The Volvo XC90 D5 diesel cambelt and water pump replacement is a major service job. The auxiliary belt must come off first, followed by the bottom pulley, before the cambelt covers can be removed. The water pump is held by 10mm bolts and runs from the cambelt.
Timing the XC90 D5 is done by aligning a small mark on the top of the crank pulley with the engine casing mark, plus verifying the cam position. The engine turns over very easily with the glow plugs removed.
When You Need This Job
- Cambelt replacement interval reached — typically 6 years or 100,000 miles
- Coolant loss or wet belt area indicating water pump leak
- Preventative replacement on high mileage vehicle
- Any noise from the cambelt area
Tools You'll Need
Step-by-Step Guide
Remove engine covers and clear the area
Remove the engine top cover. Bungee the power steering reservoir out of the way to give clear access to the auxiliary belt area.
Remove the auxiliary belt cover — two T30 Torx
The cover over the auxiliary belt is held by two T30 Torx bolts. Remove it and set aside.
Remove the auxiliary belt
A T60 Torx fits the tensioner pulley underneath. Insert it and push the tensioner down to release belt tension. Wiggle the belt off one pulley and pull it clear.
Turn engine to TDC using the 30mm socket
Fit a 30mm socket onto the bottom pulley centre bolt. Turn the engine clockwise until the small mark on the crank pulley aligns with the mark on the engine casing — this is TDC.
Remove the bottom pulley — four 13mm bolts plus the 30mm centre bolt
Undo the four 13mm bolts and the centre 30mm bolt. Wiggle the pulley off — it may be stuck due to corrosion on the dowel. Persevere until it comes free.
Verify TDC and remove the cambelt covers
Recheck the timing mark alignment. Remove the remaining cambelt covers to gain full access to the belt, tensioner, idler and water pump.
Release the cambelt tensioner — 12mm and 6mm Allen key
Undo the 12mm tensioner bolt partially to allow movement. Use the 6mm Allen key to wind the tensioner back off the belt, removing all tension. Remove the old cambelt.
Remove the tensioner and idler — 10mm and 12mm bolts
Fully remove the tensioner and idler pulley. These are replaced as part of the new kit.
Remove the water pump — 10mm bolts
Undo all 10mm bolts on the water pump. Pull it out carefully — coolant will pour out. Have a tray ready. Clean the mating surface thoroughly before fitting the new pump.
Fit the new water pump
The new pump comes with a paper gasket. Two locating dowels guide it into position. Fit new bolts from the kit and tighten to spec.
Fit new idler and tensioner
Fit the new guide roller (10mm bolt) and the new tensioner (12mm bolt). The tensioner has an arrow indicating the direction to move the 6mm Allen key during tensioning.
Fit the new cambelt
Feed the belt around all pulleys in the reverse order it was removed. Ensure it is seated in every pulley groove.
Tension the belt
Move the tensioner using the 6mm Allen key per the arrow direction until the indicator sits correctly in the fork position. Tighten the 12mm tensioner bolt.
Turn engine over twice and verify timing
Turn the engine two full revolutions using the 30mm socket on the bottom pulley. Check the TDC timing mark re-aligns correctly. Verify the cam mark aligns. Then reassemble everything in reverse.
Torque Specifications
With the glow plugs out there is no compression resistance and the engine turns over very freely by hand — much easier when setting the timing.
While the auxiliary belt is off inspect it carefully for cracking or glazing. Replace it at the same time as the cambelt if there is any doubt.
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