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Kallekula's $350 S40 Topic is solved

Help, Advice, Owners' Discussion and DIY Tutorials devoted to the second generation C70, S40 and V50 Volvos -- awkwardly model year 2004 ½ onwards -- plus where to go for advice and discussion on Volvo's sporty C30 Coupe powered by Volvo's ubiquitous inline 5-cylinder power plant.
kallekula
Posts: 217
Joined: Sun Mar 02, 2014 12:34 pm
Year and Model: S70 2000
Location: Orange County, CA
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Kallekula's $350 S40

Post by kallekula » Sat Aug 12, 2017 2:05 pm

Got a really sweet deal on a 2005 S40 recently. The engine had overheated and the head was warped.
I began with spilling a couple of gallons of water inside the car so I had to take the seats and all of the carpet out to dry :evil:
Next i replaced all interior lights with LED ones, looks really good at night. Also refurbished the headlights because the plastic had turned completely yellow.
Currently replacing piston rings while the head is at the machine shop. Here are some pictures:
Attachments
IMG_1206.JPG
IMG_1206.JPG (2.45 MiB) Viewed 510 times
IMG_1205.JPG
IMG_1205.JPG (2.01 MiB) Viewed 510 times
IMG_1166.JPG
IMG_1166.JPG (553.75 KiB) Viewed 510 times
S70 2000 Base
S40 2005 2.4i
XC90 2005 2.5T FWD *SOLD*
S70 1999 T5 *SOLD*

MadeInJapan
MVS Moderator
Posts: 13331
Joined: Thu Mar 31, 2005 7:14 am
Year and Model: '98 S70 T5 '07S40T5
Location: Knoxville, TN American but born in Japan
United States of America

Re: Kallekula's $350 S40

Post by MadeInJapan » Sat Aug 12, 2017 9:12 pm

Good find! How much do you expect it will cost you to rebuild the engine? How much are you doing yourself?
'98 S70 T5 Emrld Grn Met/Beige Tons of Upgrades Mobil-1
'04 V70 2.5T Red/Taupe Some Upgrades Mobil-1
'07 S40 T5 AWD 6 speed manual! Silver/Black Stage1 Heico & Elevate
'07 S60 2.5T Blue/Taupe- my kid's Volvo

kallekula
Posts: 217
Joined: Sun Mar 02, 2014 12:34 pm
Year and Model: S70 2000
Location: Orange County, CA
Been thanked: 1 time
United States of America

Re: Kallekula's $350 S40

Post by kallekula » Sun Aug 13, 2017 10:46 am

MadeInJapan wrote:
Sat Aug 12, 2017 9:12 pm
Good find! How much do you expect it will cost you to rebuild the engine? How much are you doing yourself?
I have calculated that all parts needed and machining the head will cost around $700. I'm doing all the work myself except the head.
S70 2000 Base
S40 2005 2.4i
XC90 2005 2.5T FWD *SOLD*
S70 1999 T5 *SOLD*

MadeInJapan
MVS Moderator
Posts: 13331
Joined: Thu Mar 31, 2005 7:14 am
Year and Model: '98 S70 T5 '07S40T5
Location: Knoxville, TN American but born in Japan
United States of America

Re: Kallekula's $350 S40

Post by MadeInJapan » Wed Aug 16, 2017 7:27 pm

That's awesome!! Keep us posted on your progress.
'98 S70 T5 Emrld Grn Met/Beige Tons of Upgrades Mobil-1
'04 V70 2.5T Red/Taupe Some Upgrades Mobil-1
'07 S40 T5 AWD 6 speed manual! Silver/Black Stage1 Heico & Elevate
'07 S60 2.5T Blue/Taupe- my kid's Volvo

kallekula
Posts: 217
Joined: Sun Mar 02, 2014 12:34 pm
Year and Model: S70 2000
Location: Orange County, CA
Been thanked: 1 time
United States of America

Re: Kallekula's $350 S40

Post by kallekula » Sun Sep 03, 2017 6:24 pm

Finally got some time to work on the S40 again :)

