Engine Controls - Removal & Installation: Other Volvo 960 I рестайлинг

BATTERY DISCONNECT PRECAUTIONS & RELEARN PROCEDURES

Driveability

When the ignition has been switched off, wait at least 5 minutes before cutting the power to the car. This is so that there is sufficient time for information to be stored in the ECM.

When the battery has been disconnected, the car may have to be driven for a few minutes before the engine runs normally. Some engine related Diagnostic Trouble Codes (DTCs) may be set. Clear as necessary using scan tool.

Removal and installation procedure is not available from manufacturer. For exploded view of components (Scheme 9)

Scheme 9

ENGINE CONTROL MODULE

1. Turn ignition off. On 1994 models, remove fuse No. 24. On 1995 models, fuse 1 (11B/1) in central relay unit(in engine compartment, in front of left shock tower).
2. On all models, remove sound insulation and left front valance. (Scheme 10)
3. Remove ECM. (Scheme 11)
4. To install, check ECM and connectors for damage to pins and sleeves. Install ECM. Replace sound insulation and left front valance. Replace fuse. (Scheme 10)

Note. Programming a new Engine Control Module (ECM) requires a Volvo factory scan tool. Aftermarket scan tools may not be able to program a replacement ECM.

Scheme 10

Scheme 11

Removal and installation procedure is not available from manufacturer. (Scheme 12)

Scheme 12

Programming a new Engine Control Module (ECM) requires a Volvo factory scan tool. Aftermarket scan tools may not be able to program a replacement ECM.

The CMP sensor consists of the trigger rotor (1), hall-effect sensor (2), and cover (3). (Scheme 13) Sensor trigger rotor turns at same speed as camshaft (4). Removal and installation procedure is not available from manufacturer.

Scheme 13

EGR temperature sensor is connector to EGR valve. For removal and installation procedure. See EGR VALVE under EMISSION SYSTEMS & SUB-SYSTEMS.

Removal and installation procedure is not available from manufacturer. (Scheme 14)

Scheme 14

ENGINE SPEED (RPM) SENSOR

Note. Engine speed (RPM) sensor may also be known as impulse sensor.

The sensor incorporates the housing (1), the permanent magnet (2), and the coil (3). (Scheme 15) Removal and installation procedure is not available from manufacturer.

Scheme 15

Scheme 16

1. Disconnect battery negative lead. Remove draining hose on left side on 4-door models. On 5-door models, fold forward seat back. Remove carpet and covers in trunk.
2. Unplug connectors. Remove cover over tank gauge unit. (Scheme 16) Clean area around unit and hose connections. Remove hoses from unit.
3. Remove gauge unit and gasket. Remove clamps around filler pipe. Disconnect electrical connector. (Scheme 17) Press out rubber grommet.
4. Withdraw lead to gauge unit. Remove nut on gauge unit with tool (999 5448-9). (Scheme 18) Lift out gauge. Replace nut on tank neck or it may swell, causing nut to be difficult to refit and tank to leak.
5. Replace leveling sensor by first unhooking the lower catch and then the upper catch.
6. Unsolder electrical leads. Fit new unit and reassemble in reverse order. Install in reverse order of removal.

Scheme 17

Scheme 18

FUEL PUMP RELAY

Removal and installation procedure is not available from manufacturer. (Scheme 19)

Scheme 19

Locating Fuel Pump Relay (B. Fuel Injection System Relay). Scheme 20

Removal and installation procedure is not available from manufacturer. (Scheme 21)

Scheme 21

THROTTLE POSITION SENSOR

Removal and installation procedure is not available from manufacturer. (Scheme 9)and (Scheme 22).

Scheme 22

IGNITION COILS AND POWER UNITS

Note. Power unit may also be known as Motronic power stage.

The ignition coils are mounted directly on the spark plugs (20/3-8). Two power units (4/38 and 4/39) and mounted on the intake manifold. (Scheme 23) The front unit is connected to cylinders 1, 3 and 5. The rear unit is connected to cylinders No. 2, 4 and 6.

Scheme 23

FUEL SYSTEMS

FUEL FILTER

1. Drain fuel system. See «DRAINING FUEL TANK»(ref-160825-S15515160782004030200000).
2. Loosen quick release couplings from fuel filter using a 17 mm wrench to push back sleeves. (Scheme 24) Loosen filter clamp retaining screw.
3. Change filter. Install filter in reverse order of removal.

