Guide: replacing PCV/ oil seperator system - Page 6

pierremcalpine · Jul 1st, 2017, 13:00

Pretty sure that Phil is the only one who can do that. I'm also pretty sure that he is subscribed to this thread. He will very likely chime in shortly.

ikiller · Jul 1st, 2017, 17:17

Unfortunately I am going to start digging into the car right now. I hope Phil sees this, but it would be great if someone else who has the guide could post it up somewhere and PM me a link or put a link here.

I can use his text from the first post, but pictures would be nice.

phil_r · Jul 1st, 2017, 20:41

Evening, dropbox changed settings recently.

Try this https://www.dropbox.com/s/a38lb5aueusvdbn/pcv.pdf?dl=0

Hope you manage to get everything cleaned and replaced as needed

Phil

ikiller · Jul 2nd, 2017, 00:07

Thanks a bunch. I'm going ahead and replacing cam shaft seals at the same time since I thought they overlapped well and I'm trying to solve some oil leaks.

Thanks again,

Mario

nickar · Feb 3rd, 2019, 21:12

This guide is very useful. Thank you. I am midway through the job and a few of those steps have saved a lot of frustration.

nickar · Feb 5th, 2019, 19:16

I am at the stage where everything is off with new parts ready to go back on. Before I attach it all, is cleaning gunk I can see (it was almost solid like charcoal) out of the pipes on the engine enough? I was just wondering if I need to blow some air through to dislodge any stuff further inside (if I can find an air duster can).

Pics of the pipes as they were when I took the PCV box off:

I don't need to worry about the PCV system itself because I have new pipes and a new plastic box.

Thanks.

phil_r · Feb 5th, 2019, 19:49

It was a long time ago, i think i just got as much crud out as i could, probably with a screwdriver. I think mine looked really bad as yours does in the picture but wasn't much further inside than what you can see.

nickar · Feb 5th, 2019, 20:16

Quote:

Originally Posted by phil_r

It was a long time ago, i think i just got as much crud out as i could, probably with a screwdriver. I think mine looked really bad as yours does in the picture but wasn't much further inside than what you can see.

Thank you. I thought that was the case but wasn't sure what was beyond those pipes. I may just attach an old vacuum to suck out any other bits!

nickar · Mar 16th, 2019, 20:02

A few problems I had along the way for anybody else doing this:

- The turbo engine needs a few more bits removed (eg. The bug aluminium pipe that feeds the turbo).
- There are THREE versions of the PCV pipework and they are all the same at the back end. However, the front end that attaches to the inlet manifold is different on all of them. Even my local Volvo showroom were unsure which one my car needed so careful what you buy. Some suppliers online are listing the wrong one.
- Definitely ensure you have a 1/4 inch ratchet as others have advised. It's extremely useful - the smaller the better.
- There are some gasket washers you will need when fitting the back end of the pipe. They are part number 947282. Only two are needed but more is better as you will drop at least two if you are like me. They are copper crush washers with 12mm inside diameter, 15mm outside and 1.4mm thick.

Charlton Volvo Centre on eBay were cheapest for the new pipework and box. They are now aware (thanks to me) of the different pipes too.

I'll post here if I think of anything else.

Jul 1st, 2017, 13:00	#51
pierremcalpine Premier Member Last Online: Jan 3rd, 2024 14:43 Join Date: Feb 2012 Location: Toronto Canada	Pretty sure that Phil is the only one who can do that. I'm also pretty sure that he is subscribed to this thread. He will very likely chime in shortly. __________________ 2003 V40 1.9T B4204T4, 197,000miles (sold but alive!), 2004 S60 2.5T, 160,000miles, 2010 V70 3.2, 125,000miles, 2002 V70XC 2.4, 175,000miles Click here for my x40 and V70 P3 repair guides

Jul 1st, 2017, 20:41	#53
phil_r Senior Member Last Online: Apr 20th, 2024 21:28 Join Date: Dec 2008 Location: Malton	Evening, dropbox changed settings recently. Try this https://www.dropbox.com/s/a38lb5aueusvdbn/pcv.pdf?dl=0 Hope you manage to get everything cleaned and replaced as needed Phil __________________ 2002 V40 1.9D SE, 218k miles 2002 V40 1.9D S 200k miles, for spare parts and storing things in!

Feb 5th, 2019, 19:49	#57
phil_r Senior Member Last Online: Apr 20th, 2024 21:28 Join Date: Dec 2008 Location: Malton	It was a long time ago, i think i just got as much crud out as i could, probably with a screwdriver. I think mine looked really bad as yours does in the picture but wasn't much further inside than what you can see. __________________ 2002 V40 1.9D SE, 218k miles 2002 V40 1.9D S 200k miles, for spare parts and storing things in!

Jul 1st, 2017, 17:17	#52
ikiller New Member Last Online: Jul 29th, 2017 22:33 Join Date: Apr 2013 Location: San Rafael	Unfortunately I am going to start digging into the car right now. I hope Phil sees this, but it would be great if someone else who has the guide could post it up somewhere and PM me a link or put a link here. I can use his text from the first post, but pictures would be nice.

Jul 2nd, 2017, 00:07	#54
ikiller New Member Last Online: Jul 29th, 2017 22:33 Join Date: Apr 2013 Location: San Rafael	Thanks a bunch. I'm going ahead and replacing cam shaft seals at the same time since I thought they overlapped well and I'm trying to solve some oil leaks. Thanks again, Mario

Feb 3rd, 2019, 21:12	#55
nickar Junior Member Last Online: Nov 17th, 2019 13:43 Join Date: Nov 2018 Location: Chester	This guide is very useful. Thank you. I am midway through the job and a few of those steps have saved a lot of frustration.

Feb 5th, 2019, 19:16	#56
nickar Junior Member Last Online: Nov 17th, 2019 13:43 Join Date: Nov 2018 Location: Chester	I am at the stage where everything is off with new parts ready to go back on. Before I attach it all, is cleaning gunk I can see (it was almost solid like charcoal) out of the pipes on the engine enough? I was just wondering if I need to blow some air through to dislodge any stuff further inside (if I can find an air duster can). Pics of the pipes as they were when I took the PCV box off: I don't need to worry about the PCV system itself because I have new pipes and a new plastic box. Thanks.

Mar 16th, 2019, 20:02	#59
nickar Junior Member Last Online: Nov 17th, 2019 13:43 Join Date: Nov 2018 Location: Chester	A few problems I had along the way for anybody else doing this: - The turbo engine needs a few more bits removed (eg. The bug aluminium pipe that feeds the turbo). - There are THREE versions of the PCV pipework and they are all the same at the back end. However, the front end that attaches to the inlet manifold is different on all of them. Even my local Volvo showroom were unsure which one my car needed so careful what you buy. Some suppliers online are listing the wrong one. - Definitely ensure you have a 1/4 inch ratchet as others have advised. It's extremely useful - the smaller the better. - There are some gasket washers you will need when fitting the back end of the pipe. They are part number 947282. Only two are needed but more is better as you will drop at least two if you are like me. They are copper crush washers with 12mm inside diameter, 15mm outside and 1.4mm thick. Charlton Volvo Centre on eBay were cheapest for the new pipework and box. They are now aware (thanks to me) of the different pipes too. I'll post here if I think of anything else.

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