Volvo Truck 2003-05

Camshaft (Cylinder Head) Cover

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Removal & Installation



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.  

Left Camshaft Cover
  1. With cable harness for the Bank 2 moved aside and ignition coils 2, 4, 6, and 8 removed:
    1. Remove the seven M6 bolts holding the camshaft cover.
    2.  
    3. Remove the Bank 2 camshaft cover.

      Click image to see an enlarged view

      Fig. Camshaft cover bolt location (Bank 2)-8-Cylinder Engine

      Camshaft cover bolt location (Bank 2)-8-Cylinder Engine
    4.  

  2.  

To install:

  1. Installation is the reverse of removal for Bank 1 and Bank 2 camshaft covers.
  2.  
  3. Tighten the M6 camshaft cover bolts to 88 inch lbs. (10 Nm).
  4.  
  5. Tighten the M6 power steering clamp bolts and fitting pipe bolts to 88 inch lbs. (10 Nm).
  6.  
  7. Install ignition coil packs, refer to Ignition Coil Pack removal and installation.
  8.  

Right Camshaft Cover
  1. Disconnect or remove the following:

    One M6 bolt at pipe clamp near alternator
     
    Two M6 bolts from power steering pipe clamp and fitting into the power steering pump

    Click image to see an enlarged view

    Fig. Location of pipe clamp near alternator-8-Cylinder Engine

    Location of pipe clamp near alternator-8-Cylinder Engine

    Click image to see an enlarged view

    Fig. Power steering pipe removal-8-Cylinder Engine

    Power steering pipe removal-8-Cylinder Engine
     

  2.  
  3. With Bank 1 ignition coils 1, 3, 5, and 7 removed:
    1. Remove the seven M6 bolts holding the camshaft cover.
    2.  
    3. Remove the Bank 1 camshaft cover.

      Click image to see an enlarged view

      Fig. Camshaft cover bolt location (Bank 1)-8-Cylinder Engine

      Camshaft cover bolt location (Bank 1)-8-Cylinder Engine
    4.  

  4.  

5- & 6-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 spark plugs from:
    1. Cylinders 1 and 5-5-cylinder engine
    2.  
    3. Cylinders 2 and 5-6-cylinder engine
    4.  

  6.  
  7. Install two camshaft cover press tools 999 5454 into the vacated spark plug holes. Ensure that the bolt in the spark plug well is fully tightened 22 ft. lbs. (30 Nm).
    NOTE
    Leave a 0.079- 0.118 inch (2-3mm) gap to the camshaft cover when installing the press tools 999 5454.

  8.  
  9. Remove variable valve timing (VVT) solenoid.

    Click image to see an enlarged view

    Fig. Camshaft cover press tool 999 5454 installed-5- and 6-Cylinder Engine

    Camshaft cover press tool 999 5454 installed-5- and 6-Cylinder Engine
  10.  
  11. Remove all bolts securing the camshaft cover to cylinder head.
  12.  
  13. Use pliers 999 5670 to lift camshaft cover from cylinder head.
    1. Install pliers at the stop lugs. Start with cylinder 1 and work alternately backwards.
    2.  
    3. Slacken off the wing nuts approximately 2 turns.
    4.  
    5. Repeat the procedure working toward rear of engine.

      Click image to see an enlarged view

      Fig. Using pliers 999 5670 on Camshaft cover-5 & 6-cylinder engines

      Using pliers 999 5670 on Camshaft cover-5 & 6-cylinder engines
    6.  

  14.  
  15. Carefully press out the front and rear camshaft seals.
  16.  
  17. Remove the two press tools 999 5454 from spark plug holes.
  18.  
  19. Remove the camshaft cover.
  20.  

To install:

  1. Install new O-rings around spark plug wells at cylinder head.
  2.  
  3. Apply liquid gasket 1161 059 to the camshaft cover using roller 951 2767.
    NOTE
    The surface must be covered without any excess. Ensure that no liquid gasket gets into the oil ducts.

  4.  
  5. Lubricate camshaft lobes, camshaft bearing surfaces, and valve lifters with clean engine oil.
  6.  
  7. Put camshaft cover in place.
  8.  
  9. Install the two press tools 999 5454.
  10.  
  11. Begin to tighten the camshaft cover bolts alternately, keeping camshaft cover parallel to the cylinder head using the press tools.
  12.  
  13. Tighten the bolts in sequence from the center and outwards to 88 inch lbs. (10 Nm).
  14.  
  15. Remove the press tools 999 5454.
  16.  
  17. Install:

    Variable valve timing (VVT) solenoid. Use a new gasket. Tighten center screw to 89 ft. lbs. (120 Nm), center plug to 26 ft. lbs. (35 Nm)
     
    Spark plugs and tighten to 22 ft. lbs. (30 Nm)
     
    Intake Manifold, refer to Intake Manifold removal and installation
     

  18.  

 
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