Home/Volvo/C70/Volvo C70 I (1997-2005)/Repair manual/Engine Control Systems/Engine Electrical - Specifications, Removal & Installation …
Contents Wiring diagrams Section: Engine Control Systems All sections

Engine Electrical - Specifications, Removal & Installation (Coupe): Other Volvo C70 I

Engine Control Systems 33 illustrations ~4324 words

Removing the radiator unit

  1. Remove the engine cooling fan (FC) according to «Engine cooling fan (FC), replacing»(ref-438955-S01575650452011120700000) .

Scheme 602

Scheme 602
  1. Disconnect the charge air pipe from the charge air cooler (CAC) on the left-hand side (turbocharged engines only). If necessary, use a hot air gun to make removal easier
  2. Remove the screws for the radiator unit on the front cover plate.

Scheme 603

Scheme 603

Remove

  1. the two upper screws holding the radiator unit together
  2. the expansion tank cap.

Scheme 604

Scheme 604

Block the upper radiator hose with lock grip pliers

Scheme 605

Scheme 605: Work under the car

Remove

  1. the air baffles
  2. the lower oil cooler hose from the radiator unit (automatics only)
  3. NOTE: Collect the oil from the oil cooler in a container.
  4. the screw for the mounting for the cable duct for engine wiring at the front edge of the sub-frame.

Work from above

  1. Remove the upper radiator hose. Place it to one side. Seal the openings.

Scheme 606

Scheme 606: Work under the car
  1. Disconnect the connector from the receiver drier and the cable from the holder
  2. Hang up the condenser using tie straps on the right-hand side in the pipe for the receiver drier and on the left-hand side in the pipe for the condenser
  3. Remove the lower screws holding the radiator unit.

Scheme 607

Scheme 607
  1. The following requires two people: Disconnect the radiator and the charge air cooler (CAC) firstly from the left and then from the right-hand side by removing the two screws
  2. On the right-hand side, press the cable duct and the compressor hose towards the engine. At the same time release the radiator and charge air cooler (CAC) downwards on the right-hand side. Then release the radiator and charge air cooler (CAC) on the left-hand side. Ensure that the mounting for the radiator and charge air cooler (CAC) passes the AC pipe
  3. Disconnect the hose from the radiator to the expansion tank
  4. Replace the radiator / charge air cooler (CAC).

Installing the radiator and charge air cooler (CAC)

  1. Hold the radiator unit and secure the hose from the expansion tank to the radiator
  2. Install the connector from the receiver drier and the cable from the holder.
  1. Lift up the radiator and charge air cooler (CAC) on the left-hand side. Ensure that the mounting for the charge air cooler (CAC) passes above the AC pipe. Lift the right-hand side while pressing the cable duct and the compressor hose towards the engine
  2. Thread the screws for the radiator and charge air cooler (CAC) into the member.
  1. Install the lower screws to assemble the radiator unit. Tighten the screws. Tighten to 10 Nm
  2. Remove the tie straps
  3. Check that the radiator unit is against the rubber seal
  4. Tighten the radiator unit to the member. Tighten to 25 Nm .
  1. Install the lower radiator hose
  2. Remove the lock grip pliers
  3. Install the screw for the mounting for the engine wiring cable duct at the front edge of the sub-frame
  4. Install the lower oil cooler hose on the radiator unit (automatic gearboxes only).

Install

  1. the upper radiator hose. Remove the lock grip pliers
  2. the charge air pipe to the charge air cooler (CAC) on the left-hand side (turbocharged engines only).
  1. Install the upper screws to assemble the radiator unit. Tighten the screws
  2. Tighten to 10 Nm .
  1. Install the screws for the radiator unit on the front cover plate
  2. Tighten to 10 Nm

Installing the engine cooling fan (FC)

To install the engine cooling fan (FC), see Engine cooling fan (FC), replacing .

Topping up the coolant

  1. Install the cap on the expansion tank
  2. Run the engine until the thermostat has opened
  3. Stop the engine. Top up if necessary.

