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2003 V40 Exhaust Manifold Replacement

Help, Advice, Owners' Discussion and DIY Tutorials on S40 and V40. In this forum you'll find S40/V40-specific owners asking and answering questions on maintenance, ownership, repairs, tutorials and almost every do-it-yourself thing you can do to save money owning these Volvos.

1996 - 2004 S40
1996 - 2004 V40

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zulu-v40
Posts: 123
Joined: 9 August 2011
Year and Model: 2003 V40
Location: Lansing, MI

2003 V40 Exhaust Manifold Replacement

Post by zulu-v40 »

I've suspected an exhaust manifold leak for some time now. From a cold start the engine is quite loud, but as it heats up the leak seems to seal. Today, I decided to check the problem out. One of the exhaust manifold bolts on the periphery was not even finger tight. After tightening that bolt, I went from bolt to bolt checking for tightness. A second bolt seemed to be spinning freely when I attempted to tighten it. As it turns out, the stud was sheered in half.

At 120,000 miles, the exhaust manifold gaskets need replacing, if not the manifold itself. What's the best way to remove that stud? My thought is a pair of vice grips, but there is not much clearance back behind the engine. Any thoughts or recommendations?

Exhaust Manifold
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Context in Engine Bay
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Sheered Exhaust Manifold Bolt
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2003 V40 T4, silicone vacuum hoses, K&N air filter, iPd Boost Gauge, iPd HD TCV, PowerSlot Rotors

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