Exhaust System: Service and Repair

Exhaust System Complete

Service Repair No - 30.11.01

Exhaust System Assembly:

To improve sealing and accuracy of assembly, a two piece exhaust system is fitted.

NOTE: Ensure no exhaust leaks are evident in either a new or old exhaust system, as this will affect vehicle performance.

WARNING: To prevent personal injury occurring from a hot exhaust system, DO NOT attempt to disconnect any components until exhaust system has cooled down.

Remove

Catalysts - remove and refit 1 to 5

1. Raise vehicle on a ramp [hoist].
2. Catalyst vehicles only: Disconnect two heated oxygen sensor wiring connectors.

NOTE: NAS models have four heated oxygen sensors fitted.

3. Remove two nuts securing rear exhaust assembly to front exhaust assembly.
4. Remove nuts and release front downpipes from manifolds. Discard gaskets.
5. Lower front exhaust assembly with catalysts (if fitted), retain olive.

NOTE: Assistance is required for removing and refitting rear exhaust assembly.

6. Remove bolts securing three hanger brackets to chassis. Lower exhaust assembly onto rear axle. Detach rubbers from hanging brackets.
7. Place extended axle stands underneath chassis, in front of chassis mounted rear towing brackets.
8. Lower ramp[hoist] until vehicle weight is supported securely on stands.
9. Lower ramp [hoist] until rear shock absorbers are ALMOST fully extended.
10. Move rear exhaust to a diagonal position, center silencer to right of vehicle.
11. Facing rear of vehicle, twist assembly anti-clockwise clear of rear axle.
12. Remove rear exhaust assembly from vehicle.

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