Question about exhaust manifold

[classicswede]

Originally Posted by TonyS9

You can weld the 940 manifold fairly easily, if its genuine Volvo the material is high quality, maybe steel.

I've done 2 with no issues.

Grind out cracks

Preheat in oven to 250C

Weld on low power, Mig, I used standard steel and CO2.

Put back in oven, leave for 20 mins to stabilise then switch off and leave to cool for an hour or so.

The oven bit might not even be needed, I actually used sand blasting sand to slow the cooling.

Without the pre heat and controlled cooling the weld will crack.

[SalvadorP]

btw, does the b230fk have a gasket between manifold and block?
if so, what is the part number?

[Forrest]

Originally Posted by SalvadorP

Any recommendations of the best place to buy good M8 studs? Skandix sells them for 10€ each. And Volvo Portugal just doesn't have anything ever.

https://www.rendcarparts.com/parts-f...3048/RD953048A

More an observation than a recommendation. You need to be careful you get the right length. Non-turbo exhaust studs (part number 953047) are 45mm long. Turbo exhaust studs (part number 953048) are 48mm long.

35mm stud (part number 1336261) for the turbo to the manifold.

[SalvadorP]

Originally Posted by Forrest

https://www.rendcarparts.com/parts-f...3048/RD953048A

More an observation than a recommendation. You need to be careful you get the right length. Non-turbo exhaust studs (part number 953047) are 45mm long. Turbo exhaust studs (part number 953048) are 48mm long.

35mm stud (part number 1336261) for the turbo to the manifold.

I was just realizing that. In fact the 10€ per piece is the price of the mani to turbo studs. Those I run aftermarket, changed them last time I swaped the turbo. But the other I want oem or equivalent. That's the only thing that stresses me out on this job is breaking a stud on the block and having to drill it out.

My issue with rendcarparts is the delivery cost. 30€ for delivery to portugal is a steep price to pay on a small order.

[Forrest]

I’m afraid that is an occupational hazard of DIY on an old car. If you follow an old school approach of repeated heat, lubricant and small, gentle loosening and retightening with hand tools you might strike lucky. Possibly use one of those nut splitter tools if you can reach with one. Or get yourself some left-handed drill bits and accept the inevitable.

Good luck!

[Chris1Roll]

I found the studs were cheaper from Volvo Penta (same part number). Unusual, as normally if something involves a boat, its more expensive!

For release agent, a mix of 50% Acetone (nail polish remover) and ATF is standing me in good stead at the moment. Using that and gentle winding and unwinding I just managed to get two manifolds off without breaking a single stud.
What I did was put a load of it on, then soak some tissue in it and squish it round the nuts so it kept it in place and damp, and left it overnight.


Many years ago I had a cracked manifold on my 480 turbo. At the time my mate worked with a guy who used to do aerospace welding. He welded it up no problem at all and it was good for the several years of somewhat hard use that I gave that car.

[SalvadorP]

I've found an already repaired manifold for 75€ plus shipping. The seller is a specialized volvo parts dealer and he says he has repaired mani manifolds in the past.
I'm thinking if i remove mine and have it repaired, it's probably going to cost me at least 50€ to weld it, plus gas to bring it to the shop. I'll be at least 75€ deep and have to have the car at the shop for several days at least.
Buying the spare is looking to be the best option.

[TonyS9]

Originally Posted by SalvadorP

btw, does the b230fk have a gasket between manifold and block?
if so, what is the part number?

There are 4 discrete exhaust gaskets between the head and exhaust manifold. There is a single gasket on the inlet manifold.

[baggy798]

Have an uncracked manifold here I could send you for say 130€ shipped, so 75€ is a pretty good deal.

271704 was the number for the gaskets.