Exhaust System: Service and Repair
Exhaust System Replacement (V6)
Removal Procedure
Warning:
Refer to Exhaust Service Warning Exhaust Service Warning.
Warning:
Refer to Protective Goggles and Glove Warning Protective Goggles and Glove Warning.
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).
2. Remove the left pre-catalytic convertor heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1.
3. Remove the right pre-catalytic convertor HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
5. Remove the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2.
6. Remove the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2.
7. Support the exhaust system securely with a suitable jack.
8. Remove the underbody brace fasteners (1) and remove the underbody brace (2).
Note:
The catalytic converter to cross-over pipe retaining fasteners (3) and crossover pipe to catalytic convertor sealing ring are single use parts. They must be discarded after removal.
9. Remove the exhaust crossover pipe assembly (2) to catalytic convertor (1) retaining fasteners (3).
Discard the fasteners.
10. Remove the left rear hanger bracket fasteners (1).
11. Remove the right rear hanger bracket fasteners (1).
12. Remove the center insulator hanger bracket to differential retaining fastener (1).
13. Detach the exhaust system from the center insulator hanger bracket retaining stud (1) and support with a suitable hanger or jackstand.
14. With the aid of a second technician, remove the exhaust crossover pipe (2), from the exhaust isolators (1), and lower the exhaust to the floor.
Note:
The catalytic converter to cylinder head retaining fasteners (2) and sealing gasket are single use parts. They must be discarded after removal.
15. Remove the fasteners (2) attaching the left hand catalytic convertor to the cylinder head. Remove the left hand catalytic convertor assembly (3) from the vehicle. Discard the retaining fasteners and gasket.
Note:
The catalytic converter to cylinder head retaining fasteners (2) and sealing gasket are single use parts. They must be discarded after removal.
16. Remove the fasteners (2) attaching the right hand catalytic convertor to the cylinder head. Remove the right hand catalytic convertor assembly from the vehicle. Discard the retaining fasteners and gasket.
Installation Procedure
Note:
Do not fully tighten the left hand catalytic converter to cylinder head retaining fasteners (3) at this stage.
1. Ensure that the gasket mating surfaces on the cylinder head and catalytic convertor are flat and free from defects or old gasket material.
Install a new exhaust gasket (1) to the studs on the cylinder head.
Install the right hand catalytic convertor (2) to the cylinder head.
Install the retaining fasteners (3) but do not fully tighten at this stage.
Note:
Do not fully tighten the left hand catalytic converter to cylinder head retaining fasteners (3) at this stage.
2. Ensure that the gasket mating surfaces on the cylinder head and catalytic convertor are flat and free from defects or old gasket material.
Install a new exhaust gasket (1) to the studs on the cylinder head.
Install the right hand catalytic convertor (2) to the cylinder head.
Install the retaining fasteners (3) but do not fully tighten at this stage.
Danger:
To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
4. Install the exhaust crossover pipe (2) into the exhaust isolators (1).
Note:
The catalytic converter to exhaust manifold retaining fasteners (2) are single use parts. They must be replaced with new parts on installation.
5. Install NEW exhaust flange sealing rings (1) to both the left hand and right hand catalytic convertor exhaust flanges.
6. With the aid of an assistant, install the cross-over pipe assembly (3) to the vehicle. Support the cross-over pipe assembly with a suitable jack.
7. Install the NEW exhaust crossover pipe assembly to catalytic convertor retaining fasteners (2). Do not fully tighten at this stage.
Caution:
Refer to Fastener Caution Fastener Caution.
8. Install the center insulator hanger bracket and tighten the fastener (1) to 45 Nm (33 lb ft).
9. Install the underbody brace (2) and tighten the fasteners (1) to 58 Nm (43 lb ft).
10. With the aid of an assistant, install the right rear muffler (1) to the vehicle.
11. Connect the right rear muffler (1) to the exhaust crossover pipe assembly (3) and tighten the fasteners (2) to 45 Nm (33 lb ft).
12. With the aid of an assistant, install the left rear muffler (1) to the vehicle.
13. Connect the left rear muffler (1) to the exhaust crossover pipe assembly (2) and tighten the fasteners (3) to 45 Nm (33 lb ft).
14. Install the left rear hanger bracket fasteners (1) and tighten to 26 Nm (19 lb ft).
15. Install the right rear hanger bracket fasteners (1) and tighten to 26 Nm (19 lb ft).
16. Lower the vehicle.
17. Install the left hand catalytic convertor to cylinder head retaining fasteners (2) and tighten to 45 Nm (33 lb ft).
18. Install the left hand catalytic convertor to cylinder head retaining fasteners (2) and tighten to 45 Nm (33 lb ft).
Danger:
To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.
19. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
20. Install the catalytic convertor (1) to cross-over pipe (2) and tighten the fasteners (3) to 45 Nm (33 lb ft).
21. Make sure that the exhaust system is clear of all other components and chassis. If the exhaust system is not clear of all the other components loosen all retaining fasteners and re-align.
22. Install the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2.
23. Install the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2.
24. Lower the vehicle.
25. Install the right exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Right Side Exhaust Manifold Heat Shield Replacement - Right Side.
26. Install the right pre-catalytic convertor HO2S sensor. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1.
27. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Removal 2. Oil Level Indicator and Tube Removal.
28. Install the left exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Left Side Exhaust Manifold Heat Shield Replacement - Left Side.
29. Install the left pre-catalytic convertor HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1.
30. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).