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Your mechanic is at least double the price he should be at for this work. Locally with shops that charge $55-70 per hour, this kind of work would run about $500 for a head gasket/timing belt job, and $1200 for a replacement (good used) engine. These aren't difficult cars, the parts are cheap, and major organs like a complete engine fail so rarely that good examples can be had for $400-500 from junkyards. Whole running cars are under $1000 here. I just gave away a great running '86 for peanuts.
Anyway, it really might be time to make some phone calls and look for another shop. $4000 is close to double the wholesale value of the car. The mechanic gave you this price because he either does not want to do the job, or has no clue what it will really cost, or he's making a down payment on a boat.
For example, you could go to a junkyard, ask for a complete head, and probably have it removed (by them) and carried to your car for $200. Another $60 at a local machine shop will cover having it "planed" which is having the bottom surface cleaned up for installation. Heads regularly trade at around $150 on Ebay, for instance.
Take that to your mechanic along with a timing belt kit (under$20) and a head gasket set (under $80). If he charges more than 4 hours labor to do this, he's slow. Another $40 for oil, antifreeze, and miscellaneous nuts and odds and ends, and that's the whole job.
There are even cheaper methods for do-it-yourself, but it would require some investment in tools and service manuals.
I wish you luck with your goal of having your Volvo back soon!
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Rob Bareiss, New London CT ::: '87 244DL/M47- 220K, 87 244DL- 230K, 88 744GLE- 198K, 91 244 180K, 88 244GL 145K
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