Volvo 240/740/760/780/940/960 1990-1998

Camshaft, Bearings and Lifters

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REMOVAL & INSTALLATION



The 2.3L 4-cylinder, 2.9L 6-cylinder, and 2.3 and 2.4L 5-cylinder engines all use camshafts that ride directly over the followers (lifters). After camshaft removal, they can be lifted out of their bores and inspected. If removal is necessary, mark the followers to assure their placement in the correct bore.

The 2.8L 6-cylinder engine uses rocker shaft mounted followers. Please refer to Rocker Arm/Shaft removal/installation for their removal.

When installing a camshaft, always lubricate the camshaft, seats, and lifters with the proper camshaft lube or moly grease.

2.3L 4-Cylinder Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the drive belts.
  4.  
  5. Set the engine to TDC of the No. 1 cylinder.
  6.  
  7. Remove the timing belt.
  8.  
  9. Remove the valve cover.
  10.  
  11. Remove the camshaft center bearing cap. Install camshaft press tool 5021 or equivalent over the center bearing journal to hold the camshaft in place while removing the other bearing caps.
  12.  
  13. Remove the 4 remaining bearing caps.
  14.  
  15. Remove the seal from the forward edge of the camshaft.
  16.  
  17. Release camshaft press tool and lift out the camshaft.
  18.  


WARNING
Do not rotate the crankshaft while the camshaft is removed from the cylinder head.

To install:
  1. Apply sealant to the outer sealing surfaces of the front and rear caps.
  2.  
  3. Lubricate the camshaft with cam lube or moly grease, and place into position. The guide pin for the timing gear should face up.
  4.  
  5. Install the rear bearing cap.
  6.  
  7. Slide the camshaft back and forth to check the camshaft end-play. End-play should be 0.004-0.016 in. (0.1-0.4mm).
  8.  
  9. Install the camshaft press tool.
  10.  
  11. Install the camshaft seal.
  12.  
  13. Lubricate and install the remaining caps starting in the center and working out.
  14.  
  15. Tighten the bolts to 14 ft. lbs. (20 Nm).
  16.  
  17. Lubricate the front seal and install, using tool 5025 or equivalent.
  18.  
  19. Install the camshaft gear and spacer washer.
  20.  
  21. Remove the tools.
  22.  
  23. Install the timing belt.
  24.  
  25. Install the remaining components.
  26.  
  27. Connect the negative battery cable.
  28.  

2.8L 6-Cylinder Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Set the engine to TDC of the No. 1 cylinder.
  4.  
  5. Remove the cylinder head.
  6.  
  7. Remove the camshaft rear cover plate.
  8.  
  9. Remove the camshaft retaining fork at the front of the cylinder head.
  10.  
  11. Pull the camshaft out the rear of the head.
  12.  

The camshaft does not have bearings, the journals in the head are machined to fit the camshaft. The retaining fork is used to adjust end-play to position the camshaft in the correct position.

To install:
  1. Oil the camshaft and followers and install.
  2.  
  3. Tighten the camshaft retaining bolt to 7-11 ft. lbs. (10-15 Nm).
  4.  
  5. Install the camshaft retaining fork.
  6.  
  7. Install the rear cover plate.
  8.  
  9. Install the cylinder head.
  10.  
  11. Connect the negative battery cable.
  12.  

2.9L 6-Cylinder Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the drive belts.
  4.  
  5. Set the engine to TDC of the No. 1 cylinder.
  6.  
  7. Remove the timing belt.
  8.  

Do not turn the crankshaft while the belt is removed.

  1. Remove the camshaft pulleys, using the holding tool 5199 or equivalent.
  2.  
  3. Remove the top half of the cylinder head.
  4.  
  5. Tap the joint lugs and camshaft front ends lightly.
  6.  
  7. Remove the camshafts.
  8.  

To install:
  1. Lubricate the camshafts and bearing seats with cam lube or moly grease.
  2.  
  3. Place the camshafts into position.
  4.  
  5. Install the holding tool 5453 or equivalent to the front end and the locking tool 5452 or equivalent to the rear end of the cylinder head upper section.
  6.  
  7. Install the upper cylinder head section and tighten against the lower section, using the press tools 5454 or equivalent.
  8.  
  9. Install and tighten the retaining bolts to 13 ft. lbs. (17 Nm), starting from the inside and working outwards.
  10.  
  11. Remove the tools.
  12.  
  13. Lubricate the camshaft front seals and tap into place.
  14.  
  15. Install the camshaft pulleys.
  16.  
  17. Tighten the camshaft pulley bolts alternately to 15 ft. lbs. (20 Nm).
  18.  
  19. Install the timing belt.
  20.  
  21. Install the tensioner and tighten the bolts to 18 ft. lbs. (25 Nm). Check that the timing marks on the crankshaft and camshaft pulleys are correctly aligned.
  22.  
  23. Install the remaining components.
  24.  
  25. Install the drive belts.
  26.  
  27. Connect the negative battery cable.
  28.  

