1995 850 turbo: edit : Manifold won't come out

volvo850freek · Post by **volvo850freek** » 11 Oct 2015, 10:49

Hi Guys, long time lurker,finally started doing some real repairs on my car and of course i run into breaking something. I searched up and and down and couldn't find this issue so here i am

I was following a video on how to do a PCV system replacement, and i get to the vacuum tree, the first 2 parts of it had tubes on them, third one was plugged up, and those 2 were real tight on. Well I sprinkled some wd-40 and i tried to wedge them out easy with a flat head but then it came out and i pulled them hard by accident. Next thing i know, i get the 2 vacuum lines out and there was a third line below those 2 that was connected to the egr, the rubber part of it broke in half! the actual tube didn't tear but the rubber elbow is broken in half, the other half is clamped to the egr i believe. so how screwed am i right now, and what kind of solutions do i have?

EDIT: OK i went ahead and kept going the PCV replacement, I took out dipstick, unscrewed the bolt under the intake, then i took out the top 3 bolts on the manifold, loosened the bottom four, although my 10mm got stuck on the bolt under the thermostat,i figured i'll take the manifold off and then take it out...but manifold doesn't come out! it keeps hitting against the head i can't lift it out. I circled in red the part that keeps hitting that metal notch when i try to lift the whole thing up. Is there something else stopping it from coming out??

Sommerfeldt · Post by **Sommerfeldt** » 11 Oct 2015, 11:23

I'm not sure I understand what happened - do you just need a new rubber elbow...?

- S

volvo850freek · Post by **volvo850freek** » 11 Oct 2015, 12:06

Basically i was pullting 2 rubber elbows off the vacuum tree and didn't realize there was a third tube going to the egr and that one broke off. But actually I guess a new rubber elbow for the egr is all i need... i just wasn't sure if this was a special piece because it was clamped on, but i guess i could just peel off the broken rubber parts and fit on a new one? Well if that's all than thanks.

Post by **polskamafia mjl** » 11 Oct 2015, 14:11

Ya new rubber elbow or even just vacuum hose should work too.

Post by **abscate** » 12 Oct 2015, 04:25

You need to loosen the bottom four to get some movement of the manifold towards the front the car...not just crack them. On my 1999, this was 2-3.full turns, or even take them out. Find them and put them back in to reinstall of course.

Sommerfeldt · Post by **Sommerfeldt** » 12 Oct 2015, 07:07

What abscate said. Loosen them quite a bit, then tilt and lift.

- S

Post by **tryingbe** » 12 Oct 2015, 07:26

Use smart phone or mirror to take a look down there to see if there is anything holding the intake manifold.

volvo850freek · Post by **volvo850freek** » 12 Oct 2015, 08:22

i can't seem to find anything else holding it, it just keeps bumping into that notch when i try to lift it up. I've just given up and tried to put everything back together...EXCEPT now i have yet another issue is that the manifold for some reason got shift to the right, if you can see in the pic. I can't push it back for some reason... i don't know what made it do that....

volvo850freek · Post by **volvo850freek** » 12 Oct 2015, 08:58

should i just remove the lower four bolts?? does having an EGR mean there's more bolts to take off??

Post by **cn90** » 12 Oct 2015, 09:18

- Underneath the Intake Manifold: reach your hand down, there are two (2) 12-mm bolts holding the Manifold to the L-shaped bracket(longer bolt) and Engine Oil Dipstick (shorter bolt). If they don’t come out, get a socket and long extension passing in front of the subframe and come from underneath with breaker bar (R hand hold socket/swivel extension; L hand holding ratchet/break bar). No need to have car on ramp. I did all this job from above.