1996 Volvo 850 GLT Starts, whistles, dies

crisnumbertwo · Post by **crisnumbertwo** » 05 Jun 2015, 21:38

Hello all,

May I start by saying, you guys have helped me through many a problem, and this is the first time I've felt the need to take part, but not the first time the community has got me out of a jam, and I'm confident you guys can help me out here.

So, I just replaced my PCV system with the IPD kit (which didn't have the genuine Volvo breather tube that runs under the intake manifold). When pulling the PCV breather off the oil separator I snapped both hard plastic hoses, so I jimmy rigged a hard/soft vacuum hose from flame trap to left side of intake manifold, and used their 240 hose for the breather tube, which should also be hard plastic.

I try to start it up, it turns over, makes a whistle noise, and abruptly dies. I get a P0201 code (injector 1), but nothing really changed and the wire is on tight.

Vacuum lines? Should I redo it after ordering genuine Volvo hard plastic breather and vacuum tubes?

Goes without saying, any thoughts, comments, help is very appreciated.

Post by **Ozark Lee** » 05 Jun 2015, 22:27

With the whistle I would double check that nothing got pinched under the intake manifold when you bolted it back on.

...Lee

crisnumbertwo · Post by **crisnumbertwo** » 05 Jun 2015, 23:32

That was concern of mine. Thank you. I'll be back tomorrow after pulling her back apart.

crisnumbertwo · Post by **crisnumbertwo** » 06 Jun 2015, 14:45

Felt around the vacuum tubes, nothing seemed to be pinched. Took it back apart and didn't see any signs of pinching.
Also, I would rather install the hard plastic PCV pipe (http://www.volvopartswebstore.com/produ ... 35636.html) than have the soft 240 hose, but can't seem to figure out how it fits around the manifold, any thoughts?

Post by **Ozark Lee** » 06 Jun 2015, 18:13

There are at least three versions of the N/A PCV hoses and they are not interchangeable. All of my factory hoses have had the solid line that runs from the oil trap to the flame trap but a common modification uses a 5/8" heater hose and it actually works better, there are details on the modification in the repair database. The rigid plastic lines get brittle over time and then they crack. Typically the rigid line is wrapped with a soft foam cover.

The only strange PCV routing was the early version for the '93 and very early '94 models, with the others it just routes under the intake manifold and typically on a '96 there will be an additional line that goes over to the #1 cylinder end of the intake manifold. I'm not sure what you used that has a soft hose if it was part of a kit. To get the proper kit you need to use the engine serial number.

Can you post up some pictures of what you have going on?

...Lee

crisnumbertwo · Post by **crisnumbertwo** » 06 Jun 2015, 18:56

This is where I'm at, after taking it back apart. It should be noted that this is the most complicated job I've done, but it is pretty straight forward. Have to wait for a new gasket before I can put it back together. Going to buy a 3/16 or 1/4 vacuum line for manifold to flametrap connection. After watching videos and reading forums, I just can't figure out where I went wrong. I do wish there were videos that were NA replacements, but they're all turbos.

crisnumbertwo · Post by **crisnumbertwo** » 13 Jun 2015, 18:41

Put it back together, started right up. Don't know what happened; I might have put a tear in the gasket putting the manifold back on? Thanks again, guys.