Volvo Owners Club Forum - View Single Post - Exhaust manifold

daveo2002 · Oct 15th, 2021, 15:39

Definitely BugJ, those oil cooler hoses were totally shot.

Parts and Suppliers... Huge thanks to Brookhouse Classic Volvo Parts for their help and a shout-out to Skandix for their very comprehensive website.

This is for a 1998 940 B230FK M90,

Heater hoses came from Skandix - their reference 1028237 for the upper hose and for the lower hose I cut a mash-up of parts 1017855 and 1017358. Truthfully either of those could be persuaded to fit on its own, but having both made for a neat job.
The new heater valve is skandix part 1017972 (volvo 9447896). Really nice quality part.

Engine mounts (x2) were from Brookhouse (B1378657) and same part fits both sides of the car. Switching these whilst the heater hoses are disconnected, and the turbo out of the way, just makes a lot of sense.

Oil cooler hoses were do88 kit ref 167 which was from PFS. That didn't include any jubilees, so a selection of 14-22/16-25mm stainless is needed as well.

Oil cooler rebuild required three seals which Brookhouse found for me.
967343 - slim green seal which fits to block
3547188 - thick black seal which fits internally
957189 - aluminium crush washer for banjo bolt (or skandix ref 1017141)
Once dismantled, I recommend letting the oil cooler sit in WD40 or similar for a few days to soften the crud before giving it a good clean with brake cleaner. I was amazed how much muck it released.

Turbo/Manifold fixings:
All the studs and nuts were M8-1.25 threads with 13mm heads. It really helped having a stubby tap wrench to clear the threads, which was £8 from amazon.

The turbo-downpipe studs (3) came from Skandix, ref 1022606/1357769
The turbo-manifold gasket (1) came from Skandix, ref 1021401/8642450
The turbo-manifold studs (4) also Skandix, ref 1017355/13362617
Nuts for the turbo (7) also Skandix, ref 1017358/977209

The exhaust manifold gaskets (4) came from Brookhouse, ref B271704
The exhaust manifold studs (8) also Brookhouse, ref 953049
(953047 would also work, slightly (2mm) stubbier)
The flat washers for the manifold (6) also Brookhouse, ref 949362
Nuts for the exhaust manifold (8) also Brookhouse, ref 985868

Turbo plumbing:
The Kinugawa turbo came with its own fitting kit with stainless braided teflon hoses and AN connectors. Noteworthy points were the supplied 1.5mm restrictor for oil supply line and the general decent quality of the fittings.
However, the fit for the oil drain line is hopeless, a teflon hose just can't bend to the radius needed. I tried a Mamba kit with similar results. Keep the stock lines in your back pocket! The oil return pipe seal (to block) is available from Skandix and Brookhouse, ref 1306264.

Oct 15th, 2021, 15:39	#9
daveo2002 Junior Member Last Online: Sep 4th, 2023 19:01 Join Date: Dec 2010 Location: Birmingham	Definitely BugJ, those oil cooler hoses were totally shot. Parts and Suppliers... Huge thanks to Brookhouse Classic Volvo Parts for their help and a shout-out to Skandix for their very comprehensive website. This is for a 1998 940 B230FK M90, Heater hoses came from Skandix - their reference 1028237 for the upper hose and for the lower hose I cut a mash-up of parts 1017855 and 1017358. Truthfully either of those could be persuaded to fit on its own, but having both made for a neat job. The new heater valve is skandix part 1017972 (volvo 9447896). Really nice quality part. Engine mounts (x2) were from Brookhouse (B1378657) and same part fits both sides of the car. Switching these whilst the heater hoses are disconnected, and the turbo out of the way, just makes a lot of sense. Oil cooler hoses were do88 kit ref 167 which was from PFS. That didn't include any jubilees, so a selection of 14-22/16-25mm stainless is needed as well. Oil cooler rebuild required three seals which Brookhouse found for me. 967343 - slim green seal which fits to block 3547188 - thick black seal which fits internally 957189 - aluminium crush washer for banjo bolt (or skandix ref 1017141) Once dismantled, I recommend letting the oil cooler sit in WD40 or similar for a few days to soften the crud before giving it a good clean with brake cleaner. I was amazed how much muck it released. Turbo/Manifold fixings: All the studs and nuts were M8-1.25 threads with 13mm heads. It really helped having a stubby tap wrench to clear the threads, which was £8 from amazon. The turbo-downpipe studs (3) came from Skandix, ref 1022606/1357769 The turbo-manifold gasket (1) came from Skandix, ref 1021401/8642450 The turbo-manifold studs (4) also Skandix, ref 1017355/13362617 Nuts for the turbo (7) also Skandix, ref 1017358/977209 The exhaust manifold gaskets (4) came from Brookhouse, ref B271704 The exhaust manifold studs (8) also Brookhouse, ref 953049 (953047 would also work, slightly (2mm) stubbier) The flat washers for the manifold (6) also Brookhouse, ref 949362 Nuts for the exhaust manifold (8) also Brookhouse, ref 985868 Turbo plumbing: The Kinugawa turbo came with its own fitting kit with stainless braided teflon hoses and AN connectors. Noteworthy points were the supplied 1.5mm restrictor for oil supply line and the general decent quality of the fittings. However, the fit for the oil drain line is hopeless, a teflon hose just can't bend to the radius needed. I tried a Mamba kit with similar results. Keep the stock lines in your back pocket! The oil return pipe seal (to block) is available from Skandix and Brookhouse, ref 1306264. Last edited by daveo2002; Oct 15th, 2021 at 17:47.