Camshaft Gear/Sprocket: Service and Repair
Camshaft Seal/variable Valve Timing (VVT) Unit, replacing
Special tools: 999 5452, 999 5651, 999 5719, 999 5718, 999 5474, 999 5451, 999 5919, 999 5450
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.
Warning: There are a number of versions of the variable valve timing unit. Therefore it is extremely important to always read the information referring to the engine variant/model year to be remedied.
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.
Preparatory Work
Disconnecting The Battery Lead
Remove the battery lead.
Removal
Removing components
Remove:
- the screw holding the engine stabilizer brace to the bracket on the engine
- the screws holding the engine stabilizer brace to the suspension turrets
- the engine stabilizer brace
- the inlet hose for the turbocharger (TC) from the air cleaner (ACL) cover. Place it to one side
- the charge air pipe over the engine. Seal the openings
- the upper timing belt cover
- the cover over the ignition coils
- the brackets for the engine stabilizer brace on the cylinder head
- the camshaft position (CMP) sensor housing
- the trigger wheel
- 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.
- 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:
- the right front wheel
- the nuts for the cover in the fender liner
Install the upper timing cover
Turn the crankshaft clockwise. turn until the markings on the crankshaft and camshaft pulley correspond.
Turn the crankshaft a further quarter turn clockwise, then turn back counter-clockwise until the markings correspond.
The markings are illustrated
Remove the upper timing cover
Removing The Timing Belt
- the belt tensioner
- 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 999 5452 at the rear of the camshafts. Screw the adjustment tool sections together into one.
Remove:
- the center plugs for the variable valve timing units (Tx55)
Note: Collect any oil spillage using paper or similar.
- the center screws for the variable valve timing units (Tx55). Pull or work off the variable valve timing units and timing gear pulleys.
Removing The Front Camshaft Seal
Carefully press in tool 999 5651 between the sealing ring and the camshaft.
Carefully pry out the seal.
Installation
Cleaning
Note! When cleaning work around the shaft journal, not in and out. It is essential that 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:
- install the new seal for the intake camshaft. Use drift 999 5719
- the new seal for the exhaust camshaft. Use drift 999 5718
Installing The Crankshaft Adjustment Tool
Remove:
- the charge air pipe between the charge air cooler (CAC) and the throttle body (TB)
- the 3 mounting screws for the starter motor. Move the starter motor to one side
- the blind cover plug for the hole for the adjustment tool.
Turn the crankshaft slightly clockwise.
Install adjustment tool 999 5451. Ensure that the camshaft adjustment tool reaches the cylinder block.
Aligning The Crankshaft
Carefully turn the crankshaft counterclockwise. Turn the crankshaft until it stops against the crankshaft adjustment tool. Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.
Installing The Variable Valve Timing (VVT) Unit On The Exhaust Camshaft
Note: The purpose of the "installing the VVT unit/timing gear pulley" 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 fault-tracing.
Slacken off, but do not remove, the screws which secure the timing gear pulley to the variable valve timing unit.
Press the timing gear pulley and variable valve timing (VVT) unit on to the camshaft. Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly
Turn the variable valve timing unit counter-clockwise as far as it will go. Remove the center screw. Position the upper timing cover. Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position. Continue turning clockwise until the timing gear pulley marking is 1 cog before the marking on the upper timing cover.
Note: Do not turn counter clockwise during this procedure.
Check that the timing gear pulley is still in the limit position in the oval holes. Tighten the center screw in the VVT unit.
Check that the variable valve timing unit does not rotate when tightening. Tighten the center plug.
Installing The Timing Gear Pulley On The Intake Camshaft
Install the timing gear pulley on the intake camshaft using the 2 screws, but do not tighten. Check that the markings on the timing gear pulley and the upper timing cover correspond.
Installing The Timing Belt
Turn the variable valve timing unit clockwise to the stop. Hold it secure in the limit position (Tx55).
Caution: It is essential that the variable valve timing unit is turned up to ensure correct VVT control.
Install The Belt In The Following Order:
- crankshaft
- the idler pulley
- intake cam
- exhaust cam
- water pump
- tension pulley.
Note: Adjust the timing gear pulleys so that the screws are not at the limit positions in any of the oval holes.
