Timing jump interference engine

Tiny
ENGINEERINGDAD
  • MEMBER
  • 2004 VOLVO S80
  • 2.9L
  • 6 CYL
  • TURBO
  • 2WD
  • AUTOMATIC
  • 174,000 MILES
Problem: I accelerated hard to pass another vehicle, and then my car went into an extreme rough conditions “like timing jumped” codes came up “misfire cylinder #3 and #5, and ox sensors p0420 and p0430. The coil packs are not the issue, i’ve switched them around prior to checking the timing belt/crank alignment-and it’s still coded misfire #3 & #5 and oxygen sensors

(1) Worked Performed in Steps:
(2) Pulled Timing Cover Off
(3) Removed the Serpentine Belt
(4) Removed Harmonic Balancer
(5) Volvo Dealership Mechanic said I didn’t need to use
the cam locking tool at this point since he felt the
timing jumped. So I didn’t use it.
(6) Observed both Cam Wheels at 2 o’clock positions,
Crank Gear Mark at 9 o’clock
(7) Loosen Belt Tensioner.
(8) Removed Timing Belt.
(9) Cam Marks (intake & exhaust would only turn back to
12:30 (advanced) missing their original marks with
Timing Cover.
(10) Crankshaft mark was at 9 o’clock (retard)
(11) Hand turn Crankshaft Nut Clockwise to get at proper
Timing Mark.
(12) Hand turn Cam shaft wheels forward and back to stop
position (non-spring loaded) best I could get was about
12:30 position, not at 12 o’clock position with cover
marks.
(13) Reinstalled Timing Belt.
(14) Tighten belt tensioner as instructed by Volvo. Torqued
to Spec’s
(15) Hand Cranked Crankshaft two full turns Clockwise, No
metal sounds hitting,
(16) Reassembly car’s trim.
(17) Started car and get P0017 Code (Cam Position Sensor)
and rough idle, and co2 codes P0420 & P0430.

Keep in Mind: The Timing Belt, Water Pump, Tensioner, Glides Wheels, Serpentine Belt, Spark Plugs, Coil Packs (oem) I replaced 09/2018 @ 131.000 Miles. Installed to Volvo’s Specifications and Torque and per 2CarPros. Com and VolvoSpeed. Com. Everything was 100% perfect after the first Timing Belt Job, although I didn’t replace the Timing Belt Tensioner.I might have shot myself in the foot. The belt I think (not sure) jumped?

Where do I go from here? To get it all back on Track since nothing matches to marks.
Friday, December 20th, 2019 AT 1:29 PM

12 Replies

Tiny
JIS001
  • MECHANIC
  • 3,408 POSTS
The misfire codes P0303 cylinder #3 and P0305 cylinder #5 misfires could be setting P0420 and P0430 for the catalyst failure. If swapping the coils did not change then swap the spark plugs and then fuel injectors to see if any of those will follow.

As for the new code P0017 and the diagram you posted your timing is not set right. In fact you are so far off that I am surprised it even starts? At this point you now need the cam lock tool to properly set the timing now.
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Sunday, December 22nd, 2019 AT 4:33 PM
Tiny
ENGINEERINGDAD
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Now when I use the cam lock tool, which I've done in the past on my timing belt job and everything was 100% okay. After getting cams marks (hand cranking engine) set to timing belt cover timing marks-if the crank sprocket gear is off mark then what? Leave cams lock and clockwise rotate crank gear to it proper marks. PS, it does run without any misfire codes, only get the P0420 and 430 from the turbo and cat issue, which are semi okay but I have a new Volvo cat and rebuilt turbos to install in next few weeks. Issue now is what if all don't match up.
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Wednesday, December 25th, 2019 AT 10:27 PM
Tiny
SCGRANTURISMO
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Hello,

If I could jump in here, Direct Trouble Codes[DTC][s] P0420 and P0430 are for bank 1 and bank 2, respectfully, catalytic converters being worn out. They have nothing to do with any DTC for a turbo. What is the issue you are having with your vehicle's turbo?

