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Ignition and Control Systems - Removal, Replacement and Installation: Other Volvo XC90 I

Engine Control Systems 68 illustrations ~4975 words

ENGINE CONTROL MODULE (ECM), REPLACING

see ENGINE CONTROL MODULE (ECM), REPLACING

FUEL PUMP DRIVER MODULE

see FUEL PUMP DRIVER MODULE

KNOCK SENSOR (KS), REPLACING

see KNOCK SENSOR (KS), REPLACING

REPLACING THE THERMOSTAT AND/OR ENGINE COOLANT TEMPERATURE SENSOR

see REPLACING THE THERMOSTAT AND/OR ENGINE COOLANT TEMPERATURE SENSOR

TEMPERATURE AND PRESSURE SENSORS, REPLACING

see TEMPERATURE AND PRESSURE SENSORS, REPLACING

Special tools

see 9995722

Scheme 9

Scheme 9: POINTS TO OBSERVE WHEN REPLACING THE CONTROL MODULE
Scheme 9: POINTS TO OBSERVE WHEN REPLACING THE CONTROL MODULE
CAUTIONNew software can only be ordered when the control module is installed in the vehicle. VIDA reads off the new control module identity which is required to order the correct software. The software can only be ordered when the control module is installed in the car.
CAUTIONWait 2 minutes after the ignition has been switched off. The main relay must be voltage-free before the control module can be removed from the car. If the engine cooling fan runs on after the ignition has been switched off, wait until it stops and then wait for another 2 minutes.
CAUTIONAlways check that the control module and control module box connector pins and sleeves are not bent or damaged. This may have caused the fault.

Scheme 10

Scheme 10: REMOVING THE ENGINE CONTROL MODULE (ECM)
Scheme 10: REMOVING THE ENGINE CONTROL MODULE (ECM)
  1. Ignition off. Wait for 2 minutes
  2. Remove the cover over the control module box. Put the cover to one side
  3. Insert tool see «9995722»(ref-460875-S03732819042012033000000) around the control module.
  4. Move the upper section of the tool backwards as far as it will go. Pull up the tool
  5. Carefully pull up the control module.

Scheme 11

Scheme 11: INSTALLING THE ENGINE CONTROL MODULE (ECM)
Scheme 11: INSTALLING THE ENGINE CONTROL MODULE (ECM)
  1. Check that no pins or sockets are damaged on the connector.
  2. Carefully press the control module down into the grooves on the inside of the control module box. Press to the limit position
  3. Insert tool see «9995722»(ref-460875-S03732819042012033000000) around the control module.
  4. Move the upper section of the tool forwards as far as it will go. Pull up the tool
  5. Press the cover into place over the control modules
  6. Check that the air ducts are correctly positioned.

ORDERING SOFTWARE

Order software according to the table below.

XC909438288

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

FINISHING

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

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

FUEL SYSTEM PRESSURE RELEASE

Operation Number(s)

Start the engine.

Remove the fuel pump fuse. Placement may vary between engine types and model year. See the Owner's manual or wiring diagram.

The engine will stop after approx. 20 seconds.

Turn over the engine 3-5 seconds.

Switch off the ignition.

Replace the fuse.

Scheme 12

Scheme 12: REMOVING THE FUEL PRESSURE SENSOR
Scheme 12: REMOVING THE FUEL PRESSURE SENSOR
CAUTIONCollect any spill using paper or similar.

Remove

  1. the tie strap for the cable for the sensor
  2. the screw for the sensor
  3. the sensor.

INSTALLING THE FUEL PRESSURE SENSOR

Note. For tightening torques, see TIGHTENING TORQUE .

Install

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

Remove the seals from the charge air pipe. Reinstall the charge air pipe over the engine.

Start the engine. Check for fuel leakage.

Materials
DesignationPart number
Plug974688
Control module30769225
Cable harness30724838

Note. Removal steps in this procedure may contain installation details.

Scheme 13

Scheme 13: VEHICLES WITH FUEL PUMP DRIVER MODULE LOCATED IN THE RIGHT-HAND REAR WHEEL HOUSING
Scheme 13: VEHICLES WITH FUEL PUMP DRIVER MODULE LOCATED IN THE RIGHT-HAND REAR WHEEL HOUSING

Fuel pump driver modules that are located under the inner fender on the right-hand side in the front part of the rear wheel housing are installed when replacing on the right-hand side under the rear bench

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

Remove

  1. the covers over the seat rails
  2. screws for seat rails-body frame, 12 pcs

Lift out the seats.

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17

Fold the carpet back

Remove

  1. ventilation pipe
  2. the insulation block
  3. the insulation block

Scheme 18

Scheme 18
Scheme 18

Remove the cover on the right-hand side over the fuel pump.