Scheme 24

1. Turn ignition off. Fuel pump should also be turned off.
2. On vehicles with pressure regulator mounted on fuel distribution manifold, go to step 4.
3. On vehicles with pressure regulator mounted on the intake manifold, drain fuel system. See «DRAINING FUEL TANK»(ref-160825-S15515160782004030200000).
4. Loosen cruise control vacuum reservoir from its mounting.
5. Remove fuel injector valve covers. Loosen connections from injector valve.
6. Turn injector valve 90°. (Scheme 25) Fit clamp (999 5471) over injector valves which are not to be changed.
7. Remove fuel distribution manifold retaining screws. (Scheme 26)
8. Lift fuel distribution manifold with complete injector valves. Place paper under injector valves to be changed to soak up any fuel spillage.
9. Change fuel injector valve.

Scheme 25

Scheme 26

1. Replace all damping rubbers in intake manifold.
2. Grease all injection valve "O" rings with petroleum jelly.
3. Fit fuel rail to intake manifold. (Scheme 25)
4. Fit new screws and tighten. Remove tool holding injector valve and turn to correct position.
5. Fit connections to injector valves. Fit vacuum hose to pressure regulator. Fit injection valve covers.

FUEL PUMP(1994)

Note. For 1994 models, the vehicle is equipped with 2 fuel pumps. The main fuel pump is located on a shelf under the vehicle, under rear seat. There is also a fuel feed pump in the fuel tank. The tank pump may be referred to as a fuel primer pump. The 1995 models are equipped with only one fuel pump.

Removal and installation procedure is not available from manufacturer. (Scheme 27)

Scheme 27

FUEL PUMP (IN TANK)

Note. For 1994 models, the vehicle is equipped with 2 fuel pumps. The main fuel pump is located on a shelf under the vehicle, under rear seat. There is also a fuel feed pump in the fuel tank. The tank pump may be referred to as a fuel primer pump. The 1995 models are equipped with only one fuel pump.

Scheme 28

Scheme 29

Scheme 30

Scheme 31

1. On 4-door vehicles, remove spare wheel cover and lift floor carpeting. (Scheme 29)
2. On 5-door models, lift rear wheel arch cover. Fold down seatback to reach nuts, then draw panel forwards and upwards. (Scheme 30)
3. Remove tank unit cover. (Scheme 31) Clean around tank unit and hose connections.
4. To remove quick release coupling from tank hose, simultaneously press on hose and slide sleeve upwards.
5. Remove hose clips around nut. Remove nut to tank unit with Tool (999 5448). Lift up tank unit as far as electrical leads allow.
6. Remove seals. (Scheme 32) If nut is not replaced within about 12 hours, it must be changed or it will not fit and leakage will result.
7. To loosen in-tank fuel pump, first detach lower pump fastener then upper fastener. Disconnect electrical leads. Loosen hose clip at pump. (Scheme 33)
8. Carefully remove in-tank fuel pump from hose.

Scheme 32

Scheme 33

1. Connect in-tank fuel pump electrical wiring. Fit pump to hose and tighten hose clip. Attach upper fastener first, then press in lower fastener.
2. Fit new seal to tank opening. Grease tank unit contact surface with a thin layer of petroleum jelly.
3. Lower tank unit into tank, taking care not to damage pump fittings against tank wash-plates. Check that seal is not drawn into tank.
4. Locate position marks against tank plastic joints. (Scheme 34) Install nut and tighten with Collar (999 5448), taking care not to damage nipples. Lock with hose clip.
5. Fit hoses. Check that hoses cannot slip off pipes on tank unit. Fit tank unit cover. Check pump measurement functions. On models with 4 doors, fit spare wheel cover and trunk floor carpeting. On models with 5 doors, replace rear wheel arch cover and panel behind rear seat.

