Volvo Truck 2003-05

Camshaft, Bearings & Lifters

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Inspection



  1. Check the camshaft journals for wear. If the journals are badly worn, replace the camshaft.
  2.  
  3. Check the cam lobes for damage. If the lobe is damaged or excessively worn, replace the camshaft.
  4.  
  5. Measure the cam lift height. The specifications for cam lobe height:
    1. 5-Cylinder Engines-Intake 0.331 inch (8.40mm), Exhaust 0.356 inch (9.05mm)
    2.  
    3. 6-Cylinder Engines-Intake 0.331 inch (8.40mm), Exhaust 0.356 inch (9.05mm)
    4.  

  6.  
  7. Check the cam surface for abnormal wear or damage, and replace if necessary.
  8.  
  9. Check each bearing for damage. If the bearing surface is excessively damaged, replace the cylinder head assembly or camshaft bearing cap, as necessary.
  10.  

Bearing Replacement



Check each bearing for damage. If the bearing surface is excessively damaged, replace the cylinder head assembly or camshaft bearing cap, as necessary.

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Front cover
     
    Timing belt
     
    Ignition coil cover
     
    Camshaft Position (CMP) sensor or distributor, as equipped
     
    Switch holder and shield at left rear of the engine
     
    Ignition coils
     
    Camshaft sprockets
     
    Cylinder head cover
     
    Camshafts
     
    Hydraulic lash adjusters
     

  4.  


NOTE
Keep all valvetrain components in order for assembly.

To install:

  1. Install or connect the following:

    Hydraulic lash adjusters
     
    Camshafts
     
    Cylinder head cover and tighten the bolts to 13 ft. lbs. (17 Nm)
     
    Camshaft sprockets and tighten the bolts to 15 ft. lbs. (20 Nm)
     
    Ignition coils
     
    Switch holder and shield at left rear of the engine
     
    CMP sensor or distributor, as equipped
     
    Ignition coil cover
     
    Timing belt
     
    Front cover
     
    Accessory drive belts
     
    Negative battery cable
     

  2.  

8-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove intake manifold. Refer to Intake Manifold removal and installation.
  4.  
  5. Remove air induction pipe.
  6.  
  7. Remove ignition coils on the left and right banks, refer to Ignition Coil Pack removal and installation.
  8.  
  9. Remove camshaft covers, refer to Camshaft Covers removal and installation.
  10.  
  11. Remove timing chain, refer to Timing Chain and Sprockets removal and installation.
  12.  
  13. Turn the crankshaft back approximately 45° so that the position setting tool is straight up.
    NOTE
    The camshafts should rotate freely.



    Click image to see an enlarged view

    Fig. Position setting tool installed backed off 45°-8-Cylinder Engine

    Position setting tool installed backed off 45°-8-Cylinder Engine
  14.  
  15. Remove load from the camshafts and valve lifters:
    1. For Bank 1, cylinders 1-3-5-7, turn the camshafts approximately 45° clockwise.

      Click image to see an enlarged view

      Fig. Removing load from Bank 1 camshafts-8-Cylinder Engine

      Removing load from Bank 1 camshafts-8-Cylinder Engine
    2.  
    3. For Bank 2, cylinders 2-4-6-8, turn the camshafts approximately 10° counter-clockwise.

      Click image to see an enlarged view

      Fig. Removing load from Bank 2 camshafts-8-Cylinder Engine

      Removing load from Bank 2 camshafts-8-Cylinder Engine
    4.  

  16.  
  17. Remove the variable valve timing (VVT) unit:

    Remove the 4 M6 bolts and the cap
     
    Remove the 2 M6 bolts for the chain tensioner
     
    Discard the 2 filters

    Click image to see an enlarged view

    Fig. Removing the variable valve timing (VVT) unit-8-Cylinder Engine

    Removing the variable valve timing (VVT) unit-8-Cylinder Engine
     

  18.  
  19. Remove the 8 M6 bolts holding the intake camshaft bearing caps.
    NOTE
    Ensure that the camshaft is relieved from load against the valve lifters to prevent damaging the components. Note location of components.

