Method G, Turbo Only, All Markets

REPLACING PCV-SYSTEM, WASTE-GATE ACTUATOR, AND ON THE US/CDN MARKET, ALSO DELETING THE EGR-SYSTEM

NOTE: Method "A" should be performed prior to this method if the vehicle is older than M/Y 96 (production date 03/96).





Special Tools Required:
- Injector clamps (4) 999 5533
- Injector clamp (1) 999 5620
- H-cleaner 1161436-9
- Metal adhesive 1161351-0

Parts Required, All Markets
PCV-System:
- PCV kit 272438-3
- Thermostat housing 9207845-0
- Gasket x2 1397574-3
- Inlet manifold gasket 9146266-3





- Vacuum labels See table

Waste-Gate Actuator System:
- Waste-gate actuator kit 1270463-1

Additional Parts Required, US/CDN Only
EGR-System:
- EGR-basic kit 272250-2





- Engine Control Module (ECM) see table





- Vacuum labels see table

G1 Remove:
- Battery negative lead
- Throttle pulley cover
- Engine coolant





G2 Removing Engine Coolant Fan Shroud
Remove:
- Air intake scoop in front and inlet hose to the Air Cleaner (ACL)
- Air duct to the control module box
- 4 screws on engine coolant fan (FC) shroud.





G3 Remove:
- Change air pipe between the Charge Air Cooler (CAC) and hose on the Throttle Body (TB).
- EVAP valve including hoses from fan shroud (if applicable).
- EGR controller from upper air guide and from EGR controller connector.





G4 Remove:
- Clamp from insulation (if EVAP-valve is insulated)
- Hose from EVAP-valve.





G5 Remove:
- EGR controller with hoses and discard.

Install:
- Rubber plug on multi nipple.





G6 Remove:
- Disconnect and tree the two connectors (A) to the engine coolant fan (FC)
- The cable from the tie straps (B) on the engine coolant fan (FC) shroud.
Place the air guide with the relays on the engine.

Remove:
- Engine coolant fan (FC), by pulling engine coolant fan (FC) and shroud upwards.
Cover the radiator with protective panel P/N 999 5474 or equivalent.





G7 Remove:
- Throttle cable from bracket and throttle pulley.





Removing Intake Manifold
G8 Remove:
- Ignition lead cover
- Upper hose from cylinder head





G9 Remove:
- Fuel rail cover
- Connections and mountings from injectors
- Lower bolt and clamp
- Upper clamp.
When removing the fuel rail the injectors should be fixed so that they cannot twist loose and spray fuel.

Removing Fuel Rail And Injectors
G10 Install:
Early fuel rail:
- Five clamps 999 5533 to the injectors

Later fuel rail (with quick coupling):
- Four clamps 999 5533 and one clamp 999 5620 to the injectors. Position clamp 999 5620 closest to the fuel pressure line as illustrated at G11 below.

Press in the clamps so that they are in good contact with injectors.





Screw down adjustment screw so that the contact plate is in contact with the fuel rail, turn the screw another half turn.





G11:
The illustration shows clamp 999 5620 positioned closest to the fuel pressure line (late fuel rail).





G12 Remove:
- Vacuum hose from multi nipple
- Bolts holding fuel rail
- Lift the fuel rail twisting it carefully aside.

NOTE: Handle injectors carefully so as not to damage fuel jets and fuel needles.





Removing the Throttle Body (TB)
G13 Remove:
- Inlet hose from Throttle Body (TB)
- Idle Air Control (IAC) valve and Throttle Position (TP) sensor connectors
- Throttle Body (TB) link.





G14 Remove:
- Throttle Body (TB) link
- Throttle Body (TB) from intake manifold
- 4 bolts (they will be reused)
- Gasket between Throttle Body (TB) and intake manifold.
Ensure that no gasket residue is left on the intake intake manifold manifold gasket face.
Clean throttle body if dirty.

NOTE: Throttle Body (TB) must be removed to not damage the throttle.





G15 Remove:
- Pipe from EGR valve (tap pipe back)
- EGR temperature sensor wire from connection
- Cable harness from throttle control bracket
- Intake manifold three upper bolts
- Dipstick mounting from intake manifold
- Brake booster hose from intake manifold.
Loosen the lower intake manifold bolts.

Remove:
- Intake manifold support bracket bolt
- Intake manifold, by lifting it approx. 20 mm (1") to free it from the engine
- Intake manifold gasket.

Install:
- Plug on EGR temperature sensor connection
Clean gasket faces on cylinder head and intake manifold.

