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1998 2.4 Camshafts in 1999 T5

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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xApprchsNfnty
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Re: 1998 2.4 Camshafts in 1999 T5

Post by xApprchsNfnty » Sun Mar 22, 2020 10:38 pm

That list is super helpful, really increases my odd at the JY! I couldn't see any type of identification on either end of my cam but I'll try to clean them really well and take another look. Thanks again

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Re: 1998 2.4 Camshafts in 1999 T5

Post by RickHaleParker » Mon Mar 23, 2020 12:02 am

xApprchsNfnty wrote:
Sun Mar 22, 2020 10:38 pm
That list is super helpful, really increases my odd at the JY! I couldn't see any type of identification on either end of my cam but I'll try to clean them really well and take another look. Thanks again
Image
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Platform: P80 1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package, Plant: Uddevalla Sweden.
Platform: X40 (Nedcar) 2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000. Plant: Born Netherlands.
Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0, Plant Torslanda Sweden.
Platform P2 2004 S60R, B2524T4, AW50/51 AWD, Bosch Motronic 7.0, BorgWarner K24 turbocharger, Plant Ghent Belgium.

xApprchsNfnty
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Re: 1998 2.4 Camshafts in 1999 T5

Post by xApprchsNfnty » Sat Apr 25, 2020 10:36 am

Changing gears here a little bit with a quick update:

I was finally able to drill/tap into the broken bolt in the intake cam. I locked the gears, removed belt, removed sprockets/vvt hub, replaced front/rear seals, put back together, new belt/pump/tensioner/idler, serviced PCV (banjo bolt hole was clogged), replaced with banjo bolt w/ check valve, and put it all back together. It's not starting and plugs are fouling so I did a compression test: 2nd cylinder @ 150psi, every other cylinder @ 30-60psi. Car ran fine before disassembly so I have to assume my mechanical timing is off. Turned engine over by hand many times before starting with only compression as resistance. Belt installed with cams locked, VVT hub pre-loaded clockwise with timing marks lined up with engine cover, intake mark with engine cover, crank mark aligned, belt on, tension set, turns by hand, but low compression.

I will try to buy a leak down tester today ($80 even at Harbor Freight?!) and try to pin-point. It's the 2nd cylinder's 150psi that puzzles me, if they were all around 30-60psi then I would assume timing, but 150 is what I would expect for a 200k mile T5.

Any suggestions? I've been searching the forums and many others have had this experience after TB replacements but most of those resolved with realizing their timing was off. I can't see how mine would be.

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Re: 1998 2.4 Camshafts in 1999 T5

Post by bmdubya1198 » Sat Apr 25, 2020 12:56 pm

Make for 100% sure your timing is right. That's really the only thing I can think would be wrong in this situation. You never had the cams out of the engine, correct?
2000 V70R Venetian Red/Charcoal M56 Swapped 195k
2003 S60 2.4T Silver/Black 112k
2007 XC90 V8 AWD Sport Titanium Grey/Black 166k
1991 944 Turbo Dark Green/Beige 173k
1992 245 Base White/Beige 249k
2006 BMW 330i
1999 BMW 528i
Sold-
2000 S70 GLT Mystic Silver/Taupe 253k
1993 944 Base Beige/Beige 221k
1998 V70 GLT Black/Beige 199k
1998 S90- Silver/Gray 207k
1995 850 GLT Tropic Green... crushed
2001 S60 2.4T Black/Black 230k
1988 744 Turbo M46 Beige Metallic/Beige 188k

xApprchsNfnty
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Re: 1998 2.4 Camshafts in 1999 T5

Post by xApprchsNfnty » Sat Apr 25, 2020 1:37 pm

Correct, cams stayed in the head. I bought the LD tester from HF (it's a POS) and I'm definitely leaking past the valves with each cylinder at TDC except cyl 2 (how is that possible?!). But I'm also leaking a bit passed the rings, no surprise. I was pressurizing just before TDC, TDC, and just after to try figuring out the valves' position but couldn't determine which is advanced/retarded, I could try again more scientifically.

The only thing that I can think of is when I put the gear/hub back on the cams, there is space for the bolts to be clocked cw/ccw. With the intake gear I could see the impression of where the bolts were before so I matched that, and the exhaust hub I placed it, snugged the bolt, rotated against the spring until it was on the mark, then tightened it down. Checked both marks afterwards. Maybe my crank is just a little off, would make sense because it's a smaller radius so a bit off would make more of a difference? But wouldn't there still be a point in the stroke where all valves are closed and it would hold pressure? Hmmm...

