Engine Controls - Removal & Installation: Other Volvo V40 I рестайлинг

BATTERY DISCONNECT/RECONNECT PRECAUTIONS

Disconnect Cable

All vehicles are equipped with an anti-theft stereo system that requires a code to activate. Record stereo code BEFORE disconnecting negative battery cable. Disconnect negative battery cable.

Reconnect Cable

Turn ignition to position II. Reconnect negative battery cable. Enter code into stereo and reset clock. Check that the SRS warning light on the dashboard goes out.

TURBOCHARGER BY-PASS VALVE

Note. By-pass valve can be serviced with turbocharger installed or removed.

Remove 3 bolts holding by-pass valve in place. (Scheme 16) Check and service valve membrane if necessary. Tighten by-pass valve bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 16

Disconnect electrical connector. Remove control valve from air cleaner housing. Mark each hose and disconnect. (Scheme 17)

Install in reverse order of removal. Red-marked hose goes to intake pressure side of turbocharger control valve. Yellow-marked hose goes to boost pressure control valve. White-marked hose goes to turbocharger air by-pass valve.

Scheme 17

Scheme 18

Scheme 19

Scheme 20

1. Remove air cleaner assembly. Remove cover over engine and rear engine cover. Remove turbocharger heat shield.
2. Remove hoses from turbocharger control valve. Loosen clamp and remove intake hose from turbocharger. (Scheme 17)and (Scheme 18).
3. Remove cover over upper charge air pipe connector. Remove clamps and pipe.
4. Drain engine coolant. See «DRAINING ENGINE COOLANT»(ref-159330-S41853431192004011400000).
5. Remove heat shield from firewall. (Scheme 19)
6. Remove upper and lower turbocharger coolant lines. Remove upper turbocharger oil line. Remove clamp from lower turbocharger oil line. Remove banjo bolt from engine-side oil pipe and catch any spilled oil. (Scheme 20)
7. Remove heated oxygen sensors from exhaust. Separate exhaust pipe from manifold. Pull front exhaust pipe downward and remove gasket. (Scheme 21)
8. Remove nuts holding turbocharger. Mark hoses from control valve and disconnect. Remove turbocharger with catalytic converter from exhaust manifold. Pull return tube out of engine block and rotate turbocharger to remove. Cover all openings on engine and turbocharger. (Scheme 22)
9. Remove two hoses at by-pass valve. Disconnect oil return line and separate catalytic converter.

Scheme 21

Scheme 22

Note. Catalytic converter can be fitted to turbocharger with turbocharger installed on engine. Volvo recommends installing catalytic converter with turbocharger removed.

Scheme 23

Scheme 24

1. Connect oil return line to turbocharger if removed. Attach two hoses at by-pass valve. Fit catalytic converter onto turbocharger. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-159330-S18421788792003112600000). (Scheme 23)
2. Clean exhaust manifold mating surface. Use new gaskets. Install turbocharger and tighten fasteners to specification. Fit a new "O" ring on return line and insert line into block. (Scheme 22)and «TORQUE SPECIFICATIONS»(ref-159330-S18421788792003112600000).
3. Install catalytic converter onto exhaust pipe and tighten nuts to specification. NOTE: Use new copper washers for coolant pipes and upper oil pipe.
4. Loosen turbocharger coolant pipe connection nut and bend pipe to one side. Tighten connection nut to specification. Fit new "O" rings to oil pipes and apply grease to engine side. Install upper coolant pipe. Install lower coolant pipe. Fit oil pipe clamp to bracket. (Scheme 24)and «TORQUE SPECIFICATIONS»(ref-159330-S18421788792003112600000).
5. Install oxygen sensors and connect exhaust pipe. Use a new gasket and tighten bolts to specification. Install engine cover. (Scheme 21)
6. Fit upper charge air pipe and tighten clamps to specification. Install cover over connector. Install turbocharger heat shield and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159330-S18421788792003112600000).
7. Lubricate air intake hose using a soap solution. Press hose onto turbocharger and tighten clamp. Install EVAP hoses and connect electrical connectors. Fit vacuum hoses to turbocharger control valve. Install air cleaner assembly.
8. Fill cooling system. Run engine and adjust turbocharger control valve. See appropriate ON-VEHICLE ADJUSTMENTS article. Top off coolant if necessary. Install engine cover.

