release connector plastic pipe on the carbon filter container
The 4 bolts for the fuel tank securing strap
Remove the clamp for the fuel filler pipe
Remove the clamp for the bleed pipe
18. Lower the lifting table to access the plastic pipes on top of the tank.
19. Remove the plastic pipe.
20. Remove the ABS cable harness from the clips on both sides of the fuel tank.
21. Remove the fuel tank.
Fig. Removing fuel tank straps and heat shield
Removing fuel tank straps and heat shield
To install:
1. Place the fuel tank on the lifting table.

2. Raise the lifting table to install the plastic hoses on the right-hand level sensor and in the grooves in the tank.
3. Secure the hoses in place using silver tape.
4. Install the ABS cable harnesses in the clips on both sides of the tank.
5. Align the fuel filler pipe and the bleed pipe.
6. Insert the cable harnesses for the level sensor and the fuel tank pressure sensor through the inspection holes in the floor.
7. Raise the fuel tank to the installation position.
NOTE
Ensure that the fuel filler pipe and bleed pipe slide into position while raising the fuel tank.
8. Install the 4 bolts for the fuel tank securing strap. Tighten to 18 ft. lbs. (24 Nm).
9. Remove the lifting table.
The clamp for the fuel filler pipe

The clamp for the bleed pipe
The upper plastic pipe in the quick-release connector for the carbon filter container
11. Install the rear suspension:
A. Place the mobile jack: 999 5972 and plate: 999 5972 under the rear suspension.
B. Carefully raise the rear suspension.
NOTE
Ensure that no cable harness or brake lines are trapped while raising the rear suspension.
12. Install or connect the following on both sides:
The 2 bolts for the mounting bracket. Tighten to 59 ft. lbs. (80 Nm)
The bolt for the sub frame mounting. Tighten to 59 ft. lbs. (80 Nm)
The brake line in the plastic clip and bracket
13. Install the brakes.

14. Install the parking brake cable along the heat shields.
15. Install the bolts in the center and front mountings for the heat shield.
The parking brake cables on the wheel units

The parking brake cable mountings in the sub-frame. Tighten bolts to 19 ft. lbs. (25 Nm).
The mounting for the parking brake cable on the tie rods.
17. Press the guide sleeves for the parking brake cables into place on the wheel units.
NOTE
Lubricate the O-rings on the guide sleeves. Use lubricant 1161580 or silicon grease.
The expander on the cable. Press the mounting together to lock the cable in the expander
The expander between the brake shoes
The return spring.
19. Install the brake disc and the locating pin. Tighten to 88 inch lbs. (10 Nm).
20. Install the brake caliper. Use new bolts. Tighten to 44 ft. lbs. (60 Nm).
NOTE
Activate parking brake adjuster.
21. Install the rear drive shaft.
A. Position the propeller shaft as marked previously.

B. Install new bolts for the joints. Use counterhold 999 7057. Tighten all bolts to 22 ft. lbs. (30 Nm).
22. Install the exhaust system. Use a new flange gasket. Tighten the bolts to 18 ft. lbs. (25 Nm).
23. Install the cover over the level sensor.
24. Connect the wiring and the connectors.
25. Install rear wheels and tighten lug nuts to 81-103 ft. lbs. (110-140 Nm).
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Chassis Electrical
Volvo Cars 1999-05
Air Bag (Supplemental Restraint System)

Print
CAUTION
Some vehicles are equipped with an air bag system. The system must be disarmed before performing service on, or around, system components, the
steering column, instrument panel components, wiring and sensors. Failure to follow the safety precautions and the disarming procedure could result in
accidental air bag deployment, possible injury and unnecessary system repairs.
CAUTION
CAUTION
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Volvo Cars 1999-05
Arming The System

Print
1. After repairs are complete, connect the negative battery cable. Turn the ignition switch to the ON position and check the SRS light for proper
operation.
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Volvo Cars 1999-05
Disarming the System

Print

2. Disconnect the negative battery cable.
3. Wait at least 1 minute before working on the vehicle. The air bag system is designed to retain enough power to deploy the air bag for a short time
after the battery has been disconnected.
4. After repairs are complete, connect the negative battery cable. Turn the ignition switch to the ON
3. Wait at least 1 minute before working on the vehicle. The air bag system is designed to retain enough power to deploy the air bag for a short time
4. After repairs are complete, connect the negative battery cable. Turn the ignition switch to the ON position and check the SRS light for proper
operation.

2. Disconnect and isolate the negative battery cable. Wait 3 minutes for the system capacitor to discharge before performing any service.
NOTE
Wait at least 3 minutes before working on the vehicle. The air bag system is designed to retain enough power to deploy the air bag for a short time
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Volvo Cars 1999-05
Service Precautions
Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. Print
Never carry the inflator module by the wires or connector on the underside of the module.
When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away.
Place the inflator module on a bench or other surface with the bag and trim cover facing up.
With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental
deployment.
Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury.
Never carry the inflator module by the wires or connector on the underside of the module.
When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away.
Place the inflator module on a bench or other surface with the bag and trim cover facing up.
With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental
deployment.
Disconnect and isolate the battery negative cable before beginning any airbag system component diagnosis, testing, removal, or installation procedures.
Allow system capacitor to discharge for two minutes before beginning any component service. This will disable the airbag system. Failure to disable the
airbag system may result in accidental airbag deployment, personal injury, or death.
Do not place an intact undeployed airbag face down on a solid surface. The airbag will propel into the air if accidentally deployed and may result in
personal injury or death.
When carrying or handling an undeployed airbag, the trim side (face) of the airbag should be pointing towards the body to minimize possibility of injury if
accidental deployment occurs. Failure to do this may result in personal injury or death.
Replace airbag system components with OEM replacement parts. Substitute parts may appear interchangeable, but internal differences may result in
inferior occupant protection. Failure to do so may result in occupant personal injury or death.
Wear safety glasses, rubber gloves, and long sleeved clothing when cleaning powder residue from vehicle after an airbag deployment. Powder residue
emitted from a deployed airbag can cause skin irritation. Flush affected area with cool water if irritation is experienced. If nasal or throat irritation is
experienced, exit the vehicle for fresh air until the irritation ceases. If irritation continues, see a physician.
Do not use a replacement airbag that is not in the original packaging. This may result in improper deployment, personal injury, or death.
The factory installed fasteners, screws and bolts used to fasten airbag components have a special coating and are specifically designed for the airbag
system. Do not use substitute fasteners. Use only original equipment fasteners listed in the parts catalog when fastener replacement is required.
During, and following, any child restraint anchor service, due to impact event or vehicle repair, carefully inspect all mounting hardware, tether straps,
and anchors for proper installation, operation, or damage. If a child restraint anchor is found damaged in any way, the anchor must be replaced. Failure
to do this may result in personal injury or death.
Deployed and non-deployed airbags may or may not have live pyrotechnic material within the airbag inflator.
Do not dispose of driver/passenger/curtain airbags or seat belt tensioners unless you are sure of complete deployment. Refer to the Hazardous Substance
Control System for proper disposal.
Dispose of deployed airbags and tensioners consistent with state, provincial, local, and federal regulations.
After any airbag component testing or service, do not connect the battery negative cable. Personal injury or death may result if the system test is not
performed first.
If the vehicle is equipped with the Occupant Classification System (OCS), do not connect the battery negative cable before performing the OCS
Verification Test using the scan tool and the appropriate diagnostic information. Personal injury or death may result if the system test is not performed
properly.
Never replace both the Occupant Restraint Controller (ORC) and the Occupant Classification Module (OCM) at the same time. If both require replacement,
replace one, then perform the Airbag System test before replacing the other.
Both the ORC and the OCM store Occupant Classification System (OCS) calibration data, which they transfer to one another when one of them is
replaced. If both are replaced at the same time, an irreversible fault will be set in both modules and the OCS may malfunction and cause personal injury
or death.
If equipped with OCS, the Seat Weight Sensor is a sensitive, calibrated unit and must be handled carefully. Do not drop or handle roughly. If dropped or
damaged, replace with another sensor. Failure to do so may result in occupant injury or death.
If equipped with OCS, the front passenger seat must be handled carefully as well. When removing the seat, be careful when setting on floor not to drop. If
dropped, the sensor may be inoperative, could result in occupant injury, or possibly death.
If equipped with OCS, when the passenger front seat is on the floor, no one should sit in the front passenger seat. This uneven force may damage the
sensing ability of the seat weight sensors. If sat on and damaged, the sensor may be inoperative, could result in occupant injury, or possibly death.
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Drive Train
Volvo Cars 1999-05
Transmission Removal & Installation

Rear Wheel Drive Print
2. Drain the transmission fluid.

Reverse light connector at the firewall
Shift linkage
Gearshift boot
Reverse detent fork
Overdrive switch connector, if equipped
Clutch slave cylinder
Exhaust front pipe bracket
Driveshaft
Speedometer cable
Starter motor
Transmission crossmember and support the transmission with a jack
Transmission flange bolts
Transmission
To install:
Transmission and tighten the flange bolts to 30 ft. lbs. (40 Nm)
Transmission crossmember
Starter motor
Speedometer cable
Driveshaft
Reverse detent fork
Gearshift boot
Shift linkage
2. Fill the transmission to the correct level.

2. Drain the transmission fluid.

Shift linkage
Gearshift boot
Reverse detent fork
Driveshaft
Speedometer cable
Starter motor
Transmission crossmember and support the transmission with a jack
Transmission flange bolts
Transmission
To install:
Transmission and tighten the flange bolts to 30 ft. lbs. (40 Nm)
Transmission crossmember
Starter motor
Speedometer cable
Driveshaft
Reverse detent fork
Gearshift boot
Shift linkage
2. Fill the transmission to the correct level.
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Steering
Volvo Cars 1999-05

Print

2. Disconnect negative battery cable.
WARNING
Under no circumstances use an ohmmeter or other live measuring instrument to take readings on a disconnected, non-deployed pyrotechnical
Supplemental Restraint System (SRS) component. There is also a risk of the seat belt tensioner deploying. Pyrotechnical SRS components must
never be taken apart, repaired, or transferred to another vehicle.
3. Remove the air bag module:
A. With battery disconnected, move the ignition key to Position II.

1
B. Turn the steering wheel / 4 turn so that the two holes on the rear of the steering wheel are accessible.
C. Insert a screwdriver in the holes on the reverse of the steering wheel. The screwdriver must be at a right-angle to the rear surface of the
steering wheel.
D. Place the screwdriver point against the top of the spring clip as illustrated.
E. Pry the screwdriver up against the upper edge of the hole (2) so that the point of the screwdriver presses down the catch (1) until the catch
releases.
1
F. Turn the steering wheel / 2 turn in the opposite direction.
G. Repeat the process on the other side.
H. Turn the steering wheel to the neutral position.
I. Fold out the air bag.
J. Disconnect the 2 connectors (there may be more or less) for the SRS ignition cables for the air bag.
K. Remove the air bag.
CAUTION
The removed air bag module should be stored in a clean, dry place with the pad cover face up.
Fig. Placing ignition key into Position II with battery disconnected
Placing ignition key into Position II with battery disconnected
Fig. Position of steering wheel for access to air bag module retaining clips
Position of steering wheel for access to air bag module retaining clips
Fig. Releasing spring retaining clip for driver-s side air bag module
Releasing spring retaining clip for driver-s side air bag module
Fig. Disconnecting the SRS ignition cables for the air bag module
Disconnecting the SRS ignition cables for the air bag module
4. Lock the contact reel in position with the locking screw as illustrated.
5. Remove the bolt securing the steering wheel to the steering column.
6. Pull the steering wheel straight back.
7. Pull the cable harness through the hole in the steering wheel.
8. Remove the steering wheel.
Fig. Locking the contact reel and removing steering wheel
Locking the contact reel and removing steering wheel
To install:
1. Pull the cable harness through the hole of steering wheel.

