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1995 Volvo 960: How to Disconnect EGR?

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

1975 - 1993 240
1983 - 1992 740
1982 - 1991 760
1986 - 1991 780
1990 - 1998 940
1990 - 1998 960
1997 - 1998 V90/S90

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wrench2fi
Posts: 1
Joined: 28 December 2021
Year and Model: 1995 960
Location: Texas

1995 Volvo 960: How to Disconnect EGR?

Post by wrench2fi »

First time posting here, but the site has been super useful. Thanks in advance to everyone here!

I cannot seem to get the intake manifold out of my 1995 960. Every bolt along the top flange is removed, as is the 13mm nut at the bottom. I think the EGR pipe is still holding it in, but I can't figure out how to get to the EGR connections to disconnect, considering the EGR is under the manifold.

An older post on the forum suggested the manifold comes out first, but that doesn't make sense based on what I'm seeing in my car. Is the "trick" to disconnect the EGR from under the car by removing the oil dipstick tube and the starter?

As a note, I'm attempting to take out the manifold all in one piece without removing the rubber tubes that are clamped between the flange that mates with the head and the rest of the manifold body. This is something different than what the referenced post mentions, but I've read it's a bear to reconnect those tubes, so I'm trying to avoid that if at all possible.

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