Genuine Volvo S40 Camshaft

Volvo S40 Camshaft Parts and Q&A

• Camshaft
  8250527
  Q: What is the role of the Camshaft and Valve Lifter in locking the camshafts and reassembling the cylinder head on Volvo S40?

  A:

  For this procedure, Volvo tools 999 5452, 999 5754, 999 5453 and 999 5454 are required to hold the camshafts in position in the area of the cylinder head during refit of the upper part of the cylinder head and pull it in. Tools are available in the aftermarket (for example, AST 5087), with details for fabricating your own homemade alternatives provided. A tube of liquid gasket and a roller of application (short hair, available at Volvo dealers) will also be needed. Start by removing the camshaft sprockets and right hand oil seals and disconnecting the cylinder head earth strap and the crankcase breather hose from the camshaft cover, spark plugs and the WT solenoid. Progressively slacken and remove all bolts holding the cylinder head upper section in place and then gently tap or prise the upper section off the lower section, and take care not to damage the parting lugs. Once free, pull the top part off, taking care not to tip the camshafts and get them stuck. Withdraw the sealing O-rings from the spark plug recesses and get new ones for reassembly. Mark the camshafts and remove them with the rear oil seals, taking the position of oil seals for replacing. Prepare an appropriate storage solution for the tappets, marking them for identification purposes, and check the cam lobes and bearing journals for wear. Clean the mating surfaces carefully, make sure there is no oil or grease left and check valve clearances if any parts were renewed. For reassembly, apply oil to the tappet bores and the camshaft bearings, insert the tappets, and apply liquid gasket solution to the mating face of the upper section. Insert the camshafts in their proper position, lock them in the camshaft position, and insert new sealing O-rings in the lower part. Lift the assembled upper part on to the lower part, insert the pull-down tools in the spark plug holes and tighten securely, making sure the upper part is level. Refit the retaining bolts in a diagonal order to the specified torque, remove the pull-down tool, lubricate and fit new camshaft oil-seals, and fit the camshaft sprockets and timing belt. Finally, check the coolant level and you are done with the process.
• Camshaft
  8250509
  Q: How to remove and refit the Camshaft, Rocker Arm and Valve Lifter for 1.6 litre diesel engine on Volvo S40?

  A:

  To remove the 80kw engine components, the first step is to remove the cylinder head cover/manifold, followed by the camshaft position sensor and camshaft oil seal. Then undo the bolts to remove the vacuum pump and recover the O ring seals. Remove the fuel filter and mounting bracket, then disconnect the short pipe connecting turbocharger with the intercooler (remember to slacken the clamps). Move the throttle body assembly aside, after removing the mounting bolt. Slowly loosen and remove the bolts holding the camshaft cover/bearing ladder-in, lifting the camshafts along with the camshaft cover/bearing ladder. Remove the bearing caps, remembering their locations so that you can put them back on, then remove the chain tensioner assembly. Prepare 16 small containers for the rocker arms and valve lifters, making sure that the lifters are submerged in oil. For the 85kw engine then, first remove the brake vacuum pump and its O-ring seals, then the Timing Belt and camshaft oil seal. Remove the fuel filter and housing, remove the foam padding from the back of the camshaft cover and shift the inlet air pipe to the side. Remove camshaft cover, bearing ladder disconnect all pipes and hoses so camshaft can be lifted out. Inspect all parts for wear such as cam lobes, bearing surfaces, rocker arms, and lifters, replacing any worn parts. For refitting the 80kw engine, clean the mating surfaces very well, lubricate the valve lifter bores and tap the lifters back into their original locations. Place the rocker arms over the lifters, engage the timing chain and fit the chain tensioner. Lubricate the bearing surfaces, place the camshafts, replace the bearing caps and tighten the bolts. Apply sealant on the camshaft cover/bearing ladder and make sure that it aligns with the chain links, and gradually tighten the retaining bolts. Install a new camshaft oil seal, refit the camshaft sprocket and rotate the camshafts to check alignment before fixing everything back in place. For the 85kw engine it is similar cleaning and sealing processes, lubricate the camshaft bearings, and reassemble in reverse order of removal.