Volvo 240/740/760/780/940/960 1990-1998

Exhaust Manifold

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REMOVAL & INSTALLATION



Before working on the exhaust system, it is a good idea to soak the retaining hardware with a quality rust penetrant prior to attempting to remove them. After the penetrant is applied, wait at least 10-15 minutes to let the penetrant begin to work.

2.3L 4-Cylinder Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner and all necessary hoses.
  4.  
  5. Remove the EGR valve pipe from the manifold.
  6.  
  7. Remove the exhaust pipe from the exhaust manifold.
  8.  
  9. Remove the turbo, turbo pipes, and attaching hardware.
  10.  
  11. Remove the manifold nuts and manifold.
  12.  

To install:
  1. Position and install the manifold using a new gasket.
  2.  
  3. Tighten the manifold bolts to 10-20 ft. lbs. (14-27 Nm).
  4.  
  5. Install the turbo, turbo pipes, and attaching hardware.
  6.  
  7. Install the EGR valve pipe.
  8.  
  9. Install the air cleaner and any necessary hoses.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Start the vehicle and check for leaks.
  14.  

2.8L 6-Cylinder Engine

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Unbolt the crossover pipe from the left and right side of the exhaust manifolds, if equipped.
  6.  

If the vehicle has the Y-type exhaust pipe disconnect this pipe at the left and right manifolds.

  1. Remove any other necessary hardware.
  2.  
  3. Remove the manifold nuts.
  4.  
  5. Remove the manifold(s) from the cylinder head(s).
  6.  

To install:
  1. Install the manifold(s) on the cylinder head(s).
  2.  

Always use new gaskets when reinstalling the manifolds.

  1. Tighten the manifold bolts to 7-11 ft. lbs. (10-15 Nm).
  2.  
  3. Connect the Y or crossover pipe.
  4.  
  5. Install any removed hardware.
  6.  
  7. Lower the vehicle.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the vehicle and check for leaks.
  12.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the exhaust manifold assembly-2.8L 6-cylinder engine

2.9L 6-Cylinder Engine
  1. Disconnect the negative battery lead.
  2.  
  3. Remove the exhaust pipe mounting nuts at the manifold joints.
  4.  
  5. Remove the heat shield retaining bolts and heat shield.
  6.  
  7. Remove the exhaust manifold mounting nuts.
  8.  
  9. Remove the exhaust manifold and gasket.
  10.  

To install:
  1. Before installation, clean the manifold and cylinder head mating surfaces.
  2.  
  3. Fit a new gasket and place the exhaust manifold into position.
  4.  
  5. Install the mount lifting lug on the studs between the 3rd and 4th exhaust branches.
  6.  
  7. Tighten the mounting nuts to 18 ft. lbs. (25 Nm).
  8.  
  9. Install the heat shield to the rear manifold. Tighten to 11 ft. lbs. (15 Nm).
  10.  
  11. Install the front exhaust pipe to manifold. Using threadlocking compound, tighten to 44 ft. lbs. (60 Nm).
  12.  

Loosen the joint at the catalytic converter and re-tighten to 18 ft. lbs. (25 Nm). This is necessary to prevent stress on the system.

  1. Connect the negative battery lead.
  2.  
  3. Start the engine and check for leaks.
  4.  

2.3L and 2.4L 5-Cylinder Engines

See Figures 2, 3, 4, 5, 6, 7, 8, 9 and 10

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Disconnect the exhaust pipe from the manifold by removing the nuts on the flanged joint.
  6.  
  7. If equipped, remove the turbo, turbo pipes, and attaching components.
  8.  
  9. Remove the carriage bolts from the manifold.
  10.  
  11. Remove the two heat shields from the exhaust manifold.
  12.  
  13. Remove the exhaust manifold bolts.
  14.  
  15. Push the manifold toward the firewall and lift it out from the top.
  16.  


WARNING
When removing or installing the exhaust manifold, be careful not to damage the air conditioning pressure switch, if so equipped.

To install:
  1. Check the gasket surface of the cylinder head, clean if necessary.
  2.  
  3. Install the exhaust manifold using new gaskets.
  4.  
  5. Line up the exhaust manifold with the pipe using the carriage bolts.
  6.  
  7. Install the exhaust manifold bolts using a locking compound on the threads.
  8.  
  9. Tighten the bolts to 18 ft. lbs. (25 Nm).
  10.  
  11. Install the turbo, turbo pipes, and attaching components.
  12.  
  13. Install the heat shields.
  14.  
  15. Tighten the carriage bolts using thread sealing compound.
  16.  
  17. Tighten the nuts to no more than 86 inch lbs. (10 Nm). Remember to install the springs and washers with the nuts.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Run the engine and check for leaks.
  22.  



Click image to see an enlarged view

Fig. Fig. 2: Remove the exhaust pipe-to-manifold flange retaining hardware ...



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Fig. Fig. 3: ... and disconnect the flange



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Fig. Fig. 4: Remove the manifold heat shield



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Fig. Fig. 5: The EGR tube is connected on the drivers side of the manifold



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Fig. Fig. 6: Use two wrenches to remove the EGR tube fitting



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Fig. Fig. 7: The EGR valve and tube are located beneath the throttle body



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Fig. Fig. 8: Unfasten the fitting on the EGR valve and remove the tube from the vehicle



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Fig. Fig. 9: Unfasten the retaining bolts and remove the manifold from the engine



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Fig. Fig. 10: The exhaust manifold uses individual gaskets around each port in the head; replace them before manifold installation

 
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