Hello all, I have looked at threads for two days and have not been able to find an answer to my question. What is going on is BOTH my 240's are down for the count and I am driving my 1956 Chevrolet truck everyday now so I could really use some help :) My 1991 240 Wagon has the EGR stuff on it, it also has the O2 sensor behind the flange of the Cat (so it's in the pipe before the Cat) anyway, the rattling STOPPED, not a good sign, kind of like when the drums stop you know you are about to be attacked. Anyway, the rattle stopped, then I got a check engine light several days later. The code I pulled says the O2 sensor is bad. Since the Cat is bad, and was rattling etc right next to the O2 sensor, it makes sense. I don't want to drive the thing with a stopped up Cat, so I parked it until I could figure out what to do. Then my 87 quit because of fuel issues (another thread). So, all the Cats I find say "Non EGR" So I am wondering, what is involved in removing all the EGR stuff? Is it just a matter of changing exhaust manifolds, head pipes and replacing the EGR computer with a Non EGR computer (Dan, you out there?) Here in Texas, I only have another year on the treadmill fof the emissions test, then it will be SAFETY sticker Only from now on. So I really want to femove ALL of the EGR STUFF and would appreciate some help figuring out what I need to do to remove all of it for good. Any help or advise welcome :)

Very Tired Scott IN Dallas

Ok, with the exception of Phil's reply, I received no help on this one, as the EGR equipped 240 is an odd bird I would guess. My car was bought in Sweden and brought over to the states so it has some strange things on it. I am writing this Epilogue, in case another unfortunate EGR equipped owner comes across this thread. I could NOT find a replacement CAT anywhere. MIne had/had three features. 1) the flange that attaches to the head pipe is NOT fixed but movable (you can spin it around). 2) it has the O2 (Oxygen) sensor just AFT of the non-fixed flange, BEFORE the CAT itself. 3) it is a CAT that came on an EGR equiped car. Nearly every CAT available says that it is NOT for an EGR equipped car.

So I needed a CAT that was FOR an EGR equipped car, it had to have a bung hole for the O2 sensor after the flange, but BEFORE the CAT, and it had to have a movable (non-fixed) flange where it attaches to the head pipe. I found several CAT's that had 2 out of 3, but NOT one that had all three. The BIG mystery to me is WHAT is the difference between an original CAT from an EGR equipped car, and a CAT from a car without EGR. All I can guess is that the head pipe may be different where the two connect. My EGR equipped car DOES have a different exhaust manifold, in that there is a pipe going into the manifold where normally the O2 sensor would go. That is, my 1987 240 (non EGR) car has the O2 sensor screwed into the exhaust manifold in the same spot as there is a PIPE going into the manifold on my 1991 EGR equipped car. Anyway, I contemplated going to the wrecking yard and buying an Intake and Exhaust manifold off of a NORMAL (no EGR) 240 and then removing the EGR manifolds, and ALL of the EGR assorted stuff, and then also replacing the LH module with a NON EGR Module etc. but then I would also have had to replace the head pipe as well. A lot of work, and I have no spare time at the moment. SO.... I just went up to the muffler shop and had them weld in a Universal CAT that also had the O2 sensor in the same spot, and problem solved for a mere $225. I hope someday to determine what exactly the differences are, and I still plan on removing ALL the EGR stuff and replacing them with conventional 240 items, so in the future I can order whatever I need with the click of the mouse. Anyway, don't know if this manifesto will help anyone, but the path of least resistance is to just go get a universal CAT welded in. When I figure it all out I will post my results some day. For the moment I am just glad to have my wagon back in front line service :)

Scott in Dallas

I have an 1989 240 with EGR. I purchased a volvo OEM cat for it from eeuroparts.

Catalytic Converter by Genuine Volvo

Catalytic converter for any 89-93 240 with EGR (loose flange to header pipe). Includes gaskets and mounting hardware. For cars without an 02 sensor bung after the flange.

http://www.eeuroparts.com/Parts/7779/Catalytic-Converter-8551606G/

Sorry I didn't see this sooner. The actual Cat is the same for both. It is the manifold connector that is different because of the dumb EGR garbage.

Keep'em rolling.

--
My back feels better when I sit in a Volvo seat

Thank you for your post back!

I think you have indeed come with the best answer to your situation.
It's back on line at that's what really matter today!
The ECU and EGR stuff, hey, no big deal!

You sure had a mixed "bag of goodies" going on there but you did a great job of shaking out the right bones from it!

I Bet you didn't know you had to be part "witch doctor" to cure the problem. (:-)

I agree the odds are low that there are cars over here, from there, the same!
Your post is out there, in the virtual land, so who knows!

Phil

Thanks Phil, that means a lot coming from you :)

I am no expert in this area but I surmise that the exhaust flow is reduced and therefore the sensor is not getting hot enough to work.

Another guess on my part is the only difference between the cats is where the sensor is located. Either in it or up stream of the cat. If your is up piped to be up stream I would say it's an non-EGR type on there. That might be a factory transition in production run or a previous owner change.
It anyone guess which transpired.

I have passed an emissions test on my '84 with the insides gutted out and the shell showing it was there. The machine never hinted that the engine was not running clean.

The next thing is.... I would not worry about the EGR system.
Again from what I know about them, you will be hard pressed to tell any great performance improvement by deleting the system.
It does not work all the time but just under certain criteria for idle emissions.

I have followed newer cars, that stunk to high heaven, while climbing in mountains passes.
No amount of EGR was going to correct those cats! They were hot from unburned fuel, period!

If a car is tuned and firing properly it should not need one under normal state by state testing stations. Most are not that sophisticated.
As far as I know, the test booths can't simulate a change of the atmospheric pressure on the air used even with dynamo loading.

It's all a spoof from the manufacturers and the politicians, IMHO!
It's an all around crap shoot! Both of them using crap shooting lip movements, to bite into our ever thinning shorts, to transfer money back and forth from our wallets.

Guess it's almost April 15th, you think? (:-( sorry!

Phil