Installing the exhaust manifold and three-way catalytic converter (TWC)

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2006 Volvo S80, 2005 Volvo S80, 2004 Volvo S80, 2003 Volvo S80, and 2002 Volvo S80. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

For tightening torques, see: Tightening torque .

NOTE:

To ensure that there is no exhaust leakage, see: Flanged joint, assembling .

Fig 1: Identifying Exhaust Manifold & Three-Way Catalytic Converter Installation

Courtesy of VOLVO CARS OF NORTH AMERICA.

Clean the gasket faces. Check that the studs are tightened.

Install new gaskets.

Lubricate the studs. Use paste 116 1408.

WARNING:

Avoid skin contact with the paste.

Seal the thread for the upper heated oxygen sensor (HO2S).

Right-hand drive only

Lift the manifold and three-way catalytic converter (TWC). Put it to one side.

Install (right-hand drive cars)

the heat deflector plate over the steering gear. Tighten the screws
the manifold and the three-way catalytic converter (TWC). Check that the gaskets are correctly positioned
the upper collision guard at the steering gear. Tighten the screws. Tighten to 80 Nm.

Left-hand drive cars only

Lift and install the manifold and three-way catalytic converter (TWC). Check that the gaskets are correctly positioned.

Fig 2: Front Heated Oxygen Sensor

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install (right-hand drive cars)

the nuts securing the manifold to the cylinder head. Use new nuts. Do not tighten
the lower heat deflector plate over the three-way catalytic converter (TWC). Do not tighten.

Tighten all the nuts securing the manifold to the cylinder head. Tighten to 25 Nm.

Install (right-hand drive cars)

the upper heat deflector plate above the manifold
the screws. Tighten all the screws holding the heat deflector plates.

Install (left-hand drive cars)

the nuts securing the manifold to the cylinder head. Use new nuts. Tighten to 25Nm
the heat deflector plate above the manifold.

Install the upper heated oxygen sensor (HO2S). Lubricate the threads. Use paste 116 1408.

WARNING:

Avoid skin contact with the paste.

Tighten the heated oxygen sensor (HO2S). Tighten to 45 Nm. Use tool 9995543 .

Connect the connectors for the heated oxygen sensor (HO2S) to the wiring at the rear edge of the transmission.

Secure the heated oxygen sensor (HO2S) wiring at the rear engine mounting (2 mounting points).