I have a 1989 240 DL and need to replace the header/front pipe. Has anybody done this and or can advise of any difficulties you might have had? It does not look that difficult. Just want to see if anybody has any tips or suggestions. If any body know of a good place to buy the header pipe would be very helpful. I have foulnd some places but they seem very expensive.
Thanks for your help in advance

Again, plenty of penetrating oil in the days before. The toughest part in doing mine was getting the old flange off the catalytic converter. Due to impatience, I dropped the whole exhaust from the car and carried it all inside to play with. One note for the install: get everything started at the flange before playing with the manifold end, you might need the leverage. Also, have plenty of extensions for the rachet to reach around things. Best of luck.

Ditto with the PBlaster / penetrating oil. Likewise with ratchet extensions, make sure to have LONG extensions available!

An independent muffler shop replaced the header pipe on my brick this summer. The guys charged me $200 for the entire job - header pipe / supplies ($125) + labor ($75). They worked long and hard to remove my old pipe, due to years of rust and corrosion. However, I regret that I was too IMPATIENT to order the same (or better) quality parts online for HALF the cost.

I heard the the following sites were highly recommended:
http://www.fcpgroton.com/volvo.htm
http://www.importpartsspec.com/

[[ southern fried volvo '91 240 124k mi ]]

I got mine from FCP Groton as well. My mechanic could only find Volvo brand for like $300 or something outrageous. I brought the part to him and he fit in like a charm.
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'86 245 DL Volvo Blue/ Blue Vinyl M46 -- For Sale!!!

...got my new one (1981 244) from FCP-Groton for $50 which didn't seem too bad when you look at the welding, the flanges, the 2-into-one joint, etc. It was a "Starla" brand, which the muffler shop said was pretty decent stuff. The guy was sceptical when I came in with my own parts, saying they often don't fit right, but they took just minutes to fit it with their air tools and car up on the hoist. Personally I hate doing exhaust work, but it LOOKED easy enough. Use a lot of 'PBlaster' on the nuts and studs the night before, and you should be OK. Getting (safely!) enough room under the car to wrestle pipes around would be the biggest hassle, I think.
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Bob (81-244GL B21F, 83-244DL B23F)