The original part (volvo part #3536202) has 3 heat shields made of aluminum with asbestos inside for insulation. The heat shields allow water to remain in contact with the downpipe and facilitate corrosion. This corrosion allows premature cracking of the welds. The weld failures allow exhaust to leak out before it leaves the exhaust system. I purchased a new down pipe from volvo, it doesn't have any heat shields! Volvo realized that there was a problem with the heat shields causing corrosion, and changed the way they manufacture the downpipe. Volvo offers no recourse to me.*Ak
Engine & cooling
Volvo 240DL Engine problems by year
2 complaints filed with NHTSA about the Volvo 240DL's engine & cooling. Stalling, loss of power, oil consumption, overheating, head gaskets, timing chains and engine failure.
Engine complaints by model year
Latest 240DL engine complaints
The vehicle continually shuts down, several repair attempts (idle speed motor,valve and throttle body) which have to not remedied the stalling problems. *Mjs
Source: U.S. National Highway Traffic Safety Administration (NHTSA) complaints and recalls, checked daily. Complaints are owners' own reports and are not verified. How we use the data