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Volvo 240 replacement exhaust system 200 1985

Hi all, I need a new exhaust system for my 244 DL. Does anyone have advice based on the best application available these days?

eEuroparts sells what they claim to be a Genuine Volvo cat back system for $269 (link below). However I believe that Volvo itself is really not manufacturing these.

https://www.eeuroparts.com/Parts/132448/Exhaust-System-Kit-31372147/

The other option I see is Starla which is ~$190. Might the two kits really contain the exact same parts given that Starla is supposed to be the OEM supplier to Volvo? Any help would be appreciated. I am looking to do this myself on the ground - already was able to unscrew the nuts on the the exhaust manifold downpipe. Will have to get downpipe and cat separately from this kit





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    Volvo 240 replacement exhaust system 200 1985

    FCP guarantees theirs for life,





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      Volvo 240 replacement exhaust system 200 1985

      Thanks, good to know on the guarantee. I saw a post that the Starla system doesn't fit together super well and that the joints are loose and leak a bit. Is this true from the experience of others, and if so, how did you remedy, if at all? Thank you





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        Volvo 240 replacement exhaust system 200 1985

        I haven't noticed any problem with the fit. I use Muffler Cement on all of my connections. I works well at sealing all leaks. Here is the link https://shop.advanceautoparts.com/p/nickson-muffler-cement-16oz-83106/11019698-p?c3ch=PLA&c3nid=11019698-P&adtype=pla_with_promotion&gclid=EAIaIQobChMI5NbOs-P14AIVklqGCh3j6gtEEAQYASABEgJILfD_BwE&gclsrc=aw.ds
        --
        Bruce S. near D.C.





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        Volvo 240 replacement exhaust system 200 1985

        I had a Starla exhaust installed on my 1990 sedan by a local volvo indie garage about 2 years ago. It was apparently easy to fit, and is still quiet and leak-free. One caveat is that there's no proper winter where I live, and the old exhaust had deteriorated internally in the mufflers.





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          Volvo 240 replacement exhaust system 200 1985

          All the non-Volvo factory systems are crap. Starla cat-back systems and Bosal downpipes are probably the best of the lot. Here in wintry New England I never had any of the cat-back systems and the down pipes last longer than 3 years. The only good parts in that exhaust system are the manifold and the cat. When I sold my 90 240 at 20 years old and 300k+ it still had its original exhaust manifold. The cat lasted 17 years.
          --
          Will I buy another Volvo??? We'll see....





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    Volvo 240 replacement exhaust system 200 1985

    Thanks for bringing up something I was going to ask.

    Are you in California?

    It's my understanding that those of us in California can NOT use federal catalytic converters in our cars or we'll fail smog.

    Any suggestions as to brands/models for California?

    Thanks





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    Volvo 240 replacement exhaust system 200 1985

    Hello

    The kit in the link is an over axle kit, and it says its Genuine Volvo. However every 76-93 240 I have come across has been under axle. These kits started to appear a few years back and don't understand why. The only over axle 240 I had seen until then was my 75, but that's a different animal.

    The Starla kit is under axle, which I prefer. I think they are easier to put together, and present less potential for alignment and clunking problems.

    We also have to consider our choice when mixing and matching future individual part replacements.

    Can anyone else elaborate on the origins of the over axle kit?
    --
    Bruce S. near D.C.





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      Over axle vs under axle 200 1985

      "Can anyone else elaborate on the origins of the over axle kit?"

      This happened more than a few years ago. The last Volvo cat-back I purchased from Volvo for a 240 cost $204 with my VCOA discount from Herb Gordon down your way in January 2001. The 271421 was under axle just like the one I was replacing. Before that, in May 2000, one cost $261. That same time Starla sold theirs for $119. I switched to Starla after learning Volvo's warranty did not extend to the pipes, only the mufflers.

      It was shortly after then the Volvo dealers no longer stocked the under-axle kit, explained to me as a space-on-the-shelves move, claiming "either type fits." For a time I was stuck with one of those over-axle resonators on my shelf, no pipe to match.

      In the intervening 18 years I've used many Starla kits. The price goes up and down; I cringe at paying more than $110 and know I've found them for less than $90 without looking up records. I don't pay much attention to the debates one reads about exhaust restriction by the squashed under-axle pipe vs. the same restriction from tight bends out of the resonator. We don't race. Always have a spare kit on hand (with 5 daily driver 240's in the family) as I don't want to wait for shipping when an axle pipe rusts out.

      One item that's worth getting from Volvo is the rubber ring used to hang the resonator. The 91-cent aftermarket rings don't stretch far before snapping, but those I've received from Volvo and have their part number molded in are worth six times that price.

      As for Bosal, I've not ever found/used a Bosal cat-back kit, but have on many occasions used Bosal cats and Bosal head pipes. Mixed results on the head pipes, but that's another story.


      --
      Art Benstein near Baltimore

      It may be that your sole purpose in life is simply be kind to others.





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        Over axle vs under axle 200 1985

        Hi Art and others, thanks for the helpful dialogue.

        My car currently has the under axle set up with aftermarket parts. After I put new coil springs in the rear end, I now have a clunk when I go over bumps. Must be because the body sits a tad higher with new springs - thus the pipe is pretty close to the axle and bangs into it. Now that I need to replace exhaust, I was looking to get something that would eliminate this issue.

        Would not the over axle variety eliminate this issue? Most seem in favor of under axle set up to eliminate clunking and vibrating; my situation seems to suggest the opposite?

        Thanks in advance





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          Over axle vs under axle 200 1985

          Davegcc wrote--"Would not the over axle variety eliminate this issue? Most seem in favor of under axle set up to eliminate clunking and vibrating; my situation seems to suggest the opposite?"
          There's nothing wrong with using the over the axle setup. There are more spots it has to clear so it does take some careful positioning. I use a thin layer of the red high temp silicone on exhaust joints which makes it easier to re-position the pipes if necessary.
          I seem to recall a time when all the 240 series cars I saw had the over the axle pipes--and then the under the axle pipe is what became available. - Dave





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          Over axle vs under axle 200 1985

          "Would not the over axle variety eliminate this issue?"

          Given your new springs give extra lift to the body, it makes sense to me. But maybe you bought the springs to carry more load in the back seat or farther.


          --
          Art Benstein near Baltimore

          Nobody cares if you can't dance well. Just get up and dance.





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    Volvo 240 replacement exhaust system 200 1985

    I looked at the system listed by eeuro and could see the muffler had welded seams at the inlet and outlets like Volvo original parts -- I don't think Starla or Walker have have that--folded seams -- shorter life span. You might also look into Borla. Whichever you use--I'd suggest using the original style clamps rather than the U-bolt type--the original type seals better and doesn't deform the pipes -- much easier to loosen and re-adjust if necessary.-- Dave





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