Engine Control - Specifications, Removal & Installation: Other Volvo V70 II

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 pressure switch/pressostat

Disconnect connector.

Unscrew pressure switch/pressostat.

Installing pressure switch/pressostat

Screw pressure switch/pressostat into place.

Install the switch.

Replacing radiator/charge air cooler (CAC)

Special tools

9995972

Scheme 399

Applies to cars with air conditioning (A/C)

Drain A/C system according to Draining/vacuum pumping/filling with coolant and leak-finding .

Remove the condenser hoses at the compressor and at the drier.

Remove

1. the negative battery cable. First read «Battery, disconnecting»(ref-406866-S10988298012011070100000) .
2. air duct to control module box.
3. air cleaner (ACL) housing intake pipe from connection above radiator. Twist the pipe up.
4. The canister purge (CP) valve from mounting on the fan shroud.
5. release wiring from fan shroud.

Lift out expansion tank hose from the holders on top of fan shroud.

Disconnect both engine cooling fan (FC) connectors.

Remove

1. the charge air pipe over the engine.
2. both screws holding fan shroud. Carefully lift engine cooling fan (FC).
3. expansion tank cap.

Block upper radiator hose with lock grip pliers.

Scheme 400

1. the splash guard under the engine
2. screw for engine wiring cable duct mounting at front edge of subframe.

Scheme 401

Drain coolant

1. Remove front splash guard and air baffles.
2. Block lower hose with lock grip pliers.
3. Apply a hose on nipple at radiator.
4. Feed the hose down to a container.
5. Open nipple and drain off coolant.

Scheme 402

Remove

1. upper radiator hose. Put to one side
2. expansion tank hose at tank. Disconnect hose from clip so that it comes with the radiator
3. intake hose to and outlet hose from charge air cooler (CAC). HINT: When disconnecting outlet hose it is easier if the connection is heated with hot air gun 115 82 84 around the terminal.

Scheme 403

Remove

1. drain hose and tighten nipple on radiator
2. lower radiator hose. Place to one side and seal openings.
3. container

Position a mobile jack with universal plate 9995972 under the radiator assembly.

1. both mounting screws

Hold the radiator assembly and carefully lower it.

Scheme 404

Place the air conditioning aggregate on a level surface.

Remove the four screws holding the air conditioning aggregate together.

Replace cooler unit/charge air cooler (CAC).

Assemble air conditioning aggregate with the four screws.

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 405

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 406

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.

Scheme 407

The central electrical unit is located by the cowl panel on the left or right depending on the model. The engine compartment central electrical unit is located under a cover.

Remove

1. the screws for the cover
2. the cover.

Scheme 408

Replace the relay. Position the relay as shown in the illustration.

1. Test relay function.

Install the cover and screws. Check that the cover has an airtight seal with the edges of the central electrical unit.

1. Test relay function.

Position of relays in engine compartment central electrical unit

1. 101/102 Cruise control
2. 103 Fuel pump
3. 104/108 Headlamp relay and bulb failure warning sensor
4. 105 Overload relay X
5. 106 Overload relay 15I
6. 107 Spare.

Removing

Remove

1. battery negative lead.
2. relay. Position of relays as shown in the illustration: «Installing»(ref-441137-S33029520142011121500000) .

Scheme 409

Install relay.

Connect battery negative lead.

1. Test relay function.

Relay position, engine compartment

1. 1) Main relay.
2. 2) Pulsed secondary air injection system (PAIR) pump / Glow plug relay (Diesel).
3. 3) Starter relay.
4. 4) Air conditioning (A/C) relay.
5. 5) Engine cooling fan (FC).

Replacing spark plugs

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

Scheme 410

Remove

1. any charge air pipe over the engine. Seal the openings.
2. the upper camshaft belt cover.
3. the cover over the ignition coils.

Scheme 411

Mark up the ignition coils.

Remove

1. the ignition coils. Mark up their locations. Put the ignition coils to one side without disconnecting the connectors.
2. the spark plugs.

Scheme 412

Install new spark plugs

1. Check the spark plug gap. NOTE: Turbocharged engines: Correct spark gap: 0.7 - 0.8 mm (0.02- 0.03 in).
2. Lubricate the spark plug threads with paste. P/N: 116 1408. Tighten to 30 Nm (22 lb. ft) .

Scheme 413

Normally aspirated engine

1. Lubricate the spark plug threads with paste. P/N: 116 1408. Tighten to 30 Nm (22 lb. ft) .

Install

1. the ignition coils. Check the marking. Tighten to 10 Nm (7.4 lb. ft) .
2. the cover over the ignition coils. Tighten to 8 Nm (6 lb. ft) .
3. the upper camshaft belt cover. Tighten to 8 Nm (6 lb. ft) .
4. any charge air pipe over the engine. Remove the seals from the openings.

Checking work

Function test

1. start the engine and check that it functions normally.

Wipe the steering wheel and gear selector lever clean.

Scheme 414

Remove

1. steering wheel and steering wheel covers. «Steering wheel with switches»(ref-406868-S28023876122011070100000) , Interior, exterior, S70/V70, 1997-.
2. SRS contact reel screws.
3. connector.

Installing

Install

1. SRS contact reel.
2. SRS contact reel screws.
3. connector.
4. steering wheel and steering wheel covers. «Steering wheel with switches»(ref-406868-S28023876122011070100000) , Interior, exterior, S70/V70, 1997-.

Preparations

1. Check that the ignition is switched off.
2. Remove soundproofing.

Scheme 415

1. Depress brake pedal and lock it in the depressed position with a pedal jack.
2. Press stop (brake) light switch housing forward towards the pedal mounting bracket to release the white locking sleeve.
3. Pull the white locking sleeve towards the tip of the stop (brake) light switch as far as it will go.
4. Push in stop (brake) light switch catches and remove switch.
5. Disconnect connector.

Check

Check the new stop (brake) light switch to ensure

1. that the white locking sleeve is pulled out towards the tip of the stop (brake) light switch as far as it will go.
2. that the catches are not in contact with the white locking sleeve.

Note. Brake pedal must be depressed.

1. Connect the connector.
2. Install stop (brake) light switch. Check location of switch in bracket.
3. Press stop (brake) light switch into place. There is a distinct click when the catches engage with the bracket.
4. Remove pedal jack.

1. Carefully pull up brake pedal to its highest position. The stop (brake) light switch will then adjust itself automatically.
2. Shake (do not pull) the stop (brake) light switch lightly and check that it is secure.

1. Check that the stop (brake) lights is working.
2. In cars with automatic transmission and shift-lock, check that shift-lock is working.
3. Reinstall soundproofing.

Heated oxygen sensor (HO2S), replacing (B5234T3; B5254T2; B5254T4; B5244T5; 2001-2007)

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

1. For B5xx4T -2004, see «Heated oxygen sensors (HO2S), replacing»(ref-406881-S12516602262011070100000)
2. For B5xx4T 2005-, see «Heated oxygen sensor (HO2S), replacing»(ref-406881-S28557634062011070100000) .

Heated oxygen sensors (HO2S), replacing (B5234T3; B5244T3; 2001)

Special tools

9995543

Note. The diagnostic information uses the designations "Bank 1" and "Bank 2" respectively. Bank 1 stands for cylinders 1-2-3 and Bank 2 for cylinders 4-5-6.

Removing the center member

Remove the screws from the center member. Remove the member.

Remove the flange between the exhaust pipe and three-way catalytic converter (TWC).

Unhook the rubber pads for the rear mounting for the exhaust pipe to prevent damage to the boots on the three-way catalytic converter (TWC).

