Volvo 850 Manual de usuario
2.4L 5-CYL VIN [55]
1995 Volvo 850
1995-96 ENGINES
Volvo - 2.4L 5-Cylinder
850
* PLEASE READ THIS FIRST *
NOTE: For repair procedures not covered in this article, see
ENGINE OVERHAUL - GENERAL INFORMATION article in GENERAL
INFORMATION section. Repair information for this engine is
not available at time of publication.
ENGINE IDENTIFICATION
Engine may be identified by using Vehicle Identification
Number (VIN) stamped on a metal pad, located near lower left corner of
windshield. The sixth and seventh character identifies engine model.
Engine identification number, located on left side of
cylinder block below cylinder head, may be required when ordering
replacement parts.
ENGINE IDENTIFICATION CODES TABLE
Engine Code
2.4L (Non-Turbo) ...................................... 55
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
Engine is equipped with hydraulic lifters. No valve
adjustment is necessary.
REMOVAL & INSTALLATION
NOTE: For reassembly reference, label all electrical connectors,
vacuum hoses and fuel lines before removal. Also place
mating marks on other major assemblies before removal. Hood
removal is not necessary, as hood opens to horizontal
position. Removal and installation information for
turbocharger is not available at time of publication.
FUEL PRESSURE RELEASE
Fuel Pump Pressure Release
Before disconnecting any lines, cover fuel line connector
with shop towel to absorb any fuel left in line. With ignition key
removed from ignition switch, reconnect relay.
ENGINE
Removal
1) Remove expansion tank cap. Raise and support vehicle.
Remove splash guard and air baffle under engine. Drain all coolant by
opening drain cocks on cylinder block and radiator. Remove front
wheels, steering arm/wheel spindle joints, and nuts securing ball
joints to support arms.
2) Remove ABS wire and brake line retaining bracket bolt
located on inner fender panel, close to bottom of strut. Remove left
drive axle shaft. See AXLE SHAFTS - FWD article in DRIVE AXLES
section. Disconnect 2 thin Black hoses from evaporative fuel canister.
Remove White vacuum hose from vacuum reservoir.
3) Remove right drive shaft and intermediate bearing cap.
Carefully place components on steering servo pipes. Remove 2 right
engine mounting bolts. Loosen wheel arch liner to allow access to
mounting. Remove torque arm in gearbox. See Fig. 1. Install Sealing
Plugs (5488) in drive shaft holes.
Fig. 1: Removing Drive Shaft, Engine Mount Bolt & Torque Arm
Courtesy of Volvo Cars of North America.
4) Remove front exhaust pipe nuts and springs. Remove front
exhaust pipe bolts. Disconnect speedometer. Remove engine mounting
shield bolt. Lower vehicle.
5) Remove battery, battery self, and fresh air hose between
air intake and air cleaner housing. Disconnect MAF sensor connector
and primary lead between distributor and coil. Remove throttle pulley
cover. If equipped with cruise control, disconnect all necessary
electrical wiring and vacuum hose.
6) Disconnect intake hose at throttle body and idle air
control valve hose. Disconnect vacuum hose and crankcase ventilation
hose from intake hose. Disconnect vacuum hoses and connector from
solenoid valve. Disconnect heater hose. Remove air cleaner housing.
Disconnect throttle cable from throttle pulley. Remove torque arm.
7) Disconnect 2 heater hoses at firewall, brake servo hose,
and 2 HO2S connectors. Remove upper nut on rear engine mount.
Disconnect gear selector cables from mounting bracket on transmission.
Disconnect rubber-mounted section of cable bracket. On automatic
transmission equipped vehicles, disconnect 2 oil cooler hoses. On
manual transmission equipped vehicles, remove clutch slave cylinder
retaining ring. Remove slave cylinder from transmission.
8) On all vehicles, disconnect negative battery cable.
Disconnect lower radiator hose at radiator. Loosen and move air
cleaner mounting bracket aside. Remove rubber mount from air cleaner
bracket. On manual transmission equipped vehicles, remove clutch slave
cylinder through front hole in air cleaner bracket and place aside. On
all vehicles, place air cleaner bracket aside.
9) Remove electric cooling fan relays from fan shroud.
Disconnect connectors and place wiring aside. Remove 2 control module
box cooling air ducts. Remove 4 fan shroud screws from radiator. Use a
piece of plywood to protect radiator and slide fan housing back
slightly and remove air intakes. Remove fan.
10) Remove 2 long mounting bolts in A/C compressor. Leave
compressor in position until removing engine. Remove front engine
mounting pad nut and cable duct bracket mounting bolts. Remove intake
manifold and starter support brackets.
