Idler Pulley Removal

[a_e_cole]

09 S80 V8. I had the lower idler pulley go bad. When I tried to take it out to change it the bolt hits the frame rail. Any ideas on how to get this out?

[Roger_850T]

I looked through the procedure, and it doesn't say anything special to do to avoid the frame rails. Just remove the upper torque rod, one wire, and what looks like a power steering pipe. Don't know if that's helpful or not...

Roger

[a_e_cole]

I managed to get a hold of a Volvo tech. On the S80 the engine has to be unbolted form the mounts and either lifted or lowered to get the bolt to slide out. I am going to attempt taking the lower motor mount out and lowering the engine this weekend since a lot more is involved in lifting it out. It was certainly an over site when they shoe horned the V8 under the hood of the S80. Also in my research I found out the drive axle has to come out to change the alternator if it fails. Lot of work to have such an amazing engine shoved under the hood.

[a_e_cole]

UPDATE: I attempted to take the motor mount out that is located at the crank. I got the front bolt off but the rear one would not come out despite many efforts and penetrating oil. It just was not going to come out. I called in some extra help and we came up with a unique solution. Right above where the bolt hits the frame rail is a hole about 17 mm big hole. With the engine unbolted from the motor mount and lifted a little bit the head of the bolt would go in to the hole but the shoulder of the bolt stopped it. We took a step up drill bit and cut off the end that was smaller than the hole to make it shorter. With the step up drill bit in the hole we applied pressure on it with a flat pry bar and turned it with a wrench. This takes a lot more time than if you had a drill but eventually you will widen the hole large enough to where the stubborn bolt will slide in to the frame rail with the engine lifted slightly letting you get the pulley and it out. While not ideal it is probably faster than taking the motor mount out to drop the engine two inches if you can even get the bolts to break loose. It seems when the mounts need replaced the axle will have to come out so a ratchet and pull handle could get on it to break it loose.

[Roger_850T]

Wow, that's quite an ordeal! I'm glad you were able to get it in the end though.

Roger

[ThommyKent]

It`s easier to cut the head of the bolt with a small hacksaw ( it`s mild steel ) then you can get the bolt out and the pulley. Then enlarge the hole your tool of choice. I used a small air angle grinder with a rotary file bit. You could use a file.