Volvo Cars 1999-05

Timing Belt, Cover, Sprockets, & Seal

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Lift the expansion tank and place it on top of the engine.
  4.  
  5. Install lifting beam 99-7103 or equivalent and tighten.
  6.  
  7. Remove or disconnect the following:

    Engine limiter
     
    Engine pad on the cylinder head
     
    Front transmission covers
     
    Right hand front wheel
     
    Inner fender liner
     
    Delivery line from the power steering pump
     
    Accessory drive belt
     
    Vibration damper
     
    Upper timing belt cover
     

  8.  
  9. Lower the engine slightly until the belt tensioner bolts can be accessed from beneath.
  10.  
  11. Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulleys correspond.
  12.  
  13. Slacken off the center bolt for the belt tensioner slightly and hold the center bolt still. Turn the tensioner clockwise to 10 o-clock.
  14.  
  15. Remove the timing belt.
  16.  


    Click image to see an enlarged view

    Fig. Identifying the timing marks

    Identifying the timing marks

    Click image to see an enlarged view

    Fig. V50 timing belt routing

    V50 timing belt routing

To install:

  1. Install the timing belt in the following order:
    1. Around the crankshaft
    2.  
    3. Around the idler pulley
    4.  
    5. Around the intake camshaft pulley
    6.  
    7. Around the exhaust camshaft pulley
    8.  
    9. Around the water pump
    10.  
    11. Onto the belt tensioner
    12.  

  2.  
  3. Carefully turn the crankshaft clockwise until the timing belt is tensioned. The belt must be tensioned between the intake camshaft pulley, the idler pulley and the crankshaft
  4.  
  5. Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position.
  6.  
  7. Then turn the belt tensioner eccentric back so that the indicator reaches the marked position in the center of the window and tighten the center bolt to 15 ft. lbs. (20 Nm).
  8.  
  9. Press the belt to check that the indicator on the tensioner moves easily.
  10.  
  11. Install or connect the following:

    Front timing belt cover
     
    Upper timing belt cover
     
    Vibration damper and tighten the center nut to 133 ft. lbs. (180 Nm) and 4 outer bolts to 18 ft. lbs. (25 Nm) plus 60 degrees.
     
    Accessory drive belt
     
    Delivery hose for power steering pump
     
    Inner fender liner
     
    Front wheel
     
    Front transmission covers
     
    Engine pad on the cylinder head
     
    Engine limiter
     

  12.  
  13. Remove the lifting beam.
  14.  
  15. Install the expansion tank.
  16.  

4-Cylinder Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Right hand engine cover
     
    Cover over the right headlamp
     
    Accessory drive belt
     
    Front timing cover
     
    Servo reservoir
     

  4.  
  5. Position Volvo lifting beam 999 5006 or equivalent slightly in front of the front lifting eyelet for the engine. Use Volvo lifting arm 999 5383 or equivalent and Volvo lifting hook 999 5460 or equivalent to raise the front of the engine a few millimeters.
  6.  
  7. Remove or disconnect the following:

    Right-hand engine mount
     
    Right front wheel
     

  8.  
  9. Turn the crankshaft until the markings on the crankshaft and camshaft pulley correspond. Turn the crankshaft a further14
  10.  
  11. Slacken off the center screw for the belt tensioner slightly.
  12.  
  13. Turn the tensioner clockwise to 10 o'clock.
  14.  
  15. Remove or disconnect the following:

    Air baffles
     
    Lower belt cover
     
    Timing belt
     

  16.  


    Click image to see an enlarged view

    Fig. Timing belt alignment markings

    Timing belt alignment markings

To install:

  1. Turn all the pulleys listening for bearing noise. Check to see that the contact surfaces are clean and smooth. If the tensioner pulley lever or idler is seized, replace it.
  2.  
  3. If replacing with a new idler pulley, tighten to 18 ft. lbs. (24 Nm).
  4.  
  5. If replacing tension pulley, screw into place using the center bolt by hand. Ensure that the tensioner fork is centered over the cylinder block rib. Ensure that the Allen hole on the eccentric is at "10 o'clock".
  6.  
  7. Install the timing belt in the following order:
    1. Around the crankshaft sprocket
    2.  
    3. Around the idler pulley
    4.  
    5. Around the camshaft sprockets
    6.  
    7. Around the water pump
    8.  
    9. Onto the belt tensioner
    10.  

