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PCV Oil Separator wrongly routed IMPORTANT, EVERYONE READ!

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.
1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

PCV Oil Separator wrongly routed IMPORTANT, EVERYONE READ!

Postby MadeInJapan » 09 Feb 2008, 16:00

Although not from our site here I thought this was really excellent and have added it to the repair database.

http://lakesidedp.com/uploadpics/pcv/

If you're having trouble even after your PCV replacement, check your PTC nipple as it probably is clogged. The write-up includes this. This is the first time I've seen it mentioned on a PCV how-to!

Regards,
MIJ

JUST EDITED:
IT IS IMPERATIVE THAT YOU SCROLL DOWN AND READ MY 17, 2008 9:58 PM POST
Last edited by MadeInJapan on 18 Feb 2008, 03:36, edited 4 times in total.
'98 S70 T5 Emrld Grn Met/Beige Tons of Upgrades Mobil-1
'04 V70 2.5T Red/Taupe Some Upgrades Mobil-1
94 850 Sedan NA Drk Blue/Tan
'00 V40 Purple/Grey Mobil-1
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Postby lewismug » 09 Feb 2008, 16:24

That write-up would have been really, really nice to have as a reference last year when I tackled the PCV job on my S70! Thanks for the link MIJ. I'm sure that will help plenty of folks!
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Postby MadeInJapan » 09 Feb 2008, 17:19

Always glad to help. Yes, it would have helped me a couple of years ago when I did mine too.

In the meantime, it appears that if anyone is having PCV trouble, CHECK YOUR PTC NIPPLE FIRST
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Very helpful post

Postby redbrick » 09 Feb 2008, 18:43

That is a very nice writeup. Thanks.
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97 - 850 T5
99 - V70 GLT
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Postby tailor » 09 Feb 2008, 20:15

Fantastic write- up could have used that a few months ago. :(

An extra check, make sure the rubber on the bayonett connector is not saturated with oil and has lost it's hold on the turbo hose, thereby letting un-metered air in.

Image
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Postby MadeInJapan » 09 Feb 2008, 21:31

Right...when that happens there really is no good corrective measure and your only remedy is to replace the entire accordion hose (it comes with the PTC Nipple). The good news is that fcpgroton (and I believe eeuroparts.com) sells these and they aren't really that bad of an expense. So, to recap:

1. Check the PTC Nipple which is on the bayonet connector at the bottom of the accordion hose from the air filter housing to the turbo. If it's clogged, unclog it (drill bit if it's solid, pipe cleaners with brake fluid, alcohol or whatever works) and if the bayonet connector is bad, go ahead and order the accordion hose.
2. See if after #1 is done your PCV system is breathing correctly (no smoke from the oil dipstick tube when idling a warm engine, and no positive pressure when you hold your hand over the oil cap filler neck).
3. Go ahead with the PCV replacement if #2 is still a problem.
'98 S70 T5 Emrld Grn Met/Beige Tons of Upgrades Mobil-1
'04 V70 2.5T Red/Taupe Some Upgrades Mobil-1
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THIS IS IMPORTANT- EVERYONE READ THIS!

Postby MadeInJapan » 18 Feb 2008, 02:58

Something else I just found over on V.S. that I think everyone should be aware of. Both the diagrams over at FCP and those in VADIS show a confusing routing for the hose from the air intake and the one that goes up to the top of the engine from the oil separator (They are wrong for pre '99's).
Please make sure you get it right. It will make a difference. This is the correct routing:
Image

If routed wrong, it will send oil into your turbo and thus into your intercooler pipes. Here is why:

Image
The condensation rolls down the side of the walls of the oil separator and back into the engine. There's a baffle in the center of the plastic box that allows exhaust back into the air intake without the oil. If the hoses are reversed then the oil trap would become saturated without a way to re-route just the exhaust. Instead, oil would be routed (also it will clog faster). This might be why some complain of more oil in their turbo hoses after the PCV replacement and then wonder if their turbo is going out.

