Exhaust Install Question - ZR-1 Net Registry Forums

TheBlackPearl · 03-31-2014

Does anyone know when removing the factory exhaust do you unscrew the 3 bolts on the passenger side headpipe flange or just the clamp. In the Corsa instructions it says just remove the clamp, but that the 90 also has a headpipe flange which other years don't. It doesn't say anything about unscrewing the three bolts. I've done everything else and I'm trying to pull the exhaust off and it won't budge.

Franke · 03-31-2014

My 90 didn't have a head pipe flange on the passenger side. Just a clamp. I put on a Corsa system and used the new band clamp to reinstall that came with the kit. I think you need to remove the bolts based on what I see. You may have to modify your new Corsa pipe for a flanged connection..

TheBlackPearl · 03-31-2014

Well I took the bolts off along with the exhaust. Problem is the flange is in the way and won't come off so now I need to cut it off because it won't hammer off. Any other ideas to get it off without cutting?

TheBlackPearl · 03-31-2014

Franke · 03-31-2014

Yes. Does that flange look like it has a slip fit pipe behind it or is it welded in place? If slip fit then split the pipe from the slip side lengthwise with a cold chisel or air chisel and peel it off. If welded, the pipe will have to be cut or leave it in place and modify the new pipe to fit with a flange.

TheBlackPearl · 03-31-2014

It's a slip fit. Damn thing just won't budge though. I'll either take a chisel to it or get out the saw.

Franke · 03-31-2014

You could possibly use a 4 inch cut off wheel and split the pipe. Just don't go too deep. When the tension relaxes it will come off.

TheBlackPearl · 03-31-2014

Just what I was thinking. Thanks Franke for helping me out.

mike100 · 03-31-2014

I ran into a similar problem which I solved by welding the mating half of a 3" triangular flange to my aftermarket pipes. I limped it to my exhaust guy because he's only 1 mile down the road. and yes, it was really loud.

TheBlackPearl · 03-31-2014

I think I want to start it up while the exhaust is off, maybe scare a couple kids in the neighborhood.

Corsa wants the slip pipe to be taken off, and cutting it off will be the easiest way to get the system on the car.

03-31-2014	#1
TheBlackPearl Join Date: Oct 2013 Location: NJ Posts: 50	Exhaust Install Question Does anyone know when removing the factory exhaust do you unscrew the 3 bolts on the passenger side headpipe flange or just the clamp. In the Corsa instructions it says just remove the clamp, but that the 90 also has a headpipe flange which other years don't. It doesn't say anything about unscrewing the three bolts. I've done everything else and I'm trying to pull the exhaust off and it won't budge.

03-31-2014	#2
Franke Join Date: May 2013 Location: Beaver, PA Posts: 515	Re: Exhaust Install Question My 90 didn't have a head pipe flange on the passenger side. Just a clamp. I put on a Corsa system and used the new band clamp to reinstall that came with the kit. I think you need to remove the bolts based on what I see. You may have to modify your new Corsa pipe for a flanged connection.. Last edited by Franke; 03-31-2014 at 06:43 PM.

03-31-2014	#3
TheBlackPearl Join Date: Oct 2013 Location: NJ Posts: 50	Re: Exhaust Install Question Well I took the bolts off along with the exhaust. Problem is the flange is in the way and won't come off so now I need to cut it off because it won't hammer off. Any other ideas to get it off without cutting?

03-31-2014	#4
TheBlackPearl Join Date: Oct 2013 Location: NJ Posts: 50	Re: Exhaust Install Question

03-31-2014	#5
Franke Join Date: May 2013 Location: Beaver, PA Posts: 515	Re: Exhaust Install Question Yes. Does that flange look like it has a slip fit pipe behind it or is it welded in place? If slip fit then split the pipe from the slip side lengthwise with a cold chisel or air chisel and peel it off. If welded, the pipe will have to be cut or leave it in place and modify the new pipe to fit with a flange.

03-31-2014	#6
TheBlackPearl Join Date: Oct 2013 Location: NJ Posts: 50	Re: Exhaust Install Question It's a slip fit. Damn thing just won't budge though. I'll either take a chisel to it or get out the saw.

03-31-2014	#7
Franke Join Date: May 2013 Location: Beaver, PA Posts: 515	Re: Exhaust Install Question You could possibly use a 4 inch cut off wheel and split the pipe. Just don't go too deep. When the tension relaxes it will come off.

03-31-2014	#8
TheBlackPearl Join Date: Oct 2013 Location: NJ Posts: 50	Re: Exhaust Install Question Just what I was thinking. Thanks Franke for helping me out.

03-31-2014	#9
mike100 Join Date: Feb 2011 Location: San Marcos CA Posts: 1,786	Re: Exhaust Install Question I ran into a similar problem which I solved by welding the mating half of a 3" triangular flange to my aftermarket pipes. I limped it to my exhaust guy because he's only 1 mile down the road. and yes, it was really loud.

03-31-2014	#10
TheBlackPearl Join Date: Oct 2013 Location: NJ Posts: 50	Re: Exhaust Install Question I think I want to start it up while the exhaust is off, maybe scare a couple kids in the neighborhood. Corsa wants the slip pipe to be taken off, and cutting it off will be the easiest way to get the system on the car.