Finished up the voyage repairs on my 84 245Ti/AW71 which needed new headgasket at 195K miles.

Once removed, the old gasket showed why it was leaking in cylinders 3 and 4.

While the job is conceptually "straightforward" as some have indicated on the board, there are rough spots and many parts/components to reinstall and hook up right and without leaks (vacuum lines, fuel lines, wiring, timing belt, turbo hoses). The Turbo complicates things; little room to work, stuck manifold and header pipe fasteners/brackets (lots of PB Blaster, took it nice and easy with no broken studs), pesky oil feed line alignment/gaskets and little room to work.

Two full days of wrenching. Local San Diego Volvo agencies didnt have the B21FT headgasket kit in stock; would have taken days to get it. So FCP Groton came thru with an Airborne Express Saturday delivery (Thanks Nick!).

Car ran well on 500 mile trip back north, in the left lane on the interstate keeping up with 75-80 mph traffic and AC and cruise control on, even up the grapevine grade. No coolant or oil loss. I didnt baby it and it passed the test. I'll retorque the head once more and adjust the timing belt tensioner because of the new belt.

Now, opinions requested: As I cleaned up the head surface to reinstall I saw something unsettling. A tiny 1/4" long crack has developed (remember, 195K and 19 years of demanding service, never seriously overheated) between the intake and exhaust valve seats for each cylinder. I reinstalled the head, knowing that the engine ran OK before and not having the time nor inclination to undergo machine shop service so far from home. What's the prognosis for this head? Would rather have this one eventually repaired/welded right rather than try to find one. Are these cracks common in the turbo heads?

Thanks, Robert

84 245Ti
88 245DL