Exhaust System Replacement (For Access)

Exhaust System Replacement (V8 - For Access)

Removal Procedure

Warning: Refer to Exhaust Service Warning (Service Precautions).

Warning: Refer to Protective Goggles and Glove Warning (Protective Goggles and Glove Warning).

1. Ignition OFF.
Warning: Refer to Battery Disconnect Warning (Battery Disconnect Warning).

2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).





Note: The left catalytic converter to exhaust manifold retaining nuts (1) are single use parts. They must be discarded after removal.

3. Remove the left catalytic converter to exhaust manifold retaining nuts (1).
Discard the nuts.
4. Disconnect the left catalytic converter (2) from the exhaust manifold (3).





Note: The right catalytic converter to exhaust manifold retaining nuts (3) are single use parts. They must be discarded after removal.

5. Remove the right catalytic converter to exhaust manifold retaining nuts (3).
Discard the nuts.
6. Disconnect the right catalytic converter (2) from the exhaust manifold (1).

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.


7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).





Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution (Vehicle Damage Warnings)

8. Disconnect the left pre-catalytic converter HO2S electrical connector (1).




9. Disconnect the right pre-catalytic converter HO2S electrical connector (1).




10. Disconnect the left post-catalytic converter HO2S electrical connector (1).




11. Disconnect the right post-catalytic converter HO2S electrical connector (1).




12. Detach the exhaust system (2) by removing the front insulator hangers (1).
13. Support the exhaust system with a suitable jack.




14. Remove the transmission tunnel cross-brace to body retaining bolts (2).
15. Remove the transmission tunnel cross-brace (1).




16. Remove the rear insulator hanger to body retaining bolts (1).




17. Remove the centre insulator hanger bracket to differential retaining nut (1).
18. Detach the exhaust system assembly from the centre insulator hanger bracket to differential retaining stud (1).
19. With the aid of an assistant or using a suitable jack; carefully lower the exhaust system from the vehicle.

Installation Procedure

1. With the aid of an assistant or using a suitable jack; carefully raise the exhaust system to the vehicle.




2. Align the exhaust system to the centre insulator hanger bracket to differential retaining stud (1).

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the centre insulator hanger bracket to differential retaining nut (1) and tighten to 45 Nm (33 lb ft).




4. Install the rear insulator hanger to body retaining bolts (1) and tighten to 26 Nm (19 lb ft).




5. Install the transmission tunnel cross-brace (1).
6. Install the transmission tunnel cross-brace to body retaining bolts (2) and tighten to 12 Nm (9 lb ft).




7. Align the exhaust system (2) to the front hanger studs and install the front insulator hangers (1).
8. Remove the jack supporting the exhaust system.




9. Connect the left post-catalytic converter HO2S electrical connector (1).




10. Connect the right post-catalytic converter HO2S electrical connector (1).




11. Connect the left pre-catalytic converter HO2S electrical connector (1).




12. Connect the right pre-catalytic converter HO2S electrical connector (2).





Note: Make sure that a NEW sealing ring is fitted prior to installation. Failure to comply may cause the exhaust system to perform poorly.

13. Push up and forward on the left catalytic converter (2) to connect to the exhaust manifold (3).

Note: Do not fully tighten the left catalytic converter to exhaust manifold retaining nuts (1) at this stage.

14. Install the NEW left catalytic converter to exhaust manifold retaining nuts (1).
Do not fully tighten at this stage.





Note: Make sure that a NEW sealing ring is fitted prior to installation. Failure to comply may cause the exhaust system to perform poorly.

15. Push up and forward on the right catalytic converter (2) to connect to the exhaust manifold (1).

Note: Do not fully tighten the right catalytic converter to exhaust manifold retaining nuts (3) at this stage.

16. Install the NEW right catalytic converter to exhaust manifold retaining nuts (3).
Do not fully tighten at this stage.
17. Lower the vehicle.




18. Tighten the left catalytic converter to exhaust manifold retaining nuts (1) to 45 Nm (33 lb ft).




19. Tighten the right catalytic converter to exhaust manifold retaining nuts (1) to 45 Nm (33 lb ft).
20. 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 nuts and re-align. Refer to Exhaust System Alignment (Procedures).
21. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).