Page 1 of 8 2005 Volvo S40 2.4L Eng Base TIMING BELT REPLACEMENT - 2.4L & 2.5L TURBO, 5-CYLINDER REMOVAL & INSTALLATION CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. REMOVAL & INSTALLATION > TIMING BELT > REMOVAL Question: More info somewhere? 1. Lift coolant expansion tank out of holder and place on top of engine. Fit Lifting Beam (999-7103). See Fig 1. Fig 1: Installing Lifting Beam 2. Remove bolts for engine mount limiter. Remove limiter. Remove bolts holding engine mount to cylinder head. See Fig 2. Remove engine mount.

Page 2 of 8 Fig 2: Removing Engine Mount & Limiter 3. Remove front transmission cover bolts and covers. 4. Raise and support vehicle. Remove right front wheel. Remove fender liner. Lower vehicle so that timing belt pulley is visible and Lifting Beam is accessible. 5. Disconnect power steering pressure line from pump. See Fig 3. Clean any spilled fluid immediately. Seal line and pump opening.

Page 3 of 8 Fig 3: Disconnecting Power Steering Pressure Line From Pump 6. Remove outer accessory drive belt. Rotate outer tensioner clockwise and remove belt. 7. Remove vibration damper. Remove 4 outer damper bolts first using crankshaft center nut to counter. Use Counterhold (999-5433) to hold damper and remove crankshaft center nut. See Fig 4. Remove Counterhold and work vibration damper loose.

Page 4 of 8 Fig 4: Using Counterhold To Remove Vibration Damper Courtesy of VOLVO CARS OF NORTH AMERICA 8. Turn crankshaft clockwise until crankshaft and camshaft timing marks align. See Fig 5. Lower engine so that belt tensioner bolts are accessible from underneath.

Page 5 of 8 Fig 5: Aligning Crankshaft & Camshaft Timing Marks 9. Loosen belt tensioner center bolt slightly. Hold center bolt and turn eccentric clockwise using a 6mm Allen key. Turn to 10 o'clock position and remove timing belt from pulleys. NOTE: Tensioner and idler pulley will not be reused. 10. Remove belt tensioner and idler pulley. Discard both. REMOVAL & INSTALLATION > TIMING BELT > INSTALLATION NOTE: Timing belt tensioner and idler pulley MUST be replaced with timing belt.

Page 6 of 8 1. Fit new tensioner with center bolt. Ensure tensioner fork is centered over rib in engine block. Ensure Allen key hole on eccentric is at 10 o'clock position. Install new idler pulley and tighten bolts to specification. See TORQUE SPECIFICATIONS. 2. Ensure timing marks are aligned. Install timing belt in the following order: 1. Crankshaft. 2. Idler pulley. 3. Intake camshaft. 4. Exhaust camshaft. 5. Water pump. 6. Tensioner. NOTE: Engine MUST be cold to accurately adjust timing belt tension. Approximately 20 C (68 F) is a suitable temperature. At higher temperatures (engine at operating temperature or a high outside temperature, for example) the indicator is further to the right. See Fig 1. Fig 1: Adjusting Timing Belt Tension 3. Install crankshaft center nut. Turn crankshaft slowly clockwise until timing belt tension is correct. Belt must be in tension between intake camshaft pulley, idler pulley and crankshaft pulley. 4. Hold tensioner center bolt still and turn eccentric clockwise until tensioner indicator passes marked position. Then turn eccentric back so indicator reaches marked position in center of window. Hold eccentric still and tighten center bolt to specification. See Fig 2 and TORQUE SPECIFICATIONS. Ensure indicator is still in correct position.

Page 7 of 8 Fig 2: Adjusting Timing Belt Tensioner Courtesy of VOLVO CARS OF NORTH AMERICA 5. Press on timing belt between pulleys and ensure tensioner moves easily. Install upper timing cover. Turn crankshaft clockwise 2 revolutions and ensure crankshaft and camshaft timing marks align. 6. Ensure tensioner indicator is within marked area. If not, adjust belt tension again. If so, go to next step. 7. Install vibration damper. Use Counterhold (999-5433) to tighten crankshaft center nut. Tighten bolts to specification. See TORQUE SPECIFICATIONS. 8. Install outer accessory drive belt. Connect pressure hose to power steering pump. Do not forget to remove seals from pipe and pump openings. 9. Install fender liner and front wheel. Tighten wheel lugs to specification. See TORQUE SPECIFICATIONS. 10. Lower vehicle. Install front transmission covers. Install engine mount and limiter. Remove Lifting Beam. Fit coolant expansion tank. 11. Fit all remaining components. Start engine and check function.

Page 8 of 8 Fig 3: Identifying Timing Belt Routing