Ignition and Control Systems - Removal, Replacement and Installation: Other Volvo S80 I

Control module fuel pump (FP), replacing

Note. Some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 4

Scheme 5

Remove

1. luggage compartment mat/floor hatches so that the spare wheel well can be released
2. connector from control module
3. control module from Velcro fastener

Install

1. new control module
2. connector for control module
3. luggage compartment mat/floor hatches

Engine control module (ECM), replacing

Special tools

9995722

Scheme 6

Scheme 7

1. Ignition off. Wait for 2 minutes
2. Remove the cover over the control module box. Put the cover to one side NOTE: Do not touch the control module terminal pins with your fingers. Static electricity may damage components in the control module.
3. Insert tool «9995722»(ref-403953-S10522720692011061000000) around the control module.
4. Move the upper section of the tool backwards as far as it will go. Pull up the tool
5. Carefully pull up the control module.

Scheme 8

1. Check that no pins or sockets are damaged on the connector.
2. Carefully press the control module down into the grooves on the inside of the control module box. Press to the limit position
3. Insert tool «9995722»(ref-403953-S10522720692011061000000) around the control module.
4. Move the upper section of the tool forwards as far as it will go. Pull up the tool
5. Press the cover into place over the control modules
6. Check that the air ducts are correctly positioned.

Ordering software

Order software according to the table below.

Note. After downloading the software or replacing the engine control module (ECM), the throttle unit must be adapted according to vehicle communication input: "Adapting the throttle unit".

Finishing

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

Test drive the car. Check the function of the engine.

Replacing knock sensors (KS)

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 is always correct.

Removing the knock sensor (KS)

Remove

1. the cable from the battery negative terminal. First read «Battery, disconnecting»(ref-440259-S31019869382011121400000)
2. the intake pipe between the front cover plate and the air cleaner (ACL) Detach the pipe from the charge air cooler at the throttle housing. Push the pipe to one side
3. the dip stick and its holder
4. the screws for the knock sensors (KS)
5. the tie strap at the connector. Disconnect the connector. Pull the sensors downwards and past the rear edge of the starter motor bracket.

Scheme 9

Install the new sensor. Tighten by hand.

Route the cables on the outside of the starter motor bracket.

Align the sensors. The cable from the sensor for cylinder 2 = 3 o'clock and from the sensor for cylinder 4 = 6 o'clock.

Tighten the knock sensors (KS) to 20 Nm .

Connect the knock sensor (KS) connectors. Check that the wiring is in the correct position. Secure with a tie strap at the starter motor bracket.

Install

1. the dip stick
2. the pipe between the throttle body (TB) and the charge air cooler (CAC)
3. the intake pipe between the front cover plate and the air cleaner (ACL)
4. the negative battery cable. First read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .

Installing the temperature and pressure sensors

Install a new sensor.

Thermostat / temperature sensor, engine coolant, replacing

See Thermostat / temperature sensor, engine coolant, replacing

Note. Some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 10

Open Luggage Compartment Lid/tailgate

Remove

1. luggage compartment mat/floor hatches and side panels on the right side
2. backseat's seat cushion

Fold the rear seat backrest forward.

Remove the right side upholstery Upholstery, side cushion, replacing

Remove the right part of the backrest

Use new bolt, 1 pc. M10.

Tighten with 50 Nm.

Scheme 11

Remove bracket for child seat from the floor.

Use new bolt and nut.

1 pc. M10, tighten with 50 Nm.

1 pc. M12, tighten with 80 Nm.

Move aside the insulating mat.

Scheme 12

Remove

1. right floor hatch over fuel tank
2. the cable harness

Scheme 13

Disconnect

1. cable harness connectors by wheel housing/sill and fuel pump
2. cable from brackets

Scheme 14

Cut off the cable harness as shown. This is done to make it easier to remove the cable harness.

Remove the remaining part of the cable harness with connector.

Scheme 15

Raise the car

Remove

1. the connector from the control unit
2. control module from the vehicle
3. cable harness from its brackets
4. cable harness from the vehicle

Check that the fuel line is located in its clamps.

Vehicles with fuel pump module located in spare wheel well's right trailing edge.

Remove

1. luggage compartment mat/floor hatches so that spare wheel well can be released
2. the connector from the control unit
3. the control module from Velcro fastener

Scheme 16

Connect a new cable harness to the connector by the sill and the fuel tank.

