Volvo PCV Breather System Replacement (850 Turbo) 

Shop the parts used in this video: Volvo PCV Breather System Kit (850 C70 S70 V70 Turbo): www.fcpeuro.com/products/volvo-pcv-breather-system-kit-850-c70-s70-v70-turbo-850t200?

For those wondering, the process is nearly identical for a '98 S70 T5. Only a couple differences, with the way the fuel rail is connected to the intake manifold, and the vacuum tree is slightly different. Take the fan off to make your life way easier. The toughest part of the repair is getting the 2 bolts on the bottom of the manifold (at 3:45 in the video), and also the left-most manifold bolt is pretty tough to get to. Ben makes the dipstick and manifold bolts look really easy but that's because he knows exactly where the bolts are. Finding them in the first place is the hardest part, but putting those bolts back in place when you're done should be a lot easier.

I did this a couple of years back with the help of this video. Just stumbled on this video again today and realized I never said thank you. So, THANK YOU! Would never had done it without this.

Dang man. You make it look like putting lego pieces together :):) For me it would be a one whole day job if I don't break anything. Job well done.

such an easy fix took me just under 3 hours including the new cam seal behind the distributor. you are my go to guys for all my Volvo needs. The fuel injector orings were fine,

Excellent video, commentary, step by step.Well done young man! I just did this on our 96' Volvo 850 turbo sedan with the help of your video. My fiancee's volvo she purchased new. 278,977 miles and still going strong. Greatly appreciate your video!

Thanks for the video! I was reluctant to tackle disassembly of such a complex system until I'd seen it done step by step. Smoking dipstick is now fixed.

I have 2 850's and come back to this video every time I do a pcv system. Thanks FCP!

If I ever have to do this job again, I will use Genuine Volvo parts, the aftermarket kit I purchased works, but doesn't line up so well and I spent a ton of time fiddling with it. I would also suggest replacing knock sensors at this time, since you have to take the intake manifold off to do that when they go. The car in this video has the original knock sensors still, a great DIY video from FCP would be teaching people how to install the Volvo upgraded knock sensor kit. You have to splice the wires and all of that, a solid DIY video would be super helpful to others on that topic.

The best manual on the Internet. Fast and useful. Thanks a lot! I had to remove intake manifold because of vacuum leak in it. Caused misfire, unstable idling, stalling, very bad mpg and low performance. Now it is working perfectly. Thanks again for the video.

Ben, Really appreciate your video! I spent almost one day to finish the PCV replacement, spark plug replacement, rotor and distributor replacement, all based on your videos yesterday. After I finished all these jobs, I started my car and expected the perfect running of the car. But unfortunately, the car cannot be started. The check engine light is on, the code is P0201, 202, 203, 204. After reviewing your video the last night, finally, I realized that no-starting may be caused by fuel system. This noon, after I checked the fuel injectors, I found that the fuel injectors are not wired ( I plugged the wires into them in, but in fact, they are not connected). So after plugging the wires into the fuel injector correctly, the car runs great! Thank you very much!

Thanks Ben and FCP for the video! I used this step by step procedure to fix the PCV system on my 1998 V70 T5. Instructions were great and easy to follow. charles

What a brilliant video. I've just got the bits to do this job (and full service) on my '97 non-turbo V70 2.5 20v (UK spec). I'm happy to take bits apart and this gives me absolute confidence to do it now! Thank you :D And keep up the excellent videos, all makes owning these lovely cars even easier.

Great tutorial, very informative. I had to do this on a NA version, but the procedure is close enough to follow with success. I used a FCPeuro kit and everything fit perfectly. thanks

Great video! Thanks a million Ben and FCP. I it really helped when I tackled my PCV system last summer. I have only one suggestion: Don't bother trying to unbolt the fuel lines from the dark recesses of the engine. Moving the lines and fuel rail out of the way while still connected caused a huge headache for me, and I ended up bending the lines a little out of shape. Just empty the pressure from the fuel lines by using the schrader valve at the end of the fuel rail, and then disconnect the fuel rail from the fuel lines. You also won't have to worry about the injector popping out as much since it won't spill as much fuel.

Thank you for sharing. I had a volvo and always loved them. My girlfriend is in the process of purchasing a XC90 -06 and she is scared because of the horrors of foreign car costs. I believe in Volvo and I told her as long as she talkes care of them they will last forever.

