PCV -help needed

[M-R-P]

Ok guys, I'm in the process of gearing-up to sort my now, rather blocked, PCV system. I know I'll need a new manifold gasket and I'm plannin on renewing various boost/vac hoses but what are my chances of being able to clean out the PCV hoses and ports without replacing anything other than jubilee clips.
After new disks, clutch fluid, and DIM, I really can't afford the 150 quid for a PCV kit. I'm anally surgeon-like when working on things (I build/repair PCs and laptops to supplement my wages) even with my banana-fingers! so I'm hoping that it's possible.
What do you ever-knowledgeable peeps recon?

[M-R-P]

Anybody?

[Dave86]

Ok guys, I'm in the process of gearing-up to sort my now, rather blocked, PCV system. I know I'll need a new manifold gasket and I'm plannin on renewing various boost/vac hoses but what are my chances of being able to clean out the PCV hoses and ports without replacing anything other than jubilee clips.
After new disks, clutch fluid, and DIM, I really can't afford the 150 quid for a PCV kit. I'm anally surgeon-like when working on things (I build/repair PCs and laptops to supplement my wages) even with my banana-fingers! so I'm hoping that it's possible.
What do you ever-knowledgeable peeps recon?

You will need to buy a new oil trap (not expensive) i did just clean the pipes and ports the first time but due to the internal diameter if the pipes and the bends Its hard to do it effectively but you can have a go it will buy you some time but ultimately the pipes will need to be replaced.

[M-R-P]

You will need to buy a new oil trap (not expensive) i did just clean the pipes and ports the first time but due to the internal diameter if the pipes and the bends Its hard to do it effectively but you can have a go it will buy you some time but ultimately the pipes will need to be replaced.

Thanks Dave, I read somewhere that the trap can be flushed with large amounts of carb cleaner and lots of shaking about! If anybody has a spare for a good price tho...?

[Dave86]

I suppose you could try and clean it but think i paid about £20 for a new one can't remember if that was from rufe or partsforvolvos.com. I did try to clean mine but after 2 cans of carb cleaner and brake cleaner nothing was coming out so i smashed it open and found it was just solid with brown greasy slime lol

[M-R-P]

Hmmm. She's done 181k so probably best to look into a new tank! errrg bloody thing's costing me more than the house!

[Yorkshiresxi]

I am just doing mine too, so i am going to replace mine box which i have got from jamest5r and replace the pipe to the ptc with silicone hose i got from eurocar parts and then instead of putting it in to the intake put it into a oil catch tank. Seal the intake off and hopefully it will be ok! thous no vac pipe from the inlet to leak anymore and capped that off and no more rubbish to go in to the inlet...the only thing i can see been a problem is that there will be no suction to suck the rubbish out of the pcv box...so it might get bunged up...but will have to keep an eye on it i guess.
I was going to get rid of the lot and just let it go to the catch tank but thought i better not as its must be there for a reason

[M-R-P]

Just phoned my local stealer and got a quote for the catch tank, the little hoses that go to the block and inlet manifold gasket....£32.45+vat! I'm hoping that I won't damage any of the other parts when disassembling. :)

[Dave86]

Just phoned my local stealer and got a quote for the catch tank, the little hoses that go to the block and inlet manifold gasket....£32.45+vat! I'm hoping that I won't damage any of the other parts when disassembling. :)

Sounds a good price. The only trouble i had was removing the intake manifold as the fuel line comes up through the gaps in it and i couldnt undo the coupling so i had to pull the fuel line from the rail and keep turning the manifold about until i could get the fuel line through. Trying to get it back in was just as interesting lol. although im sure there's and easier way

[M-R-P]

Well, as always, I'll be taking photos of the progress and will post any quick fixes I find along the way.
Watch this space...:)

[M-R-P]

Just been digging around in the engine bay and I recon that I can do this without taking the inlet mani off! keep ya posted and expect smugness if I can!