Scheme 416

Removing the front member

Carefully position the mobile jack under the three-way catalytic converter (TWC).

Pull the rear exhaust system backwards so that the joint at the three-way catalytic converter (TWC) separates by 50 mm (2.0").

Remove the four screws from the front member.

Turn the member.

Remove the screws from the front mounting for the exhaust pipe.

Unhook the brake pipes.

Remove the clamps for the cable harnesses.

Remove the member.

Lower the rear edge of the three-way catalytic converter (TWC) 120 mm (4 3/4").

Remove the heat deflector plate.

When replacing the left heated oxygen sensor (HO2S)

Remove the left front wheel.

Scheme 417

1. Separate the connector for the heated oxygen sensor (HO2S). Expose the cable harness.

Remove the heated oxygen sensor (HO2S).

Use tool 9995543 . See the illustration.

1. Use tool «9995543»(ref-403953-S02065961212011061000000) . Install the heated oxygen sensor (HO2S). Tighten to 45 Nm
2. Install the mounting for the cable harness
3. Route the cable harness. Connect the connector.

1. Install the heat deflector plate
2. Carefully raise the mobile jack to the installation position for the exhaust system
3. Install the front member. Tighten to 25 Nm . NOTE: Do not reinstall the rivets.
4. Reconnect the exhaust flange. Tighten to 25 Nm
5. Install the center member. Tighten to 25 Nm . NOTE: Do not reinstall the rivets.
6. Reinstall the rubber pads for the exhaust mounting. Tighten to 25 Nm .

1. Remove the mobile jack.

Finishing

Start the engine. Check that the exhaust system does not leak at the flange.

Erase Diagnostic Trouble Codes (DTCs).

Reset trim.

Knock sensor (KS), replacing (turbocharged engines)

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

1. For B5xx4T, see «Replacing knock sensors (KS)»(ref-406817-S15358998012011070100000)
2. For B5244T5 2005-, see «Knock sensor (KS), replacing»(ref-406817-S12161751282011070100000) .

S60, V70 2000

1. For B5254T4, see «Knock sensor (KS), replacing»(ref-406817-S12161751282011070100000) .

Knock sensor (KS), replacing (naturally aspirated engines)

S60, V70 2000-, S80

1. For B5xx4S/S2 2001- see «Knock sensor, replacement»(ref-406817-S10538912822011070100000)
2. For B5xx4S/S2 -2002 see «Knock sensor, replacement»(ref-406817-S06050890822011070100000)
3. For B5xx4S/S2 2003- see «Knock sensor, replacement»(ref-406817-S25467889402011070100000) .

S60, V70 2000

1. For B5xx4S6 2003- see «Knock sensor (KS), replacing»(ref-406817-S16075521542011070100000) .

Replacing knock sensors (KS) (B5xx4S/S2; 1999-)

Note. For model year 2001-, see Knock sensor, replacement .

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.

Scheme 418

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

Disconnect the intake manifold between the air cleaner (ACL) and the throttle body (TB) and put to one side.

Scheme 419

Remove the throttle body (TB).

Scheme 420

Remove the sensor.

Disconnect the connector.

Installing knock sensors (KS)

Install

1. the sensor. Route the cable behind the starter motor bracket. Tighten to 20 Nm
2. the connector.

1. the throttle body (TB). Use a new gasket . Tighten to 20 Nm .

1. the intake pipe between the air cleaner (ACL) and throttle body (TB)
2. the intake pipe between the front cover plate and the air cleaner (ACL) housing.

Scheme 421

Drain the fuel injection system forwards of the fuel filter.

Remove

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

Scheme 422

1. intake manifold between the air cleaner (ACL) and throttle body (TB) with vacuum hoses
2. throttle body (TB)
3. vacuum hoses to intake manifold, left-hand side
4. the fuel rail cover
5. the ignition coils cover, left-hand side
6. the crankcase ventilation hose from the top

Scheme 423

1. fuel rail
2. fuel delivery hose from fuel delivery pipe
3. air distribution pipe

Scheme 424

1. dipstick pipe
2. bracket screw on the underside of the intake manifold
3. intake manifold
4. intake manifold vacuum hose, right-hand side

Scheme 425

1. sensor
2. connector.

Installing knock sensor (KS)

Install

1. the sensor. Route the cable behind the starter motor bracket and tighten to 20 Nm (14.75 lb. ft).
2. connector

1. new gasket to intake manifold
2. vacuum hoses to intake manifold, right-hand side
3. intake manifold. Tighten to 17 Nm (12.54 lb. ft)
4. bracket screw on the underside of the intake manifold
5. dipstick pipe
6. air distribution pipe
7. fuel delivery hose from fuel delivery pipe
8. fuel rail with new screws . Tighten to 10 Nm (7.4 lb. ft)
9. the crankcase ventilation hose to the top
10. the ignition coils cover, left-hand side
11. the fuel rail cover
12. vacuum hoses to intake manifold, left-hand side

1. the throttle body (TB) with new gasket . Tighten to 17 Nm (12.54 lb. ft)
2. intake manifold between the air cleaner (ACL) and throttle body (TB) with vacuum hoses

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

Scheme 426

Remove the pipe between the air cleaner (ACL) and the turbo / throttle body at the mass air flow (MAF) sensor.

Disconnect the connector from mass air flow (MAF) sensor.

Remove the screws holding 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.

Installing the mass air flow (MAF) sensor

Note. Apply water to the O-ring in the air filter cover to facilitate installation of the mass air flow sensor.

Install the new mass air flow (MAF) sensor.

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

Install the screws. Tighten.

Install the pipe on the mass air flow (MAF) sensor.

Connect the mass air flow (MAF) sensor connector.

Pedal position sensor clutch, replacing

S60 and V70

1. For M56 and M58 2000- see «Pedal position sensor clutch, replacing»(ref-441122-S23299041272011121500000) .

Pressure regulator, checking/adjusting

Special tools

9995646

9995544

Preparation

To simplify the following text, the terms turbo1 and turbo2 are used.

turbo1 is for cylinders 1,2,3. turbo2 is for cylinders 4, 5, 6.

Note. Always check / set both the pressure regulators.

Scheme 427

Remove

1. the screw for the engine stabilizer brace mounting on the engine
2. the cross stay between the suspension turrets
3. the plastic charge air pipe. Place to one side
4. the plastic intake pipe. Put it to one side.

Remove the pressure regulator hoses at the T piece

Position the turbo1 pressure regulator hose so that it can be reached from underneath the car later on.

Scheme 428

Raise the car.

Remove the lower splash guard.

Pull down the hose from the pressure regulator.

Remove the split pin from the lever.

Lift off the push rod.

Scheme 429

Connect

1. manometer «9995646»(ref-403953-S17881977312011061000000) to the pressure regulator hose
2. pressure regulator «9995544»(ref-403953-S05241159092011061000000) to the manometer.

Note. When taking readings the manometer must always hang vertically from its hook. This is to ensure that the correct values are obtained. Set the three-way junction handle to the middle position.

Screw out the adjustment screw for the pressure regulator completely.

Connect compressed air to pressure regulator.

Screw in the adjustment screw for the pressure regulator so that the manometer displays the value applicable to the relevant engine, according to the table below.

The three-way junction connector has a vent (drilled hole) where it connects to the pressure regulator to facilitate setting the correct pressure.

Scheme 430

Push the boost pressure control (BPC) valve lever towards the turbocharger (TC) housing. The boost pressure control (BPC) valve should be closed.

Check that the push rod locates on the lever lug.

If necessary, adjust the push rod until it locates.

