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Back in September, my car failed the Texas Emissions Inspection due to high NOx (the converter, bought from IPD, was 61 months old with 45K miles).
I bought a new header pipe and catalytic converter pipe from FCP. The car passed the re-test perfectly, BUT, the new header pipe wouldn't attach to the mounting bracket, the O2 sensor was bumping into the under carriage, as was part of the converter pipe toward the rear muffler.
Nick at FCP was nice enough to send me a new header pipe (at no charge, including freight and a return freight call tag--Thank You Nick!). I have been dreading doing this repair, as I didn't know if it was the header pipe, the converter pipe or both.
Today I took measurements and then took out the system that was in place. I re-installed the old system, of which the header pipe was a Genuine Volvo part, that I had replaced about 8 years prior. (Thank goodness I didn't throw it out (or sell it to a recycler). I took measurements and then worked on a solution.
I took a 3lb hand sledgehammer and gently adjusted the undercarriage of my car near the end of the converter pipe before it enters the first muffler. I also adjusted the area above the O2 sensor.
I was surprised with the old system that you could barely fit a finger between the converter pipe and the undercarriage of the car.
Next, I installed the new header pipe.
After comparing the old FCP replacement pipe to the new FCP replacement pipe, I could see that the bends were off just a little, and that the bracket mount was also off by about 1/4 of an inch. The new catalytic converter was also about 1/4 of an inch shorter than the old one.
I loosely installed the new header pipe to the exhaust manifold on one end and the converter pipe on the other end. That was the answer! Everything fit perfectly! I tightened everything and installed the header pipe bracket. I started the car and didn't hear anything tapping on the undercarriage of my car.
NOTE: While I was under the car, I noticed that the insulation on the wire that comes from the gear selector to the transmission was disintegrating. I took a paintbrush and some Liquid Electrical Tape and covered up the bare wire. The same thing is happening to the wires that go the speedometer magnet in my rear axle. I’m going to replace that wire when I drain and refill the rear axle oil this weekend.
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If it needs to be maintained, repaired or replaced on a 1990 240, I've probably done it. '90 240DL, 255K looking forward to 300K badge (or sticker??). >>You haven't really worked on a car until you draw blood<< :-}
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