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Valve Clearance Setting & Adjusting (2000)

NOTE: Adjusting valve clearance requires removing camshaft cover.
  1. Remove the cable from the battery negative terminal. See BATTERY DISCONNECT PRECAUTIONS & RELEARN PROCEDURES .
  2. Remove the following components:
    • Cross stay between the suspension turrets
    • Ground strip from the cylinder head
    • Upper engine stabilizer brace
    • Cover in the cylinder head at the rear of the exhaust camshaft
    • Crankcase ventilation hose from the top of the camshaft cover
    • Radiator breather tube from the expansion tank
  3. Lift up the brake fluid reservoir. Disconnect the ABS sensor connector. Place the brake fluid reservoir over the engine.
  4. Disconnect the connector for the level sensor in the expansion tank. Lift up and place the expansion tank on top of the engine.
  5. Remove the serpentine belt. Remove the front timing belt cover.
    6. 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.
  6. 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. See Figure. Remove the upper timing cover.
  7. Slacken off the center screw for the belt tensioner slightly. Hold the center screw still. Turn the tensioner eccentric clockwise to 10 o'clock using a 6 mm Allen key. Remove the timing belt from the camshaft pulleys. It is not necessary to remove timing belt from engine.
  8. Install Camshaft Adjustment Tool (999 5452) at the rear of the camshafts. Check that the screws securing the adjustment tool to the camshafts and the screw holding the tool together are well tightened. See Figure.
  9. On timing gear pulley with variable valve timing unit, remove the plug at the front of the variable valve timing unit. See Figure. Remove the center screw in the variable valve timing unit. Carefully pull out the variable valve timing unit with the timing gear pulley. On timing gear pulley without variable valve timing unit, remove the screws securing the timing gear pulley on the camshaft. Remove timing gear pulley.
  10. Remove Camshaft Adjustment Tool (999 5452) from rear of the camshafts.
  11. Reinstall the expansion tank and the brake fluid reservoir at the fender liner.
  12. Remove the variable valve timing (VVT) solenoid. Remove spark plugs for cylinders 1 and 5.
  13. Install 2 Cylinder Head Press Tools (999 5454). See Figure. Leave a 2-3 mm gap to the camshaft cover. Ensure that the screw in the spark plug well is fully tightened. Remove all the screws securing the camshaft cover to the cylinder head.
  14. Use Pliers (999 5670) to lift the cover from the cylinder head. See Figure. Install the pliers at the stop lugs. Start with cylinder 1 and work alternately backward. Slacken off the wing nuts approximately 2 turns. Repeat the procedure with the pliers.
  15. Carefully press the camshaft seals free. Take care not to damage the sealing surfaces on the camshafts. See Figure.
    16. CAUTION: If reusing old lifters, they must be installed in their original location.
  16. Remove the camshaft cover. Noting installed position, remove the camshafts. Noting installed position, lift out the valve lifters. Mark up the valve lifters so that the original positions can be established.
  17. Use a razor blade or a gasket scraper and gasket solvent (P/N 1161 440) on the camshaft cover. Use a fume hood or extractor when using gasket solvent. Use only a gasket scraper or razor blade on the cylinder head. 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. Dry and blow all surfaces clean.
  18. Carefully tap the end of the valve stem to ensure that the valve is correctly located in the seat. Use a plastic, aluminum or brass drift to protect the valve and the surface of the valve lifter. See Fig 1. The sound made by tapping reveals if the valve is correctly seated.
    Fig 1: Setting Valve In Seat
    G00240406Courtesy of VOLVO CARS OF NORTH AMERICA.
    19. NOTE: The valve clearance tolerances are less at setting. When checking the valve clearance through the plug hole the tolerances are larger.
  19. Install both the valve lifters for the inlet valves at cylinder No. 1. Select new valve lifters if necessary. Only install two valve lifters. The valve lifters must be placed at the same cylinder. The valve clearance on a cold engine (68°F; 20°C) must be .008" +/- .001" (.20 +/- 0.03 mm) for intake valves and .016" +/- .001" (.40 +/- 0.03 mm) for exhaust valves.
  20. Install the intake camshaft. Ensure that the lobes at cylinder No. 1 point upwards. Apply a little oil to the cam lobe and the upper side of the valve lifter to facilitate measurement later.
  21. Install the lower section of Camshaft Press (999 5765) at the intake valves for cylinder No. 1. See Fig 2. Tighten the tool against the cylinder head. Tighten bolt to 13 ft. lbs. (17 N.m). Turn the camshaft until it stops against the camshaft press.
  22. Install the upper section of the camshaft press tool. Tighten the bolt which tensions the camshaft. Tighten to 106 INCH lbs. (12 N.m). See Fig 3.
