PCV -help needed

[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...

[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?

[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...

[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...

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...


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...

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.....?

[M-R-P]

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

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