Flex plate timing 2.3 sohc at tdc - 1990 Volvo 740

look for a mark on timing gear it have always mark and u all ways on tdc

Get Ford timing tool kit, part = otc-6488 (For about $119 USD on eBay)

4 timing chains (3 front including the optional balance shaft chain + 1 back)

2 cam guides (1 front + 1 back)

2 oil tensioners (1 front + 1 back)

1 jackshaft tensioner (1 front)

1 jackshaft guide/cassette (1 front)

1 balance shaft tensioner (1 front) (will probably be ok, so dont replace it)

1 balance shaft guide (1 front) (will probably be ok, so dont replace it)

new sprockets + bolts + gaskets etc.

new spark plugs + throttle body cleaner + lithium grease spray + oil change

head gaskets

some of these parts (the front stuff) can be obtained as a primary timing chain rattle noise kit Part# = 2u3e-6d256-** ab for 4*4 & bb for 2*4.

The kits also have later part numbers for us$ 76 @ http://www.fordpartsonline.com

My parts order (without the balance shaft stuff) was:

$76.04 KIT-TENSIONER TIMING 2u3e-6d256-ab

$47.93 Engine, Camshaft and timing, Timing chain, TIMING CHAIN, Explorer, Mountaineer, Rear - 4.0L SOHC - 4.0L SOHC

$57.36 Engine, Camshaft and timing, Chain guide, CHAIN GUIDE, Explorer, Mountaineer, Jackshaft To Cam - 4.0L SOHC - 4.0L SOHC

$103.22 Engine, Overhaul gasket set, OVERHAUL GASKET SET, Explorer, Mountaineer, Upper (Valve Grind) - 4.0L SOHC - 4.0L SOHC

$28.93 Engine, Camshaft and timing, Tensioner, TENSIONER, Explorer, Mountaineer, Upper - 4.0L SOHC - 4.0L SOHC

Its worth mentioning that this procedure is not enjoyable at all and should be undertaken with at least 8 full days to completion (I recon you could do it in half the time the second time).

It is basically on entire engine re-build with both heads off and the engine out of the vehicle.

It is not possible to do the rear chain or sprocket with the engine in the car as the flywheel needs to come off + at least 1 head, but it is possible to do the front primary chain and or front cam chain with the engine in the car.

You will be a ford exploder and timing expert after you do this - the main reason should be the love of your American built vehicle. Its a solid car - except for the plastic guides!

Disclaimer Note: This is how i successfully did the job, but i am not a ford mechanic and don't hold me responsible if this does not work for you.
Timing Overview

A Small Sprocket on the crank turns a larger (2 to 1 ratio) jackshaft sprocket that is in turn connected front & back to the 2 camshafts.

Thus a 360o turn of the crank will turn both the camshafts 180o.

Firing order is 1-4 2-5 3-6, Right side numbers 1,2,3. Left Side = 4,5,6.

At TDC pistons 1 & 5 are fully raised, thus 1 is about to spark & 5 is evacuated.

The engine will turn freely (no piston to valve contact) with the cams 180o out, it will even run (roughly) with 1 out 180o, any other settings may cause major damage to the valves.

The 2 cam shafts come with timing markings, "yes" real timing marks that anyone can use (even without special tools) to ensure correct timing.

The way to time it is to ensure both the off centre cam shaft slits are level/flat with the head.

With the engine at TDC both the cams need to have the off centre slot in the same position either up and level or down and level.

It is super critical that both the camshafts are 100% in sink with each other, i.e. not a few degrees off, the engine computer can compensate for crank timing but not engineering failure.

Be warned the camshafts can turn easily fast & hard by themselves as a few springs are compressed at TDC, I got my finger jammed and its still healing + if the engine is not at TDC you may damage a valve.

Now heres the hard thing that you will need special tools for - if you need to change the timing, you will need to be able to undo the cam sprocket bolt on both cams & these are done up real tight.

There is a tool that you attach that has 2 pencil thick shafts that fit into the sprocket and prevent it from turning - then you need to put about 90Nm of force on the bolt (remember the rear one if LHT)

For the $money$, its well worth getting yourself the tool kit - it will save you hours in the long run. Search eBay for otc-6488 should be US $119 - then sell them again for say $100.

There is also a tool version of the oil tensioner in the kit that screws right in and puts the correct amount of force on the chain + guide, to enable you to do up the cam bolt with the chain and sprocket in the right spot on the cam.

chain. R&R instructions from autozone.com pasted below. let me know if you have any more questions.

