Engine - Removal, Replacement and Installation (Xc): Other Volvo V70 II

Crankshaft seal, rear, replacing

Special tools

9995112

9995651

9991801

9995678

9995676

9512050

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 609

Remove the gearbox

1. For M56 and M58 2000- see «Transmission, removing»(ref-431009-S39305687502011101900000) .
2. For M66AWD 2004- and M66 2005- see «Transmission, removing»(ref-451858-S42679128682012020900000) .

Remove the flywheel / carrier plate. Use gear sector 9995112 as a counterhold when slackening off the screws.

Scheme 610

Note. Do not damage the mating surfaces of the crankshaft and cylinder block

Remove the old seal using extractor 9995651 .

Clean around the crankshaft flange at the front and rear. Remove any thread sealant residue from the screw holes.

If necessary wash off the oil on the rear cylinder block surface and the gearbox clutch housing. Blow clean using compressed air.

Scheme 611

Note. To clean the crankshaft, use cloth 9511024.

Installing the sealing ring

Lubricate the sealing ring mating surface against the cylinder block and the lips of the seal.

Scheme 612

Thread the seal onto the beveled section of the inner section of tool 9997174 with the felt side of the seal outwards. Install the drift on the crankshaft, 2 x screws, for the flywheel. Pull in the seal using the outer section of the drift: 9997174 using the screw in the center of the tool. The seal is in position when the outer drift bottoms out against the inner drift. Remove the tool: 9997174 . Discard the old screws for the flywheel.

Scheme 613

Install

1. the flywheel and carrier plate
2. the 3 studs «9995678»(ref-403953-S14391401472011061000000) distributed as shown in the illustration. Turn the short thread length towards the crankshaft.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel / carrier plate. The position of the guide hole is marked.

1. Align gear sector: «9995112»(ref-403953-S01318438012011061000000) .
2. Pull the flywheel / carrier plate towards the crankshaft using the 3 nuts on special tool «9995678»(ref-403953-S14391401472011061000000) . The turned section of the nut must be turned towards the flywheel / carrier plate.

1. Install the other screws. Tighten. See «Summary of specific components and tightening torques»(ref-430997-S07821985842011101900000)
2. Replace the 3 special screws with new standard screws. Tighten. See «Summary of specific components and tightening torques»(ref-430997-S07821985842011101900000)
3. Then angle tighten all 10 screws crosswise. Use «9512050»(ref-403953-S36645634772011061000000) . Tighten. See «Summary of specific components and tightening torques»(ref-430997-S07821985842011101900000) .
4. Ensure that the flywheel sensor and bracket are installed. Install the clutch driven plate and clutch.

Installing the gearbox

Install the gearbox

1. For gasoline M56 and M58 2000- see «Transmission, installation»(ref-431009-S26387521342011101900000) .
2. For gasoline M66AWD 2004- and M66 2005- see «Transmission, installing (M66AWD 2004- and M66 2005-)»(ref-431033-S17119974052011101900000) .

Checking the engine

Test drive the car to check the function of the engine and the gearbox.

Crankshaft seal, front, replacing

Replace the front crankshaft seal. See Oil pump / crankshaft seal, front, replacing .

Replacing the carrier plate

Special tools

9995112

9995678

Preparatory work

Remove the transmission according to Transmission, removing .

Removing the carrier plate

Remove the engine speed (RPM) sensor with the bracket. Place it to one side.

Scheme 614

Block the carrier plate using gear sector 9995112 .

Remove

1. all screws
2. the carrier plate
3. gear sector «9995112»(ref-403953-S01318438012011061000000) .

Scheme 615

Check the crankshaft seal for leakage.

To replace the crankshaft seal, refer to the appropriate service information.

Scheme 616

Note. Ensure that the mating surfaces on the crankshaft and carrier plate are completely clean.

Use tool 9995678 , which consists of 3 studs with nuts.

Install

1. The 3 studs belonging to tool «9995678»(ref-403953-S14391401472011061000000) , distributed as shown in the illustration
2. the carrier plate.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the carrier plate.

Locate gear sector 9995112 against the carrier plate.

Pull the flywheel towards the crankshaft using the three nuts on special tool 9995678 .

Install 7 new screws. Tighten crosswise. Tighten to 45 Nm .

Remove the 3 nuts and studs.

Install the remaining 3 new screws. Tighten the screws. Tighten to 45 Nm . Then angle-tighten all 10 screws crosswise. Tighten to 50°.

Install the engine speed (RPM) sensor with the bracket. Tighten to 10 Nm .

Finishing

Install the transmission according to Transmission, installation .

Special tools

9995112

9997174

9991801

9995678

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

Removing the flywheel and carrier plate

Remove the gearbox

1. For M56 and M58 2000- see «Transmission, removing»(ref-431009-S39305687502011101900000) .
2. For M66AWD 2004- and M66 2005- see «Transmission, removing»(ref-451858-S42679128682012020900000) .

Remove the flywheel / carrier plate. Use gear sector 9995112 as a counterhold when slackening off the screws.

Removing the seal

Note. Do not damage the mating surfaces of the crankshaft and cylinder block

Remove the old seal using extractor 9995651 .

Clean around the crankshaft flange at the front and rear. Remove any thread sealant residue from the screw holes.

If necessary wash off the oil on the rear cylinder block surface and the gearbox clutch housing. Blow clean using compressed air.

Note. To clean the crankshaft, use cloth 9511024.

Lubricate the sealing ring mating surface against the cylinder block and the lips of the seal.

Scheme 617

Thread the seal onto the bevelled part of the inner section of 9997174 with the felt side of the seal outward.

Screw the drift onto the crankshaft (2 screws) of the flywheel.

Pull in the seal with the outer part of the drift, 9997174 , using the screw in the center of the tool. The seal is in place when the outer drift bottoms against the inner drift. Remove tool 9997174 . Scrap the old flywheel screws.

Installing flywheel and carrier plate

Install

1. the flywheel and carrier plate
2. the 3 studs «9995678»(ref-403953-S14391401472011061000000) distributed as shown in the illustration. Turn the short thread length towards the crankshaft.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel / carrier plate. The position of the guide hole is marked.

1. Align gear sector: «9995112»(ref-403953-S01318438012011061000000) .
2. Pull the flywheel / carrier plate towards the crankshaft using the 3 nuts on special tool «9995678»(ref-403953-S14391401472011061000000) . The turned section of the nut must be turned towards the flywheel / carrier plate.

1. Install the other screws. Tighten. See «Summary of specific components and tightening torques»(ref-430997-S07821985842011101900000) .
2. Replace the 3 special screws with new standard screws. Tighten. See «Summary of specific components and tightening torques»(ref-430997-S07821985842011101900000) .
3. Then angle-tighten all 10 screws crosswise. Use «9512050»(ref-403953-S36645634772011061000000) . Tighten. See «Summary of specific components and tightening torques»(ref-430997-S07821985842011101900000) .
4. Ensure that the flywheel sensor and bracket are installed. Install the clutch driven plate and clutch.

Install the gearbox

1. For gasoline M56 and M58 2000- see «Transmission, installation»(ref-431009-S26387521342011101900000) .
2. For gasoline M66AWD 2004- and M66 2005- see «Transmission, installing (M66AWD 2004- and M66 2005-)»(ref-431033-S17119974052011101900000) .

Test drive the car to check the function of the engine and the gearbox.

See Crankshaft seal, front, replacing

See Replacing the carrier plate

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

See Replacing the carrier plate

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

Flywheel

Special tools

9995112

9995678

Replacing flywheel

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.

Preparations

Removing the transmission: see Transmission, removing .

To remove the clutch: for gasoline see Pressure plate/clutch driven plate, replacing .

Note. The illustrations display a dual mass flywheel, but the method is the same for cars with a massive flywheel.

Removing the flywheel

Remove the engine speed (RPM) sensor with the bracket. Place it to one side.

Slacken off all the screws for the flywheel. Remove all the screws except for one.

Remove the gear sector 9995112 .

Detach the flywheel from the crankshaft. Remove the remaining screw.

Remove the flywheel.

Checking the crankshaft seal

Check the crankshaft seal for leakage.

To replace the crankshaft seal, refer to the appropriate service information.

Installing the flywheel

Note. Check that the contact surfaces on the crankshaft and flywheel are completely clean.

Use tool 9995678 , consisting of 3 studs with nuts.

Install

1. The 3 studs belonging to tool «9995678»(ref-403953-S14391401472011061000000) distributed as shown in the illustration
2. the flywheel.

Note. Check that the guide pin on the crankshaft is positioned directly opposite the hole in the flywheel.

Note. Only applies to engines with dual mass flywheels: There is a marking in the form of a shallow hole (see arrow in illustration). The marking indicates the direction to the guide hole on the flywheel.

Fit the gear sector 9995112 against the flywheel.

Tighten in the flywheel against the crankshaft, alternate between nuts when tightening. Use the 3 nuts that belong to tool 9995678 .

Install 7 new screws. Tighten crosswise with 45 Nm .

Remove the 3 nuts and studs.

Install the remaining 3 new screws for the flywheel and tighten with 45 Nm . Then angle-tighten all 10 screws crosswise 65°.

Install the impulse sensor with bracket. Tighten with 10 Nm .

To install the clutch: for gasoline see Pressure plate/clutch driven plate, replacing .

To install the gearbox: for gasoline see Transmission, installation .

Cylinder head/gasket, replacing

Special tools

9995452

9995454

9995670

9995451

9512050

9512767

9995450

9995718

9995719

Note. Since the illustrations in the information are used for different model years and/or models, there may be some deviations. However, the essential information in the illustrations is always correct.

Scheme 618

Remove

1. the radiator breather tube from the expansion tank. Install lock grip pliers
2. the negative battery lead. First read «Battery, disconnecting»(ref-430959-S32245976082011101900000) .
3. the right front wheel.

Scheme 619

Raise the car.

Remove the splash guard under the engine.

Open the engine nipple.

Drain the coolant into a container.

Close the nipple.

Scheme 620

Remove

1. the clamp between the oil pressure pipe and the oil return line at the turbocharger (TC)
2. the pipe screw that holds the oil pressure pipe to its connector on the cylinder block
3. the oil return line. Seal the opening in the cylinder block
4. the screws and spacers at the exhaust manifold support bracket
5. the lower screw that holds the heat deflector plate over the turbocharger (TC)
6. the nuts for the front exhaust pipe connection to the turbocharger (TC). Lift off the exhaust pipe and tie it up. Seal the opening in the exhaust pipe. NOTE: The front exhaust pipe's metal hose is very sensitive to twisting. Handle it with care to avoid leakage later on.

