Hi Everyone,

I have a lovely hole in my header pipe, hence I need to replace it. I was able to replace the exhaust system starting from the front muffler no problem a year ago, but I am bit worried about replacing the header pipe. Is this something that I can easily do myself with some basic tools and time, or have y'all found that this is an experience best left to the pros? I would greatly appreciate any advice that you have found helpful, as I am inexperienced with this repair.

dan
'87 245 DL 224,000 miles and still rolling.

It's an easy repair.

Be sure to get two new gaskets -- one for the pipe-to-manifold, and one for the cat flange. In this case, original Volvo metal-clad gaskets are advised.

The one problem you should expect is that the three bolts securing the pipe flange to the mating flange on the catalytic converter will be rusted solid, and the bolt heads will be so rusted that a wrench won't bite. If you don't have an acetylene torch torch to help, then simply cut through the bolts. If your flange is the threaded type, then drill through the rusted-in remaining portions of the bolts to create clearance holes for new bolts. Then secure the new pipes with new bolts and nuts.
--
Don Foster (near Cape Cod, MA)

This is not a big job at all, with the exception catalytic converter bolts. When the headpipe on my 87 245 broke a couple of years ago, I was out of state, and patched it together with a tin can and muffler clamps to get it home, where I had a parts car. The headpipe on the parts car was cracking at the weld as well, so I took it out (cat and all), had it welded at a cost of $5, and installed the complete assembly using high-temp copper RTV silicone. It served me well for the duration of ownership. Now I only wish I'd saved that other converter.