2. Install the steering wheel in place.
3. Install the center bolt for the steering wheel. Use a new bolt. Tighten in 2 steps:
A. Step 1-22 ft. lbs. (30 Nm).

B. Step 2-angle-tighten 30Â°
4. Remove the locking screw holding the contact reel.

5. Install the air bag module:
NOTE
For air bags (replacement part) supplied without keypads, for Audio, RTI, and cruise control, an upgrade kit must be ordered.
A. Install the 2 connectors (there may be more or fewer).

B. Press the air bag into place.
CAUTION
Ensure that the wiring is not trapped during installation.
6. Check that the SRS is functioning properly:
A. Install the battery negative lead.

B. Check that the SRS indicator lamp is not defective by turning the key to Position II.
C. The SRS indicator lamp must light and go out after approximately seven seconds.
D. Check that the SRS indicator lamp in the combined instrument panel is not constantly lit. Fault-trace the SRS if the lamp is constantly lit.
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Volvo Cars 1999-05
Steering Wheel
Print
CAUTION
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Suspension
Volvo Cars 1999-05
Coil Springs

2. Remove the strut assembly from the vehicle.
3. Install a spring compressor and tighten until the strut is loose inside the spring.
Upper strut mount

Spring retainer
Coil spring
To install:
Coil spring
Spring retainer
Upper strut mount. Tighten the nut to 52 ft. lbs. (70 Nm).
2. Remove the spring compressor.

3. Install the strut to the vehicle.
4. Check the wheel alignment and adjust as necessary.
2. Remove the strut from the vehicle.
Upper strut mount

Spring retainer
Coil spring
Fig. Spring strut assembly-960, S90 and V90 models
Spring strut assembly-960, S90 and V90 models
To install:
Coil spring
Spring retainer


2. Remove the strut from the vehicle.
Upper strut mount

Spring retainer
Coil spring
Fig. Spring strut assembly-960, S90 and V90 models
Spring strut assembly-960, S90 and V90 models
To install:
Coil spring
Spring retainer


2. Remove the strut assembly from the vehicle.
Upper strut mount

Spring retainer
Coil spring
To install:
Coil spring
Spring retainer


2. Remove the strut assembly
3. Install spring compressor 951-2911 or suitable equivalent on the coil spring.
4. Remove the shock absorber mounting nut using socket 999-5500 using a TorxÂ® as a counterhold.
Shock absorber
Spring seat
Bump stop
Coil spring
To install:

Bump stop
Coil spring
Spring seat
Shock absorber and tighten mounting nut to 52 ft. lbs. (70 Nm)

4. Install the strut into the vehicle.
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Volvo Cars 1999-05
Lower Ball Joints

1. Remove the front wheels.

2. Remove the nut from the control arm. Use a Torx wrench as a counterhold.
WARNING
Ensure that the tension strap is correctly secured in the control arms.
1. Pull down the control arms (1) using a tension strap (2).
2. Release the spring strut from the control arm.
3. Remove the bolt from the halfshaft. Use a screwdriver as a counterhold on the brake disc.
4. Remove the halfshaft from the hub. Knock the halfshaft out using a brass drift.
5. Push the spring strut to one side.
6. Remove the bolts from the ball joint.
7. Remove the rubber seal (1).
Fig. Removing rubber seal-S60, S70, S80, V70
Removing rubber seal-S60, S70, S80, V70
Installing the inner sleeve (P/N 999 5781-1)
Fig. Guide bolts installed-S60, S70, S80, V70
Guide bolts installed-S60, S70, S80, V70
1. Install the inner sleeve so that both halves hook securely in the flange (see arrow) on the ball joint.
2. Turn the inner sleeve so that the slit is at right angles to the bolt holes.
Installing the outer sleeve (P/N 999 5781-2)

Fig. Guide bolt identification-S60, S70, S80, V70
Guide bolt identification-S60, S70, S80, V70
Fig. Installing outer sleeve-S60, S70, S80, V70
Installing outer sleeve-S60, S70, S80, V70
Fig. Installing inner sleeve-S60, S70, S80, V70
Installing inner sleeve-S60, S70, S80, V70
1. Install the outer sleeve around the inner sleeve halves. Tighten the bolt (1).
2. Install an M12 nut on the ball joint bolt (2).
3. Screw on the nut so that the ball joint bolt is just protruding from the nut.
Installing the guide bolts (P/N 999 5781-3)

Fig. Ball joint removal tool installed-S60, S70, S80, V70
Ball joint removal tool installed-S60, S70, S80, V70
Fig. Support tool installed-S60, S70, S80, V70
Support tool installed-S60, S70, S80, V70

NOTE
The guide bolts have a wrench grip (see arrow) which is asymmetrically positioned. 1. Aluminum wheel spindle: Use the bolt (1) with the greater distance
from the wrench grip 2. Steel wheel spindle: Use the bolt (2) with the shortest distance from the wrench grip.
1. Screw in the guide bolts (1) fully.

2. Install the support (P/N 999 5781) using 3 wheel studs.
3. Screw the guide bolts (1) down until they are in contact with the support.
4. Position the supplementary support (2) (P/N 999 5781-4) on the hydraulic press (1).
5. Screw the connector (3) (P/N 999 5781-5) into place on the hydraulic press.
6. Install the connector on the nut on the ball joint.
7. Press off the ball joint.
8. Remove the tool and the ball joint.
WARNING
Use protective goggles.
1. Clean the ball joint seat and the mating surfaces of the ball joint to the wheel spindle. Use a rotary wire brush.
2. Lubricate the seat using wheel bearing grease.
To install:
1. Loosely install the new ball joint using the guide bolts.
WARNING
Leave the protective cap for the ball joint in position to prevent damaging the rubber seal.
1. Press the ball joint up towards the seat using the impact drift (1) (P/N 999 5796). Check that the ball joint is centered in the seat.
2. Knock in the ball joint using a copper mallet.
3. Tighten the ball joint using new bolts. Tighten to 37 ft. lbs.(50 Nm)
4. Remove the protective cap (1).
5. Install the halfshaft in the hub. Install a new bolt.
6. Align the ball joints (1) in the control arm.
CAUTION
Take care when releasing the tension strap.
1. Slowly release the control arms (1) by releasing the tension strap (2).
2. Install a new nut.
NOTE
The ball joint pinion must not rotate. Use a Torx wrench as a counterhold so that the rubber boot is not damaged. Tighten to 59 ft. lbs. (80 Nm).
1. Install the wheels. Tighten to 103 ft. lbs. (140 Nm).
1. Raise the car.

2. Slacken off the ball joint nut as much as possible.
NOTE
Clean the ball joint thread using a wire brush. Use rust penetrator. If the ball joint releases in the cone, position a transmission jack under the control arm.
Carefully lift (not more than so the front spring is in the resting position) until the cone jams. Remove the nut.
1. Remove the stud in the front edge

2. Remove the two bolts at the rear edge. Move the wheel to one side. Pull out the control arm from the cross member.
NOTE
Ensure that the halfshaft is not pulled out of the transmission.
1. Slacken off the nut positioned on the ball joint as much as possible. Press the rubber down.
WARNING
Secure the tool to prevent damage.
1. Press out the ball joint.

2. Remove the nut and draw out the control arm.
To install:
CAUTION
Replace the ball joint rubber ring if it is worn or damaged.
Fig. Inspect the rubber rings-S40, V40
Inspect the rubber rings-S40, V40
1. Clean the area around the ball joint.

2. Remove the old rubber ring.
3. Lubricate the new ring and install it.
4. Ensure that the locking springs are correctly installed.
5. Install the control arm with the ball joint on the wheel spindle.
6. Install the control arm in the cross member. Install the bolt and nut.
7. Install the two bolts in the rear bushing.
8. Tighten all bolts and nuts by hand.
9. Post-tighten the two rear bolts. Tighten to 68 ft. lbs. (90 Nm).
10. Press the ball joint all the way down. Tighten to 51 ft. lbs. (67 Nm).
11. Remove the support and rock the car a few times so that the bushings come into the correct position.
12. Tighten the nut. Tighten to 68 ft. lbs. (90 Nm) + 60 deg.
13. Check the front mounting and wheel alignment.
Fig. Lower control arm final tightening-S40, V40
Lower control arm final tightening-S40, V40
1. Remove the wheel

2. Remove the halfshaft bolt. Use a counterhold.
3. Detach the halfshaft end at the hub Tap in the shaft end approximately 10-15 mm. Use a rubber or copper mallet.
4. Blow clean around the ball joint with compressed air.
5. Generously spray the ball joint and the bolt and nut retaining the ball joint using rust penetrator.
NOTE
Do not insert a screwdriver or punch between the ears on the wheel spindle.
1. If the bolt has rusted solid, slacken off the nut a few turns. Knock the bolt so that it loosens.
2. Remove the bolt and the nut.
3. Spray the ball joint with rust penetrator again.
NOTE
The inner diameter of the socket must be larger than the outer diameter of the cover. This is to prevent damage to the cover.
1. Tap the ball joint off the wheel spindle. Use a socket as a spacer.
3. Move the ball joint up and down by hand (or a jimmy bar can be used) until the ball joint detaches from the wheel spindle.
4. Withdraw the halfshaft from the hub.
5. Twist the spring strut to one side. Hang the halfshaft so that the control arm is not in contact with the halfshafts.
6. Remove the two bolts from the engine pad on the right side.
7. Remove the bolt (1) from the rear engine pad
8. Remove the bolt (3) from the front engine pad
9. Remove the bolt and nut (2) from the torque rod.
On the left side:
1. Position a jack on the torque rod mounting in the transmission.
Fig. Support the torque rod with a jack-S40, V40
Support the torque rod with a jack-S40, V40
NOTE
Use a wooden block as a shim.
1. Remove the four bolts from the control arm

2. Remove the control arm.
On the right side:
1. Position a jack against the oil pan.
NOTE
1. Lift the engine to access the control arm bolts.

2. Remove the four bolts (1) from the control arm
To install:
On the left side:
1. Install the control arm on the sub-frame. Use new bolts. Tighten to 49 ft. lbs. (65 Nm). Angle-tighten 90 deg.
2. Lower and remove the jack.
On the right side:
2. Lower and remove the mobile jack.
3. Install the two bolts (1) at the engine pad on the right side. Tighten to 27 ft. lbs. (35 Nm). Angle-tighten 90 deg.
NOTE
Use new bolts.
1. Install the bolts (1, 3). Tighten to 37 ft. lbs. (50 Nm).
2. Install the bolt and nut (2) for the torque rod. Tighten to 30 ft. lbs. (40 Nm). Angle-tighten 40 deg.
NOTE
Use a new bolt and nut.
1. Clean the hub and the halfshaft splines.

