Today I installed a new turbo cam, crank seal, intermed. seal, cam seal, belt and tensioner, in the 86 740T. I am having a few problems putting it all back together, mainly getting the belt to track right.
It all started with the realization that the crank pulley had been installed 180 degrees off (I think)some time in the past. When the rotor pointed a number one, the No. 1 Cyl was at TDC (using a straw to determine) and the No. 1 valves looked 'perky', the timing mark on the crank was out by 180 degrees. The plug wires on the distributor cap, reading from pass side to driver side has the number oe wire in the third position. Is this where it is supposed to be, or has somone mover the plug wires around to accommodate a 1800 degree shifted crank pulley?
When I pulled the crank pulley I found that not only was the timing mark off 180 degrees, but someone had bodged a keeper about half the size it should have been.
Being a 16 hour drive from the nearest Volvo dealer, or 3 days by bus for parts delivery, I bodged my own keeper out of some key stock.
Putting this thing back together I determined I would line up the TDC marks on the crank, the TDC mark on the cam, and put the belt on. The first problem with this is that the cam belt keeps tracking forward off the cam gear and idler when I turn the engine over a few times by hand (clockwise rotation). I have pulled the various pulleys off a few times to assess their condition, no joy. I have whittled down my bodged keeper so the spacer and crank gear sit flush, and still the belt keeps tracking off.
The second problem is that it feels as though the valves are nudging the pistons when I try to turn the cam independanly of the crank. I specifically asked IPD whether their Turbo cam would turn this B230FT into an interference cam, and was given an emphatic NO. So, what's going on??
Any one run into this sort of problem? any advice?
JD