Dynamic Stability Assistance (DSA) Control Module is located under right side A-pillar trim next to blower fan. Remove trim and mounting bolt to remove module. Reverse procedure to install. (Scheme 25)

Scheme 25

1. Remove screws from left and right center console side panels. Switch ignition OFF and wait at least 30 seconds.
2. Drill out security screw from security strap on Engine Control Module (ECM). Ensure whole security screw is removed. Remove security strap. Remove screws holding ECM and work ECM forward on right side. Disconnect wire harness. (Scheme 26)
3. Ensure connector and ECM have no damaged pins or connections. Install in reverse order of removal. Use a NEW security screw for security strap.

Scheme 26

PROGRAMMING

A new ECM is delivered WITHOUT software. Vehicle must be connected to Volvo VADIS system to download ECM software.

1. Remove A/C system refrigerant. See appropriate article in HVAC. NOTE: It may be necessary to remove battery clamp to access sensor. (Scheme 27)
2. Clean area around pressure sensor and disconnect connector. Remove sensor and discard "O" ring.
3. Fit new "O" ring and lubricate with compressor oil. Install in reverse order of removal. Tighten sensor to specification. See «TORQUE SPECIFICATIONS»(ref-159330-S18421788792003112600000).
4. Recharge A/C system.

Scheme 27

HEATED OXYGEN SENSOR

Note. It may be necessary to lift vehicle to service rear sensor.

Remove relay cover to access wiring. Remove Black connector if removing front sensor. Remove White connector if removing rear sensor. Apply rust solvent around sensor and remove sensor from manifold. Trace wiring and disconnect at mounting points. (Scheme 28)

Install sensor with a new sealing ring. Apply copper paste to entire thread length. Tighten to specification. See TORQUE SPECIFICATIONS . Place wire upward and route wire so it is clear of exhaust system and fixed in 3 places.

Scheme 28

Remove front engine cover and disconnect sensor connector. Remove sensor. Use a new "O" ring when installing. Tighten fastener to specification. See TORQUE SPECIFICATIONS. Connect electrical connector and install engine cover. (Scheme 29)

Scheme 29

Scheme 30

Scheme 31

1. Remove relay cover and trim cover. Remove knock sensor connector from bracket. Open clamps on protective tube and pull out knock sensor wire. (Scheme 30)
2. Disconnect negative battery cable. Remove front engine cover. Remove starter cover. Remove support bracket from intake manifold and disconnect starter wiring. Remove starter bolts and starter. (Scheme 31)
3. Remove knock sensor mounting bolt. Remove sensor and wiring from underneath. CAUTION: DO NOT over-tighten or under-tighten knock sensor. It will not function properly if not tightened to specification. Wiring MUST be routed as shown.
4. Install knock sensor. (Scheme 32) Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-159330-S18421788792003112600000). Ensure sensor wire is routed inside protective tube. Follow reverse order of removal to complete installation. Retrieve and diagnose DTCs.

Scheme 32

Remove Mass Air Flow (MAF) sensor clamp and air intake tube. Disconnect MAF sensor connector and remove two screws. Remove sensor and discard "O" ring. (Scheme 33)

Install using a new "O" ring. Position MAF sensor with connector facing up and reverse removal procedure to complete installation. Check function and diagnose any DTCs.

Scheme 33

1. Disconnect throttle cable and air intake tube from throttle body. Unbolt throttle body.
2. Clean area around Throttle Position (TP) Sensor. Remove mounting screws and pull sensor off throttle body. (Scheme 34)
3. Use threadlock (1-161-053) or equivalent when installing. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-159330-S18421788792003112600000). Reverse removal procedure to complete installation.

Scheme 34

1. Remove splash guards over engine. Disconnect purge valve connector. Note location of each hose and remove. Lift valve off bracket by pressing catches together. (Scheme 35)
2. Install in reverse order of removal.

Scheme 35

1. Remove cover over throttle cable. Disconnect electrical connector and remove mounting screws. Remove idle air control valve and gasket from intake manifold. Do not reuse gasket. (Scheme 36)
2. Locate new gasket with tab pointing downward and right. Install idle air control valve and tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-159330-S18421788792003112600000). Connect electrical connector and check function. Install throttle cable cover if working properly. Retrieve and diagnose DTCs.

