How to Replace timing belt on Volvo S40 2.0 2002

Volvo S40 2.0 2002 cambelt change instructions and replacement inteval. Full guide!

Special tools

• None required.

Special precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove spark plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• DO NOT turn engine via camshaft or other sprockets.
• Observe all tightening torques.

Repair times – hrs

Camshaft drive belt/chain – R & I

2,10

Valve timing procedures

Removal

1. Remove:
   • Engine top cover.
   • RH engine compartment cover (Turbo).
   • RH headlamp cover (Turbo).
   • Auxiliary drive belt. DO NOT reuse belt.
   • Timing belt upper cover [1] .
   • PAS hose bracket (2001).
2. Raise engine slightly.
3. Support engine.
4. Remove RH engine mounting.
5. Raise and support front of vehicle.
6. Remove:
   • RH front wheel.
   • RH lower splash guard.
   • Engine undershield.
   • Auxiliary drive belt tensioner (if required) [2] .
   • Timing belt front lower cover [3] .
   • Engine mounting bracket [4] .
7. Turn crankshaft clockwise until timing marks aligned [5] & [6] .
8. Turn crankshaft a further 1/4 turn clockwise, then anti-clockwise until timing marks aligned [5] & [6] .
9. Remove:
   • Timing belt rear upper cover.
   • Tensioner bolt [7] .
   • Tensioner pulley.
   • Timing belt rear lower cover [8] .
   • Timing belt.

Installation

1. Check guide pulley. Replace if necessary.
2. Fit new tensioner pulley with Allen key hole at 10 o’clock position.
3. Tighten tensioner bolt to 3 Nm [7] .
4. Ensure timing marks aligned [5] & [6] .
5. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets.
6. Fit timing belt rear upper cover.
7. Turn tensioner pulley anti-clockwise until pointer [9] passes alignment marks [10] . Use Allen key (6 mm) [11] .
8. Turn tensioner pulley slowly clockwise until pointer is aligned according to engine temperature:
   • -20°C left of alignment marks [12] . 20°C
   • centre of alignment marks [13] . 50°C
   • right of alignment marks [14] .
9. Tighten tensioner bolt to 20 Nm [7] .
10. Press down on belt and ensure tensioner pointer moves freely [9] .
11. Turn crankshaft two turns clockwise.
12. Ensure timing marks aligned [5] & [6] .
13. Ensure tensioner pointer correctly aligned:
    • -20°C left of alignment marks [12] . 20°C
    • centre of alignment marks [13] . 50°C
    • right of alignment marks [14] .
14. If not: Repeat tensioning procedure.
15. Install components in reverse order of removal.