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Steps to replace your Volvo 240 cambelt and front engine seals.
| STEP 1 | Disconnect the the battery cables. |
| STEP 2 | SAFETY CAUTION: Apply parking brake and raise the front of the car and SECURE with jack stands. |
| STEP 3 | Remove the cooling fan, it is held by 4 nuts on the pulley. |
| STEP 4 | Remove the two small screws in the fan shroud. |
| STEP 5 | Remove the alternator belts and A/C compressor. |
| STEP 6 | Remove the top part of the timing cover. |
| STEP 7 | Use a 24mm socket on the crankshaft bolt, to turn the engine to top dead center.
The white dot on the cam gear will point to the mark on the cambelt cover at 12 o'clock. |
| STEP 8 | Under the car and remove the 6 bolts in the reinforcement bracket between the engine and the transmission.
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| STEP 9 | Place a screwdriver between the teeth of the flywheel and the bellhousing, to lock the flywheel and the crankshaft.
Loosen the crankshaft pulley bolt.
Note: When ret-ightening the bolt, move the screwdriver to the opposite side of the bellhousing. |
| STEP 10 | Remover the crank pulley, with a puller if needed. |
| STEP 11 | To replace the three front engine seals, loosen the camshaft and intermediate gear bolts.
It is a good idea to replace all three seals. |
| STEP 12 | Loosen the nut on the belt tensioner and pull on the old belt to compress the spring while inserting a nail
into the hole of the shaft to take the pressure off the belt. |
| STEP 13 | Remove the timing belt and all 3 gears. |
| STEP 14 | Use a Seal Pick to pull out the old seals or a small thin screwdriver.
If necessary, drill 2 small holes in the seals to pull them out with the seal pick.
CAUTION: Be careful not to damage anything when drilling. |
| STEP 15 | Clean the seal area and install the new seals.
Be sure to use plenty of oil or grease to lubricate each seal.
It is recommended that you fit the new seals 3mm deeper so they contacts on a fresh surface. |
| STEP 16 | Install the back of the timing cover. |
| STEP 17 | Install the cam gear and hand tighten the bolt. |
| STEP 18 | Install the intermediate gear and hand tighten the bolt. |
| STEP 19 | Install the crankshaft rear guideplate facing away from the belt, then install the gear. |
| STEP 20 | Ensure that all gears are set to their marks.
Cam gear to 12 o'clock.
Intermediate gear to 3 o'clock.
Crank gear to 12 o'clock. |
| STEP 21 | Install OLD cambelt in any position and remove the nail to release tensioner spring and tighten the tensioner nut.
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| STEP 22 | Tighten the cam gear bolt to the required torque setting.
37lbf-ft or 50 Nm.
Ensure that the belt does not slip. |
| STEP 23 | Tighten the intermediate gear bolt to the required torque setting.
37lbf-ft or 50 Nm.
Ensure that the belt does not slip. |
| STEP 24 | Loosen tensioner nut and take the pressure off of the belt again by inserting the nail in the shaft hole.
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| STEP 25 | Remove the old belt and replace with the new belt.
Make sure all the gears are on their marks and the belt marks line up with the gear marks.
Start installing belt from crank gear and work your way upwards. |
| STEP 26 | Remove nail from tensioner and tighten the tensioner nut. |
| STEP 27 | Install front guideplate on crank gear facing away from belt. |
| STEP 28 | Install belt lower cover. |
| STEP 29 | Install crank pulley and tighten the bolt to the required torque setting.
44lbf-ft or 60 Nm and turn it an extra 60 degrees. |
| STEP 30 | Install the upper timing cover. |
| STEP 31 | Remove the screwdriver from flywheel and install the reinforcement plate. |
| STEP 32 | Reinstall the fan and shroud. |
| STEP 33 | Disconnect the coil wire.
Reconnect the positive battery cable first.
Then reconnect the negative battery cable.
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| STEP 34 | Turn engine over using only the starter motor 2 times.
Lloosen the tensioner nut 1 turn and remove the rubber plug through the hole in the belt cover.
Re-tighten the nut to normal settings and reconnect the coil wire. |
| STEP 35 | Start engine and warm up for 5 minutes.
Repeat re-tenstioning belt again.
Install the rubber plug in the timing cover. |
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