I could not find much info on the details of installing a muffler. Hopefully this will help if you have to do the same thing
This was physically difficult for me to do, a lot of being under the car, which I don't like.
Note: The red bentley manual as a good exploded view, it also has the torque spec for the pipe clamps ... although I seem to have lost it.... you can get them from amazon here
Step 1: Get the Parts
Step 2: Document Part Numbers
Step 3: Practice Assembly - Pipe Clamps
Step 4: Spring Clamps and Tool
Step 5: Rubber Hangers
Step 6: Gasket for Down Pipe 'toilet Bowl'
Step 7: Yikes - What a Big Thing
Step 8: Inspect the Pathway and Hangers Under the Car
Step 9: Remove the Old Down Pipe
Will reuse the heat shields.
Not sure if there is a small crack in the exhaust manifold -- does not look like damage, but does not seem like it should be there.
Step 10: Jack Up the Back of the Car and Get a Light
Step 11: Install the Tail Pipe and Muffler -- Needs to Be Snaked Into Place
Step 12: Secure With Rubber Hangers
Step 13: Deal With Rust
Step 14: Chip and Cut Away All the Rust
I used an angle grinder with a cut-off disc to cut back to good metal.
To weld you need a clean surface, so go around the edges with a wire brush disc on the grinder.
Step 15: Patch the Hole With Sheet Metal
To get the right shape I first cut a scrap piece of aluminum (bottom of a 'catering tray') then traced the shape onto the steel. I used nippers to cut out the shape, this is sort of a pain, but it does work.
Welder settings: MIN Power and Wire Speed 2
Weld the new piece in place. 22 gauge is a bit thin, 18 gauge would have been better. 18 is the minimum thickness that should be used with this welder. Had to patch a few holes after putting in the large piece.
Step 16: Transfer the Heat Shield to New Down Pipe
Step 17: Install Down Pipe With Spring Clips
- First installed passenger side clip from under the car.
- Held up the downpipe with my knee while attaching the clip
- Install driver side clip from above the car.
- I was able to pull the bottom of the pipe towards the drivers side, stretching the passenger side clip. This made it possible to install clip.
- It was hard to get the clamp off
Step 18: Install Middle Muffler Part...
Step 19: Seal Joints and Tighten Clamps
The sealant was messy, most of it squeezed out of the joint.
Step 20: Straighten Everything Out
I was able to get everything lined up okay by twisting the muffler. You want to get the pipes so they are close to the bottom of the car, not hanging down all over.
Step 21: Done for Now
As long as it doesn't fall off I'm happy for now. In the end it will have to pass a 'smog test', should be fine.