Exhaust System Replacement V8 - For Access

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

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

1. Ignition OFF.

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

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




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.

Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution in the Preface section.




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.

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 in the Preface section.

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



4. Install the rear insulator hanger to body retaining bolts (1) and tighten to 26 N·m (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 N·m (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 N·m (33 lb ft).



19. Tighten the right catalytic converter to exhaust manifold retaining nuts (1) to 45 N·m (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.
21. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.

Exhaust System Replacement V8 - Complete

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

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

1. Ignition OFF.

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

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




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.

Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution in the Preface section.




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.
20. Remove the left pre-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1.
21. Remove the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2.
22. Remove the right pre-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1.
23. Remove the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2.

1. Install the left pre-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1.




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

2. From underneath the vehicle, position the left catalytic converter (2) to the exhaust manifold (3).

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

3. Install the NEW left catalytic converter to exhaust manifold retaining nuts (1).

Do not fully tighten at this stage.

4. Install the right pre-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1.




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

5. From underneath the vehicle, position the right catalytic converter (2) to the exhaust manifold (1).

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

6. Install the NEW right catalytic converter to exhaust manifold retaining nuts (3).

Do not fully tighten at this stage.

7. Lower the vehicle.

Caution: Refer to Fastener Caution in the Preface section.




8. Tighten the left catalytic converter to exhaust manifold retaining nuts (1) to 45 N·m (33 lb ft).



9. Tighten the right catalytic converter to exhaust manifold retaining nuts (1) to 45 N·m (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.

10. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
11. Install the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2.
12. Install the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2.
13. With the aid of an assistant, or using a suitable jack; position the exhaust crossover pipe assembly to the vehicle.



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



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



17. Align the exhaust crossover pipe exhaust assembly (2) to the right catalytic converter (1).
18. Install the intermediate exhaust assembly to right catalytic converter retaining nuts (3) and tighten to 40 N·m (30 lb ft).



19. Align the exhaust crossover pipe exhaust assembly (2) to the left catalytic converter (1).
20. Install the intermediate exhaust assembly to left catalytic converter retaining nuts (3) and tighten to 40 N·m (30 lb ft).



21. Install the centre insulator hanger bracket to differential retaining nut (1) and tighten to 45 N·m (33 lb ft).



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



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



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



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



26. Install the transmission tunnel cross-brace (1).
27. Install the transmission tunnel cross-brace to body retaining bolts (2) and tighten to 12 N·m (9 lb ft).



28. Install the right rear muffler (1) to the vehicle.



29. Connect the right rear muffler (1) to the exhaust crossover pipe assembly (2).
30. Install the right rear muffler to exhaust crossover pipe assembly retaining bolts (2) and tighten to 45 N·m (33 lb ft).



31. Install the left rear muffler (1) to the vehicle.



32. Connect the left rear muffler (1) to the exhaust crossover pipe assembly (2).
33. Install the left rear muffler to exhaust crossover assembly retaining bolts (3) and tighten to 45 N·m (33 lb ft).



34. Install the rear insulator hanger to body retaining bolts (1) and tighten to 26 N·m (19 lb ft).
35. 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.
36. Lower the vehicle.
37. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.

Exhaust System Replacement V6 - For Access

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

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

1. Ignition OFF.

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

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

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.

Caution: Refer to Heated Oxygen and Oxygen Sensor Caution in the Preface section.

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



12. Remove the centre insulator hanger bracket to differential retaining nut (1).
13. Detach the exhaust crossover pipe assembly.
14. With the aid of an assistant or using a suitable jack; carefully lower the exhaust system from the vehicle.
15. If required, remove the right catalytic converter. Refer to Catalytic Converter Replacement - Right Side.
16. If required, remove the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side.

1. If removed, install the right catalytic converter. Refer to Catalytic Converter Replacement - Right Side.
2. If removed, install the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side.
3. With the aid of an assistant or using a suitable jack; carefully raise the exhaust system up into the vehicle.



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

Caution: Refer to Fastener Caution in the Preface section.

