Timing Belt: Service and Repair Dismantling the Belt Drive. Dismantling Belt drive, dismantling Special tools: , ,

Size: px

Start display at page:

Download "Timing Belt: Service and Repair Dismantling the Belt Drive. Dismantling Belt drive, dismantling Special tools: , ,"

Derick Merritt
5 years ago
Views:

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.

1 2005 Volvo XC90 L5-2.5L Turbo VIN 59 B5254T2 Page 1 Timing Belt: Service and Repair Dismantling the Belt Drive Dismantling Belt drive, dismantling Special tools: , , 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. Aligning the engine according to the marking Install the upper timing belt cover. Turn the crankshaft clockwise until the markings on the crankshaft belt pulley and the timing belt pulley are aligned with the markings on the oil pump and the upper timing belt cover. Remove the upper timing cover. emoving the vibration damper Remove the 4 screws. Use the crankshaft center nut as a counterhold. Install counterhold Remove the center nut. Remove counterhold Work the vibration damper loose. emoving the timing belt

Remove the timing belt from the timing gear pulley for the camshafts. Remove the timing belt.

2 2005 Volvo XC90 L5-2.5L Turbo VIN 59 B5254T2 Page 2 Slacken off the center screw for the belt tensioner slightly. Hold the center screw in place. Turn the belt tensioner eccentric clockwise to 10 o'clock using a 6mm Allen key. Remove the timing belt from the timing gear pulley for the camshafts. Remove the timing belt. emoving the crankshaft pulley Caution: The crankshaft must not rotate. Use puller and two 45 mm M8 screws with washers. Pull off the timing gear pulley. emoving the belt tensioner and idler pulley

emoving the oil pump Remove the belt protection from the oil pump. Remove the 4 screws for the oil pump. Carefully work the oil pump out.

3 2005 Volvo XC90 L5-2.5L Turbo VIN 59 B5254T2 Page 3 Remove the belt tensioner and idler pulley. Check the rolling surface and the bearings. Check for any noise. Check for any play in the bearings. Check that the rolling surfaces are smooth and clean. emoving the oil pump Remove the belt protection from the oil pump. Remove the 4 screws for the oil pump. Carefully work the oil pump out. Use a groove-cut chisel with stop lugs. Carefully draw the oil pump past the end of the crankshaft. Carefully clean the gasket face and mating surfaces. Remove tool hecking the oil pump

2005 Volvo XC90 L5-2.5L Turbo VIN 59 B5254T2 Page 4 Unscrew the oil pump. Note the position of the outer/inner pump wheel and the piston/spring for the relief valve. Clean and check all components.

A new sealing ring is first installed after the pump has been installed in the cylinder block. ssembling the oil pump Place the inner and outer pump wheels in the oil pump housing.

4 2005 Volvo XC90 L5-2.5L Turbo VIN 59 B5254T2 Page 4 Unscrew the oil pump. Note the position of the outer/inner pump wheel and the piston/spring for the relief valve. Clean and check all components. Check for damage and wear. Replace the oil pump in the event of a fault. When replacing the sealing ring. Carefully tap the sealing ring out. Use a carefully selected drift and hammer. A new sealing ring is first installed after the pump has been installed in the cylinder block. ssembling the oil pump Place the inner and outer pump wheels in the oil pump housing. The inner pump wheel has a inset surface around the hole for alignment to the crankshaft. The inset surface should be positioned towards the sealing ring in the oil pump housing. Install the spring and piston for the relief valve. Screw the pump together. Tighten the screws. See Specifications. emoving the coolant pump/timing belt cover

2005 Volvo XC90 L5-2.5L Turbo VIN 59 B5254T2 Page 5 Remove the screws. Carefully tap the pump pulley with a rubber mallet. Work the pump loose. Carefully clean the gasket face and mating surfaces.

Lift out the thermostat Remove the hose for the water heated crankcase ventilation. Remove the thermostat housing from the cylinder head. Carefully clean the gasket face and mating surfaces.

