POORLY DESIGNED Volvo S60 PCV System *COMPLETELY Clogged With CARBON*
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- Опубликовано: 30 сен 2019
- There is a lot that needs fixed on the $450 2001 Volvo S60 2.4t. The root of the cam seal issue is a completely clogged PCV system which builds crankcase pressure until something else gives out. On these Volvos the something else is the cam seals, so before we replace those we're going to fix the PCV system. That involves removing the intake, removing the PCV canister, then removing the carbon build up from the engine itself.
Thank you To FCPEuro for sponsoring this video and build!
Replace Front Struts with OEM Hardware
Volvo Strut Kit 6 Piece: www.fcpeuro.com/products/volv...
Volvo Strut Hardware Kit: www.fcpeuro.com/products/volv...
Replace Timing Belt And Cam Seals
Volvo Timing Belt and Water Pump Kit: www.fcpeuro.com/products/volv...
Volvo Camshaft Locking Tool: www.fcpeuro.com/products/volv...
Replace PCV
Volvo PCV Breather System Kit: www.fcpeuro.com/products/volv...
Volvo Fuel Injector O Ring Set x5: www.fcpeuro.com/products/volv...
Volvo Throttle Body Mounting Gasket: www.fcpeuro.com/products/volv...
Oetiker Hose Clamp Pliers: www.fcpeuro.com/products/ear-...
Because The Comments Told Me To
Volvo Oil Filler Cap Gasket: www.fcpeuro.com/products/volv...
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#Volvo #CheapVolvo #CarFlip 
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![How to Replace the PCV Diaphragm on a Volvo T5 [Money Saving Way]](/img/1.gif)
I remember the good old days when the PCV valve was right on top of the engine, right through the valve cover. Took almost 10 seconds to replace.
The Volvos really isn't just a PCV but more like a recirculation filter box. The old ones is just a hose.
Honda V6 is still like that.
Took me 2 minutes on my 011 Kia Optima 2.0T
Most NA cars still ARE like that. Welcome to turbo land! They got to move MORE fresh air, when under boost with these fancy ventilation systems
Most common cause of oil leaks and trouble with Volvo's is clogged PCV systems, Dealer or good (And I stress GOOD) Indie workshops will change the box and flame traps out regularly.
DIY owners not so much because on all Volvo's from the mid 80's 700 series they are buried under the intake and hard to get to.
people also shortcut and dont replace the O rings between the block and box and this creates leaks too which can be hard to diagnose.
Then they suffer Cam seals popping or worse Crank seals even though this is extreme neglect as the oil caps will weep for ages well before it pops a seal.
I do the workshop glove over the oil filler test checking for high + crankcase pressure but in all honestly theres so many variables from bad oil quality to late oil and filter changes that you are just best off replacing the lot so you have a known quantity and this applies to both the older Red block engines and the later modular white block engines in 4, 5 and 6 cylinder.
As a rule I just order a few kits from FCP Euro so i have them on hand and as they ship fast and reasonable rates even to Australia.
tony66au :😉🍻
If there was a way to delete or substitute the PCV system with a better work around I bet they'd sell like hotcakes.
@@thomas316 You could run a catch can inline with the PCV, but it's not something that people totally replace.
Redblock PCVs are easy. I haven't done one on a turbo, but on the NA it was stupid easy compared to the white blocks. I didn't even need to pull the intake manifold.
@@radnybolt5327 I wasn't sure if they were different, I know some guys with turbos say to remove the intake. On my cousin's '91 240 it wasn't necessary. I used to have an '88 740 turbo, currently have a '93 NA 940. I love red blocks, but white blocks are awesome too... I've certainly had more of them! My current daily is a manual swapped 2000 V70R.
This is just so damn satisfying. I love seeing older cars getting the attention they need. If I had a shop space, or a garage, there's no doubt I would be doing this.
I agree with you 100%.
its slightly depressing though when you think that all this work adds up to a no time job on other cars. I am in the process of pulling my car apart for this repair as we speak and I am learning the fun of removing that left most bolt near the thermostat 7:01. what a place to put a bolt...
The PCV on the turbo is quite a job at some points - banjo bolt, left intake bolts. Also take an appointment for a lower back massage when finished. A wobble 3/8" drive adapter is quite a must and I would have removed the rad fan first. It's a perfect time to replace the thermostat housing too and test the evap canister purge valve
I love your videos. So nice to watch.
