850 1995 Petrol 2,5 L 20S Exhaust manifold Topic is solved

Post by **manovlov** » 17 Nov 2022, 11:53

Hy Buddies,

Some questions.

On my engine, to what the aluminum hose is connected to engine side (1) ?

On the exhaust manifold, the part N° 2 seems to be not still available at Volvo shop...

: Exhaust manifold.jpg (68.8 KiB) Viewed 772 times

454cid · Post by **454cid** » 17 Nov 2022, 12:43

It goes to the air filter box, which has a diverter door that selects between the heated air, and air from the front of the car. I removed mine due to a non-functional door.

Post by **Chuck W** » 18 Nov 2022, 06:16

Is your flex joint bad on your exhaust manifold (#2)?

When I had my NA '96 GLT, that failed in me as well. I was able to find a new flex joint with a flange on it and welded it on as a replacement.

Post by **manovlov** » 18 Nov 2022, 09:54

Chuck W wrote: ↑18 Nov 2022, 06:16 Is your flex joint bad on your exhaust manifold (#2)?

When I had my NA '96 GLT, that failed in me as well. I was able to find a new flex joint with a flange on it and welded it on as a replacement.

Good opportunity to learn to weld

Post by **Chuck W** » 18 Nov 2022, 10:55

I just looked it back up. The Volvo PN is 9471933.

Post by **volvolugnut** » 18 Nov 2022, 14:03

manovlov wrote: ↑18 Nov 2022, 09:54
Chuck W wrote: ↑18 Nov 2022, 06:16 Is your flex joint bad on your exhaust manifold (#2)?

When I had my NA '96 GLT, that failed in me as well. I was able to find a new flex joint with a flange on it and welded it on as a replacement.

Good opportunity to learn to weld

This is a complex weld - steel to stainless steel. It is only possible with a specific welding wire (309?) with MIG or TIG process.

volvolugnut

850oldschool · Post by **850oldschool** » 18 Nov 2022, 14:15

I saved my old manifold with a failed flex coupling, thinking I might replace it someday. Getting the rotational alignment right seems a bit daunting. I suppose you could assemble the coupling to the cat and the manifold to the engine and then scribe an alignment line on the two parts. Chuck, did you just eyeball it?

Post by **Chuck W** » 18 Nov 2022, 16:14

850oldschool wrote: ↑18 Nov 2022, 14:15 I saved my old manifold with a failed flex coupling, thinking I might replace it someday. Getting the rotational alignment right seems a bit daunting. I suppose you could assemble the coupling to the cat and the manifold to the engine and then scribe an alignment line on the two parts. Chuck, did you just eyeball it?

It was 6-7 years ago. I think I made sure the flex flange was "parallel" to the head flange (made sure the bolt holes were all in roughly the same "horizontal" alignment) and burned it together. I don't recall any odd twists when mating the system back together. I also put in a new (smaller) cat at that time too.

volvolugnut wrote: ↑18 Nov 2022, 14:03
This is a complex weld - steel to stainless steel. It is only possible with a specific welding wire (309?) with MIG or TIG process.

volvolugnut

I MIG'd it with my standard wire. Didn't have any issues. Was it the "correct" way? Maybe not. Did it work? Yes.

I've welded other stainless parts to aluminized exhaust tubing with no issues over the past few years. I at least coat the welds up with some hi-temp paint at a minimum when I'm done.

Post by **manovlov** » 19 Nov 2022, 11:40

I'm nort a rich guy. However, i will replace this part by a new one. Otherwise, my MVS Buddy Project would have any sense ... (to me, of course).