Note. The boost pressure control (BPC) valve spindle must be mounted on the lever when the lock-nut is adjusted. The diaphragm in the pressure regulator will be damaged if the push rod is twisted.

Finishing

Install the split pin on the lever.

Tighten the locknut on the lever.

Remove the test equipment.

Insert the hose upwards following previous routing.

Install the lower splash guard.

Lower the car.

Scheme 431

Remove

1. the turbocharger (TC) intake pipe
2. the charge air pipe from the turbocharger (TC)
3. the heat deflector plate over the turbocharger (TC).

Checking and adjusting push rod

1. Check and adjust the push rod. See «Checking and adjusting push rod»(ref-441137-S11623807622011121500000) .

Install the split pin on the lever.

Tighten the locknut on the lever.

Remove the test equipment.

Install

1. the heat deflector plate over the turbocharger (TC). Tighten to 25 Nm
2. the charge air and intake pipes to the turbocharger (TC). Align against the plastic pipes and tighten.

Lower the car.

1. the engine stabilizer brace between the suspension turrets. Tighten the screws at the suspension turret. Tighten to 50 Nm
2. the screw for the engine stabilizer brace mounting on the engine. Tighten to 80 Nm .

Press the plastic pipes into place and tighten the clamps.

1. the mounting screws for plastic pipes and tighten
2. the hoses from the pressure regulators to the T piece.

Replacing electronic throttle module (ETM)

Note. Click here Throttle body (electronic throttle module, ETM), replacing if you are working on the S80.

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 432

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 433

Jack up the car.

Remove the LH front wheel.

Uncover the wiring.

Disconnect the connectors.

Jack up the car.

Scheme 434

Uncover the wiring.

Remove lambda probes using tool 9995543 .

Replacing the accelerator pedal module

Note. If you are working on the S80, click here Replacing the accelerator pedal module .

Scheme 435

Remove the stop lug in the connector on the pedal module.

Disconnect the pedal module connector.

Remove the pedal module.

Installing the accelerator pedal module

Install the pedal module. Tighten to 10 Nm .

Connect the module connector.

Install the stop lug in the connector on the pedal module.

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.

Note. Before replacing the control module all the program data should be read from the control unit. This is done in VIDA vehicle communication. After replacement the program data should be written to the new control module.

Scheme 436

Remove

1. the dashboard cover panel as described in «Panel and SRS passenger airbag module»(ref-441140-S11882149622011121500000) .

Scheme 437

1. driver information control unit. Disconnect contacts.
2. lock and alarm receiver.

Order software as described in 9438416 .

Programming the control unit

After the control module has been replaced, the customer parameters should be programmed in again. Finish off by checking that no diagnostic trouble codes have been displayed when replacing. Both programming of the control module and reading the diagnostic trouble codes can be found in VIDA vehicle communication.

Replacing the engine control module (ECM) (2001)

Special tools

9995722

Scheme 438

Scheme 439

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 440

1. Check that no pins or sockets are damaged on the connector.
2. Gently press the control module down into the grooves inside the control module box. NOTE: 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 the tool up.
5. Press the cover into place over the control modules.
6. Check that the air ducts are correctly positioned.

Order software according to

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

Test drive the car. Check that the function of the engine is OK.

Replacing the engine control module (ECM) (2001-2007)

Note. Click here: Engine control module (ECM), replacing , if you are working on the S60, V70 2000- or S80.

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.
3. NOTE: Do not touch the control module terminal pins with your fingers. Static electricity may damage components in the control module.
4. Insert tool «9995722»(ref-403953-S10522720692011061000000) around the control module.
5. Move the upper section of the tool backwards as far as it will go. Pull up the tool.
6. 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 9438297 .

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

Test drive the car. Check that the function of the engine is OK.

Scheme 441

Disconnect the intake manifold from mass air flow (MAF) sensor.

Disconnect the connector from mass air flow (MAF) sensor.

Remove the screws holding 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.

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

Install the screws. Tighten.

Install the intake manifold on the mass air flow (MAF) sensor.

Connect the mass air flow (MAF) sensor connector.

Scheme 442

Lift the valve away from the air cleaner (ACL) cover.

Remove the connector from the valve.

Mark up and pull off the hoses.

Installing the turbocharger (TC) control valve

Install

1. the hoses according to the marking on the control valve
2. the connector on the valve
3. the valve on the air cleaner (ACL) cover.

Replacing the camshaft position sensor (CMP)

S60, V70 2000-, XC70, S80, XC90

1. For B5xx4Tx -2002 see: «Replacing the camshaft position sensor (CMP)»(ref-406817-S23552407432011070100000)
2. For B5xx4Tx 2003- see: «Position sensor camshaft, replacing»(ref-406817-S23026582442011070100000)
3. For B5xx4Sx see: «Replacing camshaft position sensor (CMP)»(ref-406817-S27311890992011070100000)
4. For B6xx4X see: «Camshaft position sensor (CMP), replacing»(ref-406819-S40853247402011070100000)

Replacing the camshaft seals / variable valve timing (VVT) unit (B5234T3; 2001-2004)

Special tools

9512050

9995450

9995451

9995452

9995651

9995718

9995719

9995919

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

Removing the camshaft seal

The abbreviation VVT stands for

Variable

Valve

Timing.

Note. Crankshaft or camshafts must not, under any circumstances , be rotated more than is listed below. Failure to follow these instructions may cause damage to the valves.

Remove

1. the cable from the battery negative terminal. «Battery, disconnecting»(ref-406866-S10988298012011070100000) .
2. the charge air pipe over the engine. Seal the openings.
3. the upper camshaft belt cover.
4. the cover over the ignition coils.
5. lift the solenoid valves away from the air cleaner (ACL) cover.
6. the air intake hose for the turbocharger (TC) from the air cleaner (ACL) cover. Put to one side.
7. the upper torque rod bracket.
8. the camshaft position (CMP) sensor housing.
9. the trigger wheel.
10. the rear cover for the intake camshaft.
11. the servo reservoir and the expansion tank. Lift up and place on top of the engine. NOTE: Take care not to spill servo oil from the bleed hole in the cap. Place paper wipe around the reservoir and then cover with a plastic bag as protection. Spilled servo oil is highly inflammable.
12. 3 nuts for the cable duct at the right suspension turret. Lift the duct away from the screws.
13. the auxiliaries belt.
14. the front camshaft belt cover.

Scheme 443

Raise the car.

Remove

1. the right front wheel.
2. the nuts for the cover in the fender liner.

Install the upper camshaft belt cover.

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

Turn the crankshaft a further 1/4 of a turn clockwise, then back counter-clockwise until the markings correspond.

The markings are shown in the illustration.

Remove the upper camshaft belt cover.

Scheme 444

Slacken off the belt tensioner.

Slacken off the belt tensioner center screw slightly.

Hold the center screw still and turn the tensioner eccentric clockwise with a 6 mm (15/64") Allen key to "10 o'clock".

Remove the camshaft belt from the belt tensioner, camshaft pulley and idler pulley.

Scheme 445

Use camshaft adjustment tool

1. Install camshaft adjustment tool «9995452»(ref-403953-S02369714572011061000000) at the rear edge of the camshafts. First screw in the part of the tool intended for the exhaust camshaft.

Scheme 446

Screw the camshaft adjustment tools together

1. Carefully turn the exhaust camshaft clockwise with the camshaft adjustment tool until the intake camshaft tool can be applied.
2. Screw the camshaft adjustment tools together as shown in the illustration.

Scheme 447

Remove

1. Exhaust camshaft pulley
2. The plug at the front edge of the variable valve timing (VVT) unit (TORX 55). The center screw from the variable valve timing (VVT) unit (TORX 55). Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit.

