Pcv Breather Hose

[Seagrams]

So after pressure testing my turbo to check for leaks, I snapped the PCV breather hose that runs to the fresh air intake pipe and hooks on to the PTC nipple like a dumbass while putting everything back together (that b*tch was brittle .) The break is roughly by the BCS and I've so far been driving it without issue but I do want that breather hose working again before it starts getting cold since it's my understanding that it is important for the function of the PTC. I was hoping it wouldn't be a big deal so I got a new hose and from looking at the VADIS diagram and realized I was going to have to remove the intake manifold to get to everything... Just so there is no confusion the replacement hose in question I got is #7 in this pic and also includes #'s 6, 8, 10, and 11, everything running through that foam housing...

So my question is this: I don't think i need to do a full PCV Job, and I don't want to buy the whole kit and end up with two of these hoses, so i was thinking at most I'd just buy a new oil trap and clean everything out while i'm in there. It looks like i'll be taking the intake off (i've read you can do it without removing it, but getting that little vac elbow back on the PS side of the intake alone is not something i want to try again with the intake mani on the car). Then again maybe redoing the PCV, while not wholly necessary now, might be in the future and this doesn't seem like something i want to have to do again in 3 months or whatever.

So what other parts am I going to need? A new Intake Manifold gasket correct? Any gaskets or bolts or volvo specific parts? What else should I do while I'm in there? check the EGT (if i have one, i think half the 96 models do and half don't)? What else? Any particular "gotcha" spots i should look out for based on people's experience? I already plan on having an assortment of clamps and a new fuel hose in the likely event i need to cut it to get it off.

Would like to get everything i need all sorted before i start this and realize i left something out and have to wait a week to get another part.

Thoughts? I know the PCV replacement threads have been beaten to death here, but I think this is somewhat unique in that the PCV still works like a top, and i have researched the writeups and have gotten a decent idea of how to get everything apart so pls don't tell me to search, i'm just looking for ideas and suggestions on how to maximize the work i can do while replacing this $&%#* hose.

Thanks guys!

Colin

[Chilled man]

have any vac hose left over from redoing your vac lines ?

;)

[Seagrams]

have any vac hose left over from redoing your vac lines ?

I do. Mostly the bigger one, but some assorted lengths. I forgot to mention that i was also considering redoing the Brake Booster line with that fat silicon one just for posterity. What are you thinking?

[--Aaron--]

I do. Mostly the bigger one, but some assorted lengths. I forgot to mention that i was also considering redoing the Brake Booster line with that fat silicon one just for posterity. What are you thinking?

just be sure to bring some patience with ya that 2nd one is a PIA....i took the lazy way n did the easy half for now lol

[Seagrams]

just be sure to bring some patience with ya that 2nd one is a PIA....i took the lazy way n did the easy half for now lol

what 2nd one?

[StylinMotors]

You can use silicone on both hoses. #7 and the brake booster. Think the Brake booser is 10mm or 3/8".

[Seagrams]

You can use silicone on both hoses. #7 and the brake booster. Think the Brake booser is 10mm or 3/8".

yea i was going to use my 10mm stylin hose on the brake booster (i think it's just long enough) but i already have the OEM hose #7....

[Cal3thousand]

WOW... I did the same EXACT thing. And YES that thing is more brittle than Michael Jackson's face.

I ran with the cracked line for a couple months. Didn't have much issue. Replaced the #7 tube during my head rebuild and the catch can was empty

Not sure why, but it's all butter now. I would order the #7 if I were you and reuse the rest after cleaning.

[--Aaron--]

what 2nd one?

oops i meant 2nd half, there's the first section which goes from the TB to a coupler and the second section which runs under all the abs, brake line yada yada....very tight space

You can use silicone on both hoses. #7 and the brake booster. Think the Brake booser is 10mm or 3/8".

10 is just about perfect....i tried to use 8 the first time and i got it on but it was VERY difficult, 10 went on with a little resistance but much better

[Seagrams]

WOW... I did the same EXACT thing. And YES that thing is more brittle than Michael Jackson's face.

I ran with the cracked line for a couple months. Didn't have much issue. Replaced the #7 tube during my head rebuild and the catch can was empty

Not sure why, but it's all butter now. I would order the #7 if I were you and reuse the rest after cleaning.

Yeah i have the # 7 line sitting in my car right now, i picked it up yesterday.