Place the cable harness in the seal ring's slot and in the bracket on the body.

Install the floor hatch and tighten with 6 Nm .

Check carefully that the seal is in place when the hatch is installed.

Scheme 17

Open the vehicle's cable channel and lay down the cable harness.

Close the cable channel.

Scheme 18

The control module shall be placed in the spare wheel well's rear part on the right side, between the two markings and below the bead of sealing compound.

Remove the protective tape from the self-adhesive Velcro fastener and install the control module.

Plug in the connector from the cable harness to the control module.

To install, reverse the removal procedure.

Vehicles with fuel pump module originally located in spare wheel well's right trailing edge.

Install

1. new control module
2. the connector to the control module
3. the luggage compartment mat/floor hatches

Upholstery, side cushion, replacing

Upholstery, side cushion, replacing

Carry out operation Side cushion .

Scheme 19

Unhook the upholstery from the frame.

Installation

Install

Hook the upholstery onto the frame.

See Engine control module (ECM), replacing

See Replacing knock sensors (KS)

Temperature and pressure sensors, replacing

See Temperature and pressure sensors, replacing

See Thermostat / temperature sensor, engine coolant, replacing

See Engine control module (ECM), replacing

Installing the fuel pressure sensor

Note. For tightening torques, see Tightening torque .

Install

1. the sensor
2. the screw for the sensor. Tighten
3. the tie strap for the wiring. Connect the cable to the sensor
4. 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.

Scheme 20

Lower the tank to access the pressure sensor from above.

Remove

1. the screw
2. the connector
3. the hose clamp and hose.

In reverse order

See Replacing knock sensors (KS)

Replacing the thermostat and/or engine coolant temperature sensor

See Replacing the thermostat and/or engine coolant temperature sensor

See Temperature and pressure sensors, replacing

See Engine control module (ECM), replacing

Removing the pressure sensor

Lower the tank to access the pressure sensor from above. See Fuel tank, replacing

Remove

1. the screw
2. the connector
3. the hose clamp and hose.

In reverse order

Fuel system, draining

To drain the fuel from the system, see Draining the fuel system

Draining the tank

If the fuel tank is more than half full, drain the fuel tank. See Draining the fuel tank

In the passenger compartment

Remove

1. the backrest. See «The backrest»(ref-461704-S33201830142012040200000)

Scheme 21

Remove

1. the insulation panel.

Scheme 22

1. Remove the covers over the fuel level sensors
2. Disconnect the 2 connectors on the left and 2-3 on the right-hand side. Let them follow the fuel tank down.

Exhaust pipe, rear section

Scheme 23

Raise the car

Remove

1. the rear section of the exhaust pipe. Support the front section of the exhaust pipe so as not to put strain on the exhaust manifold.

Heat deflector plate

1. Remove the left rear wheel
2. Remove the rear plastic nut from the plastic fender liner.

Scheme 24

1. Drill out the two blind rivets holding the heat deflector plate at the rear sub-frame mounting and the third rivet on the rear bracket for the exhaust system. Use a 5 mm drill bit
2. Remove the plastic nuts and the heat deflector plate.

Exposing the fuel tank

Scheme 25

Remove

1. the plastic pipe with the largest connection to the carbon filter container by pressing towards the container, pressing the two catches and pulling off. Position the pipe forwards towards the fuel tank
2. the plastic pipe between the canister purge (CP) valve and the carbon filter container from the clip on the fuel tank
3. the ABS wiring from the fuel tank
4. the bracket for the fuel filter
5. the brake cable from the left rear brake. See «Replacing brake cables»(ref-461712-S27472504692012040200000)
6. the screws from the heat shield at the front of the fuel tank. Position the brake cables in front of the heat shield
7. the hose clamps, fuel filler pipe and the shut-off pipe at the fuel tank.

Tank, lowering

Scheme 26

Apply the transmission jack with fixture 9995972 under the tank.

Remove

1. the tank retaining straps and lower the tank slightly
2. the hoses from the tank unit.

Check that the lines and wiring are unimpeded during the rest of the lowering.

Draining fuel tank

Drain the fuel from the fuel tank. See Draining the fuel tank .

