Installation Steps:
Using a 15mm socket, remove the double bolt clamp and intermediate pipe and set the clamp aside. You will need the clamp for a later step when installing your new exhaust.
Next, remove the front and rear muffler hangers and tail pipe hanger from the rubber insulators. (You can spray the insulators with a soapy water mix to help in this step, DO NOT USE WD40 as it will dry out the rubber insulators) This can be accomplished by sliding the entire system towards the rear of the vehicle. (*Note) If you do not plan on keeping your stock exhaust, you can simply cut it in half with a sawzall to make it easier to remove.
You should now have your old, restrictive stock exhaust completely removed.
Now that you have your stock exhaust apart, now is a good time to remove all of the Corsa exhaust system components from the shipping cartons.
After you have removed all components, you should have: (1) Package of Anti-Seize, (2) 3" clamps, (7) 1 1/2" clamps, (2) Exhaust hanger brackets, (2) Rubber solators, (1) Zip tie, Intermediate pipe, Intermediate pipe w/ hanger, Muffler, Y-pipe, Passenger over axle pipe, Driver over axle pipe, Passenger tail pipe, Driver tail pipe and (2) 4" Tip assemblies
Now on to the fun part, installing your new exhaust! Locate the double bolt clamp you set aside earlier and locate your new intermediate pipe. Slide the NON-NOTCHED end into the factory double bolt clamp and tighten to a snug fit. Next, slide the supplied 2 1/2" TORCA clamp over the notched end.
Installation Note: Be sure to apply the anti-seize lubricant that has been provided to all bolts, fasteners and clamps. A pouch with anti-seize lubricant is included with the hardware kit. Apply the supplied anti-seize lubricant to the threads ONLY of all TORCA band clamps. Failure to follow this procedure can cause the nuts to seize on clamps and potentially damage threads.
After installing the double bolt clamp on the intermediate pipe, slide it over the stock exhaust manifold and snugfit clamp. Now, find the intermediate pipe with hanger (shown above) and insert it through stock rubber isolator and into intermediate pipe and snug fit TORCA clamp.
You are now ready to fit the muffler onto the intermediate pipe with hanger. Slide a 3" TORCA clamp over the expanded end of muffler and then slide over the intermediate pipe with hanger, and snug fit clamp.
Installation Note: Make sure that the small drain or weep hole in the rear of the muffler faces down when muffler is installed.
Place a 3" TORCA clamp over the expanded end of the Y-pipe.
You can then slide the hanger into the rubber isolator and once through the isolator, slide the expanded end of the Y-pipe over the muffler outlet and snug fit the clamp.
