On Mon, 23 Feb 2004, Jim Felder wrote:

> Though the diesel setup is much simpler than on my 90, I've never seen
> one installed and need some input. The engine has two flanges, right
> and left, that more or less match the two flanges on the muffler (I
> haven't measured but it looks so). Should there rubber pieces for
> flexibility, or should muffler and engine flanges bolt up directly?

The flange on the left side of the van is mounted to the engine carrier
via two rubber isolators, one on the side and one on top, and the muffler
bolts directly to it.  On the right side, a rubber isolator goes between
the muffler and the mount.  All the isolators are the same -- a piece of
rubber sandwiched between two metal places, one of which has two holes in
it and the other has two studs.

These isolators have a tendancy to tear, so look yours over before you
install the exhaust and replace them if necessary.  Van-again has a good
price on them.  If the isolators aren't good the exhaust system has a
tendancy to vibrate pretty severely.

The hardest part of installing the muffler, for me, is getting the pipe
and the studs all lined up at the same time so I can slide the muffler
home.  I also tend to have leaks where the muffler clamps to the pipe.
The muffler has to come off to get at the crank pully nut to turn the
engine over for checking the timing, so I've had it off a couple times
now.

David Brodbeck, N8SRE
'82 Volkswagen Diesel Westfalia
'86 Volvo 240DL wagon