IMPORTANT WARRANTY & INSTALLATION INSTRUCTIONS ATTACHED Please Forward All Attached Information to Consumer. Warranty Not Valid Unless Returned to CORSA Exhaust We ask that you take a few moments to Complete our warranty registration form. To Activate Your 10 Year LIMITED WARRANTY, Go To: CORSAPERFORMANCE.COM/WARRANTY MADE IN THE USA For Full-Color Installation Instructions, Please Visit: CORSAPERFORMANCE.COM & Search Part # Please be sure to review the enclosed instructions prior to beginning the installation process. If you have any questions about the enclosed parts, instructions or encounter a problem during installation, CALL CORSA PERFORMANCE TECHNICAL ASSISTANCE AT 800.486.0999 CORSA Performance Exhaust / 140 Blaze Industrial Pkwy / Berea, OH 44017
Thank you for purchasing a CORSA Performance exhaust system, the best premium exhaust system in the world. If this is your first CORSA Performance exhaust system, I would like to welcomee you to the CORSA family. If you are one of our many loyal repeat customers, welcome back. You have purchased the finest sounding and highest quality performancee exhaust system on the market today. Once you climb into the driver s seat, you will immediately notice thatt your driving experience is different. Your vehicle now has a new voice and your friends will listen when it speaks. Our acoustic designers create the finest sound, styled specifically for you and your vehicle. You will also benefit from improved performance and better fuel economy. Our unique technology and sound places us apart from all other aftermarket exhaust manufacturer (systems). We can assure you that we strive to meet and exceed your expectations with every system that we deliver, every day. We stand by our promise to always provide you with a quality product, the finest sound and NO interior drone. Our Limited Lifetime Warranty** guarantees your CORSA Performance exhaust system for as long as you own your vehicle. We pride ourselves in providing superior customer service and an ongoing relationship with our customers after a sale is made. It is very important to us to listen to your needs and opinions about our systems and any way we can improve your CORSA experience. We utilize customer feedback coupled with our design and manufacturing technology to provide the best premium exhaust system in the world. Frankly, we could not do it without you and your input. We ask that you take a few moments to complete our warranty registration form to activate your lifetime* ** warranty. You can register on line at www.corsaperformance.com/warranty. Thank you for your support and confidencee in CORSA Performance. We willl be sure to keep you up-to-date on all new CORSA product introductions. Be sure to visit our Web site: www.corsaperformance.com for the latestt CORSA Performance news. Again, thank you for choosing CORSA Performance. Sincerely, Oscar J. Mifsud President *U.S. patent numbers: 5,952,625; 6,199,658 other patents pending **Corsa Performance exhaust systems are warranted for life to the original purchaser. 140 Blaze Industrial Parkway / Berea, Ohio 44017 / 800.486.0999 / fax 440.891.1868 / corsaperformance.com
Please take time to read and understand these installation instructions. CORSA recommends that installation of this system be performed by a qualified service center or professional muffler installer who has the necessary equipment, tools and experienced personnel. However, if you decide to perform this install, the use of a hoist and an additional person will be required. CAUTION: Never work on a hot exhaust system. Allow time for the vehicle to cool. Always wear eye protection when working under a vehicle. Please confirm that all parts are present before beginning the factory exhaust system removal and CORSA exhaust system installation. Bill of Materials: Head Pipe Assembly (23HT4026) Touring Muffler 14633 or Sport Muffler 14635 Tailpipe Assembly (23HT4027) 4.0 Pro-Series Tip Assembly (23HT3000) Hardware Kit (16TA7018) (1) Packet Anti-Seize Lubricant Safety Glasses 15mm socket and ratchet Pipe cutter Grommet pullers Anti-Seize Lubricant Hardware Kit (16TA7018) Exhaust System Installation Cat-Back Exhaust System 2007-08 HUMMER H2 6.0L Single Rear Exit with Twin Pro-Series 4.0 Tips SPORT PN 14211 / TOURING PN 14149 Recommended Tools: Vehicle Spare tire removal kit Soapy water Torque wrench Pro-Series 4.0 Tip Assembly (23HT3000) Tailpipe Assembly (23HT4027) Touring Muffler 14633 Sport Muffler 14635 Head Pipe Assembly (23HT4026) Technical Assistance: 800.486.0999. INS5079 1/31/07 CORSA Performance 140 Blaze Industrial Parkway Berea, Ohio 44017-2930 P. 800.486.0999 F. 440.891.1868 E-mail: sales@corsaperformance.com www.corsaperformance.com 1