G16 Remove:
- Drive belt for auxiliary equipment





- Power steering pump
screw with spacer (1)
3 screws inside pulley (2)
2 screws on bracket(3)
bracket (4)





G17 Remove:
- Connector
- Cover on thermostat housing with upper radiator hose
- Thermostat
- Thermostat housing, 3 screws
Use Torx 40 and pipe wrench for lower screw.





G18 Install:
- New thermostat housing. Use 2 gaskets
- Thermostat
- Connector.





G19 Install:
- Bracket (4)
- Collision protection system (1). Install screws loosely.
- Screws (2), as illustrated. Install screws loosely.
- Screws (3), as illustrated. Including bracket for hose.
Install screws loosely.
Torque tighten screws in the following order: (1), (2) and (3).
Tighten to 25 Nm (18 ft.lbs).

NOTE! It is vital that the screwed joints are tightened in the correct order.

Install:
- Drive belt.

G20 Only Motronic 4.3
Remove:
- EGR valve and discard.





Install:
- Cover plate and gasket using new bolts.
Torque 10 Nm (7.5 ft.lbs).





ALL

G21 Replacing Front Manifold Plug

NOTE: Wear protective goggles!

Remove:
- Knock front plug out of intake manifold using an extension rod.
Clean sides of hole using H cleaner P/N 1161436-9.





G22:
- Position the plug so that the pipe is horizontal in the car.





G23 Install:
- Nipple plug using a 10 mm (3/8") socket.

NOTE: On older cars without a stop ridge be careful so that the nipple plug does not go in too far. It should be 0.5 to 1.0 mm below the edge.





G24 When nipple plug is in place:
- Secure the nipple plug by staking the manifold with a chisel in 4 places
- Apply a bead of metal adhesive P/N 1161351-0 around the edge.





Replacing Crankcase Ventilation (PCV) Hose And Waste-gate Actuator
G25 Remove:
- Intake manifold bracket from the engine block.
- Starter motor bracket
- Crankcase ventilation (PCV) hose from oiltrap and PTC nipple.





G26 Only Motronic 4.3
Remove:
- Clamp supporting charge air pipe by engine torque control arm.





G27 Only Motronic 4.3
Remove:
- Lower clamp by Turbo-Charger (TC).
Fold charge air pipe out of the way.

NOTE: Cover turbo-charger outlet with paper or a rag to prevent debris from falling into it.





G28 Only Motronic 4.3
Remove:
- Heat deflector plates
- Ground strip.





G29 Only Motronic 4.3
Remove:
- Lock pin at waste-gate
- Rear waste-gate actuator screw (1)
- Front rear waste-gate actuator screw (2)

Install:
- New waste-gate actuator
- Screws and tighten to 20 Nm (15 ft.lbs).





G30 Only Motronic 4.3
Carry out basic adjustment of pressure arm:
- Connect manometer 999 5230 and pressure tester 998 5496 to pressure servo
- Pump up pressure to 12.5 kPa (1.82 psi)
- Pump waste-gate actuator spindle towards turbine housing (closed valve)
- Adjust pressure arm so that it fits onto spindle lug exactly
- Install lock pin at waste-gate
- Tighten pressure arm locknut
- Remove manometer and pressure tester.

NOTE: The tester arm must not be twisted when adjusting it. Otherwise the pressure servo membrane may be damaged.





G31 Only Motronic 4.3
Remove:
- EGR pipe from exhaust manifold
- Nipple from exhaust manifold.

Install:
- Plug and nut on exhaust manifold and discard.
Torque 60 Nm (44 ft.lbs).





G32 Only Motronic 4.3
Install:
- Heat deflector plates
- Ground strip.





G33 Only Motronic 4.3
Remove:
- Cover from Turbo-Charger (TC) outlet.

Install:
- charge air pipe.





G34 Only Motronic 4.3
Install:
- Clamp around charge air pipe by engine torque control arm.





G35 ALL:
Install:
- New crankcase ventilation hose (PCV) to the oil trap.





G36 Remove:
- The four lugs on the oil trap cover with a sharp knife.





G37 Install:
- Oil trap cover
- Intake manifold bracket to the engine block.
- Starter motor bracket to the engine block
- Starter motor.

NOTE: Use soap water solution when installing the oil trap cover against the auxiliary bracket.

On cars with A/C:
- Check that the B+ cable is free from A/C hoses.
If necessary reposition the cable in the clamp.

G38 Remove:
- Fresh air hose between air filter housing and turbo charger unit.





G39:
- Cut radiator hose 70 mm (2 3/4") from terminal between rubber and coupling to firewall.

Install:
- T-coupling
- Hose on T-coupling
- Hoses on coolant pipe on crankcase ventilation hose.
Check hose routing between T-coupling and coolant pipe on crankcase ventilation hose. Adjust and, if necessary, shorten hose so that it is not in contact with anything.





G40 Drill PTC to 7 mm (9/32").