When replacing or working on the cylinder head

Lift out the tappets. Use a magnet or suction cup.

Note. Keep the tappets in an oil-filled container to avoid self-drainage.

Remove the thermostat housing.

Note. Work very carefully to avoid damaging the contact faces.

Scheme 621

Clean the gasket faces for

1. the manifold. Check that the studs are tightened.
2. the coolant bypass channel
3. the thermostat housing.
4. the intake manifold
5. the cylinder block
6. camshaft cover.

Blow the oil ducts clean.

Note. Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440.

Variable valve timing unit, checking and adjusting

Check and adjust the variable valve timing unit. See: Variable valve timing unit, checking and adjusting

Scheme 622

Install

1. front timing cover
2. the cable duct to the mountings on the right suspension turret
3. the auxiliaries belt
4. the expansion tank
5. the servo oil reservoir
6. the bleed hose to the expansion tank. Tighten the clamp.

Check that the hoses are positioned correctly.

Connect the connectors for the ABS sensor at the right suspension turret and for the coolant level sensor in the expansion tank.

Scheme 623

Install

1. the starter motor
2. the pipe screw for the water-heated crankcase ventilation at the rear of the cylinder head. Use new seal washers. Tighten to 26 Nm .
3. the camshaft position sensor (CMP) housing and trigger wheel
4. a new cover at the rear of the intake camshaft
5. the upper engine stabilizer brace.

Scheme 624

Install

1. bracket and lifting eyelet for the engine stabilizer brace bracket
2. the ignition coils and ground terminals according to earlier markings.

Connect the connector for the variable valve timing solenoid.

1. the clamp for the positive lead at the lifting eyelet bracket
2. the plastic intake pipe to the mass air flow (MAF) sensor. Tighten the clamp.

Connect the connector to the mass airflow (MAF). Clamp the wiring at the front of the air cleaner (ACL).

Scheme 625

Clean the intake manifold gasket face to the cylinder head.

Install a new gasket on the cylinder head. Secure with the three screws in the lower row.

Lower and twist the intake manifold so that the fuel pressure line goes through the cavity in the intake manifold.

Note. Be very careful so that the fuel delivery pipe is not damaged.

Route the crankcase ventilation hose through the cavity in the intake manifold.

Install

1. the pipe screw for the crankcase ventilation on the underside of the intake manifold. Use new seal washers. Tighten to 26 Nm .
2. the rest of the screws holding the intake manifold to the cylinder head. Tighten to 19 Nm .
3. the hose to the evaporative emission system (EVAP) valve.
4. the control hose for the turbocharger (TC) by-pass valve
5. the brake vacuum hose.
6. the crankcase ventilation hose to the top of the camshaft cover. Use a new clamp
7. the cover over the ignition coils
8. the upper timing cover
9. the upper engine coolant hose for the engine and radiator. Tighten the clamp
10. the screw holding the dip stick pipe to the intake manifold.

Connect the connector for the electronic throttle module (ETM).

1. the charge air pipe between the throttle body (TB) and the charge air cooler (CAC). Remove the seal. Tighten the clamp.

Scheme 626

Install

1. the fuel rail. Use new screws.

Press the quick-release connector for the fuel pressure line until it clicks.

1. the clamp for the injector wiring at the rear of the cylinder head
2. the protective cover over the injector connectors
3. the charge air pipe over the engine. Tighten the pipe using the three screws on the engine. Tighten the clamps.

Installing components

Raise the car. Install

1. the pipe screw that holds the turbocharger (TC) oil pressure pipe to the engine. Use new seal washers. Tighten to 38 Nm .
2. the turbocharger (TC) oil return line. Use a new gasket and sealing ring. Tighten to 12 Nm .
3. the clamp between the oil pressure pipe and the oil return line.
4. the screws and spacers at the manifold support bracket and cylinder block.

Tighten the three nuts that hold the front exhaust pipe to the turbocharger (TC). Tighten to 30 Nm .

1. the splash guard under the engine.
2. the plastic nuts for the hatch in the right fender liner
3. the right front wheel. See «Installing wheels»(ref-451813-S27758047502012020900000) .

Lower the car

Tighten the pipe screw for the turbocharger (TC) oil pressure pipe. Tighten to 26 Nm .

Install

1. the heat deflector plate above the turbocharger (TC).
2. the ground strips between the cylinder head and the firewall.
3. the engine stabilizer brace between the suspension turrets. Clamp the servo hose at the right engine stabilizer brace mounting.
4. the negative battery lead. First read «Battery, disconnecting»(ref-430959-S32245976082011101900000) .

Check

Replace the oil and oil filter if necessary.

Check

1. the engine oil level
2. the servo oil level
3. the coolant level.

Warm up the engine until the thermostat opens.

Check the engine for leaks.

Top up the coolant if necessary.

Preparation

Remove

1. the radiator breather tube from the expansion tank. Install lock grip pliers
2. the battery negative lead. First read «Battery, disconnecting»(ref-430959-S32245976082011101900000)
3. the right front wheel.

Removing components

Remove

1. the clamp between the oil pressure pipe and the oil return line at the turbocharger (TC)
2. the pipe screw that holds the oil pressure pipe to the connector on the cylinder block
3. the oil return line. Seal the opening in the cylinder block
4. the lower screw that holds the heat deflector plate over the turbocharger (TC)
5. the nuts for the front exhaust pipe connection to the turbocharger (TC). Lift off the exhaust pipe and tie it up. Seal the opening in the exhaust pipe NOTE: The metal hose for the front exhaust pipe is easy to damage if it is twisted. Handle it with care to avoid leakage.

Depressurizing the fuel system

Lower the car.

Depressurize the fuel system according. to: Fuel system pressure release .

Remove

1. the engine stabilizer brace between the suspension turrets
2. the ground strips between the engine and the firewall
3. the heat deflector plate above the turbocharger (TC)
4. the plastic charge air pipe above the engine. Seal the openings
5. the cover over the nozzle pipes
6. the cover over the ignition coils
7. the upper engine coolant hose for the engine and radiator
8. the screw holding the dip stick pipe to the intake manifold
9. the brake vacuum hose from the intake manifold.

Undo the clamp holding the plastic charge air pipe to the electronic throttle module.

Remove

1. the connector from the mass air flow (MAF) sensor
2. the intake hose from the mass air flow (MAF) sensor. Seal the opening.

Release the hoses from the bracket at the rear of the cylinder head. Remove the bracket.

Remove

1. the clamp for the positive lead at the rear of the cylinder head
2. the torque bracket
3. the pipe screw for the water-heated crankcase ventilation.

Scheme 627

1. Remove the clamp for the injector wiring at the rear of the cylinder head
2. Detach the wiring from the injectors
3. Remove the fuel rail mounting screws
4. Spray universal oil or similar around the injector connectors on the intake manifold
5. Gently work the fuel rail and injectors loose
6. Separate the quick-release connector for the fuel line. See «Fuel line, lock»(ref-430989-S27372086052011122100000) .
7. Carefully put the fuel rail to one side.

Removing ignition coils

1. Mark up the ignition coils so that their original positions can be established
2. Remove the mounting screws for the ignition coils and the screws at the two ground terminals
3. Disconnect the connector for the variable valve timing solenoid
4. Lift up and place the ignition coils and wiring to one side.

Remove

1. the crankcase ventilation hose from the top of the camshaft cover
2. the camshaft position sensor (CMP) housing and trigger wheel.

Removing intake manifold

Remove

1. The EVAP hose from the intake manifold
2. the by-pass valve vacuum hose. Disconnect the connector for the electronic throttle module (ETM)
3. the upper row of screws holding the intake manifold to the cylinder head. Slacken off the lower screws. Lift up the intake manifold. Remove the pipe screw for the water heated crankcase ventilation underneath the intake manifold
4. the pipe screw for the crankcase ventilation from the underside of the intake manifold.

Lift up and remove the intake manifold.

Note. Make sure that the fuel pressure pipe is not damaged.

Disconnect the connectors for the ABS sensor and level sensor in the expansion tank.

Lift up the expansion tank and servo oil reservoir. Place them on top of the engine.

Note. Make sure that oil does not leak from the breather hole in the filler cap.

Remove the auxiliaries belt.

Remove

1. front timing cover
2. the hose for the water-heated crankcase ventilation from the thermostat housing.

Separate the connector for the engine coolant temperature (ECT) sensor.

Setting up the engine

Remove the nuts from the cover on the fender liner.

Turn the crankshaft clockwise until the markings on the crankshaft and camshafts correspond.

Remove the upper timing cover.

Removing the timing belt

Slacken off the center screw for the belt tensioner slightly.

Hold the center screw secure and turn the tensioner eccentric clockwise with a 6 mm Allen key to 10 o'clock.

Remove

1. the timing belt from the timing gear pulley
2. the screw that holds the inner timing cover to the cylinder head.

Install tool 9995452 at the rear of the camshafts.

Removing the timing gear pulley

Remove the cable duct from its mountings on the right-hand suspension turret.

Note. Do not damage the paintwork.

Hold the cable duct out of the way and remove

1. the plug at the front of the variable valve timing unit (TX55). NOTE: Use paper or similar to absorb oil that drains.
2. the center screw in the variable valve timing unit (TX55).

Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit.

Remove tool 9995452 .

Removing components from turbocharger (TC)

Remove

1. the heat deflector plate above the manifold
2. the upper engine coolant pipe. Place it to one side
3. the oil pressure pipe for the turbocharger (TC)
4. the pipe screw at the lower coolant pipe for the turbocharger (TC). Put the pipe to one side
5. the nuts and washers holding the manifold to the cylinder head.

Lift off the turbocharger and manifold. Carefully put them on top of the transmission.

Releasing the inlet pipe for the coolant pump

Remove

1. the screw that holds the coolant pump intake pipe to the engine block a few turns. Leave the screw in place
2. the two screws for the connection between the coolant pipe and the bypass channel. Carefully turn the pipe to remove it from the cylinder block.

Removing the camshaft cover and cylinder head

1. Remove the spark plugs from cylinders 1 and 5
2. Install 2 tools «9995454»(ref-403953-S30108818292011061000000) . Leave a 2-3 mm gap to the camshaft cover. NOTE: Make sure that the screw in the sparkplug thread is fully tightened. VVT-solenoid (variable valve timing).
3. The variable valve timing solenoids.
4. Remove all the screws securing the camshaft cover to the cylinder head.

