Exhaust System: Service and Repair
Exhaust System Replacement (V8)
Removal Procedure
Warning:
Refer to Exhaust Service Warning Exhaust Service Warning.
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 (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).
Note:
The left catalytic converter to exhaust manifold retaining nuts (1) are single use parts. They must be discarded after removal.
3. Remove the left catalytic converter to exhaust manifold retaining nuts (1).
Discard the nuts.
4. Disconnect the left catalytic converter (2) from the exhaust manifold (3).
Note:
The right catalytic converter to exhaust manifold retaining nuts (3) are single use parts. They must be discarded after removal.
5. Remove the right catalytic converter to exhaust manifold retaining nuts (3).
Discard the nuts.
6. Disconnect the right catalytic converter (2) from the exhaust manifold (1).
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.
7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
Caution:
Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution
8. Disconnect the left pre-catalytic converter HO2S electrical connector (1).
9. Disconnect the right pre-catalytic converter HO2S electrical connector (1).
10. Disconnect the left post-catalytic converter HO2S electrical connector (1).
11. Disconnect the right post-catalytic converter HO2S electrical connector (1).
12. Detach the exhaust system (2) by removing the front insulator hangers (1).
13. Support the exhaust system with a suitable jack.
14. Remove the transmission tunnel cross-brace to body retaining bolts (2).
15. Remove the transmission tunnel cross-brace (1).
16. Remove the left rear insulator hanger to body retaining bolts (1).
17. Remove the right rear insulator hanger to body retaining bolts (1).
18. Remove the center insulator hanger bracket to differential retaining nut (1).
19. Detach the exhaust system assembly from the center insulator hanger bracket to differential retaining stud (1).
20. With the aid of an assistant or using a suitable jack; carefully lower the exhaust system from the vehicle.
21. Remove the left pre-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1.
22. Remove the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2.
23. Remove the right pre-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1.
24. Remove the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2.
Installation Procedure
1. Install the left pre-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1.
Note:
Make sure that a NEW sealing ring is fitted prior to installation. Failure to comply may cause the exhaust system to perform poorly.
2. From underneath the vehicle, position the left catalytic converter (2) to the exhaust manifold (3).
Note:
Do not fully tighten the left catalytic converter to exhaust manifold retaining nuts (1) at this stage.
3. Install the NEW left catalytic converter to exhaust manifold retaining nuts (1).
Do not fully tighten at this stage.
4. Install the right pre-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1.
Note:
Make sure that a NEW sealing ring is fitted prior to installation. Failure to comply may cause the exhaust system to perform poorly.
5. 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 (3) at this stage.
6. Install the NEW right catalytic converter to exhaust manifold retaining nuts (3).
Do not fully tighten at this stage.
7. Lower the vehicle.
Caution:
Refer to Fastener Caution Fastener Caution.
8. Tighten the left catalytic converter to exhaust manifold retaining nuts (1) to 45 Nm (33 lb ft).
9. Tighten the right 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.
10. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
11. Install the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2.
12. Install the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2.
13. With the aid of an assistant, or using a suitable jack; position the exhaust crossover pipe assembly to the vehicle.
14. Align the exhaust system to the center insulator hanger bracket to differential retaining stud (1).
15. Align the exhaust system (2) to the front hanger studs and install the front insulator hangers (1).
16. Remove the jack supporting the exhaust system.
17. Align the exhaust crossover pipe exhaust assembly (2) to the right catalytic converter (1).
18. Install the intermediate exhaust assembly to right catalytic converter retaining nuts (3) and tighten to 40 Nm (30 lb ft).
19. Align the exhaust crossover pipe exhaust assembly (2) to the left catalytic converter (1).
20. Install the intermediate exhaust assembly to left catalytic converter retaining nuts (3) and tighten to 40 Nm (30 lb ft).
21. Install the center insulator hanger bracket to differential retaining nut (1) and tighten to 45 Nm (33 lb ft).
22. Connect the left post-catalytic converter HO2S electrical connector (1).
23. Connect the right post-catalytic converter HO2S electrical connector (1).
24. Connect the left pre-catalytic converter HO2S electrical connector (1).
25. Connect the right pre-catalytic converter HO2S electrical connector (2).
26. Install the transmission tunnel cross-brace (1).
27. Install the transmission tunnel cross-brace to body retaining bolts (2) and tighten to 58 Nm (43 lb ft).
28. Install the right rear muffler (1) to the vehicle.
29. Connect the right rear muffler (1) to the exhaust crossover pipe assembly (2).
30. Install the right rear muffler to exhaust crossover pipe assembly retaining bolts (2) and tighten to 45 Nm (33 lb ft).
31. Install the left rear muffler (1) to the vehicle.
32. Connect the left rear muffler (1) to the exhaust crossover pipe assembly (2).
33. Install the left rear muffler to exhaust crossover assembly retaining bolts (3) and tighten to 45 Nm (33 lb ft).
34. Install the left rear insulator hanger to body retaining bolts (1) and tighten to 26 Nm (19 lb ft).
35. Install the right rear insulator hanger to body retaining bolts (1) and tighten to 26 Nm (19 lb ft).
36. 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.
37. Lower the vehicle.
38. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).