My 2002 Volvo s40 started making loud noises a few day ago and I took it to a mechanic. The noise was near the engine compartment, thus I did not believe it was from the muffler. He put it on the stand and stated that the flex collar just upstream from the catalytic converter was the problem.

It has corroded off from the inline catalytic converter. It will need to be replaced.

I was also told that one cannot buy the flex collar separately. I will need to buy a whole new catalytic converter that comes with this part integrated into the line upstream from the converter.


Is this true? Can one just buy the collar then weld or bolt it into the catalytic converter? If so where can I buy it?


If I must buy it as part of a catalytic converter, can I just buy an aftermarket one?


Any help appreciated. Thanks in advance.


Respectfully,




Newport_j

 

Depends.

How much metal is left where the flex pipe connects to the cat? If it has rusted all the way into the cat alot of shop will not mess with it, as they cannot gaurantee it won't leak. I have been told that with a muffler that didn't have any metal pipe left to weld too.

The flex pipes themselves are common and cheap, they just need some good metal left to weld them too.

Cats are $$$ though, shame to throw it out. I would check around town for indy shops, or check craigslist for guys working out of their garage. They might be more inclined to just make it work

 

yep, waiting for the warm weather to replace mine as well. If you are not in California, you can get a Bosel aftermarket flexpipe/cat for about $300 (check out FCP Euro and eEuroparts to price out). Volvo OEM is 3X that price...

 

It seems like this can be easily repaired by simply cutting out the flexpipe and replacing it. Or cutting the flexpipe on the side nearest the catalytic converter and then unbolting the whole flxpipe assembly and replacing it. Then re-welding the flexpipe after it is bolted on the car and that is it.

I am unsure of the diameter required of the flexpipe.

What is the diameter of a flexpipe for a 2002 olvo s40? It has the 1.9 L engine.

Any help appreciated. Thanks in advance.

Respectfully,

Newport_j

 

I've just had this problem repaired on my 2000 V40. A local shop cut out the broken flex pipe and welded in a new one. Cost, $220 total.

Here are your options:

1. New Volvo cat, ballpark $1,000+ installed.

2. New aftermarket cat from FCP Euro, about $330 in parts plus labor.

3. This clever fix, available on eBay and elsewhere, $86 plus miscellaneous parts and labor.

4. Cut and weld in a new flex pipe as I did. If you go this route you need to specify a flex pipe with an interlock liner, not a woven liner.

 

Okay, that sounds reasonable. The part you have in your link (to Ebay) would not fit my 2002 Volvo s40 because my exhaust pipe is oval not round as shown in the picture.

I would order it today if I could be sure it would fit my car, which has an oval shaped exhaust pipe to the flex pipe.

Is this a generic picture. I would call the people, but they are closed today.

Thanks in advance.

Respectfully,

Newport_j

 

I need to replace the flex pipe too on my 2000 S40 - I'm tempted to use this as an excuse to buy my own welder! just waiting for some warmer weather... I mean its almost April and its 32F outside right now here in CT...

 

If you needed it with the cat, this one is affordable. I put it on with a buddy. If the link dies "2000 2001 2002 2003 2004 Volvo S40 1.9L catalytic converter with flex REAR" from seller exhaustdealz