For this procedure Volvo tools 999 5452, 999 5453 and 999 5454 are needed to lock the camshafts in position in the cylinder head upper section during refitting and to pull the upper section into position. Details for making home made alternatives are given. A tube of a liquid gasket and a short-haired application roller are also required. Models with the 2.5 litre engine from late 1999 onwards may have a variable valve timing system, which should be visible by a large hub assembly on the front camshaft sprocket, and consultancy from a Volvo dealer is recommended. Start by disconnecting the battery negative lead, cooling system drainage and removal of the
Timing Belt. Mark the camshaft sprockets to identify them, and remove them, slacken all bolts fixing the cylinder head upper section in a progressive diagonal order. Gently tap or prise the upper section off being careful of the camshafts. Withdraw the sealing O-rings and mark the camshaft before lifting them out. Remove oil seals and get a suitable storage solution for the hydraulic tappets, making sure to identify and soak in oil. Check the cam lobes and tappets for wear, and thoroughly clean the mating surfaces before reassembling. Install the camshafts in the upper section using special tools and ensuring proper alignment and fixing of the camshafts. Put new sealing O-rings in the bottom part and raise the top part into position and use pull-down tools to press the top part against the valve springs. Tighten the retaining bolts in a progressive sequence, aligning diagonally, lubricate and fit new camshaft oil seals and re-attach the camshaft sprockets and align the timing marks. Perform the other operations and fill the cooling system upon completion.