1. Use pliers «9995670»(ref-403953-S00526374942011061000000) to lift the cover from the cylinder head.
2. Install the pliers at the stop lugs. Start with cylinder 1 and work alternately backwards
3. Slacken off the wing nuts approximately 2 turns. Repeat the procedure.

Carefully press out the front and rear camshaft seals.

Remove

1. tools «9995454»(ref-403953-S30108818292011061000000)
2. the camshaft cover
3. the camshafts
4. the screws holding the cylinder head onto the cylinder block. Start at the sides and work alternately towards the center.

Get some help and lift of the cylinder head. Place the cylinder head on two wooden blocks.

Note. Work carefully to avoid damaging the contact faces.

Lift out the valve lifters. Use a magnet or suction cup.

Remove the thermostat housing and transfer it to the new cylinder head.

Note. Work carefully to avoid damaging the contact faces.

Scheme 628

Unscrew the screw (1).

Bend out the secondary lock (2). Pull out the catch.

Remove the fuel rail.

Installing the lock

Note. Screw in the screw until it takes.

Install the fuel rail.

Press in the secondary lock (2).

Screw the screw (1) right in.

Note. For tightening torques, see: Tightening torque .

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

Cleaning

Clean the gasket faces for

1. the manifold. Check that the studs are tightened
2. the coolant bypass channel
3. the thermostat housing
4. the intake manifold
5. the cylinder block
6. camshaft cover.

Blow the oil ducts clean.

Note. Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440.

1. Position the crankshaft
2. Remove the starter motor mounting screws. Pull out the starter motor and place it to one side
3. Remove the blind cover plug
4. Turn the crankshaft slightly clockwise .
5. Install crankshaft stop «9995451»(ref-403953-S26663901482011061000000) . Ensure that it bottoms out against the cylinder block.
6. Turn the crankshaft counter-clockwise until it stops against the crankshaft stop
7. Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.

Installing the cylinder head

1. Ensure that all studs at the exhaust ports are tightened
2. Lubricate the studs with paste 116 1408.
3. Install a new cylinder head gasket
4. Install the cylinder head
5. Lubricate and install all the screws (use new screws).
6. Tighten the screws as shown in the illustration. Tighten. See «Summary of specific components and tightening torques»(ref-430997-S07821985842011101900000) . Use protractor «9512050»(ref-403953-S36645634772011061000000) .

Installing valve lifters and camshafts

1. Lubricate the valve lifter wells. NOTE: If the cylinder head has been replaced, the valve clearance must be adjusted. See «Valve clearance»(ref-430977-S37533082122011101900000) .
2. Install all valve lifters
3. Lubricate the camshaft bearing positions
4. Install the intake camshaft. Ensure that the groove at the back of the camshaft is above an imaginary center line
5. Position the exhaust camshaft. Ensure that the groove at the back of the camshaft is below an imaginary center line.

Applying liquid gasket

Install new O-rings around the spark plug wells at the cylinder head.

Apply liquid gasket 1161 059 to the camshaft cover.

Use roller 9512767 . The surface must be covered without any excess .

Note. Make sure that no liquid gasket ends up in the oil channels.

Installing the camshaft cover

1. Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters
2. Install the camshaft cover
3. Install press tool «9995454»(ref-403953-S30108818292011061000000) (2x).
4. Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools
5. Install all the screws. Tighten the screws from the middle and outwards
6. Remove the press tools.

Install

1. the variable valve timing (VVT) solenoid. Use a new gasket.
2. the spark plugs. Tighten. See «Summary of specific components and tightening torques»(ref-430997-S07821985842011101900000)
3. the hose for water-heated crankcase ventilation to the thermostat housing. Tighten the clamp.

Connect the connector for the engine coolant temperature (ECT) sensor.

Install the inlet pipe for the coolant pump on the cylinder head. Use a new gasket.

Note. Apply thread sealant, 116 056 to the screw threads.

Tighten the screw for securing the coolant pump inlet pipe to the cylinder block.

Installing the manifold and turbocharger (TC)

Install

1. new gaskets. Lift and install the manifold and turbocharger (TC)
2. the nuts and washers holding the manifold to the cylinder head
3. the upper and lower turbocharger (TC) coolant pipes. Tighten the clamp on the rubber hose
4. the pipe screws for the coolant pipes. Use new seal washers. Tighten
5. the oil pressure pipe
6. the pipe screw holding the oil pressure pipe to the turbocharger (TC). Use new seal washers. NOTE: Do not tighten.

Lubricate the studs on the turbocharger (TC). Use paste 116 1408 .

Install the front exhaust pipe onto the turbocharger (TC). Use new nuts. Install the heat deflector plate over the manifold.

Note. Do not tighten.

Installing the rear camshaft seal

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

Note. For 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 seal ring is installed.

Use drift 9995450 .

Lubricate the surface of the seal that the camshaft rotates against.

Press in the seal until the drift bottoms out.

Note. If there are grooves on the camshaft, the seal can be pressed in a further 2 mm: Reverse the sleeve.

Install camshaft adjustment tool 9995452 at the rear of the camshafts.

Ensure that the screws retaining the adjustment tool to the camshafts and the screws holding the tool together are well tightened.

Installing the front camshaft seals

1. Use drift «9995718»(ref-403953-S24775656662011061000000) .
2. Lubricate the surface of the seal that the camshaft rotates against.
3. Use the variable valve timing unit / timing belt pulley mounting screws. Tighten the screws until the drift bottoms out
4. Remove the drift
5. Install the screw holding the inner timing cover to the cylinder head.

Checking and adjusting the variable valve timing unit

Check and adjust the variable valve timing unit. See: Variable valve timing unit, checking and adjusting

Install

1. front timing cover
2. the cable duct to the mountings on the right suspension turret
3. the auxiliaries belt
4. the expansion tank
5. the servo oil reservoir
6. the bleed hose to the expansion tank. Tighten the clamp.

Check that the hoses are installed correctly.

Connect the connectors for the ABS sensor at the right suspension turret and for the coolant level sensor in the expansion tank.

Install

1. the starter motor
2. the pipe screw for the water heated crankcase ventilation at the rear of the cylinder head. Use new seal washers. Tighten to 26 Nm
3. the camshaft position sensor (CMP) housing and trigger wheel
4. the lower engine stabilizer brace bracket in the cylinder head
5. the upper engine stabilizer brace.

Install

1. the bracket and lifting eyelet for the engine stabilizer brace bracket
2. the ignition coils and ground terminals according to earlier markings. Connect the connector for the variable valve timing solenoid
3. the clamp for the positive lead at the lifting eyelet bracket
4. the plastic intake pipe to the mass air flow (MAF) sensor. Tighten the clamp.

Connect the connector to the mass air flow (MAF) sensor. Use a clamp on the wiring at the front of the air cleaner (ACL).

Installing intake manifold

Clean the intake manifold gasket face to the cylinder head.

Install a new gasket on the cylinder head. Secure with the two screws in the lower row.

Lower and twist the intake manifold so that the fuel pressure line goes through the cavity in the intake manifold.

Note. Work carefully to avoid damaging the fuel pressure pipe.

Route the crankcase ventilation hose through the cavity in the intake manifold.

Install

1. the pipe screw for the crankcase ventilation on the underside of the intake manifold. Use new seal washers. Tighten to 26 Nm
2. the rest of the screws holding the intake manifold to the cylinder head. Tighten to 19 Nm
3. the hose to the canister purge (CP) valve
4. the control hose for the turbocharger (TC) by-pass valve
5. the brake vacuum hose
6. the crankcase ventilation hose to the top of the camshaft cover. Use a new clamp
7. the cover over the ignition coils
8. the upper timing cover
9. the upper engine coolant hose for the engine and radiator. Tighten the clamp
10. the screw holding the dip stick pipe to the intake manifold. Connect the connector to the electronic throttle module (ETM)
11. the charge air pipe between the throttle body (TB) and the charge air cooler (CAC). Remove the seal. Tighten the clamp.

Installing the fuel rail

Install

1. the fuel rail. Use new screws. Press the quick-release connector for the fuel pressure line until it clicks. See «Fuel line, lock»(ref-430989-S27372086052011122100000)
2. the clamp for the injector wiring at the rear of the cylinder head
3. the protective cover over the injector connectors
4. the charge air pipe over the engine. Tighten the pipe using the three screws on the engine. Tighten the clamps.

Raise the car. Install

1. the pipe screw that holds the turbocharger (TC) oil pressure pipe to the engine. Use new seal washers. Tighten. See «Summary of specific components and tightening torques»(ref-430997-S07821985842011101900000)
2. the turbocharger (TC) oil return line. Use a new gasket and sealing ring. Tighten. See «Summary of specific components and tightening torques»(ref-430997-S07821985842011101900000)
3. the clamp between the oil pressure pipe and the oil return line. Tighten the three nuts that hold the front exhaust pipe to the turbocharger (TC). See «Summary of specific components and tightening torques»(ref-430997-S07821985842011101900000) .
4. the lower screw for the heat deflector plate over the turbocharger (TC)
5. the splash guard under the engine
6. the plastic nuts for the hatch in the right fender liner
7. the right front wheel. See «Installing wheels»(ref-430991-S20645896442011101900000) .

Lower the car.

Tighten the pipe screw for the turbocharger (TC) oil pressure pipe. See Summary of specific components and tightening torques .

Install

1. the ground strips between the cylinder head and the firewall
2. the engine stabilizer brace between the suspension turrets Clamp the servo hose at the right-hand engine stabilizer brace mounting
3. the negative battery lead. First read «Battery, disconnecting»(ref-430959-S32245976082011101900000) .

Replace the oil and oil filter if necessary.

Check

1. the engine oil level
2. the servo oil level
3. the coolant level.

Warm up the engine until the thermostat opens.

Check the engine for leaks.

Top up the coolant if necessary.

Conditions

All mating surfaces must be thoroughly cleaned.

Always replace gaskets, nuts and screws with new ones.

Always use those components shown in the replacement parts range for the relevant area.

Always ensure

1. that there are not cracks or other damage at the mating surfaces which could result in leakage
2. that all threads are working correctly
3. that the gasket faces are flat.

Always remedy if necessary

Procedure

Always use the listed tightening torques.

Always use copper paste 1161 408 where indicated in the method.

Always follow the listed procedure for tightening torques and, where applicable, angle-tightening.

Scheme 629

Raise the car.

Remove

1. the splash guard under the engine
2. the torque rod from the transmission and sub-frame.

