BRExhaust 167592 Sunfire Direct Fit Exhaust Kit Instruction Manual

: June 13, 2024
: BRExhaust

Table of Contents

BRExhaust 167592 Sunfire Direct Fit Exhaust Kit
Product Information
Product Usage Instructions
INSTALLATION INSTRUCTIONS
CUT TO FIT INSTALLATION INSTRUCTIONS
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

BRExhaust 167592 Sunfire Direct Fit Exhaust Kit

Product Information

The product is an exhaust system designed for vehicles. It includes various components, such as isolators, nuts, bolts, clamps, and pipes. The product is manufactured by BRExhaust, a
company based in Oceanside, CA. The product is intended to replac the vehicle’s OEM (original equipment manufacturer) exhaust system.

Product Usage Instructions

Disconnect the vehicle’s battery before removing the OEM exhaust system to prevent electrical accidents and reset the computer if applicable.
Remove the existing exhaust system from the vehicle, only removing the parts that will be replaced.
Clean the existing flange with a wire brush to ensure proper sealing.
Attach item 5 to the isolators.
Connect item 2 to the existing exhaust with item 1 for 122.9 WB (nuts and bolts not included).
If the vehicle has a WB of 117.9 or 108.3, cut item 2 to fit accordingly (STEP 3A).
Connect item 4 to the existing isolators and to item 2 with item 3.
Connect item 2 to item 5 with item 3.
Attach the clamp provided with item 5 to secure the slip fit joint.
Ensure that the new exhaust is not contacting any portion of the underbody of the vehicle or drivetrain.
Tighten all clamps starting from the rear of the vehicle. Do not exceed 30FT-LB when tightening the clamp. Check all clamps after driving for 50 miles and retighten if necessary.

Important Safety Warning

When working on, under, or around any vehicle, exercise caution. Allow the vehicle’s exhaust system to cool before removal to avoid severe burns. If working without a lift, always consult the vehicle manual for correct lifting specifications. Always wear safety glasses and ensure a safe work area. Failure to follow safety measures could result in serious injury or death. BRExhaust recommends professional installation for all products. For technical support, contact 1-800-631-7271.

INSTALLATION INSTRUCTIONS

BILL OF MATERIALS

167592
168479
169305
168476
168480

STEP 1
(Carefully read all instructions before installation) Disconnect the vehicle’s battery before removal of the OEM exhaust system. This will prevent electrical accidents and will reset the computer if it applies to the vehicle. Remove the existing exhaust system from the vehicle. Only remove parts that will be replaced. Clean the existing flange with a wire brush to ensure proper sealing.
STEP 2
Attach item 5 to isolators
STEP 3
Connect item 2 to existing exhaust with item 1 for 122.9” WB (nuts and bolts not included)
STEP 3A
Cut Item 2 to fit for 117.9” and 108.3” WB
STEP 4
Connect item 4 to existing isolators and to item 2 with item 3
STEP 5
Connect item 2 to item 5 with item 3
STEP 6
Attach clamp provided with item 5 to secure slip fit joint
STEP 7
Ensure new exhaust is not contacting any portion of the underbody of the vehicle or drivetrain.
STEP 8
Tighten all clamps starting from rear of the vehicle. (DO NOT EXCEED 30FT-LB WHEN TIGHTENING CLAMP AND CHECK ALL CLAMPS AFTER 50 MILES. RETIGHTEN IF NECESSARY)

WARNING

When working on, under, or around any vehicle exercise caution. Please allow the vehicle’s exhaust system to cool before removal, as exhaust temperatures may cause severe burns. If working without a lift, always consult vehicle manual for correct lifting specifications. Always wear safety glasses and ensure a safe work area. Serious injury or death could occur if safety measures are not followed.

CUT TO FIT INSTALLATION INSTRUCTIONS

DESIGN TABLE

DESIGN STYLE 1: CUT TO FIT INTERMEDIATE PIPE

DESIGN STYLE 2: CUT TO FIT INLET

DESIGN STYLE 3: CUT TO FIT TAIL PIPE

MATCH PURCHASED KIT’S CUT TO FIT DESIGN TO GRAPHIC IN DESIGN TABLE

DESIGN STYLE 1

STEP 1
Attach item 1 to existing exhaust
STEP 2
Attach item 3 to existing isolators
STEP 3
Cut item 2 4” longer than the distance between the installed parts, this will allow for a 2” overlap for each slip fit (cutting part too short will increase likelihood of leaks)

DESIGN STYLE 2

STEP 1
Attach item 3 to existing isolators
STEP 2
Attach item 2 to item 3
STEP 3
Cut item 2 2” longer than the distance between item 2 and OEM part, this will allow for a 2” overlap (cutting part too short will increase likelihood of leaks)

DESIGN STYLE 3

STEP 1
Attach item 1 to existing isolators
STEP 2
Attach item 3 to existing isolators

WARNING

When working on, under, or around any vehicle exercise caution. Please allow the vehicle’s exhaust system to cool before removal, as exhaust temperatures may cause severe burns. If working without a lift, always consult vehicle manual for correct lifting specifications. Always wear safety glasses and ensure a safe work area. Serious injury or death could occur if safety measures are not followed.