I had to do what ended up being a replacement that included header pipe, cat, and entire cat back exhaust on a '87 240 not too long ago. The exhaust was rusting out, the heat shields were coming off the header pipe, and the cat was breaking apart and created a near-stall condition. After checking around, I ended up purchasing header from FCPGroton (Bosal), cat from Autozone (Bosal), and the cat back exhaust system from Volvo dealer. Volvo's exhaust system is considered high quality and the price was competitive. Bosal, I understand, is OEM for Volvo. I didn't touch the exhaust manifold. Don't forget proper gaskets, fasteners, washers, clamps, etc. Not all came with the exhaust parts, particularly for installing the header pipe and cat. In my case, I remember a couple of trips to the auto parts store during installation because this or that bolt was the wrong length, etc; very inconvienient and made the job take longer than necessary. If I remember right, I needed a donut type gasket for the flange fitting at back of the header pipe and front pipe to cat. Autozone's cat comes with the front and and back pipes already attached. I used a heat resistance antisieze at all fittings and set all fittings at proper torque. I think Bentley's has all the torque values. Good luck; I hope this information helpful and not too basic.
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