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I hadn’t even thought about it when putting the head back on.

Had to remove all the studs except 3……put the backing plate and intake manifold in place inc sealant. Make sure it didn’t move then use 2 nuts to make the studs…… bolts in effect. What a twat. ???
 
if you take the fuel pump off you can put the inlet manifold back on. PM me and I will try and explain

its back on but thanks for the offer!

Was to scared to take the fuel pump off. I’ve read setting injection timing 8 times in the manual but still don’t understand it! ??
 
Valve clearances all done. Thanks to @kashurst for his guidance on that. Triple checked the lot. I know the firing / rock pattern of by heart now ??

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The sealant king has been at it again! Stripped the oil cooler which he “overhauled”. No need for new seals….just reuse with sealant….
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No copper washers required…..use sealant ?

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now……corrosion. Good catch. What’s the fix……what’s it made of. I recall some peeps getting them repaired / machined

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Still got to knock to core out……bit scared!
 
The pink colour may just be superficial. Give it a rub with some wire wool or a scouring pad and see what is underneath. The heat exchangers do not have anodes. Volvo - unusually - seem to have used a proper bronze material on the KAD series. Good luck knocking the core out - do you really need to?
 
The pink colour may just be superficial. Give it a rub with some wire wool or a scouring pad and see what is underneath. The heat exchangers do not have anodes. Volvo - unusually - seem to have used a proper bronze material on the KAD series. Good luck knocking the core out - do you really need to?

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it’s the housing mate…..common issue
 
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it’s the housing mate…..common issue
pitting doesn t look to be at the bottom but somewhere on the side, right? in the pic above you are holding it 180deg rotated, right? I agree pink is superficial.
Can you somehow remove the seal from there before attempting removing the core? that's what I did on mine but construction on the IVECOs is much more user friendly. Is the other endcap off as well? If so, you know, flat piece (pref round and just fitting in) block of wood on it, hammer, it will givein. Obvs no idea if there are special tricks to get them off on a volvo...
 
now……corrosion. Good catch. What’s the fix……what’s it made of. I recall some peeps getting them repaired / machined
I was watching an episode of car sos where they has a badly corroded gearbox bell housing, they used layers of weld to build up the material and then ground it back down into shape. Could do something similar here?

No doubt an engineering shop will have some way of sorting it.
 
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