11) Disconnect upper radiator hose from thermostat housing.
Remove coolant hose between expansion tank and thermostat housing.
Remove expansion tank lower hose from fitting on engine. Remove drive
belt. Disconnect temperature sensor wiring from bracket on servo pump.
Remove 6 servo pump bolts. Leave servo pump in position at this time.
12) Remove protective cover over fuel distribution manifold.
Remove upper and lower fuel pipe clips. Remove fuel distribution
manifold bolts. Disconnect braided ground lead from engine. Secure
injectors with 5 Holders (5465). Lift and place fuel distribution
manifold (including injectors) aside. Remove engine wiring harness.
See Fig. 2.
Fig. 2: Removing Engine Wiring Harness
Courtesy of Volvo Cars of North America.
13) Remove spark plug cover and attach Lifting Lugs (5459 and
5464) to engine. Lift servo pump and place aside. Remove A/C
compressor and place on sub-frame. Lift out engine and transmission
using Lifting Yokes (2810 and 5428).
Installation
1) Attach Lifting Lug (5429) to rear of engine. Using Lifting
Yoke (5428) and Lifting Tool (2810), lower engine and transmission
into position. Guide engine mountings into position and tighten top
nuts to 37 ft. lbs. (50 N.m).
2) Support transmission with jack and remove lifting yoke
from engine. Using 2 Support Rails (5033), Lifting Beam (5006) and
Lifting Hook (5115), support rear of engine. Remove jack under
transmission. Using Transmission Lifting Fixture (5972), raise
transmission. Install transmission support member. Tighten bolted
joints between support member and side members. Tighten transmission
bump stop nut to 37 ft. lbs. (50 N.m).
3) Install control rod and reaction arm to lever mounting.
Install locking clip. Install oxygen sensor and reconnect electrical
connector. Using Socket (5244), tighten front and rear couplings.
Ensure "O" ring is okay and install air preheater pipe to exhaust
pipe.
4) Install air conditioning compressor to mounting. Reconnect
oil cooler lines. Tighten fittings to 26 ft. lbs. (35 N.m). Remove
lifting tools.
5) Reinstall coolant hoses to firewall. Install timing pick-
up and camshaft sensor connectors. Reconnect engine connector to
wiring harness connector on left wheel housing. Reconnect relay and
install wiring duct mounting nuts. Install harness connector cover.
6) Install fuel hoses, cruise control vacuum hose, ECC vacuum
hoses, brake servo vacuum hose, throttle cable and throttle pulley
cover. Install air mass meter and intake hose. Reconnect idling valve
hose and connector. Reconnect oil trap hoses. Reconnect 2 EVAP vacuum
hoses.
7) Install servo pump and drive belt. Install radiator and
radiator hoses, expansion tank hoses, and transmission oil cooler
lines. Tighten cooling line fittings to 26 ft. lbs. (35 N.m). Install
cooling fan. Install battery and reconnect positive cable.
8) Jack up vehicle and reconnect cooling lines to
transmission. Tighten fittings to 26 ft. lbs. (35 N.m). Install
exhaust pipe and heat shield. Install radiator mounting bolts, air
baffle under radiator, and splash guard under engine. Fill engine with
oil and cooling system. Connect negative battery cable. Start engine
and check for leaks.
INTAKE MANIFOLD
Removal & Installation
For intake manifold removal and installation, see
CYLINDER HEAD under REMOVAL & INSTALLATION.
EXHAUST MANIFOLD
Removal
Remove exhaust manifold-to-cylinder head nuts. Disconnect
front exhaust pipe. Remove 2 heat shields from exhaust manifold. Lift
manifold off studs, turn it 90 degrees, and lift out of engine
compartment. On vehicles with A/C, use care to avoid damage to switch
on A/C pipe.
Installation
Install manifold with NEW gaskets. Install front exhaust pipe
to manifold. Tighten manifold-to-cylinder head nuts to 18 ft. lbs. (25
N.m). Install heat shields. Using Loctite on bolts, and ensuring
springs and washers are under exhaust pipe nuts, tighten front exhaust
pipe-to-manifold nuts to end of threads. Do not tighten to more than
84 INCH lbs. (10 N.m).
CYLINDER HEAD
Removal
1) Disconnect negative battery cable. Remove expansion tank
cap. Remove splash guard under engine. Open drain cocks on cylinder
block and radiator and drain coolant. Remove exhaust manifold-to-front
exhaust pipe nuts. Remove exhaust manifold. See EXHAUST MANIFOLD under
REMOVAL & INSTALLATION. Remove timing belt. See TIMING BELT under
REMOVAL & INSTALLATION.