Yes, the pcv system on the turbo engines are hard to work on. On the 2.4 non turbos they are easier within reach and cost less time to replace them.
These 5 cilinder Volvo engines are really bullit proof if you maintain them right. Proof, look at the valves on this particular engine.
Here in Holland I have seen some of these engines reach more than 800.000 km's without serious issues. Totally impossible with newer direct injection and turbo engines. VW's modern engines I have seen them break after only 40.000 km's. Audi TFSI engines need a complete overhaul after 100.000 km's which costs thousands of dollars.
Volvo makes really strong cars and compared to modern cars are still relatively easy to work on.
Keep on going making these great videos!
anfahrt: 😉🍻
2:46 that teamwork tho. JR and Gabe work so good together. I enjoy watching them work together. You guys need trademark boost bazooka.
This was a best of episode, for those times when reruns are necessary. Very instructive video.
Your doing awesome jr! Seeing channels blow up and become successful is awesome. I know the work you put in for it. You deserve it.
nice to see you are so thorough, i repair volvos on the daily and know this job well, a few tips, the strut bar doesnt need to come off(though understand why you did because of the cams), the fuel rail also does not have to come off, as for the bastard bolt its alot easier to get if you take off the thermostat housing, a tip with those volvo clips is to get a flathead that just fits,twist, then pop the tab, quick and easy, really enjoying your videos keep it up
Help........there is a pressed in pop off cap of some kind, mirrored on the valve cover, just past the oil cap in the same spot. Closer to the firewall i guess you could say. Well mine blew off and im trying to figure out what its called, or how do i replace it? Or.......any advice would help. 01 v70 xc cross country thank you
@@chrismckamey3082 never seen one of them pop out before, im sure the right sized frost plug would fit it (I have the same car)
Why’s it called a “bastard” bolt? *Before I could get the bolt off, the brittle plastic line attached to it broke off 😡
@@homesold because its a bastard to get at
Yup that banjo bolt is the devils work haha. It took me the better part of 4 hours to get that thing back in place after doing the PCV on my C70.
Logan Abner: Oh. So. True. 😉🍻
This dude needs a sponsorship for every product he uses. JR calls everything by brand-name and exact name. Especially CRC!
As a JR myself I have to say CRC products are the beez kneez lol but that is funny tho!
love this ! have a v70 myself .... keep them coming . greetings from the Netherlands
Love your vids man. Keep on growing!
One man's poorly designed PCV system is another man's mortgage payments.
Clarence Calkins: 😂🤣 Gold!!!
even though I don't own most of your cars its super awesome that you hit all challenges with such gusto.The details in your break down is getting better. Before you kinda just breezed through it so quick and so many people watch you for the details like Chris fix.
wisely bob: We are glad you are enjoying it!!😉🍻
This is perhaps the biggest reason why I'm really happy with my normally-aspirated 270K 2001 S60; The PCV system in these NAs is much more straight forward, and my previous PCV system lasted 197,123 miles, and 15 years!! And it would've lasted even longer, if I didn't replace it because there was actually nothing wrong with it! This is also why keeping up with oil changes is extremely important!
You still mess around with those N/A 2.4 volvo 5s?
You guys work well together. The banter keeps things interesting.
ghogue61: 😉🍻
Well Gabe is an extraordinary assistant, he's a veteran so his sense of humor is.... Augmented. Yeah...
KeenCrafting: BWAHAHAHA!!! Accurate. Cheers my friend!😉🍻
KeenCrafting idk man vets (myself and my gf included) that don’t have some crazy dark sense of humor from our military days 😂😂
@@marktate2683 exactly if you asked for an 2" extension you had to be specific and look with your eyes or a penis was placed in your hand... and you never leaned into an engine bay without checking your 6 LOL miss those days.....
