2007 S60 2.5T Serpentine Belt & Tensioner Topic is solved

[MoVolvos]

What is a stubby idler pulley? Link or photo?

Ye olde Volvo idler. Factory or the one replaced more than ~10 years ago, when the replacement was still good. I just change pulley these days. May start just regreasing the bearing preventative when I retire and have time for that

.
This is my first serpentine pulley on a Volvo. Perhaps I should just go with the olde? Link? The cover is easy to remove but is a thin piece of rubberized metal so have to be careful not to kink it. Gentle prying a large blade.
.
https://www.walmart.com/ip/Box-Cutter-R ... 5354394197
.

[volvolugnut]

This is the HF tool. I have not tried it on alternator.

volvolugnut

[vtl]

This is my first serpentine pulley on a Volvo. Perhaps I should just go with the olde? Link? The cover is easy to remove but is a thin piece of rubberized metal so have to be careful not to kink it. Gentle prying a large blade.
.
https://www.walmart.com/ip/Box-Cutter-R ... 5354394197
.

You can replace just the pulley: https://www.fcpeuro.com/Volvo-parts/XC7 ... &year=2005

The bearing is 6203RS. Can add more high-temp-high-speed grease into the fresh bearing, they often come half-dry.

[MoVolvos]

This is the HF tool. I have not tried it on alternator.

volvolugnut

.
The HB tool looks like it's for other make and model alternators. The serpentine belt tensioner uses a T60 Torx or H3/8 Hex to adjust / release the tensioner / belt with. A T50 is used for the pulley. The alternator has 3 bolts per video but we're suppose to loosen the 2 AC compressor bolt for some reason. Will figure that out when the time comes.
.

.

[MoVolvos]

This is my first serpentine pulley on a Volvo. Perhaps I should just go with the olde? Link? The cover is easy to remove but is a thin piece of rubberized metal so have to be careful not to kink it. Gentle prying a large blade.
.
https://www.walmart.com/ip/Box-Cutter-R ... 5354394197
.

You can replace just the pulley: https://www.fcpeuro.com/Volvo-parts/XC7 ... &year=2005

The bearing is 6203RS. Can add more high-temp-high-speed grease into the fresh bearing, they often come half-dry.

.
I'm about to order one for the old tensioner as a back up. Will see what the INA pulley grease looks like compared with the other new unit.
.

[cn90]

The reason for loosening the bottom 2 bolts on the AC compressor...if you don't loosen these 2 bolts, you will not be able to install the new alternator.

I posted some photos in forum in the thermostat, banjo bolt PCV DIY thread...

[vtl]

A/C compressor has 2 lower bolts and 2 upper bolts that it shares with the alternator. Compressor mounts stack with alternator mounts and push those against the plate. You need to slacken the lower bolts, so the compressor can be pulled up.

[MoVolvos]

.
The new tensioner and belt is smooth and quiet. It was drizzling so didn’t remove and regrease with the Lucas Red Tacky.

The H3/8 HEX socket worked perfectly but the 3/8 ratchet handle was short so struggled with finding good leverage pushing the tensioner down. The car is quieter though the broken pulley never made any noise to indicate it was failing till the last perhaps 1/2 hour before grenading .

In summary, removing the ECM enclosure and timing cover allowed for replacement from the top. Be sure to move the PWST reservoir together with the hose for more room.
.

.

[MoVolvos]

.
Thanks everyone for all the help!.

(EDIT) I did check the alternator pulley and it rotated smoothly while feeling like it was packed with grease. With the screw driver holding the impeller it didn’t rotate at all in the other direction.
.

[MoVolvos]

.
The alternator bolt was missing and driven a year under our ownership. From how dirty the bolt contract surface was it's been missing for sometime. Looking at the description on various parts websites found an equivalent at Lowe's. 2 bolts at half the price of a single on FCP. Was going to install it as a precaution but was too cold last week. Since FCP's order came today decided to install the Volvo OE.

Large pry bar for leverage and went in unhindered.
.

Alternator Bolt.png (1.13 MiB) Viewed 1118 times

.