'99 S80 T6 Top End Rebuild Pics

Post by **boosted5cyl** » 07 Jan 2011, 10:57

This post is a work in progress right now........................I'm working on updating this......its taking a while......

Fine mess of parts for me to put back together.

Pistons\Cyinders. Heavy carbon deposits. #4 was especially bad. LOT of carbon in there, loose too.

Pistons\Cyinders. Now much prettier

Combustion chambers in head before any work was done. A lot of carbon, but the pic really doesnt show it.

Head after cleaning, decoking and skimming. .006" removed to true it at the machine shop. I also reground the valves by hand and replaced the valve stem seals.

Valvetrain portion of head before cleaning. Not bad for 186K miles!

Valvetrain portion of head ater cleaning. Much prettier now.

Panic time: Turbo #2 has evidence of the wheel rubbing the compressor housing. ##it!

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Turbo #2's CHRA (Center Housing Rotating Assembly) and compressor housing separated for inspection.

Compressor side of turbo #2. When I check the axial and radial free play it all came within spec. Writing on the CHRA and the different type nut on the wheels compared to #1 lead me to believe that it had already been rebuilt and the contact with the housing happened before I owned the car.

Hand-ground exhaust valve seats. After on left, before on right. Yeah, ideally you get a shop to do this, but I couldn't afford that. Besides, if you look at them it would have been hard to make them much worse!

Exhaust valves. After lapping on left, before on right.

Post by **JDS60R** » 07 Jan 2011, 12:06

What did you use to clean the block and pistons?

Post by **JDS60R** » 07 Jan 2011, 12:09

I see evidence of small coolant leak in cylinder 1 and even smaller in cylinder 2 . Was the head and block square?

Left most cylinder in your pics being cylinder 1

grntrdbx · Post by **grntrdbx** » 07 Jan 2011, 12:32

Do you have any more pics? How much time do you think you have into the disassembly? Did you have a clean-up cut done on head or did you just clean it, check for flatness and stone the surface? Other than a blown head gasket, were there any other indicators that led you to pulling the head? Was it running or were you just losing coolant/passing it through the exhaust? Sorry about all the questions. Thanks.

Post by **precopster** » 07 Mar 2011, 04:37

Excellent write-up of the disassembly/assembly.

Can you show us a pic of the valve spring compression tool you used?

I'm currently looking around for one and there is such a huge choice and I'm not sure what fits these Volvo heads. I'm told I should just cut down an old spark plug tool (13/16) and use a large clamp but not sure if this will do the job.

Post by **boosted5cyl** » 07 Mar 2011, 11:04

I used one form sears but I had to cut up some tubing to make it work. Ill take a few pics of it and post them later.

Post by **precopster** » 07 Mar 2011, 16:47

Thanks that would be great. Can you also post the dimensions, particularly length?

mrjacobrussell · Post by **mrjacobrussell** » 07 Mar 2011, 21:36

There is a Valve spring tool on eBay it bolts to head and has a bar that runs across ill try and find a pic of mine

beetlebob · Post by **beetlebob** » 10 Mar 2011, 12:57

Do you have the tool that pulls the cam top half down to the head so you do not strip the 10mm bolts out when trying to pull the top half of the head down with them. or how did you do it.

Post by **boosted5cyl** » 10 Mar 2011, 14:49

I tapped the cam cover with a rubber mallet where the lugs were, then used the bolts gradually and progressivly to clamp it down. It required very little torque on the bolts in my case. Maybe it had been off before? But anyway, no tools used, just patience and a ratchet.