tolerance data 2009.1 tools 1. "999-5452” =

Tolerance Data 2009.1 Volvo, 850 2,5 - 20V

Tools

1. "999-5452” = Camshaft locking tool.1. "999-5452” = Camshaft locking tool.1. "999-5452” = Camshaft locking tool.1. "999-5452” = Camshaft locking tool.2. “999-5451” = Crank locking tool.1. "999-5452” = Camshaft locking tool.2. “999-5451” = Crank locking tool.1. "999-5452” = Camshaft locking tool.2. “999-5451” = Crank locking tool.3. "999-5199" = Crankshaft pulley / vibration damper locking tool.

1. "999-5452” = Camshaft locking tool.2. “999-5451” = Crank locking tool.3. "999-5199" = Crankshaft pulley / vibration damper locking tool.


Dismount 1

1. Note: The engine can be fitted with two different types of camshaft wheels!!!1. Note: The engine can be fitted with two different types of camshaft wheels!!!1. Note: The engine can be fitted with two different types of camshaft wheels!!!1. Note: The engine can be fitted with two different types of camshaft wheels!!!2. ---------------------------------------1. Note: The engine can be fitted with two different types of camshaft wheels!!!2. ---------------------------------------1. Note: The engine can be fitted with two different types of camshaft wheels!!!2. ---------------------------------------3. Switch off ignition and wait at least 15 minutes before removing chassis cable.

1. Note: The engine can be fitted with two different types of camshaft wheels!!!2. ---------------------------------------3. Switch off ignition and wait at least 15 minutes before removing chassis cable.4. Dismantle any upright discs

1. Note: The engine can be fitted with two different types of camshaft wheels!!!2. ---------------------------------------3. Switch off ignition and wait at least 15 minutes before removing chassis cable.4. Dismantle any upright discs

1. Note: The engine can be fitted with two different types of camshaft wheels!!!2. ---------------------------------------3. Switch off ignition and wait at least 15 minutes before removing chassis cable.4. Dismantle any upright discs5. Dismount :



• upper timing belt cover.


• upper timing belt cover.• expansion tank and move it aside.


• upper timing belt cover.• expansion tank and move it aside.


• upper timing belt cover.• expansion tank and move it aside.• power steering fluid reservoir and push aside.





6. Remove :



6. Remove :



6. Remove :• the air intake of the air filter.



6. Remove :• the air intake of the air filter.• camshaft sensor.



6. Remove :• the air intake of the air filter.• camshaft sensor.



6. Remove :• the air intake of the air filter.• camshaft sensor.• cooling fan.



6. Remove :• the air intake of the air filter.• camshaft sensor.• cooling fan.



6. Remove :• the air intake of the air filter.• camshaft sensor.• cooling fan.• the starter.







7. Dismount :




7. Dismount :• front wheels.




7. Dismount :• front wheels.




7. Dismount :• front wheels.• inner wing.









8. Remove the multi-belt.





8. Remove the multi-belt.9. Dismount timing belt cover.





8. Remove the multi-belt.9. Dismount timing belt cover.





8. Remove the multi-belt.9. Dismount timing belt cover.10. Attach the engine fixing.





8. Remove the multi-belt.9. Dismount timing belt cover.10. Attach the engine fixing.





8. Remove the multi-belt.9. Dismount timing belt cover.10. Attach the engine fixing.11. Dismount :











• engine suspension and fitting on engine.






• engine suspension and fitting on engine.• crankshaft pulley / vibration damper (use counter hold).






• engine suspension and fitting on engine.• crankshaft pulley / vibration damper (use counter hold).






• engine suspension and fitting on engine.• crankshaft pulley / vibration damper (use counter hold).• timing belt cover.






• engine suspension and fitting on engine.• crankshaft pulley / vibration damper (use counter hold).• timing belt cover.


