IPD sale XeMODeX - Experts in Volvo Electronics Free shipping all USA - Experts in Brakes
Did you know? 🤔
Logged in users can get email notification of topic replies Log in or register (free).
Amazon Link Buy your stuff using this and it helps MVS!

2002 2.9 S80 oil leak driving me mad Topic is solved

Help, Advice, Owners' Discussion and DIY Tutorials on the Volvo S80 model. Sometimes called an "executive car", the S80 was and continues to be Volvo's top-of-the-line passenger car.
SlowLane
Posts: 14
Joined: Sun Sep 15, 2013 7:16 am
Year and Model: 1996 855 Turbo
Location: Livermore, CA
Has thanked: 0
Been thanked: 1 time
United States of America
SlowLane

2002 2.9 S80 oil leak driving me mad

Post by SlowLane » Sun Jan 26, 2020 10:41 pm

My wife's 2002 S80 with the 2.9 N/A engine started to leak oil badly on the right-hand side back in October at just under 200,000 miles. The entire underside on the right side of the car would be soaked in oil and dripping on the garage floor after parking it.

So I did some research and started "fixing" it. The first suggestion that I got was that was likely the front crank seal or oil pump. Since the mileage was close to the timing belt change interval, I changed out the timing belt and water pump while I was in there. Also swapped out the PCV system, even though I had exchanged that just a few years ago and the one that came out was clean as a whistle.

Still leaking, so I spent the entire four-day Thanksgiving weekend dropping and re-sealing the oil pan. No joy, and I discovered that only two of the rubber seals in the "comprehensive" oil seal kit from Volvo actually applied to my engine.

During all this I also managed to clean up some pesky coolant leaks, so the time spent wasn't totally wasted.

Okay, back to square one. The leak appears to be only down at the lower end of the engine. The camshaft seals don't appear to be leaking, as the back sides of the camshaft sprockets are bone-dry. Then I found DIY Robert's video on how easy it is to screw up while installing the crank seal, so I ordered his installation tool and installed a second oil pump seal kit. It was very clear that I had screwed up the first installation, as the seal compression spring was completely off of the seal and riding on the crankshaft, where it left a shiny ring on the shaft. Was very careful installing the second seal with Robert's tool (which is of sublime quality, BTW), and was sure that it had gone in correctly, but we're still having leakage, albeit somewhat less than before. I'm a little worried that the seal's lip is actually riding on the part of the shaft that the spring had worked against. Next seal I install will be pressed not quite all the way in, hoping that will avoid the worn bit. Grasping at straws a bit at this point.

I'm now approaching the problem on two fronts:
  • On the assumption that I've missed something, I'm gathering all the parts and tools to replace the crank seal (again), the camshaft seals and the VVT hub (this engine has intake VVT only) as well as the piston-cooling squirter valve and gasket that someone else mentioned here. I'm afraid that this is the oft-tried yet usually futile tactic of throwing parts at the problem until it goes away or I run out of money. The new VVT hub has just arrived, but I'm afraid that it may be defective. It has about 3 mm of axial play on the inner collar, but having never handled one before, I can't judge whether that's normal or not. I will be planning a trip to the local wreckers soon to see if I can pull off some sample VVT hubs and get a better feel for them. I'm loathe to pull the hub off of my engine because it seems to be working just fine.
  • On the suspicion that my engine at 200,000 miles has worn to the point where the crankcase pressure under load is now great enough to overcome the capacity of the stock PCV system, thus blowing oil past the crank seal regardless of how finely the seal is installed, I will be modifying an oil cap with a pipe fitting to monitor crankcase pressure with a manometer while driving. Even though the case has decent negative pressure at idle or revving with no load, the worst leaks seem to occur after a high-speed run on the highway, which is what has me leaning more towards this hypothesis.
Last edited by SlowLane on Tue Jan 28, 2020 11:13 pm, edited 1 time in total.
Current Volvos:
2002 2.9 S80 - Wife's car, the "Silver Flash"
1996 855 Turbo - Formerly daughter's ride. My toy now.

Former Volvos:
1997 855 GLT - Totalled by daughter. Now she appreciates Volvos. :wink:
1984 244 DL B23F - warped head after radiator blew
1982 245 GL B21A - My first Volvo. Sold with 400,000 km on it.

Other:
1981 VW Westfalia

User avatar
SuperHerman
Posts: 1341
Joined: Mon Dec 01, 2014 1:28 pm
Year and Model: 2004 & 2016 XC90
Location: Minnesota
Has thanked: 0
Been thanked: 135 times
United States of America
SuperHerman

Re: 2002 2.9 S80 oil leak driving me mad

Post by SuperHerman » Mon Jan 27, 2020 8:10 pm

Have you looked at the oil cooler and hoses?

