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Uncle xanadu,
Congrats on your recent 1978 Volvo 242 DL acquisition! The (1976+ with B19 and B21) 1978 to 1980 (1981?) year range of Volvo 240 model offerings epitomizes the simplicity and mythology the Volvo 240s that comes Bosch K-Jetronic injection-ignition or carburetter-equipped.
Replacing the exhaust system from the exhaust port rearward should be very much a bolt-on-affair for you. (Autos with injection call the exhaust manifold an exhaust port, same as the intake manifold as an intake port on injection-equipped engines.)
Parts Vendors and Information
As you are in the Atlantic NE, please see the available exhaust provisions FCP Groton, in Groton CT. See the FCP Groton website for 1978 240 exhaust options.
100893 - Replacement Exhaust System 1977-1993 240 Non-Turbo [Starla] (Go to the iPd website and search fopr Volvo 240 model family exhaust options)
102804 - Sport Exhaust for Non Turbo Models [Upgrade Option] (Can't add an URL, the website SPAM filter craps out) On this page, see the PDF containing the iPd NA 240 sport exhaust installation instructions.
You may want to read this iPd article "10051 Replacing Exhaust in 200/700/900 Models" (Again, we cannot add URLs. JARROD!)
Most exhaust hanging components made by Starla are of a well more than satisfactory quality for most RWD 240 owners, as you read their articles, here on the brickboard. You may want to visit the 700/900 FAQ for more information.
You may want to compare FCP Groton and iPd prices with that you'll find on Tasca Volvo Parts. (No URLS)
You can consider an all stainless exhaust system at a greatly increased price, yet may last as long as your 1978 242 thrives and lives.
FCP Groton sells the system in the more or less stock configuration.
Clamps
Use these:
[No pictures, else the CloudFlare spam craps out]
You'll want to use the Volvo OEM-style pipe-to-pipe clamps and not the u-bolt clamps.
The more typical exhaust clamps that come in the "Volvo Exhaust System Muffler Kit (240) - Starla 240EXH $133.92" do not apply even, concentric clamping force. Consider it an upgrade and peace of mind.
You may want to add one additional nut after applying torque to the clamp securing hardware, and tighten the second nut against the first. Some enthusiasts suggest applying a moly or other non-lead anti-seize compound to the thread in the rear event you need to dissemble your system for component replacement. Some will use two clamps at every union.
Exhaust System Grounding
In addition to the ground through the exhaust port to the cylinder head, and the header pipe bracket support assembly and connection just in front of the header pipe output to catalytic converter input, you may want to connect the rear exhaust sections at the hanger points to the support hanger metal anchors secured to fasteners in the 242 sheet metal.
Still, others, will run a braided soft stainless steel cable from the clamp to exhaust hanger anchor points on the body, sandwiching between washers on the metal anchor hardware stack. Grounding the exhaust system after the bell housing to lower header pipe bracket can slow exhaust system corrosion, as you see on more expensive automobiles. The soft, braided stainless stands up to years of service in the under-auto environment, yet shears when needed should the car, unfortunately, come into an accident that damages the undercarriage, including the exhaust system.
Rear Header Pipe Support Bracket Assembly
Verify you have all hardware, from the bracket that secures to the bell-housing bolts, to the L-shaped steel plate that secures between the bell-housing bracket lower end of the header pipe. Securing this hardware ensures the exhaust port and header pipe are secure together, are well braced, are somewhat isolated from rear exhaust system movement, and is grounded to the 242 body. Many 240 owners ignore securing this bracket. Some others, or shop mechanics, when removing and replacing the transmission, do not reinstall this truly critical support assembly for the front exhaust system section.
Rear Stabilizer Bar and Rear Exhaust Pipe Routing
With the stock, 1978 factory installed rear stabilizer, or sway, bar, the pipe section between the front resonator (muffler) output to the rear muffler input routes over that rear stabilizer bar between the left side frame rail and the fuel tank. Sometime in the early to mid 1980s, that pipe section was routed under the rear stabilizer bar to reduce the chance of fuel tank puncture in an accident. Correspondingly, the rear stabilizer bar, then, changed with an upward bent section on the passenger side, of course.
Please inspect whether the rear stabilizer bar on your 242 comes with the upward bend or not. You may may need to, then, purchase the kit with a change to the pipe section between the front resonator and rear muffler.
Also, if your rear stabilizer is the 1978 factory installed 15mm or 17mm rear bar, and does not have the upward passenger side bend, yet you want to upgrade your rear stabilizer bars and use a more modern rear stabilizer bar with the upward bend now to in the future, please keep in mind you options as you restore and upgrade your 242.
