Exhaust Pipe: Service and Repair
Exhaust Crossover Pipe Replacement
Removal Procedure
1. Disconnect the battery ground cable from the battery. 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).
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.
Warning:
Refer to Exhaust Service Warning Exhaust Service Warning.
Warning:
Refer to Protective Goggles and Glove Warning Protective Goggles and Glove Warning.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
3. Remove the underbody brace fasteners (1) and remove the underbody brace (2).
4. Support the exhaust system using a suitable jack.
Caution:
Refer to Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution.
5. Disconnect the left post-catalytic converter heated oxygen sensor (HO2S) electrical connector (1).
6. Disconnect the right post-catalytic converter HO2S electrical connector (1).
Note:
The intermediate exhaust assembly to left catalytic converter retaining nuts (3) are single use parts. They must be discarded after removal.
7. Remove the intermediate exhaust assembly to left catalytic converter retaining nuts (3).
Discard the nuts.
8. Disconnect the intermediate exhaust assembly (2) from the left catalytic converter (1).
Note:
The intermediate exhaust assembly to right catalytic converter retaining nuts (3) are single use parts. They must be discarded after removal.
9. Remove the intermediate exhaust assembly to right catalytic converter retaining nuts (3).
Discard the nuts.
10. Disconnect the intermediate exhaust assembly (2) from the right catalytic converter (1).
11. Remove the intermediate exhaust assembly to rear muffler retaining bolts (3).
12. Detach the intermediate exhaust assembly (2) from the front exhaust isolators (1).
13. Detach the intermediate exhaust assembly by removing the centre insulator hanger bracket to differential retaining bolt (1).
14. Carefully lower the intermediate exhaust assembly from the vehicle.
15. Remove the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 for 3.6L engine or Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 for 6.0L engine.
16. Remove the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 for 3.6L engine or Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 for 6.0L engine.
Installation Procedure
1. Clean all threads and flange faces of the intermediate exhaust system.
2. Always check the condition of the catalytic converter to intermediate pipe flange gaskets and replace as necessary.
3. Install the left post-catalytic converter HO2S to the intermediate exhaust system. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 for 3.6L engine or Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 for 6.0L engine.
4. Install the right post-catalytic converter HO2S to the intermediate exhaust system. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 for 3.6L engine or Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 for 6.0L engine.
Warning:
Refer to Exhaust Service Warning Exhaust Service Warning.
Caution:
Refer to Exhaust System Inspection Caution Exhaust System Inspection Caution.
5. Position the intermediate exhaust assembly to the vehicle using a suitable jack.
6. Attach the intermediate exhaust assembly (2) by installing the centre insulator hanger bracket to differential retaining bolt (1).
7. Attach the intermediate exhaust assembly (2) into the exhaust isolators (1).
Caution:
Refer to Fastener Caution Fastener Caution.
8. Tighten the intermediate exhaust assembly to rear muffler fasteners (3) to 45 Nm (33 lb ft).
9. Align the intermediate exhaust assembly (2) to the right catalytic converter (1) and tighten the fasteners (3) to 40 Nm (30 lb ft).
10. Align the intermediate exhaust assembly (2) to the left catalytic converter (1) and tighten the fasteners (3) to 40 Nm (30 lb ft).
11. Tighten the intermediate exhaust assembly to left catalytic converter retaining nuts (3).
12. Connect the right post-catalytic converter HO2S electrical connector (1).
13. Connect the left post-catalytic converter HO2S electrical connector (1).
14. Connect the left rear muffler (1) to the intermediate exhaust assembly (2).
15. Install the left rear muffler to intermediate exhaust assembly and tighten the fasteners (3) to 45 Nm (33 lb ft).
16. 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.
17. Install the underbody brace (2) and tighten the fasteners (1) to 58 Nm (43 lb ft).
18. Lower the vehicle to the ground.
19. Connect the battery ground cable to the battery. 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).
20. If re-programming is required. Refer to 72864.
21. Perform diagnostic system check using diagnostic scan tool, clear all relative DTCs and inspect the system for correct operation.