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    1. #36
      Member Hounddogger's Avatar
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      Why not melt the stud out of the head? There are chemicals that will eat the iron in the stud and not the aluminum.
      Exponents kill
      Elsa: 2004 V70R Silver Metallic&Nordkap Back from Valhalla @ 357,098 miles

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    3. #37
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      Slowest project ever? Between work and family and my gf sabotaging all my free time ... finally carved out some time for disassembly. Decided to shim it. Need to grab a T60 socket and I'll be able to take the accessory belt off, then timing belt, and goal is to have the head off in time to watch GoT tomorrow.

      Then will measure my sleeve-to-sleeve clearance, order shims from https://www.deeworks.ca/product/volv...iner-shim-kit/, and order whatever else I need. So far thinking new head gasket, new timing belt, maybe new water pump, and new PCV stuff. Already have an 05+ PS reservoir going in. What am I missing?



      Maybe I'm missing something but the farthest left bolt for the intake manifold won't come out until I remove the coolant feed fitting block. That's why the gasket is still sitting there.

      04 V70R, 05 M3, 92 Stealth TT, 94 Stealth TT soon to be single T

    4. #38
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      Rain delay today. I had to stop yesterday at the timing alignment stage since I realized I don't have a 30mm socket. Hopefully the rain clears up in time.

      A comment, working on a California car is soooo much better than working on cars back home in Vermont / the northeast. Knock on wood, but there hasn't been a single rusty bolt.

      Next steps:

      -Line up timing marks
      -Lock cams in place
      -Remove timing belt
      -Remove coolant passage behind head
      -Remove VVT solenoids
      -Remove cam cover
      -Remove head

      Last edited by lawdogg; 05-19-2019 at 12:13 PM.
      04 V70R, 05 M3, 92 Stealth TT, 94 Stealth TT soon to be single T

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    6. #39
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      Back after a week on the road for work, timing belt off, in the process discovered timing has been a hair off.



      04 V70R, 05 M3, 92 Stealth TT, 94 Stealth TT soon to be single T

    7. #40
      Member Hounddogger's Avatar
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      Those cam marks are only applicable if you're the last person to touch the timing or its never had a tbelt done... c
      Exponents kill
      Elsa: 2004 V70R Silver Metallic&Nordkap Back from Valhalla @ 357,098 miles

    8. #41
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      Quote Originally Posted by Hounddogger View Post
      Those cam marks are only applicable if you're the last person to touch the timing or its never had a tbelt done... c
      What do you mean?
      04 V70R, 05 M3, 92 Stealth TT, 94 Stealth TT soon to be single T

    9. #42
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      Well, head is off. Cylinders look excellent - crosshatching still there. No cracks in sleeves. Lots of carbon on pistons, but I can clean that off. Cams look good, cam journals look good. Not bad for 230k miles.

      Looks like I have ~35 thou gap in 3 of the sleeve gaps, and ~37.5 thou in the last one. Going to get shims on order.

      My block code is 317XXXX, so I can order the right head gasket now.









      And the bastard up close. Anyone have a good shop to recommend in Los Angeles that can extract this (and maybe clean up the rest of the head)?

      Last edited by lawdogg; 05-25-2019 at 07:25 PM.
      04 V70R, 05 M3, 92 Stealth TT, 94 Stealth TT soon to be single T

    10. #43
      Member Hounddogger's Avatar
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      Quote Originally Posted by lawdogg View Post
      What do you mean?
      Because the cam sprockets are slotted there is no relationship between those marks and the crank unless you’ve crosschecked them against the actual position of the camshafts at the back of the engine. Each time I do the job I just paint new marks on the cam sprockets because it’s not worth the effort to move the sprockets in their slots unless you need like half a tooth of adjustment.
      Exponents kill
      Elsa: 2004 V70R Silver Metallic&Nordkap Back from Valhalla @ 357,098 miles

    11. #44
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      I see. For whatever it's worth, I had to move mine in their slots. With the timing aligned, I had to move them in the slots in order to get the cam lock tool installed.
      04 V70R, 05 M3, 92 Stealth TT, 94 Stealth TT soon to be single T

