Checking and adjusting the variable valve timing unit: Overview

Special tools:

NOTE:

The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

CAUTION:

This element must be carried out with precision as any deviation could generate a fault symptom.

Installing the crankshaft adjustment tool

Fig 1: Identifying Adjustment Tool (999 5451)

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the starter motor mounting screws. Pull out the starter motor and put it aside.

Remove the blind cover plug for the adjustment tool hole. Turn the crankshaft clockwise slightly. Install the adjustment tool 9995451 . Ensure the adjustment tool bottoms against the engine block.

Aligning the crankshaft

Turn the crankshaft counterclockwise to its stop against the crankshaft adjustment tool. Check that the marking on the crankshaft timing gear pulley aligns with the marking on the oil pump.

Installing the variable valve timing (VVT) unit on the exhaust camshaft

Fig 2: Identifying Timing Mark Offset

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Slacken off, but do not remove the screws which secure the timing gear pulley to the VVT unit
Press the variable valve timing unit and timing gear onto 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. Slacken off 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 cogs 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. See Tightening torque . Check that the variable valve timing unit does not rotate when tightening
Install and tighten the center plug according to Tightening torque .

Fig 3: Identifying Alignment Marks

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Turn the variable valve timing unit clockwise to the limit position. Turn the timing gear pulley so that the markings correspond.

Installing the variable valve timing (VVT) unit on the intake camshaft

Fig 4: Identifying Timing Mark Offset

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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 variable valve timing unit to the camshaft. Tighten slightly
Turn the variable valve timing unit counter-clockwise as far as it will go
Slacken off the center screw
Turn the timing belt pulley clockwise until the screws at the oval holes are in the end-position. Continue turning clockwise until the timing belt pulley marking is 2 cogs before the marking on the upper timing casing.
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. See Tightening torque . Check that the variable valve timing unit does not rotate when tightening
Install and tighten the center plug according to Tightening torque

Fig 5: Identifying Alignment Marks

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Turn the variable valve timing unit clockwise to the limit position. Turn the timing gear pulley so that the markings correspond.

Installing the camshaft belt

Fig 6: Identifying Camshaft Belt

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Tighten the timing belt tensioner center screw. Tighten to 5 Nm .

Install the belt in the following order:

crankshaft
idler pulley
intake cam
exhaust cam
water pump
tension pulley

The variable valve timing units do not have a return spring and are easily dislodged when installing the timing belt. Check that the markings correspond.

NOTE:

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

Preparations for adjusting the timing belt

Fig 7: Identifying Tensioning The Camshaft Belt

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This setting is done on a cold engine. A suitable temperature is approximately 20°C/68°F . At higher temperatures, for example if the engine is warm or ambient temperature is higher, the indicator assumes a position farther to the right. The illustration shows the indicator position at different engine temperatures.

Adjusting the timing belt

Hold the belt tensioner center screw fixed and turn the belt tensioner eccentric clockwise until the tensioner indicator passes the marked position.

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 secure and tighten the center screw. Tighten to 25 Nm .

Check that the indicator is in the correct position.

Check:

that the timing gear pulley is not in the limit position in the oval holes
the timing gear pulley so that the markings line up with the upper timing cover.

Tighten the screws for the timing gear pulleys. See Tightening torque

Checking the markings and belt tension

Fig 8: Identifying Alignment Marks

Courtesy of VOLVO CARS OF NORTH AMERICA.

Jerk the camshaft belt to check that the indicator on the tensioner moves easily
Position the upper timing cover.
Turn the crankshaft two turns. Check that the markings on the crankshaft timing gear pulley and the camshaft timing gear pulley match up with the markings on the oil pump and upper timing cover respectively
Check that the indicator on the belt tensioner is within the marked position