Volvo Cars 1999-05

Exhaust Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust manifold heat shield
     
    Exhaust front pipe
     
    Turbocharger, if equipped
     
    Exhaust manifold
     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifold and tighten the fasteners to 18 ft. lbs. (25 Nm)
     
    Turbocharger, if equipped
     
    Exhaust front pipe and tighten the fasteners to 44 ft. lbs. (60 Nm)
     
    Exhaust manifold heat shield and tighten the fasteners to 86 inch lbs. (10 Nm)
     

  2.  
  3. Loosen the joint at the catalytic converter and re-tighten to 18 ft. lbs. (25 Nm). This is necessary to prevent stresses in the system.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Turbocharger/manifold assembly and gasket
     
    Exhaust manifold from the turbocharger assembly
     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifold to the turbocharger assembly
     
    Turbocharger/manifold assembly with a new gasket. Tighten the mounting bolts to 27 ft. lbs. (37 Nm).
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks
  4.  

4-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Heat deflector plate
     
    Exhaust manifold bracket
     
    Catalytic converter
     
    Turbocharger
     
    Rear engine cover
     
    Front exhaust pipe
     
    Oil pipe bracket
     
    Upper oil pipe connection -the nuts for the exhaust manifold
     
    Air cleaner hose
     
    Charge air cooler (CAC) hose
     
    Lower oil pipe
     
    Exhaust manifold
     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifold with new gaskets. Tighten bolts to 18 ft. lbs. (25 Nm).
     
    Exhaust manifold support bracket. Tighten to 17 ft. lbs. (24 Nm).
     
    Lower oil pipe
     
    Turbocharger
     
    Catalytic converter
     
    Upper oil pipe connection. Tighten to 17 ft. lbs. (24 Nm).
     
    Heat deflector plate
     
    Air cleaner hose
     
    CAC hose
     
    Oil pipe bracket
     
    Front exhaust pipe
     

  2.  
  3. Start engine and check for leaks.
  4.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Heat deflector plate
     
    Exhaust manifold bracket
     
    Catalytic converter
     
    Turbocharger
     
    Rear engine cover
     
    Front exhaust pipe
     
    Oil pipe bracket
     
    Upper oil pipe connection -the nuts for the exhaust manifold
     
    Air cleaner hose
     
    Charge air cooler (CAC) hose
     
    Lower oil pipe
     
    Exhaust manifold
     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifold with new gaskets. Tighten bolts to 18 ft. lbs. (25 Nm).
     
    Exhaust manifold support bracket. Tighten to 17 ft. lbs. (24 Nm).
     
    Lower oil pipe
     
    Turbocharger
     
    Catalytic converter
     
    Upper oil pipe connection. Tighten to 17 ft. lbs. (24 Nm).
     
    Heat deflector plate
     
    Air cleaner hose
     
    CAC hose
     
    Oil pipe bracket
     
    Front exhaust pipe
     

  2.  
  3. Start engine and check for leaks.
  4.  

6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine stabilizer brace
     
    Charge air pipe, if equipped
     
    Turbo air intake pipe, if equipped
     
    Air preheating hose
     
    Heat deflector plate
     
    Left front wheel
     
    Splash guard
     
    Rear Side Impact Protection System (SIPS) member, if equipped
     
    Catalytic converters
     

  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Right hand half shaft
     
    Bolts for coolant hoses and place to one side
     
    Bolts for oil pressure outlet on the engine
     
    Bolts for oil return hoses and place to one side
     
    Turbochargers, if equipped
     
    Exhaust manifold for cylinders 1, 2 and 3
     
    Exhaust manifold for cylinders 4, 5 and 6
     

  8.  

To install:

  1. Install or connect the following:

    Exhaust manifold for cylinders 1, 2 and 3 with new gasket. Tighten fasteners to 18 ft. lbs. (25 Nm).
     
    Exhaust manifold for cylinders 4, 5 and 6 with new gasket. Tighten fasteners to 18 ft. lbs. (25 Nm).
     
    Turbochargers, if equipped
     
    Oil return lines with new gasket and tighten to 9 ft. lbs. (12 Nm)
     
    Oil pressure outlet on the engine with new gasket washers and tighten to 28 ft. lbs. (38 Nm)
     
    Coolant hoses with new gasket washers and tighten to 19 ft. lbs. (26 Nm).
     
