1996 850 - d $ m n... rear seal, no - gasket!

Teddy1975 · Post by **Teddy1975** » 02 Jun 2016, 09:10

I did pick up an intake manifold gasket Tuesday, so I'll see if I can't get the PCV cleaned up tomorrow afternoon.

Teddy1975 · Post by **Teddy1975** » 03 Jun 2016, 09:37

Ok, now I know the PO was a sadist... What on Earth this poor car did to him I'll never know, but it ain't pretty... Pics to come.

Teddy1975 · Post by **Teddy1975** » 03 Jun 2016, 13:23

I spent about 5 hours on the PCV today in the sun, walking from the car to the computer and back again.

Thanks a bunch Justin, jblackburn, for the great how-to on PCV replacement.

The state of the ports in the how-to are not exactly what those in my car were:

And even worse:

Yes, that is 100% blocked!

And the top hole on the oil separator:

Too bad you can't report a guy for car neglect, he obviously spent more time putting in faulty blue LEDs all over the car, instead of having it serviced regularly.

I used a screw driver to pick out the worst gunk of the holes, then sprayed with degreaser, used an old tooth brush to get them as clean as I could.
I should probably have replaced the box with a new one, but with the help of compressed air, a whole can of degreaser and the screw driver again, I at least got free flow through it.

I replaced the vacuum line using generic vacuum hose with an ID of 4mm and 5/8" ID heater hose. I'm afraid it'll kink too much, so I'll be going back in and install a couple of anti-kink coils, like these.

Oh, when I took off the throttle body cover, I noticed the top port of the vacuum tree wasn't being used and from the amount of dirt on it, it seems like it's been that way for a long time. Does anyone have any idea of what that is meant for? I couldn't find any loose vacuum lines and for now I've blocked it off with a piece of vacuum hose and a screw... That actually made the idle drop from ~950 rpm to ~850.

Thanks a lot for all the tips

DeathRex · Post by **DeathRex** » 03 Jun 2016, 20:41

Mine is a 96 turbo and it only has 2 lines coming out and 3 plugs. One line to the intake manifold, and the other goes back behind the battery.

There's supposed to be a diagram under the hood. The diagram says my other goes to a gauge.

Post by **abscate** » 04 Jun 2016, 00:20

Ugh. That's nasty. How is the crankcase pressure now?

Teddy1975 · Post by **Teddy1975** » 04 Jun 2016, 05:24

Well, glove was being pulled a little into the oil filler hole at idle and no smoke from the dipstick, I didn't test at higher RPMs though. At the time I just wanted to close the hood, go home and take a long cool shower. The sun hit me head on from about 3 PM to 7:30PM where I had everything back together.

I started the engine forgetting to plug in a hose to the EGR which resulted in idle RPM at 2500 and check engine light coming on. So at last I get to use my flash out code reader to clear that.

I can't say if the oil leak has been stopped, I put in another 2.5 liters before heading home last night and I'll replace oil + filter tomorrow at my sister's house. That's about 60 miles from here, so I hope most of the loosened up crud will be in the filter or come out with the oil.

Post by **MadeInJapan** » 04 Jun 2016, 06:41

Did you buy new hoses for the PCV system and possibly the oil separator box?

Teddy1975 · Post by **Teddy1975** » 04 Jun 2016, 07:58

For now, I put in a generic 5/8" heater hose from the box to the flame trap housing and a generic 4mm vacuum hose from intake manifold to flame trap housing. And I had to reuse the box, but spent my time cleaning it out.

I'm going to buy a new separator box and I'm thinking of maybe buying new hoses as the heater hose I've had to install is made of EPDM. I'm also not happy with the tight bends in the heater hose.

Post by **MadeInJapan** » 04 Jun 2016, 11:59

I wouldn't skimp on that hose that goose-necks up to the top of the engine- you don't want to have to get in there again...so, buy the Volvo hose- most places sell it for about $30. Uro hose is awful and won't last any time. I'm not sure about other company's hoses, but one I got was such slippery plastic rather than rubber than I couldn't keep it on with a tight clamp.

Teddy1975 · Post by **Teddy1975** » 04 Jun 2016, 13:37

I don't have that hose going to the top of my engine. Only thing that come close to that is a metal pipe going to the rear of the engine into a valve and from there down towards the throttle body (not sure exactly where it hooks up to as of now).

I'm not at all sure of what that valve is for or the name of it. There's a purple vacuum plastic line going to it.