Replacing TCV hoses

Post by **j_cd** » 19 May 2010, 11:45

The vacuum hoses on my TCV (Turbo Control Valve) are pretty tore up. My silicone replacements are here. How do I reach the other end of the red labeled hose at the compressor? Is it easier from underneath the car, or do you have to reach down in there from above? I know this is a lazy question, but I'm asking it anyway.

Post by **MNCO1** » 19 May 2010, 11:58

I had much better luck throwing a thick blanket over the top of the block, about center, and laying on it from the front of the car. Reached in from drivers side too. From underneath I could access coolant and oil lines. Its like playing twister, watch for cramps.

Post by **charlyW** » 19 May 2010, 14:37

Removing the top of the airbox then raising the bottom part makes it far easier to replace your hoses on the TCV, if they're genuine Volvo ones with the spring clips a pair of long nose pliers or Clip R removers work well you wont need new clips with silicone pipe if its not like mine and old

Post by **j_cd** » 20 May 2010, 11:30

Yeah you definitely have to take the airbox off. I replaced the air intake hose and the one that goes to the wastegate, but so far I can't reach the bottom of the one that goes to the compressor. When I follow it down there is grease or oil residue all over it. One of my mechanic neighbors had a look and said it's a real pain to get that one unless you take apart the exhaust system. I'm impressed with anyone who can replace that hose without doing so. I'll keep trying.

The part of the hose that I'm most worried about is at the top where it goes into the TCV. It's kinda stretched and collapsed. I may put a short piece of silicone hose into the TCV and join it to the other one with a connector. I thought this might be recommended against because it could change the pressure, but if the connector is wide enough I don't see why it would be a problem. And this is a GLT "light turbo", so as long as I don't gun it off the line I don't think it'll blow. I'll use clamps on the connector.

Post by **charlyW** » 20 May 2010, 14:04

Utter utter utter rubbish you do not have to undo the exhaust !!!!!!

Remove the fresh air hose from the airbox to turbo charger then remove the airbox both top and bottom halves you then have access to fit the compressor pipe, sheesh I use a wheelchair and I managed it, ok you will get covered in oil but hey a little bit of dirt never hurt anyone

Silicone is easier as once you start it sliding it will slide over the pipe

Post by **j_cd** » 20 May 2010, 14:15

I did have the whole air box out. Guess I'll try again when the car cools down.

I have fat arms, what can I say?

Post by **charlyW** » 21 May 2010, 04:41

volvo seemed to delight in the 1990's of fitting the largest engines into the smallest spaces possible it seems, you just have to look at a 760 GLT with A/C, the 740 Turbo or even the 960 engine tiny engine bays massive engines

Post by **j_cd** » 21 May 2010, 08:37

That's true, Volvo must've had little elves working for them in the 90's.

I'm sorry, but I just don't see where I can fit my arm in to reach down to the other end of that hose. Perhaps if some other things were removed. I started to take off one hose that's in the way, but it turned out to be a water hose. I quickly re-tightened the clamp before water started shooting out.

I'll have to post a picture. Until then, I already cut the end off the old hose and used a vacuum connector to attach it to a new silicone hose that's going into the TCV. Now at least it's not collapsed. Works just fine.

Maybe next time I replace the distributor cap and rotor I'll have more room to work with.

redroostr · Post by **redroostr** » 20 Jun 2010, 12:33

Doing this job this weekend on my 99 GLT but, having problems connecting the bottom compressor hose. Any tips?

Post by **j_cd** » 20 Jun 2010, 13:12

Not sure, but the turbo is much more accessible if you remove the heat shield. I'm getting ready to take my turbo out for service. It's covered in oil.