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N/A PCV System Replacement
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Jun 17th, 2010, 07:23
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skinnny
Junior Member
Last Online: Jan 17th, 2024 16:39
Join Date: Oct 2009
Location: London
Car
1994 Volvo 850 2.0 GLT 20v Auto
Chimps
Me and a friend. The most either of us had done before was fitting spark plugs!
Tools
Socket set
Ratchet handle
18" (in total) extension
Universal joint
8, 10, 12mm sockets
10, 12mm closed spanners
10, 12mm closed ratchet spanners
Torx screw driver
Torch
Hammer!
Coat hanger
Notable by it's absence is a torque wrench. We didn't have one. And I wasn't willing to spend £££ on one when I didn't even know if the car would start again after our hamfisted efforts. But it
did
start... so maybe it's worth getting one now!
Parts
PCV kit
Oil Trap
Breather hose
PCV hose
PCV valve
Large coupling piece
Small coupling piece
Flame shield
Inlet manifold gasket
About 10" of narrow hose
About 10 assorted hose clips
Steps
DISCLAIMER: This is what worked for me... prob not the "correct" way to do it.
Remove fuel rail
Remove cover Just pops off.
Unplug injector power plugs Lost a rectangular seal from one of the plugs.
Unclamp fuel pipes Undo 8mm bolt at back-left of engine.
The left-most injector fell out of the rail which caused fuel to **** out of the hole it left... no biggee... apparently
Remove throttle drum/IACV assembly and vacuum tree
Remove cover
Detach throttle cable from drum
Detach ball joint linkage
Unplug IACV power
Undo 4x 10mm bolts
Remove manifold
Remove manifold bolts
Remove 3x 10mm top bolts
Loosen 4x 10mm bottom bolts No need to completely remove these as the manifold can be lifted off them.
Bottom-left bolt is a nightmare, managed it with about 10" of extension plus universal joint.
Remove 12mm dip-stick bolt Used 18" extension and came at it from underneath
Remove 12mm bracket bolt Used 18" extension and came at it from underneath
Detach pipes
Detach PCV breather pipe from cylinder head Need to remove spark plug cover
Remove fat air pipe that goes from air box to throttle body
Remove oil trap
Remove 2x 10mm boltsLoosen bracket bolt and twist bracket out of the way to get at the right-hand bolt.
Reverse the steps, replacing old stuff with new stuff as and when.
Notes
Our biggest problems were very-difficult-to-reach bolts, but persistence and trying different approaches paid off.
Re-aligning the bottom manifold bracket with the hole in the manifold took 5 or 6 (stressful) attempts.
Didn't fit the flame shield, as advised by various sources.
A couple of narrow hoses connected to the vacuum tree broke while we were removing it. We couldn't find exact matches so we used a slightly larger bore hose with hose clips.
We had one bolt left over at the end!!! :O
It took us 24 man-hours, spread over 2 days \o/
We used the hammer to knock the new oil trap in as far as we could.
We used the coat hanger to retrieve the myriad bits and pieces we dropped into the engine... and to clean out the gunged up holes going into the block after we removed the oil trap.
You may also want to have some new injector seats handy.
Last edited by Jod T5; Jun 19th, 2010 at
14:39
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