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

General Data

Scheme 167

Bore (D) in mm

Scheme 168

Piston diameter (D)

Scheme 169

Piston running clearance (example)

Piston rings

Scheme 170

Axial clearance

Compression ring dimension

Dimension, three piece oil ring

Piston pin

Scheme 171

Valve crown diameter (A)

Valve stem diameter (B)

Valve stem diameter (B1)

Valve stem diameter (B2)

Total valve length (C)

Disc edge height (D)

Mating surface angle (E)

Scheme 172

Valve stem vertical position

Scheme 173

Angles

Scheme 174

Tappets, dimensions

Valve springs

Valve springs, dimensions

Scheme 175

Clearance between new components

Maximum play for used components

Camshafts

Scheme 176

Maximum out-of-true

Scheme 177

Crankshaft

Scheme 178

Big end journals

Main bearing journals

Scheme 179

Connecting rods

Note. Blow the fracture surface clean using compressed air before reinstalling the cap.

Engine Oil

Filling with oil after reconditioning.

Oil volume including oil filter

Oil grade

Oil pressure (minimum)

Thermostat

Fuel Line Pressure

Install Switches, Steering Wheel Covers And Steering Wheel

2 Torx 20 screws in the switches.

3 Torx 20 screws in the steering wheel covers.

If the steering wheel was not installed straight, it must not be turned on the steering column. Carefully remove the steering wheel and try again.

Install Center Screw

Scheme 180

Remove screw from lock position (B) and install it in the parking position (A). Do not detach the screw from the plastic strip.

The contact reel is now unlocked (unsecured) and the steering wheel can be turned.

Align Front Wheels

Drive the car straight forwards or backwards on a level surface so that the wheels point straight ahead.

Carefully turn the steering wheel and check that it can be turned to full lock in each direction.

If the steering wheel is not straight

Start again from removing the steering wheel and aligning the wheels.

If the steering wheel will not turn to full lock

Start again from removing the steering wheel. (The contact reel probably needs to be zeroed.)

Tighten Steering Wheel Screws

2 Torx 30 screws. Tighten to 10 Nm .

Scheme 181

Note. Do not forget to replace the steering wheel module decal on the driver's side B-post with a new decal.

The date decal is supplied with the new passenger airbag module.

Scheme 182

Check

Check that

1. the steering wheel can be turned easily.
2. the horn is working by pressing the four corners of the steering wheel module.
3. the SRS indicator lamp in the combined instrument panel is not lit all the time. If the lamp is lit see the appropriate SRS Airbag diagnostic service information.

Note. Check that the SRS indicator lamp is intact by turning the key to position II. The SRS indicator lamp should light and go out after approximately 15 seconds.

Taking Fuel Pressure Readings While Driving The Car

Special tools

9995011

9512614

9812270

9812273

9812282

Scheme 183

Corrective actions

1. Assemble fuel pressure gauge «9995011»(ref-403953-S13051471402011061000000) and new adapter hose 951 2614 .
2. Use foam wrapping around the fuel pressure gauge and all metal joints to avoid scratching the interior of the car or damaging the exterior paintwork.

Scheme 184

Corrective actions

1. Remove protective cap from the fuel pressure line nipple.
2. Install the adapter hose nipple loosely on the nipple on the fuel pressure line. The nipple will be tightened later.
3. Arrange hose as shown in the illustration.

Scheme 185

1. Install the T-valve to the left door mirror using tape. NOTE: Protect the door mirror and wing edge with foam protection as shown in the illustration.

Scheme 186

The unit must be operating when the measuring equipment's hose is connected to the engine in order to reduce the risk of fuel spillage.

Corrective actions

1. Connect the fuel drainage unit hose to the T-valve on the door mirror (position 3 in illustration).
2. Turn the T-valve cock to the middle position (position 2 in the illustration).
3. Start the evacuation unit to get suction in the measurement unit hose to the engine.

Scheme 187

Corrective actions

1. Tighten nipple on fuel rail.

Scheme 188

1. Turn the T-valve cock so that it is pointing toward the engine (position 1 in the illustration) to shut off the suction from the evacuation equipment.