Thanks,
Alex
2CarPros
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Thursday, December 26th, 2019 AT 7:38 AM
Tiny
ENGINEERINGDAD
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Scratch the Turbos.I'll install my rebuilt Mitsubishi's TD03's later. Lets forget I mention it. P0420 and P0430 are for bank 1 and bank 2, catalytic converters being worn out-YES I'M AWARE. The original wore out two years ago the aftermarket installed (2017) is noisy and garbage, I have a OEM Volvo to install. My issue is; see: Wednesday, December 25th, 2019 AT 10:27 PM / Friday, December 20th, 2019 AT 1:29 PM Questions.
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Thursday, December 26th, 2019 AT 12:19 PM
Tiny
SCGRANTURISMO
  • MECHANIC
  • 4,897 POSTS
Hello again,

Okay so we are talking about DTC P0303 and P0305 and you have installed new spark plugs, new coil packs and the timing is dead on. If the timing belt did slip it would be because the tensioner failed. But, if you say it is running fine without setting DTC's P0303 and P0305 then what is the issue you are having an issue with? Is it the catalytic converter DTC's or the misfire DTC's?

Thanks,
Alex
2CarPros
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Thursday, December 26th, 2019 AT 6:58 PM
Tiny
ENGINEERINGDAD
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  • 35 POSTS
The issue I would have is the timing out of sequence on the Crank Shaft Gear. Even if I lock the cams in the right position my timing on the Crank Shaft Gear will be off. Your absolutely right though the Timing Belt Tensioner did probably failed and allowed the belt to jump a few notches. I order a new OEM Tensioner on Amazon. Its the Crank Gear that's I'm concern with. Do I after locking cams in their right position:
(1) Remove Timing Belt
(2) Rotate Crank Shaft Gear Clockwise to right marks and then re-assemble Timing Belt.
Note: it is a Interference Engine TDC does not apply.
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Friday, December 27th, 2019 AT 10:09 AM
Tiny
ENGINEERINGDAD
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I guess what I'm asking is, after locking the cams in their right settings can I independently move the crank gear to it proper mark and then reassemble, since the belt jumped a few notches?
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Friday, December 27th, 2019 AT 6:43 PM
Tiny
SCGRANTURISMO
  • MECHANIC
  • 4,897 POSTS
Hello again,

Okay, so in the diagrams down below I have included the instructions for the removal, installation, and adjustments for the timing belt for your vehicle from the vehicle manufacturer. Please go through this guide from the vehicle manufacturer and get back to us with how everything turns out. I hope that this helps. Happy Holidays.

Thanks,
Alex
2CarPros
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Friday, December 27th, 2019 AT 8:53 PM
Tiny
ENGINEERINGDAD
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Doesn't help me on the present issue of: "If timing belt jump crankshaft gear a couple notches" what to do next, to get everything back to a normal alignment? The images you've sent I've already done during last year's timing belt job and everything lined up. I just failed to install a new timing belt tensioner at that time and that's why the belt jumped in the present.
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Saturday, December 28th, 2019 AT 6:16 PM
Tiny
SCGRANTURISMO
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Hello again,

The only way to be certain that your timing marks line as they should is to reset everything and go from there. The timing marks will never line up again once the engine has been rotated even one revolution. This is the only way that you can ensure that that timing is correct.

Thanks,
Alex
2CarPros
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Saturday, December 28th, 2019 AT 10:17 PM
Tiny
ENGINEERINGDAD
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Thanks Alex. I'm going to try a method I found on Volvoswedenforum. It go's like this:

Conversation.

I just wanted to give everyone an update. I removed the timing belt and once I did, I was able to move the crank clockwise again. With the cams TDC, the crank was about 10-11 o'clock.I think the belt jumped a couple teeth when I originally tried to remove the crank bolt. Since I was able to return the crank to TDC (had the cams locked with the rear locking tool), where everything lined up, should I expect any timing or interference issues now? I feel like I should be in good shape if everything aligns and the crank turns freely once I reinstall the timing belt.

As long as it turns freely after you install the timing belt, I would give it a go. Start it first without the cover and without the accessory serpentine belt on just to make sure it's okay before buttoning it up. It may not be a bad idea to run a compression check at some point but make sure it runs okay first.

It will be fine, just do what you were planning, get it back together and move on.

Make sure you turn it over by hand, clockwise, 2 full revolutions of the crank shaft pulley and check that the timing marks all line up still. Do not try to start the car before doing this. If something is off you can just rotate CCW to get back where you started and try again.

Good luck and let us know how you make out!
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Monday, December 30th, 2019 AT 9:29 AM
Tiny
SCGRANTURISMO
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Hello again,

Okay, please let us know how it turns out.

Thanks,
Alex
2CarPros
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Monday, December 30th, 2019 AT 2:36 PM

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