Scheme 19

Scheme 19
Scheme 19

Remove

  1. the cable harness connectors from the fuel pump
  2. connection to the sill
  3. the mounting on the floor for the cable harness

Scheme 20

Scheme 20
Scheme 20

Cut off the removed cable so that both connectors can be removed. This is done so that the cable can be removed from underneath.

Scheme 21

Scheme 21
Scheme 21

Remove the right rear wheel.

Remove the rivet and plastic nuts for the inner fender.

Bend the fender liner out of the way.

Scheme 22

Scheme 22
Scheme 22

Remove

  1. the module from the wheel housing assembly with the mounting
  2. the cable harness with mountings

Scheme 23

Scheme 23: VEHICLES WITH FUEL PUMP DRIVER MODULE LOCATED UNDER THE RIGHT-HAND REAR BENCH SEAT.
Scheme 23: VEHICLES WITH FUEL PUMP DRIVER MODULE LOCATED UNDER THE RIGHT-HAND REAR BENCH SEAT.

Scheme 24

Scheme 24
Scheme 24

Remove

  1. covers over seat rails
  2. the 4 screws

Lift out the seat on the right-hand side.

Scheme 25

Scheme 25
Scheme 25

Fold up the carpet. Detach the sill trim panel slightly.

Carefully lift up the insulation block and place a block under the insulation block to access the module.

Install the new module and connect the cable connector.

Remove the block and fold the carpet back. Press the sill trim panel into place.

Scheme 26

Scheme 26: VEHICLES WITH FUEL PUMP DRIVER MODULE ORIGINALLY LOCATED IN THE RIGHT-HAND REAR WHEEL HOUSING
Scheme 26: VEHICLES WITH FUEL PUMP DRIVER MODULE ORIGINALLY LOCATED IN THE RIGHT-HAND REAR WHEEL HOUSING

Install two rubber plugs for the wheel housing.

Use: Plug, 974688

Install the inner fender with plastic nuts and rivets

Install wheel. See INSTALLING WHEELS

Scheme 27

Scheme 27
Scheme 27

Place the module on the two embossings in the floor leaving a clearance for the seat frame of at least 5 mm.

Use: Control module, 30769225

Remove the protective tape for the Velcro attachments and install the control module.

Install the cable mounting for the connection at the sill, fuel pump and module as well as the mounting in the floor.

Use: Cable harness, 30724838

Check the cover seal for faults and check that the cables are in the cut-outs.

Check that the plugs are in the seal.

Install the cover and tighten to 6 Nm.

Scheme 28

Scheme 28
Scheme 28

Mark and make a hole for the module in the insulation block.

Fold the carpet back

Install

  1. ventilation pipe (1)
  2. the insulation block (2)
  3. the insulation block (3)

Install

  1. the seats. Use new screws, 12 x M10. Tighten to 50 Nm.
  2. the covers over the seat rails

VEHICLES WITH FUEL PUMP DRIVER MODULE ORIGINALLY LOCATED UNDER THE RIGHT-HAND REAR BENCH SEAT.

Install the seat. Use new screws, 4 x M10

Tighten to 50Nm

REMOVING THE KNOCK SENSOR (KS)

Disconnect the battery negative lead. First read, see BATTERY, DISCONNECTING .

Scheme 29

Scheme 29: REMOVING THE KNOCK SENSOR (KS)
Scheme 29: REMOVING THE KNOCK SENSOR (KS)

Remove the intake manifold and gasket. See INTAKE PIPE/GASKET, REPLACEMENT .

Remove

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

Scheme 30

Scheme 30: INSTALLING KNOCK SENSORS (KS)
Scheme 30: INSTALLING KNOCK SENSORS (KS)
CAUTIONTighten to the correct torque. If the knock sensor is over-tightened it may deform. If it is too loose it may disrupt the function of the sensor.
  1. Install the new sensors using the screws in the cylinder block
  2. Route the cables on the outside of the starter motor bracket
  3. Align the sensors (looking from the front)
  4. The cable from the sensor at cylinder 3 = 3 o'clock and from the sensor for cylinder 5 = 6 o'clock
  5. Tighten the knock sensors. See «TIGHTENING TORQUE»(ref-476949-S36419418602012060500000)
  6. Press the knock sensor (KS) connectors together. Check that the wiring is in the correct position. Use a clamp if necessary.

Install the intake manifold according to INTAKE PIPE/GASKET, REPLACEMENT .

