Hello,

Our 1989 240 wagon needs a new catalytic converter. Our Volvo mechanic wants around $325 to replace it. This seems honest but since it looks like a replacement can be had for less than $150 and money is tight, I was wondering if this is a job I could do myself.

Can someone tell me what is involved in replacing the cat on a 240? Does it require elevating the car or can it be reached without doing that?

Thanks,
David.

hello, what is wrong with your current cat? rust, pieces coming out, clogged exhaust?

regards,
byron golden
86 245
92 245

The job is not too hard. I did it myself about three years ago. As
I recall it took only about 2-3 hours.

You do need to get under the vehicle. I use two ramps under the
front wheels, and two jack stands under the rear axles. You can
then lie under the vehicle and do what you need.

If memory serves me correctly there is a three bolt flange in the
front, and a muffler pipe clamp in the rear. Thus a total of
only four bolts to loosen. Because of the elevated temperature
in the system, these bolts will be corroded and should be replaced.
Also make sure you have a new gasket for the forward flange.
Mine came with the catalytic converter I ordered from FPC Groton,
but make sure when you order.

The biggest problem I had with the job was getting rid of the old
converter. I had to cut it in half (the piping not the converter)
because the trash collection would not accept anything so long.

Donald E Booth
1984 245DL, B23F engine, M46 Transmission, 245,000 miles

It can be done in your driveway if you have the tools (Jackstands, grinder w/ cutting wheel, ratchet/sockets/box end wrenches) and do not mind getting filthy.

1) Before you buy a replacement-jack up the car and place jackstands and examine the existing Cat front flange to Down pipe connection. Is the downpipe flange good? If not plan on replacing the downpipe as well because you will trash a marginal flange during installation.

2) If the downpipe flange is good. Then look at the cat and exit pipe. Measure the distance from the Cat forward flange to the exit pipe and add 1 1/2 to 2 inches. Look at the type of clamp used to secure the cat pipe to the pipe to the resonator. If its U clamp plan on trashing it and replace with circular type.

3) Since you are trashing the cat you don't care about the cat to downpipe bolts so cut them off w/ a grinder and punch out with a hammer and punch. FCP and others sell the new bolts and nuts for $5 a set-cheap at any price!
Remove the O2 sensor if installed in the cat. It sometimes comes free with a open end wrench but you can get/rent a O2 socket that makes it easier.

4) Cut bolt on old rear pipe clamp. Take a propane torch and heta up the connection and smack it w/ a hammer. Wear gloves and try and turn the cat pipe. If it won't come loose try using a screwdriver or drift to open the seam between the cat pipe and the rear pipe. Once you get it off take a file and clean the inside of the rear pipe.

5) Clean downpipe flange face and install gasket and 1 bolt. Install clamp on rear pipe. Line up cat exit pipe with rear pipe and slide it in. Line up cat front flange to gasket/bolt and hang it on the bolt and install the nut witha few spins.

6)Install remainder of bolts (2) and wrench tighten them. Check the rear pipe clamp fit and leave it loose.

7) Tighten front flange bolts, remove O2 plug and install O2 sensor if needed.
Tighten rear pipe clamp.

8) Have a beer, you earned it.

I've never done it, but I would do it myself if I needed it done.

You will definitely need to get beneath the car. The bolts will most likely be rusted solid, so start putting penetrating oil on them a day or two before you do the job. Even then, you may end up twisting the bolts in two to get them off. 6-point sockets or closed-end wrenches are best for putting maximum torque on really rusty bolts.

There are inexpensive ways to raise a car. I prefer my plastic ramps, but metal jackstands are inexpensive, or you can visit a construction site dumpster and salvage enough scraps of 6" to 10" wide boards to make ramps to get you up 6" or so. I have been known to drive two wheels up on a curb in a pinch. Of course you know to never put so much as your toes under a car that is supported only by the car jack.

The easiest way is to get it shippe dto you from www.fcpgroton.com and then take it to your local muffler shop for 1 hour labor - DIY exhaust can be a real PITA for even an experienced mechanic... it helps to have a torch, pipe expander, and heavy tools...

It should cost you 1/2 your quoted price.

Greg Mustang
Montreal
Canada

I too would try the local muffler shop. Tell them you have a factory OEM cat, already ordered, that you would like them to install. Our local shop will install an after market, universal cat converter unless the customer has the factory unit. Either way, it is about one hour labor.....it is much too cold here to be working under a car unless your garage has great heat...

Jay
88 740 GLE 189k
84 245 GLTi 228k