Exhaust System Replacement

Exhaust System Replacement (LY7 - Gas, 6 Cylinder, 3.6L, SFI, V6)

Removal Procedure - Up to 31 May 2007

1. Disconnect the battery ground cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
2. Remove the engine dress cover. Refer to Engine Cover Replacement (Service and Repair) .





Notice: Refer to Heated Oxygen and Oxygen Sensor Notice (Heated Oxygen and Oxygen Sensor Notice) .

3. Disconnect the left pre-catalytic converter heated oxygen sensor (HO2S) electrical connector (2).




4. Disconnect the right pre-catalytic converter HO2S electrical connector (1).




Caution: Refer to Exhaust Service Caution (Service Precautions) .
Caution: Refer to Protective Goggles and Glove Caution (Protective Goggles and Glove Warning) .

Important: The left catalytic converter to exhaust manifold retaining nuts (2) are single use parts. They must be discarded after removal.


5. Remove the left catalytic converter to exhaust manifold retaining nuts (2).
Discard the nuts.
6. Pull down and back on the left catalytic converter (3) to disconnect from the left exhaust manifold (1).





Important: The right catalytic converter to exhaust manifold retaining nuts (3) are single use parts. They must be discarded after removal.


7. Remove the right catalytic converter to exhaust manifold retaining nuts (3).
Discard the nuts.
8. Pull down and back on the right catalytic converter (2) to disconnect from the right exhaust manifold (1).
Caution: Refer to Vehicle Lifting Caution (Service Precautions) .
9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair) .




10. Remove the transmission tunnel cross-brace to body retaining bolts (2).
11. Remove the transmission tunnel cross-brace (1).




12. Disconnect the left post-catalytic converter HO2S electrical connector (1).




13. Disconnect the right post-catalytic converter HO2S electrical connector (1).
14. Support the exhaust system using a suitable jack.




15. Detach the exhaust system (2) by removing the front insulator hangers (1) if fitted.




16. Detach the exhaust system (2) by removing the centre insulator hanger bracket to differential retaining bolt (1).




17. Remove the rear insulator hanger to body retaining bolts (1).
18. With the aid of an assistant or using a suitable jack; carefully lower the exhaust system from the vehicle.
19. Remove the left pre-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (Service and Repair) .
20. Remove the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (Service and Repair) .
21. Remove the right pre-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (Service and Repair) .
22. Remove the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (Service and Repair) .



Installation Procedure - Up to 31 May 2007

1. Install the left pre-catalytic converter HO2S to the left catalytic converter. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (Service and Repair) .
2. Install the left post-catalytic converter HO2S to the intermediate exhaust assembly. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (Service and Repair) .
3. Install the right pre-catalytic converter HO2S to the right catalytic converter. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (Service and Repair) .
4. Install the right post-catalytic converter HO2S to the intermediate exhaust assembly. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (Service and Repair) .

Notice: Refer to Exhaust Service Caution (Service Precautions) .

5. With the aid of an assistant or using a suitable jack; carefully raise the exhaust system to the vehicle.





Important: Make sure that a NEW sealing ring is fitted prior to installation. Failure to comply may cause the exhaust system to perform poorly.


6. Push up and forward on the left catalytic converter (3) to connect to the left exhaust manifold (1).

Important: Do not fully tighten the left catalytic converter to left exhaust manifold retaining nuts (2) at this stage.


7. Install the NEW left catalytic converter to left exhaust manifold retaining nuts (2).
Do not fully tighten at this stage.




8. Push up and forward on the right catalytic converter (2) to connect to the right exhaust manifold (1).

Important: Do not fully tighten the right catalytic converter to right exhaust manifold retaining nuts (3) at this stage.


9. Install the NEW right catalytic converter to right exhaust manifold retaining nuts (3).
Do not fully tighten at this stage.




10. Attach the exhaust system (2) by installing the front insulator hangers (1) if fitted.





Notice: Refer to Fastener Notice (Fastener Notice) .

11. Attach the exhaust system (2) by installing the centre insulator hanger bracket to differential retaining bolt (1).

Tighten the bolt to 45 N.m (33 lb ft).





12. Install the rear insulator hanger to body retaining bolts (1).

Tighten the bolts to 26 N.m (19 lb ft).





13. Connect the left post-catalytic converter HO2S electrical connector (1).




14. Connect the right post-catalytic converter HO2S electrical connector (1).




15. Install the transmission tunnel cross-brace (1).
16. Install the transmission tunnel cross-brace to body retaining bolts (2).

Tighten the nuts to xx N.m (xx lb ft).

17. Remove the jack supporting the exhaust system.
18. Lower vehicle.




19. Tighten the left catalytic converter to left exhaust manifold retaining nuts (1).

Tighten the nuts to 45 N.m (33 lb ft).





20. Tighten the right catalytic converter to right exhaust manifold retaining nuts (1).

Tighten the nuts to 45 N.m (33 lb ft).

21. 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 (LY7 and L98 Engines) (Exhaust System Alignment) .




22. Connect the left pre-catalytic converter HO2S electrical connector (2).




23. Connect the right pre-catalytic converter HO2S electrical connector (2).
24. Install the engine dress cover. Refer to Engine Cover Replacement (Service and Repair) in Engine Mechanical - 3.6L.
25. Connect the battery ground cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
26. If re-programming is required. Refer to Control Module References (Programming and Relearning) .
27. Perform diagnostic system check using diagnostic scan tool, clear all relative DTCs and inspect the system for correct operation.



