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replace cat as routine maintenance? 900 1993

posted by  benfingland on  Mon Feb 16 05:49 CST 2004
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last visit: Thu Aug 7 07:54 CST 2014
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Realized that both of my mufflers are going and whole exhaust system from cat back will need to be replaced this Spring, I'm looking forward to doing this myself, but I've got some questions:

-Is it a good idea to replace the 11-year old cat anyway? It passed emissions last year, but it's very rusty, and it looks like I can get a replacement one from FCP Groton for only $125. If I do the whole system from the end of the front pipe back, it should be much easier, right? (Just unbolt cat and take system down, hang new system and bolt in new cat, no worries about having to remove then re-attach rusty old cat to new system).

-Anyone know what type of bolts are used from end of front pipe to cat, and do I need a gasket in there - according to some parts lists, a gasket is required for cars with EGR, and I don't have EGR - but it seems like there should be, because this is a different fitting from the rest of the system. There are no bolts listed on any parts lists, but my old ones are really rusted, I'll need to replace them.

Thanks a bunch!

-Ben








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    replace cat as routine maintenance? 900 1993

    posted by  someone claiming to be kevin walsh on  Mon Feb 16 09:56 CST 2004 [RELATED]

    i did a cat last year on '91 940 t. oe original made it to 140K AND RUSTED
    out at fwd inlet pipe to cat part of cat. FCP aftermarket cat went on a bit
    difficult but no big deal. My concern was OE cat was 2X as big, pipes same size
    but main part of CAT significantly smaller. my first thought was - reduced flow?
    after installing and driving I have had no problems in last year and power is ok. If you get on you'll see, what do we want for $120.00???








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    replace cat as routine maintenance? 900 1993

    posted by  Chris W on  Mon Feb 16 06:05 CST 2004
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    Ben - hope this helps. Entry from my diary on a cat replacement I did a year ago:

    Anne’s 161k 92 940 failed the NOX test two weeks ago during a TX state inspection. I ordered a 'borla' cat from groton - arrived at my door for $125 and included a donut gasket. A year ago, I ordered a cat back exhaust system from volvo independent in houston, tx. It was also all walker parts and hangers. The cat back system fit perfectly - and I didn't even need to use the provided hangers. One thing that allowed it to fit perfectly was the new walker pipe that connected to my old cat converter - the flange was opened up to fit over my old cat. So when I went to install my new 'borla/walker' cat, the end that lead OUT from the cat (toward the back of the car), the flanged end was also expanded. In other words, I had two expanded flange ends to mate up. Got the sawzall out and cut the flanged end off the new cat (BTW - the bends on the new cat were not identical to the original cat - this proved to be problematic). Long story short, I could never get the ends mated up - Had to butt them up, wrap aluminum ducting tape around them and use three band-style radiator clamps to keep things tight. Really had no choice, as I couldn't get the car to a muffler shop to have it all welded up. Today is my last chance on the inspection (TX gives you two weeks to get your problem fixed - and gives you one free retest). Today is the last day of my grace period. Well – the car passed with flying colors.

    Ben - I would think if you buy the whole kit from FCP - it will be a perfect fit (and bolt right on) - good luck. And not a bad idea.








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      replace cat as routine maintenance? 900 1993

      posted by  benfingland on  Mon Feb 16 06:43 CST 2004
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      last visit: Thu Aug 7 07:54 CST 2014
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      Thanks, Chris. That's good advice. Seems like FCP really knows their stuff, I think that's exactly what I'll do.







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        replace cat as routine maintenance? 900 1993

        posted by  mvftw on  Wed Feb 18 06:05 CST 2004
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        I also replaced the whole exhaust from Groton (great company) last year. I failed this years NYS inspection (high NOX). I called Groton and they sent me a free CAT. I passed but barely. Other members here have expressed concern that the aftermarket CAT's are too small. They maybe right...








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        replace cat as routine maintenance? 900 1993

        posted by  someone claiming to be art on  Mon Feb 16 07:18 CST 2004 [RELATED]

        If there's any question about the fit, I'd recommend an email or phone call prior to clicking up your order.







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