Cylinder Head Replacement

Post by **djm850** » 04 Feb 2010, 19:40

Well, this Saturday makes 4 weeks into the job. While I'd imagine it could be done by a volvo mechanic in probably 2-3 days, I’m traveling 30 miles to a friend’s shop where the car is, as well as I like to be thorough and rarely rush things like this. I posted a few questions within other topics here and appreciate the responses.

Timeline: I completed the teardown in about 10 hours. Shipped out the head to Cylinder-Heads.com in Clearwater for rebuild and I just got it back today. In the meantime, I disassembled the intake manifold and completely cleaned it including the throttle body, cleaned up the injectors (replacing both O-rings and seats), sandblasted the exhaust manifold, and have 3 piston tops still to clean before reinstallation (which I hope to begin this weekend). Here are some pics from along the way.

: Head2.jpg (126.98 KiB) Viewed 17361 times

: Head1.jpg (282.82 KiB) Viewed 17361 times

: Crank Marks.JPG (234.62 KiB) Viewed 17361 times

: Cams.jpg (99.8 KiB) Viewed 17361 times

Post by **djm850** » 04 Feb 2010, 19:44

: Block1.jpg (331.67 KiB) Viewed 17358 times

: Block2.jpg (307.97 KiB) Viewed 17358 times

: #1.JPG (262.41 KiB) Viewed 17358 times

: #2.JPG (273.68 KiB) Viewed 17358 times

: #3.JPG (279.4 KiB) Viewed 17358 times

: #4.JPG (272.19 KiB) Viewed 17358 times

: #5.JPG (292.92 KiB) Viewed 17358 times

Post by **djm850** » 04 Feb 2010, 19:50

: C#1.JPG (300.93 KiB) Viewed 17358 times

: C#2.JPG (305.29 KiB) Viewed 17358 times

: C#3.JPG (321.73 KiB) Viewed 17358 times

: C#4.JPG (305.89 KiB) Viewed 17358 times

: Burn 2.jpg (290.28 KiB) Viewed 17358 times

: Burn 3.jpg (284.41 KiB) Viewed 17358 times

Post by **djm850** » 04 Feb 2010, 20:04

: Head Bottom.jpg (266.61 KiB) Viewed 17357 times

: Head Exh1.jpg (263.9 KiB) Viewed 17357 times

: Head Int1.jpg (260.7 KiB) Viewed 17357 times

: Head Int2.jpg (306.22 KiB) Viewed 17357 times

: Cam1.jpg (291.52 KiB) Viewed 17357 times

: Cam2.jpg (313.42 KiB) Viewed 17357 times

: Cam3.jpg (281.04 KiB) Viewed 17357 times

Post by **djm850** » 04 Feb 2010, 20:09

: Fuel Rail.jpg (276.7 KiB) Viewed 17357 times

: Intake1.jpg (276 KiB) Viewed 17356 times

: Intake2.jpg (302.5 KiB) Viewed 17356 times

: Intake3.jpg (268.62 KiB) Viewed 17356 times

: Intake4.jpg (263.98 KiB) Viewed 17356 times

Post by **djm850** » 04 Feb 2010, 20:14

: New Head1.jpg (315.78 KiB) Viewed 17356 times

: New Head2.jpg (310.66 KiB) Viewed 17356 times

: I thought this was a little heavy-handed. Hopefully it won't affect the seal; milling.jpg (255.4 KiB) Viewed 17356 times

: Not too happy about this either.; Dent1.jpg (287.48 KiB) Viewed 17356 times

: Dent2.jpg (272.83 KiB) Viewed 17355 times

Well, that's all as of now. I’ll continue to post pics for the remainder of the job. I look forward to any comments that will help me or anyone else that does this repair and I'll be glad to answer any questions. I also would like to say a public "thank you" to fordman for sending me his homemade cam holding tool

Post by **Ozark Lee** » 04 Feb 2010, 21:25

This is some great documentation. I wish you were 1/8th of a turn further on the timing marks but you are close enough so long as you get the crankshaft timing mark lined up spot on before you use the camshaft alignment tool. The real test is to get all of the marks lined up before you pull the grenade pin on the tensioner. Pull the crankshaft through by hand a couple of revolutions and recheck the timing marks on the crank and the cams before you put the coals to it.

Your exhaust valves were toast for sure. Do you run premium, or at least mid grade fuel? Low octane fuel is death for a turbo and it always rears its ugly head on the exhaust valves.

The Clearwater head looks great. I have not yet had the misfortune to use them but they do have a very good reputation from the postings of other members.

Keep the pictures coming!

...Lee

Post by **djm850** » 04 Feb 2010, 21:37

Those pics of the cams in the top half were prior to sending the head. They were just placed in there for the pics. I've got the tool to align and hold them in place. I run regular octane, but it's a N/A. I doubt I'll be entirely finished by the weekend. I'll have most of tomorrow and part of Sunday to get the rest of the block cleaned up, install the head, and maybe get the cams/top half installed. Next week I hope to start buttoning up the rest, but I only get to work a few hours a couple days of the week. Ready to get it going again though.

Post by **wheelsup** » 05 Feb 2010, 08:37

Wow this is some cool stuff. Can I ask how did you clean your intake manifold and throttle body so nicely? They look brand new. I would like to do that to my car.

Post by **boosted5cyl** » 05 Feb 2010, 09:13

What happened to the motor. Looks like maybe a timing belt let go (not a lot of valve damage though), but then theres lots of deposits on the valves and what looks like coolant?!?

:S