  20.  
  21. Remove the chain tensioner.
  22.  
  23. Remove the camshaft.
  24.  
  25. To remove exhaust camshaft, remove the 8 M6 bolts holding the exhaust camshaft bearing caps and remove exhaust camshaft.
  26.  
  27. Remove the valve lifters using a magnet or suction cup. Make note of the position of each lifter.

    Click image to see an enlarged view

    Fig. Removing camshaft and chain-8-Cylinder Engine

    Removing camshaft and chain-8-Cylinder Engine
  28.  

To install:

  1. Install valve lifters, refer to Valve Lifters adjustment.
  2.  
  3. Install VVT unit on the camshaft with 1 M10 bolt, but do not tighten.
  4.  
  5. Install the camshaft, chain, and chain tensioner.
    NOTE
    Adjust the marking on the VVT unit to the color marking on the camshaft chain.



    Click image to see an enlarged view

    Fig. Aligning timing marks on VVT unit-8-Cylinder Engine

    Aligning timing marks on VVT unit-8-Cylinder Engine
  6.  
  7. Install the camshaft bearing caps and tighten to 88 inch lbs. (10 Nm).
  8.  
  9. Install 2 new filters.
  10.  
  11. Install the 4 M6 bolts on the end cap of the camshafts and tighten to 18 inch lbs. (10 Nm).
  12.  
  13. Install the 2 M6 bolts for the chain tensioner and tighten to 18 inch lbs. (10 Nm).
  14.  
  15. Install tool 999 7236.

    Click image to see an enlarged view

    Fig. Installation of camshaft tool 999 7236-8-Cylinder Engine

    Installation of camshaft tool 999 7236-8-Cylinder Engine
  16.  
  17. Minimize the slack of the camshaft chain.
    1. Use tool 999 7232.
    2.  
    3. For cylinder head 1, 3, 5 and 7 (Bank 1), turn the VVT unit on the exhaust camshaft counter-clockwise, until the chain is tensioned underneath.
    4.  
    5. For cylinder head 2, 4, 6 and 8 (Bank 2), turn the VVT unit on the exhaust camshaft counter-clockwise, until the chain is tensioned on top.
    6.  
    7. Tighten the bolt in the center of the intake camshaft VVT unit. Tighten to 15 ft. lbs. (20 Nm).
    8.  

  18.  
  19. Install tool 999 7229 on the intake camshaft.
  20.  
  21. Tighten the center 1 M10 bolt on the camshaft to 37 ft. lbs. (50 Nm).
  22.  
  23. Remove the counterhold.

    Click image to see an enlarged view

    Fig. Adjusting camshaft chain tension-8-Cylinder Engine

    Adjusting camshaft chain tension-8-Cylinder Engine

    Click image to see an enlarged view

    Fig. Installation of camshaft tool 999 7229-8-Cylinder Engine

    Installation of camshaft tool 999 7229-8-Cylinder Engine
  24.  
  25. Install timing chain, refer to Timing Chain and Sprockets removal and installation.
  26.  
  27. Install camshaft covers, refer to Camshaft Covers removal and installation.
  28.  
  29. Install ignition coils on the left and right banks, refer to Ignition Coil Pack removal and installation.
  30.  
  31. Install air induction pipe.
  32.  
  33. Install intake manifold. Refer to Intake Manifold removal and installation.
  34.  

5- & 6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Negative battery cable
     
    Accessory drive belt
     
    Front cover
     
    Timing belt
     
    Ignition coil cover
     
    Camshaft Position (CMP) sensor or distributor, as equipped
     
    Switch holder and shield at left rear of the engine
     
    Ignition coils
     
    Camshaft sprockets
     
    Cylinder head cover
     
    Camshafts
     
    Hydraulic lash adjusters
     

  4.  

To install:

  1. Install or connect the following:

    Hydraulic lash adjusters
     
    Camshafts
     
    Cylinder head cover and tighten the bolts to 13 ft. lbs. (17 Nm)
     
    Camshaft sprockets and tighten the bolts to 15 ft. lbs. (20 Nm)
     
    Ignition coils
     
    Switch holder and shield at left rear of the engine
     
    CMP sensor or distributor, as equipped
     
    Ignition coil cover
     
    Timing belt
     
    Front cover
     
    Accessory drive belt
     
    Negative battery cable
     

  2.  

 
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