So, this is the final installment of my timing belt saga. Took it to the mechanic this morning. He redid the timing. He said it was only a few teeth off. As I suspected the crankshaft was not properly seated on the gear. He said it didn't do any damage, but it was not good. Hopefully it didn't weaken the gear in anyway.

I really do like to try things when it comes to repairs and I've done quite a few things on both this car and our BMW. On this car there are things that are pretty easy to fix/replace (like the thermostat, expansion tank and radiator). But this timing belt repair really threw me off. I don't think I will attempt it again. But who knows, maybe I will change my mind in 50K miles.

Many thanks to all who have advised me through this.

You disassembled and reassembled the belts and covers and fan, That's the hard stuff, it sounds like you missed a couple of Specific details on the Belt and Crank Gear assembly. Give it another go in 50K and just pay attention to the Nub on the Crank Gear... and sometimes when you release the tensioner, the Cam sprocket can rotate back, causing it to be a tooth off.

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'75 Jeep CJ5 345Hp ChevyPwrd, two motorcycles, '85 Pickup: The '89 Volvo is the newest vehicle I own. it wasn't Volvos safety , it was Longevity that sold me http://home.lyse.net/brox/TonyPage4.html

Missing the nub on the crank gear was bad form on my part. No excuse for that one. What messed me up was undoing the crankshaft bolt. I bought the special tool to do this and in order for the special tool to engage with the crankshaft I couldn't have the markings lined up at TDC. Then once I tried to loosen the bolt it traveled even more off the mark. Once the bolt was loose I didn't know if I could move the crankshaft back to TDC, so I didn't.

Ahh, see, you know what the issues are. So you are ready to do it with confidence next time.

Yes you can move any of the three sprockets with out worry of internal parts crashing into each other. This engine is a 'Noninterference' engine.
Crack the crank bolt loose. Then you can still snug the bolt back up to situate the Timing marks then you can get the bolt back off. Even easier if you pull teh Spark plugs out..no compression.

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'75 Jeep CJ5 345Hp ChevyPwrd, two motorcycles, '85 Pickup: The '89 Volvo is the newest vehicle I own. it wasn't Volvos safety , it was Longevity that sold me http://home.lyse.net/brox/TonyPage4.html

That is what I will do next time. It makes me mad that I was not able to complete it successfully this time. But, I am determined to try again.

Go to www.stepbystepvolvo.com for free guide to changing timing belts.

Congratulations on your effort. Not many women* would try it—although there's no real reason for that. You came real close and at least got it running on your first attempt. Other first-timers have come up short there.

* Google volvogirl for inspiration. I don't think Lee Holman writes anywhere now but I'll bet her tools aren't getting rusty.

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Bruce Young, '93 940-NA (current), 240s (one V8), 140s, 122s, since '63.

Thanks Bruce!! I will definitely google volvogirl. Didn't know there was a kindred spirit out there!

If you go to Volvo meets (check out Rolling Mag and Swedespeed.com, as well as gatherings
on this site) you will find you are DEFINITELY not alone!
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George Downs, Bartlesville, Heart of the USA!

Thanks! I will!