95 850 Turbo PCV Install Issues

iruleyounow · Post by **iruleyounow** » 23 Jul 2014, 20:58

Hey everyone, I'm new here so I'm not too sure if im posting this right. This might also be a double post. If it is, I apologize!

So I dug into the PCV repair today. Took everything apart, installed all the new hoses and flame trap. I go to put the the intake manifold back on, and it will not sit down on the bolts. The Flame trap box is preventing it from going all the way down. I took everything apart numerous times, but it still will not fit. The parts are all Genuine Volvo with matching numbers, ordered from FCP.

I was thinking that maybe its due to the fact that I installed the Snabb intake. I had to pull the hose back a little in order for it to fit over the PTC fitting. I'm thinking its pulling the flame trap up a little bit, but still don't see how this would stop the intake manifold from seating properly, as i was able to easily tighten the bolts down.

Please help with this issue. I've spent the last 7 hours messing with it. 3 of them just on trying to get the manifold to bolt up! Extremely frustrated!!!!

Any help is greatly appreciated!

Post by **erikv11** » 23 Jul 2014, 23:12

Are you sure the little bracket that goes on the bottom right manifold bolt, is not in the way? Doubtful from your description I know but thought I'd throw it out there, it is a common problem.

So the oil trap box, is it aligned with both of its holes (I think there are three?) and bolted snugly on to the block? If it is, then I don't think the trap per se is your problem. More likely one of the hoses.

I wonder if the hose from the oil trap to the top of the valve cover is the problem. One thing that many people don't realize, is that there are two different hoses from the oil trap up to the top of the valve cover and it does matter which one you get (in fact some of our most respected members here flat out deny this fact lol, and have repeatedly insisted that this is not true, that there is only one hose that works for all, etc.). One of the hoses is shaped to route up through the intake manifold between cylinders 1 and 2, the other one between cylinders 2 and 3. Similarly, the intake manifolds have "cutouts" that provide space for the corresponding hose to slip through easily. (There are also two different short, fat hoses for the trap, corresponding to two different trap shapes, but that is a different matter). Anyway, the part numbers are different, and the shape of the hoses is obviously different when you compare them side by side. I have forced one of the "wrong" hoses to work before and the fit through the IM is tight when you do it that way.

So, bottom line: do you still have the old hose from the trap to the valve cover? Can you compare the shape of it to the shape of the one you put on; do they naturally route through the same gap in the intake manifold? In the current configuration, is that hose to the valve cover hanging up in the IM ?

Post by **kahl** » 24 Jul 2014, 04:54

have you looked at the oil dip stick housing to see if it positioned correctly where it bolts onto the bottom of the manifold? Is the oil dipstick fully seated into the block?

Post by **rspi** » 24 Jul 2014, 05:29

The PTC fitting is back by the turbo intake so that can not be in the way of the intake manifold.

Post by **rspi** » 24 Jul 2014, 05:31

Post by **Ben850** » 24 Jul 2014, 05:53

I also installed a Snabb intake tube in my wagon, but did not use the OEM hoses to PTC.

I ran a "5/8 heater hose from the oil trap to the PTC and a silicone vacuum line from the end of the manifold. I ran the heater hose up next to the top radiator hose, around the front as to not kink it anywhere and flow freely to the PTC nipple.

This routed things where they were out of the way from under the manifold and where I wanted them.

You can follow my routing in these photos. I used blue silicone heater hose to match.

: 3" Throttle body modification with 3" intake to turbo.

: 3" Snabb to turbo intake.

iruleyounow · Post by **iruleyounow** » 24 Jul 2014, 08:10

erikv11 wrote:Are you sure the little bracket that goes on the bottom right manifold bolt, is not in the way? Doubtful from your description I know but thought I'd throw it out there, it is a common problem.

So the oil trap box, is it aligned with both of its holes (I think there are three?) and bolted snugly on to the block? If it is, then I don't think the trap per se is your problem. More likely one of the hoses.

I wonder if the hose from the oil trap to the top of the valve cover is the problem. One thing that many people don't realize, is that there are two different hoses from the oil trap up to the top of the valve cover and it does matter which one you get (in fact some of our most respected members here flat out deny this fact lol, and have repeatedly insisted that this is not true, that there is only one hose that works for all, etc.). One of the hoses is shaped to route up through the intake manifold between cylinders 1 and 2, the other one between cylinders 2 and 3. Similarly, the intake manifolds have "cutouts" that provide space for the corresponding hose to slip through easily. (There are also two different short, fat hoses for the trap, corresponding to two different trap shapes, but that is a different matter). Anyway, the part numbers are different, and the shape of the hoses is obviously different when you compare them side by side. I have forced one of the "wrong" hoses to work before and the fit through the IM is tight when you do it that way.

So, bottom line: do you still have the old hose from the trap to the valve cover? Can you compare the shape of it to the shape of the one you put on; do they naturally route through the same gap in the intake manifold? In the current configuration, is that hose to the valve cover hanging up in the IM ?

I have compared everything. They all appear to be the exact same. I actually forgot about the bracket when I was first trying to install. Im getting ready to go back out and dig back into it. Hopefully I can see the issue!

iruleyounow · Post by **iruleyounow** » 24 Jul 2014, 08:11

kahl wrote:have you looked at the oil dip stick housing to see if it positioned correctly where it bolts onto the bottom of the manifold? Is the oil dipstick fully seated into the block?

Yes I haven't installed the dipstick yet. I left that out when I was attempting to get the manifold to seat right

iruleyounow · Post by **iruleyounow** » 24 Jul 2014, 08:12

rspi wrote:The PTC fitting is back by the turbo intake so that can not be in the way of the intake manifold.

What I meant was the hose that runs from the flame trap, to the PTC, is pulled kind of tight so it can reach the PTC. I was thinking maybe the hose is pulling the top of the flame trap up a little too high.

iruleyounow · Post by **iruleyounow** » 24 Jul 2014, 08:14

Ben850 wrote:I also installed a Snabb intake tube in my wagon, but did not use the OEM hoses to PTC.

I ran a "5/8 heater hose from the oil trap to the PTC and a silicone vacuum line from the end of the manifold. I ran the heater hose up next to the top radiator hose, around the front as to not kink it anywhere and flow freely to the PTC nipple.

This routed things where they were out of the way from under the manifold and where I wanted them.

You can follow my routing in these photos. I used blue silicone heater hose to match.

IMG_2900.JPG

IMG_2903.JPG

This is pretty cool. I might do that if I can't get it all together. Where did you get the hose?