Installing cooler unit

Position the radiator assembly on the mobile jack's universal plate 9995972 .

Hold cooler unit and carefully raise it into position in the bodywork.

Install both the mounting screws and tighten to 25 Nm .

Install

  1. lower radiator hose. Remove lock grip pliers
  2. screw for engine wiring cable duct mounting at front edge of subframe
  3. front splash guard and air baffles.

Scheme 608

Scheme 608

Install

  1. upper radiator hose. Remove lock grip pliers
  2. hose to expansion tank. Secure hose with clips
  3. the plastic pipe to the charge air cooler (CAC)
  4. the condenser hoses at the compressor and at the drier.

Scheme 609

Scheme 609: Installing engine coolant fan (FC)

Carefully lower the fan shroud and align it with the holes at the sides of the radiator.

Tighten both mounting screws.

Connect engine cooling fan (FC) connectors.

Install charge air pipe over engine.

Press hose down from expansion tank into holder on fan shroud.

Secure wiring with tie straps as before.

Press canister purge (CP) valve into holder on fan shroud.

Turn down air cleaner (ACL) intake manifold and locate against sleeve connector above air conditioning aggregate.

Connect the negative battery cable. First read Battery, disconnecting .

Fill the AC system. See Draining/vacuum pumping/filling with coolant and leak-finding .

Fill coolant

Install expansion tank cap.

Run the engine until the thermostat has opened.

Stop engine and top up coolant if necessary.

Removing the engine coolant temperature (ECT) sensor

Remove

  1. the upper timing belt cover
  2. cable from the sensor
  3. the sensor from the thermostat housing. Use socket «9512885»(ref-403953-S00557342822011061000000) .

Note. Put paper underneath the sensor to prevent coolant spillage.

Installing the engine coolant temperature (ECT) sensor

Install

  1. the sensor with a new seal
  2. Tighten to 22 Nm , use socket «9512885»(ref-403953-S00557342822011061000000)
  3. the upper camshaft cover.

Preparation

Remove the cap from the expansion tank.

Install a hose clamp on the upper coolant hose.

Raise the car. Remove the lower splash guard.

Position a container under the engine drain cock. Drain 2 liters of engine coolant.

Close the cock. Install the lower splash guard. Lower the car.

Disconnect the sensor cable connector.

Remove the upper timing belt cover.

Removing the thermostat

Remove

  1. the upper timing belt cover
  2. the auxiliaries belt.

Remove the delivery pipe from the power steering pump.

Note. Put paper under the generator (GEN) to avoid oil spillage.

Remove

  1. the servo pump
  2. the connector from the sensor
  3. the thermostat housing from the cylinder head.

Replacing the thermostat

Remove the cover and the thermostat.

Install a new thermostat with a new gasket.

Note. Ensure that the thermostat is positioned correctly in the thermostat housing.

Installing the thermostat

CAUTIONFor tightening torques not in the text, see Tightening torque .

Install

  1. the thermostat housing. Use a new gasket
  2. the connector for the sensor
  3. the servo pump
  4. the delivery line for the power steering pump
  5. the upper timing belt cover.

Finishing

Remove the hose clip.

Fill with coolant.

Install the cap on the expansion tank.

Test drive the engine until the thermostat has opened.

Check for leakage.

Top up the coolant and oil if necessary.

Scheme 610

Scheme 610: Leak diagnostic

Vapor which evaporates from the fuel in the fuel tank is routed to and stored in the EVAP canister from where it is guided into the combustion process via the canister purge (CP) valve and negative pressure in the intake manifold. A leak diagnostic has been introduced in certain markets to ensure that there are no leaks in the fuel tank system. The diagnostic is constructed in such a way that the system detects any leaks corresponding to a hole that is 1 mm (0.0394 in) or larger.

The fuel tank system consists of fuel tank, fuel filler pipe, EVAP canister, canister purge (CP) valve and lines between these components. To be able to diagnose the fuel tank system, it is also equipped with fuel tank pressure sensor and EVAP canister shut-off valve.

