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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
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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

Postby RobTheModd » 26 Nov 2009, 15:09

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
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

P1010116.JPG

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

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

Postby FCPGroton » 27 Nov 2009, 16:12

Awesome write-up. They should had this to the blog.
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Re: Cam seal and sensor. replacement. *lots of pics*

Postby matthew1 » 27 Nov 2009, 16:34

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

Postby matthew1 » 27 Nov 2009, 16:43

And Rob, agreed, very good writeup. I made your rank "MVS Contributor".
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Re: Cam seal and sensor. replacement. *lots of pics*

Postby RobTheModd » 27 Nov 2009, 17:19

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

Postby howie » 29 Nov 2009, 14:15

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

Postby RobTheModd » 30 Nov 2009, 03:20

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

Postby stone123 » 18 Oct 2010, 09:39

is this how a 93 850 glt cam sensor comes out as well
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Re: Cam seal and sensor. replacement. *lots of pics*

Postby RobTheModd » 20 Oct 2010, 01:45

From what I know, yes.


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

Postby JimBee » 20 Oct 2010, 03:16

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

Postby coedwards » 14 Sep 2011, 03:21

Thank you for the write up! Worked out just like in your description for my '98 V70XC, making for a very easy job. I appreciate the help.
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Re: Cam seal and sensor. replacement. *lots of pics*

Postby erikv11 » 14 Sep 2011, 03:58

JimBee wrote:...
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.
...

These were a bunch of great tips except I disagree with the ones I put in bold.

A perfectly installed cam seal will sit flush with the outer head surface, not all the way in. Don't push them in too far.

So you actually want a piece of pipe slightly slightly larger than the diameter of the seal, but thick-walled enough to overlap with the seal surface at the same time. This way the pipe will stop pushing the seal when the pipe contacts the outer head surface, and the seal will be flush like it is supposed to be.
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Re: Cam seal and sensor. replacement. *lots of pics*

Postby nepersonne » 14 Dec 2011, 18:55

I just finished replacing my rear cam seal. I accidentally followed the DIY for the non-turbo version! But it got me through it enough I was able to figure out the rest.

The one part that threw me was the lower bolt/screw on the cover was also holding a tubing bracket. Those tubes don't like to move up and out of the way easily!

Ok, so everything is back together, car starts up and runs, there don't appear to be any leaks from the area however.... I'm a bit concerned after reading everyones comments as to how far back to push the new seal. When I was following the DIY (for the non turbo) it said put the seal flush with the bevel... so I did, but from reading this thread seems like that might be too far. I've attached a pic of the area (circled in yellow) that I considered "the bevel" and thus pushed the seal in to this point.

Am I correct, or did I put it in too far?

Thanks,
Tim
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Cam seal and sensor. replacement. *lots of pics*

Postby Choguy03 » 14 Dec 2011, 19:59

No the rear's seat much farther back then the front seals. You will be fine.

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