Volvo Cars 1999-05

Valve Lash (Clearance) Adjustment

Print

All engines covered use hydraulic lash adjusters. No adjustment is necessary. However, when the camshaft is replaced, the following procedures must be followed.

  1. Remove the cable from the battery negative terminal.
  2.  
  3. Remove:

    The cross stay between the suspension turrets
     
    The ground strip from the cylinder head
     
    The upper engine stabilizer brace
     
    The cover in the cylinder head at the rear of the exhaust camshaft
     
    The crankcase ventilation hose from the top of the camshaft cover
     
    The radiator breather tube from the expansion tank. Install lock grip pliers.
     

  4.  
  5. Lift up the brake fluid reservoir.
  6.  
  7. Disconnect the ABS sensor connector.
  8.  
  9. Place the brake fluid reservoir over the engine.
  10.  


WARNING
Ensure that no fluid is spilled on the engine. It is extremely flammable!

  1. Disconnect the connector for the level sensor in the expansion tank.
  2.  
  3. Lift up and place the expansion tank on top of the engine.
  4.  
  5. Remove:

    The auxiliary-s belt
     
    The front timing cover.
     

  6.  
  7. Position the upper timing cover.
  8.  
  9. Turn the crankshaft clockwise until the markings on the crankshaft belt pulley and the timing belt pulley are aligned with the markings on the oil pump and the upper timing cover.
  10.  
  11. Remove the upper timing cover.
  12.  


CAUTION
Crankshaft and camshafts must not be turned more than is stated in the method description. If the shafts are turned in any other way the valves may be damaged.



Click image to see an enlarged view

Fig. Setting the timing marks

Setting the timing marks
  1. Slacken off the center bolt for the belt tensioner slightly.
  2.  
  3. Hold the center bolt still. Turn the tensioner eccentric clockwise to 10 o'clock using a 6 mm Allen key.
  4.  
  5. Remove the timing belt from the camshaft pulleys.
  6.  
  7. Install camshaft adjustment tool 999 5452 at the rear of the camshafts.
  8.  
  9. Check that the bolts securing the adjustment tool to the camshafts and the bolt holding the tool together are well tightened
  10.  
  11. Remove: (timing gear pulley with variable valve timing unit)

    The plug at the front of the variable valve timing unit
     
    The center bolt in the variable valve timing unit. Carefully pull out the variable valve timing unit with the timing gear pulley.
     

  12.  
  13. Remove: (timing gear pulley without variable valve timing unit)

    The bolts securing the timing gear pulley on the camshaft
     
    The timing gear pulley.
     

  14.  
  15. Remove tool 999 5452.
  16.  
  17. Reinstall the expansion tank and the brake fluid reservoir at the fender liner.
  18.  
  19. Remove:

    The variable valve timing (VVT) solenoid
     
    spark plugs for cylinders 1 and 5.
     

  20.  
  21. Install 2 tools 999 5454. Leave a 2-3 mm gap to the camshaft cover.
  22.  
  23. Ensure that the bolt in the spark plug well is fully tightened.
  24.  
  25. Remove all the bolts securing the camshaft cover to the cylinder head.
  26.  
  27. Use pliers 999 5670 to lift the cover from the cylinder head.
  28.  
  29. Install the pliers at the stop lugs. Start with cylinder 1 and work alternately backward.
  30.  
  31. Slacken off the wing nuts approximately 2 turns. Repeat the procedure with the pliers.
  32.  
  33. Carefully press the camshaft seals free.
  34.  


NOTE
Take care not to damage the sealing surfaces on the camshafts.



Click image to see an enlarged view

Fig. Camshaft press installed

Camshaft press installed
  1. Remove:

    Tool 999 5454
     
    The camshaft cover
     
    The camshafts.
     

  2.  
  3. Lift out the valve lifters. Mark up the valve lifters so that the original positions can be established.
  4.  
  5. Use a razor blade or a gasket scraper and gasket solvent on the camshaft cover.
  6.  


WARNING
Use a fume hood or extractor when using gasket solvent!

  1. Use only a gasket scraper or razor blade on the cylinder head.
  2.  


CAUTION
Take great care around the oil ducts for the variable valve timing solenoid. This applies to both the camshaft cover and the cylinder head. The solenoid is extremely sensitive to contaminants.