The diagnostic is divided into different phases in which the various components are tested. If a fault is detected in any of the phases the diagnostic is interrupted and the diagnostic trouble code (DTC) for the component identified is stored.

The diagnostic test works as follows

  1. The fuel tank pressure sensor is checked for an unstable signal. Diagnostic trouble code (DTC) ECM-4308 (faulty signal) is stored if the signal oscillates more than 5 times +/- 10 hPa (+/- 0.145 psi) during 5 seconds. The fuel tank pressure (A) is checked so for stability and that the short-term fuel trim is not too low.
  2. EVAP canister shut-off valve (B) is shut and an evaporation check is carried out by gauging how much fuel tank pressure increases. This provides a value for how much fuel evaporates, and this value is used later to calculate leakage flow. If fuel tank pressure sinks, this indicates that the canister purge (CP) valve is leaking and diagnostic trouble code (DTC) ECM-4008 canister purge (CP) valve open is stored.
  3. EVAP canister shut-off valve (B) is opened, the tank system is open. Canister purge (CP) valve (C) starts to pulse. As a result of the vacuum in the intake manifold the engine starts to suck in air through the EVAP canister. Because EVAP canister shut-off valve (B) is open, the fuel tank (A) pressure drops slowly. If fuel tank pressure sinks rapidly this indicates that the EVAP canister shut-off valve is clogged and diagnostic trouble code (DTC) ECM-4019 EVAP canister shut-off valve shut is stored.
  4. EVAP canister shut-off valve (B) closes the canister purge (CP) valve (C) which pulses with a duty cycle of approximately 17%. Fuel tank pressure (A) sinks to -10 hPa (-0.145 psi). Diagnostic trouble code (DTC) ECM-4308 large leak (signal too low) is stored if this pressure is not reached within ten seconds. This indicates a larger leak in the fuel tank. Diagnostic trouble code (DTC) ECM-4308 large leak (faulty signal) is stored if the fuel tank pressure does not change within 2 seconds. This indicates a defective fuel tank pressure sensor or clogged piping.
  5. Canister purge (CP) valve (C) closes, EVAP canister shut-off valve (B) is shut. There is now a negative pressure in the fuel tank. This negative pressure will decrease slowly. The decrease rate depends on fuel level, fuel evaporation and any leaks. Leakage flow is calculated by comparing pressure increase speed with the pressure decrease speed from stage 4 and by compensating for the evaporation measured in stage 2. Diagnostic trouble code (DTC) ECM-430D small leak is stored if the calculated leakage flow exceeds a certain level. This indicates a smaller leakage in the fuel tank system.
  6. EVAP canister shut-off valve (B) is opened, the diagnostic test is concluded.

During the different phases when the system gauges whether the fuel tank system pressure acts normally or not, there are a number of circumstances which are taken account of, for example

  1. the amount of fuel in the tank
  2. height above sea level
  3. fuel temperature and evaporation

The system can calculate this information. Therefore it is not possible to describe how quickly/much the pressure is permitted to increase or fall in the different phases.

To carry out the diagnostic it is necessary that

  1. there are no diagnostic trouble codes (DTCs) registered for: Vehicle speed signal, canister purge (CP) valve, EVAP canister shut-off valve and fuel tank pressure sensor.
  2. fuel trim must be active
  3. the engine must be idling
  4. speed 0 km/h (0 mph)
  5. vehicle below 2500m above sea level
  6. outside temperature must be above -8°C (17.6°F)
  7. engine coolant temperature (ECT) must be above -8°C (17.6°F) and below 120°C (248°F)
  8. pressure in fuel tank must be above -10 hPa (-0.145 psi)
  9. the concentration of fuel fumes in the EVAP canister must not be too high

The diagnostic starts 17 minutes after starting the engine at the earliest, when all conditions have been met. It takes approximately 30 seconds. If the diagnostic is interrupted for any reason, it will try to start again the next time all conditions are met. The control module performs a maximum of 4 diagnostic attempts during an operating cycle. If no fault is detected the diagnostic will not run again in the same operating cycle. If a fault is detected two further attempts are made to evaluate the fault.

