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850 air intake replacement

Help, Advice and DIY Tutorials on Volvo's P80 platform cars -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, including 850 R, 850 T-5R, 850 T-5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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etzal
Posts: 20
Joined: 12 August 2006
Year and Model: 95 850 GLT
Location: Maryland
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850 air intake replacement

Post by etzal »

The flexible rubber hose that connects the air cleaner box and the intake manifold in a non-turbo 850 was a bad design.
It has to be bent almost 90 deg which puts a lot of stress on the outside bend.
Holes eventually develop due to the erosive effect of air flow compounded by the heat and stress.
You can patch the holes with duct tape or you can get a factory or aftermarket replacement part for $20-50 which include the bottom 90 deg adapter.
I got tired of looking at the duct tape and was not satisfied with the original design.

So I bought a 90 degree silicone coupler hose for about $12.
It has an inside diameter of 70mm with 4 inch legs.
At the air cleaner outlet it fits snug but extended too far out so I cut off about 1 inch from the end.
About 1 inch must also be removed from the other end.
The hose is not that flexible and a little tough to cut using a utility knife given its multi-ply construction.
In order to provide a flexible connection to the bottom 90 deg adapter I reused sections of the old hose.
I cut off the bottom section of the old hose with 6 rings left.
I cut off the top section of the old hose with 1 ring left.
The idea is to join top and bottom sections by inserting the ring of the top section inside the top ring of the bottom section.
In order to fit the top section ring the circumference has to be reduced by about 1/4 inch.
The hybrid section can then join the silicone hose and bottom adapter.
The flexible section is compressed more on one side because the angle between the outlet and inlet axes is > 90 deg.
disassembled parts
disassembled parts
assembled parts
assembled parts
installed in car
installed in car

rguzz
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Joined: 7 October 2015
Year and Model: 1996 850 turbo
Location: VA
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Post by rguzz »

Looks nice and sturdy, well done.

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dyn blin
Posts: 177
Joined: 1 November 2015
Year and Model: 1997 850 Wgn
Location: Sonoma Co, CA
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Post by dyn blin »

Looks great and an economical alternative.

Too bad for many of us in some counties in California, it wouldn't pass visual inspection for biannual smog checks
'97 850 GLT Wagon- Driving to see 300k in the rearview

loveMy850
Posts: 369
Joined: 8 October 2006
Year and Model: 1994 850 WAGON
Location: California
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Post by loveMy850 »

That's ingenious, mines split almost completely off, going to order a cheep version bc it's cold out hope the new one don't cracking install it. IF SO I may do your genius ideal. Koodos

loveMy850
Posts: 369
Joined: 8 October 2006
Year and Model: 1994 850 WAGON
Location: California
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Post by loveMy850 »

I found a rubberized version, is that OK on the intake hose. That plastic cracks like crazy.

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abscate
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Year and Model: 99: V70s S70s,05 V70
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Post by abscate »

Ancient post. Check suppliers for new options on this part

Anyone have a part number in this hose?
Empty Nester
A Captain in a Sea of Estrogen
1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 XC90-in-Red
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