Intake Manifold Installation Guidelines

Intake Manifold Installation Guidelines

Intake Gasket
We recommend using a brand-new, OEM-quality intake manifold gasket between the head and the intake flange.

O-Rings & Lubrication
Lightly lubricate all O-rings with silicone grease prior to installation. This includes:

  • Injector O-rings (upper and lower)
  • Any additional O-rings used on fittings or ports
    Silicone grease helps prevent damage during assembly and ensures proper sealing.

Vacuum & Brake Booster Fittings
Use thread sealant, Loctite, or equivalent on:

  • Your choice of 1/8” NPT vacuum fittings
  • The 3/8” NPT brake booster fitting located under the manifold
    Do not over-tighten NPT fittings—tighten only as required to seal.

Manifold Flange Hardware
Do not over-tighten the intake manifold flange bolts.

  • The manifold is O-ring sealed, not gasket-crushed
  • Tighten by hand using a ¼-drive ratchet or Allen key only. Firm, even torque is sufficient

Material & Finish
This intake manifold is supplied in raw aluminium, cast from ASTM A356 alloy.

  • A356 offers higher strength than most common cast aluminium alloys
  • A slightly rough surface finish is normal and is a trade-off for strength and durability

Surface Coating
These manifolds look great powder-coated or Cerakoted. If coating with powdercoat:

  • Do not coat sealing faces
  • Do not coat threads
  • Do not coat O-ring ports
    Mask all critical interfaces to ensure correct fitment and sealing after coating.

Throttle Body Compatibility
The throttle body flange is designed for a Bosch Motorsport 68 mm drive-by-wire throttle body.

  • Uses an O-ring seal at the throttle interface
  • Ensure the O-ring is installed and lightly lubricated before fitting

Fuel Rail Recommendation
We recommend the Nuke Performance fuel rail, which is considered the gold standard for Volvo applications at the time of this manifold’s development.

Enjoy

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