How difficult to remove header pipe from 90 240

Discussion in 'Volvo 240' started by notdeadyet, Jun 20, 2010.

  1. notdeadyet

    notdeadyet Guest

    I have a 90 240 with 100K miles and I need to replace the header pipe.
    That's the pipe between the exhaust manifold and the catalytic
    converter. Where I live we have real winter and hot summer. The car
    is quite rusted, but works like a new one.

    Given it has never been unscrewed, I'm concerned about breaking the
    bolts from the exhaust manifold.

    The nuts are copper, btw. (At least the new ones I got).

    Any advice as to the best method/tools/technique to use to achieve
    that while minimizing the risk of damaging the exhaust manifold.

    In case you wonder, rust has perforated holes in the header pipe and I
    do need to change it.

    Thank you
    notdeadyet, Jun 20, 2010
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  2. At work we use the "hot wrench" (the acetylene powered one), but a
    good plumber's torch works too. Get the nuts HOT (glowing orange with
    the big torch, or as hot as the little one can manage), then socket on,
    air-impact on reverse, and blaaap!

    In the absence of air tools, a tight fitting socket, extension and longish
    ratchet should suffice. As well as the heat, you may want to soak the nuts
    (with Liquid Wrench, WD40, PB Blaster, whatever you've got) for a day or
    two beforehand to help break the rust bond.
    MasterBlaster, Jun 20, 2010
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  3. you may have missed the important point in all that. hot metal
    expands. you want to heat the nut & keep the bolt cooler. this will
    loosen the "rust seal". be careful! WD40 is light oil & keroscene. can
    we say flame hazard? if this doesn't work, acetylene is great, but
    mapp gas is easier to come by. even a Dremel tool w/ diamond bits will
    work. i'm worried about copper nuts on base metal bolts. where i live
    the dielectric effect would kill that connection quite quickly. bon
    Richard W Langbauer, Jun 20, 2010
  4. notdeadyet

    James Sweet Guest

    I just use a propane turbotorch, mapp gas works better though. It's a
    bit of a tight fit for impact sockets, I just use a ratchet or a box end
    wrench. Usually after a bit of heat they come right off.
    James Sweet, Jun 20, 2010
  5. notdeadyet

    notdeadyet Guest

    Thanks to all for your answers. I'll keep you posted on the outcome.
    Might be a few days before I find the time to do it.
    notdeadyet, Jun 20, 2010
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