Transferring components

Transfer

1. the right-hand level sensor and pump. See: «Replacing the right-hand level sensor and pump»(ref-461649-S07230636952012040200000)
2. the left-hand level sensor. See: «Level sensor, fuel tank, left, replacing»(ref-461647-S39724064902012040200000)
3. the fuel tank pressure sensor. See: «Pressure sensor, fuel tank, replacing»(ref-440263-S07866549672011121400000) (certain markets only)
4. the hoses for the fuel filler pipe and breather pipe
5. the fuel filler extension in the fuel tank
6. the heat shield under the fuel tank
7. the clip for the brake cable
8. the tank straps.

Fuel tank

Note. To ensure that there is no exhaust leakage, see: Flanged joint, assembling .

1. Lift up the fuel tank.
2. Install the hoses on the fuel tank unit. Ensure that no lines or wiring are trapped
3. Position the wiring to be routed into the passenger compartment uppermost
4. Install the fuel filler pipe and the bleed pipe. Use new screw clips NOTE: Install the screw clips so that they can be easily tightened.
5. Tighten the screws for the tank retaining strap. Tighten to 25 Nm
6. Remove the mobile jack

Install

1. the fuel filter with the bracket Tighten to 25 Nm
2. The ABS wiring in the clips on the fuel tank
3. the brake cables behind the heat shield at the front edge of the fuel tank and in the clips. Screw the heat shield into place
4. the brake cable at the left rear brake. See «Replacing brake cables»(ref-461712-S27472504692012040200000)
5. the plastic pipe between the canister purge (CP) valve and the carbon filter container in the clip on the fuel tank
6. the plastic pipe with the largest connection to the carbon filter container. A "click" must be heard.

Heat deflector plate

Scheme 27

1. Position the heat deflector plate and install the plastic nuts
2. Install the pop rivets, one at the bracket for the exhaust system and two on the rear mounting for the sub-frame
3. Install the left rear wheel.

The rear section of the exhaust pipe

1. Install the exhaust system. Tighten the screws. Tighten to 25 Nm .

The passenger compartment

Install

1. The 2-3 connectors on the right and the 2 connectors on the left
2. the covers over the level sensors. Check that the gasket is correctly positioned
3. the insulation panel
4. the backrest. See «The backrest»(ref-461704-S33201830142012040200000) .

See Replacing knock sensors (KS)

See Replacing the thermostat and/or engine coolant temperature sensor

See Temperature and pressure sensors, replacing

See Engine control module (ECM), replacing

Pressure sensor, fuel tank, replacing

See Pressure sensor, fuel tank, replacing

See Replacing knock sensors (KS)

See Replacing the thermostat and/or engine coolant temperature sensor

See Temperature and pressure sensors, replacing

S60, V70 2000-V70 XC 2001-/XC70, S80

1. For all 5 and 6 cylinder engines -2001, see «Engine control module (ECM), replacing»(ref-440263-S06314018662011121400000)
2. For B52xxS, 2002- see «Engine control module (ECM), replacing»(ref-440263-S06314018662011121400000)
3. For B52xxT / B6xx4x 2002-, see «Engine control module (ECM), replacing»(ref-440263-S39287429992011121400000) .

Special tools

9995722

Points to observe when replacing the control module

Removing the engine control module (ECM)

1. Ignition off. Wait for 2 minutes
2. Remove the cover over the control module box. Put the cover to one side NOTE: Do not touch the control module terminal pins with your fingers. Static electricity may damage components in the control module.
3. Insert tool «9995722»(ref-403953-S10522720692011061000000) around the control module.
4. Move the upper section of the tool backwards as far as it will go. Pull up the tool
5. Carefully pull up the control module.

Installing the engine control module (ECM)

1. Check that no pins or sockets are damaged on the connector.
2. Carefully press the control module down into the grooves on the inside of the control module box. Press to the limit position
3. Insert tool «9995722»(ref-403953-S10522720692011061000000) around the control module.
4. Move the upper section of the tool forwards as far as it will go. Pull up the tool
5. Press the cover into place over the control modules
6. Check that the air ducts are correctly positioned.

Order the software according to the tables below.

Petrol

Diesel

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

Test drive the car. Check the function of the engine.

Scheme 28

Remove

1. Intake manifold between front cover plate and air cleaner (ACL) housing. Applies only to B6xx4T .

Scheme 29

1. the connector from the sensor
2. the sensor from the intake manifold. NOTE: The above must be carried out manually.

Installing charge air temperature sensor

Install

1. a new sensor
2. the connector
3. the intake manifold between the front cover plate and the air cleaner (ACL) housing. Applies only to B6xx4T .

Remove the cable from the battery negative terminal. First read Battery, disconnecting .

