Worst timing belt refresh 1999 Volvo s70-GLT

[800artfreed]

Just a quick update. Taking a hiatus for a few days due to the heat and other obligations. Some of the things I will try are:
1) Turn the Continental TB around so that it is running opposite to how I have been installing it. The Continental label is currently oriented to be readable when looking from the passenger side of the car. The label will be "backwards" to test for bias in the belt as it rotates.

2) Fuss with the tension on the belt with the tensioner.

3) Will grab a C.S. gear from a 1999 S70 at the PnP is #1 doesn't cure my problem. Only considering this due to the over torquing of the crankshaft nut previously (small chance in hell this will do anything).

Will keep everyone informed when I take the next steps. Thanks for staying interested in this issue. It means a lot.

[800artfreed]

Latest update:

I removed and reversed the direction of rotation of the TB. I also adjusted the tensioner again, after the belt was installed. There was some improvement. The belt now rides at the edge of all the pulleys and gears (cam gears, water pump gear, tensioner, idler and crankshaft gear-C.S.G.) not over the edge of the idler and tensioner. Not optimal but I will run the car this way.

I removed the harmonic balancer (HB) pulley for the serpentine belt. Everything looked normal. There is a ridge machined onto the crankshaft that positions the HB on the shaft and therefore the attached C.S.G. No damage or out of position occurred from the over-torquing with my impact tool. The C.S.G. has a flange that provides the material for the 4 bolts that hold the HB onto the gear. The HB & C.S.G. are positioned by the ridge on the CS and pushed as in far as allowed by the 30mm crankshaft bolt. This C.S.G. flange is the place that the belt comes closest to touching.

I marked the TB with a number of vertical yellow crayon marks to show if the belt touched the flange surface of the C.S.G. No indication of the TB touching this surface. I will grab some photos to show the final result.

Thanks for all your support. I appreciate it and hope the engine survives my efforts.

P.S. This project all started because of a horrendous noise that sounded like marbles in the engine itself! Removing the serpentine belt and examining the T.B. area both at idle and engine off showed no noise but revealed dried coolant residue. This prompted the water pump to be R&R. With the engine running and the accessories off of the serpentine belt the noise was not active. The noise in question appears to be the A/C compressor pulley bearing. I will begin that work shortly and start a new thread.