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91 240 exhaust questions 200

posted by  miracleman49 on  Thu Apr 11 04:52 CST 2002
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last visit: Wed Apr 6 15:53 CST 2011
[RELATED]

i am going to replace the exhaust on a 91 240 from the cat on back (both mufflers, axle pipe and tail pipe.

while down there, im gonna change two other gaskets; the exh manifold to exh header pipe gasket and exh header pipe to cat gasket.

my exhaust manifold has two exhports that lead to the exh header pipe inlet. The exh header pipe has reduces those two ports so that there is only one exh port into the cat.

my question is, i can see that there is a flat gasket (with 3 bolt holes)between the exh manifold and exh header pipe, but is there also a "donut" in each of the exh ports?

same question for the exh header pipe to cat?

thanks for your help








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    91 240 exhaust questions 200

    posted by  jtwoods on  Thu Apr 11 10:15 CST 2002
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    last visit: Tue Nov 28 16:33 CST 2000
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    I replaced everything except my cat and exhaust manifold sometime last year on my '91 245. The only doughnut I saw was on the kitchen table-no just kidding. There was one on the end of the header pipe to align and mate with the cat. I'm still trying to remember my situation exactly because I ended up having the wrong header pipe for the cat that I had. I'm pretty sure that the initial header pipe I ordered had that donut to mate with the cat, but the bolt pattern on my cat was different so I exchanged that header pipe for one that mated with my cat exactly. I mention this because 1. it may happen to you 2. there is more than 1 header pipe that will work (they look the same until you get to the bolt pattern that mates with the cat) 3. I think the other type of header pipe that worked for the cat I had simply had a gasket instead of that metal doughnut (not sure though) for mating with the cat. There were no doughnuts between the exhaust manifold and the header pipe--just a gasket.

    Sorry for getting you involved in my checkered past. Just make sure your bolt patterns are correct for the cat you have and if there is a doughnut--use it








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      91 240 exhaust questions 200

      posted by  miracleman49 on  Thu Apr 11 17:45 CST 2002
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      last visit: Wed Apr 6 15:53 CST 2011
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      JT,

      thank you and the others for the input. I do have one more question. Did you happen to look into or through your cat while you had both ends open?

      i am wondering if it is possible to see the 'honeycomb' and determine if it is in good condition?







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        91 240 exhaust questions 200

        posted by  jtwoods on  Fri Apr 12 05:30 CST 2002
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        last visit: Tue Nov 28 16:33 CST 2000
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        I actually didn't examine mine too closely, my guess is that when they go you know it. Distinctive rotten sulfur smell and complete loss of power when its plugged up--adding too much resistance to the exhaust side. I am for all practical purposes a neophyte--maybe there is some way to determine if your cat is ready for replacement before the above circumstances occur? Hopefully we get some more words from the wise.








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          91 240 exhaust questions 200

          posted by  miracleman49 on  Fri Apr 12 17:29 CST 2002
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          last visit: Wed Apr 6 15:53 CST 2011
          [RELATED]

          i searched the brickboard archives and believe it or not, there is an input from the Fluke company describing how to accurately test the efficiency of a cat. (fluke makes all types of electronic measuring equipment, like voltmeters and temp sensors,etc)

          they say to remove one of the spark plug wires and start the engine (run on 3 cylinders). Use a temp sensor to measure the temp at the inlet and outlet of the cat. should be in the area of 800 degrees. The important thing is, the difference between the inlet and outlet should be at least 50 degrees. if it is less than 50 degrees, the cat needs replacing.

          if interested, web page is

          http://www.brickboard.com/FAQ/700-900/Exhaust1.shtml

          c ya








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    91 240 exhaust questions 200

    posted by  someone claiming to be dlot on  Thu Apr 11 10:12 CST 2002 [RELATED]

    Hi,
    Make sure you soak the manifold to head pipe bolts for several days before
    you try to remove them. If you break a stud, it's an ugly job fixing that
    spot on the manifold. Most of the time the cat bolts are too far gone to remove
    so I cut them off with a grinder and install new ones when I put it back together. Your cat uses the outlet pipe that runs all the way to the first
    muffler. You may want to cut the pipe behind the muffler and work on removing
    the pipe from the inlet side of the first muffler off the car. That stuff gets
    really stuck on there over the years. I usually cut the old exhaust off with
    one of those pipe cutter type exhaust tools. You can usually buy that tool
    locally. Makes removing the old stuff much easier. Hope this helps you some.
    Dave 82 242ti 268k mi.








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    91 240 exhaust questions 200

    uid 5559's pic
    posted by  Guid on  Thu Apr 11 07:13 CST 2002
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    last visit: Thu May 9 12:04 CST 2013
    [RELATED]

    The answer to both questions: No.

    When I replaced my '88's head pipe about 6 months ago, the only gaskets I had to replace were the one-piece flat units (one at each end).

    Best of luck with the project.






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