    12. #45
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      wow that head and engine looks really good ...cam gears = you can put back any way you wana as long as they are cocked clockwise...those timing align marks stamp are most likely produced by factory where they landed by volvo corp techs...i like to put my back by the actual marks not the tech ones and the 8mm adjustment bolts centered exactly in the center just in case you're off...never once was i off that i had to readjust.
      2006 S60R 2.4 T5 mostly stock fine tuned by https://urbastuning.wordpress.com
      ipd = sways, inter-cooler, inlet/TB/OTE silicone piping, cat back exhaust, rear camber bushings, sub-frame inserts,
      Originally Posted by John C "We are in the presence of greatness! "

    13. #46
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      Quote Originally Posted by dougy View Post
      wow that head and engine looks really good ...cam gears = you can put back any way you wana as long as they are cocked clockwise...those timing align marks stamp are most likely produced by factory where they landed by volvo corp techs...i like to put my back by the actual marks not the tech ones and the 8mm adjustment bolts centered exactly in the center just in case you're off...never once was i off that i had to readjust.
      I have never opened up my engine but did notice something strange in the pictures.

      If you look at the 3'rd picture down which shows the bottom side of the head, in the top of the view around the end combustion chamber it does not look right compared to the other end of the head in the same view.

      Is this normal?

    14. #47
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      Quote Originally Posted by dcm0123 View Post
      I have never opened up my engine but did notice something strange in the pictures.

      If you look at the 3'rd picture down which shows the bottom side of the head, in the top of the view around the end combustion chamber it does not look right compared to the other end of the head in the same view.

      Is this normal?
      you mean the spark plug missing from cyl #1 ?
      2006 S60R 2.4 T5 mostly stock fine tuned by https://urbastuning.wordpress.com
      ipd = sways, inter-cooler, inlet/TB/OTE silicone piping, cat back exhaust, rear camber bushings, sub-frame inserts,
      Originally Posted by John C "We are in the presence of greatness! "

    15. #48
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      Thanks dougy

      And yeah plugs 1 and 5 are out because of the head tool (999 5454)

      If anyone spots anything wrong that I missed PLEASE say something!
      04 V70R, 05 M3, 92 Stealth TT, 94 Stealth TT soon to be single T

    16. #49
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      Quote Originally Posted by lawdogg View Post
      Thanks dougy

      And yeah plugs 1 and 5 are out because of the head tool (999 5454)

      If anyone spots anything wrong that I missed PLEASE say something!
      Use the cam cover press tool on 2...4 cyls.
      2006 S60R 2.4 T5 mostly stock fine tuned by https://urbastuning.wordpress.com
      ipd = sways, inter-cooler, inlet/TB/OTE silicone piping, cat back exhaust, rear camber bushings, sub-frame inserts,
      Originally Posted by John C "We are in the presence of greatness! "

    17. #50
      Member Hounddogger's Avatar
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      You didn’t have to pull the CVVT hubs from the cams to get the head apart. Engine looks as one would expect. Make sure to do the banjo bolt of doom.
      Exponents kill
      Elsa: 2004 V70R Silver Metallic&Nordkap Back from Valhalla @ 357,098 miles

    18. #51
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      Quote Originally Posted by dougy View Post
      Use the cam cover press tool on 2...4 cyls.


      Quote Originally Posted by Hounddogger View Post
      You didn’t have to pull the CVVT hubs from the cams to get the head apart. Engine looks as one would expect. Make sure to do the banjo bolt of doom.
      Haven't heard this term before - is this the PCV banjo bolt into the head on the driver's side (or the PCV banjo bolt into the intake manifold)?
      04 V70R, 05 M3, 92 Stealth TT, 94 Stealth TT soon to be single T

    19. #52
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      Intake.. houndog is correct ,get an upgraded one.
      2006 S60R 2.4 T5 mostly stock fine tuned by https://urbastuning.wordpress.com
      ipd = sways, inter-cooler, inlet/TB/OTE silicone piping, cat back exhaust, rear camber bushings, sub-frame inserts,
      Originally Posted by John C "We are in the presence of greatness! "

