The notorious Variable Valve Timing (VVT) gear oil leak on the 01 Volvo S40 can be a costly repair at a dealership. This guide details a successful DIY replacement of the VVT gear, offering a significant cost savings. A subtle oil spray, often mistaken for other seal leaks, is the telltale sign of this issue. The oil accumulates in the plunger depression on the VVT gear, confirming the diagnosis.
Pinpointing the Problem: VVT Gear Plunger
Look closely at the VVT gear. The plunger, located between the gear hub and outer gear, has a small rod extending to contact the outer gear. Oil pooling in the plunger’s depression indicates a leaking VVT gear. Replacing the o-ring alone is often a temporary fix, with leaks reappearing shortly after.
Cost Comparison: DIY vs. Dealership
Dealership quotes for this repair typically range from $2000 to $2600, excluding cam and crank seals. This cost is largely attributed to the estimated 8 hours of labor involved. A DIY approach, utilizing a timing belt (TB) kit, new VVT gear, cam seals, and the essential cam lock tool, can reduce the cost to around $450.
Essential Tool: The Cam Lock Tool
The cam lock tool, available used for around $65 or new for $120, is crucial for this repair. This specialized tool ensures proper timing during the VVT gear replacement, preventing potential engine damage.
DIY Repair Process and Considerations
This is an advanced repair, requiring meticulous attention to detail and patience. The process involves removing numerous components from the back of the engine (driver’s side) to access and utilize the cam lock tool. Bagging, labeling all removed parts, and taking detailed notes are strongly recommended.
Time Commitment and Complexity
For a non-mechanic, this repair can take up to three days. Each step should be approached methodically, ensuring accuracy and proper reassembly. The complexity of the task and the potential for engine damage if the timing is incorrect underscore the high labor costs quoted by dealerships. A successful DIY repair, however, provides a rewarding sense of accomplishment and significant cost savings.