Intake camshaft pulley

Remove the screws and remove the timing gear pulley.

Scheme 448

Replacing the camshaft seal

1. Carefully press in tool «9995651»(ref-403953-S26733550812011061000000) between the sealing ring and the camshaft. Carefully pry out the seals.

Scheme 449

Install a new seal

1. Grease the new seal.
2. Install the new seal for the intake camshaft using drift «9995719»(ref-403953-S10206011822011061000000) .
3. Install the new seal for the exhaust camshaft using drift «9995718»(ref-403953-S24775656662011061000000) .

Scheme 450

Remove

1. detach the brake vacuum hose from the intake.
2. the air duct for the control module box and the air cleaner (ACL) air intake hose.
3. the connectors, relays and canister purge (CP) valve from the fan shroud. Place the wiring to one side.
4. the screws for the fan shroud and the relay holder mounting.

Lift up the relay holder and remove the upper hose between the charge air cooler and the intake.

Seal the openings.

Slacken off the screw clip on the throttle body (TB) (electronic throttle module) so that the charge air pipe can be pressed backwards.

Press the charge air pipe backward and lift up the engine cooling fan (FC) with its cover.

As shown in the illustration.

Scheme 451

Install the adjustment tool.

Pull the charge air pipe forward

Remove the 3 starter motor screws for the starter motor mounting.

Place the starter motor to one side.

Remove the blind cover plug and the sealing washer.

Turn the crankshaft clockwise slightly to avoid the camshaft adjustment tool being in the wrong position.

Install camshaft adjustment tool: 9995451 .

Ensure that the camshaft adjustment tool reaches down to the cylinder block.

Turn the crankshaft back counter-clockwise until it stops against the drift.

Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.

Scheme 452

Install the variable valve timing (VVT) unit with the toothed belt pulley

Slacken off, but do not remove, the screws which secure the timing gear pulley to the variable valve timing (VVT) unit.

Press the timing gear pulley and variable valve timing (VVT) unit on to the camshaft.

Install the center screw which secures the variable valve timing (VVT) unit to the camshaft.

Note. Do not tighten yet.

Install the upper camshaft belt cover.

Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position.

Continue turning clockwise until the timing gear pulley marking is 1 cog before the marking on the upper timing cover.

Check that the timing gear pulley is still in the limit position in the oval holes.

Tighten the center screw in the variable valve timing (VVT) unit to 120 Nm (88 lb. ft) .

Check that the variable valve timing (VVT) unit does not rotate when tightening.

Install the center plug. Tighten to 35 Nm (26 lb. ft) .

Install the timing gear pulley on the intake camshaft

Install the timing gear pulley on the intake camshaft with two screws, but do not tighten .

Check that the markings on the timing gear pulley and the upper timing cover correspond.

Scheme 453

Install the timing belt

Tighten the center screw on the camshaft belt tensioner to 5 Nm (4 lb. ft) .

Turn the variable valve timing (VVT) unit clockwise until stop.

Hold the variable valve timing (VVT) unit secure at the clockwise limit position when the belt is being installed.

As shown in the illustration.

Install the belt in the following order

1. Install the camshaft belt over the pulley on the crankshaft.

Then install the belt as follows

1. 1. Idler pulley.
2. 2. Intake cam pulley.
3. 3. Exhaust cam pulley.
4. 4. Water pump.
5. 5. Belt tensioner.

Note. Adjust the timing gear pulleys so that the screws are not at a limit position in the oval holes.

Scheme 454

Adjust the belt tensioner

Note. This adjustment is to be made with a cold engine. A suitable temperature is 20°C/68°F. At a higher temperature, for example with a warm engine or a higher ambient temperature, the needle is further to the right. The illustration shows the needle position when adjusting the camshaft belt tensioner at different engine temperatures.

Scheme 455

Tighten the timing belt as follows

Hold the belt tensioner center screw secure and turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position.

Tighten the screws on the exhaust camshaft timing gear pulley to 10 Nm (7.4 lb. ft) .

Install the screw missing on the intake camshaft belt pulley.

Tighten the screws on the intake camshaft timing gear pulley to 20 Nm (15 lb. ft) .

Note. The variable valve timing (VVT) unit must not be released from the limit position until after the timing gear pulleys have been tightened.

Then turn the eccentric back so that the needle reaches the marked position corresponding to the relevant temperature.

Remember to hold the center screw secure at the same time.

At 20°C the needle must be centered in the window.

See the illustration above.

Hold the eccentric secure and tighten the center screw to 20 Nm (15 lb. ft) .

Check that the indicator is in the correct position.

As shown in the illustration.

If the indicator is not in the correct position, a new alignment must be carried out.

Remove

1. the camshaft adjustment tools.
2. the crankshaft stopper. Install the plug with a new sealing washer. Tighten to 40 Nm (29 lb. ft) .

Scheme 456

Check

1. Press the belt to check that the indicator on the tensioner moves easily.
2. Install the upper timing belt cover.
3. Turn the crankshaft two turns and check that the markings on the crankshaft and camshaft pulley correspond.
4. Check that the indicator on the belt tensioner is within the marked area.

Reinstall

Install

1. the front camshaft belt cover. Tighten to 12 Nm (8.8 ft. lb) .
2. the upper camshaft belt cover. Tighten to 8 Nm (6 lb. ft) .
3. the auxiliaries belt.
4. the cable duct. 3 nuts.
5. the expansion tank.
6. the servo reservoir. Wipe clean. Check the level and top up as necessary. NOTE: Check that the hoses are correctly positioned.
7. the starter motor. Tighten the screws at the transmission to 40 Nm (29 lb. ft) . Tighten the support bracket screw to 25 Nm (18 lb. ft)
8. the engine cooling fan (FC).
9. the hose between the charge air cooler and the intake. Remove the seals. Tighten the clamp on the charge air pipe at the throttle body (TB).
10. screw the relay bracket and the fan shroud into place.
11. the canister purge (CP) valve, relays and connectors.
12. the air ducts.
13. the brake vacuum hose.
14. the trigger wheel. Tighten to 17 Nm (12 lb. ft) .
15. the camshaft position (CMP) sensor housing and a new cover. Tighten the screws.
16. the torque rod bracket. Tighten to 50 Nm (37 lb. ft) .
17. the upper torque rod. Tighten to 35 Nm (26 lb. ft) . Angle-tighten 90 degrees .
18. the cover over the ignition coils. Tighten to 8 Nm (6 lb. ft) .
19. the charge air pipe over the engine. Remove the seals.
20. the air cleaner (ACL) cover and the intake air hose.
21. the solenoid valves on the air cleaner (ACL) cover.
22. the cable to the battery negative terminal. «Battery, disconnecting»(ref-406866-S10988298012011070100000) .
23. The cover in the fender liner.
24. The front wheel.

Check the engine function by test driving the car.

Wipe clean and check the engine compartment.

Wipe the steering wheel and the gear selector lever.

Replacing the rear seal

The following components must be removed when replacing the rear seal

1. the solenoid valves. Lift out from the air cleaner (ACL) cover.
2. the air hose from the air cleaner (ACL) to the turbocharger (TC). Place to one side. Seal the hose.
3. place the air cleaner (ACL) cover to one side.
4. the charge air pipe over the engine. Seal the openings.
5. the cover over the ignition coils.
6. the upper torque rod bracket.
7. the camshaft position (CMP) sensor housing.
8. the trigger wheel.

Scheme 457

Remove and replace the seal

Carefully pull out the old seal.

Use extractor 9995919 .

Scheme 458

Install new seals

Grease and install the new seal.