Scheme 630

1. install the new torque rod
2. Tighten the screws (A) to the transmission. Tighten to 35 Nm . Angle-tighten 40°
3. tighten the nuts (B) to the sub-frame. Tighten to 65 Nm . Angle-tighten 60°
4. Tighten the nuts (C). Tighten to 35 Nm . Angle-tighten 90° .

Bushing sub-frame, replacing

Special tools

9995716

9995460

9995717

9995589

9995352

9995457

9995567

9995575

9995576

9512564

9512050

Note. It is arbitrary which of tools 999 5575, 999 5576 and 951 2564 is used.

Scheme 631

Scheme 632

Install lifting tools 9995716 and lifting hooks 9995460 .

Lift the engine to relieve the load on the engine pads.

Scheme 633

Remove

1. the front wheels
2. the splash guard under the engine.

Scheme 634

1. the air baffle.

Scheme 635

1. the screw for the cable duct
2. the control module box evacuation pipe mounting from the sub-frame.

Scheme 636

Remove the lower screw for the front engine pad.

Scheme 637

Remove both the nuts retaining the lower torque rod.

Scheme 638

Slacken off the right lower front part of the fender liner.

Remove the plastic nuts on the fender liner.

Remove the cover plate.

Bend out the fender liner.

Scheme 639

Remove the screws holding the right-hand engine mounting in the engine.

Scheme 640

Remove

1. the four nuts and screws holding the steering gear
2. the nut (A), holding the lower half of the collision protection ( only applies to right hand drive cars ).

Scheme 641

Remove the delivery pipe for the steering gear from the snap fasteners along the sub-frame

Remove the hose for the EVAP canister.

Remove the fuel line for the engine block heater (if applicable).

Scheme 642

Remove and hang the engine block heater (if applicable) on the left front mounting for the sub-frame.

Remove the fuel line for the engine block heater (if applicable) on the sub-frame from the snap fasteners.

Position a lifting table under the sub-frame.

Apply the lifting table so that the load is taken off the sub-frame screws.

Remove the sub-frame screws together with the accompanying brackets and washers.

Carefully lower the sub-frame approximately 50 mm.

Note. Ensure that the steering gear screws are released from the sub-frame.

Scheme 643

Remove the bracket for the heated oxygen sensor (HO2S) from the sub-frame.

Lower the sub-frame a further 40 mm.

Scheme 644

Install the hydraulic tool and press sleeve as shown in the illustration.

Press the bushings out of the sub-frame, see the following illustration.

Note. It is arbitrary which of tools 999 5575, 999 5576 and 951 2564 is used.

Scheme 645

Lift up the sub-frame slightly, approximately 50 mm from the car body.

Install the wiring for the heated oxygen sensor (HO2S) on the sub-frame.

Scheme 646

Scheme 647

Clean the hole for the bushing in the sub-frame.

Press out the bushing by hand.

Marking the left-hand rear bushing

Note. The left-hand rear bushing on the sub-frame is a different version to the other three bushings. The hole in the center of the bushing is oval. The oval must be positioned lengthways to the car, as shown in the illustration.

Scheme 648

Install the hydraulic tool and press sleeve as shown in the illustration.

Press the bushings into the sub-frame, see the following illustration.

Note. It is arbitrary which of tools 999 5575, 999 5576 and 951 2564 is used.

Scheme 649

Lifting the sub-frame

Lift the sub-frame up completely.

At the same time locate the mounting screws for the steering gear on the sub-frame and, on right-hand drive cars, the screw for the collision protection system.

Install the sub-frame brackets loosely together with the washers.

Install the four screws for the sub-frame. Use new screws. Do not tighten yet .

First tighten the screws on the left side of the sub-frame. Tighten to 105 Nm . Angle tighten 120° . Then tighten the right-hand side to the same values as the left side.

Finally tighten the screws for the brackets on both sides. Tighten to 50 Nm .

Install the engine block heater (if applicable) on the left front mounting for the sub-frame.

Installing the nuts and screw for the steering gear

Install

1. the four nuts and screws holding the steering gear. Use new nuts and new screws. Tighten to 50 Nm .

Applies to right-hand drive cars

1. nut (A), holding collision protection lower half. Tighten to 50 Nm .

Installing the delivery line from the steering gear

Install the delivery pipe from the steering gear along the mountings on the sub-frame.

Install the hose for the EVAP canister.

Install the fuel line for the engine block heater (if applicable).

Installing the screws for the engine mounting to the engine

Reinstall the screws holding the engine mounting to the engine. Tighten to 35 Nm . Angle-tighten 90° .

Note. Use new screws.

Installing the protective plate

Install

1. the right lower front section of the fender liner
2. the protective plate
3. the plastic nuts for the protective plate.

Scheme 650

Install the front engine pad screw. Tighten to 50 Nm .

Installing the air intake cover

Install

1. the screw for the cable duct
2. the evacuation pipe on the sub-frame.

1. the air baffle.

Installing the protective cover

Install the splashguard under the engine.

Removing the lifting tools

Lower the car.

Remove the lifting tools.

Install the wheels. See Installing wheels .

Engine mount, rear, replacing

Special tools

9512050

9995972

Scheme 651

Remove

1. the screw holding the mounting for the torque rod at the bracket on the engine
2. the screws for the torque rod mounting at the wheel arches
3. the engine stabilizer brace
4. the upper nut for the rear engine pad.

Raise the car

Remove

1. the splash guard under the engine.

Scheme 652

1. Remove the lower screw for the engine pad
2. remove both the screws for the mountings holding the three-way catalytic converter (TWC)
3. fold the mountings forward.

Scheme 653

1. Remove the screw and nut at the lower torque rod mounting to the bracket on the transmission
2. position a mobile jack under the transmission
3. carefully lift up the engine so that the engine pad can be replaced
4. remove the engine pad by pulling it forwards between the bevel gear and the transmission.

1. Install the new engine pad
2. install a new screw in the lower mounting for the engine pad. Do not tighten yet
3. carefully lower the engine
4. NOTE: Ensure that the guide pin at the top of the engine pad locates correctly.
5. remove the mobile jack.

Finishing

1. Install a new screw and nut on the lower torque rod. Tighten to 35 Nm . Angle-tighten 90° . Use bevel protractor «9512050»(ref-403953-S36645634772011061000000) .

1. Tighten the lower screw in the engine pad. Tighten to 50 Nm
2. install both the screws for the mountings for the three-way catalytic converter (TWC). Tighten to 10 Nm
3. install the splashguard under the engine. Tighten to 25 Nm .

Lower the car.

Install

1. A new nut in the upper mounting for the engine pad. Tighten to 50 Nm .

Scheme 654

Install

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

Remove

1. the battery lead. See «Battery, disconnecting»(ref-430959-S32245976082011101900000)
2. the torque rod. See «Replacing the torque rod»(ref-430989-S35211663652011101900000) .

Scheme 655

Remove

1. the air intake between the air cleaner (ACL) and the front panel
2. the charge air pipe from the charge air cooler (CAC) are on the left-hand side. Heat the charge air pipe using a hot-air gun. This will make removal easier.

Remove

1. the nut on the top for the engine pad
2. raise the car.

Remove

1. the splash guard and the air intake cover under the engine
2. the screw for the engine pad.

Scheme 656

1. Remove the screw and nut at the lower torque rod mounting to the bracket on the transmission
2. position a mobile jack with universal plates «9995972»(ref-403953-S08076234722011061000000) under the transmission
3. Check that the plate does not catch in the sub-frame
4. carefully lift up the engine so that the engine pad can be replaced.

1. install a new screw in the lower mounting for the engine pad. Do not tighten yet
2. carefully lower the engine
3. NOTE: Ensure that the guide pin at the top of the engine pad locates correctly.
4. remove the mobile jack.

Finishing

1. Use a new screw and nut on the lower torque rod. Tighten to 35 Nm . Angle-tighten 90° . Use bevel protractor «9512050»(ref-403953-S36645634772011061000000)
2. Tighten the lower screw in the engine pad. Tighten to 50 Nm
3. install the splash guard and the air intake cover under the engine
4. lower the car.

Install

1. the nut on the top of the engine pad. Tighten to 50 Nm
2. the charge air pipe to the charge air cooler (CAC)
3. the air intake between the air cleaner and the front panel
4. the torque rod. See «Replacing the torque rod»(ref-430989-S35211663652011101900000)
5. the battery lead. See «Battery, disconnecting»(ref-430959-S32245976082011101900000)

Engine mount, right, replacing

Special tools

9512050

9995972

Scheme 657

Raise the car.

Remove

1. the right front wheel
2. both the plastic nuts and the reinforcement panel holding the cover in the right fender liner. Bend the fender liner out of the way
3. the four screws for the right engine pad
4. the splash guard under the engine.

Scheme 658

1. Position a mobile jack with universal plate «9995972»(ref-403953-S08076234722011061000000) under the oil pan on the right side of the engine
2. Check that the plate does not catch in the sub-frame
3. Carefully lift the engine slightly so that the engine pad can be removed.

Scheme 659

Install

1. the new engine pad
2. use new screws for the mounting in the sub-frame and engine. Do not tighten yet .

1. Carefully lower the engine and remove the mobile jack
2. Tighten the screws against the engine. Tighten to 35 Nm . Angle-tighten 90° . Use bevel protractor «9512050»(ref-403953-S36645634772011061000000)
3. Tighten the screws to the sub-frame. Tighten to 65 Nm and angle-tighten 60° . Use bevel protractor «9512050»(ref-403953-S36645634772011061000000) .

1. the splash guard under the engine. Tighten to 25 Nm
2. both the plastic nuts and the reinforcement panel holding the cover in the right fender liner
3. the right front wheel. See «Installing wheels»(ref-430991-S20645896442011101900000)

Sub-frame front, replacing

Special tools

9995716

9995460

9995045

9512050

1. Install lifting beam «9995716»(ref-403953-S41765249862011061000000) . Install lifting hooks «9995460»(ref-403953-S32932431362011061000000)
2. Lift the engine to relieve the load on the engine pads.

Remove

1. the front wheels
2. the splash guard under the engine.

Scheme 660

1. the air duct cover.

1. the cable duct screw.

Remove

1. the oil pipes from the steering gear from the snap fasteners on the sub-frame
2. the hose for the EVAP canister along the sub-frame
3. the fuel line for the engine block heater and the engine block heater (if applicable) on the left side of the sub-frame.

Scheme 661

Remove

1. the hose for the EVAP canister in the joint by pulling apart the hose. Pull it forwards under the anti-roll bar and remove it from the snap fastener on the sub-frame.

