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Replacing the Timing Belt Replacing the Timing Belt

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Replacing the Timing Belt Replacing the Timing Belt "VCC -145044 EN 2009 -10 -28" Replacing the timing belt Special tools: 999 5433 , 999 5456 Removing the timing belt Note! As the illustrations in this service informationinformation araree used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct. Preparation Caution! Remove the ignition key. Remove - the screw holding the engine stabiliser brace to the bracket on the engine - the screws holding the engine stabiliser brace to the suspension turrets - the engine stabiliser brace. Applies only to B6xx4T engines: Remove the plastic pipes between the turbocharger (TC) and charge air cooler (CAC) and between the air cleaner (ACL) and turbocharger (TC). Put them to one side. Remove the clamp from the intake manifold for the turbocharger (TC) for cylinders 1, 2 and 3. Turn the upper section of the pipe towards the bulkhead. Relieve the load from the belt tensioner. Remove the auxiliaries belt. Remove the upper timing belt cover. Remove the front timing belt cover. For cars with chassis numbers 203779203779----, see Timing cover front, replacing . Lift up the servo reservoir and place it on top of the engine. Note! Ensure that the oil does not leak from the ventilation hole in the filler cap. Seal the hose between the expansion tank and the radiator. Disconnect the hose at the tank. Lift up the expansion tank and place it on top of engine. Raise the car. Remove - the right front wheel - the plastic nuts on the cover in the wing liner. Install the upper timing belt cover. Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulleys correspond. Turn the crankshaft a further 1/4 turn clockwise. Then turn back counter-clockwise until the markings © Copyright 2004 Volvo Car Corporation. All rights reserved. 1(11) "VCC -145044 EN 2009 -10 -28" correspond. Remove the upper timing belt cover. Remove the 4 vibration damper screws. Counterhold the crankshaft central nut. Remove - the vibration damper - the auxiliaries belt - the belt cover behind the crankshaft pulley for the auxiliaries belt. Spray universal oil or similar around the rubber sleeve on the underside of the oil pump. Remove the rubber sleeve. Removing the timing belt Slacken off the belt tensioner Slacken off the centre screw for the belt tensioner slightly. Hold the centre screw still. Turn the tensioner eccentric countercounter----clockwiseclockwise using a 6 mm Allen key. Turn to 10 o'clock. Unhook and remove the timing belt. Caution! Do not turn the camshafts or the crankshaftcrankshaft when the timing belt has been removed. Checking the tensioner pulley and idler pulley Check bearing wear: Spin the idler pulley and listen for noise. If replacing with a new idler pulley, tighten to 24 Nm . Spin the tension pulley and listen for noise. When replacing, screw the tension pulley into place using the centre screw. Screw in the centre screw by hand. Ensure that the tensioner fork is centred over the cylinder block rib / bracket. Ensure that the Allen hole on the eccentric is at "10 o'clock". Installing the timing belt IIInInnnssssttttaaaalllllliiiinnnngggg ttththhheeee tttitiiimmmmiiiinnnngggg bbbebeeelllltttt © Copyright 2004 Volvo Car Corporation. All rights reserved. 2(11) "VCC -145044 EN 2009 -10 -28" Install the belt in the following order: - crankshaft - the idler pulley - intake cam - exhaust cam - water pump - tension pulley. Note! The variable valve timing unit on B6304S engines does not have a return spring. The unit is easily dislodged when reinstalling the timing belt. Tensioning the timing belt This adjustment is carried out on a cold engine. A suitable temperature is approximately 20 ° C / 68 ° F. At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right. The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures. Carefully turn the crankshaft clockwise until the timing belt is tensioned. The belt must be in tension between the intake camshaft pulley, the idler pulley and the crankshaft. Hold the belt tensioner centre screw secure. Turn the belt tensioner eccentric clockwise until the tensioner indicator passes the marked position. Then turn the eccentric back so that the indicator reaches the marked position in the centre of the window. Hold the eccentric secure. Tighten the centre screw to 25 Nm. Check that the indicator is in the correct position. Check Press the belt to check that the indicator on the tensioner moves easily. Install the upper timing belt cover. Turn the crankshaft 2 turns. Check that the markings on the crankshaft and camshaft pulley correspond. Check that the indicator on the belt tensioner is within the marked area. © Copyright 2004 Volvo Car Corporation. All rights reserved. 