Engine: D5: - broken cambelt, ruined engine, help!

appleyard · Sep 10th, 2009, 11:53

I recently purchased a reconditioned alternator and had a local garage fit it to a 2003 S60 D5. This was because the original alternator was faulty, with the clutch pulley (freewheel) having ceased. The old alternator belt was refitted as it appeared to be fine.

The car had covered less than 150 miles when the engine became noisy again. Upon inspection the alternator belt had started to shred on the edge facing the engine, indeed there was a thin strand actually flapping against hoses etc adjacent to the alternator belt. There was however, also a slight noise from the other end of the camshafts which wasa puzzling but not explored.

The car was returned to the garage, a new alternator belt fitted and then as the car was moved out of the workshop, the cambelt snapped, indeed one of the cambelt pulleys has broken off from the engine casting. This has caused unknown but catastrophic damage to the cylinder head/valves etc. Upon inspection pieces of the shredded alternator belt were found on the cambelt pulley cogs.

The garage claim the alternator belts (both old and new) were correctly fitted, the alternator supplier claims that an alternator cannot shred a belt, particularly on a grooved pulley system.

Any thoughts on what could have happened and what to do next?

Tempted to list the car in the for sale section on this site, or to break for spares. Does anyone know of a good secondhand engine; they seem pretty scarce. The car is an S60 D5 S. The cambelt was replaced at 97000 miles by Volvo. It has a F V S H till 130,000 and has now just completed around 150,000. Other than the engine problem, the car is in excellent overall condition.

Any thoughts, ideas or offers greatly appreciated.

appleyard · Sep 16th, 2009, 11:09

Just to let you know that the car has now been sold as a non runner. On the basis that "the first loss is the best". I decided to put it on evilbay and a Lithuanian dealer bought it, paid cash, collected on time ,and I presume it is now heading east.

This episode has cost me more than any other car I have owned and at the last count that was 130! What appears to have happened was that a shredded alternator belt was picked up by the cambelt and as a result it overtightened and sheared a pulley and its mounting off the block as well as damaging valves pistons etc.

I have got over trying to apportion blame for the incident but I hope it is a reminder to all D5 owners that either 1) worn belts can shred, or 2) always check that a refitted belt is correctly seated in all the pulley grooves.

(It all started by the way because the alternator clutch pulley had seized and as a result the belt was flapping and noisy).

Now that the car is no more, here are my final thoughts on the S60 D5.

Performance and economy: fantastic.

Turning circle: abysmal

Interior: rather dull and not up to 740 series quality

Driving position and comfort: Ok but again not brilliant and nothing like a Saab 9000.

Finish: Bubbling on the roof strips otherwise good.

Value for money. Most expensive car I have ever owned when purchase and sale price considered!!!!

111 · Sep 16th, 2009, 12:41

Thats all a bit of a bummer! I have emailed 2 garages for a quote to get the belt done (81k and an 2003 d5) with a service, Both in the North east and on the list of specialists linked to this site, but neither have been arsed to reply, no wonder these places are closing down if this type of service is to go by. So ill get it done a kwikfit. lol. Anyone know the cost at a dealers??

Steve-T5 · Sep 18th, 2009, 05:50

Quote:

Originally Posted by 111

Thats all a bit of a bummer! I have emailed 2 garages for a quote to get the belt done (81k and an 2003 d5) with a service, Both in the North east and on the list of specialists linked to this site, but neither have been arsed to reply, no wonder these places are closing down if this type of service is to go by. So ill get it done a kwikfit. lol. Anyone know the cost at a dealers??

What's wrong with just calling them and asking?

hobbyhorse · Sep 18th, 2009, 08:30

The clutch pulley is a replaceable component so theres no need to replace the complete alternator ~ reconditioned often means removed from a scrapper then cleaned. I wonder if the replacement alternator was also faulty...

S60D5NI · Sep 18th, 2009, 10:38

This gives me the shivers!

I had a very similar incident with a TDi Passat. Alternator clutch pulley seized - Aux. belt flapping about - didn't immediately fix (as didn't know that pulley had seized or there even that it was fitted with a clutch!) - 1 week later belt broke and wrapped itself around timing belt & car ground to a halt on the motorway.

Luckily for me (relevant to appleyard's sad tail) the timing belt had only slipped a few teeth and pistons / valves had not met. So £400 later with new timing and aux. belts + new alternator clutch I was up and running. Bummer was that timing & aux. belts had only been replaced 2 month earlier. Don't know if garage checked alternator pulley, and in any case I don't think the failure was related to the new belt as car was fitted with hydraulic tensioner so impossible to over-tighten aux. belt and stress alternator pulley.

I will now keep a careful eye on the Volvo's alternator clutch / aux. drive belt! Moral of the tail is if you aux. belt is jumping about, it may not be a worn belt / broken tensioner. Check the alternator pulley without delay!

kdst5 · Sep 18th, 2009, 13:42

Does the freewheel on the alternator only apply to the diesel engine or also to the petrol?

atlantic64 · Sep 18th, 2009, 23:23

According to haynes its only on diesels, but please check to see if thats correct.