[p fandango]

Just been digging around in the engine bay and I recon that I can do this without taking the inlet mani off! keep ya posted and expect smugness if I can!
there is alot easier access with the ME7 inlet manifold

[M-R-P]

there is alot easier access with the ME7 inlet manifold

I appreciate that Mr. Fandango but I have forearms like popeye so it will have it's own special challenges for me ;)
Do you recon I should disconnect the battery encase I do something aggravating to the throttle?
I gotta admit, I'm not looking forward to this job. inlet mani or not.

[p fandango]

I appreciate that Mr. Fandango but I have forearms like popeye so it will have it's own special challenges for me ;)
Do you recon I should disconnect the battery encase I do something aggravating to the throttle?
I gotta admit, I'm not looking forward to this job. inlet mani or not.
yeh i'd take the battery off, as you know P2's are fussy/annoying at the best of times so better be safe than sorry. The manifolds not hard to take off anyway. The lower bolts under the manifold are slotted so only have to be lossened not fully removed

[M-R-P]

yeh i'd take the battery off, as you know P2's are fussy/annoying at the best of times so better be safe than sorry. The manifolds not hard to take off anyway. The lower bolts under the manifold are slotted so only have to be lossened not fully removed

Yeah, I've done loads of research, so much so, I recon I could do it blindfolded (I won't tho unless it's for a a 4 figure bet!).
That's why I'm gonna try to do it without taling the mani off - the less I remove the less I can upset!

[p fandango]

the less I remove the less I can upset!
in theory, well good luck with it sir

[M-R-P]

in theory, well good luck with it sir

Thanks mate, will try to do a post as I go thingy depending on how it goes:)

[M-R-P]

Let the games begin... Charge air hoses coming off...

[M-R-P]

Just starting to remove pcv pipes - there's something extremely sharp behind the throttle body! Cut my finger right to the bone.
Tool drop count is now at 3!
And so it continues...

[M-R-P]

Just discovered that that the little pipe that runs round the block with the pcv pipe, in the foam covering is a bloody coolant pipe!

[M-R-P]

Catch tank is now off... But in my billy-big-££££££ haste to do the job without removing the inlet mani, I didn't stop to think weather or not the tank would fit through the limited space to get the damn thing out 5'oh :(
So, now the radiator fan is off the car, I can start cleaning...
http://i1100.photobucket.com/albums/g413/martinrpeachey/Photo0043.jpg

[M-R-P]

Bit worried now, catch tank is only a tiny bit gunked up. Air flows freely through all ports. Filler cap hose was a little gunged up but again, air flows freely. Pipe to air intake seems clear too. Why the ££££ was I getting smoke from the filler and dipstick when all flows freely? Given the ports in the block a good poking, the lower one had a bit of sludge in it but didn't cover even 10% of the hole.
Anybody got any ideas?
http://i1100.photobucket.com/albums/g413/martinrpeachey/IMG00170-20111015-1425.jpg
http://i1100.photobucket.com/albums/g413/martinrpeachey/IMG00169-20111015-1425.jpg
http://i1100.photobucket.com/albums/g413/martinrpeachey/IMG00168-20111015-1325.jpg

[M-R-P]

Bit worried now, catch tank is only a tiny bit gunked up. Air flows freely through all ports. Filler cap hose was a little gunged up but again, air flows freely. Pipe to air intake seems clear too. Why the ££££ was I getting smoke from the filler and dipstick when all flows freely? Given the ports in the block a good poking, the lower one had a bit of sludge in it but didn't cover even 10% of the hole.
Anybody got any ideas?

Found it!:) teeny weeny little banjo bolt located on the underside of the manifold with a coolant pipe round it, with a teeny weeny hole in it which was blocked solid with crud!
Onwards with the rebuild...
http://i1100.photobucket.com/albums/g413/martinrpeachey/Photo0042.jpg

[M-R-P]

Dropped tool count now at 11, one gone inside bumper assembly! :(

[M-R-P]

Pcv pipes back on, dropped tool count now at 19 and my effin finger is still bleeding!

[Yorkshiresxi]

i m laughin reading this but i know were ur coming from..i dropped the socket of my head when i was trying to remove the bolt from under the inlet manifold with like 4 extension bars...
hope you have got it all together ok pal, mines still in bits i am sooo hoping i can have mine back together tomorrow afternoon and see if shes boosting 18 psi....