Scheme 189

1. Use a tie strap to lock the cock in the position toward the engine.

Scheme 190

1. Remove the draining unit hose from the T-valve hose connector.
2. Turn off the evacuation unit when the hose is empty.
3. Arrange the measuring equipment hose along the rubber list on plenum chamber cover at the left bonnet hinge in such a position that the hose and bonnet are not damaged (as shown in illustration).
4. Carefully close the hood.

Scheme 191

Corrective actions

1. Start the engine.
2. Drive the car and read off fuel pressure while the car is being driven. The fuel pressure should be: 375-395 kPa (54.4 - 57.3 psi) .

Scheme 192

Corrective actions

1. Connect the evacuation unit hose to the hose nipple on the door mirror (see black arrow in illustration).
2. Start the evacuation unit so there is suction in the hose.

Corrective actions

1. Remove the tie strap locking the cock on the T-nipple.
2. Turn the cock to the middle position (position 2) to obtain suction in the hose to the nipple in the fuel manifold on the engine.

Temperature And Pressure Sensor, Replacing

Manifold absolute pressure (MAP) temperature sensor

V70 2000

1. For B5xx4T -2004, see «Intake Air Temperature Sensor (IAT Sensor), replacing»(ref-406817-S30526609542011070100000)
2. For B5xx4T 2005-, see «Temperature and pressure sensors, replacing»(ref-406817-S04045610112011070100000) .

V70 2000

1. For D5244Tx, see «Thermostat, replacing»(ref-406868-S14377672482011070100000) .

Manifold absolute pressure (MAP) sensor

V70 2000-, V70

1. For B5xx4T, see «Manifold absolute pressure (MAP) sensor, replacing»(ref-406817-S00311517172011070100000) .

V70 2000

1. For D5244Tx, see «Manifold absolute pressure (MAP) sensor, replacing»(ref-406817-S00311517172011070100000) .

Preparation

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

Scheme 193

1. Remove the engine cover by pulling it straight up
2. Remove the expansion tank cap
3. Install a hose clamp on the upper coolant hose
4. Raise the car. Remove the lower splash guard
5. Position a container under the engine drain cock. Drain approximately 2 liters of engine coolant. Close the cock
6. install the lower splash guard. Lower the car.

Removing The Temperature Sensor

Remove the upper timing belt cover.

Remove the temperature sensor. Use tool 9512885 .

Clean the temperature sensor mating surfaces.

Installing The Temperature Sensor

Install

1. a new temperature sensor. Use a new gasket . Tighten to 22 Nm
2. use tool «9512885»(ref-403953-S00557342822011061000000)
3. the connector for the sensor cable
4. the upper timing belt cover.

Scheme 194

Lift up servo reservoir and place on top of engine. Ensure that oil leaks out of the ventilation hole in the cover. Relieve the load on the auxiliaries belt tensioner. Remove the belt.

Remove

1. the clamp on the pressure line for the power steering pump
2. the stay at the rear of the power steering pump
3. the 3 screws holding the power steering pump
4. the power steering pump and place it to one side.

Scheme 195

Remove

1. the connector for the sensor on the thermostat housing
2. the 2 screws for the thermostat housing, the lower screw through the upper hole in the bracket
3. the thermostat housing and gasket.

Detach the sensor using sleeve 9512885 . Transfer it to the new housing. Tighten to 20Nm .

Installing The Thermostat

Install

1. a new thermostat housing. Use a new gasket . Tighten the screws. Tighten to 17 Nm
2. the connector on the sensor
3. the power steering pump. Tighten the screws. Tighten to 24 Nm
4. the stay at the rear edge of the power steering pump
5. the clamp on the pressure line for the power steering pump
6. the auxiliaries belt
7. the servo reservoir.

Finishing

Remove the hose clip.

Fill with coolant.

Install the cap on the expansion tank.

