Your Vehicle: 2000 Volvo S80 T6 L6-2.8L Turbo VIN 90 B6284T
       
 
Vehicle » Engine, Cooling and Exhaust » Engine » Camshaft Gear/Sprocket » Service and Repair » Front Camshaft Seal Variable Valve Timing (VVT) Unit icon_note_blank.gif  Notes
 
 
  Front Camshaft Seal Variable Valve Timing (VVT) Unit  
 

Special Tools
999 5452
999 5651
999 5718
999 5719
999 5451
999 5919
999 5450
999 5750

Replacing the front camshaft seal variable valve timing (VVT) unit

Note: As the illustrations in the information are used for different model years and / or models, certain variations may occur. However, the essential information in the illustrations is always correct.

Preparation

Caution: Interrupt the current by removing the battery negative lead. First read Note when disconnecting / connecting the battery lead.

Removing components

Remove

  

  • the screw for the torque rod mounting at the bracket on the engine.
  • the screws at the cross rod mounting at the right suspension turret.

Applies only to B6xx4T engines:
Remove the plastic pipes between the turbocharger (TC) / charge air cooler and between the air cleaner (ACL) / turbocharger (TC). Place them to one side.
Remove the clamp for the intake manifold at the turbocharger (TC) for cylinders 1, 2 and 3 and turn the upper section of the pipe towards the firewall.

  

Relieve the load from the belt tensioner. Remove the auxiliaries belt.

Raise the cross rod and remove
  • the upper camshaft belt cover.
  • the front camshaft belt cover. Lift up the servo reservoir and place it on top of the engine

Note: Ensure that 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 care and remove.

  • the right front wheel.
  • the plastic nuts from the cover in the fender liner.

Aligning the engine

  

Position the upper timing cover.
Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond.

Remove
  • the upper timing cover.
  • the deflection limiter washer from the piston rod for the tensioner / damping unit.

Compressing the tensioner / damping unit

  

Screw together and install tool 999 5750 between the lever wheel and the lifting lug at the power steering pump.
Unscrew the screw in the tool so that there is clearance of approximately 10 mm (0.39 inch) between the screw head and the tool.
Allow the tool spring to compress the tensioner / damping unit.

Remove
  • the camshaft position (CMP) sensor housing and the trigger wheel.
  • the cover in the rear edge of the camshaft.

Removing the variable valve timing (VVT) unit / timing gear pulley B6xx4S

  

Install camshaft adjustment tool 999 5452at the rear edge of the camshafts.
Screw the adjustment tool sections together into one.
Remove the plug from the front edge of the variable valve timing (VVT) unit (Tx55).
Remove the center screw from the variable valve timing (VVT) unit (Tx55).
Carefully pull out the variable valve timing (VVT) unit with the timing gear pulley.

The following applies to timing gear pulleys without variable valve timing (VVT) :
Remove the screws.
Remove the timing gear pulley.

Removing the variable valve timing (VVT) unit / timing gear pulley B6xx4T

  

Install camshaft adjustment tool 999 5452at the rear edge of the camshafts.
Screw the adjustment tool sections together into one.
Remove the center plug at the front edge of the variable valve timing (VVT) unit (Tx55).
Remove the center screw from the variable valve timing (VVT) unit (Tx55).
Carefully pull out the variable valve timing (VVT) unit with the timing gear pulley.

The following applies to timing gear pulleys without variable valve timing (VVT) :
Remove the screws.
Remove the timing gear pulley.

Replacing the camshaft seal

  

Carefully press in tool 999 5651between the seal and the camshaft. Pry out the seal.
Lubricate and install a new seal.
For camshafts with variable valve timing (VVT) use drift 999 5718.
For camshafts without variable valve timing (VVT) use drift 999 5719.

Installing the crankshaft adjustment tool

  

Remove the starter motor mounting screws. Pull out the starter motor and place it to one side.
Remove the blind cover plug from the hole for the adjustment tool. Turn the crankshaft clockwise slightly. Install camshaft adjustment tool 999 5451, ensure that it reaches down as far as the cylinder block.
Turn the crankshaft counter-clockwise until it stops against the 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 / timing gear pulley B6xx4S

  

Installing the variable valve timing (VVT) unit with the timing gear pulley
Slacken off, but do not remove, the screws which secure the timing gear pulley to the variable valve timing (VVT) unit.
Press the variable valve timing (VVT) unit / timing gear pulley on the camshaft.
Install the center screw which secures the variable valve timing (VVT) unit to the camshaft and tighten slightly.
Turn the variable valve timing (VVT) unit anti-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 1/2 Cog before the marking on the upper timing cover

Note: Do not turn anti-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 variable valve timing (VVT) unit to 120 Nm (88 ft. lbs.) .
Check that the variable valve timing (VVT) unit does not rotate when tightening.
Install and tighten the center plug to 35 Nm (26 ft. lbs.) .
Turn the variable valve timing (VVT) unit clockwise to the limit position.
Turn the timing gear pulley so that the markings correspond.

