New timing belt on my '92 960 will not clear tensioner roller

jdm1 · Post by **jdm1** » 14 Aug 2019, 10:06

Hope you guys can give me some help. I am changing the timing belt on my new to me '92 960 sedan. No service records came with the car so this was first on the list. Got a new Aisin water pump and timing kit and got everything apart. I had lined up all the timing marks before removing the old belt. Got all the new parts in and started to put the belt on. I kept the belt nice and snug until I got to the tensioner roller. Now I cannot get enough slack to get the belt over the tensioner roller. It looks like I need about 1/8 of an inch. The belt has no slack in it and is positioned correctly on the crank. Am I missing something? Should it be this hard to get the new belt on? No, I have not pulled the hydraulic tensioner pin. This is my first 960 TB. I do not remember fighting to get the belt on any of my red-block engines. Thanks John

Post by **RickHaleParker** » 15 Aug 2019, 16:13

Look at the bottom of the crank gear.
May sure the belt is on the bottom of the Crankshaft gear and not on the guard next to the bottom of the Crankshaft gear.

Gwbunce · Post by **Gwbunce** » 17 Aug 2019, 06:12

Compress the tensioner with a vice and invert a pin that you can remove after installed. Volvo has a special tool for this but I always found ways to hold the tensioner back while you slip the belt on.

dm635 · Post by **dm635** » 20 Aug 2019, 15:04

one thing on the 960 is there is a post sticking out below the crank pulley. If you're not aware of this post it's very easy to miss it. And I see how that would keep the belt from seating properly. and if you were able to get it to fit you would instantly trash valve timing due to the belt not properly timed. Would be a bad day.

Post by **jimmy57** » 20 Aug 2019, 19:56

You did remove the hydraulic tensioner cylinder and compress it didn't you? You can fit the belt and then install the tensioner cylinder last.

dm635 · Post by **dm635** » 21 Aug 2019, 07:41

I've done quite a few timing belts on the 960. I'm on my 4th 960 now and have had my current one over 6 years. The tensioner is pinned and in place before sliding the belt on.

Do look for the post that sticks out directly below the crank pulley. Cant see it looking straight down, you'll see it from the bottom. The belt must clear that post sticking out or else the belt will not be fully seated at the bottom of the crank pully. Let's say the 6:00 position.

As far as timing belts go the 960 is relatively easy in my opinion. But I've done enough of them that I have my own sequence.

jdm1 · Post by **jdm1** » 29 Aug 2019, 12:22

Thanks everyone, I did get it on and yes, it was not fully on the crank pulley. I was replacing everything so the tensioner was pinned. It still seemed tight but I finally got it in place and the car is running perfectly. I appreciate the responses.

dm635 · Post by **dm635** » 30 Aug 2019, 16:54

Consider yourself lucky. Had you been able to get the belt on and not fully seated on the crank pulley, you'd have had to replace the head at a minimum. Most 960's are thrown away at that point due to cost. I've done an engine and transmission swap on my 960 because I love these cars. But no way would have I have paid someone else to perform the expensive repairs.

jdm1 · Post by **jdm1** » 04 Sep 2019, 06:31

Feel the same way. I love this car, had another years ago and was always sorry I sold it. This one is in great shape except the AC. Where do you source AC parts for the 960? Thanks in advance,

dm635 · Post by **dm635** » 12 Sep 2019, 06:46

Just got to do another belt change on my 960 yesterday. Timing belt idler roller was starting to scream on the 1st start of the day. Started a couple weeks ago and would last about 15 seconds, it got to where it was lasting about 10 minutes. Belt only had 20K on it, but I went ahead and did the belt since it was off. Idler roller had a lot of friction while in my hand. So no telling how much time I had before the bearing locked up or threw the belt.