Hi new frends. Thanks to the OP for havig this forum available to us volvo users.

I have just replaced the engine in my car. I went to a decent salvage yard and bought the engine block wich was turning fully. I kept my old cylinder head (keep that in mind). I turned the yard's engine block and it turned flawlessly. And all pistons stopped at top lined up with block. Cylinder 5 did not reach 100% but about 99%. In fact you coud see the difference in the color of the cylinder slightly burnt. Ok.

I put the cylinder head back to the new* block and fixed the timing in place. I turned it twice until back at tdc.

When i started the car it started as expected. But this time i heard this noise like a valve is hitting a piston. Or a valve cap not returning back to top fully.

I turned off the car and noticed that the timing on the front cam was one tooth beyond the mark. I readjusted timing and restarted the car. SAME PROBLEM WITH THE NOISE.

Facing little time to fix this car i took the cylinder head off. All pistons were intact. No signs of cracks or dings. I went to the yard to get a cylinder head thinking about a non vissibly bent valve off the current head valve.

I found an almost brand new looking cylinder head with all valves closed. No gaps at all. I came home and cleaned the valve springs and put assembly lube throughout before putting the caps back.

I then put everything back together. Turned engine twice to tdc. Aligned timing marks. Turned on the car and it does the same thing. Something is hitting something really bad.

The car idles pretty good.

My questios are:

Where may that noise come from?
Is the oil pump a factor to look at?
Should i consider this many hours of work (by myself. Including dropping the engine and putting the other one in with only two small hydrologic jacks) a learning experience AND get another engine out of a wrecked s40 and start all over again?

Lets make this a fun thread! Thanks for the help. Ask me open ended cuestions maybe i forgot something

 

You may have a rod bearing bashed out - that would explain why #5 didn't come to the top of the block. Since the engine runs, one experiment you could do is unhook the coil or fuel injector on that cylinder. If one of them gets quiet when not firing, you would expect to find a bad bearing in the reciprocating assembly on that cylinder.

 

Hi man whats up!! I just tried that. I also checked the spark plugs to see if it got hit by the pistons and all good with the plugs.

 

Hello. I just wanted to say thank you for the suggestion one more time (i did in my other post too) i focused mainly on the head valves and even swapped the cylinder head. In the end, 3 seconds before giving up i stepped the game up and put my abilities on high throttle. I tackled the rod bearings and finally it all ended there.

Thank you kindly.