  1. Dry and blow all surfaces clean.
  2.  
  3. Carefully tap the end of the valve stem to ensure that the valve is correctly located in the seat.
  4.  
  5. Use a plastic, aluminum or brass drift to protect the valve and the surface of the valve lifter.
  6.  
  7. The sound made by tapping reveals if the valve is correctly seated.
  8.  
  9. Install both the valve lifters for the inlet valves at cylinder 1.
  10.  
  11. Check the notes made earlier. Select new valve lifters if necessary.
  12.  


NOTE
Only install two valve lifters. The valve lifters should be placed at the same cylinder!

  1. Other valve lifters are available as replacement part/replacement part kits.
  2.  
  3. The valve clearance on a cold engine, approximately 68°F (20°C) should be:

    Inlet valve: 0.008 +/- 0.001 inch (0.20 +/- 0.03 mm).
     
    Exhaust valve: 0.016 inch +/- 0.001 inch (0.40 0.03 mm).
     

  4.  


    Click image to see an enlarged view

    Fig. Checking the valve clearance

    Checking the valve clearance

    Click image to see an enlarged view

    Fig. Camshafts properly positioned

    Camshafts properly positioned


NOTE
The tolerances are less at setting! When checking the valve clearance through the plug hole the tolerances are larger.

  1. Position the intake camshaft. Ensure that the lobes at cylinder 1 point upwards.
  2.  
  3. Apply a little oil to the cam lobe and the upper side of the valve lifter to facilitate later measurement.
  4.  
  5. Install the lower section of camshaft press 999 5765 at the inlet valves for cylinder 1.
  6.  
  7. Tighten the tool against the cylinder head. Tighten to 13 ft. lbs. (17 Nm).
  8.  
  9. Turn the camshaft until it stops against the camshaft press.
  10.  
  11. Install the upper section of the camshaft press.
  12.  
  13. Tighten the bolt which tensions the camshaft. Tighten to 84 inch lbs. (12 Nm).
  14.  


NOTE
Measurements should only be taken on a cold engine. A suitable temperature is approximately 68°F (20°C).

  1. Using a feeler gauge, press with a finger so that the feeler gauge lies parallel to the upper side of the valve lifter.
  2.  
  3. Move the feeler gauge sideways when taking the reading in order to obtain as accurate a measurement as possible.
  4.  
  5. The valve clearance measured on cold engines (approximately 68°F (20°C) should be:

    Inlet valve: 0.008 inch +/- 0.001 inch (0.20 +/- 0.03 mm).
     
    Exhaust valve: 0.016 inch +/- 0.001 inch 0.40 +/- 0.03 mm.
     

  6.  


NOTE
The tolerances are less at setting! When checking the valve clearance through the plug hole the tolerances are larger.

  1. Differences in valve clearance for different engines/ambient temperatures:

    -0.0004 inch (- 0.01 mm) at 59°F (15°C)
     
    +0.0004 inch (+ 0.01 mm) at 77°F (25°C)
     
    +0.0008 inch (+ 0.02 mm) at 86°F (30°C)
     
    +0.0012 inch (+ 0.03 mm) at 95°F (35°C)
     
    +0.0016 inch (+ 0.04 mm) at 113°F (45°C)
     

  2.  
  3. Correcting measured clearance:
    1. Lift out the upper section of the press tool.
    2.  
    3. Lift out the camshaft.
    4.  
    5. Adjust the play by replacing the valve lifters.
    6.  
    7. Other valve lifters are available as replacement part / replacement part kits.
    8.  
    9. Reinstall the camshaft and the upper section of the press tool. Tighten to 84 inch lbs. (12 Nm).
    10.  
    11. Take a new measurement.
    12.  

  4.  
  5. When the correct valve clearance is reached, remove:

    The press tool 999 5765
     
    The camshaft
     
    The valve lifters.
     

  6.  
  7. Carefully mark the valve lifters so that exact reinstallation can be carried out.
  8.  

For example:

Intake side: I1, I2, I3........I10.

Exhaust side: A1, A2, A3........A10.

