The installation of a Cobra Sport exhaust system requires careful attention to detail and adherence to specific procedures. This article details the steps involved in removing an existing exhaust system and installing a new Cobra Sport system, based on the provided documentation. The documentation emphasizes safety precautions, proper component alignment, and post-installation checks to ensure optimal performance and prevent leaks.
Preparing for Installation
Prior to commencing the installation, several preparatory steps are recommended. The vehicle should be parked on a level surface and allowed sufficient time to cool down. If work will be conducted near electrical connections, disconnecting the battery is advised. Users should wear appropriate protective equipment, including eye goggles.
To safely elevate the vehicle, ramps and a jack should be used in conjunction; relying solely on a jack is not recommended. When using ramps, the emergency brakes must be engaged, and the front wheels should be blocked to prevent movement.
Before beginning disassembly, all bolts, joints, and mounts on the existing exhaust system should be sprayed with a releasing fluid. Allowing approximately one hour for penetration will facilitate removal. Laying out the new exhaust system on the ground prior to installation allows for a preliminary check to ensure all components fit together correctly. It is also important to ensure all worn rubber mounts are replaced with new ones.
Removing the Old Exhaust System
The removal process begins by unbolting the old exhaust system, starting from the rear of the vehicle and working forward. In some cases, stock exhaust systems are installed as a single piece and may require cutting at the appropriate junction to facilitate removal.
Once unbolted, the exhaust system should be carefully removed from the hangers. The documentation notes that some systems can be heavy, necessitating assistance or adequate support during removal. If removing rubber hangers proves difficult, an alternative solution involves removing the bracket from the vehicle body. The removed exhaust components should be set aside for disposal or recycling.
Installing the New Cobra Sport Exhaust System
With the old exhaust system removed, the installation of the new Cobra Sport system can begin. Depending on the vehicle’s hanger type, the new hangers should be attached to the exhaust pieces first.
Prior to assembly, gaskets should be placed between the components. Applying a small amount of high-temperature silicone sealant inside each slotted joint or flange is recommended to prevent leaks upon startup. The documentation specifically cautions against using exhaust putty on any parts prior to the catalytic converter.
The new system should then be carefully positioned, ensuring correct alignment of the tailpipes. All clamps and bolts on the new system should be tightened, but care must be taken to avoid over-tightening. Any grease, oil, or marks on the new exhaust system should be wiped off. It is essential to replace any covers, brackets, or heat shields that were removed during the installation process.
Post-Installation Checks and Adjustments
After installation, a thorough inspection for leaks is crucial. The vehicle should be started, and the exhaust system checked for any escaping gases. Following the initial check, a test drive is recommended.
After the test drive, the system should be re-checked, including all joints and clearances. Any necessary adjustments should be made once the vehicle has cooled down. The documentation highlights the importance of checking the clearance around the exhaust, allowing for expansion of up to 25mm when hot.
Technical Support
Cobra Sport provides technical support for installation inquiries. Their technical team can be contacted by phone at +44 (0)114 244 733 or via email at [email protected].
Conclusion
Installing a Cobra Sport exhaust system involves a series of steps, from preparing the vehicle and removing the old system to installing the new components and performing post-installation checks. Adhering to the outlined procedures, prioritizing safety, and utilizing available technical support will contribute to a successful installation and optimal exhaust system performance. The documentation emphasizes the importance of careful alignment, leak prevention, and thorough post-installation inspection.