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They maintain it would have been too expensive to replace the hoses? Who was footing the bill? You were, right? Who is, in theory, is footing the bill this time? You again, right? Any competent technician knows the coolant hoses were compromised. Any competent technician would have advised the service writer and the service manager (who should know the same information) that they would like to replace the coolant hoses. At that time, you should have been phoned and given the option, to replace, or not to replace.
Further, you went back for basically what sounded like predetonation, or coolant boiling and popping in a closed system after the head was replaced. The fact that they flushed the system again because there was "gunk" in it, should have alerted them to the fact that maybe, just maybe, the original problem wasn't fixed (my theory). At any rate, the coolant hoses were, once again, compromised, and once again, you weren't given the option to replace the hoses.
As you speak with them, alert them to the fact that deciding the coolant hoses were too expensive to replace was NOT their decision to make. It was yours. By denying you the choice, they also denied you culpability. They made, what they considered to be, a RESPONSIBLE decision. They actually TOLD you that; they just offered you your winning hand. They made a decision on your behalf, and that decision just cost you a motor. Let your attorney run with that.
Personally, I think the block was toast before and they should have replaced the motor, not the head. If the head got hot enough to "crack" at an oil journal, it got "freakin" hot. I'd say there is little to no chance the block survived the first round, but again, that is my OPINION. What I think happened is this:
I suspect the car was overboosting, hence the problems with the air mass meter and such. Overboosting can take out the headgasket. Headgasket blows, head gets hot enough to crack at an oil journal, Boo-wam, Volvo replaces the head. You go back with your noise, and "gunk" instead of oil and coolant. I suspect the "seal" supplied by the headgasket is not "sealed" well. I "think" the block was warped, allowing compression into the cooling system, giving you your noise that they, in theory, didn't hear, and once again allowing for some mixing of fluids, giving you your "gunk". They flushed, you drove away. With time, the compression leakage into the cooling system, took out your weakened coolant hose, you lost coolant, you truly overheated, and now you are where you were before. It is ironic though, isn't it, that they now believe you need an entire motor? Doesn't it make you wonder if their thinking is following the same path as mine?
Hope this helps just a smidge,
Chris
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