2001 S60 Any preventive maintenance proposal? Topic is solved

[zoli_m13]

Useless onboard phone unit out - cuphlder in + bluetooth loudspeaker unit installation (NOKIA) attached to onboard microphone and speaker.

[zoli_m13]

Worn steering rod, boots, tie rods, tie rod ends,

[zoli_m13]

Oil change.




New spark plugs.



Set of brand new summer tyres: Laufenn 205/55R16

[zoli_m13]

If you need much info in case of any repairs:
1. Much detailed photos: https://goo.gl/photos/jS1z777LDqJSQqPDA
2. Post me!

[zoli_m13]

http://new.volvocars.com/ownersdocs/200 ... nance.html

[zoli_m13]

Well, I have a plan to eliminate the positive crankcase pressure (glove test failed) by replacement of:

1. 1x Oil separator trap
2. 1x Connecting sleeve to block
3. 1x Connecting elbow to block
4. 1x Hose to cylinder head
5. 5x Replacement hose clips
6. 1x Main PCV Hose Assembly

These parts will be changed as well:
1. 1x Intake manifold gasket
2. 1x ETM Gasket
3. 5x injector O-rings
4. Oil sump O-ring and gasket set

Do you think: is there anything else could be replaced?
Edit: ETM unit will be cleaned.

[zoli_m13]

I made some simple blow tests (see below the diagram to identify the hoses by numers):

1. Inserted a suitable diameter plastic tube into the oil level check tube (oil stick removed). Blew air through the tube: I got massive resistance and the air came back from the tube (behaved like a party balloon) => the system is airtight (or clogged). Removed the oil filler cap and blew in air again: no resistance realised, pretty easily the air came out through the oil filler hole; so tube #2, #6 are clean. May be the PTC nipple clogged.

2. Cleaned the PTC unit (whole intake tube between the turbo and the MAF removed) and performed another test: connected a suitable size hose to the end of the L-shape tube (#12) and blew some air; some resistance realised; removed the oil filler cap and now the air came out pretty well. It means: the tube #8 is clean.

3. Everything put together and blew air through the oil dipstick tube: slight resistance realised, but the overpressure gone away within some seconds. Removed the air filter cover and blew again: very well audible hissing noise at the ir filter house detected, no resistance. It means: air flow channels are free!

4. Oil consumption is less than 1 quart per 6K miles, no oil leak visible - bottom of the engine is super dry; my understanding: tube #4 and related oil gallery in the oil trap are clean

BUT!

Glove test failed again (very minor positive pressure). Probably reason: the combustion gases bypasses the worn piston rings and causing overpressure in the crankcase system.

Any comment to be appreciated!

(Some photos about the PTC nipple cleaning.)

[jbeebo]

It's near impossible to get perfectly balanced neutral pressure in a crankcase, so a slightly positive (for turbo engines) or negative (for N.A. engines) pressure is not unusual IMHO. Sounds like everything is working as it should.
Many engineers over many generations have struggled with this and continue to invent new ways, just check GM's new L5P diesel engine oil separator design (text, video).


Positive pressure could be coming from the rings as you mentioned, or from turbo blowby. Some amount of blowby is to be expected, even on a new turbo. Turbo seals are simultaneously simplistic and highly complex beasts. By design they have clearances to the ShaftWheel Assembly, and thus leak small amounts of air (bringing some oil along with it).

Keep up the good work Zoli

[precopster]

Great work Ludwig. I haven't seen too many people get so involved with their Volvo's restoration as you have. I hope it manages to survive for quite a few years with your TLC!!

Just a question about the factory phone installation. Did you manage to wire the keypad into the car with the factory phone setup as I didn't see the end result in your pics apart from the Nokia hands-free unit you cleverly wired into the HU-603. You would have needed the rear mounted phone module (it's rear mounted in my 2001 V70) and a bunch of wiring to make it work. Is this going well? I'm asking because my own T5 has the phone installed however the SIM card receiver is built into the rear mounted module under the luggage boards. This makes it almost impossible to use as I carry a lot of equipment and tools around. My dash mounted keypad has no SIM card slot however I managed to get a front mounted keypad from an '02 S60 with a front SIM slot and I was wondering if this may fit my own car.

Does the S60 system have a rear mounted module as well as the keypad board?

[zoli_m13]

... Did you manage to wire the keypad into the car with the factory phone setup as I didn't see the end result in your pics apart from the Nokia hands-free unit you cleverly wired into the HU-603...
Does the S60 system have a rear mounted module as well as the keypad board?

Hi Precopster - thx for the comment!
There was a factory installed keypad with SIM slot, but this unit doesn't work as a GSM phone anymore here. Even I removed the handset: it was useless for me.
Regarding the rear mounted module: could you drop me a photo about the unit and I will look for it in my car.