Scheme 662

Remove

1. the mounting for the exhaust pipe on the bracket
2. the screws holding the bracket for the exhaust pipe. Release the brake pipe from the snap fastener on the bracket
3. the bracket.

1. Remove the heated oxygen sensor (HO2S) wiring from the mounting.

Scheme 663

1. Remove the anti-roll bar links from the anti-roll bar. Counterhold using a Torx wrench so that the ball joint boot is not damaged.

1. Remove both the nuts retaining the lower torque rod
2. Remove the screw and bend up the bushing with the holder towards the torque rod.

1. Remove the front engine pad screw.

1. Slacken off the right lower front section of the fender liner
2. Remove the plastic nuts on the fender liner
3. Remove the splash guard
4. Bend out the fender liner.

Scheme 664

1. Remove both the right hand engine mounting screws.

1. Remove the four nuts and the screw holding the steering gear to the sub-frame
2. Remove the delivery line from the clips on the sub-frame
3. Remove nut (A) holding the lower half of the collision protection. (Applies only to right-hand drive cars).

Scheme 665

1. Remove the nuts from the ball joints. Counterhold with a Torx wrench so that the ball joint boot is not damaged.

Scheme 666

1. Remove and hang up the engine block heater (if applicable) on the left front mounting for the sub-frame
2. Position a lifting table under the sub-frame
3. Remove the screws holding the sub-frame brackets to the bodywork on both sides
4. Remove the four screws from the sub-frame
5. Carefully lower the sub-frame. NOTE: Ensure that the steering gear screws release from the sub-frame.

Scheme 667

Hang the steering gear from a hook 9995045 so that the lower steering shaft does not come apart.

On right-hand drive cars the hook is installed on the right-hand side.

Scheme 668

Transfer

1. the control arms. Use new screws and new nut. Tighten the front screws. Tighten to 65 Nm . Angle-tighten 90° . Use bevel protractor «9512050»(ref-403953-S36645634772011061000000) . Tighten the rear screw. Tighten to 105 Nm . Angle-tighten 90°
2. the anti-roll bar. Tighten to 60 Nm
3. the right-hand engine mounting. Tighten the screws. Tighten to 65 Nm . Angle-tighten 60°
4. the mounting for the heated oxygen sensor (HO2S) wiring
5. the engine pad.

Install new pipe / hose holders.

Installing the sub-frame

1. Position the sub-frame on a lifting table
2. Carefully lift the sub-frame
3. Locate the control arms on the ball joints and the steering gear on its mountings
4. Remove the hook (999 5045) that is holding the steering gear
5. Lift the sub-frame up completely
6. Reinstall the engine block heater (if applicable).

1. Install the engine block heater (if applicable) on the left front mounting for the sub-frame
2. Install the four screws in the sub-frame together with the sub-frame brackets. Use new screws . Lubricate the screws
3. First tighten the screws on the left side of the sub-frame. Tighten to 105 Nm . Angle tighten to 120° . Then tighten the right-hand side to the same value
4. Finally tighten the screws for the brackets on both sides to 50 Nm .

Install

1. the right-hand engine mounting. Use new screws. Tighten to 35 Nm . Angle-tighten 90° .

1. the front engine pad. Tighten to 50 Nm .

1. lower torque rod. Tighten the screw and nut. Tighten to 35 Nm . Angle-tighten 90° . The lower torque rod must be tightened last to avoid tension being introduced. Tighten the front nuts. Tighten to 65 Nm . Angle-tighten 90° . Use bevel protractor «9512050»(ref-403953-S36645634772011061000000) .

Note. Use new screws and nuts.

1. the fender liner and the splash guard with both the plastic nuts.

1. the four nuts and the screw holding the steering gear. Use new nuts and a new screw. Tighten to 50 Nm Clip the cable in position. the nut (A), holding the lower half of the collision protection system. (Applies only to right-hand drive cars). Tighten to 50 Nm .

1. the wiring for the heated oxygen sensor (HO2S) in its mounting.

1. the mountings for the exhaust pipe on the bracket. Tighten to 10 Nm
2. the brake pipe on the bracket for the exhaust pipe
3. the bracket for the exhaust pipe. Tighten the bracket screws. Tighten to 25 Nm .

1. EVAP canister hose. Press the joint together.

1. oil pipes to steering gear
2. any fuel line for engine block heater
3. any engine block heater.

1. new nuts on the ball joints. Tighten. See: «Tightening torque»(ref-431150-S39115879022011101900000) . Counterhold using a Torx wrench to prevent damaging the ball joint boot.

1. the anti-roll bar links. Use new nuts. Tighten to 50 Nm . Counterhold with a Torx wrench so that the boot is not damaged.

1. the cable duct screw.

1. the air duct cover.

1. the splash guard under the engine. Tighten to 20 Nm
2. Lower the car.

1. Install the wheels. See «Installing wheels»(ref-430991-S20645896442011101900000)
2. Remove the lifting tools for the engine

Engine/transmission, installing

Special tools

9512050

9995972

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.

Note. For tightening torques, see Tightening torque

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

Scheme 669

Raise the engine and the transmission unit. Use a lifting table with locating pins.

Stop when the sub-frame is approximately 15 cm below the frame members.

Scheme 670

Install (left and right-hand sides)

1. the drive shaft to the hub. Install the center screws. NOTE: Do not tighten yet.
2. the ball joint to the control arm. Install the nuts. NOTE: Do not tighten yet. NOTE: Ensure that the mating surfaces on the ball joints and control arms are clean.

Twist the engine block heater (option) into position. Check that the air conditioning (A/C) compressor is correctly positioned.

Check that the tie rod is in the correct position. Check that the transmission cable is routed between the steering shaft and the firewall.

Align the steering shaft joint on the steering gear.

Lift the engine and transmission unit up to the frame members.

Note. Ensure that no hoses, wiring or anything else catches.

Install

1. a new screw in the lower steering shaft joint. Tighten to 20 Nm
2. new screw in the sub-frame. Lubricate the screws
3. the washes at the front edge and the support plates at the rear edge of the sub-frame.

Tighten the screws for the sub-frame. Tighten to 105 Nm . Angle-tighten 120° . Use bevel protractor 9512050 . Start on the left hand side of the sub-frame. Continue with the right hand side.

Tighten the screws for the brackets at the rear of the sub-frame. Tighten to 50 Nm .

Remove the lifting table.

Installing the propeller shaft (all-wheel drive (AWD) only)

1. For M58 and AW50WD gasoline -2002, see «Replacing the pinion seal for the bevel gear»(ref-431009-S24146996482011101900000)
2. For M58 and AW50WD gasoline 2003-, see «Pinion seal bevel gear, replacing»(ref-431009-S04702454422011101900000)
3. For AW50WD D5244Tx 2003-, see «Pinion seal bevel gear, replacing»(ref-431009-S04702454422011101900000)
4. For M66AWD D5244Tx 2004-, see «Replacing the pinion seal for the bevel gear»(ref-451742-S24085054312012020900000) .

Installing the three-way catalytic converter (TWC) (all-wheel drive (AWD) only)

Lubricate the studs where the exhaust system separates downstream of the three-way catalytic converter (TWC). Use paste 116 1408.

Lift up the exhaust system and connect it to the rear system. Use a new gasket and new nuts.

HINT: Use a mobile jack with universal plate 9995972 as a support.

Note. The routing of the heated oxygen sensor (HO2S) wiring over the brake pipe.

Install the screws holding the SIPS member to the bodywork. Tighten the screws.

Press the brake pipe into place in the holders on the SIPS member.

Installing the front exhaust pipe

Lubricate the studs on the turbocharger (TC). Use paste 116 1408.

Install the front exhaust pipe on the turbocharger (TC). Use new nuts. Tighten to 30 Nm .

Clamp the wiring for the rear heated oxygen sensor (HO2S) into place at

1. the bracket at the rear of the sub-frame
2. the clips on the power steering pipe at the steering gear
3. the clamp at the right-hand side of the steering gear.

Scheme 671

When assembling the fuel lines, see also: Fuel system, quick-release connectors .

Connect the quick-release connector and the fuel line to

1. the motor
2. the engine block heater (option).

Press the EVAP line together at the rubber joint.

Fuel system, quick-release connectors

Special tools

9995666

9512666

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.

There are different types of quick-release connector in the fuel system. Special tools are required for some connectors (see below).

Scheme 672

If the catch appears as illustrated, special tool 9995666 must be used to press in the catch.

Scheme 673

If the connector has an internal catch, special tool 9512666 must be used.

Scheme 674

Install

1. the tie rods. Use new nuts. Tighten to 70 Nm
2. the link rod to the anti-roll bar. Use new nuts. Tighten to 50 Nm . Counterhold with Tx27
3. the bracket for the brake pipe to the body.

Tighten

1. the nut for the ball joint and control arm. Tighten to 80 Nm . Counterhold using Tx40
2. the center screw in the drive shaft. Tighten to 50 Nm .

Scheme 675

Connect the heater connector at the vehicle wiring.

Ensure that the connector and wiring are secured at the body.

Rivet the fender liner to the fender edge.

Check that the quick-release fuel line connector is secure at the engine block heater.

Scheme 676

Install the 4 screws while the compressor is loose.

Raise the compressor and screw it into place.

Note. Handle the compressor carefully. Ensure that there are no kinks in the air conditioning (A/C) pipes.

Connect the one-pin connector to the compressor magnetic clutch.

Scheme 677

Connect the engine wiring to the control module box. See Central electrical unit, engine compartment, replacing .

Install

1. the ground lead to the ground terminal at the right fender edge in the engine compartment
2. the auxiliaries belt
3. the intermediate piece for the control module box
4. the control modules. See «Engine control module (ECM), replacing»(ref-430961-S10976842282011101900000)
5. the cover for the control module box
6. expansion tank. Connect the radiator breather tube to the expansion tank. Tighten the clamp. Connect the connector for the level sensor in the expansion tank
7. servo oil reservoir. Check that the hoses are correctly positioned.

Clamp the ABS cable to the power steering hose.

Scheme 678

Install

1. the heat deflector plate above the turbocharger (TC)
2. the 2 ground strips on the top of the cylinder head.

Clamp the wiring for the front heated oxygen sensor (HO2S) to

1. the coolant pipe
2. the heat deflector plate above the manifold
3. the turbo control hose at the plastic intake pipe for the turbocharger (TC).

Scheme 679

Install

1. the positive lead for the starter motor
2. the connector for the engine wiring
3. the cover over the central electrical unit.

