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S40 / V40 '96-'04 General Forum for the Volvo S40 and V40 (Classic) Series from 1995-2004. |
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2003 S40 1.8s manual cambelt issuesViews : 665 Replies : 2Users Viewing This Thread : |
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Jul 22nd, 2020, 17:22 | #1 |
To Roll (Latin for Volvo)
Last Online: Yesterday 20:24
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Location: Rhyl-North Wales
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2003 S40 1.8s manual cambelt issues
fitted cambelt, camshafts moved from 12 to ten when old belt released,
i then turned them back to the marks where i had set them. fitted new belt, tensioner, pulley, set the tab in the middle with the 6mm allan key on tensioner and then tightened it up. Then put it all back together, started it up ran like it was firing on 1 cylinder then shut down, started again a couple times more, same again. I then took spark plugs out no damage at all, put them back in turned the engine by crank pulley no horrible noises and rotation was as before i took old belt off, then took timing case off belt seems really loose but timing marks still align. can anyone advise what i have done wrong here please, is there a remedy? is my engine a non interference or interference, all help would be greatly appreciated. for the record the nut on the crankcase pulley is jammed solid, so i took off the bottom guard and slipped the belt on that way. i couldnt check the crankcase alignment mark obviously but does'nt the crank alogn with the cam marks when i first set up the timing marks? Jason |
Jul 25th, 2020, 14:48 | #2 |
To Roll (Latin for Volvo)
Last Online: Yesterday 20:24
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Location: Rhyl-North Wales
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sorted...
i stopped thinking i was charlie bananas and thinking i could sort this timing belt problem by using next too no tools, my first mistake was i never realigned the crank from when i threw it out of sync trying to get the pulley bolt off, 3 tooth slip! any hows in the end a 10.5mm drill bit in the fly wheel directly visible from pulley wound it in till snug and tight, turned crank ever so slightly backwards till no movement and bit was firmly wedged.
Then got my 30mm nut and breaker bar and hey presto, nut came off with a screech. Re-aligned with rib on crank flange with the slightly raised case mark and then got a real shag nasty cheap cam gear tool to hold them in place. Now prior to me getting the tool i took everything apart thinking it will be okay as long as i kept an eye on cam alignment marks with cam cover etched notches. what i never expected was the cams spring loaded movement, all they moved was from say 12pm to either 1pm or 11pm as the numerics on a clock would show, or if you like 5 minutes either way, DO NOT PANIC IF THIS HAPPENS TO YOU, CAMS AND CRANK IF REALIGNED (double check tdc at piston 1 and 4) WILL BE OKAY! if tho your cams spin a 360 and some then you are bolloxed. lesson learned here, get the bloody tools and put them in place before you even think of taking a an old timing belt off, other than this really is the easiest timing belt in the world to do if done correctly! hope this helps at least somebody! Jason |
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Jul 25th, 2020, 20:00 | #3 |
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Last Online: Nov 15th, 2022 22:34
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Location: London / Essex
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Glad you got it sorted. Nice learning curve
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Current car: 2002 S40 1.9D, 1992 240SE Nullius in Verba
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cambelt, noise, s40, timing |
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