I did the PCV replacement back in July 4th. When undo all 7 screws of the intake manifold, one of the 4 lower screw had difficulty to come out during the unscrew process. All other 6 screws came out so easy and smooth except this one. I encountered resistance while unscrewing. I worked it out slowly and finally it came out. I could see the screw threads had aluminium on it. Now, the oil separator and all hoses are replaced. I worry about this particular screw may not be able to be tightened. I am going to use all new 7 intake screws to install the manifold. Would this problem screw hole in the engine block cause any leak after installation ? This screw hole is the 3rd hole from thermostat housing. This was my very first PCV job. So I think that the screw hole may already bad before I unscrewed the intake manifold screw.

Also, I was so surprised that the lower hole between oil separator and engine block itself was so clean, no built up after 16 years/250k miles. I saw other members' pictures and most of them were clogged up with gunk. The throttle body hole into EGR valve was plugged up with gunk !!

Any comment on the stripped intake manifold screw hole is appreciated. I have not installed the manifold yet because I am waiting for the Volvo part (metal nipple between EGR valve and EGR tube). I could not reuse the old one because it stuck inside the old EGR valve so bad. I just broke the nipple when trying to unscrew it !! Same thing to the EGR temperature sensor. These 2 parts were there since 1995.

Ching-Ho Cheng
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1995 855 NA, Bilstein Strut & Shocks, Volvo Protective Grill, K&N Filter, E-Code Lens, ClearCorner Light, Alpine CD-Changer, AutoDim RearView Mirror, 6000K HID