Engine Coolant Temperature Sensor, Replacing

V70 2000-, V70

1. For B5xx4x -2001, see «Thermostat / temperature sensor, engine coolant, replacing»(ref-406880-S41161998922011070100000)
2. For B5xx4x 2002-2004, see «Replacing the thermostat and/or engine coolant temperature sensor»(ref-406880-S13577915242011070100000)
3. For B5xx4Tx 2005-, see «Thermostat / temperature sensor, engine coolant, replacing»(ref-406880-S19835938232011070100000) .

Reference

Reference phase for leakage, and operating check of the leak diagnostic unit (DMTL), is in progress.

If no fault is detected during this phase, the check for major leakage starts.

If a fault is detected during this phase the test is stopped and the parameter "DMTL, test status" shows "Fault Found". The diagnostic trouble code (DTC) for the detect fault is stored in the Engine control module (ECM).

Major Leak

Investigation of the fuel tank system in progress.

If no fault is detected during this phase, the check for minor leakage starts.

If leakage is detected during this phase the test is stopped and the parameter "Tank system test result" shows "Major leak found". The diagnostic trouble code (DTC) is stored in the Engine control module (ECM).

Minor Leak

Investigation of the fuel tank system in progress.

If leakage is detected during this phase the test is stopped and the parameter "Tank system test result" shows "Minor leak found". The diagnostic trouble code (DTC) is stored in the Engine control module (ECM).

Not In Progress

Leakage diagnosis not in progress. Quick-test tank system has not started, has been finished, or has been blocked.

Reference phase for leakage, and operating check of the leak diagnostic unit (DMTL), is in progress.

If no fault is detected during this phase, the check for major leakage starts.

If a fault is detected during this phase the test is stopped and the parameter "DMTL, test status" shows "Fault Found". The diagnostic trouble code (DTC) for the detect fault is stored in the Engine control module (ECM).

Investigation of the fuel tank system in progress.

If no fault is detected during this phase, the check for minor leakage starts.

If leakage is detected during this phase the test is stopped and the parameter "Tank system test result" shows "Major leak found". The diagnostic trouble code (DTC) is stored in the Engine control module (ECM).

Investigation of the fuel tank system in progress.

If leakage is detected during this phase the test is stopped and the parameter "Tank system test result" shows "Minor leak found". The diagnostic trouble code (DTC) is stored in the Engine control module (ECM).

Leakage diagnosis not in progress. Quick-test tank system has not started, has been finished, or has been blocked.

General

Increasing demands for further functionality in the vehicle, both by statutory requirement and customers, have led to an increased complexity in the vehicle.

This, in turn, has encouraged developments towards more flexible electrical systems. The CAN-net (Controller Area Network) is a result of this research. The network permits the transmission and receipt of a large number of different commands and messages on the same wiring. Every command or message used to require a separate cable. Using networks has allowed functionality to be expanded without increasing the number of cables.

The number of commands and messages which can be handled on the network depends on factors such as the network speed and the length of the message or command. The Volvo network which is based on a control area network (CAN), can transmit over 500 different signals and approximately 100 messages. These messages are also called frames. Each message can contain several signals.

Advantages Of A Network

Easier to add further functions and install accessories

Because the control modules in the network are already connected to each other and are easy to add more information to, all that is required is

1. To connect the sensors to the nearest control module
2. To connect the controlled component to the nearest control module
3. To download software to the control module to modify the configuration.

The length of the wiring and the number of components which are introduced with the car is less than previously.

An example of this is the addition of cruise control for the car.

Before the introduction of the network the installation of control modules, switches, vacuum pumps, vacuum servos, hoses and cable harnesses was necessary.

With the network all that is required is the installation of a switch and the downloading of software which alters the configuration of the car.

Easier to introduce logical functions

Logical functions can be explained as "If this occurs then the following corrective action must be carried out". For example, the system is programmed so that if a tail light is broken, a message is transmitted via the control area network (CAN) to the driver information module (DIM) to warn the driver.

All that is required to introduce a logical function is to change the programming of the affected control module - the central electronic module (CEM) and driver information module (DIM) in the example above. Introduction of logic functions does not increase the number of components or cables.

