Exhaust System: Service and Repair

Exhaust System

Service Repair No - 30.10.08

Special Service Tools





Removal
1. Disconnect the battery ground cable.

2. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.
3. Remove the engine undershield.
4. Remove the transmission crossmember.
5. Release the LH front HO2S wiring harness.
^ Disconnect the electrical connector.





6. Release the RH front HO2S wiring harness.
^ Disconnect the electrical connector.





7. Release the LH rear HO2S wiring harness.
^ Disconnect the electrical connector.
8. Release the RH rear HO2S wiring harness.
^ Disconnect the electrical connector.





9. Disconnect the LH catalytic converter from the exhaust manifold.
^ Remove and discard the 2 bolts.





10. Disconnect the RH catalytic converter from the exhaust manifold.
^ Remove and discard the 2 bolts.





11. With assistance, remove the exhaust system.
^ Disconnect the 5 exhaust hangers.





12. NOTE: Do not disassemble further if the component is removed for access only.

Using the special tool, remove the 4 HO2S from the catalytic converters.





Installation

1. CAUTION: Make sure the anti-seize compound does not contact the HO2S tip.

Using the special tool, install the HO2S to the catalytic converters and tighten to 45 Nm (33 ft. lbs.).
^ Clean the components.
^ Apply an anti-seize compound to the thread of the HO2S.
2. With assistance, install the exhaust system.
^ Attach the exhaust hangers.
3. Position the RH catalytic converter to the exhaust manifold.
^ Clean the components.
^ Tighten the new bolts to 22 Nm (16 ft. lbs.).

4. CAUTION: Make sure there is a clearance (A) of 25 mm to 30 mm between the closest points of the LH catalytic converter and the front driveshaft.

Position the LH catalytic converter to the exhaust manifold.
^ Clean the components.
^ Tighten the new bolts to 22 Nm (16 ft. lbs.).





5. CAUTION: Make sure the HO2S wiring harness is not twisted more than 180° and is not in contact with either the exhaust or driveshaft.

Connect the HO2S electrical connectors.
^ Attach the HO2S wiring harnesses.
6. Install the transmission crossmember.
7. Install the engine undershield.
8. Connect the battery ground cable.