  1. Repeat the procedure for measuring the valve clearance for all cylinders on both the intake and exhaust sides.
  2.  
  3. Lubricate the valve guide wells.
  4.  
  5. Install all the valve lifters.
  6.  
  7. Lubricate the camshaft bearing seats and the upper sides of the valve lifters.
  8.  
  9. Position the intake camshaft. Ensure that the groove at the rear edge of the camshaft is above an imaginary center line.
  10.  
  11. Position the exhaust camshaft. Ensure that the groove at the rear edge of the camshaft is below an imaginary center line.
  12.  
  13. Wipe the oil film off the mating surfaces on the camshaft cover and cylinder head.
  14.  
  15. Install new O-rings around the spark plug wells at the cylinder head.
  16.  
  17. Apply liquid gasket 1161 059 on the camshaft cover. Use roller 951 2767.
  18.  


NOTE
The surface must be completely covered without any excess.


CAUTION
Ensure that no liquid gasket gets in to the oil ducts.

  1. Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters.
  2.  
  3. Install the camshaft cover.
  4.  
  5. Install press tool 999 5454 (2x).
  6.  
  7. Tighten the camshaft cover bolts alternately, keeping it parallel to the cylinder head using the press tools.
  8.  
  9. Install all the bolts. Tighten the bolts from the middle and outwards.
  10.  
  11. Remove the press tool 999 5454
  12.  
  13. Install:

    The variable valve timing (VVT) solenoid. Use a new gasket
     
    The spark plugs. Tighten to 22 ft. lbs. (30 Nm)
     
    The plugs for the test holes. Tighten to 15 ft. lbs. (20 Nm)
     
    The crankcase ventilation hose to the top of the camshaft cover
     
    The ignition coils according to the earlier marking
     
    The ground terminals between the ignition coils.
     

  14.  
  15. To clean the shaft journal and mating surface, use emery cloth.
  16.  


    Click image to see an enlarged view

    Fig. Front seal installation tools

    Front seal installation tools

    Click image to see an enlarged view

    Fig. Timing marks, with variable timing units

    Timing marks, with variable timing units

    Click image to see an enlarged view

    Fig. Tensioning indicator at different temperatures

    Tensioning indicator at different temperatures

    Click image to see an enlarged view

    Fig. Checking belt tension

    Checking belt tension


NOTE
When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

  1. Use drift 999 5450.
  2.  
  3. Lubricate the surface of the seal that the camshaft rotates against.
  4.  
  5. Press in the seal until the drift bottoms out.
  6.  


NOTE
If there are wear grooves on the camshaft, the seal can be pressed in a further 2 mm by reversing the sleeve.

  1. Install camshaft adjustment tool 999 5452 at the rear of the camshafts.
  2.  
  3. Check that the bolts securing the adjustment tool to the
  4.  
  5. Lift up and position the brake fluid reservoir and the expansion tank on top of the engine.
  6.  
  7. Use drift 999 5718 on camshafts with variable valve timing units. Use drift 999 5719 on camshafts without variable valve timing.
  8.  
  9. Use new seals and lubricate the surface of the seal that the camshaft rotates against.
  10.  
  11. Use the variable valve timing unit/timing belt pulley mounting bolts. Tighten the bolts until the drift bottoms out.
  12.  
  13. Remove the drift.
  14.  
  15. Remove:

    The mounting bolts for the starter motor. Pull off the starter motor. Place the starter motor to one side
     
    The blind cover plug and the seal washer.
     

  16.  
  17. Turn the crankshaft slightly clockwise.
  18.  
  19. Install the crankshaft stop 999 5451 Ensure that it bottoms out against the cylinder block.
  20.  
  21. Turn the crankshaft counter-clockwise until it stops against the crankshaft stop.
  22.  
  23. Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.
  24.  


NOTE
The purpose of the section is to ensure that the VVT unit is correctly positioned and to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later fault-tracing.

  1. Slacken off, but do not remove the bolts which secure the timing gear pulley to the variable valve timing unit.
  2.  
  3. Press the variable valve timing unit/timing gear onto the camshaft.
  4.  
  5. Install the center bolt which secures the variable valve timing unit to the camshaft. Tighten slightly.
  6.  
  7. Turn the variable valve timing unit counter-clockwise as far as it will go.
  8.  
  9. Remove the center bolt.
  10.  
  11. Position the upper timing cover.
  12.  
  13. Turn the timing gear pulley clockwise until the bolts at the oval holes are in the limit position.
  14.  
  15. Continue turning clockwise until the timing gear pulley marking is 1 tooth before the marking on the upper timing cover.
  16.  


