Yeah, to be honest it came out quite well. The worst part was probably disconnecting the exhaust downpipe – the bolts needed some heat.

I took my time and just made certain everything was properly disconnected and free. I think that was made a little easier in the knowledge I didn't have to label all the wiring, but I made sure I disconnected it properly rather than just snipping, because I wanted the experience for the XC.

I was very surprised that there wasn't much information out there but I managed to piece together what help I needed from various forum guides.

FWIW this is roughly what I did:
  1. Removed front bumper
  2. Drained fluids, inc. fuel line (mine was empty anyway from all the compression testing..!)
  3. Removed the strut tower bracing and engine covers, charge air piping, air box, etc
  4. Removed the intercooler, radiator, cooler assembly from the front end. Hugely helped by the fact I cut the front crash bar out.
  5. With car in the air...:
  6. Remove the front brakes inc. the calipers, pumped out some brake fluid
  7. Removed the front drive shafts – bit of a fight here with the ball joints
  8. removed the AC pump and the aux belt (probably didn't need to)
  9. Removed the coolant bottle and moved the power steering bottle out of the way. Removed hose to the PS pump too and tied it up.
  10. Slowly removed the electrical harness, sensors etc and moved aside
  11. Removed the heat shield and the exhaust downpipe. Found that after removing the bolts to the rear section of exhaust this was easier – must've been under some stress.
  12. Remove the AWD driveshaft. Access to the 8mm hex bolts is good and with the front wheels off the ground you can spin the shaft. After dropping out the mid-section support the shaft ends almost came out. I gave it a knock with a block of wood to push it out the rest of the way at the front. Then the rear needed a solid back-forth tug.
  13. Checked for anything else still attached that might be in the way..
    • disconnected the fuel line (almost missed it!)
    • removed the auto trans cable at the 'box end and set aside
    • removed the brake fluid bottle
  14. Lowered the car again
  15. Removed nuts from all of the engine mounts – ready to lift!
  16. Realised it was a good idea to remove the ABS module and move the hydraulic lines out the way.
  17. After that it was up and away, just careful to adjust the position and angle it out. You definitely want a load leveller for this.
Little tip from my recent experience. Make sure you swap the engine loom over from the old engine before you slot it in. Saves time and effort down the track when the car chucks a wobbly when some of the wiring doesn't line up.
Regards Paul
as in from the donor? No can do, it was crushed in the wreck..!
Nope from your car. Sounds like you don't have a choice.
I'm just going to go with "Reinstallation is the reverse of removal". The harness is completely removed from the donor anyway, so I'll just plug her in once she's safely mounted.

What I need to work out next is which other bits of the S60 are either upgrades (eg: bigger brakes like your S40) or worth removing and selling – without going too crazy. But I figure I can get much of the cost back as well as some free upgrades, and some good vibes :)
Have you decided if you are going to refresh the donor engine?
I'm going to do the belts, tensioners, water pump, thermostat, and any other typical wear items I can think of.

I'm now fairly certain I made a mistake with the compression test by getting fuel in the cylinders, so I don't think I'm going to pull it apart.

I'm in no great rush to drop it in – the shed is still blocked up with my old wagon, which I'm now scrapping. So I've got time to play with it a bit.

I've got new engine mounts, subframe bushes, strut mounts, control arm bushings, sway bar links etc ready to go in, to give the suspension a new lease of life. Toying with a set of Eibach springs while I'm at it. Have to remember this is meant to just be the family beater though! :)

Nonetheless, tempting to whack a chinacharger 19T on it and see how it goes!

I don't know if you've watched the exploits of Tyler Hoover on YouTube, and I'm not saying you are like him, but if not you might find them interesting :)
hah sounds like a man after my own heart. AKA an idiot.
a month later
Wow where have I been! Yas rippin into er. Nice.
Aye, it's almost kick-off time!

Some more tidying away to do first but the beast is finally in the shed – thankfully it limped there under its own steam.


Nice shed, wish mine was like that
cheers, money well spent I reckon – bit short but much better than being in the garage.

on the left out of shot i've got my pegboard and tool chest. All the gear...