3(11) "VCC -145044 EN 2009 -10 -28" Finishing Install the auxiliaries belt around the pulley on the crankshaft. Install - the rubber sleeve on the underside of the oil pump - the vibration damper. Use new screws . Tighten to 35 Nm . Angle-tighten 50° . Use the crankshaft centre nut as a counterhold - the plastic nuts for the cover in the right-hand wing liner - the right front wheel. See Installing wheels . Lower the car. - the front timing belt cover. For cars with chassis numbers 203779203779----, see Timing cover front, replacing . Tension the auxiliaries belt. - the expansion tank - the hose between the expansion tank and the radiator. Remove the lock grip pliers - the servo reservoir - the upper timing belt cover. Applies only to B6xx4T engines: Twist the intake pipe for the turbocharger for cylinders 1, 2 and 3 into position. Tighten the clamp. Install the plastic hoses between the turbocharger (TC) and the charge air cooler and between the air cleaner (ACL) and the turbocharger (TC). Tighten the hose clamps. - the engine stabiliser brace. Tighten to 50 Nm - the screw holding the engine stabiliser brace to the bracket on the engine. Tighten to 80 Nm . © Copyright 2004 Volvo Car Corporation. All rights reserved. 4(11) "VCC -145044 EN 2009 -10 -28" Final check Check and top up if required - coolant level - the servo fluid level. Test drive the engine. Replacing the camshaft seals / variable valve timing unit Removing the front camshaft seal Note! The illustrations in this service information are used for different model years and / or models. Therefore there may be some variation. However, the essential information in the illustrations is always correct. Caution! There are a number of versions of the variablevariable valve timing unit. Therefore it is extremely important to always read the information referring to the engine variant/model year to be remedied. Replacing the rear camshaft seal See Removing/Installing the rear camshaft seal . Preparation Caution! Interrupt the current: Disconnect the batterybattery negative lead. First read Note when disconnecting/connecting the battery lead . Remove the timing belt from the timing gear pulley for the camshafts. See Replacing the timing belt . Check the tensioner and idler pulleys. See Replacing the timing belt . Remove camshaft position (CMP) sensor housing and the trigger wheel. Remove the cover at the rear edge of the camshaft. Removing the variable valve timing unit / timing gear pulley Install adjustment tool 999 5452 at the rear of the camshafts. Screw the adjustment tool sections together into one. Remove the plug from the front © Copyright 2004 Volvo Car Corporation. All rights reserved. 5(11) "VCC -145044 EN 2009 -10 -28" edge of the variable valve timing unit (Tx55). Remove the centre screw from the variable valve timing unit (Tx55). Carefully pull out the variable valve timing unit with the timing gear pulley. The following applies to timing gear pulleys without variable valve timing: Remove the screws. Remove the timing gear pulley. Removing the front camshaft seal Carefully press in tool 999 5651 between the seal and the camshaft. Pry out the seal. Installing the front camshaft seal Note! The purpose of the “““Installing“Installing the VVT unit/timing gear pulleypulley”” section described here is to ensure that the VVT unit is correctly positioned and to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later faultfault----tracing.tracing. Note! For tightening torques, see Tightening torque . Cleaning To clean the shaft journal and mating surface, use emery cloth P/N 951 1024. Note! When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed. Installing the front camshaft seal Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal. For camshafts with variable valve timing: Use drift 999 5718 . Use the mounting screw for the variable valve timing unit. Tighten until the drift bottoms out. for camshafts without variable valve timing: Use drift 999 5719 . © Copyright 2004 Volvo Car Corporation. All rights reserved. 6(11) "VCC -145044 EN 2009 -10 -28" Checking the variable valve timing (VVT) unit Check the variable valve timing (VVT) unit. See: Variable valve timing unit, checking and adjusting Finishing Install: - the starter motor. Tighten screws at gearbox. Tighten. See Tightening torque - the screw at the support bracket for the starter motor. Tighten - the trigger wheel. Tighten the screw - the camshaft position (CMP) sensor housing. Tighten the screws - the new cover in the rear edge of the camshaft - the intake pipe between the charge air cooler (CAC) and the electronic throttle module (ETM). Install the auxiliaries belt around the pulley on the crankshaft. Install: - the plastic nuts for the cover in the right-hand wing liner - the right front wheel. See Installing wheels .
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