REMOVAL & INSTALLATION
SOHC Engine See Figures 1, 2, 3 and 4

1. Disconnect the negative battery cable.
2. Remove the timing chain front cover.

During timing chain and sprocket removal, position the crankshaft 90 degrees past Top Dead Center (TDC), to make sure the pistons will not contact the valves upon assembly.

1. Carefully rotate the crankshaft clockwise so the timing mark on the crankshaft sprocket and keyway align with the main bearing cap split line (90 degrees past TDC).
2. Remove bolts, then remove the timing guides and tensioner.
3. Remove the camshaft sprocket bolt, using a 7 / 8 in. (21mm) wrench to hold the camshaft. Then remove the timing chain and camshaft sprocket. Remove the crankshaft sprocket, if necessary.

To install:

1. Inspect the chain for wear and damage. Check the inside diameter of the chain, it should be no more than 16.77 in. (426mm). Inspect the chain guides for wear or cracks and the timing sprockets for teeth or key wear. Replace components as necessary.
2. Verify that the crankshaft is positioned 90 degrees clockwise past TDC from the keyway (keyway at 3 o'clock).
3. Bring the camshaft up to No. 1 TDC by loosely installing the sprocket and rotating the sprocket until the timing pin can be inserted. The camshaft contains wrench flats to assist in turning the shaft. The dowel pin should be at 12 o'clock when the camshaft is at TDC and a timing pin ( 3 / 16 in. drill bit) should then install at about the 8 o'clock position.
4. If removed, install the crankshaft sprocket, then rotate the crankshaft counterclockwise 90 degrees up to No. 1 TDC (keyway at 12 o'clock).
5. Position the chain under the crankshaft sprocket and over the camshaft sprocket. If necessary remove the camshaft sprocket, then slide the camshaft sprocket into position with the chain already engaged. The timing chain should be positioned so that one silver link plate aligns with the reference mark on the camshaft sprocket and the other aligns with the downward tooth (at the 6 o'clock position) on the crankshaft sprocket. The letters FRT on the camshaft sprocket must face forward, away from the cylinder head and excess chain slack should be located on the tensioner side of the block.
6. Temporarily install the timing pin to verify proper alignment of the camshaft and sprocket, then install and tighten the sprocket bolt to 75 ft. lbs. (102 Nm). Again, use a wrench on the camshaft flats to hold the shaft in position while tightening the bolt. Do not allow the camshaft retaining bolt to torque against the timing pin or cylinder head damage will result.
7. Install the chain guides with the words FRONT facing out. Install the fixed guide first and verify the chain is snug against the guide, then install the pivot guide. Tighten the bolts to 19 ft. lbs. (26 Nm) and verify that the pivot guide moves freely.
8. Retract the tensioner plunger and pin the ratchet lever using a 1 / 8 in. No. 31 drill bit inserted in the alignment hole at the bottom front of the component. Install the tensioner and tighten the bolts to 14 ft. lbs. (19 Nm), then remove the drill bit.
9. Make one final check to verify all components are properly timed, then remove all timing pins.
10. Install the timing chain front cover.
11. Connect the negative battery cable, start the engine and check for leaks.
    

Fig. Fig. 1: At 90 degrees past TDC, the crankshaft sprocket timing mark and keyway will align with the main bearing cap split line

Fig. Fig. 2: Exploded view of the timing chain and sprocket assembly-SOHC engine

Fig. Fig. 3: Insert the timing pin to ensure that the camshaft is at No. 1 TDC-SOHC engine

Fig. Fig. 4: When the camshaft is at TDC, rotate the crankshaft counterclockwise 90 degrees to achieve TDC

Timing Chain and Sprockets
REMOVAL & INSTALLATION

1. 
   
   
   
   Fig. 1: At 90 degrees past TDC, the crankshaft sprocket timing
   mark and keyway will align with the main bearing cap split line
   
   
   
   
   
   
   
   Fig. 2: Exploded view of the timing chain and sprocket
   assembly - SOHC engine
   
   
   
   
   
   
   
   Fig. 3: Insert the timing pin to ensure that the camshaft is at
   No. 1 TDC - SOHC engine
   
   
   
   
   
   
   
   Fig. 4: When the camshaft is at TDC, rotate the crankshaft
   counterclockwise 90 degrees to achieve TDC
   
   

DOHC Engine

1. Disconnect the negative battery cable.
   
2. Remove the timing chain front cover.
   NOTE: During timing chain and sprocket removal, position the
   crankshaft 90 degrees past Top Dead Center (TDC) to make sure the pistons will
   not contact the valves upon assembly.
   