jajrst · Sep 19th, 2009, 18:33

I have one on my petrol 2.4

Sep 10th, 2009, 11:53	#1
appleyard New Member Last Online: Dec 28th, 2009 10:30 Join Date: Oct 2007 Location: kington	broken cambelt, ruined engine, help! I recently purchased a reconditioned alternator and had a local garage fit it to a 2003 S60 D5. This was because the original alternator was faulty, with the clutch pulley (freewheel) having ceased. The old alternator belt was refitted as it appeared to be fine. The car had covered less than 150 miles when the engine became noisy again. Upon inspection the alternator belt had started to shred on the edge facing the engine, indeed there was a thin strand actually flapping against hoses etc adjacent to the alternator belt. There was however, also a slight noise from the other end of the camshafts which wasa puzzling but not explored. The car was returned to the garage, a new alternator belt fitted and then as the car was moved out of the workshop, the cambelt snapped, indeed one of the cambelt pulleys has broken off from the engine casting. This has caused unknown but catastrophic damage to the cylinder head/valves etc. Upon inspection pieces of the shredded alternator belt were found on the cambelt pulley cogs. The garage claim the alternator belts (both old and new) were correctly fitted, the alternator supplier claims that an alternator cannot shred a belt, particularly on a grooved pulley system. Any thoughts on what could have happened and what to do next? Tempted to list the car in the for sale section on this site, or to break for spares. Does anyone know of a good secondhand engine; they seem pretty scarce. The car is an S60 D5 S. The cambelt was replaced at 97000 miles by Volvo. It has a F V S H till 130,000 and has now just completed around 150,000. Other than the engine problem, the car is in excellent overall condition. Any thoughts, ideas or offers greatly appreciated.

Sep 16th, 2009, 11:09	#2
appleyard New Member Last Online: Dec 28th, 2009 10:30 Join Date: Oct 2007 Location: kington	update on post Just to let you know that the car has now been sold as a non runner. On the basis that "the first loss is the best". I decided to put it on evilbay and a Lithuanian dealer bought it, paid cash, collected on time ,and I presume it is now heading east. This episode has cost me more than any other car I have owned and at the last count that was 130! What appears to have happened was that a shredded alternator belt was picked up by the cambelt and as a result it overtightened and sheared a pulley and its mounting off the block as well as damaging valves pistons etc. I have got over trying to apportion blame for the incident but I hope it is a reminder to all D5 owners that either 1) worn belts can shred, or 2) always check that a refitted belt is correctly seated in all the pulley grooves. (It all started by the way because the alternator clutch pulley had seized and as a result the belt was flapping and noisy). Now that the car is no more, here are my final thoughts on the S60 D5. Performance and economy: fantastic. Turning circle: abysmal Interior: rather dull and not up to 740 series quality Driving position and comfort: Ok but again not brilliant and nothing like a Saab 9000. Finish: Bubbling on the roof strips otherwise good. Value for money. Most expensive car I have ever owned when purchase and sale price considered!!!!

Sep 18th, 2009, 10:38	#6
S60D5NI Member Last Online: May 10th, 2012 22:15 Join Date: Mar 2008 Location: Belfast View Photos By: S60D5NI	This gives me the shivers! I had a very similar incident with a TDi Passat. Alternator clutch pulley seized - Aux. belt flapping about - didn't immediately fix (as didn't know that pulley had seized or there even that it was fitted with a clutch!) - 1 week later belt broke and wrapped itself around timing belt & car ground to a halt on the motorway. Luckily for me (relevant to appleyard's sad tail) the timing belt had only slipped a few teeth and pistons / valves had not met. So £400 later with new timing and aux. belts + new alternator clutch I was up and running. Bummer was that timing & aux. belts had only been replaced 2 month earlier. Don't know if garage checked alternator pulley, and in any case I don't think the failure was related to the new belt as car was fitted with hydraulic tensioner so impossible to over-tighten aux. belt and stress alternator pulley. I will now keep a careful eye on the Volvo's alternator clutch / aux. drive belt! Moral of the tail is if you aux. belt is jumping about, it may not be a worn belt / broken tensioner. Check the alternator pulley without delay! __________________ MY2007 S60 D5 SE Sport (185) A 'diseasel' Volvo - Mr Clarkson would approve!

Sep 16th, 2009, 12:41	#3
111 Darkest Stockton-on-Tees Last Online: Jan 17th, 2024 08:06 Join Date: May 2007 Location: Stockton-on-Tees	Thats all a bit of a bummer! I have emailed 2 garages for a quote to get the belt done (81k and an 2003 d5) with a service, Both in the North east and on the list of specialists linked to this site, but neither have been arsed to reply, no wonder these places are closing down if this type of service is to go by. So ill get it done a kwikfit. lol. Anyone know the cost at a dealers??

Sep 18th, 2009, 08:30	#5
hobbyhorse Premier Member Last Online: Jan 26th, 2015 21:30 Join Date: Dec 2006 Location: Billericay	The clutch pulley is a replaceable component so theres no need to replace the complete alternator ~ reconditioned often means removed from a scrapper then cleaned. I wonder if the replacement alternator was also faulty...

Sep 18th, 2009, 13:42	#7
kdst5 Senior Member Last Online: Today 12:55 Join Date: Jun 2007 Location: Horsham	Does the freewheel on the alternator only apply to the diesel engine or also to the petrol?

Sep 18th, 2009, 23:23	#8
atlantic64 New Member Last Online: Mar 21st, 2016 11:57 Join Date: Jan 2009 Location: Liverpool	According to haynes its only on diesels, but please check to see if thats correct.

Sep 19th, 2009, 18:33	#9
jajrst Volvo S80 SE Owner Last Online: Jul 24th, 2023 18:57 Join Date: Aug 2007 Location: Westcliff on Sea	I have one on my petrol 2.4

Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)