Front Pipe

REMOVAL & INSTALLATION

1. Support the vehicle securely by using jackstands or equivalent under the frame of the vehicle.
2. Remove the exhaust pipe clamps and any front exhaust pipe shield.
3. Soak the exhaust manifold front pipe mounting studs with penetrating oil. Remove attaching nuts and gasket from the manifold.

   NOTE: If these studs snap off, while removing the front pipe the manifold will have to be removed and the stud will have to be drilled out and the hole tapped.

4. Remove front pipe from the muffler/catalytic converter.
5. Remove any exhaust pipe mounting hanger or bracket.

   To install:

6. Upon installation use a new gasket at every disassembled junction.
7. Connect the exhaust pipe loosely to the hangers.
8. Install the front pipe on the manifold with seal if so equipped.
9. Connect the pipe to the muffler/catalytic converter. Assemble all parts loosely and position the pipe to insure proper clearance from body of vehicle.
10. Tighten mounting studs, bracket bolts and exhaust clamps.
11. Install exhaust pipe shield.
12. Start engine and check for exhaust leaks.

    Fig. 1: Exhaust components — Montero 3.0L

    Fig. 2: Exhaust components — Montero 2.6L

    Fig. 3: Exhaust components — Pickup truck 1983–86

    Fig. 4: Exhaust components — Pickup truck 1986 and later