Pcv on a turbo/ pictures and comments

[tailor]

1994 850 Turbo Wagon 266000km(Canada)

So finally I started the pcv job after I completed the speedo fix, the car was out of action for a week due to my getting a tad sidetracked and performing some really genius type moves which would make any mother proud.(huge dose of sarcasm here).Most of the parts came from FCP Groton and some came from the local Volvo Dealers. It was a major PITA to get parts from the local Volvo Dealers because almost all the parts had to be special ordered, so it was another day lost before I got back to working on the car. Murphy's and Sod's Laws were ever present!!

Car in pieces:

Thought it would be better to remove most of the "guts"

Have I gone too far!!!


Cleaned up manifold, showing hole where the throttle body attaches.The top hole is for the vacuum tree.


"Dry" fitting oiltrap and pipes:


Almost complete:


Below is a list of parts that due to my,...... well lets just say I needed to replace in addition to the Pcv parts.
1) 1 x manifold bolt here I am thinking that all seven should have been replaced!( 1 fell down somewhere)I read in the Haynes manual all 10mm bolts longer than 4 1/2 inches should be replaced.
2)Egr bolts x 2 : part # 3547506. I managed to shear the one bolt head right off as I was torgueing, in Haynes they say 37 ftlbs, I wastn't even close to getting a click when there was a snap and a flurry of expletives that would have made most hardened sailors blush. I had some doubts over the accuracy of the torque specs and was more than a little apprehensive about torque for the rest of the repairs. I have since spoken to a few people who inform me there are "torgue wrenches" and "torque wrenches". I now know which one I have!!!
The bolt was extracted carefully using a small drill bit and a bolt remover tool. It was made easier due to the fact the manifold was off the car and I fliped it over on the table to get better access to the broken bolt. (and if anyone is even wondering if it's the dining room table? NO of course not!)
See post: https://www.matthewsvolvosite.com/chat/p ... hp?t=13198.
On the issue of the EGR, I believe that it might be easier to attach the EGR to the manifold 1st and then attach the manifold to the block, I only thought of it afterwards so I could not test my theory. I would welcome any thoughts on this subject for the benifit of other forum members.
3)5 manifold injector seals: no expletives here! : part # 3528217
4) 5 sets of o rings for the injectors: just a few here: part # 30731375
5)An extra torx screw to mount a vacuum bracket on the air box, nope none here !
6)A bolt to re-attach the ABS sensorwire bracket to the wheel well( heard thunking thought it was suspension)sometimes a good thing to look under the car!
7)Throttle body gasket, part # 9135990.
O ring for the vacuum tree, part # 978111
9)The dipstick o ring at the bottom, in the block and one on the dip stick handle, parts #'s 30637865 and 947114 respectively.
10)Replaced all the black tubing conduit that was broken, injector wires etc and other bits.
11) Really cleaned up the manifold insides, scrubbed and washed over and over see pics.

I still have an erratic idle,see post
https://www.matthewsvolvosite.com/chat/p ... hp?t=13466
code 232 (long term fuel code being thrown and the evap cannister is hissing. I also get a 241 code from the A2.
I also have a new turbo intake hose from FCP as this happened to my old one,see below

This baynet connection gets very clogged and the rubber has perished from oil saturation which is coming from the turbo.


I could not fix it, see attempt with gasket"stuff" in picture below.



New part no 9186200, it has more nipple holes than swiss cheese, so I have to plug some of them for my model car. I have not put in the new part yet, so this might improve the whole performance. I am a little concerned about the oil that is collecting on this pipe.

In summation there was not a whole lot of blockage,the biggest blockage was on the concertina pipe nipple shown in above three pics. The job itself was not hard,just a little time consuming due to some bad moves on my part.
I might have been better off just cleaning everything out instead of changing everything out, I will be better informed for next time and try not make a career out of the job. A sense of satisfaction was achieved.

Tailor

[Necromancer]

You might have taken a part a little more than you needed to but overall it looks like you did a good job.
I did mine about 4 months ago (a 97 T-5 wagon) and didn't have a complete blockage either.
How was your intake manifold as far as carbon buildup?
Mine was very bad so I used a wire brush that is normally for cleaning out glass carboys (used for making beer / wine and lots of intake cleaner.
By far the worst part of the job.

I did mine without removing the fuel lines / injector assembly. You can do this if you remove the fuel line clamps, one on top of and one on the back of the engine. Also, you can leave the throttle wheel and bracket on the intake next time.

I too broke something during my attempt. The throttle kickdown switch assembly that mounts to the firewall snaped when I leaned to hard on it trying to reach the turbo intake hoses.

[tailor]

How was your intake manifold as far as carbon buildup?

Not too much gunk in the holes, but a good deal of "varnish" I took a variety of stiff bristel brushes, spray tubes(like the ones you get with a brake cleaner) and really dug deep into the manifold. I also soaked it in a engine degreaser, rinsed with regular water and then compressor and towel dried.Tried to make it shine!

It was fun while it lasted, I would recommend anybody who wants to tackle a "bigish" job to do it in kinder weather or have a great big garage with heater.

Tailor