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

Rocker Arm (Valve) Cover

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REMOVAL & INSTALLATION



2.3L 4-Cylinder Engines

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Label and remove the spark plug wires.
  4.  
  5. Remove the attaching bolts for the valve cover.
  6.  
  7. Remove the valve cover from the cylinder head. If necessary, lightly tap the valve cover with a soft hammer to aid in removal.
  8.  

To install:
  1. Thoroughly clean the valve cover and cylinder head gasket mating surfaces.
  2.  
  3. Install the valve cover on the cylinder head using a new gasket.
  4.  
  5. Tighten the valve cover bolts to 14 ft. lbs. (20 Nm) in a crisscross pattern.
  6.  
  7. Install the spark plug wires.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the engine and check for leaks.
  12.  



Click image to see an enlarged view

Fig. Fig. 1: Valve cover and gasket assembly

2.8L 6-Cylinder Engine
  1. Disconnect the negative battery cable.
  2.  
  3. The following steps are necessary if your car has A/C and if you are removing the passenger side valve cover, if you do not need to remove the passenger side valve cover, skip them.
    1. Remove the A/C compressor belt and the compressor from the mounting bracket located on the passenger side of the engine. Do not remove the lines from the compressor.
    2.  
    3. Place the compressor with the lines attached on the passenger side front shock tower and secure.
    4.  
    5. Remove the compressor bracket.
    6.  

  4.  
  5. Remove the air cleaner-to-throttle body hose.
  6.  
  7. Label and remove all necessary electrical and vacuum connections.
  8.  
  9. Remove the attaching bolts for the valve cover(s).
  10.  
  11. Remove the valve cover(s) from the cylinder head(s). If necessary, lightly tap the valve cover with a soft hammer to aid in removal.
  12.  

To install:
  1. Thoroughly clean the valve cover(s) and cylinder head gasket mating surfaces.
  2.  
  3. Install the valve cover(s) on the cylinder head(s) using new gaskets.
  4.  
  5. Tighten the valve cover bolts to 11 ft. lbs. (15 Nm) in a crisscross pattern.
  6.  
  7. Install all necessary electrical and vacuum connections.
  8.  
  9. Install the air cleaner assembly.
  10.  
  11. Install the A/C bracket (if removed).
  12.  
  13. Install the A/C compressor and belt (if removed).
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Start the engine and check for leaks.
  18.  

2.3L and 2.4L 5-Cylinder, and 2.9L 6-Cylinder Engines

See Figures 2, 3, 4, 5 and 6

The 2.3L and 2.4L 5-cylinder, and 2.9L 6-cylinder engines have a two-piece cylinder head, the upper half and the lower half. The upper half is basically the same as a valve cover, except that it incorporates the bearing caps for the camshafts into the underside.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the spark plug access cover.
  4.  
  5. Label and remove the ignition coils and vent hoses or the distributor cap and wires if equipped.
  6.  
  7. Check the cam alignment before removing the cylinder head.
  8.  
  9. Remove the bolts attaching the upper cylinder head.
  10.  
  11. Remove the upper cylinder head, lightly tap with a soft hammer if necessary.
  12.  

To install:
  1. Thoroughly clean the upper and lower cylinder head gasket mating surfaces.
  2.  
  3. Apply liquid sealing compound to the upper cylinder head mating surface.
  4.  


WARNING
Use a roller or your finger to spread sealant, do not use an excessive amount of sealant, or the oil passages could become clogged.

  1. Place the upper cylinder head onto the lower cylinder head.
  2.  
  3. Check the cam alignment before tightening the cylinder head.
  4.  
  5. Install Volvo tool number 5454 or equivalent to the upper cylinder head.
  6.  
  7. Tighten the nut on the tools to seat the upper cylinder head.
  8.  
  9. Tighten the upper cylinder head bolts, beginning from the center out to 13 ft. lbs. (17 Nm).
  10.  
  11. Install the ignition coils and hoses or the distributor cap and wires.
  12.  
  13. Install the spark plug access cover.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Start the vehicle and check for leaks.
  18.  



Click image to see an enlarged view

Fig. Fig. 2: Remove the clamp and detach the vent hose



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Fig. Fig. 3: Remove the spark plug cover and the plug wires or ignition coils to access the retaining bolts



Click image to see an enlarged view

Fig. Fig. 4: Remove the retaining bolts



Click image to see an enlarged view

Fig. Fig. 5: A light tap with a soft-faced hammer is usually required to loosen the valve cover



Click image to see an enlarged view

Fig. Fig. 6: Carefully lift the upper cylinder head up and off the lower section. Note the integral camshaft bearing caps in the casting

 
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