IMPORTANT: Blow away swarf after drilling.

Install:
- Plug and clamp on PTC nipple.
- Fresh air hose between air filter housing and turbo charge unit.
- Crankcase ventilation hose to the PTC nipple with a new clamp.





G41 Install:
- Hose from T-nipple on coolant pipe at crankcase ventilation hose. Check that the hose is not in contact with the fresh air intake hose, coolant hose or power brake booster. If necessary shorten hose so that it is unimpeded.
- Hose on pipe with hose clamp.

Installing Intake Manifold
G42 Install:
- New gasket with four lower bolts.





G43 Install:
- Crankcase ventilation (PCV) (small) hose on nipple plug.
Install clamp correctly.
- Hose to the cylinder, between manifold pipe 2 and 3.





G44 Install:
- Intake manifold
- Dipstick mounting on intake manifold
- Intake manifold three upper bolts
Tighten all seven bolts to 17 Nm (12 ft. lbs).

Install:
- Intake manifold support bracket bolts and tighten bolts
- Brake booster hose to intake manifold.





G45 Install:
- Hose with hose clamps between nipple cover and pipe on ventilation hose.





G46 Install:
- Hose with hose clamps between nipple cover and thermostat housing





G47 Installing Parts
Install:
- Throttle Body (TB) gasket.





G48 Install:
- Throttle Body (TB).
Reuse the four bolts, torque 10 Nm (7.5 ft. lbs).





G49 Adjust link:
- Undo link locknut.
Check that the link can be pulled out and that it springs back when released.





G50 Install:
- Link between throttle pulley and throttle spindle.

Check:
- That throttle spindle is in contact with adjustment screw
- That throttle pulley is in contact with idling stop.
Tighten link locknut.
Open and close throttle.

Check:
- That the throttle spindle is in contact with adjustment screw.





G51 Install:
- Inlet hose on Throttle Body (TB)
- Idle Air (IAC) valve and Throttle Position (TP) sensor connectors
- By-Pass hose to inlet manifold.

NOTE: Clean inside inlet hose on Throttle Body (TB) with H-cleaner.





G52 Install:
- Fuel rail
- Bolts holding fuel rail.

IMPORTANT: Tightening torque 10 Nm (7.5 ft.lbs) + 75° angle tightening. Use new screws.

Install:
- Vacuum hose to lower rear fitting of multi nipple.

NOTE: Handle injectors carefully not to damage fuel injectors. Check the injector seals are in place.





G53 Remove:
- Injector clamps.

Install:
- Clamps holding fuel rail
- Connectors on injectors
- Fuel rail cover.





G54:
- Clean hose and nipple clean.

Install:
- Upper crankcase ventilation oil trap hose on the cylinder head
- Ignition lead cover.





G55 Install:
- Throttle cable on throttle pulley and bracket.





G56 Remove:
- Protective panel from the radiator.

Install:
- Engine coolant fan (FC) and shroud
- The two lower engine coolant fan (FC) screws.
Fix the cable with the tie strap and clip.
Connect two connector to engine coolant fan (FC).





G57 Install:
- EVAP hose with clips to the coolant fan
- EVAP valve with two screws
- Install charge air pipe (and hose between charge air cooler and Throttle Body (TB).





G58 Install:
- Hose to EVAP-valve
- Clamp insulation with strip clamp.





G59 Install:
- Two spacer washers on top
- Upper air guide
- Two upper engine coolant fan (FC) and tighten all tour
- Air intake (new) and inlet hose to the Air Cleaner (ACL)
- Throttle pulley cover.





G60 Only Motronic 4.3
Install:
- Plug and clip as shown and park the EGR controller connector in the plug.





G61 Only Motronic 4.3 and US/CDN
Replace:
- Engine Control Module (ECM).

NOTE: Apply one of the enclosed TMA-adhesive labels on the side of the ECM. Do not forget to enter the return into the Parts Volvo Vision core return screen (option 2, TMA testing returns) and enclose packing list.
For US, pack the ECM in a box, labelled with the second TMA-label, and send it to TMA, Rockleigh, for re-programming.
For Canada, the ECM should be handled the normal way, i.e. shipped to TMA, Toronto. This means that the second label from the kit shouldn't be used.





G62 Only Motronic 4.3 and US/CDN
Clean:
- Surfaces on current vacuum hose- and emission labels
- Surface on hood for the new label "C".

Install:
- Vacuum hose label "A" on top of the old one
- Emission label "B" on top of the old one.
- Vacuum hose label "C"

G63:
- Fill coolant.

G64 Install:
- Battery negative lead
- Reset radio anti-theft code.

Perform Test Drive:
- Check that there are no DTC's stored in the system after the test-drive.