Need some advice with Intake Manifold Removal for PCV Job

skifasttakechances · Post by **skifasttakechances** » 01 May 2011, 14:50

My 1989 740GL Estate Wagon 5spd, B230F engine (non turbo) no mods really other than a Cone Style Air filter and missing muffler. At least 200K. Speedo works after 30 miles or so stuck at 197K for a long time.

I replaced my Oil Cap Gasket b/c there was leakage about 3 months ago, I thought the leakage would stop at this point but I noticed there was still fresh leakage around the block, towards the back of the engine near the distributor as well, Dipstick was smoking and when removing Oil Cap, oil spattered out.., I realized that the car had all the symptoms of a clogged PCV system. After doing lots of reading on the topic and procedure, I ordered a new Breather Box, Hoses, Flame Trap etc, from IPD for about $40..I'd rather not do this job very often.

It's starting to get warm enough in Colorado to get my hands dirty, Yesterday It took me about 10 minutes just to find the flame trap, the hose from the intake manifold was already off. I pulled everything off that I could reach except the breather box Inspected the hoses, none of them appeared clogged, flame trap could probably use replacing anyway though. There was still smoking from the Dipstick tube, This proved to me that my breather box is clogged up .

I was wondering though, There's alot going on with the Fuel system and intake, and throttle, etc.. What is the best way to go about getting access to the breather box, There's really no way I could do it without removing the manifold, Some have mentioned it's possible to just remove the throttle body.

Will I be able to get access if I just start unbolting the manifold and maybe move it back a few inches So I can access the Breather Box? Or is this not a good idea since the throttle cables, fuel lines etc are all in the mix? I have a Haynes Manual, it doesn't have really any drawings about removing the parts.

russellengineering · Post by **russellengineering** » 01 May 2011, 21:16

Hey,

I have a 940 with the B230 so it should be the same. I did mine by getting my air intake hose out of the way on the throttle body side and removing the idle air control valve. It gave me enough room to get at the breather box for cleaning.

I have read the the hose under the breather box to the oil pan has to carefully protected from dislodging, so be careful of that issue.

Cleaning your TB and putting a new gasket on it would be a good maintenance move and you would find it more roomy. So that is something to consider if you have the time.

Good luck!

Dave

skifasttakechances · Post by **skifasttakechances** » 01 May 2011, 22:32

Thanks alot, I just saw that people have unscrewed the manifold and pulled the whole assembly it back to the strut tower,sounds simple but that manifold bolt clearance is also tight.

I think I will try removing the hoses on the throttle body side and I found that I should probably clean the IAC and AMM while I'm in there. Can't wait to see how she runs after this.

I did seafoam it a while ago so I bet with the clogged breather box, my throttle body wasn't getting as dirty. I'll check that out anyway.

Post by **writer100** » 03 May 2011, 17:21

Do yourself a favor -- do not take off the intake manifold.

Go to the auto parts store and get a length of rubber hose and some carburetor cleaner. undo the flame trap from the breather box and connect your rubber hose. Just before you change your oil, shoot carburetor cleaner down the rubber hose into the breather box. This should loosen up the gunk inside. To test it, removing your oil filler cap and blow through the hose connected to the breather box. You should be able to blow through without obstruction. This indicates that your breather box is clear. Now, change your oil to remove the carburetor cleaner, and switched to a synthetic, which is less likely to coke up as the dino oil did.

skifasttakechances · Post by **skifasttakechances** » 05 May 2011, 08:58

Thanks alot, I still haven't dug into this yet, I keep looking under the hood, looking at the parts that I will need to check, the throttle body removal doesn't look bad however, the linkages are plastic, I'm pretty sure they could break easily, So I'm going to make sure I have a supply of all the hoses and miscellaneous parts that I want to replace.

Doing a carb cleaner spray in the breather box sounds like a good short term solution until I'm ready to tackle putting in the replacement breather.

Post by **writer100** » 05 May 2011, 11:01

Doing a carb cleaner spray in the breather box sounds like a good short term solution until I'm ready to tackle putting in the replacement breather.

It is not just a short-term solution.

What I tried to express was that if you clean the breather box as I described, there is no reason, point, or benefit to replacing it.

Post by **billofdurham** » 05 May 2011, 11:20

+1.

It also means you can't pull out the hose from the breather box to the oil sump. If that does come out it is a major job to replace it.

Bill.

tomatoes4all · Post by **tomatoes4all** » 10 Jun 2011, 15:18

hello all,
Sorry to high jack this post, but my breather box is plugged up ( oil leaks under the car) and I was quoted about 5 hours of labour to replace this by a local Volvo specialist. So the carb cleaner method sounds very attractive.... Can i use this method on my 960 as well? If so, would anyone have a picture/schematic handy to show me where the breather box is located? My car is a LPG vehicle and there is so much clutter everywhere, its hard to see where to look sometimes...
Thank you and regards from Down Under,

Erik, Adelaide, Australia.

Post by **writer100** » 15 Jun 2011, 16:35

Sorry, I can't speak re a 960. Perhaps Bill of Durham can?

chefbob · Post by **chefbob** » 15 Jun 2011, 18:09

Hello there. I just did the pcv system repair on a 1998 s70 turbo and the tutorial in the repair database was invaluable. If you have not yet looked at it you will find it under "pcv system repair on a five cylinder volvo" in the data base It may be some help locating everything.
Chef Bob