2. Fold out and twist the spring strut and locate the halfshaft in the hub. Use an adjustable wrench to hold the control arm down.
3. Install a new halfshaft bolt. Tighten to 27 ft. lbs. (35 Nm). Angle-tighten 90 deg. Counterhold the brake disc.
NOTE
Lubricate the threads and flange on the bolt.
1. Check that the groove on the ball joint spindle lines up with the bolt hole in the wheel spindle.
NOTE
Press the ball joint upwards so that the conical top is visible above the bolted joint on the wheel spindle. Use a new locknut in the wheel spindle bolt.
Tighten to 38 ft. lbs. (50 Nm).
1. Install the wheel.
Front wheel
Stabilizer bar link
Lower ball joint from the lower control arm
Lower ball joint from the strut
To install:
Lower ball joint. Tighten the strut bolts to 22 ft. lbs. (30 Nm) plus 90 degrees.
Lower control arm. Tighten the nut to 44 ft. lbs. (60 Nm).
Stabilizer bar link
Front wheel
Front wheel
Steering knuckle pinch bolt
Lower control arm bolts
Lower ball joint
To install:
Lower ball joint. Tighten the pinch bolt to 37 ft. lbs. (50 Nm).
Lower control arm bolts. Tighten the bolts to 13 ft. lbs. (18 Nm) plus 120 degrees.
Front wheel
Fig. Front suspension assembly-960, S90 and V90 models
Front suspension assembly-960, S90 and V90 models

Front wheel
Steering knuckle pinch bolt
Lower control arm bolts
Lower ball joint
To install:
Lower ball joint. Tighten the pinch bolt to 37 ft. lbs. (50 Nm).
Lower control arm bolts. Tighten the bolts to 13 ft. lbs. (18 Nm) plus 120Â°.
Front wheel
1. Remove the stub axle

2. Place the stub axle in a soft jawed vise
3. Remove the two bolts holding the ball joint in the stub axle.
4. Tap out the ball joint alternately. Use a drift.
Fig. Ball joint removal-V70XC
Ball joint removal-V70XC
To install:
1. Clean the stub axle mating surfaces of the ball joint.

2. Center the ball joint against the stub axle. Use the bolt (but do not tighten the bolt yet)
NOTE
Use new bolts.
3. Tap the ball joint fully into the stub axle. Tap alternately with a drift.
4. Tighten the bolts. Tighten to 37 ft. lbs. (50 Nm).
5. Install the stub axle

2. Remove the nut from the control arm. Use a TorxÂ® wrench as a counterhold.
WARNING
3. Pull down the control arms (1) using a tension strap (2).
5. Remove the bolt from the halfshaft. Use a screwdriver as a counterhold on the brake disc.
6. Remove the halfshaft from the hub. Knock the halfshaft out using a brass drift.
8. Remove the bolts from the ball joint.
9. Remove the rubber seal (1).
Fig. Removing rubber seal-S60, S70, S80, V70
Removing rubber seal-S60, S70, S80, V70
Installing the inner sleeve (P/N 999 5781-1)
Fig. Guide bolts installed-S60, S70, S80, V70
Guide bolts installed-S60, S70, S80, V70
1. Install the inner sleeve so that both halves hook securely in the flange (see arrow) on the ball joint.
2. Turn the inner sleeve so that the slit is at right angles to the bolt holes.
Installing the outer sleeve (P/N 999 5781-2)

Fig. Guide bolt identification-S60, S70, S80, V70
Guide bolt identification-S60, S70, S80, V70
Fig. Installing outer sleeve-S60, S70, S80, V70
Installing outer sleeve-S60, S70, S80, V70
Fig. Installing inner sleeve-S60, S70, S80, V70
Installing inner sleeve-S60, S70, S80, V70
1. Install the outer sleeve around the inner sleeve halves. Tighten the bolt (1).
2. Install an M12 nut on the ball joint bolt (2).
3. Screw on the nut so that the ball joint bolt is just protruding from the nut.
Installing the guide bolts (P/N 999 5781-3)

Fig. Ball joint removal tool installed-S60, S70, S80, V70
Ball joint removal tool installed-S60, S70, S80, V70
Fig. Support tool installed-S60, S70, S80, V70
Support tool installed-S60, S70, S80, V70
NOTE
The guide bolts have a wrench grip (see arrow) which is asymmetrically positioned. 1. Aluminum wheel spindle: Use the bolt (1) with the greater distance
from the wrench grip 2. Steel wheel spindle: Use the bolt (2) with the shortest distance from the wrench grip.
1. Screw in the guide bolts (1) fully.

2. Install the support (P/N 999 5781) using 3 wheel studs.
3. Screw the guide bolts (1) down until they are in contact with the support.
4. Position the supplementary support (2) (P/N 999 5781-4) on the hydraulic press (1).
5. Screw the connector (3) (P/N 999 5781-5) into place on the hydraulic press.
6. Install the connector on the nut on the ball joint.
7. Press off the ball joint.
8. Remove the tool and the ball joint.
WARNING
Use protective goggles.
9. Clean the ball joint seat and the mating surfaces of the ball joint to the wheel spindle. Use a rotary wire brush.
10. Lubricate the seat using wheel bearing grease.
To install:
1. Loosely install the new ball joint using the guide bolts.
WARNING
Leave the protective cap for the ball joint in position to prevent damaging the rubber seal.
2. Press the ball joint up towards the seat using the impact drift (1) (P/N 999 5796). Check that the ball joint is centered in the seat.
3. Knock in the ball joint using a copper mallet.
4. Tighten the ball joint using new bolts. Tighten to 37 ft. lbs. (50 Nm)
5. Remove the protective cap (1).
6. Install the halfshaft in the hub. Install a new bolt.
CAUTION
8. Slowly release the control arms (1) by releasing the tension strap (2).
9. Install a new nut.
NOTE
The ball joint pinion must not rotate. Use a TorxÂ® wrench as a counterhold so that the rubber boot is not damaged. Tighten to 59 ft. lbs. (80 Nm).
10. Install the wheels. Tighten to 103 ft. lbs. (140 Nm).
1. Raise the car.

NOTE
Clean the ball joint thread using a wire brush. Use rust penetrator. If the ball joint releases in the cone, position a transmission jack under the
control arm. Carefully lift (not more than so the front spring is in the resting position) until the cone jams. Remove the nut.

NOTE
WARNING

To install:
CAUTION
Fig. Inspect the rubber rings-S40, V40
Inspect the rubber rings-S40, V40

12. Tighten the nut. Tighten to 68 ft. lbs. (90 Nm) plus 60 deg.
Fig. Lower control arm final tightening-S40, V40
Lower control arm final tightening-S40, V40

1. Remove the wheel

3. Detach the halfshaft end at the hub Tap in the shaft end approximately 10-15mm. Use a rubber or copper mallet.
NOTE
NOTE
12. Installation is the reverse order of removal. Replace the ball joint wheel spindle nut with a new one and tighten to 52 ft. lbs. (70 Nm).
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Volvo Cars 1999-05
Lower Control Arms

1. Remove the front wheels

2. Remove the nut on the ball joint. Use a Torx wrench as a counterhold so that the rubber boot is not damaged.
3. Remove the splash guard under the engine.
4. Install the retaining strap to bend the control arms down.
WARNING
1. Pull down the control arms using a tension strap.

2. Release the spring strut from the control arm
3. Remove the tensioner strap.
4. Remove the bolt from the halfshaft. Use a counterhold on the brake disc
5. Remove the halfshaft from the hub. Knock the halfshaft out using a brass drift
Fig. Left lower control arm removal-S60, S70, S80, V70
Left lower control arm removal-S60, S70, S80, V70

Fig. Right lower control arm removal-S60, S70, S80, V70
Right lower control arm removal-S60, S70, S80, V70
On the right side:
1. Remove the hose from the EVAP canister and the fuel line from the engine block heater (where applicable) from their mountings. Move the hose
and fuel line to one side.
2. Lift the engine approximately 10 mm using a mobile jack so that the front 2 bolts on the control arm can be removed
3. Position a mobile jack with a universal plate under the oil pan on the right side of the engine.
4. Remove the bolts and the nut from the control arm in the sub-frame
On the left side:
1. Lift the engine approximately 15 mm using a mobile jack so that the front bolts on the control arm can be removed.
2. Position a mobile jack with a universal plate under the oil pan on the left side of the engine.
3. Remove the bolts and the nuts from the control arm in the sub-frame
To install:
On the right side:
1. For the right-hand control arm, lift the engine 10 mm using a mobile jack.
2. Install the control arm on the sub-frame. Use new bolts and a new nut
3. Tighten the front bolts. Tighten to 49 ft. lbs. (65 Nm). Angle-tighten 90 deg.
4. Tighten the rear bolt and nut. Tighten to 77 ft. lbs. (105 Nm). Angle-tighten 90 deg.
5. Remove the jack.
6. Install the hose at the EVAP canister and the fuel line for the engine block heater (if applicable) in their mountings on the sub-frame.
7. Reinstall the splash guard under the engine.
On the left side:
1. Lift the engine 15 mm using a mobile jack.

2. Install the control arm on the sub-frame. Use new bolts and new nuts
5. Remove the mobile jack
7. Turn in the wheel spindle and locate the halfshaft in the hub.
NOTE
Check that the seal is not worn or damaged. Replace if necessary. Ensure that the sealing ring is correctly positioned on the halfshaft.
1. Clean the splines on the halfshaft.

2. Install the halfshaft in the hub.
3. Install a new bolt. Use a counterhold. Tighten to 27 ft. lbs. (35 Nm) plus 90 deg.
4. Install the retaining strap to bend the control arms down
NOTE
NOTE
1. Slowly release the control arms by releasing the tension strap.

2. Install a new nut
NOTE
The ball joint pinion must not rotate. Use a Torx wrench as a counterhold so that the rubber boot is not damaged. Tighten to 59 ft. lbs. (80 Nm).
1. Install the wheels.
1. Remove the stub axle and engine splash guard.
On the left side:
1. Remove the front engine mounting bolt.

2. Lift the left side of the engine approx. 1 inch (25 mm) to expose the control arm bolt.
3. Remove the bolts for the control arm in the sub-frame and remove the control arm.
On the right side:
1. Remove the vibration damper, if equipped with a 6-cylinder engine.

