Well, I got through the hell of getting the intake off my $400 95 850 turbo wagon. I hope I remember where everything goes! Since mines a turbo, it only has the oil trap box right? Does this really need replaced or can I shoot carb cleaner in it? I really need to get this put back together, and I don't want to wait till Tuesday to go get one. It doesn't really seem like this box does much, and mine isn't terribly dirty, it's not like it's supposed to be filled with anything right? It's just an empty plastic box? I don't even think that was the culprit, the EGR hole in the intake was completely gunked shut, I would think this would be more to blame for the smoke. I read here that there is supposed to be some kind of O ring for the trap box, but I don't see where it would go, anyone know about this, or it that only on non turbos? One problem I do have in putting everything back together is one of the thick O rings on one of the injectors apparently fell off, and I can't find the thing. Can I actually buy them other than through Volvo? Also, I found 3 very odd looking things, like O rings with the outer edge cut out, do these go between the rail and the injector? I hope not because that means I am missing 2 of them also.

 

You should be able to get the injector o-rings at a auto parts store.

Are the seals blue or black?
The early cars had seals between the injectors and the intake.
Then yes you would need them. Look behind the starter.(It likes to hide parts)

 

Hi jmana,

With the age of the car, I would replace all PCV components, rather than cleaning them (to do this, you need to remove the intake manifold so be sure to buy the gasket as well). Here's a vendor many of use here use:

http://www.fcpgroton.com/volvo850oiltrap.htm(NA PCV kit)
http://www.fcpgroton.com/volvo850oiltrapturbo.htm(Turbo PCV kit)
http://www.fcpgroton.com/volvoeng850engine.htm(Intake manifold gasket)
http://www.fcpgroton.com/volvo850fuelsystem.htm(Injector seals, O-rings, etc...)
http://www.fcpgroton.com/volvo.htm#850(Top page)

Note, that there seem to be some differences for engines with different serial numbers, as well as model year. Also, someone noted that the illustrations for turbo & non-turbo are backwards on FCP Groton's web, so call them to make sure you're getting the right kit.

The EGR design on the 850 was poor; at sharp turn the oil gets to the EGR port/throttle body areaand clog them up. So, clean them good.

I hope this helps.


JPN

 

If I could wait for parts to arrive, then put it back together I would, but tomorrow is the last day I have off for a really long time, so I will have to just clean everything and hope for the best. I really don't uderstand why the oil trap would even be recommended to be replaced unless it's leaking, because it seems like it would take a huge amount of grease buildup to affect it's use. I am replacing any dried up rubber, the one vac line had a rubber connector that was completely gone. As for the intake gasket, mine looks good.

 

^The buildup accumulates quickly, and eventually, the pressure is going to blow out your seals and cause even more headache. One more thing, the hoses/lines get brittle after time, so if you can replace the hoses, it'd be the best option.

 

I got everything put back together today, and started it up, and still smoke flying out the dipstick. So I thought maybe it just needed driven a little, so I left the dipstick out a little so as to not blow any seals and took it for a short 1/2 mile drive and on the way back it went to shut off on me, I kept the pedal depressed and kept it going but just barely and there was a bunch of black smoke coming out the exhaust. I died when I got in the driveway and for some reason it blew a bunch of oil out the dipstick and all over the engine. So now what's going on? Anyone have any ideas?

 

Get the PCV replaced. Oil coming out where it's not is a classic PCV symptom.

 

Something still may be colgged. One of the hard plastic lines for the PCV.
Did you make sure all were clean and clear?

 

Is it possible that the carb cleaner could have screwed something up? The car starts, but it's really rough, and if I hold the pedal down and steady the rpms stay low but then will shoot up to normal. There's still lots of black smoke. The only other thing that I can think of is I accidentally broke the little plastic nipple that's on the air intake hose, but I don't think that could be causing the rough running, because when it didn't start acting up till I turned around to come home. And all the lines do seem clear, I was able to blow though them, I may have to replace them after all though.

 

Maybe the Mass flow sensor got conatminated and went bad.
Usually when the system is clogged it sucks oil into the system.
Also how dirty is the throttle body?

 

What a dummy I am. Apparently I had loosened the hose clamp for the big hose that goes back towards the turbo, and while I was driving it the hose blew completely off. Put it back on, and it runs great, no black smoke, and just a hint of white smoke out the dipstick, it's really not visible unless you really look for it. Now I just have to get the AC working!

 

Congrats on finding the problem.

 

.


JPN

 

Maybe if I invite you for some great Argentine beef you will come over and fix the same problem in my 850

Congrats

 

I guess the prolem isn't fixed after all. I went to start it up after it sat for a while, and it started smoking as bad as it was before. Pulled the dipstick out a little so it wouldn't smoke out the tailpipe, but again it pushed some oil out, which may be due to the level being a little too full. I don't understand why it's still smoking, I pulled all he lines and was able to blow through them. Is it possible that a bad egr valve would cause this? That's the only thing that I wasn't sure how to test.

 

EGR valve usually won't cause the issue.
You could blow through the vent box good?

 

Axel, I'm on my way to Argentina.

Jmana,

There is still crankcase pressure building up. The oil is smoking because some engine parts get hot enough to cause spraying (some oil is sprayed onto parts during operation) oil to smoke. Check for oil level and drain some if overfilled. Otherwise, a new PCV kit may be necessary.


JPN

 

I could blow through the vent box just fine. It seems like the box is pretty much just an empty plastic box with some baffles inside, right? Or is is supposed to have some kind of filter media in it? The only thing that I know isn't right, is the nipple being broke off the intake hose, would that line not being connected cause the pcv system to build pressure? I would love some advice on how to replace that nipple. What exactly causes the blowby to do what it is supposed to do, in other words what keeps the pressure from building up? I am not figuring out the purpose of all the hoses and vacuum lines, does anyone have a diagram of how the gasses are supposed to flow though the system?

 

I think I've finally got this thing cleaned out and working. The piece that fit's into the turbo hose which has the 2 connections for the large and small vac lines which run to the oil trap was completely clogged up. This piece also has a wiring connector on it, but I have no idea what is does. The lines themselves were fine, but this piece only has about a 1/4 inch hole in the bottom, and it was completely crudded over, which I could only see by taking it out. Also the nipple for the small vac line was completely filled with crap. Now it doesn't blow smoke out the dipstick. It doesn't seem like there is a lot of vacuum, I tried the paper over the oil fill, and it didn't exactly get sucked in, but at least it's not smoking anymore. There was a small amount of smoke out the exhaust, but it's really intermittent and seems like it's just residual oil burning off. I kind of firgured this whole thing out by accident, I went to pull out the large vac hose and the fitting came with it. I don't see that this part is even listed on the parts page for the PCV system, but it would be nice to be able to buy it, because the rubber part which fits into the tube was very deteriorated. I would say if you have a turbo with a smokey engine, that this fitting should be the first place to look. At this point I wish I wouldn't have wasted my time removing the intake, because all those parts were clear.

 

I am trying to get rid of the blue smoke and PCV problem in my car without disassembling too much.

Could you post a picture of the parts/connections that were gunked up?

If I want to clean the EGR port, do I have to separate the intake manifold and lose theintake manifold gasket?

Thanks in advance.
Axel