Well, I've killed it !

[nobananas]

Tore the lump apart this weekend ! I'm just hoping that by the time I come to put it back together my short term memory loss problems haven't kicked in !
http://images5.theimagehosting.com/engine parts.th.jpg (http://server5.theimagehosting.com/image.php?img=engine parts.jpg)

Upper cylinder wear could have been better, anyone got a good bottom end kicking around ?

[Andrew]

WOW - I admire those that can weild a spanner - unfortunatly I'm crap at that sort of thing. Give me a piece of technology any day.

[dreadly]

Tore the lump apart this weekend ! I'm just hoping that by the time I come to put it back together my short term memory loss problems haven't kicked in !
http://images5.theimagehosting.com/engine%20parts.th.jpg (http://server5.theimagehosting.com/image.php?img=engine%20parts.jpg)

Upper cylinder wear could have been better, anyone got a good bottom end kicking around ?

I may be telling you how to suck eggs, but...
There are some good volvo breakers who advertise on this board discounts for members, might be worth a quick call.
If you have a lot of bore wear then you will probably need new pistons if there is any sign of blowpast or scratching on the sides of them.
Also you need to hone it and fit new rings.
Another option that is fairly popular with classic car specialists is to have a rebore .2 or .4 oversize and a new set of oversize pistons, this will also give you slightly more power.
I believe volvo sell a set of oversize pistons for the T5, you could upgrade to S60 pistons, I believe these are lighter, smaller and stronger :)

Have fun, I have used alloy wheel cleaner to decoke in the past and clean the ways.
Adam is the chap to ask on Monday I believe.

[nobananas]

Cheers dreadly. The bore wear is only in the last cm or so of the upper cylinder (caused by the piston 'rocking' as it changes direction) below that the original honing marks are still present. I know a re-bore and oversized pistons would be the best option but it would cost far more than the cars worth ! If I can't find a better block I shall glaze-bust the bores, soften the wear lip (to prevent possible damage to new rings) and chuck in some new rings. The big-end bearing shells were more worn then i'd hoped too so i'll change them as well.