Use drift 9995450 .

Note. The seal is normally pressed in so that it is level with the internal beveled edge. If the shaft journal is showing signs of wear, the seal can be pressed in 2 mm (0.079 in) deeper by turning the drift socket.

Install

1. the trigger wheel. Tighten to 17 Nm (12 lb. ft) .
2. the camshaft position (CMP) sensor housing and a new cover. Tighten to 10 Nm (7.4 lb. ft) .
3. the torque rod bracket. Tighten to 50 Nm (37 lb. ft) .
4. the upper torque rod. Tighten to 35 Nm (26 lb. ft) . Angle-tighten 90 degrees . Use bevel protractor: «9512050»(ref-403953-S36645634772011061000000)
5. the cover over the ignition coils. Tighten to 8 Nm (6 lb. ft) .
6. the charge air pipe over the engine. Remove the seals.
7. the air cleaner (ACL) cover and the intake air hose.
8. the solenoid valves on the air cleaner (ACL) cover.
9. connect the battery negative terminal. «Battery, disconnecting»(ref-406866-S10988298012011070100000) .

Check the engine compartment and wipe it clean.

Checking the engine

Check the engine function by test driving the car.

Wipe the steering wheel and gear selector lever clean.

Removing the front camshaft seal

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

Replacing the rear camshaft seal

See Removing/Installing the rear camshaft seal .

Remove the timing belt from the timing gear pulley for the camshafts. See Replacing the timing belt .

Check the tensioner and idler pulleys. See Replacing the timing belt .

Remove camshaft position (CMP) sensor housing and the trigger wheel.

Remove the cover at the rear edge of the camshaft.

Removing the variable valve timing unit / timing gear pulley

Install adjustment tool 9995452 at the rear of the camshafts. Screw the adjustment tool sections together into one. Remove the plug from the front edge of the variable valve timing unit (Tx55).

Remove the center screw from the variable valve timing unit (Tx55). Carefully pull out the variable valve timing unit with the timing gear pulley.

The following applies to timing gear pulleys without variable valve timing

Remove the screws. Remove the timing gear pulley.

Scheme 459

Carefully press in tool 9995651 between the seal and the camshaft. Pry out the seal.

Installing the front camshaft seal

Note. The purpose of this installation service information is to ensure that the VVT unit is correctly positioned and to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later fault-tracing.

Note. For tightening torques, see Tightening torque .

Cleaning

To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

Note. When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal. For camshafts with variable valve timing

Use drift 9995718 .

Use the mounting screw for the variable valve timing unit. Tighten until the drift bottoms out. for camshafts without variable valve timing

Use drift 9995719 .

Checking the variable valve timing (VVT) unit

Check the variable valve timing (VVT) unit. See: Variable valve timing unit, checking and adjusting

Install

1. the starter motor. Tighten screws at gearbox. Tighten. See «Tightening torque»(ref-406899-S19208646662011070100000)
2. the screw at the support bracket for the starter motor. Tighten
3. the trigger wheel. Tighten the screw
4. the camshaft position (CMP) sensor housing. Tighten the screws
5. a new cover at the rear edge of the camshaft.

Install the auxiliaries belt around the pulley on the crankshaft.

Install

1. the plastic nuts for the cover in the right-hand wing liner
2. the right front wheel. See «Installing wheels»(ref-406900-S36743861182011070100000) .

Scheme 460

Install

1. front timing cover. Tension the auxiliaries belt. Check that it is correctly positioned on all pulleys
2. the expansion tank
3. the hose between the expansion tank and the radiator. Remove the lock grip pliers
4. the servo reservoir
5. the upper timing cover.

Scheme 461

Install

1. the engine stabilizer brace. Tighten the screws
2. the screw holding the engine stabilizer brace to the bracket on the engine. Tighten
3. the battery negative lead. Also read «Battery, disconnecting»(ref-406866-S10988298012011070100000) .

Final check

Check and top up if required

1. coolant level
2. the servo fluid level.

Test drive the engine.

Remove

1. the intake manifold between the electronic throttle module (ETM) and air cleaner (ACL) cover
2. the air cleaner (ACL) cover. Place it to one side
3. the camshaft position (CMP) sensor housing and the trigger wheel.

Removing the rear camshaft seal

Pull out the seal. Use puller 9995919 . To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

Note. When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal. Use drift 9995450 .

Note. The seal is normally positioned at the same level as the internally bevelled edge. If the shaft journal is showing signs of wear, the seal can be pressed in a further 2 mm : Turn the drift socket.

Install

1. the trigger wheel. Tighten the screw
2. the camshaft position (CMP) sensor housing. Tighten the screws
3. the air cleaner (ACL) cover
4. the intake manifold between the electronic throttle module and the air cleaner (ACL) cover.

Test drive the engine.

Replacing the timing belt (B5234T3; B5244T3; 2001)

Special tools

9995433

9995456

Remove

1. the screw for the torque rod mounting at the bracket on the engine.
2. the screws at the cross rod mounting to the suspension turret.
3. the cross stay.

Applies only to B6xx4T

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

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

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

Remove the upper camshaft belt cover.

Remove the front camshaft belt cover.

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.

Raise the car.

Remove

1. the right front wheel.
2. the plastic nuts from the cover in the fender liner.

Install the upper camshaft 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 camshaft belt cover.

Scheme 462

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

Remove

1. the vibration damper.
2. the auxiliaries belt.

Scheme 463

Install counterhold 9995433 .

1. the crankshaft center nut. Remove counterhold 999 5433.
2. the pulley for the auxiliaries belt.

Scheme 464

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

First remove the upper screw for the tensioner / damping unit.

Then remove the lower screw.

Turn the tensioner / damping unit so that the cylinder comes free.

Remove

1. the lower screw.
2. the tensioner / damping unit.
3. the timing belt.

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

Note. The crankshaft or camshafts must not be rotated while the timing belt is removed.

Checking the tensioner and idler pulleys

Spin the pulleys and listen for noise from the bearings. Check that the pulley surfaces to the belt are clean and smooth.

Check the tension pulley lever and mounting.

The tension pulley lever. Torque 30 Nm. The idler pulley, tightening torque 25 Nm.

Scheme 465

Check that there is no visible leakage.

Press the tensioner/damping unit together with tool 9995456 . Position the tensioner/damping unit in the tool and screw the tool center nut to the bottom. Wait until it is compressed and then install a lock pin in the piston.

Note. The tensioner damping unit must be replaced if there is leakage or there is no resistance when pushed in or if it cannot be pushed in.

Install the tensioner/damping unit. Tighten to 25 Nm .

Scheme 466

Install the belt in the following order

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

Note. The variable valve timing unit on B6304S does not have a return spring. The unit is easily dislodged when reinstalling the timing belt.

Scheme 467

Pull the lock pin out of the tensioner / damping unit.

Install the pulley for the auxiliaries belt.

Install the crankshaft center nut.

Turn the crankshaft two revolutions and check that the markings on the crankshaft and camshaft pulleys align.

Install counterhold 9995433 tighten the crankshaft's center nut to 300 Nm .

Install the auxiliaries belt around the pulley on the crankshaft.

Install

1. the vibration damper with new screws . Tighten to 35 Nm . Angle-tighten 50° . Use the crankshaft center nut as a counterhold.
2. the plastic nuts in the cover in the right fender liner.
3. the right front wheel. See «Installing wheels»(ref-441117-S09770525422011121500000) .

Lower the car.

1. the front camshaft belt cover.

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 camshaft belt cover.

Applies only to B6xx4T

Turn the intake pipe for the turbocharger for cylinders 1, 2 and 3 into place and tighten the clamp.

