Important note Important note The intervals and procedures given are subject to alteration by the manufacturer at any time. Check the regularly updated Timing Belts section on our website to ensure that you are kept informed of any changes that may occur between issues of the Autodata CD. http://www.autodata-cd.com Timing belt replacement intervals Where possible the recommended intervals have been compiled from vehicle manufacturers' information. In a few instances no recommendation has been made by the manufacturer and the decision to replace the belt must be made from the evidence of a thorough examination of the condition of the existing belt. Apart from the visible condition of the belt, which is explained fully in the General Instructions/Toothed Timing Belts section, there are several other factors which must be considered when checking a timing belt: Is the belt an original or a replacement. When was the belt last replaced and was it at the correct mileage. Is the service history of the vehicle known. Has the vehicle been operated under arduous conditions which might warrant a shorter replacement interval. Is the general condition of other components in the camshaft drive, such as the tensioner, pulleys, and other ancillary components driven by the timing belt, typically the water pump, sound enough to ensure that the life of the replacement belt will not be affected. If the condition of the existing belt appears good, can you be satisfied that the belt will not fail before the next check or service is due. If the belt does fail, have you considered the consequences. If the engine is an INTERFERENCE type then considerable expensive damage may well be the result. The cost of replacing a belt as part of a routine service could be as little as 5 to 10% of the repair cost following a belt failure. Make sure your customer is aware of the consequences. If in doubt about the condition of the belt - RENEW it. Refer to the Toothed Timing Belts/Service Replacement section for further information relating to arduous or adverse operating conditions, inspection and service replacement. Replacement Interval Guide Replacement Interval Guide Volvo recommend: Timing belt: All model years: Check and adjust every 20,000 miles or 2 years. 96/97MY additions: Check at 10,000 miles or 1 year, 50,000 miles or 5 years and 90,000 miles or 9 years. 98MY additions: Check at 10,000 miles or 1 year and 90,000 miles or 9 years. Replacement every 80,000 miles or 8 years (tensioner must also be replaced). Injection pump belt: All model years: Check and adjust every 20,000 miles or 2 years. 96/97MY additions: Check at 10,000 miles or 1 year, 50,000 miles or 5 years and 90,000 miles or 9 years. 98MY additions: Check at 10,000 miles or 1 year and 90,000 miles or 9 years. 98MY: Replacement at 40,000 miles or 4 years, 80,000 miles or 8 years and then every 80,000 miles or 8 years (tensioner must also be replaced). 99MY : Replacement every 80,000 miles or 8 years (tensioner must also be replaced). The previous use and service history of the vehicle must always be taken into account. V410-22017
Check For Engine Damage Check For Engine Damage CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head. Repair Times - hrs Repair Times - hrs S/V70 TDI 1997-98 Check and adjust 0,90 Remove and install 2,10 Special Tools Special Tools Camshaft sprocket holding tool - Volvo No.999 564 Crankshaft pulley locking tool - Volvo No.999 564 Tensioner pulley spanner - Volvo No.999 564 Special Precautions Special Precautions Disconnect battery earth lead. DO NOT turn crankshaft or camshaft when timing belt removed. Remove glow plugs to ease turning engine. Turn engine in normal direction of rotation (unless otherwise stated). DO NOT turn engine via camshaft or other sprockets. Observe all tightening torques. Check diesel injection pump timing after belt replacement. Removal - Timing Belt Removal Engine upper cover. Coolant expansion tank. PAS reservoir (if required). Turbocharger air hoses. Auxiliary drive belt and tensioner. Timing belt upper cover [1]. Injection pump belt cover. Raise and support front of vehicle. Splash guard. RH front wheel. V410-22017
