Genuine Volvo S40 Valve Lifter

Volvo S40 Valve Lifter Parts and Q&A

• Valve Lifters
  1298588
  Q: What steps are involved in refitting the Camshaft, Rocker Arm and Valve Lifter for 2.0 litre 4-cylinder diesel engine on Volvo S40?

  A:

  A new camshaft oil seal will be required on refitting. Begin by removing the Timing Belt, timing chain tensioner and air cleaner assembly. At the left hand end of the Cylinder Head, remove the hose from the vacuum pump, undo the nut fixing the EGR pipe and fuel supply hose and then remove the pump after undoing the three Allen bolts. Check the condition of the pump O-ring seals and replace if needed. Next, remove the high pressure fuel pipe between the fuel rail and high pressure pump, remove the old pipe and cover the openings to avoid contamination. Disconnect fuel supply and return hoses from high pressure pump, taking care to plug or seal the openings. Disconnect wiring plug(s) from the high-pressure fuel pump then undo the three retaining bolts to remove from pump, ready for fuel spillage. To remove the sprocket from the exhaust camshaft, remove the injectors and the retaining bolt that holds the sprocket in place, using a tool to stop the sprocket from turning. Remove the engine mounting bracket from the right hand end of the cylinder head/block, then undo the bolts fixing the timing belt inner cover and the EGR pipe. Unscrew the injector mounting studs one at a time, apply steady and equal tension to the bolts holding the top of the cylinder head and carefully pull it out of position, paying special attention to possible reluctance due to the presence of sealant and corrosion. Lift up the camshafts, disengage the timing chain and remove the exhaust camshaft seal. Prepare a box separated by segments to store and identify the rocker arms and hydraulic adjusters to make sure that they will return to the original positions. Examine for wear/pitting of the bearing surfaces in the cylinder head and for wear of the lobes and journals on the camshaft and renew worn items. Inspect the rocker arms and hydraulic adjusters and replace them if necessary. Make sure the cylinder head and camshaft bearings tops are clean and the secondary timing chain lower guide rail is in place. Smear clean engine oil on the hydraulic adjusters and re-fit them with their rocker arms. Align the timing chain on the camshaft sprockets, lubricating the camshaft and cylinder head bearing journals and lowering the camshafts into position and align the mark on the intake camshaft to the 12 o'clock position. Put a thin bead of Volvo sealant on the mating surface of the cylinder head, making sure the chain tensioner oil supply hole is clear of sealant. Lower the top part of the cylinder head in place and tighten the retaining bolts to the correct torque in sequence. Refit the injector mounting studs and tighten them, refit the camshaft timing chain tensioner assembly and tighten the retaining bolts, then release the guide rail to tension the timing chain. Fit a new exhaust camshaft oil seal, secure the timing belt inner cover and slide a part for the exhaust camshaft in place which will fit the timing belt and lock the timing key. Tighten the sprocket retaining bolt, which prevents the sprocket from rotating, refit the engine mounting bracket and tighten the bolts. Complete the refitting by reversing the steps used for removal, making sure to refit the injectors, install the new timing belt, tensioner and idler pulley, tighten all the fasteners to their specified torque and check the engine oil and coolant levels.
• Valve Lifters
  1298596
  Q: How to remove and refit the Camshaft, Rocker Arm and Valve Lifter for 2.0 and 2.4 litre 5-cylinder diesel engine on Volvo S40?

  A:

  To remove the camshaft, first remove the camshaft oil seal, then the high pressure fuel pump and the inlet manifold. Next, undo the bolt which holds the timing inner cover in place on the right-hand camshaft bearing cap, and then remove the three bolts holding the camshaft bearing cap at the left-hand end of the engine and the two bolts at the right-hand end, being careful to take note of the bearings on the camshaft bearing caps. Gradually loosen bolts on the bearing caps on the intake camshaft until the tension has been relieved and remove the bolts and caps, then repeat the process for the exhaust camshaft. Lift from the camshafts and remove the oil seal of the intake camshaft, remove together with the rocker arms and the valve lifters, with care to mark their positions. For inspection, unclip the valve lifters from the rocker arms and check for damaged parts, spin the roller on each rocker arm to check for noise and check the cam lobes and bearing journals for wear. During refitting, clip each lifter back in position on the rocker arms, make sure the lifter bores are clean and lubricate them before lowering each into position, checking that the rocker arms are located over the valve stems. Clean and lubricate the camshaft bearing positions, align the marks on the camshaft with the drive gears, and drop it into place, lubricating the journals. Refit the bearing caps and screws and tighten them evenly, then insert a camshaft locking pin through the cylinder head. Apply a light film of Volvo liquid sealant to the mating surfaces of the bearing/sealing caps prior to refitting and tightening the screws to the specified torque. Finally, re-install the camshaft oil seal and finish the refitting by making sure all fasteners are tightened to recommended torque, and allowing a minimum of 30 minutes for the valve lifters to settle before turning the engine over.