GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Daewoo 🢒 2009 🢒 W200 🢒 Engine 🢒 Engine Exhaust 🢒 Exhaust Crossover Pipe Replacement

Removal Procedure
  1. Ignition OFF.

    2. Caution: Refer to Exhaust Service Caution in the Preface section.

    Caution: Refer to Battery Disconnect Caution in the Preface section.

  2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.

    3. Caution: Refer to Protective Goggles and Glove Caution in the Preface section.

    Caution: Refer to Vehicle Lifting Caution in the Preface section.

  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  4. Remove the right post-catalytic converter heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2.
  5. Remove the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2.

    6. Object Number: 2179318 Size: SH
  6. Remove exhaust crossover pipe assembly to catalytic converter retaining nuts (3).
  7. Separate the exhaust crossover pipe assembly (2) from the catalytic converter assemblies (1).

    8. Object Number: 1949716 Size: SH
  8. Remove the transmission tunnel cross-brace to body retaining bolts (2).
  9. Remove the transmission tunnel cross-brace (1).
  10. Support the exhaust system with a suitable jack.

    11. Object Number: 1947045 Size: SH
  11. Remove the exhaust crossover pipe assembly to rear muffler retaining bolts (3)
  12. Disconnect the rear left muffler (1) from the exhaust crossover pipe assembly (2)

    13. Object Number: 1949729 Size: SH
  13. Remove the exhaust crossover pipe assembly to rear muffler retaining bolts (2)
  14. Disconnect the rear right muffler (1) from the exhaust crossover pipe assembly (3)

    15. Object Number: 1947047 Size: SH
  15. Remove the centre insulator hanger bracket to differential retaining nut (1).
  16. Detach the exhaust crossover pipe assembly.
  17. Carefully lower the exhaust crossover pipe assembly from the vehicle.

Installation Procedure
  1. Clean all threads and flange faces of the exhaust crossover pipe assembly.
  2. Replace the catalytic converter to intermediate pipe flange gaskets.

    3. Notice: Refer to Exhaust System Inspection Notice in the Preface section.

    Caution: Refer to Exhaust Service Caution in the Preface section.

  3. Position the exhaust crossover pipe assembly to the vehicle using a suitable jack.

    4. Object Number: 1947047 Size: SH
  4. Align the exhaust system to the centre insulator hanger bracket to differential retaining bolt.

    5. Notice: Refer to Fastener Notice in the Preface section.

  5. Install the centre insulator hanger bracket to differential retaining nut (1).

    6. Tighten
    Tighten the nut to 45 N·m (33 lb ft).


    Object Number: 1947045 Size: SH
  6. Connect the left rear muffler (1) to the exhaust crossover pipe assembly (2).
  7. Install the left rear muffler to exhaust crossover pipe assembly retaining bolts (3).

    8. Tighten
    Tighten the bolts to 45 N·m (33 lb ft).


    Object Number: 1949729 Size: SH
  8. Connect the right rear muffler (1) to the exhaust crossover pipe assembly (3).
  9. Install the right rear muffler to exhaust crossover pipe assembly retaining bolts (2).

    10. Tighten
    Tighten the bolts to 45 N·m (33 lb ft).


    Object Number: 1949716 Size: SH
  10. Install the transmission tunnel cross-brace (1).
  11. Install the transmission tunnel cross-brace to body retaining bolts (2).

    12. Tighten
    Tighten the bolts to 12 N·m (9.0 lb ft).


    Object Number: 2179318 Size: SH
  12. Align the catalytic converter assemblies (1) to the exhaust crossover pipe assembly (2).
  13. Install the exhaust crossover pipe assembly to catalytic converter retaining nuts (3).

    14. Tighten
    Tighten the nuts to 40 N·m (30 lb ft).

  14. 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.
  15. Install the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2.
  16. Install the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2.
  17. Lower the vehicle.
  18. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.