Crankshaft Front Seal & Oil Pump: Removal

1. Remove the upper timing belt cover. Remove the power steering servo reservoir and expansion tank. Lift up and place on top of the engine. Remove the accessory drive belt (fan belt). See DRIVE BELT ROUTING . Remove the front timing belt cover.
2. Raise the car. Remove the right front wheel. Install the upper timing belt cover. Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond. See Figure. Turn a further 1/4 turn clockwise and then back counterclockwise until the markings correspond. Remove the upper camshaft cover.
3. Remove the timing belt. Loose the belt tensioner center bolt slightly. Hold the center bolt still and turn the tensioner eccentric clockwise with a 6 mm Allen key to 10 o'clock position. See Figure. Remove the timing belt.
4. Install Counterhold (999 5433) on the vibration damper. Secure counterhold and remove the crankshaft center nut. See Fig 1. Work the vibration damper loose and remove by hand. Remove the timing belt.
   Fig 1: Removing/Installing Crankshaft Pulley Bolt

   Courtesy of VOLVO CARS OF NORTH AMERICA.
CAUTION: Install puller so that the claws are on the bolts, not in the camshaft pulley. Ensure that the puller claws do not damage the pulley teeth.
Fig 2: Removing Crankshaft Pulley
Courtesy of VOLVO CARS OF NORTH AMERICA.
5. Remove the crankshaft timing gear pulley using an appropriate puller and two of the vibration damper bolts. See Fig 2. Tighten both the bolts by hand to stop in the pulley.
6. Remove the old seal using a groove-cut chisel or Remover/Installer Tool (999 5455). See Fig 3. Clean the mating surface. Grease and install a new seal using Installer Tool (999 5455). Press in the seal using a drift and the crankshaft center nut. Check thoroughly that the crankshaft does not rotate when pressing in the crankshaft seal.
   Fig 3: Removing/Installing Front Crankshaft Seal

   Courtesy of VOLVO CARS OF NORTH AMERICA.
7. Remove the oil pump. Remove the four oil pump bolts. Remove the oil pump. Use a groove-cut chisel and carefully break at the stop lugs. See Fig 4. Clean the gasket face and the mating surfaces.

Fig 4: Identifying Oil Pump Stop Lugs

Courtesy of VOLVO CARS OF NORTH AMERICA.