I have several (possibly related) issues with a beloved 1994 940 non-turbo with Bosch ignition and 149k miles. The car is like an old friend and I have lost all perspective on its repair and maintenance.

Most recently, I have been getting a check engine light with codes 232 & 131. These codes came on after a hole emerged in the header pipe - - there had been a round, raised, bulging (bunge hole?) area on the heavily rusted header pipe which popped out.

As background, last year, I replaced the cat back part of the muffler and could tell that the catalytic converter and header pipe would need attention. As a very short term fix to cut down on the muffler noise, I sealed the cat forward header hole area with exhaust tape, muffler paste and a part of a tin can held on by a circle clamp.

Although the car is just used for short, infrequent drives, I recently had to drive it about 200 miles. I had been able to clear the CEL light before the trip. The car ran well until the end of the trip, when the CEL came back on and the car began to idle very roughly. It also stalled several times after stopping. Each time it stalled, it started right up again.

I plan to replace the catalytic converter and header pipe. Do you think that will solve the CEL problem? Other suggestions or advice?

For the header pipe, how do I know if I have EGR? Are there any recommended brands of aftermarket catalytic converters?

Thanks!