Lessons learned from Major work on 1997 Volvo 964 sedan
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Lessons learned from Major work on 1997 Volvo 964 sedan
After two solid days of wrenching over two weekends I have learned a lot.
Some conclusions:
1. The 960 sedan engine compartment is a joy to work in, compared to some cars.
2. The right tools make ALL the difference. Not expensive, just right. Specifically:
A. a 1/4" drive breaker and two ratchets- one short and one long, plus a breaker bar. Corresponding short and deep well 6-8-10-12-13mm sockets and 3" and 6" extensions.
B. a 3/8" breaker and long ratchet, plus extensions and 12-13 mm sockets
C. Torx screwdriver from the Volvo kit and a good T-45 for the replacement tensioner idler.
D. Good lighting and several good LED flash lights
E. A piece of thick cardboard about 15" x 15" to put in front of the radiator after you remove the fan to do your front engine work.
F. A flat work table large enough to lay out parts and tools.
G. For the 964, I have built two constructions using four each 16" long 4x4 wooden beams screwed together. They create a 16x16x4 space on which the car can be driven or jacked for terrific access when doing the timing belt. Plus they are safer than jack stands or ramps. The car can never fall off them. And they can be stacked.
3. Research the jobs and be familiar with everything. I used a hybrid of the timing belt instruction sets and they served me well, even though they forgot to tighten the idler tensioner and had removal of two items in opposite order.
4. CHECK ALL YOUR PARTS! I did an inventory of all items purchased from FCP Euro in two kits and am glad I did. They sent the wrong serpentine belt ( About 6"too short, maybe for the 850?) and one cam seal had the wrong part number. Plus the numbers on the 2.9L intake manifold gasket didn't match. And no label for the timing belt cover. I'm making my own with more info, I might even make a metal engraved one, not sure. Certainly a plasticized note for the maintenance history as well.
I was a little surprised at this, since I spent about $450.00 to get two standard kits, nothing exotic. I sent them a note, am awaiting an answer. I reused the old belt since it only had 20,000 on it.
I was most surprised at how well Volvo have simplified construction, using so many common fasteners. I was not a fan of Torx, but am now.
Only thing I don't like are the Volvo cast battery clamps. But that can be changed.
In the meantime, onward to the first of the 850 cars, which needs timing belt, water pump, serp belt, new idler and tensioner gizmos, plus EGR set-up and struts.
After that, another 850 and 14 Mercedes diesels!
No lack of opportunities to excel chez moi!
Some conclusions:
1. The 960 sedan engine compartment is a joy to work in, compared to some cars.
2. The right tools make ALL the difference. Not expensive, just right. Specifically:
A. a 1/4" drive breaker and two ratchets- one short and one long, plus a breaker bar. Corresponding short and deep well 6-8-10-12-13mm sockets and 3" and 6" extensions.
B. a 3/8" breaker and long ratchet, plus extensions and 12-13 mm sockets
C. Torx screwdriver from the Volvo kit and a good T-45 for the replacement tensioner idler.
D. Good lighting and several good LED flash lights
E. A piece of thick cardboard about 15" x 15" to put in front of the radiator after you remove the fan to do your front engine work.
F. A flat work table large enough to lay out parts and tools.
G. For the 964, I have built two constructions using four each 16" long 4x4 wooden beams screwed together. They create a 16x16x4 space on which the car can be driven or jacked for terrific access when doing the timing belt. Plus they are safer than jack stands or ramps. The car can never fall off them. And they can be stacked.
3. Research the jobs and be familiar with everything. I used a hybrid of the timing belt instruction sets and they served me well, even though they forgot to tighten the idler tensioner and had removal of two items in opposite order.
4. CHECK ALL YOUR PARTS! I did an inventory of all items purchased from FCP Euro in two kits and am glad I did. They sent the wrong serpentine belt ( About 6"too short, maybe for the 850?) and one cam seal had the wrong part number. Plus the numbers on the 2.9L intake manifold gasket didn't match. And no label for the timing belt cover. I'm making my own with more info, I might even make a metal engraved one, not sure. Certainly a plasticized note for the maintenance history as well.
I was a little surprised at this, since I spent about $450.00 to get two standard kits, nothing exotic. I sent them a note, am awaiting an answer. I reused the old belt since it only had 20,000 on it.
I was most surprised at how well Volvo have simplified construction, using so many common fasteners. I was not a fan of Torx, but am now.
Only thing I don't like are the Volvo cast battery clamps. But that can be changed.
In the meantime, onward to the first of the 850 cars, which needs timing belt, water pump, serp belt, new idler and tensioner gizmos, plus EGR set-up and struts.
After that, another 850 and 14 Mercedes diesels!
No lack of opportunities to excel chez moi!
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