Finally, I'm doing the timing belt and cam seals (front and rear). And, as I just now discovered, the drive belt, drive belt tensioner, and right engine mount.

Volvo S40 leaking front cam seals

Volvo S40 replacement front cam seals

The old seals were haggard. The timing belt is old enough that it's date code has faded completely.

Parts on order from Rockauto. I also just discovered I don't own a 30mm socket of any kind...

The drive belt tensioner is so cooked, it has lots of play in every direction. I think this explains a weird noise I occasionally was hearing on decel.

I'm pretty sure the service book recommends changing the water pump too. At least that's what I recall from 20 years ago.

Morning

I can loan you my 30mm socket if you need it urgently

All good on the socket, thanks anyway

Got into the rear seals today, found the source of most of the oil leak. Ironically forgot to buy this one seal! I also found while rinsing all the oil off of the engine that the rear timing cover was broken. Will see what Volvo want for a new one, if it's excessive I might order online and just cop the delay. Because it's the rear cover, I can't install any of the new timing gear until it's replaced.

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@Roinik I mulled the water pump over, if I was restoring the car I might do it, but this one feels fine, no bearing noise, no excessive play, I don't see it failing any time soon and I've already blown my budget on this car.

Okay well aside from the timing belt being exposed, it's all done. Both front cam seals, the rear exhaust cam seal, the rear intake cam cap, timing belt, drive belt, drive belt tensioner pulley, driver's side engine mount. I also adjusted the turbo actuator, the peg that pulls the wastegate open is pretty worn, the actuator has eaten a fair way into it. To be honest if I went further with this car I'd probably just slap a new cartridge in.

I also changed the oil and oil filter as they were both almost certainly overdue.

Car runs great, fixing that engine mount has reduced NVH a bit too.

I'll fix the timing cover but I need to order the parts from overseas and I'd rather pull it back apart than have it taking up space in my garage for two weeks.

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Nice going. It's a fiddly job with not much access.

13 days later
2 months later

The fix-ups continue, I finally managed to get some new roof trims a.k.a. the most stupidly awkward to transport part imagineable. Bought from @iceton1975 at Monash Prestige Auto, who delivered them to @AshDVS, who muled them up to Nats in his V70R, then they went to @Slowbrick who brought them up to Sydney in his 245T.

The before:
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Much more presentable. Still need a grille sash

    jamesinc Still need a grille sash

    I knew there was a reason I didn't throw this out. Phase 2 grille missing a tooth. Gave the sash a quick polish and it comes up nice. Take the whole grille if you like or just the sash. I can drop it round if you like. I owe you for a few stickers and sunglasses!

    I'm assuming the Phase 1 & 2 sashes are the same.

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      They definitely look the same, I'll check the part numbers. But yes, that would be amazing!

      a month later

      Hmmmm, noticing a fuel smell coming from the tank area lately, I don't think it's the filler cap, and it's definitely not coming from the engine bay.

      I don't know much about S40 fuel systems, any likely suspects?

      7 days later

      Hey look at that! It's a Volvo again……… 🙂

      Nice to see the T4 once more, it seems to be "that little bit better" each time I see it.

      Got a photo of the new parcel shelf speakers too, stereo sounds much better now!

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      a month later

      I have put stock control arms back in:
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      I've also replaced the tie rods, ends, and bellows:

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      Doing the bellows was such a hassle, it's really hard to get enough access to pull the rubber boots over the ends of the rack body.

      2 months later

      ORIGINAL (stamped 1999) transmission mount replaced

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      New one from Skandix:

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      It made a bigger difference than I expected, even with those polyurethane engine mounts the NVH is pretty minimal. Torque steer under hard acceleration has improved although that is not so surprising.

      5 days later

      I took the AC centre vents out and repaired all the cracked and broken fascia, I kept all the pieces that had fallen off so it's now in one piece again. I used JB Weld, and I've been sick the last few days so it got time to well and truly cure fully.

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      The controls were all creaky so I gave them all a tiny spot of MX6 grease. Turns out this unit was the source of all the interior rattles, the cabin experience is pretty nice now!

      The radio antenna also got stuck in the up position, after going through everything, it turns out the head unit is the problem, it's holding the antenna trigger at 12V at all times, I'm assuming there is a power transistor inside that has failed with low impedance but that is pure speculation. It is the cheapest wireless Android Auto headunit on Aliexpress so not completely shocked!

      I thought those carbon fibre centre vents would be stronger than the normal ones 🙂

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