Removing intake manifold from '96 960 wagon - Volvo Forums - Volvo Enthusiasts Forum

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Old 07-06-2010, 08:18 AM
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Join Date: Apr 2010
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Default Removing intake manifold from '96 960 wagon

I have a 1996 960 wagon that I am removing the intake manifold (installing a new gasket and cleaning up the crankcase ventilation system mess). I got everything loose and tied back, and surely enough the rubber bushing on the bottom of the manifold. It is not easy to see, and in Volvo style there is probably only one secret way to remove it easily...

Could someone please post a photo of the manifold as removed from the car, and the fastener sizes and locations for these? I am trying to find a service manual, wants $315 for the entire legacy lot of TP51935 "Classic Service Information". I'm not even sure it's the right documents, but wow...

Hopefully I can get this car back on the road soon. Thanks.
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Old 07-06-2010, 09:12 AM
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Join Date: Jul 2009
Location: Chicago
Posts: 185

There is a single nut at the bottom of the bulbous portion of the intake, it is a 13-14 size wrench, and you do not have to remove the nut, just loosen it, the bolt fits into a slot that the nut tightens down on. So removal is not needed.

It's lucky that it does not need to be removed, because it is a bear to reach, you can try to get it from the underside, but I usually kneel on top of the engine and reach down, one's hand and arm are still a tight fit from either direction.

If you choose to kneel on the engine, be sure to remove the plastic cover on the head first.

DanR '94 964 353,000 miles (119,000 miles on the new engine)
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