For those that may have wandered into this thread, I found the answer. I aligned the cams by setting the writing on the end (the part number) of the intake cam DOWN and the writing on the exhaust cam UP. Then I set the timing as usual and everything was fine. OH! and don't forget to reinstall the VV...

After refreshing a new-to-me engine with only 42000 actual miles, I drove it around for a few thousand miles, and for most of that had code P0016. The car seemingly performed fine, so I waited till I had the time. When i got the time, I set up the car to adjust the timing, set TDC etc, and because I...

I did the unthinkable....Whilst on vacation, I volunteered to help out a buddy with an ailing S40 with electrical gremlins. My payback for my grievous error of judgement is that I now have 2 wires that can plug into his 2002 Volvo S40 2.0t (US spec) oil pressure sensor. The harness was de-loomed bec...

What most likely happen last time is the guy did not pull the timing belt tight as he work his way around the pulleys. When he set the tensinor, the slack between the intake and exhaust moved one pulley one tooth off Exactly This is too easy to screw up. I had a couple-three pints in me (the usual ...

Was your timing messed up prior to the rebuild? My intake cam seems to be off by a tooth and the exhaust doesn't have a mark, so Rick mentioned that I need to set the timing from scratch. I don't know if the doc you attached includes the process that would set it from scratch. But if your timing wa...

OP Not sure if you have this. I uploaded timing belt instructions for the T5 (no difference in this case). It's what I used last year when I rebuilt the engine on my S40. I used the cam-lock tool that RickHaleParker mentioned to hold the cams. Worked perfectly. The hardest part for me was that the t...

I'm late...I know, but this is useful information. OP, Why not swap a Mambatek 14t turbo (349.00 dollars US) and call Upsolute and they will set you up with a good tune? Add a decent downpipe and 2.5 inch exhaust and that's worth over 50 horsepower (at the wheels) more than the stock mitsubishi 12t ...

A little late to this thread but I can add that I added an open element filter to my US spec. 2002 S40 with a 14T conversion, bolt-ons and Upsolute tune. The noise wasn't at all pleasant BTW, and I also gained nothing but noise. You see cold air isn't the whole issue, the convoluted/corrugated intak...

Thanks! As soon as the monsoon-like rains and wind stops(gusts over 65 MPH), I plan to go out and put the most-excellent advice of you two guys to the test. If my guess, and alsnertzes keen eyesight were wrong, DeadErics advice on blowing into the tubing will likely point to the line connected to th...

2002 Volvo S40 turbo American Spec. Ok, I'd like to be able to blame someone else :D ....but after a pint or three I pulled out the evap purge AND fuel lines....and forgot which one is the fuel line. My guess is that it's the center one in the photo (if the photo uploads). If not, at the firewall th...