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!982 Volvo 244 GLT Pulsair Removal 200 1982

posted by  r2grom on  Sun May 3 16:45 CST 2020
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last visit: Sat Nov 24 23:09 CST 2012
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Afternoon all,
The Pulsair Piping System on my 82 GLT was/is split and making a horrible sound.
I managed to patch it up so that it is again quiet with some muffler epoxy but
I'm working on deleting this system from the car. I would like to know if anyone has one of these heads on a work bench so I can get the measurements and maybe a template of the holes that have to be filled below the exhaust manifold exhaust ports. Anyone out there that can help with these measurement ??

Thanks in advance,

Sincerely

John I.








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    !982 Volvo 244 GLT Pulsair Removal 200 1982

    posted by  Rolandp on  Mon May 4 06:11 CST 2020
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    last visit: Wed Oct 15 17:36 CST 2014
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    John, you mention you have a GLT 1982 with pulsair exaust system.

    Here in Canada 1982 GLT model was equiped with CIS injection on a B23 engine I beleive.

    On the other hand I am very familiar with pulsair because my DL 1982 carburated engine has it. I just replaced lately that air injection manifold with one in good condition I had picked up at a junk yard, 20 years ago may be. It was part of a head gasket job to begin with.

    The engine head has small holes under the exaust manifold ports where the pulsair 3/8 inch tube are connected. They have flanges that are squeezed against the head and held there with a small fork and 10mm screw. Seal is done with a gasket washer.

    It is narrow space there and I beleive you will have to remove the exaust manifold. Be carefull not to break studs or pulsair screws.

    Your best option is to plug (weld ?) the pulsair flanges near the head as long as the car meet environment rules in your region.

    Hope that helps.

    Roland








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      !982 Volvo 244 GLT Pulsair Removal 200 1982

      posted by  r2grom on  Mon May 4 07:40 CST 2020
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      last visit: Sat Nov 24 23:09 CST 2012
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      Morning Roland,
      Thanks for the reply. Yes my 82 GLT is a Canadian car. I already have all of the retaining nut in the exhaust system broken free and ready for the project but before I do the removal I'd like to make up all of the parts for the delete
      of the pulsair system. I will be ordering the block off plugs from Sandik. Insted of using the small retainer clips I would like to make a plate that will hold all of the plugs at once. That's the reason for the template.
      I'll keep looking for a removed head to make a template

      Thanks again for your help

      John I.







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        !982 Volvo 244 GLT Pulsair Removal 200 1982

        posted by  Rolandp on  Mon May 4 09:10 CST 2020
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        last visit: Wed Oct 15 17:36 CST 2014
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        John, why would you want to use a template instead of the retainer clips ?

        If you use steel it may have a different expansion coefficient versus the aluminum head, plus that template will get very hot from the manifold heat. I did not know block plug off were available.

        Just my un-expert opnion.







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          !982 Volvo 244 GLT Pulsair Removal 200 1982

          posted by  r2grom on  Mon May 4 11:24 CST 2020
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          last visit: Sat Nov 24 23:09 CST 2012
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          The plugs are available through Sandix. Take a look at the site posted below.
          I wanted to make an aluminum plate that would hold all four of the plugs in the block. I suppose that the clips/studs or bolts would do the same thing.
          Just my way of cleaning up things.



          https://www.skandix.de/en/spare-parts/accessories/din-assembly-parts/fasteners/plug-cylinder-head-hole-pulsair/1038970/

          Thanks for the reply

          John I.








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            1982 Volvo 244 GLT Pulsair Removal - Exh. manifold studs 200 1982

            uid 46171's pic
            posted by  kittysgreyvolvo on  Sat May 9 09:53 CST 2020
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            last visit: Sat Oct 18 15:23 CST 2014
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            The Pulsair intake into the exhaust is through holes in the cylinder head?

            Exploded diagrams of the Pulsair air injection rail.


            https://www.volvopartswebstore.com/products/1117876/1277457.html

            It is so!

            Plug #46 in exploded view illustration.


            Plug is Volvo PN 1277457.

            This Pulsair plug is available from Tasca (Volvo) Parts in Rhode Island, US. Versus buying from Scandix in Germany.

            https://www.tascaparts.com/oem-parts/volvo-plug-1277457

            There is also a gasket kit to seal the plug to the cylinder head recess. This seal is NOT part of the Pulsair air injection rail you are removing.

            https://www.tascaparts.com/oem-parts/volvo-gasket-kit-271776

            Plug seal is #47 in illustration and is Volvo PN 271776:


            There exist the four factory installed studs and nuts to secure the keepers to secure the Pulsair air injection rail to the cylinder head. Volvo did offer a replacement stud with a different PN 953032 (different from the factory installed stud. Both studs are NLA.

            Scandix sells the seals and the nuts. Hopefully Europa quality.

            So you should be able to get OEM from your nearby dealership in Canada.

            Congrats on exh. manifold removal! Always a tense moment!

            A Volvo issued tech. service bulletin recommends new exhaust manifold OEM studs. A new bolt or tap to aid in cleaning out the cylinder head stud threaded bores. Much Kroil / Liquid Wrench and tapping to loosen. Use high temp nickel anti-seize (Permatex) on reassembly on all mating part thread interfaces.
            --
            Jonathan Harshman Winters III: The Mightiest, Greatest, & Most Powerful North American Comedian & Comedic Actor in Perpetuity!








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              1982 Volvo 244 GLT Pulsair Removal - Exh. manifold studs 200 1982

              posted by  r2grom on  Sun May 10 07:21 CST 2020
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              last visit: Sat Nov 24 23:09 CST 2012
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              Thanks kittygrey for all the pic's and part numbers.. Much appreciated
              a great help

              ttys

              John I.







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