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

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RickHaleParker
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Volvo Repair Database 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by RickHaleParker »

Prepping to remove the Cylinder head. Has anybody gotten the exhaust manifold off without pulling the right axle and the bevel gear?
1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
2004 S60R, B8444S TF80 AWD.
2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
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Re: 2004 S60R Exhaust Manifold removal.

Post by - Pete - »

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?
2001 V70XC 151k
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2004 V70R M66 146k
2004 XC70 293k
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Re: 2004 S60R Exhaust Manifold removal.

Post by RickHaleParker »

- Pete - wrote: Fri Apr 03, 2020 10:31 pm 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. :o
1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
2004 S60R, B8444S TF80 AWD.
2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
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Re: 2004 S60R Exhaust Manifold removal.

Post by chrism »

RickHaleParker wrote: Sat Apr 04, 2020 12:10 am
Things are pointing toward the previous owner had the head rebuilt but did not torque and stretch the head bolts. :o
Or they reused the old bolts and they DID torque them but now they’re over-stretched and weakened???
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Re: 2004 S60R Exhaust Manifold removal.

Post by RickHaleParker »

chrism wrote: Sat Apr 04, 2020 7:08 am 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.
1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
2004 S60R, B8444S TF80 AWD.
2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
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Re: 2004 S60R Exhaust Manifold removal.

Post by RickHaleParker »

- Pete - wrote: Fri Apr 03, 2020 10:31 pm 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).

IMAG0051.jpg
IMAG0052.jpg
IMAG0053.jpg
IMAG0055.jpg
Last edited by RickHaleParker on Wed Apr 08, 2020 10:57 am, edited 1 time in total.
1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
2004 S60R, B8444S TF80 AWD.
2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
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Re: 2004 S60R Exhaust Manifold removal.

Post by - Pete - »

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.
2001 V70XC 151k
2004 V70 AWD 145k
2004 V70R M66 146k
2004 XC70 293k
2006 XC70 155k Sold
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Re: 2004 S60R Exhaust Manifold removal.

Post by RickHaleParker »

- Pete - wrote: Wed Apr 08, 2020 10:38 am 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.
IMAG0058.jpg
1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
2004 S60R, B8444S TF80 AWD.
2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
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Re: 2004 S60R Exhaust Manifold removal.

Post by - Pete - »

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

This is one of the questions I’d ask.
2001 V70XC 151k
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2004 V70R M66 146k
2004 XC70 293k
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Re: 2004 S60R Exhaust Manifold removal.

Post by bmdubya1198 »

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.
'00 V70R Venetian Red/Charcoal M56 Swapped 200k
'03 S60 2.4T Silver/Black 118k
'07 XC90 V8 AWD Sport Titanium Grey/Black 174k
'91 944 Turbo Dark Green/Beige 175k
'92 245 Base White/Beige 249k
'98 V70 GLT Black/Beige 205k
'99 BMW 528i
'01 Mountaineer 5.0
Sold-
2000 S70 GLT Mystic Silver/Taupe 253k
1993 944 Base Beige/Beige 221k
1998 S90- Silver/Gray 207k
1995 850 GLT Tropic Green... crushed
2001 S60 2.4T Black/Black 230k
1988 744 Turbo M46 Beige Metallic/Beige 188k
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