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19.01.2005: Exhaust joint
Clean the end of the flex pipe with a wire brush and fit it to the pipe from the catalitic converter.

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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