giantrobot9000 Posted October 28, 2007 Report Share Posted October 28, 2007 What a PITA!! Granted, I probably don't have the tools (or experience) but this sucks. I've managed to finally get the intake manifold off, after struggling with the stupid bottom bolts. Other than taking a good 3-4 hrs already, I've managed to break the skinny white fuel line that runs across the injectors. I was trying to get the rubber vacuum hose off the end,because it was torn (and possibly the source of the fuel smell and some running issues), and snapped the hard plastic line while doing so. Do you think I can find it at Napa or somewhere other than the dealer?I'm gonna take some pics tomorrow and post them, because I want to clean everything I should before putting it back together. The part that looks the dirtiest is actually the inlet to the turbocharger around the backside. When I pulled off that end of the long PCV hose, I noticed how sludged that opening was. The intake side doesn't seem quite that bad, and the canister itself really didn't seem very dirty. :huh: Link to comment Share on other sites More sharing options...
850newb Posted October 28, 2007 Report Share Posted October 28, 2007 silly, you probably broke a vacuum line. white/yellowish that runs from the fpr to the t/b vacuum neck? It might cost you a dollar at a local auto parts store Link to comment Share on other sites More sharing options...
JBVolvo Posted October 28, 2007 Report Share Posted October 28, 2007 silly, you probably broke a vacuum line. white/yellowish that runs from the fpr to the t/b vacuum neck? It might cost you a dollar at a local auto parts storeI give you credit for trying...but if you thought that a vac line was a fuel line, you probably shouldnt be doing the job yourself Link to comment Share on other sites More sharing options...
giantrobot9000 Posted October 28, 2007 Author Report Share Posted October 28, 2007 silly, you probably broke a vacuum line. white/yellowish that runs from the fpr to the t/b vacuum neck? It might cost you a dollar at a local auto parts storeYeah, that's the one. I don't know why I said fuel line. Link to comment Share on other sites More sharing options...
jdlc Posted October 28, 2007 Report Share Posted October 28, 2007 I replaced that vacuum line w/ silicone tubing but I'm sure rubber vacuum tubing available at parts store will do just fine.Yeah, that's the one. I don't know why I said fuel line. Link to comment Share on other sites More sharing options...
Dmsee Posted October 28, 2007 Report Share Posted October 28, 2007 Wow where is out PCV Specialist aka Oreo931 :lol: Link to comment Share on other sites More sharing options...
TM850R Posted October 28, 2007 Report Share Posted October 28, 2007 Silicone or use rubber elbows and a nylon line that came stock. Even a rubber one will work fine. Just be sure it will fit over the two nipples.Any auto parts store will have plenty hose to choose from. Link to comment Share on other sites More sharing options...
giantrobot9000 Posted October 30, 2007 Author Report Share Posted October 30, 2007 That vacuum hose was the least of my worries now. For some damn reason, I stripped an intake bolt and then broke another one. I borrowed a torque wrench to tighten them correctly, and one of them snapped right in the head (the right lower corner one).I give up on this crap. I thought I was gonna save money, but now I have to have the damn car towed and finished up anyways. I guess I am clearly not a mechanic. :( Link to comment Share on other sites More sharing options...
Oreo931 Posted October 30, 2007 Report Share Posted October 30, 2007 That vacuum hose was the least of my worries now. For some damn reason, I stripped an intake bolt and then broke another one. I borrowed a torque wrench to tighten them correctly, and one of them snapped right in the head (the right lower corner one).I give up on this crap. I thought I was gonna save money, but now I have to have the damn car towed and finished up anyways. I guess I am clearly not a mechanic. one of the bolts snapped off in the head? You need to drill it out and buy an extractor. Just so you know, repairs rarely go perfect for anyone. Its part of murphys law. The first time I did the PCV system it took me about 14 hours over two days. I lost bolts, and had to go to the dealer several times to get other parts. I also had to go out and buy a couple tools....another example is when i was doing my tstat, first i put the gasket on wrong and lost tons of coolant and didnt figure out why for about 2 or 3 hours. then I lost one of the tstat bolts! my car sat for a whole day because the dealer is closed on sunday and i lost the bolt on saturday.My point is, we all have hardships, NONE of my repairs have every gone 100% perfect...I changed my oil the other day for the first time and ended up losing about a quart on the floor because i didnt realize it was going to shoot out (i had the car on ramps.)...Take a break, relax, get the tools that you need to get to finish the job and get it done. once you finish it you will feel really relieved and happy that you saved money. Link to comment Share on other sites More sharing options...