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

Tighten the hose clamps.

1. the cross stay. Use new screws . Tighten to 50 Nm .
2. a new screw for the torque rod mounting at the bracket on the engine. Tighten to 80 Nm .

Check and top up if required

1. the coolant level.
2. the servo fluid level.

Test-run the engine.

Replacing the variable valve timing solenoid

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

Scheme 468

Applies only to B6xx4T

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

Put them to one side.

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

Scheme 469

Remove the upper timing belt cover.

Note. Clean the area around the variable valve timing (VVT) solenoid thoroughly to avoid contaminated oil entering the ducts / the variable valve timing (VVT) unit.

Remove

1. the connector for the check valve
2. the screws holding the valve
3. the control valve and the gasket.

Installing the variable valve timing solenoid

Clean the gasket faces. Note the cleanliness requirements above.

Install a new gasket.

Install

1. a new check valve Tighten the control valve crosswise. Tighten to 10 Nm
2. the connector
3. the upper timing belt cover.

Applies only to B6xx4T

Turn back the intake manifold for the turbocharger (TC) for cylinders 1, 2, 3 and tighten the clamp.

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

Tighten the hose clamps.

Replacing the EVAP canister shut-off valve

Note. Click here if you are working on the S80 Replacing the carbon filter container .

Scheme 470

Scheme 471

1. Disconnect the connector Removing the clamp: squeeze the clamp with a pipe wrench. Hold in place pry apart with a small screwdriver. NOTE: These are reusable.
2. Remove the clamps (2) at the EVAP canister and rear axle joint, and one tie strap. Removing the clamp: squeeze the clamp with a pipe wrench. Hold in place pry apart with a small screwdriver. NOTE: These are reusable.
3. Disconnect hoses.
4. Remove the rubber mounting from the bracket.

Installing the EVAP canister shut-off valve

In reverse order.

Installing the clamp

1. squeeze the clamp with a pipe wrench until it locks.

Note. Use a new screw clip at the EVAP canister. See replacement parts catalogue. Use a new tie strap. Reuse the clamp at the rear axle joint.

Removing the canister purge (CP) valve

1. Remove the intake manifold between the front cover plate and the air cleaner (ACL) housing.
2. Disconnect the canister purge (CP) valve connectors.
3. Pull off the valve from the bracket on the fan shroud.
4. Mark up and pull off the hoses from the valve.

Installing a new canister purge (CP) valve

1. Install the hoses according to the marking.
2. Install the canister purge (CP) valve on the bracket on the fan shroud.
3. Connect the canister purge (CP) valve connectors.
4. Install the intake manifold between the front cover plate and air cleaner (ACL) housing.

Scheme 472

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

Scheme 473

Disconnect the canister purge (CP) valve connectors.

Pull off the valve from the bracket on the fan shroud.

Mark up and pull off the hoses from the valve.

Installing the canister purge (CP) valve

Install

1. the new canister purge (CP) valve
2. the hoses according to the markings
3. The canister purge (CP) valve on the bracket at the fan shroud. Connect the canister purge (CP) valve connectors

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

Fuel tank pressure sensor, replacing

1. For V70 (not AWD), see «Pressure sensor, fuel tank, replacing»(ref-406817-S33611353882011070100000)
2. For V70 (AWD) and V70 XC/XC70, see «Pressure sensor, fuel tank, replacing»(ref-407124-S25387722992011070100000) .

Fuel tank, replacing

Special tools

9812270

9812273

9812282

9985972

9995533

9995485

9995486

9995972

Safety

First read Safety regulations for handling fuel .

Draining the fuel tank

To drain the fuel tank, see Draining the fuel tank AWD and 2WD/ORVR (IE00 (IE01)).

Draining the fuel system

To drain the fuel system, see Draining fuel injection system .

Note. Do not drain the fuel tank via the fuel filler pipe as this may damage the check valve.

Scheme 474

5-door models

1. Remove all the floor hatches. Fold the carpet out of the way
2. Remove the cover over the fuel pump (FP) unit.

4-door models

1. Fold the right rear seat forward
2. Remove the cargo compartment carpet
3. Fold back the corner of wheel housing panel at the shock absorber mounting
4. Remove the cover over the fuel pump (FP) unit.

Scheme 475

Scheme 476

1. Separate all the connectors on the bracket
2. Remove the rubber bracket around the wiring
3. Remove the ground lead for the fuel filler pipe from the nut on the cover of the fuel tank level sensor
4. Ensure that all cables routed through the hole at the fuel pump (FP) unit are unimpeded. Ensure that the cables can freely follow the fuel tank when it is lowered.

Scheme 477

1. Carefully disconnect the quick-release connectors for the delivery and return lines
2. Use tool «9995666»(ref-403953-S24236455152011061000000) . Slide the outer sleeve of the connector upward. Avoid squeezing the sleeve.

Scheme 478

1. Remove the fuel tank filler cap
2. Remove the snap ring securing the rubber seal
3. Release the rubber seal from the bodywork.

Scheme 479

1. Disconnect the connector / inlet. Press in the catch and pull.

Scheme 480

1. Position the mobile jack with fixture «9995972»(ref-403953-S08076234722011061000000) under the fuel tank. Check that the lifting table is level so that the tank will not be damaged
2. Undo the tank retaining straps and lower the tank slightly.

Scheme 481

1. Disconnect the hose (1) between the EVAP canister shut-off valve and air cleaner (ACL) from the fuel tank clamp. Cut the tie straps on the fuel filler pipe. Disconnect the hose (2), air cleaner (ACL) and shield from the fuel filler pipe. Put to one side
2. Remove the entire mounting from the bracket: Pull it towards the right of the car
3. Note the position of the hoses in the clamp. Open the clamp. The hoses must be reinstalled in their original positions.

Scheme 482

1. Lower the fuel tank slightly
2. All hoses are secured on top of tank by a quick-release clip. Use a screwdriver to disconnect the clip at the top
3. Lower the tank.

Scheme 483

1. Disconnect the hose connectors to the shut-off pipe and the fuel filler pipe
2. Remove the two screws on the flange that holds the fuel filler pipe. Pull out the pipe with its rubber seal and check valve.

Scheme 484

1. Remove the screw
2. Remove the clamp. NOTE: Reuse the clamp.

Removing the clamp

1. Squeeze the clamp using a pipe wrench. Hold in place
2. Pry apart using a small screwdriver
3. Disconnect the hose
4. Remove the cable harness
5. Install the pressure sensor on the new fuel tank, route the cabling as before.

Installing the clamp

1. Squeeze the clamp using a pipe wrench until it locks.

Scheme 485

Remove the nuts securing

1. The level sensor. Use wrench «9995486»(ref-403953-S07991867542011061000000)
2. The fuel pump (FP) unit. Use wrench «9995485»(ref-403953-S37993232752011061000000) .

Scheme 486

1. Lift out the fuel pump (FP) unit and level sensor.

1. Remove the seals.

Installing the fuel tank

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

Scheme 487

When installing a new fuel tank use new nuts. When servicing the fuel tank use the old nuts as the material expands. Failure to do so may result in fuel leakage.

Components to be replaced when installing a new fuel tank

1. The level sensor nut (white)
2. The gasket for the level sensor nut
3. Fuel pump (FP) nut (black)
4. The gasket for the fuel pump (FP) nut
5. The gasket for the fuel filler pipe.

Transfer the reinforcement plate from the underside of the old fuel tank to the new fuel tank. Transfer the protective plate from the left-hand side of the old fuel tank to the new fuel tank. Tighten to 10 Nm .