    Fig 2: Installing Camshaft Press (999 5765) Lower Section
    G00240408Courtesy of VOLVO CARS OF NORTH AMERICA.
    Fig 3: Installing Camshaft Press (999 5765) Upper Section
    G00240409Courtesy of VOLVO CARS OF NORTH AMERICA.
    Fig 4: Identifying Installation Of Camshaft Press (999 5765)
    G00240410Courtesy of VOLVO CARS OF NORTH AMERICA.
    23. NOTE: Measurement must be carried out on a cold engine (about 68°F; 20°C). Lifter clearance will vary depending on temperature. See VALVE CLEARANCE ADJUSTMENT SPECIFICATION VARIANCE  table.
  23. Measure the valve clearance, using Feeler Gauge (999 5752). Press with a finger so that the feeler gauge lies parallel to the upper side of the tappet. Move the feeler gauge sideways when taking the reading in order to obtain as accurate a measurement as possible. The valve clearance must be .008" +/- .001" (.20 +/- 0.03 mm) for intake valves and .016" +/- .001" (.40 +/- 0.03 mm) for exhaust valves.
    VALVE CLEARANCE ADJUSTMENT SPECIFICATION VARIANCE

    Temperature - °F (°C) Clearance Change - In. (mm)
    60 (15) -.0004 (-.01)
    77 (25) .0004 (.01)
    86 (30) .0008 (.02)
    95 (35) .0012 (.03)
    113 (45) .0016 (.04)
  24. To correct the measured clearance, lift off the upper section of the press tool. Lift out the camshaft. Adjust the clearance by changing the valve lifters with appropriate replacement.
  25. Install the camshaft and the upper section of the press tool. Tighten to 106 INCH lbs. (12 N.m). Take a new measurement. See step  23.
  26. When the correct valve clearance is reached, remove Camshaft Press Tool (999 5765), the camshaft and the valve lifters. Carefully mark the valve lifters so that exact reinstallation can be carried out. Repeat the procedure for measuring the valve clearance for all cylinders on both the intake and exhaust sides.
    27. NOTE: Ensure that the lifters are replaced in the previous position as before.
  27. When clearance adjustment is complete, install the valve lifters and camshafts. Lubricate the valve guide wells. Install all the valve lifters. Lubricate the camshaft bearing seats.
  28. Install the intake camshaft. Ensure that the groove at the rear edge of the camshaft is above an imaginary center line. Position the exhaust camshaft. Ensure that the groove at the rear edge of the camshaft is below an imaginary center line. See Figure.
    29. NOTE: Ensure that no liquid gasket gets into the coolant or oil ducts.
  29. Wipe the oil film off the mating surfaces on the camshaft cover and cylinder head. Install new "O" rings around the spark plug wells on the cylinder head. Apply Liquid Gasket (116 1059) to the camshaft cover. The surface must be completely covered without any excess. Only a thin layer of liquid gasket is required.
  30. Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters. Install the camshaft cover. Install Cylinder Head Press Tools (999 5454). See Figure. Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools
  31. Install all the camshaft cover screws. Tighten the screws from the middle and outwards. See TORQUE SPECIFICATIONS in SPECIFICATIONS - 2.3L & 2.4L, 5-CYLINDER TURBOCHARGED ENGINES. Remove the Cylinder Head Press Tools (999 5454).
  32. Install the following components:
    • Variable valve timing (VVT) solenoid. Use a new gasket.
    • Spark plugs
    • Plugs for the valve clearance test holes
    • Crankcase ventilation hose to the top of the camshaft cover
    • Ignition coils according to the earlier marking
    • Ground terminals between the ignition coils
  33. To install rear camshaft seal, clean the camshaft journal and mating surface using emery cloth. 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. Lubricate the surface of the rear camshaft seal that the camshaft rotates against. Press in the seal until the drift bottoms out using Drift (999 5450). See Figure. If there are wear grooves on the camshaft, the seal can be pressed in a further 2 mm by reversing the sleeve.
  35. Install Camshaft Adjustment Tool (999 5452) at the rear of the camshafts. See Figure. Check that the screws securing the adjustment tool to the camshafts and the screws holding the tool together are well tightened.
  36. Lift up and position the brake fluid reservoir and the expansion tank on top of the engine. To install front camshaft seals, use Drift (999 5718) on camshafts with variable valve timing units. Use Drift (999 5719) on camshafts without variable valve timing. See Figure. Use new seals and lubricate the surface of the seal that the camshaft rotates against. Use the variable valve timing unit/timing belt pulley mounting screws. Tighten the screws until the drift bottoms out. Remove the drift.