  8.  
  9. Carefully turn the crankshaft clockwise until the timing belt is tensioned. The belt must be tensioned between the intake camshaft pulley, the idler pulley and the crankshaft
  10.  
  11. Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position.
  12.  
  13. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window and tighten the center bolt to 15 ft. lbs. (20 Nm).
  14.  
  15. Press the belt to check that the indicator on the tensioner moves easily.
  16.  
  17. Install or connect the following:

    Lower belt guard
     
    Air baffles
     
    Upper timing cover
     

  18.  
  19. Turn the crankshaft two turns. Check that the markings on the crankshaft and camshaft pulley correspond.
  20.  


NOTE
Check that the indicator on the belt tensioner is within the marked area.

  1. Install or connect the following:

    Lower timing cover
     
    Front timing cover and tighten to 9 ft. lbs. (12 Nm)
     
    Accessory drive belt
     
    Engine mount and tighten to 49 ft. lbs. (67 Nm)
     
    Servo reservoir. Tighten bolts to 37 ft. lbs. (50 Nm).
     
    Front wheel
     
    Right hand engine cover
     
    Cover over the right headlamp
     
    Negative battery cable
     

  2.  

5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine stabilizer brace
     
    Servo reservoir
     
    Expansion tank
     
    Accessory drive belt
     
    Front timing belt cover
     
    Right front wheel
     
    Inner fender liner
     

  4.  
  5. Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond.
  6.  
  7. Turn the crankshaft a further 1/4 turn clockwise and then back again until the markings correspond.
  8.  
  9. Remove the upper timing belt cover.
  10.  
  11. Slacken off the belt tensioner center screw slightly.
  12.  
  13. Hold the center screw still and turn the eccentric on the tensioner clockwise to 10 o'clock.
  14.  
  15. Remove the vibration damper using Volvo counterhold 999 5433 or equivalent.
  16.  
  17. Remove the camshaft belt.
  18.  

To install:

  1. Turn all the pulleys listening for bearing noise. Check to see that the contact surfaces are clean and smooth. If the tensioner pulley lever or idler is seized, replace it.
  2.  
  3. If replacing with a new idler pulley, tighten to 18 ft. lbs. (24 Nm).
  4.  
  5. If replacing tension pulley, screw into place using the center bolt by hand. Ensure that the tensioner fork is centered over the cylinder block rib. Ensure that the Allen hole on the eccentric is at "10 o'clock".
  6.  
  7. Install the camshaft belt over pulley wheel on the crankshaft.
  8.  
  9. Install the vibration damper and tighten the center nut to 133 ft. lbs. (180 Nm).
  10.  
  11. Install the timing belt in the following order:
    1. Around the crankshaft sprocket.
    2.  
    3. Around the right idler pulley
    4.  
    5. Around the camshaft sprockets
    6.  
    7. Around the water pump
    8.  
    9. Onto the tensioner pulley
    10.  

  12.  
  13. Carefully turn the crankshaft clockwise until the timing belt is tensioned. The belt must be tensioned between the intake camshaft pulley, the idler pulley and the crankshaft
  14.  
  15. Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position.
  16.  
  17. Then turn the belt tensioner eccentric back so that the indicator reaches the marked position in the center of the window and tighten the center bolt to 15 ft. lbs. (20 Nm).
  18.  
  19. Press the belt to check that the indicator on the tensioner moves easily.
  20.  
  21. Install or connect the following:

    Front timing belt cover and tighten to 9 ft. lbs. (12 Nm)
     
    Upper timing belt cover
     
    Accessory drive belt
     
    Servo reservoir
     
    Expansion tank
     
    Engine stabilizer brace. Tighten the bolts at the suspension turrets to 37 ft. lbs. (50 Nm). Tighten the engine bracket bolt to 59 ft. lbs. (80 Nm).
     