Connect the battery lead. See BATTERY, DISCONNECTING .

see REPLACING THE THERMOSTAT AND/OR ENGINE COOLANT TEMPERATURE SENSOR

INSTALLING THE TEMPERATURE AND PRESSURE SENSORS

Install a new sensor.

see ENGINE CONTROL MODULE (ECM), REPLACING

see FUEL PUMP DRIVER MODULE

REPLACING KNOCK SENSORS (KS)

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

Remove

  1. the cable from the battery negative terminal. First read, see «BATTERY, DISCONNECTING»(ref-476746-S00156360512012060500000)
  2. the intake pipe between the front cover plate and the air cleaner (ACL) Detach the pipe from the charge air cooler at the throttle housing. Push the pipe to one side
  3. the dip stick and its holder
  4. the screws for the knock sensors (KS)
  5. the tie strap at the connector. Disconnect the connector. Pull the sensors downwards and past the rear edge of the starter motor bracket.

Scheme 31

Scheme 31: INSTALLING KNOCK SENSORS (KS)
Scheme 31: INSTALLING KNOCK SENSORS (KS)

Install the new sensor. Tighten by hand.

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

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

Tighten the knock sensors (KS) to 20 Nm .

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

Install

  1. the dip stick
  2. the pipe between the throttle body (TB) and the charge air cooler (CAC)
  3. the intake pipe between the front cover plate and the air cleaner (ACL)
  4. the negative battery cable. First read, see «BATTERY, DISCONNECTING»(ref-476746-S00156360512012060500000) .

see TEMPERATURE AND PRESSURE SENSORS, REPLACING

THERMOSTAT / TEMPERATURE SENSOR, ENGINE COOLANT, REPLACING

see THERMOSTAT / TEMPERATURE SENSOR, ENGINE COOLANT, REPLACING

see ENGINE CONTROL MODULE (ECM), REPLACING

Operation Number(s)

Note. Removal steps in this procedure may contain installation details.

Scheme 32

Scheme 32: FUEL PUMP DRIVER MODULE
Scheme 32: FUEL PUMP DRIVER MODULE

Remove

  1. covers over seat rails
  2. screws, 4 pcs.

Fold up the carpet. Detach the sill trim panel slightly.

Carefully lift up the insulation block and place a block under the insulation block to access the module.

Install the new module and connect the cable connector.

Remove the block and fold the carpet back. Press the sill trim panel into place.

Install the seat. Use new screws, 4 x M10. Tighten to 50 Nm.

see REPLACING KNOCK SENSORS (KS)

see TEMPERATURE AND PRESSURE SENSORS, REPLACING

see THERMOSTAT / TEMPERATURE SENSOR, ENGINE COOLANT, REPLACING

CONTROL MODULE FUEL PUMP (FP), REPLACING

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

Remove

  1. the covers over the seat rails
  2. screws, 4 pcs.

Lift out the seat on the right-hand side.

Fold up the carpet. Detach the sill trim panel slightly.

Carefully lift up the insulation block and place a block under the insulation block to access the module.

Disconnect the connector and remove the old module from the Velcro.

Remove the block and fold the carpet back. Press the sill trim panel into place.

Install the seat. Use new screws, 4 x M10

Tighten to 50 Nm.

see ENGINE CONTROL MODULE (ECM), REPLACING

REMOVING THE TEMPERATURE SENSOR

Remove the cap from the expansion tank.

Raise the car. Remove the lower splashguard.

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

Close the cock.

Install the lower splash guard.

Lower the car.

Scheme 33

Scheme 33: REMOVING THE TEMPERATURE SENSOR
Scheme 33: REMOVING THE TEMPERATURE SENSOR

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

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

Remove the cross stay.

Scheme 34

Scheme 34
Scheme 34

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

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

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

Scheme 35

Scheme 35
Scheme 35

Remove

  1. the upper timing belt cover. Lift up the servo reservoir and place it on top of the engine. WARNING: Seal the cover for the servo reservoir. Check that no oil leaks out. Servo oil is highly inflammable.
  2. the screw for the front timing belt cover.
  3. the timing belt cover. Disconnect the connector for the sensor cable.

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

Remove the screw for the cable duct.

Scheme 36

Scheme 36
Scheme 36

Remove the thermostat housing with the cable duct.

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

Scheme 37

Scheme 37
Scheme 37

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

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

INSTALLING THE TEMPERATURE SENSOR

Note. For tightening torques, see TIGHTENING TORQUE .

