I have a 1991 240 without the EGR system. With my entire exhaust system going to hell in a handbasket I decided to replace everything needing replacement (the manifold and cat were fine). I ordered the parts and things were swell until I tried to connect the new header pipe to my original cat. converter, the bolt patterns to the flanges do not line up between the two. Has anyone seen this before? Did volvo change this so we'd have to purchase a new cat at the same time? Everything else fits I can get more specific if this peaks anyones interest. Thanks for any information.

The flange off of the cat converter should be triangular and have 3 bolt , or stud holes. These holes will only fit one way. try rotating the pipe between the cat and front muffler if it will not fit I would suspect you have the wrong exhaust kit.

Good Luck

Bob Davis

Old Volvo Mechanic

Svendaswede

Thanks for your response Bob, turns out I did have the wrong part #. It was tough to track down b/c in the middle 1991 volvo switched the bolt pattern or something on the 240 where it meets the cat. My car was from the beginning of that year with the older style header pipe than what was sent to me. Problem solved except I can't hear the engine anymore.