Torx or Bolt ? 2003 D5

Willow place · Jun 17th, 2019, 15:54

Just been trying to release the tension on the Serpentine belt, the tensioner appears to have a small hole, a Torx 55 -60 doesn't fit, but on Youtube there is mentions of a plastic cap with a 14mm bolt hidden behind it even Haynes state that !

cheshired5 · Jun 17th, 2019, 16:22

Every tensioner I've ever done on a Euro 3 D5 needed a T60 torx so perhaps yours isn't a genuine Volvo one or your torx tools aren't accurate or the torx hole has got mangled.

Technically, you can use the bolt under the tensioner pulley cap but the force required to release and reinstate the tension will be greater than the correct tightening torque for the pulley bolt so you risk shearing the bolt.

oragex · Jun 17th, 2019, 16:47

If you see no bolt, there might be a plastic cap, see at the begining of this video https://www.youtube.com/watch?v=jTi558-Q9ZI

Brendan W · Jun 17th, 2019, 17:01

The original tensioner on mine was a hex hole. When I replaced it with the first timing belt the new assembly had a torx hole.
Are both tensioner pulleys secured with hex head screws? The newer type has a csk screw on one of them with a flatter plastic cover.
The unload hole has no plastic cover. Haynes may be referring to the practice of removing a pulley cover and using it's screw to unload the belt. Given the big tension on the belt and the sensitivity of the bearings on the pulley that is a practice I would discourage and may be why Volvo went away from the hex screw in the first place.

Willow place · Jun 17th, 2019, 17:23

I am trying to fit a Torx into the middle of a plastic"cap, am I doing it wrong ? Is there somewhere else that I should be trying ? I may wait until dark to find this elusive item !! Sun is so bright and 90 plus heat is not helping !!! Any photos would help, please .

Brendan W · Jun 17th, 2019, 17:39

The recess for the torx is not visible easily. You have to feel your way to. It's on the moving arm to the moving pulley, the one nearest the timing belt cover.

R-P · Jun 17th, 2019, 21:53

Will look for pics on my phone.

I used the 14mm but that tightens/loosens the bolt on a bearing (it did the job for me, but it could have backfired). I think that might be what Cheshired5 is talking about. Everything is still in one piece, but it is not the correct way... (it is under the black covers shown on the pic below in the centre of the rollers)

Does this pic help? This is how a tensioner is supplied: it features the pin (visible in the lowest part of the pic) that keeps it 'wound up' for ease of installing. Once installed and after putting the belt in place, you need the T60 torx to put even more pressure on it, remove the pin and then slowly release it to it put tension on the belt.

Willow place · Jun 18th, 2019, 17:34

Well I took the plastic cover off as I didn't have the right Torx bit and used a 14mm socket and bar, it works ! So onto checking if everything is going to be easy ? The plastic lining !! Metal pop rivets ! The Swedes really know how to put a motor together, normally plastic stuff on a "normal" car, gave up now as I have the airport run, so hot, can only touch tools with gloves on, s'pose it is better raining on and off ?

Jun 17th, 2019, 15:54	#1
Willow place Senior Member Last Online: Jan 1st, 2023 17:41 Join Date: May 2017 Location: Los Finos Almeria	Torx or Bolt ? 2003 D5 Just been trying to release the tension on the Serpentine belt, the tensioner appears to have a small hole, a Torx 55 -60 doesn't fit, but on Youtube there is mentions of a plastic cap with a 14mm bolt hidden behind it even Haynes state that !

Jun 17th, 2019, 16:22	#2
cheshired5 Premier Member Last Online: Dec 26th, 2021 13:42 Join Date: Dec 2013 Location: Crewe	Every tensioner I've ever done on a Euro 3 D5 needed a T60 torx so perhaps yours isn't a genuine Volvo one or your torx tools aren't accurate or the torx hole has got mangled. Technically, you can use the bolt under the tensioner pulley cap but the force required to release and reinstate the tension will be greater than the correct tightening torque for the pulley bolt so you risk shearing the bolt. __________________ 2002 S60 SE D5 Manual 209000 miles

Jun 17th, 2019, 16:47	#3
oragex Premier Member Last Online: Jul 26th, 2021 21:24 Join Date: Jun 2013 Location: Coldnada	If you see no bolt, there might be a plastic cap, see at the begining of this video https://www.youtube.com/watch?v=jTi558-Q9ZI __________________ Several Volvo Repair Videos https://www.youtube.com/playlist?lis...ECTts0FSVSOT_c

Jun 17th, 2019, 17:01	#4
Brendan W Premier Member Last Online: Apr 2nd, 2024 19:50 Join Date: Dec 2007 Location: Wexford	The original tensioner on mine was a hex hole. When I replaced it with the first timing belt the new assembly had a torx hole. Are both tensioner pulleys secured with hex head screws? The newer type has a csk screw on one of them with a flatter plastic cover. The unload hole has no plastic cover. Haynes may be referring to the practice of removing a pulley cover and using it's screw to unload the belt. Given the big tension on the belt and the sensitivity of the bearings on the pulley that is a practice I would discourage and may be why Volvo went away from the hex screw in the first place. Last edited by Brendan W; Jun 17th, 2019 at 17:04.

Jun 17th, 2019, 21:53	#7
R-P Master Member Last Online: Mar 26th, 2024 14:00 Join Date: Apr 2009 Location: Rozenburg NL	Will look for pics on my phone. I used the 14mm but that tightens/loosens the bolt on a bearing (it did the job for me, but it could have backfired). I think that might be what Cheshired5 is talking about. Everything is still in one piece, but it is not the correct way... (it is under the black covers shown on the pic below in the centre of the rollers) Does this pic help? This is how a tensioner is supplied: it features the pin (visible in the lowest part of the pic) that keeps it 'wound up' for ease of installing. Once installed and after putting the belt in place, you need the T60 torx to put even more pressure on it, remove the pin and then slowly release it to it put tension on the belt. __________________ Ex police Jan '04 V70 D5 AWD geartronic, and I've got the antenna-holes to prove it. Last edited by R-P; Jun 17th, 2019 at 22:00.

Jun 17th, 2019, 17:23	#5
Willow place Senior Member Last Online: Jan 1st, 2023 17:41 Join Date: May 2017 Location: Los Finos Almeria	I am trying to fit a Torx into the middle of a plastic"cap, am I doing it wrong ? Is there somewhere else that I should be trying ? I may wait until dark to find this elusive item !! Sun is so bright and 90 plus heat is not helping !!! Any photos would help, please .

Jun 17th, 2019, 17:39	#6
Brendan W Premier Member Last Online: Apr 2nd, 2024 19:50 Join Date: Dec 2007 Location: Wexford	The recess for the torx is not visible easily. You have to feel your way to. It's on the moving arm to the moving pulley, the one nearest the timing belt cover.

Jun 18th, 2019, 17:34	#8
Willow place Senior Member Last Online: Jan 1st, 2023 17:41 Join Date: May 2017 Location: Los Finos Almeria	Well I took the plastic cover off as I didn't have the right Torx bit and used a 14mm socket and bar, it works ! So onto checking if everything is going to be easy ? The plastic lining !! Metal pop rivets ! The Swedes really know how to put a motor together, normally plastic stuff on a "normal" car, gave up now as I have the airport run, so hot, can only touch tools with gloves on, s'pose it is better raining on and off ?

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