remove and replace testarossa exhaust instructions?

Remove the airbox and heat shield

Jack the car up
Remove the lower valance panel and center grill peice.

Unscrew and remove the exhaust gas temp sensors and swing them out of the way.

Mark and unplug the 02 sensors and remove clamps fastening the leads to the bellhousing. Let them hang or tie wrap them to the exhaust.

Undo the test port tube clamps at the bell housing, if your car still has them. Most have either rotted away or have been removed by now. Remove gently from the stud.

Undo the 8 spring bolts which hold the rear section to the pre-cats. Wiggle that sucker until she comes free of the exhaust flange gaskets.


Place a jack in the center of the muffler and apply slight pressure. Undo the 4 upper mounting bolts. It's best to have a helper for this step. Lower the entire rear section down to the floor. You may have to jack the car up a fair amount for it to clear the body work to get it completey out in one peice. Or remove the bumper.

Hope this helps.

 

Undo the clamps that join the headers to the precat sections. I keep the exhaust as one assembly when I remove it. Jack up the car pretty high in the back so you can get the exhaust out. I loosen the top hangers but don't remove them, then remove the header-to-precat bolts and nuts (as well as the O2 sensors etc) then I put my floor jack below the 2 precats (I have a crossbar that spans the two, you can get one at harbor freight). Then with the floor jack supporting the exhaust assembly, I take it the top hangers bolts, then slowly lower the floor jack, balancing the exhaust assembly on that. It's easy to wheel out then.

Also as noted previously, make sure you mark which O2 sensor went in to which bung!!!

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The original muffler is heavy!

 

Careful taking those emission test tubes off. Can easily break. I used WD40 on all the bolts that see heat

 

I was also going to do this this very soon and it definetly makes it clearer. I am in the midst of changing injectors. We should have a friendly bet on what the stock exhaust weighs and also weigh the new exhaust????? Just a mild comparison. Every 9 pounds reduced is about........1 horsepower...........and better on the car over all......so if I lost 30 pounds...................hmm.

 

I'd estimate a full TR exhaust system (muffler, cats, and pre-cats) weighs around 85 pounds. I have a complete TR exhaust system out in the garage...I'll have to put it on the scale tonight....and report back.

 

I have a Tubi with post cat delete pipes that I came across and it really is pretty heavy. I am going to weigh it also and compare to the same parts I pull off which are the original stuff.