GM S10/S15/Sonoma Pick-Ups 1982-1993 Repair Manual

Front Pipe/Crossover Pipe

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REMOVAL & INSTALLATION



Safety glasses should be worn at all times when working on or near the exhaust system. Older exhaust systems will almost always be covered with loose rust particles which will shower you when disturbed. These particles are more than a nuisance and could injure your eye.

Except MFI-Turbo
  1. Raise and support the front of the truck safely using jackstands.
  2.  
  3. Spray all fasteners which are to be disconnected using a penetrating oil.
  4.  
  5. Remove the front pipe(s)-to-manifold(s) nuts and separate (pry, if necessary) the front pipe (usually a ball joint fitting) from the exhaust manifold(s).
  6.  
  7. At the catalytic converter, loosen the front pipe-to-converter clamp nuts, then slide the clamp away from the converter and separate the front pipe from the converter.
  8.  

Use a twisting motion to separate the front pipe-to-converter slip joint connection. If the front pipe cannot be removed from the catalytic converter, use a hammer (to loosen the connection) or wedge tool to separate the connection.

  1. Inspect the pipe for holes, damage or deterioration; if necessary, replace the front pipe.
  2.  
  3. Installation is the reverse of removal.
  4.  

Be sure to use a sealing compound such as 1051249 or equivalent, at the slip joint connection.

  1. Lubricate the front pipe-to-manifold(s) studs/nuts and the front pipe-to-converter clamp threads. Torque the front pipe-to-exhaust manifold bolts to 15 ft. lbs. (20 Nm) and the front pipe-to-converter clamp nuts to 35 ft. lbs. (47 Nm).
  2.  
  3. Start the engine and check for exhaust leaks.
  4.  

MFI-Turbo
  1. Raise and support the front of the truck safely using jackstands.
  2.  
  3. Spray all fasteners which are to be disconnected using a penetrating oil.
  4.  
  5. Remove the nuts retaining the pipe to the left exhaust manifold.
  6.  
  7. Remove the nuts retaining the pipe to the right exhaust manifold.
  8.  
  9. Remove the manifold from the vehicle.
  10.  

To install:
  1. Install the pipe to the vehicle and loosely install the retaining nuts to the manifolds.
  2.  
  3. Tighten the manifold nuts evenly to 12 ft. lbs. (16 Nm).
  4.  
  5. Remove the jackstands and carefully lower the vehicle.
  6.  
  7. Start the engine and check for leaks.
  8.  

 
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