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Bosal header pipe: You get what you paid for. With PICs! 200 1989

posted by  someone claiming to be tjts1 on  Tue Dec 12 05:36 CST 2006 [RELATED]

I took a few pics of the Bosal header pipe (down pipe to some) in order to show just how completely different it is from the stock 240 exhaust. It is so much longer than stock exhaust. I aligned the old stock exhaust and the new bosal by the bell housing mount nut. As you can see both the front and rear sections of the bosal are much longer. On initial installation the catalytic converter was banging up against the transmission mount cross member. But after a little adjustment and re torque all is well. So it does fit... just.

Lined up in the middle


Direct fit they say... HA


Oh dear...


The bosal has a welded flange as opposed to Volvo's spin flange. No worries. It still seals up nicely with a new gasket. The old one had a doughnut gasket which I replaced with flat type gasket. No leaks.


After this crack opened up it allowed the two down pipes to vibrate relative to each other which eventually murdered the welds where they meet. It was leaking all over the place.





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