Skip to content

Install | Exhaust

Step-by-Step Exhaust Installation for Your Sprinter Van

Step 1: Gather your tools

Step 2: Remove the Existing Exhaust

  1. Locate the Exhaust Coupling:

    • Slide under your Sprinter Van and locate the exhaust coupling near the catalytic converter.
    • Spray WD-40 or penetrating oil on the coupling threads and connection points to make removal easier.

  2. Loosen the Exhaust Clamp:

    • Using a 13mm socket, loosen the exhaust clamp. Do not remove it entirely, as you will reuse it.

  3. Remove the Exhaust Hanger:

    • Locate the exhaust hanger (a rubber boot) towards the rear of the Sprinter Van.
    • Pull the exhaust forward to release it from the hanger and the coupling. The exhaust will slide out of the back of the van.

Step 3: Install the New Exhaust System

  1. Prepare the New Exhaust:

    • Slide one of the provided stainless steel clamps over the new exhaust pipe and position the exhaust hanger on the pipe. The “Mickey Mouse ears” on the hanger should face towards the exhaust outlet.

  2. Position the New Exhaust Under the Van:

    • Slide the new exhaust pipe into place, ensuring that the hanger lines up with the mounting points on the van.

  3. Install the Exhaust Hanger:

    • Insert the blue bushing into the exhaust hanger bracket and secure it to the van’s chassis using the provided bolts, washers, and nuts. Tighten the hardware enough to hold the exhaust in place but leave it slightly adjustable for now.

  4. Connect the Exhaust to the Coupling:

    • Attach the new exhaust to the coupling by sliding it onto the existing exhaust section. Make sure everything is aligned correctly.

  5. Install the Exhaust Tip:

    • Place the second stainless steel clamp onto the exhaust tip.
    • Position the tip so that it extends just past the van’s pinch weld, preventing exhaust gases from entering under the van. Tighten the clamp securely.

Step 4: Tighten and Adjust the Exhaust

  1. Tighten the Exhaust Hanger:

    • Use a 9/16" socket and a 7/32 Allen wrench to tighten the exhaust hanger. Ensure that the bushing is centered, and the hanger is securely fastened to the van’s chassis.

  2. Check Exhaust Tip Position:

    • Adjust the exhaust tip so that it is positioned correctly near the pinch weld. Ensure the exhaust is not too high or too low.

  3. Tighten the Exhaust Coupling:

    • Return to the exhaust coupling and tighten the clamp you initially loosened. Ensure the connection is secure and the exhaust is properly aligned.

Step 5: Relocate the Bracket (If Necessary)

  • If your Sprinter Van does not have aftermarket suspension, you may need to relocate a bracket near the exhaust.
    1. Remove the Existing Bracket:
      • Using a 10mm socket, remove the bracket that is close to the exhaust.
    2. Install the New Bracket:
      • Install the new bracket from your kit and zip-tie it to the existing cables for better clearance.

Step 6: Final Check

  1. Test the Exhaust:
    • Ensure everything is tight and secure.
    • Check for clearance, especially near the bump stop and axle. You should have adequate space between the exhaust and other components of your Sprinter Van.
  2. Inspect and Clean:
    • Wipe off any anti-seize from your hands and tools, as it can easily spread.

Congrats on installing your new gear from Owl!

Remember, Owl is the #1 manufacturer of Off Road gear and accessories for Adventure vans. We have our van experts standing by at our HQ in Arizona if you have any questions. Our gear for Mercedes Sprinter vans, Ford Transit and Winnebago Revel is Made in the USA, and many products are in stock and ship fast.

More soon,
John Willenborg