What I did today thread...

[big_yin]

Replaced the front brake discs and pads as the old ones where warped. The new ones are Genuine Volvo discs and pads.

Next weekend I am going to replace the intercooler

[P156KWJ]

Rear discs, pads and shoes, and a new caliper for the offside done today. The shoes were certainly not a job I'd say I enjoyed!

[adiosboss]

Front bearings changed today which has fixed suspension noises. Now on to timing belt, aux belt with new tensioner and alternator pulleys. That's a job for next weekend though.

[Ripmax]

Deconstructed the angle gear box on my R after discovering play in the output to the propshaft. This is what I found. oops!

New bearings and seals on their way as we speak. Can hopefully get the car back on the road soon!!

[big_yin]

Replaced my intercooler. Very warm work

[adiosboss]

Originally Posted by big_yin

Replaced my intercooler. Very warm work

Did you pull the IC out from the top or from underneath? When I did mine I went from the top but with the pipe connections it was tough. I've got my dad's d5 S80 to do and wondering if we'd be better going from underneath.

[Thassos]

I too had the same question before replacing the ic on my S60, saw a youtub of someone removing the bumper and top panel but decided from below would be less stuff to remove, and it worked fine, you need the car an axle stands with around 40cm gap min below the rad area, i used some thick wire, and also a chain with cable ties onto the bottom bracket of the aircon (frontmost) radiator, worked a treat as you could quite easily damage this if not supported, was originally considering leaving coolant and rad in place but drained it off so it coild be removed together, the tiny fir tree clips 3 + 3 on top and bottom flat plastic plates youll prob need some more of, volvo £3-4 per clip ! .. you can get those from pbay new versions have a peg but can be a fiddle to get back on the top side with limited space.. anyway hope thats useful, dont know if the S80 setup is similar tho..

[big_yin]

Originally Posted by adiosboss

Did you pull the IC out from the top or from underneath? When I did mine I went from the top but with the pipe connections it was tough. I've got my dad's d5 S80 to do and wondering if we'd be better going from underneath.

I took it out from the top. It was a bit tricky but the AC radiator dropped down far enough. Putting the new intercooler back in was more work then taking the old one out.

[adiosboss]

Originally Posted by big_yin

I took it out from the top. It was a bit tricky but the AC radiator dropped down far enough. Putting the new intercooler back in was more work then taking the old one out.

Found that myself, might take Thassos' advice and go from underneath then.

As for me, I replaced the timing belt and timing belt tensioners. While aux belt was off I changed the aux belt idler and tensioner pulleys as well as the alternator pulley before putting on a nice new aux belt. The timing belt was actually a couple of teeth on the crankshaft out of time, carefully corrected that and now I'm sure it's running quieter.

Next job, track down the cause of the popping sound from oil filler. Suspected leak from brake booster side of the vacuum pump

[BillDD5]

Today I’ve replaced the blower fan control module so now the fan responds correctly to orders from the CCM and no longer spends time trying to flatten the battery!
One of the blower fixing screws was a bit fiddly (only lost skin off one knuckle) as I don’t have a flexible driver for Torx bits but after slackening the awkward screw I pushed a short length of 6mm rubber fuel hose over the bit and was able to tease it out.
Bill