REMOVAL & INSTALLATION
See Figures 1 to 15
Support the vehicle securely by using jackstands or equivalent under the frame of the vehicle.
Remove the exhaust pipe clamps and any front exhaust pipe shield.
Soak the exhaust manifold front pipe mounting studs with penetrating oil. Remove attaching nuts and gasket from the manifold.
If these studs snap off, while removing the front pipe the manifold will have to be removed and the stud will have to be drill out and the hole tapped.
Remove any exhaust pipe mounting hanger or bracket.
Remove front pipe from the muffler/catalytic converter.
Install the front pipe on the manifold with seal if so equipped.
Connect the pipe to the muffler/catalytic converter. Assemble all parts loosely and position the pipe to insure proper clearance from body of vehicle.
Tighten mounting studs, bracket bolts on exhaust clamps.
Install exhaust pipe shield.
Start engine and check for exhaust leaks.
Fig. Fig. 1: Exhaust system-1973-75
Fig. Fig. 2: Exhaust system-1980 US models
Fig. Fig. 3: Exhaust system-1976-79
Fig. Fig. 4: Exhaust system-1980 Canada models
Fig. Fig. 5: Exhaust system-1981-83 2wd models with Z22 engines (except HD)
Fig. Fig. 6: Exhaust system-1981-83 2wd models with Z22 engines (HD)
Fig. Fig. 7: Exhaust system-1981-83 4wd models with Z22 engines
Fig. Fig. 8: Exhaust system-1981-83 models with SD22 engines
Fig. Fig. 9: Exhaust system-1986-88 2wd models with Z24i engines (D21-D series)
Fig. Fig. 10: Exhaust system-1984-86 models with Z20 and Z24 engines (720-D series)
Fig. Fig. 11: Exhaust system-1984-86 models with SD25 engines (720-D series)
Fig. Fig. 12: Exhaust system-1986-88 4wd models with Z24i engines (D21-D series)
Fig. Fig. 13: Exhaust system-1986-88 models with VG30i engines
Fig. Fig. 14: Exhaust system-1986-87 models with SD25 engines (D21-D series)
Fig. Fig. 15: Standard torque specifications and fastener markings