   
   
3. Carefully rotate the crankshaft clockwise so the timing mark on the
   crankshaft sprocket and keyway align with the main bearing cap split line.
   
4. Remove the bolts, then remove the timing guides and tensioner.
   
5. Remove the camshaft sprocket bolts, using a 7?8 in. (21mm) wrench
   to hold the camshaft. Then remove the timing chain and camshaft sprocket. Remove
   the crankshaft sprocket, if necessary.
   To install:
   
   
6. Inspect the chain for wear and damage. Check the inside diameter of the
   chain, it should be no more than 23.15 in. (588mm). Inspect the chain guides for
   wear or cracks and the timing sprockets for teeth or key wear. Replace
   components as necessary.
   
7. Verify that the crankshaft is positioned 90 degrees clockwise past TDC. The
   crankshaft keyway should be at 3 o'clock aligned with the main bearing cap split
   line to prevent piston and valve damage.
   
8. Install the camshaft sprockets, retaining bolts and washers. Make sure the
   letters FRT on the sprockets face forward, away from the cylinder block. Use the
   wrench flats provided on the camshafts to hold the shaft and tighten the bolts
   to 75 ft. lbs. (102 Nm).
   
9. Bring the camshafts up to No. 1 TDC by rotating the camshafts and sprocket
   until the dowel pins are at 12 o'clock. Install a 1?6 in. drill bit
   into the hole in the sprocket about 9 o'clock.
   
10. If removed, install the crankshaft sprocket, then rotate the crankshaft
    counterclockwise 90 degree up to No. 1 TDC (keyway and sprocket timing mark at
    12 o'clock, in alignment with the block timing mark).
    
11. Position the timing chain under the crankshaft sprocket and over the
    camshaft sprockets so 2 silver link plates align with the reference marks on the
    camshaft sprockets and another 2 plates align with the downward tooth (at 6
    o'clock position) on the crankshaft sprocket. Excess chain slack should be
    located on the tensioner side of the cylinder block.
    
12. Verify that the crankshaft reference mark aligns with the cylinder block
    mark at 12 o'clock and that the timing pins are installed in the holes at about
    the 9 o'clock position. Remove the timing pins from the camshaft sprockets.
    
13. Install the timing chain fixed guide to the right of the block face toward
    the water pump. Tighten the bolts to 21 ft. lbs. (28 Nm) and verify the chain is
    snug against the guide.
    
14. Install the pivoting chain guide and check for clearance between the block
    and head. Tighten the bolt to 19 ft. lbs. (26 Nm) and verify the guide pivots
    freely.
    
15. Install the 2 forward camshaft bearing caps and the upper timing chain
    guide, then tighten the retaining bolts to 124 inch lbs. (14 Nm).
    
16. Retract the tensioner plunger and pin the ratchet lever using a 1?8 in. (3.18mm) No.
    31 drill bit inserted in the alignment hole at the lower front of the component.
    Install the tensioner and tighten the bolts to 14 ft. lbs. (19 Nm), then remove
    the drill bit.
    
17. Make one final check to verify all components are properly timed, then
    remove all timing pins.
    
18. Install the timing chain front cover.
    
19. Connect the negative battery cable, start the engine and check for leaks.
    
    
    
    
    
    Fig. 5: Rotate the crankshaft clockwise until the timing mark
    on the crankshaft sprocket and keyway align with the main bearing cap split line
    
    
    
    
    
    
    
    
    Fig. 6: Loosen the timing chain tensioner mounting bolt . . .
    
    
    
    
    
    
    
    Fig. 7: . . . and remove the tensioner from the engine block
    
    
    
    
    
    
    
    Fig. 8: Retract the tensioner plunger and pin the ratchet lever
    with a 1?8
    in. (3.18mm) drill bit inserted in the alignment hole
    
    
    
    
    
    
    
    Fig. 9: Remove the mounting fasteners from both timing guides .
    . .
    
