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Cam seal and sensor. replacement. *lots of pics*

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.
1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
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RobTheModd
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Year and Model: s70T5 1998
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Cam seal and sensor. replacement. *lots of pics*

Postby RobTheModd » Thu Nov 26, 2009 3:09 pm

Cam seal replacement.
Tools needed.
[*] Wrentch, 10mm socket. *to remove the bolt*
[*] T40 screw driver. *to remove the 2 screws*
[*] Flat head screwdriver *to remove seal and sensor
[*] Flash light *extra light*
[*]Rag to clean

Tools I used
P1010123.JPG


Here is where you begin. It is easier to remove the air box just because it gives you some room to move around, I started off with it still in, but I decided to just remove it to make it easier on myself.
This is the rear cam sensor, you must remove the 2 T40 screws in order to get it off.
P1010106.JPG
rear Cam sensor
P1010107.JPG

Once you get it unscrewed preceed to getting out your flat head!
This is the second hardest part to do.
Either pry Carefully, or get a hammer and lightly tap on the top screw area from the engine side. Look at pictures.
*note how i have the flat head screwdriver on the bottom screw area as it is easier to go in that way*
You will need to *Wiggle* it out, by prying the top, then bottom, then top, and so on untill it comes out fully.
P1010110.JPG

P1010111.JPG

P1010112.JPG

Once it comes off The sensor side should look like this.
P1010114.JPG

If you are looking to replace just the sensor, it plugs in here. Just follow the wire. if not, than skip this photo. *Once you replace your sensor, just put the cap back on, line up the screw holes and tighten the screws*
P1010130.JPG

Next is taking out the 10mm bolt
URGENT!!! REMEMBER HOW THIS PART COMES OUT!!! I ADVISE YOU TAKE A PHOTO!!! SO YOU CAN REFRENCE IT WHEN YOU PUT IT BACK IN!!, Also, it has to key back in to the position you removed it from.
P1010115.JPG

Heres what it looks like once out.
front, and back.
P1010117.JPG
FRONT

P1010116.JPG
BACK

Once you take that out it reveals the seal.
Your on your own on getting that out, Unfortunitly for me mine did not fall apart like I had hopped. so I had to pry it out. I used my flat head, but wish i could have found my glasses repair kit so i could have gotten it out easier.
P1010118.JPG

Once its removed. No seal
P1010121.JPG
No seal

Take your new seal and place it back in where the old one came out. Make sure it goes in all the way. Should sit flush or even in a little bit.
might have to force it in.
P1010122.JPG

Once you get it back in seal it all back up.
MAKE SURE YOU PUT THAT METAL PIECE YOU TOOK OUT BACK IN THE SAME WAY IT CAME OUT!
Once everything is put back in place and screwed shut. *and tools removed from engine bay*
Leave the hood open. Start the car up and let it run for a few.
If when you start the car it turns over and stalls, or just doesnt turn on, DO NOT FREAK OUT. *like i did.... * just remove the cover, unscrew the 10mm bolt and rotate the metal piece. It will only go in 2 ways. one being wrong, and the other being right.
Screw everything back up, and have fun driving.
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matthew1
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Re: Cam seal and sensor. replacement. *lots of pics*

Postby matthew1 » Fri Nov 27, 2009 4:34 pm

Already done :-).

If it has a gear icon next to it like this -> Image it's in the Volvo Repair Database (and if it's among the 10 most recently added, it's also on the blog on the Home page).
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1997 850 T5, MSD ignition coil, Hallman manual boost controller, injectors, R bumper, OMP strut brace
2004 V70 R [gone]

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matthew1
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Re: Cam seal and sensor. replacement. *lots of pics*

Postby matthew1 » Fri Nov 27, 2009 4:43 pm

And Rob, agreed, very good writeup. I made your rank "MVS Contributor".
Please buy from MVS sponsors. It keeps this site on the web.
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How to help MVS.

1997 850 T5, MSD ignition coil, Hallman manual boost controller, injectors, R bumper, OMP strut brace
2004 V70 R [gone]

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RobTheModd
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Joined: Thu Aug 20, 2009 6:39 pm
Year and Model: s70T5 1998
Location: Orlando, Florida

Re: Cam seal and sensor. replacement. *lots of pics*

Postby RobTheModd » Fri Nov 27, 2009 5:19 pm

Thanks FCP, ill be browsing your site later today for some parts! since people are asking what to get me for christmas.

And Matt, Keep up the great site, Ive found the Repair database a great addition that other volvo sites should have. Makes it easier to get things done for ALOT less money. *mechanic was going to charge me 150$ for the seal replacement*
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howie
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Re: Cam seal and sensor. replacement. *lots of pics*

Postby howie » Sun Nov 29, 2009 2:15 pm

Awesome write up!!

I have one question, the sensor plug is held by a bracket with the spring loaded lock on the bottom which disconnects the main harness from the sensor. My question is how to you remove the sensor plug from the bracket? It appears that it slides out toward to drivers side. Is there a release on the metal mounting bracket itself?

