Volvo Maintenance Hints for 7xx/9xx - Bill Garland's Nuclear ...

hole and retested. This time the timing was correct. I then marked the cam gear to the camshaft
so I would not have this problem again. So all you 960 owners out there be careful with the cam
gears. I do not know but the 850s may be the same way.
[Response and Caution: Jim Bowers] The Volvo tools to set the cams cost about $250. There is
a tool for locking the crankshaft in position, about $50, and one that attaches to the back ends of
the cams, almost $200, and puts everything in sync. In addition to the three possible choices
with the holes in the gear/pulley, the holes are elongated so you still have several degrees of
choice once you get the correct holes lined up. The car will probably run, but will not be set at
factory settings if you don't use the tools. Maybe you can find a place to borrow the tools? Or,
once you have it in running condition get to a dealer and have the timing set. I just ordered a set
from Kent-Moore, the Volvo tool supplier. Same tools are used for the 850 and probably for the
S40? All that having been said, you would have saved your self a lot of hassel if you had spent
the few $ to get the Volvo Service manuals for the engine. One of the books I have (TP31714/2)
takes you, in pretty good detail, through changing a head gasket.
[Tip from Tom Irwin:] I've heard the following is critical to re-assembling the head: bottle of
gasket goo, rollers and tension spreaders? The stuff I have is "Volvo #1161059-3, High
Temperature, Chemical Gasket", it comes in a 50ml tube.
Engine Problems:
960 Valve and Head Problems.
Sticking Valves. [Summary of tips from Tom Irwin] To avoid the sticking valve problem in the
B6304 engine which causes valve and piston collisions and consequent head meltdown, follow
carefully this advice for 960 owners from Mr. Barrington of Barrington Engine of LA, rebuilders of
many toasted 960 heads:
1. The Abe Crombie Tune-Up is a GOOD thing!
2. Put a fitting behind the AMM for occasional, brief WATER introduction to the Hot engine...
while
running Shatters and blows away the carbon build-up.
3. ALWAYS ALWAYS use PURE SYNTHETIC OIL! VERY insistent on that one!
Failure of Timing Belt and Bent Valves. If your timing belt in the B6304 engine fails, your engine
almost certainly has experienced major damage including multiple bent valves, cracked valve
guides, possible damaged pistons, and head damage. This will cost a fair amount to repair since
it is both labor and skill intensive. Some tips: [Chuck Jeckell] Any guides that need to be
replaced CANNOT BE HAMMERED OUT AND BACK IN!. The head must be heated and the
guides cooled/frozen to replace them properly. Volvo has had a problem with people
experiencing oil leaks when their valve guides leak after being installed incorrectly. Most
machine shops are not set up to install them properly: ask around (and see the note above).
Once the head is off, the broken guides will obvious to the shop. Be aware that piston damage
is possible, but not likely. Use the orange glue/sealer with a roller when reinstalling the head: