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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.
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kallekula
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Kallekula's $350 S40

Post by kallekula »

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
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IMG_1166.JPG (553.75 KiB) Viewed 3258 times
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IMG_1205.JPG (2.01 MiB) Viewed 3258 times
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IMG_1206.JPG (2.45 MiB) Viewed 3258 times

BMW 540i 2002
S70 Base 2000
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MadeInJapan
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Post by MadeInJapan »

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
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kallekula
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Post by kallekula »

MadeInJapan wrote: ↑12 Aug 2017, 21:12 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.

BMW 540i 2002
S70 Base 2000
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MadeInJapan
MVS Moderator
Posts: 13434
Joined: 31 March 2005
Year and Model: '98 S70 T5 '07S40T5
Location: Knoxville, TN American but born in Japan
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Post by MadeInJapan »

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
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kallekula
Posts: 1074
Joined: 2 March 2014
Year and Model: S70 2000
Location: Orange County, CA
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Post by kallekula »

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

Cylinder 1 honed
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IMG_1232.JPG (2.41 MiB) Viewed 3059 times
Cleaning piston
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IMG_1236.JPG (2.85 MiB) Viewed 3059 times
Piston after cleaning
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Oil pickup looking pretty clogged
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IMG_1237.JPG (1.47 MiB) Viewed 3059 times
Oil pickup cleaned
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IMG_1247.JPG (1.53 MiB) Viewed 3059 times
Lazy as I am I had the machine shop clean the oil pan
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IMG_1241.JPG (1.97 MiB) Viewed 3059 times
One down four more to go
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IMG_1249.JPG (1.94 MiB) Viewed 3059 times

BMW 540i 2002
S70 Base 2000
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MadeInJapan
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Posts: 13434
Joined: 31 March 2005
Year and Model: '98 S70 T5 '07S40T5
Location: Knoxville, TN American but born in Japan
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Post by MadeInJapan »

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
Top
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kallekula
Posts: 1074
Joined: 2 March 2014
Year and Model: S70 2000
Location: Orange County, CA
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Post by kallekula »

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

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BMW 540i 2002
S70 Base 2000
Top
MadeInJapan
MVS Moderator
Posts: 13434
Joined: 31 March 2005
Year and Model: '98 S70 T5 '07S40T5
Location: Knoxville, TN American but born in Japan
Has thanked: 17 times
Been thanked: 35 times

Post by MadeInJapan »

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
Top
User avatar
kallekula
Posts: 1074
Joined: 2 March 2014
Year and Model: S70 2000
Location: Orange County, CA
Has thanked: 58 times
Been thanked: 75 times

Post by kallekula »

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

BMW 540i 2002
S70 Base 2000
Top
MadeInJapan
MVS Moderator
Posts: 13434
Joined: 31 March 2005
Year and Model: '98 S70 T5 '07S40T5
Location: Knoxville, TN American but born in Japan
Has thanked: 17 times
Been thanked: 35 times

Post by MadeInJapan »

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
Top
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