2004 S60 Extra Bolts - replacing pcv system

mickjenkins · Post by **mickjenkins** » 18 Oct 2014, 16:54

i trying replacing my pcv system and put everything back together and i have some extra bolts. i have 1 12 mm bolt and 2 torx screws, what uses torx other that the spark plug cover, also i have some small 10mm bolts left over.....i am freaking out please help. i put the car back together and now whitish smoke and water is dripping from the tail pipe. car is running terrible now, i need help.

also i was attempting to remove a coil pack for better access and the coil pack came apart and i was a spring, i put it back and bolted it down, is this coil pack going to fail. please help.

Post by **FLXC90** » 18 Oct 2014, 18:11

okay, I have an S70 and an XC90, on my vehicles, torx are also used for throttle covers, mounting MAF sensors etc. on my S70, a 12mm head bolt holds the dipstick bracket to the Intake, and the intake to an L-bracket. Did you follow one of the guides in the database? Do you remember which hoses you ran to the intake vs the top of the motor?

Post by **chrism** » 18 Oct 2014, 18:41

Is your car a turbo? If so, I wonder if you got the hoses crossed on part #13 in the linked parts list. One is manifold vacuum and one is carrying coolant:

http://www.volvopartswebstore.com/showA ... evel=11150

Also, any chance part #5 is the left-over bolt?

mickjenkins · Post by **mickjenkins** » 18 Oct 2014, 19:28

okay thank you for the reply, it runs just not good, im gonna take it apart and redo again, this time im gonna change out the intake gasket, maybe the torx are just from the covers. does the fuel injector cover take a torx or 10mm? im gonna look at the diagram right now.

mickjenkins · Post by **mickjenkins** » 18 Oct 2014, 19:30

i did not follow the guides and i should of...

Post by **FLXC90** » 18 Oct 2014, 20:51

Thanks for the diagram Chrism... guess your system is cleaner than the earlier one. Bolt 5 should be 10mm head, and there should be 2. 12mm head will be used for a solid mount like an attach bracket.

As you disassemble this time.. check as you go, you may find your error early on.

On mine, the fuel rail uses 10mm head bolts (I think they are classed as M6, and the 12mm head are M8) Do the torx screws you have out have a thick shoulder flange on them like the ones on the coil cover? Are they from the timing gear cover at the end of the coil cover?

Good luck, learning this way always sucks! I did my PCV today on my S70, and just because, I was rerouting my Cam Position sensor leads to undo previous owners hack work, and the connector disintegrated, I'm just glad it was the sensor end, not the harness end, I can get a sensor.

mickjenkins · Post by **mickjenkins** » 18 Oct 2014, 21:07

Can a coil pack come apart to the expose a spring and still be reassembled and work. i would instantly get misfire codes right? i have some old ones i switched out when i changed all of them i could put one of them in.

Does the fuel injector plastic cover thing take torx or 10mm, thank you so much for all your help. i think when when i go back i will find out what i did wrong. i was so tired when i did the job because ive been taking care of my newborn. i think maybe i took of a 12mm bolt accidentally to the left of the pcv box if so i have to put that back.

Post by **FLXC90** » 18 Oct 2014, 21:57

First off then, congratulations!
Next, Get some sleep!
Yes, plastic covers commonly use torx head screws.
And yes, if the coil came apart, you should change it. If you have one that was not previously coding for a misfire, use it at least for now.
Can you post a picture later of the coil that came apart? The spring may just be for centering, guiding the coil and boot over the plug, was the spring under the boot part of the coil (where it covers the sides of the plug)?

Post by **chrism** » 18 Oct 2014, 22:35

"...12mm head will be used for a solid mount like an attach bracket..."

Like maybe the bracket that supports the underside of the manifold?

mickjenkins · Post by **mickjenkins** » 20 Oct 2014, 08:54

Well I took it apart and put it back together this time i changed intake manifold gasket. i also reset the ecu so i would not get a check engine light. It appears to be running as good at least it was pre surgery. Smell of burning oil is still present. I order a new oil filler cap from fcp. i feel that i can deal with a small oil leak as long as i know its not going to blow out my gaskets...

I have not gotten any misfire code so as far as putting the coil pack together everything appears to be fine.

This was a stressful job for a newb like my self but extremely educational. i don't recommend some try this if it is your only means of transportation like myself. everything worked out okay but again it was stressful.

The second time i took everything off and put it back only took about 2 1/2 hours.