PCV replacement/overhaul 2003 XC70 2.5

[Blacklab467]

I finally got around to replacing my PCV system this weekend. I was going to do a full writeup on the job with pictures and videos but there are countless resources already available on this site and throughout the internet on this job already. Provided are some pictures and guidance on some areas that have proven troublesome for DIY'ers when tackling this job. PCV replacement is a manageable job for the home mechanic and can be done in about 6 hours, I had a free weekend and did it over 2 days working slowly and methodically. Also a good time to change some other parts while you're in there, I elected to change the radiator hoses and thermostat, you might elect to change the serpentine belt, spark plugs and/or coil packs as you will have good access to these at this time.
I used A1 Auto's video to get started, removing the cross brace, dipstick tube, fuel rail and injector wiring harness and charge air pipe and associated hoses and tubing, fairly straightforward.

Intake.jpg (564.04 KiB) Viewed 746 times

There are then 6 intake bolts 10mm to remove, they are torqued to 20 Nm so can be removed with a 3/8 drive or 1/4 drive socket. 5 are easy to get at, the sixth one is on the passenger bottom and has been the cause of consternation for many. It has poor access and requires a very short 10mm socket or a wobble socket or a wobble extension due to its proximity to the thermostat. Some have said its a straight shot from the top of the alternator with a 10 inch extension, I did not find this possible. The picture below will illustrate the problem:

Manifold socket.jpg (473.05 KiB) Viewed 746 times

I chose to replace the thermostat which required removing the serpentine belt and Power Steering Pump to provide unrestricted access to this manifold bolt.
Once the intake manifold is unbolted, the banjo bolt can be removed with a 17mm box end wrench or socket. The PCV box is next removed.

PCV box.jpg (473.02 KiB) Viewed 746 times

At 302000 kms, I expected a lot more stuff in the box and engine port although my car passed the "glove test". I cleaned out the block port and carried on with the rest of the PCV tubing removal.

Block Port.jpg (361.99 KiB) Viewed 746 times

The driver's side of the engine is a rat's nest of wiring, vacuum hoses and unrelated hardware which hides the second banjo bolt fitting for coolant. You can't even see it and it looks impossible to access it, let alone change it! In reality it wasn't very difficult at all. I removed the air box lid and hose, radiator hose, and moved everthing out of the way and was able to access the banjo bolt. Remove the rest of the PCV piping and put the new one in place, as mentioned I replaced the radiator hose at this time. It is much easier to remove and replace the PCV piping with the radiator hose removed.

Driver's side.jpg (640.91 KiB) Viewed 746 times

The reassembly is basically just a reverse of removal. Now is a good time to clean and inspect all your hoses and wiring that lives under the intake manifold. Many who have done this job lament about how difficult it is to reattach the banjo bolt under the manifold, I had no trouble with this at all. My method was to hold the driver's side up with a helper and use my left hand above the alternator to start the bolt by hand.
I've seen this in a recent post and believe its a common problem with the charge air pipe:

Charge air Pipe.jpg (388.25 KiB) Viewed 746 times

The metal sleeve falls out of the plastic pipe and the heat causes the pipe to melt/shrink such that you cannot get the sleeve back in place. Then the band clamp gets tightened on the charge air pipe and crushes it little by little. I ordered a new one and a new coupler for installation later.

Used parts.jpg (398.53 KiB) Viewed 746 times

All things considered, it was a rewarding job to have complete. It is not a difficult job, but it does take a long time and you will have to take many things apart so be vigilant and take lots of pictures! As I mentioned, it is a good time to address other areas and replace service parts that may be nearing their useful life. I didn't include a picture but the throttle body was also cleaned while the manifold was off, it was quite dirty! Good luck and feel free to contact me if you have any questions about this job.