After fixing a stuck idle air control valve on my girlfriend's car two weeks ago, I was dismayed to find that it was 5k overdue (110k) for a timing belt when browsing the owners manual. This was particularly disconcerting, because we drove from Washington DC to San Francisco starting at 104k!

Anyway, I found two sets of instructions online, one here: http://volvospeed.com/Repair/s40_timing_belt.html

and one here: http://ww2.justanswer.com/uploads/JH...5201_early.pdf

All in all, the repair went very smoothly. I need to go back and torque down the engine mount studs tomorrow - don't have a 15 mm deep socket, and I could only snug them up with a 5/8ths.

One thing worth noting is that the tool recommended in the first set of instructions actually kept me from being able to put on the new belt - had to remove it and move the cam gears around a bit to get the new belt on so that I could progressively tension it. Save yourself $40 and don't get it. After $140 for the belt kit from ipd and $60 in tools, we still saved $300 over having the auto shop across the street from our apartment do it. Took me two hours and 45 minutes from start to finish.

It is also worth noting that while I removed the engine mount, I did not have to remove the bracket that attaches it to the engine. Nor did I need to remove the crank pulley as shown in the first set of instructions.

Never really worked on foreign type cars before - I'm a Chevy guy myself. Had good luck keeping the volvo up so far. My only gripe is the stupid special tool you need to get the oil filter off - what the ****? They couldn't put a square drive hole into the housing? I'll probably be trolling the forum now and again when that S40 gives us issues. Until then, just wanted to share my two cents on changing the belt.

 

Nightmare. Makes me think I had a starter after my belt change after all. However this time maybe i'll succeed in the Volvo.