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Unprepared Digging Into The Pcv System


Joe_m

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I am hoping to take a look at the vacuum hoses/pcv system this weekend. Do I need to get the hoses and elbows from the dealer or can I get generic stuff from any auto parts store?

I would like to start digging into it when I take the intake off to clean the throttle body. Do I need to buy any parts beforehand (definitely need to replace)? I've never worked on a PCV system. I only know what I have read searching old threads here.

Thanks.

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lets see

5 injector o rings

5 injector washers

1 intake gasket

Pray to God you dont have an EGR valve

1 new PCV catch can (goes under the intake)

some new hose to go from the fuel return line

various size hose clamps

some good carb spray cleaner

some round wire brushes of various size

might as well change the oil since you will be knocking all kinds of trash into it.

6 qts of oil and a filter.

might still want to get the various elbows connectors or look at getting a silicons hose kit with 4mm 6mm and 8 or 10mm

if you have another vehicle it might be good too (in case you need to go to dealership/parts store)

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lets see

5 injector o rings

5 injector washers

1 intake gasket

Pray to God you dont have an EGR valve

1 new PCV catch can (goes under the intake)

some new hose to go from the fuel return line

various size hose clamps

some good carb spray cleaner

some round wire brushes of various size

might as well change the oil since you will be knocking all kinds of trash into it.

6 qts of oil and a filter. 

might still want to get the various elbows connectors or look at getting a silicons hose kit with 4mm 6mm and 8 or 10mm 

if you have another vehicle it might be good too (in case you need to go to dealership/parts store)

- Will I need the injector stuff it I am not pulling the injectors out?

- The intake gasket goes between the intake and the throttle body?

- what size hose? Is that vacuum hose?

- should I buy elbows? Are they items I can get from any auto parts store or are they Volvo specific?

- what is the PCV catch can? Is that the whole can below the intake? Should that need replacing?

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Guest Guest_prasamin_*

You will need to pull the injectors out if you want to access the PCV system...so get the injector stuff!

You will need a throttle body gasket (between intake manifold and throttle) and a intake manifold gasket (between intake manifold and cylinder head)

You can buy some good silicone hoses for the vac lines if you don't want to drop cash on the PCV piping...just clean it with the wire brushes...

You will need a variety of hose size....www.hosetechniques.com is good...get the Universal Starter Kit, and that will cover your needs

Buy a few elbows and about 2 meters of hard plastic vac line from the dealer or FCPGroton....it may come in handy, and is pretty cheap...other than that, do everything that Will mentioned in his reply...

I'll be doing my PCV soon...let us know how yours goes...

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Aint this fun :D also the two bolts under the intake manifold are a PAIN to get back in. (one holds the dip stick tub the other is a mount that connects the block to the intake) to access the bolts that hold the intake to the block you have to pull the fuel rail. use two wrenches to loosen the fuel fittings i think it is a 15 and 17mm. most of those crimp on band clamps have to be cut off. DO NOT take the bolts out of the bottom of the intake just loosen them a couple of turns because they are not "through" bolts ( the intake has a notch that sits on these bolts there are 4 or 5 i think) but you will need to remove the 4 bolts on the top edge of the intake. There are two bolts that hold the catch can to the block one is kinda hidden behind a wire loom. you will need to carefully remove the knock sensor from above the catch can ( make sure you torque this back to the right amount of ft lbs/ Nm) if you need anything PM me

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Guest Guest_prasamin_*

jeeez...everytime i think about doing the PCV, i think of something else that I can do while I'm in there...might as well pay someone to do it...i can't afford to have more than one day of down time!

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Guest AlvinL

... to access the bolts that hold the intake to the block you have to pull the fuel rail...

I didn't have to... on my 95. The intake manifold can be removed without pulling out the injectors. I did the same work on a 93 and on that I had to. Just couldn't get to the bolts.

I'd leave the two bolts on. Pull up on the cover that's over the injectors and it will snap off. The cover is the one that's in the way of the manifold bolts. Reinstalling is the reverse- snapped back on. Like Merlin says, disconnect the fuel lines. Replace the rubber one with a new one with screw clamps for future work. If you've got a lot of miles, do yourself a favor and replace that oil separator- doesn't matter turbo or n/a. When the separator is pulled off, look for carbon that may be clogging the ports into the block.

Similar topic.

Good luck.

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  • 2 months later...

You can pull the intake manifold and leave the injector rail in place. :)

Use your new intake manifold gasket as a guide to finding the bolts. Removing the fuel rail is a much easier way to find them, but it isn't necessary.

Taking of that fuel rail is a PITA the first time around. I got a little dizzy from all the fumes.

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Get the elbows from the dealer... Cheap insurance that they will fit.

You won't need a new PCV 'catch-can' unless yours is busted. Mine just needed a good cleaning. However the hoses that run from it to the intake were shattered. They're made of hard plastic - I probably broke them taking it apart.

I didn't need a new intake manifold gasket, but I was probably just lucky.

Oh and get some paint and polish and make that intake purdy! :P

Intake011.jpg

BoltsandIntake003.jpg

BoltsandIntake007.jpg

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So I'm doing said project right now.... Got the PCV box all cleaned out.

This is a picture of the hose running from the top of the PCV box to the turbo. What the hell does that little vacuum line connect to!?!?

P6090002.jpg

Here's a picture of the other end that connects to the PCV box. The rubber elbow of the vacuum line in question is also broken, and I can't even remember what it connects to.

P6090003.jpg

Here's a picture of where the hose connects in to the intake piping heading for the turbo. I couldn't see anything a vac line that small would have gotten ripped off from.

P6090001.jpg

Flame only if you help at the same time! :D

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  • 4 weeks later...

Question, I read the info in bay 13 about cleaning out the egr, buy why would you remove the intake also? Additionally, what is the "oil separator" mentioned above??? What is the fuel return line and does it need to be replaced?

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Chris - how did you polish all your bolts? Bench grinder? I vaguely remember your thread about this i think ??? I'm having an intake professionally polished that I will be swapping in soon, but forgot about those pesky bolts.

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