Exhaust System Replacement (Complete)
Exhaust System Replacement (V6 - Complete)
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).
3. Remove the engine cover. Refer to Engine Cover Replacement (Service and Repair).
Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (Heated Oxygen and Oxygen Sensor Caution).
4. Remove the left pre-catalytic convertor heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (Service and Repair).
5. Remove the left exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Left Side (V8) (Exhaust Manifold Heat Shield Replacement - Left Side)Exhaust Manifold Heat Shield Replacement - Left Side (V6) (Exhaust Manifold Heat Shield Replacement - Left Side).
6. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Removal.
7. Remove the right pre-catalytic convertor HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (Service and Repair).
8. Remove the right exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Right Side (V8) (Exhaust Manifold Heat Shield Replacement - Right Side)Exhaust Manifold Heat Shield Replacement - Right Side (V6) (Exhaust Manifold Heat Shield Replacement - Right Side).
Note: The left catalytic converter to exhaust manifold retaining nuts (1) are single use parts. They must be discarded after removal.
9. Remove the left catalytic converter to exhaust manifold retaining nuts (2).
Discard the nuts.
Note: The right catalytic converter to exhaust manifold retaining nuts (3) are single use parts. They must be discarded after removal.
10. Remove the right catalytic converter to exhaust manifold retaining nuts (3).
Discard the nuts.
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.
11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
12. Remove the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (Service and Repair).
13. Remove the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (Service and Repair).
14. Remove the transmission tunnel cross-brace to body retaining bolts (2).
15. Remove the transmission tunnel cross-brace (1).
16. Support the exhaust system with a suitable jack.
17. Remove the rear insulator hanger to body retaining bolts (1).
18. Remove the centre insulator hanger bracket to differential retaining nut (1).
19. With the aid of an assistant or using a suitable jack; detach the exhaust system from the centre insulator hanger bracket retaining stud (1) and carefully lower the exhaust system from the vehicle.
Installation Procedure
Note: Make sure that a NEW sealing ring is fitted prior to installation. Failure to comply may cause the exhaust system to perform poorly.
1. From underneath the vehicle, position the right catalytic converter (2) to the exhaust manifold (1).
Note: Do not fully tighten the right catalytic converter to exhaust manifold retaining nuts (1) at this stage.
2. Install NEW right catalytic converter to exhaust manifold retaining nuts (1)
Do not fully tighten at this stage.
Note: Make sure that a NEW sealing ring is fitted prior to installation. Failure to comply may cause the exhaust system to perform poorly.
3. From underneath the vehicle, position the left catalytic converter (3) to the exhaust manifold (1).
Note: Do not fully tighten the left catalytic converter to exhaust manifold retaining nuts (3) at this stage.
4. Install NEW left catalytic converter to exhaust manifold retaining nuts (1)
Do not fully tighten at this stage.
5. Lower the vehicle.
Caution: Refer to Fastener Caution (Fastener Caution).
6. Tighten the right catalytic converter to exhaust manifold retaining nuts (1) to 45 Nm (33 lb ft).
7. Tighten the left catalytic converter to exhaust manifold retaining nuts (1) to 45 Nm (33 lb ft).
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.
8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
9. With the aid of an assistant, or using a suitable jack, position the exhaust crossover pipe assembly to the vehicle.
10. Align the exhaust system to the centre insulator hanger bracket to differential retaining stud (1).
Note: Make sure that NEW flange gaskets are fitted prior to installation. Failure to comply may cause the exhaust system to perform poorly.
11. Connect the catalytic converter assemblies (1) to the exhaust crossover pipe assembly (2).
12. Install the exhaust crossover pipe assembly to catalytic converter retaining nuts (3) and tighten to 45 Nm (33 lb ft).
13. Install the centre insulator hanger bracket to differential retaining nut (1) and tighten to 45 Nm (33 lb ft).
14. Install the transmission tunnel cross-brace (1).
15. Install the transmission tunnel cross-brace to body retaining bolts (2) and tighten to 12 Nm (9 lb ft).
16. Install the right rear muffler (1) to the vehicle.
17. Connect the right rear muffler (1) to the exhaust crossover pipe assembly (2).
18. Install the right rear muffler to exhaust crossover pipe assembly retaining bolts (2) and tighten to 45 Nm (33 lb ft).
19. Install the left rear muffler (1) to the vehicle.
20. Connect the left rear muffler (1) to the exhaust crossover pipe assembly (2).
21. Install the left rear muffler to exhaust crossover assembly retaining bolts (3) and tighten to 45 Nm (33 lb ft).
22. Install the rear insulator hanger to body retaining bolts (1) and tighten to 26 Nm (19 lb ft).
23. Remove the jack supporting the exhaust system.
24. 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).
25. Install the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (Service and Repair).
26. Install the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (Service and Repair).
27. Lower the vehicle.
28. Install the right exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Right Side (V8) (Exhaust Manifold Heat Shield Replacement - Right Side)Exhaust Manifold Heat Shield Replacement - Right Side (V6) (Exhaust Manifold Heat Shield Replacement - Right Side).
29. Install the right pre-catalytic convertor HO2S sensor. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (Service and Repair).
30. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Removal.
31. Install the left exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Left Side (V8) (Exhaust Manifold Heat Shield Replacement - Left Side)Exhaust Manifold Heat Shield Replacement - Left Side (V6) (Exhaust Manifold Heat Shield Replacement - Left Side).
32. Install the left pre-catalytic convertor HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (Service and Repair).
33. Install the engine cover. Refer to Engine Cover Replacement (Service and Repair).
34. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).