For this procedure the Volvo camshaft locking tool 999 5452 is required to prevent the camshafts from turning round while the sprockets are taken off. Details for making a home-made alternative are given. Models with the 2.5 litre engine from late 1999 onwards may have a variable valve timing system which can be identified by a large hub assembly on the front camshaft sprocket and it is worth asking a Volvo dealer for advice. Start by removing the
Timing Belt, marking both camshaft sprockets for identification and undoing the three bolts to remove the appropriate sprocket to get at the failed seal using a suitable tool to restrain the sprockets. Carefully remove the seal without damaging the sealing face of the shaft and clean the seal seat and check whether there is wear on the shaft. Lubricate the new oil seal with clean engine oil and fit it over the shaft with lips inwards, tap it home until flush with the housing. Check alignment of camshafts before refitting sprocket(s), remove air cleaner assembly and inlet ducts for access. Remove the engine upper steady bar and its bracket, disconnect the camshaft position sensor wiring and remove the sensor housing and the rotor plate. For models that have a distributor, remove the distributor cap and rotor arm; and for those that don't, raise out your camshaft sensor and end cover. Make sure that the slots on the back of the camshafts are parallel to the join between the upper and lower parts of the cylinder heads and then secure the camshafts in position with the locking tool. Check that the crankshaft sprocket timing marks are aligned, attach the locking tool and refit the camshaft sprocket/s with timing marks aligned and secure with retaining bolts. Once you've done the necessary operations, refit the remaining bolts and tighten them to the amount specified by the torque wrench, then remove the locking tool. Continue with the timing belt refitting procedure with no reconnection of the battery at this time. Refit components specific to the model, being sure to reconnect and secure all of the wiring, then finally check to see if everything has been refitted correctly before reconnecting the battery.