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960 Intake Gasket Replacement Hints[900/93] posted by Ron on
Sunday, 11 June 2000, at 8:32 p.m.
I will be changing my intake manifold gasket due to a leak on my 1993 960 wagon. Are there any trick of the trade or hints that anyone can provide to make the job a sucess or easier. Also, while its off, is their any PM that I should do. Thanks for all your good advice in the past.
Ron
--Ron
Re: 960 Intake Gasket Replacement Hints[900/93] posted by Jim Bowers on
Monday, 12 June 2000, at 9:27 a.m.
I did mine a few months ago. If you don't have the factory manual I strongly suggest you get one. If you find the publication # from the web page at; http://www.kencook.com/vcna/volvo.html and then call their 800# with your credit card handy you'll have the manual in about 3 days or less.
1) If you are carefull, you can reuse the hose clamps on the rubber tubes between the inner and outer manifolds. Have a couple available as spares. I used an awl to spread the crimp enough to release the barbs. I only took off the outer ones. Reform them to ease reuse when you put them back on. I used a large wire cutter as a crimping tool to put them back on.
2) The nut attaching the bottom of the outer manifold to the motor mount bracket was a SOB on my car as it was covered by a shield for the wiring harness. It is slotted so you don't have to take it all the way off. only back it off and make sure it is real loose. Also the bolts on the bottom side of the manifold are in slots so they only need to be loosened to get the manifold off and they can hold the new gasket in place when you reassemble.
3) Have a set of seals for the injectors handy to be able to replace them if needed.
4) Be sure the new gasket you get from Volvo is of the improved design. Looks sort of green in color and appears to incorporate metal in its design.
These are my first thoughts, if I think of more I'll add later.
5) Clean out the oil breather box and replace the gaskets on it. clean or replace the flame trap and check the condition of the vacuum hoses.
--Jim Bowers, North of Boston, 96 965 w/70K, Had a '85 745 Turbo diesel for 200K
Re: 960 Intake Gasket Replacement Hints[900/93] posted by Tom Irwin on
Monday, 12 June 2000, at 11:07 a.m.
Hi Ron:
Jim has you covered on everything. If I could be so bold as to SLIGHTLY disagree on one minor point....
Personally, I wouldn't try to re-use those Oetiker clamps, unless I were stuck somewhere.
During my 'career' working as a supplier to Coca Cola, we had some extensive training in how their equipment goes together and they use a LOT of Oetikers, (stepless one-ear, constant tension clamps). Re-using them tends to defeat their design purpose. As weird as these cars are about intake leaks, I wouldn't.
The Oetikers in that app. are 56.0mm EVEN AT FULL-BLOWN rape-retail you are paying about $3.50 each. About 1/4th of that if you find an Oetiker distributor.
Also, I would go ahead and clean out the Throttle Body and IAC motor too while I had the chance.
Tom
--Tom Irwin