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

Applies only to B6xx4T

Scheme 30

Disconnect the hose between the turbocharger (TC) and the charge air cooler (CAC) at its upper end. Push it to one side.

Disconnect the hose between the intake and the bypass valve on the pipe between the intake and the charge air cooler (CAC).

Remove the hose between the bypass valve and the pipe between the air cleaner (ACL) and the turbocharger (TC).

Scheme 31

Disconnect the connectors for the boost pressure sensor and the charge air temperature sensor from the pipe between the charge air cooler and the throttle body (TB).

Scheme 32

Remove the pipe between the throttle body (TB) and the charge air cooler.

Remove

Scheme 33

1. the screws for the knock sensors (KS)
2. the tie strap at the connector. Pull the sensors downwards and past the starter motor bracket at the rear edge.

Installing the knock sensors (KS)

Install the new sensors with the screws in the cylinder block.

Route the cables on the outside of the starter motor bracket.

Align the sensor (looking from the front towards the rear). The cable from the sensor for cylinder 3 = 5 o'clock and from sensor for cylinder 5 = 6 o'clock.

Tighten the knock sensors (KS) to 20 Nm .

Press the knock sensor (KS) connectors together. Check that the wiring is in the correct position. Clamp if necessary.

Applies only to B6xx4T

Install the pipe between the throttle body (TB) and the charge air cooler (CAC).

Install the connectors for the boost pressure sensor and the charge air temperature sensor.

Install the hose for the bypass valve.

Install the hose between the turbocharger (TC) and the charge air cooler (CAC).

Install

1. the intake pipe between the front cover plate and the air cleaner (ACL)
2. the battery lead. First read «Battery, disconnecting»(ref-440259-S31019869382011121400000) .

Removing boost pressure sensor

Remove

1. the intake manifold between the front cover plate and the air cleaner (ACL) housing. Applies only to B6xx4T .

Scheme 34

1. the connector from the sensor
2. the sensor from the intake manifold.

Install

1. a new sensor
2. the connector.

1. the intake manifold between the front cover plate and the air cleaner (ACL) housing. Applies only to B6xx4T engines .

Lower the tank to access the pressure sensor from above. See: Replacing the fuel tank

Remove

1. the screw
2. the connector
3. the hose clamp and hose.

In reverse order

Removing temperature sensor

1. Remove expansion tank cap Only turbocharged (TC) engines Remove turbocharger (TC)/charge air cooler (CAC) and air cleaner (ACL)/turbocharger (TC) plastic hoses. Remove the clamp to intake manifold at turbocharger (TC) 1, 2, 3 and turn the pipe upper section to the firewall.
2. Raise the car. Only turbocharged (TC) engines Remove turbocharger (TC)/charge air cooler (CAC) and air cleaner (ACL)/turbocharger (TC) plastic hoses. Remove the clamp to intake manifold at turbocharger (TC) 1, 2, 3 and turn the pipe upper section to the firewall.
3. Remove lower splash guard. Only turbocharged (TC) engines Remove turbocharger (TC)/charge air cooler (CAC) and air cleaner (ACL)/turbocharger (TC) plastic hoses. Remove the clamp to intake manifold at turbocharger (TC) 1, 2, 3 and turn the pipe upper section to the firewall.
4. Position a container under engine drain cock, drain engine coolant. Only turbocharged (TC) engines Remove turbocharger (TC)/charge air cooler (CAC) and air cleaner (ACL)/turbocharger (TC) plastic hoses. Remove the clamp to intake manifold at turbocharger (TC) 1, 2, 3 and turn the pipe upper section to the firewall.
5. Close stopcock. Only turbocharged (TC) engines Remove turbocharger (TC)/charge air cooler (CAC) and air cleaner (ACL)/turbocharger (TC) plastic hoses. Remove the clamp to intake manifold at turbocharger (TC) 1, 2, 3 and turn the pipe upper section to the firewall.
6. Lower the car. Only turbocharged (TC) engines Remove turbocharger (TC)/charge air cooler (CAC) and air cleaner (ACL)/turbocharger (TC) plastic hoses. Remove the clamp to intake manifold at turbocharger (TC) 1, 2, 3 and turn the pipe upper section to the firewall.
7. Remove upper timing belt cover.
8. Lift up the servo reservoir and place on top of engine.
9. Remove the hose between the expansion tank and the radiator.
10. Lift up expansion tank.
11. Disconnect level sensor connectors.
12. Place reservoir over engine.
13. Remove screw to front camshaft belt cover.
14. Disconnect sensor cables connectors.
15. Disconnect hose for control module box air at the box.
16. Hold the air hose to one side and pull up the front camshaft belt cover.
17. Disconnect sensor wire connector
18. Remove sensor wire cable duct screw.
19. Remove thermostat housing with cable duct.
20. Secure thermostat housing in a vise and remove sensor. NOTE: Handle the thermostat housing carefully when securing in the vise.