    Catalytic converters. Tighten fasteners to 18 ft. lbs. (25 Nm).
     
    Rear SIPS member. Tighten to 18 ft. lbs. (25 Nm).
     
    Splashguard
     
    Front wheel
     
    Heat deflector plate. Tighten bolts to 18 ft. lbs. (25 Nm).
     
    Air preheating hose
     
    Engine stabilizer brace. Tighten the bolts at the suspension turrets to 37 ft. lbs. (50 Nm). Tighten the engine bracket bolt to 59 ft. lbs. (80 Nm).
     
    Turbo air intake pipe, if equipped
     
    Charge air pipe, if equipped
     
    Negative battery cable
     

  2.  
  3. Start engine and check for leaks.
  4.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine stabilizer brace
     
    Charge air pipe, if equipped
     
    Turbo air intake pipe, if equipped
     
    Air preheating hose
     
    Heat deflector plate
     
    Left front wheel
     
    Splash guard
     
    Rear Side Impact Protection System (SIPS) member, if equipped
     
    Catalytic converters
     

  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Right hand halfshaft
     
    Bolts for coolant hoses and place to one side
     
    Bolts for oil pressure outlet on the engine
     
    Bolts for oil return hoses and place to one side
     
    Turbochargers, if equipped
     
    Exhaust manifold for cylinders 1, 2 and 3
     
    Exhaust manifold for cylinders 4, 5 and 6
     

  8.  

To install:

  1. Install or connect the following:

    Exhaust manifold for cylinders 1, 2 and 3 with new gasket. Tighten fasteners to 18 ft. lbs. (25 Nm).
     
    Exhaust manifold for cylinders 4, 5 and 6 with new gasket. Tighten fasteners to 18 ft. lbs. (25 Nm).
     
    Turbochargers, if equipped
     
    Oil return lines with new gasket and tighten to 108 inch lbs. (12 Nm)
     
    Oil pressure outlet on the engine with new gasket washers and tighten to 28 ft. lbs. (38 Nm)
     
    Coolant hoses with new gasket washers and tighten to 19 ft. lbs. (26 Nm).
     
    Catalytic converters. Tighten fasteners to 18 ft. lbs. (25 Nm).
     
    Rear SIPS member. Tighten to 18 ft. lbs. (25 Nm).
     
    Splashguard
     
    Front wheel
     
    Heat deflector plate. Tighten bolts to 18 ft. lbs. (25 Nm).
     
    Air preheating hose
     
    Engine stabilizer brace. Tighten the bolts at the suspension turrets to 37 ft. lbs. (50 Nm). Tighten the engine bracket bolt to 59 ft. lbs. (80 Nm).
     
    Turbo air intake pipe, if equipped
     
    Charge air pipe, if equipped
     
    Negative battery cable
     

  2.  
  3. Start engine and check for leaks.
  4.  

5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Splash guard under the engine
     
    Right halfshaft.
     
    Heat deflector plate for the oil cooler
     
    Support bracket between the cylinder block, manifold and three-way catalytic converter (TWC)
     
    Brake pipe
     
    Bolts holding the front Side Impact Protection System (SIPS) member to the body
     
    Front exhaust pipe
     
    Engine stabilizer brace
     
    Air preheating hose
     
    Upper heated oxygen (HO 2 S) sensor
     
    Turbocharger, if equipped
     
    Upper heat deflector plate over the manifold
     
    Exhaust manifold with the TWC
     

  4.  

To install:

  1. Install or connect the following:

    Manifold with new gasket and TWC. Tighten fasteners to 18 ft. lbs. (25 Nm).
     
    Heat deflector plate over the manifold
     
    Upper heated oxygen (HO 2 S) sensor
     
    Air preheating hose
     
    Engine stabilizer brace
     
    Front exhaust pipe with new gasket. Tighten fasteners to 18 ft. lbs. (25 Nm)
     
    Front SIPS member. Tighten to 18 ft. lbs. (25 Nm).
     
    Brake pipe
     
    Support bracket between the cylinder block, manifold and TWC
     
    Turbocharger, if equipped
     
    Heat deflector plate for the oil cooler
     
    Right halfshaft
     
    Splash guard
     
    Front wheel
     

  2.  
  3. Start engine and check for leaks.
  4.  

 
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