Installing the timing gear pulley on the exhaust camshaft
Install the timing gear pulley on the exhaust camshaft with two screws, but do not tighten.

Installing variable valve timing (VVT) unit / timing gear pulley B6xx4T

  

Installing the variable valve timing (VVT) unit with the timing gear pulley
Slacken off, but do not remove, the screws which secure the timing gear pulley to the variable valve timing (VVT) unit.
Press the variable valve timing (VVT) unit / timing gear pulley on the camshaft.
Install the center screw which secures the variable valve timing (VVT) unit to the camshaft. Do not tighten yes!
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 1/2 Cog before the marking on the upper timing cover

  

Check that the timing gear pulley is still in the limit position in the oval holes.
Tighten the center screw in the variable valve timing (VVT) unit to 120 Nm (88 ft. lbs.) .
Check that the variable valve timing (VVT) unit does not rotate when tightening.
Tighten the center plug to 35 Nm (26 ft. lbs.) .

Installing the timing gear pulley on the intake camshaft
Install the timing gear pulley on the intake camshaft with two screws, but do not tighten.

Finishing

  

Install the tensioner / damping unit. Tighten to 25 Nm (18 ft. lbs.) .

Note: Applies only to B6xx4T engines: Turn the variable valve timing (VVT) unit clockwise until stop. Hold it secure in the limit position.

Install the belt in the following order:
  • crankshaft.
  • idler pulley.
  • intake cam.
  • exhaust cam.
  • water pump.
  • tension pulley. The variable valve timing (VVT) unit on B6304S engines does not have a return spring. It is easily dislodged when reinstalling the timing belt.

Note: Adjust the timing gear pulleys so that the screws are not at the limit positions in any of the oval holes.

Tighten the timing belt

  

Screw together and remove compression tool 999 5750.
Optimize the camshaft belt tension by pressing it between the camshaft timing gear pulleys and between the water pump and exhaust camshaft.

Note: Applies to B6xx4S engines: Check that the variable valve timing (VVT) unit is in its limit position.

Note: Applies to B6xx4T engines: The variable valve timing (VVT) unit must not be released from the limit position until after the timing gear pulleys have been tightened.

Tighten the three timing gear pulley screws on the variable valve timing (VVT) unit to 10 Nm (7 ft. lbs.) .
Install the third screw at the timing gear pulley without variable valve timing (VVT) unit. Tighten the three screws to 20 Nm (15 ft. lbs.) .
Install the deflection limiter washer on the piston rod for the tensioner / damping unit.
Remove crankshaft adjustment tool 999 5451.
Install the plug with a new blind cover Plug. Tighten to 40 Nm (29 ft. lbs.) .
Position the upper camshaft belt cover.
Turn the crankshaft two revolutions and check that the markings on the crankshaft and timing gear pulleys correspond.		 Remove camshaft adjustment tools 999 5452from the rear edge of the camshafts.

Note: Remember to take the load off compression tool 999 5750 when it is not in use.

Install

  

  • the starter motor. Tighten the screws at the transmission to 40 Nm (29 ft. lbs.) and the screw at the support bracket to 25 Nm (18 ft. lbs.) .
  • the trigger wheel. Tighten to 17 Nm (12 ft. lbs.) .
  • the camshaft position (CMP) sensor housing.
  • a new cover at the rear edge of the camshaft.

Install

  

  • the front camshaft belt cover. 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 camshaft belt cover.

Applies only to B6xx4T engines:
Turn the intake manifold for the turbocharger (TC) for cylinders 1, 2, and 3 back into place and tighten the clamp.
Install the plastic hoses between the turbocharger (TC) / charge air cooler and the air cleaner (ACL) / turbocharger (TC).
Tighten the hose clamps.

Install

  

  • the cross stay. Tighten to 50 Nm (37 ft. lbs.)
  • the screw for the torque rod mounting at the bracket on the engine. Tighten to 80 Nm (59 ft. lbs.) .
  • the battery negative lead. Also read Note when disconnecting connecting the battery lead. Raise the car.
  • the plastic nuts for the cover in the right fender liner.
  • the right front wheel.

Final check
Check and top up if required

  • the coolant level.
  • the servo fluid level. Test drive the engine.