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 to allow the exhaust system to cool.

NOTE:
- The assistance of a second mechanic is required for removing and refitting the rear exhaust assembly.
- Ensure that no exhaust leaks are evident in either a new or old exhaust system as this will affect vehicle performance.

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

Exhaust System:

2. Catalyst vehicles only: Disconnect the two lambda sensor wiring connectors.
3. Remove the two bolts securing the rear exhaust assembly to the front exhaust assembly.
4. Remove the nuts and release the front downpipe from the manifolds. Discard the gaskets.
5. Lower the front exhaust assembly, retrieving the doughnut from the joint.
6. Remove the bolts securing the three hanger brackets to the chassis. Lower the exhaust assembly onto the rear axle. Detach the rubbers from the hanging brackets.
7. Place extended axle stands underneath the chassis, in front of the chassis mounted rear towing brackets.
8. Lower the hoist until the vehicle weight is supported securely on the stands.
9. Lower the hoist until the rear shock absorbers are almost fully extended.
10. Move the rear exhaust to a diagonal position with the center silencer to the right of the vehicle.
11. Facing the rear of the vehicle, twist the assembly counter-clockwise until it clears the rear axle.
12. Remove the rear exhaust assembly from the vehicle.

REFIT
1. Position the rear exhaust assembly over the rear axle in a diagonal position, as for removing.
2. Twist the assembly clockwise until it is in the mounting position.
3. Reverse the removing instructions 1. to 9. using new manifold gaskets and applying exhaust sealer to the system joint.
4. Examine the system for leaks and ensure that the system does not foul any underbody components. Rectify as necessary.