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Check Out my Exhaust Manifold Flex Pipe Repair Please...

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
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

plumsmooth
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Re: Check Out my Exhaust Manifold Flex Pipe Repair Please...

Post by plumsmooth » Fri Nov 18, 2016 7:20 am

I will link it again, this is a much better option:

Exhaust Flex Pipe Leaking
viewtopic.php?t=39723
Pardon me cn90 I didn't mean to brush off your sharing of that link.

I had seen and enjoyed that idea; however it had occurred to me that by the time one removes the Manifold one might as well just replace it rather than all the work involved in splicing in a replacement flex pipe?

plumsmooth
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Re: Check Out my Exhaust Manifold Flex Pipe Repair Please...

Post by plumsmooth » Fri Nov 18, 2016 7:23 am

IS there something wrong with this manifold... That I am missing?

I mean I only plan on trying to keep this car another maybe even one year...
Maybe as a back-up vehicle for a few more years after that?



https://www.fcpeuro.com/products/volvo- ... DQodyJ8LCQ

cn90
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Re: Check Out my Exhaust Manifold Flex Pipe Repair Please...

Post by cn90 » Fri Nov 18, 2016 7:26 am

plumsmooth,

I am not the author of that facebook link, but from reading it, this is my understanding:
- Leave things in place.
- Use a Sawzall and cut the bad part (flex accordion portion + some of the solid pipe), leaving enough to re-connect.
- Weld the generic flex pipe to both ends and you are done.

Basically they weld both ends with the exhaust manifold in place.
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

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Re: Check Out my Exhaust Manifold Flex Pipe Repair Please...

Post by cn90 » Fri Nov 18, 2016 7:27 am

Re PPS vs OBX...I don't know, just go with either generic flex pipe vs OBX.
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

plumsmooth
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Re: Check Out my Exhaust Manifold Flex Pipe Repair Please...

Post by plumsmooth » Fri Nov 18, 2016 7:45 am

Regarding the size of the flex pipe the posts I read mentioned Millimeters (65-67) which I think translated to 2-1/2 inch.
It seems the manifold side flex pipe goes IN then welded; and the tailpipe side it wraps the outside?

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erikv11
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Re: Check Out my Exhaust Manifold Flex Pipe Repair Please...

Post by erikv11 » Fri Nov 18, 2016 8:10 am

plumsmooth wrote:IS there something wrong with this manifold... That I am missing?

I mean I only plan on trying to keep this car another maybe even one year...
Maybe as a back-up vehicle for a few more years after that?



https://www.fcpeuro.com/products/volvo- ... DQodyJ8LCQ
This should be fine for your purposes. But why not get the OBX one for $110? Many people have used that one with success. It comes with gasket(s) but they are worthless, get new ones.

If tomorrow you are still trying to figure out details of how the flex pipe attaches let me know, at that time I can grab a manifold from the garage and take a close look.
'95 854 T5-R, Motronic 4.4, 185k
'96 855 NA, 145k
'98 S70 NA, 220k (living out west)
'98 V70, T5 tune-injectors-turbo, LPT engine, 286k
'06 S60 R, 167k
'99 Camry V6 :shock: 125k
gone: '96 NA 850 210k, '98 NA V70 182k

plumsmooth
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Re: Check Out my Exhaust Manifold Flex Pipe Repair Please...

Post by plumsmooth » Fri Nov 18, 2016 10:41 am

If tomorrow you are still trying to figure out details of how the flex pipe attaches let me know, at that time I can grab a manifold from the garage and take a close look.
I am very curious of the details especially since I have wanted a welder recently (to learn) and if one of the Harbor Freight Welders could do this job I would consider doing it my self...

I'm guessing that one chooses a flex pipe diameter that is a compromise between the inside dimensions of the manifold and the outside diameter of the tailpipe to CAT...

Looks like with the manifold cover off one can do at least half of it from above.
With a bad angle on the back through...

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Re: Check Out my Exhaust Manifold Flex Pipe Repair Please...

Post by j-dawg » Fri Nov 18, 2016 7:16 pm

ZuluR wrote:I tied my whole down pipe in heat insulating wrapping tape that is usually used on the exhaust manifold.
That is a thing you could try perhaps.
Be careful with this if your car leaks any fluids. Header wrap and other fabricky materials can soak up fluids and catch fire when the exhaust gets hot.

I got a 3" stainless flex section welded into my exhaust pipe at a local custom muffler shop for a total of ~$100, materials and labor included, and a 15-minute wait. A smaller-diameter carbon-steel flex pipe plus installation will probably be cheaper. I don't think it's worth spending $30 plus one's own time on hacked-up kinda-sorta solutions when the most-correct solution probably costs $60 and will last as long as the rest of the exhaust.
1999 V70 T5 5-SPD | ~270k mi | burns more oil than gasoline

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Re: Check Out my Exhaust Manifold Flex Pipe Repair Please...

Post by tryingbe » Fri Nov 18, 2016 7:20 pm

Can RTV catch on fire? I guess plumsmooth will let us know.
85 GLH, 367 whp
00 Insight, 72 mpg

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misha
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Re: Check Out my Exhaust Manifold Flex Pipe Repair Please...

Post by misha » Sat Nov 19, 2016 10:08 am

plumsmooth wrote:...however it had occurred to me that by the time one removes the Manifold one might as well just replace it rather than all the work involved in splicing in a replacement flex pipe?
When you remove manifold,time required for welding a new flexi pipe in is about 15min.That 15 minutes includes removal of old flexi pipe and welding in a new one.
Besides flexi pipe,you will need new exhaust manifold gasket for this procedure.
tryingbe wrote:Can RTV catch on fire?...
It shouldn't...it's silicone.
'97 850 2.5 20v / fully equipped / Motronic 4.4 from the factory / upgraded with S,V,C,XC70 instrument cluster / polar white wagon
'91 Citroen XM 2.0 SI /fully equipped/mandarine red metallic
History of Volvos in the family:
'71 144 S
'73 144 De Luxe
'78 244 DL
'78 244 DL
'79 244 GLE
'85 340 GLS

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