Exhaust pipe not fitting to turbo Topic is solved

Volvoblackdog · Post by **Volvoblackdog** » 06 Sep 2020, 20:39

Installing my exhaust back on my 2001 s40 when I noticed that the exhaust from the turbo to the catalytic converter is not going to reach. I looked up the correct installation and saw that your should loosen the pipe just aft of the catalytic converter then attach to the down pipe south of the turbo. I did that but now the pipe will not fit back into the gap aft of the cat. Is there an extension that I can get for the down flow south of the turbo to make up this slack I need in order to make this fit. Anyone have this issue? I realize now that I should have taken the old turbo off of my old engine before sending it off.

Lesson learned the hard way I suppose.

Post by **RickHaleParker** » 06 Sep 2020, 21:53

What is the donor car?
What is the donor engine?

Volvoblackdog · Post by **Volvoblackdog** » 06 Sep 2020, 22:46

Don't understand the question. Stock car. 2001 Volvo S40 Stock engine and turbo. I replaced the engine with the same model (stock) engine. No modification done to the engine or the frame. Don't know why the exhaust is not fitting. Almost like the exhaust has shrunk.

Post by **alschnertz** » 07 Sep 2020, 05:38

Are you using the original exhaust?
I have had fittment issues with aftermarket exhaust systems, but never heard of needing a "spacer(?)".

I know the aftermarket flex pipe / rear cat. can be very stubborn in the way it bends up to meet the front cat. Unfortunately it stresses the joint so much that it'll only last 2-3 years.

Volvoblackdog · Post by **Volvoblackdog** » 07 Sep 2020, 11:59

Yes, everything is stock but I am starting to wonder that after I bought the car there was a modification to the exhaust system. I bought it in 2002 so cant imagine that too much was done to it? No aftermarket stuff to my knowledge. I may have to try welding an extension to the down pipe off of the turbo. I may look for a spacer of about 3" or so may do. I cant seem to find anything on line for that though.

Thanks for your input.

Post by **volvolugnut** » 07 Sep 2020, 12:35

Go to a local muffler shop and have them bend and weld in the spacer section you need? Not sure what is needed or why, but a muffler shop can do this.
volvolugnut

Post by **alschnertz** » 07 Sep 2020, 14:25

Maybe this will help? Here's what the front pipe should look like.
https://www.rockauto.com/info/787/DV-020-1__ra_p.jpg

the mid pipe...
https://www.rockauto.com/info/9/56088__ra_p.jpg

and the rear...
https://www.rockauto.com/info/403/VL12647_T__ra_p.jpg

Sounds like you're saying the gap is between the front and mid pipe, right? That's weird.

Volvoblackdog · Post by **Volvoblackdog** » 01 Nov 2020, 10:19

Thanks to all the responses. I have had a muffler shop check it out and it indeed fits. Thanks again