A few tips for installation:
1. Make sure the vehicle has had sufficient time to cool down.
2.
Gather all tools you'll need before you begin.
3.
Spray all bolts with a lubricant such as LiquidWrench and allow to penetrate for about an hour.
4.
Have a back-up plan ready in case you aren't able to perform the entire project yourself (we needed to seek assistance from a professional welder to complete the project).
5.
Use protective eye wear. Our tools consisted of a socket set, vise grips, adjustable wrench and some wire snips.

 

Parts Installed:


 

 Step 1:
Jack the car up and secure it with jack stands. Give yourself enough room to work underneath the car. Locate all bolts that will have to be removed and spray them with a lubricant to ease removal. After the lubricant has had a chance to penetrate, we began removing the 10 bolts necessary to remove the entire exhaust system.
We started with the bolts connecting the downpipe to the turbo/exhaust manifold. The image to the right was taken looking up under the car and shows the location of the three bolts.


 

Step 2:
Remove the bolt located just before the catalytic converter (circled in red below). For image quality purposes, we used some images with the exhaust already removed.


Step 3:
Remove the three bolts between the catalytic converter and the muffler. This would be a good time to find something to support the weight of the exhaust system, as it will begin to hang down lower with every bolt you remove. We used a scrap block of wood. This helps take the strain off of the remaining exhaust hangers and also prevents the exhaust from crashing down when the final bolts are removed.


Step 4:
Remove the three remaining bolts holding the muffler to the car. Two of the three bolts are shown to the right, circled in red. The third is located just above the exhaust tip.

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Step 5:
Once all the remaining bolts are removed, you can lower the exhaust system and slide it out from underneath the car. We laid out our new unit side-by-side with the old one to show you the difference. Notice the larger piping, the straight-line design, and of course, the polished stainless steel.

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Step 6:
Installation is opposite of removal. We found it helpful to bolt all pieces together beforehand, yet not tighten them down all the way. This makes it easy to make any necessary positioning adjustments once the system is bolted to the car. You may have to modify a couple of the gaskets that come with your new exhaust in order for them to fit the bolt pattern used by the other components. One example is the connection between the catalytic converter and the exhaust system; the bolt holes weren't lined up exactly with the gasket, so we cut bigger holes in the gasket. Slide the new system under the car and bolt the downpipe up to the turbo/exhaust manifold using a new gasket.


Step 7:
The new system will use all of the existing stock rubber hangers. However, notice how the old system used bolts to fasten the brackets to the hangers. The new system won't need those bolts, as it simply slides into the existing hangers.

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Step 8:
We did come across one snag towards the end of the installation. Once we bolted everything up to the car, we noticed a problem. The vehicle we're working on is All Wheel Drive(AWD), so it uses a driveshaft. The new exhaust system was missing a bracket on the downpipe. This bracket keeps the unit from shifting and coming in contact with the driveshaft (see image below). This meant that we had to call on the services of a friend of ours who also happens to be a professional welder. He used a piece of steel rod and welded one side to the downpipe and the other side to the hanger on the car. This solved our problem. If you're planning on installing a downpipe, you probably won't encounter this problem.

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Step 9:
Tighten down all bolts and double-check all hangers to ensure you've connected them all. Remove the jack stands and lower the car. Start it up and check for any obvious leaks.