Warnings and Safety Measures
When Working on under or around any vehicle exercise caution. Please allow the vehicle’s exhaust system to cool before removal, as exhaust system temperatures may cause severe burns. If working without a lift, always consult vehicle manual for correct lifting specifications. Always wear safety glasses and ensure safe work area. Serious injury or death could occur if safety measures are not followed. Professional installation recommended.
Please follow the exhaust install instructions carefully. Extreme caution must be taken to ensure proper alignment of the exhaust tips. Do not tighten any of the band clamps or connections until everything is in place and the tips are aligned perfectly.
1) WHEN DISASSEMBLING THE STOCK EXHAUST SYSTEM, UNBOLT THE REAR MUFFLERS using a 15mm socket.
2) Remove the factory cross member using a 15mm socket. Save the bolts and cross member for re-installation later.
3) Take out the two oxygen sensors located in the front pipe assembly. One on the drivers side, one on the passenger side. Use a 22mm or 7/8” wrench.
4) Carefully plan the removal of your stock exhaust system. Depending on many factors the exact methods may change.
5) Remove the four nuts using a 15mm socket at the front pipe to catalytic converter connection. Save these flared 15mm nuts for use when installing the new Solo system.
6) Pull down on rear of the exhaust system by the muffler. When the rubber hangers stretch, squirt soapy water into the rubber where the hangers go. You could use WD40 or grease but that would not be good for the rubbers. It starts to deteriorate them. Using a fair size channel lock pliers, squeeze the backside of the rubber and the hanger rod. This will push the hanger knob into the rubber. Carefully remove the exhaust system from all the hangers.
7) Re-install the factory GM cross member. This cross member will support the Solo G8 front muffler section and make the install easier.
8) The stock exhaust system is now disassembled and its time to put your new kit on!
NOTE: If you snug everything first instead of fully tightening,
it will allow for movement and adjustments once the new system is on.
Snug, align, snug some more and then do your final tighten.
1) Being careful not to bang the rear valence, slip the left and right tail tips into the hangers. Approximately 1inch of the rod hanger ultimately sticks thru the rubber.
2) Slide the front muffler section from the front of the car to the back of the car going over the GM body brace. Slide hanger rods into rubbers and align. Loosely hand tighten the 4 front nuts.
3) Assemble the four band clamps provided by SOLO and slip 2 of them onto the rear pipes of the muffler section. The band clamp bolts should face inward and upward. Slide the other two band clamps onto the tail pipe sections.
4) Slide the mid pipe sections over the front muffler section until it bottoms out. Manipulate each tail section over the rear portion of the mid pipes.
5) MANIPULATE THE EXHAUST SYSTEM INTO PLACE BEFORE YOU TIGHTEN ANYTHING. THE “WIGGLE” ROOM IS MINIMAL BUT IT IS THERE AND IT SHOULD BE USED TO YOUR ADVANTAGE BEFORE ANY TIGHTENING STARTS TO HAPPEN.
6) THE TAIL PIPES DO NOT HAVE TO “BOTTOM OUT” ON THE MID PIPE.
7) Make sure the tips are equal distance in and out and centered in the cut out of the valence. A helper with a good eye is recommended to hold the tips.
8) Hand tighten each of the 4 band clamps to a snug position. Make sure the SOLO band clamps are equal distance on each pipe.
NOTE: If further manipulation is needed to get the tail tips aligned you can take out the long bolts that hold the rear hangers to the body of the car. You can use a washer to shim one side only and this will “tweak” the level. You could shim each side evenly and this would adjust the height. Shimming these 4 bolts bolts properly can do a lot to align the tail tips perfectly if needed. Since the front muffler section and the mid X-Pipe section are “tied” together there is very little forgiveness in the system. One or 2 washers between the body of the car and the top of the hanger can do wonders to level and align the tail tips.
9) Ensure that the tail pipes are still in perfect position and lightly snug the 4 front nuts and each of the 4 band clamps.
10) IF THERE IS ANY FURTHER ADJUSTMENT TO BE MADE IN THE TAILPIPES PLEASE REFER TO THE ABOVE NOTE…
Note: Do not over tighten the 4 front nuts. When you see the flanges flex tight, its more than enough tension.
OLO band clamps: Hold the top nut with a 9/16” wrench and lightly snug the bottom bolt head with a 9/16 socket. THIS FLAT BAND CLAMP WILL FORM AROUND EACH LAYER OF PIPE.
11) Ensure that everything is still aligned and proper. Perform a tight snug on all 4 clamps, and the 4 front nuts.
12) Check again then perform your final tighten to all four band clamps.
13) Install and tighten your two oxygen sensors. Rotate the O2 sensor counterclockwise about 5 or 6 turns before threading it in clockwise. This will prevent unnecessary twisting of the O2 wire once it’s tightened.
14) Drive away and ……