CAUTION
Do not turn counter-clockwise during this procedure.

  1. Check that the timing gear pulley is still in its limit position at the oval holes.
  2.  
  3. Tighten the center bolt for the variable valve timing (VVT) unit. Tighten to 88 ft. lbs. (120 Nm). Check that the variable valve timing unit does not rotate when tightening.
  4.  
  5. Install the center bolt. Tighten to 26 ft. lbs. (35 Nm).
  6.  
  7. Install the timing gear pulley. Install the bolts.
  8.  
  9. Install two bolts without tightening. Allow the third bolt to protrude.
  10.  
  11. Adjust the timing gear pulleys so that the markings on the timing gear pulleys / upper timing cover correspond.
  12.  
  13. Tighten the center bolt on the belt tensioner. Tighten to 44 inch lbs. (5 Nm).
  14.  
  15. Turn the variable valve timing unit clockwise to the stop.
  16.  
  17. Hold it secure in the limit position.
  18.  
  19. Install the belt in the following order:

    Crankshaft
     
    The idler pulley
     
    Intake cam
     
    Exhaust cam
     
    Water pump
     
    Belt tensioner
     

  20.  


NOTE
Adjust the timing gear pulleys so that the bolts are not at a limit position in the oval holes. Also check that the markings correspond.


NOTE
This adjustment is always carried out on a cold engine. A suitable temperature is approximately 68°F (20°C).

At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.

The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.

  1. Hold the center bolt secure and turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position.
  2.  


NOTE
Check that the variable valve timing unit is in its limit position.

  1. Tighten the three bolts at the intake camshaft timing gear pulley. Tighten to 74 inch lbs. (10 Nm).
  2.  
  3. Tighten the three bolts at the exhaust camshaft timing gear pulley. Tighten to 15 ft. lbs. (20 Nm).
  4.  
  5. Turn the eccentric on the belt tensioner back so that the indicator reaches the marked position in the center of the window. Remember to hold the center bolt secure at the same time.
  6.  
  7. Hold the eccentric secure and tighten the center bolt. Tighten to 15 ft. lbs. (20 Nm).
  8.  
  9. Check that the indicator is in the correct position.
  10.  
  11. Remove camshaft adjustment tool 999 5451 and crankshaft stop 999 5452.
  12.  
  13. Install the plug with a new blind cover plug. Tighten to 29 ft. lbs. (40 Nm).
  14.  
  15. Press the timing belt to check that the indicator on the tensioner moves easily.
  16.  
  17. Turn the crankshaft two turns. Check that the markings on the crankshaft timing gear pulley and the camshaft timing gear pulley match up with the markings on the oil pump and upper timing cover respectively.
  18.  
  19. Check that the indicator on the belt tensioner is within the marked position.
  20.  
  21. Remove the upper timing cover.
  22.  
  23. Install:

    front timing cover
     
    The auxiliary-s belt
     
    The expansion tank
     
    The servo oil reservoir
     
    The bleed hose for the expansion tank
     

  24.  
  25. Close the clamp and check that the hoses lie correctly.
  26.  
  27. Connect the connectors for the:

    The ABS sensor by the right suspension turret
     
    The coolant level sensor in the expansion tank
     

  28.  
  29. Install:

    The starter motor
     
    The plastic nuts for the cover in the fender liner
     
    The right front wheel
     

  30.  
  31. Install:

    The trigger wheel.
     

  32.  


NOTE
Ensure that the trigger wheel is correctly positioned against the camshaft.



The camshaft position sensor housing
 
The cover at the rear of the exhaust camshaft
 
The bolts holding both the ground strips from the firewall to the cylinder head
 
The upper engine stabilizer brace
 
The cover over the ignition coils
 
The upper timing cover
 
The crankcase ventilation hose on the inlet hose
 
The inlet hose between the air cleaner and throttle body
 
The engine stabilizer brace between the suspension turrets. Secure the servo hose at the right mounting for the engine stabilizer brace in the bodywork
 
The cable to the battery negative terminal.
 

  1. Check the level in the expansion tank and the brake fluid reservoir.
  2.  
  3. Test drive the engine until the thermostat opens and check for any leakage.
  4.  

All engines covered use hydraulic lash adjusters. No adjustment is necessary.

