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

Distributor Cap and Rotor

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REMOVAL & INSTALLATION



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

Depending on the reason you have for removing the distributor cap, it may (in some cases) make more sense to leave the spark plug wires attached. This is the case, for example, if you are testing spark plug wires, or if removal is necessary to access other components (and wire play allows you to reposition the cap out of the way).

  1. Disconnect the negative battery cable.
  2.  
  3. On some models, it is necessary to remove the air cleaner housing and attaching hoses.
  4.  
  5. Remove the retaining screws for the distributor cap.
  6.  
  7. Carefully lift the distributor cap STRAIGHT up and off the distributor, in order to prevent damage to the rotor blade.
  8.  
  9. Remove and label the spark plug wires from the distributor cap.
  10.  
  11. If equipped, remove the screws retaining the rotor to the distributor shaft.
  12.  
  13. Remove the rotor from the distributor shaft, noting its position for reinstallation.
  14.  
  15. Inspect both the distributor cap and rotor for damage; replace as necessary.
  16.  

To install:
  1. Install the rotor on the distributor shaft, in the correct position.
  2.  
  3. Install and tighten the retaining bolt on the rotor (if equipped).
  4.  
  5. Install the distributor cap on the distributor.
  6.  
  7. Install and tighten the distributor cap retaining screws.
  8.  
  9. Install the spark plug wires in the correct locations on the distributor cap.
  10.  
  11. Install the air cleaner housing and hoses if removed.
  12.  
  13. Start the vehicle and ensure that it starts and runs normally.
  14.  
  15. Connect the negative battery cable.
  16.  



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Fig. Fig. 1: To remove the air cleaner housing, remove the heated air intake tube from the exhaust manifold ...



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Fig. Fig. 2: ... and the air intake pickup tube from the front of the vehicle, next to the radiator ...



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Fig. Fig. 3: ... along with the air cleaner retaining bolt, then lift the housing out of the engine compartment



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Fig. Fig. 4: A flat bladed screwdriver usually works best to remove the distributor cap retaining screws



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Fig. Fig. 5: Gently pull the cap outward to remove it from the distributor



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Fig. Fig. 6: Matchmark the plug wires to avoid confusion during installation



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Fig. Fig. 7: Rotate the wires to loosen them, then separate them from the cap



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Fig. Fig. 8: Remove the rotor cover before unfastening the bolts



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Fig. Fig. 9: The rotor is attached to the shaft by three bolts



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Fig. Fig. 10: Typically, a 3mm Allen wrench is used to remove the bolts



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Fig. Fig. 11: After the bolts are removed, separate the rotor from the distributor

INSPECTION



See Figures 12, 13 and 14

After removing the distributor cap and rotor, clean the components (both inside and outside of the cap) using soap and water. If compressed air is available, carefully dry the components (wearing safety goggles) or allow the parts to air dry. You can dry them with a clean, soft cloth, but don't leave any lint or moisture behind.

Once the cap and rotor have been thoroughly cleaned, check for cracks, carbon tracks, burns or other physical damage. Make sure the distributor cap's carbon button is free of damage. Check the cap terminals for dirt or corrosion. Always check the rotor blade and spring closely for damage. Replace any components where damage is found.



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Fig. Fig. 12: Inspect the distributor cap for cracks, burns, wear and damage



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Fig. Fig. 13: Inspection points for the distributor cap



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Fig. Fig. 14: Inspection points for the distributor rotor

 
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