1997 960....serpentine belt snapped. With 206K and relegated to a 3rd vehicle status, I shall fix it myself!

Any special tools I will neeed for success??
Any advice and or counsel on how to do it with minimal grief and busted knuckles??

Thanks- Mike

As well as the tensioner pulley, check the idler (fixed) pulley for noise and smoothness. You can give them both a spin by hand with the belt off, while listening closely for any grinding or rattling noises. Anything other than smooth and quiet means replacement is called for.

Your '97 engine may have the updated belt and routing...I was completely flummoxed by having a very loose belt after my attempts to route the new belt, using an outdated diagram, before a helpful BB'er posted Volvo's revised routing diagram referred to by Dewfpo.
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Bob: son's XC70, dtr's '94-940, my 81GL, 83-DL, 89-745(V8) and 98-S90. Also 77-MGB and some old motorcycles.

Hi -

Putting the new belt on will require that the tensioner to be loosened. (I recommend a new tensioner and idler, as long as you are in there.)

Special tool for the loosening operation is an impact wrench adaptor for a 1/2-inch drive (female end) to 3/4-inch drive (male end). The impact wrench spec. is just because they are apparently not available otherwise.

I found a set of three adaptors at Harbor Freight, they may be available at Northern Tools, too.

Any clue as to what caused the belt to fail? I have had mine changed with the timing belt - at the 75,000 mile interval. My 1997 965 has 212300, and I just located my last 200,000 mile High Mileage badge.

Good Luck,

Bob

:>)

Changing the serpentine belt is fairly straightforward. Get the right belt (Volvo P/N 9458411) which is longer than the original belt and use this new belt route : http://www.volvoforums.org.uk/showthread.php?t=124228

Check the serpentine tensioner pulley as well for smoothness, ease of rotation noise.

DEWFPO
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1998 S90 083,228 and 1995 964 154,100

A diagram of the belt's routing would be quite helpful to you. Proper tensioning of the tensioner and/or tensioner replacement (if needed) is critical.

Never done the job myself but here are some other resources to learn more about the job:

1. Post your question to the AWD side too. Your 6 cylinder engine was used in later FWD/AWD cars. Also search the Brickboard.

2. Try Matthew's Volvo Site - MatthewsVolvoSite.com

3. Check Volvospeed.com

4. Get a good repair manual for your 960

FAQ: http://www.brickboard.com/FAQ/700-900/EngineSealsBeltsVent.htm#960SerpentineBeltInstallation

Make ABSOLUTELY sure your timing belt is in good shape along with the pulleys and tensioners. It has to be changed on time or you say goodbye to the engine. See the FAQ discussion.
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See the 700/900 "FAQ" at the menu bar top screen left side.

The seriousness or gravity with which you asked the question prompts a need to clarify what you refer to as the "serpentine" belt ...

Usually, a "serpentine" belt is the one that extends around multiple driven accessories such as the water pump, alternator, p/s and a/c compressors. It's serpentine because one flat belt snakes around to reach all their pulleys, instead of the older approach using multiple separate V-belts.
When such a serpentine belt snaps, it's not a big deal to replace it (except for dealing with the tensioner, which could be a challenge, and just placing the belt properly on all the pulleys).

But your gravity hints that you may be referring to what is more properly called the "timing" belt, which is also somewhat "serpentine" in its appearance in that it is flat and wraps around multiple pulleys (or sprockets). Such a snapped timing belt is indeed serious, because it usually is accompanies by internal damage to valves and pistons.

I hope it's the former, rather than the latter. Good luck.