Repair 7

How to Upgrade a Diesel Exhaust System

A diesel exhaust system is designed to remove the emissions from a diesel engine, which differs from a gasoline engine in several ways. The biggest is that diesel engines dont have spark plugs: The diesel fuel ignites spontaneously in the engine rather than needing a spark to ignite. A diesel exhaust system is similar to a gasoline exhaust system in layout, but the specifics differ slightly and requires attention when you upgrade it.

Instructions

1

Raise the vehicle up on a jack or hydraulic lift so that you can upgrade the diesel exhaust system safely.

2

Locate the turbo in the engine and remove the band clamp connecting it to the downpipe with a screwdriver.

3

Disconnect the down pipe from the transmission and the muffler with a welding torch or simply by removing the support bolts, depending on the vehicle.

4

Detach the muffler and the catalytic converter if necessary. Not every exhaust system upgrade requires it, but if a new muffler or converter is involved, the old ones should be removed. You can use either a blowtorch or wrenches to remove the bolts, depending on how they are secured.

5

Install the new downpipe in position, but do not tighten it in place just yet. You want it connected to the turbo firmly, but loose enough you can adjust its alignment once other parts of the diesel exhaust system are installed. You can use a bungee cord or rubber hangers to do this if the downpipe isnt otherwise set up for it.

6

Install the new muffler and/or catalytic converter, if appropriate. Like the downpipe, you want mufflers and catalytic converters to be fitted into position but not tightened or welded into place until you have aligned them properly with the rest of the diesel exhaust system.

7

Connect the straight pipe between the muffler and the downpipe, clamping it into place but still keeping it loose enough to adjust. You may need to adjust the size of the pipe in order to fit the proper distance between the downpipe and the muffler.

8

Attach the hangers and clamps to the diesel exhaust system, checking to make sure that each one is aligned and fits where it should.

9

Connect the tail pipe behind the muffler, leaving it fitted in place but loosely attached, as with the rest of the diesel exhaust system.

10

Check the alignment and clearance of each component in the exhaust system, starting with the downpipe and moving back towards the tail pipe. At each step, you can tighten the clamps or weld the seals for the respective parts, moving step by step through each portion of the system.

11

Tighten the clamp between the downpipe and the turbo, which should complete the upgrade.

12

Check the system for any leaks or gaps. You may want to start the engine and check for any exhaust emissions emerging where they shouldnt. You can seal any leaks with a soldering iron.

13

Lower the vehicle off the lift.