Method F, Non-Turbo Only, All Markets
REPLACING PCV/PRE-HEATING SYSTEM ON FENIX, MOTRONIC 4.3 AND ON MOTRONIC 4.4 ENGINES, 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
Pre-Heating System:
- Pre-heating basic kit 272252-8
- Additional pre-heating parts see table
Labels, US/CDN Only:
- Vacuum labels see table
Additional Parts Required, Motronic 4.3, USA/CDN Only
EGR-System:
- EGR-basic kit 272250-2
- Engine Control Module (ECM) see table
Labels, US/CDN Only:
- Vacuum and emission labels see table
Labels, Sweden only (engine B5252S)
F1 Remove:
- Battery negative lead
- Throttle pulley cover
- Engine coolant
Removing Engine Coolant Fan Shroud
F2 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.
F3 Remove:
- EVAP valve including hoses from engine coolant fan (FC) shroud (if applicable)
- EGR controller from upper air guide and from EGR controller connector
F4 Remove:
- Clamp from insulation (if EVAP-valve is insulated).
- Hose from EVAP-valve.
F5 Motronic 4.3 only
Remove:
- EGR controller with hoses and discard.
Install:
- Rubber plug on multi nipple.
F6 ALL
Remove:
- Disconnect and free 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.
F7 Remove:
- Throttle cable from bracket and throttle pulley.
Removing Intake Manifold
F8 Remove:
- Ignition lead cover
- Upper hose on cylinder head.
F9 Remove:
- Fuel rail cover
- Electrical connectors from injectors
- Lower and upper clamp.
When removing the fuel rail the injectors should be fixed so that they cannot twist loose and spray fuel.
F10 Install
Early fuel rail:
- Five clamps 999 5533 to the injectors.
Later fuel rail (with quick connect 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 F11 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.
F11:
The Figure shows clamp 999 5620 positioned closest to the fuel pressure line (late fuel rail).
F12 Remove:
- Vacuum hose from multi nipple
- Bolts holding fuel rail
- Lift the fuel rail twisting it carefully to the side.
NOTE: Handle injectors carefully so as not to damage fuel jets and fuel needles.
F13 Remove:
- Inlet hose between air cleaner and Throttle Body (TB)
- Idle Air Control valve (IAC) hose and hose for crankcase ventilation (PCV) from inlet hose
- Idle Air Valve (IAC) and Throttle Position (TP) sensor connectors.
F14 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 manifold gasket face.
Clean Throttle Body (TB) if dirty.
NOTE: Throttle Body (TB) must be removed to not damage the throttle.
F15 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.
F16 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)
F17 Remove:
- Connector
- Cover on thermostat housing with upper radiator hose
- Thermostat
- Thermostat housing, 3 screws
Use Torx 40 and pipe wrench for lower screw.
F18 Install:
- New thermostat housing. Use 2 gaskets
- Thermostat
- Connector
F19 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.
F20 Motronic 4.3 only
Remove:
- EGR pipe from exhaust manifold and discard
- Nipple from exhaust manifold and discard.
Install:
- Plug and nut on exhaust manifold. Torque 60 Nm (44 ft.lbs).
F21 Motronic 4.3 only
Install:
- EGR temperature sensor connector plug.
F22 Motronic 4.3 only
Remove:
- EGR valve and discard.
Install:
- Cover plate and gasket using new bolts.
Torque 10 Nm (7.5 ft.lb).
Replacing Front Manifold Plug
CAUTION: Wear protective goggles.
NOTE: Applies only to cars without nipple cover.
F23 Remove:
- Knock front plug out of intake manifold using an extension rod.
F24:
- Clean sides of hole using H-cleaner P/N 1161436-9.
Install:
- Nipple plug using a 30 mm (1 3/16") 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).
F25 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) Hoses
F26 Remove:
- Intake manifold bracket from the engine block.
- Crankcase ventilation (PCV) hose from oil trap and from fresh air hose.
Install new crankcase ventilation
F27 Install:
- Hose on coolant pipe before installing crankcase ventilation pipe on oil trap.
- Rubber plug on flame trap.
Remove:
- Flametrap and discard.
F28 Install:
- New crankcase ventilation hose (PCV) to the oil trap.
F29 Installing Oil Trap Cover And Starter Motor Bracket
10-valve engines
Install:
- Oil trap cover
- Intake manifold bracket to the engine block
- Starter motor bracket
NOTE: Use a 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
20-valve engines
Remove:
- The four lugs on the oil trap cover with a sharp knife.
F30 Install:
- Oil trap cover
- Intake manifold bracket to the engine block
- Starter motor bracket.
NOTE: Use a 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.
Install The Intake Manifold
F31 Install:
- New gasket and enter the four lower bolts.
F32 Install
- Crankcase ventilation (small) hose on nipple plug
- Hose to the cylinder head, between manifold pipe 2 and 3 (not applicable on all engines).
F33 Install:
- Intake manifold
- Dipstick mounting on intake manifold
- EGR valve pipe and EGR temperature sensor wire connector (not Motronic 4.3)
- Intake manifold three upper bolts.
