Follow these instructions to change the spark plugs on all Volvo 5 cylinder petrol engines from 1991 to 1998, Volvo models 850, S70, V70, C70 with 5 cylinder engines 2.0 10v, 2.0 20v, 2.4 10v, 2.4 20v, 2.5 10v, 2.5 20v, 2.0 Turbo, 2.4 Turbo, 2.5 Turbo, 2.3 Turbo T-5 and 2.3 Turbo R.
This tutorial don’t apply if your car is a 1999 or later S70, V70 or C70 petrol engine.
The alternator on my Volvo 850 Turbo have failed last weekend.
After studing several tutorials on the Internet, I end up finding a method that allowed me to replace the alternator without the need to remove the power steering pump hoses or water pipe. In order to achieve it, be very carefully to follow the steps in the exact order.
Parts needed
- New alternator – Volvo part number: 5003996
- New auxiliary belt – Volvo part number: 9186352
Tools needed
- Combination of 12 and 13 mm spanner’s / rachet’s
- 18mm nut and bolt (see step 2)
- 3mm drill bit or hex key
Note: During this job, all bolts are 12mm and all nuts are 13mm.
Step 1. Disconnect the battery
Step 2. Remove the ventilation hose for the ECU housing.
Just push it on the box and on the back of the radiator and it will pop out easily.
Step 3. Remove the auxiliay belt and tensioner
You’ll need to move the tensioner to the front of the car and then lock it with a 3mm drill bit or hex key. This image with the ECU housing removed will help understand how it works:
To move the tensioner you’ll need a 3/4″ breaker bar. As it is not easy to place a 3/4″ breaker bar between the engine and the ECU housing, I use a 18mm (exterior) nut slightly smoothed on two opposite vertices, well attached to a bolt.
Then I insert the nut side on the tensioner (not that here I already had a hex key locking the tensioner)
and with a spanner rotate the tensioner to the front of the car until the holes on the tensioner allign to insert the locking device.
Once that’s done, remove the aux belt. (it is advisable to replace the aux belt for new one on re-installation).
With the belt removed you’ll be able to remove the 2 bolts holding the tensioner in place and remove the tensioner.
Step 4. Remove the black plate, on the front of the steering oil reservoir, that supports the power steering pump.
You’ll have to remove the top long bolt and nut on the top marked with A, the bottom bolt and nut marked with B and the bolt marked with C that is on the right side of the steering pump, under the water hose.
This last “C” bolt also holds the temperature sensor plug support. Don’t forget to put it back on re-installation.
Once the 3 bolts are out, you’ll be able to remove the plate.
Step 5. Remove the bolts holding the power steering pump
The power steering pump is held in place by 3 bolts.
Two of them are acessible via 2 holes on the power steering pulley (“D” in the image). You’ll have to find the correct position for the holes in the pulley to be alligned with the bolts.
The third one (“E” in the image) is immediately under the tensioner bolts. This one bolts to a small bracket that is attached to the back of the steering pump. Once it’s removed, the steering pump will be loose.
You’ll now be able to carefully move it to the sides in the next steps to help access the remaining bolts and alternator.
Step 6. Disconnect the two wires to the alternator.
The smaller one is a quick connector (“F” in the picture). The larger one is hold by a 13mm nut (“G” in the image). You’ll have to remove a plastic cap to see the nut.
Step 7. Remove the last 2 bolts holding the alternator in place.
The second to last bolt is located on the lower right side of the alternator. Marked “H” in the image is the rachet wrench placed in the bolt, as it’s not possible to take picture of the bolt itself.
The last bolt is located on the left side of the alternator (marked “J”). You’ll have to access it through a hole in the tensioner braket. This bolt is attached to a 13mm nut near the inlet manifold that you’ll have to counter-hold.
The alternator is now free to be pulled from the car!
Re-installation
As usually, for the re-installation you just need to follow the steps in reverse. Nevertheless, I found it helpfull not to fully tight the bolts until evertyhing is back in it’s place.
So, until you have the big black plate that holds the power steering pump in place (step 4) , every time you install a bolt, do leave it with a slight clearence to allow some play in the alternator and power steering.
Then, before you install the auxiliary belt tensioner, just go through all bolts again and fully tighten them.
The instructions in this tutorial will work in the following models / years:
– 1997, 1998 Volvo S70
– 1997, 1998 Volvo V70
– 1997, 1998 Volvo C70 Coupe and Convertible / Cabrio
– Volvo 850 T-5 225 hp B5234FT, made / sold in 1994, 1995, 1996 and 1997
– Volvo 850 T-5 R 240 hp B5234T5, made / sold in 1995
– Volvo 850 R 250 hp B5234T4, made / sold in 1996 and 1997
– Volvo 850 R Auto 240 hp B5234T5, made / sold in 1996 and 1997
– Volvo 850 2.3T 218 hp B5234T2, made / sold in 1995, 1996 and 1997
– Volvo 850 2.5T 193 hp B5254T, made / sold in 1997
– Volvo 850 GLT 2.0T 210 hp B5204FST, made / sold in 1994, 1995, 1996 and 1997
– Volvo 850 GLE 2.0T 180 hp B5204T2, made / sold in 1996 and 1997
– Volvo 850 2.0 20V 143 hp B5204FS, made / sold in 1992, 1993, 1994, 1995 and 1996
– Volvo 850 2.0 10V 126 hp B5202FS, made / sold in 1995, 1996 and 1997
– Volvo 850 2.5 20V 170 hp B5254FS LH 3.2, made / sold in 1992, 1993, 1994, 1995 and 1996
– Volvo 850 2.5 20V 170 hp B5254FS, made / sold in 1996 and 1997
– Volvo 850 2.5 10V 144 hp B5252FS, made / sold in 1993, 1994, 1995, 1996 and 1997
– Volvo 850 2.3 20V 144 hp B5234FS, made / sold in 1994, 1995, 1996 and 1997