2.3L and 2.4L 5-Cylinder Engines

See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 and 11

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the drive belt.
  4.  
  5. Set the engine to TDC of the No. 1 cylinder.
  6.  
  7. Remove the timing belt.
  8.  
  9. Remove the ignition coils cover.
  10.  

Do not turn the crankshaft while the belt is removed.

  1. Remove the camshaft position sensor and shutter at the right rear of camshaft assembly.
  2.  
  3. Remove the switch holder and shield at the left rear of assembly.
  4.  
  5. Remove the ignition coils. Mark their locations.
  6.  
  7. Mark the pulleys for reference so they can be returned to their original sides, then remove the camshaft pulleys, using holding tool 5199 or equivalent.
  8.  
  9. Remove the top half of the cylinder head.
  10.  
  11. Tap the joint lugs and camshaft front ends lightly.
  12.  
  13. Remove the camshafts.
  14.  
  15. Thoroughly clean the mating surfaces between the upper and lower halves of the cylinder head.
  16.  


WARNING
Do not use a metal scraper. Use a soft putty knife and gasket solvent cleaner with an exhaust fan. The surfaces must be totally clean to assure a tight seal.

To install:
  1. Lubricate the camshafts and bearing seats.
  2.  
  3. Place the camshafts into position.
  4.  
  5. Install the holding tool 5453 or equivalent to the front end and the locking tool 5452 or equivalent to the rear end of the cylinder head upper section.
  6.  
  7. Remove No. 1 and No. 5 spark plugs
  8.  
  9. Using a roller, apply liquid gasket 161 059-9 or equivalent to the upper half of the cylinder head.
  10.  

Make sure that no liquid gasket gets into the oil passages. Only a thin coating is required.

  1. Install the upper cylinder head section and tighten against the lower section, using the press tools 5454 or equivalent.
  2.  
  3. Install and tighten the retaining bolts to 13 ft. lbs. (17 Nm), starting from the inside and working outwards.
  4.  
  5. Remove the tools.
  6.  
  7. Lubricate the camshaft front seals and tap into place.
  8.  
  9. Mount the upper timing cover.
  10.  
  11. Install the camshaft sprockets and line up the camshaft timing marks.
  12.  
  13. Install two camshaft sprocket bolts furthest from the timing mark and tighten until they are just touching the sprocket.
  14.  
  15. Remove the upper timing cover.
  16.  
  17. Make sure that the remaining camshaft sprocket bolt hole is centered.
  18.  
  19. Turn all the idler pulleys listening for bearing noise.
  20.  
  21. Check to see that the contact surfaces are clean and smooth.
  22.  
  23. Remove the tensioner pulley lever and idler pulley, lubricate the contact surfaces and bearing with grease. If the tensioner pulley lever or idler is seized, replace it.
  24.  
  25. Install the tensioner pulley lever and tighten to 18 ft. lbs. (25 Nm).
  26.  
  27. Install the idler pulley and tighten to 18 ft. lbs. (25 Nm).
  28.  
  29. Compress the tensioner fully with tool 999 5456 or equivalent.
  30.  
  31. Install the timing belt.
  32.  
  33. Install the rear camshaft seal using drift 999 5450 or equivalent and press it carefully into position flush with the inner chamfer edge.
  34.  
  35. Install the remaining components
  36.  
  37. Connect the negative battery cable.
  38.  
  39. Start the engine and run it until the thermostat opens.
  40.  
  41. Check the engine for leaks.
  42.  



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Fig. Fig. 1: Remove the camshaft pulley cover



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Fig. Fig. 2: Prior to removal, mark the exhaust camshaft pulley ...



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Fig. Fig. 3: ... and the intake camshaft pulley



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Fig. Fig. 4: Install the pulley holding tool ...



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Fig. Fig. 5: ... and remove the pulley retaining bolts



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Fig. Fig. 6: Remove the pulley from the camshaft



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Fig. Fig. 7: Carefully lift the intake camshaft from the cylinder head



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Fig. Fig. 8: Remove the exhaust camshaft



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Fig. Fig. 9: Remove the camshaft seals



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Fig. Fig. 10: Inspect the camshaft lobes for wear



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Fig. Fig. 11: Remove the camshaft followers, noting their position

 
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