Volvo: 2004 S80 2.5T timing belt, vibration damper, center screw

Question
I am looking for any kind of detailed procedure for replacing the timing belt on this vehicle. SO far my search has led me nowhere. Do you know of any sources or do you have a procedure you could share?
Thanks

Answer
Josh,
2004 Volvo S80 L5-2.5L Turbo VIN 59 B5254T2  
Vehicle Level Engine, Cooling and Exhaust Engine Timing Belt Service and Repair
Replacing the Timing Belt  
Replacing the Timing Belt
Notes
Timing belt, replacing
Special tools: 999 5433

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 is always correct. Remove components

Caution: Remove the ignition key.

Remove:



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.

Warning: Ensure that no power steering fluid is spilled. Extremely flammable.

the auxiliaries belt

the front timing belt cover.

Position the engine according to the marking



Remove the right front wheel

Remove the nut from the cover in the fender liner

Install the upper timing belt cover

Turn the crankshaft clockwise until the markings on the crankshaft and camshaft
pulley correspond

Turn the crankshaft a further 1/4 turn clockwise and then back again until the
markings correspond. The markings are illustrated

Remove the upper timing belt cover.

Removing the timing belt



Slacken off the belt tensioner.

Slacken off the center screw for the belt tensioner slightly. Hold the center
screw still. Turn the tensioner eccentric clockwise using a 6 mm Allen key to 10
o'clock.

Remove the timing belt from the tension pulley, camshaft pulley and water pump.



Remove the vibration damper.

Remove the vibration damper. Use counterhold 999 5433. Work the vibration damper
loose. Remove the timing belt

Checking the tensioner pulley and idler pulley
Check bearing wear:



spin the idler pulley and listen for noise. If replacing with a new idler pulley,
tighten to 24 Nm

spin the tension pulley and listen for noise. When replacing, screw the tension
pulley into place using the center screw.

Screw in the center screw 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".

Installing the timing belt



Install the timing belt over the pulley on the crankshaft.

Install the vibration damper. Tighten the center nut. Tighten to 180 Nm . Use
counterhold 999 5433.

Remove the counterhold and install new screws.

Tighten the screws. Tighten to 25 Nm and angle tighten 30°

Install the new belt in the following order:

crankshaft

the idler pulley

intake camshaft pulley

exhaust camshaft pulley

water pump

belt tensioner.

Tighten the timing belt



This adjustment is carried out on a cold engine. A suitable temperature is
approximately 20°C/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.

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 screw 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 screw. Tighten to 20 Nm .

Check that the indicator is in the correct position.

Check
Checking markings:



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.

Reinstall
Reinstall the removed components:



the front timing belt cover. Tighten to 12 Nm

the upper timing belt cover

install the auxiliaries belt

the servo reservoir

the expansion tank.

Note: Ensure that the hoses are correctly positioned.

the engine stabilizer brace. Tighten the screws at the suspension turrets.
Tighten to 50 Nm . Tighten the engine bracket screw. Tighten to 80 Nm .

Wipe clean and check the engine compartment

the cover in the fender liner

the front wheel.

Checking work
Function test:

Test drive the engine.