How to Install Diesel Exhaust

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    Exhaust Removal

    • 1). Loosen and remove the bolts that secure the exhaust down-pipe to the turbocharger with a ratchet and socket. Depending on the design of the flange, you may need a large socket extension to reach the bolts.

    • 2). Cut the stock exhaust pipe just behind the muffler with a hack saw or reciprocating saw.

    • 3). Cut the stock exhaust in front of the muffler with the saw.

    • 4). Remove the stock exhaust system from the rubber hangers.

    • 5). Pull the muffler, tailpipe and down-pipe from the vehicle.

    Exhaust Installation

    • 1). Place the down-pipe onto the turbocharger and install the bolts in the flange. Hand-tighten the bolts to hold the down-pipe in position but allow it to be rotated. Place an exhaust clamp on the end of the down-pipe and install the first extension pipe. Hand-tighten the clamp.

    • 2). Position the lowering brackets from the exhaust kit into the rubber hangers along the frame. These are numbered in order starting from the turbocharger.

    • 3). Place one end of the muffler into the exhaust pipe. Install an exhaust clamp and hand-tighten the bolts. Place the tailpipe into position. Insert it through the clamps so that the hangers hold the tailpipe into position.

    • 4). Measure the distance between the muffler output and the tailpipe. Add 4 inches for pipe overlap and cut the extension pipe with the saw. Install the pipe and hand-tighten the clamps.

    • 5). Align the exhaust system from the turbocharger to the tip. Tighten each bolt with a ratchet and socket. Start the engine and check for leaks.

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