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

Timing Chain and Gears

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REMOVAL & INSTALLATION



2.8L 6-Cylinder Engine

See Figures 1, 2, 3 and 4

  1. Remove the timing chain cover.
  2.  
  3. Set the engine to TDC of the No. 1 cylinder.
  4.  
  5. Remove the oil pump sprocket and drive chain.
  6.  
  7. Slacken the tension in both camshaft timing chains by rotating each tensioner lock 1 / 4 turn counterclockwise and pushing the rubbing block piston.
  8.  
  9. Remove both chain tensioners.
  10.  
  11. Remove the 2 curved and the 2 straight chain damper/runners.
  12.  
  13. Remove the camshaft sprocket retaining bolt, 10mm Allen head, and the sprocket and chain assembly. Repeat for the other side.
  14.  

To install:
  1. Install the chain tensioners and tighten to 60 inch lbs. (7 Nm).
  2.  
  3. Install the curved chain damper/runners and tighten to 7-11 ft. lbs. (10-15 Nm).
  4.  
  5. Install the straight chain damper/runners and tighten to 60 inch lbs. (7 Nm).
  6.  
  7. First install the drivers side camshaft sprocket and chain:
    1. Rotate the crankshaft, using crankshaft nut, if necessary, until the crankshaft key is pointing directly to the drivers side camshaft and the drivers side camshaft key groove is pointing straight-up (12 o'clock).
    2.  
    3. Place the chain on the drivers side sprocket so the sprocket notchmark is centered precisely between the 2 white lines on the chain.
    4.  
    5. Position the chain on the crankshaft sprocket (inner), making sure the other white line on the chain aligns with the crankshaft sprocket notch.
    6.  
    7. While holding the drivers side chain and sprockets in this position, install the sprocket and chain on the drivers side camshaft, chain stretched on tension side, so the sprocket pin fits into the camshaft recess.
    8.  
    9. Tighten the sprocket center bolt to 51-59 ft. lbs. (69-80 Nm); use a suitable tool to keep the cam from turning.
    10.  

  8.  
  9. To install the passenger side camshaft sprocket and chain:
    1. Rotate the crankshaft clockwise until the crankshaft key points straight down (6 o'clock).
    2.  
    3. Align the camshaft key groove so it is pointing halfway between the 8 and 9 o'clock positions; at this position, the No. 6 cylinder rocker arms will rock.
    4.  
    5. Place the chain on the passenger side sprocket so the sprocket notchmark is centered precisely between the 2 white lines on the chain.
    6.  
    7. Then, position the chain on the middle crankshaft sprocket, making sure the other white line aligns with the crankshaft sprocket notch.
    8.  
    9. Install the sprocket and chain on the camshaft so the sprocket notch fits into the camshaft recess.
    10.  
    11. Tighten the sprocket nut to 51-59 ft. lbs. (69-80 Nm).
    12.  

  10.  
  11. Rotate the chain tensioners 1 / 4 turn clockwise each. The chains are tensioned by rotating the crankshaft 2 full turns clockwise. Recheck to make sure the alignment marks coincide.
  12.  
  13. Install the oil pump sprocket and chain.
  14.  
  15. Install the timing chain cover.
  16.  



Click image to see an enlarged view

Fig. Fig. 1: Relieving the chain tension



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Fig. Fig. 2: Exploded view of timing chain, tensioner and sprocket assembly



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Fig. Fig. 3: Drivers side timing chain installation sequence



Click image to see an enlarged view

Fig. Fig. 4: Passenger side timing chain installation sequence

 
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