Easy to adapt the system to customer and market requirements

The functions can be modified depending on the requirements of the customer and market. An example of this could be fog tail lamps. Certain markets use two fog tail lamps, others only use one on the driver's side. Previously it was required that different replacement parts were stored for different markets. Now the same replacement part can be used for all markets, by changing the programming depending on the market.

Similar basic systems can be used for a whole model program

Similar networks (hardware) can be used for a large number of different cars.

The only thing which differentiates the cars is

1. Which components (control modules, sensors controlled components etc.) are connected to the system
2. Which components do what
3. Which components/functions are standard /optional/accessories
4. Configuration/programming of the system.

Thermostat, Replacing (B5234T3; B5254T2; B5254T4; 2003-2004)

V70 2000

1. For B5xx4Tx 1999-, see «Thermostat / temperature sensor, engine coolant, replacing»(ref-406880-S41161998922011070100000)
2. For B5xx4Tx -2002, see «Replacing the thermostat and/or engine coolant temperature sensor»(ref-406880-S13577915242011070100000)
3. For B5xx4Tx 2005-, see «Thermostat / temperature sensor, engine coolant, replacing»(ref-406880-S19835938232011070100000) .

Throttle Body (Electronic Throttle Module (ETM)), Replacing

S60, V70 (00-), S80 (-06)

1. For B5xx4Sx -2003, see «Throttle body (electronic throttle module, ETM), replacing»(ref-406881-S23065213692011070100000) .
2. For B5xx4Sx 2003-, see «Throttle body (electronic throttle module (ETM)), replacing»(ref-406881-S17263126822011070100000) .
3. For B5xx4Tx -2001, see «Throttle body (electronic throttle module (ETM)), replacing»(ref-406881-S39360642122011070100000)
4. For B6xx4Sx, -2001, see «Throttle body (electronic throttle module (ETM)), replacing»(ref-406883-S19533382912011070100000)
5. For B6xx4Tx -2001, see «Throttle body (electronic throttle module (ETM)), replacing»(ref-406883-S11365620592011070100000)

C70 Coupe (-03), C70 Conv (-05), S70, V70 (-00) and V70 XC (-00)

1. For B5xx4Tx -2002, see «Replacing the throttle body (electronic throttle module)»(ref-441122-S03705348002011121500000)

C70 Coupe (-03), C70 Conv (-05), S70, V70 (-00)

1. For B5xx4Sx, see «Replacing electronic throttle module (ETM)»(ref-441137-S16495753752011121500000)

Throttle Body (TB), Cleaning (B5234T3; B5244T3; 2001-2004)

S60, V70 (-00), V70 XC (01-) / XC70, S80 (-06)

1. For -2004, see «Throttle body, cleaning»(ref-406870-S13069261692011070100000)
2. For 2005- B5xx4T, does not apply to B5244T5, see «Throttle body (TB), cleaning»(ref-406870-S07975894692011070100000)
3. For 2005- B5244T5, see «Throttle body (TB), cleaning»(ref-406870-S34333953322011070100000) .

S70, V70 (-00) and V70 XC (-00)

1. For 1999 and 2000, see «Crankcase ventilation and electronic throttle module (ETM), cleaning»(ref-406819-S38798362832011070100000)

Throttle Body (TB), Cleaning (B5244S; B5244S6; 2001-2004)

S60, V70 (00-), S80 (-06)

1. For B5xx4S 2003-, see «Throttle body, cleaning»(ref-406870-S23694741192011070100000)
2. For B5xx4S -2002, see «Cleaning throttle body (ETM) DENSO»(ref-406870-S07954817842011070100000)

C70 Coupe (-03), C70 Conv (-05), S70 and V70 (-00)

1. For B5xx4S -2000, see «Cleaning throttle body (ETM) DENSO»(ref-406870-S07954817842011070100000)

Removing The Front Timing Cover

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

Scheme 196

Loosen hose thermostat housing-expansion tank from the thermostat housing by pressing in the locks, then press in the connection against the thermostat housing, then pull out the connection.

Scheme 197

Note. Make sure that the belt cover has cleared the nipple on the thermostat housing before the cover is pulled up, to prevent damaging the nipple.