SlowLane
Posts: 14
Joined: Sun Sep 15, 2013 7:16 am
Year and Model: 1996 855 Turbo
Location: Livermore, CA
Has thanked: 0
Been thanked: 1 time
United States of America
SlowLane

Re: 2002 2.9 S80 oil leak driving me mad

Post by SlowLane » Mon Jan 27, 2020 11:03 pm

SuperHerman wrote: ↑
Mon Jan 27, 2020 8:10 pm
Have you looked at the oil cooler and hoses?
Oh, yes, I forgot to mention that. I replaced the oil cooler, hoses and seals when I did the oil pan.

To further eliminate the cooler as the source, I've wrapped a cloth rag around the join between the cooler and the pan, held on with a large zip tie. Not to try and stop the leak, understand, but to isolate the cooler as the culprit. I have yet to get back under the car to see if the rag is oil-soaked from the inside.

Thanks for the feedback.
Current Volvos:
2002 2.9 S80 - Wife's car, the "Silver Flash"
1996 855 Turbo - Formerly daughter's ride. My toy now.

Former Volvos:
1997 855 GLT - Totalled by daughter. Now she appreciates Volvos. :wink:
1984 244 DL B23F - warped head after radiator blew
1982 245 GL B21A - My first Volvo. Sold with 400,000 km on it.

Other:
1981 VW Westfalia

User avatar
SuperHerman
Posts: 1341
Joined: Mon Dec 01, 2014 1:28 pm
Year and Model: 2004 & 2016 XC90
Location: Minnesota
Has thanked: 0
Been thanked: 135 times
United States of America
SuperHerman

Re: 2002 2.9 S80 oil leak driving me mad

Post by SuperHerman » Tue Jan 28, 2020 10:32 am

Oil dipstick o-ring?

SlowLane
Posts: 14
Joined: Sun Sep 15, 2013 7:16 am
Year and Model: 1996 855 Turbo
Location: Livermore, CA
Has thanked: 0
Been thanked: 1 time
United States of America
SlowLane

Re: 2002 2.9 S80 oil leak driving me mad

Post by SlowLane » Tue Jan 28, 2020 11:07 pm

Yup, that too. Fairly new dipstick as well. Also been using ipd's Viton oil cap seal for some time now, which does a dandy job of sealing.

Also replaced the gasket under the VVT solenoid, which reduced some of the oil puddling on the top of the engine.

I might also mention that I've owned this car for 13 years and have always used synthetic oil in it. When I removed the oil pan there was only a small patch of easily removed "sludge" in the middle of the pan.
Current Volvos:
2002 2.9 S80 - Wife's car, the "Silver Flash"
1996 855 Turbo - Formerly daughter's ride. My toy now.

Former Volvos:
1997 855 GLT - Totalled by daughter. Now she appreciates Volvos. :wink:
1984 244 DL B23F - warped head after radiator blew
1982 245 GL B21A - My first Volvo. Sold with 400,000 km on it.

Other:
1981 VW Westfalia

SlowLane
Posts: 14
Joined: Sun Sep 15, 2013 7:16 am
Year and Model: 1996 855 Turbo
Location: Livermore, CA
Has thanked: 0
Been thanked: 1 time
United States of America
SlowLane

Re: 2002 2.9 S80 oil leak driving me mad

Post by SlowLane » Thu Feb 06, 2020 10:01 am

SlowLane wrote: ↑
Sun Jan 26, 2020 10:41 pm
The new VVT hub has just arrived, but I'm afraid that it may be defective. It has about 3 mm of axial play on the inner collar, but having never handled one before, I can't judge whether that's normal or not. I will be planning a trip to the local wreckers soon to see if I can pull off some sample VVT hubs and get a better feel for them.
Thought I would follow up by answering my own question about the VVT hub.

Here is what had me concerned that the new hub was defective. The center collar could easily be moved in and out by a couple of mm with light finger pressure. This concern was reinforced by a couple of officious-sounding YooToob videos which identified such play as a sign of a faulty hub.
IMG_20200206_075253544.jpg
IMG_20200206_075239438_HDR.jpg
So I took a field trip to the local pick'n'pull to educate myself about VVT hubs and get some practice at removing one. I discovered that when unmounted, the hub I removed had about the same amount of play as my new one, but when mounted had virtually no play at all. Closer examination of how the hub mounted onto the camshaft revealed that two surfaces of the hub abut onto the camshaft mounting surface: the collar itself and the annular ring around the periphery of the hub socket. When the hub is bolted onto the camshaft, the collar fully extends, which means that the amount of end play is determined by the difference between the annular mounting surface and the mounting surface of the collar. In the pictures below I show how measured the difference between the two, which turned out to be 0.004". I'm quite happy with that, and also happy that I didn't waste $300 on a boat anchor that would undoubtedly be a struggle to return.
IMG_20200206_075159388.jpg
IMG_20200206_075148065.jpg
You do not have the required permissions to view the files attached to this post.
Current Volvos:
2002 2.9 S80 - Wife's car, the "Silver Flash"
1996 855 Turbo - Formerly daughter's ride. My toy now.