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

Install

  1. the new sensor. Use a new gasket . Tighten to 20 Nm . Ensure that the sensor cable is correctly routed in the thermostat housing and in the cable duct
  2. the thermostat housing using a new gasket. Tighten to 17 Nm
  3. the screw for the cable duct. Tighten to 10 Nm
  4. the variable valve timing solenoids. Tighten to 10 Nm
  5. the front timing belt cover. See «INSTALLING THE FRONT TIMING COVER»(ref-476755-S27397020582012060500000) . The mudguard over the right drive shaft boot may come loose. If this happens, secure it from underneath
  6. the screw for the front timing belt cover. Tighten to 12 Nm
  7. the servo reservoir. Check that the hoses are correctly positioned
  8. the upper timing belt cover.

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

Install the crankcase ventilation pipe on the intake manifold.

Tighten all hose clamps.

Install

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

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.

Remove the cable from the battery negative terminal. First read, see BATTERY, DISCONNECTING .

Scheme 38

Scheme 38: REMOVING THE KNOCK SENSOR (KS)
Scheme 38: REMOVING THE KNOCK SENSOR (KS)

The intake manifold. See INTAKE MANIFOLD / GASKET, REPLACING .

Scheme 39

Scheme 39
Scheme 39

Remove

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

INSTALLING KNOCK SENSORS (KS)

Note. For tightening torques, see TIGHTENING TORQUE

CAUTIONTighten to the correct torque. If the knock sensor is over-tightened it may deform. If it is too loose it may disrupt the function of the sensor.
  1. Install the new sensors using the screws in the cylinder block
  2. Route the cables on the outside of the starter motor bracket
  3. Align the sensor (looking from the front towards the rear)
  4. The cable from the sensor for cylinder 3 = 3 o'clock and from the sensor for cylinder 5 = 6 o'clock . Tighten the knock sensors. See «SUMMARY OF TIGHTENING TORQUES FOR SPECIFIC COMPONENTS»(ref-476949-S07944404162012060500000) .

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

Install

  1. the intake manifold. See «INSTALLATION»(ref-476768-S09877488862012060500000)
  2. the battery lead. First read, see «BATTERY, DISCONNECTING»(ref-476746-S00156360512012060500000) .

see TEMPERATURE AND PRESSURE SENSORS, REPLACING

see ENGINE CONTROL MODULE (ECM), REPLACING

ENGINE COOLANT TEMPERATURE (ECT) SENSOR, REPLACING

see ENGINE COOLANT TEMPERATURE (ECT) SENSOR, REPLACING

Materials
DesignationPart number
Plug974688
Control module30769225
Cable harness30724838

Note. Removal steps in this procedure may contain installation details.

VEHICLES WITH FUEL PUMP DRIVER MODULE LOCATED IN THE RIGHT-HAND REAR WHEEL HOUSING

Fuel pump driver modules that are located under the inner fender on the right-hand side in the front part of the rear wheel housing are installed when replacing on the right-hand side under the rear bench

Remove

  1. the covers over the seat rails
  2. screws for seat rails-body frame, 12 pcs

Lift out the seats.

Fold the carpet back

Remove

  1. ventilation pipe
  2. the insulation block
  3. the insulation block

Remove the cover on the right-hand side over the fuel pump.

Remove

  1. the cable harness connectors from the fuel pump
  2. connection to the sill
  3. the mounting on the floor for the cable harness

Cut off the removed cable so that both connectors can be removed. This is done so that the cable can be removed from underneath.

Remove the right rear wheel.

Remove the rivet and plastic nuts for the inner fender.

Bend the fender liner out of the way.

Remove

  1. the module from the wheel housing assembly with the mounting
  2. the cable harness with mountings

VEHICLES WITH FUEL PUMP DRIVER MODULE LOCATED UNDER THE RIGHT-HAND REAR BENCH SEAT.

Remove

  1. covers over seat rails
  2. the 4 screws

Lift out the seat on the right-hand side.

Fold up the carpet. Detach the sill trim panel slightly.

Carefully lift up the insulation block and place a block under the insulation block to access the module.

Install the new module and connect the cable connector.

Remove the block and fold the carpet back. Press the sill trim panel into place.

VEHICLES WITH FUEL PUMP DRIVER MODULE ORIGINALLY LOCATED IN THE RIGHT-HAND REAR WHEEL HOUSING

Install two rubber plugs for the wheel housing.

Use: Plug, 974688

Install the inner fender with plastic nuts and rivets

Install wheel. See INSTALLING WHEELS

Place the module on the two embossings in the floor leaving a clearance for the seat frame of at least 5 mm.

Use: Control module, 30769225

Remove the protective tape for the Velcro attachments and install the control module.

Install the cable mounting for the connection at the sill, fuel pump and module as well as the mounting in the floor.

Use: Cable harness, 30724838

Check the cover seal for faults and check that the cables are in the cut-outs.

Check that the plugs are in the seal.

Install the cover and tighten to 6 Nm.

