Date:         Sat, 20 Aug 2005 14:48:07 -0400
Reply-To:     Roger Sisler <rogersisler2000@YAHOO.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Roger Sisler <rogersisler2000@YAHOO.COM>
Subject:      Re: exhaust system

I think the biggest part of this job is the removal of the old exhaust.On
conventional(normal) vehicles , this is only a cut here and there with a
torch.Old system ---gone.With the vanagon, the nuts and studs that hold the
pipes to the 4 exhaust ports are the issue.I dont know your tolerance for
difficult repairs, but the loosening of these 8 nuts can tell you if you
should proceed to do it yourself.With the engine cool, get your sockets on
these nuts and try to loosen.If they want to cooperate, you, or your
mechanic are in good shape.If 1 or 2 are a problem , consider taking your
vehicle to a shop and have them remove these.The rest of the system, If
replacing the total, is not difficult.Does your new system have a NEW
muffler strap? Be sure to get one($20).Make sure your estimate is from
someone who has done this repair before!To istall the new stuff, put the 2
header pipes on first with NEW hardware and gaskets.If loose, the new
gaskets will burn through very soon.Next, install the strap in place.After
this(and on the driveway ), assemmble the tail pipe, to the muffler.
These ,to the catalytic.These 3 items now install to the J-pipe.Best to get
a new oxygen senser installed into the new J- pipe after the job is
finished.Lastly, take this assembly under the van with you and install it
to the 2 exhaust pipes(new gaskets and hareware everywhere!).Your done now-
Whew!