Exhaust manifold / gasket, replacing: Preparation

Remove 

• the right front wheel
• the splash guard under the engine
• the right drive shaft.

  See Rear axle, drive shafts - removal, replacement and installation .

Fig 1: Heat Deflector Plate Above Coolant Pipes

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove 

• the heat deflector plate above the coolant pipes and hoses for the oil cooler
• the support bracket between the cylinder block and the manifold and three-way catalytic converter (TWC)
• the nuts where the front exhaust pipe and three-way catalytic converter (TWC) join.

Remove the brake pipe from the holders at the front SIPS member.

Remove the screws holding the SIPS member to the bodywork.

Unhook the rubber mountings for the rear exhaust system from the holders.

Pull the exhaust system back so that it releases from the flange at the manifold and three-way catalytic converter (TWC). Put it to one side.

Fig 2: Front Heated Oxygen Sensor

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove 

• the engine stabilizer brace between the suspension turrets
• the air preheating hose between the air cleaner (ACL) and the heat deflector plate.

Disconnect the connector for the front heated oxygen sensor (HO2S).

Remove the heated oxygen sensor (HO2S) wiring from the rear engine mounting.

Remove the front heated oxygen sensor (HO2S).

Seal the opening for the heated oxygen sensor (HO2S).

Remove the upper heat deflector plate over the manifold.

Right-hand drive only 

Remove the lower heat deflector plate over the three-way catalytic converter (TWC).