Timing belt-CAM locking tool

Tiny
ENGINEERINGDAD
  • MEMBER
  • 2004 VOLVO S80
  • 2.9L
  • 6 CYL
  • TURBO
  • 2WD
  • AUTOMATIC
  • 129,000 MILES
I downloaded a Volvo Master Mechanic instructions on how to change the cam seals and timing belt to include aligning the timing marks on the 1999-2006 Volvo S80 T6 (twin turbo) with twin VVT’s. The instructions seemed inconclusive for the T6 VVT engines per explaining the following:
(1) What if the two slotted cams (opposite end to cam sprockets/driver side) do not line up perfectly with the locking tool? What do you do?
(1a) Do I hand turn the crank pulley close as possible to the two timing marks on the cover?
(1b) Do I take off the timing belt first and then gradually tweak by hand the cams sprockets to allow the cam locking tool to lock in place?
(2) If so, the timing marks might be off center with the cover? Would I then loosen the cam sprockets and turn slightly too proper marks with cam locking tool still in place and then re-tighten?
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Thursday, July 19th, 2018 AT 4:57 AM

9 Replies

Tiny
ASEMASTER6371
  • EXPERT
Good morning.

There are two tools required for this procedure. I attached them in this post. The procedure is below.

Since this is an interference engine, moving the cams and crank is critical to not move it. If you have to, move the crank gear about 90 degrees then no piston is at top dead center. Then you can move the cams into position.

Roy

Replacing the timing belt

Special tools:
999 5433 COUNTERHOLD See: Vehicle > Electrical / Mechanical Repair > 999 5433 Counterhold
999 5456 COMPRESSION TOOL See: Vehicle > Electrical / Mechanical Repair > 999 5456 Compression Tool

Removing the timing belt

Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Preparation

imageZoom/Print

Caution! Remove the ignition key.

Remove
- the screw holding the engine stabilizer brace to the bracket on the engine
- the screws holding the engine stabilizer brace to the suspension turrets
- the engine stabilizer brace.

Applies only to B6xx4T engines:
Remove the plastic pipes between the turbocharger (TC) and charge air cooler (CAC) and between the air cleaner (ACL) and turbocharger (TC). Put them to one side.
Remove the clamp from the intake manifold for the turbocharger (TC) for cylinders 1, 2 and 3. Turn the upper section of the pipe towards the firewall.

ImageZoom/Print

Relieve the load from the belt tensioner. Remove the auxiliaries belt.
Remove the upper timing belt cover.
Remove the front timing belt cover.
For cars with chassis numbers 203779-, see Timing cover front, replacing See: Timing Cover > Removal and Replacement > Timing Cover Front, Replacing.
Lift up the servo reservoir and place it on top of the engine.

Note! Ensure that the oil does not leak from the ventilation hole in the filler cap.

Seal the hose between the expansion tank and the radiator. Disconnect the hose at the tank.
Lift up the expansion tank and place it on top of engine.

ImageZoom/Print

Raise the car.

Remove
- the right front wheel
- the plastic nuts on the cover in the fender liner.

Install the upper timing belt cover.
Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulleys correspond.
Turn the crankshaft a further 1/4 turn clockwise.
Then turn back counter-clockwise until the markings correspond.
Remove the upper timing belt cover.

ImageZoom/Print

Remove the 4 vibration damper screws. Counterhold the crankshaft central nut.

Remove
- the vibration damper
- the auxiliaries belt
- the belt cover behind the crankshaft pulley for the auxiliaries belt.

Spray universal oil or similar around the rubber sleeve on the underside of the oil pump.
Remove the rubber sleeve.

Removing the timing belt

imageZoom/Print

Slacken off the belt tensioner
Slacken off the center screw for the belt tensioner slightly.
Hold the center screw still. Turn the tensioner eccentric counter-clockwise using a 6 mm Allen key. Turn to 10 o'clock.
Unhook and remove the timing belt.

Caution! Do not turn the camshafts or the crankshaft when the timing belt has been removed.

Checking the tensioner pulley and idler pulley

Check bearing wear:
Spin the idler pulley and listen for noise. If replacing with a new idler pulley, tighten to 24 Nm.
Spin the tension pulley and listen for noise. When replacing, screw the tension pulley into place using the center screw.
Screw in the center screw by hand.
Ensure that the tensioner fork is centered over the cylinder block rib / bracket.
Ensure that the Allen hole on the eccentric is at "10 o'clock".
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Thursday, July 19th, 2018 AT 7:28 AM
Tiny
ENGINEERINGDAD
  • MEMBER
Send images of the: 999 5433 COUNTERHOLD and 999 5456 COMPRESSION TOOL. Amazon yes/no?
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Thursday, July 19th, 2018 AT 9:07 AM
Tiny
ENGINEERINGDAD
  • MEMBER
Wrong engine. I have a B6294T six cylinder-with Twin Turbo The tension-er unit described 999 5456 compression does not apply. The following images of the belt tension-er and tool is all should need with naturally a complete Volvo timing kit wit pump, gasket, idle pulley, tension-er, timing belt, serpentine belt, etc, etc. Please answer my original question without doing a cut and paste from justanswers. Com
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Thursday, July 19th, 2018 AT 10:04 AM
Tiny
ENGINEERINGDAD
  • MEMBER
  • 2004 VOLVO S80
  • 2.9L
  • 6 CYL
  • 2WD
  • AUTOMATIC
  • 129,000 MILES
https://www.2carpros.com/questions/timing-belt-cam-locking-tool

See above link and respond with correct information. It should be a simple enough to understand my questions 1a and 1b.

Yes, I will be replacing all belts pulleys, tension-er, water pump and gasket.
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Thursday, July 19th, 2018 AT 5:37 PM (Merged)
Tiny
ASEMASTER6371
  • EXPERT
My answer came from Alldata, not another website.

I understood just fine your question. I responded to 1B already in my answer

As far as turning the cams, yes, as I stated before move the crank off top dead center then move the cams.
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+1
Friday, July 20th, 2018 AT 12:33 PM
Tiny
ENGINEERINGDAD
  • MEMBER
Sorry for the long delay on the completion. Everything went in Perfection with the instructions your provided plus adding a YouTube Swede Video of the Volvo B6294T Engine Timing Belt replacement. Not sure why some shops won't do a Interference Engine...but I'm glad they didn't, because I kept the $750.00 Labor. I guess as a MME I need to stop panicking and remember the basic lectures of mechanical physics/engineering.

https://www.youtube.com/watch?v=o4uLvH151-c
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Tuesday, February 12th, 2019 AT 10:32 AM
Tiny
ASEMASTER6371
  • EXPERT
Glad to hear it is done.

Roy
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Tuesday, February 12th, 2019 AT 10:39 AM
Tiny
ENGINEERINGDAD
  • MEMBER
Thanks Roy, My apologizes for being an ass on the previous Q&A's
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Tuesday, February 12th, 2019 AT 11:02 AM
Tiny
ASEMASTER6371
  • EXPERT
No worries. We are all good.

Roy
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Tuesday, February 12th, 2019 AT 11:06 AM

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