Call for help - PCV replacement

[wczimmerman]

2005 XC70 - Replaced the timing belt, idler pulley, belt tensioner, water pump, serpentine belt, serpentine belt tensioner, thermostat housing, and then the entire PCV system. I thought the banjo bolt on the driver's side of the motor was a nightmare but was I wrong: I have just spent 6 hours of my life trying to get the intake manifold bolt started and for the life of me I cannot get it going. The bolt threads in fine on its own but through the fitting I just cannot get it started.

Can someone tell me if there's a trick to this? Once this bolt is in everything else is a cakewalk. Do I need a particular tool? I can't get a socket in there so I now have blisters on the sides of my fingertips from turning the bolt for so long.

[wczimmerman]

If someone is near northeast Mississippi, I'll be happy to handsomely reward someone that knows how to get this in and can swing by....

[firstv70volvo]

2005 XC70 - Replaced the timing belt, idler pulley, belt tensioner, water pump, serpentine belt, serpentine belt tensioner, thermostat housing, and then the entire PCV system. I thought the banjo bolt on the driver's side of the motor was a nightmare but was I wrong: I have just spent 6 hours of my life trying to get the intake manifold bolt started and for the life of me I cannot get it going. The bolt threads in fine on its own but through the fitting I just cannot get it started.

Can someone tell me if there's a trick to this? Once this bolt is in everything else is a cakewalk. Do I need a particular tool? I can't get a socket in there so I now have blisters on the sides of my fingertips from turning the bolt for so long.

I spent hours without success too and finally took the time to remove the power steering pump and loosened the alternator to make some room and the banjo bolt threaded right in. Some say to leave the intake manifold loose for a little extra room so you could try this first if you haven't already. To loosen the alternator you'll need to remove the radiator fan and shroud and loosen the two bottom bolts of the AC compressor and remove the top two bolts to move the alternator. Disconnect the battery too. I don't think it took more than an hour to remove the PS pump and move the alternator and I wondered why I just didn't do this first thing.

[chrism]

Consider replacing the hex bolt with a torx type bolt. That way you can probe into it with a much skinnier tool. I’ve thought about doing this in the past but just never actually did. I think it would be worth a try. I don’t see why it wouldn’t work.

[XC70Rider]

As shown in the FCP video I left the intake manifold hanging while installing the banjo bolt.



I used a 17mm closed end ratcheting wrench. Couldn't get a socket in there.

[velorider]

A 1/4 socket on a long wobble extension.

viewtopic.php?t=53218