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Discussion Starter · #1 · (Edited)
After a timing belt swap, which required removal of all the plastic pre-and post-turbo ductwork on top of the engine, I noticed it was idling quite high - 1000rpm in gear, 1400rpm in neutral. Engine RPM would surge madly during cold start warmup period. CEL was on but my code scanner wasn't working. Turbos were glowing red after easy driving. I had a hunch it was a vacuum issue but all lines were connected, nothing egregious was apparent.

I did a cigar-smoke check and found smoke pouring from the "Fresh Air Hose" Volvo PN 30636760. This sits right on top of the engine, going from the airflow sensor at the filter box and feeds the turbos at the rear of the engine. See below.



Apparently, the big box looking things are Helmholtz resonators or something, added to eliminate some noise. Trouble is, they're snapped in place with gaskets. I think the act of pulling this part off and reinstalling it flexed the unit and opened leaks...they were substantial. I had to field-fix it with much duct tape with gorilla tape over that.

FYI, this P/N is supposed to fit Volvo XC90 2.9l 6 cylinder Turbo 2003, 2004, 2005, 2006 according to http://www.volvopartswarehouse.com/p/Volvo__/Fresh-air-hose/42800674/30636760.html

I learned that a similar piece exists without the goofy boxes, it's part number 8683743, it fits all these models (for your junkyard/ebay search pleasure):

Volvo S80 2.0l 5 cylinder Turbo 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Volvo S80 2.3l 5 cylinder Turbo 2000, 2001, 2002, 2003, 2004
Volvo S80 2.4l 5 cylinder 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Volvo S80 2.4l 5 cylinder Turbo 2001, 2002, 2003, 2005, 2006
Volvo S80 2.5l 5 cylinder Turbo 2003, 2004, 2005, 2006
Volvo S80 2.5l 5 cylinder Turbo (Diesel) 1999, 2000, 2001
Volvo S80 2.8l 6 cylinder Turbo 1999, 2000, 2001
Volvo S80 2.9l 6 cylinder 2000, 2001, 2002, 2003, 2004, 2005, 2006
Volvo S80 2.9l 6 cylinder Turbo 2002, 2003, 2004, 2005, 2006
Volvo S80 3.0l 6 cylinder 1999
Volvo XC90 2.9l 6 cylinder Turbo 2003, 2004, 2005, 2006

per http://www.volvopartswarehouse.com/p/Fresh-air-hose/42801062/8683743.html

Got it on ebay for $50 to the door, compared to $150+ship for new parts.

It looks like this (bottom), compared to the original on top:


As you can see it eliminates all the seams and gaskets:


It fit perfectly. The engine cover snapped right over.

OK, this was after a timing belt replacement, so there were a few variables that may not be 'normal,' but I felt this was worth sharing. I'm glad there are far less opportunities for vacuum leaks now.

Hope this helps someone, someday, who's chasing their ass cleaning MAFs, suspecting ETMs, etc.
 
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