Exhaust Pipe: Service and Repair

Exhaust Crossover Pipe Replacement (V8)

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).
6. Support the exhaust system using a suitable jack.





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

7. Remove the exhaust crossover pipe assembly to left catalytic converter retaining nuts (3).
Discard the nuts.





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

8. Remove the exhaust crossover pipe assembly to right catalytic converter retaining nuts (3).
Discard the nuts.
9. Separate the exhaust crossover pipe assembly (2) from the catalytic converter assemblies.




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




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




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




16. Detach the exhaust system (2) by removing the front insulator hangers (1).




17. Remove the centre insulator hanger bracket to differential retaining nut (1).
18. Detach the exhaust crossover pipe assembly from the centre insulator hanger to differential retaining stud (1).
19. With the aid of an assistant or using a suitable jack; carefully lower the exhaust system 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 exhaust crossover pipe assembly flange gaskets.
3. With the aid of an assistant or using a suitable jack; position the exhaust crossover pipe assembly to the vehicle.




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




5. Attach the exhaust crossover pipe assembly (2) to the transmission support by installing the front insulator hangers (1), if fitted.





Caution: Refer to Fastener Caution (Fastener Caution).

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




9. Align the exhaust crossover pipe assembly (2) to the right catalytic converter (1).
10. Install the exhaust crossover pipe assembly to right catalytic converter retaining nuts (3) and tighten to 40 Nm (30 lb ft).




11. Align the exhaust crossover pipe assembly (2) to the left catalytic converter (1).
12. Install the exhaust crossover pipe assembly to left catalytic converter retaining nuts (3) and tighten to 40 Nm (30 lb ft).




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




15. Connect the left rear muffler (1) to the exhaust crossover pipe assembly (2).
16. Install the exhaust crossover pipe assembly to left rear muffler retaining bolts (3) and tighten to 45 Nm (33 lb ft).
17. Install the right post-catalytic converter heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (Service and Repair).
18. Install the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (Service and Repair).
19. 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).
20. Lower the vehicle.
21. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).