Before removing the fuelrail, you can always release the fuel pressure by pressing the little valve next to your throttlebody on the fuelrail.

I successfully completed this repair last week, thanks to this video. Although, i cut up my hands pretty bad trying to get the bolts off the bottom of the manifold. When I put them back on, I used a couple ratchet extensions and approached them from the bottom of the car, as opposed to trying to reach under the manifold again. Running great now!

Hey Ben, Thanks so much for this video as well as all the others. I just did this job this weekend on our '98 S70 T5 and the video was a HUGE help. Keep up the great work!!!

Awesome video. Thank you very much Ben! I've been getting all my parts from FCP as I have restored three 98 Volvo s70's so far. Looking for a T5 with spoiler. The 98 s70 in my opinion is the last great car Volvo has built! All mechanical linkage. In regards to video I didn't mess with the throttle linkage or the idle control valve. It is safer to get it out of the way but just be careful where you place the manifold when removing. I also jacked up the front and removed the oil bracket from under car. The job took five hours, but that was having lunch and being extremely methodical. All and all piece of cake.

Thx Ben! Your video helped a lot yesterday when I did this job on my Volvo V70 1997 170 bhp Petrol. I removed the thermostat hose to give me more room to reach the lower left bolt on the intake manifold, otherwise all went really well, hade to spray some penetration oil on top of each injector to be able to remove the injector block from the manifold.

Thank you very much for the video! I have a V70-98 series that needed the system replaced, saved me some money doing this myself with the help of a friend and this video.

Excellent video Ben, it takes the mystery out of replacing the PCV unit.

Awesome job on the video Ben! I would have done the job myself if this video was out a month earlier! Always next time. keep up the great work! This is a very valuable asset and makes me feel great about getting my parts from FCP

Thank you for this awesome guide! Will be doing this sometime this week and have been a bit nervous about it... until now. Really, great guide which will help many doing this themself!

You did this in less than half am hour like a puzzle. Very informative too bad I am not a mechanic but you make me systematically want to tackle this

Best automotive instructional video I have ever seen. Thanks.

I don't have any volvo but enjoy to watch , you described it very clear. Thanks bro

that was absolutely amazing job well done I have to take a nap now you may be tired keep up the good work

Hi Ben, car runs perfect again, took down the injector cables again and checked them with a multi meter, they were all ok, then I cleaned the contacts on each injector a bit, then lastly sprayed some contact spray on the cable side but not on the injector side, also tapped on each injector with a large screw driver - one time firmly on each one, tapped with the plastic handle side, then the car started perfectly and now runs better than ever! Thx for you gr8 video, helped me a lot especially with the fuel line trick, just put all to the left, I would say the job is quite time consuming for a first timer and I must say that the hardest part was to put back the two screws, one for the intake manifold underneath and the other one for the oil dipstick, hard to do when you have big hands like me, almost 6ft10 and 245 pounds guy...... My neighbour had to help me since I did not manage and almost got mad trying. I also could not putt the injectors out in the first place, they did not want to come out, I sprayed some penetration oil and then they came out easily. But again the video is great but you must be prepared to spend like 8 hours for a first timer, this is when you really take time to clean all and mark up each screw, bolt and connectors, I used different type of coloured tape to help me keep track.

wow this job is a backbreaker if you've never done it. I couldn't have done it without FCP, Thank you!

This young man is some mechanic wow he's awesome!

Thanks for this. On the XC70, it was a difficult job, but I got through it successfully thanks to this video. (I wouldn't have tried it otherwise.) Your PCV kit was fantastic. Only suggestion I have would be to include standard screw-in hose clamps instead of the one-time use clamps. I found it easier to get the manifold back on using standard clamps, and without the right tool, the pinch clamps seem a bit risky. Keep up the great kits and videos!

Awesome video thanks - can’t believe you do it so quick - not looking forward to it but this helps big time!

Very timely, I ordered this kit yesterday! Thanks!

