Installing the Control System/Valve Housing

Installing the control system / valve housing

Transferring the balls to the new valve housing

Use Volvo Genuine parts petroleum jelly P/N 116 11 51-4 so that the balls remain in the relevant ducts during the installation of the valve housing.

Transferring
Balls 373 (2 x). Apply petroleum jelly to each duct. Install the balls (the petroleum jelly should cover the balls).
Balls 372 (4 x). Apply petroleum jelly to each duct. Install the balls.

Checking the balls in the valve housing

Turn the valve housing so that the balls are upside down.
The balls should remain position. (If any of the balls fall out, use more petroleum jelly).
Turn the valve housing back again.

Installing new gaskets

Caution! Make sure that the gaskets are correctly positioned.

Install gasket 371 marked V on the valve housing.

Install the distribution plate 370 on the gasket.
The strainers must be replaced if they are damaged. See the illustration for their positions.
Lock the gasket and the distribution plate in the valve housing using the two plastic plugs. Apply a little petroleum jelly to the outer ends of the distribution plate so that the gasket C does not slide.

Install gasket 369 marked C on the distribution plate.

Replacing the seal on the pump shaft

Pull out the pump shaft.
Replace the seal around the shaft.
Reinstall the pump shaft.

Installing the balls for the control system housing

Apply petroleum jelly (P/N 116 11 51-4) to each duct (372) for the balls.
Reinstall the balls. Ensure that the petroleum jelly holds the balls in place in the housing.

Installing the valve housing to the control system housing

Preparations

Check that:
- the surface of the valve housing is clean

Note! Use lint-free paper.

- the balls remain in the petroleum jelly
- the pump shaft is in position
- the screws 377 to secure the valve housing are to hand
- the screw 376 and guide sleeve 410 are to hand.

Installing the valve housing

Carefully install the valve housing over the pump shaft (Be careful with the (2) strainers).

Caution! The valve housing may not be twisted.

Hold it in position against the housing and install the screws 377, lightly tightened.
Install guide sleeve 410 and the screw 376 on the valve housing tightened lightly.

Note! The guide sleeve ensures that the distribution plate/valve housing are positioned correctly.

Transferring

1. Pressure switch -2002
2. Pressure switch 2003-

Caution! The screws are of different lengths. It is important that the screws are installed in the right place.

Control system for cars of model year -2002
Transfer the pressure sensor to the new valve housing.

Note! Note the position of screws 381 in the illustration (the screws are self-tapping).

Install the remaining screws for the valve housing.

Tightening torques

Tighten the screws in the following order:
- 381 to 8 Nm
- 376 to 12 Nm
- 377 to 12 Nm
- 374 to 12 Nm
- 375 to 12 Nm
- 378 to 12 Nm
- 384 to 12 Nm
- 379 to 12 Nm
- 380 to 25 Nm.
Check tighten all the screws.

Control system for cars of model year 2003-

Installing the oil pump
Install the oil pump according to Replacing the oil pump Service and Repair.

Installing the cable harness

Install:
- all the connectors on the solenoids
- the temperature sensor in the mounting
- the cable in the clamp.
Check that all components are installed correctly.

Installing the side cover
Install the side cover according to Installing the gearbox side cover Installing the Gearbox Side Cover.

Filling with gearbox fluid
Fill with gearbox fluid according to Transmission oil / oil filter, replacing Removal and Replacement.
Carry out a road test.