97 850 Wagon Exhaust Manifold Replacement Help

CJFusco · Post by **CJFusco** » 01 Aug 2015, 14:35

Hey all -- I have a normally-aspirated 5-cyl 20v 850 Wagon, which recently developed an exhaust leak at the flex pipe, which I gather is exceedingly common. Coming from a Porsche-tuning background, I figured, "well, as long as I'm replacing, I might as well upgrade," and bought the exhaust manifold-with-flexpipe replacement from OBX Racing. The part fit beautifully except for one detail: the Secondary Air System port on the side of the new manifold seems to be a totally different size diameter than the OEM part. What's the solution here? Is there a slight model-year/trim difference that I missed? Is there an adapter that I need to buy? Or can I get the Secondary Air System pipes from a different-year/model/trim Volvo in order to make it fit?

Any guidance you could offer would be most appreciated. Thanks in advance!

Post by **Ozark Lee** » 01 Aug 2015, 15:37

SAS pipe or the EGR? The horizontal bung is for EGR and the EGR pipe will need to be bent to make it fit on an OBX header. The pipe is steel and it really doesn't want to bend. A pipe bender is the preferred method but my son and I just forced it to bend around a support post in the garage. It kinked a bit but not badly. An actual pipe bender is the preferred method.

If it is for SAS I don't think that header will work.

...Lee

CJFusco · Post by **CJFusco** » 01 Aug 2015, 16:30

Thanks for the quick reply. I guess it is the EGR. The problem isn't that the pipe is bent the wrong way (although we did notice that and had the pipe-bender out and ready to use), but rather that the male end of the EGR is too small in diameter for the female end of the OBX exhaust manifold.

For now, we plugged the exhaust manifold with an 18mm drain plug, and the car seems to run fine with no warning lights... but I recognize that this is a temporary solution.