As an aside, stabilizer bar upgrades from the factory installed stock 1978 242 DL 19mm front/17 mm rear include:
- 23mm front and 21mm (coupe/sedan) or 19mm (wagon) rear from turbo 240 or aftermarket.
- 25mm front and 23mm rear on stock factory spring height, usually from SAMS or iPd.
- 25mm front and rear on usually lowered springs.
- You can vary spring wire diameter and height against different bar setups as you need with some research with changes to over and under steer and rise quality
Some with rear locking differential may want heavier rear springs over a heavier stabilizer bar so the rear live axle can be more independent.
Catalytic Converter and Oxygen (02) Sensor Issues
The stock configuration uses the Bosal-brand catalytic converter and two mufflers. One muffler, actually a resonator, resides in front of the rear axle and fuel tank, about under the passenger side seat. Your 1978 242 DL should come with the Lamda-Sond system with frequency valve and single-wire 02 sensor as part of the Bosch K-Jetronic Continuous injection system. You may want to verify you have a properly functioning 02 Sensor. See 02 sensor diagnostic tips in the 700-900 FAQ and in brickboard threads and articles.
Contrary to some myths about emissions controls and performance, if your 1978 Volvo 242 is equipped with the Lambda-Sond oxygen sensor system, the system require that:
- The 02 sensor function well and requires replacement at 50k miles.
- The Bosch K-Jetronic injection and ignition systems works in fin fettle, with optimum fuel to air ratio set at the fuel-air control assembly (with plate venturi and CO adjustment via a 3mm Allen hex key wrench).
- Injectors atomize fuel evenly, and cold start injector does not leak.
A fuel to air ratio that is to lean or rich will ruin your new catalytic converter. If your state of Rhode Island does not require emissions testing, you very well could forgo the catalytic converter, yet you'll need the 02 sensor for the Lambda-Sond feedback loop to control the frequency valve. You can replace the catalytic converter with a pipe section from the header pipe output to the front resonator input or a single pipe piece secured by hardware or welded to the header pipe output to the sport exhaust rear muffler.
If you can perform such work and have access to exhaust pipe bending mandrels, welding tools, and other exhaust tools, you could build a custom exhaust setup using steel or, if able, stainless, and build the entire system from the header pipe reward.
Performance Upgrades
please check Turbobricks for additional information.
You may want to research the brickboard for threads with articles that provide other anecdotal information and opinion for options.
Normally aspired (NA) = without turbo or super charging
Upgrade Options
1. Modern Normally Aspired B230 Exhaust Port on the 1978 242 DL B21DF Engine.
The more modern exhaust port uses a much better exhaust output port length and exhaust pulse balance when combining from four ports to the two output ports at the exhaust port output to header pipe inputs. One drawback on most later B230 exhaust ports is a lack of a threaded 02 sensor input. If you can find a late-model B230 from a 200, 700, or 900 series with EGR (exhaust gas recirculation), the EGR pipe connects at just about the same point on the exhaust port as the single wire 02 sensors do. You could use a newer NA B230 exhaust port and have your trusty machine shop machine in a receiving threaded hole matching the 02 sensor position on the B21F exhaust port.
2. Turbo 240 Exhaust Setup Option on NA 240
iPd offers a 240 Turbo exhaust option, see "102804 - Sport Exhaust for Non Turbo Models", above. A single rear resonator / muffler of a more durable quality used on the turbo 240 yields a somewhat louder, very low tone exhaust note that is utterly nothing like what you here on any rice grinder, or Italian or French so-equipped auto. The note is loudest when the exhaust is cold and quiets as the exhaust gas and metal exhaust parts warm. The solution secures from the catalytic converter output all the way rewards. A single "front strap hanger" secures the exhaust pipe long run and weight at the same point where the front resonator secures using round, rubber hangars to the metal anchors on your 242. You replace one metal metal anchor for the front strap hanger. There is a link to a PDF file containing the iPd NA sport exhaust installation instructions that may help.
Other options and caveats exist I may not think of here.
Again, research the 700-900 FAQ and additional articles here on the brickboard. Turbobricks may offer further information, though accessing Turbobricks requires an account.
Questions?
Hope that helps.
I'm envious you have a 242. My favorite RWD model. The 242 Coupe is an ever rarer classic; certainly with manual transmission. You'll have a host of mechanical restoration to perform. I hope it came with the factory manual steering gear rack and not power steering.
Else, the 164. If Volvo had made the 162, well, that'd be at the top of my list.
Also, you cannot be to quick to get on any rust inspection, remediation, and undercoating treatment. See POR-15 as cold chemical a rust remediation method. Use Waxoyl as a method of displacing blind compartment moisture and rust prevention.
cheers,
MacDuff.
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No funny pictures as CloudFlare spam filter SUCKS! JARROD!
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