2. Remove both right hand engine mounting bolts.
3. Lift up the ride side of the engine approx. 1 inch (25 mm) to expose the control arm bolt.
To install:
1. Install the control arm on the sub-frame using new fasteners. Tighten the front bolts to 48 ft. lbs. (65 Nm) plus 90 degrees and tighten the rear bolt
to 77 ft. lbs. (105 Nm) plus 90 degrees.
On the left side:
1. Lower the engine and tighten the front engine mounting bolt to 37 ft. lbs. (50 Nm).
On the right side:
1. Lower the engine and tighten the right engine mounting bolts to 26 ft. lbs. (35 Nm) plus 90 degrees.
2. Install the vibration damper using new bolts and tighten to 26 ft. lbs. (35 Nm) plus 50 degrees.
Applies to either side:
1. Install the stub axle and engine splash guard.
1. Remove the wheel

3. Detach the halfshaft end at the hub Tap in the shaft end approximately 10-15 mm. Use a rubber or copper mallet.
NOTE
NOTE
On the left side:
NOTE

On the right side:
NOTE

To install:
On the left side:
On the right side:
3. Install the two bolts (1) for the engine pad on the right side. Tighten to 27 ft. lbs. (35 Nm). Angle-tighten 90 deg.
NOTE
Use new bolts.
NOTE

NOTE
NOTE
Press the ball joint upwards so that the conical top is visible above the bolted joint on the wheel spindle. Use a new locknut in the wheel spindle bolt.
Tighten to 38 ft. lbs. (50 Nm).
Front wheel
Lower ball joint
Lower control arm
To install:
Lower control arm. Tighten the subframe bolts to 48 ft. lbs. (65 Nm) plus 120 degrees
Lower ball joint. Tighten the bolts to 13 ft. lbs. (18 Nm) plus 90 degrees.
Front wheel

Front wheel
Lower ball joint
Stabilizer bar link
Locator rod
Control arm
To install:
Control arm. Tighten the inner bolt to 63 ft. lbs. (85 Nm).
Locator rod. Tighten the inner bolt to 63 ft. lbs. (85 Nm) and the control arm bolt to 70 ft. lbs. (95 Nm).
Stabilizer bar link.
Lower ball joint. Tighten the nut to 44 ft. lbs. (60 Nm).
Front wheel

Front wheel
Lower ball joint
Lower control arm
To install:
Lower control arm. Tighten the subframe bolts to 48 ft. lbs. (65 Nm) plus 120Â°
Lower ball joint. Tighten the bolts to 13 ft. lbs. (18 Nm) plus 90Â°.
Front wheel
1. Remove the stub axle.

On the left side:
On the right side:
1. Remove the hose from the EVAP canister and the fuel line from the engine block heater (where applicable). Move the hose and fuel line to one side.
NOTE
When removing the rear bolt on the front mounting from the control arm, the engine must be raised slightly using a prybar
Fig. Lower control arm removal-V70XC
Lower control arm removal-V70XC

2. Remove the bolts and nut from the control arm in the sub-frame
3. remove the control arm.
To install:
1. Lift the engine slightly when installing the right control arm. When installing the rear bolt in the front mounting for the control arm, see removing
the right front control arm.
2. Install the control arm on the sub-frame. Use new bolts and a new nut.
5. Install the stub axle.
7. Install the hose for the EVAP canister and the fuel line for the engine block heater (if applicable) in their mountings on the sub-frame.
1. Remove the front wheels

2. Remove the nut on the ball joint. Use a TorxÂ® wrench as a counterhold so that the rubber boot is not damaged.
4. Install the retaining strap to bend the control arms down.
WARNING
5. Pull down the control arms using a tension strap.

6. Release the spring strut from the control arm
Fig. Left lower control arm removal-S60, S80, V70
Left lower control arm removal-S60, S80, V70
Fig. Right lower control arm removal-S60, S80, V70
Right lower control arm removal-S60, S80, V70

7. Remove the tensioner strap.
8. Remove the bolt from the halfshaft. Use a counterhold on the brake disc
9. Remove the halfshaft from the hub. Knock the halfshaft out using a brass drift
On the right side:
1. Remove the hose from the EVAP canister and the fuel line from the engine block heater (where applicable) from their mountings. Move the hose
and fuel line to one side.
2. Lift the engine approximately 10mm using a mobile jack so that the front 2 bolts on the control arm can be removed
3. Position a mobile jack with a universal plate under the oil pan on the right side of the engine.
On the left side:
1. Lift the engine approximately 15mm using a mobile jack so that the front bolts on the control arm can be removed.
2. Position a mobile jack with a universal plate under the oil pan on the left side of the engine.
3. Remove the bolts and the nuts from the control arm in the sub-frame
To install:
On the right side:
1. For the right-hand control arm, lift the engine 10mm using a mobile jack.
2. Install the control arm on the sub-frame. Use new bolts and a new nut
5. Remove the jack.
6. Install the hose at the EVAP canister and the fuel line for the engine block heater (if applicable) in their mountings on the sub-frame.
On the left side:
1. Lift the engine 15mm using a mobile jack.

2. Install the control arm on the sub-frame. Use new bolts and new nuts
5. Remove the mobile jack
7. Turn in the wheel spindle and locate the halfshaft in the hub.
NOTE
Check that the seal is not worn or damaged. Replace if necessary. Ensure that the sealing ring is correctly positioned on the halfshaft.

9. Install the halfshaft in the hub.
10. Install a new bolt. Use a counterhold. Tighten to 27 ft. lbs. (35 Nm) plus 90 deg.
11. Install the retaining strap to bend the control arms down
NOTE

NOTE
13. Slowly release the control arms by releasing the tension strap.
14. Install a new nut
NOTE
The ball joint pinion must not rotate. Use a TorxÂ® wrench as a counterhold so that the rubber boot is not damaged. Tighten to 59 ft. lbs. (80 Nm).
15. Install the wheels.
1. Remove the stub axle and engine splash guard.
On the left side:
1. Remove the front engine mounting bolt.

2. Lift the left side of the engine approx. 1 inch (25mm) to expose the control arm bolt.
On the right side:
1. Remove the vibration damper, if equipped with a 6-cylinder engine.

2. Remove both right hand engine mounting bolts.
3. Lift up the ride side of the engine approx. 1 inch (25mm) to expose the control arm bolt.
To install:
1. Install the control arm on the sub-frame using new fasteners. Tighten the front bolts to 48 ft. lbs. (65 Nm) plus 90Â° and tighten the rear bolt to 77
ft. lbs. (105 Nm) plus 90Â°.
On the left side:
1. Lower the engine and tighten the front engine mounting bolt to 37 ft. lbs. (50 Nm).
On the right side:
1. Lower the engine and tighten the right engine mounting bolts to 26 ft. lbs. (35 Nm) plus 90Â°.
2. Install the vibration damper using new bolts and tighten to 26 ft. lbs. (35 Nm) plus 50Â°.
Applies to either side:

1. Install the stub axle and engine splash guard.
1. Remove the wheel

3. Detach the halfshaft end at the hub Tap in the shaft end approximately 10-15mm. Use a rubber or copper mallet.
NOTE
NOTE
On the left side:

NOTE

On the right side:

NOTE

To install:
On the left side:
On the right side:
3. Install the two bolts (1) for the engine pad on the right side. Tighten to 27 ft. lbs. (35 Nm). Angle-tighten 90 deg.
NOTE
Use new bolts.
NOTE

NOTE
NOTE
Press the ball joint upwards so that the conical top is visible above the bolted joint on the wheel spindle. Use a new locknut in the wheel spindle
bolt. Tighten to 38 ft. lbs. (50 Nm).
1. Raise the car.

NOTE
Clean the ball joint thread using a wire brush. Use rust penetrator. If the ball joint releases in the cone, position a transmission jack under the
control arm. Carefully lift (not more than so the front spring is in the resting position) until the cone jams. Remove the nut.

NOTE
WARNING

Fig. Support the torque rod with a jack-S40, V40
Support the torque rod with a jack-S40, V40
To install:
CAUTION

12. Tighten the nut. Tighten to 68 ft. lbs. (90 Nm) plus 60 deg.
Bushing Replacement
1. Remove the bushing. Use a press. Lubricate the tool with soap water to facilitate removal.
2. Cut the bushing in the necessary places so that the tool can be correctly installed.
3. Press the bushing out of the control arm.
4. Using a press, press the new bushing into the control arm.
NOTE
Do not press in more than the measured bushing position.
CAUTION
Caution! Ensure that the bushing is at the correct angle in the control arm.
Fig. Press the control arm bushing out of the control arm
Press the control arm bushing out of the control arm

The control arm bushings are serviced with the control arm as an assembly.
1. Remove the bushing. Use a press. Lubricate the tool with soap water to facilitate removal.
2. Cut the bushing in the necessary places so that the tool can be correctly installed.
3. Press the bushing out of the control arm.
4. Using a press, press the new bushing into the control arm.
NOTE
Do not press in more than the measured bushing position.
CAUTION
Caution! Ensure that the bushing is at the correct angle in the control arm.
Fig. Press the control arm bushing out of the control arm
Press the control arm bushing out of the control arm
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Volvo Cars 1999-05
Shock Absorbers

2. Remove the strut assembly
4. Remove the shock absorber mounting nut using socket 999-5500 using a TorxÂ® as a counterhold.
5. Remove the shock absorber.
Fig. Removing the shock mounting nut
Removing the shock mounting nut
To install:
1. If replacing, transfer the ABS line holder to the new shock absorber.
Shock absorber and tighten the upper shock nut to 52 ft. lbs. (70 Nm)
Strut assembly
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Volvo Cars 1999-05
Stabilizer Bar (Sway Bar) & Links


NOTE
The anti-roll bar bushings and caps are vulcanized to the anti-roll bar and cannot be replaced separately.
2. Install the lifting tool 999 5716 , modified according to the tool bulletin for version C, and lifting hooks 999 5460.
3. Lift the engine to relieve the load on the engine pads.
Fig. Installation of lifting tool 999 5716 and lifting hooks 999 5460
Installation of lifting tool 999 5716 and lifting hooks 999 5460
5. Slacken off the right lower front part of the fender liner.
The plastic nuts on the fender liner

The protective plate
Bend out the fender liner
Bolts for the right-hand engine mounting (1)
Fig. Location of right-hand engine mounting bolts
Location of right-hand engine mounting bolts
The splash guard under the engine

The skid guard, if equipped
The 4 mounting bolts for the Side Impact Protection System (SIPS) member
The brake pipe from the snap fastener on the member
The SIPS member
Fig. Location and removal of the SIPS member
Location and removal of the SIPS member
The rubber mountings for the exhaust pipe

The nuts and bolts holding the steering gear to the sub-frame
The power steering line from the clips on the sub-frame
The bracket for the heated oxygen sensor (HO2S) from the sub-frame
The heated oxygen sensor wiring from the right side of the sub-frame (only applies to 6-Cylinder engines)
9. Lower the sub-frame:

A. Position a mobile jack with universal plate 999 5972 at the rear of the sub-frame.
B. Remove the bolts holding the sub-frame bracket in the body.
C. Remove the rear bolt for the sub-frame with the bracket and washer.
1
D. Carefully lower the sub-frame until the clearance A between the sub-frame and the body is 4 / 3 inches (110mm).
Fig. Lowering the sub-frame using a mobile jack with universal plate 999 5972
Lowering the sub-frame using a mobile jack with universal plate 999 5972
Fig. Lowering the sub-frame to the appropriate clearance
Lowering the sub-frame to the appropriate clearance
10. Remove the anti-roll bar on both sides. Use a TorxÂ® wrench as a counterhold so that the boot is not damaged.
11. Remove the bolts for the anti-roll bar.
12. Remove the anti-roll bar.
Fig. Location and removal of anti-roll bar bolts
Location and removal of anti-roll bar bolts
To install:

NOTE
Use a TorxÂ® wrench as a counterhold so that the gaiter is not damaged.
The anti-roll bar

The (M10) bolts for the anti-roll bar. Tighten to 37 ft. lbs. (50 Nm)
The nut for the anti-roll bar link on both sides. Tighten to 59 ft. lbs. (80 Nm)
2. Install the sub-frame:
A. Raise the sub-frame.

