Engine: D5: Exhaust manifold and EGR headache.

[Stellaman94]

Hi everyone, im borderline about to set fire to my own car because volvo love making access to their components as fun as possible.

I have an engine bay exhaust leak, i have a loud hiss and you can see soot around the heat shield and the lower rear of the block. I removed the exhaust manifold, (well tried to) thinking it might be a manifold gasket but on closer inspection, the ribbed pipe from the manifold to the cooler has a large split in it. Am i right in thinking this is the cause of the leak and a loss in boost.

I cant for the life of me unclip that ribbed pipe off the manifold, to make things better, 4 of the manifold studs came out with the nuts still on the end.

So basically, that manifolds not coming off until i can remove that pipe. Also note to anyone thats never removed a turbo on this engine, BE CAREFUL OF THAT METAL COOLANT PIPE ON TOP OF THE TURBO, IT WILL P*** COOLANT EVERYWHERE.

[MrJames]

I feel your pain! I'm trying to get the transmission off my car and need to remove the EGR cooler and I can't get the stupid flexi pipe off the manifold either!

[Dancake]

The flexi pipe can be a nightmare to take off, so it's better to disconnect it from the EGR by taking the two bolts out, then you can work at the flexi when the exhaust manifold is off. Some heat and they normally come off fairly quickly.

[Stellaman94]

Ive got the euro 4 engine and I cant see 2 bolts just another jubilee clip, i was strongly considering using exhaust repair paste to fill the crack but yeah, ive still got to get my remaining manifold studs back in and they dont seem to want to go in straight.