    
    
    
    
    
    
    Fig. 10: . . . and remove the timing guides from the engine
    
    
    
    
    
    
    
    Fig. 11: Remove the camshaft sprocket bolts, using a 7?8 in. (21mm) wrench
    to hold the camshaft
    
    
    
    
    
    
    
    Fig. 12: Remove the timing chain and camshaft sprockets
    
    
    
    
    
    
    
    Fig. 13: Insert the timing pins to verify that the camshafts
    are at TDC
    
    
    
    
    
    
    
    Fig. 14: Make sure that the silver link plates and reference
    marks are all in alignment as shown
    
    

2.0L Engine SOHC ENGINE

1. Remove the drive belt and timing cover.
2. Raise the car and support it with safety stands.
3. Remove the right-hand splash shield and the crankshaft pulley. Fig. 11: The timing marks on both the camshaft and crankshaft pulleys must be aligned like this before removing or installing the timing belt — 2.0L SOHC engines
   
   
4. Align the timing marks as illustrated in the accompanying illustration.
5. Refer to the accompanying illustration and remove the timing belt as follows:
   1. Loosen the timing belt tensioner bolt (1).
   2. Use an 8mm Allen wrench, and turn the tensioner (2) counterclockwise 1⁄4 turn.
   3. Insert a 1⁄8 inch drill bit in the hole (3) to lock the belt tensioner in place.
   4. Remove the timing belt (4). Fig. 12: Remove the timing belt by following these 4 numbered steps (refer to the text for an explanation) — 2.0L SOHC engine
      
      
   5. Inspect the belt for damage and signs of oil leakage. To install: NOTE: Install the timing belt over the sprocket in a counterclockwise direction starting at the crankshaft. Keep the belt span between the crankshaft and camshaft tight when installing the belt over the camshaft.
      
6. Install the timing belt and remove the drill bit.
7. Tighten the tensioner bolt to 15–22 ft. lbs. (20–30 Nm).
8. Rotate the engine two complete revolutions and make sure the timing marks are aligned.
9. Install the timing belt cover and crankshaft pulley.
10. Install the right-hand splash shield and the drive belt.
11. Start the car and check for proper operation.

DOHC ENGINE NOTE: A camshaft alignment timing tool (No. T94P-6256-CH or equivalent) and a crankshaft Top Dead Center (TDC) timing peg tool (No. T97P-6000-A or equivalent) are required for this procedure. NOTE: Make sure the correct notch in the pulley is indexed to the lower cylinder block. Refer to the accompanying illustration. Fig. 13: A camshaft alignment timing tool . . .
Fig. 14: . . . and a crankshaft TDC timing peg tool are required when removing and installing the timing belt

1. Remove the spark plugs.
2. Rotate the crankshaft to TDC.
3. Locate and remove the plug bolt by the Crankshaft Position (CKP) sensor (refer to the illustration) and install the TDC timing peg. Fig. 15: Remove the plug bolt by the Crankshaft Position (CKP) sensor and install the TDC timing peg
   
   
4. Raise the car and support it with safety stands.
5. Unfasten the splash shields bolts and remove the shield.
6. Lower the car and remove the water pump pulley.
7. Remove the valve cover and the timing belt covers.
8. Align the camshafts and install the camshaft alignment tool on the back of the camshafts as illustrated. Fig. 16: Align the camshafts and install the alignment tool
   WARNING
   If the camshaft belt is being reused, mark the direction of the camshaft belt to the rotation of the camshaft prior to removal, or premature wear and belt failure could occur.
   
9. Loosen the tensioner pulley bolt and relieve the tension on the belt by disconnecting the tensioner tab from the timing cover back plate.
10. Slide the belt off the sprockets.
11. Inspect the belt for wear and replace as necessary. Fig. 17: Timing belt routing — 2.0L DOHC engine
    To install:
    
12. If, for any reason, the engine was disturbed, the camshafts moved or the sprockets replaced, perform the following procedure: NOTE: Make sure the correct notch in the pulley is indexed to the lower cylinder block.
    1. Position the crankshaft just prior to Top Dead Center (TDC).
    2. If not already done, locate and remove the plug bolt by the Crankshaft Position (CKP) sensor (refer to the illustration) and install the TDC timing peg.
    3. Rotate the crankshaft clockwise against the TDC peg. NOTE: Installation of the alignment tool into the exhaust camshaft may require the camshafts to be rotated clockwise.
       
    4. Install the camshaft alignment tool on the back of the camshafts.
    5. Install the timing belt and engage the timing belt tensioner tab into the upper timing cover backplate. NOTE: A 3⁄8 inch drive, 10mm, 2 inch torque adapter offset is required to tighten the tensioner bolt.
       
