Radiator failure...Overheat...Head gasket failure...Engine damage ...Swap the engine from one of my spares.

I will be exchanging the entire engine/transmission/suspension (less struts)/subframe. I have the bad engine removed. It took 5 hours.
I will be replacing every rubber hose on the assembly going in. I do not want another failure soon. Once I've got it all together, I will flush the transmission fluid, too.

The trickiest part of removing the old assembly was dropping the subframe low enough to get it out from under the car. I did this by dropping it onto 2X6s sitting tall. That gave me clearance to get the floor jack out from under the front crossmember on the subframe. I had loosened the subframe bolts and this left me enough clearance to fully remove the bolts. I then tipped the 2X6s over and inched the assembly out from under the car. No real complications.
Tomorrow I hope to finish removing the assembly from the parts car. Then I'll get to do it all in reverse!

 

Good luck! pics would be nice..

 

Stuck on the steering bolt because it snapped off. It's always the last fastener! But here's some pix uploaded while I take a lunch break.

 

The turbo on the engine going in had a 13T on it. It will be replaced with the turbo on the engine coming out - a 15T. Both turbos had very little shaft play, but the 13T was oily from leaking seals.

Found some pretty crappy work. Someone patched the heater hose with short pipe and hose...and 3 hose clamps! Buy a new hose for crying out loud! How cheap can someone be. I showed it to my daughter to urge her to find a good mechanic when she's on her own.

 

Subframe reattached yesterday. Engine harness 90% reinstalled. Looking good!

I made a metal bracket to replace a broken tab on the side of the radiator. I welded a tab onto some perforated 1.5 inch angle. The holes matched perfectly although my welding was not so perfect. I'll post a photo if anyone's interested.

 

I can see the end of the tunnel. Today's progress was all exhaust.

First up was mating a FWD downpipe with an AWD muffler. The mating pieces are 7 5/8 inches apart. Fortunately the necked down section just before the
mating "ball/socket" just fits inside a 2.5 inch exhaust pipe. So I cut the narrowed section in the middle, leaving enough on each piece to fit into the end of a straight pipe and weld with an overlap joint.

Next was designing and building a bracket to hang it. The old center plate was rusted and unusable. And to make matters worse, I broke off two of the bolts on the same side in the underbody. After much thought, I took a bolt with and integrated washer and ground flats on it to slip inside the oblong holes in the underbody near where I broke the bolts. Once I slipped the head up inside the hole, I secured with a fender washer and nut. I now have studs on opposite sides of the exhaust. That was the easy part.

I finally came up with a fairly simple solution to support the exhaust on one side up in the center tunnel. I'll be welding the pieces together shortly. All in all a simple, functional solution.

All that remains are the driver side vacuum lines and the associated connections on the turbo intake tube. I don't have any more complications to resolve, so hopefully by the end of the day tomorrow...

 

Exhaust hanger photos.

 

A little late on the update, but the car is finished. I had a scare yesterday, though. On my way to look at a '98 V70 5 speed, the lower oil cooler line popped out of the radiator, spewing oil down the road. As soon as I saw the oil pressure light come on, I coasted to a stop and shut it down. I replaced the clamp with a new one, and put a hose clamp over it, filled it with oil, listened for bad noise (and heard none) and went on my way.