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Timing belt replacement on 1999 S80

Help, Advice, Owners' Discussion and DIY Tutorials on the Volvo S80 model. Sometimes called an "executive car", the S80 was and continues to be Volvo's top-of-the-line passenger car.

Timing belt replacement on 1999 S80

Postby mikeyfood » 19 Sep 2011, 22:33

Dealer is recommending I replace the timing belt, drive belt and tensioner. $375 for parts and total $1000! How hard is it do it yourself and how can I find out how?
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Re: Timing belt replacement on 1999 S80

Postby retcoastie » 31 Oct 2011, 18:47

I recently replaced the water pump in a T6. I took the timing belt off in order to do it. I had to come at it from the front wheel well. I removed the inner fender. That and moving the coolant and power steering tanks allowed about 2 inches of working room. Make sure you can locate the cam and crankshaft positions. I marked them with a grease pencil and in doing the work almost rubbed off the mark on the rear cam. Make your marks by scratching the gears!!!!!!!! I think I would count the belt teeth between the marks also to insure alignment.

I reset the tension piston by putting it in a vise and very slowly compressing it. It has a very small hole for the hydraulic fluid to pass through so be patient. Make sure the pin you put in is stronger enough. Wait awhile before reinstalling so that if the pin bends you can correct it on the bench, not in the 2" space in the car. :)

Good Luck

Ken
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Re: Timing belt replacement on 1999 S80

Postby boosted5cyl » 31 Oct 2011, 21:21

It's a little trickier than your typical timing belt job as you dont have a lot of room to work and the VVT pulley on the exhaust cam can cause people headaches if they dont lock the cams at the back of the head. To make it easy on yourself you should look into getting the cam lock tool.
Unless you know with 100% certainty when the parts were last done, I would do everything. By that I mean hydrualic dampener, pulleys and water pump. You could do the cam oil seals too, however this can be tricky without the cam lock tool.
'04 XC90 2.5T AWD (Angus) 134K.
'99 S80 T6 (Medusa) 214k. On borrowed time LOL
'98 V70 T5 (Vivienne). RIP @ 228K. Spun rod bearings.
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Re: Timing belt replacement on 1999 S80

Postby UncleBoost » 20 Nov 2011, 20:26

I too am faced with this delimna. Head is Done, back on and torqued down....now comes the confusing part Installing the Cams, finding what cylinder is should be where...I put the engine @TDC, which I read thats where it should be, and I also read it's not... can someone clarify please!!!!??.. I can see the mark on the Crank mount where the large plate bolts to. This mark is nowhere near TDC for Cyl 1. Am I correct in saying Lining the Crank with the vertical Hash, and Locking the Camshafts with a Lock tool, Will this be the correct way to BEGIN the belt placement? Does the Lining of crank mark, and the locking of the cams take the complication out of the equation as far as MECHANICALLY Not having to be TDC? Does this mean theoretically if the belt were on, and 2 complete revs by hand of the crank there would be no interference? Or do I need to go thru that treacherous procedure for VVT Cam installation?.. Please Help!! Stuck at this point.. The various write ups I've seen seem to be contradictory in critical areas...What the Official procedure for the 2000 S80 T6 Twin turbo with VVT? VVT is on the Exhaust Cam...I can supply photos if needed... I have the engine at TDC, the mark on the Crank is about @ the 2 oclock position...
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Re: Timing belt replacement on 1999 S80

Postby boosted5cyl » 20 Nov 2011, 20:37

Basically you can forget about TDC, its not relevant for your motor. When the marks line up on the crank pulley and oil pump, you will not be at TDC. This is normal. Whats relevant is that everything is on its appropriate marks when you start putting the belt on.
My recommendation would be to remove the starter motor, pull the allen plug behind it and drop a 3/8" extension into the hole to ensure you are lined up on the crank and more importantly, that you stay there.

In terms of setting the VVT, the end goal is to have the inner hub fully tensioned (turned clockwise) when the marks on the crank, cams and cam pulleys line up.
'04 XC90 2.5T AWD (Angus) 134K.
'99 S80 T6 (Medusa) 214k. On borrowed time LOL
'98 V70 T5 (Vivienne). RIP @ 228K. Spun rod bearings.
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Re: Timing belt replacement on 1999 S80

Postby UncleBoost » 20 Nov 2011, 21:39

Now after 2 weeks of reading over various posts, procedures, this is the ABSOLUTE BEST explanation I've read.!!! When I get home I'll post Fotos of what have so far. This is like finding a UFO crashed in the back yard....and a schematic to the ship! I'll be in touch in a few hours... Thanks!
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Re: Timing belt replacement on 1999 S80

Postby boosted5cyl » 20 Nov 2011, 22:15

Yeah its one of those concepts that easy in principle, but can be hard to describe. Post back if you have issues.
'04 XC90 2.5T AWD (Angus) 134K.
'99 S80 T6 (Medusa) 214k. On borrowed time LOL
'98 V70 T5 (Vivienne). RIP @ 228K. Spun rod bearings.
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Re: Timing belt replacement on 1999 S80

Postby UncleBoost » 20 Nov 2011, 23:53

Here are some photos of where I am in this task.
Image
Asking, IS this where I need to Align the Green mark with the Red Reference?