    20. #53
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      Quote Originally Posted by dougy View Post
      Intake.. houndog is correct ,get an upgraded one.
      Got it - this one?

      https://youtu.be/oEOzIoVxO4s?t=518
      04 V70R, 05 M3, 92 Stealth TT, 94 Stealth TT soon to be single T

    21. #54
      Member Hounddogger's Avatar
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      Quote Originally Posted by lawdogg View Post
      Make sure to use the latest banjo bolt PN 31325709
      Exponents kill
      Elsa: 2004 V70R Silver Metallic&Nordkap Back from Valhalla @ 357,098 miles

    22. #55
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      Thanks

      Anything else I should make sure to do while it's all apart?

      Here's a platform newb question ... all the Volvo hose clamps that came off, replace with Volvo hose clamps, or use generic hose clamps?
      Last edited by lawdogg; 05-26-2019 at 04:06 PM.
      04 V70R, 05 M3, 92 Stealth TT, 94 Stealth TT soon to be single T

    23. #56
      Senior Member ScottishBrick's Avatar
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      Quote Originally Posted by lawdogg View Post
      Thanks

      Anything else I should make sure to do while it's all apart?

      Here's a platform newb question ... all the Volvo hose clamps that came off, replace with Volvo hose clamps, or use generic hose clamps?
      Use oteker clamps. They’re specified for a reason and work perfectly. Worth it to have a pair of crimp pliers for them anyway.


      Sent from my iPhone using Tapatalk
      2003 V70 T5 - Mystic/Graphite - M56LK - 197k - K24/Greens/Do88 IC/SMF & P2R Clutch/DW300C/H&R/Bilstein TC/Delrin/316mm & 308mm Brakes - SteveO Tuned
      1999 V70 T5 - Pewter/R Graphite & Alcantara - AW42 - 291k - Daily/Work Wagon
      1999 V70 T5 - Nautic/R Graphite & Alcantara - M56H - 174k - Rescued
      1999 V70 T5 - Emerald/Graphite - M56H - 119k - Garage Queen
      2000 V70 T5 - Mystic/Graphite - AW42 - 238k - Moms Unicorn
      2000 S70 GLT SE- Mystic/Graphite - AW42 - 212k - Sisters

    24. #57
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      Quote Originally Posted by ScottishBrick View Post
      Use oteker clamps. They’re specified for a reason and work perfectly. Worth it to have a pair of crimp pliers for them anyway.
      Where's the best place to buy them?
      04 V70R, 05 M3, 92 Stealth TT, 94 Stealth TT soon to be single T

    25. #58
      Senior Member ScottishBrick's Avatar
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      Quote Originally Posted by lawdogg View Post
      Where's the best place to buy them?
      The most validated way is to match the PNs across the engine through Volvo then make a list of what they are. A full box of assorted sizes will run $25 if you’re feeling adventurous.


      Sent from my iPhone using Tapatalk
      2003 V70 T5 - Mystic/Graphite - M56LK - 197k - K24/Greens/Do88 IC/SMF & P2R Clutch/DW300C/H&R/Bilstein TC/Delrin/316mm & 308mm Brakes - SteveO Tuned
      1999 V70 T5 - Pewter/R Graphite & Alcantara - AW42 - 291k - Daily/Work Wagon
      1999 V70 T5 - Nautic/R Graphite & Alcantara - M56H - 174k - Rescued
      1999 V70 T5 - Emerald/Graphite - M56H - 119k - Garage Queen
      2000 V70 T5 - Mystic/Graphite - AW42 - 238k - Moms Unicorn
      2000 S70 GLT SE- Mystic/Graphite - AW42 - 212k - Sisters

    26. #59
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      Quote Originally Posted by dougy View Post
      you mean the spark plug missing from cyl #1 ?

      No, on the bottom of the view below the end cylinder there are three water ports

      In the top of the view above the end cylinder instead of three water ports there appears to be a long slot with a section missing in the middle. Not sure about the missing section.

