QuestionQUESTION: Hello Ray. I hope you can help me. For a 2001 Volvo S80 2.9 (non-turbo):
Can you describe the proper procedure for replacing the timing belt on this car. I know that you have to position the crankshaft to #1 TDC and lock the cams in place with a cam lock tool (marks on camshafts should align with something?...each other?).
But with CVVT (Continuously Variable Valve Timing) on this engine is there some special way to position the crank to #1 TDC?
I thought I read something about rotating the crank clockwise to TDC and then go another 90 degrees (quarter turn) clockwise and then back (counter clockwise) to TDC? Is that right? Will it damage the engine if you turn it too far counter clockwise? (pistons will hit valves?)
Also, how to you set the tension on the timing belt tensioner. Mine is the mechanical one (not hydraulic).
And do you have torque values for:
-- timing belt tensioner bolt
-- timing belt idler pulley bolt
-- the four bolts that hold on the crankshaft dampener (if I need to remove it to replace the timing belt).
Your help greatly appreciated. Thank you.
ANSWER: Gordon,
Here it is
2001 Volvo S80 2.9 L6-2.9L VIN 94 B6294S
Vehicle Level Engine, Cooling and Exhaust Engine Timing Belt Service and Repair Replacing the Timing Belt
Replacing the Timing Belt
Notes
REPLACING THE TIMING BELT
Special tools: 999 5433
999 5456
Removing the timing belt
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.
Preparation
Caution! Remove the ignition key.
Remove
the screw holding the engine stabilizer brace to the bracket on the engine
the screws holding the engine stabilizer brace to the suspension turrets
the engine stabilizer brace.
Applies only to B6xx4T engines:
Remove the plastic pipes between the turbocharger (TC) and charge air cooler (CAC) and between the air cleaner (ACL) and turbocharger (TC). Put them to one side. Remove the clamp from the intake manifold for the turbocharger (TC) for cylinders 1, 2 and 3. Turn the upper section of the pipe towards the firewall.
Relieve the load from the belt tensioner.
Remove the auxiliaries belt. See: Drive Belt\Service and Repair
Remove the upper timing belt cover.
Remove the front timing belt cover.
Lift up the servo reservoir and place it on top of the engine.Note! Ensure that the oil does not leak from the ventilation hole in the filler cap.
Seal the hose between the expansion tank and the radiator.
Disconnect the hose at the tank.
Lift up the expansion tank and place it on top of engine.
Raise the car. Remove
the right front wheel
the plastic nuts on the cover in the fender liner. Install the upper timing belt cover.
Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulleys correspond.
Turn the crankshaft a further 1/4 turn clockwise. Then turn back counter-clockwise until the markings correspond.
Remove the upper timing belt cover.
Remove the 4 vibration damper screws. Counterhold the crankshaft central nut.
Remove
the vibration damper
the auxiliaries belt
the belt cover behind the crankshaft pulley for the auxiliaries belt. Spray universal oil or similar around the rubber sleeve on the underside of the oil pump.
Remove the rubber sleeve.
Removing the timing belt
Slacken off the belt tensioner
Slacken off the center screw for the belt tensioner slightly.
Hold the center screw still.
Turn the tensioner eccentric counter-clockwise using a 6 mm Allen key.
Turn to 10 o'clock.
Unhook and remove the timing belt.Caution! Do not turn the camshafts or the crankshaft when the timing belt has been removed.
Checking the tensioner pulley and idler pulley Check bearing wear:
Spin the idler pulley and listen for noise. If replacing with a new idler pulley, tighten to 24 Nm .
Spin the tension pulley and listen for noise. When replacing, screw the tension pulley into place using the center screw.
Screw in the center screw by hand.
Ensure that the tensioner fork is centered over the cylinder block rib / bracket.
Ensure that the Allen hole on the eccentric is at "10 o'clock".
Installing the timing belt
Install the belt in the following order:
crankshaft
the idler pulley
intake cam
exhaust cam
water pump
tension pulley.Note! The variable valve timing unit on B6304S engines does not have a return spring. The unit is easily dislodged when reinstalling the timing belt.
Tensioning the timing belt
This adjustment is carried out on a cold engine. A suitable temperature is approximately 20°C / 68°F .
At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.
The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.
