Exhaust System Replacement (For Access)

Exhaust System Replacement (V6 - For Access)

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).

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

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).




6. Remove the exhaust crossover pipe assembly to catalytic converter retaining nuts (3).
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 rear insulator hanger to body retaining bolts (1).




12. Remove the centre insulator hanger bracket to differential retaining nut (1).
13. Detach the exhaust crossover pipe assembly.
14. With the aid of an assistant or using a suitable jack; carefully lower the exhaust system from the vehicle.
15. If required, remove the right catalytic converter. Refer to Catalytic Converter Replacement - Right Side (V8) (Catalytic Converter Replacement - Right Side)Catalytic Converter Replacement - Right Side (V6) (Catalytic Converter Replacement - Right Side).
16. If required, remove the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side (V8) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (V6) (Catalytic Converter Replacement - Left Side).

Installation Procedure

1. If removed, install the right catalytic converter. Refer to Catalytic Converter Replacement - Right Side (V8) (Catalytic Converter Replacement - Right Side)Catalytic Converter Replacement - Right Side (V6) (Catalytic Converter Replacement - Right Side).
2. If removed, install the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side (V8) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (V6) (Catalytic Converter Replacement - Left Side).
3. With the aid of an assistant or using a suitable jack; carefully raise the exhaust system up into the vehicle.




4. Align the exhaust system to the centre insulator hanger bracket to differential retaining stud (1).

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. Install the rear insulator hanger to body retaining bolts (1) and tighten to 26 Nm (19 lb ft).




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





Note: Make sure that NEW flange gaskets are fitted prior to installation. Failure to comply may cause the exhaust system to perform poorly.

9. Connect the catalytic converter assemblies (1) to the exhaust crossover pipe assembly (2).
10. Install the exhaust crossover pipe assembly to catalytic converter retaining nuts (3) and tighten to 45 Nm (33 lb ft).
11. Remove the jack supporting the exhaust system.
12. 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).
13. Install the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (Service and Repair).
14. Install the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (Service and Repair).
15. Lower the vehicle.
16. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).