When I read the above, I had to go check my routing. It is hard to tell once the intake is back on but with a strong flash light you can peer down from between the fuel rail and the engine and tell that the hose routed to the top of the engine is a shiny black one whereas the the one routed to the the air intake (accordion) hose is more matt black. Just to make sure I found a coat hanger and jiggled the shiny black hose and it moved the hose all the way up to the top one at the engine so I was relieved.
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'04 V70 2.5T Red/Taupe Some Upgrades Mobil-1
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Postby chuckcintron » 18 Feb 2008, 14:49

Whoa! This is pretty interesting. I did this PCV job about 7 months ago, and have since developed an oil leak around the turbo. I figured something was up with the send/return lines at the turbo, and I would just address it in the spring, when the weather gets warm enough to work out in the garage again.

So, for my 1997 GLT you are saying that the topside routing of the box is essentially backward, in the FCP/VADIS diagram, right?

I'm going to have to check this tonight when I get home. Since I usually print those diagrams off and follow them when I'm working on the car, there's a pretty good chance it was done wrong.

If it's been installed backward all this time do you think the breather box is saturated and now needs to be replaced? The thought of doing this job again is not a very happy thought, right now... :cry:

-Chuck
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Postby MadeInJapan » 19 Feb 2008, 00:55

chuckcintron wrote:So, for my 1997 GLT you are saying that the topside routing of the box is essentially backward, in the FCP/VADIS diagram, right?

If it's been installed backward all this time do you think the breather box is saturated and now needs to be replaced? The thought of doing this job again is not a very happy thought, right now... :cry:
-Chuck


Yes, there is a possibility that you installed it backwards. I believe someone over on V.S. has been in contact with FCP so hopefully they'll change their diagram....and VADIS seems wrong as well...at least from the actual construction of the oil separator. I'm trying to thing what would happen if you didn't change out the separator. Maybe, taking it loose and dumping the oil out the top would be enough to restore things...but if you do that far, why not just replace it? I think the other hoses would be ok and would clear on their own after a few hundred miles. Yes, it is a :cry:
Just check with a strong flash light when you get a chance...it is a tight view but you should be able to tell without taking the manifold loose.
Sorry for this bad new (but hopefully you're ok).
'98 S70 T5 Emrld Grn Met/Beige Tons of Upgrades Mobil-1
'04 V70 2.5T Red/Taupe Some Upgrades Mobil-1
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Postby chuckcintron » 19 Feb 2008, 02:10

Well, good news...with my billion candlepower light (well...not quite...) I was able to see the routing, and for some strange reason I had it correct.

Oil leak must be something else around the turbo...I may have to check that intake PTC area again.

Whew. :shock:

Thanks,
Chuck
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Colour pic of oil seperator

Postby tailor » 21 Feb 2008, 00:45

Here is a nice colour picture of the fitting.

Image
Double click the pic to read script boxes.
I hope this is clearer.
1994 850 Auto Turbo wagon 306000km (Sold)
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Postby MadeInJapan » 21 Feb 2008, 03:24

Thanks for the great picture!
I'm making this thread a sticky.
'98 S70 T5 Emrld Grn Met/Beige Tons of Upgrades Mobil-1
'04 V70 2.5T Red/Taupe Some Upgrades Mobil-1
94 850 Sedan NA Drk Blue/Tan
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Postby luketrash » 13 Mar 2008, 20:24

Before I dismantle my car, do the N/A cars have the PTC nipple?

I have smoke blowing out the dipstick hole and have had for the entire time I've owned the car, including my PCV system complete replacement, including pipes/hoses. My 1994 model is a bit different than pictured above.
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Postby Ozark Lee » 13 Mar 2008, 20:51

do the N/A cars have the PTC nipple?


Neither of mine do. One is a '94 and the other is a '96 but I found out yesterday that the motor in the '96 is actually out of a '94 or '95.

...Lee
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