2002 Volvo S60

VALVE TIMING (VVT) Engine With Mountings And Equipment-Ignition And Control Systems

VALVE TIMING (VVT)

Engine With Mountings And Equipment-Ignition And Control Systems

VALVE TIMING (VVT)

CAMSHAFT SEAL / VARIABLE VALVE TIMING (VVT) UNIT, REPLACING (B5234T3; B5244T3;
2001)

Special tools:

9995452

9995651

9995718

9995719

9995451

9995919

9995450

9995750

Removing the front camshaft seal

NOTE: As 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.

Replacing the rear camshaft seal

See Removing/Installing the rear camshaft seal.

Preparation

CAUTION: There are a number of versions of the variable valve timing unit. Therefore
it is extremely important to always read the information referring to the
engine variant/model year to be remedied.

Removing the front camshaft seal / variable valve timing unit

CAUTION: Interrupt the current: Disconnect the battery negative lead. First read
Battery, disconnecting .

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 2002 Volvo S60
VALVE TIMING (VVT) Engine With Mountings And Equipment-Ignition And Control Systems

 Remove the timing belt from the timing gear pulley for the camshafts. See Replacing the timing belt .
 Check the tensioner and idler pulleys. See Replacing the timing belt .
 Remove the camshaft position (CMP) sensor housing and the trigger wheel
 Remove the cover at the rear edge of the camshaft.

Removing the variable valve timing unit / timing gear pulley

Fig. 1: Identifying Camshaft Adjustment Tool 9995452 Installed

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install adjustment tool 9995452 at the rear of the camshafts. Screw the adjustment tool sections together into
one.

Remove the plug from the front edge of the variable valve timing unit (Tx55). Remove the center screw from
the variable valve timing unit (Tx55). Carefully pull out the variable valve timing unit with the timing gear
pulley.

The following applies to timing gear pulleys without variable valve timing:

Remove the screws and the timing gear pulley.

Removing the front camshaft seal

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 2002 Volvo S60
VALVE TIMING (VVT) Engine With Mountings And Equipment-Ignition And Control Systems

Fig. 2: Identifying Seal And Special Tool 9995651

Courtesy of VOLVO CARS OF NORTH AMERICA.

Carefully press in tool 9995651 between the seal and the camshaft. Pry out the seal.

Installing the front camshaft seal

NOTE: The purpose of the instruction set, "Installing the variable valve timing
unit/timing gear pulley", described here is to ensure that the variable valve
timing unit is correctly positioned but also to reset the camshaft timing gear
pulley to the correct position using the markings made at the factory. This is to
ensure that the conditions are correct for any later fault-tracing.

NOTE: For tightening torques, see: Tightening torque .

Cleaning

To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

NOTE: When cleaning work around the shaft journal, not in and out. It is essential that
any residue from the emery cloth and any other contaminants are completely
removed before the new sealing ring is installed.

Installing the front camshaft seal

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 2002 Volvo S60
VALVE TIMING (VVT) Engine With Mountings And Equipment-Ignition And Control Systems

Fig. 3: Identifying Camshaft Special Tools 9995718 And 9995719

Courtesy of VOLVO CARS OF NORTH AMERICA.

Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal.

For camshafts with variable valve timing: Use drift 9995718 .

Use the mounting screw for the variable valve timing unit. Tighten until the drift bottoms out.

For camshafts without variable valve timing: Use drift 9995719 .

Checking the variable valve timing (VVT) unit

Check the variable valve timing (VVT) unit. See: Variable valve timing unit, checking and adjusting

Finishing

Install:

 the starter motor. Tighten screws at gearbox. Tighten. See Tightening torque .
 the screw at the support bracket for the starter motor. Tighten
 the trigger wheel. Tighten the screw
 the camshaft position (CMP) sensor housing. Tighten the screws

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 2002 Volvo S60
VALVE TIMING (VVT) Engine With Mountings And Equipment-Ignition And Control Systems

 a new cover at the rear edge of the camshaft.

Install the auxiliaries belt around the pulley on the crankshaft.

Install:

 the plastic nuts for the cover in the right-hand wing liner
 the right front wheel. See Installing wheels .

Fig. 4: Identifying Expansion Tank And Servo Reservoir

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

 front timing cover. Tension the auxiliaries belt. Check that it is correctly positioned on all pulleys
 the expansion tank
 the hose between the expansion tank and the radiator. Remove the lock grip pliers
 the servo reservoir
 the upper timing cover.

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 2002 Volvo S60
VALVE TIMING (VVT) Engine With Mountings And Equipment-Ignition And Control Systems

Fig. 5: View Of Under Hood Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

 the engine stabilizer brace. Tighten the screws

 the screw holding the engine stabilizer brace to the bracket on the engine. Tighten
 the battery negative lead. Also read Battery, disconnecting .

Final check

Check and top up if required:

 coolant level
 the servo fluid level.

Test drive the engine.

Removing/Installing the rear camshaft seal

Preparation

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 2002 Volvo S60
VALVE TIMING (VVT) Engine With Mountings And Equipment-Ignition And Control Systems

Fig. 6: View Of Under Hood Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

 the intake manifold between the electronic throttle module (ETM) and air cleaner (ACL) cover
 the air cleaner (ACL) cover. Place it to one side
 the camshaft position (CMP) sensor housing and the trigger wheel.

Removing the rear camshaft seal

Fig. 7: Identifying Special Tool Extractor 9995919

Courtesy of VOLVO CARS OF NORTH AMERICA.

Pull out the seal. Use puller 9995919 .

To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

NOTE: When cleaning work around the shaft journal, not in and out. It is essential that
any residue from the emery cloth and any other contaminants are completely
removed before the new sealing ring is installed.

Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal. Use drift 9995450 .

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 2002 Volvo S60
VALVE TIMING (VVT) Engine With Mountings And Equipment-Ignition And Control Systems

NOTE: The seal is normally positioned at the same level as the internally bevelled
edge. If the shaft journal is showing signs of wear, the seal can be pressed in a
further 2 mm : Turn the drift socket.

Finishing

Fig. 8: View Of Under Hood Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

For tightening torques, see: Tightening torque .

Install:

 the trigger wheel. Tighten the screw

 the camshaft position (CMP) sensor housing. Tighten the screws
 the air cleaner (ACL) cover
 the intake manifold between the electronic throttle module and the air cleaner (ACL) cover.

Final check

Test drive the engine.

CAMSHAFT SEAL / VARIABLE VALVE TIMING (VVT) UNIT, REPLACING (B5204T5; B5254T4;
2005-2007)

S60, V70 2000-, V70 XC 2001-/XC70

 For B5xx4T -2001, see Camshaft seal/variable valve timing (VVT) unit, replacing
 For B5xx4T 2002-, see Camshaft seal/variable valve timing (VVT) unit, replacing .

S60, V70 2000-

 For B5254T4, see Camshaft seal/variable valve timing (VVT) unit, replacing

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 2002 Volvo S60
VALVE TIMING (VVT) Engine With Mountings And Equipment-Ignition And Control Systems

CAMSHAFT SEAL / VARIABLE VALVE TIMING (VVT) UNIT, REPLACING (B5244S; B5244S6;
2005-2006)

S60, V70 2000-, S80

 For B5244S/S2, see Camshaft seal/variable valve timing (VVT) unit, replacing
 For B5244S6, see Camshaft seal/variable valve timing (VVT) unit, replacing .

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