Installing the transmission cable

Automatic transmissions : Install the screws holding the bracket and transmission cable to the transmission.

Manual transmissions : Install the transmission cable. Assemble the clutch cable. See Transmission, installation .

Scheme 680

Install

1. the lower engine coolant hose to the radiator. Tighten the clamp
2. the lower oil cooler hose for the transmission to the radiator (automatic transmissions only). Use new O-rings
3. the plastic charge air pipe between the throttle body (TB) and the charge air cooler (CAC). Only connect the plastic pipe at the throttle body (TB). Do not tighten the clamp.

Remove radiator protection 999 5474

Install

1. the engine cooling fan (FC). Tighten the screws securing the fan shroud to the front panel
2. the plastic charge air pipe to the connection at the charge air cooler (CAC). Tighten both the clamps. Connect the connectors for the temperature and pressure sensors in the plastic pipe
3. the canister purge (CP) valve to the bracket at the fan shroud. Secure the EVAP hose to the clip at the lower section of the fan shroud
4. the brake vacuum hoses
5. the upper oil cooler hose for the transmission to the radiator (automatic transmissions only). Use new O-rings.

Scheme 681

Press down the right side of the cooler unit. Pull the wiring for the pressure switch (Pressostat) into the drier bottle.

Connect the connectors to

1. the engine cooling fan (FC) (x2)
2. the canister purge (CP) valve.

Secure

1. the breather tube for the radiator at the top of the fan shroud
2. the wiring at the lower right corner and at the top of the fan shroud.

Install

1. the rubber hose to the inlet side of the charge air cooler (CAC)
2. the plastic charge air pipe above the engine. Tighten all clamps. Secure the pipe on the engine
3. the upper coolant hose. Tighten the clamp
4. the ventilation pipe between the control module box and fan shroud
5. the air cleaner (ACL) assembly. Connect the plastic hose to the mass air flow (MAF) sensor. Tighten the clamp
6. the air cleaner (ACL) intake pipe.

Connect the connector to the mass air flow (MAF) sensor. Secure the wiring at the front of the air cleaner (ACL) housing.

Install the support brace between the suspension turrets. Secure the servo hose to the right mounting on the support brace.

Scheme 682

Connect the connector to the pressure switch (Pressostat) in the drier bottle. Secure the wiring.

Tighten the lower screw on the cooler unit.

Connect the connectors to both the heated oxygen sensors (HO2S).

Scheme 683

Install

1. the splash guard under the radiator
2. the splash guard under the engine
3. the front wheels. See «Installing wheels»(ref-451813-S27758047502012020900000)
4. the battery negative lead. Also read «Battery, disconnecting»(ref-430959-S32245976082011101900000) .

Final check

Top up

1. coolant
2. engine oil
3. power steering fluid.

Start the engine.

Warm up the engine until the thermostat opens.

Check for leakage.

Check the oil and coolant levels. Adjust if necessary.

Check the transmission oil level (automatic transmissions only). Top up if necessary.

Engine/transmission, removing

Special tools

9995474

9995722

Note. Since the illustrations in the information are used for different model years and/or models, there may be some deviations. However, the essential information is always correct.

Remove

1. the negative battery cable. First read «Battery, disconnecting»(ref-430959-S32245976082011101900000) .
2. the cross stay between the suspension turrets
3. the air cleaner (ACL) assembly. Seal the opening in the plastic pipe for the turbocharger (TC)
4. the plastic charge air pipe above the engine. Seal the openings
5. both the ground strips at the top of the cylinder head.

Remove

1. the cover over the central electrical unit
2. the connector for the engine wiring from the central electrical unit
3. the positive lead for the starter motor from the terminal block.

Scheme 684

Remove

1. control module unit cover
2. the control modules. Use tool «9995722»(ref-403953-S10522720692011061000000) . See also «Engine control module (ECM), replacing»(ref-430961-S10976842282011101900000) .

Separate the control module box. Disconnect the engine wiring. Also see Central electrical unit, engine compartment, replacing .

Remove the ground terminal for the engine wiring at the right wheel arch.

Scheme 685

Remove

1. the brake vacuum hose from the ejector valve
2. The canister purge (CP) valve from the mounting on the fan shroud. Disconnect the connector.

Expose the wiring and the breather tube for the radiator.

Disconnect the connectors for the engine cooling fan (FC).

Remove

1. the screws securing the fan shroud to the front panel
2. the dip stick
3. the upper oil hose for the transmission at the connection to the radiator (automatic transmissions only). Seal the openings.

Lift up and remove the engine cooling fan (FC).

Remove

1. the connectors for the pressure sensor and temperature sensor in the plastic charge air pipe between the charge air cooler (CAC) and the throttle body (TB)
2. the rubber hose at the intake for the charge air cooler (CAC)
3. the brake vacuum hose at the intake manifold
4. the plastic pipe between the throttle body (TB) and the charge air cooler (CAC)
5. the lower oil hose for the transmission at the connection to the radiator (automatic transmissions only). Seal the openings.

Install radiator protection 9995474 .

Removing the transmission cable

Automatic transmissions : Remove the screws for the transmission cable bracket at the transmission.

Manual transmissions : Separate the clutch cable and remove the transmission cables. See Transmission, removing .

Tie up the cable(s) to the central electrical unit.

Raise the car.

Remove

1. the left and right front wheels
2. the splash guard under the radiator
3. the splash guard under the engine.

Scheme 686

Position a container under the radiator drain cock.

Drain the coolant.

Close the cock.

Cars with engine block heaters (option)

Drill out the first three blind rivets at the right mounting for the fender lining to the fender edge, seen from the front edge and upwards.

Bend the fender liner out of the way.

Disconnect the connector from the engine block heater.

Separating the fuel line

Note. If an engine block heater is installed, mark the position of the fuel lines.

Separate the quick-release connectors for the fuel pressure line and engine block heater (option). See also: Fuel system, quick-release connectors .

HINT: Use tool 9995666 .

Pull apart the EVAP line at the rubber joint behind the rear right mounting for the sub-frame.

Scheme 687

Remove the screw from the wiring clamp that holds the wiring for the heated oxygen sensor (HO2S) at the right side of the steering gear.

Remove the wiring from the clips at the power steering line on the steering gear.

Remove

1. the screw for the wiring clamp at the bracket at the rear edge of the sub-frame
2. the lower screw that holds the heat deflector plate over the turbocharger (TC)
3. the three nuts that hold the front exhaust pipe to the turbocharger (TC).

Tie up the front exhaust pipe at the right suspension turret (cars without All-wheel drive (AWD)).

Removing the air conditioning aggregate

Disconnect the connector from the pressostat in the air conditioning (A/C) receiver drier.

Slacken off the lower right screw for the cooling unit.

Pull the cooling unit down. Carefully pull the wiring for the pressostat through the cavity at the mounting for the cooling unit.

Release the lower ventilation pipe for the control module box from the sub-frame.

Exposing the air conditioning (A/C) compressor

Remove the upper radiator hose.

Remove the auxiliaries belt.

Disconnect the one-pin connector for the compressor magnetic clutch.

Remove the four screws holding the air conditioning (A/C) compressor to the engine.

Tie up the compressor in the front cover plate.

Note. Handle the compressor carefully to make sure that there is no bending of the AC-pipes.

Expose the wiring for the front heated oxygen sensor (HO2S).

Disconnect the connector for the level sensor in the expansion tank.

Remove

1. the heat deflector plate above the turbocharger (TC)
2. the hoses for the heater unit at the terminal in the firewall
3. the bleed hose for the radiator at the expansion tank
4. the ABS line and clips and the power steering hose.

Lift up the power steering fluid reservoir and the expansion tank. Place them on top of engine.

Scheme 688

Remove the ignition key.

Remove the screw from the joint between the steering gear and the steering shaft.

Scheme 689

On one side, measure the length of the track rod in relation to the steering gear housing. Note the measurement.

Press up the joint from the steering gear.

Removing the three-way catalytic converter (TWC) (all-wheel drive (AWD) only)

Remove

1. the nuts where the exhaust pipe divides downstream of the three-way catalytic converter (TWC)
2. the screws securing the SIPS member to the bodywork.

Remove the brake pipe from the holders on the SIPS member.

Lift off the front exhaust pipe from the turbocharger (TC) and the rear system.

Lower and pull back the three-way catalytic converter (TWC) with the SIPS member.

Note. The routing of the heated oxygen sensor's cable harness over brake pipe.

Removing the propeller shaft from the transmission and drive distribution box (all-wheel drive (AWD) only)

remove the propeller shaft from the transmission and drive distribution box (all-wheel drive (AWD) only).

1. For M58 and AW50WD gasoline -2002, see «Replacing the pinion seal for the bevel gear»(ref-431009-S24146996482011101900000)
2. For M58 and AW50WD gasoline 2003-, see «Pinion seal bevel gear, replacing»(ref-431009-S04702454422011101900000)
3. For AW50WD D5244Tx 2003-, see «Pinion seal bevel gear, replacing»(ref-431009-S04702454422011101900000)
4. For M66AWD D5244Tx 2004-, see «Replacing the pinion seal for the bevel gear»(ref-451742-S24085054312012020900000) .

Scheme 690

Use a post hoist with a lifting table and stud guides.

Position the lifting table against the sub-frame.

Note. Make sure that the lifting table is centered under the sub-frame for optimal weight distribution. Check that the lifting table is correctly applied against the sub-frame.

Remove

1. the sub-frame brackets screws
2. the screws for the sub-frame.

Lower the engine and transmission approximately 15 cm so that the drive shafts describe a horizontal line between the hub and transmission.

Unhook the control arms from the ball joint pinion.

Hold the constant velocity joint. Pull the drive shaft off the hub. Let the drive shafts rest against the control arms.

Turn the engine block heater out of its position.

Check that the air conditioning (A/C) compressor is hanging free.

Continue lowering the engine and transmission unit.

Removing the oil sump

Slacken off all screws holding the oil sump.

Remove all screw except for four. It is recommended that the four screws in the corners of the sump are left in place.

Carefully tap the sump with a rubber mallet until the joint and its liquid gasket releases.

Remove the four remaining screws.

Remove the sump.

Cleaning gasket surfaces

Clean the gasket surfaces on the oil sump and cylinder block. Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440.

Scheme 691

Apply liquid gasket 1161 059-9 to the sump. Use roller 9512767 .

Install

1. new O-rings.
2. the oil sump. Secure it loosely with a few screws.
3. the remaining screws loosely.

