DIY 1998 Volvo V70 Exhaust Manifold Replacement

CN90 shows us how to DIY 1998 Volvo V70 exhaust manifold replacement on Volvo 5-cylinder engines.


MVS Forums Contributor and Volvo wizard CN90 shows us how to DIY 1998 Volvo V70 exhaust manifold replacement on Volvo 5-cylinder engines, with great photos and illustrations. This tutorial is close enough to the P2 Volvo family that I’m including those categories in this post’s category list.

Background – Exhaust Manifold Replacement

Alright, my exhaust leak has been chronic for a few years, as it turns out, it is a leak at the Flex Pipe, just in front of the Catalytic. It gets worse and noisy, so I decided to tackle it.

Search forum for “OBX Exhaust Manifold” brand, about $200 on ebay etc., many people seem OK with it. I could not find any long-term report (such as 5 years or more) of happiness with OBX, also from my research the Honda people have some issues with OBX. Since this is a job I don’t want to do again for another 10 years, I decided to go with Volvo OEM because the OEM held up for more than 10 years!

The good news is Waltrip Volvo offers a very competitive price!
I used OEM Gaskets as well; again, this is not a job I want to do again in 10 years!

These are what I ordered from Waltrip Volvo (Franklin TN):
* OEM Volvo Exhaust Manifold: PN 9471934….$365
* Gasket Set (at Manifold, sold as set of 5): PN 271735….$24.
* Gasket @ Catalytic (qty =1) PN 9135122….$10

I regret I did not order the 4 studs at the catalytic, so had to run to local autoparts store.
Volvo PN is 978342….$2.00/each; these are M8 x 1.25 x 35 mm long. So I strongly recommend that you order these 4 studs ahead to avoid aggravation!

I re-used all the nuts, they came out fine.

DIY 1998 Volvo V70 Exhaust Manifold Replacement

Tools for Exhaust Manifold Replacement

  • 10-mm, 12-mm, 13-mm sockets.
  • Extension and swivel joint (this is a must).
  • 2-foot section of 1″ iron pipe (few dollars at Home Depot), this gives me a lot of torque to remove the stubborn nuts.
  • Make-up mirror: a very useful tool! You can get this at Target, Walmart, Walgreen for a few dollars.
  • I broke the Heated Air Hose (Aluminum) feeding the Air Filter. Dealer wanted $50 for this piece of junk! So I got it from OReilly Autoparts for $6.00, make sure the I.D. = 2″ and length is 18 inches or so.
  • I could not remove the 4 studs on the Exhaust Manifold-Catalytic side, even with this out of the car and lots of heat from the torch, I called Volvo dealer and they said it will take 2-3 days to get them, so I went to Advance Autoparts and got their “Water Pump Stud Kit” (PN 25735 on the package: 3 separate sizes and 4 of each type, so 12 studs and 12 nuts total for a cheap $5.00! I only used four (4) M8x1.25×35 studs from the kit). Or you can ask your local muffler shop if they have the studs.
  • Propane Torch ($12 at hardware store): use only 2″ of blue flame.
  • WD-40 etc.
  • “White-out” (liquid paper to label nuts). Make sure you label the nuts and bolts properly, it will make install a lot easier.

I just paint one dot or two dots etc on the nuts/bolts and make notes. Or you can group them together as a group in ziploc bags.

DIY 1998 Volvo V70 Exhaust Manifold Replacement

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