Method C, Motronic 4.3, Turbo Auto, US/CDN Only
DELETING THE EGR-SYSTEM AND REPLACING THE WASTE-GATE ACTUATOR
NOTE: Method "A" should be performed prior to this method if the vehicle is older than M/Y 96 (production date 03/96).
Parts Required:
- EGR-kit 272250-2
- Waste-gate actuator kit 1270463-1
- Engine Control Module (ECM) see table
- Vacuum and emission labels see table
C1 Remove:
- Battery negative lead
- Throttle pulley cover.
Removing Engine Coolant Fan (FC) Shroud
C2 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.
C3 Remove:
- Charge air pipe between the Charge Air Cooler (CAC) and hose on the Throttle Body (TB) (turbocharged cars)
- EVAP valve including hoses from fan shroud (if applicable)
- EGR controller from upper air guide and disconnect EGR controller connector.
C4 Remove:
- EGR controller with hoses and discard.
Install:
- Rubber plug on multi nipple.
C5 Remove:
- Disconnect the two connectors (A) to the engine coolant fan (FC)
- Free cable harnesses from fan shroud.
Place the air guide with the relays on top of 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.
Replacing Waste-gate Actuator
C6 Remove:
- Fresh air hose between Turbo-Charger (TC) and air filter.
C7 Remove:
- Clamp supporting charge air pipe by engine torque control arm.
C8 Remove:
- Lower clamp by Turbo-Charger (TC).
Fold charge air pipe out of the way.
NOTE: Cover Turbo-Charger outlet with paper or a rag to prevent debris from falling into it.
C9 Remove:
- Heat deflector plates
- Ground strip.
C10 Remove:
- Lock pin at waste-gate
- Rear waste-gate actuator screw (1)
- Front waste-gate actuator screw (2)
- Waste-gate actuator and discard.
Install:
- New waste-gate actuator
- Screws and tighten to 20 Nm (15 ft.lbs)
C11 Carry out basic adjustment of pressure arm:
- Connect manometer 999 5230 and pressure tester 998 5496 to pressure servo
- Pump up pressure to 12.5 kPa (1.82 psi).
- Pump waste-gate actuator spindle towards turbine housing (closed valve)
- Adjust pressure arm so that it fits onto spindle lug exactly
- Install lock pin at waste-gate
- Tighten pressure arm locknut
- Remove manometer and pressure tester.
NOTE: The tester arm must not be twisted when adjusting it. Otherwise the pressure servo membrane may be damaged.
Deleting EGR-system
C12 Remove:
- EGR pipe from exhaust manifold
- Nipple from exhaust manifold.
Install:
- Plug and nut on exhaust manifold.
Torque 60 Nm (44 ft.lb).
C13 Remove:
- EGR temperature sensor wire from connector
- EGR valve pipe coupling
- EGR valve and pipe and discard.
Clean gasket face on manifold.
Install:
- New cover plate and gasket using new bolts on intake manifold.
Torque 10 Nm (7.5 ft.lb).
- Plug on the EGR temperature sensor wire connector.
Re-installing Parts
C14 Install:
- Heat deflector plates
- Ground strip.
C15 Remove:
- Cover from Turbo-Charger (TC) outlet.
Install:
- Charge air pipe.
NOTE: Install the hose clamp so the waste-gate valve is not affected.
The hose clamp should be located a few millimeters in from the end of the hose.
C16 Install:
- Clamp supporting charge air pipe by engine torque control arm.
C17 Install:
- Fresh air hose to Turbo-Charger (TC).
Re-installing Parts
C18 Remove:
- Protective panel from the radiator.
Install:
- Engine coolant fan (FC) and shroud
- The two lower engine coolant fan screws loosely.
Fix the cable with the tie strap and clip.
Connect the two connectors to engine coolant fan (FC).
C19 Install:
- EVAP hose with clips to the coolant fan
- EVAP valve
- Install charge air pipe and hose between charge air cooler and Throttle Body (TB).
C20 Install:
- Two spacer washers on top
- Upper air guide
- Two upper screws on engine coolant fan (FC) and tighten all four
- Air intake (new) and inlet hose to the Air Cleaner (ACL)
- Throttle pulley cover.
C21 Install:
- Plug and clip as shown and park the EGR controller wire in the plug.
C22 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.
C23 Clean surfaces on the current vacuum hose and emission labels
Install:
- Vacuum hose label "A" on top of the old one.
- Emission label "B" on top of the old one.
C24 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.