All engines covered use hydraulic lash adjusters. No adjustment is necessary. However, when the camshaft is replaced, the following procedures must be followed.

  1. Remove the cable from the battery negative terminal.
  2.  
  3. Remove:

    The cross stay between the suspension turrets
     
    The ground strip from the cylinder head
     
    The upper engine stabilizer brace
     
    The cover in the cylinder head at the rear of the exhaust camshaft
     
    The crankcase ventilation hose from the top of the camshaft cover
     
    The radiator breather tube from the expansion tank. Install lock grip pliers.
     

  4.  
  5. Lift up the brake fluid reservoir.
  6.  
  7. Disconnect the ABS sensor connector.
  8.  
  9. Place the brake fluid reservoir over the engine.
    WARNING
    Ensure that no fluid is spilled on the engine. It is extremely flammable!

  10.  
  11. Disconnect the connector for the level sensor in the expansion tank.
  12.  
  13. Lift up and place the expansion tank on top of the engine.
  14.  
  15. Remove or disconnect the following:

    The accessory drive belt
     
    The front timing cover.
     

  16.  
  17. Position the upper timing cover.
  18.  
  19. Turn the crankshaft clockwise until the markings on the crankshaft belt pulley and the timing belt pulley are aligned with the markings on the oil pump and the upper timing cover.
  20.  
  21. Remove the upper timing cover.
    CAUTION
    Crankshaft and camshafts must not be turned more than is stated in the method description. If the shafts are turned in any other way the valves may be damaged.



    Click image to see an enlarged view

    Fig. Setting the timing marks

    Setting the timing marks
  22.  
  23. Slacken off the center bolt for the belt tensioner slightly.
  24.  
  25. Hold the center bolt still. Turn the tensioner eccentric clockwise to 10 o'clock using a 6mm Allen key.
  26.  
  27. Remove the timing belt from the camshaft pulleys.
  28.  
  29. Install camshaft adjustment tool 999 5452 at the rear of the camshafts.
  30.  
  31. Check that the bolts securing the adjustment tool to the camshafts and the bolt holding the tool together are well tightened
  32.  
  33. Remove: (timing gear pulley with variable valve timing unit)

    The plug at the front of the variable valve timing unit
     
    The center bolt in the variable valve timing unit. Carefully pull out the variable valve timing unit with the timing gear pulley.
     

  34.  
  35. Remove: (timing gear pulley without variable valve timing unit)

    The bolts securing the timing gear pulley on the camshaft
     
    The timing gear pulley.
     

  36.  
  37. Remove tool 999 5452.
  38.  
  39. Reinstall the expansion tank and the brake fluid reservoir at the fender liner.
  40.  
  41. Remove:

    The variable valve timing (VVT) solenoid
     
    spark plugs for cylinders 1 and 5.
     

  42.  
  43. Install 2 tools 999 5454. Leave a 2-3mm gap to the camshaft cover.
  44.  
  45. Ensure that the bolt in the spark plug well is fully tightened.
  46.  
  47. Remove all the bolts securing the camshaft cover to the cylinder head.
  48.  
  49. Use pliers 999 5670 to lift the cover from the cylinder head.
  50.  
  51. Install the pliers at the stop lugs. Start with cylinder 1 and work alternately backward.
  52.  
  53. Slacken off the wing nuts approximately 2 turns. Repeat the procedure with the pliers.
  54.  
  55. Carefully press the camshaft seals free.
    NOTE
    Take care not to damage the sealing surfaces on the camshafts.



    Click image to see an enlarged view

    Fig. Camshaft press installed

    Camshaft press installed
  56.  
  57. Remove:

    Tool 999 5454
     
    The camshaft cover
     
    The camshafts.
     

  58.  
  59. Lift out the valve lifters. Mark up the valve lifters so that the original positions can be established.
  60.  
  61. Use a razor blade or a gasket scraper and gasket solvent on the camshaft cover.
    WARNING
    Use a fume hood or extractor when using gasket solvent!

  62.  
  63. Use only a gasket scraper or razor blade on the cylinder head.
    CAUTION
    Take great care around the oil ducts for the variable valve timing solenoid. This applies to both the camshaft cover and the cylinder head. The solenoid is extremely sensitive to contaminants.

