'03 s60 needs good engine shop

[vtl]

I had a head resurfaced at home as well. Was 0 mm W and 0.05 mm L in one spot only. Managed to have all zeroes.

Finding a flat area of a 3/8" thick glass. You get the head as flat as the glass is.



Dykem steel blue (wasn't really needed)



3M adhesive



18 sheets of 220 grit 3M sandpaper (the best one) and 18 of 400 for the final mirror-like surface (not actually needed)



This is a wet sanding, so some WD-40 is needed:







See the high spots?



Got his:



From this:

[jonesg]

Great job.
The best Lathes have the bed hand lapped/scraped to get that final accuracy. Better than the machine can do.
Machine is just way faster and close enough for engine heads.

[vtl]

Great job.
The best Lathes have the bed hand lapped/scraped to get that final accuracy. Better than the machine can do.
Machine is just way faster and close enough for engine heads.

Yes. Having good tools does help. However I went low this time, the biggest investment was a $50 glass shelf I actually had parts from the donor engine, just in case I screw it up, but it turned out pretty well. With all the consumables the head resurfacing project still was under $100 plus few beers, I think.

[abscate]

I would love to know the details of how much time and pressure was used on the head. Did you just move it back and forth by 15 cm? How many passes ?

[vtl]

No pressure! The head is heavy enough, you just need to push and pull it, as horizontally as you can.

Because of a fine grit and wet sanding it took a few hundreds of passes, but in return it gives you a precise control of how much material is removed. I stopped when I had a couple of cavities reduced to a level where a new head gasket would seal it properly. It could be the coarse grit was even 320, not 220, forgot which one it was. 220 would work as well, however it need more frequent controls.

I think the sheet is a standard letter size, the head fits on two sheets with a good margin, so one stroke is slightly over 11" or 28 cm.

[SantaFe75]

Volvo horns awarded for removing 6 thou of warp with sandpaper!

That’s dedication !

Did you use new head bolts? That’s recommended by Volvo but I’ve always wondered if they are truly in the deformation limit

You had to go there . No, I know that I should have. When I was ordering the h2o pump, pulleys, belts,..... I forgot.
I did tighten all to spec., and so far no problems. The boy has been cruising her daily.

[SantaFe75]

I had a head resurfaced at home as well. Was 0 mm W and 0.05 mm L in one spot only. Managed to have all zeroes.

Finding a flat area of a 3/8" thick glass. You get the head as flat as the glass is.

Dykem steel blue (wasn't really needed)

Very nice job.
That's how I did it. I didn't have the blueing, but I have a ton of sharpies.

[SantaFe75]

good job, any problems encountered ?

Sorry so late.

I always have problems . Time, was my biggest issue. When I measured cam gaps I found that they were well worn.
Most (16) were within spec. I did try to find single lifters, but with our Volvo dealer closed, there were none to be had
in time. I believe the worst had a gap of +.07 over "max". Needless to say, My "Volvo tick" is prominent. When I can get
the needed lifters, I'll pop the cover off and do it again.

[abscate]

For what it’s worth I measured a whole set of removed head bolts and was unable to measure length differences from a Volvo one, within resolution of =-50 microns. I doubt they are torqued past elastic deformation, so reuse isn’t crazy

I just removed a valve cover on an RN and retorwued head bolts to address an oil seep, so far successfully

[jonesg]

good job, any problems encountered ?

Sorry so late.

I always have problems . Time, was my biggest issue. When I measured cam gaps I found that they were well worn.
Most (16) were within spec. I did try to find single lifters, but with our Volvo dealer closed, there were none to be had
in time. I believe the worst had a gap of +.07 over "max". Needless to say, My "Volvo tick" is prominent. When I can get
the needed lifters, I'll pop the cover off and do it again.

don't they sell valve shims for that?