C70: PCV replacement on a later 2005 C70.

[krussel]

I just thought I would upload this to help anyone who may be searching in the future.

I recently replaced my PCV tank and upper breather pipe on my 2005 C70. I used this excellent guide linked below which is for the older engine but most is the same.

http://www.volvoforums.org.uk/showth...light=breather

Here is a link to my other thread which shows the problems I came across and fixed.

http://www.volvoforums.org.uk/showthread.php?t=183065

The guide above is for the earlier engine and I found a few revisions which made the job a touch harder.

Just to recap the PCV system here is a couple of diagrams. The second showing the later revision.





I ordered a new PCV kit from Swansea Volvo (via Simon on here). With the forum discount (mention C3) it came to £72 delivered.



The first problem I came across is the location of the coolant feed from the thermostat reduces even further the access to the final bottom left 10mm manifold bolt. You are going to need some small socket extensions and one universal joint.



I found the “ONLY” access was above the alternator after I had removed the manifold coolant hose. Even so and using the slimmest 10mm socket I have the best I could achieve was the socket half on the bolt. Luck that the bolts are only torque to 20 lbs so they come undone quite easy. Even so you need a lot of patience to not round off the bolt because the only way to remove the bolt fully is to remove the thermostat housing.



When you come to remove the manifold (following the guide) remember the large 19mm banjo bolt on the under side (not in the guide). Don’t do what I did and turn the manifold 45 degs to remove this bolt as you will most likely snap the ridged breather pipe (see my other thread above). So once again take your time to save extra work.



When you replace the oil catch tank (firebox) the bottom lower bolt is hidden and must be feed in by feel (same on all models) An old tip is to put a little Vaseline or grease into the end of the socket to help hold the bolt.



The rest is the same. I did not replace the long pipe which runs around the engine. Due to the fact that it is heated its priced at over £100. If you find that your tank is pretty badly clogged with muck it may be a good idea to remove it and flush it through.

I fitted a new O ring to the quick release fuel line it was 8mm x 1.5mm.



Finally when you come to replace the manifold gasket the proper way is to remove the thermostat housing to remove the last left lower bolt. I looked at the inlet manifold and noticed that there is no actual casting under the bolt so I took a short cut and cut the gasket. It seems fine at the moment with no leaks.



Hope all this helps.

Kruss