Edit: I got it out with no problem, 14 years of oil and corrosion made it seem like it would not move. Once I installed the new CPS she fired right up and is running like a chance. I am going to order a new cam seal and replace it this week and hopefully get some life out of the new CPS.
2000 Volvo S70 SE, 145.000 on the clicker

1998 V70R 195.000

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RobTheModd
Posts: 1071
Joined: Thu Aug 20, 2009 6:39 pm
Year and Model: s70T5 1998
Location: Orlando, Florida

Re: Cam seal and sensor. replacement. *lots of pics*

Postby RobTheModd » Mon Nov 30, 2009 3:20 am

howie wrote:Awesome write up!!

I have one question, the sensor plug is held by a bracket with the spring loaded lock on the bottom which disconnects the main harness from the sensor. My question is how to you remove the sensor plug from the bracket? It appears that it slides out toward to drivers side. Is there a release on the metal mounting bracket itself?

Edit: I got it out with no problem, 14 years of oil and corrosion made it seem like it would not move. Once I installed the new CPS she fired right up and is running like a chance. I am going to order a new cam seal and replace it this week and hopefully get some life out of the new CPS.


Word of advise... Once you start removing the seal... DONT stop. I realized this half way in, after I runied my current seal that there is a point of no return... But then again I used needle nose plyers to get the seal out. Im sure if I could have located my eyeglass repair kit *just picked up a replacement* it would have been a bit easier to use the tiny flat head. Good luck and post here if you get stuck. or just pm me.
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stone123
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Year and Model: 850 GLT 93
Location: dallas,tx

Re: Cam seal and sensor. replacement. *lots of pics*

Postby stone123 » Mon Oct 18, 2010 9:39 am

is this how a 93 850 glt cam sensor comes out as well

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RobTheModd
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Year and Model: s70T5 1998
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Re: Cam seal and sensor. replacement. *lots of pics*

Postby RobTheModd » Wed Oct 20, 2010 1:45 am

From what I know, yes.


Fronts are not the same.
but the rears are.
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JimBee
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Re: Cam seal and sensor. replacement. *lots of pics*

Postby JimBee » Wed Oct 20, 2010 3:16 am

The '93 850 is the same. Did mine last weekend. Rob beat me to the pic's with a really helpful writeup. I'll add a couple of things, and a few more pics.
First, some bad wrenching left me with a lower Torx screw that was almost rounded out. I used plently of PB Blaster and with help finally got it out. That was almost a project stopper. Make sure you have a good sharp bit to avoid that problem.

The exhaust seal has a metal face—the surface you're looking at when you remove the back plate with the center screw. That plate only goes on one way. If you try to put it on the other way it doesn't set flat. That's because the slot in the end of the camshaft cuts a little below the center line—designed so you can't install the plate wrong. Rob was lucky I think that turning the engine over with that plate on unevenly didn't take out his timing sensor (the two come very close when the camshaft is turning).

I bought the long handle seal remover from Harbor Freight and have found a couple of uses for it; but not on this seal. I suggest you don't try to dig out the seal like Rob's pic shows. Maybe no harm was done, but you might score the shaft or the aluminum housing that holds the seal. Instead, drill a small hole through the metal face of the seal. I center punched mine first to hold the drill on point. With the hole drilled, find a screw that's a bit bigger than the hole and screw it in slowly. The screw point will contact the middle of the back of the housing behind the seal. That's as far as the screw can go. Keep turning the screw slowly and the threads will hold in the seal's metal face and walk the seal right out.

NEXT: Clean things up in there with a rag wrapped around a prod of some kind—like a screw driver. Make sure there's no crud around the outside of the seal housing where the edge of the seal needs to be leak free.

Then: Spray some silicone inside the housing and you'll get some on the camshaft at the same time.
Also spray silicone around the outside of the seal (the rubber rim).
Put some GREASE on the inside rim of the seal where it will contact the shaft. You don not want the shaft to turn on a dry seal.

INSTALLATION TRICK: Hit the PVC bins at your local big box hardware store and get a pvc cap that's inch and a quarter (1 1/4")
A sleeve will do. You just want a round cylinder to evenly press the new lubed seal into its seat. It goes in a ways before seating. The pvc works perfectly for this. (If you do the intake seals, I think those are inch and a half. Take your seals with you to the store and just find the pvc fitting that is closest to the diameter of the seal without going over.

Getting the first old seal out was the most time consuming for me until I punched and drilled them. I did not want to scratch or gouge anything in there. The drill worked perfectly. Oh, yeah, I have the close area drill attachment (Harbor Freight has one on sale this week, I think-good to have when you need it).

With the right tools, replacing the seals is quite easy.
PS I did all 4 of mine; the punch and drill worked perfectly on the intake seals as well. (I also did the front main seal while I was at it; getting to it is another story, but the punch and drill to remove it worked there too. So far, nice and dry!
Good luck!


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