  64.  
  65. Dry and blow all surfaces clean.
  66.  
  67. Carefully tap the end of the valve stem to ensure that the valve is correctly located in the seat.
  68.  
  69. Use a plastic, aluminum or brass drift to protect the valve and the surface of the valve lifter.
  70.  
  71. The sound made by tapping reveals if the valve is correctly seated.
  72.  
  73. Install both the valve lifters for the inlet valves at cylinder 1.
  74.  
  75. Check the notes made earlier. Select new valve lifters if necessary.
    NOTE
    Only install two valve lifters at a time. The valve lifters should be placed at the same cylinder.

  76.  
  77. Other valve lifters are available as replacement part/replacement part kits.

    Click image to see an enlarged view

    Fig. Checking the valve clearance

    Checking the valve clearance

    Click image to see an enlarged view

    Fig. Camshafts properly positioned

    Camshafts properly positioned
  78.  
  79. The valve clearance on a cold engine, approximately 68°F (20°C) should be:
    NOTE
    The tolerances are less at setting! When checking the valve clearance through the plug hole the tolerances are larger.



    Inlet valve: 0.008 plus or minus 0.001 inch (0.20 plus or minus 0.03mm).
     
    Exhaust valve: 0.016 inch plus or minus 0.001 inch (0.40 plus or minus 0.03mm).
     

  80.  
  81. Position the intake camshaft. Ensure that the lobes at cylinder 1 point upwards.
  82.  
  83. Apply a little oil to the cam lobe and the upper side of the valve lifter to facilitate later measurement.
  84.  
  85. Install the lower section of camshaft press 999 5765 at the inlet valves for cylinder 1.
  86.  
  87. Tighten the tool against the cylinder head. Tighten to 13 ft. lbs. (17 Nm).
  88.  
  89. Turn the camshaft until it stops against the camshaft press.
  90.  
  91. Install the upper section of the camshaft press.
  92.  
  93. Tighten the bolt which tensions the camshaft. Tighten to 108 inch lbs. (12 Nm).
    NOTE
    Measurements should only be taken on a cold engine. A suitable temperature is approximately 68°F (20°C).

  94.  
  95. Using a feeler gauge, press with a finger so that the feeler gauge lies parallel to the upper side of the valve lifter.
  96.  
  97. Move the feeler gauge sideways when taking the reading in order to obtain as accurate a measurement as possible.
  98.  
  99. The valve clearance measured on cold engines (approximately 68°F (20°C) should be:
    NOTE
    The tolerances are less at setting! When checking the valve clearance through the plug hole the tolerances are larger.



    Inlet valve: 0.008 inch plus or minus 0.001 inch (0.20 plus or minus 0.03mm)
     
    Exhaust valve: 0.016 inch plus or minus 0.001 inch (0.40 plus or minus 0.03mm)
     

  100.  
  101. Differences in valve clearance for different engines/ambient temperatures:

    -0.0004 inch (- 0.01mm) at 59°F (15°C)
     
    +0.0004 inch (+ 0.01mm) at 77°F (25°C)
     
    +0.0008 inch (+ 0.02mm) at 86°F (30°C)
     
    +0.0012 inch (+ 0.03mm) at 95°F (35°C)
     
    +0.0016 inch (+ 0.04mm) at 113°F (45°C)
     

  102.  
  103. Correcting measured clearance:
    1. Lift out the upper section of the press tool.
    2.  
    3. Lift out the camshaft.
    4.  
    5. Adjust the play by replacing the valve lifters.
    6.  
    7. Other valve lifters are available as replacement part/replacement part kits.
    8.  
    9. Reinstall the camshaft and the upper section of the press tool. Tighten to 108 inch lbs. (12 Nm).
    10.  
    11. Take a new measurement.
    12.  

  104.  
  105. When the correct valve clearance is reached, remove:

    The press tool 999 5765
     
    The camshaft
     
    The valve lifters.
     

  106.  
  107. Carefully mark the valve lifters so that exact reinstallation can be carried out.
  108.  

For example:

Intake side: I1, I2, I3........I10.

Exhaust side: A1, A2, A3........A10.

