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2002 S60 n/a Crankshaft Position Sensor Bracket Replacement

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive P2 platform cars sold as model years 2001-2007 (North American market year designations).

2001 - 2007 V70
2001 - 2004 V70 XC (Cross Country)
2004 - 2007 XC70 (Cross Country)
2001 - 2009 S60
2003 - 2007 S60 R
2004 - 2007 V70 R
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regent
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2002 S60 n/a Crankshaft Position Sensor Bracket Replacement

Post by regent »

Has anyone replaced the holder for the Crankshaft Position Sensor?

(Item # 12 on diagram http://volvopartslisle.com/assembly/830 ... ion-System, Bracket, part number = 30637803)

It looks like one of the two mounting screws (holding the Bracket to the engine block) is a real bear to get to; is there a smarter approach besides pulling the transmission out first?
Thanks in advance :D
Example of Precision: Measure with a Micrometer, mark it with Chalk, and then cut it with an Axe.
Disclaimer: We (very) seldom do that

2015 BMW 335i
2015 XC60 T5 Premier Plus
2002 S60 2.4 n/a - retired :(
1987 340 DL - retired :(
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xiami
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Post by xiami »

What lead you to a broken senor bracket? I have 2002 S80 that has rare intermittent cold start problems for several years that dealers and shops could not fix because they could not replicate the problem. Car always start while in the shop. Car finally threw RPM sensor fault. I inspected sensor and the resistance tested fine. I replaced the wiring harness but problem persist. I have my son reinstall the RPM sensor and he broke the plastic sensor bracket. I replaced the bracket and the car starts consistently now!! Must have been a tiny crack or defect in the bracket.

You can remove the bracket with star bit, I think it is T30 or T40. Space is tight. Access is improved by moving and disconnecting all nearby hoses and wires.

Please give followup.
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regent
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Post by regent »

Thanks for the hints.
I recently noticed mine was epoxy-glued in the past (the prevoius owner probably broke it). As the plastic and epoxy have become brittle with age and thermal expansion, the bracket is almost falling apart on me.
I have not had a no start condition or any other symptoms yet other than a misfire code every so often. I've ruled out EMI from excessive starter draw (that's when I discovered the broken bracket). Now I want to replace it and the sensor; I've got the spares.
Thanks again!
Example of Precision: Measure with a Micrometer, mark it with Chalk, and then cut it with an Axe.
Disclaimer: We (very) seldom do that

2015 BMW 335i
2015 XC60 T5 Premier Plus
2002 S60 2.4 n/a - retired :(
1987 340 DL - retired :(
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precopster
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Post by precopster »

I chose to remove mine before pulling the motor recently and I was sorry that I tried. That rear 10mm bolt is a bear!! The next time I pulled the motor from the donor car I simply removed the crank sensor.
Current cars VW Transporter 2.5TDI, 2010 XC90 D5 R Design
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regent
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Post by regent »

There seems to be a small area of the transmission case casting that obstructs access to that one rear torx bolt. It appears to be just a stub for the purpose no other than impeding access to the sensor bracket. It does not look like a structural or functional element, so I feel very much tempted to grab my dremmel and shave some aluminium off, and then access will be quite easier.

The other option (that I don't want to consider) would be to separate the box from motor... 8)
Example of Precision: Measure with a Micrometer, mark it with Chalk, and then cut it with an Axe.
Disclaimer: We (very) seldom do that

2015 BMW 335i
2015 XC60 T5 Premier Plus
2002 S60 2.4 n/a - retired :(
1987 340 DL - retired :(
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hcritz
Posts: 94
Joined: 10 December 2007
Year and Model: 2000 v70
Location: Mississippi

Post by hcritz »

I just ran into that on an engine swap...should have put the bracket on the engine first before mounting the tranny. I shortened the bolt just a bit and was able to get it in...that's no help getting one out though. I see no reason for it being there...so I'd dremel the thing off!!!
Ed
1995 850 turbo wagon 340,000
2000 v70 280,000
2002 v70 140,000
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regent
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Post by regent »

Yes, I figured the Swedish Elves decided to build our cars around the sensor bracket... :lol:
Example of Precision: Measure with a Micrometer, mark it with Chalk, and then cut it with an Axe.
Disclaimer: We (very) seldom do that

2015 BMW 335i
2015 XC60 T5 Premier Plus
2002 S60 2.4 n/a - retired :(
1987 340 DL - retired :(
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