1995 volvo960 engine replacement

Old Jul 4, 2009 | 12:12 PM
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artesano's Avatar
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Default 1995 volvo960 engine replacement

Im preparing to replace the engine but never did before, need advice on what to remove first, is there any order of parts removal from car before installing new engine. The only engine I replaced before was a camaro and I know is not the same. Any advice? Thanks in advance for the help... artesano...
 
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Old Jul 9, 2009 | 03:29 PM
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It will be much the same as the camaro, I guess it will depend on your approach, will you take the trans out with it (suggested)? Will the new engine have the wire harness?
Disconnect/remove:
battery, battery ground lead, wiring connected to positive battery terminal, the batteries cables will be coming out with the engine. Loosen/remove what is necessary for that.

Remove: auxiliary drive belt, cooling fan, drain coolant.

Disconnect upper and lower radiator hoses, expansion vessel hose from radiator and from manifold pipe, transmission cooling lines at the trans.

Undo top engine mount bolts both sides, remove air mass meter, all of the vacuum hoses and intake pipes, pre heater hose, throttle pulley cables. Disconnect both pressure and return fuel lines.

Undo power steering pump, undo a/c compressor.

Unplug wire harness main plugs, disconnect cooling/heater hoses.
Disconnect: cam sensor, rpm sensor and brake servo vacuum line.

Remove radiator, undo exhaust down pipe. Disconnect the mechanism for the gear selector. Unplug 02 sensor, disconnect drive shaft on trans, remove trans support member, keep trans tail supported.

Use care when separating the trans wire connectors, avoid cracking them.
Also beware there will be two alignment dowels to mate the trans and engine, make sure to use them, they should stay in the engine but I had one fall out and the other stuck with the trans.

You might consider changing the rear main seal, and the seal on the input shaft of the trans while it open and separated.

There may be a few other things I omitted, this should get started.

Good luck and go slow.

DanR '94 964 343,000 miles (109,000 on the new engine)
 
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Old Jul 22, 2009 | 08:59 PM
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Thank you dan550i for your reply and help. This car is for my 17 year old son and will serve as school transport. It will be an expirience for him to participate in this project, maybe he will appreciate it. We will follow your directions and keep posting the progress. This forum and members like you are truly a blessing. Thanks.....artesano.
 
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