Removal of Stock System: Exhaust System Installation Cat-Back Exhaust System 2007-08 HUMMER H2 6.0L Single Rear Exit with Twin Pro-Series 4.0 Tips SPORT PN 14211 / TOURING PN 14149 1) In order to remove the stock system, locate the section of pipe between the front hanger and front face of the muffler and mark the pipe in the middle of the straight section of pipe after the front hanger. (See Fig. A) 2) Cut the pipe at your mark. (See Fig. B). NOTE: For safety, be sure to support the muffler to prevent injury. 3) Remove the front and rear tailpipe hangers from the factory rubber grommets using grommet pullers or similar device. (See Figs. C & D) NOTE: Using a soapy water solution on the grommet hole will make the job easier. 4) Remove the muffler and tailpipe section from the vehicle by lifting the tailpipe over the rear axle and towards the front of the vehicle. (See Fig. E) 5) Using a 15mm socket and ratchet, remove the flange nuts at the flange connection of the head-pipe. (See Fig. F) 6) Remove the head-pipe hanger from the factory rubber grommet using grommet pullers or similar device. (See Fig. G) NOTE: Using a soapy water solution on the grommet hole will make the job easier. 7) Remove the head-pipe section from the vehicle by lifting it up a little bit and sliding it out of the stud holes and towards the rear of the vehicle. This completes removal of the stock system. FIG. A FIG. B FIG. C FIG. D FIG. E FIG. F FIG. G INS5079 1/31/07 Technical Assistance: 800.486.0999. CORSA Performance 140 Blaze Industrial Parkway Berea, Ohio 44017-2930 P. 800.486.0999 F. 440.891.1868 E-mail: sales@corsaperformance.com www.corsaperformance.com 2
Exhaust System Installation Cat-Back Exhaust System 2007-08 HUMMER H2 6.0L Single Rear Exit with Twin Pro-Series 4.0 Tips SPORT PN 14211 / TOURING PN 14149 Installation of CORSA Exhaust System: NOTE: Apply the anti-seize lubricant (supplied) to the threads ONLY of all the clamps and flange bolts. Failure to follow this procedure can cause nuts to seize on clamps and potentially destroy threads. After applying anti-seize lubricant, be sure to thoroughly clean hands as lubricant will tarnish stainless steel. All clamps should be tightened using a properly calibrated Torque Wrench. Using an air impact gun will damage the clamp and reduce its ability to effectively seal the joint. It may also cause the joint to separate thereby causing damage to your exhaust system and your vehicle. 1) Locate the CORSA head-pipe assembly and slide the studs through the holes on the flange. While holding the head-pipe assembly flush against the flange, use the nuts supplied with the CORSA hardware kit and thread onto the studs until they are about 1/2 from contacting the flange. Then insert the hanger into the factory rubber grommet. (See Figs. H & I) NOTE: Using a soapy water solution on the grommet hole will make the job easier. FIG. H CLAMP Position slot 90 off of bolt Position clamp at end of expanded tube 2) Using a torque wrench, tighten the flange nuts down to 30 ft.-lbs. (See Fig J) 3) Slide a supplied 3 Torca clamp over the inlet of the CORSA muffler. Make sure the drain hole is facing down. Slide the muffler onto the head-pipe assembly and pre-tighten the clamp. (See Figs. K & L) 4) Locate the CORSA tailpipe assembly and slide a supplied 3 Torca clamp over the inlet. From the rear of the vehicle, slide the pipe over the axle and insert the pipe over the muffler exit. (See Figs. M & N) MAKE SURE DRAIN HOLE IN MUFFLER FACES DOWN. FIG. I FIG. J FIG. K FIG. L FIG. M FIG. N INS5079 1/31/07 CORSA Performance 140 Blaze Industrial Parkway Berea, Ohio 44017-2930 P. 800.486.0999 F. 440.891.1868 E-mail: sales@corsaperformance.com www.corsaperformance.com 3
Exhaust System Installation Cat-Back Exhaust System 2007-08 HUMMER H2 6.0L Single Rear Exit with Twin Pro-Series 4.0 Tips SPORT PN 14211 / TOURING PN 14149 5) Insert the tailpipe hangers into the factory rubber grommets and pre-tighten the clamp. (See Figs. O, P & Q) NOTE: Using a soapy water solution on the grommet hole will make the job easier. 6) Locate the CORSA tip assembly and slide a supplied 3 Torca clamp over the inlet end. (See Fig. R & S) 7) Slide the tip assembly onto the tailpipe making sure that the tips are level and pre-tighten the clamp. (See Figs T & U) 8) Starting from the front of the CORSA exhaust system, tighten all clamps to 45 ft.-lbs. using a torque wrench. 9) It is strongly recommended that all clamps be checked and tightened after road testing the vehicle once the system has cooled. FIG. O FIG. P FIG. Q FIG. R FIG. S FIG. T FIG. U NOTE: During cold weather start-ups, you may experience an exhaust sound that is deeper and louder in tone than usual. This is temporary and will diminish to normal levels once your engine has reached its normal operating temperature. NOTE: Immediately following the installation of your CORSA exhaust system, you may experience a trace of smoke after initial start-up. DO NOT be alarmed. The smoke is caused by the burning of a small amount of forming oil residue used in the manufacturing process. If you have any questions about the installation process, call CORSA Performance and ask one of our Sales & Technical Service Representatives. Do not attempt to make any modifications to parts as this will void your warranty. INS5079 1/31/07 CORSA Performance 140 Blaze Industrial Parkway Berea, Ohio 44017-2930 P. 800.486.0999 F. 440.891.1868 E-mail: sales@corsaperformance.com www.corsaperformance.com 4