AFT_B912

T he 2.0 and 2.4-litre diesel D5 engines used over time by Volvo in almost every variant in the manufacture’s range, but notably in the popular XC60 and XC90 siblings, features a timing belt driven water pump. As replacing the belt also requires the auxiliary drive system to be removed, Dayco best practice recommends that all the system’s components – both primary and auxiliary drive – be replaced at the same time. This step by step technical guide will help technicians through the process, avoiding complications and ensuring a first-rate, professional job. As with all primary drive system jobs, the work should be undertaken when the engine is cold, so ideally, the vehicle will not have been run for at least four hours. Special slot Start by removing the engine cover, then the front right wheel and cowling to expose the two belts of the auxiliary drive system. Use the special slot to slacken off the belt tensioner (fig.1), remove the belt, followed by the five crankshaft pulley bolts. Then detach the ride height detector, remove the crankshaft pulley and then the tensioner. From underneath, take off the engine shield, securely support the engine and remove the engine’s lower links. Returning to the top, remove the cooling fluid reservoir, the upper engine support rod and mounting plate. Remove the two fasteners that support the hydraulic pipe by the timing belt cover, release the retaining clips and remove the cover. Using the central crankshaft pulley bolt, rotate the crankshaft so that the crankshaft and camshaft pulley timing references align, then loosen the timing belt tensioner and remove the belt, followed by the tensioner. Camshaft pulley As the camshaft pulley is not fitted directly on the shaft and its holes are slotted, to ensure it is refitted in the correct position, mark its position with paint before removing it (fig. 2). Once the camshaft pulley is detached, take off the idler and then the rear timing belt cover to allow the removal of the water pump. After flushing out the cooling system to remove any debris, cover both sides of the gasket with a thin layer of sealant before carefully positioning it in relation to the two pins in the housing before fitting the new water pump from Dayco kit KTBWP5920. 20 AFTERMARKET DECEMBER/JANUARY 2020 TECHNICAL www.aftermarketonline.net VOLVO D5 TIMING BELT KIT INSTALLATION Dayco offers a guide to installing a timing belt in the Volvo D5 engine via Dayco kit KTBWP5920 Fig. 1 Fig. 2