DIY: Installation of Magnaflow Exhaust

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05-14-2004

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DIY: Installation of Magnaflow Exhaust

<h1>Required Tools:</h1>

1. Jack
2. At least 2 jackstands, 4 would be better not to mention safer. 
3. 14 millimeter open close wrench.
4. 14 millimeter socket and wrench.
5. 12 millimeter open close wrench or socket/ socket wrench.
6. Blocks of wood or extra jackstand.
7. WD40 or any other penetrating oil.
8. Safety goggles.

<h1>Setup: </h1>

1. Make sure the car has cooled enough to touch.
2. Place car on Jackstands
3. I recommend you were safety goggles before going under car because dirt will fall in your eyes during this install.
4. Spray boltsconnected to catalytic converter and resonator with oil and let penetrate for 5 minutes.

<h1>Removal of Stock exhaust system: </h1>

1. Using a 14mm wrench or socket, begin removing the three nuts on the rear of the catalytic converter (see red arrows on picture).Depending on the <img height="310" alt="" hspace="0" src="/diyimages/remove_stock.jpg" width="444" align="right" border="0" />
amount of rust, it may be really tight.Keep in mind the top nut is a little difficult to get too.If you have a breaker bar, it will give you leverage on loosening the bolts or even better, an impact gun. Always loosen a few turns on each nut to avoid stripping of bolts.
 
2. Next step is to begin removing the two bolts that connect the stock muffler to the stock resonator in the rear.Use a 12mm socket and wrench and begin removing the tension bolt.Be sure to loosen a couple turns each side. The bolts and spring will come off.
<img src="/diyimages/stockMuf_stock_res.jpg" alt="" border="0">

<h1>Remove muffler: </h1>
3. Now that all the bolts have been removed, begin removing the stock muffler from the hangers.Locate the two rubber mounts above the muffler.The <img height="288" alt="" hspace="0" src="/diyimages/remove_hangers.jpg" width="384" align="right" border="0" />
best way to remove this is to remove the rubber mounts from the hangers that are attached to the chassis.Your going to have to work it off the mounts and it will be a little difficult.Just keep pulling.
4. Next step is to remove the resonator and piping.Begin removing the rubber mounts above resonator from the hangers.Again, this will be a little difficult just like it was with the muffler.Once you get it off, lower the resonator and pull the rest of the stock piping off.Your stock exhaust should be completely removed.

<img src="/diyimages/remove_resonator_&_piping.jpg" alt="" border="0">

<h1 align="center">INSTALLATION OF MAGNAFLOW EXHAUST</h1>

1. Now we are ready to install our new exhaust.Install the resonator first by connecting it back to the rubber mounts and attaching it to the hangers.This will make it easier to install the piping (no picture).

2. Connect the flange to the rear of the catalytic converter and begin to tighten all three bolts until tight or roughly 40lbs of torque.

3. Place clamp over pipe (do not tighten yet) and connect pipe to flange (pipes slip over each other).With other clamp on the other end of the pipe, connect pipe to the resonator.I used blocks of wood to hold one end in place.


<img src="/diyimages/Connect_the_flange.jpg">    

4. Next, install new muffler on to hanger using old rubber mounts.


<img src="/diyimages/install_new_muffler_on_to_hanger.jpg">     <img src="/diyimages/install_new_muffler_on_to_hanger_pt2.jpg">


5. Connect muffler end to resonator.

<img src="/diyimages/Connect_muffler_end_to_resonator.jpg" alt="" border="0">

6. Turn clamps sideways so they are not oiting downwards and tighten. You're finished!!!! 
When you first start your car, check for leaks.As the car warms up, your piping and exhaust will begin to smoke.THIS IS NORMAL, it will burn off after 10 or 15 minutes of driving.

<img src="/diyimages/end_result.jpg" alt="" border="0">   <img src="/diyimages/end_result_2.jpg" alt="" border="0">