Installing fuel pump (FP) / level sensor

1. Lubricate the inside and upper surface of the fuel pump (FP) unit and level sensor seal using petroleum jelly
2. Install the seals.

Scheme 488

Install

1. The fuel pump (FP) unit
2. The level sensor.

Note. Check the seating of the fuel pump (FP) unit and level sensor as shown in the illustration.

1. Install the heater connector on the right and the level sensor with its cable on the left, see arrow in (Scheme 488).

Scheme 489

1. Tighten the large nut. Tighten to 40 Nm
2. Tighten the small nut. Tighten to 30 Nm
3. Check that cable is routed from the level sensor as shown in the illustration.

Installing the fuel filler pipe

1. Install the rubber gasket on the fuel tank connector
2. Lubricate the inside of the seal and the lower end of the filler pipe if necessary
3. Check that the check valve is seated correctly with its flap in position on the pipe (shake the tank and listen to ensure that it does not rattle)
4. Press the pipe firmly into the seal so that it slides into position.

Install

1. The filler pipe flange
2. The screws. Tighten to 10 Nm
3. The hose for the shut off pipe.

A new fuel tank has been introduced. See " Service Bulletin 23-0047".

1. Position the fuel tank on the jack
2. Use the same fixture and lifting table as for removing it
3. Lift the tank slightly.

Installing the fuel lines

1. Lubricate the delivery and return connectors lightly using petroleum jelly
2. Install the delivery and return lines on the fuel pump (FP) unit. The delivery pipe is marked yellow. The pump has a corresponding color marking
3. Install the connectors straight onto the lines. Press down towards the flat surface of the pump. Do not damage the O-rings. NOTE: Ensure that the lines are correctly positioned.
4. Position all the cables in the clip on top of the fuel tank. Lock the clip.

Scheme 490

1. Raise the fuel tank so that the front holder can be installed on the bracket. Position hoses and wiring in the holder. Lock the holder by pressing it until it locks securely onto the bracket
2. Ensure that the wiring routed through the hole at the fuel pump (FP) unit will not be trapped when the fuel tank is installed
3. Raise the fuel tank. Secure the fuel tank to the bodywork. Tighten to 25 Nm
4. Install the EVAP canister shut-off valve hose in the clamp on the fuel tank. Install the hose, air cleaner (ACL) and shield onto the fuel filler pipe. Use 4 tie straps.

1. Install the connector / inlet on the EVAP canister. Check that its catch engages.

Scheme 491

1. Check that the inner rubber seal is correctly seated and that the drain pipe is inside the inner seal
2. Check that the snap ring (1) is in position
3. Lubricate the sealing surfaces (2) of the rubber cover with petroleum jelly
4. Install the rubber cover (ensure that it is correctly seated on the bodywork)
5. Install the snap ring (4) and drain pipe (3).

1. Check that the fuel tank is centered in the holes
2. Connect all the connectors. WARNING: Install the ground lead for the fuel filler pipe onto level sensor cover
3. Install the rubber bracket around the wiring
4. Install panels, covers and carpets.

Note. When filling the tank after replacing it: fill the first 8 liters slowly (maximum 15 l/min). Failure to do so may result in fuel spillage.

Fuel tank, replacing (B5234T3; B5244T3; 2001-2004)

1. For V70 (not AWD), see «Fuel tank, replacing»(ref-406871-S14195952972011070100000)
2. For V70 (AWD), see «Fuel tank, replacing»(ref-441137-S06646055012011121500000)

In the passenger compartment

Remove

1. the backrest. See «The backrest»(ref-441129-S41208196852011121500000)

Scheme 492

Remove

1. the insulation panel.

Scheme 493

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.

Viscous/AOC coupling

Remove the clutch. See Clutch (AOC), replacing

Scheme 494

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.

Exposing the fuel tank

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 cables from the rear brakes. See «Replacing brake cables»(ref-441139-S12307757012011121500000)
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 central heat deflector plate in the transmission tunnel
8. the hose clamps, fuel filler pipe and the shut-off pipe at the fuel tank.

Scheme 495

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.

Transferring components

Transfer

1. the right-hand level sensor and pump. See: «Replacing the right-hand level sensor and pump»(ref-407124-S41145338192011070100000)
2. the left level sensor. See «Level sensor, fuel tank, left, replacing»(ref-407124-S18833343072011070100000)
3. the fuel tank pressure sensor, see «Pressure sensor, fuel tank, replacing»(ref-407124-S25387722992011070100000) (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
5. NOTE: Install the screw clips so that they can be easily tightened.
6. Tighten the screws for the tank retaining strap. Tighten to 25 Nm
7. Remove the mobile jack.

Install

1. the central heat deflector plate in the transmission tunnel
2. the fuel filter with the bracket Tighten to 25 Nm
3. The ABS wiring in the clips on the fuel tank
4. 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
5. the brake cables at the rear brakes. See «Replacing brake cables»(ref-441139-S12307757012011121500000)
6. the plastic pipe between the canister purge (CP) valve and the carbon filter container in the clip on the fuel tank
7. the plastic pipe with the largest connection to the carbon filter container. A "click" must be heard.

Install the coupling. See Clutch (AOC), replacing

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-441129-S41208196852011121500000)
5. fold down the rear seat cushion.

Scheme 496

Drain the fuel injection system. See Fuel system pressure release .

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

Scheme 497

Remove the upper section of the intake manifold. Cover the hole using tool 9995723 . Only applies B6xx4S engines .

Remove the fuel rail.

Disconnect the connectors from the injectors.

Remove the mounting screws from the fuel rail.

Separate the fuel line's quick-release connector, see also: Fuel line, lock . Use tool 9512666 .

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

Scheme 498

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 O-ring for the new injector using petroleum jelly.

Install the injector.

Installing the pulsation damper

Lubricate the O-ring for the new pulsation damper using petroleum jelly.

Install the 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.

Press down the fuel rail. Check that all injectors are correctly positioned.

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

Install all connectors on the injectors.

Press the quick-release connector together until a clicking sound is heard. See Fuel line, lock .

Applies only to B6xx4T . Remove the seals. Install the plastic pipes between the turbocharger (TC) / charge air cooler (CAC) and the air cleaner (ACL) / turbocharger (TC).

Applies only to B6xx4S engines . Remove tool 999 5723. Clean the gasket faces and install a new gasket . Install the upper section of the intake manifold. Tighten to 17 Nm . Start from the center and tighten alternately.

Installing injectors and pulsation dampers

Lubricate the injector O-rings with lubricant 116 1580.

Install the new injector.

Note. If the fuel nozzle has worked loose from the injector, a new injector must be used.

Lubricate the new pulsation damper O-ring with lubricant 116 1580.

Install the new pulsation damper.

Installing the mounting rail

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

Scheme 499

Press the fuel rail down. Ensure that all injectors locate correctly.

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

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

At the same time connect all the connectors to the injectors.

Reinstall the cover over the fuel rail.

Start the engine. Check for fuel leakage.

Replacing fuel pressure regulator

Special tools

9995533

9995972

Scheme 500

1. Drain fuel system

5-door cars

1. remove all floor hatches and fold back carpet.
2. remove cover over fuel pump (FP) unit.

4-door cars

1. fold forward right rear seat
2. remove cargo compartment carpet.
3. fold back corner of wheel housing panel at shock absorber mounting.
4. Remove cover over fuel pump (FP) unit.

Scheme 501

1. Carefully disconnect quick-release connector on return line from fuel pump (FP) unit.
2. The return line is not marked in yellow.

Use tool 9995533 . Slide outer sleeve of connector upward. Avoid squeezing sleeve.