Excellent work, thanks for sharing.

thanks man i did it.......took me a couple days as it was my first time......video is amazing thanks again

We didn't leave anything out of the video, but of course some years will vary slightly. Glad you ended up getting everything replaced ok.

after watching this vid..didnt even think twice,i subd immediately!!! great video

I did this job last Summer on my 1994 850 Turbo and, after taking everything apart, I found that the previous owner had the PCV system replaced seemingly right before I bought the car. All the PCV stuff looked brand new(Genuine Volvo parts) so I decided to just reuse everything and return all the parts that I bought. Before I did the PCV job, there had been oil accumulating on the top of the cylinder head by the spark plugs, but I thought it was the oil cap o-ring. Fast forward to today and I noticed that there was even more oil on the top of the cylinder head. It turns out that the oil was seeping out from around the upper PCV hose port. I loosened the clamp and noticed a large crack in the end of the hose. So, now I have to do the whole job over again just to replace that top hose. I should have just replaced everything the last time. Grr.

Great job! Thanks for this video!

Well explained and made video, thank you !

Ben, thanks for the great video. It is very helpful. You make it look so easy! Wade

Dude knows his work.

excellent and very systematic!

what an excellent instructional video!!! thanks brother

Superb video Ben. Thanks.

Hey Ben what a great detailed video, I will be replacing my split breather tube soon. I found the problem myself after spending over £250-00 on so called experts to cure a rough idle and excessive fuel consumption. Tom

This is great- do you have a video showing a P2 xc70 PCV replacement? This video definitely makes me feel a bit more knowledgable and confident about performing this job on my own car soon! Thanks!

Very good job, thanks.

Wow. Fantastic video!

Having done this job back in 2008 on my 95 850T, I wish you had this video up then, because from my own memory, I don't think I did my PCV valve job correctly. I was using the Brickboard.com's instructions. And I have to concur with the poster that added that this job is a PITA. It defines PITA nicely. And my dipstick tube has condensate in it yet again.

Thank you, very informative!

thank you! managed to get it done in a day!

Yup you should be able to follow this just fine.

fantastic tutorial. thx so much.

Great video mate, Liked + subbed

Hi FCP, I'm currently having trouble figuring out how to pass my emissions. First thanks for all your help w/ your videos. They're great. My NO (smog) test was the only portion of the video I failed. I have a 98 S70 Volvo. I understand there's no EGR valve. Didn't know what else I could look at to help. I checked for vacuum leaks at most places I could see w/ carb cleaner, but didn't get any change in engine idle. I bought some seafoam to insert in a vacuum line and the gas can to help. Any suggestions? Thanks, Kyle

Excellent video - Thank You I am about to change the PCV system on my 1999 C70. How many man hours did it take u start to finish ?

This is great! I am doing this on my 2001 xc70...is the procedure more or less the same, or is there additional steps to be aware of? Thanks!

We've added it to our list!

Love this video! Any advice for the same job on a 1995 960? I can't seem to get the intake manifold out. Does the EGR have to be disconnected somehow to remove the manifold, and if so, how do you get to it (considering it's under the manifold)?

Great video, Ben. Thanks you! Wow, do all these apply to a 2003 S40 as well?

I need to do exactly this job now on my V70 1997 170 Bhp non turbo, Some animal bit off the vacuum rubber hose going into the intake manifold on the left side of the manifold, it's supposed to be going further to the brake cylinder so I will have to replace this one at the same time.

WOW I’m impressed

Is it the same procedure for a 2002 Volvo C70 Coupe Automatic Trans? Great video, and great detail !.

You'll want to check the crankcase vacuum at the oil dipstick to see where if you have negative or positive pressures after the replacement.

The PCV system is usually a breather tube and a PCV valve. The tube connects the crankcase to a clean source of fresh air that flows into the engine after passing through some sort of screen to stop any flame fronts. Inside the engine air circulates clearing away combustion gases that exit through another screen to trap oil droplets before being drawn out through the PCV valve, and into the intake manifold. It’s essentially a way for gases to escape in a controlled manner from the crankcase.

Practical information! Thank you. I replaced the flame trap along with the PCV box. Do I need to check anything else?

Great Job!!!!

Great video, thanks.

The EGR valve doesn't have to be removed however you'll have to remove the line to the valve. As far as testing the valve its best to remove it and apply vacuum to the diaphragm. At this time you can inspect for carbon blockage and clean as necessary. Hope that helps!