The malfunction indicator lamp (MIL) lights in the event of misfiring

The malfunction indicator lamp (MIL) lights in the event of misfiring. If there is risk of damage to the three way catalytic converter due to misfiring, the malfunction indicator lamp (MIL) will flash and then switch to a constant light.

The engine control module (ECM) registers and stores the RPM and load parameters within which the misfire occurred. For the diagnostic trouble code (DTC) to be stored, the misfire must occur a further two times within the same RPM and load parameters. The malfunction indicator lamp (MIL) is lit if the diagnostic trouble code (DTC) for misfire is stored in the previous operating cycle and a new diagnostic trouble code (DTC) for misfire is stored in the next operating cycle.

If the misfire stops, the requirements for the RPM and load parameters must be met without misfiring before the engine control module (ECM) will begin counting down to extinguish the warning lamp and erase stored diagnostic trouble codes (DTCs).

Removing pressure servo

Remove

  1. boost pressure control (BPC) valve spindle lock pin
  2. turbocharger (TC) control valve hose
  3. fresh air hose from turbocharger (TC) and mass air flow (MAF) sensor and move to one side.

Note. Remove the following in the order specified.

Scheme 611

Scheme 611
  1. rear pressure servo screw (1)
  2. front pressure servo screw (2).

Installing pressure servo

Install

  1. new pressure servo
  2. screws and tighten to 20 Nm.

Scheme 612

Scheme 612: Initial setting of the push rod
  1. Connect manometer «9995230»(ref-403953-S08208420282011061000000) and pressure tester «9985496»(ref-403953-S16783487572011061000000) to pressure servo.
  2. Pump up pressure to 18 1 kPa.
  3. Push boost pressure control (BPC) valve spindle towards turbocharger (TC) housing (closed valve).
  4. Adjust pushrod so that it fits onto spindle lug exactly.
  5. Install lock pin to boost pressure control (BPC) valve spindle.
  6. Tighten pushrod locknut.
  7. Remove manometer and pressure tester.

Note. Pushrod must not be twisted during adjustment, otherwise pressure servo diaphragm may be damaged.

Reinstall/reconnect

Install

  1. hose on turbocharger (TC) control valve
  2. fresh air intake between turbocharger (TC) and mass air flow (MAF) sensor
  3. heat deflector plate

Scheme 613

Scheme 613: Removing the throttle body

Disconnect the cable from the battery's negative terminal.

Remove the intake manifold between front plate and the air filter.

Remove the intake manifold between the air filter and throttle body and lay aside.

Scheme 614

Scheme 614

Remove the throttle body and lay aside.

Clean gasket surface.

Remove the starter motor and lay aside.

Disconnect the throttle body's connector.

Installing the throttle body

Install

  1. starter motor, tighten with 40 Nm against the transmission and 30 Nm for the bracket against the engine block
  2. the new throttle body's connector with the cable on the outside of the starter motor bracket.

Secure the cable so that the risk of damage and contact separation is eliminated.

Install

  1. new throttle body with new gasket . Tighten with 10 Nm
  2. intake manifold between air filter and throttle body and connected hoses
  3. the intake pipe between the front cover plate and the air cleaner (ACL).
  4. the cable to the battery's negative terminal.

Ordering software

Order the software. See 9438298 .

Check that no diagnostic trouble codes have been stored during the repair.

Test-drive the car and check that the engine function is OK.

Scheme 615

Scheme 615: Points to observe when replacing the control module
  1. When changing an engine control module (ECM) from one car to another, remember to note any diagnostic trouble code (DTC) (s) before removing component.
  2. The engine control module (ECM) must not be removed from the car until the main relay has interrupted its power supply. This may take up to 150 seconds (Motronic 4.4) (cars with an immobilizer 245 seconds and 90 seconds for cars with Motronic 4.3) after the ignition has been switched off.
  3. Always check the control module and connector on the control module box for bent or damaged pins or sockets.

