Volvo Repair: 2002 Volvo S40 Valve timing, haynes manual, gdi engine

Question
QUESTION: Dear Roger, We recently replaced a head gasket on my son's Volvo S40 and we are not sure about the location of the crankshaft timing mark. When I set the mark where the handbook indicates, all the pistons are on the same level.
The engine starts difficult, detonates and splutters before smoothing out.
Please assist.
Best regards, Lourens

ANSWER: Lourens, you needed to use the special tool to hold the cams together.  The mark is on the back of the crankpulley and it needs to line up with the notch that is on the crank housing.  Number 1 should be up and 3 should be up.  2 and 4 should be on the down stroke.  What book are you using?  Sounds like a timing issue with the VVT valve.  Roger

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QUESTION: Hi Roger, We are using the Haynes Manual. We are working according to the Non-GDI engine. I failed to mention to you that this is a 2002 S40 2.0 Turbo. Does this make any difference to the issue? I seem to remember that I had the cams locked into place and tried to get No.1 piston at TDC and had resistance as the valves touched the pistons.

ANSWER: Lourens, sorry to say that Haynes is nothing but useless toilet paper when it comes to this kind of stuff.  No, the engine doesnt make a difference.  Thats the only one I deal with here.  Even though its locked down, that special tool prevents the VVT unit from being moved.  There is a special procedure and torque spec of timing that car to proper specs.  I dont know what you did, but it would need to be looked at and properly set back up.  Roger

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QUESTION: Thanks for your expert advise. I think what we should have done is get the crank timing on it's mark, and then drop  the cams into their place, bolt the cam box down and lock the cams into place.
What manual do you suggest?

Answer
Lourens, that would have been fine but like I said, Without the cam tool, you are almost guessing which way they go unless you left the VVT and intake cam in place, how are you going to know which way the cams should be in place?  They are probably not in the right sequence.  You can buy a factory manual from the dealer.  If I had to choose a manual, it would be bentleys.  All these manuals are good general information that can get people in trouble.  The Factory manual is the best.  Roger