So running with the broken line left your oil trap empty and after you replaced it it's all buttery inside? weird. Yeah i haven't had any obvious performance issues (DTC's etc.) running with the cracked line but like i said, i'd like to get it fixed before it gets chilly up here (so my PTC functions dandy and all that).

So again, to reiterate, i'm going to be pulling the intake mani so i can get to everything easily (i've had enough of working in a gravel driveway contorting myself and blindly fumbling with my hands rushing to get something connected before my lower back starts to spasm ) What do i need other than a new intake mani gasket? I'm not planning on removing the TB so i don't think i'll need a new gasket there and the same goes for the EGR assuming i have one.

Since my PCV has been functioning, can i presumably get away with just inspecting, removing, and cleaning it all out? (assuming i don't break anymore damn hoses) What makes them fail? Clogging? Broken lines?

Is there anything else i should do while i'm in there?

And i see what you're saying Aaron, the half going to the fire wall looks like a pita, but since my booster is working ok, i'd just be doing it because it's there and why not!

[Jippi 855 GLT]

i have one of those left over from a pcv swap.

pm me if you want it..

[Seagrams]

i have one of those left over from a pcv swap.

pm me if you want it..

I have the hose!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! Right now at this moment!!!!!!!!!!!!!!!!!!!!!

gosh!

What else do i need/should i do once i remove the intake mani!!!!!! what else other than a new intake mani gasket should i procure!!!!!!

:lol: :P

[Cal3thousand]

I have the hose!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! Right now at this moment!!!!!!!!!!!!!!!!!!!!!

gosh!

What else do i need/should i do once i remove the intake mani!!!!!! what else other than a new intake mani gasket should i procure!!!!!!

:lol:

If the manifold gasket hasn't been replaced in the last 15k miles and you are taking the thing off, I would replace it.

And cleaning and replacing parts is cool if they haven't deformed. The can is a definite reuse in my book. I did replace the hose that goes to the bottom though.

BTW, butter = good in that last post.

[Seagrams]

If the manifold gasket hasn't been replaced in the last 15k miles and you are taking the thing off, I would replace it.

And cleaning and replacing parts is cool if they haven't deformed. The can is a definite reuse in my book. I did replace the hose that goes to the bottom though.

BTW, butter = good in that last post.

lol, when i hear butter when talking about oil i assume milkshaky badness

Which is the bottom one? the stubby guy #4? I don't see anything being deformed (assuming i don't deform them myself ) but maybe just a bit gummy and grimey. When the hose broke and i looked down the thing it had a tiny bit of gunky mcgunkerson in it, nothing serious so i'd expect more of the same.

But in my experience while working on my car, I've found that 99% of the things i've checked out that i've heard tend to be fouled have been totally cherry.... guess being thorough on your maintenance pays off in more ways than one.

But one thing, who goes and changes out the intake manifold gasket as part of a regular service? I'd imagine it has never been changed, so I'm certainly going to be going for a new one

So any other things i can check out while i'm in there? Ideas?

Thanks guys!

[sconeman]

I don't know C-man, I would replace the whole package just to be sure because it's definately not fun to do this job. I wouldn't want to ever do it again on the same car.

However if you didn't want to to spend the extra $$I would at least replace the snaky line that goes to the valve cover as well as the one you broke. + clean clean clean everything especially the intake pipe, PTC heater plate and orifices, and the holes into the block. Then obviously change your oil afterward. Definately get the intake mani gasket from the dealer.

Also one more tip, do yourself a favour and buy the parts from the dealer. I bought the kit from Eeuroparts when I did mine. One of the vac elbows (the one that attaches to the PTC vac nipple) had a tear in it. Not from getting damaged but from being a total piece of crap. It was providence that I found it and if I hadn't I would have have that vac leak conundrum of the century on my hands. Seriously.

I ordered a replacement part from the dealer for $2 and it was similar to the difference between a mercedes and a Yugo. If you remember those. The walls of the elbow were 3 times as thick and totally uniform, whereas the walls on the euro-crap was thick on one side and about 5 microns thick on the other side hence the rip.

One more thing make sure you have at least 2 wobble extensions for the 10mm socket and a magnetic pickup is a pretty good idea.

G/L

EDIT one more thing zip tie the vac elbow that goes onto the pass side nipple on the intake mani. My slipped off about a month after I replaced the whole system (at 17psi) it took a lot of patience to get that elbow back on and zip tied. You'd be better off doing it when the mani is off.