I searched this question but I couldn't find my answer.

My 91 240 has just 154,xxx miles. I need to replace my oil separator because I think it, or something related to it, is leaking oil. I want to know the quickest/easiest way to to it. I already bought all of the separator parts, including the O ring and I've already replaced all of the parts that are above it all the way to the manifold. I have the separator, O ring and one hose left to replace. I have the ability to get the car fairly high off the ground but I'll still have to work on my back when I'm working underneath the car. I bought the intake manifold gasket and the injector O rings and other related injector parts but if its easier to get to from the bottom, I'd rather go that route.

Any suggestions or camments will be greatly appreciated.

Thanks
Kyle

Thanks guys for all of the really great responses to my question. I appreciate all of them. I'm probably going to take the manifold off to gain access to it. I had forgotten that the heater hoses are easily accessible when the intake manifold is off. That’s also something I should get out of the way.

Note, I've been coming to the Brickboard since the morning in 2001 when my 85 240 wagon wouldn't start. It acted like it wanted to start but wouldn't. I tried all sorts of things to get it to start... MAF, PCM, coil, cap and rotor, timing belt.... I even installing a fuel gage in the pressure line near the fuel rail to verify fuel pressure. Several people on the BB advised me to replace the rotting engine wire harness so I finally gave in and replaced it. After replacing it, the car started right up. I've been hooked on this site ever since. I was an ASE Master Technician specializing in Ford fuel injection systems fro 1984 to 1998. I now work on medical equipment. I've always performed all of my own repairs. I'm 51 y/o and no one has ever worked on my cars except to do alignments and put refrigerant in the ac. I've even performed those services to my cars on occasion. I'm in my third 240 wagon now (79, 85 and 91) I love the Brickboard. Thanks again guys.

Kyle245

removing the manifold is not that hard to do. While it is off I would replace that heater hose that has the clamp below the manifold.

Hi,

I agree all the way with mtd240 as I have also done it both ways and if it is your first time doing the job or if you haven't replaced the intake manifold gasket in a while, I would remove the manifold.

Either way, be careful in the area of the heater hoses.

Make sure you have the wiring harness detached from the top of the breather box before you try to remove it, you might and you might not have a box that has the wiring harness clamp attached to the top.

Good luck,

Travis

I have done it two ways:

1. Removing the manifold.
Cons: Need to replace intake manifold gasket. Alot more time (probably ~1.5 hours).
Pros: Very, very easy to access the box and be sure you mount the new one correctly.

2. Don't remove the manifold. Remove accordion tube, IAC bracket, and use long extensions with a universal joint (12 mm socket if I remember correctly)
Cons: Alot of manuevering to get the box out. Difficult to align the new one correctly.
Pros: Time saved (takes ~30-35 minutes this way, 20 if you have done it before), money saved (intake manifold gasket).

I don't know if removing the starter would help the situation - everything can be done from above.

I only did method #1 because I was already replacing a leaky intake manifold gasket and fuel injector seals. #2 isn't bad at all.

Note* Make sure you use an OEM Oil Separator - I had an aftermarket (FCP "Ramac" brand) fail at the "glued" seam after a few hundred miles. The OEM unit doesn't even really have a "seam" - from what I have heard/researched, they basically "plastic weld" it together - making one solid piece of plastic. If you don't have an OEM replacement, it would probably be better to clean out the old OEM and put it back in.

Mike

Mike is right.

Don't screw around with anything but a Volvo separator box. I had two aftermarket jobs fail at the "welded" seams.

And you can get the box out without removing the manifold. You have to kind of squish the wiring harness tight up against the manifold to give yourself enough room to pull the box up and then out.

Marty Wolfson

Proud member of the 300K club.

Also, I am sure you have read this in several places, but DO NOT give in to the temptation to pull the oil separator hose out of the block!! Oil pan removal will be necessary at that point...

If you are going to change the oil right after the job, you could scrape the inside of the hose a bit to unclog it, I suppose.

Unfortunately, I believe you will need to remove the manifold. I'm pretty sure that the separator needs to be lifted upward before it can be removed. I removed one a few weeks ago with the manifold off, and remembered thinking that it would be impossible to get off without removing the manifold for future reference. I've never tried it with the manifold on though, so I could be wrong.
--
1966 122s, 1968 142s, 1969 144s, 1979 245dl, 1989 244gl

It can be done without removing the manifold. But its a PIA if you have a model with an EGR. No EGR and its not that bad even with Manifold in place. Remove intake bellows and IAC and brackets. Use a long extension to hit the separator bolts from above(down thru Manifold openings).