Remove

1. the air duct, cover, surround and control module box
2. the hose between the thermostat housing and the expansion tank
3. the front timing belt cover.

Scheme 198

Note. Make sure that the belt cover is in position before the cover is pressed in against the rear timing casing, to prevent damage to the nipple on the thermostat housing.

Install

1. the front timing belt cover
2. the hose between the thermostat housing and the expansion tank
3. the surround, cover and air ducts for the control module box.

Scheme 199

Continuous variable valve timing (CVVT) control, general

The engine combustion can be improved by changing the shift angle of the camshaft. This reduces emissions, gives lower fuel consumption and better performance. The shift angle of the camshaft is controlled by the control module which changes the pulse ratio of the reset valve. The pulse ratio of the reset valve affects the variable valve timing unit which changes the camshaft position compared to the crankshaft position (CKP). This ensures quick and precise control of the shift angle of the camshaft.

Definition of "Camshaft shift angle" (X°)

When the camshaft (A) is set at the factory it is aligned to top dead center (TDC) on the crankshaft which is 0° (B). The camshaft position when aligned to the crankshaft TDC is the camshaft 0 position (0°). With continuous variable valve timing (CVVT) the camshaft 0 position is offset, the value of the offset of the camshaft 0 position is the camshaft shift angle (x°).

Scheme 200

The control module interpretation of camshaft shift angle

(The illustration shows the camshaft shift angle at 10°)

The camshaft shift angle is checked by the control module by comparing the position of the crankshaft with the position of the camshaft.

The camshaft (A) is divided into 4 flanks per camshaft rotation (flanks 1-4). The angles are: between flanks 1-2 = 103°, flanks 2-3 = 90°, flanks 3-4 = 90° and flanks 4-1= 77°. The difference in angle between the flanks allows the control module to determine which flank is currently detected and therefore which cycle the camshaft is in. The control module detects the flanks using the signal from the camshaft position (CMP) sensor.

The crankshaft has four reference positions, one for each camshaft flank. Two reference positions are detected for each crankshaft rotation. Two engine rotations are required to detect all the camshaft flanks: flank 1 at 0°, flank 2 at 206°, flank 3 at 386° and flank 4 at 576° (flanks 3 and 4 are detected during the second rotation of the engine).

The reference positions on the crankshaft correspond exactly to the respective camshaft flank when the camshaft shift angle = 0°. The control module detects the reference positions for the camshaft flanks using the engine speed (RPM) sensor signal.

If, for example, the camshaft shift angle is +10°, the flanks correspond to the crankshaft reference positions for the respective camshaft flank and +10° from the crankshaft reference positions.

Example

If the camshaft flank 1 is detected at 10° from the crankshaft reference position for flank 1 (0° +10°), the camshaft shift angle is 10°. If the camshaft shift angle is the same (10°), flank 2 is detected at 216° (206° + 10°), flank 3 at 396° (386° + 10°), and flank 4 at 576° (586° + 10°). The shift angle can be positive (+) or negative (-) depending on whether the flank is detected before or after the different crankshaft reference positions.

Scheme 201

Adaptation of the camshaft shift angle, flanks 1-4

(The illustration shows the adaptation of the camshaft shift angle at 10°)

When the engine has the "basic setting", the ideal value for the camshaft adaptation value is 0°. The different camshaft flanks correspond exactly with the reference positions for the respective flanks. These values may deviate because of tolerances in the materials and installation. By adapting these deviations the camshaft shift angle can be exact.

Adaptation is carried out as follows

Camshaft control not active, the pulse ratio on the camshaft reset valve is set to approximately 90% by the control module. This means that the camshaft 0 position (mechanical resting position) is assumed and the camshaft angles (x°) for flanks 1-4, which are then detected by the control module, are the adaptation values which are stored. (The adaptation values will be 0° if the camshaft adjustment in relation to the crankshaft is exact). When the control module operates the camshaft to a particular target value, the stored adaptation value is added to the control module's target value.