5 2005 Volvo XC90 L5-2.5L Turbo VIN 59 B5254T2 Page 5 Remove the screws. Carefully tap the pump pulley with a rubber mallet. Work the pump loose. Carefully clean the gasket face and mating surfaces. Remove the inner timing belt cover. emoving the thermostat and thermostat housing Remove the cover over the thermostat (Tx40). Lift out the thermostat Remove the hose for the water heated crankcase ventilation. Remove the thermostat housing from the cylinder head. Carefully clean the gasket face and mating surfaces. Remove the fuel pressure line. hecking the opening function of the thermostat The thermostat can be tested in warm water. Maximum opening must occur within 2 minutes in water at opening temperature. Marking 90 C Starts to open at 90 C Fully open at 105 C Assembly Belt drive, assembly Special tools: , , , 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.

2005 Volvo XC90 L5-2.5L Turbo VIN 59 B5254T2 Page 6 Tightening torque For tightening torques not in the text, see specifications. Installing the water pump Install the rear timing cover.

6 2005 Volvo XC90 L5-2.5L Turbo VIN 59 B5254T2 Page 6 Tightening torque For tightening torques not in the text, see specifications. Installing the water pump Install the rear timing cover. Screw into place at the three mounting points. Install the water pump with a new gasket. Apply thread sealant, P/N , to all the screws for the water pump. Tighten the screws crosswise. nstalling the oil pump Use a new gasket and a new O-ring around the oil pump housing and new screws. Alternatively, apply thread sealant to the underside of the old screw heads. Screw sliding sleeve into place at the front of the crankshaft journal. Press in the pump over the sliding sleeve. Install the screws as a guide. Carefully tap in the oil pump with a rubber mallet. Tighten the oil pump crosswise. Remove the sliding sleeve

be installed in one position on the crankshaft journal splines (see the

nstalling the idler pulley and belt tensioner nstall: - idler pulley.

nstalling the timing gear pulley for the camshafts Note: The purpose of the

7 2005 Volvo XC90 L5-2.5L Turbo VIN 59 B5254T2 Page 7 Installing front crankshaft seal See Oil pump/crankshaft seal, front, replacing. nstalling the crankshaft timing gear pulley Note: The timing gear pulley can only be installed in one position on the crankshaft journal splines (see the illustration). Carefully tap in the timing gear pulley with a rubber mallet. nstalling the idler pulley and belt tensioner nstall: - idler pulley. - the belt tensioner and the center screw so that the tensioner fork is centered over the cylinder block rib. Do not tighten - the lower belt guard at the oil pump - the fuel delivery line. nstalling the timing gear pulley for the camshafts Note: The purpose of the "Installing the timing gear pulley" section described here is to ensure that the VVT unit is correctly positioned and to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any

8 2005 Volvo XC90 L5-2.5L Turbo VIN 59 B5254T2 Page 8 later fault-tracing. Note: Do not turn counter clockwise during this procedure. Slacken off, but do not remove, the screws which secure the timing gear pulley to the variable valve timing unit. Press the variable valve timing unit and timing gear pulley onto the camshaft. Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly. Turn the variable valve timing unit counterclockwise as far as it will go. Remove the center screw. Position the upper timing cover. Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position. Continue turning clockwise until the timing gear pulley marking is 1 cogs before the marking on the upper timing cover. Check that the timing gear pulley is still in the limit position in the oval holes. Tighten the center screw in the variable valve timing unit. Check that the variable valve timing unit does not rotate when tightening. Install and tighten the center plug. Turn the variable valve timing unit clockwise to the limit position. Turn the timing gear pulley so that the markings correspond. nstalling the variable valve timing (VVT) unit on the intake camshaft Note: Do not turn counter clockwise during this procedure. Slacken off, but do not remove, the screws which secure the timing gear pulley to the variable valve timing unit. Press the variable valve timing unit and timing gear pulley onto the camshaft. Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly. Turn the variable valve timing unit counterclockwise as far as it will go. Remove the center screw. Position the upper timing cover. Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position. Continue turning clockwise until the timing gear pulley marking is 1½ cogs before the marking on the upper timing cover. Check that the timing gear pulley is still in the limit position in the oval holes.