Scheme 692

Press the sump against the transmission. Tighten the screws (1), (2), (3) and (4) to 3 Nm . First tighten the screws (5) to 25 Nm . Then tighten to 48 Nm .

Tighten all screws in the sump joint to 17 Nm. Start at the transmission and continue forwards in pairs.

Install the screw for the bracket for the fuel line.

Connect the oil cooler to the sump. Use new O-rings. Reinstall the pipe on the sub-frame.

Install

1. a new oil filter.
2. the oil plug with a new gasket.
3. the oil dipstick and its pipe. Use a new O-ring. NOTE: Check that the O-ring is correctly positioned.

Fill with engine oil. Run the engine to operating temperature.

Check for oil leaks from the oil sump or oil cooler.

Install the splashguard under the engine.

Check the oil level. Top up if required.

Auxiliaries belt / belt tensioner, replacing

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 693

1. Use a wrench and turn clockwise as far as possible to relieve the load on the belt
2. Remove the belt.

Scheme 694

1. Remove both the screws for the belt tensioner mounting from the auxiliaries belt bracket
2. Remove the tensioner
3. Install the new belt tensioner. Tighten to 25 Nm .

Installing the auxiliaries belt

Use a wrench and turn the belt tensioner clockwise as far as possible.

Install the belt in the following order

1. 1. Crankshaft
2. 2. Generator (GEN)
3. 3. A/C compressor. Idler pulley
4. 4. Power steering pump
5. 5. Belt tensioner.

Wipe clean.

Carry out a function test

Start the engine.

Check the rotation of the belt and the function of the belt tensioner.

Wipe the steering wheel and gear selector lever clean.

Camshaft seal/variable valve timing (VVT) unit, replacing

Special tools

9995452

9995651

9995719

9995718

9995474

9995451

9995919

9995450

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.

Note. Crankshaft and camshafts must not be turned more than is stated in the method description. If the shafts are turned in any other way the valves may be damaged.

Disconnecting the battery lead

Remove the battery lead. See Battery, disconnecting .

Scheme 695

Remove

1. the screw holding the engine stabilizer brace to the bracket on the engine
2. the screws holding the engine stabilizer brace to the suspension turrets
3. the engine stabilizer brace
4. the inlet hose for the turbocharger (TC) from the air cleaner (ACL) cover. Place it to one side
5. the charge air pipe over the engine. Seal the openings
6. the upper timing belt cover
7. the cover over the ignition coils
8. the brackets for the engine stabilizer brace on the cylinder head
9. the camshaft position (CMP) sensor housing
10. the trigger wheel
11. the cover at the rear edge of the intake camshaft. Insert a screwdriver into the center of the cover and then pry the cover off. NOTE: Clear up any oil spillage under the cover.
12. the servo reservoir and the expansion tank. Lift up and place on top of the engine. WARNING: Ensure that no power steering fluid is spilled. Extremely flammable.

Aligning the engine according to the marking

Raise the vehicle

Remove

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

Install the upper timing belt cover.

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

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

The markings are shown in the illustration.

Remove the upper timing belt cover.

Scheme 696

Remove

1. the belt tensioner
2. the center screw for the belt tensioner slightly.

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

Remove the timing belt from the camshaft pulleys.

Scheme 697

Install camshaft adjustment tool 9995452 at the rear of the camshafts. Screw the adjustment tool sections together into one.

Remove

1. the center plugs for the variable valve timing units (Tx55) NOTE: Collect any oil spillage using paper or similar
2. the center screws for the variable valve timing units (Tx55). Pull or work off the variable valve timing units and timing gear pulleys.

Scheme 698

Carefully press in tool 9995651 between the sealing ring and the camshaft.

Carefully pry out the seal.

Note. For tightening torques, see: Tightening torque .

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.

Use emery cloth 951 1024 to clean the shaft journal and mating surface.

Scheme 699

Lubricate the seal using Volvo quality engine oil.

Install

1. install the new seal for the intake camshaft. Use drift «9995719»(ref-403953-S10206011822011061000000)
2. the new seal for the exhaust camshaft. Use drift «9995718»(ref-403953-S24775656662011061000000) .

Check and adjust the variable valve timing unit. See: Variable valve timing unit, checking and adjusting

Install

1. the mixer. Tighten the screw
2. the camshaft position (CMP) sensor housing. Tighten the screws
3. the cover at the rear edge of the intake camshaft
4. the engine stabilizer brace on the cylinder head. Tighten. See «Summary of specific components and tightening torques»(ref-430997-S07821985842011101900000) .

Install

1. the front timing belt cover
2. the cover over the ignition coils
3. the upper timing belt cover
4. the auxiliaries belt
5. the expansion tank
6. the servo reservoir. Check that the hoses are correctly positioned
7. the starter motor. Tighten the screws at the gearbox unit. See «Summary of tightening torques for specific components»(ref-430990-S19395668212011101900000)
8. the charge air pipe between the charge air cooler (CAC) and the throttle body (TB)
9. the inlet hose for the turbocharger (TC) from the air cleaner (ACL) cover
10. the charge air pipe above the engine. Remove the seals
11. the engine stabilizer brace between the suspension turrets.

Installing the battery lead

Install the battery lead. See Battery, disconnecting .

Install

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

Test drive the car to check the function of the engine.

Remove

1. the screw holding the engine stabilizer brace to the bracket on the engine
2. the screws holding the engine stabilizer brace to the suspension turrets
3. the engine stabilizer brace
4. the solenoid valves. Lift these away from the air cleaner (ACL) cover
5. the air hose from the air cleaner (ACL) for the turbocharger (TC). Put the air hose to one side. Seal the openings
6. the cover over the ignition coils
7. the engine stabilizer brace on the cylinder head
8. the camshaft position (CMP) sensor housing and the trigger wheel.

Scheme 700

Carefully pull out the old seal. Use extractor 9995919 .

Lubricate the new seal using Volvo quality engine oil. Install the seal on the exhaust camshaft. Use drift 9995450 .

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

Note. For tightening torques, see: Tightening torque .

Install

1. the trigger wheel. Tighten the screw
2. the camshaft position (CMP) sensor housing. Tighten the screws
3. the engine stabilizer brace on the cylinder head
4. the cover over the ignition coils
5. the charge air pipe over the engine.

Remove

1. the air cleaner (ACL) cover and the intake air hose
2. the solenoid valves on the air cleaner (ACL) cover
3. the engine stabilizer brace. Tighten the screws
4. the screw holding the engine stabilizer brace to the bracket on the engine. Tighten.

Check the engine compartment. Wipe the engine compartment clean.

Timing belt, replacing

Special tools

9995433

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 is always correct.

Position the engine according to the marking

1. Remove the right front wheel
2. Remove the nut from the cover in the wing liner
3. Install the upper timing belt cover
4. Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond
5. Turn the crankshaft a further 1/4 turn clockwise and then back again until the markings correspond. The markings are shown in the illustration
6. Remove the upper timing belt cover.

Slacken off the belt tensioner.

Slacken off the center screw for the belt tensioner slightly.

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

Remove the timing belt from the tension pulley, camshaft pulley and water pump.

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

Scheme 701

Remove the vibration damper.

Remove the oscillation damper. Use counterhold 9995433 . Work the oscillation damper loose.

Remove the timing belt

Scheme 702

Check bearing wear

1. spin the idler pulley and listen for noise. If replacing with a new idler pulley, tighten to 24 Nm .
2. spin the tension pulley and listen for noise. When replacing, screw the tension pulley into place using the center screw.

Screw in the center screw by hand.

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

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

Scheme 703

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

Install the timing belt over the pulley on the crankshaft.

Install the oscillation damper. Tighten the center nut to 180 Nm . Use counterhold 9995433 .

Remove the counterhold and install new screws. Tighten the screws to 25 Nm . Angle-tighten 30°

Install the new belt in the following order

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

Scheme 704

This adjustment is carried out on a cold engine. A suitable temperature is approximately 20°C/68°F.

At higher temperatures, for example with the engine at operating temperature or at higher ambient temperature, the needle is further to the right.

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

Scheme 705

Tension the timing belt as follows

1. turn the crankshaft clockwise carefully until the timing belt is tensioned. The belt must be tensioned between the intake camshaft pulley, the idler pulley and the crankshaft
2. hold the center screw on the belt tensioner fixed. Turn the belt tensioner eccentric counter-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
3. Secure the eccentric and tighten the center screw to 20 Nm .

Check that the indicator is in the correct position.

For engine serial no. from 3188689

Tension the timing belt as follows

1. turn the crankshaft clockwise carefully until the timing belt is tensioned. The belt must be tensioned between the intake camshaft pulley, the idler pulley and the crankshaft
2. hold the center screw on the belt tensioner fixed. 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
3. Secure the eccentric and tighten the center screw to 20 Nm .

Check that the indicator is in the correct position.

Scheme 706

Checking markings

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 2 turns. 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

Reinstall the removed components

1. the front timing belt cover. Tighten to 12 Nm. .
2. the upper timing belt cover
3. install the auxiliaries belt
4. the servo reservoir
5. the expansion tank. NOTE: Ensure that the hoses are positioned correctly.
6. the cross member. Tighten the screws at the suspension turret to 50 Nm and the screw for the engine bracket to 80 Nm . Wipe clean and check the engine compartment
7. the cover in the wing liner
8. the front wheel according to «Installing wheels»(ref-430991-S20645896442011101900000) .

Checking work

Function test

1. Test drive the engine.

Scheme 707

Remove

1. the upper timing belt cover.

Note. Clean the area around the variable valve timing (VVT) valve thoroughly to prevent anything else than clean oil from entering the channels/ variable valve timing (VVT) valve.

Scheme 708

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

Applies to B5244Sx model years 1999-2001

A modified VVT-solenoid is now available as spare part for B5244Sx model years 1999-2001 . This means that the connector on the cable must be replaced.

Note. Note the position of the electric connections.

Cut the cables next to the connector.

Scheme 709

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

Scheme 710

Remove the lock

Scheme 711

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

Scheme 712

Install the catch.

Install the casing.

Splice the cables. Joining the cables

Scheme 713

Applies to all: Installing 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.

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 714

Relieve the belt. 9997109

Remove the belt

Scheme 715

Remove

1. both mounting screws from the auxiliaries belt bracket for the belt tensioner
2. the belt tensioner. Install the new belt tensioner. Tighten.

Note. For tightening torques, see Tightening torque .

Turn the belt tensioner clockwise as much as possible.

9997109

Fit the belt.

Start the engine.

Check the rotation of the belt and the function of the belt tensioner.