    Inner fender liner
     
    Front wheel
     
    Negative battery cable
     

  22.  


    Click image to see an enlarged view

    Fig. Timing mark alignment

    Timing mark alignment

    Click image to see an enlarged view

    Fig. Belt tensioner

    Belt tensioner

    Click image to see an enlarged view

    Fig. Timing belt installed

    Timing belt installed

    Click image to see an enlarged view

    Fig. Tension indicator at different temperatures

    Tension indicator at different temperatures

6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Engine stabilizer brace
     
    Pipes between the turbocharger (TC) and charge air cooler (CAC), if equipped
     
    Pipes between the air cleaner (ACL) and turbocharger (TC), if equipped
     
    Clamp from the air intake pipe for the turbocharger (TC) for cylinders 1, 2 and 3, if equipped, and twist pipe toward the rear
     
    Accessory drive belt
     
    Front timing belt cover.
     
    Servo reservoir
     
    Expansion tank
     
    Right front wheel
     
    Inner fender liner
     

  4.  
  5. Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulleys correspond. Turn the crankshaft a further14
  6.  
  7. Turn back counter-clockwise until the markings correspond.
  8.  
  9. Remove the upper timing belt cover.
  10.  
  11. Remove or disconnect the following:

    Vibration damper
     
    Belt cover behind the crankshaft pulley for the auxiliaries belt
     

  12.  
  13. Slacken off the center screw for the belt tensioner slightly.
  14.  
  15. Hold the center screw still and turn the tensioner eccentric counter-clockwise to 10 o'clock.
  16.  
  17. Remove the timing belt.
  18.  


NOTE
Do not turn the camshafts or the crankshaft when the timing belt has been removed.

To install:

  1. Turn all the pulleys listening for bearing noise. Check to see that the contact surfaces are clean and smooth. If the tensioner pulley lever or idler is seized, replace it.
  2.  
  3. If replacing with a new idler pulley, tighten to 18 ft. lbs. (24 Nm).
  4.  
  5. If replacing tension pulley, screw into place using the center bolt by hand. Ensure that the tensioner fork is centered over the cylinder block rib. Ensure that the Allen hole on the eccentric is at "10 o'clock".
  6.  
  7. Install the camshaft belt over pulley wheel on the crankshaft.
  8.  
  9. Install the timing belt in the following order:
    1. Around the crankshaft sprocket.
    2.  
    3. Around the right idler pulley
    4.  
    5. Around the camshaft sprockets
    6.  
    7. Around the water pump
    8.  
    9. Onto the tensioner pulley
    10.  

  10.  
  11. Carefully turn the crankshaft clockwise until the timing belt is tensioned. The belt must be tensioned between the intake camshaft pulley, the idler pulley and the crankshaft
  12.  
  13. Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position.
  14.  
  15. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window and tighten the center bolt to 18 ft. lbs. (25 Nm).
  16.  
  17. Press the belt to check that the indicator on the tensioner moves easily.
  18.  
  19. Install or connect the following:

    Accessory drive belt
     
    Vibration damper. Tighten the bolts to 26 ft. lbs. (35 Nm) plus 50 degrees
     
    Inner fender liner
     
    Front wheel
     
    Front timing belt cover
     
    Expansion tank
     
    Servo reservoir
     
    Clamp for the air intake pipe
     
    Pipes between the air cleaner (ACL) and turbocharger (TC), if equipped
     
    Pipes between the turbocharger (TC) and charge air cooler (CAC), if equipped
     
    Engine stabilizer brace. Tighten the bolts at the suspension turrets to 37 ft. lbs. (50 Nm). Tighten the engine bracket bolt to 59 ft. lbs. (80 Nm).
     

  20.  

 
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