V70 II T5 Inlet Manifold Removal

V70IIT5 · Post by **V70IIT5** » 02 Feb 2017, 12:03

Hi, I am new to the forum. I recently bought a V70 II T5 (250bhp) with 103k miles, blowing oil over near the spark plugs and dripping from the turbo. Its clear that it is coming from the PCV nipple into the turbo intake.

There is a good guide on here to remove the air intake manifold but mine is the T5 turbo and has a load of pipework underneath it.

Please could somebody advise me on how to remove things on this car?

Experienced advice would be much appreciated! Thanks.

Kurica · Post by **Kurica** » 02 Feb 2017, 13:48

ive done it recently and is farily easy for someone who has some tool mileage, the major issue u can find is the PCV tube under the intake mainfold left side where u have to unscrew it right after getting the top mainfold screws and lossen the bottom ones, and the gasoline pipe, it a interior spring whitch u can use the proper tool( its a piece of plasitic to slide over the pipe) or u can gently remove it whit PACIENCE and a smal flathead screwdriver.
feel free to ask.

V70IIT5 · Post by **V70IIT5** » 03 Feb 2017, 12:50

Hi, sorry I am not sure I follow. Today I managed to release the intake manifold having removed air pipes under it to the throttle, although I am stuck at the moment trying to work out how to release the banjo bolt.

I am confused by the banjo bolt, it looks like the water and breather go through it?

Post by **chrism** » 03 Feb 2017, 13:46

The banjo bolt would have been easier to crack loose with the manifold still attached to the engine. Anyway, the coolant circulates AROUND the banjo fitting in an attempt to keep the vacuum line warm, reducing the tendency for the vacuum tube to clog up - but it still clogs up. The hard plastic tube can be quite difficult to clean out without breaking it so it's usually best to go pick up a new one at the dealer - approximately $35 and it comes with the coolant tube, banjo fitting, and vacuum line as all one assembly.

This parts breakdown may help to clear the muddy water:

http://www.volvopartswebstore.com/showA ... Line=11324

Post by **precopster** » 03 Feb 2017, 17:26

Removing the alternator and power steering pump is my own way of dealing with this. The banjo bolt is 17mm

The part chrism is referring to is an S80 part which solves the issue without the need to replace the entire coolant tube.

Post by **chrism** » 03 Feb 2017, 18:41

precopster wrote:Removing the alternator and power steering pump is my own way of dealing with this. The banjo bolt is 17mm

The part chrism is referring to is an S80 part which solves the issue without the need to replace the entire coolant tube.

I don't think it's just S80. According to the Volvo parts break down, P/N 9202208 is used on many different 5 cyl (and some 6 cyl) turbos from 1999-up, including V70.

Post by **precopster** » 03 Feb 2017, 21:56

That's not the part I'm referring to chrism. That part number you quoted doesn't include the vacuum hose.

The part includes the plastic pipe and is a different part number 30731007 and includes the plastic hose in case it is broken during manifold removal.

I see that it's now listed as a 5 cylinder part and it should be. 3 years ago when I bought it for my 2001 XC70 it was officially an S80 or XC90T6 part. Nonetheless the part number hasn't changed. If you look it up on Vida 2012b it is only an S80 part so it must have been updated to suit other models after the "cheat" was discovered by 5 cylinder mechanics. If you look up any of the PCV components on Vida for a 2001 XC70 you would be buying the entire coolant pipe at about $160 in a genuine part (9470330) IPD USA has a cheaper non-genuine alternative though.

I agree with chrism about cracking the banjo bolt while the manifold bolts are still reasonably tight.

V70IIT5 · Post by **V70IIT5** » 04 Feb 2017, 04:08

I can't see how you think it is easier to undo the banjo bolt with the intake manifold fixed in place, how on earth are you supposed to get your arm right underneath? Access is fouled by the throttle isn't it?

Post by **abscate** » 04 Feb 2017, 04:42

I think I have a picture in my 1999 maintenance thread. I remember threading the banjo against the tension of the hose with the IM in place was really tough, but loosening it would be easier

Post by **precopster** » 04 Feb 2017, 06:37

Removing the throttle first is the wisest choice, I can get one off a 2001 turbo in around 15 minutes. It's all done by feel. Without a firmed down manifold how do you expect to undo a 17mm bolt with a 10mm thread while it's flopping around? Those copper washers on either side of the banjo bolt can really bite!!