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INTAKE Cam....With the Cam installed in the head, Should the OFFSET Slash be Below or Above the Centerline?
Where should the EXHAUST Slash Be Below or Above Centerline?
Image

I will post pictures later of the Cam shaft Gears. The Intake cam gear was removed from the Camshaft BEFORE I bought the car. The V V T Camshaft is still in Tact. I looked at BOTH gears and found the FACTORY Marks for both COGS...Are the factory marks on the Cogs the reference to marks that line up with the cutouts in the Plastic Timing Backplate?
Thanks
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Re: Timing belt replacement on 1999 S80

Postby UncleBoost » 13 Dec 2011, 21:55

boosted5cyl wrote:Basically you can forget about TDC, its not relevant for your motor. When the marks line up on the crank pulley and oil pump, you will not be at TDC. This is normal. Whats relevant is that everything is on its appropriate marks when you start putting the belt on.
My recommendation would be to remove the starter motor, pull the allen plug behind it and drop a 3/8" extension into the hole to ensure you are lined up on the crank and more importantly, that you stay there.

In terms of setting the VVT, the end goal is to have the inner hub fully tensioned (turned clockwise) when the marks on the crank, cams and cam pulleys line up.


Image

Ok so looking at my Diagram, when I 1st install the cams, Locked, Cranked mark lined up, Crank Locked with extension, I install the V V T hub/gear (gear with the 3 bolts lightly snugged full left) 1.5 teeth away from Timing mark, no tension on the hub yet and Center Bolt snugged. When I turn the gear AGAINST the spring until it stops or bottoms out, (Timing mark on gear should line up Dead Nuts with the timing cover reference) IS THAT where I torque the V V T center bolt to 120nm? Will the hub spring back when I let the gear go? Or will the gear stay lined up with the mark? This is where I get confused...

Thanks for you help.
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Re: Timing belt replacement on 1999 S80

Postby UncleBoost » 13 Dec 2011, 21:57

..so basically keep "Easter egging" the hub position to achieve LINED UP MARKS with bolt Fully Torqued to 120nm?
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Re: Timing belt replacement on 1999 S80

Postby UncleBoost » 21 Dec 2011, 02:39

Ok...so I have it all down. Cams are Locked, (I gotta build a better lock tool to withstand the 120nm of torque though)..I have pictures here with Questions... I presume I am to be ALIGNING the Factory mark with the Square Slots in the timing cover..as In Center the Hash mark? .. my only question is am I centering the Hash mark or the "U" shaped Valley/ notch in the Cog / Gear pulley? See the Photos below...this is where I am now....


Image
INTAKE CAM~ Timing mark aligned with Cover slot

Image
Factory mark in reference with and relation to the Width of the notch and Cog valley/tooth


Image
VVT Hub @ Rest, 1.5 teeth from Mark in Timing Cover.


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VVT Hub, Limit postion. Before it was 1.5 teeth from Mark...This photo is with the VVT Hub Loaded @ it's Limit. The Cog was passed the cover slot so I back it up while still holding tension on the VVT Spring/ Hub to Align with the Slot....Is this the wrong thing to do? ( This the Best Angle I could get with the Camera... so I tried to make a Parallax line to show the correlation.

Image

Image

Image
This photo I took from from the Top. I matched the timing mark and Scribed it on the cover so you can see how it lines up with the Gear Cog "U" or Valley..

AS soon as you guys recommend or guide me here...I'll begin to install the Timing Belt.. Everything is Locked and Loaded.. I will build a Better Cam Shaft lock tool however.
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Re: Timing belt replacement on 1999 S80

Postby UncleBoost » 22 Dec 2011, 14:08

*Bump
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Re: Timing belt replacement on 1999 S80 Better Mouse trap

Postby UncleBoost » 23 Dec 2011, 05:26

With the force of trying to Torque the VVT camshaft to 120nm, My Cam lock tool was a little flimsy and began to flex alot.. So I had to build a Bigger and Better one where I milled down some Angle iron to 4.523mm to fit the slots in my cams like a honeymoon Fit....


Image

Image

Image

Image
I was using my 1st Camshaft lock tool from my 850 R.. I hope these will stand the extra torque..
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Re: Timing belt replacement on 1999 S80

Postby UncleBoost » 24 Dec 2011, 15:42

Ok...since it seems I'm the only one who has time to fool with this.. :lol: I've taken the Bull by horns and did what Common sense humans may do...exactly like I've Read. After NOT trusting my Old 850 Static Camshaft Locking Mechanism since all you need is to lock the Cams in place, the structure was not able to withstand 120nm (88 ft-lbs) or torque for the V V T cam. So I had to build a Better mouse trap so to speak.

Image
See the difference? :o

Now, after torquing the V V T Hub, my marks aligned like the many Write-ups I've read.

Image
Intake camshaft, Belt installed, tensioned, 2 revs on the Crank, no interference, here is where I ended.

Image
Can't get an absolute perpendicular angle on the taking this photo but you can see Parallaxingly speaking, it is in the mark when viewed from a afar... The VVT Hub is at it's Spring Stop limit, Marks Aligned, Crank Aligned...It's time for a compression test and then Ignition once everything is back on. The only thing i DON'T like is the Fact that my (Exhaust) Cam Cog, the 3 hub bolts are almost at their limit (bolts far left in the slot) by about 1-2mm...I was thinking they should be closer to the center but this is what I have.
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