QuestionI am currently working on a 1998 Volvo V70 Turbo Diesel in Abuja, Africa. I don't have access to service manuals, or people that have information or experience. I have to rely on what I know from experience. The problem with this vehicle at this time is that the injection pump timing is wrong. Do you know of an information site on-line that will give me diagrams of how to accurately set the timing in relation to TDC for #1? I would really appreciate it if the site was accessable free of charge. I have the timing close, but I need for it to be right. The initial problem with this vehicle's engine was that someone did not torque the crankshaft screw properly, after replacing the harmonic balancer. The engine lost time, and bent all valves. The camshaft also broke into five pieces. The engines head was removed without accurately marking the camshaft-injection pump relationship. The engine has been repaired by replacing the camshaft and valves. The camshaft-crankshaft relationship has been set. The injection pump has no marks that I was able to see. I set it as close as I could by getting the pump to spray fuel just as the piston for #1 reached TDC. I got the vehicle to run, but I want accuracy.
Thank you,
Ivan
AnswerHello Ivan,
there is one site but I do not know you can find there that you are looking for, but look there. "howstuffworks.com" Also, I put some info for you, I hope they are beneficial for you...GoodLuck...
Preparation and removing of components
Preparation:
Note! The camshaft belt tensioner should be checked and adjusted when the engine is at room temperature (max 30°C).
Remove the engine cover.
Removing components:
Lift up the expansion tank.
Disconnect the contact and place the expansion tank to one side.
Remove:
-drive belt for the auxiliary unit,
-auxiliary belt tensioner,
-camshaft belt casing,
-lower plate under the camshaft belt casing (2 screws).
Raise the car and remove the noise damper under the engine.
Removing nuts for silencer and mudguard liner
Lower the car to a convenient working height.
Remove:
-front RH wheel,
-nuts for the silencer and mudguard liner.
Put the silencer on one side, push part of the mudguard liner aside and fasten it in the open position.
Removing lower screw and lower plate
Remove the lower screw and lower plate.
Turning the crankshaft
Caution! Turn the crankshaft at least 2 turns to top dead centre (TDC) by turning it in the direction of rotation (clockwise) so that the TDC mark on the outside of the vibration damper lines up with the mark on the panel (LH figure).
Adjust the TDC position by using the mark on the flywheel, which can be checked through the space in the lower part of the gearbox cover (RH figure). Adjustment must not be made by reverse rotation.
Removing charge air pipe and pump belt casing
Lower the car to a convenient working height.
Remove the charge air pipe between the rubber hose on the charge air cooler and induction pipe.
Remove the pump belt casing.
Carry out the following procedure in the engine compartment:
-check that the marks on the pump rotor and pump bracket are centred with each other.
If the marks do not line up, rotate the crankshaft one more turn.
The pump marks will eventually line up with each other on alternate turns of the crankshaft.
Locking the pump
Lock the pump by removing the locking screw and removing the spacer.
Note! The spacer is exposed and easy to lose.
Tighten the screw to 30 Nm to lock the pump.
Checking the water pump
Loosen the centre screw and release the camshaft belt wheel.
Loosen the centre screw on the camshaft belt wheel (1 turn).
Tap the camshaft belt wheel with a mandrel and plastic hammer to loosen it.
Installing counterhold
Lower the car
Fasten the counterhold by replacing the screw with the screw that belongs to the tool.
Removing vibration damper
Raise the car.
Loosen the crankshaft centre bolt.
Loosen the four screws that fasten the vibration damper to the toothed pulley.
Removing camshaft belt and belt tensioner
Remove:
-camshaft belt,
-belt tensioner.
Checking belt protector screw (M6)
When the parts are removed, the belt protector screw (M6) should also be checked.
Checking the water pump
Checking the water pump:
Check by hand that there is no play in the water pump bearings.
Using a mirror, look for any green coolant deposits on the water pump outlet.
If there is leakage, or if there is play in the bearing, the water pump should be replaced.
Installing components
Installing belt tensioner and camshaft belt
Install:
-new belt tensioner,
-new camshaft belt.
Tighten the belt until the pointer is 2 mm below the fixed mark.
Tighten the screw to 20 Nm.
Note! Use a mirror and lamp in order to see the pointer from directly in front.
Note! If the pointer has passed more than 2 mm below the mark, the tensioner must be completely turned back. The belt should then be tensioned again clockwise from the start position. Adjustment must not be made by reverse rotation.
Installing vibration damper
Raise the car
Install the vibration damper (4 new screws).
Note! The screws must not be lubricated. Clean the vibration damper and crankshaft.
The vibration damper will only fit in one position. Check that it is positioned correctly.
Tighten the screws by hand.
Use a new centre screw.
Note! The screws must not be lubricated.
Tighten the centre screw to 160 Nm. Then tighten through an angle of 180°. This can be carried out in stages, but it is important to tighten to an angle of 180°.
Then tighten the four screws alternately to 20 Nm. Then tighten through an angle of 90°.
install the original screw. Tighten to 25 Nm.
Checking the crankshaft
Check that the crankshaft is still at top dead centre (TDC).
If not, adjust to TDC.
Only adjust in the direction of rotation.
Tightening screw to camshaft belt wheel
Tighten the screw marked 8.8 to the camshaft belt wheel to 85 Nm, or the screw marked 10.9 to 100 Nm.
Installing a spacer on the fuel pump
Remove the pump retaining screw from the pump.
Fit the spacer on the fuel pump and tighten the screw to 12.5 Nm.
Checking the belt tension
Turn the crankshaft at least 2 turns.
Check that the belt tension is correct. If it is not, step Installing belt tensioner and camshaft belt is to be repeated where appropriate.
Installing components
Install:
-lower plate under the camshaft belt casing (2 screws). Tighten to 10 Nm.
-auxiliary belt tensioner. Tighten to 40 Nm.
Note! Short screw uppermost. Tighten to 40 Nm.
-camshaft belt casing,
Note! Check that the cover is positioned correctly.
-drive belt for the auxiliary unit,
-expansion tank.
Installing lower screw on lower plate
Raise the car to a convenient working height.
Install lower screw in lower plate.
Tighten to 10 Nm.
Installing noise damper, silencer and mudguard liner
Install the noise damper under the engine.
Install the silencer and the mudguard liner, and secure them with the nuts.
Install the wheel.
Installing charge air pipe and bleeding the cooling system
If the water pump is replaced:
Fill with coolant.
The cooling system should hold approx. 12 litres.
Set the heater control to its highest setting and check that warm air is coming out.
Install the charge air pipe.
Run the engine until it is warm and fill the expansion tank with coolant as required.
Note! If the fuel heater is mounted under the vehicle, the water system should be bled.
Bleeding the water system:
Set the heater control to MAX heat (manual heater unit only).
Place a 12 mm steel ball,in the hose from the engine and connect the hose to the pipe.
Fill the coolant container completely.
Run the car until warm air can be felt coming from the floor/ defroster outlets.
Rev the engine up until the steel ball is pushed up towards the pipe and forms a seal.
Put a pair of pliers on the hose as near to the pipe as possible.
Turn engine off.
Loosen the hose and remove the steel ball.
If necessary, you can tap on the steel pipe with something.
Connect the hose to the pipe.
Tighten the clamp.
Turn the engine on for a few seconds.
Connect the heater.
Check that warm air is coming from the floor/ defroster outlets.
Fill up coolant.
Carefully clean up any coolant spillage!
Check the pump setting
Installing the pump belt casing and engine cover
Install:
-pump belt casing
-the engine cover
Regards//Vedat...
