torniojaws
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- May 4, 2019
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Man, what a chore that was to do, even though it's technically simple to do. Attached some pictures btw of the old parts.
Some tips if someone else is going to do it:
But it's a lot of handwork and "fighting".
Some tips if someone else is going to do it:
- You only need to lift the front of the car on jackstands, as you can easily reach the rear parts without lifting the back separately
- If it is the original exhaust, you need a cutting tool (angle grinder made short work of it) as it is a single assembly all the way from the manifold to the rear
- Install the new muffler and pipe starting from the rear working towards the front
- Removing the rubber mounts was really tough, but there's two tricks you can use:
- If you want to save the old rubber mount, you can use scissor-style plumbing pliers to pinch the rubber off the "mushroom". The pliers need to be quite long though, as the steel hanger is quite long.
- If you are going to put new rubbers, you can easily cut the old ones with regular scissors
- Pour copious amounts of silicone paste on the rubber mounts before installing, otherwise you're going to have a fight of the week
- Attached the rubber mounts on the car hangers first. I put plenty of silicone paste on the rubber holes. I first tried putting the mounts on the muffler and then on the car, but that was really really difficult to do, as there is very little room to push on them with the muffler on the way.
- I pushed the muffler hanger against the middle-of-the-car side rubber mount first, which was quite easy. The muffler hanger slipped in place without much effort, just by pulling the muffler towards the car front.
- Then I lifted the muffler using a jack and aligned it with the rear bumper rubber mount. I pulled the muffler against the rubber in a backwards-forwards rocking motion until it popped into the rubber mount.
- Then I slipped the 45 mm exhaust clamp on the front side of the muffler pipe
- Then I applied a generous amount of exhaust mounting paste around the middle pipe outside, and inside the muffler pipe, and "screwed" the middle pipe into the muffler end until it was all the way in (make sure it is as far as it goes! Or you will have a really hard time in the next steps), and then tightened (as tight as possible) the exhaust clamp on the connection, and applied some extra mounting paste on the outside of the connection.
- Now, the tricky part. I ended up lifting the middle pipe up using a jack on the spot where it bends from center of the car to the side where the muffler connection is.
- Then in the front of the car, after removing the old gasket and sanding the manifold flange a bit, I added the new exhaust gasket on one side of the manifold flange and wiggled the middle pipe to align it, and pushed a new M8x20 stainless steel bolt through the manifold flange, gasket, and the middle pipe flange, and finger-tightened a stainless steel nut on the other side
- The tricky part was how to get the other side of the flange into position. In my case, the fit was ridiculously tight, impossible to do by hand. So I ended up lifting it into position using a bottle jack, and had to work carefully so that both the gasket and the middle pipe flange aligned at the same time with the manifold flange.
- Then finally got them to align and was able to put the second bolt through it, and tigthened both sides to really tight.
- And tightened the middle pipe ring clamp (13 mm bolt) to the car front lip for that.
- Then started the car and checked no leaks appeared. Then sprayed some soapy water on the connections, and made sure no bubbles formed.
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