Removal Procedure - From 31 May 2007

1. Disconnect the battery ground cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
2. Remove the engine dress cover. Refer to Engine Cover Replacement (Service and Repair) .





Notice: Refer to Heated Oxygen and Oxygen Sensor Notice (Heated Oxygen and Oxygen Sensor Notice) .

3. Disconnect the left pre-catalytic converter heated oxygen sensor (HO2S) electrical connector (2).
Caution: Refer to Vehicle Lifting Caution (Service Precautions) .
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair) .




5. Disconnect the right pre-catalytic converter HO2S electrical connector (1).




Caution: Refer to Exhaust Service Caution (Service Precautions) .
Caution: Refer to Protective Goggles and Glove Caution (Protective Goggles and Glove Warning) .

Important: The left catalytic converter to exhaust manifold retaining nuts (2) are single use parts. They must be discarded after removal.


6. Remove the left catalytic converter to exhaust manifold retaining nuts (2).
Discard the nuts.
7. Pull down and back on the left catalytic converter (3) to disconnect from the left exhaust manifold (1).





Important: The right catalytic converter to exhaust manifold retaining nuts (3) are single use parts. They must be discarded after removal.


8. Remove the right catalytic converter to exhaust manifold retaining nuts (3).
Discard the nuts.
9. Pull down and back on the right catalytic converter (2) to disconnect from the right exhaust manifold (1).
Caution: Refer to Vehicle Lifting Caution (Service Precautions) .
10. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair) .




11. Remove the transmission tunnel cross-brace to body retaining bolts (2).
12. Remove the transmission tunnel cross-brace (1).




13. Disconnect the left post-catalytic converter HO2S electrical connector (1).




14. Disconnect the right post-catalytic converter HO2S electrical connector (1).
15. Support the exhaust system using a suitable jack.




16. Detach the exhaust system (2) by removing the centre insulator hanger bracket to differential retaining bolt (1).




17. Remove the rear insulator hanger to body retaining bolts (1).
18. With the aid of an assistant or using a suitable jack; carefully lower the exhaust system from the vehicle.
19. Remove the left pre-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (Service and Repair) .
20. Remove the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (Service and Repair) .
21. Remove the right pre-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (Service and Repair) .
22. Remove the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (Service and Repair) .



Installation Procedure - From 31 May 2007

1. Install the left pre-catalytic converter HO2S to the left catalytic converter. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (Service and Repair) .
2. Install the left post-catalytic converter HO2S to the intermediate exhaust assembly. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (Service and Repair) .
3. Install the right pre-catalytic converter HO2S to the right catalytic converter. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (Service and Repair) .
4. Install the right post-catalytic converter HO2S to the intermediate exhaust assembly. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (Service and Repair) .

Notice: Refer to Exhaust Service Caution (Service Precautions) .

5. With the aid of an assistant or using a suitable jack; carefully raise the exhaust system to the vehicle.





Important: Make sure that a NEW sealing ring is fitted prior to installation. Failure to comply may cause the exhaust system to perform poorly.


6. Push up and forward on the left catalytic converter (3) to connect to the left exhaust manifold (1).

Important: Do not fully tighten the left catalytic converter to left exhaust manifold retaining nuts (2) at this stage.


7. Install the NEW left catalytic converter to left exhaust manifold retaining nuts (2).
Do not fully tighten at this stage.




8. Push up and forward on the right catalytic converter (2) to connect to the right exhaust manifold (1).

Important: Do not fully tighten the right catalytic converter to right exhaust manifold retaining nuts (3) at this stage.


9. Install the NEW right catalytic converter to right exhaust manifold retaining nuts (3).
Do not fully tighten at this stage.





Notice: Refer to Fastener Notice (Fastener Notice) .

10. Attach the exhaust system (2) by installing the centre insulator hanger bracket to differential retaining bolt (1).

Tighten the bolt to 45 N.m (33 lb ft).





11. Install the rear insulator hanger to body retaining bolts (1).

Tighten the bolts to 26 N.m (19 lb ft).





12. Connect the left post-catalytic converter HO2S electrical connector (1).




13. Connect the right post-catalytic converter HO2S electrical connector (1).




14. Install the transmission tunnel cross-brace (1).
15. Install the transmission tunnel cross-brace to body retaining bolts (2).

Tighten the nuts to xx N.m (xx lb ft).

16. Remove the jack supporting the exhaust system.
17. Lower vehicle.




18. Tighten the left catalytic converter to left exhaust manifold retaining nuts (1).

Tighten the nuts to 45 N.m (33 lb ft).





19. Tighten the right catalytic converter to right exhaust manifold retaining nuts (1).

Tighten the nuts to 45 N.m (33 lb ft).

20. 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 (LY7 and L98 Engines) (Exhaust System Alignment) .




21. Connect the left pre-catalytic converter HO2S electrical connector (2).




22. Connect the right pre-catalytic converter HO2S electrical connector (2).
23. Install the engine dress cover. Refer to Engine Cover Replacement (Service and Repair) in Engine Mechanical - 3.6L.
24. Connect the battery ground cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
25. If re-programming is required. Refer to Control Module References (Programming and Relearning) .
26. Perform diagnostic system check using diagnostic scan tool, clear all relative DTCs and inspect the system for correct operation.