Scheme 616

Scheme 616: Removing security strap (Motronic 4.4)

As part of the anti-theft system on cars equipped with an engine immobilizer, the engine control module (ECM) box in the engine compartment is locked into place with a locking strip. The locking strip is installed with a security screw.

  1. Mark up the center of the screw and drill a suitable hole for a screw puller. Insert screw puller and remove the screw.
  2. Remove the security strap across the control module box cover.
  3. Clean the control module box cover carefully so that no dirt or residue falls into the box when it is opened.

Scheme 617

Scheme 617: Removing the control module
  1. Check that supply from main relay has been interrupted. Easiest method is to place fingertips on idle air control (IAC) valve. When the valve stops vibrating, the main relay has cut off supply to the system.

Scheme 618

Scheme 618
  1. Open engine control module (ECM) box cover and remove Motronic 4.3/4.4 engine control module (ECM) (module nearest engine).

Scheme 619

Scheme 619: Installing new engine control module (ECM)

Inspect connector pins and sockets for damage.

  1. Install new engine control module (ECM).
  2. Switch on ignition.
  3. Read off any diagnostic trouble codes (DTCs).
  4. Erase diagnostic trouble codes (DTCs) and reset adaptive functions according to «Erasing diagnostic trouble codes (DTCs) and resetting adaptive functions»(ref-438954-S28568249542011120700000)

Installing security strap (Motronic 4.4)

As part of the anti-theft system on cars equipped with an engine immobilizer, the engine control module (ECM) box in the engine compartment is locked into place with a locking strip. The locking strip is installed with a security screw.

CAUTIONBefore reinstalling security strap, ensure that the car has been repaired and no faults persist.
  1. Locate the slit underneath the control module box with your fingers and hook the locking strip into it.
  2. Fold over the locking strip and tighten the security screw (P/N 1334099-7) so that its head breaks off.

Scheme 620

Scheme 620: Erasing diagnostic trouble codes (DTCs) and resetting adaptive functions

It is important both that diagnostic trouble codes (DTCs) are erased and adaptive functions are reset when the engine control module (ECM) is replaced or when remedying diagnostic trouble codes (DTCs) EFI-231, EFI-232 and EFI-233. If this is not done the car may run poorly despite an absence of faults. This can be carried out in two ways

  1. Diagnostic trouble codes (DTCs) are erased and adaptation reset separately. Reset adaptive functions

Note. If using the engine control module (ECM) from another car, diagnostic trouble codes (DTCs) (if any) must be erased and adaptive functions reset as described above before engine control module (ECM) is reinstalled in car.

Removing the engine speed (RPM) sensor

Applies only to B6xx4S

Remove the preheating hose from the air cleaner (ACL) housing. Place it to one side.

Scheme 621

Scheme 621: Removing the engine speed (RPM) sensor

Applies only to B6xx4T

Remove the intake pipe between the front cover plate and the air cleaner (ACL).

Remove the clamp for the intake pipe.

Disconnect the connector for the turbocharger (TC) control valve and the mass air flow (MAF) sensor.

Remove the air cleaner (ACL) housing. Put it to one side.

Scheme 622

Scheme 622

Remove the hose bracket.

Remove the wiring from the bracket.

Disconnect the connector from the bracket.

Disconnect the connector for the sensor.

Scheme 623

Scheme 623

Remove the mounting screw for the sensor.

Pull up the sensor.

Installing the engine speed (RPM) sensor

Install

  1. a new sensor.

Press the sensor into place. Tighten to 10 Nm .

Connect the connector.

  1. the wiring on the bracket
  2. the connector on the bracket
  3. clamp the wiring
  4. the hose bracket.

Scheme 624

Scheme 624

Applies only to B6xx4S

  1. the air preheating hose for the air cleaner (ACL) housing.

Applies only to B6xx4T

  1. the air cleaner (ACL) housing
  2. the connector to the turbocharger (TC) control valve and the mass air flow (MAF) sensor
  3. the clamp for the intake manifold
  4. the intake pipe between the front cover plate and the air cleaner (ACL) housing.

