Exhaust Pipe: Service and Repair

Exhaust Crossover Pipe Replacement (V6)

Removal Procedure

Warning: Refer to Exhaust Service Warning (Service Precautions).

Warning: Refer to Protective Goggles and Glove Warning (Protective Goggles and Glove Warning).

1. Ignition OFF.
Warning: Refer to Battery Disconnect Warning (Battery Disconnect Warning).

2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).

Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.


3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
4. Remove the right post-catalytic converter heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (Service and Repair).
5. Remove the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (Service and Repair).





Note: The exhaust crossover pipe assembly to catalytic converter retaining nuts (3) are single use parts. They must be discarded after removal.

6. Remove exhaust crossover pipe assembly to catalytic converter retaining nuts (3).
Discard the nuts.
7. Separate the exhaust crossover pipe assembly (2) from the catalytic converter assemblies (1).




8. Remove the transmission tunnel cross-brace to body retaining bolts (2).
9. Remove the transmission tunnel cross-brace (1).
10. Support the exhaust system with a suitable jack.




11. Remove the exhaust crossover pipe assembly to rear muffler retaining bolts (3)
12. Disconnect the rear left muffler (1) from the exhaust crossover pipe assembly (2)




13. Remove the exhaust crossover pipe assembly to rear muffler retaining bolts (2)
14. Disconnect the rear right muffler (1) from the exhaust crossover pipe assembly (3)




15. Remove the centre insulator hanger bracket to differential retaining nut (1).
16. Detach the exhaust crossover pipe assembly.
17. Carefully lower the exhaust crossover pipe assembly from the vehicle.

Installation Procedure

Caution: Refer to Exhaust System Inspection Caution (Service Precautions).

1. Clean all threads and flange faces of the exhaust crossover pipe assembly.
2. Replace the catalytic converter to intermediate pipe flange gaskets.
3. Position the exhaust crossover pipe assembly to the vehicle using a suitable jack.




4. Align the exhaust system to the centre insulator hanger bracket to differential retaining bolt.

Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the centre insulator hanger bracket to differential retaining nut (1) and tighten to 45 Nm (33 lb ft).




6. Connect the left rear muffler (1) to the exhaust crossover pipe assembly (2).
7. Install the exhaust crossover pipe assembly to left rear muffler retaining bolts (3) and tighten to 45 Nm (33 lb ft).




8. Connect the right rear muffler (1) to the exhaust crossover pipe assembly (3).
9. Install the exhaust crossover pipe assembly to right rear muffler retaining bolts (3) and tighten to 45 Nm (33 lb ft).




10. Install the transmission tunnel cross-brace (1).
11. Install the transmission tunnel cross-brace to body retaining bolts (2) and tighten to 12 Nm (9 lb ft).




12. Align the catalytic converter assemblies (1) to the exhaust crossover pipe assembly (2).
13. Install the NEW exhaust crossover pipe assembly to catalytic converter retaining nuts (3) and tighten to 40 Nm (30 lb ft).
14. Make sure that the exhaust system is clear of all other components and chassis. If the exhaust system is not clear of all the other components loosen all retaining nuts and re-align. Refer to Exhaust System Alignment (Procedures).
15. Install the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (Service and Repair).
16. Install the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (Service and Repair).
17. Lower the vehicle.
18. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).