2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by **RickHaleParker** » 03 Apr 2020, 00:14

Prepping to remove the Cylinder head. Has anybody gotten the exhaust manifold off without pulling the right axle and the bevel gear?

Post by **- Pete -** » 03 Apr 2020, 22:31

viewtopic.php?f=9&t=82001

I haven’t had the exhaust manifold, nor head, off. After spending a couple hours under the car today working in that vicinity, though, I have to say, I think Mike may be right.

Can you share a photo of the deck when you get it opened up?

Post by **RickHaleParker** » 04 Apr 2020, 00:10

- Pete - wrote: ↑03 Apr 2020, 22:31 I haven’t had the exhaust manifold, nor head, off. After spending a couple hours under the car today working in that vicinity, though, I have to say, I think Mike may be right.

Can you share a photo of the deck when you get it opened up?

I was thinking the same thing. Hang the turbo then maybe there is enough room to tilt the manifold away from the head or just pull the manifold along with the head.

When I get it open I'll photograph and share the deck. Are just curious about the condition or wanting to see some specific information?

Every bolt I have taken out so far was not torqued. I took the flange nuts off the manifold with a 12 point 13MM socket. I just need to tap the end of the racket to break them loose. Got to the last bolt and had to use a off set box end wrench. Put a 13mm on the nut, nothing. Checked the wrench against a removed flange nut. They are 12mm not 13mm. Same story of the intake manifold bolts.

There is fresh sealer between the cam cover and the head. The intake ports and intake valves are clean as a whistle. They are spotless. The small part of the head gasket that sticks out looks like it has not been there long. The intake manifold gasket looks new.

Things are pointing toward the previous owner had the head rebuilt but did not torque and stretch the head bolts.

Post by **chrism** » 04 Apr 2020, 07:08

RickHaleParker wrote: ↑04 Apr 2020, 00:10
Things are pointing toward the previous owner had the head rebuilt but did not torque and stretch the head bolts.

Or they reused the old bolts and they DID torque them but now they’re over-stretched and weakened???

Post by **RickHaleParker** » 04 Apr 2020, 14:09

chrism wrote: ↑04 Apr 2020, 07:08 Or they reused the old bolts and they DID torque them but now they’re over-stretched and weakened???

Snapped head bolts was one of my early theories. Until I encounter the nuts and bolts on the manifolds. If he knew how to tighten a head bolt it stands to reason he would tighten the manifolds correctly. However you can never be sure what a incompetent has done.

Post by **RickHaleParker** » 08 Apr 2020, 10:16

- Pete - wrote: ↑03 Apr 2020, 22:31 Can you share a photo of the deck when you get it opened up?

Here you go.
Got it off without pulling the right axle and the bevel gear.
Engine serial number is after 2979611 (3180225).

Post by **- Pete -** » 08 Apr 2020, 10:38

Thats a strangely shaped piston top.

Did it crack into the ring land, I wonder? No sleeve cracking, but thats about it for the good news.

Hmm, so many questions I have for whoever did the work.

I assume you’ll be sticking a different engine in that one’s place.

Post by **RickHaleParker** » 08 Apr 2020, 11:54

- Pete - wrote: ↑08 Apr 2020, 10:38 I assume you’ll be sticking a different engine in that one’s place.

Still investigating and trying to weigh out the options.
Turbocharger will need a overhaul. The coolant in the charge pipe seized it. It will not spin.

Post by **- Pete -** » 08 Apr 2020, 12:21

RickHaleParker wrote: ↑08 Apr 2020, 11:54
The coolant ...

This is one of the questions I’d ask.

Post by **bmdubya1198** » 08 Apr 2020, 23:04

Wow, that engine is seriously forked. That's some serious damage to cylinder 3, thinking maybe it was an overheating issue?
I take it the engine previously jumped time, that would explain the new-ish looking head gasket and poorly torqued head bolts.

But just to add to the original topic (obviously you've gotten past that point), yes, I've gotten an exhaust manifold off one of these with the axle and angle gear in place. These S60s are tight back there, especially with AWD, but it's doable.