Seeking Tips/Suggestions for Cylinder Head Replacement

b gillespie · Post by **b gillespie** » 20 Apr 2013, 03:52

Hi. I bought a 2001 S80 T6 last month with 163k miles. Took it in right away to get it checked out; got fluids changed but they didn't recommend anything major.

ETM had to be replaced last week--a Xemodex which I installed easily. Unfortunately, after driving a mile down my street to test out the new ETM, the timing tensioner exploded.

With the initial shock of the ordeal behind me, I've decided to fix the broken cylinder heads myself.
To be honest, before changing the ETM, replacing spark plugs was the most difficult job I'd ever done mechanically.

So my question is this: Do you have any tips, warnings, suggestions, or informed stories regarding the process of replacing cylinder heads in a Volvo? (especially regarding an s80 turbo). I've encountered a few posts that have been helpful, including this amazing account: https://www.matthewsvolvosite.com/forums ... 11&t=35482 . But I'm trying to accumulate as much information as I can about potential hidden costs of tools/parts, things to avoid, ways to ensure a thorough repair, and other things I should consider replacing/cleaning while I have it opened up (i.e. changing the water pump while replacing the timing belt).

Thanks for your time. I know this will be a big task, but I can bike to work and have some spare time, as well as a buddy who has done a few cylinder head replacements on Fords (and is willing to help, bless his heart).

Post by **precopster** » 20 Apr 2013, 15:48

I just saw a set of engine alignment tools for Volvo whiteblocks for $54 on Alibaba from a seller with good feedback. Even if they only make it through 2 or 3 jobs they are well worth it. Search for "volvo timing" on alibaba site.

You might want to put some rebuild kits through the turbos while you're there. Yep if you're going to have the head off replace as much as possible while you're in there so water pump and accessory belt and its dler as well.

When you have it apart could you report back on which component failed and see if you can identify the brand name on it?

b gillespie · Post by **b gillespie** » 21 Apr 2013, 12:28

Thanks a ton precopster! That's great help. I'll let you know; hopefully with pictures or video too.

Eldoninoz · Post by **Eldoninoz** » 21 Apr 2013, 16:33

The timing belt tensioner is what gave out on me just 2 weeks ago on my car. The part was a genuine Volvo part, judging by the date etched 98-10-08 it may have been the original... Needless to say I am replacing everything. Also the bank 2 turbo's wastegate was open at least 25% without any pressure on the actuator so that is getting replaced as well.

Post by **precopster** » 21 Apr 2013, 17:51

Belt life is a 7 year or miles first situation.

Without knowing the history of a car it's always best to replace the belt and tensioner as a minimum.
Nothing else can ruin your day more than a broken timing belt on a Volvo (except for a broken transmission of course)

Eldoninoz · Post by **Eldoninoz** » 21 Apr 2013, 21:21

Unfortunately I was told the maintenance schedule was followed and all that the car was in need of was control arms and ball joints up front. At least that is what the guy who was selling the car said the dealership said it needed the last time it was in for service. Expensive lesson learned...

b gillespie · Post by **b gillespie** » 22 Apr 2013, 00:16

Yeah I was wondering if I should replace the turbos too... guess I'll check them out when I get in there.