What are 2 socket wrenches you used. I like that gyro and breaker bar sized one

Hi FCP Euro, was thinking about replacing this kit on a 1998 Volvo s90. do you have a video on replacement for that car?? thanks

Can't believe how similar this is to my moms '06 s60 I'm stuck working on right now lol

Very excellent video, as always. Thanks. When/how often should this maintenance be done?

Thank you!

Great video! A poster on one of the forums made mention of a banjo bolt somewhere, though from your video I only see you interacting with basic hoses and clamps. Is there in fact a banjo bolt somwhere in the system? Also, if i want to remove the fuel rail instead of bending it back, is it connected to the intake fuel line with a basic threaded connector and crush washer?

Gracias!!! Me va a servir mucho!!

hi i've been checking my pcv at the dipstick after i saw this..is it normal at idle that air is pushing out?but when i rev it the air is sucking in...volvo s40 2.0t 2001 user...tq

Nice video. Do you also have any video for 2001 volvo s80 t6 one or similar. thanks

Hi Ben, did last work yesterday but when starting the car did not run normal, sounded not to run on all five cylinders, all injectors and electrical wires were put back as they should, any idea, I took it slow and I have not forgotten and hoses or vacuum. Regards and thx.

It was so painful watching him bend the hell out of that fuel rail. You can easily remove it by taking off that one fitting and the small clamp. Lol very helpful video to say the least.

my car is a volvo 98 v70 5t. didnt see nothing change. well i need to change that part too. omg i need a man help. theres things i can do , but theres other part little hard to remove .i did like the way you it. easy and clean. nice job !!

Great vid! I've been working on my dads 96 Volvo 960 wagon since the car failed emissions due to code P0440... Reading through some Volvo forums and some vids I came to a conclusion that the 960 might need a new PCV system that I will be ordering from your website. Also, I've noticed whitish smoke coming out of the oil dipstick while idling, I wonder if that's because of the PCV being clogged or is it the EGR valve? Thanks for your help

I've added it to our list, keep an eye out.

nice evo in the back

Good job dude.

Thank you.

The EGR Valve does not have to be removed as it bolts closer to the intake manifold not the exhaust manifold on this vehicle. You may have to loosen the EGR piping however. Hope that helps.

It would be nice to know what tools you used so we can own the correct tools. I struggled removing the two 12mm bolts under manifold from below. You made it look easy doing it from above. What were the tools? I also struggled with the first manifold bolt on the passenger side (US) .

Hi The kit you have advertised, will it fit a Volvo 850 CD 1996? thanks.

I purchased kit 850T100 , is installing generally the same as 850T200? What should I look out for?

Hi would having a snapped pipe for the pvc cause the car to struggle starting? I’ve got a Volvo 850 petrol that takes a while of cranking and throttle presses to get going, it struggles to hold the idle to begin with once it’s going but gets better once it’s warm. Could there be any other causes for it to struggle like this? Appreciate any help!

The first thing I would check would be the accessories I.E. A/C compressor ( which is right near the filter; see if the noise changes in pitch with the A/C on and off ) Alternator, PS pump, and Tensioner pulley. A whine is usually accessory bearing related. Hope that helps.

What silicone do you use to get the injectors into the intake manifold? I've tried without putting silicone on the o rings but the injectors doesnt want to go all the way down

great job

A quart a day is a lot of oil to be losing from the dipstick. But it's a small fairly easy seal to replace. It might be worth trying then seeing where you stand.

I did the PCV system replacement. Had some issue especially with the throttle and vacuum hoses. I have a 1995 Volvo 850 Turbo and I want a GOOD vacuum schematic to to check my vacuum hoses. I need to know what this vacuum is called beause I dont't see a hose that attaches to this hard plastic tube that goes to the front of EGR and under the side of the radiator fan (attached to side of fan). A round rubber holder holds the vacuum there, There is a nipple on the other side and it does suck air when running. Does that hard plastic hose connect on that nipple? I may have lost the rubber connector to that nipple and hard plastic vacuum tube. What size rubber connector is that to connect them two together. I have looked online for good vacuum hoses pictures for my car. Thank you

You could have a clogged oil drain passage to the block or a sliced/loose hose. Or it's possible you could have installed a faulty vacuum valve that could be faulty. Hope that helps.