Exhaust Manifold Pipe Replacement (ZW9)

Exhaust Manifold Pipe Replacement (ZW9)

Removal Procedure

Warning: Refer to Exhaust Service Warning Service Precautions

Warning: Refer to Hot Exhaust System Warning Hot Exhaust System Warning





1. Remove the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis) Service and RepairHeated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) Service and RepairHeated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) Service and Repair.
2. Support the transmission with a suitable transmission jack.
3. Remove the transmission support crossmember. Refer to Transmission Support Crossmember Replacement (2WD 1500 Series) Transmission Support Crossmember Replacement (4WD 1500 Series) Transmission Support Crossmember Replacement (2WD 2500/3500 Series) Transmission Support Crossmember Replacement (4WD 2500/3500 Series)




4. Remove the exhaust muffler to exhaust manifold pipe nuts (1).
5. Replace the exhaust gasket (2).




6. Remove the exhaust manifold pipe to exhaust manifold nuts (1) and replace the seal (2) with a NEW one.
7. Using the transmission jack, lower the transmission slightly.




8. Separate the exhaust manifold pipe rod (1) from the exhaust isolator bracket (2).

Installation Procedure




1. Install a NEW exhaust manifold pipe gasket onto the muffler studs.
2. Install the exhaust manifold pipe hanger rod (1) into the exhaust isolator (2).




3. Install any necessary exhaust muffler insulators that were separated from the muffler.
4. Using the transmission jack, raise the transmission slightly.

Caution: Refer to Fastener Caution Fastener Caution.

5. Install the exhaust manifold pipe (3) with the exhaust manifold nuts 1) and tighten to 50 Nm (37 lb ft).




6. Install the exhaust muffler to exhaust manifold pipe nuts (1) and tighten to 45 Nm (33 lb ft).
7. Install the transmission support crossmember. Refer to Transmission Support Crossmember Replacement (2WD 1500 Series) Transmission Support Crossmember Replacement (4WD 1500 Series) Transmission Support Crossmember Replacement (2WD 2500/3500 Series) Transmission Support Crossmember Replacement (4WD 2500/3500 Series)
8. Remove the support from the transmission.
9. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis) Service and RepairHeated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) Service and RepairHeated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) Service and Repair.
10. Start the engine and check the front exhaust system for leaks.