Before I get started, let me thank all those who contributed to my last post, "960 running on four cylinders". The responses were very helpful. The problem turned out to be a whole in one of the exhaust valves of the #2 cylinder.

The FAQ section was great help in removing cam cover and head. Also a great help in putting bottom half of head on the block. That is how far along I am. The reason I am posting, is that I'm having a heck of a time figuring how to place the camshafts in correct timing sequence. I have crank at #1 TDC. According to a diagram I got from a shop, the barely noticable marks on the cam sprocket should align with the indintations on the top part of the timing belt cover. The problem is, when I do this, the lobe on the exhaust cam for the #6 cylinder would be pushing the valve down. Of course, #6 piston is at the top of its stroke, like #1, so an open valve would wreck into the top of it. The intake positioning does not have an open valve on #1 or #6, so it might be fine.
I'm afraid the previous owner may have taken the cam gear or gears off at some time and put them on wrong.

I hope I'm making sense so far. Anyway, if there is a picture or diagram available showing the position of the cam lobes for #1 cylinder at TDC, I think I could get this puppy put back together. If no visuals exist, a discription would also be most welcome. As always, any consideration shown is much appreciated.

Sounds like the cam gears were not marked before removal, so that means you have three possibilities for each cam (slots on cam gears). The Volvo cam tool fits at the back and keeps the slots on the tail of the cam shafts in the same plane, the plane being nearly running paralell with the ground, that should narrow down your choices. Maybe some one else has a better short cut.

DanR 94 964 282,000 miles (48,000 miles on the new engine)
--
DanR

Okay, here is your first problem, you put it at TDC. Is it really at TDC and you know this because you had the head off and set it there yourself, you say that the number 6 is a TDC too so I have to assume that they are in fact at TDC. You need to set the alignment mark for the crank where it belongs and this is not at TDC, it is actually quite a ways off. The instructors at Volvo school explain this as the sweet spot where nothing should hit when you go back together. So set the crank alignment marks and then install your cams and see how that goes.

Don't feel bad, the first one of these I did way back in the day had me scratching my head as well. All these years of setting the cams and cranks up on their alignment marks that were TDC and now with the white engine they threw that out the window.

Mark

Mark,

Thank you for your response, I think (and hope) you solved my problem. I ran out, and looked and looked for a mark on the the crank gear, to match up with the mark on the block. Could'nt, for the life of me, find one. Then, as I was turning the crank one last time, I noticed a mark on the "thing" that is bolted to the crankshaft. Please pardon the highly technical terminology, sometimes I get carried away.

If it's not too much trouble, could you please verify that I have found the correct mark.

Here ya go, if you look close you will see the upraised line in the face of the oil pump and the corresponding mark on the crank gear is actually a notch cut in the bottom, backside of one of the teeth on the gear itself. It is a pain in the ass way to do things but once you know where it is and what you are looking for it is no big deal.

http://www.volvospeed.com/Repair/timingbelt2.php

Mark

Thanks again. I will have to wait until the light of day tomorrow morning, to try and tackle this again. Darn, why could'nt it have been that easy mark on the pulley. Oh well, can't wait to hunt for that dude tomorrow. Your info has been invaluble, Mark. You're alright, man. I'll let you know if I get it running without blowing it up.