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Timing Belt Failure

2002 S60 2.4T AWD, purchased 1 yr ago with 124,000. Timing belt service was done at time of purchase. At 131,000 the head gasket blew, was replaced, and heads reworked. 4,000 miles later the timing belt has failed and of course the engine is ruined. The belt was being pushed away from the engine, almost wore a hole through the cover, and there was only 1/4 to 3/8 width of belt left. The rest of the timing belt had ground off and was laying inside the cover. The tensioner and idler check out fine. Question, what would cause the belt to be mis-aligned and push to the outside and wear against the timing belt cover? The mechanic that did the head gasket work told me he had a tough time getting the timing right. Is it possible that the cam sprockets were mis-aligned? He did not remove the tensioner, idler or water pump when performing the head work.

Looking for possible causes of failure. Please respond with master mechanic insight!
 

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The only time I ever see the belt come through the cover like that is when the idler comes off the tensioner or the bearings fail in it.Cam gears could not be misaligned.A timing problem would not cause this either.
 
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