Scheme 625

Scheme 625: Removing fender liner
  1. Remove left front wheel.
  2. Remove fender liner fixed with 3 plastic nuts and 9 rivets. Use a drill to remove the rivets.

Removing EVAP canister shut-off valve

  1. Disconnect EVAP canister shut-off valve connector.
  2. Remove valve from its mounting on the bodywork.
  3. Remove the hose from the valve.

Scheme 626

Scheme 626: Installing EVAP canister shut-off valve
  1. Connect hose to EVAP canister shut-off valve. Use a new clamp, see Spare Parts Catalogue for correct P/N.

Note. It is important to use the correct clamp to avoid fuel leakage at the joint.

  1. Install valve on mounting in bodywork.
  2. Connect valve connector.

Installing fender liner

  1. Install fender liner, use new rivets, see Spare Parts Catalogue for correct P/N.
  2. Reinstall left front wheel.

Scheme 627

Scheme 627: Removing ignition coils

Remove

  1. the charge air pipe over the engine. Seal the openings

Scheme 628

Scheme 628
  1. the upper timing belt cover
  2. the cover over the ignition coils Disconnect the ignition coil connector.
  3. the mounting screw. Pull the coil up.

Installing ignition coils

Install the new coil.

Align the coil and press it down. Install the screw. Tighten to 10 Nm .

Press in the connector until a clicking sound is heard.

Install the cover over the ignition coil.

Install the upper timing belt cover.

Remove the seals from the charge air pipe. Reinstall the charge air pipe over the engine.

Empty the fuel injection system according to Fuel system pressure release .

Remove the charge air pipe over the engine. Seal the openings

Scheme 629

Scheme 629

Remove the cover over the fuel rail.

Disconnect the injector connectors.

Blow clean around the injectors.

Remove the mounting screws from the fuel rail.

Open the fuel line's quick-release connector using tool 9512666 .

Spray universal oil or similar around the injector terminals on the intake manifold.

Gently work the fuel rail and injectors loose.

Note. Handle the injector valves carefully to avoid damaging the injector valves' nozzles with needles.

Removing injectors

Remove

  1. the screws holding the mounting rail to the fuel rail
  2. the mounting rail
  3. the injector.

Removing the pulsation damper

Remove

  1. the screws holding the mounting rail to the fuel rail
  2. the mounting rail
  3. the pulsation damper.

Installing injectors

Lubricate the injector O-ring with a thin layer of petroleum jelly.

Install the new injector.

Installing the pulsation damper

Lubricate the new pulsation damper O-ring with a thin layer of petroleum jelly.

Install the new pulsation damper.

Position the mounting rail. The injectors may need to be pulled away from the fuel rail a few millimeters to install the rail.

Tighten the mounting rail to the fuel rail. Tighten to 6 Nm .

Lubricate the injector O-rings with petroleum jelly.

Depress the fuel rail. Ensure that all injectors sit correctly.

Screw the fuel rail into place. Use new screws. Tighten to 10 Nm .

Connect all the connectors for the injectors.

Press the quick-release connector together until a clicking sound is heard.

Reinstall the cover over the fuel rail.

Remove the seals from the charge air pipe. Reinstall the charge air pipe over the engine.

Start the engine. Check for fuel leakage.

Intake air temperature (IAT) sensor inlet

Temperature, °CResistance ohmsVoltage, V
060001.55
1040002.01
2024502.62
2520002.13
3018002.00

Intake air temperature (IAT) sensor inlet

Scheme 630

Scheme 630: Locating Engine Sensor And Relay Components

Location of components

  1. Engine coolant temperature (ECT) sensor
  2. Coolant level sensor
  3. A/C pressure sensor
  4. Injector
  5. Ignition coil
  6. Camshaft sensor
  7. Brake pedal sensor
  8. Fusebox
  9. Relay box
  10. Air assisted control valve (AACV)
  11. Engine speed (RPM) sensor
  12. Mass air flow (MAF) sensor with integrated temperature sensor
  13. Canister purge (CP) valve
  14. Throttle unit
  15. Manifold absolute pressure (MAP) sensor
  16. Outer temperature sensor
  17. Engine cooling fan (FC) relay
  18. Engine control module (ECM) ground terminal
  19. Knock sensor (KS)
  20. Engine control module (ECM).