5. Install the centre insulator hanger bracket to differential retaining nut (1) and tighten to 45 N·m (33 lb ft).



6. Install the rear insulator hanger to body retaining bolts (1) and tighten to 26 N·m (19 lb ft).



7. Install the transmission tunnel cross-brace (1).
8. Install the transmission tunnel cross-brace to body retaining bolts (2) and tighten to 12 N·m (9 lb ft).




Note: Make sure that NEW flange gaskets are fitted prior to installation. Failure to comply may cause the exhaust system to perform poorly.

9. Connect the catalytic converter assemblies (1) to the exhaust crossover pipe assembly (2).
10. Install the exhaust crossover pipe assembly to catalytic converter retaining nuts (3) and tighten to 45 N·m (33 lb ft).
11. Remove the jack supporting the exhaust system.
12. 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.
13. Install the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2.
14. Install the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 .
15. Lower the vehicle.
16. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

Exhaust System Replacement V6 - Complete

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

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

1. Ignition OFF.

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

2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the engine cover. Refer to Engine Cover Replacement.

Caution: Refer to Heated Oxygen and Oxygen Sensor Caution in the Preface section.

4. Remove the left pre-catalytic convertor heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1.
5. Remove the left exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Left Side .
6. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Removal .
7. Remove the right pre-catalytic convertor HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 .
8. Remove the right exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Right Side.




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

9. Remove the left catalytic converter to exhaust manifold retaining nuts (2).

Discard the nuts.





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

10. Remove the right catalytic converter to exhaust manifold retaining nuts (3).

Discard the nuts.

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.

11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
12. Remove the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 .
13. Remove the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 .



14. Remove the transmission tunnel cross-brace to body retaining bolts (2).
15. Remove the transmission tunnel cross-brace (1).
16. Support the exhaust system with a suitable jack.



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



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

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

1. From underneath the vehicle, position the right catalytic converter (2) to the exhaust manifold (1).

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

2. Install NEW right 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.

3. From underneath the vehicle, position the left catalytic converter (3) to the exhaust manifold (1).

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

4. Install NEW left catalytic converter to exhaust manifold retaining nuts (1)

Do not fully tighten at this stage.

5. Lower the vehicle.

Caution: Refer to Fastener Caution in the Preface section.




6. Tighten the right catalytic converter to exhaust manifold retaining nuts (1) to 45 N·m (33 lb ft).



7. Tighten the left catalytic converter to exhaust manifold retaining nuts (1) to 45 N·m (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.

8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
9. With the aid of an assistant, or using a suitable jack, position the exhaust crossover pipe assembly to the vehicle.



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




Note: Make sure that NEW flange gaskets are fitted prior to installation. Failure to comply may cause the exhaust system to perform poorly.

11. Connect the catalytic converter assemblies (1) to the exhaust crossover pipe assembly (2).
12. Install the exhaust crossover pipe assembly to catalytic converter retaining nuts (3) and tighten to 45 N·m (33 lb ft).



13. Install the centre insulator hanger bracket to differential retaining nut (1) and tighten to 45 N·m (33 lb ft).



14. Install the transmission tunnel cross-brace (1).
15. Install the transmission tunnel cross-brace to body retaining bolts (2) and tighten to 12 N·m (9 lb ft).



16. Install the right rear muffler (1) to the vehicle.



17. Connect the right rear muffler (1) to the exhaust crossover pipe assembly (2).
18. Install the right rear muffler to exhaust crossover pipe assembly retaining bolts (2) and tighten to 45 N·m (33 lb ft).



19. Install the left rear muffler (1) to the vehicle.



20. Connect the left rear muffler (1) to the exhaust crossover pipe assembly (2).
21. Install the left rear muffler to exhaust crossover assembly retaining bolts (3) and tighten to 45 N·m (33 lb ft).



22. Install the rear insulator hanger to body retaining bolts (1) and tighten to 26 N·m (19 lb ft).
23. Remove the jack supporting the exhaust system.
24. 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.
25. Install the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2.
26. Install the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 .
27. Lower the vehicle.
28. Install the right exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Right Side.
29. Install the right pre-catalytic convertor HO2S sensor. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1.
30. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Removal .
31. Install the left exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Left Side.
32. Install the left pre-catalytic convertor HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 .
33. Install the engine cover. Refer to Engine Cover Replacement.
34. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .