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Intake boot alternatives for 1996 960?

Help, Advice, Owners' Discussion and DIY Tutorials on all Volvo's "mid era" rear wheel drive Volvos.

1975 - 1993 240
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1986 - 1991 780
1990 - 1998 940
1990 - 1998 960
1997 - 1998 V90/S90

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Paulbo
Posts: 3
Joined: 14 June 2025
Year and Model: 1996 960
Location: SF Bay Area

Intake boot alternatives for 1996 960?

Post by Paulbo »

I have a 1996 Volvo 960 wagon and I’m wondering if anyone has figured out an available alternative for Volvo 3531927? It’s the rubber boots that go between the intake flange and the runners/plenum on the B6304 6cyl. It looks like the factory part is discontinued now :(

Looks to be a simple rubber coupler, but what size? I’m hoping someone else already went through this and measured the OD’s so I don’t have to disable my car to measure :lol: :wink:

Here’s the part I’m talking about for reference:
https://www.fcpeuro.com/products/volvo- ... 531927?#qa

Paulbo
Posts: 3
Joined: 14 June 2025
Year and Model: 1996 960
Location: SF Bay Area

Post by Paulbo »

Update: intake manifold side is 48mm OD, cylinder head side is 50mm. I ended up using silicone intake couplers from Ali Express cut to size which worked alright. The thicker wall thickness of the silicone made fitting the intake back on a little tricky but it all worked out.

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