Mass air flow (MAF) sensor, replacing (B5234T3; 1999, B5254T4; 1999-)

Mass air flow (MAF) sensor, replacing (B5234T3; 1999)

  1. See «Mass air flow (MAF) sensor, replacing (B5234T3; 1999)»(ref-438954-S33530549132011120700000) .

Mass air flow (MAF) sensor, replacing (B5254T4; 1999-)

  1. See «Mass air flow (MAF) sensor, replacing (B5254T4; 1999-)»(ref-438954-S22309020392011120700000) .

Removing the mass air flow (MAF) sensor

Remove

  1. the screws for the mass air flow (MAF) sensor
  2. the mass air flow (MAF) sensor.

Installing the mass air flow (MAF) sensor

Install

  1. the mass air flow (MAF) sensor
  2. the screws. Tighten.
  1. air cleaner (ACL) assembly
  2. the hose clamp for the mass air flow (MAF) sensor
  3. the nuts for the air cleaner (ACL) housing. Tighten
  4. the inlet hose
  5. the screws for the inlet hose. Tighten
  6. the turbocharger control valve on the air cleaner (ACL).

Connect the connector to the mass air flow (MAF) sensor.

Mass air flow (MAF) sensor, replacing (B5234T3; 1999-)

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 631

Scheme 631: Removing the mass air flow (MAF) sensor

Remove

  1. the inlet hose from the mass air flow (MAF) sensor
  2. the connector from the mass air flow (MAF) sensor
  3. the screws securing the mass air flow (MAF) sensor to the air cleaner (ACL) cover.

Pull and work the mass air flow (MAF) sensor loose from the air cleaner (ACL) cover.

Note. Apply water to the O-ring in the air cleaner (ACL) cover to facilitate installation of the mass air flow (MAF) sensor.

Install the new mass air flow (MAF) sensor.

Press the mass air flow (MAF) sensor into place.

Install the screws. Tighten.

Install the inlet hose on the mass air flow (MAF) sensor. Tighten the hose clamp.

Press the connector for the mass air flow (MAF) sensor into place.

Removing the shut-off valve

Remove the carbon filter container according to Replacing the carbon filter container .

Disconnect the connector, clamps and hoses from the EVAP canister shut-off valve.

Remove the EVAP canister shut-off valve.

Installing the shut-off valve

Install the clamps and hoses on the shut-off valve. Check that the hoses are correctly positioned and are not twisted or kinked.

Connect the connector. Press the quick-release connector together until a clicking sound is heard.

Install the carbon filter container according to Replacing the carbon filter container .

Scheme 632

Scheme 632: Removing the throttle body (TB)

Remove the intake manifold between the front cover plate and the air cleaner (ACL) housing.

Disconnect the battery negative lead. Battery, disconnecting .

Scheme 633

Scheme 633

Disconnect the hose between the charge air cooler (CAC) and the throttle body (TB) at the end of the throttle body (TB). Move to one side.

Remove the tie strap at the connector.

Scheme 634

Scheme 634

Disconnect the throttle body (TB) connector.

Remove the throttle body (TB).

Clean the mating surfaces thoroughly.

Installing the throttle body (TB)

Install

  1. a new throttle body (TB) with a new gasket . Tighten to 10 Nm Connect the throttle body (TB) connector
  2. the tie strap at the connector
  3. the pipe between the throttle body (TB) and the charge air cooler (CAC)
  4. the intake manifold between the front cover plate and the air cleaner (ACL) housing
  5. the battery negative lead. «Battery, disconnecting»(ref-438953-S33389199492011120700000) .

Note. After replacing the throttle unit, the throttle unit must be adapted using the vehicle communication input: "Adaptation of the electronic throttle unit".

Remedy as necessary.