D4204T Timing belt change new shape 2004 volvo s40

[HEAVY747]

HOW I CHANGED TIMING BELT ON MY NEW SHAPE VOLVO S40 2.0D

Chock back wheels of car. Raise drivers side front of car and put on stand. Remove mud shield from within wheel arch to expose engine side view and crank pulley. Remove protective under tray from car. Unbolt and remove top plastic cover timing belt cover. Put wheel back on car and lower car to ground again but slightly raised to gain excess to crank pulley from front of the car.

Remove and lift expansion tank within the engine compartment to one side.

Remove starter motor. Remove drivebelt by turning tensioner with ring spanner. Next lock to camshaft pulley by placing 5mm drill bit in the inner surace - only one hole present and locking position is at 3 o'clock.

Lock flywheel teeth with Volvo locking tool or screwdriver or crowbar.

Remove TDC sensor bottom left of crank pulley. Next undo crank pulley bolt using a quality socket piece and extension tube.

Make sure the socket fits firmly and completely onto the bolt - no second chances here if you chew head of!! Use WD40 to help loosen.

This bolt is very tight so all four wheels on the ground!! I found that some needs to push head of rachet with piece of wood from side of car whilst other person loosens bolt. This bolt is tight so be very very careful - think tactics before doing anything. Again use WD40!!! You may need to move bolt backwards and forwards to help it come out. Gently does it please!!

Raise front drivers side front off ground

Once bolt off remove pulley without dropping and carefully remove TDC sensor ring underneath without damaging circumference. Remove black plastic timing belt cover now.

Lock screwdriver into flywheel so bottom of engine does not move. Mark exposed timing cog with tipex and also on engine so as to record position.

Slacken timing belt tensioner and remove. Remove timing belt pulley and also water pump (drain water from radiator first). Place bucket under engine when removing water pump.

Fit new water pump using sealant on surfaces and replace timing pulley with new one - do not over tighten water pump bolts as you may break head so careful does it. Fit timing belt tensioner and timing belt carefully and fit to instructions supplied. Make sure you fit timing belt as per your markings.

Rest is just reversal of what you did but work carfully and don't forget to add water to engine and make sure you fit NEW crank pulley bolt available from the volvo dealership for a couple of quid.

The above is the procedural experience is what I did to my car and strictly speaking is rough idea of what is involved. If you intend to do change yoursel then you need to read Haynes manual few times on the procedure before attempting.

My experience highlighted that damage to the crank bolt head can scupper the whole job so make sure you get this blighter loose first before doing any further work.

Remember there is no need to take of engine mount as there is space to work around.

See pictures below and if you have questions please feel free to email me.

http://i168.photobucket.com/albums/u...t/DSC00331.jpg
http://i168.photobucket.com/albums/u...t/DSC00327.jpg
http://i168.photobucket.com/albums/u...t/DSC00325.jpg
http://i168.photobucket.com/albums/u...t/DSC00324.jpg
http://i168.photobucket.com/albums/u...t/DSC00321.jpg
http://i168.photobucket.com/albums/u...t/DSC00319.jpg
http://i168.photobucket.com/albums/u...t/DSC00318.jpg
http://i168.photobucket.com/albums/u...t/DSC00316.jpg
http://i168.photobucket.com/albums/u...t/DSC00313.jpg
http://i168.photobucket.com/albums/u...t/DSC00308.jpg
http://i168.photobucket.com/albums/u...t/DSC00307.jpg
http://i168.photobucket.com/albums/u...t/DSC00305.jpg
http://i168.photobucket.com/albums/u...t/DSC00303.jpg
http://i168.photobucket.com/albums/u...t/DSC00295.jpg
http://i168.photobucket.com/albums/u...t/DSC00290.jpg

Volvo garage price if thousand quid!! I hope this gives some idea to the ordinary person.

Best Wishes
HEAVY747

[Guru]

I'm having problems releasing the drive aka serpentine belt on my car, as you can see in the photos it's shredding and needs to be changed.

Now, you mentioned in your write up that the drivebelt is removed by "turning tensioner with ring spanner"

My question is> How is that done? is the nut circled in red on my photos the right one to turn with the spanner?? i have tried with a 17" spanner turning clockwise i think and it became undone, so i fastened it again, and continued anticlockwise but could not achieve anything... how much force is needed? or am i doing it wrong?

[HEAVY747]

Hi Guru

My apologies for late reply - I was not aware you had posted question. Best bet is to work from under car no need to remove front drivers side tyre. Open bonnet and remove under tray from below engine to gain access. Use long ring spanner and turn anti clockwise the circled bolt. I will not come loose but will release tension on the belt. Pull off belt. Fit new belt around all of top pulleys and just lipit over power steering motor and tensioner. Now turn tensioner bolt anticlockwise with ring spanner and force belt over tensioner whilst keeping it hooked on p/s motor. Quickly turn p/s motor and it will drag itself onto completely. This job will take 1/2 hr at most - there is a shortage of these belts at Euro car parts they cost 7 quid inc. VAT. Main dealers 25 quid which is what I paid With all your force Make drawing of how old belt fitted round pulleys before doing this. All above work done lying on your back with car raised using stand but don't take wheel off. Let me know if you need any further help Guru.

Remeber tensioner is pre-tensed so turning the bolt anti-clockwise will loosen the tension on belt but will not loosen bolt - needless to say there no need for the bolt to be taken of.

You can do this job as I was bit apprehensive at first but very simple task.

I also changed fuel filter for which I can advise if needed.

All the best
Heavy747

[Guru]

Everything's in check chief! Got it

I was afraid of applying too much force on that bolt at the begining not to snap its head off, but once i gathered the courage to do so, everything went smooth from there...

My belt cost 24 € from Contitech /made in Germany/

Thank you very much for your adivise!

As for the fuel filter... i don't have any fuel system bleeding tools/pumps to do it by myself, but thanks again for offering.

Take care.

[HEAVY747]

No problems Guru - take care

[supafly]

Hi,

I'm just finally getting round to doing this on my wifes s40. Got all the bits together but don't have a haynes. Is there a specific way of achieving the correct tension on the cambelt via the tensioner. I've done a few timing belts now so I've come across these types before, just don't know where I should set the pointer to before I lock the nut off. Do these engines have a woodruff key as the last one I did was on a clio dci and it was a horrible desing where I managed to turn the crank and nothing else when I tried turning the engine to check the marks lined up.

Is there just the two places to lock the engine at tdc? 5mm drill bit in cam wheel and screwdriver/crow bar in flywheel teeth where the starter was.

I'm also gonna do a coolant flush and change. Is there a specific way to bleed these or is it just heaters hot and slowly fill and run til it self bleeds?

Sorry for all the questions, don't want to make a pigs ear of it and hopefully these questions and answers may help someone else in future.

Thanks in advance

[supafly]

One more...

How do you find tdc before removing the crank pulley?