Example: The control module has adapted flanks 1-4 to an average value of +10° (as the result of an incorrectly set camshaft for example). When the control module needs to operate the camshaft to +10° (target value), the adaptation value is added to the target value which then gives a target value of 20° (10° +10°=20°).

The control module can adapt 20°. A diagnostic trouble code (DTC) is stored in the control module if the adaptation is higher or lower than 10°.

Other information

1. If the timing belt is incorrectly positioned by one tooth on the variable valve timing unit, this corresponds to approximately 17° on the crankshaft. This gives a theoretical adaptation value of 17°.
2. If the timing belt is incorrectly positioned by one tooth on the variable valve timing unit, this corresponds to approximately 34° on the crankshaft. This gives a maximum adaptation value (20°)
3. The setting of the variable valve timing unit in relation to the camshaft and crankshaft affects the adaptation value (between -20° and +20°)
4. If the slide in the camshaft reset valve has jammed, the camshaft will be operate at maximum angle. This which will give an adaptation value at the maximum limit (+20° or -20°)
5. The function of the variable valve timing unit affects the adaptation value (between -20° and +20°).

Variable Valve Timing Solenoid, Replacing

V70 2001

1. See «REPLACING THE VARIABLE VALVE TIMING SOLENOID»(ref-441137-S18361606522011121500000) .

Scheme 202

Applies only to B6XX4T

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

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

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

Scheme 203

Remove

1. the upper timing belt cover. Disconnect the control valve connector.

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

1. the screws holding the valve
2. the control valve and the gasket.

Installing The Variable Valve Timing (VVT) Control Valve

Clean the gasket faces. Note the cleanliness requirements above.

Install a new gasket .

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

Connect the connector.

Install the upper timing belt cover.

Applies only to B6xx4T

Install the seals.

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

Tighten all the hose clamps.

Variable Valve Timing Unit, Checking And Adjusting (B5234T3; B5244T3; 2001)

Special tools

9995451

9995456

9995452

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

Installing And Adjusting The Variable Valve Timing Unit/Gear Pulley On The Camshafts.

Note. This procedure must be carried out with precision as any deviation could generate a fault symptom.

Variable Valve Timing Unit, Checking And Adjusting (B5244S; 2001-2007)

Special tools

9995451

9995452

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

Installing And Adjusting The Variable Valve Timing Unit/Timing Gear Pulley On The Camshaft

Note. This element must be carried out with precision as any deviation could generate a fault symptom.

Scheme 204

Remove the mounting screws for the starter motor.

Pull out the starter motor and place it to one side.

Remove the blind cover plug from the hole for the adjustment tool. Turn the crankshaft clockwise slightly.

Install: 9995451 . Ensure that the tool bottoms out against the cylinder block.

Aligning The Crankshaft

Turn the crankshaft counter-clockwise until it stops against the adjustment tool.

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

Installing The Variable Valve Timing Unit On The Camshaft

Note. Oil the center screw before installation.

Push on the variable valve timing unit/timing gear pulley on the camshaft.

Install the center screw (1) which secures the variable valve timing unit to the camshaft. Tighten slightly.

Slacken off, but do not remove the screws (2) which secure the timing gear pulley to the variable valve timing unit.

Turn the timing gear pulley until the screws at the oval holes are in the center position. Tighten the screws (2) slightly.

Turn the variable valve timing unit to its limit position so that the unit is in its end position.

Position the upper timing cover.

Undo the center screw and continue turning clockwise until the timing gear pulley marking aligns with the marking on the upper timing cover.

Tighten the center screw in the variable valve timing unit. Tighten. See: Summary of specific components and tightening torques .

Installing The Timing Belt

Note. Variable valve timing units do not have return springs and are easily thrown out of position when the camshaft belt is installed. Check that the markings align.

Install the belt in the following order

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

Scheme 205

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

At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.

The illustration shows the position of the indicator when aligning the timing belt tensioner at approximately 20 °C/68 °F.

Note. There are two different tensioners depending on model year.