B. Install the sub-frame four bolts together with the sub-frame brackets and engine heater, if installed.
NOTE
Use new bolts. Lube the bolts with oil. Tighten the sub-frame bolts starting on the left-hand side, then the right, using 2 steps: Step 1-78 ft.
lbs. (105 Nm), Step 2-angle-tighten 120Â°.
3. Tighten the M10 bolts for the brackets M10 to 37 ft. lbs. (50 Nm).
4. Remove the lifting table.
NOTE
Use soap solution to facilitate installing the rubber mountings.
The nuts and bolt for the steering gear. Use new nuts and bolt. Tighten to 37 ft. lbs. (50 Nm)
The rubber mountings for the exhaust pipe
6. Install the SIPS member:
A. Install the brake pipe in the snap fastener on the member.

B. Install the SIPS member. Tighten the M8 bolts to 18 ft. lbs. (24 Nm).
The skid plate, if equipped, up into the bumper wraparound. Press forwards until the mounting brackets engage in the sub-frame
The M10 skid plate bolts. Tighten to 37 ft. lbs. (50 Nm)
The splash guard under the engine. Tighten the M8 bolts to 18 ft. lbs. (24 Nm)
8. Install the right-hand engine mounting:
A. Install the bolts for the right-hand engine mounting. Use new bolts. Tighten in 2 steps:
Step 1-89 ft. lbs. (120 Nm)
Step 2-angle-tighten 40Â°
9. Fold the fender liner back into position.

10. Install the plastic nuts.
11. Install the front wheels and tighten lug nuts to 81-103 ft. lbs. (110-140 Nm).
12. Remove the lifting tools 999 5716 and lifting hooks 999 5460.
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Volvo Cars 1999-05
Steering Knuckle

2. Raise and support the vehicle safely.
3. Remove front wheel.
The anti-roll bar link from the spring strut. Use a fixed wrench as a counterhold
The ABS sensor. Hang up the sensor using a piece of wire
The ABS sensor cable from the spring strut
The brake caliper mounting bolts. Hang the caliper up using a piece of wire
The halfshaft bolt. Use a screwdriver as a counterhold on the brake disc
The locating pin holding the brake disc
1 1
The brake disc. Detach the end of the halfshaft in the hub by knocking the drive shaft into the hub approximately /3- / 2 inch (10-15mm).
Use a rubber or copper mallet
The tie rod ends from the steering arm
5. Measure the position of the steering knuckle and spring strut for installation purposes.
6. Remove the bolts retaining the spring strut and the steering knuckle.
Fig. Location of bolt removal of steering knuckle
Location of bolt removal of steering knuckle

7. Press out the steering knuckle. At the same time pull the halfshaft from the transaxle.
8. Suspend the drive shaft from a hook 999 5045.
NOTE
Take care not to damage the halfshaft boot.
Fig. Suspending halfshaft from hook 999 5045
Suspending halfshaft from hook 999 5045

9. Disconnect the ball joint pinion from the control arm. Use tool 999 7062.
10. Install cap nut 7062-1 on the ball joint pinion.
11. Tighten the nut against the control arm.
12. Then turn back one turn to form a gap between the cap nut and the control arm.
13. Position the extractor on the control arm. Detach the ball joint from the control arm.
Fig. Using tool 999 7062 to extract ball joint
Using tool 999 7062 to extract ball joint
To install:
1. Install the steering knuckle on the trailing arm.

2. Install a new nut on the ball joint. Tighten to 59 ft. lbs. (80 Nm). Use a TorxÂ® wrench as counterhold.
NOTE
Make sure that the mating surfaces on the ball joint and link are clean.

4. Turn the steering knuckle and bring the halfshaft into the hub.
5. Install halfshaft bolt and finger-tighten. Lubricate the bolt.
6. Install bolts retaining the spring strut in the steering knuckle. Use new bolts and nuts. Tighten to 78 ft. lbs. (105 Nm) and then angle-tighten 60Â°.
NOTE
Ensure that the sensor seat in the steering knuckle is absolutely clean. Clean the ABS sensor with a soft brush.
NOTE
Ensure that the brake disc and wheel rim hub mating surfaces are clean.
The anti-roll bar link to the spring strut. Use a new nut. Counterhold using a TorxÂ® wrench so that the boot is not damaged. Tighten to 37 ft.
lbs. (50 Nm)
The ABS sensor cable
The ABS sensor onto the steering knuckle. Tighten the ABS sensor to 88 inch lbs. (10 Nm)
The tie rod end onto the steering knuckle. Use a new nut. Tighten to 59 ft. lbs. (80 Nm)
The brake disc. Tighten the brake disc locating pin to 88 inch lbs. (10 Nm)
8. Tighten the halfshaft bolt. Use a screwdriver as a counterhold on the brake disc. Tighten to 26 ft. lbs. (35 Nm), plus 120Â°.
9. Install the brake caliper. Use new bolts
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Volvo Cars 1999-05
Strut (MacPherson Strut) Assembly

Wheel
Brake hose
ABS cable
Anti-roll bar link
Wheel spindle
Strut upper mount nuts
Strut assembly
To install:
Strut assembly and tighten the upper mount nuts to 33 ft. lbs. (45 Nm)
Wheel spindle and tighten the bolts to 66 ft. lbs. (90 Nm)
Anti-roll bar link and tighten the bolts to 33 ft. lbs. (45 Nm)
ABS cable
Brake hose
Wheel
Wheel
Half shaft retainer bolt
Ball joint from the wheel spindle
Brake caliper
Half shaft from the wheel hub
Anti-roll bar link
2. Remove the lower strut mounting bolt and carefully tap the wheel spindle down until it release from the strut assembly.
3. Remove the three top strut mounting bolts and remove the strut assembly.
To install:
Strut assembly using new fasteners

Wheel spindle to strut assembly and tighten to 66 ft. lbs. (90 Nm)
Half shaft into the wheel hub
Ball joint to the wheel spindle and tighten to 52 ft. lbs. (70 Nm)
Half shaft retainer bolt
Brake caliper
Anti-roll bar link
Wheel
Wheel
Anti-roll bar link
ABS sensor
Bolts holding the strut in the wheel spindle
Strut assembly
To install:
NOTE
Use new fasteners for assembly.
Strut assembly onto the wheel spindle and tighten to 77 ft. lbs. (105 Nm) plus 90 degrees
Anti-roll bar link and tighten to 37 ft. lbs. (50 Nm)
ABS sensor
Wheel
Front wheel
Outer tie rod end
Wheel speed sensor and wiring bracket
Stabilizer bar link
Brake caliper and rotor
Brake hose bracket
Lower ball joint
Upper strut mount
Strut assembly
To install:
Lower ball joint and tighten the nut to 44 ft. lbs. (60 Nm)
Brake hose bracket
Stabilizer bar link
Wheel speed sensor and wiring bracket
Outer tie rod end and tighten the nut to 44 ft. lbs. (60 Nm)
Front wheel
2. Support the lower control arm with a jack stand.
Front wheel
Stabilizer bar link
Wheel speed sensor and wiring
Strut bracket bolts
Upper strut mount nuts
Strut assembly
To install:
NOTE
Strut bracket bolts and tighten the bolts to 48 ft. lbs. (65 Nm) plus 90 degrees
Stabilizer bar link
Front wheel

2. Support the lower control arm with a jack stand.
Front wheel
Stabilizer bar link
Strut bracket bolts
Upper strut mount nuts
Strut assembly
To install:
NOTE
Strut bracket bolts and tighten the bolts to 48 ft. lbs. (65 Nm) plus 90Â°
Stabilizer bar link
Front wheel
Wheel
Brake hose
ABS cable
Anti-roll bar link
Wheel spindle
Strut assembly
To install:
Wheel spindle and tighten the bolts to 66 ft. lbs. (90 Nm)
Anti-roll bar link and tighten the bolts to 33 ft. lbs. (45 Nm)
ABS cable
Brake hose
Wheel
Wheel
Halfshaft retainer bolt
Ball joint from the wheel spindle
Brake caliper
Halfshaft from the wheel hub
Anti-roll bar link
2. Remove the lower strut mounting bolt and carefully tap the wheel spindle down until it release from the strut assembly.
3. Remove the three top strut mounting bolts and remove the strut assembly.
To install:
Strut assembly using new fasteners

Wheel spindle to strut assembly and tighten to 66 ft. lbs. (90 Nm)
Halfshaft into the wheel hub
Ball joint to the wheel spindle and tighten to 52 ft. lbs. (70 Nm)
Halfshaft retainer bolt
Brake caliper
Anti-roll bar link
Wheel
Wheel
Anti-roll bar link
ABS sensor
Bolts holding the strut in the wheel spindle
Strut assembly
To install:
NOTE
Strut assembly onto the wheel spindle and tighten to 77 ft. lbs. (105 Nm) plus 90Â°
Anti-roll bar link and tighten to 37 ft. lbs. (50 Nm)
ABS sensor
Wheel
Overhaul (Coil Spring Removal & Installation)
1. Secure the strut in a vise.
2. Remove:
The nut for the shock absorber bearing.

Washer
Mounting.
3. Take the load off the spring seat. Use hydraulic tool 951 2911 together with 951 2914.
4. Remove:
The fixing nut on the shock absorber.

The spring seat
The spring
The rubber bump stop and gaiter.
5. Check that the spring strut bearing (1), spring seat (2) and rubber bump stop with boot (3) are free of damage. Replace if necessary.
Fig. Identification of spring strut components for inspection
Identification of spring strut components for inspection
To install:
1. Compress the new spring. Use spring clamps.

Fig. Compressing the spring
Compressing the spring
Fig. Installing the spring on the strut
Installing the spring on the strut

2. Install:
The bump stop with the boot

The spring
The spring seat.
3. Install the fixing nut. Tighten to 51 ft. lbs. (70 Nm).

4. Remove the spring clamps.
5. Install:
Bearing
Washer
The nut. Tighten to 51 ft. lbs. (70 Nm).
6. Install the spring strut in the bodywork using the new nuts. Tighten to 18 ft. lbs. (25 Nm).
7. Install the spring strut on the steering knuckle. Use new bolts and new nuts.
8. Adjust the spring strut and steering knuckle to the measured value. Tighten to 77 ft. lbs. (105 Nm), plus 90Â°.
9. Install:
NOTE
Ensure that the ABS sensor seat in the steering knuckle is absolutely clean. Clean the ABS sensor with a soft brush.
The anti-roll bar link to the spring strut. Use a new nut. Tighten to 37 ft. lbs. (50 Nm). Counterhold using a TorxÂ® wrench to prevent damage
to the boot
The ABS sensor. Tighten to 88 inch lbs. (10 Nm)
The ABS sensor cable in the bracket

The wheel and tighten lug nuts to 81-103 ft. lbs. (110-140 Nm).
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Volvo Cars 1999-05
Upper Control Arms


2. Raise the vehicle.
The wheel
The brake caliper. Hang the brake caliper on a hook in the sub-frame.
Fig. Using a hook to safely hang the brake caliper out of the way
Using a hook to safely hang the brake caliper out of the way
4. Slacken off the bolt for the outer control arm mounting by 3 turns.
5. Use tool: 951 2923 , 999 7031 and 999 7030 together with threaded rod 999 7039 to press off the steering knuckle.
Fig. Using a press on the steering knuckle
Using a press on the steering knuckle

Fig. Using puller 998 5434 with counterhold 999 7074 on rear control arm mounting
Using puller 998 5434 with counterhold 999 7074 on rear control arm mounting
6. Remove the bolt for the drive shaft.
7. Press in the drive shaft and remove the spindle.
NOTE
Only press until the bushing releases from the splined area.
8. Slacken off the bolt three turns for the rear control arm mounting. Use puller 998 5434 with counterhold 999 7074.
The bolt for the inner rear control arm mounting

The two bolts for the inner front control arm mounting
The control arm
To install:
The bolts for the inner rear control arm mounting

The bolts for the front inner control arm mounting
The bolts for the outer control arm mounting
2. Install tensioner 999 5659.

