Volvo Truck 2003-05

Timing Belt, Cover, Sprockets, & Seal

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Removal & Installation



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

    The cross stay between the suspension turrets
     
    The upper timing belt cover
     
    The servo reservoir and the expansion tank. Lift up and place on top of the engine.
     
    The auxiliary drive belt
     
    The front timing belt cover.
     
    Remove the right front wheel
     
    Remove the nut from the cover in the fender liner
     

  4.  
  5. Install the upper timing belt cover
  6.  
  7. Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond
  8.  
  9. Turn the crankshaft a further14
  10.  
  11. Remove the upper timing belt cover.
  12.  
  13. Back off the center bolt of the belt tensioner slightly.
  14.  
  15. Hold the center bolt still. Turn the tensioner eccentric clockwise, using a 6 mm Allen key, to 10 o'clock.
  16.  
  17. Remove the timing belt from the tension pulley, camshaft pulley and water pump.
  18.  
  19. Remove the vibration damper. Use a counterhold. Work the vibration damper loose.
  20.  
  21. Remove the timing belt.
  22.  
  23. Spin the idler pulley and listen for noise. If replacing with a new idler pulley, tighten to 18 ft. lbs. (24 Nm).
  24.  
  25. Spin the tension pulley and listen for noise. When replacing, bolt the tension pulley into place using the center bolt. Screw in the center bolt by hand.
  26.  
  27. Ensure that the tensioner fork is centered over the cylinder block rib.
  28.  
  29. Ensure that the Allen hole on the eccentric is at "10 o'clock".
  30.  


    Click image to see an enlarged view

    Fig. Timing mark alignment

    Timing mark alignment

    Click image to see an enlarged view

    Fig. Belt tensioner-5-cylinder engine

    Belt tensioner-5-cylinder engine

    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

To install:

  1. Install the timing belt over the pulley on the crankshaft.
  2.  
  3. Install the vibration damper. Tighten the center nut. Tighten to 133 ft. lbs. (180 Nm).
  4.  
  5. Remove the counterhold and install new bolts. Tighten to 18 ft. lbs. (25 Nm) and angle-tighten 30 degrees.
  6.  
  7. Install or connect the following:

    Crankshaft
     
    The idler pulley
     
    intake camshaft pulley
     
    Exhaust camshaft pulley
     
    Water pump
     
    Belt tensioner.
     

  8.  


NOTE
The following adjustment is carried out on a cold engine. A suitable temperature is approximately 68°F. At higher temperatures, for example with the engine at operating temperature or at higher ambient temperature, the needle is further to the right. The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.

  1. Tension the timing belt as follows:

    Turn the crankshaft clockwise carefully until the timing belt is tensioned. The belt must be tensioned between the intake camshaft pulley, the idler pulley and the crankshaft
     
    Hold the center bolt on the belt tensioner secure. Turn the belt tensioner eccentric counter-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 and tighten the center bolt. Tighten to 15 ft. lbs. (20 Nm). Check that the indicator is in the correct position.
     

  2.  
  3. To check the alignment:

    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.
     

  4.  
  5. Install or connect the following:

    The front timing belt cover. Tighten to 105 inch lbs. (12 Nm).
     
    The upper timing belt cover
     
    install the auxiliaries belt
     
    The servo reservoir
     
    The expansion tank.
     

  6.  


NOTE
Ensure that the hoses are correctly positioned.



The engine stabilizer brace. Tighten the bolts at the suspension turrets. Tighten to 37 ft. lbs. (50 Nm). Tighten the engine bracket bolt. Tighten to 58 ft. lbs. (80 Nm).
 
The cover in the fender liner
 
The front wheel.
 

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

    The bolt holding the engine stabilizer brace to the bracket on the engine
     
    The bolts holding the engine stabilizer brace to the suspension turrets
     
    The engine stabilizer brace.
     

  4.  
  5. Remove the plastic pipes between the turbocharger and charge air cooler and between the air cleaner and turbocharger. Put them to one side.
  6.  
  7. Remove the clamp from the intake manifold for the turbocharger for cylinders 1, 2 and 3. Turn the upper section of the pipe towards the firewall.
  8.  
  9. Relieve the load from the belt tensioner. Remove the auxiliary belt.
  10.  
  11. Remove the upper timing belt cover.
  12.  
  13. Remove the front timing belt cover.
    1. The air duct, cover, surround and control module box
    2.  
    3. The hose between the thermostat housing and the expansion tank
    4.  
    5. The front timing belt cover.
    6.  

