Do I need to remove the exhaust manifold to remove the head?

02V70 · Post by **02V70** » 24 Dec 2021, 14:23

On my 2002 Volvo v70 XC with turbo, I am removing the head to replace the gasket. However, to remove the exhaust manifold, I need to remove the turbo or push it aside to disconnect from the exhaust. I am having trouble with that. Can I leave the exhaust manifold in place, and just disconnect it from the head, and pull the head forward to get it off so the studs are not stuck?

Post by **abscate** » 24 Dec 2021, 14:37

There are raised bosses in the head that prevent lateral movement until it is lifted about 1-2 cm. Remove the three bolts from the drop pipe and then you can lift it up with turbo attached. There are pictures in the p80 forum of my recent build

Post by **vtl** » 24 Dec 2021, 14:44

Yes, it is possible.

You need to support the manifold, just a tiny bit. I used my cherry-picker, floor jack + wooden bricks or something like that would work as well.

02V70 · Post by **02V70** » 24 Dec 2021, 16:20

A jack with wood won't be able to support the manifold since the drivetrain and stuff is in the way. I also don't have a cherry picker. Any ideas of how I would support it? Also how strong would it have to be and how much would it have to be held up?

Post by **vtl** » 24 Dec 2021, 16:51

I'm sure you can find ways how to support the manifold. It's not very heavy and you need to lift it maybe 1/2".

Post by **RickHaleParker** » 24 Dec 2021, 20:41

02V70 wrote: 24 Dec 2021, 16:20 Any ideas of how I would support it?

Options:

1. Cut a 2X4 to length, lay it across between the fender ( not on top of the fenders ), them use a ratchet strap to to pull the manifold up and support it.

2. Make a support bar out of a 2X4, a threaded hook bolt and some big fender washers. Use the threads to lift the manifold t and support it.

3. Spend $80 - 100 for a real engine support bar.

02V70 · Post by **02V70** » 21 Feb 2022, 21:19

When I was putting the head back on and maneuvering it to fit in the exhaust manifold, I scratched the head gasket and made a small gouge in it between a coolant hole and a cylinder. I have a new gasket coming. Would it be better to remove the studs, or the exhaust manifold so I don't have to put the head in sideways and prevent this from happening again?

Post by **vtl** » 21 Feb 2022, 21:28

Use the head gasket packaging as a protection, lay the cylinder head atop, aiming its exhaust studs into the manifold at the same time. Slightly lift the head from intake side and pull the cardboard out.

Just in case, blow the cardboard clean before using it.

02V70 · Post by **02V70** » 01 Mar 2022, 12:59

Should I cut the cardboard into pieces so that it is not on top of the raised bosses?

Post by **vtl** » 01 Mar 2022, 13:14

As you wish. I did just like on the pic above, w/o cutting anything around bosses.