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Is header pipe replacement needed? 200

1990 Volvo 240 DL Sedan. Location New England.

Six years ago, my mechanic welded a broken connection from the header pipe to the inlet flanges at the catalytic converter. This saved the cost of replacing both the header pipe and converter. The weld has not failed since.

For the last two inspections, my mechanic noted that the front exhaust down pipe is getting rusty. The section of this pipe that connects to the manifold is rusted and pitted from the bend up (see picture). I looked at it; it appears to be solid with no weak spots. But I’m not a mechanic.

The catalytic converter is still okay. Both the header pipe and converter may be original equipment on the car.

If the header pipe must be replaced, then given the once failed and now welded connection to the converter, it probably makes sense to also replace the converter, even though it is still okay.

I don’t like to replace parts before it is necessary, and would opt to try a solution like I did 6 years ago with the welding before investing in new parts.

Given the current state of the header pipe, is there any way for me to extend its life?

Or might the header pipe be okay for a few more years in its current state, so just wait until there are holes in the pipe?

I realize that without seeing the pipe, this is difficult to answer. I'm just looking for whatever thoughts folks might have.

NOTE: I am currently replacing the exhaust system from the converter back. But I don’t see this as a reason to fix something that right now is not broken.

NOTE: Nlot sure how to include 2 pictures. Picture 11263 in the library is a better picture, but the pitting does not show up as well on it.









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    Is header pipe replacement needed? 200

    "I don’t like to replace parts before it is necessary,"

    And neither do I. The problem is that necessity often pops in for a visit at the most inconvenient times. Only you can judge if the piece of mind of a new exhaust system is worth the price of admission.

    If it's a car which will be used for out of town trips or must be counted on for daily service, I would renew the system from stem to stern before the snow and slush are ass deep.

    Rich Near Pittsburgh








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    Is header pipe replacement needed? 200

    Down-pipe exterior shows some severe material cavitation in that photo.

    So the down-pipe output is welded directly to the cat. converter input?

    Secured to the bracket that secures to the bell-housing bolts? You better support that exhaust piping weight!

    If the cat converter substrate looks good inside the cat converter, and is not clogged, and your 240 passes emissions test if you have to in your state, and the housing is strong, cut the connection with the failing down pipe at the weld, ream or file, perhaps use a sleeve between the two and reweld the connection with the new down-pipe.

    Starla or the other brand that I forget all the time. Don't use what Midas/Meinekeye or the other nation brand foists on you. Or Volvo OEM. Forget the other after-market brand.

    Remember, go to the junkyard or the dealer! Get the hardware tyhat secured to the downpipe end and the bracket on the passenger side bellhousing to carry the downpipe and cat converter weight! Also grounds the exhaust at the point, so the oh-two sensor works better


    Research grounding the exhaust system for wet, icy, and snowy (and salty) places like you Kings in New England.

    cheers,

    Bastards in the PacNW
    --
    Wacky, WACKY, WACKINGTON state!!!!!!







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