This page was taken from NJNE with premission from Bob.
MONZA EXHAUST SYSTEM
INSTALLATION HELP AND
GALLERY
Ok, here's a picture of what you get. Two seperate sections of exhaust pipe, a muffler, and two chrome-plated tips. The arrow represents where the two sections of pipe connect. There should also be five exhaust pipe clamps. Three of the clamps are 2.5" and they are used on the exhaust pipe connections. The other two clamps are 2.25" and are used to hold the tips to the muffler.
This picture compares the two systems. The exhaust pipe is almost exactly the same except that it is 2.5" in diameter while the stock pipe is 2.25" in diameter. Also note that the Monza system is slightly heavier than it's stock counterpart.
Installation is fairly straightforward. First, you must remove the old components. Jack up the car on ramps or jack stands (don't use the stock jack alone, please). Remove the factory muffler using a 15mm wrench and by taking the rubber hangers off their mounts. A large hammer can be used to get it off of the factory exhaust pipe. Now, remove the 15mm connection at the catalytic converter, remove the other hanger halfway back on the long exhaust pipe, and pull it out from under the car. Watch you're eyes for falling rust.
Now it's time for the new stuff. I found the easiest way to do this is to assemble everything under the car but do not tighten anything down yet. Be sure all the clamps point down to make it easier to tighten.
This picture represents the trickiest part of installation. It is the area over top the left rear axle. The pipe comes very close to the spare tire wheel well. Be sure to get it as far away as possible by twisting the various pipe connections. Once everything is bolted up and seems right, tighten the clamps but don't go too tight. Don't worry about exhaust leaks at this point. Get out from under the car and start it. Drive it around gently for a little bit to listen for rattles. The only rattle I had was one where the pipe connects to the catalytic converter. By loosening the connection between the two sections of Monza pipe, I was able to push down the entire assembly to allow more clearance between the floorpan and the catalytic converter.
After I tightened everything down and made sure it was rattle-free, I had to straighten the muffler a bit. It sat too high and too far in on the right side so I used a pipe wrench to tweak this muffler hanger. It used to stick straight out. Now's a good time to align those cool looking tips and tighten their connections down.
Go back out for another test drive and make sure nothing rattles or squeaks. If it's hitting you may have to loosen/tweak/tighten some of the connections or bend some of the hangers.
Once it's all done, it looks quite nice...
A few more tips:
Monza system purchased from NOPI.
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