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Cutting exhaust pipe is an important part of removing and installing an exhaust system on your vehicle. Power saws can cut exhaust tubing quickly, but they throw hot metal chips flying in the air while you are cutting. This can cause injury to your eyes and burn your skin. Chain pipe cutters use a chain with cutting wheels to cut through the thin wall of the exhaust tubing and create a burr-free square cut without throwing hot metal shavings around.

Instructions

1

Place the pipe wrap around the exhaust tubing and wrap it around the pipe. Make sure that the sides of the pipe wrap are even so the pipe wrap is square on the exhaust pipe.

2

Run the permanent marker along the edge of the pipe wrap to create a erence line for the cut you need to make around the exhaust pipe.

3

Remove the pipe wrap from the exhaust pipe and slide the chain of the chain exhaust pipe cutter around the exhaust pipe.

4

Pull the chain of the chain exhaust pipe cutter tightly to the exhaust pipe and hook the chain into the holding hook attached to the handle of the chain exhaust pipe cutter.

5

Apply cutting fluid to the cutting wheels of the chain exhaust pipe cutter and push the handle of the chain exhaust pipe cutter around the exhaust pipe.

6

Tighten the chain of the chain exhaust pipe cutter to apply additional pressure to the exhaust pipe and repeat step 6. Repeat the process until you cut through the exhaust pipe.

7

Wipe the surface of the cut exhaust pipe with a clean rag to remove excess cutting fluid from the exhaust pipe to complete the cutting process.

In order for fuel and air to combust properly in your engine, there has to be a waste product created. Once this exhaust is expelled from the engine, it must be routed out. Y pipes are one design used for this.

Identification

There are a number of different design schemes that can be applied to vehicle exhaust systems. One of these is the Y-pipe design. They can be located or installed into a number of different automobiles ranging from Fords to Nissans to Porsches.

Basic Design

The manifold in your car is the mechanism that receives the exhaust output from your engines cylinders. It then has to route that exhaust into the exhaust pipe so that it can be emitted from the automobile. If the manifold has two "branches" or outlets, the top portions of the Y-pipe match up to them. The exhaust is then funneled into the tail of the Y and into the exhaust pipe.

Extended Assembly

In some cases, the Y pipe will lead into the catalytic converter before being sent into the exhaust pipe. After it has been sent through the exhaust pipe, the exhaust then reaches the muffler for sound dampening. It is then sent out through the tailpipe at the rear of your vehicle.

A vehicles exhaust pipe is primarily responsible for directing the noxious exhaust gases produced by the engine away from the interior of the vehicle. Exhaust pipes also operate to rout the exhaust gases through a muffler to quiet the noise produced by the gases. In some cars, they rout exhaust gases through a catalytic converter designed to reduced emissions. When a defective muffler or catalytic converter needs to be replaced, the first step is to remove the exhaust pipe.

Instructions

1

Lift the vehicle with a floor jack and support the weight with jack stands.

2

Use a wrench to disconnect the exhaust manifold from the engines cylinder head. The exhaust manifold attaches to the engines cylinder head with several bolts. Once the bolts have been removed, pull the exhaust manifold away from the engine.

3

Disconnect the exhaust pipe from the exhaust manifold from underneath the vehicle. The exhaust pipe connects to the manifold with two bolts, which can be removed with a wrench.

4

Pull the exhaust manifold out of the engine compartment.

5

Disconnect the exhaust pipes hanger. The hanger is used to hold the exhaust pipe to the vehicles frame, and is typically located towards the rear of the vehicle. The hanger can either be disconnected from the exhaust pipe or from the frame by removing the hangers bolt(s) with a wrench.

If you take your Jeep Wrangler off road often, rust problems can develop on your exhaust system due to water and moisture. Whether you are replacing your exhaust with an aftermarket kit or a factory system, the process is virtually the same. Exhaust kits may be purchased at any local auto parts store and installed yourself using simple tools. Eye protection must be worn to protect against falling debris.

Instructions

Removal of Stock Exhaust

1

Cut the exhaust pipe directly behind the muffler using a hack saw.

2

Remove the bolts on the flange that connects the muffler to the catalytic converter using a ratchet and socket. Remove the muffler from the vehicle.

3

Remove the stock tailpipe hangers off the factory mounts located on the frame by pulling them out of the rubber bushings with your hands.

4

Pull the stock tailpipe out of the vehicle.

Installation of New Exhaust

5

Slide the tailpipe hangers into the stock bushings located on the frame.

6

Lift the muffler into position. Slide one end into the tailpipe.

7

Install the flange onto the catalytic converter and tighten the bolts using a ratchet and socket.

8

Place the exhaust clamp that came with the kit over the muffler and tailpipe connection. Tighten the bolts using a ratchet and socket.

9

Start the vehicle and check for leaks in the system.

Your vehicle exhaust manages the removal of waste gases produced within the engines combustion chambers. Exhaust piping and component quality determines engine power, fuel efficiency and sound. Over time, exhaust piping can corrode and becomes comprised with age. Compromised components decrease performance and may allow harmful exhaust gas chemicals into the air. The specific make and model of your vehicle determines the specific exhaust design but each design includes similar components and hardware including bolts, hangers, clamps, an exhaust manifold, front pipe, catalytic converter, muffler and tailpipe. Installing new muffler assembly and tailpipe isnt difficult with proper instruction and tools.

Instructions

Removal Of Existing Exhaust

1

Open the hood and disconnect the vehicle battery using a socket set. This nullifies any electrical concerns during installation and resets the system to the new exhaust once reconnected.

2

Place the floor jack in the recommend owner manual positions and lift the vehicle off the ground. Place floor jacks underneath the vehicle until all wheels are off the ground. Leave ample room to work underneath.

3

Locate the two-bolt flange connecting the muffler assembly into the catalytic converter piping and unbolt the two bolts using the socket set. The bolt flange mates the muffler assembly to the catalytic converter or resonator, if applicable.

4

Locate the hangers or rubber fasteners still holding the loose muffler assembly underneath the vehicle chassis. Also, refer to a vehicle specific repair guide for the locations of any other bolts securing the muffler in place.

5

Remove the remaining bolts and lift the muffler assembly off the hangers, if applicable. Place the removed muffler alongside its corresponding hardware.

6

Unbolt the resonator from the catalytic converter piping, if applicable. If there is not a resonator skip this step. Review the installation instructions that came with your new exhaust pipe. Complete any other removal procedures specific to your vehicle

Installing New Muffler & Tailpipe

7

Loosely fasten the two flange bolts mating the muffler assembly and catalytic converter together by way of the two-bolt flange. Also, mount a gasket in-between the flange and new muffler assembly, if included with the new system.

8

Reinstall any fasteners or clamps that secured the muffler piping in place prior to removal. Hook the proper piping connectors to the corresponding exhaust hangers specific to your vehicle. Do not tighten.

9

Mount the new tailpipe and secure to the muffler piping, if applicable. Refer to the new exhaust installation instructions for the specifics.

10

Align the new exhaust piping in its proper position. Leave at least a -inch space between piping and bodywork to avoid cosmetic damage due to exhaust heat.

11

Tighten the two-bolt flange bolts and proceed with tightening each bolt, clamp or fastener from the front to rear of the vehicle. Refer to the proper torque specifications required by each bolt in your owner manual or installation instructions.

12

Reconnect the vehicle battery and turn on the vehicle. Listen for exhaust leaks.