Volvo S40 2.4i Timing Belt & Camshaft Oil Seal Replacement 

Undoing the camshaft sensor wheel screw can be a problem sometimes. A common cordless impact wrench with 3 variable strength/speed can be used to undo the screw, I tried with the medium strength and it worked. You can bag and tag the bolts, the nuts and the screws to help when it is time to refit the parts.

How much you got it for pal ?

Get rid of it something is always breaking on them

I got a 04 s40 1 year ago nothing but trouble

Thanks for sharing, It is always useful to have more choice when working on a project.

Yes! In 2010 the brand new British hard cover Haynes book Volvo S40 no: 4731 was about 25$ plus shipping, I ordered it to get the basic information. The rest is more than 45 years of DIY.

I don't know, I never asked my local Volvo dealer service representative. Probably at first, 5 or 6 hours for labor, plus parts like the timing belt, the camshaft oil seal and the expansion plugs. But during the work, depending on the quantity of oil that leaked on the inner parts, and how old are some parts, they could have strongly suggested to also add more time to replace extra parts like the drive belt tensioner, the idler pulley, the water pump (& coolant fluid), the oily timing belt covers, the oily plastic shield behind the timing belt and the two drive belts.

In Canada this model was equipped with a Mitsubishi 1.9L engine and I don't know this engine. Ask your local Volvo dealer.

Those timing belts would brake before stretching out, like you described it. On this S40 2.4 engine, first the crankshaft marks are aligned to obtain a proper dead center, then, the camshaft slotted ends are parallelly aligned (or re-aligned) with the upper surface of the cylinder head using the camshaft locking tool. Therefore, the sprocket timing marks should be aligned (or re-aligned) with the plastic sprocket cover timing notches. When the bolt(s) of a sprocket is (are) torqued down, it is possible that the sprocket(s) could have rotated a fraction and lost the adjustment, this is why, I always double checked the notches alignments after. A defective VVT phasing system can cause a problem but it is extremely rare. A defective timing belt tensioner or a tensioner installation could cause belt tension problems like skipping a tooth or getting too lose. Assuming that you have installed the proper timing belt, you may have to re-check your installation to avoid catastrophic problems. Note: I noticed years ago that a guy used a single steel flat bar to align the camshafts, this was a mistake because the slotted ends of the camshafts are offsetted differently and it changes the timing a bit.

@@mtlcarguy Thanks for your reply ✌️ I did one timing belt a few years ago on a Hyundai and all worked perfectly, now this Volvo is kind of a pain with due to space restrictions, and I'm stuck trying to remove the crankshaft but, and I assume it does get loose counterclockwise. I had put oil for 3 days to she if that penetrate and loose it ...but so far nothing..

​@@simengineering9183 When you say ''trying to remove the crankshaft'' I assume you mean ''trying to remove the crankshaft center nut''. Trying to undo the big center nut with a common cordless impact wrench or a common 1/2'' drive ratchet, sometimes, it doesn't work without a lot of effort, this is why I use a more powerful electric impact wrench like it is shown @ 2:51. The crankshaft center nut and the camshaft sensor wheel screw do get loose counterclockwise. I did undo the camshaft sensor wheel screw on two other Volvo engines and it worked with a common cordless impact wrench without damaging the screw or the Torx bit socket.

@@mtlcarguy I finally got it out, Heat up the nut and I used a impact gun, funny I use a cheap one and before that I was using a breaker bar with a pipe and nothing, but my bad as I was using 3/4 to 1/2 extension and I noticed it wasn't moving, just flexing on the weak joint now I got the 3/4 proper extension but heat did the magic trick. 😄 now to install all the new parts and hopefully I will get it done today🙏

340-440$ for labor