2) Lift and place fuel distribution manifold and injectors
aside. Install Holders (5465) to injectors. Disconnect 2 braided
ground leads from engine. Remove 4 fan shroud retaining screws. Remove
control module box cooling air ducts. Bend shroud aside slightly, lift
relay holder, and disconnect electric cooling fan connectors. Remove
control module box and air cleaner intakes. Lift out electric cooling
fan assembly.
NOTE: Avoid damage to injector nozzles and needles.
3) Disconnect Idle Air Control (IAC) valve and Throttle
Position (TP) potentiometer connectors. Disconnect crankcase
ventilation and EVAP canister hoses. Disconnect servo (vacuum)
reservoir and intake manifold vacuum servo hoses. Remove intake hose.
4) Remove 3 intake manifold upper mounting bolts. Remove oil
dip-stick and bracket from intake manifold. Loosen manifold lower
mounting bolts a few turns. Remove manifold bracket bolt. Remove
intake manifold.
5) Disconnect upper radiator hose from thermostat housing.
Mark camshaft pulleys for reassembly reference and remove camshaft
pulleys. Remove timing belt cover inner bolt. Remove air cleaner
housing and hoses. Remove Camshaft Position (CMP) sensor and shutter.
Remove distributor cover, rotor and ignition lead clip. Remove torque
arm and brackets. Starting at outer edge and working inward, remove
bolts in upper half of cylinder head. Remove upper cylinder head by
very carefully tapping upward with a copper mallet at parting lugs and
camshaft pulley end. Mark camshafts for reassembly reference and
remove camshafts.
6) Remove 2 coolant pipe bolts. Starting at outer edge and
working inward, remove cylinder head bolts. Remove cylinder head. See
Fig. 3. Remove cylinder head gasket.
Fig. 3: Exploded View Of Engine Assembly
Courtesy of Volvo Cars of North America.
Fig. 4: Removing Components From Rear Of Engine
Courtesy of Volvo Cars of North America.
Installation
1) Remove starter and protective plug. Install Crankshaft
Locking Tool (5451). See Fig. 5. Turn crankshaft counterclockwise
until stopped by tool. Using NEW gasket, install bottom half of
cylinder head. Oil bolts and tighten, in sequence, in 3 steps. See
Fig. 6. See TORQUE SPECIFICATIONS. Install coolant pipe with NEW
gasket.
Fig. 5: Attaching Crankshaft Locking Tool (5451)
Courtesy of Volvo Cars of North America.
Fig. 6: Cylinder Head Bold Tightening Sequence
Courtesy of Volvo Cars of North America.
2) Install NEW cylinder head gasket and "O" rings in spark
plug wells. Remove No. 1 and No. 5 spark plugs. Oil lower camshaft
bearing seats. Using a roller, apply Sealing Compound (1 161 059-9) to
upper section of cylinder head. Ensure sealer does not penetrate oil
passages. Oil upper camshaft bearing seats. Install camshafts in upper
cylinder head section, using Holder (5453) at front and Locking Tool
(5452) at rear to secure camshafts. See Fig. 7.
Fig. 7: Using Locking Tool (5452) To Secure Camshafts
Courtesy of Volvo Cars of North America.
3) Install upper cylinder head. Tighten against lower section
using 2 Press Tools (5454). Tighten retaining bolts to 13 ft. lbs. (17
N.m), starting from inside and working outward. Remove 2 press tools.
4) Using Drift (5449), install camshaft front seals. Install
camshaft pulleys and align timing marks. See Fig. 8. Tighten each
pulley with 2 bolts, just until bolts are in contact with pulleys.
Fig. 8: Aligning Camshaft & Crankshaft Timing Marks
Courtesy of Volvo Cars of North America.
5) Remove upper timing belt cover. Install belt tensioner and
tighten bolts to 18 ft. lbs. (25 N.m). Place timing belt over camshaft
pulleys, around coolant pump, and press over tensioner pulley. Loosen
camshaft pulley bolts and remove tensioner locking pin.
6) Install third camshaft pulley bolt. Hold camshaft pulleys
still and tighten bolts alternately to 15 ft. lbs. (20 N.m). Install
inner timing belt cover bolt. Install upper timing belt cover. On both
engines, remove crankshaft locking tool and install protective plug.
Install starter. Remove camshaft locking tool. Install upper
transmission cover.
7) Turn crankshaft through 2 revolutions. Ensure timing marks
on crankshaft and camshaft pulleys are correctly aligned. See Fig. 8.
Install outer timing belt cover. On both engines, use D rift (5450),
and install right rear camshaft seal. See Fig. 9. Install torque arm
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