Fix the belt tensioner center screw in position and turn the belt tensioner eccentric counterclockwise until the tensioner indicator passes the marked position and reaches the end position. Then turn the eccentric back so the indicator reaches the marked position shown in the illustration. Tighten the center screw. See Summary of specific components and tightening torques .

Check that the indicator is in the correct position.

Final Check

Remove

1. «9995452»(ref-403953-S02369714572011061000000) from the rear of the camshafts
2. «9995451»(ref-403953-S26663901482011061000000) .

Install

1. the plugs with new sealing washers. Tighten. See: «Summary of specific components and tightening torques»(ref-406973-S28846051262011070100000)
2. the deflection limiter washer on the piston rod for the tensioner/damping unit.

Scheme 206

Position the upper timing cover.

Turn the crankshaft 2 rotations. Check that the markings on the crankshaft and timing gear pulleys correspond.

Remove the upper timing cover.

Variable Valve Timing Unit, Checking And Adjusting (B5XX4TX; 1999-2001)

Special tools

9995451

9995452

Note. This procedure must be carried out with precision as any deviation could generate a fault symptom.

Install the belt in the following order

1. the belt pulley on the crankshaft
2. the idler pulley
3. cam wheel, intake camshaft
4. water pump
5. belt tensioner.

Scheme 207

Turn the variable valve timing unit clockwise to the stop.

Note. Hold the VVT unit fixed in the limit position clockwise when the belt if fitted.

Check that the markings on the belt pulley and the upper timing cover align.

Fit the timing belt over the exhaust camshaft's cam wheel.

Variable Valve Timing Unit, Checking And Adjusting (B5XX4S and B5XX4S2; 2002-)

Special tools

9995451

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

Scheme 208

Remove the starter motor mounting screws. Pull out the starter motor and put it aside.

Remove the blind cover plug for the adjustment tool hole. Turn the crankshaft clockwise slightly. Install the adjustment tool 9995451 . Ensure the adjustment tool bottoms against the engine block.

Turn the crankshaft counterclockwise to its stop against the crankshaft adjustment tool. Check that the marking on the crankshaft timing gear pulley aligns with the marking on the oil pump.

Scheme 209

Press the variable valve timing unit/timing gear pulley onto the camshaft. Install the center screw (1) that holds the variable valve timing unit to the camshaft. Tighten slightly.

Loosen but do not remove the screws (2) holding the timing gear pulley to the variable valve timing unit. Turn the timing gear pulley so that the screws at the oval holes are in the center position and then tighten the screws (2) slightly.

Turn the variable valve timing unit clockwise to its stop so that the unit is in its end position. Install the upper timing cover.

Scheme 210

Undo the center screw and continue turning clockwise until the timing gear pulley marking aligns with the marking on the upper timing cover.

Tighten the center screw in the variable valve timing unit.

Tighten, see: Summary of tightening torques for specific components .

Scheme 211

Note. The variable valve timing units do not have a return spring and are easily dislodged when installing the timing belt. Check that the markings match.

Install the belt in the following order

1. crankshaft
2. idler pulley
3. intake camshaft
4. exhaust camshaft
5. water pump
6. tensioner pulley.

Scheme 212

This adjustment is done on a cold engine. A suitable temperature is approx. 20°C/68°F. At higher temperatures, for example when the engine is hot or in high ambient temperatures, the gauge needle is further to the right.

The position of the needle, when aligning the camshaft belt tensioner at different engine temperatures, is shown in the illustration.

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

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

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

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

Check that the indicator is in the correct position.

Scheme 213

Undo the 3 timing gear pulley screws slightly. Install the center plug in the variable valve timing unit. Tighten following Summary of tightening torques for specific components .

Hold the center plug in place with 25 Nm while the 3 screws on the camshaft timing gear pulley are tightened. See Summary of tightening torques for specific components . This is to ensure that the variable valve timing unit is in its end position when the timing gear pulley is fastened.

Variable Valve Timing Unit, Checking And Adjusting (B6XX4T; 2002-2006)

Special tools

9995451

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

Turn the crankshaft counterclockwise to its stop against the crankshaft adjustment tool. Check that the marking on the crankshaft timing gear pulley aligns with the marking on the oil pump.

