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Southern Fried,
I can try to help on the breather box. My 242 has 101k and you wouldn't think the breather box would be clogged with that low mileage, but it was. Downtream from it, above it physically, was a plastic fork with one line leading to the intake manifold and the other bigger one to the air intake system below the bellows below the throttle body. The Volvo mechanic,when shown the plastic Y piece, said that was not the flame trap. It was just a fork in the trail. The flame trap itself on some of the earlier models was actually stuffed into the spout of the breather box. I found it in there, this weird copper looking stuff. Well, if the flame trap isn't serviced regularly, things tend to clog up upstream just like a river when damned, which is exactly what mine did. Upstream in this case being the breather box itself. I'm new at this, so I'm reading posts and asking a lot of questions like mad. Lots of people offer help. Foster says to idle the car and watch the breather box spout for blowby, so I do it. No indication of blowby at all so I decide to remove the breather box and buy a new one. Well, after getting lots of great advice from lots of brickboarders, and removing the intake manifold and the starter, and moving the fuel distributor, I manage to take out the breather box. I cleaned up the nipple and tried to blow through it. No way I could. So, yes, they definitely can clog up even at fairly low mileage if the system hasn't been maintained. My engine was blowing oil all over the place when I took off the oil filler cap at idle, and leaking some oil. Anyway, now I have the new breather box ($36 from Volvo) on the bench and a new o-ring, along with fuel injector seals, new modern flame trap, gaskets, etc. The car should breathe as well as when it was new. It has turned into a fun project, once I realized that I wouldn't be done in a day. I may also replace the engine harness while I'm at it. I still haven't decided about the sensors under the manifold on the head. Good luck. If it's clogged on nearly so, let it breathe.
DougC 81 242 Brick on Blocks
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