02 S40 Rear Camshaft?

[JoV]

Hey guys, so I'm tearing into this engine and I come across where I have to install tool 999-5452 at the rear of the camshaft. Now my problem is how am I supposed to get off the black cap on the left (red circle):




So that I can get on this:



AllData seems to have a different picture in the instructions so I am all confused. All is says is "Install at rear of camshafts." I am just not getting it. Anyone who has any experience with it, your advise is greatly appreciated. Thanks guys!!!!

[jimmy57]

Feel the center of that cap and you'll find the spot where the metal has a hole in it in the center. You pan pierce it with a screw driver and pry the cap out.

[JoV]

Thanks jimmy, now there's a hole in the middle, do I have to replace it with a new one? What is the part called? Thanks again !!!!

[keithatcpt]

Volvo Engine Camshaft Plug - Volvo 1397381

Just did this on my S40 (had a bad VVT gear). I used the screwdriver method as well. I found a ton of sludge behind the cover, and no oil seal. Buying replacement parts, I bought replacement oil seals for both the intake and exhaust cams and re-assembled. The motor made it 165k miles (not the original motor in my 183k mile S40) so I guess the intake cam seal isn't strictly needed, although it definitely is on the exhaust side to keep the camshaft position sensor clean.

- Keith

[jimmy57]

Usually the cap has to be replaced as it often will not be a snug fit into the head. I have seen a few that were re-used. They siliconed a coin over the hole. I thought that was actually a pretty clever way to deal with it.
I have some Swedish coins. I could really mess with someone's head by gluing one of those in place on one of the models where that seal is out in the open......

[JoV]

Thanks guys, that is exactly the one I needed. Your help is greatly appreciated.