For a number of reasons, exhaust system work can be among the most dangerous type of work you can do on your car. Always observe the following precautions:
A number of special exhaust system tools can be rented from auto supply houses or local stores that rent special equipment. A common one is a tail pipe expander, designed to enable you to join pipes of identical diameter.
It may also be quite helpful to use solvents designed to loosen rusted bolts or flanges. Soaking rusted parts the night before you do the job can speed the work of freeing rusted parts considerably. Remember that these solvents are often flammable. Apply only to parts after they are cool!
See Figures 1 and 2
System components may be welded or clamped together. The system consists of a head pipe, catalytic converter, intermediate pipe, muffler and tail pipe, in that order from the engine to the back of the vehicle.
The head pipe is bolted to the exhaust manifold, on one end, and the catalytic converter on the other. Various hangers suspend the system from the floor pan. When assembling exhaust system parts, the relative clearances around all system parts is extremely critical. See the accompanying illustration and observe all clearances during assembly. In the event that the system is welded, the various parts will have to be cut apart for removal. In these cases, the cut parts may not be reused. To cut the parts, a hacksaw is the best choice. An oxy-acetylene cutting torch may be faster but the sparks are DANGEROUS near the fuel tank, and, at the very least, accidents could happen, resulting in damage to other