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2000 Volvo V40 Question: Where can I downlond instructions on replacing a timing belt



RonLaFa, 1.9L 4 Cylinder Turbo, Green Bay, WI, January 26, 2011, 10:34

Where can I download instructions on how to replace a timing belt on a V40 volvo

2 Answers
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  • Answer #1

    January 26, 2011, 10:45

    good luck labor intensive job.


    Replacing toothed (timing) belt

    Special tools: 951 2661, 999 5433, 5006, 5383, 5460


    Note! Service interval for timing belt and tensioner pulley: 165,000 km/105,000 miles.

    Remove auxiliaries belt

    Remove the right engine compartment cover and the cover above the right headlight unit
    Release the auxiliaries belt by turning the pulley screw clockwise
    Remove the auxiliaries belt
    Release the belt tensioner (counterclockwise).

    Remove upper timing gear covers

    Remove two screws and remove upper cover by undoing the two clips at the side
    Remove the screw and take the cover off.

    Install lifting beam and lifting lug

    Note! Remove the nut from the body support.

    Position the lifting beam 999 5006 centrally above the engine and install the lifting lugs 999 5460 in the lifting eyes.
    Install the extra support 999 5383 (if necessary). Lift the engine up a few mm at the front.

    Remove engine mounting on timing gear side

    Remove three bolts and the screw from the mounting at body side and pull out the mounting with the rubber.

    Remove lower timing gear cover

    Undo bottom cover and move backwards.

    Remove engine bracket

    Remove the four bolts and pull bracket from engine. Lift engine if necessary.
    Turn wheel to the right.
    Open lid in side cover.

    Align timing gear and crankshaft according to the markings

    Place the upper cover in position.
    Turn the crankshaft clockwise until the markings, camshaft gear, inner timing gear cover and the crankshaft/gear wheel align with the oil pump housing.
    Remove upper rear timing cover.

    Remove timing belt at the top side

    Remove bolt (A) and take tensioner off
    Remove timing belt and move it downwards
    Clean and check the gears.

    Check idler pulley

    Rotate the pulley rapidly and listen for abnormal noise from the bearing.
    When replacing: torque setting idler pulley 25 Nm .
    Check that all pulley contact surfaces for the belt are clean and smooth.

    Remove the engine splashguards


    Remove timing belt at lower side

    Remove the two bolts from the snow cap
    Remove the timing belt and take it out with a turning movement
    Clean surrounding.
    Note: For additional Variable Valve Timing adjustment info see Variable Valve Timing, Adjustments See: Variable Valve Timing Actuator\Adjustments

    Install timing belt at lower side

    Place the timing belt between damper and engine block.
    Route belt upwards.

    Install cover plates

    Place the lower snow cover and fit the two bolts
    Place the front and rear engine splashguards.

    Install new timing belt and tensioner pulley

    Check timing marks
    Position the new tensioner, and finger tighten bolt (A)
    Turn excenter from tensioner in lowest position, see picture
    Route the belt around the crankshaft (1) and the idler pulley (2)
    Route the belt over both timing gears (3.4)
    Route the belt over the water pump (5) and around the tension pulley (6)
    Install upper rear timing cover on engine (do not tighten)
    Check alignment.

    Adjusting timing belt tension

    Tighten bolt (B) to 3 Nm
    Place a 6 mm hex tool in the tensioner and turn tensioner anti clockwise until the toothed belt is tensioned
    Move the adjuster until the indicator pin is in the middle (A)
    Tighten the bolt (B) to 20 Nm without moving the tensioner
    Re-adjust if necessary
    Press pin (A) clockwise and anti-clockwise to check.

    Check timing belt tension

    Rotate the crankshaft two revolutions and check that the markings on the crankshaft pulley and timing gears align with the marks on the timing gear cover
    Check the adjustment of the tensioner (indicator pin (A) in the middle)
    Adjust again if necessary
    Note! After adjustment always turn crankshaft twice.

    Remove upper timing cover.

    Install engine bracket

    Clean mounting pin, position bracket and install bolts. Tightening torque 35 Nm + 75°

    Install timing gear covers

    lower timing gear cover. Check lower cover and water hose fittings
    the top cover (1x screw) (B), torque setting 10 Nm
    the top timing cover and tighten.
    Note! Close lid in side cover move front wheels straight.

    Install auxiliaries belt

    Clean the pulley grooves
    Turn the tensioning device clockwise
    Install the auxiliaries belt as illustrated
    Release the belt tensioner (counterclockwise)
    Tighten the bracket. Torque to 10 Nm
    Install power steering hose. Torque 10 Nm .

    Install engine suspension on timing gear side

    Position the support on the engine and tighten the bolts (A) to 67 Nm
    Loosely install the bolts in the body support
    Remove the lifting beam 999 5006
    Tighten the body support (13) nut to 98 Nm .
    Test drive engine

    Start the engine and check function.
    Install the right engine compartment cover and headlight unit cover.

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  • Answer #2

    January 26, 2011, 11:08

    Roy's instruction is very accurate, but you might want to see some graphics also, which -unfortunately- we can't post here.
    You can find great repair manuals with step-by-step instructions, diagrams, parts locations and other important information here: http://bit.ly/mitchell_repair_manuals_online


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