RR #2, Almonte, Ontario, Canada, K0A 1A0
Phone: (613) 256-6763 e-Mail: Fkc43@aol.com
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Vanagon Stainless Steel Exhaust System
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Installation Instructions
Congratulations on purchasing a Vanagon Stainless Steel Exhaust System, the finest exhaust system available for your Volkswagen Vanagon.
Begin by unpacking your exhaust system and inspect for any damage that may have occurred in shipping, notify me and the shipping company immediately of any damage or missing parts. You should have the muffler with integrated tailpipe, gasket and mounting hardware; muffler mounting brackets and hardware, J-pipe and mounting hardware; front and rear header pipes; cast iron collector with mounting hardware; catalytic converter; oxygen sensor and header pipe gasket and hardware mounting kit.
Start by removing your existing exhaust system. Remove your existing muffler hangers. Remove all bolts and studs from the engine exhaust ports. Clean and repair as necessary any damaged threads in the header ports, clean the gasket surface and insure they are flat and level on both the header port surface and exhaust pipe flange surface, clean all surfaces with solvent, lightly coat the header pipe gaskets with Loctite Ultra Copper High Temp RTV Silicon sealant, place the gaskets in position, flat metal side against the head and bolt the header pipes to the engine using 18 ft.lbs. torque. Do not install the push rod tube covers at this time, you can loosen the lower header bolts later when your finished installing and testing the exhaust system to install the push rod tube covers. Now install the collector insuring the surfaces are flat and clean using the sealant on the gaskets here also, now install the J-pipe but do not tighten the bolts at this time, instead install the muffler mounting brackets and do not tighten the bolts, install the CAT to the muffler Please note that some CATs do not have the inside bevel to accept the doughnut gasket. If your CAT does not have the necessary bevel you must create it. Using a rotary grinding tool, bevel the inside of the flange and tube to a 45 degree angle so that the doughnut gasket will seat well in the end of the CAT. Click HERE for picture detail. Leave the bolts loose enough so that the CAT can be rotated on the muffler flange, install the muffler and CAT assembly in the muffler mounting brackets, connect the J-pipe to the CAT and do not tighten the bolts, adjust the muffler, muffler brackets, CAT and J-pipe tighten the bolts slowly as you proceed so that the tail pipe is below the rear valence but does not touch and the muffler to CAT, CAT to J-pipe and J-pipe to collector connections are as straight as possible. Once your satisfied with all clearances, connections and adjustments, tighten all connections to 20 ft.lbs. Install the OXY sensor, OXY sensor guard and connect. If your old OXY sensor guard is missing or damaged you can get one form your VW dealer or order it from me. Start the engine, check for leaks, if none, good, if any, shut off engine and repair, after there are no leaks with the engine running, run the engine for 15 minutes, shut off, let cool, install the push rod tube covers and check all connection to insure they are tight. Now it's time for a test drive with your new Stainless Steel exhaust system. Enjoy !
Important Notes
Use Loctite Ultra Copper High Temp RTV Silicon sealant on all joints & gaskets.
Make sure all mating surfaces are flat and clean, especially those on the heads.
It is highly recommended to repair all exhaust port flange thread holes before installing your new exhaust header pipes. For best results install helicoils in all threaded holes. Then use new stainless steel bolts of the correct length as the ones provided. Using bolts of the correct length is critical as too long will crack the head upon tightening and too short will not provide adequate sealing pressure. Remember the lower bolts all the exhaust ports must be long enough to accommodate the tab of the push rod tube covers. You can modify the tabs of the push rod tube covers by making the holes into slots so that they can be installed or removed without removing the bolts. Make sure that all holes in the header pipe flanges line up with the exhaust port holes. If necessary tweak the header pipes so that the holes line up properly and there is no tension on the sides of the bolts.
Check the CAT. One end may not have a bevelled surface for the doughnut gasket provided at the muffler connection. You will have to create the bevel with a rotary grinder. Click HERE for picture detail.
The connections at the muffler inlet and both ends of the J-pipe use loose flanges with doughnut gaskets. This feature will allow the installer to adjust the system to insure the least amount of joint stress.
Re-tighten all flange connections after the system has reached operating temperature.
Check all flange connections periodically for tightness.
The OXY sensor provided is a BOSCH generic model. You must cut and splice on your old OEM plug to the new sensor. Wire joints must be connected with the provided crimp connectors and covered with the provided heat shrink. Stager the joints so they are not near one another. Cover the entire wire with suitable automotive high temperature split loom or similar material. Insure the OXY sensor guard is in place.
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This page was updated on November 13, 2007
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