Genuine Volvo S40 Cam Gear

Volvo S40 Cam Gear Parts and Q&A

• Camshaft Gear
  30646225
  Q: How do Cam Gear and Variable Timing Solenoid relate to the procedure for using the camshaft locking tool 999 5452 and fabricating a home-made alternative on Volvo S40?

  A:

  For this procedure, the Volvo camshaft locking tool 999 5452 is required to prevent camshafts turning while the sprockets are removed and details for making a home-made alternative are provided. Remove the timing belt, then the air cleaner assembly and intake ducts to get to the left-hand end of the two camshafts. Disconnect brake servo vacuum pipe and EVAP pipe to the intake manifold, and then take off the screws to remove the intake manifold, plug the lower openings to avoid pollution. Unhook the EVAP canister valve, undo the fuel pipe bracket bolt, and unhook the oxygen sensor wiring plug. Using a screwdriver, remove the plastic blanking plug on the end of the camshafts, then undo the screws and remove the rotors, being willing for oil spillage. Make sure the slots in ends of camshafts are parallel to the join between upper and lower cylinder head sections before locking them in position. Get the volvo or make your own way of locking the camshafts, check that the crankshaft sprocket timing marks match and lock the locking tool in place. If both camshaft sprockets are to be removed, mark the sprockets for identification. For a sprocket with a variable valve timing unit, use a Torx 55 key to remove the plug and central retaining screw and withdraw the sprocket. For a non-variable valve timing sprocket, remove the three bolts and the sprocket, holding it back with a suitable tool. Carefully remove the seal, without damaging the sealing face of the shaft, clean the seal seat, and lubricate the new oil seal, and fit it over the shaft. Temporarily refit timing belt upper cover, check the position of the crankshaft, and turn it clockwise a little. Take out the starter motor, unscrew the blanking plug and insert the Volvo tool. Rotate the crankshaft in the anti-clockwise direction until it stops against the tool, making sure that the marking on the crankshaft sprocket lines up with the marking on the oil pump housing. Press the VVT unit/camshaft sprocket onto the camshaft and re-fit the central retaining screw without tightening it. Refit the camshaft sprocket with the timing marks aligned, tighten the retaining bolts just enough to allow the sprockets to turn and check the crankshaft pulley marks. Remove timing belt upper cover and install new timing belt and tighten VVT unit central retaining screw and non-VVT sprocket bolts to the specified torque. Refit centre plug to VVT unit and check timing belt tensioner arm position and adjust if needed. Finally remove the camshaft locking tools and crankshaft stop tool and turn the crankshaft clockwise two complete revolutions and ensure that all the timing marks can be realigned, and the tensioner pointer is aligned with the central notch if fitted. The rest of the process is to reverse the removal process.
• Camshaft Gear
  30646226
  Q: How to remove and refit the belt tensioner and cam gear along with the camshaft, crankshaft, fuel pump, coolant pump, and idler pulleys for 1.6 litre diesel engine on Volvo S40?

  A:

  To shift the camshaft sprocket, remove the Timing Belt, and then unscrew the locking tool in the camshaft sprocket/hub and loosen the sprocket hub retaining bolt with a sprocket holding tool to ensure that the camshaft does not rotate. Then remove the retaining bolt on to the sprocket hub and glide the sprocket and hub down the camshaft and make sure the sprocket is cleaned and replaced as required in case there are wear and tear marks. To refit, screw the camshaft sprocker to the camshaft maintaining a good fit followed by screwing the sprocket hub retaining bolt and tightening it to the required torque without causing the camshaft to turn. Install the engine assembly/valve timing slot/hole on cylinder head and align camshaft in position with a timing pin and then attach the timing belt around the pump and camshaft sprockets and tension it. Removal of crankshaft sprocket again take off timing belt, align the engine assembly/valve timing holes, and slide off the sprocket on the crankshaft assembling the Woodruff key. Check the crankshaft oil seal to ensure that there are no leaks and clean the sprocket clean or renew it depending on the case. To refit, put the key back on to the crankshaft and then fit and tighten the timing belt by attaching crankshaft sprocket with flange facing the pulley. With the fuel pump sprocket, loosen the timing belt, unscrew the retaining nut with an appropriate socket and so that the sprocket remains still, place a locking pin or a fork object. A simple homemade equipment might be required to free the taper fit of the sprocket of the pump shaft. Have cleaned the sprocket, refit it and the retaining nut, and screw it firmly to the required torque without rotating. There is a pump coolant sprocket that cannot be removed and the sprocket is part of the pump. With the tensioner pulley, pull away the timing belt, loosen the retaining bolt and slide the pulley off its stud of technique. Wipe the pulley off with no harsh solvents, inspect on whether it is free to rotate and refresh it. Install the tensioner pulley and retaining bolt back and reconnect puzzle the timing belt. In the case of the idler pulley, take off the timing belt, unscrew the retaining bolt/nut then pull away the pulley. Wipe it down, examine for free movement and replace as necessary. Lastly, put the idler pulley into the engine, install the retaining nut/ bolt tightly, attach it to the designated torque, and reconnect the timing belt.