Third attempt to start, heard a soft cough/clunk?

Tiny
VORTICE
  • MEMBER
  • 1994 VOLVO 850
  • 2.3L
  • 5 CYL
  • TURBO
  • 2WD
  • AUTOMATIC
  • 217,000 MILES
So, it started when I was driving down a dirt road, it was dark, I knew I was driving a bit too fast and hit a rut at like 15, 20mph. Came back down sheared off the CV axle clean from the rotor hub. I didn't want to leave her, I limped her home about 4 miles. When I got home, I put her in park, while still running I was curious, I pulled the gear selector back in to reverse. Made the most awful grinding, clinking sound ever. Scared the hell out of me so I shifted as fast as I could back into park and shut her down.

A few months roll by like two or three before I can attain the parts for her. Went on a road trip for a few weeks, came back and all of her goodies had arrived. I thought I might as well buy more than just the CV axles, seeing as I noticed most of all her parts were still from the factory (30-year-old spark plugs, fuel injectors, CV axles, pretty much everything).

So, I get to work, I disassemble as little as possible in the sense of not wanting to bleed the brakes or fuss with the rotors. I'm not sure if there's a trick to installing them, but I just put a small helping of factory splined joint grease on all the splines and kind of nudged them in until I felt a solid clunk. Then I installed the new towers and struts, all according to torque specs.

Then I started disassembling everything that I needed to, to get the intake manifold out. But in the process, I got coolant all over the starter and I'm not sure if some splashed into where the valves sit. Got it out (my goal being to change the old PCV system out for new). It was a waste of time because the old system was torn out and left in the engine bay, I still don't understand why or how. So, I just kind of half installed it under the intake manifold and the tubing that goes to the turbo left it to hang out there. The current system works with only two tubes coming from the turbo.

Then I changed out the factory fuel injectors, for some cheapo ones for like $50.00, they were off of eBay, the name of them was: 5x Upgrade Fuel Injectors 0280155766 for Volvo 850 V70 C70 2.3L Turbo 1996-1998). At first, I was thinking to myself these can't be right, they were half the thickness and weight of the factory ones. But I tried them out with the old fuel injector seat rings, and they fit snug. So, I installed the intake manifold and new crush gasket on, but I noticed there was a bolt missing under the manifold that went into a little bracket that held a small wire harness. I wondered if it was important, like to ground the starter solenoid? But I didn't have the strength in me to get it in there and left it.

I'm working on the car off and on for a few months like this casually, and it rained a whole lot and temperatures were in the low 20s. This is why it took me so long; at times I noticed I didn't shut the hood all the way and left it a smidge open because tools were all over under there. I didn't think anything of it, like, oh its fine water is not going to get all in there. But now I'm wondering.

Then when I was ready to start her, I lost an intake manifold bolt, and I don't think the one by the thermostat is torqued, was impossible to reach. It took a few more days for me to figure out the top radiator hose was in fact a cold air hose, as well as figure out the routing from the throttle body mouth.

After all that I lowered her down (I had her front end up like three four feet high for the whole duration. Oh, I also replaced the fuel filter. Anyways I finally had all the clamps tightened and hopped in to start her.

Turned her key ignition to just before starting and let her wake up a bit. The battery was out for that duration as well. Then cranked her she whirred and whined for a few seconds, so I stopped. I left in the position before start again and tried her again this time she was almost half alive I heard her growl. I was ecstatic. So, I did what I did again and the 3rd time she just whined for a few seconds then made a soft cough mixed with a clunk, scared me it was an ugly sound. It was only as loud as if you dropped a half inch wrench on carpet almost like.

Please help me!
Monday, February 27th, 2023 AT 9:15 PM

3 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,179 POSTS
Hi,

Are you sure that the spark plug wires were installed correctly? Is it possible for you to record the engine cranking and upload it for me to hear?

Let me know. I'm not sure, but it sounds like the spark plug wires may not be installed in the correct order.

I attached two pics below showing where the spark plugs should go between the distributor and the spark plugs. Make sure they are in the order shown.

Let me know.

Joe

See pics below.
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Tuesday, February 28th, 2023 AT 8:01 PM
Tiny
VORTICE
  • MEMBER
  • 2 POSTS
Yes I'll try to send you a sound clip. Here it is but it's not the original sound now it just won't do anything.
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Wednesday, March 1st, 2023 AT 6:58 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,179 POSTS
Hi,

Wow. That isn't a starter issue. I have a feeling the timing belt has failed. Do me a favor. Remove the front timing belt cover top section and see if the belt is still attached and if the cam pulleys turn when it cranks. (See pic 1)

Let me know what you find.

Joe

See pic below.
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Wednesday, March 1st, 2023 AT 6:09 PM

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