Exhaust odor inside 1994 850 Turbo

[PREGRE01]

Last summer my water pump seized while on vacation and caused a ton of damage to the valves (bent 5 of them when timing belt broke). Since the car was returned to me (after the head was pulled for the damaged valves), we have had a problem with exhaust odor in the passenger compartment. I thought that I had identified the source as the fresh air intake at the base of the windshield drawing air from the engine compt. past the weather stripping,
but after re-sealing the stripping, the odor is now back with a vengeance.

Is there something that may have been disconnected when the head was removed, that was mis-connected when the head was re-installed ? I ask this question because the odor is definitely entering the cabin via the ventilation system. It emanates from the "fresh air" ventsThe last time this garage had worked on a Volvo was never.

Any ideas?

My local Vovo specialist is stymied.

The car is a 1994 850 Turbo wagon with 190,00 km

[MadeInJapan]

The only time I've ever smelled exhaust in the cabin was when we had a turbo oil return line leak that dripped oil onto the hot exhaust. Do you have any oil leaks under the engine?

[PREGRE01]

I'll check it out..


Thanks

[sntee]

Take a look at the pipes that make up your PCV system.

I managed to fracture the main pipe that runs from the Oil Trap to the Air Intake whilst doing a head gasket change. Now the crank case gases just vent into the engine compartment then into the cabin.

This particular pipe is extremely brittle on older cars and very easily broken, but because it is encased in a foam sleeve, you probably wouldn't even know that it was damaged.

check for signs of smoke / fumes coming from the end of the foam sleeve nearest the main air intake pipe (about 12" from the air filter box).

[akitawagon]

Yes, as sntee mentioned, check or have a knowledgeable Volvo shop check out your PCV system; this might be your problem. Until we fixed ours, it was venting into the main cabin and felt like someone had hooked up an exhaust pipe to our vents.

If you can't get to it right away, make sure you have the windows down a bit to get fresh air in; too much of the exhaust fumes and you could lose consciousness. There have been accidents around here where they originally thought the driver had fallen asleep, but the actual direct cause was from exhaust/gas fumes flooding the cabin.

[PREGRE01]

I can't see the oil separator. Does the intake manifold have to be removed?

[akitawagon]

Yes. Unfortunately you have to remove the manifold to get to it.

Here's another thread for another possible source of the fumes:
http://volvospeed.com/vs_forum/index.php?showtopic=3498

[MadeInAmerica]

I was getting fumes in from the gas tank because the ring became loose and vapors were coming out where the fuel pump is. Does the tank leak a little after fill up for you? If so check where the fuel pump is in the trunk and if so you need to tighten the ring or put a new seal in. I tightened it with a large srew driver and mallet by the way . Tapping on the ring to get it to turn.

When the windows were down it was drawing the fumes into the cabin from the fuel pump area.

Cheers

[PREGRE01]

Thanks a bunch. Since I'm presently studying for apprentice mechanic, I'll take a stab at it. I can always use the practice. Is there anything else to do in the vicinity while the intake manifold is off?

[rippertele]

Is there any way to reroute the intake for the cabin? I have the same problem and even though I've reconnected the hose to the oil exhaust under the manifold there is so much old oil and residue that it's still affecting the cabin air. I don't see smoke anymore but when I leave the car running and heating in the mornings I smell it badly when I enter the car. Please, any suggestions?