  1. Repeat the procedure for measuring the valve clearance for all cylinders on both the intake and exhaust sides.
  2.  
  3. Lubricate the valve guide wells.
  4.  
  5. Install all the valve lifters.
  6.  
  7. Lubricate the camshaft bearing seats and the upper sides of the valve lifters.
  8.  
  9. Position the intake camshaft. Ensure that the groove at the rear edge of the camshaft is above an imaginary center line.
  10.  
  11. Position the exhaust camshaft. Ensure that the groove at the rear edge of the camshaft is below an imaginary center line.
  12.  
  13. Wipe the oil film off the mating surfaces on the camshaft cover and cylinder head.
  14.  
  15. Install new O-rings around the spark plug wells at the cylinder head.
  16.  
  17. Apply liquid gasket 1161 059 on the camshaft cover. Use roller 951 2767.
    NOTE
    The surface must be completely covered without any excess.


    CAUTION
    Ensure that no liquid gasket gets in to the oil ducts.

  18.  
  19. Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters.
  20.  
  21. Install the camshaft cover.
  22.  
  23. Install press tool 999 5454 (2x).
  24.  
  25. Tighten the camshaft cover bolts alternately, keeping it parallel to the cylinder head using the press tools.
  26.  
  27. Install all the bolts. Tighten the bolts from the middle and outwards.

    Click image to see an enlarged view

    Fig. Front seal installation tools

    Front seal installation tools

    Click image to see an enlarged view

    Fig. Timing marks, with variable timing units

    Timing marks, with variable timing units

    Click image to see an enlarged view

    Fig. Tensioning indicator at different temperatures

    Tensioning indicator at different temperatures

    Click image to see an enlarged view

    Fig. Checking belt tension

    Checking belt tension
  28.  
  29. Remove the press tool 999 5454
  30.  
  31. Install:

    The variable valve timing (VVT) solenoid. Use a new gasket
     
    The spark plugs. Tighten to 22 ft. lbs. (30 Nm)
     
    The plugs for the test holes. Tighten to 15 ft. lbs. (20 Nm)
     
    The crankcase ventilation hose to the top of the camshaft cover
     
    The ignition coils according to the earlier marking
     
    The ground terminals between the ignition coils.
     

  32.  
  33. To clean the shaft journal and mating surface, use emery cloth.
    NOTE
    When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

  34.  
  35. Use drift 999 5450.
  36.  
  37. Lubricate the surface of the seal that the camshaft rotates against.
  38.  
  39. Press in the seal until the drift bottoms out.
    NOTE
    If there are wear grooves on the camshaft, the seal can be pressed in a further 2mm by reversing the sleeve.

  40.  
  41. Install camshaft adjustment tool 999 5452 at the rear of the camshafts.
  42.  
  43. Check that the bolts securing the adjustment tool to the
  44.  
  45. Lift up and position the brake fluid reservoir and the expansion tank on top of the engine.
  46.  
  47. Use drift 999 5718 on camshafts with variable valve timing units. Use drift 999 5719 on camshafts without variable valve timing.
  48.  
  49. Use new seals and lubricate the surface of the seal that the camshaft rotates against.
  50.  
  51. Use the variable valve timing unit/timing belt pulley mounting bolts. Tighten the bolts until the drift bottoms out.
  52.  
  53. Remove the drift.
  54.  
  55. Remove:

    The mounting bolts for the starter motor. Pull off the starter motor. Place the starter motor to one side
     
    The blind cover plug and the seal washer.
     

  56.  
  57. Turn the crankshaft slightly clockwise.
  58.  
  59. Install the crankshaft stop 999 5451 Ensure that it bottoms out against the cylinder block.
  60.  
  61. Turn the crankshaft counter-clockwise until it stops against the crankshaft stop.
  62.  
  63. Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.
    NOTE
    The purpose of the section is to ensure that the VVT unit is correctly positioned and to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later fault-tracing.

  64.  
  65. Slacken off, but do not remove the bolts which secure the timing gear pulley to the variable valve timing unit.
  66.  
  67. Press the variable valve timing unit/timing gear onto the camshaft.
  68.  
  69. Install the center bolt which secures the variable valve timing unit to the camshaft. Tighten slightly.
  70.  
  71. Turn the variable valve timing unit counter-clockwise as far as it will go.
  72.  
  73. Remove the center bolt.
  74.  
  75. Position the upper timing cover.
  76.  
  77. Turn the timing gear pulley clockwise until the bolts at the oval holes are in the limit position.
  78.  
  79. Continue turning clockwise until the timing gear pulley marking is 1 tooth before the marking on the upper timing cover.
    CAUTION
    Do not turn counter-clockwise during this procedure.

