Engine 850: B5254S/2.4/20v: Head gasket done, lump rebuilt, exhaust stinks

[dinky1]

Hi guys,

First of all this lump is in a Renault safrane and is technically the B5254FS (F being fuel injected).

So the original engine went wrong (now sitting in storage), cooling failed HGF followed.

Dropped another engine in (this one hadn't run for a few years and was on a pallet outside but started almost instantly), similar thing. Stripped it down, gasket on this was rusted away.. ordered in the genuine Volvo parts, head skimmed, put back together.. in the process my torque angle gauge came apart, rather than leave that one built tightened I loosened it. Volvo dealer said they've reused bolts..

Went with cardboard for the angle tightening on the next attempt..

Upgraded the hydraulic tensioner to an automatic one in the process.. something that I thought was a Renault modification but the bolt hole was already in place by Volvo..

Got it running, cooling still shot, found that fault, car went through an MOT for the first time in 12 years - but they did struggle on the emissions.

It has a brand new catalytic converter from motor parts direct but this didn't want to seal up properly against the flexible downpipe but wasn't a big issue - MOT tester was fine with it but it only cost £90.. Maybe not the best quality.

Exhaust has been rattling a bit and getting worse but the exhaust absolutely STINKS. There's clearly something very wrong with it.

I'm starting to wonder if there is something else going on here mechanically inside the engine like blocked oil channels in the pistons and Conrods causing metal to burn? - engine hasn't lost any power but it is losing coolant. On that note I had no idea the thermostat housing needed two gaskets so it only has one.. But I've also seen evidence of a leak by the radiator too so it might not be burning coolant (but it might! More investigation needed there..)

Anyway.. this exhaust stink is my main concern, it's clearly awful and surrounds the entire car when crawling in first or stationary. Can't say it smells sweet, more of nasty chemicals maybe even metal? Not nice whatever it is.

Also I've seen black water drops coming off one of the exhaust u bolts..

Any ideas where to start? - money is really tight so need to check the cheapest stuff first..

Don't really want to waste the car, took over a decade to get back on the road!