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DIY exhaust kit job? 200 1991

I ordered up a complete Starla/Walker kit from FCP Groton when I did mine, but from what I've been hearing lately, the OEM Volvo kit is of superior quality.

I think you can tackle this job with sockets and wrenches, and maybe a few other tools. You'll need to get the passenger side of the car up on jack stands. A hacksaw, or preferably a Sawzall, is good for making quick work of removing the old exhaust if the pipes and mufflers are rusted together. You can use a single edge razor blade or utility knife to cut the old rubber hangers if the kit comes with new ones.

The new exhaust should fit together like butter. But since you'll likely be keeping the cat converter pipe, some sanding may be in order to slip the front muffler over this pipe. Also, a pry bar or large screwdriver will be helpful in stretching the new rubber hangers over their mounting points. As weird as it sounds, I used dish soap to lube the rubber hangers to get everything to slip and slide the way it needed to.

Other than that, it's a simple slip-and-clamp operation. Took me an hour or two as a first-timer to remove the old exhaust and hang the new one. Great accomplishment factor when you get done!

Good luck!






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