Installing temperature sensor

1. Install new sensor with new gasket. Tighten temperature sensor to 22 Nm. Only turbocharged (TC) engines Turn intake manifold backwards to turbocharger (TC) 1, 2, 3 and tighten clamp. Install the plastic hoses between the turbocharger (TC)/charge air cooler and the air cleaner (ACL)/turbocharger (TC). Tighten hose clamps.
2. Ensure that the sensor cable is correctly routed in the thermostat housing and in cable duct. Only turbocharged (TC) engines Turn intake manifold backwards to turbocharger (TC) 1, 2, 3 and tighten clamp. Install the plastic hoses between the turbocharger (TC)/charge air cooler and the air cleaner (ACL)/turbocharger (TC). Tighten hose clamps.
3. Install thermostat housing with new gasket. Tighten to 17 Nm. Only turbocharged (TC) engines Turn intake manifold backwards to turbocharger (TC) 1, 2, 3 and tighten clamp. Install the plastic hoses between the turbocharger (TC)/charge air cooler and the air cleaner (ACL)/turbocharger (TC). Tighten hose clamps.
4. Install screw to cable duct. Tighten to 10 Nm. Only turbocharged (TC) engines Turn intake manifold backwards to turbocharger (TC) 1, 2, 3 and tighten clamp. Install the plastic hoses between the turbocharger (TC)/charge air cooler and the air cleaner (ACL)/turbocharger (TC). Tighten hose clamps.
5. Put control module box air hose to one side and depress the front camshaft belt cover. Only turbocharged (TC) engines Turn intake manifold backwards to turbocharger (TC) 1, 2, 3 and tighten clamp. Install the plastic hoses between the turbocharger (TC)/charge air cooler and the air cleaner (ACL)/turbocharger (TC). Tighten hose clamps.
6. Press the air hose into place in control module box. Only turbocharged (TC) engines Turn intake manifold backwards to turbocharger (TC) 1, 2, 3 and tighten clamp. Install the plastic hoses between the turbocharger (TC)/charge air cooler and the air cleaner (ACL)/turbocharger (TC). Tighten hose clamps.
7. Install front camshaft belt cover screw. Tighten to 12 Nm. Only turbocharged (TC) engines Turn intake manifold backwards to turbocharger (TC) 1, 2, 3 and tighten clamp. Install the plastic hoses between the turbocharger (TC)/charge air cooler and the air cleaner (ACL)/turbocharger (TC). Tighten hose clamps.
8. Connect level sensor connector. Only turbocharged (TC) engines Turn intake manifold backwards to turbocharger (TC) 1, 2, 3 and tighten clamp. Install the plastic hoses between the turbocharger (TC)/charge air cooler and the air cleaner (ACL)/turbocharger (TC). Tighten hose clamps.
9. Install expansion tank. Only turbocharged (TC) engines Turn intake manifold backwards to turbocharger (TC) 1, 2, 3 and tighten clamp. Install the plastic hoses between the turbocharger (TC)/charge air cooler and the air cleaner (ACL)/turbocharger (TC). Tighten hose clamps.
10. Secure the hose between expansion tank and the radiator in the expansion tank. Only turbocharged (TC) engines Turn intake manifold backwards to turbocharger (TC) 1, 2, 3 and tighten clamp. Install the plastic hoses between the turbocharger (TC)/charge air cooler and the air cleaner (ACL)/turbocharger (TC). Tighten hose clamps.
11. Install the reservoir tank and check that the hoses lie correctly. Only turbocharged (TC) engines Turn intake manifold backwards to turbocharger (TC) 1, 2, 3 and tighten clamp. Install the plastic hoses between the turbocharger (TC)/charge air cooler and the air cleaner (ACL)/turbocharger (TC). Tighten hose clamps.
12. Install upper camshaft belt cover. Only turbocharged (TC) engines Turn intake manifold backwards to turbocharger (TC) 1, 2, 3 and tighten clamp. Install the plastic hoses between the turbocharger (TC)/charge air cooler and the air cleaner (ACL)/turbocharger (TC). Tighten hose clamps.

