I am getting ready to replace my intake. I was wondering how difficult a job it is? Any advise or helpful tips appreciated!

Also I had a guy at a repair shop quote me $123 to change the gasket.
All things considered should I let them do it (I am capable of doing it myself) ?


Thanks for the input.

Thanks for the great advise.
The tips here were very helpful. I did'nt get to change out the Throttle Body Gasket or clean it because I was in too big of a hurry to get it put back together this time.
It took me about 1 1/2 hours to do the job, and all I had to use is a 13mm socket, and a 13mm wrench.

Had to cut one end of the tab off of the gasket to make it fit correctly, but it works great. this was an easy fix.

The thing that took the longest was figuring out which hoses to take off to get at the nuts which hold the intake on.

Thanks to all. I spent $7.50 on this job instead of $128.00

Next up is the exhaust system!

Do it yourself. It's not difficult to wiggle the fuel injector rail out of the manifold and set it aside with the fuel lines still attached. Replace the injector o-rings and caps while you're in there. I've had to take my manifold out a few times to gain access to the ECT. First to replace it, then to splice in a new wiring harness connector. I think I can now take it apart and put it back together in less than an hour....be sure to torque the bolts correctly.
Jon

It's easy. While you're at it clean out your throttle body, flame trap, and IAC air valve. They're all very easy to get to with the manifold off, and you won't have to do it for another two years or so.

Shit for that I'll do the intake, the throttle body and toss in an oil change...

Go for it. I replaced mine with little problem - actually just moving it back.

The only thing I really moved was the large hose that vents the crankcase (goes down between 3 & 4).

There was a bit of concern about how tight to tighten the bolts - as I did not have a torque wrench. I suspect that most who do this job do not. Anyway - maybe someone will have a pointer on the tightening of the bolts without a torque qrench.

--
'94 940T (160K) , '92 745T (200K+)

As Evan said, this job is one that anyone familiar with a socket wrench can do, so I'm sure you can save almost all that money. Get both the intake and the Throttle body gaskets since the TB gasket is 75 cents at FCP Groton. It is an excellent chance to clean the throttle body (throttle plate cleaner and a toot brush) and if you are slightly more ambitions, change your heater hoses while you have the manifold off and it's easy. Clean your flame trap too.

Check out the FAQ under Features at the top of this page. Those items are effectively the same on a 240 as they are on a 740.

obvious correction:

I am getting ready to replace the intake manifold gasket.

Mostly it's a case of remove and replace.

There are a couple of nuts holding it in place that aren't obvious how to access. Use some creativity. A trick I use involves temoving the throttle body. One more gasket to potentially replace, but having it out of the way makes two of the nuts easier to see and access. Also gives you an excuse to clean the TB.

In a fit of silliness, Volvo ran parts of the wiring harness through the webbing of the intake manifold. Actually removing the manifold requires some de-wiring. Without removing any wires, you can still back the manifold off the head a couple inches so that you can clean the mating surfaces and install a new gasket.
--
'73 142, '75 242, '75 245, '80 245, '83 244, '86 244, '87 745T, 92 244 (for sale)