2003 s60 2.4t 118000 miles.
I'm thinking of having the t belt replaced. The more I dig for information the bigger the job gets. I saw that the water pump should be replaced also. Now this mechanic said I should have the front seals done also. Where does this job stop ...

 

A 2003 should have had the belt replaced @ 105000 miles or @ 10 years. If it was not - you should not drive the car until it is replaced or positively verify when it was done.

Water pumps are optional - if the original pump has no evidence of leakage and the bearing feels normal - I have seen the factory brand (make sure it is ) last over 400,000 miles. So are the cam seals - if there is no evidence of leakage - do not replace them. However with that mileage the PCV system could easily be clogged or partially clogged. Really depends on the frequency of oil changes and the type of oil used. The factory schedule of XXXX miles WILL CLOG the PCV system using standard motor oil. Pure Synthetic prevents some problems. Replacement of the PCV system is many, many hundreds of dollars.

And yes you are correct "where does this job stop" - You have a 18 year old Volvo - the repairs Will not stop - You will put things off, you might break down when your radiator leaks - you might overheat the car and cause $4000 worth of damage. The transmission might require replacement - the AC will have problems, your gauges will stop working - the list can go on and on - Just remember - you do not own a Toyota, you have a 18 year old Volvo. I am not trying to burst your bubble but for 40 years I had a Volvo shop - and watched this stuff happen to my customers.

 

I would like to say that the most affordable way to own a Volvo, and some other European cars, is if you do the work your self. Now I wouldn't want anyone to go and try to do anything they are incapable of, like myself doing my timing for the first time on my 850, but its the truth. PCV system, parts wise, is like $200 or so and the timing parts aren't outrageous. Maintenance is your best friend, FCP offers lifetime warranty on almost all items and makes oil changes practically free, depends if you have to pay shipping or if you burn oil etc. I did my water pump and timing and a lot of other stuff when I first got my 06 s60 because I had no maintenance records and wanted to be safe.

It's funny hoonk mentioned radiator leaks. My coolant was rusty so I tried one of those rust removers for the coolant, which didnt really work except it showed that the radiator was rusted up and eventually leaked at the seal between the plastic and the aluminum. A slow leak thank god, but could have been worse.

 

the point your tech was making is that when the timing belt is off, its pretty easy to service the water pump as well as the cam seals. +1 on hoonk's comments - they don't need to be replaced just because you can. Most cam seal leaks are caused by clogged PCVs causing positive crank pressure which can push out the seals or push oil by the seals. Fix the PCV, push the seals back into place and go on your way. As to the timing belt job, you'd want to replace the belt, tensioner and on some models the idler. Also inspect the serpentine belt and its pulleys (if its noisy, good time to update those). Certainly I'd throw on a new serpentine belt unless its known to be less than 5 years old.

You can do you own test of the crankcase pressure by using a rubber "surgeons" glove - place it over the oil filler (cap removed first) and start the car. If the glove inflates hard, have the shop address the PCV system including hoses, block ports, oil separator etc. If it sucks in and out, that's normal. If it sucks in hard and you have oil consumption, then your oil separator (part of the PCV system) may have a torn diaphram and should be replaced.