Then read Follow-up work .

See Engine control module (ECM), replacing

Knock sensor (KS), replacing

See Knock sensor (KS), replacing

Replacing engine coolant temperature (ECT) sensor

See Replacing engine coolant temperature (ECT) sensor

See Engine control module (ECM), replacing

Intake Air Temperature Sensor (IAT Sensor), replacing

See Intake Air Temperature Sensor (IAT Sensor), replacing

See Knock sensor (KS), replacing

Manifold absolute pressure (MAP) sensor, replacing

See Manifold absolute pressure (MAP) sensor, replacing

Removing the temperature sensor

Remove the cap from the expansion tank.

Raise the car. Remove the lower splashguard.

Position a container under the engine drain cock. Drain the engine coolant.

Close the cock.

Install the lower splash guard.

Lower the car.

Scheme 35

Remove the screw holding the engine stabilizer brace to the bracket on the engine.

Undo the clamp holding the return hose for the power steering.

Remove the cross stay.

Scheme 36

Applies only to B6xx4T

Remove the crankcase ventilation pipe from the intake manifold. Start with the cover.

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

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

Scheme 37

Remove

1. the upper timing belt cover. Lift up the servo reservoir and place it on top of the engine WARNING: Seal the cover for the servo reservoir. Check that no oil leaks out. Servo oil is highly inflammable.
2. the screw for the front timing belt cover Applies only to B6xx4T engines . For cars with chassis numbers 203779- , see «EXPANSION TANK»(ref-440390-S19360483282011121400000)
3. the timing belt cover. Disconnect the connector for the sensor cable.

Remove the variable valve timing solenoids and place them to one side.

Remove the screw for the cable duct.

Scheme 38

Remove the thermostat housing with the cable duct.

Clean the mating surfaces of the cylinder block. Ensure that no dirt enters the fluid ducts.

Scheme 39

Secure the thermostat housing in a vise. Remove the sensor.

Note. Handle the thermostat housing carefully when securing it in the vise.

Installing the temperature sensor

Clean the thermostat housing mating surfaces. Ensure that there is no dirt left in the thermostat housing.

Install

1. the new sensor. Use a new gasket . Tighten to 20 Nm . Ensure that the sensor cable is correctly routed in the thermostat housing and in the cable duct
2. the thermostat housing using a new gasket. Tighten to 17 Nm
3. the screw for the cable duct. Tighten to 10 Nm
4. the variable valve timing solenoids. Tighten to 10 Nm
5. the front timing belt cover. Applies only to B6xx4T engines . For cars with chassis numbers 203779- , see «Installing the front timing cover»(ref-440390-S09737832492011121400000) . The mudguard over the right drive shaft boot may come loose. If this happens, secure it from underneath
6. the screw for the front timing belt cover. Tighten to 12 Nm
7. the servo reservoir. Check that the hoses are correctly positioned
8. the upper timing belt cover.

Applies only to B6xx4T

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

Install the crankcase ventilation pipe on the intake manifold.

Tighten all hose clamps.

Install

1. the engine stabilizer brace. Tighten to 50 Nm
2. the torque rod on the bracket on the engine. Tighten to 80 Nm
3. the clamp holding the return hose for the power steering.

See Engine control module (ECM), replacing

See Intake Air Temperature Sensor (IAT Sensor), replacing

See Knock sensor (KS), replacing

See Manifold absolute pressure (MAP) sensor, replacing

Replacing the engine coolant temperature (ECT) sensor

See Replacing the engine coolant temperature (ECT) sensor

See Engine control module (ECM), replacing

See Knock sensor (KS), replacing

See Replacing engine coolant temperature (ECT) sensor

Position sensor camshaft, replacing

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.

Scheme 40

Disconnect the connector from the sensor.

Remove

1. the screw for the sensor
2. the sensor.

Installing the position sensor

Install

1. the sensor
2. screws. Tighten.

Connect the connector for the sensor.

Start the engine. Check the function.

Scheme 41

Remove the tie strap from the torque rod.

Open the hose clamp.

Remove

1. the hoses
2. the connector from the sensor
3. the nut for the sensor
4. the sensor.

