Exhaust manifold removal

[Quicksilver]

Got to do this job soon as at least one stud broken and blowing, any hints and tips would be welcome from those that have done this job? anything I should look at/replace while I’m at it?

Cheers
Steve

[LeeT5]

What makes you think the studs broken?

They nearly always work loose, especially on cylinder 1 and 2.

Just carefully tighten them back up, but do not overtighten or you'll strip the thread in the head.

[MoleT-5R]

Got to do this job soon as at least one stud broken and blowing, any hints and tips would be welcome from those that have done this job? anything I should look at/replace while I’m at it?

Cheers
Steve

If it's been blowing a while then, I would look at replacing the gasket/gaskets (depending on whether you have the one piece item or the individual ones). Hopefully as Lee suggested they have just come loose (possibly to the point of falling out, so may look as if they have broken) and then could simply be replaced and or tightened (carefully). Biggest ball ache there is removing the turbo heatshield to access all the manifold bolts to make sure they are all tightened correctly.

P.S. if you are replacing the individual manifold gaskets, make sure they are on the right way up, If not you will complete the job and find it is still blowing, as a few on here have in the past...:troutslap

[Quicksilver]

What makes you think the studs broken?

They nearly always work loose, especially on cylinder 1 and 2.

Found the broken nut/stud laying on top of the manifold of No1 cylinder.

[Quicksilver]

If it's been blowing a while then, I would look at replacing the gasket/gaskets (depending on whether you have the one piece item or the individual ones). Hopefully as Lee suggested they have just come loose (possibly to the point of falling out, so may look as if they have broken) and then could simply be replaced and or tightened (carefully). Biggest ball ache there is removing the turbo heatshield to access all the manifold bolts to make sure they are all tightened correctly.

P.S. if you are replacing the individual manifold gaskets, make sure they are on the right way up, If not you will complete the job and find it is still blowing, as a few on here have in the past...:troutslap

Heat shield is already off, that’s been off for a while! Which way is the right way with the gaskets?

[MoleT-5R]

Heat shield is already off, that’s been off for a while! Which way is the right way with the gaskets?

The correct way up to seal ...lol.... not much help I know, but I could tomorrow take a couple of shots to show the difference, as I will be in the shed tomorrow and have an engine a some old gaskets handy.

[MoleT-5R]

Well got a bit of time to take these, don't know how people can get them on wrong, but they have in the past, may be it's just because they are going by feel down the back of the head. Here's a couple of shot to show the difference :-
https://farm8.staticflickr.com/7827/33196820348_bbc4d1829b_b.jpg (https://flic.kr/p/Szuo8w)2019-02-12_01-44-20 (https://flic.kr/p/Szuo8w)
And a blurred but correct shot
https://farm8.staticflickr.com/7870/47019706602_aee728af13_b.jpg (https://flic.kr/p/2eCYhCA)2019-02-12_01-43-42 (https://flic.kr/p/2eCYhCA)

[Quicksilver]

When you look at those pictures it is hard to believe. I suppose I should replace the turbo oil return line seal?

[MoleT-5R]

I'm not going to name anyone, but some good volvo guys have fallen foul with those individual gaskets, that's why many like the later v50 t5 item, (IIRC) which from what I can remember just needs the corner snipping of where the part no. is to make it fit. As for the turbo return seal, for the cost it is a good shout whilst it is all apart, there would be nothing worse than getting it all back together and then finding a small weep has developed and it has to then be replaced.