  80.  
  81. Check that the timing gear pulley is still in its limit position at the oval holes.
  82.  
  83. Tighten the center bolt for the variable valve timing (VVT) unit. Tighten to 88 ft. lbs. (120 Nm). Check that the variable valve timing unit does not rotate when tightening.
  84.  
  85. Install the center bolt. Tighten to 26 ft. lbs. (35 Nm).
  86.  
  87. Install the timing gear pulley. Install the bolts.
  88.  
  89. Install two bolts without tightening. Allow the third bolt to protrude.
  90.  
  91. Adjust the timing gear pulleys so that the markings on the timing gear pulleys / upper timing cover correspond.
  92.  
  93. Tighten the center bolt on the belt tensioner. Tighten to 44 inch lbs. (5 Nm).
  94.  
  95. Turn the variable valve timing unit clockwise to the stop.
  96.  
  97. Hold it secure in the limit position.
  98.  
  99. Install the belt in the following order:
    NOTE
    Adjust the timing gear pulleys so that the bolts are not at a limit position in the oval holes. Also check that the markings correspond.


    NOTE
    This adjustment is always carried out on a cold engine. A suitable temperature is approximately 68°F (20°C).



    Crankshaft
     
    The idler pulley
     
    Intake cam
     
    Exhaust cam
     
    Water pump
     
    Belt tensioner
     

  100.  

At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.

The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.

  1. Hold the center bolt secure and turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position.
    NOTE
    Check that the variable valve timing unit is in its limit position.

  2.  
  3. Tighten the three bolts at the intake camshaft timing gear pulley. Tighten to 88 inch lbs. (10 Nm).
  4.  
  5. Tighten the three bolts at the exhaust camshaft timing gear pulley. Tighten to 15 ft. lbs. (20 Nm).
  6.  
  7. Turn the eccentric on the belt tensioner back so that the indicator reaches the marked position in the center of the window. Remember to hold the center bolt secure at the same time.
  8.  
  9. Hold the eccentric secure and tighten the center bolt. Tighten to 15 ft. lbs. (20 Nm).
  10.  
  11. Check that the indicator is in the correct position.
  12.  
  13. Remove camshaft adjustment tool 999 5451 and crankshaft stop 999 5452.
  14.  
  15. Install the plug with a new blind cover plug. Tighten to 29 ft. lbs. (40 Nm).
  16.  
  17. Press the timing belt to check that the indicator on the tensioner moves easily.
  18.  
  19. Turn the crankshaft two turns. Check that the markings on the crankshaft timing gear pulley and the camshaft timing gear pulley match up with the markings on the oil pump and upper timing cover respectively.
  20.  
  21. Check that the indicator on the belt tensioner is within the marked position.
  22.  
  23. Remove the upper timing cover.
  24.  
  25. Install:

    front timing cover
     
    The accessory drive belt
     
    The expansion tank
     
    The servo oil reservoir
     
    The bleed hose for the expansion tank
     

  26.  
  27. Close the clamp and check that the hoses lie correctly.
  28.  
  29. Connect the connectors for the:

    The ABS sensor by the right suspension turret
     
    The coolant level sensor in the expansion tank
     

  30.  
  31. Install:

    The starter motor
     
    The plastic nuts for the cover in the fender liner
     
    The right front wheel
     

  32.  
  33. Install:
    NOTE
    Ensure that the trigger wheel is correctly positioned against the camshaft.



    The trigger wheel.
     



    The camshaft position sensor housing
     
    The cover at the rear of the exhaust camshaft
     
    The bolts holding both the ground strips from the firewall to the cylinder head
     
    The upper engine stabilizer brace
     
    The cover over the ignition coils
     
    The upper timing cover
     
    The crankcase ventilation hose on the inlet hose
     
    The inlet hose between the air cleaner and throttle body
     
    The engine stabilizer brace between the suspension turrets. Secure the servo hose at the right mounting for the engine stabilizer brace in the bodywork
     
    The cable to the battery negative terminal.
     

  34.  
  35. Check the level in the expansion tank and the brake fluid reservoir.
  36.  
  37. Test drive the engine until the thermostat opens and check for any leakage.
  38.  

 
label.common.footer.alt.autozoneLogo