    6. Using a 6mm Allen wrench, adjust the tensioner until the index marks are aligned and tighten the bolt to 17–20 ft. lbs. (22–28 Nm).
    7. Rotate the crankshaft clockwise against the TDC alignment peg, then remove the camshaft alignment tool.
    8. Remove the TDC peg tool and install the plug bolt.
    9. Install the timing and valve covers.
    10. Install the water pump pulley and the splash shield.
    11. Install the spark plugs. If the engine or the camshaft were not disturbed in any way, or the sprockets were not removed, perform the following procedure:
        
13. Install the timing belt and engage the timing belt tensioner tab into the upper timing cover backplate. Fig. 18: Engage the timing belt tensioner tab into the upper timing cover backplate . . .
    Fig. 19: . . . then use a 6mm Allen wrench to adjust the tensioner until the index marks are aligned
    Fig. 20: A 3⁄8 inch drive, 10mm, 2 inch torque adapter offset is required to tighten the tensioner bolt (arrow) — 2.0L DOHC engine
    NOTE: A 3⁄8 inch drive, 10mm, 2 inch torque adapter offset is required to tighten the tensioner bolt.
    
14. Using a 6mm Allen wrench, adjust the tensioner until the index marks are aligned and tighten the bolt to 17–20 ft. lbs. (22–28 Nm).
15. Rotate the crankshaft clockwise against the TDC alignment peg, then remove the camshaft alignment tool. Fig. 21: Rotate the crankshaft clockwise against the TDC alignment peg
    
    
16. Remove the TDC peg tool and install the plug bolt.
17. Install the timing and valve covers.
18. Install the water pump pulley and the splash shield.
19. Install the spark plugs.

Fig. 1: At 90 degrees past TDC, the crankshaft sprocket timing mark and keyway will align with the main bearing cap split line.




Fig. Insert the timing pin to ensure that the camshaft is at No. 1 TDC-SOHC engine




Fig. : When the camshaft is at TDC, rotate the crankshaft counterclockwise 90 degrees to achieve TDC




Fig.: Insert the timing pins to verify that the camshafts are at TDC




Fig. : Make sure that the silver link plates and reference marks are all in alignment as shown


Hope help with this (remember comment and rated this).

1.5L And 1.6L Engines



Fig. Proper pulley alignment for timing belt installation at TDC-Hyundai 1.5L DOHC engines




Fig. Proper pulley alignment for timing belt installation at TDC-Hyundai 1.5L SOHC engines



1.5L Engines



Fig. Proper pulley alignment for timing belt installation at TDC-Hyundai 1.5L DOHC engines




Fig. Proper pulley alignment for timing belt installation at TDC-Hyundai 1.5L SOHC engines




Fig. Proper pulley alignment for timing belt installation at TDC-Hyundai 1.5L SOHC engines, 1.6L similar



1.8L (VIN M) And 2.0L (VIN F) Engines



Fig. Proper alignment of the timing belt alignment marks for belt removal and installation-Hyundai 1.8L and 2.0L (VIN F) engines



2.0L (VIN P) Engines



Fig. Oil pump and crankshaft inner timing belt sprocket alignment marks-Hyundai 2.0L (VIN P) engines




Fig. Timing belt sprocket alignment mark locations and positioning for belt removal and installation-Hyundai 2.0L (VIN P) engines



3.0L (VIN G)



Fig. Installation of the timing belt-3.0L (VIN G) engine







Fig. Timing belt sprocket alignment mark positioning for belt removal and installation-Hyundai 3.0L engine


Hope this helped (remember comment and rated this post).

Could the flex plate be incorrect for your car, if the tdc sensor does not get the correct signaloff of the flexplate because of incorrect spacing, this would cause your problem.

You line up the crankshaft at TDC byaligning the marks on the flywheel/flex plate with the pointer on the bellhousing. On the radiator side of the engine block where it bolts to the trans mission about half way up there is a rubber plug witch you can remove to gane access to the pointer on the trans bellhousing to line up the timing marks

When changing the timing belt you need to place the cam shaft a TDC( clock wise), then rotate the crankshaft to TDC (clockwise), then back off the crankshaft (counter clockwise) THREE TEETH then back (clockwise) 1/2 tooth before TDC place your timing belt arround the crankshaft- water pump- and camshaft finally putting arround the tensioner pulley, holding 25 flbs of torque on the tensioner pulley to get the correct tension then push up on the hydrolic tensioner and tighten and you should have it.... rotate the crankshaft twice, if the camshaft pulley ends back on TDC then you have it correct.