NOTE
The tensioner must be positioned as far out as possible on the tensioner plates to achieve the correct lifting force.
3. Tighten the M12 bolts for the inner rear control arm mounting to 59 ft. lbs. (80 Nm).
4. Tighten the M12 bolts for the front inner control arm mounting to 59 ft. lbs. (80 Nm).
5. Tighten the M12 bolts for the outer control arm mounting to 59 ft. lbs. (80 Nm).
NOTE
Tighten the bolts when the rear suspension is in the normal position.
6. Remove tensioner 999 5659.

7. Install the wheel and tighten lug nuts to 81-103 ft. lbs. (110-140 Nm).
NOTE
If the vehicle is equipped with Bi-Xenon lamps, the position sensor must be calibrated. Carry out calibration according to VIDA vehicle
communication (Function area 3, Electrical system, Rear Electronic Module).
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Volvo Cars 1999-05
Wheel Bearings
1. Slacken off the center nut from the halfshaft.

2. Remove the wheel.
3. Remove the lock clip. Remove the brake hose from the bracket.
4. Remove the two bolts from the brake caliper holder and hang them up to prevent damage to the brake hose.
5. Remove the brake disc.
6. Remove the nut from the halfshaft.
7. Clean thoroughly around the sensor.
8. Remove the ABS cable from the bracket.
9. Remove the bolt. Carefully remove the sensor from the wheel spindle with a twisting movement.
10. Remove the halfshaft nut.
11. Remove the tie rod ball joint.
12. Remove slacken off the wheel spindle nut as much as possible.
13. Remove the two wheel spindle bolts.
14. Use a universal puller to withdraw the halfshaft from the wheel spindle. .
15. Remove the nut from the ball joint.
WARNING
Secure the tool by tying it into place to prevent damage.

2. Remove the wheel spindle.
3. Clean the hub.
4. Screw together special tools 5635-1 and 5635-2 in the conical opening in the end of the tie rod.
5. Install the wheel spindle with the hub downwards in special tool 999 5635.
6. Press the hub out of the bearing.
Fig. Snap ring removal-S40, V40
Snap ring removal-S40, V40

Fig. Hub bearing removal-S40, V40
Hub bearing removal-S40, V40
Fig. Tool 5635-S40, V40
Tool 5635-S40, V40
NOTE
the inner ring can be left in place on the hub.
1. Remove the inner sealing ring

2. Remove the snap ring.
3. Turn the wheel spindle over in the tool.
4. Press the hub out of the wheel spindle.
NOTE
Move the inner ring to the other side of the bearing if necessary.
Fig. Tool assembly-S40, V40
Tool assembly-S40, V40
Fig. Seal removal-S40, V40
Seal removal-S40, V40
1. Connect special tool 998 5433 and 998 5434.

2. Connect special tool 999 5310 to the hub. Pull off the bearing cap.
3. Remove the sealing ring.
4. Connect special tool 998 5433 and-998 5434.
5. Connect special tool 999 5310 to the hub. Pull off the bearing-cap.
Fig. Tool 5310 installed-S40, V40
Tool 5310 installed-S40, V40
NOTE
When installing a new wheel spindle, a new splash guard must be installed on the wheel spindle.
1. Secure it in three places with a screwdriver.

2. Press out the wheel studs. Pull the wheel stud into place with a wheel nut and a spacer.
To install:
1. Install the wheel spindle in the special tool 999 5635.

2. Install the bearing with the text turned inwards.
3. Apply locking fluid to the wheel spindle
4. Guide the bearing and press it into place.
5. Install a new snap ring.
6. Position the hub under a press.
NOTE
Avoid damaging the wheel studs.
1. Press the wheel spindle over the hub.

2. Clean the control arm. Position the wheel spindle over the ball joint. Tighten the lock nut as much as possible. Press the halfshaft inwards. Install the
halfshaft in the wheel spindle.
3. Install the wheel spindle in the spring strut. Install the two bolts.
4. Install the nut and the snap ring in the halfshaft as far in as possible.
NOTE
Cars with turbocharged engines have only a nut.
NOTE
Oil the turbo splines.
1. Install two new nuts on the wheel spindle bolts.

2. Press the wheel spindle to the bottom. Tighten the wheel spindle bolts. Tighten to 68 ft. lbs. (90 Nm).
3. Tighten the ball joint nut. Tighten to 51 ft. lbs. (67 Nm).
4. Install the tie rod ball joint on the wheel spindle
5. Clean the hub. Install the brake disc.
6. Install the brake caliper bracket on the wheel spindle. Tighten to 76 ft. lbs. (100 Nm).
7. Install the brake hose in the bracket. Install the snap ring.
8. Remove any dirt from the sensor seat so that the sensor is in the correct position in relation to the pulse wheel.
9. Use compressed air to blow off any dirt on the pulse wheel.
10. Lightly lubricate the sensor and install it. Tighten to 19 ft. lbs. (25 Nm).
11. Ensure that the brake disc and wheel rim mating surfaces are clean.
13. Tighten the new nut for the halfshaft. Tighten to 91 ft. lbs. (120 Nm) +60 deg.
14. Install the hub cap.

5. Remove the brake backing plate.
6. Pull the steering arm out of the wheel spindle.
8. Remove the ABS sensor and hang in a suitable position.
11. Remove the ball-joint from the wheel spindle.
12. Press the half shaft out of the wheel spindle.
13. Remove the wheel spindle from the spring strut.
14. Secure the wheel spindle in a hydraulic press using socket 999-7090 and drift 999-1801 to press out the bearing.
To install:
1. Press both halves of 7090-1 between the bearing and the hub on the press.
2. Press the bearing into the wheel spindle.
3. Install the wheel spindle on the strut assembly.
4. Press the half shaft into the wheel spindle.
5. Install the ball-joint onto the wheel spindle and tighten the nut to 52 ft. lbs. (70 Nm).
6. Install the center nut for the half shaft.
ABS sensor
Steering arm to the wheel spindle
Brake backing plate
Brake disc
Brake caliper
Wheel
Fig. Securing the wheel spindle in a hydraulic press
Securing the wheel spindle in a hydraulic press
Front wheel
Wheel speed sensor
Spindle nut
Hub retainer bolts
Hub and bearing assembly
To install:
Hub and bearing assembly. Tighten the bolts to 33 ft. lbs. (45 Nm) plus 60 degrees.
Spindle nut. Tighten the nut to 89 ft. lbs. (120 Nm) plus 60 degrees.
Wheel speed sensor
Front wheel

Front wheel
Wheel speed sensor
Spindle nut
Hub retainer bolts
Hub and bearing assembly
To install:
Hub and bearing assembly. Tighten the bolts to 33 ft. lbs. (45 Nm) plus 60Â°.
Spindle nut. Tighten the nut to 89 ft. lbs. (120 Nm) plus 60Â°.
Wheel speed sensor
Front wheel

3. Remove the lock clip. Remove the brake hose from the bracket.
7. Clean thoroughly around the sensor.
8. Remove the ABS cable from the bracket.
9. Remove the bolt. Carefully remove the sensor from the wheel spindle with a twisting movement.
10. Remove the halfshaft nut.
13. Remove the two wheel spindle bolts.
14. Use a universal puller to withdraw the halfshaft from the wheel spindle. .
15. Remove the nut from the ball joint.
WARNING
Secure the tool by tying it into place to prevent damage.

17. Remove the wheel spindle.
18. Clean the hub.
Fig. Snap ring removal-S40, V40
Snap ring removal-S40, V40
Fig. Hub bearing removal-S40, V40
Hub bearing removal-S40, V40

19. Screw together special tools 5635-1 and 5635-2 in the conical opening in the end of the tie rod.
20. Install the wheel spindle with the hub downwards in special tool 999 5635.
Fig. Tool 5635-S40, V40
Tool 5635-S40, V40

21. Press the hub out of the bearing.
NOTE
the inner ring can be left in place on the hub.
22. Remove the inner sealing ring

23. Remove the snap ring.
24. Turn the wheel spindle over in the tool.
25. Press the hub out of the wheel spindle.
NOTE
Move the inner ring to the other side of the bearing if necessary.
Fig. Tool assembly-S40, V40
Tool assembly-S40, V40

Fig. Seal removal-S40, V40
Seal removal-S40, V40

26. Connect special tool 998 5433 and 998 5434.
Fig. Tool 5310 installed-S40, V40
Tool 5310 installed-S40, V40

27. Connect special tool 999 5310 to the hub. Pull off the bearing cap.
29. Connect special tool 998 5433 and-998 5434.
30. Connect special tool 999 5310 to the hub. Pull off the bearing-cap.
NOTE
When installing a new wheel spindle, a new splash guard must be installed on the wheel spindle.
32. Secure it in three places with a screwdriver.

33. Press out the wheel studs. Pull the wheel stud into place with a wheel nut and a spacer.
To install:
1. Install the wheel spindle in the special tool 999 5635.

2. Install the bearing with the text turned inwards.
3. Apply locking fluid to the wheel spindle
4. Guide the bearing and press it into place.
5. Install a new snap ring.
6. Position the hub under a press.
NOTE
Avoid damaging the wheel studs.
7. Press the wheel spindle over the hub.

8. Clean the control arm. Position the wheel spindle over the ball joint. Tighten the lock nut as much as possible. Press the halfshaft inwards. Install the
halfshaft in the wheel spindle.
9. Install the wheel spindle in the spring strut. Install the two bolts.
10. Install the nut and the snap ring in the halfshaft as far in as possible.
NOTE
Cars with turbocharged engines have only a nut.
NOTE
Oil the turbo splines.
11. Install two new nuts on the wheel spindle bolts.

12. Press the wheel spindle to the bottom. Tighten the wheel spindle bolts. Tighten to 68 ft. lbs. (90 Nm).
13. Tighten the ball joint nut. Tighten to 51 ft. lbs. (67 Nm).
14. Install the tie rod ball joint on the wheel spindle
15. Clean the hub. Install the brake disc.
16. Install the brake caliper bracket on the wheel spindle. Tighten to 76 ft. lbs. (100 Nm).
17. Install the brake hose in the bracket. Install the snap ring.
18. Remove any dirt from the sensor seat so that the sensor is in the correct position in relation to the pulse wheel.
19. Use compressed air to blow off any dirt on the pulse wheel.
20. Lightly lubricate the sensor and install it. Tighten to 19 ft. lbs. (25 Nm).
21. Ensure that the brake disc and wheel rim mating surfaces are clean.
23. Tighten the new nut for the halfshaft. Tighten to 91 ft. lbs. (120 Nm) plus 60 deg.
24. Install the hub cap.