Dismount 2

1. Note: The engine can be fitted with two different types of camshaft wheels!!!1. Note: The engine can be fitted with two different types of camshaft wheels!!!1. Note: The engine can be fitted with two different types of camshaft wheels!!!1. Note: The engine can be fitted with two different types of camshaft wheels!!!2. ---------------------------------------1. Note: The engine can be fitted with two different types of camshaft wheels!!!2. ---------------------------------------1. Note: The engine can be fitted with two different types of camshaft wheels!!!2. ---------------------------------------3. On older 5 cyl. versions cam marks must be at half past 11 on the intake and half past 2 on the

1. Note: The engine can be fitted with two different types of camshaft wheels!!!2. ---------------------------------------3. On older 5 cyl. versions cam marks must be at half past 11 on the intake and half past 2 on the

exhaust.


exhaust.


exhaust. 4. Engines with VVT and without turbo have adjustable cam wheels at the intake. Engines with VVT





and with turbo have adjustable cam wheels at the exhaust. Older engines do not have VVT.



and with turbo have adjustable cam wheels at the exhaust. Older engines do not have VVT.5. On newer models there are VVT-units on both camshafts.



and with turbo have adjustable cam wheels at the exhaust. Older engines do not have VVT.5. On newer models there are VVT-units on both camshafts.



and with turbo have adjustable cam wheels at the exhaust. Older engines do not have VVT.5. On newer models there are VVT-units on both camshafts.6. Turn crankshaft in its rotational sense to compression TDC on cylinder 1.



and with turbo have adjustable cam wheels at the exhaust. Older engines do not have VVT.5. On newer models there are VVT-units on both camshafts.6. Turn crankshaft in its rotational sense to compression TDC on cylinder 1.



and with turbo have adjustable cam wheels at the exhaust. Older engines do not have VVT.5. On newer models there are VVT-units on both camshafts.6. Turn crankshaft in its rotational sense to compression TDC on cylinder 1.7. The cam marker must be at 12.



and with turbo have adjustable cam wheels at the exhaust. Older engines do not have VVT.5. On newer models there are VVT-units on both camshafts.6. Turn crankshaft in its rotational sense to compression TDC on cylinder 1.7. The cam marker must be at 12.8. Turn crankshaft to approx. 10° after compression TDC on cylinder 1.



and with turbo have adjustable cam wheels at the exhaust. Older engines do not have VVT.5. On newer models there are VVT-units on both camshafts.6. Turn crankshaft in its rotational sense to compression TDC on cylinder 1.7. The cam marker must be at 12.8. Turn crankshaft to approx. 10° after compression TDC on cylinder 1.



and with turbo have adjustable cam wheels at the exhaust. Older engines do not have VVT.5. On newer models there are VVT-units on both camshafts.6. Turn crankshaft in its rotational sense to compression TDC on cylinder 1.7. The cam marker must be at 12.8. Turn crankshaft to approx. 10° after compression TDC on cylinder 1.9. Dismount the blind cover plug at flywheel.



and with turbo have adjustable cam wheels at the exhaust. Older engines do not have VVT.5. On newer models there are VVT-units on both camshafts.6. Turn crankshaft in its rotational sense to compression TDC on cylinder 1.7. The cam marker must be at 12.8. Turn crankshaft to approx. 10° after compression TDC on cylinder 1.9. Dismount the blind cover plug at flywheel.



and with turbo have adjustable cam wheels at the exhaust. Older engines do not have VVT.5. On newer models there are VVT-units on both camshafts.6. Turn crankshaft in its rotational sense to compression TDC on cylinder 1.7. The cam marker must be at 12.8. Turn crankshaft to approx. 10° after compression TDC on cylinder 1.9. Dismount the blind cover plug at flywheel.10. Mount locking tool "999-5451" in engine block



and with turbo have adjustable cam wheels at the exhaust. Older engines do not have VVT.5. On newer models there are VVT-units on both camshafts.6. Turn crankshaft in its rotational sense to compression TDC on cylinder 1.7. The cam marker must be at 12.8. Turn crankshaft to approx. 10° after compression TDC on cylinder 1.9. Dismount the blind cover plug at flywheel.10. Mount locking tool "999-5451" in engine block



and with turbo have adjustable cam wheels at the exhaust. Older engines do not have VVT.5. On newer models there are VVT-units on both camshafts.6. Turn crankshaft in its rotational sense to compression TDC on cylinder 1.7. The cam marker must be at 12.8. Turn crankshaft to approx. 10° after compression TDC on cylinder 1.9. Dismount the blind cover plug at flywheel.10. Mount locking tool "999-5451" in engine block11. Turn engine counter clockwice until the crankhaft touches the TDC set pin "Mot. 1766".



