My '87 Volvo 240 is in need of several repairs. The transmission needs to be rebuilt and the water pump needs to be replaced and the oil is leaking, among other things.

The separator box had never been replaced as far as I knew and my car was failing the "glove test", so, I decided to replace all the PCV system parts before proceeding with the other repairs.

Well, my mechanic did the job in about a full day and the car still fails the "glove test". I am going to have to pay him for the labor even though the car still fails.

Unlike the guys at IPD, my mechanic did not think that the separator box return hose needed to be replaced. I had him replace it. It was quite a pain to remove it as it broke into a bunch of pieces, many of which had to be scraped off the the wall of the hole in the engine block, with a lowered oil pan. After he put the oil pan back on, he pushed the new separator hose through the hole in the engine block. It did not go in easily. I am wondering if it got kinked. I have read another thread regarding the same issue and the failed "glove test" after a PCV system replacement. It leads to three suggestions (the thread was inconclusive though):

1. the separator hose is kinked and the way to test it is to try to blow air through it with another hose from the top (after removing the oil separator box and oil filler cap).

2. the Vacuum connection on the top of the Intake Manifold is clogged and needs to be cleaned with a stiff wire or paper clip.

3. do a compression test (I'm not sure what this would do to change things).

I am a little overwhelmed. Thoughts? Any suggestions on what I should do? What should I tell the mechanic to do before paying him? Should I cut my losses and retire this car?

Thank you,
G

Gaucho,

I've replaced this hose on all of my cars, 4 to be precise.

It is my opinion, that this hose can not correctly be replaced with the oil pan on, it has to be off as the rubber hose is held in place with a metal bracket/clamp to keep it aligned correctly.

Its anyone's guess as to the state of that hose now that it is in there. You may have to have it replaced yet again as it may be damaged at this point.

Just my 2 cents for what it is worth.

Regards,

Matt
--
1989 - 245, 1990 - 245, 1991 - 245, and 1993 - 245

Running a pipe cleaner through the manifold vacuum orifice, and then through the small hose to the flame trap housing would be step 1. Are you sure your guy didn't already do this?

Replacing that dip tube is a horror story, for sure. I can't imagine a kink, but also don't understand why it didn't fit the bore. Volvo's part suppliers aren't in business to keep 30-year-old cars like new, perhaps, or maybe the tech didn't want to risk a broken wire from a wire brush down the bore. Then there's that clamp you need to have the oil pan off to reach! Yikes.

In the end I think your idea to blow test it with separator removed is just what I would do.

Sadly, depending on the car's oil maintenance history, you might just be at the point where the rings are not containing the blowby they once did, and even when the PCV contraption is at maximum performance, the gases those rings pass are too much for it. I've read of many stop-gap solutions from increasing the manifold orifice bore to ditching the PCV for a catch can. Main thing you want to do is be certain where your car is on this scale.


--
Art Benstein near Baltimore

http://cleanflametrap.com/pcv_test.html

any pcv service means cleaning the vacuum port on the intake. SHOULD already be clean.

the 85-88 b230s have softer blocks than the later ones. it's worse in turbos because of the extra pressure from the boost. i suspect the bores are worn too much, causing blowby. i would get a compression leakdown test down and see how much leakage there is past the rings. a compression test doesn't always expose blowby. good luck, chuck.

Been down that road myself. If you haven’t done the following here are some simple suggestions you can do yourself. I had a very difficult time finding a clog in the PCV on my 90 240.
1. As you mentioned, clean out the “nipple” on the intake manifold.
2. Have you replaced both vacuum hoses that run off the flame trap?
3. Is the flame trap screen still there? Consider throwing it away.

#2 was the winner in my case. The vacuum line from the flame trap to the intake manifold was clogged. Very satisfying when I finally found the problem as it also eventually cured a minor rear main seal leak...:)
--
Will I buy another Volvo??? We'll see....