Carefully turn the crankshaft clockwise until the timing belt is tensioned. The belt must be in tension between the intake camshaft pulley, the idler pulley and the crankshaft.
Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric clockwise until the tensioner indicator passes the marked position. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window.
Hold the eccentric secure. Tighten the center screw to 25 Nm .
Check that the indicator is in the correct position.
Check
Press the belt to check that the indicator on the tensioner moves easily.
Install the upper timing belt cover. Turn the crankshaft 2 turns. Check that the markings on the crankshaft and camshaft pulley correspond.
Check that the indicator on the belt tensioner is within the marked area.
Finishing
Install the auxiliaries belt around the pulley on the crankshaft.
Install
the rubber sleeve on the underside of the oil pump
the vibration damper.
Use new screws.
Tighten to 35 Nm .
Angle-tighten 50°.
Use the crankshaft center nut as a counterhold
the plastic nuts for the cover in the right-hand fender liner
the right front wheel.
Lower the car.
the front timing belt cover. Tension the auxiliaries belt.
the expansion tank
the hose between the expansion tank and the radiator. Remove the lock grip pliers
the servo reservoir
the upper timing belt cover.
Applies only to B6xx4T engines:
Twist the intake pipe for the turbocharger for cylinders 1, 2 and 3 into position.
Tighten the clamp.
Install the plastic hoses between the turbocharger (TC) and the charge air cooler and between the air cleaner (ACL) and the turbocharger (TC). Tighten the hose clamps.
the engine stabilizer brace. Tighten to 50 Nm
the screw holding the engine stabilizer brace to the bracket on the engine. Tighten to 80 Nm .
Final check
Check and top up if required
coolant level
the servo fluid level. Test drive the engine.
---------- FOLLOW-UP ----------
QUESTION: Many thanks Ray! This is what I needed to give me the confidence to do this job myself. But a couple of follow up questions:
1. What is the purpose of turning the crankshaft 90 degrees past TDC and then back to TDC? Does this have something to do with VVT (Variable Valve Timing)?
2. Can you explain what is meant by this:
Note! The variable valve timing unit on B6304S engines does not have a return spring. The unit is easily dislodged when reinstalling the timing belt.
Where is this part located? If the VVT unit becomes "dislodged" (falls out?) can it just simply be reinserted? Or do you have to reset it? Is there anything else I need to know about this? This part scares me...
3. There is no mention of locking the cams in place with a cam lock tool, but I guess that would be a good idea? Your take?
4. Necessary to remove the speak plugs in order to turn the engine?
Thanks!
Gordon
ANSWER: Gordon,
To set the VVT back to it's normal position or without any advance/retard in it.
If the VVT gets "messed up" best thing is to replace it. There is a very complex system to replace a new one. It will require special tools and a couple more hours labor.
If you follow the procedure to set the cams to TDC when you remove the belt the gears will not move.
If the plugs are removed it makes turning the engine by hand easier.
---------- FOLLOW-UP ----------
QUESTION: Thank you for your quick response Ray.
Can you just please tell me where the VVT unit is located so I make sure I don't "dislodge it" as mentioned in the note above (my question #2 above). What does it look like? And how would it get dislodged?
I searched the Volvo boards and some Volvo parts sites for a diagram or picture or mention of the VVT unit but didn't find anything. Do you have any advice or suggestions for making sure it does not get dislodged when reinstalling the timing belt?
The note says "it does not have a return spring" so it sounds like it needs to be "held in place" in some fashion??? Duct tape? Piece of wire? Clamp?
Once again Ray, I greatly appreciate all your help and advice!
Gordon
AnswerGordon,
The VVT works on oil pressure. The valve is opened electrically to allow oil pressure in to retard the timing. The valve is under the black top cover either on the exhaust cam or the intake cam depending on what engine is in the car. You will see the valve bolted to the cover and the gear is the moving part. It advances or retards internally in the gear on the cam. If you do not set up the engine on TDC by going passed the mark 90 degrees then backing up to TDC you stand the chance of not having the gear in the correct TDC position. When you see all the marks line up the belt can be removed and there will be little or no movement in the gears. Use the marks to keep things lined up. If you are at all not sure of all the procedures have a shop with Volvo knowlege and experience do the job.