Owned a V70R for a few years and the engine architecture is almost Identical to the 2.4L, with Volvos it's more or less about how well it was taken care of before you got the car and it looks like you picked up one that wasn't well taken care of at all. My V70R had over 40 service records and papers of each service since it was new in 04, over the three years I owned the car it only had two things go bad on me. One was an ABS sensor in the left front caliper and the other was the catalytic converter because of the bad winter mixes we get here in Michigan, I put nearly 9000 miles on that car and it never even hiccuped once after all was fixed. Don't blame the car man blame the previous owner for not taking proper care of it. Sidenote: I actually made money on my V70R, purchased for $7500 in 2015 and sold for $9800 in 2018.
oetiker clamps! Thank you for mentioning and including this in the video. I had issues with one of them in my GKI vc axle boot kit for volvo s40 fwd. ended up installing a universal metal band clamp instead with the banding tool. I will find and replace with an oetiker clamp if need be
Great job as usual JR and Gabe! Good to see you back Gabe! every video without gabe is a frown that can't be turned upside down! Lol cheers guys.
That One Guy: 🍻😉👍🏼
Extraordinary detail !
Super helpful !!
I learned lots !!!
Thanks gentlemen.
👊🏼 🔥 🧰
I love it when the PCV/oil separator on top of the engine in the XC70 and XC90s goes bad. Makes a LOUD screeching at idle and only takes 7 minutes (if you take it slow and easy) to replace. Customers are always happy afterwards 👍.
Yep I just had to do it on my s60r that I bought on my channel. Pain to do. I replaced the whole kit. With the big hoses...
Loving these Volvo vids!
Did this a couple weeks ago on my wife’s s80. Still better than doing it on my e46
Great video and such a cool car! They are maintenance heavy but worth every minute 😍👌🏼🤦♂️😎🇸🇪
On a 2012 Honda Civic, the PCV change takes less than 5 minutes and there is nothing to move out of the way.
You understand my love of Honda Civics 💯
Michael: Yup. Short. Sweet. Simple.
And the Honda is not a turbo. That is also an oil catch system while most just call it a PCV.
The PCV is more complicated on a turbo engine. The honda is just a valve with some hoses... And since this sounds like a competition, we should have a race on who can replace a timing belt the fastest. 😂
@@GCast-iv1pd s60 timing belt is so easy. the biggest thing you need to get off is a wheel. snapped mine and got everything back together with new valves in 2 working days.
Great project. Volvo s60 is a great car. Keep the vids coming.
Gettin some serious progress done! As you may or may not know, lots of these problems you´re fixing right now, is because the poor quality of engine oil in the us. Lots of engine problems in the us (with imports) is related to the much tighter gaps in the engineparts, that is possible thru better oil in europe. That is the reason why we can have engine that runs twice the milage that is normal for the us. Also we get to pay 3-4 times more money for an oilchange.. Keep up the good work, this is really good tutorial for people who do want to DIY their volvos.
Thanks for making me believe that this pcv problem is solvable and these cars have been built tough. Because we are planning to buy one for safety reasons..
Keep up the amazing work thanks for the awesome content you and gabe are doing amazing and your friendship is awesome keep it up
Hayden Croft 16 years old: Cheers, friend. 😉🍻
And I thought old 80s Ford 302s, with their hidden PCV screens below the PCV valves were bad to get to. Most people don't know about those, so when you see an old Ford with a blown rear main seal, you know why. If those screens aren't changed, you'll be doing major repairs.
My grandad junked his '91 F-150 5.0L that he loved because of the rear main seal leaking. Wish I read your comment a year ago to save him some heartache lol.
I went through this same long process with my s60 when I noticed smoke coming from under the engine area. I went through torturous process removing the intake manafold, clamps, connectors, etc. When I finally got to the Pcv system I noticed it wasn’t really that dirty or clogged so I just cleaned it a little and left it alone, but I did discover a huge vacuum leak coming from one of the plastic lines inside the foam insulation sleeve that runs underneath the intake manifold.
Yeah, those lines are terrible. They did away with them and replaced them with metal, but I'm not sure which year that happened - my 2006 S80 has metal lines.
@@looncraz Yup the 07+ S60 has the metal line and it ain't cheap. $130
@@richardpflieger2049 Not cheap, but you can just flush them out and keep using them... They should never require replacement. I replaced all the rubber with silicone radiator hoses on my S80 and my old 850 I replaced the entire PCV system with silicone hoses.
Love the work
Definitely quick cars. Borrowed an '04 S60 t5 for a couple of weeks. Solid and very quick. Got me interested in Swede cars.
I didn't even realize that was a 5 cylinder engine till this video.