[M-R-P]

Bad news... Buggered the jubilee clip that holds the charge air pipe to throttle body!:(
Good news... Father in law had an exact match in the jumble sale he calls a garage!:)

[M-R-P]

Car now back together, time for a test drive...

[Yorkshiresxi]

any good pal?

[M-R-P]

Goin for a drive in a min. Will update when I get home. Been doing this post-as-i-go thing from my crapberry (yes they work now!) So when I get home to my lappy I will post results and furnish the thread with piccies :)

[dalhousie2008]

i just had to do the same job, but i paid £50 to let swallow cars (volvo specialist) to do the job for me, much less hasle, working ok now?

[M-R-P]

Success!!!!!;);););):):):) no smoke from filler or dipstick. NO smoke, not a whisp, not a whif. Nowt! And it was all down to that banjo bolt! The rest of the system was completely clean! Gonna turn the laptop on in a bit and pad the thread out with how to info.

[M-R-P]

i just had to do the same job, but i paid £50 to let swallow cars (volvo specialist) to do the job for me, much less hasle, working ok now?
Was the price including parts? cos the full pcv kit for my P2 was 160 quid. I only bought the catch tank and the 2 pipes to connect it to the block. Planned to be very careful with the rest of it! Sounds like you got the job done for a real good price. Check your dipstick for choo choo train smoke after a run when the job is done - As I have just proved, when done properly, you will have no smoke at all.

[M-R-P]

Ok guys, Here's me being smug ;) I just fully sorted my PCV without removing the inlet manifold, injectors or rail. I won't lie, It was a hard job. I've never done this before and my popeye forearms made it even harder. after finding out that the catch tank and big pipes were all respectively clean (enough). Discovering the banjo bolt that collects pressure from the inlet manifold that allows the system to flow was an unexpected relief. This should be the first port of call when suspecting the PCV system is blocked.
It's a bitch to get to, you need to remove the charge air tube from the throttle body. Using a 19mm open ended spanner (the ring won't fit between the bolt and parts of the alternator) you will only get enough of a turn to crack the seal then you should be able to undo it with your fingertips (that's all I could get in there). drop the bolt out and have a look at it. The bolt is hollow from the threaded end and there is a 5mm hole straight through the collared end. The hollow end and hole through it are joined by a 2-3mm hole. this allows pressure from the manifold to flow through the PCV...
http://i1100.photobucket.com/albums/g413/martinrpeachey/Photo0042.jpg
You should be able to blow through the threaded end and it should come through the 2 holes in the collar. Mine was rammed - solid with hard carbon deposits and took ages to poke clean and wash in carb cleaner.
The air feed from this bolt is branched from a joint on one of the top ports to the catch tank. When you remove the tank (I mangled the clips with a screwdriver to get the pipes off the tank) plug the hole in the pipe where it attached to the tank with a cork - yea a cork! then fire a ££££load of carb cleaner down the other end of the tube from the air inlet end, round the side of the block. Leave it for a while then blow it through with an airline. It should p1ss out the banjo. To clean the actual banjo (with the bolt out) I wedged the banjo (it has a coolant pipe attached to it) outside the throttle body using a variety of tools...
http://i1100.photobucket.com/albums/g413/martinrpeachey/Photo0049.jpg
http://i1100.photobucket.com/albums/g413/martinrpeachey/Photo0048.jpg
then I used the "smart straw" unit from a WD40 can with an extended tube on the carb cleaner can to clean the inside of the banjo itself...
http://i1100.photobucket.com/albums/g413/martinrpeachey/Photo0051.jpg
Putting the banjo bit back together was an absolute B1TCH, took me an hour to get it tightened up properly then I had to re-assemble the rest of the engine. I put the new catch tank in for the hell of it and used jubilee clips on all the hoses.
So there you go. Let me bask in my glory, having a few beers to celebrate my victory. Hope this little escapade helps somebody else ;)

[AndysR]

Job well done and all for a good cause too! Sleep well tonight I'd have thought :)

[M-R-P]

Job well done and all for a good cause too! Sleep well tonight I'd have thought :)

Cheerz Andy, lots of beer, codine and diazipan then bed ;)

[AndysR]

Sounds like a typical night cap :)

[M-R-P]

Sounds like a typical night cap :)

Still gotta dodgy back so the drugs aren't for recreational purposes!

