Installing Three-Way Catalytic Converters (TWC) / Front Exhaust Pipe

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.

Fig 1: Three-Way Catalytic Converters And Front Exhaust Pipe

Courtesy of VOLVO CARS OF NORTH AMERICA.

WARNING:

Avoid skin contact with copper paste.

HINT: Use a mobile jack with universal plate 9995972 as a support.

Lubricate the studs on the turbocharger (TC). Use copper paste 116 1408 .

Lift up the exhaust system and connect it to the pipe flange. Use a new gasket and new nuts. Do not tighten.

Then connect the exhaust system to the turbocharger (TC).

Fig 2: SIPS Member

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

new nuts at the connection to the turbocharger (TC)
the front SIPS member. Do not tighten
the brake pipe in holders on the SIPS member.

Tighten the exhaust pipe at the turbocharger (TC). Tighten to 25 Nm .

NOTE:

Ensure that the flange on the exhaust pipe is flush against the turbocharger (TC).

Tighten the exhaust pipe where it separates downstream of the three-way catalytic converter (TWC). Tighten to 25 Nm .

Install the rear SIPS member. Tighten to 25 Nm .

Tighten the front SIPS member. Tighten to 25 Nm .

Connect the connector for the rear heated oxygen sensors (HO2S) and clamp the wiring.