2005 Volvo XC90 L5-2.5L Turbo VIN 59 B5254T2 Page 9 Tighten the center screw in the VVT unit.

Turn the variable valve timing unit clockwise to the limit position. Turn the timing gear pulley so that the markings correspond.

nstalling the timing belt Install the belt in the following order: - crankshaft - the idler pulley - intake camshaft - exhaust camshaft - coolant pump - belt

Check that the markings are correct. djusting the timing belt This adjustment is to be made with a cold engine. A suitable temperature is approximately 20 C/68 F.

9 2005 Volvo XC90 L5-2.5L Turbo VIN 59 B5254T2 Page 9 Tighten the center screw in the VVT unit. Check that the variable valve timing unit does not rotate when tightening. Install the center plug. Turn the variable valve timing unit clockwise to the limit position. Turn the timing gear pulley so that the markings correspond. inishing Tighten the center screw on the timing belt tensioner. Tighten to 5 Nm. nstalling the timing belt Install the belt in the following order: - crankshaft - the idler pulley - intake camshaft - exhaust camshaft - coolant pump - belt tensioner. Note: The variable valve timing units do not have a return spring and are easily dislodged when reinstalling the timing belt. Check that the markings are correct. djusting the timing belt This adjustment is to be made with 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. Hold the center screw secure and turn the belt tensioner eccentric clockwise until the tensioner indicator passes the marked position and reaches the limit position.

Turn the eccentric back so that the indicator reaches the marked position in the center of the window. Remember to hold the center screw secure at the same time.

10 2005 Volvo XC90 L5-2.5L Turbo VIN 59 B5254T2 Page 10 Tighten the 3 screws on the exhaust camshaft timing gear pulley. Tighten the 3 screws on the intake camshaft timing gear pulley. Note: Check that the variable valve timing units are in the limit position. Turn the eccentric back so that the indicator reaches the marked position in the center of the window. Remember to hold the center screw secure at the same time. Hold the eccentric secure. Tighten the center screw. Check that the indicator is in the correct position. emove: - camshaft adjustment tools from the rear edge of the camshafts - crankshaft stop the plug with a new sealing washer. hecking the markings and belt tension

2005 Volvo XC90 L5-2.5L Turbo VIN 59 B5254T2 Page 11 Press the timing belt to check that the indicator on the belt tensioner moves easily. Position the upper timing cover.

11 2005 Volvo XC90 L5-2.5L Turbo VIN 59 B5254T2 Page 11 Press the timing belt to check that the indicator on the belt tensioner moves easily. Position the upper timing cover. Turn the crankshaft 2 rotations and check that the markings on the crankshaft and camshaft pulleys correspond. Check that the indicator on the belt tensioner is within the marked area. Remove the upper timing cover. nstalling the vibration damper nstall: - the vibration damper. Use counterhold the crankshaft center nut. Remove counterhold the 4 screws. Use the crankshaft center screw as a counterhold. hecking the markings and belt tension Press the timing belt to check that the indicator on the belt tensioner moves easily. Position the upper timing cover.

12 2005 Volvo XC90 L5-2.5L Turbo VIN 59 B5254T2 Page 12 Turn the crankshaft two turns. Check that the markings on the crankshaft and timing gear pulley match up with the markings on the oil pump and upper timing cover respectively. Check that the indicator on the belt tensioner is within the marked area.

Replacing the oil pump / front crankshaft seal

"VCC097797 EN 20100518" 1(5) Replacing the oil pump / front crankshaft seal Special tools: 998 6187, 999 5433, 999 5455, 999 5919, 999 5747, 951 2050 Note! As the illustrations in the information are used