Installing the exhaust manifold: Installation

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: Identifying Exhaust Manifold Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE: Use new gaskets and O-rings.

Clean the mating surfaces.

Install the exhaust manifold. Use new gaskets.

Secure the exhaust manifold to the cylinder head. Tighten to 25 Nm . Begin tightening from the center.

Install the support bracket for the exhaust manifold. Tighten to 24 Nm .

Clean the surface thoroughly.

Insert the lower oil pipe in the cylinder block. Use a new O-ring. Secure the turbocharger (TC) to the exhaust manifold. Tighten to 45 Nm . One of the nuts must be tightened from underneath.

Install:

the upper oil pipe connection. Tighten to 24 Nm
both radiator connections. Tighten to 25 Nm . Remove the hose clips
the front heated oxygen sensor (HO2S). See Information missing
the exhaust manifold and firewall heat shields
the hose at the air cleaner. The hose for the charge air cooler (CAC)
the engine cover. The relay cover
the bracket for the oil pipe
the front exhaust pipe. Use a new gasket. See Installing turbocharger (TC) components
the rear engine cover.