For 1990-2009 cars

## Exhaust System Replacement Complete

### Removal Procedure

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

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

1. Ignition OFF

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. Remove the intake manifold sight shield. Refer to Intake Manifold Sight Shield Replacement.

Notice: Refer to Heated Oxygen and Oxygen Sensor Notice 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.

Important: The left catalytic converter to exhaust manifold retaining nuts (2) are single use parts and must be discarded after removal.

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

Discard the nuts.

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

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

Discard the nuts.

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

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.

### Installation Procedure

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

Important: 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).

Important: Do not fully tighten the left catalytic converter to exhaust manifold retaining nuts (2) at this stage.

2. Install NEW right catalytic converter to exhaust manifold retaining nuts (1)

Do not fully tighten at this stage.

Important: 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).

Important: Do not fully tighten the left catalytic converter to exhaust manifold retaining nuts (2) 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.
6. Tighten the right catalytic converter to exhaust manifold retaining nuts (3)

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

7. Tighten the left catalytic converter to exhaust manifold retaining nuts (2)

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

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

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).

Important: 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).

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

Notice: Refer to Fastener Notice in the Preface section.

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

Tighten
Tighten the nut 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).

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

Tighten
Tighten the bolts 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).

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

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

Tighten
Tighten the bolts 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 intake manifold sight shield. Refer to Intake Manifold Sight Shield Replacement.
34. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.

## Exhaust System Replacement for Access

### Removal Procedure

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

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

1. Ignition OFF

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

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

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

3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.

Notice: Refer to Heated Oxygen and Oxygen Sensor Notice 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.

### Installation Procedure

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).

Notice: Refer to Fastener Notice in the Preface section.

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

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

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

Tighten
Tighten the bolts 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).

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

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).

Tighten
Tighten the nuts 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.