B18B Engine Rebuilt

June - October 2002

Shortly after I acquire my PV544, went to the CPVV meeting with my 2 cars. Since normally CPVV only accepts 30 cars,  I had a major quote beeing the only participant with more than one car.

Unfortunatelly proved to be a bad idea. I had a new exhaust manifold installed (previous one broke in trip I had with my cousins, 10th March 2002) and the mechanic who did that job (Salgado) told me engine was in very bad condition.

I thought he was overeacting and still had many, many kilometers to do with that engine. I was wrong. 

The 25th May 2002, we left toward Óbidos, a small medieval town 250 km south Oporto, I and family in the "new" PV544 while my friend Paulo drove the P1800. I had never drove the PV544 so far, so was a litle bit concerned with it.  Car behaviour was great and I even reached 140km in speedometer without loosing security or confort. But that day was fated to be a bad one to the P1800.

Problems begun when I saw white smoke coming from radiator, after 200km. We stoped the car and put some water in radiator. Waited 30 minutes to cool engine and went again. I thought that maybe radiator was without water, or leaking, but just a few km after white smoke again plus bad noise from engine (a 'clunk') and we stop definitively. Called insurance auto-assistance to toe the car. 

The trip was doomed, but we still insisted to join the other participants for the lunch, while my friend Paulo stood near the P1800 waiting for toe, wich came only 2 hours later.

Car was taken to a park in a town nearby, Caldas da Rainha, and was only toed to Oporto the next tuesday. Meanwhile I phoned Salgado leting him know that the engine had gave up. He just mentioned something like «...I warned you...».

The saga had just started. Salgado is a mechanic working elsewhere having this afterwork small garage just for fun. Works there saturdays and few hours after work every weekday. Told me that this job would be done quietly without any rush. 

Engine was only dismantled the 17th June. Rebore wasn't needed but besides that all other parts where in very bad condition. The 20th June got from Volvo an engine repair gasket kit plus some parts. Meanwhile Salgado was always doing something else and time went by.

Until the 20th July, the rebuilt stalled. I took some pictures of the engine dismatled parts (photos).

Salgado in the middle	Engine parts allover
Block engine full of rust!	another view

That day, Salgado gave me a list of the parts he couldn't find including expander plugs, 8 valve covers plus sinoblocs. 

On the 20th August, Salgado showed a completly rust pipe. We couldn't locate it in Parts Manual. So I took some pictures and post a message in the P1800 List (wich proved very helpfull, again) http://groups.yahoo.com/group/1800list/message/30051. Had severals replies: 30054, 30055, 30057, 30073, 30133. 

It turned out to be part ref.418628 (water return pipe) and NLA. Checked GCP, inquired also several USA P1800 part suppliers and zilch! Meanwhile my good friend Hans Ghijs (from www.casaonascerdosol.com) former Belgium Volvo Owners Club director, and now living in Portugal, got in touch with friends back home and got me not one, but two pipes! By this time Salgado managed to had a new pipe custom made in a locksmith/blacksmith in copper, so I kept the others in my 'private parts collection'. 

September was a busy month, but days were passing by and litle progress. A few other small parts were missing and needed, like red ink for the engine block. Radiator was also beeing rebuilt. And time passing by. I managed to had the red ink from Volvo Penta. Other parts missing, Hans got them from Belgium supplier. Also had the cover valve chromed again (had been painted in awfull black) and was shinning again (photos 14/09/2002).

Engine was assembled and painted. On the 28th September when I got the radiator ready, Salgado showed the engine in place, but not completly assembled yet. When I arrived his shop that saturday, Salgado was not very happy. Had the exhaust manifold broke in a small corner. Another unexpected problem (photos).

This time I was quite disapointed because the last exhaust manifold I ordered took almost two months to arrive. NLA (no longer available) at GCP, got it from Swedish Classic. So, when I saw it welded in place just few days after I was quite amazed...  Salgado was only focused in the P1800, so the car was I was surprised when I saw the exhaust manifold welded in place just few days after...

On the 5th October engine was working again. Just in the garage while Salgado was adjusting the carbs (manually). But another problem was waiting: this time the clutch hidraulic circuit failed. Master cylinder was doomed. Also the metal pipe was completly roten. Another one was made in copper...

This time Salgado solved the problem quickly, managed to rebuilt the master cylinder and locksmith made the missing tube so the 9th October car was almost ready. Salgado still had the engine revving alone. 

Finally I drove the car home, under heavy rain, the 12th October, almost 5 months after the last time I drove it!

Engine ready in place	Shinning again...after 38 years!
Welded exhaust manifold	New master cylinder and custom made copper pipe

Happy, having a new 'heart' I can now devote my efforts improving other aspects of this car. A never ending task...