Volvo 850 R Project. Need advice on repairs.

ACarmona · Post by **ACarmona** » 19 May 2016, 11:08

May 19, 2016: Order from Eeuroparts has shipped! Estimated date of delivery is 24th of May. Also have ordered the rest of the parts for Stage 0 and expect to see those in about a week! I also opted to upgrade my TCV with one of iPd's HD TCV kit because the dist. cap and rotor, plugs, and wires are already new so I won't have to mess with those for a little while.
https://www.fcpeuro.com/cart
https://www.ipdusa.com/basket.asp
I will still be updating with pictures when the orders come in and before and after of the bay

Post by **scot850** » 19 May 2016, 14:39

If this is the IPD TCV you plan to fit:

http://www.ipdusa.com/products/8901/120 ... 70-v70-c70

Please take the following warning/caution when installing this to your car.

Looking at the attached picture, the 2 'side' (plastic 90 degree) legs can be screwed in all the way until they stop, BUT, the middle/front one do NOT screw in more than 3-4 turns MAX! It may feel loose, but if you screw it in all the way it pushes the little piece of gauze into the operating valve and makes it sticky or jam preventing correct operation. I found out the hard way and asked IPD (they replaced mine FOC) to update their instructions but they never have.

Neil.

ACarmona · Post by **ACarmona** » 19 May 2016, 18:49

Thanks for looking out Neil! Ill be sure to take your advice when doing the install. Sorry about the cart links, thought that would work without having to spell out all the parts lists! Does anyone also have a good vacuum line diagram to go by? I plan on replacing every other vac line along with the TCV's 3 new lines.

ACarmona · Post by **ACarmona** » 21 May 2016, 13:20

May 21, 2016:
Surprisingly, the IPD shipment came in this morning! It included the PCV kit, iPd's HDTCV and mounting kit, TCV silicone lines, 10 feet of silicone vac line, the turbo drain pipe seal kit, a new throttle body cover, and some fuses for good measure ^^

Work schedule is in the way at the moment but I should be able to get to it either Tuesday next week or the next Sunday!

Post by **abscate** » 22 May 2016, 05:24

New parts just itching to go on...cough cough...Boss, not feeling good.....cough cough.

ACarmona · Post by **ACarmona** » 07 Jun 2016, 21:04

May 31, 2016. PCV system parts replaced with the kit I got from IPD. Just one rookie mistake.
When I was done replacing PCV parts I still had the manifold out and I had tightened the bottom bracket all the way to the block. I had forgotten about it until I had one bolt left, and thought the gasket looked a little off. By this time it was getting dark really quickly and I had no flood lights or lamps for light so I didn't attempt to re-remove and re-install the manifold in the dark by myself, since my helper had to leave for work just minutes after we realized what needed to be done to fix this. It started, but idled rough, and the next time I could get to it would be the next week.

June 7, 2016. Went to fix the manifold issue early today. After taking out the manifold again, I saw that the gasket was torn on the very right by one of the screws and was also ripped through on the bottom right corner. I didn't think that the gasket would have been in this condition so I didn't have a new one to replace it with.. So with nothing I could do at the moment I put everything back together the way it should but still struggled to get that bracket tightened to the manifold and the block. The oil dipstick tube also had an issue: it either leaves space between its bracket and the manifold or it doesn't go into the block all the way if its totally connected to the manifold. Is there something that i'm missing? I've been following FCP's videos but can't get the manifold to settle straight without it being able to tilt a little on either end when its just sitting on the bottom bolts. Feeling defeated after 3-4 hours, I head inside to order a new gasket. Should be here in about a week. Also Robert from Youtube has me on his tour schedule and should be here next week also to help! Hopefully we'll get a good amount done.

ACarmona · Post by **ACarmona** » 20 Jun 2016, 17:14

June 20, 2016. Got the new intake manifold gasket from IPD again and after receiving a nice original packaged REINZ gasket, I took notice of the gasket that came with my PCV kit. it seems almost half as thick and really flimsy compared to the Reinz one, which is probably why it broke in the first place. Also the PCV kit gasket was shipped in between two cardboard lengths and taped together with no label or anything??? What can I do besides just replace this gasket about the 2 weeks my car has been decommissioned because of that?

