Locating Flame Trap Box/Breather system

dduck13 · Post by **dduck13** » 23 Aug 2011, 18:52

I am looking to find a picture or sopmething showing where this part is on a 2002 S60. I had the dealer tell me that I need to replace it but can not afford the labor cost so I have a buddy that is going to help me get it done. Thanks for anything you can do to help.

Post by **JRL** » 23 Aug 2011, 20:24

This is not something that "your buddy will help with" if he's not a mechanic
Most of it is halfway inside the engine. You need to remove the intake manifold. This is not a job to tackle unless you're a fairly competant mechanic as it has to be done correctly.

Not a hunt and peck deal here
Retail the parts (plural) alone range from $175 (aftermarket) to nearly $300 (OEM Volvo parts)

dduck13 · Post by **dduck13** » 23 Aug 2011, 20:38

yeah...i understand my buddy is a mechanic and a pretty good one he just has never heard of a flame trap box like the dealer told me... I found out it is part of the breather system so we are looking to replace it ourselves. Thanks for anything you can do to help.

Post by **DGM** » 24 Aug 2011, 07:31

Basically you have to remove the turbo air pipe, ETM and the complete air intake manifold. It is easier said than done but within the reach of a good mechanic with documentation

.

Find here a DIY of the forum on this issue covering older models which are similar.

https://www.matthewsvolvosite.com/forums ... =1&t=28487

Find also a generic view of parts involved under the intake manifold.

http://www.fcpgroton.com/product-exec/p ... gory_id/63

: Breather view P2 generic; Breather view Volvo P2 m.jpg (23.49 KiB) Viewed 5899 times

Since you are there make sure you clean up the piping and the banjo bolt itself.

See page 7 of the following document.

crankcase-ventilation-system-cleaning Method[1].pdf: (217.27 KiB) Downloaded 1283 times

This will restore system draw.

Post by **JRL** » 24 Aug 2011, 11:44

That's not for a P2
You're missing the ling, complicated pipe, the one that costs over $100
To the OP;
This is a flat rate 5 hour job.
For an expert Volvo mechanic it takes about 2.
There are other things to look for when doin this.
One pipe goes into theoil pan, if blocked you need to clean it.
Sometimes it's so bad it doesn't budge, then you have to knock it into the oil pan.
If that happens you need to run karosene through it and immediately change the oil.
Hopefully it's still soft and you can pull the sludge with a needle nose pliars

Post by **DGM** » 25 Aug 2011, 08:06

The exploded view of the breather box provided is to show its location as per OP request. It is a generic view.

The part JRL refers to is the odd shape pipe in the following picture. It is generally cleaned up in the process of replacing the breather box on these models.

: Pipe PCV.jpg (105.69 KiB) Viewed 5865 times

There is replacement kits available if you want to change it all. The following is an example.

http://www.ipdusa.com/products/4989/2e8 ... 2002-turbo

I gave you reference to the excellent DYI for older models. It is giving you an idea of the work involved and what to look for generally.

However after more research I came up with this interesting write up on PCV cleaning. This one is applicable to the model year you have even though it is for a V70 turbo. Middle of the page under PCV.

Read it carefully you have there what you need to plan and execute the job.

http://howardsvolvos.webs.com/engine.htm

Good work

,

Post by **SuperHerman** » 02 Aug 2018, 16:53

The Flame Trap or Breather box is the main component of Volvo's PCV system. It is basically a plastic canister with some internal baffling. Its purpose is to remove the vaporized oil that is in the crankcase and send it back to the oil pan rather than into the air. It is located under the intake manifold on the lower passenger side of the engine. Right under the coolant/thermostat port. It has two connections that go into the block and some hoses on the top. It is not a difficult job, but look over the various write ups others have provided and maybe watch some videos so you know what you are getting into. If I recall the main tool you will use is a 10mm socket, a 17mm box wrench and a torx screw remover. Removing the fuel components is the most problematic piece of the process, but sometimes everything come off easy.

Just read the various write ups and you will learn the special tricks and problems. If your car is not a turbo it will be easier.

Here is a recent post by a forum member which shows the gunk that needs to be cleared from the block. Your case could be better or worse.

viewtopic.php?f=11&t=86173

I like to use a pick and vacuum to keep the crud from getting pushed back. If you have build up you need to clean it out or the new parts will do nothing as the blockage is still in the block. I usually use carb cleaner and gas to flush the last pieces out of the block and pan and follow up with more gas to wash any chunks into the oil pan. It is flammable so be smart. Collect it with your used oil and send it to recycling.

If you and your mechanic friend familiarize yourself with the suggestions others provided you will have no issues. Once the intake is removed everything will be right there and straight forward.

For parts, check the site sponsors and look for their kits. They contain most of the parts you need. Purchase new Oetiker clamps before hand as you will not find them easily locally.