For Subaru BRZ owners seeking to elevate their car’s driving experience, upgrading to a Perrin Exhaust System is an excellent choice. Not only does this modification enhance the vehicle's sound with a deeper, sportier tone, but it can also improve exhaust flow, potentially boosting performance and throttle response. While professional installation is an option, many enthusiasts prefer a hands-on approach, tackling the installation themselves. A DIY installation not only saves money but also provides a rewarding sense of accomplishment and a deeper understanding of your vehicle’s mechanics. This comprehensive guide will walk you through every step of installing a Perrin Exhaust System on your Subaru BRZ, from preparation to final testing, ensuring a smooth and successful upgrade.

Understanding the Perrin Exhaust System and Its Benefits

The Perrin Exhaust System is designed specifically for the Subaru BRZ and shares its platform with the Toyota 86 and Scion FR-S. Known for quality craftsmanship and sound tuning, Perrin’s exhausts typically feature mandrel-bent piping, stainless steel construction, and a design aimed at reducing backpressure while producing an aggressive exhaust note. Unlike stock systems, which prioritize quietness and emissions compliance, a Perrin exhaust offers a more engaging auditory experience and can contribute to slight horsepower gains by improving exhaust scavenging.

Some key benefits of the Perrin Exhaust System include:

  • Improved Sound: A deeper, richer tone that enhances the sporty character of the BRZ without being overly loud or droning on the highway.
  • Performance Gains: Enhanced exhaust flow reduces backpressure, potentially improving horsepower and torque, especially when combined with other modifications.
  • Weight Reduction: Aftermarket exhausts often weigh less than stock systems, contributing to better handling and responsiveness.
  • Durability: Constructed from stainless steel or aluminized steel, Perrin exhausts resist corrosion better than factory parts.

Pre-Installation Considerations

Before diving into the installation, it’s important to prepare properly to avoid common pitfalls and ensure safety:

  • Vehicle Condition: Your BRZ should be in good mechanical condition. If your stock exhaust has significant rust, damaged hangers, or leaks, replacing it with the Perrin system will be more straightforward.
  • Time Commitment: Allocate 2–4 hours for the installation, depending on your experience level and workspace.
  • Workspace: Perform the installation in a well-ventilated, flat area with ample lighting. A garage or driveway works well.
  • Documentation: Read through the Perrin installation manual carefully before starting. The manual may include model-specific tips and torque specifications.
  • Temperature: Make sure the exhaust system is cool to the touch before beginning work to avoid burns.

Tools and Parts Needed

Gathering the right tools and parts ahead of time will streamline the installation process:

  • Socket Set and Ratchet: Metric sizes (10mm, 12mm, 14mm) are commonly used on Subaru exhaust bolts.
  • Wrenches: Combination wrenches for tight spaces.
  • Screwdrivers: Both Phillips and flat-head for clamps or brackets.
  • Jack and Jack Stands: To safely lift and support the vehicle, providing access underneath.
  • Penetrating Oil: Products like WD-40 or PB Blaster help loosen rusted or stuck bolts.
  • Rubber Mallet: Useful for gently persuading exhaust components during removal or installation.
  • Torque Wrench: To tighten bolts to manufacturer-specified torque settings, preventing overtightening.
  • Perrin Exhaust System: Including all pipes, mufflers, clamps, and hangers.
  • New Gaskets and Hardware: Typically included with the Perrin kit but verify before beginning.
  • Safety Gear: Gloves, safety glasses, and protective clothing.

Step 1: Preparing Your Vehicle

Begin by parking the Subaru BRZ on a level surface and engage the parking brake. To prevent accidental movement and provide safe access underneath the car, use a hydraulic jack to lift the vehicle. Position jack stands under the recommended jacking points on each side to securely support the car. Never rely on the jack alone, as it can fail or slip.

Wear your safety glasses and gloves to protect against debris, dirt, and accidental scrapes. Before loosening any bolts, apply penetrating oil to the exhaust bolts, clamps, and hangers where metal parts connect. This step helps break down rust and corrosion, reducing the risk of stripping bolts or breaking components during removal. Allow the oil to soak in for 10–15 minutes.

Step 2: Removing the Stock Exhaust System

With the vehicle safely elevated, slide underneath and locate the stock exhaust system. The system will typically consist of these sections:

  • Downpipe/Header Connection: Where the exhaust manifold connects to the rest of the exhaust.
  • Midpipe: The pipe running under the car, sometimes incorporating a resonator.
  • Muffler: The rear section responsible for dampening sound.
  • Exhaust Hangers: Rubber or metal mounts that secure the exhaust to the chassis.

Start by loosening the clamps or bolts between the downpipe and midpipe. Use the appropriate socket or wrench size. If bolts are stubborn, spray additional penetrating oil and allow more time to soak. If necessary, use a breaker bar for extra leverage but take care not to damage the bolts.

Once the clamps or bolts are removed, proceed to detach the exhaust hangers. These are usually rubber mounts that you can pry off using a flat-head screwdriver or exhaust hanger removal tool. It’s helpful to support the exhaust with one hand or a jack as you remove hangers to prevent it from dropping suddenly.

Carefully lower and remove the entire stock exhaust system from under the car. Inspect the condition of the gaskets at the header connection. If they appear damaged or worn, discard them and replace them with the new gaskets supplied in the Perrin kit.

Tips during removal:

  • Have a friend assist in holding the exhaust if it’s heavy or awkward to maneuver.
  • Label or take pictures of the stock exhaust arrangement for reference.
  • Inspect for any rust or damage that may require attention before installing the new exhaust.

