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Dear Blindboy,
Hope you're well. When re-assembling the crankshaft timing parts - rear washer, sprocket (gear), front washer, and crank pulley - it is critically important to ensure that the sprocket's "nub" (or protrusion) aligns with: (a) the notch in the front washer, and (b) the crank pulley's slot.
To ease this task, use white-out (or other light-colored paint) to mark on the crank pulley's face (the flat surface just below the rim) the crank pulley's slot location. Position the crank pulley onto the crankshaft, with the paint mark aligned with the "nub" on the crank sprocket. Once you've aligned the pulley and the "nub", do not turn the crank pulley: push it straight back along the crankshaft.
If the crank pulley is properly seated on the crank sprocket's "nub", you should not be able to turn the crank pulley without great effort. For, if the crank pulley is properly seated on the crank sprocket's "nub", moving the pulley requires moving the pistons and valves. If the crank pulley is not properly seated on the crank sprocket's "nub", the crank pulley can be turned with relative ease. If that occurs, slide the crank pulley towards the front end of the crankshaft, re-align the pulley with the "nub", and try again.
The "nub" protrudes only 1/16" from the front washer's surface, so it is easy to misalign the crank pulley, by, for example, turning the pulley slightly while pushing it along the crankshaft. When installing the crank pulley, be careful to push the crank pulley straight back towards the face of the engine!!
Even when the crankshaft bolt is fully torqued, a misalignment will allow the crankshaft to turn "independently" of the pully. That rotation will shear-off the crank sprocket's "nub". A replacement sprocket (#9135271) will cost about US$77 (MSRP) at a U.S. Volvo dealer.
Hope this helps.
Yours faithfully,
Spook
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