Engine 850: B5234T/2.3/20v/T5: - How to change your poly/aux belt

Jod T5 · Jan 15th, 2007, 07:54

Changing the poly or auxiliary belt as it is otherwise refered to is a easy task that should not be beyond the ability of the home mechanic....The vehicle being used for this exercise is a 1996 855 T5....
There are a few belts to choose from depending on engine number and if you have air con or not...
The belt is situated on the o/s of the block between the timing belt and the front of the car....it cannot be seen in this picture but is situated under the power steering fluid holder

To undertake this operation you will require a tensioner movement tool or one can be fabricated from a strong strip of steel cut to the dimensions of 23mm wide and 50/60 mm long....

I would also STRONGLY recommed that you draw a picture of the belt routing which will assist in the re-installing of the new belt.....
Here is the belt tensioner, note the square hole where the movement tool needs to be inserted in...

Remove the coolant bottle, disconnect the wiring and place in in top of the spark plug cover...
Using an adjustable wrench to grip your movement tool insert the tool end into the hole...bear in mind to release the tension the wrench must be forced clockwise (toward the front of the car) so make sure you insert it giving the wrench about 130 degrees of travel without fouling on the power steering resevoir...

On the tensioner there is a very small hole into which a nail or the like can be inserted when the tension is fully released from the belt....move the wrench towards the front of the car as far as it will travel and insert the pin to retain the tensioner....

Remove the wrench and tool and work the belt free from the pulley....

Note the direction of the belt should you wish to re-use it...Inspect the belt for fraying and cracking especially in the tramlines.....
The tensioner can now be removed by undo-ing the two 12mm retaining bolts....

Having replaced or inspected the tensioner to satisfaction take the tension away from the new (if fitted) tensioner and refit the belt noting that it is sitting on all the pulleys correctly and correctly routed around the idler and running in the correct direction
when the belt is routed to satisfaction, again with the tensioner tool and wrench inserted take up the tensioner strain and remove the pin...allow the tensioner to come back towards the belt to take up the belt slack.....
A fairly easy job if time is taken and a methodical approach used...
Good luck
cheers
jod

Jamesg · Dec 11th, 2008, 13:31

Do you know where one can find a diagram of how the belt should travel?

What would effect would an incorrect route have?

Jod T5 · Dec 11th, 2008, 14:23

Quote:

Originally Posted by Jamesg

Do you know where one can find a diagram of how the belt should travel? What would effect would an incorrect route have?

I expect i will have something in the volvo manuals at home....I will look a t the weekend... If the belt is not routed correctly it will not fit..!! There a a few routes that can be taken and it gets a little fustrating when it wont fit..lol..Been there.... Cheers Jod

chow · Dec 11th, 2008, 17:22

Quote:

Originally Posted by Jamesg

Do you know where one can find a diagram of how the belt should travel?

What would effect would an incorrect route have?

i would think one would find the workshop manual should contain the relevent info, as for your next question do the task IAW the manual and it wont be a issue, however if you cant be arsed buying a manual heres a nice piccy
http://volvospeed.com/Repair/850_serp.pdf

Chris_Rogers · Dec 11th, 2008, 18:10

"can't be arsed buying a manual "

Even if you could the Haynes 850 manual only shows the original fitting, which is wrong for most cars.

chow · Dec 11th, 2008, 18:18

Quote:

Originally Posted by Chris_Rogers

"can't be arsed buying a manual "

Even if you could the Haynes 850 manual only shows the original fitting, which is wrong for most cars.

which is why i very helpfully attached a link showing both types of routing,

anyway christopher, as we all know haynes isnt the only source of info out there, and the "other" source certainly does show the correct routing

Jod T5 · Dec 11th, 2008, 18:18

Quote:

Originally Posted by chow

i would think one would find the workshop manual should contain the relevent info, as for your next question do the task IAW the manual and it wont be a issue, however if you cant be arsed buying a manual heres a nice piccy
http://volvospeed.com/Repair/850_serp.pdf

Cheers for than one Chow.., didnt fancy digging thru my shed for the books at the weekend anyway....

Gracias...
Jod

chow · Dec 11th, 2008, 18:31

Quote:

Originally Posted by Jod T5

Cheers for than one Chow.., didnt fancy digging thru my shed for the books at the weekend anyway....

Gracias...
Jod

no prob mate, very good write up btw

Jan 15th, 2007, 07:54	#1
Jod T5 Phoenix from the ashes Last Online: Apr 24th, 2024 01:05 Join Date: Jan 2006 Location: Finchingfield	How to change your poly/aux belt Changing the poly or auxiliary belt as it is otherwise refered to is a easy task that should not be beyond the ability of the home mechanic....The vehicle being used for this exercise is a 1996 855 T5.... There are a few belts to choose from depending on engine number and if you have air con or not... The belt is situated on the o/s of the block between the timing belt and the front of the car....it cannot be seen in this picture but is situated under the power steering fluid holder To undertake this operation you will require a tensioner movement tool or one can be fabricated from a strong strip of steel cut to the dimensions of 23mm wide and 50/60 mm long.... I would also STRONGLY recommed that you draw a picture of the belt routing which will assist in the re-installing of the new belt..... Here is the belt tensioner, note the square hole where the movement tool needs to be inserted in... Remove the coolant bottle, disconnect the wiring and place in in top of the spark plug cover... Using an adjustable wrench to grip your movement tool insert the tool end into the hole...bear in mind to release the tension the wrench must be forced clockwise (toward the front of the car) so make sure you insert it giving the wrench about 130 degrees of travel without fouling on the power steering resevoir... On the tensioner there is a very small hole into which a nail or the like can be inserted when the tension is fully released from the belt....move the wrench towards the front of the car as far as it will travel and insert the pin to retain the tensioner.... Remove the wrench and tool and work the belt free from the pulley.... Note the direction of the belt should you wish to re-use it...Inspect the belt for fraying and cracking especially in the tramlines..... The tensioner can now be removed by undo-ing the two 12mm retaining bolts.... Having replaced or inspected the tensioner to satisfaction take the tension away from the new (if fitted) tensioner and refit the belt noting that it is sitting on all the pulleys correctly and correctly routed around the idler and running in the correct direction when the belt is routed to satisfaction, again with the tensioner tool and wrench inserted take up the tensioner strain and remove the pin...allow the tensioner to come back towards the belt to take up the belt slack..... A fairly easy job if time is taken and a methodical approach used... Good luck cheers jod __________________ Dum Spiro Spero VOC 20419 Last edited by Jod T5; Jan 15th, 2007 at 09:14.

Dec 11th, 2008, 13:31	#2
Jamesg New Member Last Online: Jul 29th, 2010 06:51 Join Date: Dec 2008 Location: Umhlanga Rocks	AUX belt diagram Do you know where one can find a diagram of how the belt should travel? What would effect would an incorrect route have?

Dec 11th, 2008, 18:10	#5
Chris_Rogers VOC Member Last Online: Apr 10th, 2017 16:55 Join Date: Jan 1970 Location: South Kent Coast	"can't be arsed buying a manual " Even if you could the Haynes 850 manual only shows the original fitting, which is wrong for most cars.

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