S90 960 PCV install write up

[96R]

Just installed new PCV into a S90, thought I share some step by step.  I have done this on the 850 but on the S90 it seems more complicated getting the intake manifold out because of the engine orientation.  You should take photos of everything you take apart if this is your first time so you remember how to put it back together.

Also, the PCV parts, I noticed some volvo dealers are selling 1993 960 for less than $40 online. Looking at the diagram it appears to be the same for the S90 at a much lower price. I wished I knew before buying the parts.

1) remove the power steering reservoir will give you more space to reach the left two bolts to take the manifold off.
    the power steering reservoir 3x 12mm bolts are behind the round pulley, there are access holes on the pulley but you also need to take the serpentine belt off.

2) you may need to remove the thermostat housing too. (2 T-40) 

3) open the blue cap at the end of the fuel rail, press the valve to lower fuel pressure. Gas will spill out so put a towel there.

4) remove the throttle cable assembly (two pieces) 5x 10mm bolts.

5) now you have room to take the fuel rail aluminum cover off, and gently pull on the fuel injectors to remove the fuel rain completely.  disconnect any cables and vacuum
    hoses that get in the way. take photos so you remember how to put it back together.

6) remove the air filter box cover, remove the air intake snorkel, and the big plastic elbow connecting the throttle body.  Lots of wires and vacuum hoses to disconnect.  take photos before you pull that apart.

7) now begin to remove a bunch of 10mm bolts holding the intake manifold to the block. they're on top, bottom, and one 13mm NUT  at the very bottom that's very difficult to get to by touch only.  Some of those 10mm bolts are hidden, so take a flash light and look! when they are all removed the manifold will move and you can pull it out.

8) Once the intake manifold is out you can see your intake valves, look for any gunk built up on top of the valves and clean gently as necessary.

9) unbolt 10mm from the PCV breather box. along with connecting vacuum hoses.  Check the vacuum tree, it has 6 ports, only one is unused with a cap. My vacuum cap was cracked with holes probably causing a vacuum leak.  Check and replace the vacuum cap and any replace any old vacuum hoses. They're cheap and local autopart store carry them.

10) Most difficult was getting some of those 10mm bolts off the manifold, and that 13mm nut way at the bottom. There are also some space issues moving everything out of the way to get to the PCV.  Give yourself a good 5 hours because those 10mm and the 13mm can ruin your day.