and with turbo have adjustable cam wheels at the exhaust. Older engines do not have VVT.5. On newer models there are VVT-units on both camshafts.6. Turn crankshaft in its rotational sense to compression TDC on cylinder 1.7. The cam marker must be at 12.8. Turn crankshaft to approx. 10° after compression TDC on cylinder 1.9. Dismount the blind cover plug at flywheel.10. Mount locking tool "999-5451" in engine block11. Turn engine counter clockwice until the crankhaft touches the TDC set pin "Mot. 1766".12. Control that markings on camshaft pulley align with markings on inner cover.



and with turbo have adjustable cam wheels at the exhaust. Older engines do not have VVT.5. On newer models there are VVT-units on both camshafts.6. Turn crankshaft in its rotational sense to compression TDC on cylinder 1.7. The cam marker must be at 12.8. Turn crankshaft to approx. 10° after compression TDC on cylinder 1.9. Dismount the blind cover plug at flywheel.10. Mount locking tool "999-5451" in engine block11. Turn engine counter clockwice until the crankhaft touches the TDC set pin "Mot. 1766".12. Control that markings on camshaft pulley align with markings on inner cover.



and with turbo have adjustable cam wheels at the exhaust. Older engines do not have VVT.5. On newer models there are VVT-units on both camshafts.6. Turn crankshaft in its rotational sense to compression TDC on cylinder 1.7. The cam marker must be at 12.8. Turn crankshaft to approx. 10° after compression TDC on cylinder 1.9. Dismount the blind cover plug at flywheel.10. Mount locking tool "999-5451" in engine block11. Turn engine counter clockwice until the crankhaft touches the TDC set pin "Mot. 1766".12. Control that markings on camshaft pulley align with markings on inner cover.13. Marks on the crank gear must match the marks on the mounting plate.



and with turbo have adjustable cam wheels at the exhaust. Older engines do not have VVT.5. On newer models there are VVT-units on both camshafts.6. Turn crankshaft in its rotational sense to compression TDC on cylinder 1.7. The cam marker must be at 12.8. Turn crankshaft to approx. 10° after compression TDC on cylinder 1.9. Dismount the blind cover plug at flywheel.10. Mount locking tool "999-5451" in engine block11. Turn engine counter clockwice until the crankhaft touches the TDC set pin "Mot. 1766".12. Control that markings on camshaft pulley align with markings on inner cover.13. Marks on the crank gear must match the marks on the mounting plate.


Dismount 3

1. Lock camshafts with tool ”999-5452” (may not be used as holding tool).1. Lock camshafts with tool ”999-5452” (may not be used as holding tool).1. Lock camshafts with tool ”999-5452” (may not be used as holding tool).1. Lock camshafts with tool ”999-5452” (may not be used as holding tool).2. Loosen bolt on belt tensioner.1. Lock camshafts with tool ”999-5452” (may not be used as holding tool).2. Loosen bolt on belt tensioner.1. Lock camshafts with tool ”999-5452” (may not be used as holding tool).2. Loosen bolt on belt tensioner.3. Turn belt tensioner clockwise until belt is loosened.

1. Lock camshafts with tool ”999-5452” (may not be used as holding tool).2. Loosen bolt on belt tensioner.3. Turn belt tensioner clockwise until belt is loosened.4. Dismount timing belt.

1. Lock camshafts with tool ”999-5452” (may not be used as holding tool).2. Loosen bolt on belt tensioner.3. Turn belt tensioner clockwise until belt is loosened.4. Dismount timing belt.

1. Lock camshafts with tool ”999-5452” (may not be used as holding tool).2. Loosen bolt on belt tensioner.3. Turn belt tensioner clockwise until belt is loosened.4. Dismount timing belt.5. Check/change packing blocks, water pumps, turning wheels and belt tensioners.

