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The Bosch water pump on my 2000 S80 T6 siezed up after 70,000 miles on the pump (175,000 miles on the engine). There were no cooling problems or leakage from the pump to warn me of this impending disaster. So, a word of warning- always change your water pump when you change the timing belt. The result was 6 bent exhaust valves and 6 bent intake valves- the pistons have valve marks on them but are ok. I removed the cylinder head myself (after receiving estimates of $4,000 to $5,000 to pull and rebuild the head). The head is now being rebuilt by a local machine shop.

My question about timing is this- My crankshaft has a flange on it with a raised rib. The rib is aligned with a tooth on the crankshaft timing belt pulley. Just above the crankshaft is a metal "U" protrusion with square corners. On the lower left leg of the U is another metal protrusion. From VADIS and other information I've gathered, the correct setup for timing the engine is to align the flange rib (and associated tooth) with the metal protrusion on the lower left leg of the U. With the crankshaft in this position and the camshaft sprocket timing marks aligned with their respective marks on the timing cover, the timing belt can be installed and the engine will be setup properly from a timing standpoint- as long as the variable valve timing unit is setup correctly.

I noticed last night that when the crankshaft is aligned as described above, the #1 piston is about half way up the #1 cylinder and not at top dead center- which is what I'm use to seeing based on past experience.

Can anyone tell me if this is normal for this engine? My engine number is 2544803 (past the engine number 1818169 when there was some type of change made by Volvo). Your help is greatly appreciated!!! I will have some nice PICS and what should be useful info. to post on this job when I finish.

Thanks- Matt.
 

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When the timing mark on the crankshaft is lined up, the piston is not all the way at the top. Where you have it is correct. It doesnt come up flush when lined up. Also be real careful when setting up your timing. When removing the timing belt on a cvvt engine you line up the marks then go 90 degrees clockwise, then turn counter clockwise back to the lines. This unloads the cvvt hub, if you dont when you remove the belt the hub will spring out of time. Since you have it torn down you need to reset the timing anyway. Dont just put the hub on, the inside of the hub most likely turned and will not be correct. If you dont set it up correctly it will either run poorly or set a check engine light because it woulnt be able to adjust. The set up procedure is in Vadis but I caution you because the directions are not the best. Damn swinglish!
 
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