Tighten all seven bolts to 17 Nm (12 ft. lbs).
Install:
- Intake manifold support bracket bolt and tighten both bolts
- Brake booster hose to intake manifold.
Install Throttle Body (TB)
F34 Install:
- Throttle Body (TB) gasket.
F35 Install:
- Throttle Body (TB).
Reuse the four bolts, torque 10 Nm (7.5 ft. lbs).
F36 Adjust link:
- Undo link locknut.
Check that the link can be pulled out and that it springs back when released.
F37 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.
F38 Replacing Air Cleaner (ACL) Housing:
The new Air Cleaner (ACL) housing has vacuum controlled air pre-heating.
NOTE: This step is only necessary for M/Y 92, 93, 94, 95 and 96 (up to production date 10:95)
Remove:
- Air Cleaner (ACL) housing with pre-heating hose and discard.
Move Mass Air Flow (MAF) sensor to new air cleaner cover
Move old filter to air cleaner filter housing.
Clean filter if necessary.
Preparation:
- Assemble the air cleaner housing (filter, cover, filter housing)
- Connect the black hose to the upper (metallic) nipple on the Air Cleaner (ACL) cover.
Install:
- New white vacuum hose to lower (plastic) nipple on Air Cleaner (ACL) cover. Use elbow connection.
- Tie the two vacuum hoses together to prevent white hose rubbing on ABS bracket.
Position the tie 50 mm (2") from the elbow connection.
F39 Install:
- Protective sleeve (150 mm, 6") on the Mass Air Flow (MAF) sensor wire.
Position the protective sleeve on the cable channel.
F40:
- Cut radiator hose 170mm (6.7") from metal terminal on firewall.
- Install T-coupling.
- Position screws on hose clamp so that they are not positioned over the highest point of the hose.
- Install hose from coolant pipe on crankcase ventilation hose to T-coupling.
- Check routing. Ensure that the hose is not in contact with anything. If necessary, adjust T-coupling and shorten the hose.
F41 Install:
- Hose between thermostat housing and coolant pipe.
- Cover on thermostat housing with upper radiator hose.
F42 Install:
- Fuel rail
- Bolts holding fuel rail.
IMPORTANT: Tightening torque 10 Nm (7.5 ft.lbs). 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.
F43 Remove:
- Injector clamps.
Install:
- Clamps holding fuel rail
- Connectors on injectors
- Fuel rail cover.
F44 Install:
- New Air Cleaner (ACL) housing
- New pre-heating hose at exhaust manifold. The new pre-heating hose should be 100 mm (4") longer than the old one, adjust if necessary (by cutting).
Connect Mass Air Flow (MAF) harness.
Install:
- Coil high tension lead on Air Cleaner (ACL) housing
- The white vacuum hose from Air Cleaner (ACL) to upper rear multi nipple outlet.
F45 Install:
- Clamp vacuum hose with injector wire to throttle pulley bracket, using provided bigger clamp.
IMPORTANT: Position vacuum hose to the rear of injector harness in clamp.
Make sure vacuum hose is not squeezed in clamp.
NOTE: Check that all nipples at multi nipple either has a hose connected or has a plug.
Installing Parts
F46 Install:
- Re-install O-ring on flame trap
- The new crankcase ventilation hose to the new (if applicable) inlet hose
- New (if applicable) inlet hose between Air Cleaner (ACL) and Throttle Body (TB)
- Idle Air Valve (CIS) hose.
F47:
Clean crankcase ventilation (PCV) hose and nipple at the cylinder head connection.
Install:
- Upper crankcase ventilation hose on the cylinder head
- Ignition lead cover.
F48 Install:
- Throttle cable on throttle pulley and bracket.
F49 Remove:
- Protective panel from the radiator
Install:
- Engine coolant fan (FC) and shroud
- The two lower engine coolant fan screws
Fix the cable with the tie strap and clip.
Connect two connector to engine coolant fan (FC).
F50 Install:
- EVAP hose with clips to the coolant fan
- EVAP valve with two screws
- EGR controller valve on upper air guide (not Motronic 4.3).
F51 Install:
- Hose to EVAP-valve
- Clamp insulation with strip clamp.
F52 Install:
- Two spacer washers on top
- Upper air guide
- Two upper engine coolant fan (FC) screws and tighten all four
- Air intake and inlet hose to the Air Cleaner (ACL)
- Throttle pulley cover.
F53 Install:
- Plug and clip as shown and park the EGR controller connector in the plug.
F54 Motronic 4.3 (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.
F55 USA/CDN and Sweden
Clean:
- Surface on the current vacuum hose label
- Surface on hood for new label "C"
Install:
- Vacuum hose label "A" on top of the old one
- Additional vacuum hose label "C"
Motronic 4.3 only (US/CDN)
Clean surface on the current emission label
Install:
- Emission label "B" on top of the old one.
F56:
Fill coolant.
F57 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.