1. Lock camshafts with tool ”999-5452” (may not be used as holding tool).2. Loosen bolt on belt tensioner.3. Turn belt tensioner clockwise until belt is loosened.4. Dismount timing belt.5. Check/change packing blocks, water pumps, turning wheels and belt tensioners.

1. Lock camshafts with tool ”999-5452” (may not be used as holding tool).2. Loosen bolt on belt tensioner.3. Turn belt tensioner clockwise until belt is loosened.4. Dismount timing belt.5. Check/change packing blocks, water pumps, turning wheels and belt tensioners.6. On older models:

1. Lock camshafts with tool ”999-5452” (may not be used as holding tool).2. Loosen bolt on belt tensioner.3. Turn belt tensioner clockwise until belt is loosened.4. Dismount timing belt.5. Check/change packing blocks, water pumps, turning wheels and belt tensioners.6. On older models:7. Lock the belt tensioner, use a hard metal pin.

1. Lock camshafts with tool ”999-5452” (may not be used as holding tool).2. Loosen bolt on belt tensioner.3. Turn belt tensioner clockwise until belt is loosened.4. Dismount timing belt.5. Check/change packing blocks, water pumps, turning wheels and belt tensioners.6. On older models:7. Lock the belt tensioner, use a hard metal pin.


Mounting 1

1. Remove the plug at the front edge of the VVT-unit1. Remove the plug at the front edge of the VVT-unit1. Remove the plug at the front edge of the VVT-unit1. Remove the plug at the front edge of the VVT-unit2. Loosen :1. Remove the plug at the front edge of the VVT-unit2. Loosen :1. Remove the plug at the front edge of the VVT-unit2. Loosen :

• the center mounting bolt on the VVT-unit (use counter hold).

1. Remove the plug at the front edge of the VVT-unit2. Loosen :

• the center mounting bolt on the VVT-unit (use counter hold).• the small bolts on the VVT-unit.





3. Turn :



3. Turn :



3. Turn :• the VVT-unit in the normal direction of rotation until great resistance can be felt.



3. Turn :• the VVT-unit in the normal direction of rotation until great resistance can be felt.



3. Turn :• the VVT-unit in the normal direction of rotation until great resistance can be felt.• the timing gear pulley on the VVT-unit clockwise, until the screws at the oval holes are in the




limit position.




limit position.




limit position.4. Continue rotation of the VVT-unit 355°, until the mark is 1 tooth before the mark on the upper









timing cover.





timing cover.


Mounting 2

1. Loosen the 3 small cam wheel bolts so the cam gear can turn around the camshaft.1. Loosen the 3 small cam wheel bolts so the cam gear can turn around the camshaft.1. Loosen the 3 small cam wheel bolts so the cam gear can turn around the camshaft.1. Loosen the 3 small cam wheel bolts so the cam gear can turn around the camshaft.2. Remove one bolt from the camshaft timing sprocket crown.1. Loosen the 3 small cam wheel bolts so the cam gear can turn around the camshaft.2. Remove one bolt from the camshaft timing sprocket crown.1. Loosen the 3 small cam wheel bolts so the cam gear can turn around the camshaft.2. Remove one bolt from the camshaft timing sprocket crown.3. Check that the small bolts are positioned centrally in their holes.

1. Loosen the 3 small cam wheel bolts so the cam gear can turn around the camshaft.2. Remove one bolt from the camshaft timing sprocket crown.3. Check that the small bolts are positioned centrally in their holes.


Mounting 3

1. Turn the VVT-unit on marks, and hold it in this position.1. Turn the VVT-unit on marks, and hold it in this position.1. Turn the VVT-unit on marks, and hold it in this position.1. Turn the VVT-unit on marks, and hold it in this position.2. Check that the markings on the camshaft sprockets are pointing vertically upwards.1. Turn the VVT-unit on marks, and hold it in this position.2. Check that the markings on the camshaft sprockets are pointing vertically upwards.1. Turn the VVT-unit on marks, and hold it in this position.2. Check that the markings on the camshaft sprockets are pointing vertically upwards.3. Tighten :

1. Turn the VVT-unit on marks, and hold it in this position.2. Check that the markings on the camshaft sprockets are pointing vertically upwards.3. Tighten :

• the cam wheel bolt in the VVT-unit 120 Nm.


