Stupid exhaust hardware question

[vanagonforever]

I'm replacing my full exhaust system today on my 83.5 1.9L WBX. Yesterday I removed the old rusty bits and today I'm putting in the van-cafe kit. The problem is that I've got a lot of hardware, no instructions, and I'm concerned that I'll choose poorly when I'm bolting all this stuff back together. I was hoping that the number of the different nuts and bolts would give things away but I'm failing to see the pattern. So...

1) Where do I need to use the locking nuts?

2) Where do I need to use the wavy washers?

3) Where do I use the long bolts?

4) Where do I use the studs?

Finally, is there a trick to removing my old O2 sensor. I've just about stripped the nut trying to get that thing out. If not is that something that my FLAPS might actually have in stock? I typically do the mail order thing but I'd hate to keep the van dry docked for another week while I wait for a simple sensor.

Thanks so much for helping a n00b out!
_________________
1986 2WD 2.1L WBX Vanagon Weekender
1983.5 1.9L WBX Vanagon Westfalia

[Dant]

If you can get to a dealer or find someone with ETKA, an illustration can be printed. It shows all the pieces parts exploded view.

I just did a print screen of it and pasted it into paint...can I attach files using the Samba's "PMAIL"?

If someone can tell me a good way to get this llustration out of ETKA and into SAMBA we could help this guy out.....
_________________
90 Carat
97 Jetta GLX
87 GL (nobody wanted it)
91 Syncro (Stripped,Plain Jane,fixed vent windows,no tach) also rusty. Hurray for me!

[vanagonforever]

Hey thanks so much for doing that. I sent you a pm with my email address if that helps at all.
_________________
1986 2WD 2.1L WBX Vanagon Weekender
1983.5 1.9L WBX Vanagon Westfalia

[tencentlife]

Easy enough to call the vendor and have them run you thru the intended use of the hardware they supply. VC is very helpful on customer service, in my experience. I know it's Sunday, but if you haven't figured it out by tonight, give them a call in the AM.
_________________
Shop for unique Vanagon accessories at the Vanistan shop:
https://intrepidoverland.com/vanistan/

Please don't PM here, I will not reply.

Experience is kryptonite to doctrine.

[sagebus]

Go to the website, www.van-cafe.com , click on the exhaust for your year van and then the hardware kit. It tells you which bolts and nuts to use where. I used this for my new exhaust install, it is all good now and sounds great. Good luck ! Oh, on the OXY sensor I got one from Auto Zone $18.95 .
_________________
1984 Vanagon GL, Wolfsburg Westy 1.9 ltr

[tencentlife]

Good to know!
_________________
Shop for unique Vanagon accessories at the Vanistan shop:
https://intrepidoverland.com/vanistan/

Please don't PM here, I will not reply.

Experience is kryptonite to doctrine.

[Jamos]

[OilNBolts]

Try to use a six-point tool on the o2 sensor. A twelve point will round too easily. Autozone should also have the appropriate oxygen sensor socket; if not, NAPA will. And, as Jamos suggested, add heat.
_________________
Current fleet: Vanagons, two '88 GLs and an 89 Bluestar. Beetles, '63, '64, '72 convertible. Plus, four Subarus and three Prius. Too many cars.

[vanagonforever]

Thanks for the tips on the O2 sensor. I ended up getting a new Bosche universal sensor for $17.95 at the local Autozone. Also that tip on the descriptions from van-cafe was even more helpful than the diagram turned out to be.

Sadly though my exhaust project is still incomplete. Thanks to several rain delays throughout the day I ended up not getting everything back together until well after dark. At that point I cranked the engine and... sigh... listened to the rhythmic chugging of a leaking exhaust. I pin-pointed the source of the leak with my hand and quickly realized how silly I was to bolt the curved piece to the manifolds last (even after I got the muffler strap on). I should have realized that all that struggling I was doing to get the bolts through would result in a less than ideal connection but hey, live and learn. So some time this week I'll have to disconnect the muffler strap and get a better fit to the manifolds.
_________________
1986 2WD 2.1L WBX Vanagon Weekender
1983.5 1.9L WBX Vanagon Westfalia