Did the same job on my 850. It was solid with carbon. Really despised the designer who thought that was a good location for the PCV.
How did I not watch this till now, lol, cheers?
I remeber doing this job on my old Volvo S70 in 2014 in my parking lot...It was a pain in the ass, but the car ran like new 😁😁
Volvos are fantastic cars (minus the side mounted timing belts) and are incredibly excellent at running well and with great gas mileage (outside of the enormous carbon buildup) and have a great ride with smooth highway driving (outside of the vacuum cruise behind the brake pedal failing often) and yes, I'd totally buy another.
Nice! I have done this 4 times now! One video is up on my channel now.
Wow what a nightmare. Great work!
justin beard:😉🍻
Unbelievable engineering. Very watchable video. Also huge bargaining leverage for someone trying to buy a Volvo.
great video...just what I needed !!! ick...what a pain in the ass
Those itty bitty wiper blades are Soooo Cute!
Boost bazooka would make an awesome T-shirt 😂😂😂
Anthony Cunningham: Yes it would!
Great vid and info! $450 is a bargain if you know how to fix it! Blame the owners, not always the car maker. There's lots to like about Volvos, like they don't rust. People beat up on them and expect them to last...S60 turbos are not easy to work on.
That is intense
!!!!! I am scared to do any of that.
Glad you’re saving this thing instead of it being sold really cheap then ending up in the scrap yard
Man I did this job 6 months ago.
That banjo bolt was a pain, sucks cuz after that my water pump was failing so I just sold it.
I miss the car to be honest with u.
All of that trouble. Welcome to the world of Volvos finest craftsmanship. In all their cars, take everything off to get to one measly bit.
Another episode of WatchJR&GabeGo, love it
Dustin Williams:😉🍻
My Volvo S60 is a great car. Incredibly reliable. Only thing failed after nearly 18 years is the alarm module and the DIM. Both cheaply and easily fixed
how'd you fix the DIM? Xemodex?
Nice video, love the banter, makes shit jobs like this somewhat tolerable. I thought the PCV location on a first gen Mazda 3 sucked, holy hell! And to think I was considering an '07 S60 2.5T AWD Vomit...not sure I need this just for a winter AWD car.
Boost bazooka lol good job guys 👍
Oh man JR, ya'll done goofed by not replacing that line that connects to the intake manifold via the banjo bolt. It's a real pain to replace the whole line, but on my S60R I did exactly what you did, just replaced the box/top breather hose and put it back together. A year later I blew out a seal because that line was still clogged. Had to go back in and replace it.
Scrubbed out the fitting, then sprayed some brake clean through it to make sure it was clear 🍻
@@WatchJRGo Nice, no clue why they made that line coming from the banjo bolt so small. I think that little line feeds into the bigger line that wraps around the block and draws air from the air intake? Thing gets clogged up so easily. Great work on this Volvo flip, it's comforting to see that even a much smarter/experienced mechanic like yourself struggles with the same things I do on my S60R lol. Love/hate relationship with Volvo.
Did my 02 S60 2.4t PCV system a year ago. Exact same process you just went through. Its annoying to do but worth it.
Is there a reason you disconnected your throttle body from the intake? i might not have caught that. i just disconnected mine from the tube and took the connector off.
Your videos are fun and useful. On the PCV job and any subsequent jobs, it would have saved you a lot of time to remove the whole front end. It is modular and it opens a lot of room to work cleanly and much faster. You just need to drain the coolant. That volvo will be good to go for a long time.
Andres R Torres:😉🍻
Ever since I started watching I always wondered what branch of the military did Gabe serve? Might be nice to make a couple of videos introducing your buddies and their backgrounds. Maybe car history for everybody I'd like to know more. O would love to see your dad in more videos that is one wicked smart man. NASA calls him when they have problems lol
Robbie H: LOL. I’m retired Army.
Funny about that oil cap. Not to name the only Volvo dealership in Wichita. They couldn’t find the oil leak and burning oil smell on a Volvo. When I got it I did my own oil changes and found oil always on top of the motor. I spent $5 on the gas cap. Fixed it. Previous owner spent hundreds at the dealership in diagnostic fees and they never found the problem.
