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1999 V70"T5 PCV Intake manifold re installation DIY

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

This topic is in the MVS Volvo Repair Database » 1999 V70 T5 PCV Intake Manifold Re Installation DIY
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abscate
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Volvo Repair Database 1999 V70"T5 PCV Intake manifold re installation DIY

Post by abscate »

The late P80 cars have thermostatted PCV. Yeah! I'm convinced they clog much less than early P80s. I changed my oil with Dino every 5k with this car and really had minimal sludging.

Reinstalling the manifold is hard though as you have extra stuff.

1 turbo induction manifold to ETM
2 electrical ETM, MAP, mTS plugs - all easily done after manifold is on.
3 banjo nut for coolant PCV hose
4 oil separator box
5 purge vacuum line
6 TCV bleed vacuum line
7?brake booster vacuum line
8 fuel line

It's 3 and 4 which cause all the problems and here is how I did them

I disconnected the oil box hose to let the PCV pipe lift up. Now the banjo is easy to bolt on with its two copper washers. The banjo hose is off the coolant nipple for this step too. ( see pic)

Put the hose clamp on the PCV pipe just tight enough so that it doesn't fall off.

Now I fitted the manifold onto the lower nut and secured it with one nut.

With tweezers, I slipped the PCV pipe over the oil box fitting and slipped it home with a socket on a long 3/8 extender. Now I tightened the hose clamp, having set up the right length extenders before ( see pic)

The rest of the stuff is all accessible after the manifold is bolted on.

There was not enough play to bolt on the banjo with the PCV nipple attached. It's also at a slight angle to the intake manifold so it's tough to get started by hand. Don't cross thread that sucker... :cry:
Attachments
Ready to tighten clamp on oil box
Ready to tighten clamp on oil box
Tightening banjo nut, note lose PCV hose
Tightening banjo nut, note lose PCV hose
image.jpg
Lug on ETM locates correct position for induction pipe
Lug on ETM locates correct position for induction pipe
Little bit of gasket to clean off to make this 2.5 rivers clean
Little bit of gasket to clean off to make this 2.5 rivers clean
Empty Nester
A Captain in a Sea of Estrogen
1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 XC90-in-Red
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