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

1. Remove in-tank fuel pump from tank. See «FUEL PUMP (IN TANK)»(ref-160825-S15527934812004030200000).
2. Lay fuel tank pump to one side, keeping it in a plastic bag or similar to avoid dirt and fumes.
3. Remove four cover mounting bolts. (Scheme 35)
4. Completely remove retaining strap bolt. Loosen outer bolts about 0.4" (10 mm). Remove retaining strap from front tank mounting. (Scheme 35)
5. Remove strut under tank. (Scheme 36)
6. Remove tank so that it rests against loose fixing brackets. (Scheme 37)
7. Place reference marks on front and rear driveshaft flanges. Remove bolts from front and rear flanges. Remove support bearing and bracket. Remove driveshaft. (Scheme 38)
8. Place appropriate trolley jack with Fixture (5972) under tank. (Scheme 39)
9. Remove front mounting. (Scheme 40) Lower tank slightly and pull forwards. Remove expansion nipple hose located over driveshaft tunnel. Remove tank. Remove protective plates from tank.
10. Check that heat shield insulation fixings lugs are in working condition. Fit protective plates to tank. (Scheme 41) Check that there is no loose matter in tank.
11. Fit 6 self-adhesive foam plastic tabs. (Scheme 42)

Scheme 41

Scheme 42

Scheme 43

1. Loosen nuts for bracket rear retaining strap fixing. Do not remove completely. Lift tank under body using appropriate trolley jack with Fixture (5972). (Scheme 43)
2. Connect hose to expansion nipple and tighten hose clip. Lift tank back to correct position. Check right fixing when tank is finally in position.
3. Tighten the two outer bolts that were loosened, but not removed. Tank will now hang down, slightly at front.
4. Fit support bearing bracket with driveshaft. Fit front flange marks. Use NEW bolts and nuts. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160825-S26694202802004030200000). Rear flange bolts should be replaced by new ones, each of the same length. Bolts can have differing lengths when they also act as balance weights. Use drive flange (999 5561) as back support.
5. Fit support strap, and then finally tighten front mounting. Tighten upper strap bracket. Fit right side mounting. Pull apart heat shield and sound insulation. Fit fuel tank strut.
6. Install in-tank fuel pump. See «FUEL PUMP (IN TANK)»(ref-160825-S15527934812004030200000).

1. Remove starter motor and oil dipstick pipe. Loosen pipe connections to EGR valve. Loosen EGR valve screws and remove valve and seal. Remove EGR temperature sensor from old EGR valve. Carefully clean sensor.
2. To install, fit EGR temperature sensor to new EGR valve. (Scheme 44) Connect EGR valve to pipe. Connect EGR valve to intake manifold with a new gasket. Tighten EGR valve pipe connector to tighten specification. See «TORQUE SPECIFICATIONS»(ref-160825-S26694202802004030200000). Install starter motor and oil dipstick pipe.

Scheme 44

1. Remove hoses from EGR vacuum controller. (Scheme 45) Remove outer screw from EGR vacuum controller bracket. Remove EGR vacuum controller and loosen connector. Remove bracket from EGR vacuum controller.
2. To install, fit new EGR vacuum controller, and reverse removal steps.

Scheme 45

Removal and installation procedures are not available from manufacturer. (Scheme 46) EVAP canister is located in left front corner of engine compartment. see scheme 1

Scheme 46

Scheme 47

Scheme 48

1. Remove cover (A) from throttle mechanism. Remove spring clip (B) on cable tensioner. Unhook cable from the throttle control pulley (C) and remove it from bracket. Remove connector (D) from kickdown switch. (Scheme 47)
2. Remove sound proofing panel (A) on driver's side. Remove knee bolster (B). (Scheme 48)
3. Remove Transmission Control Module (TCM) from bracket. Carefully raise bracket away from catch with screwdriver. (Scheme 49) Withdraw TCM downward from bracket.
4. Unhook cable from accelerator pedal. Press out cable from inside of firewall with screwdriver to release locking tabs behind cable grommet. (Scheme 50)
5. Squeeze and wrap a few turns of electrical tape around grommet, cut off the tape approximately 4" (10 cm) from seal. (Scheme 51)

Scheme 49

Scheme 50

Scheme 51

1. Install cable with kickdown switch terminal pins facing straight up.
2. Ensure that cable tags grip inside of firewall panel securely. Pull off tape around grommet and check that grommet is seated against soundproofing on panel. Ensure that rubber stop is in place in accelerator pedal lug. (Scheme 52) Hook cable and retainer onto accelerator pedal, ensuring that ball on cable end is seated in bottom of retainer.
3. Install connector on kickdown switch. Install spring clip on cable adjuster. Firmly latch cable onto throttle control pulley.
4. Install.14" (3.5 mm) shim between throttle body pulley and closed throttle position stop, ensuring that spring clip is seated against bracket. Adjust cable to light tension. (Scheme 53)
5. Remove spring clip and install cable adjuster in bracket with clip. Install cover over throttle mechanism.

Scheme 52

Scheme 53