  14.  
  15. Lift up the servo reservoir and place it on top of the engine.
  16.  


NOTE
Ensure that the oil does not leak from the ventilation hole in the filler cap.

  1. Seal the hose between the expansion tank and the radiator. Disconnect the hose at the tank.
  2.  
  3. Lift up the expansion tank and place it on top of engine.
  4.  
  5. Raise the car.
  6.  
  7. Remove:

    The right front wheel
     
    The plastic nuts on the cover in the fender liner.
     

  8.  
  9. Install the upper timing belt cover.
  10.  
  11. Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulleys correspond.
  12.  
  13. Turn the crankshaft a further14
  14.  
  15. Then turn back counter-clockwise until the markings correspond.
  16.  
  17. Remove the upper timing belt cover.
  18.  
  19. Remove the 4 vibration damper bolts. Counterhold the crankshaft central nut.
  20.  
  21. Remove:

    The vibration damper
     
    The auxiliaries belt
     
    The belt cover behind the crankshaft pulley for the auxiliary belt.
     

  22.  
  23. Spray universal oil or similar around the rubber sleeve on the underside of the oil pump.
  24.  
  25. Remove the rubber sleeve.
  26.  
  27. Slacken off the center bolt for the belt tensioner slightly.
  28.  
  29. Hold the center bolt still. Turn the tensioner eccentric counter-clockwise using a 6 mm Allen key. Turn to 10 o'clock.
  30.  
  31. Unhook and remove the timing belt. Caution! Do not turn the camshafts or the crankshaft when the timing belt has been removed.
  32.  
  33. Spin the idler pulley and listen for noise. If replacing with a new idler pulley, tighten to 17 ft. lbs. (24 Nm).
  34.  
  35. Spin the tension pulley and listen for noise. When replacing, bolt the tension pulley into place using the center bolt.
  36.  

To install:

  1. Screw in the center bolt by hand.
  2.  
  3. Ensure that the tensioner fork is centered over the cylinder block rib/bracket.
  4.  
  5. Ensure that the Allen hole on the eccentric is at 10 o'clock.
  6.  
  7. Install the belt as follows:

    crankshaft
     
    The idler pulley
     
    Intake cam
     
    Exhaust cam
     
    Water pump
     
    Tension pulley
     

  8.  


NOTE
Belt tension adjustment is carried out on a cold engine. A suitable temperature is approximately20C/68F.

  1. At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.
  2.  
  3. The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.
  4.  
  5. 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.
  6.  
  7. Hold the belt tensioner center bolt secure. Turn the belt tensioner eccentric clockwise until the tensioner indicator passes the marked position.
  8.  
  9. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window.
  10.  
  11. Hold the eccentric secure. Tighten the center bolt to 18 ft. lbs. (25 Nm).
  12.  
  13. Check that the indicator is in the correct position.
  14.  
  15. Press the belt to check that the indicator on the tensioner moves easily.
  16.  
  17. Install the upper timing belt cover.
  18.  
  19. Turn the crankshaft 2 turns. Check that the markings on the crankshaft and camshaft pulley correspond.
  20.  
  21. Check that the indicator on the belt tensioner is within the marked area.
  22.  
  23. Install the auxiliary belt around the pulley on the crankshaft.
  24.  
  25. Install:

    The rubber sleeve on the underside of the oil pump
     
    The vibration damper. Use new bolts. Tighten and angle tighten. See the torque chart. Use the crankshaft center nut as a counterhold
     
    The plastic nuts for the cover in the right-hand fender liner
     
    The right front wheel.
     

  26.  
  27. Lower the car.
  28.  
  29. Remove the front timing belt cover.
  30.  
  31. Tension the auxiliary belt.
  32.  
  33. Install the front cover:
    1. The front timing belt cover
    2.  
    3. The hose between the thermostat housing and the expansion tank
    4.  
    5. The surround, cover and air ducts for the control module box.
    6.  

  34.  
  35. Install:

    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.
     

  36.  
  37. Twist the intake pipe for the turbocharger for cylinders 1, 2 and 3 into position. Tighten the clamp.
  38.  
  39. Install the plastic hoses between the turbocharger and charge air cooler and between the air cleaner and turbocharger.
  40.  
  41. Tighten the hose clamps.
  42.  
  43. Install:

    The engine stabilizer brace. Tighten to 50 Nm
     
    The bolt holding the engine stabilizer brace to the bracket on the engine. Tighten to 80 Nm.
     

  44.  
  45. Check:

    Coolant level
     
    The servo fluid level.
     

  46.  

 
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