Im literally in the process up fixing up a 2001 s60 t5. Only done 99k miles and its a manual! Over here in the uk its hard go come by. I need to also do my pvc, thermostat and a couple other parts and she should be good for a long time. Gotta check the cam bucket seals too tho. Just so costly! Got the car for £200🤣
Great job and I enjoyed the video. But there is 1 critical step ya missed. You must clean the PTC nipple! It's located at the bottom of the intake tube coming from the air box. Don't remove it from the pipe or you will never be able to get it back into the pipe. You would have to buy a new pipe that includes a new PTC nipple. It's~ 110$ from FCP my go to Volvo parts supplier. And you didn't mention the superceded Banjo bolt. It was redesigned so the check ball in it cant come out and get sucked into the turbo. Sorry about being picky but I think it's important.
I heard they were hard to work on now I believe that no wonder the resell value is so bad I would not want one Thanks for sharing
I sure do hope you remembered to get that bolt out of the "boost bazooka"
I did, stuck a magnet down there and pulled it out 🍻
Super!! Would have hated to hear a nasty crunch otherwise!! Good work there, always a treat watching your videos 👍🏽
@@WatchJRGo Thanks for sharing that concept. I have not done that yet but if I do, I can now do it.
Glad to see you’re getting stuff done! But it’s clear the people that designed this engine didn’t have “ease of maintenance” high on their priority list...
I would feel better doing this job decades later. That way I would feel better the designers were deceased. 😶
When is the boat coming back? Super interested to see it finished and on the water.
All I know about Volvos JR taught me 👍🏻
ewan stewart Same! I now know that they suck
Was there no power steering fluid issues when you removed the power steering tube? If there is when the system is filled with power steering fluid, what needs to be done to best manage the situation?
I did that same job on my V70.. why didnt you do the coolant lines of the PCV and the part at the fresh air snorkel right by the Turbo? On mine those were about to go (cracked) and the connector part in the thermostat housing was corroded shut and caused some air bleed problems in the colling system. I would've recommended doing those too, because if you have it apart that far - it would suck to do it again in the next 30000 miles.
Ant did the same pcv job on the Wheeler Dealer Volvo wagon episode. Doesn't look like fun in either of your cars. Don't think Ant did the seals, so that will be something new. Good job. Should be a nice car when you're done.
Terry Lessmann: Don’t get us wrong, it’s a great car! It’s just tedious to work on.
@@Gabe-ABNCW3 And that's what's great about the video - it shows you have to take a crapload of parts off to get to the pcv, but it's doable and you don't need special tools. That's what DIYers want to see. And when you're done, you've added value that can differentiate it from other garden variety Volvos on the mkt that haven't addressed the pcv.
Terry Lessmann:😉🍻
Any tips and tricks on getting the bamjo bolt back into the intake manifold ?
I drive a volvo s70 turbo it has the same problem. Im too cheap and lazy to fix it so i bypassed it. Still runs good no smoke or oil leaks. I believe this happens due to the previous owner not changing the engine oil frequently enough. CHANGE YOUR OIL!
I also work in tech as a desktop support analyst for a healthcare organization, I would like to know your story and how you landed in tech recently my CompTIA certs expired and I find myself lost looking for a path. Also is Gabe in tech? Appreciate your content keep it up !!!
When cleaning out the PCV box port, into the block. All the crud goes into the oil pan area. I do an oil change soon after. But, really hate the idea of that junk going in to a clean space. Any ideas out there? Like blowing air into the oil cap? What works, to prevent it, going in there? Thanks.
Been there done that! All the Volvo's I've had were money pits, and all the Mercedes and BMW also but a lot of fun!
You sound like scotty
You were buying the wrong volvos
Aqf Qfa you have a sick idea of fun.😂
@@RealWorldGarage Every body tells me the same thing! I just got a 2001 740iL with lots of problems, that just means lots of fun!
@@ST3ADYxKICKS The worst was a 2002 V70XC and the best was a 2005 S80 T6
Wow thats crazy thts you have to do all of that just to get to the PVC. You might want to get like a reloaction kit or a oil catch can and relocate to a better spot in the motor if that possible.
