Installing down pipe

WARNING: This page is about a different car, the 2004 Volvo S40, 2003 Volvo S40, 2002 Volvo S40, 2001 Volvo S40, and 2000 Volvo S40. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Installing Down Pipe With Torque Specifications

Courtesy of VOLVO CARS OF NORTH AMERICA.

Clean all surfaces
- Apply grease (P/N 1161408) to the heated oxygen sensor (HO2S), Turn the sensor the same number of turns as when it was removed. Tighten the heated oxygen sensor. Tighten to 55 Nm .
Install the new gasket
- Apply grease (P/N 1161408) to the heated oxygen sensor (HO2S), Turn the sensor the same number of turns as when it was removed. Tighten the heated oxygen sensor. Tighten to 55 Nm .
Align the front pipe at the engine side. Align the rear exhaust pipe (move the rear of the pipe backwards)
- Apply grease (P/N 1161408) to the heated oxygen sensor (HO2S), Turn the sensor the same number of turns as when it was removed. Tighten the heated oxygen sensor. Tighten to 55 Nm .
Position the front pipe on the exhaust manifold. Install the nuts
- Apply grease (P/N 1161408) to the heated oxygen sensor (HO2S), Turn the sensor the same number of turns as when it was removed. Tighten the heated oxygen sensor. Tighten to 55 Nm .
Tighten the front pipe to the exhaust manifold. Tighten to 25 Nm starting from the middle
- Apply grease (P/N 1161408) to the heated oxygen sensor (HO2S), Turn the sensor the same number of turns as when it was removed. Tighten the heated oxygen sensor. Tighten to 55 Nm .
Tighten the clamp at the rear. Tighten to 60 Nm
- Apply grease (P/N 1161408) to the heated oxygen sensor (HO2S), Turn the sensor the same number of turns as when it was removed. Tighten the heated oxygen sensor. Tighten to 55 Nm .
Install the heated oxygen sensor (HO2S):
- Apply grease (P/N 1161408) to the heated oxygen sensor (HO2S), Turn the sensor the same number of turns as when it was removed. Tighten the heated oxygen sensor. Tighten to 55 Nm .

Check for leakage.