'99 S80 T6 Top End Rebuild Pics

[mlanctot]

Happy New Year to all...Latest update, my wife's 2001 V70XC 239500 miles just lost a cylinder. Checked compression #3 cylinder 60 PSI. Looks like a opportunity to rebuild another head. I'll keep you posted how it goes.

[boosted5cyl]

nice

[mlanctot]

Both the S80T6 and the 2001 V70XC are going strong. 285,000 for the S80 and 255,000 for the V70XC. the XC has the original tranny without any rebuild to date. In line filter and yearly tranny fluid changes may help.

[yuckuJackD]

ОК, I did a top end rebuild on my Volvo, too. It's 2.9 non turbo (B6294S).
Most of the things are told here so I'll just add some useful info and ideas.
1. Tool for closing the engine head top half.
What you need:

What should it become:







How does it work:




2. Tool for locking the shafts.
It's simple and yeasy to do so take your time and make it, even for just VVT reset process.
Nothing to describe here, just see it:










3. It's not a tool, but it's part of the process. The anaerobic sealant. In my country dealer wants 50EU for a 50ml tooth paste tube. You don't even able to use all of that "gold" - 1 euro for 1 millilitre!
I spend many hour searching alternative and finally found what's in the dealer's tube - it's a Loctite 518 packaged in a volvo tube.
OK so I need a lictite 518. It's not cheep too - 30 euros for 50 ml, BUT it' really 50ml and in propper package. Here it is:


Here it is in action:










I did the oil sump twice (don't ask) and the upper part of the engine head and I've used 40% of the tube. For sure there is enough for another engine rebuild job.

Some other important steps:
For the 6cylynder engine there is ONLY 1 mark (instead of two according to VIDA) on the main shaft gear:




You really want to prevent anything to fall in there, right


That's my baby:


















And late at night (02:00-03:00) ...


Enjoy

[precopster]

Nice job, Yucka, you always do great work!!

I love the home made top end tools and the resourcefulness. Well done!

[yuckuJackD]

some more useful info:

I searched anywhere in VIDA but I didn't found the tightening torque specs for the head cover. Again searched in web and found it should be 20nm. OK but that was info given in post in a forum, so i had to check whether that's true or not. I got one death 5 cylinder engine laying in the garage, so I tried to torque one of those bolts to 25nm. It was so close but the aluminium gave up. That made me believe the info for 20 nm tightening toque.

I also took measurements of the O-rings around the spark plug wholes and those for the oil sump suck and return line. The sheet of paper I wrote them is in the garage, but tomorrow I'll share that info, too. Dealer charge me 3 euro for a single O-ring around the spark plug. What the hell - it's just a O-ring witch should be able to resist to heat and oil. Nothing else is special in it. (and it's real price is less than a euro for a piece)