For this procedure Volvo tools 999 5452, 999 5754, 999 5453, and 999 5454 are required to lock the camshafts in position in the
Cylinder Head during refitting and to pull the upper section into place, details for fabricating home-made alternatives are provided. Begin by draining the cooling system, removing the
Timing Belt and removing the air cleaner assembly and intake ducts for access to the camshafts. Remove the charge air pipe from turbocharged engines and seal the openings. Remove the cross stay & its bracket, disconnect the wiring of the camshaft position sensor and remove the relevant bracket & plugs, for both turbo & non-turbo models. Lock the camshafts in the right position before removing the sprockets, marking them for identification. Remove ignition coils, disconnected hoses and wiring and then remove bolts holding the cylinder head upper section and gently pry it off without damaging its mating surfaces. Inspect cam lobes and tappets for wear, clean mating surfaces thoroughly, as well as inspect valve clearances, if necessary. For refitting, the oil the tappet bores and camshaft bearings, insert the tappets and make sure the mating faces are clean. Spread liquid gasket on the top part, place the camshafts properly, lock them in place and lay the top part on the bottom part. Use pull-down tools to fix the upper part, tighten the retaining bolts in a diagonal order, and then remove the tools. Lubricate and fit new camshaft oil seals, refit sprockets and timing belt and refill cooling system upon completion.