Installation Instructions for 555-30411 Cavalier Cat Back 2-1/2” Exhaust System with Turbo Mufflers

Application: 1993-2003 Cavalier

Kit fits ‘93-’03 passenger car Chevrolet Cavalier with a four cylinder engine, and ‘92 four cylinder passenger car with rear exhaust hanger behind the gas tank. Also fits ‘93-’94 Pontiac Sunbird 2.0L w/122” wheel base as well as ‘92 with rear exhaust hanger behind the gas tank; and fits ‘95-’96 Pontiac Sunfire 2.2L w/133”wheel base, as well as ‘95-’96 2.3L & 2.4L, and ‘97-’98 Sunfire.

Kit Includes:

1) FLANGED FRONT PIPE

1) EG11 GASKET

1) EXTENSION PIPE

1) UNIVERSAL HANGER #2946

1) OVER THE AXLE TAIL PIPE

1) 1/2” WIRE HANGER CLAMP #2947

1) Y-PIPE TIP

1) 5/16” WIRE HANGER CLAMP #2948

4) 2-1/4” CLAMPS

3) 5/16” x 1-1/4” BOLTS

3) 5/16” NUTS

DANGER WARNING: Should the purchaser decide to install this exhaust product at home, be warned that pleasure car or light duty truck/van “bumper” jacks are intended for emergency use only. The use of frame contact jack stands in conjunction with a floor jack as main support is highly recommended to minimize accidental dropping of a vehicle while the installation proceeds. We recommend the use of a shop hoist if possible. Please use caution!

Limitation of Liability–Disclaimers: The regulation of emissions production, noise levels and safety standards is undertaken by the federal government, each of the fifty state legislatures, and by many local municipalities, towns and counties.The manufacturer makes no warranties of merchantability, of fitness for a particular purpose, or that its products are approved for general use, or that its products comply with laws, regulations or ordinances in the states where they may be sold to the ultimate purchaser, the consumer.The entire risk as to the conformity of this product in any such state and as to repair, should the product prove to be defective or non-conforming, is on the retail purchaser, the buyer, the ultimate consumer of such product and it is not upon the seller, distributor, or manufacturer.In this connection, retail purchaser, the buyer, the ultimate consumer assumes the burden of the entire cost of any and all necessary service, alterations, and or repair.The foregoing statement limits the liability of the manufacturer.

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NOTE: DO NOT TIGHTEN ANY BOLTS OR CLAMPS UNTIL THE LAST STEP!

1. Remove the exhaust from behind the flange after the converter, leaving only the down pipe, converter, and the O.E. hanger mounts.

2. The included front flanged pipe is designed to fit different models of the Cavalier. this pipe will fit the 2.4L & 2.3L ‘95-’96, and the ‘99-’03 Cavalier without cutting, and the ‘95-’96 2.3L & 2.4L Sunfire. On the ‘93-’98 2.2L (and Sunbird), approximately 8” will need to be cut off the end of the included flanged front pipe. NOTE: before doing any cutting, lay out the entire system and verify that you will not be cutting off too much of the front pipe. After the included flanged front pipe is cut (if necessary), install the included gasket and flanged front pipe to the converter flange using the included 5/16” x 1-1/4”bolts if the original bolts and nuts cannot be re-used.3. Install the i.d. end (swedged end) of the extension pipe to the front flanged pipe using a 2-1/4” clamp.On ‘99-’03 models, you may need to cut off 1-1/2” from the o.d. (non-swedged) rear end of the extension pipe. Again before you cut, verify the length of the pipe to cut off.

4. For ‘96-’03 models only, install the 4/16” wire 2-1/4” hanger clamp to the O.E. rubber mount before the driver’s side rear wheel. You will use the clamp portion to connect the extension pipe and the over the axle tail pipe/tip in the next step.

5.From behind the rear axle, install the over the axle tail pipe section (i.d. end) of the system to the extension pipe using a 2-1/4” clamp (‘99-’03 use the clamp of the hanger in the previous step).

6. For all vehicles but ‘96-’03, locate the O.E. rubber hanger mount that is immediately behind the rear axle and install the 1/2” wire 2-1/4” hanger clamp to this O.E. rubber hanger mount and clamp to the over the axle tail pipe.

7. Install the y-pipe tip to the extension pipe using a 2-1/4” clamp. Above the driver’s side portion of they-pipe tip is another O.E. rubber hanger mount. Install the included universal hanger (the end without holes in it) to this O.E. rubber hanger mount. Use a 2-1/4” clamp to connect the universal hanger and the driver’s side portion of the y-pipe tip.

8. Tighten all clamps, nuts, bolts, fasteners and hangers. Check for clearance of the frame, body, and brake and fuel lines.