Mark and make a hole for the module in the insulation block.

Fold the carpet back

Install

  1. ventilation pipe (1)
  2. the insulation block (2)
  3. the insulation block (3)

Install

  1. the seats. Use new screws, 12 x M10. Tighten to 50 Nm.
  2. the covers over the seat rails

Install the seat. Use new screws, 4 x M10

Tighten to 50Nm

see KNOCK SENSOR (KS), REPLACING

see TEMPERATURE AND PRESSURE SENSORS, REPLACING

Scheme 40

Scheme 40
Scheme 40

Scheme 41

Scheme 41
Scheme 41

Note. Make sure that the component terminals are not bent or damaged.

Note. Make sure that the seal remains correctly located.

To install, reverse the removal procedure.

Order and download software 9438288 .

ENGINE COOLANT TEMPERATURE SENSOR (ECT)

Drain the cooling system. See COOLING SYSTEM - DRAINING, CHARGING AND BLEEDING .

Scheme 42

Scheme 42: ENGINE COOLANT TEMPERATURE SENSOR (ECT)
Scheme 42: ENGINE COOLANT TEMPERATURE SENSOR (ECT)

Charge the cooling system. See COOLING SYSTEM - DRAINING, CHARGING AND BLEEDING .

KNOCK SENSOR (KS)

Note. Removal steps in this procedure may contain installation details.

Scheme 43

Scheme 43: KNOCK SENSOR (KS)
Scheme 43: KNOCK SENSOR (KS)

Remove the intake manifold. See INDUCTION PIPE .

Scheme 44

Scheme 44
Scheme 44

Remove the oil cooler. See OIL COOLER, ENGINE

Scheme 45

Scheme 45
Scheme 45

Knock sensor. See SUMMARY OF TIGHTENING TORQUES FOR SPECIFIC COMPONENTS

To install, reverse the removal procedure

Scheme 46

Scheme 46: MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
Scheme 46: MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

Scheme 47

Scheme 47
Scheme 47

PRESSURE SENSOR, FUEL RAIL (FRP)

Note. Removal steps in this procedure may contain installation details.

Always read the safety precautions, see: SAFETY INFORMATION GASOLINE

Drain the fuel system. See FUEL SYSTEM PRESSURE RELEASE

Scheme 48

Scheme 48
Scheme 48

M5. See TIGHTENING TORQUE

SAFETY INFORMATION GASOLINE

WARNINGRisk of explosion and fire. Make sure there are no open flames or sparks in the vicinity of fuel system components. It is possible that there is no obvious warning in the form of odor or irritation before a poisonous or hazardous situation arises. This could be immediate or delayed.
WARNINGGasoline for engine operation can contain considerable amounts of benzene, which is toxic if inhaled. The concentration of gasoline fumes must be kept very low. Make sure there is suitable ventilation when handling and using gasoline. The greatest of care must be taken to avoid the serious consequences of inhaling if there is fume build-up from spills in enclosed spaces. High concentrations cause eye/nose/throat irritation, nausea, headaches, depression and signs of insobriety. Very high concentrations result in quick loss of consciousness. Special methods are to be applied to clean and maintain gasoline storage tanks. Gasoline must not be used as a cleaner. Gasoline must not be taken into the mouth. • In the event of skin contact: Take extreme care when handling hot fluids. Always wash spilled fluid off of exposed skin immediately. • In the event of consumption: Consumption can result in mouth and skin irritation and absorption from the stomach can result in drowsiness and loss of consciousness. Small amounts could be fatal to children. • In the event of inhalation: Inhaling fluid into the lungs, through vomiting, is extremely dangerous. Gasoline dries out the skin. Long-term or repeated exposure can cause irritation and skin inflammation. • In the event of contact with the eyes: Fluid in the eyes causes severe pain.
CAUTIONFuel injection equipment is manufactured with extremely tight tolerances and minimum clearance.
CAUTIONIt is vital that the utmost cleanliness is upheld when working with these components. Make sure the area around the vehicle is as clean and free of dust as possible.

see CONTROL MODULE FUEL PUMP (FP), REPLACING

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

Scheme 49

Scheme 49: PREPARATORY WORK
Scheme 49: PREPARATORY WORK

Ignition off.

Disconnect the battery negative cable. See: BATTERY, DISCONNECTING .

Scheme 50

Scheme 50: REMOVING THE ENGINE CONTROL MODULE (ECM)
Scheme 50: REMOVING THE ENGINE CONTROL MODULE (ECM)

Remove the cover by lifting it straight up.

Scheme 51

Scheme 51
Scheme 51

Remove

  1. the connectors, x2
  2. the bolts, x4
  3. the Engine Control Module (ECM).