The limit position fixture for the variable valve timing unit can now be released separately. However great care must be taken.
Tensioning The Timing Belt
This setting is carried out on a cold engine. A suitable temperature is approximately 20 degree C. At higher temperatures, for example when the engine is hot or in high ambient temperatures, the needle is further to the right. The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.
Tighten The Timing Belt
Turn the variable valve timing unit counter-clockwise as far as it will go. Hold it secure in the limit position (Tx55).
Caution: It is extremely important that the variable valve timing unit is kept tensioned in order to obtain the correct functionality from the variable valve timing unit.
Hold the center screw secure and turn the belt tensioner eccentric counter clockwise. Turn the belt tensioner eccentric until the tensioner indicator passes the marked position and reaches the limit position. Tighten the 3 screws on the timing gear pulley for the exhaust camshaft. Tighten.
Tighten the 3 screws on the timing gear pulley for the intake camshaft.
Note: The variable valve timing unit must not be released from the limit position until after the timing gear pulleys have been tightened.
Turn the eccentric back so that the indicator reaches the marked position in the center of the window. Remember to hold the center screw secure at the same time. Hold the eccentric in place and tighten the center screw. Tighten. Check that the indicator is in the correct position.
Remove:
- camshaft adjustment tools 999 5452 from the rear edge of the camshafts
- crankshaft stop 999 5451.
Install the plug with a new blind cover plug. Tighten.
Checking The Markings And Belt Tension
Press the toothed belt to check that the indicator on the tensioner moves easily. Position the upper timing cover. Turn the crankshaft 2 rotations and check that the markings on the crankshaft and camshaft pulleys correspond. Check that the indicator on the belt tensioner is within the marked position.
Remove the upper timing cover.
Installing Components
Install:
- the mixer. Tighten the screw
- the camshaft position (CMP) sensor housing. Tighten the screws
- the cover at the rear edge of the intake camshaft
- the engine stabilizer brace on the cylinder head. Tighten.
Install:
- the front timing belt cover
- the cover over the ignition coils
- the upper timing belt cover
- the auxiliaries belt
- the expansion tank
- the servo reservoir. Check that the hoses are correctly positioned
- the starter motor. Tighten the screws at the transmission unit.
- the charge air pipe between the charge air cooler (CAC) and the throttle body (TB)
- the inlet hose for the turbocharger (TC) from the air cleaner (ACL) cover
- the charge air pipe above the engine. Remove the seals
- the engine stabilizer brace between the suspension turrets.
Finishing
Install the battery lead.
Installing components
Install:
- the nuts for the cover in the fender liner
- the right front wheel.
Checking The Engine
Test drive the car to check the function of the engine.
Preparatory work
Removing components
Remove:
- the screw holding the engine stabilizer brace to the bracket on the engine
- the screws holding the engine stabilizer brace to the suspension turrets
- the engine stabilizer brace
- the solenoid valves. Lift these away from the air cleaner (ACL) cover
- the air hose from the air cleaner (ACL) for the turbocharger (TC). Put the air hose to one side. Seal the openings
- the cover over the ignition coils
- the engine stabilizer brace on the cylinder head
- the camshaft position (CMP) sensor housing and the trigger wheel.
Replacing The Rear Camshaft Seal
Carefully pull out the old seal. Use extractor 999 5919.
Lubricate the new seal using Volvo quality engine oil. Install the seal on the exhaust camshaft. Use drift 999 5450
Note: The seal is normally pressed in so that it is level with the internal beveled edge. If the shaft journal is showing signs of wear, the seal can be pressed in 2 mm deeper by turning the drift socket.
Finishing
Install:
- the trigger wheel. Tighten the screw
- the camshaft position (CMP) sensor housing. Tighten the screws
- the engine stabilizer brace on the cylinder head
- the cover over the ignition coils
- the charge air pipe over the engine.
Remove:
- the air cleaner (ACL) cover and the intake air hose
- the solenoid valves on the air cleaner (ACL) cover
- the engine stabilizer brace. Tighten the screws
- the screw holding the engine stabilizer brace to the bracket on the engine. Tighten.
Check the engine compartment. Wipe the engine compartment clean.