Tolerance Data 2009.

1 Volvo, S80 2,5 TDi

Tools

1. A = tool "3359". Fuelpump locking pin.

2. B = tool "2065-A". Camshaft locking bar.
3. C = Tool "3369" for offestting the front.
4. D = tool "2064". Fuelpump locking pin.
5. E = tool "3418". Camshaft locking bar.

1. A = tool "3359". Fuelpump locking pin.

2. B = tool "2065-A". Camshaft locking bar.
3. C = Tool "3369" for offestting the front.
4. D = tool "2064". Fuelpump locking pin.
5. E = tool "3418". Camshaft locking bar.
 Tolerance Data 2009.1 Volvo, S80 2,5 TDi

Dismount 1

1. Remove bottom shield (optional).

2. Dismount :
• front wheels.
• inner wing.
• turbo hose and turbo pipe.
3. Mark on crank pulley must align with mark on oil pump.
4. Mount belt tensioner.
5. Mark on camshaft pulley must align with bearing surface between cylinder head and valve cover.
6. Dismount :
• belt tensioner.
• valve cover.
 Tolerance Data 2009.1 Volvo, S80 2,5 TDi

Dismount 2

1. Crank engine clockwise until TDC marking is shown in the hole in the cluth case.
2. Marking on the fuelpump sprocket (1) must align with marking on the fuelpump (2).
3. If the marking on the fuelpump sprocket is not present then loosen bolt (2), remove the shim and
retighten the bolt to lock the fuelpump flywheel.
4. Remove the rear camshaft sprocket.
5. Fit locking bar "2065-A" in the rear end of the camshaft.
6. Centre the locking bar by using feeler gauges.
7. Loosen belt tensioner.
8. Dismount timing belt.

1. Crank engine clockwise until TDC marking is shown in the hole in the cluth case.
2. Marking on the fuelpump sprocket (1) must align with marking on the fuelpump (2).
3. If the marking on the fuelpump sprocket is not present then loosen bolt (2), remove the shim and
retighten the bolt to lock the fuelpump flywheel.
4. Remove the rear camshaft sprocket.
5. Fit locking bar "2065-A" in the rear end of the camshaft.
6. Centre the locking bar by using feeler gauges.
7. Loosen belt tensioner.
8. Dismount timing belt.
 Tolerance Data 2009.1 Volvo, S80 2,5 TDi

Mounting 1

1. Control markings.
2. Loosen camshaft bolt and release the sprocket from the taper.
3. Fit the timing belt in the folowing order:
4. Crank pulley.
5. Water pump.
6. Cam wheel.
7. Tensioning wheel.
8. Fuelpump timing belt:
9. Dismount camshaft locking tool.
10. Fit :
• the camshaft sprocket loosely so that it can still rotate on the axle.
• fuelpump timing belt.

1. Control markings.
2. Loosen camshaft bolt and release the sprocket from the taper.
3. Fit the timing belt in the folowing order:
4. Crank pulley.
5. Water pump.
6. Cam wheel.
7. Tensioning wheel.
8. Fuelpump timing belt:
9. Dismount camshaft locking tool.
10. Fit :
• the camshaft sprocket loosely so that it can still rotate on the axle.
• fuelpump timing belt.
 Tolerance Data 2009.1 Volvo, S80 2,5 TDi

Mounting 2

1. Tighten :
• belt tensioner clockwise with Allen key until pointer aligns with the small notch and tighten bolt.
• camshaft pulley bolt (use counter hold).
2. Fuelpump timing belt:
3. Check that the pointer of the lower tensioner aligns with the edge of the cylinderhead (D).
4. Rotate the upper tensioner counter clockwise until the pointer aligns with marking.
5. Tighten camshaft pulley bolt (use counter hold).
6. Refit the shim on the fuelpump.
7. Turn crankshaft 720°.
8. Control :
• markings.
• that pointer aligns with mark on belt tensioner.
9. Using a diagnostic tester check the dynamic injection timing.

1. Tighten :
• belt tensioner clockwise with Allen key until pointer aligns with the small notch and tighten bolt.
• camshaft pulley bolt (use counter hold).
2. Fuelpump timing belt:
3. Check that the pointer of the lower tensioner aligns with the edge of the cylinderhead (D).
4. Rotate the upper tensioner counter clockwise until the pointer aligns with marking.
5. Tighten camshaft pulley bolt (use counter hold).
6. Refit the shim on the fuelpump.
7. Turn crankshaft 720°.
8. Control :
• markings.
• that pointer aligns with mark on belt tensioner.
9. Using a diagnostic tester check the dynamic injection timing.
 Tolerance Data 2009.1 Volvo, S80 2,5 TDi

Mounting 3

1. Mount :
• valve cover.
• timing belt covers.
• crankshaft pulley / vibration damper (use counter hold).
• belt tensioner.
• auxiliary belt.
• turbo hose and turbo pipe.
• inner wing.
• front wheels.
2. Remove any bottom shield.