I should be working on SQL server but John Ross is always good to watch 😏
I've always wanted to name a kid Drop Table and watch the trainwrecks it causes 😂
WatchJRGo you’d think injection wouldn’t work anywhere anymore but I guess you don’t know until you try 😅
Index=* source=watchjrgo | table title, _time | sort - _time
@@token112 this has gone to far 😂
token 1 That looks more like SPL for Splunk than SQL
Ah, the dreaded banjo bolt. The phantom that haunts the 5cyl mechanic. It took me 2.5 hours and 2 trips to the shops to remove it.
Just a tip, Volvo designs its cars with the car on lifts during servicing. Meaning, it's easier to remove from the bottom. For the XC90, you can remove the PCV system without removing the intake man. Just remove the rad fan to get more space.
Yes, the PCV is poorly designed. I was told that it was added later on (for emission reasons) and was not implemented properly. Mine was blocked all the way to the sump so I had to remove the oil sump as well to unblock it. It is said to be replaced every 100k kms but is not included in the service schedule. I've seen other bypass it and retrofit an oil trap on the side of the engine bay.
Not only does JR teach us repair jobs, but he also cures some people of ever wanting to own certain cars... Like owning a Volvo comes to mind. 😵😖
sleepyhollow783: 😂
Did this a month ago. Fcp for the win
Around here i live they quoted me 890 to replace the flame trap and hosed for the pcv system
I’m having *ANXIETY* that you didn’t show us you removing the bolt from the *BOOST BAZOOKA *
Austin Holbrook: LOL! We got it out with a magnet. I promise!😉🍻
I changed the pvc system on an 2.4 na s60 . The bottom left intake bolt was nearly impossible to get at . Used combination of swivels etc . In retrospect I think draining the coolant and removing the thermostat housing would have been worth it . Lots of time and swearing did get it done tho .
Thermostat housing has torx that are just as hard to get out and in. Will help broaden your vocabulary of profanities.
You want to put some clean engine oil on the fuel injector o-rings before putting the fuel rail back in or plugging injectors into the fuel rail. Pretty much any o-ring you want to lube up so they don't pinch and leak. Makes installation easier too.
someusername121: Although we did that, I think we neglected to mention it.
I've got a 2004 s60 and boy is it a fucking project to work on, mines about to shit out. check engine light back on after a winter car accident. wish I could keep this beautiful s60 forever, unfortunately don't have enough money to keep up with it 😩
If the cam seals still leak after replacement, remove the VVTI mechanism on the cam and strip it. There is an o-ring inside that goes hard and is not always replaced when people change the cam seals.
I know this video is from 3 years ago but I would love to know what all the parts you used/replaced when you clean the pcv system? I would greatly appreciate it, thanks!
Jr before he lost his job : *"buying useless car just for fun"*
Jr now *"selling my cars so I can pay my rent"*
What are the symptoms of a clogging PCV box? And what is a fair price for this job? I have a Volvo S60. Getting harder to start. When starts vapor comes out of exhaust. Deal says pcv box is clogging and getting camshaft computer code.
I love that car
How did you remove the fuel line from the fuel railing?
What kinda issues does it give you when the pcv fails? When I put mine in reverse it starts vibrating like shaking and when I put it drive it’ll do the same but less..? Can someone please tell me what can that be?? I changed air filter ,maf sensor spark plugs and coil packs. I’m literally running out of ideas.
GO!
Hi guys I have a question about the PCV on a 2006 Volvo S60 R. When I do the glove test it sucks in at idle but then blows out when I press the gas. Is it supposed to blow out when adding boost? It's causing my return line o-ring to fail even after replacing the line, o-ring, and gasket after already servicing the PCV. Is there something I missed?
Update on the 420 crawler?
I want to buy a Volvo now just so I can buy fcpeuro parts lol
Zachsgreatchannel: 😉🍻
I had a 2002 Volvo S60 2.4T. They seem great at first but never again
9:54 “Well there’s your problem lady.”
South Main Auto rules! :-)
15:10
You had a small piece of metal fly to your back (stage left)
Came from in between coil 5 and the side of the head.
shh he won't miss it
Wasnt a piece of metal XD
It was just a fly... I saw it fly around seconds before 15:10 haha
at 15:06 you can see it
Does anyone know for what is this coolant tube coming from the thermostat casing for ? Is there water going through the intake ?
Step one with most Volvo 5-cyl work - remove radiator fan, you get so much more room to work in the front of the engine without the fan in the way...