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How to Replace timing chain 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

How to Replace timing belt on Volvo S40 2.0 2002
How to Replace timing belt on Volvo S40 2.0 2002

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.
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