Volvo Truck 2003-05

Timing Chain & Sprockets

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Removal & Installation



8-Cylinder Engines
  1. Disconnect the battery negative cable.
    CAUTION
    Remove ignition key.

  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the accessory drive belt, refer to Accessory Drive Belts removal and installation.
  6.  
  7. Remove the right front wheel.
  8.  
  9. Remove crankshaft damper protective cover nuts.
  10.  
  11. Push the protection towards the crankshaft damper.
  12.  
  13. Remove the center bolt using special tool 999 7196.
  14.  
  15. Install 999 7198 in the center hole of the crankshaft.
  16.  
  17. Pull off the crankshaft damper.
  18.  
  19. Remove the alternator.
  20.  
  21. Remove right engine pad
  22.  
  23. Remove the right-hand engine pad/bracket.
  24.  
  25. Disconnect the power steering pump. Place the power steering pump to one side.
  26.  
  27. Remove the bolt and clamp for the power steering hose.
  28.  
  29. Remove the pulley from the water pump.
  30.  
  31. Remove the engine bracket and idler pulley.

    Click image to see an enlarged view

    Fig. Front cover bolts-V8

    Front cover bolts-V8
  32.  
  33. Remove the 25 bolts and the front cover. Discard the gaskets.
    NOTE
    Cover the hole in oil pan using a piece of paper.

  34.  
  35. Use position setting tool 999 7235 to align the position on the crankshaft with the guide on the engine block.

    Click image to see an enlarged view

    Fig. Position setting tool 999 7235-V8 engine

    Position setting tool 999 7235-V8 engine

    Click image to see an enlarged view

    Fig. Position setting tool 999 7236-V8 engine

    Position setting tool 999 7236-V8 engine
  36.  
  37. Install position setting tool: 999 7236.
  38.  
  39. Remove the position setting tool: 999 7235.
  40.  
  41. Lock the chain tensioner using a drift.

    Click image to see an enlarged view

    Fig. Timing chain tensioners-V8

    Timing chain tensioners-V8
  42.  
  43. Remove the 2 M6 bolts for the chain tensioner.
  44.  
  45. Remove the chain tensioner.
  46.  
  47. Remove the 2 rails.
  48.  
  49. Remove the timing chain.
  50.  
  51. Remove worn chain sprockets.
  52.  

To install:

Click image to see an enlarged view

Fig. Timing chain alignment marks-V8

Timing chain alignment marks-V8


NOTE
Adjust the color marking on the timing chain to the marking on the gear.

  1. Install the timing chain, sprockets, and both rails.
  2.  
  3. Install the chain tensioner.
  4.  
  5. Remove the drift from the chain tensioner.
  6.  
  7. Minimize the slack of the chain by turning the crankshaft slightly.
    NOTE
    The front cover must be cleaned before installing. Use a razor blade or plastic scraper.



    Click image to see an enlarged view

    Fig. Liquid gasket application points-V8

    Liquid gasket application points-V8
  8.  
  9. Apply liquid gasket 307 57050 as illustrated. The bead diameter must be greater than 0.039 inch (1mm).
    NOTE
    Install the front plate within 5 minutes (curing time for liquid gasket).

  10.  
  11. Fold the front panel in at the lower edge.
  12.  
  13. Install the 23 M8 bolts for the front side and tighten to 18 ft. lbs. (24 Nm).
  14.  
  15. Install the 2 M8 bolts for the oil sump and tighten to 18 ft. lbs. (24 Nm).
  16.  
  17. Install the engine bracket and the idler pulley.
    NOTE
    The washer must be correctly installed.

  18.  
  19. Install the pulley for the water pump.
  20.  
  21. Install the power steering pump.
  22.  
  23. Install the hose clamp and the bolt.
  24.  
  25. Install the front bolt for the alternator and tighten to 18 ft. lbs. (24 Nm).
  26.  
  27. Install lifting beam tool 999 5716, converted with the addition of 999 7070 and 999 5460.
  28.  
  29. Remove tool 999 5550.
  30.  
  31. Install the right-hand engine pad/bracket.
    NOTE
    The crankshaft flange must be cleaned.

  32.  
  33. Clean the surface for the sealing ring on the crankshaft damper with cloth 951 1024.
    NOTE
    If necessary, replace the front crankshaft seal.

  34.  
  35. Install tool 999 7196, drift: 999 7198 and press in the crankshaft damper to its limit. Position using the old center bolt.
  36.  
  37. Remove the center bolt.
  38.  
  39. Insert a new bolt for the crankshaft damper and tighten 133 ft. lbs. (180 Nm).
  40.  
  41. Remove tool 999 7196.
  42.  
  43. Install the protective cover.
  44.  
  45. Install the camshaft covers.
  46.  
  47. Install the accessory drive belt tensioner.
  48.  
  49. Install the right front wheel and tighten lug nuts to 102 ft. lbs. (138 Nm).
  50.  
  51. Start the engine and run the engine to normal operating temperature.
  52.  
  53. Check for leakage. Fill fluids as necessary.
  54.  

 
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