INSTALLING THE ENGINE CONTROL MODULE (ECM)

Note. Ensure that the rubber seal is positioned correctly in its channel.

Install

  1. the Engine Control Module (ECM)
  2. the bolts, x4
  3. the connectors, x2
  4. the cover
  5. the battery's negative cable in accordance with: «BATTERY, DISCONNECTING»(ref-476746-S00156360512012060500000) .

Order the software in accordance with: 9438288 .

Check that no diagnostic trouble codes (DTC) have been stored in the control module during the repair.

Test drive the vehicle and check the function of the engine.

FUEL PRESSURE AND TEMPERATURE SENSOR, REPLACING

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

INSTALLING THE VACUUM HOSE

Install the vacuum hose (1); secure with the clamp.

INSTALLING THE UPPER ENGINE MOUNT

Install the upper engine mount. Tighten the 4 M10 screws.

INSTALLING THE UPPER CROSS STAY

Install

  1. the upper cross stay between the suspension turrets
  2. the 4 screws in the suspension turrets; tighten
  3. the screw of the cross stay mount on the engine; tighten.

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.

REMOVING THE INTAKE MANIFOLD

Remove the intake manifold. See INTAKE MANIFOLD/GASKET, REPLACING .

Scheme 52

Scheme 52: REMOVING THE KNOCK SENSOR
Scheme 52: REMOVING THE KNOCK SENSOR

Remove

  1. the knock sensor screw
  2. the connector from the knock sensor
  3. the knock sensor.

INSTALLING THE KNOCK SENSOR

Install

  1. the knock sensor.
  2. the screw; tighten as specified: «TIGHTENING TORQUE»(ref-476949-S40663846732012060500000) .
  3. the connector to the knock sensor.

INSTALLING THE INTAKE MANIFOLD

Install the intake manifold. See INTAKE MANIFOLD/GASKET, REPLACING .

CHECK

Start the engine and check the function.

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR, REPLACING

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

Scheme 53

Scheme 53: REMOVAL OF PRESSURE SENSOR INLET AIR
Scheme 53: REMOVAL OF PRESSURE SENSOR INLET AIR

Remove

  1. the connector from the sensor
  2. the 2 screws
  3. the sensor by pulling it straight up.

(In the illustration, the upper engine cover and torque arm are removed to better depict the location of the sensor.)

Note. For tightening torques, see: TIGHTENING TORQUE .

Start the engine and check the function.

TEMPERATURE SENSOR ENGINE COOLANT, REPLACING

Special tools

see 9512885

see 9512957

see 9512953

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

INSTALLING THE PROTECTIVE PLATE

Install

  1. the protective plate
  2. the 6 screws; tighten.

Scheme 54

Scheme 54: REMOVING CONNECTORS
Scheme 54: REMOVING CONNECTORS

Remove

  1. the connector of the injectors from the retainer
  2. the connector; bend aside
  3. the connector from the retainer; bend aside.

Scheme 55

Scheme 55: REMOVING THE COOLANT TEMPERATURE SENSOR
Scheme 55: REMOVING THE COOLANT TEMPERATURE SENSOR

Remove

  1. the connector from the temperature sensor
  2. the temperature sensor using see «9512885»(ref-460875-S14859709362012040200000) .

Note. For tightening torques, see: TIGHTENING TORQUE .

INSTALLING THE COOLANT TEMPERATURE SENSOR

Install

  1. the temperature sensor using see «9512885»(ref-460875-S14859709362012040200000) .
  2. the connector to the temperature sensor.

INSTALLING CONNECTORS

Install

  1. the connector to the injectors
  2. the connector of the injectors in the retainer
  3. the connector in the retainer.

INSTALLING THE AIR CLEANER INTAKE PIPE

Install

  1. the air cleaner intake pipe
  2. the 2 M6 screws; tighten.
CAUTIONMake sure the outlet hose of filling equipment is not blocked as this could damage the cooling system.

Fill with coolant using filling equipment see 9512957 and cover see 9512953 .

Check the oil level in the engine and transmission. Start the engine and allow it to warm to normal operating temperature. Check for leaks and proper function. Fill up fluids as necessary.

POSITION SENSOR CAMSHAFT, REPLACING

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

Scheme 56

Scheme 56: REMOVING THE POSITION SENSOR
Scheme 56: REMOVING THE POSITION SENSOR

Disconnect the connector from the sensor.

Remove

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

INSTALLING THE POSITION SENSOR

Install

  1. the sensor
  2. screws. Tighten.

Connect the connector for the sensor.

Start the engine. Check the function.

