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The old downpipe compared to the new one. The flex joint on the old pipe
rusted so much that it almost separated from the lower section (no wonder I
had such a leak), and it only took me a slight pull to tear it off
completely.
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The downpipe installation procedure for a 1996 Saab 900 (also applies to the
1999-2002 9-3 models). The pipe is supplied by
Jak Stoll.
It is a 3" aluminized steel downpipe with a Magnaflow high flow
catalitic converter.
Tools:
- ramps or jack stands;
- 13 mm socket or wrench: downpipe to turbo nuts, exhaust clamp bolts
(a 1/2" worked better in my case due to a tighter fit);
- 7/8" open end wrench: O2 sensors;
- flat screwdriver: to release the tab on the O2 sensor connector;
- a heavy tool or a length of pipe to bend exhaust hangers;
- wire brush: to clean the joint between the flex pipe and the cat;
- exhaust sealant: to seal the joint between the flex pipe and the cat;
- torque wrench.
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