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2001 Volvo s60 cuts out on idle after broken headlight! Electrical? S60 2001

Yes, off with the injector rail and the manifold.

FCP, and probably other suppliers as well, offer "kits". Here are a couple different options, one of which is a bit more extensive (and expensive) as it includes more parts like new injector seals:

https://www.fcpeuro.com/products/volvo-pcv-breather-system-kit-s60-v70-genuine-volvo-kit-p2naearly1p10

https://www.fcpeuro.com/products/volvo-pcv-breather-system-kit-v70-s60-v70pcvbase3

The thing you have to watch out for is that the short "L" shaped hose which comes attached to the separator box is available in two different diameters where it attaches to the engine block. The change in diameter was cut in at a certain VIN number so have your VIN available when you order. I screwed up when I ordered mine and got the wrong one, so I had to do minor surgery to retrofit the old hose onto the new box - I didn't like doing that but I was in a bind. Also, unless you have an Oetiker clamp tool, you'll have to use regular worm screw type clamps when reassembling.

The toughest part of the job is the loosening and retightening of the first (or last?) manifold bolt which is partially hidden by the thermostadt housing. The lower manifold bolt holes are slotted so you can have the bolts started into the engine before hanging the manifold back on. If you can't fully remove the bolt that interferes with the thermo housing it's not a big deal. You can slot the gasket hole when you put the new gasket on. You'll see what I mean. If I own either of our cars when the next PCV service comes due I'm going to explore the possibility of substituting that last bolt with a torx head bolt which might be easier to access.
--
Current rides: 2005 Volvo S80 2.5T, 2003 Volvo V70 2.4NA, 1973 Volvo 1800ES (getting ever closer to road worthiness)






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