Oil Separator Box replacement (P2 - base)

Mr. Detail · Post by **Mr. Detail** » 05 Apr 2022, 10:00

Hey Guys;
Just got the word from my mechanic that he won't replace my oil breather/separator box for me.
He said he is afraid about how many things will break during the process and that it may take him
longer than the book rated 3.0 hrs.
I wanted to tell him that if he is afraid to get a dog!

Anyway, does anyone have a good video for me for my P2 (Non-turbo)?
I have all of the necessary parts minus any new bolts needed. Should I be replacing any manifold bolts
or other hardware in the process? Thanks.

Post by **br0dy519** » 05 Apr 2022, 11:03

The only items outside of all of the hoses and standard stuff that comes in the PCV service kits that got me :

4 x 12mmx16mm copper washers
Throttle Body Gasket
Thermostat Gasket

YES absolutely get the 2020 upgraded banjo bolt. There are comprehensive threads that have entire shopping lists basically (I think theres one on swedespeed). Funny the mechanic refused the job. It wasn't really bad and took me about 3 hours all-in on a DIY first attempt.

The best way is to look at the comprehensive service kits on iPD/FCP and that gives you a good idea of what you should have on your bill of material.

ignatz · Post by **ignatz** » 05 Apr 2022, 12:55

On Youtube, the FCP Volvo guy goes thru the job on a 2004 S60. Watch the video and take notes on the order of things and how he gets things apart and back together.

Post by **cn90** » 05 Apr 2022, 19:25

- Just replace the hoses etc.
- The oil trap can be cleaned and re-used. They last up to 300K.
- I posted a photo some yrs ago, when I cut it in half to show people the inside anatomy...

Post by **erikv11** » 08 Apr 2022, 16:54

I mostly agree except: don't just replace the hoses - for sure also replace the banjo bolt.

Post by **abscate** » 09 Apr 2022, 02:30

If you are 150k plus it a perfect time to have your alternator rebuilt. While it’s out, the banjo bolt replacement is a lot easier.

Post by **chrism** » 09 Apr 2022, 06:03

cn90 wrote: ↑05 Apr 2022, 19:25 - The oil trap can be cleaned and re-used. They last up to 300K.

Probably not so true in this case though. The non-turbo separator boxes have a built in diaphragm that is supposed to control the amount of vacuum placed upon the PCV system. Over time it gets all coked up inside and the diaphragm can’t do it’s job. I have a photo somewhere of what mine looked like inside when I cut it open. If I can find the pic I’ll post it.

Post by **abscate** » 09 Apr 2022, 06:06

That’s why Fora Rock. When I go to do my 2005 I’ll watch out for thus

Post by **br0dy519** » 09 Apr 2022, 08:39

Crap I forgot to mention the other things I forgot that pushed my job back another day :

Fuel injector o-rings
Fuel injector pintle caps

You will need to replace some of them as they are old and brittle! Else you’ll get a leak there.

Post by **cn90** » 09 Apr 2022, 08:57

@chrism et al,

I do NOT have the cutaway view of a P2 oil trap, my guess is the P2 oil trap is very similar to P80 oil trap...

The photo below is my 1998 V70 (non-turbo) Oil Trap with 100K, I cut it in half to see the anatomy:
it is a simple box.

PS: If anyone has a P80 oil trap, please post a cutaway view...

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: PCV cutaway.JPG (69.38 KiB) Viewed 1138 times