$10,000 S80 Challenge Topic is solved

[pgill]

Because the OAP (clutched pulley) is connected to the READ and it is being driven directly the belt will move easily in one direction with the engine off and not at all in the opposite direction. (Note: this isn't true for my AUDI, the belt is driven by the crankshaft pulley and it won't move in either direction, the Volvo design is very easy to inspect and see if it is still working)

I check the pulley every oil change to make sure that it moves easily in one direction.

And then replace if it stops working or every 10 years which ever comes first.

[Luca17as]

Dear Paul,

Thank you very much for your reply and clarification about OAP vs OAD, now i'll go with the OAP.
The matter is that mine 2 engines have from the factory two different pulley, in the FL2 i've found the regular black OAD pulley, in the S80 i find a metal finished OAP, BUT there's a more important difference between these pulleys, for some reason the shaft on the S80 is 3mm shorter than expected, so there is no pulley on the market that i can buy and and simply fit, i have to make a 3mm metal shim in order to fit a new pulley on the S80.
I will buy a new OAP like your Proparts, and than add the 3mm shim.

Thank you !

[pgill]

Luca,

I think the machining mark you identified is used to press the pulley together not as a clearance for the engine.

Looking at the INA website shows the same part number for a 2008 LR2 and 2010 S80

https://webcat.schaeffler.com/web/schae ... owResult=1

https://webcat.schaeffler.com/web/schae ... 4227&csc=1

The drawing is a bit confusing because its a generic drawing

INA_1.jpg (75.73 KiB) Viewed 2447 times

For the part that I removed from my S80 the measurement that you are making is 10.5 mm

This is exactly the center of the third valley that holds the belt.

If you are at the third valley then you are good

I modified the sketch to show what the part actually looks like

INA_2.jpg (27.93 KiB) Viewed 2447 times

Thanks

Paul

[Luca17as]

Thank you very much for helping Paul !
The pulley on my LR2 measure 10.5mm, the same of your measurement, but for some strange reason the pulley on my S80 measure 7.5mm
If i try to fit the LR2 pulley on S80 it crash on the timing cover and it can't spin at all.
It seems that my particular engine has a 3mm shorter shaft, maybe a factory problem, solved with a pulley that is made and properly machined just for my engine !
I've measure even the shaft from the oil seal to the end and i've 3mm missing material.
I know that it's completely non sense, i own both engines from new, unfortunately the pulley that i need doesn't exist on the market, i've called INA and they confirm that my pulley is unique and not supply.
So i think that the only way is a new ProParts pulley with a 3mm shim on the back.
Attached you can find my strange pulley in comparison with the pulley that came from LR2.

Thank you very much

[pgill]

The Gap is small but mine doesn't rub

LR2 pictures

[Luca17as]

Dear Paul,

I've installed the Proparts OAP like yours and even brand new volvo belt/tensioner/idler/water pump etc, but now when i turn on the AC i'm experiencing a very strong ritmical vibration around 1200 RPM only with car in movement, in neutral it disappears, it seems like an old fridge compressor vibration, maybe i've misalligned the AC compressor and the belt forces when the AC turns on ?
Do you have this kind of vibration ?

Thank you very much

[pgill]

Luca,

Mine runs smooth.

With a new OAP and the engine turned off you should be able to move the belt easily in one direction.

Confirm that first.

You can compare your LR2 to you S80.

I didn't install the spring correctly between the Power Steering pump and the water pump the first time that I worked on the belt but that made a clicking sound not a vibration.

Let me know if the belt moves freely

Thanks

Paul

[Luca17as]

Dear Paul, the belt is free in one direction but absolutely to much tensioned, the tensioner works at idle is 95% of the total movement it can do !
Anyway i found the solution, the vibration was from the timing chain that was influenced by the belt overtension when AC turns ON and the tensioner is no longer capable to absorbe the vibration since it's at end of the excursion in metal to metal contact, in this situation all the system forces against the engine pulley and the timing chain.
I assume that in this type of configuration the tensioner is pretty much solid and the dampen function is achieved directly by the pulley itself, since i loose this function with an OAP instead of OAD i've no more damping action!
Now i installed a 1209mm lenght belt, the stock is 1200mm, with this setup the tensioner works at 70% of total excursion and it can dampen when the AC turn on and tight the belt.

[pgill]

Luca,

Excellent solution!!!!

For both of my 3.2 I installed the Continental 6K1200

And I believe that the 1200 is the length in millimeters

The timing chain also has a tension-er and if you don't allow the belt to move then the chain could be affected as you indicated.

That is an interesting result.

Great work finding a solution to the problem!!!!

Take care

Paul

PS I think that my tension-er is close to the 70% compressed as you indicated, this allows it to move in both directions and maintain tension on the belt

[KidsV70]

Sounds like an interesting challenge. Good luck! I'm with abscate, though- I think 10 cents a mile is optimistic. Look around online- Edmunds or some similar sites will have average cost of ownership or similar sorts of data to review.

Though I'm wondering about the comparison to older Volvos. Seems like it would be really hard to make that comparison in a systematic way. I guess you could compare cost of planned maintenance items over a given period of time.

Best,
Bert