RH wheel arch liner. 1 1 1 Turn crankshaft to TDC on No.1 cylinder. Ensure timing marks aligned [2] or [3]. Ensure injection pump timing marks aligned [4]. NOTE: If not: Turn crankshaft one turn clockwise. Slacken injection pump locking bolt [5]. Remove keeper plate [6]. Tighten locking bolt to 30 Nm [5]. Hold camshaft sprocket. Use tool No.999 564 Slacken camshaft sprocket bolt one turn [7]. Loosen camshaft sprocket from taper using a drift through hole in timing belt rear cover. Lock crankshaft pulley. Use tool No.999 564 NOTE: Ensure crankshaft does not move. Slacken crankshaft pulley centre bolt [8]. Slacken crankshaft pulley bolts [9]. Crankshaft pulley locking tool. Crankshaft pulley bolts [9]. Crankshaft pulley centre bolt [8]. Crankshaft pulley [10]. Timing belt lower cover [11]. Tensioner. Timing belt. Installation - Timing Belt Installation 1 1 1 1 1 1 1 1 Ensure rear timing belt cover screw is marked with white dot [12]. If not: Remove rear timing belt cover screw [12]. Clean threads. Apply locking compound. Fit screw and tighten. Tightening torque: 10 Nm. Mark screw with white dot. Fit new tensioner pulley. Lightly tighten tensioner pulley bolt [13]. Ensure timing marks aligned [3] & [4]. Ensure injection pump locked in position with bolt [5]. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets. NOTE: Ensure engine temperature below 30 C before adjusting timing belt. Slacken tensioner pulley bolt [13]. Adjust belt tension until pointer is 2 mm below fixed mark [14]. Use tool No.999 5649 [15]. NOTE: If distance between pointer and fixed mark is exceeded: Back off tensioner pulley completely and repeat tensioning procedure. Tighten tensioner pulley bolt to 20 Nm [13]. Fit crankshaft pulley. Fit crankshaft pulley bolts [9]. Use new bolts. Fit crankshaft pulley centre bolt. Use new bolt. Lock crankshaft pulley. Use tool No.999 564 NOTE: Ensure crankshaft does not move. Tighten crankshaft pulley centre bolt. Tightening torque: 160 Nm + 180 [8]. Tighten crankshaft pulley bolts. Tightening torque: 20 Nm + 90 [9]. Remove crankshaft pulley locking tool. Tool No.999 564 Ensure timing marks aligned [2] or [3]. Hold camshaft sprocket. Use tool No.999 564 Tighten camshaft sprocket bolt according to identification number [7]. Class 8-85 Nm. Class 9-100 Nm. 1 20. 2 2 2 NOTE: Class number identified on bolt head. Slacken injection pump locking bolt [5]. Insert keeper plate [6]. Tighten locking bolt to 12,5 Nm [5]. Turn crankshaft 2 turns clockwise. Ensure timing marks aligned [2], [3] & [4]. V410-22017
2 2 2 Ensure tensioner pointer 2 mm below fixed mark [14]. If not: Repeat tensioning procedure. Install components in reverse order of removal. Removal - Injection Pump Belt Removal Access timing belt. Remove injection pump belt cover. Turn crankshaft to TDC on No.1 cylinder. Ensure timing marks aligned [2] or [3]. Ensure injection pump timing marks aligned [4]. NOTE: If not: Turn crankshaft one turn clockwise. If timing belt has not been replaced: Check distance between tensioner pointer and fixed mark [16] : If distance exceeds 14 mm: Renew timing belt and tensioner. If distance less than 14 mm: Adjust tensioner until pointer and lower edge of fixed mark aligned [17] & [18]. NOTE: Ensure camshaft sprocket can rotate freely during timing belt adjustment. Slacken injection pump locking bolt [5]. Remove keeper plate [6]. Tighten locking bolt to 30 Nm. Slacken guide pulley nut [19]. Turn guide pulley away from belt. Tensioner. Injection pump belt. Installation - Injection Pump Belt Installation 1 1 Fit new tensioner pulley. Lightly tighten tensioner pulley bolt [20]. Ensure timing marks aligned [2] or [3]. Ensure injection pump timing marks aligned [4]. Ensure injection pump locked in position with bolt [5]. Fit injection pump belt. Ensure belt is taut between sprockets on guide pulley side. Turn guide pulley until pointer aligned with cylinder head flange contour [21]. Use Allen key [22]. Tighten guide pulley nut to 25 Nm [19]. Slacken injection pump locking bolt [5]. Insert keeper plate [6]. Tighten locking bolt to 12,5 Nm [5]. Turn tensioner pulley anti-clockwise until pointers aligned [23]. Use Allen key [24]. NOTE: If floating pointer passes fixed pointer: Back off tensioner pulley completely and repeat tensioning procedure. Tighten tensioner pulley bolt to 20 Nm [20]. Install components in reverse order of removal. V410-22017
V410-22017