Klaus and Jerry:

Thanks for the replies. Every bit of info does help. A few follow-ups:

Klaus -- I am aware of the proper way to set to #1 TDC by rotating the engine clockwise to align the cam marks, then 90 degrees (1/4 turn turn) further clockwise, then back (counterclockwise) until the cam marks line up again. This I believe removes the tension off the intake cam that is caused by the VVT unit...correct? And if the cam sprocket does move "a little" when you remove/install the belt, you can just move it back into alignment by hand? Just want to confirm this point.

Also, you said you don't have to remove the serp belt pulley in order to remove/replace the timing belt. Are you sure this applies to a 2.9 6 cylinder engine? Seems like there is VERY little room to pull out the old/snake in the new T belt with the serp pulley still on.

Jerry -- My serp belt tensioner is apparently different than yours...it takes a large (T60) Torx socket, not a 14mm wrench. I use a long ratchet wrench with it. Also FYI, a 1 3/16" socket also fits the large nut on the crank (at least on my engine)...I didn't have a metric socket that big.

On the fender liner question, I don't think you can do this job without going in from the side, at least on my S80. To get the fender liner out of the way, I did not remove the rivets. Just removed the two plastic nuts on the inside and pulled it back. I secured it out of the way with a short (about 4-5 inches long) piece of a thick coat hanger. Bend the ends at 90 degrees (or a little more) and hook one end behind the fender liner near one of the rivets and hook the other end through the hole in the fender liner. This worked good. I've also read on the boards that you can fold it back and secure it with long-reach vice grips at the fold, but I'm thinking the vice grips might get in the way.

And a question...how difficult was it to set the correct tension on the "mechanical" timing belt tensioner? I have found these instructions on the internet: http://www.babcox.com/editorial/ic/ic60326.htm. Is this how you did it? Any things to watch out for? Were you able to torque the bolt? No room to get my torque wrench in there!

Thanks,
G Squared



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2001 S80 2.9 (non-turbo), 113K miles