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Exhaust Flex Pipe Leaking

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.
1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
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Exhaust Flex Pipe Leaking

Postby cn90 » 05 Jun 2011, 04:21

Hi guys,

I was at the muffler shop and they told me the Exhaust Flex Pipe is leaking.
The manifold itself is OK, just the flex pipe that leaks.

So my options are:

1. Flex Pipe ONLY (Scan-Tech....yeah I know!): $60
- But it needs to be welded etc.
- Hoe long does this last?

2. Whole Manifold Unit, PN 9471934:

- Volvo OEM is $416.

- Scan-Tech is $200 at:
http://www.rmeuropean.com

Any advices?



Image
1998 S70 GLT 160K+
2005 XC90 2.5T 85K+
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Re: Exhaust Flex Pipe Leaking

Postby cn90 » 05 Jun 2011, 05:14

Just came across this on facebook lol:

http://www.facebook.com/pages/Sick-Sens ... 3394762035

I am posting the same pics in case people need them later:


Flex01.JPG



Flex02.JPG



Flex03.JPG
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1998 S70 GLT 160K+
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Re: Exhaust Flex Pipe Leaking

Postby erikv11 » 05 Jun 2011, 06:40

I know people on this forum have posted about getting the intake manifold for the NA from OBX exhaust. You will have to call them for a price though, they don't show it on their web site. Their exhaust systems are very well priced, worth checking into.
'96 NA 855 | 207 k | wrecked body, rebuilt engine needs a home
'96 NA 855 | 123 k
'95 R 854 | 180 k
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Re: Exhaust Flex Pipe Leaking

Postby Ozark Lee » 05 Jun 2011, 12:23

I went the OBX Racing header route. Other than the EGR routing, if your car has EGR, it is a snap and the OBX stuff is very well made. I think I paid under $125.00 / shipped for the new header and it came with gaskets.

...Lee
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'96 850 N/A
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Re: Exhaust Flex Pipe Leaking

Postby cn90 » 05 Jun 2011, 14:22

My car has EGR, could you give me the correct link to OBX item?

Also:
- The OBX Kit comes with the gaskets: How GOOD are these gaskets?
- Install gaskets dry, correct?
i.e., no extra exhaust paste etc.

Much appreciated!
Last edited by cn90 on 05 Jun 2011, 14:33, edited 1 time in total.
1998 S70 GLT 160K+
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Re: Exhaust Flex Pipe Leaking

Postby jblackburn » 05 Jun 2011, 14:30

SAS! A 98 doesn't have EGR, and the manifolds will be different :wink:
'98 S70 T5 218K miles
2012 Chevy Cruze LT 6MT


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Re: Exhaust Flex Pipe Leaking

Postby erikv11 » 05 Jun 2011, 14:39

cn90 wrote:... could you give me the correct link to OBX item?

Like I said, you will have to call them. They used to list some Volvo applications on their web site, but even then only for the turbo.

I just dealt with the leaky flex pipe on my 96 with SAS by putting on a 98 manifold without SAS. You may wish to consider this a good time to get rid of your SAS, the non-SAS manifold will probably even be a little cheaper. The diode method seems to be working very well for many people. Using tap-cons or posi-tap connectors it is a simple, non-invasive modification.
'96 NA 855 | 207 k | wrecked body, rebuilt engine needs a home
'96 NA 855 | 123 k
'95 R 854 | 180 k
'98 V70 GLT | 15g turbo | 224 k
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Re: Exhaust Flex Pipe Leaking

Postby cn90 » 05 Jun 2011, 15:02

Ozark Lee wrote:I went the OBX Racing header route. Other than the EGR routing, if your car has EGR, it is a snap and the OBX stuff is very well made...


Hey Lee,

My car has the standard heating pipe, just like the pics above.
Do you think this kit will fit?

http://cgi.ebay.com/ebaymotors/ws/eBayI ... 3557wt_913
1998 S70 GLT 160K+
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Re: Exhaust Flex Pipe Leaking

Postby Ozark Lee » 05 Jun 2011, 15:41

It should bolt up just fine but you will need to plug the EGR hole and do the SAS delete with a couple of diodes. SAS is a total waste of time and money anyway. The gaskets were fine and they have not leaked at all.

