Install an Exhaust System
If you do not know how to install a car exhaust system this article will provide guidance on to do the removal and installation from the catalytic converter back or from the rear axle back. This does not include downpipes or headers.
Steps
- Lift the car. If you don't have a lift, jack up the back end so you can get under it. Use ramps or a jack, whichever you have.
- Be sure to lock the emergency brake and chock at least one wheel that is still on the ground.
- Make sure to block the car using jack stands, wooden blocks or other sturdy blocks. Never use just a jack; the car may fall on you.
- Check the stability of your setup. If there is any doubt that your jack/block configuration is stable, adjust your setup.
- Lie on your back and position yourself under the car. Examine the situation and imagine what you will replace and how you will get it off of the car. Look for obstructions to the removal process.
- Assess the condition of all the parts of your exhaust system before beginning. You may need to begin at the exhaust manifold, the crossover pipe, or the catalytic converter.
- Plan to order all needed parts. Don't forget gaskets for between the components. If you are unsure about all that you might need, ask at your local auto parts store or find a model-specific exploded diagram of your exhaust system in a repair manual or online.
- Order and receive your parts. Don't forget gaskets for between the components, penetrating oil, and hangers.
- Dry assemble and visually test fit all of the needed parts. Lay everything out and visually test fit the assembly as accurately as possible. Try to identify and correct problems before you take off the old exhaust system.
- Unbolt the stock exhaust system starting from the back of the car and working your way forward. Generally, the bolts are rusted and hard to get off unless you have an impact gun. Use some penetrating oil to aid removal and remember that, sometimes, tightening a nut or bolt just a bit, breaks it free, allowing your to remove the bolt or nut.
- Remove the exhaust components you're going to replace. Remove the system from the hangers and set all of your parts aside. You should now have all the piping removed.
- If you have new hangers (recommended as stock ones are soft and old), cut the old ones off with some kind of cutting tool.-- A high-speed rotary tool fitted with a cutting disk or a side grinder will work.
- Depending on the type of hangers your car has, put the new hangers onto the exhaust pieces first, this is usually an easier way to put the exhaust parts back on.
- Starting from the front of the car, hang the exhaust part up then bolt it onto the upstream pipe. Do not tighten all the way until you have all pieces on.
- If you don't have new gaskets to put between the pipe segments, you can use the old ones if they're the right diameter. It's best to have new ones,though, to prevent exhaust leaks later.
- Start tightening each segment to the first, after all pipes are attached. Use a good amount of torque on each bolt to make sure its tight.
- Take a few steps back and make any alignment adjustments you need so that the tailpipes are even with the bumper and look good, when you get to the back.
- Double check and tighten all the bolts.
- Start the car up and locate any leaks you may have.
Tips
- Rent or buy a cutting torch. It makes it easier to cut the old exhaust off than to wiggle it around your rear axle or suspension.
- You generally need some socket wrenches, for foreign cars they're usually in millimeters, for American cars they're in inches. Just find the right size.
Warnings
- Let the car exhaust cool before touching it, pipes can get extremely hot.
- Cutting torches are bright, spark a lot, and can cause serious damage. Wear appropriate eyewear (UV protective). Practice on some scrap and be aware of fuel lines and other things that may inadvertently get cut or burned as a result of inexperience.
- Modifying an exhaust system may result in a violation of noise ordinances.
- Removing a catalytic converter is illegal in many jurisdictions.
- Be sure to check for exhaust leaks after firing up the car. Any leaks are a safety hazard and may result in asphyxiation (death). Exhaust leaks can be deadly, especially when the car is parked with the engine running to keep the occupants warm. Carbon monoxide, an invisible, odorless gas, may build up to dangerous levels.
Related Articles
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- Understand Compression and Power Systems in Small Engines
- Change a Car Battery
- Install an Aftermarket Air Intake
- Replace an Exhaust Manifold Gasket
Sources and Citations
- Videos provided by Engineering Explained