Scheme 36

RELAYS

For relay identification (Scheme 37)

Scheme 37

FUEL SYSTEMS

FUEL SYSTEM PRESSURE RELEASE

1. Remove throttle pulley cover. Remove shield over valve on fuel rail. Connect Adapter (999 5484) to Fuel Drainage Unit (981 2270, 2273 and 2282). see scheme 33 Connect adapter to valve on fuel rail, ensuring adapter is in locked position. Start fuel drainage unit. Unlock adapter. Raise and support vehicle.
2. Remove splash guard over fuel filter valve cap. Remove fuel filter valve cap. Connect Vent Hose (999 5480) to valve before fuel filter. System drain time is about 2 minutes.

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-159330-S18386252062003112600000).
2. Raise and support vehicle if not already lifted. Fuel filter is located near left rear wheel.
3. Release front quick-release connectors and rear line lock. Remove clamp and remove filter. (Scheme 38)
4. Reverse removal procedure to install.

Scheme 38

FUEL INJECTORS

Scheme 39

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-159330-S18386252062003112600000).
2. Disconnect quick-release connector on fuel line and wipe up any spilled fuel. Release fuel line from clamps by pressing clips together. (Scheme 39)
3. Disconnect injector connectors. Remove wire harness and clips from bracket. Remove bolts holding fuel rail. Lift rail out with injectors attached. Disconnect vacuum line from manifold. Ensure all rubber seals and bushings are retained. Remove locking plate for injectors. Remove screws and slacken holding plate. Note position of bracket and pull out locking plate. Remove injectors from fuel rail by twisting. Seals that are not torn can be reused. Lubricate seals with petroleum jelly when reinstalling. (Scheme 40)
4. Follow reverse order of removal to install. Tighten fasteners to specification and use new clips for fuel line. See «TORQUE SPECIFICATIONS»(ref-159330-S18421788792003112600000). Check system carefully for leaks after installation is complete.

Scheme 40

CRANKCASE VENTILATION SYSTEM

To identify crankcase ventilation system components (Scheme 41)

Scheme 41

1. Remove fuel tank. See «FUEL TANK»(ref-159330-S16041885752003112600000).
2. Disconnect inlet and outlet hose quick-release connectors from EVAP canister. see scheme 41 Remove 3 screws holding canister. Disconnect outlet hose leading to leak diagnostic pump. (Scheme 42)
3. Install in reverse order of removal. Ensure all components are securely fitted and will not rattle. Check thoroughly for fuel leakage both visually and using scan tool.

Scheme 42

Pump is located behind left side of fuel tank. To remove, raise and support vehicle. Remove left rear wheel. Remove left rear fender liner. Disconnect electrical connector, EVAP canister hose, pump filter and canister purge valve hose from pump. Remove bracket with fuel pump attached from vehicle. (Scheme 43) Install in reverse order of removal.

Scheme 43

1. Raise and support vehicle. Remove left rear wheel. Remove left rear fender liner.
2. Remove hose clamp holding EVAP canister hose onto pump filter. Separate hose from filter and remove clamp holding filter onto leak diagnostic pump. (Scheme 43)
3. Remove Torx screws holding filter. Cut off tie straps securing leak diagnostic filter hose onto fuel filler pipe and remove filter.
4. Install in reverse order of removal.

Scheme 44

1. Remove engine covers and upper timing cover. (Scheme 44) CAUTION: DO NOT allow debris or objects to fall into control valve opening.
2. Disconnect solenoid electrical connector. Remove mounting bolts and lift control valve straight up off engine. (Scheme 45) Cover opening immediately. Remove gasket material.
3. Clean mating surfaces thoroughly and ensure no gasket material is stuck to surface. Install in reverse order using a NEW gasket. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159330-S18421788792003112600000).

Scheme 45

1. Remove engine covers. Remove screws and release clips on timing gear side. (Scheme 44)
2. Disconnect electrical connector. Remove mounting bolt holding solenoid to Variable Valve Timing (VVT) control valve. Carefully pull solenoid off VVT control valve. (Scheme 46) Discard "O" ring.
3. Clean up any spilled oil and clean mating surfaces. Fit a NEW "O" ring onto solenoid. Fit solenoid in correct position and thread bolt. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-159330-S18421788792003112600000). Connect wiring. Install engine covers. Test drive vehicle and check function of VVT control valve using scan tool.

