PCV R&R - Losing the battle to the dreaded hidden Intake bolt Topic is solved

[GlennG2759]

Thank you, I looked at FCP video which for some reason they make everything look easy. I missed this one. Looks like the key is 3" wobble extension at the socket. I tried different variations, but not this configuration. I will try tonite !!!

[abscate]

Just had a look at my 2.4 NA

This is a classic case of fighting access with a special tool rather than getting good access with some extra work

Three M8 bolts and serp belt allow the PS pump to be pulled forward.
Cover alternator with plastic bag, remove thermostat front half with two Torx
Now the nub is gone and you have a straight shot at the M6 IM bolt

If you are even smarter, wrap the IM work into your coolant change interval and dump/change coolant and hoses on the same ticket, and the 'extra work' is saved later.

You can take the serp belt off with a broom handle to tension the pulley. Its much harder to put it on with a broom handle. Worst case, drive car to AZ without serp and borrow theirs.

Removing and replacing the thermostat cover is documented here - you have to be bit careful without the tool but its not brain science nor rocket surgery

[oragex]

Thank you, I looked at FCP video which for some reason they make everything look easy. I missed this one. Looks like the key is 3" wobble extension at the socket. I tried different variations, but not this configuration. I will try tonite !!!

In fact, it has to be a 2" extension at the socket - I tried at 3" extension and it didn't work. My extensions are indeed the wobble type, but I set it to be fixed (it has two setting when you put the socket on it). I warmly suggest also to secure the socket tight on the extension using a piece of paper because I dropped and lost my socket

This bolt near the thermostat for the 2003-2009 thermostats on non turbo engines it's the toughest guy to reach, the same bolt on the turbo engines with either the older or the newer thermostat model is easier to reach

[a3inverter]

I believe that nub is mirrored on the other half of the casting so you still need to get around it.

The other potential issue is that the gasket between the halves isn’t available from Volvo separately- at least according to the parts guy and his picture from Vida at my local dealer.

I will try to verify later today.

Just had a look at my 2.4 NA

This is a classic case of fighting access with a special tool rather than getting good access with some extra work

Three M8 bolts and serp belt allow the PS pump to be pulled forward.
Cover alternator with plastic bag, remove thermostat front half with two Torx
Now the nub is gone and you have a straight shot at the M6 IM bolt

If you are even smarter, wrap the IM work into your coolant change interval and dump/change coolant and hoses on the same ticket, and the 'extra work' is saved later.

You can take the serp belt off with a broom handle to tension the pulley. Its much harder to put it on with a broom handle. Worst case, drive car to AZ without serp and borrow theirs.

Removing and replacing the thermostat cover is documented here - you have to be bit careful without the tool but its not brain science nor rocket surgery

[abscate]

I believe that nub is mirrored on the other half of the casting so you still need to get around it.

[a3inverter]

Yeah, imagine my joy. The images from VIDA (and from all the ones I found online) are from the serpentine belt side so you can't see the nub...but I got a finger back there and felt it.

[cn90]

The Volvo engineers should be proud that due their design, this particular 10-mm bolt generated 5 pages of discussion LOL!

Well, in their defense, the I.M. is almost the same as Volvo 850, S70, but they modified the thermostat housing, partially blocking this infamous bolt!

[chrism]

Consider replacing that bolt with a torx head bolt. It might make it easier on the next person that has to loosen it.

[cn90]

From the car mfg standpoint, the pressure of cranking new model is intense.

Very often they take parts from previous generations (everyone from Volvo, Mercedes, BMW, Honda etc. does it) and install in the next gen.
In the Volvo case, the I.M. is virtually unchanged from previous gen, but they changed the thermostat housing, partially blocking this bolt. They then issue new procedure/tool to address the issue. This happens in almost all car mfgs.

[chrism]

Another crazy idea I’ve considered for that pesky bolt.....

The manifold flange is about 1/2” thick where the bolts go through it. What if you ground off 1/8” or 3/16” of material in the area of that bolt and then used a bolt that’s that much shorter. It would provide 1/8” or 3/16” additional clearance between the bolt head and the thermo housing.