[AndysR]

Still gotta dodgy back so the drugs aren't for recreational purposes!

Oh have they sussed the cure for old age now then.....? :hidesbehi

[M-R-P]

Oh have they sussed the cure for old age now then.....? :hidesbehi

Oh har effin har! I'm 31! did my back in a week ago! cheeky whipper snapper! :hilarious

[AndysR]

Oh har effin har! I'm 31! did my back in a week ago! cheeky whipper snapper! :hilarious

Ah that OLD chestnut.... :hilarious

[Yorkshiresxi]

Banjo bolt...i am sure i havnt seen a banjo bolt on my 850...hmmmmm confused muchly

glad you got it sorted though...so hope mines going to be ok too!

[M-R-P]

Banjo bolt...i am sure i havnt seen a banjo bolt on my 850...hmmmmm confused muchly

glad you got it sorted though...so hope mines going to be ok too!

I think it's only ME7 manifolds that have it buddy.

[M-R-P]

Ok guys, if I can't get a refund on the manifold gasket, I will be selling It along with the old catch tank which is almost spotless (I will clean it out completely before posting) if anybody wants to make me an offer...?

[LeeT5]

well done for not taking the manifold off, but to be honest, you should of as a new manifold gasket is part of the full PCV system kit for £160. Its not that hard to get off either and makes for superb access to PCV catch can. While your their you get a chance to properly inspect Starter motor connections and makes sure everythings clean in that area before it goes back together. Good opportunity to properly clean Manifold and mating surface with emery cloth before refitting.

Ah well....

[M-R-P]

Agreed, Lee. It did cross my mind that the mani could possibly do with a clean but time was short and considering it's an ME7 plus the fact that I'd only just got rid of that bloody orange triangle, I wasn't keen on unplugging the TCM and upsetting something ;)
All in good time, I'm now turning my attentions to the suspension - new front shocks and polybush the wishbones and lower engine mount.

[LeeT5]

Agreed, Lee. It did cross my mind that the mani could possibly do with a clean but time was short and considering it's an ME7 plus the fact that I'd only just got rid of that bloody orange triangle, I wasn't keen on unplugging the TCM and upsetting something ;)
All in good time, I'm now turning my attentions to the suspension - new front shocks and polybush the wishbones and lower engine mount.

TCM (transmission control module) ???

Do you mean ETM?

With respect, if you are capable of doing the PCV then its only a sensor, no different from unplugging the MAF!!

I cleaned my ETM a few months ago (it was quite black). They are quite resilient. Gave mine a good degunge with carb cleaner both sides till it was gleaming like a mirror inside. Refitted and boy, what a difference!!

I did take phots but i dont have them now.

[M-R-P]

ETM, that's it. trying to do dinner, control a 3 year old an be clever at the same time! something had to slip;) I might have a go when the suspension is out of the way. It's nice to know it's not as hard as I thought. It's one long learning curve for me:) loving every minute.

What sort of difference are we looking at here?

[LeeT5]

What sort of difference are we looking at here?

Major! Better idle, Better response and alot smoother to drive.

[M-R-P]

hmmmmm...;)

[Dream3r]

Success!!!!!;);););):):):) no smoke from filler or dipstick. NO smoke, not a whisp, not a whif. Nowt! And it was all down to that banjo bolt! The rest of the system was completely clean! Gonna turn the laptop on in a bit and pad the thread out with how to info.

from the dead I know but I recently replaced my PCV and definitely have a bit of positive pressure, everything is 100% clean.

BUT someone had blanked that banjo off on my old pipe and rethreaded the inlet manifold so we had to blank it again with a nut/bolt etc. Could this be the source of my crankcase pressure? Seems to fit your description!

What a horrible job it will be to do again :( and I'll have to find a new banjo with the right thread.

[Kingsford G]

I see u removed more bits than u should lol Done mine last year too,cost over £100 all the bits

[miltski]

To further resurrect this thread, think mine needs doing? :cry:
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