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1. Place the entire vehicle on a lift or jackstands. Be sure that the car is firmly supported before going ANY further with this installation! 2. Loosen the 13mm nut at the bottom of the stock muffler strap. Allow the muffler to hang. 3. Using a cutting wheel or hacksaw, cut the stock muffler from the pipe. (Tip: Try to leave between 1 and 1.5 inches of straight pipe at the inlet. This will allow the muffler to be reused more easily if necessary at some point in the future.) Be sure that at least 1.5-2.0 inches of straight piping remains at the rear of the exhaust pipe. (98-02 cars will have additional supports connecting the muffler to the pipe that must also be cut. It works best to cut these close to the pipe.) 4. Loosen the 10mm fastener at the top of the muffler strap that secures the upper cross-member to the muffler strap. Pull on the vertical section of the cross member to remove the cross-member from the strap and the exhaust mounting block. Keep the cross-member – you will reuse it. (Tip: If you lose or damage the cross member, replace it with Saturn part number 21013041.) 5. Insert the large end of the reducer/adapter pipe (included in the EXMKIT) into the muffler inlet and clamp securely into place using the enclosed stainless band-style clamp. 6. Slip the upper cross-member (Saturn part number 21013041) into the slit within the stock rubber undercarriage mount so that the tab faces the rear of the car and the bend faces the front of the car. 7. Using the enclosed 10mm fasteners, install the EXMST01 into place and fasten to the stock upper cross-member. The adjustable slots should be toward the rear of the vehicle. Insert and tighten the 10mm fastener at this time. Remove the 11mm nut at the bottom of the strap. (Tip: The tab of the upper cross member can be inserted into any of the slots within the EXMST01 strap. Using the higher slots will lower the muffler tip relative to the bumper cover, and using the lower slots will raise the muffler tip relative to the bumper cover. Adjust this connection as necessary to fine-tune the fit of your muffler onto your particular vehicle.) 8. Slip the muffler into place so that the reducer slips over the stock pipe. You can slide the enclosed ¾-inch muffler clamp into place at this point, but do not tighten at this time. 9. Adjust the fore and aft positioning of the band from the EXMST01 strap relative to the muffler so that it will hold the muffler properly once tightened. (Some experimentation may be necessary at this step. If you are using one of the lower adjustable strap slots, you will have extra bracket sticking up above the cross member. This may cause interference with the exhaust heat shield. If this happens, slide the entire strap rearward on the muffler until the bracket is beyond the end of the heat shielding so as to avoid contact.) 10. Adjust the vertical position of the EXMST01 so that the muffler tip is properly positioned relative to the rear bumper cover. 11. Make sure that the muffler is straight. 12. Tighten the clamp at the reducer/adapter. 13. Tighten the bolt at the bottom of the strap to secure the strap onto the muffler. 14. Start the vehicle and carefully inspect the muffler and adapter for exhaust leaks. 15. Retighten clamps and fasteners as necessary. |
