How to Install an Exhaust System

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How to install a cat-back or axle-back exhaust system on a car. This does not include downpipes or headers.

Steps

1. 1
   Lift the car up, if you don't have a lift, lift up the back end so you can get under it. Use ramps or a jack, whatever you have. Do not use only a jack, it may fall on you. When using ramps be sure to lock the emergency brakes and block the front wheels.

   
   
2. 2
   Assess the condition of all the parts of your exhaust system before beginning. If you need to begin at the exhaust manifold, the crossover pipe, or the catalytic converter, plan on ordering all of the needed parts prior to removing the old exhaust system
3. 3
   Lie on your back and position yourself under the car until you are looking at where the pipes bolt onto the catalytic converter.
4. 4
   Unbolt the stock exhaust system starting from the back of the car and work your way forward. Generally, the bolts are rusted and hard to get off unless you have an impact gun. Use some WD-40 to penetrate the bolts. Use some elbow grease as well.
5. 5
   Remove the exhaust you're going to replace. Remove them from the hangers and set all of your parts aside. You should now have all the piping removed and lots of rust all over you.
6. 6
   If you have new hangers (recommended as stock ones are soft and old), cut the old ones off with some kind of cutting tool (dremel will work).
7. 7
   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.
8. 8
   Starting from the front of the car, hang the exhaust part up then bolt it onto the pipe before it, do not tighten all the way until you have all pieces on.
9. 9
   If you don't have new gaskets to put between the pipe segments, either buy some new ones or you can use the old ones if they're the right diameter. Its best to have new ones to prevent exhaust leaks later.
10. 10
    After all pipes are attached, start tightening each segment to the first. Use a good amount of torque on each bolt to make sure its tight.
11. 11
    When you get to the back, take a few steps back and make any alignment adjustments you need so that the tailpipes are even with the bumper and look good.
12. 12
    Double check and tighten all the bolts.
13. 13
    Start the car up and locate any leaks you may have. HAVE FUN :)

Video

Tips

• Get some WD-40, this helps!
• 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.
• 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.

Warnings

• Let the car exhaust cool down before touching it, pipes can get extremely hot.
• Removing a catalytic converter is illegal in many jurisdictions.
• Modifying an exhaust system may result in a violation of noise ordinances.
• Exhaust leaks can be deadly, especially when the car is parked with the engine running to keep the occupants warm. Carbon Monoxide is an invisible, odorless gas.
• Cutting torches are bright, spark alot, and can cause some serious damage. Wear appropriate eye ware (UV protective) Practice on some scrap and be wary of fuel lines and other things that may inadvertently get cut or burned as a result of your inexperience.
• BE SURE to check for exhaust leaks after firing up the car. Any leaks left unfixed will be a hazard to anyone around you.

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