How to Install an Auto Exhaust Kit

Some drivers may wish to install new exhaust kits rather than stay with the stock models in place when they bought their vehicles. An aftermarket exhaust kit may be straighter than the stock model, which allows exhaust to escape more efficiently, or it may have other benefits such as adjusting the engine pitch or achieving an aesthetic look that benefits the vehicle. Only qualified mechanics should install an exhaust kit, but if you possess those skills, you can put it together yourself.

Difficulty: Moderately Challenging

Instructions

Things You'll Need:

• Jack or hydraulic lift
• Exhaust kit
• Welding torch
• Bolt cutters
• Socket wrenches

1. Determine the kind of exhaust kit you want, and decide whether it will fit your particular vehicle. Many stock exhaust systems bend around other components to the car, and your aftermarket kit will either need to fit those parameters or be modified so it will.

2. Elevate the vehicle using a hydraulic lift or a jack. You need to be able to see the exhaust system and work comfortably around it.

3. Disconnect the old exhaust system piece by piece, starting with the tailpipe and working backwards toward the catalytic converter. Some pieces can be removed by bolt cutters or wrenches, while others may require a welding torch. Take care not to damage any other components of the vehicle while you work.

4. Watch for the emissions control sensor near the catalytic converter. This should not be damaged and needs to be functioning correctly for the exhaust system to be legal.

5. Install the new catalytic converter and check the connection so that it will fit with the rest of the exhaust. It should be welded firmly into place and fit snugly within its designated space. This step may not be necessary if your exhaust kit does not include a catalytic converter.

6. Connect the exhaust tubing from the catalytic converter to the new muffler and fit it into place. It may need to be adjusted to fit the dimensions of your vehicle.

7. Fit the new muffler in place and examine it to make sure it is aligned with the rest of the exhaust kit. If it checks out, then you can bolt or weld it into place.

8. Attach the pipe from the muffler to the exhaust pipe and ensure that it is properly aligned. Bolt or weld it into place once you are satisfied that the position is correct.

9. Connect the exhaust pipe and align it with both the remainder of the kit and the rear bumper, if appropriate. Weld it into place or use bolts as appropriate to your vehicle.

10. Turn on the engine and examine the exhaust kit to check that there are no leaks and everything is performing as it should.

Tips & Warnings

• Guidelines vary on aftermarket exhaust kits and the car in which you intend to install it. Check the specific instructions carefully, and modify your steps to address any details in your particular situation.
• Most areas have strict laws that forbid the installation of exhaust systems that are too loud or release too many pollutants. Make sure the kit you install is legal and safe for your area.