Special tools

9995452

9995651

9995719

9995718

9995474

9995451

9995919

9995450

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.

Note. Crankshaft and camshafts must not be turned more than is stated in the method description If the shafts are turned in any other way the valves may be damaged.

Remove the battery lead. See Battery, disconnecting .

Remove

1. the screw holding the engine stabilizer brace to the bracket on the engine
2. the screws holding the engine stabilizer brace to the suspension turrets
3. the engine stabilizer brace
4. the inlet hose for the turbocharger (TC) from the air cleaner (ACL) cover. Place it to one side
5. the charge air pipe over the engine. Seal the openings
6. the upper timing belt cover
7. the cover over the ignition coils
8. the brackets for the engine stabilizer brace on the cylinder head
9. the camshaft position (CMP) sensor housing
10. the trigger wheel
11. the cover at the rear edge of the intake camshaft. Insert a screwdriver into the center of the cover and then pry it off NOTE: Clear up any oil spillage under the cover.
12. the servo reservoir and the expansion tank. Lift up and place on top of the engine. WARNING: Ensure that no power steering fluid is spilled. Extremely flammable.

Raise the vehicle.

Remove

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

Install the upper timing belt cover.

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

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

The markings are shown in the illustration.

Remove the upper timing belt cover.

Remove

1. the belt tensioner
2. the center screw for the belt tensioner slightly.

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

Remove the timing belt from the camshaft pulleys.

Removing the timing gear pulley with the variable valve timing unit

Install camshaft adjustment tool 9995452 at the rear of the camshafts. Screw the adjustment tool sections together into one.

Remove

1. the center plugs for the variable valve timing units (Tx55) NOTE: Collect any oil spillage using paper or similar.
2. the center screws for the variable valve timing units (Tx55). Pull or work off the variable valve timing units and timing gear pulleys.

Scheme 716

Carefully press in tool 9995651 between the sealing ring and the camshaft.

Carefully pry out the seal.

Note. For tightening torques, see: Tightening torque .

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.

Use emery cloth 951 1024 to clean the shaft journal and mating surface.

Installing the front camshaft seal

Lubricate the seal using Volvo quality engine oil.

Install

1. install the new seal for the intake camshaft. Use drift «9995719»(ref-403953-S10206011822011061000000)
2. the new seal for the exhaust camshaft. Use drift «9995718»(ref-403953-S24775656662011061000000) .

Check and adjust the variable valve timing unit. See: Variable valve timing unit, checking and adjusting .

Install

1. the trigger wheel. Tighten the screw
2. the camshaft position (CMP) sensor housing. Tighten the screws
3. the cover at the rear edge of the intake camshaft
4. the engine stabilizer brace on the cylinder head. Tighten. For tightening torques, see «Tightening torque»(ref-430997-S06371831962011101900000) .

Install

1. the front timing belt cover
2. the cover over the ignition coils
3. the upper timing belt cover
4. the auxiliaries belt
5. the expansion tank
6. the servo reservoir. Check that the hoses are correctly positioned
7. the starter motor. Tighten the screws at the gearbox unit. See «Summary of tightening torques for specific components»(ref-430990-S19395668212011101900000)
8. the charge air pipe between the charge air cooler (CAC) and the throttle body (TB)
9. the inlet hose for the turbocharger (TC) from the air cleaner (ACL) cover
10. the charge air pipe above the engine. Remove the seals
11. the engine stabilizer brace between the suspension turrets.

Install the battery lead. See Battery, disconnecting .

Install

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

Test drive the car to check the function of the engine.

Remove

1. the screw holding the engine stabilizer brace to the bracket on the engine
2. the screws holding the engine stabilizer brace to the suspension turrets
3. the engine stabilizer brace
4. the solenoid valves. Lift these away from the air cleaner (ACL) cover
5. the air hose from the air cleaner (ACL) for the turbocharger (TC). Put the air hose to one side. Seal the openings
6. the air cleaner (ACL) cover. Place it to one side
7. the charge air pipe over the engine. Seal the openings
8. the cover over the ignition coils
9. the upper and lower engine stabilizer braces
10. the camshaft position (CMP) sensor housing and the trigger wheel.

Replacing the rear camshaft seal

Carefully pull out the old seal. Use extractor 9995919 .

Lubricate the new seal using Volvo quality engine oil. Install the seal on the exhaust camshaft. Use drift 9995450 .

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

Note. For tightening torques, see: Tightening torque .

Install

1. the trigger wheel. Tighten the screw
2. the camshaft position (CMP) sensor housing. Tighten the screws
3. the engine stabilizer brace on the cylinder head
4. the cover over the ignition coils
5. the charge air pipe over the engine.

Remove

1. the air cleaner (ACL) cover and the intake air hose
2. the solenoid valves on the air cleaner (ACL) cover
3. the engine stabilizer brace. Tighten the screws
4. the screw holding the engine stabilizer brace to the bracket on the engine. Tighten.

Check the engine compartment. Wipe the engine compartment clean.

See Timing belt, replacing

Variable valve timing solenoid, replacing

See Variable valve timing solenoid, replacing

See Auxiliaries belt / belt tensioner, replacing

Special tools

9995452

9995651

9995719

9995718

9995474

9995451

9995919

9995450

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

Removing the camshaft seal

Note. Crankshaft and camshafts must not be turned more than is stated in the method description If the shafts are turned in any other way the valves may be damaged.

Remove

1. the cable from the battery negative terminal. First read «Battery, disconnecting»(ref-430959-S32245976082011101900000) .
2. the cross stay between the suspension turrets
3. the air intake hose for the turbocharger (TC) from the air cleaner (ACL) cover. Put to one side
4. the upper timing belt cover
5. the cover over the ignition coils
6. the upper engine stabilizer brace
7. the camshaft position (CMP) sensor housing
8. the trigger wheel
9. the servo reservoir and the expansion tank. Lift up and place on top of the engine. WARNING: Ensure that no power steering fluid is spilled. Extremely flammable.
10. the auxiliaries belt
11. the front timing belt cover.

Raise the car.

Remove

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

Install the upper timing 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 turn back counter-clockwise until the markings correspond.

The markings are shown in the illustration.

Remove the upper timing belt cover.

1. Slacken off the belt tensioner
2. Slacken off the center screw for the belt tensioner slightly
3. Hold the center screw still. Turn the tensioner eccentric clockwise to 10 o'clock using a 6 mm Allen key
4. Remove the timing belt from the camshaft pulleys.

Scheme 717

Use camshaft adjustment tool

1. Install camshaft adjustment tool «9995452»(ref-403953-S02369714572011061000000) at the rear of the camshafts.
2. First screw in the part of the tool intended for the exhaust camshaft (drilled hole)
3. Then carefully turn the exhaust camshaft clockwise with the camshaft adjustment tool until the intake camshaft tool can be applied (threaded hole)
4. Install the intake camshaft adjustment tool.

Screw the camshaft adjustment tools together.

Remove

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

Note. Use paper to collect any spilled oil under the variable valve timing units.

Replacing the camshaft seal

Carefully press in tool 9995651 between the sealing ring and the camshaft. Carefully pry out the seal.

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.

Scheme 718

Lubricate the new seal. Install the new seal for the exhaust camshaft. Use drift 9995718 .

Check and adjust the variable valve timing unit. See: Variable valve timing unit, checking and adjusting

Install

1. the front timing belt cover.
2. the torque rod bracket
3. the cover over the ignition coils
4. the upper timing belt cover
5. the auxiliaries belt
6. the expansion tank
7. the servo reservoir. Check that the hoses are correctly positioned
8. the starter motor. Tighten the screws at the gearbox to 40 Nm . Tighten the support bracket screw to 25 Nm
9. the charge air pipe between the throttle body (TB) and the charge air cooler (CAC).

Install

1. the trigger wheel
2. the camshaft position (CMP) sensor housing and a new cover
3. the intake air hose between the turbocharger (TC) and the air cleaner (ACL) cover
4. the engine stabilizer brace. Tighten the screws at the suspension turrets and the screw for motor bracket
5. the negative battery cable. First read «Battery, disconnecting»(ref-430959-S32245976082011101900000) .

Test drive the car to check the function of the engine.

Replacing the rear seal

The following components must be removed when replacing the rear seal

1. the cross stay between the suspension turrets
2. the air hose from the air cleaner (ACL) to the turbocharger (TC). Place to one side. Seal the openings
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 sensor (CMP) housing and trigger wheel.

Pull out the seal. Use puller 9995919 . Use emery cloth 951 1024 to clean the shaft journal and mating surface.

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 pressed in so that it is level with the internal bevelled edge. If the shaft journal is showing signs of wear, the seal can be pressed in 2 mm deeper by turning the drift socket.

Install

1. the trigger wheel
2. the camshaft position (CMP) sensor housing and a new cover
3. the torque rod bracket. Tighten
4. the cover over the ignition coils
5. the charge air pipe over the engine. Remove the seals
6. the air cleaner (ACL) cover and the intake air hose
7. the engine stabilizer brace. Tighten the screws at the suspension turrets and the screw for motor bracket

Check the engine compartment. Wipe the engine compartment clean.

See Timing belt, replacing

See Variable valve timing solenoid, replacing

Special tools

9995722

9997109

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

Scheme 719

Ignition off. Wait 2 minutes.

Remove the cover over the control module box. Put the cover to one side.

Insert tool: 9995722 around the control module. Move the upper section of the tool backwards as far as it will go. Pull up the tool. Carefully pull up the control module.

For vehicles with automatic transmissions repeat the above work.

Remove the surround from around the control module box.

Scheme 720

Note. Make a note of the routing of the belt.

Remove the auxiliaries belt. Use: 9997109 .

Replacing the belt tensioner

Remove

1. both mounting screws from the auxiliaries belt bracket for the belt tensioner
2. the belt tensioner.

Install

1. a new belt tensioner
2. the screws for the belt tensioner. Tighten.

Note. For tightening torques, see: Tightening torque .

Note. Ensure that the auxiliaries belt is correctly positioned on all the pulleys.

Install the auxiliaries belt. Use: 9997109 .

Scheme 721

Install the surround for the control module box.

Carefully press the engine control module (ECM) down into the grooves on the inside of the control module box. Press down all the way.

Install the tool: 9995722 around the control module.

Move the upper section of the tool forwards as far as it will go. Pull up the tool.

Press the cover into place over the control module. Check that the air ducts are correctly positioned.

Start the engine and check the function.

See Camshaft seal/variable valve timing (VVT) unit, replacing

See Timing belt, replacing

See Variable valve timing solenoid, replacing