Scheme 502

1. Disconnect all connectors on the bracket.
2. Ensure that all cables routed through the fuel pump (FP) unit hole are free to follow the fuel tank when it is lowered.

Removing fuel filler pipe

1. Remove circlip securing rubber seal.
2. Release rubber seal from bodywork.

Scheme 503

1. Remove the fuel line rail
2. Disconnect fuel lines from holders.

Scheme 504

1. Remove the hose connected to the pressure regulator reference air connector.
2. Disconnect delivery pipe from fuel line by engine.
3. Disconnect delivery pipe from fuel filter.
4. Remove return line from bracket above the fuel filter.

Removing fuel tank

1. Position mobile jack with fixture «9995972»(ref-403953-S08076234722011061000000) under fuel tank, check that the lifting platform is flat so as not to damage the fuel tank.
2. Undo tank retaining straps and lower tank slightly.

Scheme 505

1. Undo the front fuel line bracket.
2. Lower fuel tank further.

Scheme 506

1. Undo the upper fuel line bracket.
2. Remove the old pressure regulator.
3. Connect the new pressure regulator quick-release connector to the fuel pump (FP) unit and route it forward along the delivery line.
4. Install fuel lines and cables in the upper bracket.

Scheme 507

1. Raise the tank so that fuel lines and electrical cables can be installed in the front mounting.
2. Install fuel lines and cables in the front bracket.
3. Arrange cables running through the fuel pump (FP) unit hole so that they are not trapped when the tank is installed.
4. Raise the fuel tank and fix it to the bodywork.

Installing pressure regulator

1. Install the return line in the bracket above the fuel filter.
2. Connect delivery pipe quick-release connector to fuel filter.
3. Install fuel lines in holders.
4. Connect delivery pipe to fuel line by engine.
5. Connect reference air hose to pressure regulator.
6. Locate cable fuel line rail lengthwise.
7. Press fuel lines into place in fuel line rail.
8. Hold fuel line rail against the floor of the car and tighten.

Installing fuel filler pipe

1. Install filler housing around top of filler pipe.
2. Check that the inner rubber seal is correctly seated and that the drain pipe is inside the inner seal.
3. Check that circlip (1) is in position. Lubricate rubber cover sealing surfaces (2) with petroleum jelly. Install cover and circlip (4).
4. Connect connectors to fuel pump (FP), level sensor, ABS sensors and fuel tank pressure sensor.
5. Install panels and carpets.

Replacing fuel tank pressure sensor

Special tools

9995972

5-door cars

1. Remove all floor hatches and fold back carpet.
2. Remove cover over fuel pump (FP) unit.

4-door cars

1. Fold forward right rear seat
2. Remove cargo compartment carpet.
3. Fold back corner of wheel housing panel at shock absorber mounting.
4. Remove cover over fuel pump (FP) unit.

Disconnect connectors

1. Disconnect all connectors on the bracket.
2. Remove rubber bracket around wiring.
3. Remove fuel filler pipe ground lead from nut on fuel tank level sensor cover.
4. Ensure that all cables routed through the fuel pump (FP) unit hole are free to follow the fuel tank when it is lowered.

1. Remove the screw Removing clamp: squeeze clamp with a pipe wrench. Hold in place pry apart with a small screwdriver. NOTE: It is reusable.
2. Remove clamp NOTE: The clamp will be reused Removing clamp: squeeze clamp with a pipe wrench. Hold in place pry apart with a small screwdriver. NOTE: It is reusable.
3. Disconnect hose. Installing clamp: Press in the clamp with a pipe wrench until it locks.
4. Remove cable harness. Installing clamp: Press in the clamp with a pipe wrench until it locks.
5. Install the new pressure sensor, route cabling as before. Installing clamp: Press in the clamp with a pipe wrench until it locks.

Installing fuel tank

1. Raise the fuel tank so that the front holder can be installed to the bracket by pressing it until it locks into place.
2. Ensure that cabling routed through the fuel pump (FP) unit hole will not be trapped when the fuel tank is installed.
3. Raise the fuel tank and fix it to the bodywork.
4. Install EVAP canister shut-off valve hose in the clamp on the fuel tank.

Installing rubber cover on fuel filler pipe

1. Check that the inner rubber seal is correctly seated and that the drain pipe is inside the inner seal.
2. Check that circlip (1) is in position.
3. Lubricate rubber cover sealing surfaces (2) with petroleum jelly.
4. Install rubber cover (ensure that it is correctly positioned in relation to bodywork).
5. Install circlip (4) and drain pipe (3).
6. Connect all connectors and install fuel filler pipe ground lead.
7. Install rubber bracket around wiring.
8. Install panels, covers and carpets.

Scheme 508

1. Remove left side fuel gauge sensor as described in «Left fuel gauge sensor»(ref-441137-S32941703782011121500000)
2. Attach a piece of string or steel wire onto attachments for wire and tube system on left side fuel gauge sensor.

Scheme 509

1. Remove hatch and seal from fuel pump
2. Loosen fuel pipe
3. Loosen fuel pump lock ring using special tool «9995720»(ref-403953-S31506353462011061000000)
4. Pull up fuel pump to position 1 (see illustration) and release plastic tube.

Scheme 510

1. Turn fuel pump to position 2 (see illustration)
2. Hold float against pump housing, then turn fuel pump forwards and lift it up
3. Pull wire and tube system out using string or steel wire.

Scheme 511

1. Remove fuel pump with wire and tube system
2. Release six clamps. Note clamp positions
3. Position fuel pump correctly, loosen fixings and push level sensor up.

Level sensor with cable and pipe system

1. Position level sensor and press firmly
2. Pull out wire next to wire and tube system and install clamps. Note clamp positions.

Right side fuel pump with level sensor

1. Attach a piece of string or steel wire onto attachments for wire and tube system on left side fuel gauge sensor
2. Install wire and tube system into fuel tank
3. Pull wire and tube system towards opening for left side level sensor, and feed through.

1. Loosen plastic tube from slot in pump housing
2. Hold float against pump housing and install fuel pump in position 2 (see illustration).

1. Turn fuel pump to position 1 (see illustration)
2. Press plastic tube firmly into slot in pump housing
3. Press fuel pump down in hole
4. Install lock ring and tighten by hand.

Note. Markings on cover and fuel tank.

1. Tighten lock ring using special tool «9995720»(ref-403953-S31506353462011061000000) .
2. Install seal and hatch onto fuel pump.

1. Remove rear seat as described in «Rear seat assembly»(ref-441129-S19189862722011121500000)
2. Remove insulation
3. Fold floor mat in boot under.

Scheme 512

1. Remove level sensor cover
2. Disconnect connector
3. Loosen level sensor lock ring using special tool «9995720»(ref-403953-S31506353462011061000000)
4. Remove level sensor. It is easier if the fuel pipe bends upwards through the hole
5. Disconnect the 2 connectors from the level sensor
6. Loosen tube system by pressing release button down
7. Remove level sensor.

Fuel gauge sensor

1. Position level sensor correctly
2. Install a new rubber seal
3. Connect the 2 connectors to the level sensor
4. Press tube system onto level sensor
5. Carefully position level sensor down with tube system and wires
6. Install level sensor attaching ring but do not tighten it
7. Press level sensor into position. Note position marks on cover and tank
8. Tighten lock ring, first by hand and then using special tool «9995720»(ref-403953-S31506353462011061000000)
9. Install wire in rubber seal slots
10. Connect the connector
11. Install level sensor cover
12. The rest of the section is done in reverse order.

Additional information

To replace fuel gauge sensor on right side, see Right side fuel pump with level sensor .