Engine 850: B5234T/2.3/20v/T5: Inlet manifold removal and oil seperator/pcv hose replacement

[dmkelly]

Jod

Firstly BIG thanks for your reply and report. You are a genius. Secondly, as i have been chasing this fault for a long time and made the fault better, but not cured it, I think i might take the inlet manifold off and replace the elbow and look at the oil seperator as well. Also there are some other hoses that might not be faulty but are not in a good way.

That is one of the reasons i was asking about the hoses. Do you know if it is possible to buy generic hoses that i could then use as and where needed. or is it always better to use Volvo parts.

The problem i have is that i do not want to order them all and then not use half of them, but if i don't have it all thre ready it'll be off the road but my wife needs to use it daily.

Are all the vacuum hoses 4mm if so i'll buy a load and then get just the Volvo parts from volvo. There's no point in taking the thing apart 2 or 3 times.

BTW does the WD40 thing really work for long enough to see if its solved? i.e. will it cure it when running on the open road as my car is great a tickover and i have read somewhere that it only really shows signs of curing the fault when stationary.

[Jod T5]

Originally Posted by dmkelly

Jod

Firstly BIG thanks for your reply and report. You are a genius. Secondly, as i have been chasing this fault for a long time and made the fault better, but not cured it, I think i might take the inlet manifold off and replace the elbow and look at the oil seperator as well. Also there are some other hoses that might not be faulty but are not in a good way.

That is one of the reasons i was asking about the hoses. Do you know if it is possible to buy generic hoses that i could then use as and where needed. or is it always better to use Volvo parts.

The problem i have is that i do not want to order them all and then not use half of them, but if i don't have it all thre ready it'll be off the road but my wife needs to use it daily.

Are all the vacuum hoses 4mm if so i'll buy a load and then get just the Volvo parts from volvo. There's no point in taking the thing apart 2 or 3 times.

BTW does the WD40 thing really work for long enough to see if its solved? i.e. will it cure it when running on the open road as my car is great a tickover and i have read somewhere that it only really shows signs of curing the fault when stationary.

hi there, really the list of parts is not that long and price wise they are not that expensive, the main parts you will need is the separator and the separator to pcv thick hose, this comes with the pcv to inlet manifold pipe...the prblem is that it is likely that the thicker pipe has fractured within its protective sleeve however you cant tell until the pipe is removed by which time i can almost guarantee the pipe will be in bits..lol, you can try to repair it with hosepipe but it is not a fix i would be pleased with.....
i would by all on the list at the begining of this thread except the ones i marked as unused, i would also get assortment of jubilee clips as the volvo clips really stressed me out!!
the 4mm hoses are not part of the pcv replacement job but will work as adequate replacement for the vacuum hoses running too and from the boost control solonoid and from the inlet manifold to the blow off/re-circ valve.....keep them as short as you can and you should be fine....2 metres should last you forever...
the wd40 thing is only a short fix as it bungs the hole but soon disappears when it gets warm......you could also cover the elbow in soapy water and check for bubbles.....if you are having a juddering at WOT i would expect a boost leak and the manifold elbow is the best place to start......
cheers
jod

[dmkelly]

Jod

Thanks again. I have found the part numbers for the elbows on another website, so I will order the parts from Volvo as you suggest with the elbows and ill get the 4mm vacuum pipe for good measure and do it this weekend from your guide.

Wish me luck, it's years since i got my hands dirty but I'm really looking forward to it.

Cheers

DK

[Jod T5]

Originally Posted by dmkelly

Jod

Thanks again. I have found the part numbers for the elbows on another website, so I will order the parts from Volvo as you suggest with the elbows and ill get the 4mm vacuum pipe for good measure and do it this weekend from your guide.

Wish me luck, it's years since i got my hands dirty but I'm really looking forward to it.

Cheers

DK

of course the best of luck sir, dont forget, 12mm ratchet spanner, jubilee clips and cable ties.....
cheers
jod

[TheG]

I have too done this to my T-5R in accordance to the instructions posted by Jod that were top notch indeed, however, it appeared that I used sub-standard quality parts. I bought parts from FCP Groton because they said they were genuine volvo parts. They weren't. Not a single one.

Then the rubber elbow split and my car leaked oil like you wouldn't believe.

So off came the inlet manifold AGAIN and the gasket and elbow were replaced with proper volvo parts. All is well now.

Here are a couple of pics of what happened to the FCP part:





Just a word of warning folks. They still say they supply genuine volvo parts, but they told me in an email that they've changed suppliers and so don't any more.

[Jod T5]

Originally Posted by TheG

I have too done this to my T-5R in accordance to the instructions posted by Jod that were top notch indeed, however, it appeared that I used sub-standard quality parts. I bought parts from FCP Groton because they said they were genuine volvo parts. They weren't. Not a single one.

Then the rubber elbow split and my car leaked oil like you wouldn't believe.

So off came the inlet manifold AGAIN and the gasket and elbow were replaced with proper volvo parts. All is well now.


Just a word of warning folks. They still say they supply genuine volvo parts, but they told me in an email that they've changed suppliers and so don't any more.

im surprised at grotons tbh, whilst i have only ever used them for info and part numbers i did expect there parts to be of a good quality....
I only buy parts from either PFV or if they dont do it main dealer....
Thanks for pointing this out tom...
cheers
jod

[bigV]

Does anyone know where I can buy new fuel injector seals from?

I contacted my local volvo dealer but they only want to sell me complete injectors at 87.50 + vat EACH.



I seem to have lost two FLAT seals which sit in the top of the fuel rail thingy... NOT the plug type which sit in the manifold or the 'o' rings which fit onto the injectors....

They are flat and fit in the top metal part of the fuel injection bar thingy... I had two missing (without realising), started the car and fuel was ****ing everywhere!

[bigV]

any ideas?

[bigV]

TO anyone interested, or anyone who has the same problems as me: (removing injectors, losing seals and not being able to get new ones, oops!!)

The Bosch part numbers are as follows (for an 850 T5):

Injectors: 0 280 150 785
Spacer seals (sit in fuel rail): 1 280 113 703
'O' Rings, upper and lower: 1 280 210 752

http://apps.bosch.com.au/products/sa...rservparts.pdf

http://www.members.lycos.co.uk/maxbo...plications.pdf

[ncgt5r]

Hi folks! great set of instructions bought the bits from local volvo dealer will give it a go within the next couple of weeks so will keep you posted on the result. I nhave a dead spot on the engine at about 3000 revs so I am hoping new pipes will sort this out.