Step 3: Preparing the Perrin Exhaust for Installation

Before installing, lay out all components of the Perrin Exhaust System on a clean surface. Verify that the kit includes everything listed in the installation manual, including pipes, mufflers, clamps, gaskets, and hardware. Familiarize yourself with the parts’ orientation and how they connect.

Compare the new parts with the stock exhaust to understand the differences in design and fitment. Sometimes, Perrin exhausts have a slightly different routing or hanger locations, so reviewing this will help avoid surprises during installation.

If desired, apply anti-seize lubricant to the bolts and studs. This will facilitate future removal and prevent corrosion from seizing the fasteners.

Step 4: Installing the Perrin Exhaust System

Begin installation by positioning the Perrin downpipe or header pipe under the vehicle. Align the flange with the exhaust manifold or header outlet. Insert the new gasket between the flange faces to ensure a proper seal. Start threading the bolts by hand to avoid cross-threading.

Once all bolts are loosely installed, proceed to connect the midpipe and muffler sections as per the manual. It’s important to loosely fit all components before fully tightening to allow for adjustments and proper alignment. Use the supplied clamps and hardware to secure connections.

Attach the exhaust hangers to the vehicle’s mounting points, ensuring the exhaust is supported and properly suspended. Check the clearance between the exhaust pipes and the underbody, suspension components, and wiring to prevent contact that could cause rattling or damage.

After confirming the fitment and alignment, tighten all bolts and clamps to the torque specifications provided by Perrin. Using a torque wrench prevents overtightening, which can damage threads or warp flanges. Remember to tighten bolts incrementally in a crisscross pattern when applicable, especially around flanges, to ensure even pressure.

Alignment Tips:

  • Ensure the exhaust tip is centered within the rear bumper cutout for aesthetic appeal.
  • Check that there is adequate clearance between pipes and heat-sensitive components.
  • Use rubber exhaust hangers to reduce vibration and noise transfer.

Step 5: Final Inspection and Testing

With the Perrin Exhaust System fully installed, carefully lower the Subaru BRZ from the jack stands. Before starting the engine, visually inspect all connections, clamps, and hangers once again. Make sure no tools or debris have been left under the car.

Start the engine and listen closely for any exhaust leaks, characterized by hissing or popping sounds near connections. If leaks are detected, shut off the engine and tighten the affected clamps or bolts. It may take a few iterations to achieve a perfect seal.

Pay attention to any unusual rattling, knocking, or vibrations which could indicate loose hangers or improper clearances. Adjust as necessary.

Once satisfied, take the vehicle for a short test drive. Listen to the exhaust tone at various RPMs and throttle levels to appreciate the new sound. Feel for any changes in throttle response or engine performance. After the drive, re-inspect all hardware and tighten if needed, as exhaust components can settle during initial use.

Maintenance and Care of Your Perrin Exhaust

To keep your Perrin Exhaust System in optimal condition and prolong its lifespan, consider the following maintenance tips:

  • Regular Inspections: Periodically check clamps, hangers, and bolts for tightness, especially after spirited driving or track use.
  • Cleaning: Clean the exhaust tips with metal polish to maintain their appearance and prevent corrosion.
  • Rust Prevention: If you live in an area with harsh winters or road salt, rinse the undercarriage regularly to prevent corrosion.
  • Noise Regulations: Be mindful of local noise ordinances and emissions laws to ensure your modified exhaust remains compliant.

Additional Performance Enhancements for Your Subaru BRZ

Installing a Perrin Exhaust System is a great start to modifying your BRZ, but it can be combined with other upgrades to maximize performance gains:

  • Cold Air Intake: Improves engine breathing and complements the exhaust upgrade for better airflow.
  • ECU Tune: Custom tuning adjusts fuel and ignition maps to optimize the engine for the new exhaust, unlocking additional power.
  • Suspension Upgrades: Performance springs or coilovers improve handling to match the enhanced engine response.
  • Brake Enhancements: Upgraded pads and rotors improve stopping power for safer spirited driving.

Combining these modifications with your Perrin exhaust will transform your BRZ into a more thrilling and capable sports car.

Common Challenges and Troubleshooting Tips

While most installers find the process straightforward, some common challenges can arise during a Perrin exhaust installation:

  • Stuck or Rusted Bolts: Use penetrating oil and patience. Heat from a propane torch can help loosen stubborn bolts but requires caution to avoid damage.
  • Fitment Issues: Occasionally, aftermarket exhausts require slight adjustments or trimming. Contact Perrin support if parts seem incompatible or require modification.
  • Excessive Exhaust Noise or Drone: Check for proper alignment and secure mounting. Adding resonators or using sound-deadening materials can help mitigate unwanted noise.
  • Exhaust Leaks: Recheck gasket placement and ensure bolts are torqued correctly. Using exhaust sealant sparingly can help seal minor leaks.

Conclusion

Upgrading your Subaru BRZ with a Perrin Exhaust System is a highly rewarding project that combines performance enhancement with the satisfaction of hands-on work. By carefully preparing your workspace, gathering the right tools, and following this detailed installation guide, you can achieve a professional-quality upgrade without the cost of a shop installation.

Beyond just a louder and sportier exhaust note, the Perrin system offers potential performance benefits and improved durability over the stock setup. Remember to prioritize safety throughout the process, take your time, and double-check all connections. Once installed, your BRZ will not only sound more aggressive but also feel more responsive and exciting to drive.

Enjoy your newly transformed Subaru BRZ and the unique experience of having installed a quality exhaust system yourself!