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Installed a Bosal downpipe on my 90 240 in March. Several online vendor spec. pages gave a vehicle serial number range for each of two available parts. Downpipe showed up with welded flanges at both ends, which matched the cat. converter.
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Fit-up was very good, including the bell-housing bracket, except the flange welds at the manifold end encroached on the area for the new copper nuts. Used a lock washer as a spacer, and it cinched up just fine; no leaks. Make sure you seal or stake the plug into the O2 sensor port, if not used. Otherwise, you may lose it, and it's a non-standard plug (hard to replace).
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The bad news: After a few weeks I noticed the S-pipe on the outlet of the rear muffler was pulled forward and had contacted & melted the plastic fairing. On closer inspection, I found both rear muffler hangers stretched forward by an inch or more. Failed to see this when cinching up the new downpipe to the cat converter flange. Sure enough, the overall length of the old head pipe was an inch longer than the Bosal part.
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I've ordered a cat-back system since the resonator-to-muffler pipe has now eroded through (at the elbow, of course, on a car driven <5 miles to school). I'll have a local shop add the length back into the rear pipe.
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Check the length on your new downpipe before the install.
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Jim (90 244DL 170K miles) turbo sways w/poly, front struts & bushings, OD wiring
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