@bigal write up a guide for us will ya?
I was hoping you'd go first so I can learn from you... haha. Yes I think I'll go the rostra solenoids at some stage.

Engine going in this weekend?
no, out!

I have to refurb the donor too before it can go in. Long way to go. Busy life!
@JeremyK did the solenoid job on his xc70, a comprehensive thread is out there.
Am sure he would answer any questions.


Some decent progress. I decided to remove the fan, radiator etc to make access that much easier. Came apart well, everything so far has been pretty smooth. Having all that practice on the S60 helped a lot.

Might even have it out tomorrow, but I'm not in a rush really.

You're just showing off that dream shed aren't you!
didn't get loads done today – got the front CV's out and stopped there. I decided to pull the entire hub assembly because I've got suspension work to do anyway.

Just popped in to post another pic of my shed




I like how you can move it anywhere you like....
4 days later
As I've got to do my strut tower mounts, control arm bushes, etc etc, think i might bang in some Eibach's after all..

I want to keep the ride supple (it's a bit crashy atm due to worn bits), so might "pair" them with some Bilstein Touring's. Obviously these are just a standard shock, rather than HD, but I think it'll probably be fine, no?

Just the 2.5ton on them after all.

If I put Bilstein HD's in my wife will hate me.

Whatcha reckon gang?
Keep it comfy, it just isn't a sports car and ride is a priority.
yeah absolutely, no way I am putting the HD's in. Do you think the Eibach springs (~30mm lowering) would harshen the ride that considerably?

Eibach's always get a very good write up.

My main concern to be honest is that the tailgate hatch might be a bit low when open – I already hit my head on it.
Anything to lower these would be good. But they are 1.8ttare and 2.5t gross aren't they?
yeah I might be overemphasising there, just know people talk about OEM shocks taking a pounding with lowering springs, even in light(er) cars! But i mean, 30mm, gotta be in engineering tolerances :P

Think i might guinea pig it, not much info out there..
OK, decided to go for the Eibach's.


You could talk to Ash about the technical side of getting what you want to achieve suspension side.
2046kg Kerb weight.

I plan to install the ipd sway bars on mine and leave all else oem (including oem replacement where needed). Only problem I have with the ride is the sway. Ipd comments give me confidence it's a good way to go.
I suggest leaving the nivos up the back if still good.
Engine is out!

Once I had everything disconnected I dropped the front as low as I could on stands. Realised I'd need to remove the bonnet, bit of a pain because I know it'll be a bugger to align later.











Nasty oilyness under the cover, plugs 3-5 look pretty wet.


Again it came out pretty easy, I think the XC90 has a few tighter areas than the S60 had – bit more bulkhead intrusion I think.

And again, the biggest pain was removing the downpipe. The heat shield is in the way from the top, despite my best efforts couldn't move it out the way. And those bolts are in tight. One of them sheared in the turbo housing :angry:

Anyway, on to the fun stuff, though not looking forward to lowering an engine back in – it's going to be a challenge!

A challenge you are up to!
You're secretly a pro aren't you.
fake it til you make it!
having a crack at removing the front subframe today.

Looks simple enough but I suspect it's bloody heavy. I'll jack it down on a big chunk of wood. I've chucked the crossmember above the engine back in, so I can tie the steering rack to it..

Bodgefest!
One subframe



I had two lengths of timber horizontally jacked against it with a third length ways, then removed the subframe bolts.


Lunch today = scrubbing good times, subframe is slowly becoming de-gunked.

Removed the control arms and the fat anti-roll bar for the job, they're getting a clean up too. Might replace the ARB bushings while off.

Need to work out where I can get the new subframe and control arm bushes pressed in. Meh. Guess I'll be adding a press to my list of self-sufficient-must-haves!

or I'll be building one of these...
http://www.suspension.com/blog/how-to-install-a-bushing-without-a-press/

Soak subframe in cans of degreeser then use pressure washer on it and will come up clean
best google "home made pressure washer" too, then
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