Genuine Volvo 960 Exhaust Manifold

Volvo 960 Exhaust Manifold Parts and Q&A

• Exhaust Manifold
  3507743
  Q: How to properly work on the exhaust manifold on Volvo 960?

  A:

  Prior to working with the exhaust system, it is a good idea to saturate the retaining hardware with a good rust penetrant, and allow at least 10-15 minutes for it to work. For 2.3L 4-cylinder engine, remove the negative battery cable, remove the air cleaner and related necessary hoses, remove the EGR valve pipe on the manifold and remove the exhaust pipe on the exhaust manifold. Next would be the turbo, turbo pipes and attaching hardware, then the manifold nuts and manifold itself. To install, seat the manifold with a new gasket, tighten the manifold bolts to 10-20 ft. lbs. (14-27 nm) and reinstall the turbo, turbo pipes and EGR valve pipe, the air cleaner and hoses, and finally reconnect the negative battery cable and start the car to check for leaks. For the 2.8L 6-cylinder engine, to start, you should disconnect the negative cable of the battery, safely lift and support the car and unbolt the crossover pipe on the exhaust manifolds. If equipped with a Y-type exhaust pipe, disconnect it at the left and right manifolds, remove any other necessary hardware and the manifold nuts before taking out the manifold(s) from the cylinder head(s). When installing, install manifold(s) on cylinder head(s) with new gaskets, tighten manifold bolts to 7-11 feet pounds (10-15 newtons), reconnect Y or crossover pipe, reinstall removed hardware, lower vehicle, reconnect negative battery cable, start vehicle and check for leaks. For the 2.9L 6-cylinder engine, disconnect the negative battery lead, exhaust pipe mounting nuts at the manifold joints, or heat shield, remove the exhaust manifold mounting nuts and gasket. Before installing, have the mating surfaces cleaned, install a new gasket and place the exhaust manifold. Fit the mount lifting lug, tighten the mounting nuts to 18 ft. lbs. (25 Nm) and fit the heat shield and front exhaust pipe to the manifold using threadlocking compound and tighten to 44 ft. lbs. (60 Nm). Loosen the joint at the catalytic converter and re-tighten to 18 ft. lbs. (25 Nm) to avoid stress on the system and reconnect the negative battery lead and start the engine to check for leaks. have to be disconnected: For the 2.3L and 2.4L 5-cylinder engines, disconnect the negative battery cable, make the vehicle higher and support it, disconnect the exhaust pipe from the exhaust manifold by taking off the nuts. If equipped, remove the turbo and turbo parts, then remove the carriage bolts and heat shields and the bolts on the exhaust manifold. Push the manifold towards the firewall and lift it out. For installation, check and clean the surface of the gaskets that is cylinder head, make the exhaust manifold with new gaskets, align the exhaust manifold with the pipe using carriage bolts, use locking compound on the threads of the exhaust manifold bolts, tighten it to 18 ft. lbs. (25 Nm). Reinstall turbo and its components, the heat shields and tighten the carriage bolts with thread sealing compound, make sure that the nuts are tightened to no more than 86 inch lbs. (10 Nm) with springs and washers. Finally, re-connect the negative battery cable and start the engine to check for leaks.