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

1. Disconnect negative battery terminal. See «BATTERY DISCONNECT/RECONNECT PRECAUTIONS»(ref-159330-S37008802612004011400000). Disconnect inlet hose between air cleaner and throttle body. Disconnect brake servo vacuum line from throttle body terminal by pressing plastic ring down and pulling hose upward. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-159330-S18386252062003112600000) under FUEL SYSTEMS. Disconnect fuel line and wiring from clips at rear edge of cylinder head.
2. Remove harness cover and rear camshaft cover. Remove camshaft position sensor housing and trigger wheel. See «CAMSHAFT POSITION SENSOR»(ref-159330-S07152726562003112600000) under SENSORS & SWITCHES. Remove right engine cover and accessory belts. (Scheme 47) Remove upper and front timing covers. (Scheme 48)
3. Remove bracket for servo hose from accessory belt protector. Position Lifting Beam (999-5006) or equivalent lifting beam slightly in front engine lift eye. Position Lifting Arm (999-5383) and Lifting Hook (999-5460) or equivalent tools to lift engine upward at timing belt side. Lift engine high enough to disconnect upper right-side engine mount. Remove servo fasteners. Remove engine mount bolts and disconnect mount from engine. Remove engine mount from vehicle body. Remove lower timing cover. (Scheme 49)
4. Raise and support vehicle. Remove right front wheel. Position upper timing cover on engine and turn crankshaft until timing marks on crankshaft and camshafts correspond. (Scheme 50) When timing marks are aligned, turn crankshaft one quarter turn clockwise and then back again. Remove upper timing cover.
5. Loosen belt tensioner center bolt. Hold center bolt and turn eccentric to 10 o'clock. Remove timing belt from camshaft pulleys and then from crankshaft pulley. (Scheme 51)
6. Install Camshaft Adjustment Tool (999-5452) or equivalent tool at rear of camshafts. (Scheme 52)
7. Remove plug at front edge of Variable valve timing (VVT) unit. Remove center screw behind plug using a Torx No. 55 tool. Place towel under VVT pulley and carefully pull timing gear with VVT unit straight out of cylinder head. Catch any spilled oil. (Scheme 53)

Scheme 52

Scheme 53

Note. Camshaft Adjustment Tool (999-5452) should already be installed.

Scheme 54

Scheme 55

1. Push Variable valve timing (VVT) unit with camshaft pulley into camshaft. Put upper timing cover into place and ensure that timing marks still line up. Thread in center screw. DO NOT tighten.
2. Ensure crankshaft has not deviated from properly aligned position by checking timing marks. Fit timing belt in numerical order. (Scheme 54)
3. Tension timing belt. Hold belt tensioner center bolt and turn eccentric counterclockwise until tensioner indicator passes marked position. Then turn eccentric clockwise until indicator shows marked position in center of window. Hold eccentric securely and tighten center bolt to specification when in proper position. (Scheme 55) See «TORQUE SPECIFICATIONS»(ref-159330-S18421788792003112600000).
4. Tighten VVT unit center bolt to specification. Tighten plug to specification. See «TORQUE SPECIFICATIONS»(ref-159330-S18421788792003112600000). Remove Camshaft Adjustment Tool (999-5452). Push on timing belt to ensure indicator moves easily. Fit upper timing cover and turn crankshaft two full revolutions to ensure timing marks align.
5. Install lower, front and upper timing covers. Tighten bolts to specification.
6. Install engine mount and connect to engine. Tighten bolts to specification.
7. Remove Engine Lifting Beams (999-5006, 999-5383 and 999-5460) when engine mount is connected.
8. Fit bracket for servo hose and accessory belt protector. Install auxiliary belts. Install camshaft position sensor trigger wheel and sensor housing and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159330-S18421788792003112600000). Install rear camshaft cover. Install wire harness cover. Connect brake servo vacuum hose at throttle body. Fit hose between air cleaner and intake manifold.
9. Ensure all connectors and components are installed. Connect negative battery cable and start engine. Test drive vehicle. Retrieve and diagnose DTCs.

Remove the two mounting screws (A) for the steering shaft from underneath. (Scheme 56) Allow the steering column to sink down. Remove the two screws (B) from the surround. Remove the surround from the clips. Remove the 3 screws for the combined instrument panel. Remove the combined instrument panel. (Where applicable, the connectors and cable for the odometer remain in place on the combined instrument panel.)

Scheme 56

Position the combined instrument panel. Check that the connectors and the speedometer cable (if applicable) are correct for the combined instrument panel. Press the combined instrument panel into place. Install the surround around the combined instrument panel. Install the two screws (B) without sharp tips. Lift up the steering shaft. Install the two screws (A). (Scheme 56) Tighten to 16 ft. lbs. (21 N.m).