• the cam wheel bolt in the VVT-unit 120 Nm.


• the cam wheel bolt in the VVT-unit 120 Nm.• the plug at the front edge of the VVT-unit 35 Nm.





4. Mount timing belt.



4. Mount timing belt.5. ---------------------------------------



4. Mount timing belt.5. ---------------------------------------



4. Mount timing belt.5. ---------------------------------------6. Note: :







• Up to engine number 3188688 the eccentric must be turned ANTI CLOCKWISE to tighten the




• Up to engine number 3188688 the eccentric must be turned ANTI CLOCKWISE to tighten the




• Up to engine number 3188688 the eccentric must be turned ANTI CLOCKWISE to tighten the belt !





• From engine number 3188689 the eccentric must be turned CLOCKWISE to tighten the belt !





• From engine number 3188689 the eccentric must be turned CLOCKWISE to tighten the belt !





• From engine number 3188689 the eccentric must be turned CLOCKWISE to tighten the belt !7. ---------------------------------------





• From engine number 3188689 the eccentric must be turned CLOCKWISE to tighten the belt !7. ---------------------------------------





• From engine number 3188689 the eccentric must be turned CLOCKWISE to tighten the belt !7. ---------------------------------------8. Turn belt tensioner counter clockwise, to maximum tension.





• From engine number 3188689 the eccentric must be turned CLOCKWISE to tighten the belt !7. ---------------------------------------8. Turn belt tensioner counter clockwise, to maximum tension.9. Tighten belt tensioner clockwise with Allen key until pointer aligns with the small notch and tighten











bolt.






bolt.






bolt.10. Check that the small bolts are positioned centrally in their holes.






bolt.10. Check that the small bolts are positioned centrally in their holes.






bolt.10. Check that the small bolts are positioned centrally in their holes.11. Tighten :







• the 3 small cam wheel bolts 20 Nm.







• the 3 small cam wheel bolts 20 Nm.







• the 3 small cam wheel bolts 20 Nm.• the 3 small cam wheel bolts in the VVT-unit 20 Nm.







• the 3 small cam wheel bolts 20 Nm.• the 3 small cam wheel bolts in the VVT-unit 20 Nm.


Mounting 4

1. Dismount all locking tools.1. Dismount all locking tools.1. Dismount all locking tools.1. Dismount all locking tools.2. Install the crankshaft pulley / vibration damper, use "999-5199" to secure it, tighten 180 Nm.1. Dismount all locking tools.2. Install the crankshaft pulley / vibration damper, use "999-5199" to secure it, tighten 180 Nm.1. Dismount all locking tools.2. Install the crankshaft pulley / vibration damper, use "999-5199" to secure it, tighten 180 Nm.3. Tighten the 4 small bolts in the crankshaft pulley / vibration damper, tighten 25 Nm + 60°.

1. Dismount all locking tools.2. Install the crankshaft pulley / vibration damper, use "999-5199" to secure it, tighten 180 Nm.3. Tighten the 4 small bolts in the crankshaft pulley / vibration damper, tighten 25 Nm + 60°.4. Turn crankshaft 720° to compression TDC on cylinder 1.

1. Dismount all locking tools.2. Install the crankshaft pulley / vibration damper, use "999-5199" to secure it, tighten 180 Nm.3. Tighten the 4 small bolts in the crankshaft pulley / vibration damper, tighten 25 Nm + 60°.4. Turn crankshaft 720° to compression TDC on cylinder 1.

1. Dismount all locking tools.2. Install the crankshaft pulley / vibration damper, use "999-5199" to secure it, tighten 180 Nm.3. Tighten the 4 small bolts in the crankshaft pulley / vibration damper, tighten 25 Nm + 60°.4. Turn crankshaft 720° to compression TDC on cylinder 1.5. Control :



• of camshaft timing.


• of camshaft timing.• that belt tensioner pointers align with notches (If not adjust and control again).





6. The remainder is assembled in opposite order.



6. The remainder is assembled in opposite order.

tolerance data 2009.1 tools 1. "999-5452” =

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