Catalytic converter removal

ENGINEERINGDAD

MEMBER
2004 VOLVO S80
2.9L
6 CYL
2WD
AUTOMATIC
125,000 MILES

Do you have a step by step guide for the removal of my catalytic converter on my 2004 Volvo (turbo) S80 2.9L T6? Some say you can remove them entirely and install a Magnaflow catalytic converter in its place, but I do not see hows that is possible with the multiple of OX Sensors. Do I have a total of four or six sensors?

5 Replies

DANNY L

MECHANIC
5,648 POSTS

Hello, I am Danny.

Your catalytic converter can just be replaced using a universal replacement. The only tough spot is if you live in the state of California you have to make sure it is California certified (due to California smog laws). The exhaust does completely unbolt but why not just have the catalytic converter replaced and not the whole system? Your car has four Heated Oxygen sensors not six. A right side upstream and downstream and a left side upstream and down stream. I have attached a few pictures showing the exhaust system where it bolts to the turbo and underneath where the catalytic converter is located. Also attached a tutorial showing how to replace. Hope this helps and feel free to ask any questions needed.Thanks for using 2CarPros.
Danny-

https://www.2carpros.com/articles/catalytic-converter-replacement

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Wednesday, September 5th, 2018 AT 4:41 AM

ENGINEERINGDAD

MEMBER
35 POSTS

Thanks Danny. The right bank catalytic converter is the one showing as defective with almost equal temperatures before an after catalytic converter using a infrared gun (see one of one previous post with images). The work I planned was to replace the catalytic converter which are sold as a complete unit-both left and right catalytic converter to a "Y" see image attached. I hope this explains my question(s) more in detail. Also you can hear the rattling tin can sound when starting the car, to include extreme lost of power (in travel) and eventually a ODM Code P0240 after pulling any inclines. Not sure why most Volvo S80 T6's are are a forgotten breed, but folks like myself do not throw-in the towel on something previous owner(s) fail to do in the manufactures recommended scheduled maintenance. See attached image.

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Wednesday, September 5th, 2018 AT 6:07 AM

DANNY L

MECHANIC
5,648 POSTS

Hello again.
Yes I can understand. That rattling is the honeycomb (insides) of the converter that has broken free causing the problems. If Magnaflow makes one it will save you a lot of money! So far the most expensive converter replacement I have seen is $2,700.00. Let me know if you have any further questions. Hope this helps and thanks again for using 2CarPros.
Danny-

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Wednesday, September 5th, 2018 AT 9:49 PM

ENGINEERINGDAD

MEMBER
35 POSTS

Thanks for all the help Danny, I replaced the unit with a Bosal Complete catalytic converter unit. Bosal was rated the better in customer feedback. It's working fine, but not 100% as quiet as the OEM, but all in all there's no leaks and the original Volvo (OEM) didn't have flange gaskets when I disassembled, as their are tapered lips protruding on the catalytic converter assembly to fit into the turbo housing and then drawn 20NM's to secure.

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Tuesday, February 12th, 2019 AT 10:11 AM

DANNY L