Hello again Klaus,
I will follow your advice and take a good look for pinhole leaks in the radiator the turbo and connectors to the firewall. I assume I should see some coolant or dried traces of coolant. So far neither my mechanic friend or I have noticed any evidence of coolant in the engine compartment. But I will make an inspection today. I am more eager than you to avoid this job!
I would like your reaction to this quote from the DWM tutorial on a cylinder head transplant.
80.Replace the camshafts.
There is no need, I think, to go through the Haynes rigmarole of putting them in the cam cover, and lowering it and them on to the head (having first made a tool out of welding rod to stop them falling off when you hold it upside down). I imagine that what they are trying to achieve, by this method, is to protect the cover, and especially the shell bearings for the camshafts in it, from being damaged as the carrier is bolted down – if you don't press it down straight, things can get slightly wedged/stuck and then suddenly jump/snap into place.
So, instead, just do what the Vida instructions say and put the camshafts on the head and install the carrier/cover on top. The camshafts won't sit neatly until the cover is tightened down, because however you lay them, some of the cams will want to be exerting pressure on their valves, so the cover needs to be pressed down against the force of the relevant valve springs.
Haynes (and Volvo) make a lot of fuss about putting the camshafts in the 'right' orientation. They go on about having the slot on the inboard end of the inlet camshaft above the centreline, and the slot on the exhaust camshaft below the centreline. This is sound advice if you are going to use the camshaft locking tool, but quite unnecessary if you are doing without it. All that really matters is that you don't mix up which camshaft is which. My inlet one had an orange-painted section on it, which is how I told it apart from the other. Obviously, also, it makes sense to lay the camshafts in an orientation such that you can see the paint marks that you are going to use when re-attaching the sprockets. So just put them back approximately as they were when you made those marks. They will then be in approximately the right orientation for when you fit the timing belt – which is when their being in the right positions becomes a critical matter.
Is this sound advice? He did not use the camshaft locking tool when he did the job. He made some paint marks on the camshaft before disassembly and he is referring to this at this point [step 80] in the assembly.
And pardon my ignorance, what are the VVTs?
Bob
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