  37. Remove the mounting screws for the starter motor. Pull off the starter motor. Place the starter motor to one side. Remove the blind cover plug and the seal washer from engine block behind starter motor.
  38. Turn the crankshaft slightly clockwise. Install the Crankshaft Stop (999 5451) in side of engine block. See Figure. Ensure that it bottoms out against the cylinder block. Turn the crankshaft counterclockwise until it stops against the crankshaft stop. Check that the timing mark on the crankshaft timing gear pulley corresponds with the marking on the oil pump.
  39. Install the timing gear pulley. On camshafts with variable valve timing units, loosen, but do not remove the bolts which secure the timing gear pulley to the variable valve timing unit. Press the variable valve timing unit and timing gear on to the camshaft.
  40. Install the center bolt which secures the variable valve timing unit to the camshaft. Do not fully tighten yet. Position the upper timing cover.
  41. Remove the center screw from the variable valve timing unit. Turn the timing gear pulley CLOCKWISE until the screws at the oval holes are in the limit position. Continue turning timing gear pulley CLOCKWISE until the timing gear pulley marking is 1 cog before the marking on the upper timing cover. See Figure. DO NOT turn counterclockwise during this procedure.
  42. Check that the timing gear pulley is still in its limit position at the oval holes. Tighten the center bolt for the variable valve timing unit to 89 ft. lbs. (120 N.m). Check that the variable valve timing unit does not rotate when tightening. Install the center plug of the variable valve timing unit. Tighten to 26 ft. lbs. (35 N.m).
  43. On camshafts with timing gear pulleys without variable valve timing units, install the timing gear pulley on the camshaft with 2 bolts. Do not fully tighten bolts yet. Check that the markings on the timing gear pulley and the upper timing cover correspond. See Figure.
  44. Tighten the center screw on the timing belt tensioner. Tighten to 44 INCH lbs. (5 N.m.).
  45. Turn the variable valve timing unit clockwise to the stop. Use a Tx55 torx wrench applied at the center plug. Hold variable valve timing unit secure in the limit position.
  46. Install the belt in the following order:
    • Crankshaft
    • Idler pulley
    • Intake cam
    • Exhaust cam
    • Water pump
    • Belt tensioner
    NOTE: Adjust the timing gear pulleys so that the screws are not at a limit position in the oval holes.
  47. Ensure the camshaft timing belt alignment marks line up with marks on upper timing cover. See Figure.
    48. NOTE: Timing belt tension is always carried out on a cold engine.
    NOTE: Check that the variable valve timing unit is in its limit position.
  48. At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right. Hold the center screw secure and turn the belt tensioner eccentric counterclockwise until the tensioner indicator passes the marked position. See Figure.
  49. Tighten the three screws at the intake camshaft timing gear pulley to 89 INCH lbs. (10 N.m). Tighten the three screws at the exhaust camshaft timing gear pulley to 15 ft. lbs. (20 N.m).
  50. 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 screw secure at the same time. Hold the eccentric secure and tighten the center screw to 15 ft. lbs. (20 N.m). Check that the indicator is in the correct position.
  51. Remove Camshaft Adjustment Tool (999 5451) and Crankshaft Stop (999 5452). Install the engine block plug behind the starter with a new blind cover plug.
  52. Press the timing belt to check that the indicator on the tensioner moves easily. See Figure. 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. Check that the indicator on the belt tensioner is within the marked position. Remove the upper timing cover.
  53. Install the following:
    • Front timing cover
    • Serpentine belt
    • Expansion tank
    • Power steering reservoir
    • Bleed hose for the expansion tank
  54. Connect the connectors for the ABS sensor by the right suspension turret and the coolant level sensor in the expansion tank.
  55. Install the starter motor. Install the plastic nuts for the cover in the fender liner. Install the right front wheel.
  56. Install the following:
    • Trigger wheel (Ensure that the trigger wheel is correctly positioned against the camshaft.)
    • Camshaft position (CMP) sensor housing
    • Cover at the rear of the exhaust camshaft
    • Screws holding both the ground strips from the firewall to the cylinder head
    • Upper engine stabilizer brace
    • Cover over the ignition coils
    • Upper timing cover
    • Crankcase ventilation hose on the inlet hose
    • Inlet hose between the air cleaner and throttle body
  57. Install the engine stabilizer brace between the suspension turrets. Secure the servo hose at the right mounting for the engine stabilizer brace in the bodywork.
  58. Connect negative batter cable.
  59. Check the oil level and the coolant level. Warm up the engine until the thermostat opens. Check the engine for leaks. Top up the coolant if necessary.
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