giantrobot9000 Posted October 30, 2007 Author Report Share Posted October 30, 2007 Well, thanks for that. I guess you're right. I'm just getting frustrated losing the bolts and things not lining up or breaking like they have now. Who knows what will happen when I try to start the car and drive it! I'm expecting to have an oil leak from the short hose that comes out of the back of the PCV canister into the block. It didn't sit exactly flush, plus I didn't put the left bolt back on it. Yeah, the bolt broke in the head. I guess I could try drilling it out, but I've also got another thread that I think is stripped. It must've gotten crossthreaded or something. It seemed to go in with no issues, but when I tried to tighten it with the torque wrench it just spun and spun. I pulled it out and there were shavings all over the inside. I've only been using hand tools,also. I can't get my hands in places, and I am so close to stripping the heads trying to get my ratchets and sockets to fit in places. I'm mad,too, because the PCV system that I replaced didn't even look that clogged or dirty. The turbo inlet out back looks the most clogged and dirty,actually. I was getting oil out of the top hose onto the plugs and valve cover, and out of the dipstick. Everything has pointed to it needing service, so I'm hoping it really did. Link to comment Share on other sites More sharing options...
bum2kev Posted October 30, 2007 Report Share Posted October 30, 2007 Well, thanks for that. I guess you're right. I'm just getting frustrated losing the bolts and things not lining up or breaking like they have now. Who knows what will happen when I try to start the car and drive it! I'm expecting to have an oil leak from the short hose that comes out of the back of the PCV canister into the block. It didn't sit exactly flush, plus I didn't put the left bolt back on it. Yeah, the bolt broke in the head. I guess I could try drilling it out, but I've also got another thread that I think is stripped. It must've gotten crossthreaded or something. It seemed to go in with no issues, but when I tried to tighten it with the torque wrench it just spun and spun. I pulled it out and there were shavings all over the inside. I've only been using hand tools,also. I can't get my hands in places, and I am so close to stripping the heads trying to get my ratchets and sockets to fit in places. I'm mad,too, because the PCV system that I replaced didn't even look that clogged or dirty. The turbo inlet out back looks the most clogged and dirty,actually. I was getting oil out of the top hose onto the plugs and valve cover, and out of the dipstick. Everything has pointed to it needing service, so I'm hoping it really did.when i did mine. i lost half my O-rings for the injectors, I found some gm ones that were the same and got those on. i lost a few bolts and dropped some down inside they bay and had to search for an hour. I agree that it was hell the first time. I just took the intake mani off again a few weeks ago and it took about an hour. doing the PCV myself gave me the confidence to do pretty much most things on my car. rotors/brakes, axles, fuel pump. just keep it up... Link to comment Share on other sites More sharing options...
Hoosier Daddy Posted October 31, 2007 Report Share Posted October 31, 2007 baby steps or just jump right in. i've worked on cars all my life but volvos are a different breed. it took a while to learn their ins and outs but now my car is truly mine. i don't even like the thought of someone else working on it! i did pcv twice because i tried to half-jerk it the first time and i knew that just wasn't right so i went back in. much easier the second time around! after that the t-belt was next and it was no joke but doable. maybe i'll get under there and replace the oil sump gaskets this spring. oh, get the haynes manual! it really does help. Link to comment Share on other sites More sharing options...
Ihatespeedbumps Posted October 31, 2007 Report Share Posted October 31, 2007 Wobble sockets and extensions make this job a breeze.... Link to comment Share on other sites More sharing options...
darkside24 Posted November 1, 2007 Report Share Posted November 1, 2007 I'm curious as to how you managed to shear the head off of one of those bolts if you were torqueing them to spec ( 14lbs ) ???Not saying I haven't done the same in the past, but when I did it it was because I was torqueing to German spec "Gudentite" (no torque wrench involved)I found that doing the PCV system was a bit tedious, but got better the second time around once I realized that you don't have to completely remove the bottom bolts.I've got it down to about 2 hours now. Link to comment Share on other sites More sharing options...
giantrobot9000 Posted November 1, 2007 Author Report Share Posted November 1, 2007 I'm curious as to how you managed to shear the head off of one of those bolts if you were torqueing them to spec ( 14lbs ) ???Not saying I haven't done the same in the past, but when I did it it was because I was torqueing to German spec "Gudentite" (no torque wrench involved)I found that doing the PCV system was a bit tedious, but got better the second time around once I realized that you don't have to completely remove the bottom bolts.I've got it down to about 2 hours now.I had someone with experience help me finish it up, and he said the bolt looked like it was rusted in the middle, and therefore weak, and that's how it snapped he thinks. It pulled out in one piece and fairly easily. He went and re-threaded all the other ones and used new bolts. The oil smell is gone and so far the leaks look like they have as well! I'm still getting a fuel smell a little, though, and I found out that my upper intercooler hose needs to be replaced. He thinks part of the hesitation I have might be this hose being soft, as well as my old cap/rotor. Link to comment Share on other sites More sharing options...
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