Scheme 57

Scheme 57: REMOVING THE ENGINE SPEED (RPM) SENSOR
Scheme 57: REMOVING THE ENGINE SPEED (RPM) SENSOR

Remove the tie strap from the torque rod.

Open the hose clamp.

Remove

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

INSTALLING THE ENGINE SPEED (RPM) SENSOR

Install

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

REMOVING CAMSHAFT POSITION (CMP) SENSOR

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

Scheme 58

Scheme 58: REMOVING CAMSHAFT POSITION (CMP) SENSOR
Scheme 58: REMOVING CAMSHAFT POSITION (CMP) SENSOR

Applies only to B6xx4T

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

Scheme 59

Scheme 59
Scheme 59
  1. Remove the clamp on the hose between the mass air flow (MAF) sensor and the pipe to the turbocharger (TC)
  2. Remove the turbocharger (TC) control valve from the air cleaner (ACL) housing
  3. Disconnect the turbocharger (TC) control valve connector
  4. Remove the air cleaner (ACL) housing. Place it to one side
  5. Remove the hose clamp from the crankcase ventilation and the heater hose.

Scheme 60

Scheme 60
Scheme 60

Hose bracket.

Disconnect the connector at the bracket

Remove the cable from the clamp on the cylinder block.

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

Remove the sensor mounting screw. Pull off sensor.

INSTALLING THE CAMSHAFT POSITION (CMP) SENSOR

Install

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

Applies only to B6xx4T

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

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

REMOVING THE ENGINE SPEED (RPM) SENSOR

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 61

Scheme 61: REMOVING THE ENGINE SPEED (RPM) SENSOR
Scheme 61: REMOVING THE ENGINE SPEED (RPM) SENSOR

Remove

  1. the hose clamp for the air cleaner (ACL) / fresh air intake
  2. the air cleaner (ACL) in the intake pipe
  3. lift out the air cleaner (ACL).

Scheme 62

Scheme 62
Scheme 62

Remove the mounting nut for the sensor.

Pull up the sensor.

Install the sensor. Use a new nut. Tighten to 10 Nm .

Install

  1. the air cleaner (ACL) housing and the hose clamp for the air cleaner (ACL) / fresh air intake
  2. the intake pipe.

CAMSHAFT POSITION SENSOR (CMP)

Note. Removal steps in this procedure may contain installation details.

Scheme 63

Scheme 63
Scheme 63

M6. See TIGHTENING TORQUE

To install, reverse the removal procedure

CRANKSHAFT POSITION SENSOR (CKP)

Note. Removal steps in this procedure may contain installation details.

Scheme 64

Scheme 64
Scheme 64

M6. See TIGHTENING TORQUE

To install, reverse the removal procedure

ENGINE SPEED (RPM) SENSOR, REPLACING

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

REMOVING THE UPPER CROSS STAY

Remove

  1. the 4 screws at the suspension turrets
  2. the screws of the upper engine mount on the engine
  3. the upper cross stay.

REMOVING THE UPPER REAR ENGINE COVER

Remove the upper rear engine cover by pulling it straight up.

Scheme 65

Scheme 65: DISCONNECTING THE ENGINE SPEED SENSOR
Scheme 65: DISCONNECTING THE ENGINE SPEED SENSOR

Remove

  1. the 1 M6 screw of the engine speed sensor; pull out the sensor
  2. the connector from the engine speed sensor.

Note. For tightening torques, see: TIGHTENING TORQUE .

INSTALLING THE ENGINE SPEED SENSOR

Install

  1. the engine speed sensor; tighten the screw
  2. the connector to the engine speed sensor.

INSTALLING THE UPPER REAR ENGINE COVER AND UPPER CROSS STAY

Install

  1. the upper engine cover; press it into the mountings
  2. the upper cross stay between the suspension turrets.
  3. the 4 screws at the suspension turrets; tighten
  4. the screw of the cross stay mount on the upper engine mount; tighten.

Start the engine and check the function.

EXHAUST CAMSHAFT POSITION SENSOR, REPLACING

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

Scheme 66

Scheme 66: REMOVAL OF POSITION SENSOR, CYLINDER 1, 3, 5 AND 7 (BANK 1)
Scheme 66: REMOVAL OF POSITION SENSOR, CYLINDER 1, 3, 5 AND 7 (BANK 1)

Lift the upper coolant hose out of its mounting and bend it aside.

Remove

  1. the connector from the position sensor
  2. the 1 M6 screw
  3. the position sensor.

Remove

  1. the 4 screws at the suspension turrets
  2. the screws of the upper engine mount on the engine
  3. the upper cross stay.

Remove the upper rear engine cover by pulling it straight up.

