I am in the middle of removing my black oil box in the flame trap system and found that I have to remove the intake manifold to get the box out. I have read many posts that state removing the intake manifold is easy. My car has never that I can tell looking at the flame trap, (completly clogged) that this system has never been changes. I have a 91 740 B230 engine with 273,000 miles.

My question is: How easy is it to remove the intake manifold to access the box and get the new box installed? Is it something that a novice with the right metric wrenches and sockets can do? Or do I need to prepare myself to visit my dealer and pay a fortune?

You don't have to totally remove the manifold. You just need to move it about six inches away from the cylinder head. Just remove and loosen the obvious stuff... if something's holding the manifold back, figure out what it is instead of forcing it.

Supposedly you can do this without removing the manifold... I just couldn't figure out a way to wiggle it free.

On reassembly, just be sure not to over tighten stuff, especially the nuts holding the manifold on the studs.

Don't forget to have a new manifold gasket.

Good luck!

-Ryan
--

Athens, Ohio
1987 245 DL 314k, Dog-mobile
1990 245 DL 134k M47, E-codes, GT Sway Bars
1991 745 GL 300k, Regina, 23/21mm Turbo Sway Bars

Perhaps a good place to start is to see if you have the tools and ability necessary to reach all of the 13mm nuts that hold the manifold in place.

Can you get that box end or socket on each of the nuts and then get your rachet in place? Do you have a couple of extensions? Seems I remember that a universal added to the socket makes several of those nuts infinitely more doable.

You are only looking for a bit more clearance than is available with the manifold in place. Your helper can hold it up and out of the way while you remove the oil seperator.

Do you have a new Oring for the seperator to block seal?

Randy

Yes. I purchased the entire kit from IPD that included the O ring that needs to be replaced.

From what I have been told I should be able to just take the eight bolts off the manifold, have my helper lift the manifold up and then that should be enough room for me to remove/ replace my oil seperator black box....here goes nothing....worst I feel is that I pay a visit to my Volvo dealer....

Just my two cents but I have done two and never removed the Intake Manifold.
Remove T/B and Bellows. Remove Iac, and bracket. Remove EGR(if so equipped) and there she is. Tight fit but easier than removing Manifold. Consider replacing heater hoses and heater control valve at this time as they are all nice and exposed with all the crap you have removed. Certainly clean T/B.
Good luck

Welcome Chris, Easy is a relative term. It is extremely easy as compared to many cars. If changing the Spark Plugs makes you nervous, then maybe you shouldn't do it. If you have cut off and replaced the exhaust system, then this will be a very intuative job.
If you look, you can see the hardware that has to come off.
--
'75 Jeep CJ5 345Hp ChevyPwrd, two motorcycles, '85 Pickup: The '89 Volvo is the newest vehicle I own. it wasn't Volvos safety , it was Longevity that sold me http://home.no.net/ebrox/Tony's%20cars.htm

The trick is removing the accessories: disconnecting the throttle and kickdown cables, hoses and fuel line, disconnecting the throttle position switch connector and the fuel injection wiring. Remember how the former two are installed (or take a digital photo) so you can reinstall easily. Then loosen the manifold nuts. Use a new gasket on reinstallation. And clean your throttle body.
--
See the 700/900 FAQ at the select shortcut button on the top right of the screen.