All,

Can someone share the instructions on how to fit a mechanical TB tensioner? the link I found (http://www.babcox.com/editorial/ic/ic60326.htm) does not point to the intended article.

Your help will be very appreciated.

Best,
Paul

This is for a V/S40, but if you scroll down to the bottom you will see how to align the mechanical tensioner properly:

http://volvospeed.com/Repair/s40_timing_belt.html

Klaus
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I am not a mechanic, so can you trust what I type?

Klaus,

You are great as always. Thank you very much for your help. very appreciated.

If weather permits, tomorrow will be my big day.

Enjoy your weekend.

Best,

I am a little worried since someone mentioned a special volvo tool needed to fit a mechanical TB tensioner.

Thanks,

Hello, Fear not! The only tools you need on the tensioner are a 6mm allen key and a wrench for the center mounting bolt (10 or 12mm). It'll be straightforward since one of the tabs is notched to fit against a seam or rib on the engine block casting. The 6mm allen moves the eccentric action of the tensioner allowing you set the other metal tab to match the picture on the temperature chart. Then you tighten it down. You won't need any cam sprocket holder either. The cam shafts will stay in position since you have a non-VVT valve train. DO NOT fail to highlight the allignment marks with a sharp touch of paint. The only clinker in this job might be removng the small section of timing belt cover which skirts the lower half of the crankshaft pulley. Be ready to lift the engine an inch or two with a floor jack and block of wood as the lower right motor mount (immediately below the crank pully) might have begun collapsing, as mine had. Site sponsors sell quality parts. Kira

Thank you, Kira. We all need to be reminded from time to time about the motor mount failure. When the mount fails, it makes changing the T belt very difficult. The mount needs to be inspected whenever the belt needs to be changed.

For those who complain about not having enough room for a ratchet, etc., check the mount!

Klaus
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I am not a mechanic, so can you trust what I type?

Thank you very much, Klaus and Kira.

Just done the big job and would like to give an update.

With all the help from you great people and rich info from Volvo forums, my very first TB change job can be said smooth though there're a couple of hiccups. The job took me about 4 hours. Given the weather in NYC is in its 70s, it was enjoyable 4-hour in the sun.

One trouble I had is trying to loosen the old tensioner with a 6mm Allen wrench (followed instructions I found). After 10 years, I just could not budge the tensioner eccentric. I was afraid I bent the bolt a bit. Since I was going to replace the tensioner and belt, I decided to cut the old belt and then took the old tensioner off. Suggestion: if the old tensioner won't be reused, cut belt is much easier way--to remove tensioner and belt.

Another little trouble was when I tried to put back the crankshaft pulley cover. It has to be done before putting back serpentine belt. I had to remove the newly installed serpentine belt to install the cover.

I did not remove the spark plugs because of my laziness and afraid of dirt getting in.

After 10 years and 98K miles, both TB and serpentine belt are still in a great shape. Don't you think we are a little paranoid on TB replacement?

Best,
Paul

Let's hope you didn't find any wear on the Tbelt. It needed to be changed at 105K. More importantly, the tensioner really needed to be changed because the 1999 model tended to fail about this time.

You done good :) In 100K miles, you get to do it again!

Klaus
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I am not a mechanic, so can you trust what I type?

Thanks, Klaus.

It's definitely better to change them after 10 years especially when I am planning a long trip to Toronto (from NYC) next month.

The old tensioner really looks fine; but some grease came out of the idle pulley. The old belt does not show any wear or crack from outside; but the fabric turned yellow color (from where it's cut).

I don't have to wait another 100K miles. I have 95 850 waiting in line (with 135K miles now). :-)

Have a good one.
Paul

Just want to add. The serpentine tools loaned from the Autozone was very useful.

Also, I didn't use CAM lock tool. After today's job, I don't think it is a critical tool to have.