Scheme 67

Scheme 67: REMOVAL OF POSITION SENSOR, CYLINDER 2, 4, 6 AND 8 (BANK 2)
Scheme 67: REMOVAL OF POSITION SENSOR, CYLINDER 2, 4, 6 AND 8 (BANK 2)

Remove

  1. the M6 screw at the heat shield of the position sensor
  2. the connector from the position sensor
  3. the 1 M6 screw
  4. the position sensor.

INSTALLING THE UPPER REAR ENGINE COVER

Position the upper rear engine cover and press it into place in the mountings.

Install

  1. the cross stay between the suspension turrets
  2. the 4 screws in the suspension turrets; tighten
  3. the screw of the cross stay mount on the upper engine mount; tighten.

Start the engine and check the function.

INTAKE CAMSHAFT POSITION SENSOR, REPLACING

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

REMOVING THE FUEL RAIL

Remove the fuel rail.

Scheme 68

Scheme 68: REMOVING THE INTAKE CAMSHAFT POSITION SENSOR
Scheme 68: REMOVING THE INTAKE CAMSHAFT POSITION SENSOR

Remove

  1. the connector from the position sensor
  2. the screw
  3. the intake camshaft position sensor.

Note. For tightening torques, see: TIGHTENING TORQUE .

INSTALLING THE INTAKE CAMSHAFT POSITION SENSOR

Install

  1. the intake camshaft position sensor
  2. the screw
  3. the connector for the position sensor.

INSTALLING THE FUEL RAIL

Install the fuel rail.

IGNITION COIL, REPLACING

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

REMOVING THE ENGINE COVERS

Remove the upper engine covers by pulling straight up.

Scheme 69

Scheme 69: REMOVAL OF IGNITION COILS, CYLINDER 1, 3, 5 AND 7 (BANK 1)
Scheme 69: REMOVAL OF IGNITION COILS, CYLINDER 1, 3, 5 AND 7 (BANK 1)

Remove

  1. the 4 connectors from the ignition coils
  2. the 4 screws of the ignition coils
  3. the 4 ignition coils of the cylinders.

Scheme 70

Scheme 70: REMOVAL OF IGNITION COILS, CYLINDER 2, 4, 6 AND 8 (BANK 2)
Scheme 70: REMOVAL OF IGNITION COILS, CYLINDER 2, 4, 6 AND 8 (BANK 2)

Remove

  1. the 2 screws of the cable harness
  2. the retaining screw of the upper engine cover.

Carefully bend aside the cable harness.

Remove

  1. the 4 connectors from the ignition coils
  2. the 4 screws of the ignition coils
  3. the 4 ignition coils of the cylinders.

Note. For tightening torques, see: TIGHTENING TORQUE .

INSTALLING THE ENGINE COVERS

Install the engine covers over the front and rear cylinder bank.

Scheme 71

Scheme 71: REMOVING IGNITION COILS
Scheme 71: REMOVING IGNITION COILS

Remove

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

Scheme 72

Scheme 72
Scheme 72
  1. the upper timing belt cover
  2. the cover over the ignition coils Disconnect the ignition coil connector.
  3. the mounting screw. Pull the coil up.

INSTALLING IGNITION COILS

Install the new coil.

Align the coil and press it down. Install the screw. Tighten to 10 Nm .

Press in the connector until a clicking sound is heard.

Install the cover over the ignition coil.

Install the upper timing belt cover.

Remove the seals from the charge air pipe. Reinstall the charge air pipe over the engine.

REMOVING IGNITION COIL

Remove

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

Scheme 73

Scheme 73
Scheme 73
  1. upper camshaft belt cover
  2. the ignition coils cover
  3. the ignition coil connector
  4. mounting screw and pull up the coil.

INSTALLING IGNITION COIL

Install a new coil.

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

Press in the connector until a clicking sound is heard.

Install the ignition coil cover.

Install upper camshaft belt cover.

Applies only to B6xx4T

Remove the seals.

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

IGNITION COIL

Note. Removal steps in this procedure may contain installation details.

Scheme 74

Scheme 74
Scheme 74

Scheme 75

Scheme 75
Scheme 75

M6. See TIGHTENING TORQUE

To install, reverse the removal procedure

SPARK PLUGS

Note. Removal steps in this procedure may contain installation details.

Remove the ignition coils. See IGNITION COIL .

Scheme 76

Scheme 76: SPARK PLUGS
Scheme 76: SPARK PLUGS

Spark plugs. See TIGHTENING TORQUE

To install, reverse the removal procedure

see IGNITION COIL

see SPARK PLUGS

More articles — Ignition and Control Systems - Removal, Replacement and Installation