I posted a while back after my daughter's '95 940 overheated due to a radiator plug blow out. The car is just too nice to part out, but paying for a new engine makes no economic sense. I decided to gamble on just replacing the head. Found a nice head at a pick n pull for $40. Someone had already disconnected the exhaust manifold and front pulleys so it was a breeze to take off. I checked it with a machinists level and everything was good. Cleaned it up, then removed the old head. Amazingly the old gasket was intact. The head had warped severely and loosened the head bolts on the exhaust side. The rear timing cover was melted....
215m miles and the honing marks were still on the cylinder walls. Also, I'm convinced that synthetic oil (RotellaT 5/40) helped keep the bottom end from suffering any damage.
Long story short, I replaced all the gaskets, sensors, etc, put it all back together and everything works like a dream! This forum is an invaluable tool and I cant thank you all enough for your help and encouragement.
So far a non pulsair head is working well on the 230FD engine.
Time for a very large celebratory beer!!
Phil C