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Once you're happy with the position of the pipe, you can start putting
everything back together. This is a good time to clean the O2 sensor heads
with carb cleaner and check if the holes in the sensors are clogged with
soot. Fit the rear O2 sensor before putting the hangers on. Put some
antiseize on the threads to make the future removal
easier. Tightening torque for the sensor: 41 ft-lbs.
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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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