Hi folks.

I've lurked here over the years, but this is my first post.

I've owned two volvos (and no other makes) over the past fifteen years, first an '81 242 and then a '90 244. I just found and bought a '77 245. The previous owner was an enthusiast and made lots of pick-and-pull mods and upgrades, during the twenty-plus years he owned it. I've always wanted a stripped-down wagon for utility, and that's basically the way this one's set up.

The good:

262 front suspension, heavy duty rear springs
Vented front brakes
Virgos (plus steel wheels with OK winter tires)
Volvo R-sport steering wheel
Straight body
Towing hitch
Spare steering rack - manual
4-speed + OD (switch rerouted to dash)
Heavy swaybars.
KYB struts
Newer exhaust
Replaced main seals
New clutch
Factory accessory armrest
Decent mid-eighties front seats

The bad:

Many random spots of rust, concentration around the tailgate and hood
Heavily oxidized, polished-through blue paint; flat-black hood
Shredded rear seat
Sagging headliner
Generally beat-up interior
Missing tailgate gaskets (metal on metal rattle)
Bad seals around windows
No stereo

Aside from major cosmetic issues, the car is pretty mechanically sound. The main obstacle to getting the car inspected here in Pennsylvania is emissions. The car is old enough that it only has to pass a visual inspection and gas cap test. My problem is a rotted out EGR pipe. It leaks badly enough that I can hear sputtering inside while driving and can smell exhaust gas, which is especially strong when I am sitting and idling.

I've scoured the net for a replacement pipe (from the exhaust manifold to the EGR valve) to no avail and finally called my local dealer. He found a part number and price ($49) but told me it might be hard to get in the U.S. If it has to be ordered from Volvo Sweden it could take months to get here.

I need to get the car inspected ASAP. I am considering either trying to repair the existing pipe, fabricate a replacement, or delete the EGR system entirely. If delete the system, I know it will raise the combustion temp and perhaps mess with the computer. I could live with that for now, but I am more worried about the likelihood of an emissions inspector catching the deletion. Although, here in Pittsburgh there are a range of places that I could take it for inspection; some are definitely more lax than others...

Does anyone have any experience with the same problem. I have been scouring the boards and haven't had much luck.

I appreciate any and all feedback.

Thanks,

Blackbeard