Instructions w/pics: Changing Timing Belt/Water Pump/Tensioner

Changing Timing Belt/Water Pump/Tensioner?

KC95Turbo » I just got done with a LONG day of working on the Volvo. I feel like I got into a fist fight with the thing. Anyway, I replaced the timing belt, TB tensioner, TB Idler, TB roller, and waterpump while I was down there and thought I would share some pics and info on it in case you were about to do it. If anyone has questions then please ask and I will help with what I can.

Timing Belt/Water Pump/Tensioner on Volvo 5-cylinder

Quick list of things I did in order to replace everything:

1. remove sparkplug cover
2. loosen 10mm bolt holding down the fuel lines down by turbo.
3. take out bolt holding the fuel lines up on top of motor.
4. take out 10mm bolts on the top timing cover, leave top timing cover on though!
5. lift coolant tank up and disconnect connector on bottom and put on top of motor, then take out 12mm bolt holding the main side timing cover and remove side timing cover.
6. turn serpentine belt tensioner and lock in a pin to hold it in place.
7. remove serpentine belt
8. remove the two 12 mm bolts holding down the serpentine belt tensioner and remove that.
9. Jack up car and support on stands
10. remove right front wheel
11. remove wheel well cover nut and fold back cover and clamp vise grips on it to hold it in place.
12. put a 30mm socket on the crankshaft pulley and turn clockwise with a BIG rachet until you can find the marks on the cam gears. Those marks were very hard to see, but after a while of looking for it I finally found them.
13. once you line up the marks on the cam gears, look down on the crankshaft gear and look in the valley of the gear for a small notch, it should line up with a mark above it on the block. If you dont see it, turn the engine over another rev and line up the cam marks again and look again for it.
14. once you line up all marks, remove the top timing belt cover and then the top bolt on the tensioner and then the lower bolt, i think they were 10mm. then remove.
15. Remove two 10mm bolts on the timing belt guard on the right side behind the crankshaft pulley and remove.
16. carefully slide timing belt off of cam gears and work it out around the crankshaft pulley, jacking up the motor a little helped give some clearance.
17. now remove the tensioner idler torx bolt (T-45 I believe), that is the only thing holding that in.
18. remove the two 10 or 12mm bolts holding down the TB roller and remove.
19. Drain coolant from radiator, use a 6mm allen wrench and find a hole in the bottom radiator guard, up in there will be a petcock that you take out with the wrench. open up the coolant expansion cap to allow it to drain.
20. Remove the coolant bolt on bottom front right side of motor and allow coolant to drain.
21. remove 7 10mm bolts holding the waterpump down and gently tap with a hammer or similar to break it loose. have a catch can below it to collect some coolant. remove the waterpump.
22. clean all of the old gasket off and then put new waterpump on w/new gasket and tighten all bolts down to 15Ft-lbs.
23. install the new TB roller, TB tensioner idler.
24. work the new timing belt on starting at the right side of the crank and then around to the left until its around the crank. then go around the idler and waterpump. now pull the belt tight on the right side around the roller and start it around the intake cam and over to the exhaust side. when you start the exhaust side you should put a bungee cord on the tensioner idler to give it tension. make sure that the right side between crank and intake cam is TIGHT. If it is then install the tensioner and pull the pin out of the tensioner rod to free it.
25. turn the crankover two full revolutions and make sure all of the alignment marks are still good.
26. the rest is just putting everything back together in reverse order and then refilling the cooling system with coolant.

Here are some pics:
Pic of everything off and about to put new waterpump in:

New parts next to old parts:

New parts on:

Almost Done!:

Well.. there ya go.. after a good 7 hours of work.. I finally finished. Some things that would’ve helped me:
-IPD serpentine belt tensioner tool
-better work gloves to protect my hands!
-a lower back brace!
-a helper

Instructions w/pics when Changing Timing belt/waterpump/tens