Exhaust System: Service and Repair

Exhaust system & mountings
Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.
Refer to Service Precautions.

Remove
1. Position vehicle on lift.
2. Disconnect battery earth lead.





3. Release pre-catalyst harness leads from clips, remove multiplugs from retaining clips and disconnect.





4. Release post catalyst H02S harnesses from clips, remove multiplugs from clips and disconnect.





5. Remove and discard 4 nuts securing front pipe flanges to exhaust manifolds, release front pipe from flanges and move aside.





6. Remove and Discard the 4 nuts securing intermediate silencer mountings to body.





7. Remove 8 nuts securing rear silencer rubber mountings to body and with assistance remove exhaust assembly from vehicle.

NOTE: Do not carry out further dismantling if component is removed for access only.

8. Remove 2 nuts and collect mass damper.
9. Remove 6 mounting rubbers from main assembly, remove rubbers from body mounting brackets.
10. Remove H02S sensors from exhaust assembly and discard sealing washers.

Refit
1. Fit mass damper and tighten bolts to 25 Nm (18 ft. lbs.).
2. Fit exhaust mountings.
3. Clean exhaust pipe and exhaust manifold down pipe flanges.
4. Clean H02S, sealing washer and mating faces.
5. Fit new sealing washers and apply anti seize compound to threads of H02S sensors. Fit and tighten sensors to 50 Nm (37 ft. lbs.).

CAUTION: Ensure anti seize compound does not contact the tip of the H02S sensor.

6. Fit rubbers to exhaust mounting brackets and main assembly.
7. With assistance fit exhaust system to vehicle, align flanges to manifolds, fit and lightly tighten bolts. Fit one pair of rear silencer brackets to body and lightly tighten bolts.
8. Align remaining mounting brackets to body, fit nuts and tighten to 25 Nm (18 ft. lbs.).
9. Check exhaust for correct alignment.
10. Align exhaust flange and tighten new nuts evenly to 45 Nm (33 ft. lbs.).
11. Connect battery earth lead.
12. Start and run engine to check for leaks.