I'm surprised at how much more expensive they are over the last year or so since I bought mine. I guess steel is getting more expensive since people are now actually stealing train tracks to sell as scrap metal.

If you want to keep your SAS then it might be worth a phone call to them, I think they can make you anything you want and If you order outside of eBay it will save you a few bucks.

...Lee
'94 850 N/A
'96 850 N/A
'96 Platinum Edition Turbo
'98 S70 T5
'99 V70XC - RIP Killed by a drunk driver.
'99 V70XC - Nautic Blue
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1986 740 GLT
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Re: Exhaust Flex Pipe Leaking

Postby misha » 05 Jun 2011, 17:33

I just replaced mine flexi pipe few weeks ago.

You need:
-100mm(length) X 67mm(outer diameter)or 61mm inner diameter of flexi pipe(Bosal,Walker,Mafex... it's up to you)
-exhaust manifold gaskets ( 5 of them)
-metal gasket for joint between cat & flexi pipe

Exhaust manifold needs to go out if you want it to be welded properly.Cut off the old flexi pipe and weld in the new one.
Don't cool down freshly welded flexi pipe with water,take your time and let it cool down naturally,otherwise,it will develop little cracks where it is welded.

Install exhaust manifold & joint with new gaskets and you're done.
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Re: Exhaust Flex Pipe Leaking

Postby cn90 » 05 Jun 2011, 18:58

misha wrote:I just replaced mine flexi pipe few weeks ago.

You need:
-100mm(length) X 67mm(outer diameter)or 61mm inner diameter of flexi pipe(Bosal,Walker,Mafex... it's up to you)
-exhaust manifold gaskets ( 5 of them)
-metal gasket for joint between cat & flexi pipe

Exhaust manifold needs to go out if you want it to be welded properly.Cut off the old flexi pipe and weld in the new one.
Don't cool down freshly welded flexi pipe with water,take your time and let it cool down naturally,otherwise,it will develop little cracks where it is welded.

Install exhaust manifold & joint with new gaskets and you're done.


In the USA, I can only get Scan-Tech Flex Pipe ($60) which includes the 4-bolt flange.
I don't know where I can get Bosal,Walker,Mafex Flex Pipe.
1998 S70 GLT 160K+
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Re: Exhaust Flex Pipe Leaking

Postby cn90 » 05 Jun 2011, 19:00

Ozark Lee wrote:It should bolt up just fine but you will need to plug the EGR hole and do the SAS delete with a couple of diodes. SAS is a total waste of time and money anyway. The gaskets were fine and they have not leaked at all.
...Lee


Lee I have the SAS system.
I'd like to keep it stock (emission testing etc.).
Is it possible to tap into the OBX header for the SAS system?
1998 S70 GLT 160K+
2005 XC90 2.5T 85K+
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Re: Exhaust Flex Pipe Leaking

Postby cn90 » 06 Jun 2011, 02:26

Here is my manifold, you can see the EGR, does anyone have the solution for the OBX?
Is it possible to install an adapter so the EGR can fit in there?

This is the picture of my exhaust manifold:


98V70EGR.JPG
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1998 S70 GLT 160K+
2005 XC90 2.5T 85K+
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cn90
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Re: Exhaust Flex Pipe Leaking

Postby erikv11 » 06 Jun 2011, 03:31

cn90 wrote:Here is my manifold, you can see the EGR, does anyone have the solution for the OBX?
Is it possible to install an adapter so the EGR can fit in there?

This is the picture of my exhaust manifold:


98V70EGR.JPG

Not exactly. You were right the first time - that is an SAS valve hooked onto your exhaust manifold. Your car has SAS, it does not have EGR. The solution has already been posted - you need to talk to a welder, either someone at OBX or someone at a local exhaust shop.
'96 NA 855 | 207 k | wrecked body, rebuilt engine needs a home
'96 NA 855 | 123 k
'95 R 854 | 180 k
'98 V70 GLT | 15g turbo | 224 k
'98 NA V70 | 172 k
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