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Re: 1998 2.4 Camshafts in 1999 T5

Post by xApprchsNfnty » Sat Apr 25, 2020 4:24 pm

Image

Image

Image

Update correction:
I tested the leak again. At the above marks, cyl#1 is almost at the top of it's compression stroke (is that how it's supposed to be?) and when at TDC, it is slightly leaking out the brake booster port, not out tailpipe, and not out oil cap/dipstick/coolant tank. Same with cyl#4 at TDC but cyl#2 doesn't leak at all at TDC (I've only tested those cylinders). So now I wonder if I did somehow bend my intake valves, or maybe something fell in them while I had my intake off. But in 4 of out 5 cylinders seems unlikely.

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Re: 1998 2.4 Camshafts in 1999 T5

Post by bmdubya1198 » Sat Apr 25, 2020 7:07 pm

Just to be clear, you locked the cams from the rear with the tool, correct? If you're absolutely positive that the gear isn't attached to the cam in the wrong position, you should be alright as far as everything being aligned. If the cams were locked, it's impossible to mess it up.

It's possible that you bent some valves, maybe while cranking it at some point while the timing was off?
2000 V70R Venetian Red/Charcoal M56 Swapped 195k
2003 S60 2.4T Silver/Black 112k
2007 XC90 V8 AWD Sport Titanium Grey/Black 166k
1991 944 Turbo Dark Green/Beige 173k
1992 245 Base White/Beige 249k
2006 BMW 330i
1999 BMW 528i
Sold-
2000 S70 GLT Mystic Silver/Taupe 253k
1993 944 Base Beige/Beige 221k
1998 V70 GLT Black/Beige 199k
1998 S90- Silver/Gray 207k
1995 850 GLT Tropic Green... crushed
2001 S60 2.4T Black/Black 230k
1988 744 Turbo M46 Beige Metallic/Beige 188k

xApprchsNfnty
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Re: 1998 2.4 Camshafts in 1999 T5

Post by xApprchsNfnty » Sat Apr 25, 2020 7:22 pm

Yes the cams were locked from the rear with the locking tool. I can't think how I may have attached the cam gears incorrectly, there was pretty much only one way to do it with the cams locked. And as far as I can tell and based on my recollection, the timing was never off.

If I bent valves for some reason, wouldn't I have bent them all? And does anyone have any suggestions about how cyl#2 can have perfect compression while the other 4 are really low?

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bmdubya1198
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Re: 1998 2.4 Camshafts in 1999 T5

Post by bmdubya1198 » Sat Apr 25, 2020 9:56 pm

Well, not necessarily. Typically when these engines jump timing, several valves will be bent, but not all of them. It all depends on how fast the engine was spinning before it shut off (say, if the belt broke while driving), and of course which valves were opened at the time. Even if it happened while cranking the engine, if it’s due to being timed improperly certain valves will not always be open while each piston is at TDC, so the engine won’t always bend every valve.

That said, if it was never misaligned, this is a strange situation. I really don’t know of any other situation where you would have low compression with leakage through the intake valves aside from bent valves or improper timing.
Forgive me for asking if you’re sure again (lol), but are you sure the cams aren’t flipped 180 degrees? The groove on the back of the intake cam should be offset to the top of the cam cover, with the exhaust offset to the lower side.
2000 V70R Venetian Red/Charcoal M56 Swapped 195k
2003 S60 2.4T Silver/Black 112k
2007 XC90 V8 AWD Sport Titanium Grey/Black 166k
1991 944 Turbo Dark Green/Beige 173k
1992 245 Base White/Beige 249k
2006 BMW 330i
1999 BMW 528i
Sold-
2000 S70 GLT Mystic Silver/Taupe 253k
1993 944 Base Beige/Beige 221k
1998 V70 GLT Black/Beige 199k
1998 S90- Silver/Gray 207k
1995 850 GLT Tropic Green... crushed
2001 S60 2.4T Black/Black 230k
1988 744 Turbo M46 Beige Metallic/Beige 188k

xApprchsNfnty
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Re: 1998 2.4 Camshafts in 1999 T5

Post by xApprchsNfnty » Sat Apr 25, 2020 10:32 pm

I'm pretty close to re-doing the timing to check everything. I can't imagine how I would have turned the cams 180*, but it's possible. Although, then to get the timing mark to align I think the cam would be off by either 120* or 240* since the gear can only bolt up to the cam 3 ways.

I ordered a cheap endoscope to plug into my phone so I'll snake that down there and see if it shows me anything. Also thought about removing the intake again, shining a light through the plug hole and seeing if it comes through the valve seats. Not sure about how effective that'll be.

Since this problem isn't reflected in the title of this thread, I think I'll start a new one. Thanks for your replies and please give me more if you can!

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