5. Remove the brake backing plate.
6. Pull the steering arm out of the wheel spindle.
8. Remove the ABS sensor and hang in a suitable position.
11. Remove the ball-joint from the wheel spindle.
12. Press the halfshaft out of the wheel spindle.
13. Remove the wheel spindle from the spring strut.
14. Secure the wheel spindle in a hydraulic press using socket 999-7090 and drift 999-1801 to press out the bearing.
To install:
1. Press both halves of 7090-1 between the bearing and the hub on the press.
2. Press the bearing into the wheel spindle.
3. Install the wheel spindle on the strut assembly.
4. Press the halfshaft into the wheel spindle.
5. Install the ball-joint onto the wheel spindle and tighten the nut to 52 ft. lbs. (70 Nm).
6. Install the center nut for the halfshaft.
ABS sensor
Steering arm to the wheel spindle
Brake backing plate
Brake disc
Brake caliper
Wheel
Fig. Securing the wheel spindle in a hydraulic press
Securing the wheel spindle in a hydraulic press
W/Steel Spindle
1. Remove the wheel

2. Remove the ABS sensor.
3. Detach the ABS sensor cable from the spring strut.
4. Remove both mounting bolts from the brake caliper.
5. Hang up the brake caliper, on the spring strut for example.
NOTE
Take care not to damage the brake hose while working.
1. Remove the bolt holding the halfshaft. Counterhold the brake disc.
2. Remove the locating pin from the brake disc
4. Tap the end of the halfshaft into the hub approximately 10-15 mm. Use a brass drift.
5. Remove the upper link from the anti-roll bar from the spring strut.
6. Remove the steering arm from the wheel spindle.
7. Clean around the ball joint with compressed air.
8. Spray the area around the ball joint with plenty of rust penetrator. Spray the bolt and the nut holding the ball joint with rust penetrator. If the bolt
has rusted solid, slacken of the nut a few turns. Knock the bolt so that it loosens.
9. Remove the nut and bolt.
NOTE
Do not insert a punch between the ears on the wheel spindle.
NOTE
The inner diameter of the sleeve must be larger than the outer diameter of the cover. This is to prevent damage to the cover.

2. Move the ball joint up and down by hand (alternatively use a jimmy bar) until the ball joint detaches from the wheel spindle.
3. Install protective socket 999 5562 on the ball joint.
4. Secure the control arm in the depressed position using tool 999 5563.
5. Remove the halfshaft from the hub.
6. Turn the spring strut a half turn and lock it by positioning the steering arm on the control arm.
Fig. Securing the control arm-C70
Securing the control arm-C70
NOTE
Take care not to damage the brake hose.
1. Hang up the halfshaft on the spring strut.

2. Remove the wheel bearing unit.
3. Check the wheel spindle mating surfaces against the wheel bearing unit. Also check the bolt head mating surfaces on the wheel spindle.
To install:
1. Lubricate all the mating surfaces sparingly.

2. Install the wheel bearing unit. Use new bolts.
3. Lightly lubricate the outer threads and tighten crosswise. Tighten to 49 ft. lbs. (65 Nm). Angle-tighten the bolts for the wheel bearing unit
crosswise. Tighten an additional 60 deg.
4. Check the halfshaft for damage to the mating surfaces with the wheel bearing.
5. Check the splines.
6. Clean and check the pulse wheel. Check the shape of the cogs.
7. Lubricate the splines and mating surfaces with the wheel bearing sparingly.
8. Remove the halfshaft from where it was hung earlier. Turn the spring strut a half turn to disconnect it from the control arm.
NOTE
1. Install the halfshaft in the hub by hand. It must be possible to move the halfshaft easily backward and forward when it is in position.
2. Lubricate a newhalfshaft bolt. Screw it in a few turns by hand.
3. Clean off any rust from the ball joint and wheel spindle.
4. Lubricate the ball joint pinion. Lubricate the wheel spindle.
5. Install the ball joint in the wheel spindle
Fig. Grind the bolt flange as shown-V70
Grind the bolt flange as shown-V70
NOTE
Press the ball joint upwards so that the conical top is visible above the bolted joint on the wheel spindle.
1. Install the bolt and a new nut. Tighten to 38 ft. lbs. (50 Nm).
2. Check the dust boot on the anti-roll bar link for damage.
3. Check the threads on the link for damage.
4. Lubricate the threads.
5. Install the upper link of the anti-roll bar on the spring strut. Use a new lock nut. Tighten to 38 ft. lbs. (50 Nm).
6. Install the tie rod on the wheel spindle. Use a new lock nut. Tighten to 53 ft. lbs. (70 Nm).
7. Check that the brake disc mating surfaces with the wheel bearing unit are smooth and even.
8. Install the brake disc
9. Install the locating pin for the brake disc. Tighten to 72 inch lbs. (8 Nm).
10. Check the mating surfaces of the brake caliper and wheel spindle.
11. Clean and grease the surfaces of the steering limiter.
13. Tighten the center bolt for the halfshaft to 27 ft. lbs. (35 Nm) plus 90 degrees. Counterhold the brake disc.
14. Clean and check that the ABS sensor mating surface on the wheel spindle is true.
15. Apply a very small amount of grease to the mating surface.
16. Install the ABS sensor cable in the holder on the spring strut.
17. Install the ABS sensor. Lubricate the bolt and tighten it. Tighten to 84 inch lbs. (10 Nm).
18. Install the wheel
1. Remove the wheel

2. Remove the ABS sensor.
3. Detach the ABS sensor cable from the spring strut.
4. Remove both mounting bolts from the brake caliper.
5. Hang up the brake caliper, on the spring strut for example.
NOTE
Take care not to damage the brake hose while working.
6. Remove the bolt holding the halfshaft. Counterhold the brake disc.
7. Remove the locating pin from the brake disc
9. Tap the end of the halfshaft into the hub approximately 10-15mm. Use a brass drift.
10. Remove the upper link from the anti-roll bar from the spring strut.
11. Remove the steering arm from the wheel spindle.
12. Clean around the ball joint with compressed air.
13. Spray the area around the ball joint with plenty of rust penetrator. Spray the bolt and the nut holding the ball joint with rust penetrator. If the bolt
has rusted solid, slacken of the nut a few turns. Knock the bolt so that it loosens.
14. Remove the nut and bolt.
NOTE
Do not insert a punch between the ears on the wheel spindle.
NOTE
The inner diameter of the sleeve must be larger than the outer diameter of the cover. This is to prevent damage to the cover.

18. Move the ball joint up and down by hand (alternatively use a jimmy bar) until the ball joint detaches from the wheel spindle.
19. Install protective socket 999 5562 on the ball joint.
20. Secure the control arm in the depressed position using tool 999 5563.
Fig. Securing the control arm-2002-04 C70
Securing the control arm-2002-04 C70

21. Remove the halfshaft from the hub.
22. Turn the spring strut a half turn and lock it by positioning the steering arm on the control arm.
NOTE
23. Hang up the halfshaft on the spring strut.

24. Remove the wheel bearing unit.
25. Check the wheel spindle mating surfaces against the wheel bearing unit. Also check the bolt head mating surfaces on the wheel spindle.
To install:
1. Lubricate all the mating surfaces sparingly.

2. Install the wheel bearing unit. Use new bolts.
3. Lightly lubricate the outer threads and tighten crosswise. Tighten to 49 ft. lbs. (65 Nm). Angle-tighten the bolts for the wheel bearing unit
crosswise. Tighten an additional 60 deg.
4. Check the halfshaft for damage to the mating surfaces with the wheel bearing.
5. Check the splines.
6. Clean and check the pulse wheel. Check the shape of the cogs.
7. Lubricate the splines and mating surfaces with the wheel bearing sparingly.
8. Remove the halfshaft from where it was hung earlier. Turn the spring strut a half turn to disconnect it from the control arm.
NOTE
9. Install the halfshaft in the hub by hand. It must be possible to move the halfshaft easily backward and forward when it is in position.
Fig. Grind the bolt flange as shown-V70
Grind the bolt flange as shown-V70

10. Lubricate a new halfshaft bolt. Screw it in a few turns by hand.
11. Clean off any rust from the ball joint and wheel spindle.
12. Lubricate the ball joint pinion. Lubricate the wheel spindle.
13. Install the ball joint in the wheel spindle
NOTE
Press the ball joint upwards so that the conical top is visible above the bolted joint on the wheel spindle.
14. Install the bolt and a new nut. Tighten to 38 ft. lbs. (50 Nm).
15. Check the dust boot on the anti-roll bar link for damage.
16. Check the threads on the link for damage.
17. Lubricate the threads.
18. Install the upper link of the anti-roll bar on the spring strut. Use a new lock nut. Tighten to 38 ft. lbs. (50 Nm).
19. Install the tie rod on the wheel spindle. Use a new lock nut. Tighten to 53 ft. lbs. (70 Nm).
20. Check that the brake disc mating surfaces with the wheel bearing unit are smooth and even.
21. Install the brake disc
22. Install the locating pin for the brake disc. Tighten to 72 inch lbs. (8 Nm).
23. Check the mating surfaces of the brake caliper and wheel spindle.
24. Clean and grease the surfaces of the steering limiter.
26. Tighten the center bolt for the halfshaft to 27 ft. lbs. (35 Nm) plus 90Â°. Counterhold the brake disc.
27. Clean and check that the ABS sensor mating surface on the wheel spindle is true.
28. Apply a very small amount of grease to the mating surface.
29. Install the ABS sensor cable in the holder on the spring strut.
30. Install the ABS sensor. Lubricate the bolt and tighten it. Tighten to 88 inch lbs. (10 Nm).
31. Install the wheel
W/Aluminum Spindle

2. Remove the brake caliper and limiter bolts.
3. Hang the caliper up using a piece of wire.
4. Remove the halfshaft bolt. Use a screwdriver as a counterhold on the brake disc.
5. Remove the locating pin holding the brake disc.
7. Slacken off the end of the halfshaft in the hub by knocking the halfshaft into the hub approximately 10-15 mm.
8. Use a rubber or copper mallet.
9. Remove the nut holding the control arm. Use a Torx wrench as a counterhold.
WARNING
1. Pull down the control arm (1) using the tension strap (2)
3. Remove the halfshaft. Knock the halfshaft out using a brass drift. Hang the halfshaft as illustrated
4. Secure the spring strut in position
5. Remove the 4 bolts from the hub.
To install:
1. Install the hub. Use new bolts

2. Tighten crosswise to 15 ft. lbs. (20 Nm). Then tighten to 49 ft. lbs. (65 Nm). Angle-tighten 60 deg.
3. Turn in the spring strut and position the halfshaft in the hub.
NOTE
Check that the seal is not worn or damaged.
1. Install the bolt loosely on the halfshaft. Use a new bolt

2. Align the ball joint in the control arm
NOTE
Be very careful when releasing the tension strap.
1. Release the control arm slowly using the tension strap.

2. Install a new nut on the ball joint. Tighten to 43 ft. lbs. (80 Nm).
NOTE
The ball joint must not rotate. Use a Torx wrench as a counterhold so that the rubber boot is not damaged.
1. Install the brake disc.

2. Tighten the brake disc locating pin. Tighten to 72 inch lbs. (8 Nm).
NOTE
1. Tighten the new halfshaft bolt.

2. Remove the brake caliper and limiter bolts.
3. Hang the caliper up using a piece of wire.
4. Remove the halfshaft bolt. Use a screwdriver as a counterhold on the brake disc.
5. Remove the locating pin holding the brake disc.
7. Slacken off the end of the halfshaft in the hub by knocking the halfshaft into the hub approximately 10-15mm.
8. Use a rubber or copper mallet.
9. Remove the nut holding the control arm. Use a TorxÂ® wrench as a counterhold.
WARNING
10. Pull down the control arm (1) using the tension strap (2)
12. Remove the halfshaft. Knock the halfshaft out using a brass drift. Hang the halfshaft as illustrated
13. Secure the spring strut in position
14. Remove the 4 bolts from the hub.
To install:
1. Install the hub. Use new bolts

2. Tighten crosswise to 15 ft. lbs. (20 Nm). Then tighten to 49 ft. lbs. (65 Nm). Angle-tighten 60 deg.
3. Turn in the spring strut and position the halfshaft in the hub.
NOTE
Check that the seal is not worn or damaged.
4. Install the bolt loosely on the halfshaft. Use a new bolt
5. Align the ball joint in the control arm
NOTE
Be very careful when releasing the tension strap.
6. Release the control arm slowly using the tension strap.

