Working on our son's 1982 240 (non-turbo) wagon, including replacing the timing belt. Questions in two areas, with sub-questions:

1. The #1 exhaust valve clearance is .013, one thousandth tighter than the factory specs. I was always taught that valves can be slightly loose, but should never be tight. Is this true for this engine? If so, anyone know a reasonable source for the special pliers to remove the shims? My only alternative is to take it to a local mechanic, who has a $50 minimum -- seems like investing the $50 in the special pliers makes more sense (we also have a 1984 240 and 1987 740 with basically the same engine).

2. The belt tensioner for the timing belt rotates smoothly, but you can hear the bearings as it turns -- dry-sounding, like a roller skate or skateboard with no lubrication. The few receipts we got include a timing belt replacement 44,000 miles back, with no replacement of the belt tensioner, so it's presumably gone 70,000 miles. Am I right that this is due for replacement?

I was a Volvo mechanic in the early 80s and never used the pliers to remove the shims. If you have a compressor and a rubber tip blow gun and goggles you can blow air into the notch where the pliers go while covering the whole area with a rag. takes less time to do than explain.. Good luck.

I wouldn't bother for a single valve which is one thou tight. Frankly I doubt that the accuracy of the measurement is that good, anyway... most of us use feeler gauges which are made from shim stock and which probably have a tolerance of +/- .0003 to begin with, and then because of the valve geometry we can't get the feeler gauge in exactly square.

The general rule is to change the tensioner at every other belt change. But if the bearings make noise as you describe, change it regardless of the mileage.

You don't need the pliers, a good sharp but sturdy pick will do fine to pop them out. You do need the bucket depresser (Schlay tool from IPD) or take the whole cam out if you are comfortable with that.

There is no need to worry about a valve that is one thousandth tight. No problem. May take many more miles to tighten up furËher.
If the belt tensioner bearing makes any amount of noise, or feels rough, replace it. It contributes a great deal to belt life, and can shorten it to nearly nothing if it drags or locks up (which some do)

Bill,
I was told by my volvo indytech that valve clearance tends to tighten up and get less noisy with time, this is bad, better to hear them a little I am told, so you are right. Getting the tools would be good but how much for a kit of shims? I paid the money.
As for tensioner bearing, should be replaced if at all noisy. They say it should be replaced anyway every other belt change. Do it now while you are in there. Also check your front end seals, many here will say replace them anyway, they are cheap.
Karl
86 n/a 245 192K Kms Australia