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S70 Turbo: Returning Airbox to Stock Questions?

Help, Advice and DIY Tutorials on Volvo's P80 platform cars -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, including 850 R, 850 T-5R, 850 T-5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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WhatAmIDoing
Posts: 965
Joined: 30 July 2016
Year and Model: 1998 S/V70 T5M
Location: North America
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Re: S70 Turbo: Returning Airbox to Stock Questions?

Post by WhatAmIDoing »

Found a hardware store that sells large diameter O-rings. After some trial and error, ended up buying an O-ring labeled as 2-3/4" ID, 3-1/8" OD, 3/16" thickness, which on paper works out to 69.85mm ID, 79.375mm OD, 4.76mm (for clarification 70, 81, 5.5 was needed). I measured it on a ruler, and it seemed more like 71mm ID, 81mm OD, and about 5mm thickness. The next size up they had was just a hair too big and wouldn't sit right in the opening to the airbox. Also bought a rubber stopper of unknown size to plug the port for the hose to the air pump. Total cost: $2.60. 8)

The o-ring slid on to the MAF with very slight resistance. It sat well in the airbox opening, but not quite as snug as I would have liked (that extra half a mm thickness would have been good). The MAF seemed to slide into the airbox opening snugly with the o-ring installed. Jammed the rubber plug into the SAS elbow and used some of the handyman's secret weapon to keep it secured. Didn't have any liquid adhesive/sealant on hand that I felt would adhere rubber to plastic well under high temps. Dropped in a new Mann filter, and my S70 is now running on its stock airbox again.

For peace of mind, I want to leak test it. Thinking I'll have someone hold the throttle at a high RPM while I smoke around the SAS elbow and MAF opening, and see if any smoke is getting sucked in. Still going to look for a slightly bigger o-ring, but I think this will work for now.

On a side note, my TCV has lost its home on the front of the main fuses box. There isn't enough room for it here with the airbox installed. Will have to find a new place to mount it.
'98 S70 T5M - 323,000mi - awaiting heart transplant :shock:
'98 V70 T5M - 324,000mi - my new project
'99 S70 "AWD" - 220,000+mi - gone :cry:
Knows enough to be dangerous :wink:

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erikv11
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Year and Model: 850, V70, S60R, XC70
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Post by erikv11 »

WhatAmIDoing wrote: 27 Feb 2018, 18:38 ... my S70 is now running on its stock airbox again. ...
Looking good!
'95 854 T-5R, Motronic 4.4, 185k
'98 V70, T5 tune-injectors-turbo, LPT engine, 304k, daily driver
'06 S60 R, 197k
'07 XC70, black, 205k
'07 XC70, willow green, 212k
'99 Camry V6 :shock: 153k
gone: '96 NA 850 210k, '98 NA V70 182k, '98 S70 NA 225k, '96 855 NA 169k

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