7. Install a new nut on the ball joint. Tighten to 43 ft. lbs. (80 Nm).
NOTE
The ball joint must not rotate. Use a TorxÂ® wrench as a counterhold so that the rubber boot is not damaged.
8. Install the brake disc.

9. Tighten the brake disc locating pin. Tighten to 72 inch lbs. (8 Nm).
NOTE
10. Tighten the new halfshaft bolt.
Adjustment
The front wheel bearings are not adjustable. If the lateral run-out on the hub with the disc removed exceeds 0.0007 in.
(0.020mm), the hub must be replaced.
The front wheel bearings are not adjustable. If the lateral run-out on the hub with the disc removed exceeds 0.0007 in. (0.020mm), the hub must be
replaced.
The front wheel bearings are not adjustable. If the lateral run-out on the hub with the disc removed exceeds 0.0007 in. (0.020mm), the hub must be
replaced.
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Brakes
Volvo Cars 1999-05
Brake Pads
Front & Rear
Wheel
Caliper spring
Protective caps
Locating pins
Brake caliper and hang in a suitable position
Brake pads
NOTE
Do not depress the brake pedal while the brake pads are removed.
To install:
1. Check the rubber sleeves on the locating pins. Replace if necessary. If necessary, lubricate the locating pins using silicon grease. Insert the locating
pins in the rubber sleeves. The locating pins must slide into the sleeves easily.
2. Press the piston back into the cylinder using special tool 999-7091 or equivalent.
Brake pads
Brake caliper
Locating pins
Protective caps
Caliper spring
Wheel
Fig. Compressing the piston into the cylinder
Compressing the piston into the cylinder
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Body
Volvo Cars 1999-05
Outside Mirrors
Power Mirrors Print
Diagnosis & Testing

2. Remove power mirror switch.
3. Inspect terminal for poor connections, loose wires, bent, broken, or corroded pins, and then verify that the connector is securely fastened.
4. Check for battery voltage at the lead wire of connection to the power mirror switch.
A. If battery voltage is absent, check the fuse for the power mirror.
B. If battery voltage is present, check through the switch for power delivery.
C. Replace switch if faulty.

Motor

Disconnect the negative battery cable.

The mirror inside cover trim
The door panel
The electrical connector to mirror motor
The nut attaching mirror assembly to door frame
The outside rear view mirror
Fig. Removing cover trim and nut
Removing cover trim and nut
Fig. Removing mirrored glass from assembly
Removing mirrored glass from assembly
3. Remove the mirror glass:
A. Fold the mirror glass forwards and inwards as illustrated.

B. Grasp and pull the mirror glass lengthways until it releases.
C. Work the glass out.
4. Remove electric motor:
A. Remove the 3 screws from behind the mirrored glass.

B. Separate the connectors
NOTE
Remember the positions of the connectors.
C. Remove the mirror motor.

Fig. Removing connectors and screws holding mirror motor
Removing connectors and screws holding mirror motor
To install:
The electric motor

The electrical connections
The 3 screws that go behind the mirror
Install the terminal pins
Fold out the mirror mounting on the motor
Hook the mirror glass into the inner mounting
Press the mirror glass into place.
Place mirror in position in door
Fig. Reattaching mirror and electric motor connectors
Reattaching mirror and electric motor connectors
The nut attaching mirror assembly to door frame

The connector
The door panel
The mirror inside cover trim
The negative battery cable
Switch
Disconnect the negative battery cable.

The door panel
The electrical connector to mirror switch
Release the catches. Press the switch up and off
To install:
1. Installation is the reverse of removal procedure.
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Volvo Cars 1999-05
Sunroof
Power Sunroof Print
Diagnosis & Testing

3. Remove the power sunroof switch.
4. Inspect terminal for poor connections, loose wires, bent, broken, or corroded pins, and then verify that the connector is securely fastened.
5. Check continuity between the terminals while operating the switch.
6. If there is no continuity when the switch is in the ON position, replace switch.
7. Check for battery voltage at the lead wire of connection to the power sunroof switch.
A. If battery voltage is absent, check the fuse for the power sunroof.
B. If battery voltage is present, check through the switch for power delivery.
C. Replace switch if faulty.

Motor
When removing the motor be sure that the sunroof is in the fully closed position.

2. Remove the key from the ignition switch.
NOTE
After removing the key, wait one minute before starting work.
3. Remove the Upper Electronic Module (UEM) and rearview mirror assembly:
A. Remove the interior lighting.

B. Remove the cover over the connector for the rear view mirror and control module.
C. Remove the cable spring using a screwdriver.
D. Disconnect the connector by pressing the catch using a small screwdriver.
4. Remove plastic molding around the headliner/sunroof unit.

5. Remove the bolts for the sunroof motor.
6. Carefully lower the headliner.
NOTE
Position several spacers between the sunroof unit and the headliner to avoid long term kinks in the headliner material.
Fig. Removing the sunroof motor
Removing the sunroof motor

7. Carefully remove the bolt hidden behind the headliner.
8. Disconnect the electrical connector.
9. Remove the sunroof motor.
To install:
1. Place the sunroof motor into position with the 3 M5 bolts. Tighten to 44 inch lbs. (5 Nm)
2. Install the Upper Electronic Module (UEM) and rearview mirror assembly:
A. Connect the electrical connector.

B. Attach the cable spring.
C. Replace the connector cover.
D. Install the interior lighting.
3. Install the plastic molding around the headliner/sunroof.

NOTE
Press one corner of the headliner into place, continue along one of the long sides and continue to one of the shorter sides and to the corners. Finish
with a long side.
4. Check that the sunroof operates correctly.
Switch

The negative battery cable

The interior lighting
Press out the catches of the switch and pull the switch outwards and upwards
Remove the catch and the conductive strap
Fig. Removing the switch for the power sunroof
Removing the switch for the power sunroof
To install:
1. Press in the conductive strap. Press in the catch.

2. Correctly position the rear of the switch and press the switch into place.
3. Install the interior lighting.
4. Connect the negative battery cable.
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Engine & Vehicle Identification
Volvo Cars 1999-05
Vehicle Identification Number (VIN)

The Vehicle Identification Number (VIN) plate, which contains the Vehicle Identification Number (VIN), is located at the top rear of the Print
instrument panel or front dash board on the left (driver-s) side. It is visible from outside the vehicle by looking through the lower left (driver's)
side of the windshield. The VIN consists of 17 characters which represent codes supplying important information about your vehicle.
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Heating & Air Conditioning
Volvo Cars 1999-05

Print
NOTE
Before servicing, or working around, the SRS system, turn the ignition switch OFF , disconnect the battery and wait at least three minutes.
1. Before servicing the vehicle, refer to additional information in the Precautions Section.
The dashboard will need to be removed in order to remove the blower motor on some models.
1. Move the front seats back.

The negative battery lead.

The A-post panels of the dashboard
The end covers on both sides
The soundproofing panels
The courtesy lighting
The On-Board Diagnostic (OBD) connector
The steering wheel
The combined instrument panel
Gear selector assembly and steering wheel module
The center console
The dashboard environment panel
The connector for the hazard warning signal flasher
The cable for the parking brake at the cable terminal by the release handle.
Detach the gear selector assembly, if equipped. Turn the gear selector assembly a quarter turn with the control downwards towards the
driver's seat.
The glove compartment
The connector for the passenger air bag module
The lower mounting for the passenger air bag module
The screws holding the dashboard
Lift out dashboard.
4. Remove the fan motor from the climate control unit:

NOTE
Do not detach the air conditioning (A/C) pipes or the engine coolant hoses.
A. Remove the drain hoses from the engine and filter housing.
B. Move the drain hose out of the way.
C. Disconnect the electric connector at the fan motor.
D. Remove the screws from the blower fan motor.
E. Detach and remove the blower fan motor and fan shroud.
To install:
1. Installation is the reverse of the removal procedure.

Blower fan motor and the cover on the climate control unit
Electrical connector for the blower motor
Drain hose
Climate control unit

NOTE
Check that no wiring is trapped out of place.
Lift the dashboard into position
The dashboard. Tighten the M6 screws to 88 inch lbs. (10 Nm)

The lower mounting for the passenger air bag module. Tighten the M6 screws to 88 inch lbs. (10 Nm)
The connector for the hazard warning signal flasher
The cable for the parking brake. Hook the cable into place at the release handle
The On-Board Diagnostic (OBD) connector
The combined instrument panel
The gear selector assembly and steering wheel module
The steering wheel
The dashboard environment panel
The gear selector assembly. Tighten the M8 bolts to 18 ft. lbs. (24 Nm)
The mechanical cable for the gear selector lever knob
The center console
The courtesy lighting
The end covers of the dashboard on both sides
The A-post panels
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1999-05 - Volvo - S40 - 5 Cylinders 2.5L FI Turbo DOHC - 32993902 PDF

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1999-05 - Volvo - S40 - 5 Cylinders 2.5L FI Turbo DOHC - 32993902 PDF

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Engine Cooling

Volvo Cars 1999-05

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions section.

Negative battery cable

1. Install or connect the following:

2. Fill the cooling system.

1. Before servicing the vehicle, refer to the Precautions Section.

Negative battery cable

Fig. Water pump and gasket

Water pump and gasket

Fig. Water pump installation

Water pump installation

1. Install or connect the following:

2. Fill the cooling system.

1. Before servicing the vehicle, refer to the Precautions Section.

Negative battery cable

Fig. Water pump and gasket

Water pump and gasket

Fig. Water pump installation

Water pump installation

1. Install or connect the following:

2. Fill the cooling system.

Negative battery cable

1. Install or connect the following:

2. Fill the cooling system.

1. Before servicing the vehicle, refer to the Precautions Section.

Negative battery cable

1. Install or connect the following:

2. Fill the cooling system.

Rear Wheel Drive

Negative battery cable

1. Fill the cooling system.

Except Rear Wheel Drive

Negative battery cable

1. Install or connect the following:

2. Fill the cooling system.

Negative battery cable

1. Install or connect the following:

2. Fill the cooling system.

Volvo Cars 1999-05

6-Cylinder Engine And 1999-02 5-Cylinder Engines

Volvo Cars 1999-05

Volvo Cars 1999-05

Crankshaft & Connecting Rod Specifications

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

B5254T 2.4 2.5584- 0.0007- 0.003- 5 1.9679- NA 0.006-

B5234T3 2.3 2.5589 - NA 0.003- NA 1.9679- NA 0.006-

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

B5234T3 2.3 2.5589 - NA 0.003- NA 1.9679- NA 0.006-

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

B5234T3 2.3 2.5589 - NA 0.003- NA 1.9679- NA 0.006-

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

B5234T3 2.3 2.5589 - NA 0.003- NA 1.9679- NA 0.006-