Variable Valve Timing - Checking, Adjustment, Removal & Installation: Other Volvo S60 I

Timing belt, replacing

Special tools

9995433

9995456

Note. Since 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 575

Remove

1. the screw holding the engine stabilizer brace to the bracket on the engine
2. the screws holding the engine stabilizer brace to the suspension turrets
3. the engine stabilizer brace.

Remove the plastic pipes between the turbocharger (TC) and charge air cooler (CAC) and between the air cleaner (ACL) and turbocharger (TC). Put them to one side.

Remove the clamp from the intake manifold for the turbocharger (TC) for cylinders 1, 2 and 3. Turn the upper section of the pipe towards the bulkhead.

Scheme 576

Relieve the load from the belt tensioner. Remove the auxiliaries belt.

Remove the upper timing belt cover.

Remove the front timing belt cover. See Timing cover front, replacing .

Lift up the servo reservoir and place it on top of the engine.

Note. Ensure that the power steering oil does not leak from the breather hole in the filler cap.

Seal the hose between the expansion tank and the radiator. Disconnect the hose at the tank.

Lift up the expansion tank and place it on top of engine.

Scheme 577

Raise the car.

Remove

1. the right front wheel
2. the plastic nuts on the cover in the wing liner.

Install the upper timing belt cover.

Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulleys correspond.

Turn the crankshaft a further 1/4 turn clockwise.

Then turn back counter-clockwise until the markings correspond.

Remove the upper timing belt cover.

Scheme 578

Remove the 4 vibration damper screws. Counterhold the crankshaft central nut.

Remove

1. the vibration damper
2. the auxiliaries belt
3. the belt cover behind the crankshaft pulley for the auxiliaries belt.

Spray universal oil or similar around the rubber sleeve on the underside of the oil pump.

Remove the rubber sleeve.

Scheme 579

Slacken off the belt tensioner

Slacken off the center screw for the belt tensioner slightly.

Hold the center screw still. Turn the tensioner eccentric counter-clockwise using a 6 mm Allen key. Turn to 10 o'clock.

Unhook and remove the timing belt.

Note. The component can be reused unless it has been subjected to abnormal mechanical stress, damage or oil contamination.

Check tensioner pulley and idler pulley

Check bearing wear

Spin the idler pulley and listen for noise. If replacing with a new idler pulley, tighten to 24 Nm .

Spin the tension pulley and listen for noise. When replacing, screw the tension pulley into place using the center screw.

Screw in the center screw by hand.

Ensure that the tensioner fork is centered over the cylinder block rib / bracket.

Ensure that the Allen hole on the eccentric is at 10 o'clock.

Scheme 580

Note. The component can be reused unless it has been subjected to abnormal mechanical stress, damage or oil contamination.

Install the belt in the following order

1. crankshaft
2. the idler pulley
3. intake cam
4. exhaust cam
5. water pump
6. tension pulley.

Scheme 581

This adjustment is done with a cold engine. Suitable temperature is approximately 20 ° C/ 68 ° F.

At a higher temperature, for example with a warm engine or a higher ambient temperature, the needle is farther to the right.

The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.

Carefully turn the crankshaft clockwise until the timing belt is tensioned. The belt must be in tension between the intake camshaft pulley, the idler pulley and the crankshaft.

Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric clockwise until the tensioner indicator passes the marked position.

Then turn the eccentric back so that the indicator reaches the marked position in the center of the window.

Hold the eccentric secure. Tighten the center screw to 25 Nm.

Check that the indicator is in the correct position.

Scheme 582

Press the belt to check that the indicator on the tensioner moves easily.

Install the upper timing belt cover.

Turn the crankshaft 2 turns. Check that the markings on the crankshaft and camshaft pulley correspond.

Check that the indicator on the belt tensioner is within the marked area.

Finish

Install the auxiliaries belt around the pulley on the crankshaft.

Install

1. the rubber sleeve on the underside of the oil pump
2. the vibration damper. Use new screws . Tighten and angle tighten. See «Summary of tightening torques for specific components»(ref-445802-S21285591172012010600000) . Use the crankshaft center nut as a counterhold
3. the plastic nuts for the cover in the right-hand wing liner
4. the right front wheel. See «Installing wheels»(ref-415307-S16574462602011081500000) .

Scheme 583

Lower the car.

1. Remove the front timing belt cover. See See «Installing the front timing cover»(ref-445838-S36362391222012010600000) .

Tension the auxiliaries belt.

1. the expansion tank
2. the hose between the expansion tank and the radiator. Remove the lock grip pliers
3. the servo reservoir
4. the upper timing belt cover.

Twist the intake pipe for the turbocharger for cylinders 1, 2 and 3 into position. Tighten the clamp.

Install the plastic hoses between the turbocharger (TC) and charge air cooler (CAC) and between the air cleaner (ACL) and turbocharger (TC).

Tighten the hose clamps.

Scheme 584

1. the engine stabilizer brace. Tighten to 50 Nm
2. the screw holding the engine stabilizer brace to the bracket on the engine. Tighten to 80 Nm .

Final check

Check and top up if required

1. coolant level
2. the servo fluid level.

Test run the engine .

Preparations, B5244Sx 1999-2001

A modified VVT-solenoid is now available as spare part for B5244Sx model years 1999-2001 . This means that the connector on the cable must be replaced. Note: Note the position of the electric connections. Cut the cables next to the connector.

Note. Note the position of the electric connections.

Cut the cables next to the connector.

Scheme 585

Press up the lock tab and pull out the seat for the connector pins from the casing.

Scheme 586

Remove the lock

Scheme 587

Install the connector pins in the seat so that the locks on the pin end up in the opening on the side of the seat.

Scheme 588

Install the catch.

Install the casing.

Applies to all: Install VVT-control valve

Clean the gasket faces. Note the cleanliness requirements above.

Install a new gasket .

Install a new control valve. Tighten the control valve crosswise. Tighten to 10 Nm

Connect the connector.

Install the upper timing belt cover.

Variable valve timing unit, checking and adjusting

Special tools

9995451

9995456

9995452

Note. 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.