I would like to replace the exhaust system of my 240, i found on Fcp they sell a catalytic converter seperate from the complete exhaust system, here's the question, is it possible to replace the front muffler with the cat converter , or can you add the cat. in between the 2 mufflers?

 

Best would be to keep it the stock way.
The cat comes before all the mufflers.

 

but there is no cat at all in the system, wouldnt it be better to have it

 

Yes it would be better to have one. The cat attaches to the down pipe from the motor. Then the front muffler attaches to the back of the cat. Then there is a pipe between the front and rear muffler.
This is a link to IPD there is a picture on the page. That is how the front and rear mufflers are setup. The cat goes on the front into the front of the front muffler.
http://www.ipdusa.com/Volvo-200/Exha.../p-69-464-402/

 

Did they originally come stock with a catalytic converter? I noticed when I went over the reciepts for the car(bought it a year and a half ago)that the whole exhaust had been done, but not very well as I have already replaced clamps and rotten pipe. So the cat would attach just after the down pipe where it straightens out and before the front muffler. By the way is there any easy way to get a broken stud out of the exhaust manifold, or is the only way to remove the manifold and drill it out?

 

Yes they came stock on the car.
Yes that is where they go.
Yes sorry to say but to get it out you have to remove the manifold and pretty much drill it out.