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Need some help with engine install

Everything on the Volvo S80. Sometimes called an "executive car", the S80 was Volvo's top-of-the-line passenger car. P2 platform.
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kawasakiklx
Posts: 21
Joined: 7 July 2011
Year and Model: S80 T6 2000
Location: Chico, CA

Need some help with engine install

Post by kawasakiklx »

Hey guys,

So I am stuck on my install and I need some help. I really dislike vacuum/air lines and I think every car could do without. Almost all of my questions involve small lines.

In picture 1 I have two lines coming in from a hard line near the bottom of the engine. There is a little control module then the single line with two separate connections, I marked them in red. Where do they go?

Picture 2: What connects to that nipple, it's on the inside of the throttle body/intake manifold.

Picture 3: This line is just plain confusing. The red sections appears to connect to the rubber nipple that the arrow is pointing to, correct? Does the other end (orange) go to the PCV box under the intake? And the blue circled line goes to the arrow and then where to on the other end?

Picture 4: This big ass line connects to the intercooler and ends under the intake, where to from there (blue)? I can't believe I can't figure it out, wherever it goes it is big! Also where does the small vacuum line go (red)

Picture 5: Where does this small nipple go? I vaguely remember it having a hard plastic line but it was almost two years ago when I stripped it down so I can't remember everything.

Finally on picture 6: Where do the three lines go? I'm guessing the one with the big protected end hits that small pip above the turbos?

I dont have a picture of it but where does the large brass colored nipple go that is under the turbo pipe in the intake manifold. It's the largest one on the manifold and sort of points up at an angle.

Thanks so much for any help. This was an easy install up until now and I don't want to route anything wrong and chance screwing something up. I know it will take awhile to educate me and your time is IMMENSELY appreciated. :)
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kawasakiklx
Posts: 21
Joined: 7 July 2011
Year and Model: S80 T6 2000
Location: Chico, CA

Post by kawasakiklx »

All that info and I left out the car...haha

2000 Volvo S80 T6

jimmy57
Posts: 6694
Joined: 12 November 2010
Year and Model: 2004 V70R GT, et al
Location: Ponder Texas
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Post by jimmy57 »

pic 1. one line goes on intake and the other goes on the tube from air cleaner to turbo inlets, the black thing is the purge valve. those hoses evacuate fuel vapors from charcoal canister.

pic2 and 4. red hose in 4 goes on nipple in 2, big plastic hose goes on throttle

pic 3 that line assy should be under intake. The aluminum tube (rt red) goes onto the nipple on blk plastic inlet tube where the electrical connector plugs in in that photo. The left red and the right blue are for water to heat that crankcase vapor tube. The left end alum tube end would connect to crankcase breather box under intake.

pic 5. the fitting goes under front end (passenger) end of intake with a cross drilled hollow bolt through it using copper washer to seal the bolt to fitting and fitting to intake. a crankcase vapor hose goes to it but I can't remember where it comes from.

pic 6 yellow taped hose (u have blue circled) goes on the steel line just behind below in that photo. The hose with the accordioned end thing goes on the twin tubes over motor that goes out to intercooler. The blue taped (u marked yellow) goes on the under side (I think) of the pipe from air cleaner that splits and feeds down to both turbos. That is the turbo control valve.

kawasakiklx
Posts: 21
Joined: 7 July 2011
Year and Model: S80 T6 2000
Location: Chico, CA

Post by kawasakiklx »

Thanks so much for the reply, I followed you about 90%.

I have no idea where the line from 5 could go. :(

Thanks again!
Last edited by kawasakiklx on 12 Sep 2011, 22:18, edited 1 time in total.

kawasakiklx
Posts: 21
Joined: 7 July 2011
Year and Model: S80 T6 2000
Location: Chico, CA

Post by kawasakiklx »

I think it connects here (arrow) but I cant seem to find the connector on top of the pcv :(
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boosted5cyl
Posts: 1100
Joined: 29 January 2010
Year and Model: '98 V70 T5, '99 S80
Location: St. Paul, MN
Been thanked: 1 time

Post by boosted5cyl »

Yep, thats where it goes. To be honest, you should replace that PCV box anyway while you have it all apart.
'04 XC90 2.5T AWD (Angus) 134K.
'99 S80 T6 (Medusa) 214k. On borrowed time LOL
'98 V70 T5 (Vivienne). RIP @ 228K. Spun rod bearings.

kawasakiklx
Posts: 21
Joined: 7 July 2011
Year and Model: S80 T6 2000
Location: Chico, CA

Post by kawasakiklx »

The problem I have now is not being able to find the rubber connector on the top. I've looked everywhere.

boosted5cyl
Posts: 1100
Joined: 29 January 2010
Year and Model: '98 V70 T5, '99 S80
Location: St. Paul, MN
Been thanked: 1 time

Post by boosted5cyl »

kawasakiklx wrote:The problem I have now is not being able to find the rubber connector on the top. I've looked everywhere.
The whole thing? Let me see if I can find the part # for you..
'04 XC90 2.5T AWD (Angus) 134K.
'99 S80 T6 (Medusa) 214k. On borrowed time LOL
'98 V70 T5 (Vivienne). RIP @ 228K. Spun rod bearings.

kawasakiklx
Posts: 21
Joined: 7 July 2011
Year and Model: S80 T6 2000
Location: Chico, CA

Post by kawasakiklx »

I really just need the actual rubber elbow with the small male and large female connector.

Also where is the best place to pick up a PCV box. I know I've seen them for ~$20 but I cant seem to find that site now.

boosted5cyl
Posts: 1100
Joined: 29 January 2010
Year and Model: '98 V70 T5, '99 S80
Location: St. Paul, MN
Been thanked: 1 time

Post by boosted5cyl »

Its the rubber part im talking about. Google the part #s and see what the best prices are

PCV Tank: 9497454
Top Seal: 30713120
Lwr Seal: 8653339
Solid part of vacuum pipe (from inlet manifold to PCV box): 30731007
Flexi part of vacuum pipe (from inlet manifold to PCV box): 982697


Cant find the P/N for the rubber part you need on top the the tank though.
'04 XC90 2.5T AWD (Angus) 134K.
'99 S80 T6 (Medusa) 214k. On borrowed time LOL
'98 V70 T5 (Vivienne). RIP @ 228K. Spun rod bearings.

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