ACarmona · Post by **ACarmona** » 25 Jun 2016, 13:08

June 24, 2016.
Few days after the repairs with Robert. Ended up fixing the intake manifold gasket, front cam seal, Timing belt, water pump, tensioner, and both rollers, the thermostat, and finally re-sealed the oil cooler lines. When I went to do a secondary assessment, however, I still have some smoke coming out of the oil dipstick and oil gurgling up from the cams when I open up the oil cap. I literally just replaced all the PCV parts and the ports weren't even that clogged when I was down there but I replaced everything anyway. Secondly, the newly-sealed oil cooler lines are still leaking oil, although this time its not coming from where its sealed but from under the connector nut closer to the radiator! at first I thought it was the bottom one leaking out of the new seals cause I saw a big drop collecting on the bottom of the clip and bottom lip of the radiator, but the clip on the upper line was dry. So I checked the upper one more closely and saw a drop coming out from under the line, but not through the seal and clip. Its about a drop every 45 seconds to a minute.
My question is: Can I still drive the car a few miles a day? Will trying to tighten that nut on the radiator work? or are the connections now much worse since there are new seals and should now still replace the radiator? cause when Robert came we didn't have time to do the radiator cause my work wouldn't help me out with time off.
My other question: how do I still have positive pressure if i just changed the cam seal, all pcv parts, and even cleaned out the whole turbo inlet hard plastic tube and ptc fitting. the ports on the block weren't blocked or even had more than a small film of crust, which I cleaned out so how could I still have positive pressure?

Post by **tryingbe** » 25 Jun 2016, 20:05

If you want to keep the car, change out the radiator. Tighten the nut will possibly make it worst or crack the radiator, I've done that before.

I found with the older engines, even with new PCV parts, it is not enough. The stock PCV pipe from the separator to the intake is severely undersized for an older engine. Also, the hole at the heating element at the PTC valve is tiny, like smaller than 1/4 inch tiny. Both will restrict the flow of the crankcase gases.

To address those issues, here is what I do. Get the below parts.

A 3ft 5/8 oil compatible hose. Do not use silicone hose, as it will "sweat" oil. Do not use heatercore hose, it is not rated for oil, it will become soft and you'll have to replace it sooner. This is what I use. Buy 3, as it is sold by the foot.
http://www.ebay.com/itm/291442927889?_t ... EBIDX%3AIT

Two 5/8 elbows
http://www.ebay.com/itm/112031211577?_t ... EBIDX%3AIT

A 3 feet 3/16 vacuum hose to replace the small hose from the intake manifold to the PTC valve. I prefer silicone hose for this.

Optional, get 6 of this. I like their clamps.
https://www.ipdusa.com/products/4768/10 ... 12mm-width

Optional, wireloom to protect the hose.

Take a unibit and drill out the PTC valve holes to as big as you feel comfortable. I think I drilled mine out to about 1/2 inch.

Remove the intake manifold and replace that stock PCV hose, I cut a short hose and then use a 90 degree elbow, than a long hose, then another 90 degree elbow then another hose to the PTC valve. Replace the vacuum hose to the intake manifold to the PTC valve with the new one. Then reinstall the intake manifold.

All the crankcase gas have to go thru that tiny PTC hole!!!

Installed on car

ACarmona · Post by **ACarmona** » 27 Jun 2016, 11:59

Thanks Tryingbe, I'll have to try that! I did have trouble with the intake manifold gasket last time I did the PCV but I have no choice if I want to keep the car. Edit: The Radiator is dated the 4th month/ week of 2015 so it's barely over a year old. maybe not volvo?
I did also have some oil getting into the throttle and forming a small puddle at the bottom and in front of the flap. There is also a hissing noise coming from somewhere around the vacuum tree, but I can't seem to locate it by feeling around. Is that normal at all? Idles smooth but I still get a tiny puff of smoke at every start up.
Secondly, still get small puffs when I'm anywhere past half boost. When boosting past 3/4 I get a fast, repetitive knocking sound around what sounds like the center/passenger side of the bay for about a second and then it goes away. any ideas? (by the way, I haven't been thrashing this thing around. There were 3 controlled tests)

Volvo 850 R Project. Need advice on repairs.

Re: Volvo 850 R Project. Need advice on repairs.