Former Volvos:
1997 855 GLT - Totalled by daughter. Now she appreciates Volvos. :wink:
1984 244 DL B23F - warped head after radiator blew
1982 245 GL B21A - My first Volvo. Sold with 400,000 km on it.

Other:
1981 VW Westfalia

User avatar
MoVolvos
Posts: 2137
Joined: Sun Jan 15, 2012 6:47 pm
Year and Model: 03S80T6~08C30T5
Location: NC
Has thanked: 26 times
Been thanked: 51 times
United States of America
MoVolvos

Re: 2002 2.9 S80 oil leak driving me mad

Post by MoVolvos » Mon Feb 10, 2020 3:47 pm

-
While you're at it change the seal.
-
Damaged Seal.png
You do not have the required permissions to view the files attached to this post.
Last edited by MoVolvos on Mon Feb 10, 2020 4:03 pm, edited 1 time in total.
Blessings,

BKM

1998 S70 T5 - Donated
2003 S80 T6
2003 GS300
2003 Odyssey
2008 C30 T5
2019 Atlas SE 4 Motion

User avatar
MoVolvos
Posts: 2137
Joined: Sun Jan 15, 2012 6:47 pm
Year and Model: 03S80T6~08C30T5
Location: NC
Has thanked: 26 times
Been thanked: 51 times
United States of America
MoVolvos

Re: 2002 2.9 S80 oil leak driving me mad

Post by MoVolvos » Mon Feb 10, 2020 4:00 pm

-
If you need some advise or help...

Independent Volvo Service - Have Antonio take a look or call for advise. Friendly and Knowledgeable.
https://www.yelp.com/biz/independent-vo ... lnut-creek

Montclair Auto Tech-Volvos - 5 Stars - 103 Reviews
https://www.yelp.com/biz/montclair-auto ... -oakland-2
Blessings,

BKM

1998 S70 T5 - Donated
2003 S80 T6
2003 GS300
2003 Odyssey
2008 C30 T5
2019 Atlas SE 4 Motion

SlowLane
Posts: 14
Joined: Sun Sep 15, 2013 7:16 am
Year and Model: 1996 855 Turbo
Location: Livermore, CA
Has thanked: 0
Been thanked: 1 time
United States of America
SlowLane

Re: 2002 2.9 S80 oil leak driving me mad

Post by SlowLane » Mon Feb 10, 2020 10:25 pm

MoVolvos wrote: ↑
Mon Feb 10, 2020 3:47 pm
-
While you're at it change the seal.
Thanks. Sharp eyes, there.
However, it's a brand new seal, supplied with the brand new hub. The apparent damage in the photo is a trick of the light, compounded by the light machine oil coating. I just inspected the seal again and it's about as good as a new seal can be.

And thanks for the links for advice.
Current Volvos:
2002 2.9 S80 - Wife's car, the "Silver Flash"
1996 855 Turbo - Formerly daughter's ride. My toy now.

Former Volvos:
1997 855 GLT - Totalled by daughter. Now she appreciates Volvos. :wink:
1984 244 DL B23F - warped head after radiator blew
1982 245 GL B21A - My first Volvo. Sold with 400,000 km on it.

Other:
1981 VW Westfalia

User avatar
MoVolvos
Posts: 2137
Joined: Sun Jan 15, 2012 6:47 pm
Year and Model: 03S80T6~08C30T5
Location: NC
Has thanked: 26 times
Been thanked: 51 times
United States of America
MoVolvos

Re: 2002 2.9 S80 oil leak driving me mad

Post by MoVolvos » Tue Feb 11, 2020 2:49 pm

SlowLane wrote: ↑
Mon Feb 10, 2020 10:25 pm
MoVolvos wrote: ↑
Mon Feb 10, 2020 3:47 pm
-
While you're at it change the seal.
Thanks. Sharp eyes, there.
However, it's a brand new seal, supplied with the brand new hub. The apparent damage in the photo is a trick of the light, compounded by the light machine oil coating. I just inspected the seal again and it's about as good as a new seal can be.

And thanks for the links for advice.
Let us know, am curious what is causing the leak.
Blessings,

BKM

1998 S70 T5 - Donated
2003 S80 T6
2003 GS300
2003 Odyssey
2008 C30 T5
2019 Atlas SE 4 Motion

Post Reply
  • Similar Topics
    Replies
    Views
    Last post