I need to replace my breather (oil separator) box. I have a high idle, and leaking from the oil cap. Pinching the vacuum line for the breather box drops the idle to normal.

I remember doing it a long time ago (twice) and had to take the EGR off once for sure. I remember using a really long ratchet extension through the intake manifold and reaching the bolts, but I don't have one with me, and want to avoid spending money while here.

So - do I have to take the EGR off? And should I buy a 12"+ extension to easily reach the bolts? Or did I imagine that trick?

Cheers!
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1990 740 Turbo, on its way to stock specs, maybe beyond

Yes - I do. The EGR piping will hold the EGR from moving and prevent you from removing the breather box.

I did it in about an hour and a half, and had to rearrange the heater hose and dipstick in the process.

Steps:

Remove turbo intake pipe, intake-to-IAC tube, and IAC. Disconnect TPS, IAC, and EGR and vacuum canister lines.
Loosen nuts on EGR piping (watch your knuckles)
Remove egr-tube to intake manifold nuts
Loosen thin nut that prevents EGR from rotating and rotate it slightly.
Remove the EGR pipe (doing this now triples your ratchet's range)

Use a 3/8" drive ratchet with a 3-inch extension and 13mm socket here
Remove the bolt nearest the firewall. (once loose, I used my fingers on the extension for both bolts)
Remove the other bolt.
Remove the bolts and EGR and any debris you can to protect the oil pump and exposed gears in the block.
Carefully remove the breather box and don't lose anything down the holes. Make sure you get the o-ring out too.
Optionally (I recommend it) replace the plastic nipple above the breather box. This is not a flame trap, but is where the flame trap is on NA cars.
Now is also a good time to check the Heater Hoses and valve.


Install the new breather box. Real OEM units say Volvo Sweden on the top of the box.
Put the bolts through the EGR valve bracket and maneuver it into place. This helps prevent dropping bolts.
Fit the Egr tube from the exhaust manifold into the EGR and turn a few threads. Do not tighten.

Tighten down the front bolt. Tighten down the rear bolt(nearest firewall).
Fit the intake manifold EGR tube into the EGR valve loosely. Tighten nut a few threads, but leave somewhat loose. Install the EGR to intake manifold bolts.
Tighten the nut on the EGR tube to the intake manifold. Tighten the EGR-to-Bracket thin nut. Tighten the EGR-to-exhaust manifold nut.

Reinstall the IAC, reconnect the TPS and IAC (And EGR temp sensor), Reinstall the IAC intake and intercooler-to-intake manifold tube, and the EGR and Vacuum lines.

Make sure you didn't leave any bolts/nuts/wrenches loose and nothing else was disconnected.
Clean up the oil your car was probably forcing out the oil cap.
Enjoy!
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1990 740 Turbo, on its way to stock specs, maybe beyond

I looked at mine last week and concluded that just removing the intake manifold (or pulling it back some distance) would probably be enough to replace the breather box from above.
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See the 700/900 "FAQ" at the menu bar top screen left side.

hey will-
i didn't have to remove the EGR on my 89 when i removed the oil trap. maybe yours is different, but the EGR and all associated hoses on my car are on the other side of the block. either way it's a real knuckle buster. i didn't use a long extension; i snaked in either a wrench or a small ratchet onto those two bolts and that was that.

you could always remove the intake manifold too, that would make it REAL easy to get to.

The later model EGRs are right next to the trap, a mess of plumbing.
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See the 700/900 "FAQ" at the menu bar top screen left side.

gotchya. then yeah, i would give it a shot with an extension if you can snag one. if not you'll have to take off the manifold; of course, you'll need a new gasket for that.

Thanks guys. I'll just reach under like I usually have. It's not worth the cost of the extension for one I already have.

I am planning on selling my beloved 740T. I just don't have the time or budget to keep going on it, and I am thinking about moving on to a small pickup.

Cheers!
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1990 740 Turbo, on its way to stock specs, maybe beyond

<< I am planning on selling my beloved 740T.... I am thinking about moving on to a small pickup.>>

There are Volvo pick-up trucks out there....

http://www.flickr.com/photos/8490341@N04/2969434315/

Chris in FL, '94 945 w/ 173K