Scheme 214

1. Slacken off, but do not remove the screws which secure the timing gear pulley to the VVT unit
2. Press the variable valve timing unit and timing gear onto the camshaft
3. Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly
4. Turn the variable valve timing unit counter-clockwise as far as it will go. Slacken off the center screw
5. Position the upper timing cover
6. 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 cogs before the marking on the upper timing cover NOTE: Do not turn counterclockwise during this procedure.
7. Check that the timing gear pulley is still in the limit position in the oval holes
8. Tighten the center screw in the VVT unit. See «Tightening torque»(ref-406890-S07797727212011070100000) . Check that the variable valve timing unit does not rotate when tightening
9. Install and tighten the center plug according to «Tightening torque»(ref-406890-S07797727212011070100000) .

Scheme 215

Turn the variable valve timing unit clockwise to the limit position. Turn the timing gear pulley so that the markings correspond.

Scheme 216

1. Slacken off, but do not remove the screws which secure the timing gear pulley to the VVT unit
2. Press the variable valve timing unit / timing gear onto the camshaft
3. Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly
4. Turn the variable valve timing unit counter-clockwise as far as it will go
5. Slacken off the center screw
6. Turn the timing belt pulley clockwise until the screws at the oval holes are in the end-position. Continue turning clockwise until the timing belt pulley marking is 2 cogs before the marking on the upper timing casing. NOTE: Do not turn counterclockwise during this procedure.
7. Check that the timing gear pulley is still in the limit position in the oval holes
8. Tighten the center screw in the VVT unit. See «Tightening torque»(ref-406890-S07797727212011070100000) . Check that the variable valve timing unit does not rotate when tightening
9. Install and tighten the center plug according to «Tightening torque»(ref-406890-S07797727212011070100000)

Turn the variable valve timing unit clockwise to the limit position. Turn the timing gear pulley so that the markings correspond.

Scheme 217

Tighten the timing belt tensioner center screw. Tighten to 5 Nm .

Install the belt in the following order

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

The variable valve timing units do not have a return spring and are easily dislodged when installing the timing belt. Check that the markings correspond.

Note. Adjust the timing gear pulleys so that the screws are not at the limit positions in any of the oval holes.

Preparations For Adjusting The Timing Belt

This setting is done on a cold engine. A suitable temperature is approximately 20°C/68°F . At higher temperatures, for example if the engine is warm or ambient temperature is higher, the indicator assumes a position farther to the right. The illustration shows the indicator position at different engine temperatures.

Adjusting The Timing Belt

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

Turn the eccentric back so that the indicator reaches the marked position in the center of the window. Remember to hold the center screw secure at the same time.

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

Check that the indicator is in the correct position.

Check

1. that the timing gear pulley is not in the limit position in the oval holes
2. the timing gear pulley so that the markings line up with the upper timing cover.

Tighten the screws for the timing gear pulleys. See Tightening torque

Checking The Markings And Belt Tension

1. Jerk the camshaft belt to check that the indicator on the tensioner moves easily
2. Position the upper timing cover.
3. Turn the crankshaft two turns. Check that the markings on the crankshaft timing gear pulley and the camshaft timing gear pulley match up with the markings on the oil pump and upper timing cover respectively
4. Check that the indicator on the belt tensioner is within the marked position

Scheme 218

Remove VVT solenoid from camshaft cover.

Blow through center hole with compressed air.

Air should emerge from inner hole (1) nearest coil.

Scheme 219

Connect power to solenoid. Solenoid should click.

Blow through center hole with compressed air.

Air should emerge from outer hole (2).

If plunger is sticking or solenoid fails to operate electrically, the direction of flow will be unchanged from step 1.

Scheme 220

Remove solenoid from aluminum housing.

Scheme 221

Remove

1. snap ring (1)
2. washer (2), spring (3) and plunger (4).

Inspect and clean all parts.

Blow out aluminum housing.

Oil parts with engine oil.

Reassemble solenoid.

Check operation as described in operations 1 and 2.

Reinstall solenoid in car using new seal.