Why is my PCV Banjo bolt leaking from right side of engine? Topic is solved

gquepasa · Post by **gquepasa** » 12 Dec 2016, 14:07

Hello, I have reviewed many forums and links on the PCV replacement, and so I took on the project and replaced it with minor issue except when I started to fill the up the coolant tank. I have a heavy leak coming from the banjo bolt located on right side of the engine (not the IM banjo). I did lose the original copper washer and have since ordered a pair of replacements. The banjo washers i order were -
Gasket - crankcase ventilation TURBO 1999- part# 11994
and Gasket -crankcase ventilation 5CYL TURBO - part# 9202208
so I have a set of both,

pcv.jpg from http://www.volvopartswebstore.com/showAssembly.aspxukey_assembly=240397&ukey_make=865&ukey_model=12009&modelYear=2001&ukey_category=7072 [attachment=0]pcv.jpg

diagram on Crackcase ventilation diagram both # 14's. One is a wide and the other is thin copper washer. I dont remember which was on orginally.
I have cleaned the banjo bolt, crank it down tight not sure of torque rating, but it still leaks when I fill it with coolant.
I have searched and only find post on the turbo leaking or IM banjo problems.
Currently the wide washer is on and it leaks,.....Any ideas? Thank you much.

beigg · Post by **beigg** » 12 Dec 2016, 16:19

you're going to need a crush washer on one side of the banjo fitting and a following crush washer on the other side of the bango. Holding steady, slide banjo bolt through and tighten down.

gquepasa · Post by **gquepasa** » 12 Dec 2016, 16:28

tks, beigg. Yes, I have the crush washer on one side and the other side of the fitting, bolt tightened. The crush washers, banjo fitting and bolt are flush with the engine, but still leaks coolant just as I pour it into the coolant compartment it leaks right out the banjo bolt fitting with the new crush washers in place. I am at a dead end on my efforts.

gquepasa · Post by **gquepasa** » 12 Dec 2016, 16:30

I used the wider crush washer today and it still leaked. Tomorrow I will try the thinner crusher washer on both sides and see if it leaks....

beigg · Post by **beigg** » 12 Dec 2016, 16:48

Are you using generically procured hardware or crush washers to volvo specs? Personally, if in a time of need for the vehicle, the ports from the block can be deadheaded.

beigg · Post by **beigg** » 12 Dec 2016, 16:50

Make certain that #10 isn't still stuck onto the mating surface. You may think you've "lost" the washer when in deed it's sitting gunked onto the engine still.

gquepasa · Post by **gquepasa** » 12 Dec 2016, 17:18

Both the washers are Volvo parts, the diagram had two numbers listed from them so to be safe I ordered both and try each set to see what happens.
I'll recheck tomorrow to make sure the old washer is not attached to the surface.
I'll also try the thinner crush Volvo washers and see what happens.

gquepasa · Post by **gquepasa** » 12 Dec 2016, 17:19

Thank you for the suggestions !

gquepasa · Post by **gquepasa** » 13 Dec 2016, 10:13

I have verified that there are no existing copper washers in place. I was able to get a closer photo of the port in the block. Appears the threading on the left side is damaged, but the bolt still screws on fine not as if it was cross threaded.

: Banjo port

: Banjo port #2 upclose

Post by **vtl** » 14 Dec 2016, 10:36

Try RTV Black on threads and let it fully cure before refilling.