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

Valve Lash

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The recommended maintenance interval for valve clearance adjustment is 30,000 miles (48,000 km). The clearance may be checked with the engine hot or cold.

ADJUSTMENT



Not all Volvo engines have adjustable valves. The following engines have adjustable valves, all others use hydraulic tappets and are non-adjustable.

B230F and B230FT Engines

See Figures 1, 2, 3, 4, 5, 6 and 7

Valve clearance adjustment requires the following special tools:



Valve tappet depressor tool (Volvo tool 5022 or equivalent) to push down the tappet sufficiently to remove the adjusting disc.
 
A special designed pair of pliers (Volvo tool 5026 or equivalent) to actually remove and install the valve adjusting disc.
 
A set of varying-thickness valve adjusting discs (sometimes called shims) to make the necessary corrections.
 
Feeler gauge to check valve clearance.
 


WARNING
The use of the correct special tools or their equivalent is required for this procedure.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the valve cover.
  4.  
  5. Rotate the engine, using the crankshaft center bolt, until the No. 1 cylinder is at Top Dead Center (TDC). Both cam lobes for the No. 1 cylinder should point up at equally large angles, and the pulley timing mark should be at 0 degrees.
  6.  
  7. Insert the correct size feeler gauge, as indicated, and check the No. 1 cylinder valve clearance.
  8.  

Always check valve clearance with cylinder at TDC. Always turn1/4turn after TDC to set.

  1. If the clearance is incorrect, line up valve depressors. Turn the valve depressors so that the notches are at right angle to the engine center line.
  2.  
  3. Attach valve depressor tool 5022 or equivalent and depress the valve. Screw down the tool spindle until the depressor groove is just above the edge and accessible with the pliers. Use tool 5026 or equivalent to remove the disc.
  4.  
  5. Using a micrometer, measure the disc thickness. Calculate the thickness of disc to be used. Discs are available from 0.130-0.180 inch (3.30-4.50mm), in increments of 0.001 inch (0.05mm). Use the following example:
    1. The measured clearance is 0.02 in. (0.50mm), and the correct clearance is 0.016 inch (0.40mm); therefore, the difference is 0.004 inch (0.10mm).
    2.  
    3. The measured thickness of the existing disc is 0.150 inch (3.80mm). Therefore, the correct thickness of the new disc will be 0.150 + 0.004 inch = 0.154 inch (3.80 + 0.10mm = 3.90mm).
    4.  

  6.  

It is advisable to use metric measurements to simplify calculations.

  1. Lubricate the new disc with clean engine oil and place into position.
  2.  
  3. Remove valve depressor tool 5022 or equivalent.
  4.  

Install the discs with their marks facing DOWN.

  1. Rotate the engine crankshaft until the No. 3 cylinder is at the correct position. Both cam lobes for the No. 3 cylinder should point up at equally large angles. Check and adjust the clearance as described previously.
  2.  
  3. Repeat Step 7 for cylinder No. 4 and then for cylinder No. 2.
  4.  
  5. Rotate the engine a few turns, then recheck all cylinders.
  6.  
  7. Install the valve cover, using a new valve cover gasket.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Check engine operation.
  12.  



Click image to see an enlarged view

Fig. Fig. 1: The pulley timing mark should be at 0 when adjusting the valves-B230F and B230FT engines



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Fig. Fig. 2: Checking valve clearance for the No. 1 cylinder-B230F and B230FT engines



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Fig. Fig. 3: Line up the valve depressors-B230F and B230FT engines



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Fig. Fig. 4: Attach tool 5022, or an equivalent valve depressor, and remove the disc-B230F and B230FT engines



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Fig. Fig. 5: Measure the disc thickness using a micrometer-B230F and B230FT engines



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Fig. Fig. 6: View of a typical disc-B230F and B230FT engines



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Fig. Fig. 7: Positioning a new disc-B230F and B230FT engines

B280F Engine

See Figures 8, 9, 10 and 11

  1. Disconnect the negative battery cable.
  2.  
  3. On right side of engine:
    1. Remove the oil filler cap with hoses.
    2.  
    3. Remove the air conditioning compressor with bracket, and position aside.
    4.  
    5. Remove the oil dipstick.
    6.  
    7. Disconnect the wire bundle from the clamps on the valve cover.
    8.  

  4.  
  5. On left side of engine:
    1. Disconnect the air inlet hose.
    2.  
    3. Disconnect the main wiring harness clamp from the valve cover.
    4.  
    5. Remove the spark plug wires and fuel lines from the valve cover.
    6.  

  6.  
  7. Remove the valve covers.
  8.  
  9. Using a 36mm hex socket on the crankshaft pulley bolt, rotate the crankshaft until the mark on the pulley is opposite the 0 mark on the engine shoulder. Both rocker arms for No. 1 cylinder should have clearance.
  10.  
  11. Insert the proper size feeler gauge between the valve and adjusting screw. Check and, if necessary, adjust the following valves: Intake 1, 2 and 4 and Exhaust 1, 3 and 6.
  12.  
  13. Rotate the crankshaft one complete turn (valve overlapping No. 1 cylinder), so that the mark on the pulley is again opposite 0 mark on the engine shoulder.
  14.  
  15. Check and if necessary, adjust the following valves: Intake 3, 5 and 6 and Exhaust 2, 4 and 5.
  16.  
  17. Install the valve covers, using a new valve cover gaskets.
  18.  
  19. Reinstall all removed components.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Check engine operation.
  24.  



Click image to see an enlarged view

Fig. Fig. 8: Adjust these valves with the No. 1 piston at TDC-B280F engine



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Fig. Fig. 9: Adjust these valves with the No. 1 piston at TDC OVERLAP-B280F engine



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Fig. Fig. 10: The pulley timing mark should be at the 0 mark on the engine shoulder when adjusting the valves-B280F engine



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Fig. Fig. 11: Adjusting the valves

 
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