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Home >> Volvo >> 2001 >> V70 2.4T L5-2.4L Turbo VIN 58 B5244T3 >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Timing Components >> Camshaft Gear/Sprocket >> Service and Repair

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.

Removal

CAUTION: 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.

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:





- the cable from the battery negative terminal.
- the cross stay between the suspension turrets
- the upper timing belt cover
- the cover over the ignition coils
- the inlet hose between the air cleaner (ACL) and throttle body (TB)
- the crankcase ventilation hose from the inlet hose
- place the inlet hose to one side
- the upper engine stabilizer brace
- the camshaft position (CMP) sensor housing
- the trigger wheel
- the rear cover for the intake camshaft
- the servo reservoir and the expansion tank. Lift them up and place them on top of the engine

WARNING: Ensure that no power steering fluid is spilled. Extremely flammable.

- the auxiliaries belt
- the front timing belt cover.

Position the engine according to the marking
- Raise the car.

Remove:





- the right front wheel
- the nuts for the cover in the fender liner.
Install the upper timing belt cover.
Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond.
Remove the upper timing belt cover.

Removing the timing belt





Slacken off the belt tensioner.
- Slacken off the center screw for the belt tensioner slightly.
- Hold the center screw in place. 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





- Use Camshaft Adjustment Tool:
- Install camshaft adjustment tool 999 5452 at the rear of the camshafts.

Remove:
- the plug at the front edge of the variable valve timing unit (TORX 55)
- the center screw in the variable valve timing unit (TORX 55). Carefully pull out the timing gear pulley with the VVT unit
- timing gear pulley without VVT
- the screws and the timing gear pulley.

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 any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

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

Installing the front camshaft seal

Lubricate the seal using Volvo quality engine oil





Install
- Install the new seal for the exhaust camshaft. Use drift 999 5719.
- Install the new seal for the intake camshaft. Use drift 999 5718.

Installing the crankshaft adjustment tool





- the charge air pipe between the charge air cooler (CAC) and the throttle body
- Remove the 3 mounting screws for the starter motor. Place the starter motor to one side.
- the blind cover plug 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 back counter-clockwise. 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 procedure, "Installing the VVT unit/timing gear pulley", 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 VVT unit.
- Press the variable valve timing unit/timing gear onto the camshaft. Install the center screw which secures the VVT 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 its limit position at the oval holes.
- Tighten the center screw for the variable valve timing (VVT) unit.
- Check that the variable valve timing unit does not rotate when tightening.
- Install the center plug.

Installing the timing gear pulley for the camshafts.






Install the timing gear pulley on the intake camshaft with two screws, but do not tighten. Check that the markings on the timing gear pulley and the upper cover correspond

Timing belt, installing

Install the timing belt:





Turn the variable valve timing unit clockwise to the stop. Hold the variable valve timing unit secure in the limit position.

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 pulley
- exhaust cam pulley
- water pump
- belt tensioner.

NOTE: Adjust the timing gear pulleys so that the screws are not at a limit position in 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 adjustment is carried out on a cold engine. A suitable temperature is approximately 20 degree C / 68 degree 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.

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. Tighten.

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:
- the camshaft adjustment tools
- the crankshaft stop.
Install the plug with a new sealing washer. Tighten

Checking the markings and belt tension





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

Installing the battery lead
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.

Rear camshaft seal


The following components must be removed when replacing the rear camshaft seal:
- the inlet hose between the air cleaner (ACL) and throttle body (TB)
- the crankcase ventilation hose from the inlet hose
- place the air cleaner (ACL) cover to one side
- the cover over the ignition coils
- the upper torque rod bracket
- the camshaft position sensor (CMP) housing and trigger wheel.

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.

Removal and Installation

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

Installing components





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




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