      Edited after posting-
      I saved the picture then blew it up so I could see it better. The missing section may just be crud on the head. Can not really tell from the picture.
      Last edited by dcm0123; 05-27-2019 at 09:52 AM.

    27. #60
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      I'll put up a pic once I clean the gasket material off. I certainly don't think I blew open a new coolant passage ...
      04 V70R, 05 M3, 92 Stealth TT, 94 Stealth TT soon to be single T

    28. #61
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      Just placed an order with FCP for all the misc crap, head gasket, timing belt, gaskets, etc. Decided to shim with HF feeler gauge which I'll buy tomorrow. My clearances between sleeves (according to my junky digital calipers, so take with a grain of salt, no I don't think it's accurate to half a thou) are 0.0335, 0.0335, 0.0335, 0.0365. I fear the widest gap is too big for the thickest feeler gauge (0.035) but hope it'll work.
      Last edited by lawdogg; 05-27-2019 at 05:53 PM.
      04 V70R, 05 M3, 92 Stealth TT, 94 Stealth TT soon to be single T

    29. #62
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      Decided to trust the work to a professional, so I got a machine shop recommendation for a guy who specializes in engine building (and had a variety of heads in his shop) from a local Volvo specialty shop. Dropped the head off there just now and looking forward to getting it back. He mentioned he helped a local build an 840 block to handle some large turbo, and they went through a couple rounds of the build before discovering that shims solved the issues. That's good for my confidence level, as I will be getting the feeler gauges to use for shims soon.
      04 V70R, 05 M3, 92 Stealth TT, 94 Stealth TT soon to be single T

    30. #63
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      Back from the shop. This guy is amazing.

      Then:



      Now:



      Can't wait to get it all back together.
      04 V70R, 05 M3, 92 Stealth TT, 94 Stealth TT soon to be single T

    31. #64
      Quote Originally Posted by lawdogg View Post
      Back from the shop. This guy is amazing.
      Now:

      in "LA", would love that machine shop rec. Glad to see you got the stud out.

    32. #65
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      Wow - how much did he charge?

    33. #66
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      Quote Originally Posted by tonyc View Post
      in "LA", would love that machine shop rec. Glad to see you got the stud out.
      nice, once the head is out it is not hard to remove a broken stud ... you should have had them put in ss inserts...once one stud pulls you will be sorry you did not.












      2006 S60R 2.4 T5 mostly stock fine tuned by https://urbastuning.wordpress.com
      ipd = sways, inter-cooler, inlet/TB/OTE silicone piping, cat back exhaust, rear camber bushings, sub-frame inserts,
      Originally Posted by John C "We are in the presence of greatness! "

    34. #67
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      The guy did it the next day and charged me less than half a tank of gas.

      Dougy - good idea, but I'm not hanging nearly as large a turbo as you are LOL
      04 V70R, 05 M3, 92 Stealth TT, 94 Stealth TT soon to be single T

    35. #68
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      Quote Originally Posted by lawdogg View Post
      The guy did it the next day and charged me less than half a tank of gas.

      Dougy - good idea, but I'm not hanging nearly as large a turbo as you are LOL
      different dougy, all out of rehab and all stock tune and k24 man.



      2006 S60R 2.4 T5 mostly stock fine tuned by https://urbastuning.wordpress.com
      ipd = sways, inter-cooler, inlet/TB/OTE silicone piping, cat back exhaust, rear camber bushings, sub-frame inserts,
      Originally Posted by John C "We are in the presence of greatness! "

    36. #69
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      Quote Originally Posted by dougy View Post
      different dougy, all out of rehab and all stock tune and k24 man.
      04 V70R, 05 M3, 92 Stealth TT, 94 Stealth TT soon to be single T

    37. #70
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      2006 S60R 2.4 T5 mostly stock fine tuned by https://urbastuning.wordpress.com
      ipd = sways, inter-cooler, inlet/TB/OTE silicone piping, cat back exhaust, rear camber bushings, sub-frame inserts,
      Originally Posted by John C "We are in the presence of greatness! "

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