Cylinder 1 honed
IMG_1234.JPG
IMG_1234.JPG (2.07 MiB) Viewed 311 times
IMG_1232.JPG
IMG_1232.JPG (2.41 MiB) Viewed 311 times
Cleaning piston
IMG_1236.JPG
IMG_1236.JPG (2.85 MiB) Viewed 311 times
Piston after cleaning
IMG_1244.JPG
IMG_1244.JPG (1.65 MiB) Viewed 311 times
IMG_1243.JPG
IMG_1243.JPG (1.42 MiB) Viewed 311 times
IMG_1245.JPG
IMG_1245.JPG (2.46 MiB) Viewed 311 times
Oil pickup looking pretty clogged
IMG_1237.JPG
IMG_1237.JPG (1.47 MiB) Viewed 311 times
Oil pickup cleaned
IMG_1247.JPG
IMG_1247.JPG (1.53 MiB) Viewed 311 times
Lazy as I am I had the machine shop clean the oil pan
IMG_1241.JPG
IMG_1241.JPG (1.97 MiB) Viewed 311 times
One down four more to go
IMG_1249.JPG
IMG_1249.JPG (1.94 MiB) Viewed 311 times
S70 2000 Base
S40 2005 2.4i
XC90 2005 2.5T FWD *SOLD*
S70 1999 T5 *SOLD*

MadeInJapan
MVS Moderator
Posts: 13331
Joined: Thu Mar 31, 2005 7:14 am
Year and Model: '98 S70 T5 '07S40T5
Location: Knoxville, TN American but born in Japan
United States of America

Re: Kallekula's $350 S40

Post by MadeInJapan » Mon Sep 04, 2017 6:49 pm

That's awesome, Kallekula!!
'98 S70 T5 Emrld Grn Met/Beige Tons of Upgrades Mobil-1
'04 V70 2.5T Red/Taupe Some Upgrades Mobil-1
'07 S40 T5 AWD 6 speed manual! Silver/Black Stage1 Heico & Elevate
'07 S60 2.5T Blue/Taupe- my kid's Volvo

kallekula
Posts: 217
Joined: Sun Mar 02, 2014 12:34 pm
Year and Model: S70 2000
Location: Orange County, CA
Been thanked: 1 time
United States of America

Re: Kallekula's $350 S40

Post by kallekula » Sun Sep 17, 2017 7:02 pm

Should have gone to church today but worked on the S40 instead :roll:

IMG_1268.JPG
IMG_1267.JPG
IMG_1266.JPG
IMG_1265.JPG
IMG_1264.JPG
IMG_1263.JPG
IMG_1259.JPG
IMG_1258.JPG
S70 2000 Base
S40 2005 2.4i
XC90 2005 2.5T FWD *SOLD*
S70 1999 T5 *SOLD*

MadeInJapan
MVS Moderator
Posts: 13331
Joined: Thu Mar 31, 2005 7:14 am
Year and Model: '98 S70 T5 '07S40T5
Location: Knoxville, TN American but born in Japan
United States of America

Re: Kallekula's $350 S40

Post by MadeInJapan » Sun Sep 17, 2017 8:51 pm

So very clean- great job!!
'98 S70 T5 Emrld Grn Met/Beige Tons of Upgrades Mobil-1
'04 V70 2.5T Red/Taupe Some Upgrades Mobil-1
'07 S40 T5 AWD 6 speed manual! Silver/Black Stage1 Heico & Elevate
'07 S60 2.5T Blue/Taupe- my kid's Volvo

kallekula
Posts: 217
Joined: Sun Mar 02, 2014 12:34 pm
Year and Model: S70 2000
Location: Orange County, CA
Been thanked: 1 time
United States of America

Re: Kallekula's $350 S40

Post by kallekula » Fri Sep 22, 2017 2:26 am

Bought the last parts for the S40 yesterday. Gonna try and put it all together this weekend.

MotoRad thermostat
IMG_1272.JPG
Timing belt kit with Aisin waterpump
IMG_1271.jpg
S70 2000 Base
S40 2005 2.4i
XC90 2005 2.5T FWD *SOLD*
S70 1999 T5 *SOLD*

MadeInJapan
MVS Moderator
Posts: 13331
Joined: Thu Mar 31, 2005 7:14 am
Year and Model: '98 S70 T5 '07S40T5
Location: Knoxville, TN American but born in Japan
United States of America

Re: Kallekula's $350 S40

Post by MadeInJapan » Fri Sep 22, 2017 7:50 pm

Awesome job! Glad to see you're not cutting corners with this repair.
'98 S70 T5 Emrld Grn Met/Beige Tons of Upgrades Mobil-1
'04 V70 2.5T Red/Taupe Some Upgrades Mobil-1
'07 S40 T5 AWD 6 speed manual! Silver/Black Stage1 Heico & Elevate
'07 S60 2.5T Blue/Taupe- my kid's Volvo

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