Installing the engine speed (RPM) sensor

Install

1. the sensor. Use a new nut. Tighten to 10 Nm
2. the connector
3. the hoses and close the clamp
4. the tie strap on the torque rod.

Removing camshaft position (CMP) sensor

Remove the preheating pipe from the air cleaner (ACL): Applies only to B6xx4S engines .

Applies only to B6xx4T

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

Scheme 42

1. Remove the clamp on the hose between the mass air flow (MAF) sensor and the pipe to the turbocharger (TC)
2. Remove the turbocharger (TC) control valve from the air cleaner (ACL) housing
3. Disconnect the turbocharger (TC) control valve connector
4. Remove the air cleaner (ACL) housing. Place it to one side
5. Remove the hose clamp from the crankcase ventilation and the heater hose.

Scheme 43

Hose bracket.

Disconnect the connector at the bracket

Remove the cable from the clamp on the cylinder block.

Remove the camshaft position (CMP) sensor housing. Applies only to B6xx4T engines .

Remove the sensor mounting screw. Pull off sensor.

Installing the camshaft position (CMP) sensor

Install

1. new sensor . Tighten to 10 Nm
2. the camshaft position (CMP) sensor housing. Tighten to 17 Nm . Applies only to B6xx4T
3. the cable from the clamp on the cylinder block
4. the connector on the bracket
5. the hose bracket on the cylinder block.

Applies only to B6xx4T

1. the crankcase ventilation pipe and the heater hose. Tighten the hose clamps
2. air cleaner (ACL) housing
3. the turbocharger (TC) control valve connector
4. the turbocharger (TC) control valve from the air cleaner (ACL) housing
5. the hose between the air cleaner (ACL) housing and turbocharger (TC). Tighten the hose clamp
6. the intake manifold between the front cover plate and the air cleaner (ACL) housing.

Install the preheating pipe on the air cleaner (ACL): Applies only to B6xx4S engines .

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.

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.

Remove the hose bracket.

Remove the wiring from the bracket.

Disconnect the connector from the bracket.

Disconnect the connector for the sensor.

Scheme 44

Remove the mounting screw for the sensor.

Pull up the 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 45

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.

Camshaft position sensor (CMP), replacing

See Camshaft position sensor (CMP), replacing

Replacing the engine speed (RPM) sensor

See Replacing the engine speed (RPM) sensor

See Camshaft position sensor (CMP), replacing

Applies only to B6xx4S

Remove the preheating hose between the air cleaner (ACL) housing and the exhaust manifold. Place the hose to one side.

Remove

1. the connector from the sensor
2. the nut for the sensor
3. the sensor.

Install

1. the sensor. Use a new nut. Tighten to 10 Nm
2. the connector.

Applies only to B6xx4S

Install the preheating hose between the air cleaner (ACL) housing and the exhaust manifold.

See Camshaft position sensor (CMP), replacing

See Replacing the engine speed (RPM) sensor

Scheme 46

Remove

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

Scheme 47

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.

Removing ignition coil

Remove

1. plastic hoses turbocharger (TC)/charge air cooler (CAC) and air cleaner (ACL)/turbocharger (TC). Place them to one side. Seal the openings. Applies only to B6xx4T

1. upper camshaft belt cover
2. the ignition coils cover
3. the ignition coil connector
4. mounting screw and pull up the coil.

Installing ignition coil

Install a new coil.

Align the coil and press down. Install the screw. Tighten to 10 Nm (7.4 lb. ft) .

Press in the connector until a clicking sound is heard.

Install the ignition coil cover.

Install upper camshaft belt cover.

Applies only to B6xx4T

Remove the seals.

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

Replacing ignition coil

See Replacing ignition coil

See Replacing ignition coil

See Replacing ignition coil

Scheme 48

Remove

1. the soundproofing panel under the dashboard on the driver's side
2. the connector for the pedal module
3. the pedal module.

Installing the accelerator pedal module

Install

1. the new accelerator pedal module. Tighten to 10 Nm
2. the connector for the pedal module
3. the soundproofing panel under the dashboard on the driver's side.

Note. After replacing the accelerator pedal (AP) position sensor, the engine must be run at idling speed for a couple of minutes before normal operation can resume. The is because the system adapts the new accelerator pedal (AP) position sensor to compensate for any differences between the components. If this is not carried out there will be a dead point in the accelerator pedal (AP) position sensor.

Replacing the accelerator pedal module

See Replacing the accelerator pedal module

See Replacing the accelerator pedal module