Exhaust System: Service and Repair

WARNING: To prevent personal injury occurring from a hot exhaust system, DO NOT attempt to disconnect any of the components until ample time has elapsed tu allow the exhaust system to cool.

NOTE: Ensure that no exhaust leaks are evident in either a new or old exhaust system, as this will affect vehicle performance, and contravene Federal emission regulations.


REMOVE
1. Raise the vehicle on a suitable hoist and apply the parking brake.

Exhaust System:

2. Remove the three bolts securing the tail pipe assembly to the intermediate pipe assembly.
3. Remove the bolt securing the rear mounting bracket.to the chassis.
4. Maneuver the tail pipe over the rear axle and remove from the vehicle.
5. Retain the doughnut from the intermediate pipe for reassembly.
6. Detach the rubber from the tailpipe and hanger.
7. Remove the three bolts securing the right hand branch of the intermediate pipe to the right hand catalyst.
8. Release the pinch bolt clamp securing the left hand branch of the intermediate pipe to the left hand catalyst and slide the clamp along the pipe.
9. Remove the bolts securing the front and rear hanger brackets to the chassis.
10. Detach the rubbers from the main muffler assembly and hangers.
11. Carefully separate the intermediate pipes from the front downpipes.
12. Retain the doughnut from the right hand joint.
13. Disconnect both Lambda sensor multiplugs.
14. Remove the nuts and release the front downpipes from the manifolds, discard the gaskets.

REFIT
1. If the original system is being refitted, examine the system for damage and general condition renew sections as necessary.
2. Clean any previous putty from the doughnuts and exhaust pipe joints.
3. Fit NEW gaskets to the manifold joint face.

NOTE: Apply exhaust sealer to all exhaust system joints with the exception of the exhaust flange to manifold flange.

4. Reverse the removal instructions.
5. Examine a new or original system for leaks and ensure that the system does not foul any underbody components. If exhaust leaks or interference exists loosen the joints reseal and reset as necessary.