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30420: Installation Instructions for 555-30420 Cat Back 2-1/2” Exhaust System with Front Resonator

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Installation Instructions for 555-30420 Cat Back 2-1/2” Exhaust System with Front Resonator

Application: 2000-2004 PT Cruiser, including turbo

NOTE: this cat-back 2-1/2” system has a dual outlet.NOTE: this system does clear the spare tire, although access to it is limited. To gain access to the spare tire, the passenger side hanger must be removed and the passenger side pipe allowed to hang free.You may want to re-locate the spare tire, or carry tools to remove this portion of the exhaust in case of emergency. You may consider using a 5/16” wing nut on the passenger side, but make sure it is tight.

Kit Includes:

1) 2-1/4” clamp

1) front resonator (2-1/4” i.d./2-1/2” o.d.)

3) 2-1/2” clamps 1) 2-1/2” middle extension pipe

2) 5/16” lock washers

1) 2-1/2” over the axle pipe/left muffler/stainless tip

2) snapper grommets

1) 2-1/2” rear pipe/right muffler/stainless tip

2) 5/16” lag screws2) 5/16” x 1” bolts

2) 5/16” x 1-1/2” bolts

4) 5/16” nuts

2) 4” strap hangers #2945

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.

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

1. Remove the exhaust system after the clamp behind the converter, leaving the O.E. rubber hanger mounts on the vehicle.

2. Install the 2-1/4” i.d. end (it is notched) of the front resonator to the converter pipe. Be sure to lineup the notch on the pipe to the pin on the converter pipe. Use a 2-1/4” clamp to connect the two pieces.

3. Put the middle extension pipe to where it will run. Install the wire hanger on the middle extension pipe to the O.E. rubber mount near where the middle extension pipe runs. Use a 2-1/2” clamp to attach the 2-1/2” middle extension pipe to the straight front extension pipe.

4. Install the over the axle pipe/left muffler/stainless tip to the vehicle using a 2-1/2” clamp.

5. There is a bracket welded onto each of the rear glass pack mufflers. You will need to drill a hole at the rear of the vehicle to install a 4” strap hanger and snapper grommet using a lag screw (or a 5/16” x 1-1/2” bolt and nut--it is difficult to get the bolt in place). Do so now for the driver’s side, and also attach the electrical ground to the hanger.

6. Install the rear pipe/right muffler/stainless tip to the Y-section of the over the axle pipe/ left muffler/stainless tip using a 2-1/2” clamp. Again, you will need to drill a hole at the rear of the vehicle to install a 4” strap hanger and snapper grommet using a lag screw (or a 5/16” x 1-1/2” bolt and nut, or wing nut--see notes). Do so now for the passenger side.

7. Tighten all clamps and check for clearance of all brake and fuel lines, and clearance of the frame and of chassis components.

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Posted on
May 10, 2018
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